Patent Publication Number: US-2023163717-A1

Title: Systems and apparatuses for precipitation management in solar assemblies

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 16/440,224, filed Jun. 13, 2019, which claims the benefit of provisional U.S. Application No. 62/684,501, filed Jun. 13, 2018, the entire contents of which are incorporated herein by reference. 
    
    
     BACKGROUND 
     The “background” description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description which may not otherwise qualify as prior art at the time of filing, are neither expressly or impliedly admitted as prior art against the present invention. 
     Solar assembly structures (e.g. Single tilt carports, Dual tilt carports, etc.) can be very costly to fabricate, install and maintain. Furthermore, efficient and low cost water and snow management can be challenging. In particular, there are challenges to produce efficient solar assemblies elevated to protect a location underneath the solar assembly from rain or snow without leaking. In order for solar assembly structure (e.g. dual tilt carports) to be more viable, efficient, and functional, there needs to be a new design strategy that addresses these challenges. 
     SUMMARY 
     According to aspects of the disclosed subject matter, a solar assembly structure (e.g. carport) includes a single slope crossbeam, a plurality of clip angle brackets, and a plurality of solar or photovoltaic (PV) modules, each PV module being supported by at least two clip angle brackets. 
     According to aspects of the disclosed subject matter, the plurality of clip angle brackets are configured to create a single tilt structure supporting a plurality of shingled PV modules, and wherein the shingled PV modules are configured to direct precipitation toward a gutter. 
     According to aspects of the disclosed subject matter, the plurality of clip angle brackets are configured to create a dual tilt structure. 
     According to aspects of the disclosed subject matter, a first slope of the dual tilt structure includes a predetermined number of shingled PV modules, the shingled PV modules being configured to direct precipitation toward a gutter separating the first slope of the dual tilt structure with a second slope of the dual tilt structure. 
     According to aspects of the disclosed subject matter, the second slope of the dual tilt structure includes a predetermined number of PV modules tilted at an angle configured to face the first slope of the dual tilt structure. 
     According to aspects of the disclosed subject matter, the predetermined number of PV modules of the second slope are shingled when there is more than one PV module in the second slope. 
     According to aspects of the disclosed subject matter, the plurality of clip angle brackets have different heights in order to create the dual tilt structure. 
     According to aspects of the disclosed subject matter, downhill clip angle brackets are higher than uphill clip angle brackets. 
     According to aspects of the disclosed subject matter, the solar assembly further includes a plurality of purlins configured to support the plurality of PV modules, the plurality of purlins being attached to the single-slope crossbeam via the plurality of clip angle brackets. 
     According to aspects of the disclosed subject matter a solar assembly includes a support structure, a plurality of solar modules, each solar module being supported by the support structure, and a plurality of clip angle brackets configured to attach the plurality of solar modules to the support structure. The plurality of clip angle brackets are further configured to create an overlap between a first solar module and a second solar module, the second solar module being adjacent to the first solar module. 
     According to aspects of the disclosed subject matter, the solar assembly further includes a drip edge disposed on the first solar module and configured to prevent precipitation from entering a gap between the first solar module and the second solar module. 
     According to aspects of the disclosed subject matter, the drip edge is integrally formed on the first solar module. 
     According to aspects of the disclosed subject matter, the solar assembly further includes a flashing disposed on the first solar module and configured to prevent precipitation from entering a gap between the first solar module and the second solar module. 
     According to aspects of the disclosed subject matter, the flashing further attaches to the second solar module. 
     According to aspects of the disclosed subject matter, the flashing is flexible. 
     According to aspects of the disclosed subject matter, the solar assembly further includes a gutter disposed between two rows of solar modules and configured to guide precipitation received to an end thereof. 
     According to aspects of the disclosed subject matter, the solar assembly further includes at least one downspout configured to guide the precipitation from the gutter to a ground surface. 
     According to aspects of the disclosed subject matter, the two rows of solar modules are angled towards the gutter. 
     According to aspects of the disclosed subject matter, the solar assembly further includes gaskets configured to fill gaps between abutting PV module ends that do not overlap. 
     According to aspects of the disclosed subject matter, the support structure includes a dual-tilt support beam. 
     The foregoing paragraphs have been provided by way of general introduction, and are not intended to limit the scope of the following claims. The described embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
         FIG.  1    illustrates an exemplary overview of a solar assembly (e.g. carport) including shingled photovoltaic modules according to one or more aspects of the disclosed subject matter; 
         FIG.  2    is an exemplary view of another solar assembly including shingled photovoltaic modules according to one or more aspects of the disclosed subject matter; 
         FIG.  3    is an expanded exemplary view of the other solar assembly including shingled photovoltaic modules according to one or more aspects of the disclosed subject matter; 
         FIG.  4 A  illustrates an exemplary photovoltaic modules support structure according to one or more aspects of the disclosed subject matter; 
         FIG.  4 B  illustrates a close up view of an exemplary overlap structure of photovoltaic modules according to one or more aspects of the disclosed subject matter; 
         FIG.  4 C  illustrates a close up view of an exemplary overlap structure of photovoltaic modules according to one or more aspects of the disclosed subject matter; 
         FIG.  4 D  illustrates a close up view of an exemplary overlap structure of photovoltaic modules according to one or more aspects of the disclosed subject matter; 
         FIG.  5    illustrates exemplary water management features for a carport according to one or more aspects of the disclosed subject matter; 
         FIG.  6    illustrates a perspective view of an exemplary carport according to one or more aspects of the disclosed subject matter, and 
         FIG.  7    illustrates a perspective view of an exemplary carport according to one or more aspects of the disclosed subject matter. 
     
    
    
     DETAILED DESCRIPTION 
     The description set forth below in connection with the appended drawings is intended as a description of various embodiments of the disclosed subject matter and is not necessarily intended to represent the only embodiment(s). In certain instances, the description includes specific details for the purpose of providing an understanding of the disclosed subject matter. However, it will be apparent to those skilled in the art that embodiments may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram form in order to avoid obscuring the concepts of the disclosed subject matter. 
     Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, characteristic, operation, or function described in connection with an embodiment is included in at least one embodiment of the disclosed subject matter. Thus, any appearance of the phrases “in one embodiment” or “in an embodiment” in the specification is not necessarily referring to the same embodiment. Further, the particular features, structures, characteristics, operations, or functions may be combined in any suitable manner in one or more embodiments. Further, it is intended that embodiments of the disclosed subject matter can and do cover modifications and variations of the described embodiments. 
     It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. That is, unless clearly specified otherwise, as used herein the words “a” and “an” and the like carry the meaning of “one or more.” Additionally, it is to be understood that terms such as “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “inner,” “outer,” and the like that may be used herein, merely describe points of reference and do not necessarily limit embodiments of the disclosed subject matter to any particular orientation or configuration. Furthermore, terms such as “first,” “second,” “third,” etc., merely identify one of a number of portions, components, points of reference, operations and/or functions as described herein, and likewise do not necessarily limit embodiments of the disclosed subject matter to any particular configuration or orientation. 
     Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views,  FIG.  1    illustrates an exemplary overview of a solar assembly (e.g, carport)  100  according to one or more aspects of the disclosed subject matter. The carport  100  includes water management features where the solar or photovoltaic (PV) modules shingle each other to avoid using costly materials and installation techniques (e.g., installing mini gutters between each PV module are an added expense). Shingled modules can be employed with any desirable underlying support structure (e.g., single tilt, horizontal, dual tilt, and so on). In an exemplary embodiment, the water management features in  FIG.  1    include a dual tilt canopy where the inverse angle is created by propping up the attachment brackets on a single sloping crossbeam rather than complicated fabrication methods to create the dual tilt functionality using crossbeams of two different angles. The carport  100  can also include shingled photovoltaic modules as further described herein. 
     There has been a long standing need for protective structures (e.g. carports) in geographic areas where snow and water management pose significant challenges. For purposes of description, a dual tilt carport will be used as an example, however it should be appreciated that the invention can be applied to a wide range of solar assemblies including but not limited to fixed tilt solar installations, single tilt solar installations or carports, dual tilt solar installations or carports, and so on. In one example, example, owners of parking lots may want or need to provide their customers and tenants with protection from the snow and rain. The nature of the shingled module and/or dual tilt design allows snow, rain, hail, ice, precipitation, etc. to accumulate and remain on top of the canopy (e.g., prevents snow, ice, etc. from sliding off the canopy and causing damage and/or injury) while at the same time provides a way for liquid to accumulate in the center of the canopy where a system of gutters bring the water back down to the parking lot surface. However, the dual tilt carport has traditionally been costly to fabricate, install, and maintain. For example, traditional dual tilt carports require more parts associated with this design including mini gutters, main gutters, downspouts, gaskets, metal decking, and complicated fabrication methods to achieve the two different angles of the dual tilt. Additionally, traditional dual tilt design is more expensive than a single tilt carport without water or snow management. It also yields less energy production from the solar panels because half of the panels face a direction that is less than ideal from a solar exposure standpoint. Accordingly, the carport  100  can provide a more cost effective solution that utilizes less parts, is easier to install and maintain, and generates more energy production. 
     It should be appreciated that the shingled modules can provide an overlap structure where a first solar module overlaps a portion of a second solar module, the second solar module being adjacent to the first solar module. The shingled structure can be applied to various solar assembly structures including fixed tilt solar installations, single tilt solar installations or carports, dual tilt solar installations or carports, and so on. 
     More specifically, the carport  100  can include a gutter  105 , a plurality of PV modules  110 , one or more light fixtures  115 , a crossbeam  120 , a downspout  125 , a brace arm  130 , a column  135 , and a pier  140 . As illustrated in  FIG.  1   , and as described in greater detail below, each of the PV modules is attached to the crossbeam  120 , directly or indirectly, by a clip angle bracket, such as clip angle brackets  150   a  and  150   b . The clip angle brackets  150   a  all have the same, or similar, dimensions. The clip angle bracket  150   b  has longer legs  151 ,  152  than those of the clip angle brackets  150   a  in order to change a tilt angle of its corresponding PV module  110  and form the dual tilt structure of the carport  100 . 
       FIG.  2    illustrates another carport  200  according to exemplary aspects of the disclosed subject matter. The downspout  125 , the brace arm  130 , the column  135 , the pier  140 , and the plurality of PV modules  110  illustrated in  FIG.  2    are substantially the same as those of like reference numbers illustrated in  FIG.  1   . Therefore, no further description of these components is provided for the sake of brevity. 
     The crossbeam  120  of the carport  200  includes a section  121  that forms an angle with respect to the rest of the crossbeam that is different from 180°. This results in a crossbeam  120  that is a dual-tilt crossbeam.  FIG.  2    illustrates the section  121  as being substantially parallel to the ground surface. However, the section  121  may also be also form an angle with respect to the remainder of the crossbeam  120  such that the section  121  tilts upward, or downward. The section  121  may also be any percentage of the length of the crossbeam  120  without limitation. 
     The clip angle brackets  150   a  in  FIG.  2    may all be of similar height with sufficient variation in the heights thereof to permit shingling of the PV modules. Since the section  121  creates an angle with respect to the remainder of the crossbeam  120 , the clip angle brackets  150   a  of the PV module  110  disposed on the section  121  does not require a significantly large disparity in the lengths of the brackets in order to form a dual-tilt structure. Instead the dual-tilt structure is generated by the crossbeam  120  itself. Of course, nothing precludes the angle brackets  150   a  of the PV module  110  disposed on the section  121  may also have a significant disparity in length to augment, or lessen, the angle imparted by the section  121 . Numerous other variations on the angle of the section  121  and the lengths of the angle brackets of the PV module  110  disposed on the section  121  are also possible without departing from the scope of the disclosed subject matter. 
       FIG.  3    is an expanded view of the carport  200  of  FIG.  2   . In  FIG.  3    assembly of the carport  200  is illustrated. For example, the clip angle brackets  305 , the crossbeam  120 , the column  135 , the brace  130  are shown as being bolted together with bolts, and bolted to the pier  140  with bolts. However, other fasteners can also be used, such as rivets. The components of the carport  200  may also be welded together. Thus, the specific fasteners used to assemble the carport  200  are not limiting upon the disclosed subject matter. Furthermore, different shapes and structure of the column, pier  140  and/or brace can be employed without departing from the scope of the disclosed subject matter. 
       FIG.  4 A  illustrates an exemplary photovoltaic module (PV) support structure  400  according to one or more aspects of the disclosed subject matter. The PV support structure  400  includes at least one purlin  210  connected to the PV module  110 , at least one clip angle bracket  215  connect to each purlin  210  and to the crossbeam  120 , and blocking  220  between the purlins  210 . Additionally,  FIG.  4 A  illustrates an overlap structure  230 . 
     The shingled configuration of the PV modules  110  are achieved by adjusting the height of the two attachment brackets (e.g., clip angle bracket  215 ) that hold the PV module  110  to the structure (e.g., crossbeam  120 ) of the carport  100  (or the carport  200 ). One of the two clip angle brackets  215  supporting the PV module  110  can be an uphill clip angle which is lower in height than a downhill clip angle. The attachment point of the uphill clip angle is higher on the crossbeam  120  than the downhill attachment bracket. Additionally, to achieve the overlap configuration of the PV modules  110 , the slope of the crossbeam  120  is approximately 2 degrees steeper than the slope of the PV module  110 , for example. Of course, other slopes are possible without departing from the scope of the present disclosure. The combination of the varying heights of the clip angle brackets  215  mounted on top of the steeper crossbeam creates a condition where the lower edge of the PV module  110  is slightly higher than the upper edge of the next downhill module. Additionally, the adjacent lower module is slightly under the footprint of the adjacent upper module. These two factors prevent water from falling through the joints between the upper panel and the lower panel in a similar way to how a shingled roof works. 
     The above described structure causes the PV modules  110  to be shingled such that a PV module  110  can overlap with an adjacent lower PV module  110 . This way water can travel along and down the surface of the PV modules  110  to the gutter  105  without any significant leakage between PV modules  110 . The gutter  105  is at the valley of the carport  100  and catches the water shed by the PV modules  110 , and the downspout  125  guides the water down to the surface of, for example, a parking lot, or other surface covered by the carport  100 . 
     The dual tilt function of the carport (two opposing PV module angles that create a “V” profile) is formed by alternating the heights of the attachment brackets of the most downhill PV module. The most downhill clip angle bracket  215  is significantly higher than the uphill bracket of this PV module. This allows the lower edge of the most downhill PV module  110  to be higher than the lower edge when mounted to the crossbeam  120 . Thus the most downhill PV module slopes in the opposite direction of the crossbeam  120 . 
     Dual tilt carport can be 6 modules wide with half of the modules typically sloping to one angle and the other half sloping in an opposing angle to create the “V” profile. However, when a parking lot is oriented in a way where the parking stall striping yields a southern facing carport, the dual tilt design is not as efficient from an energy standpoint compared to a single sloping carport because only half of the modules are oriented in an effective angle towards the sun. The carport  100  solves this problem because in a 6 module design, 5 modules of the width of the carport can face south (instead of 3 in commonly found dual tilt carports). This can be achieved because the two angles of the carport are decoupled with the angle of the crossbeam using the clip angle brackets  215 . From a structural standpoint, this imbalance of modules sloped in one direction compared to the one module sloped in the opposing angle does not create an unstable structure, which is in contrast to typical dual tilt carports which need this balance because the two angles of the dual tilt are achieved by fabricating the crossbeam in a way that matches the required tilt angles. The structure would be unstable and inefficient if this balance did not occur. 
     It should be appreciated that the dual tilt design with the single crossbeam can be achieved with various combinations of how many panels are tilted in one of the two tilt angles in the dual tilt design. For example,  FIG.  1    shows 5 panels facing one direction at a 10 degree tilt angle and one panel facing a direction opposite the 5 panels at a 2 degree tilt angle. However, the dual tilt could be 4 and 2, 3 and 3, etc. Additionally, more (e.g., 7 total panels) or less (e.g., 4 total panels) could be used. Further, the tilt angles of the dual tilt design can also be customized based on geographic location, parking lot orientation, anticipated amount of precipitation, and the like. It should be appreciated that the tilt of the positive angle (e.g., the side with 5 panels in  FIG.  1   ) can range from 2-15 degrees, and the tilt of the negative angle (e.g., the side with 1 panel in  FIG.  1   ) can range from 1-5 degrees, for example. In some implementations, shingled PV modules can be supported by a substantially horizontal support structure (e.g. zero to 2 degrees tilt). 
     Because the clip angle brackets can be used to set the PV modules to various heights, the slope of the crossbeam or support structure can be flat and level and the clip angles can adjust in height to create the desired angle of the PV modules, for example. In other words, a flat horizontal system could be installed because the height of the clip angles can be adjusted such that they would create the slope of the solar panels rather than the support structure. This can allow for increased flexibility in the design of the support structure. 
       FIG.  4 B  illustrates a close up view of an exemplary overlap structure  230  of photovoltaic modules  235  and  240  according to one or more aspects of the disclosed subject matter. The overlap structure  230  can be an open joint structure which includes an upper PV module  235  and a lower PV module  240  such that the upper PV module  235  overlaps the lower PV module  240  by a first predetermined distance  245  (e.g., ½ inch). Additionally, the upper PV module  235  can be positioned above the lower PV module  240  by a second predetermined distance  250  (e.g., ½ inch). For example, the first predetermined distance  245  and the second predetermined distance  250  can be substantially the same distance. Generally, the overlap structure  230  can be configured to allow precipitation to travel down the PV modules toward a gutter (e.g., gutter  105 ). It should be appreciated that various first and second predetermined distances  245 ,  250  could be contemplated to prevent precipitation from falling through the gap in overlap structure  230  while also maximizing PV module area to maximize the energy able to be generated by the PV module. 
       FIG.  4 C  illustrates a close up view of an exemplary overlap structure  255  of photovoltaic modules according to one or more aspects of the disclosed subject matter. The overlap between two PV modules in  FIG.  4 B  is an open overlap, or joint, because there is nothing sealing the gap between the two PV modules. This may allow precipitation to work its way between the two PV modules. To prevent precipitation from entering through the gap between PV modules,  FIG.  4 C  illustrates an overlap structure  255  that includes a drip edge  420  attached to the upper PV module  235 . The drip edge  420  guides precipitation from the upper PV module  235  to the lower PV module  240  to discourage the precipitation from entering the gap therebetween. As can be appreciated the drip edge  420  may be formed from materials such as plastic, aluminum, metal, lead, stainless steel, and the like, and may be an integral part of the PV module  235  or may be affixed to the PV module  235  using adhesives, welding, bolts, screws, or any combination thereof. 
       FIG.  4 D  illustrates a close up view of an exemplary overlap structure  265  of photovoltaic modules according to one or more aspects of the disclosed subject matter. The overlap structure  265  includes flashing  450  attached to the upper PV module  235  and the lower PV module  240  to discourage precipitation from entering the gap between the two PV modules. As can be appreciated, the flashing  450  may be made of a flexible material such as plastic or foam, or may be made of a soft metal such as lead. Other materials can also be used for the flashing  450  without departing from the scope of this disclosure.  FIG.  5    illustrates exemplary water management features for a carport according to one or more aspects of the disclosed subject matter. For example, rubber gaskets  505  may be placed between each shingled column of PV modules. Alternatively, or additionally, each column of PV modules may be shingled with an adjacent column of PV modules in addition to each PV module in the column of PV modules being shingled as illustrated in  FIG.  1   .  FIG.  5    also illustrates gutters  105  and a plurality of downspouts  125  that remove precipitation from the carport. 
     The carport structures disclosed herein can be deployed to any desirable site or surface with any desirable support component without departing from the scope of the present disclosure. In one implementation, a carport can be provided on a ground surface, for example a parking lot or field. In another example a carport structure can be deployed to an above ground surface, for example on a top level of a multi-level parking garage or building. 
       FIGS.  6  and  7    illustrate perspective views of solar carports according to aspects of the present disclosure. Unless otherwise specified below, the numerical indicators used to refer to components in the  FIGS.  6  and  7    are similar to those used to refer to components or features in  FIGS.  1  and  2    above, except that the index has been incremented by 1000. 
       FIG.  6    illustrates a perspective view of a carport  1100  according to aspects of the present disclosure. The carport in  FIG.  6    includes straight crossbeams that are mounted on columns and piers. As can be seen from the figure, the PV modules are disposed on purlins that are attached to the crossbeams by clip angle brackets of various lengths to allow shingling of the PV modules. The clip angle brackets for the lowest PV modules have a greater difference in lengths in order to form a dual-incline structure by angling the lowest PV modules at an angle contrary to the angle of the other PV modules that are higher up on the crossbeam. As can be appreciated the angles of the lowest PV modules, the other PV modules, and that of the crossbeam itself are not limiting upon the present disclosure. 
       FIG.  7    illustrates a perspective view of a carport  400  according to exemplary aspects of the present disclosure. As can be seen from this figure, the crossbeam is formed of two sections having different, contrary angles. Thus, the crossbeam itself imparts a dual-incline structure to the carport. The PV modules are disposed on the crossbeam via purlins, which are held by clip angle brackets that vary in length in order to allow shingling of the PV modules. As can be appreciated, the dual-incline structure illustrated in  FIG.  7    is merely exemplary, and other dual-incline structures are possible. For example, instead of one row, two rows of PV modules may be inclined at a contrary angle to the other rows of PV modules. 
     The carport  100  includes several advantages include various water management features include shingled PV modules and a dual tilt configuration using a single slope crossbeam. Additionally, the carport  100  significantly reduces cost and makes installation significantly easier. For example, other carports may require either metal decking attached to either the underside or topside of the purlins or a system of additional gutters (e.g., mini gutters) and downspouts to manage the water accumulation that falls on the canopy. Both of these strategies are costly from both a material and installation standpoint. Additionally, other carports rely on the steel fabrication of the crossbeams to create the dual tilt functionality of the canopy. This is also costly from a material and fabrication standpoint. In contrast, the advantages of carport  100  can utilize a simple single slope crossbeam which is cost effective, and then achieve the shingled method and dual tilt functionality by adjusting the clip angle brackets on top of the crossbeam. 
     Having now described embodiments of the disclosed subject matter, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by way of example only. Thus, although particular configurations have been discussed herein, other configurations can also be employed. Numerous modifications and other embodiments (e.g., combinations, rearrangements, etc.) are enabled by the present disclosure and are within the scope of one of ordinary skill in the art and are contemplated as falling within the scope of the disclosed subject matter and any equivalents thereto. Features of the disclosed embodiments can be combined, rearranged, omitted, etc., within the scope of the invention to produce additional embodiments. Furthermore, certain features may sometimes be used to advantage without a corresponding use of other features. Accordingly, Applicant(s) intend(s) to embrace all such alternatives, modifications, equivalents, and variations that are within the spirit and scope of the disclosed subject matter.