Patent Publication Number: US-2016233818-A1

Title: Solar canopy support system

Description:
I. COPYRIGHT NOTICE AND AUTHORIZATION 
     This patent document contains material which is subject to copyright protection. 
     © Copyright 2009. Chevron Energy Solutions. All rights reserved. 
     With respect to this material which is subject to copyright protection. The owner, Chevron Energy Solutions has no objection to the facsimile reproduction by any one of the patent disclosure, as it appears in the Patent and Trademark Office patent files or records of any country, but otherwise reserves all rights whatsoever. 
     II. FIELD OF THE INVENTION 
     This invention relates to system and method for support of a solar canopy. 
     III. BACKGROUND OF THE INVENTION 
     Solar energy is a clean, renewal energy source. Photo-electro voltaic cell technology is increasing rapidly and makes installation of solar collector panels housing the photo-electro voltaic cells more and more economically feasible. Beyond the photo-electro voltaic cell technology itself are the problems of placement and support of the solar collector panels. Large numbers of solar collector panels must be assembled in series to achieve useful power production. In remote areas these may be placed on the ground without interfering with land use. In more developed areas, it is desirable to place the solar collector panels such that the land may also be used for other purposes, e.g., for parking lots, school/office hallways, playgrounds, or sports fields. To achieve this requires an elevated structure to support the solar collector panels. 
     Prior known systems for elevated structures for supporting the solar collector panels are inefficient and overly expensive since they require excessive amounts of materials, particularly steel support elements. Also, known systems take an excessive amount of time to install since welding together of the components is required on site. 
     It is desirable to have a method and system which overcomes the deficiencies of known systems. The instant invention provides such a solution. 
     IV. SUMMARY OF THE INVENTION 
     The invention includes a solar canopy support system comprising: at least two substantially horizontally disposed “C”-channel support beams for supporting at least two “C”-channels, and at least two “C”-channels for supporting at least one solar power array and fixedly attached to the at least two “C”-channel support beams, each “C”-channel having a first end disposed at an upper portion of one “C”-channel support beam and having a second end disposed at an upper portion of another “C”-channel support beam, each “C”-channel comprising a longitudinal axis substantially perpendicular to the longitudinal axis of each “C”-channel support beam. 
     In another embodiment, the invention includes a solar canopy support system comprising: at least two beam support columns, each beam support column having a first end connected to a ground surface and extending substantially vertically along a longitudinal axis from the first end to a second end; a “C”-channel support beam disposed at the second end of each beam support column, the “C”-channel support beam comprising a longitudinal axis within about 0 degrees to about 30 degrees of perpendicular to the longitudinal axis of each beam support column; at least two “C”-channels, each “C”-channel having a first end disposed at an upper portion of one “C”-channel support beam and having a second end disposed at an upper portion of another “C”-channel support beam, each “C”-channel comprising a longitudinal axis substantially perpendicular to the longitudinal axis of each “C”-channel support beam; and at least one solar power array disposed on an upper portion of at least two “C”-channels. 
     In another embodiment the invention includes a method of mounting a solar canopy comprising: affixing at least two beam support columns to a ground surface, each beam support column having a first end connected to the ground surface and extending substantially vertically along a longitudinal axis from the first end to a second end; affixing a “C”-channel support beam to the second end of each beam support column, the “C”-channel support beam comprising a longitudinal axis within about 0 degrees to about 30 degrees of perpendicular to the longitudinal axis of each beam support column; affixing at least two “C”-channels to the at least two “C”-channel support beams, each “C”-channel having a first end disposed at an upper portion of one “C”-channel support beam and having a second end disposed at an upper portion of another “C”-channel support beam, each “C”-channel comprising a longitudinal axis substantially perpendicular to the longitudinal axis of each “C”-channel support beam; and affixing at least one solar power array to an upper portion of the at least two “C”-channels. 
     These and other features and advantages of the present invention will be made more apparent through a consideration of the following detailed description of a preferred embodiment of the invention. In the course of this description, frequent reference will be made to the attached drawings. 
    
    
     
       V. BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top perspective view of one embodiment of the present invention. 
         FIG. 2  is a bottom perspective view of one embodiment of the present invention. 
         FIG. 3  is an exploded perspective view of one embodiment of the present invention. 
         FIG. 4  is a top perspective view of the embodiment of  FIG. 1  showing the support structure. 
         FIG. 5  is a top perspective view in one embodiment of the support bollard and column of the embodiment of  FIG. 1 . 
         FIG. 6  is a top perspective view in one embodiment of the rebar structure of the support bollard of the embodiment of  FIG. 1 . 
         FIG. 7  is a top perspective view in one embodiment of the rebar structure of the support bollard with attached beam support columns column of the embodiment of  FIG. 1 . 
         FIG. 8  shows a bottom perspective view in one embodiment of the solar array support structure of the embodiment of  FIG. 1 . 
         FIGS. 9A and 9B  show a bottom and top perspective view, respectively, in one embodiment of a support assembly of the invention. 
         FIGS. 10A and 10B  show cross-sectional perspective views in one embodiment of a clip assembly for attaching solar panels to “C”-channels, at the end of and in the middle of the solar canopy array, respectively, in the embodiment of  FIG. 1 . 
         FIGS. 11A and 11B  show perspective views of one embodiment of an anchor member for attaching solar panels to “C”-channels in one embodiment of  FIG. 1 . 
         FIGS. 12A and 12B  show perspective views in one embodiment of a head member of a clip assembly for attaching solar panels, at a middle section of and at an end section of the solar canopy array, respectively, to “C”-channels in the embodiment of  FIG. 1 . 
         FIGS. 13A and 13B  show perspective views in one embodiment of a clip assembly for attaching solar panels to “C”-channels, at a middle section of and at an end section of the solar canopy array, respectively, in the embodiment of  FIG. 1 . 
         FIGS. 14A and 14B  show a top perspective view in another embodiment of an anchor member of a clip assembly for attaching solar panels to “C”-channels in the embodiment of  FIG. 1 . 
         FIGS. 15A and 15B  show perspective views in another embodiment of a head member of a clip assembly for attaching solar panels, at a end section of and at a mid-section of the solar canopy array, respectively, to “C”-channels in the embodiment of  FIG. 1 . 
     
    
    
     VI. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       FIG. 1  is a top perspective view of one embodiment of the present invention. Solar canopy support system  100  is shown—both above and below grade level (shown as gray-filled plane). Reinforced concrete bollard  110  rests in the ground and provides the support for beam support column  120 . Beam support column  120  is attached to reinforced concrete bollard  110  by any known method, by embedding a lower portion of beam support column  120  in the concrete of beam support column  120  while still wet or placing it in a suitable hole and then pouring the concrete around it, or by embedding bolts in the reinforced concrete bollard  110  with protruding ends which permit attachment of the beam support column  120  by bolting, which will be described in more detail with reference to  FIGS. 5-7 . 
     The beam support columns  120  supports “C”-channel support beams  130 . The “C”-channel support beam  130  supports at least two “C”-channels  140 . This provides the solar canopy support system for supporting a solar power array  150 . The solar power array is a plurality of solar panels which may be attached to the “C”-channels  140  by any method now known or later developed. 
       FIG. 2  is a bottom perspective view of one embodiment of the present invention. In a preferred embodiment a pair of “C”-channels  140  is affixed to a pair of sub-structure assemblies comprising reinforced concrete bollards  110 , beam support columns  120 , and “C”-channel support beams  130 . Beam support columns  120 , in one embodiment are comprised of steel cylindrical columns, or steel I-beams. “C”-channel support beams  130  in one embodiment are comprised of steel I-beams or 4-sided beams. 
       FIG. 3  is an exploded perspective view of one embodiment of the present invention. 
       FIG. 4  is a top perspective view of the embodiment of  FIG. 1  showing the support structure  400 . In a preferred embodiment, the pairs of “C”-channels  140  are placed in opposite orientations. That is, when looking at end section, one of the pair of “C”-channels  140  shows the letter “C” and the other of the pair of “C”-channels  140  shows a backwards letter “C”. In a preferred embodiment the “C”-channel is constructed of any suitable material, e.g., galvanized steel/sheet metal, and has a gauge from about 11 to about 13. The maximum run lengths of each “C”-channel will depend on, e.g., ground conditions, weight of solar panels, and number of “C”-channels. Typical run, lengths in one embodiment, is from about 11 feet to about 29 feet. 
       FIG. 5  is a top perspective view in one embodiment of the reinforced concrete bollards  110  and beam support columns  120  of the embodiment of  FIG. 1 . In this embodiment the beam support columns  120  are removably attached to the reinforced concrete bollards  110  by bolting the beam support columns  120  to the reinforced concrete bollards  110  via bolts  530  embedded in the concrete of the bollards  110  and flanges  510  integral with the beam support columns  120 . This reduces construction costs since the reinforced concrete bollards  110  installation and the beam support columns  120  can be done in succession, e.g., by different crews and/or on different days in a assembly line fashion. 
       FIG. 6  is a top perspective view in one embodiment of the rebar structure  600  of the reinforced concrete bollards  110  of the embodiment of  FIG. 1 . The helix rebars  620  and vertical rebar  610 , together with threaded bolts  530  are embedded within the concrete of the bollards. They provide structural strength to resist both compression and tension forces. Compression forces exist primarily due to the weight of the overall solar canopy support structure  100  ( FIG. 1 ). Tension forces are significant because of upward pressure caused by wind against the large flat surface made by the solar power array  150  ( FIG. 1 ). Construction of the rebar configuration to provide adequate support will vary, e.g., with soil conditions, slope, and prevailing weather at the site. Exemplary construction factors and, e.g., depth, for different soil conditions are shown in the following table. 
     
       
         
           
               
               
             
               
                   
                   
               
             
            
               
                   
                 SOIL PARAMETERS 
               
               
                   
                 ASSUMED SOIL VALUES 
               
            
           
           
               
               
               
               
               
               
               
            
               
                   
                   
                   
                   
                   
                 ULTIMATE 
                 ULTIMATE 
               
               
                   
                 SOIL 
                   
                   
                 UNIT WEIGHT 
                 PASSIVE 
                 VERTICAL 
               
               
                 CASE 
                 DESCRIPTION 
                 COHESION (PSF) 
                 PHI (DEGREES) 
                 (PCF) 
                 RESISTANCE 
                 CAPACITY Q (kl pr) 
               
               
                   
               
               
                 1 
                 SOFT CLAY 
                 300 
                 0 
                 100 
                   600 psf 
                 0.94 × D × L 
               
               
                 2 
                 FIRM CLAY 
                 700 
                 0 
                 120 
                 1,400 psf 
                  2.2 × D × L 
               
               
                 3 
                 HARD CLAY 
                 1200 
                 0 
                 120 
                 2,400 psf 
                 3.09 × D × L 
               
               
                 4 
                 MEDIUM DENSE 
                 0 
                 34 
                 115 
                   400 psf 
                 0.046 × D × L 2    
               
               
                   
                 SAND 
               
               
                 5 
                 VERY HARD 
                 2000 
                 0 
                 125 
                 2,500 psf 
                 3.46 × D × L 
               
               
                   
                 CLAY 
               
               
                 6 
                 ROCK 
                 3000 
                 35 
                 130 
                 2,500 psf 
                 7.07 × D × L 
               
               
                   
               
            
           
           
               
            
               
                 Soil Parameters are to be verified for each site by a Registered Geotechnical Engineer 
               
            
           
           
               
               
               
            
               
                   
                   
                 FOOTING 
               
               
                   
                 2007 CBC SESMIC PARAMETERS 
                 DEPTH 
               
            
           
           
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
            
               
                   
                   
                 SOIL 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 UP TO 
               
               
                   
                 SITE 
                 PROFILE 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 27′ SPAN 
               
               
                 CASE 
                 CLASS 1   
                 NAME 1   
                 S S  (g) 2   
                 S 1  (g) 3   
                 F S     4     
                 F a     4     
                 F v     5     
                 S MS     6     
                 S M1     7     
                 S DS     8     
                 S D1     9     
                 V 
                 C S   
                 R 
                 “H” 
               
               
                   
               
               
                 1 
                 E 
                 SOFT 
                 2.85 
                 1.30 
                 0.90 
                 0.90 
                 2.40 
                 2.57 
                 3.12 
                 1.71 
                 2.08 
                 1.19W 
                 1.19 
                 2 
                 18′ 
               
               
                   
                   
                 SOIL 
               
               
                 2 
                 E 
                 SOFT 
                 2.85 
                 1.30 
                 0.90 
                 0.90 
                 2.40 
                 2.57 
                 3.12 
                 1.71 
                 2.08 
                 1.19W 
                 1.19 
                 2 
                 12′ 
               
               
                   
                   
                 SOIL 
               
               
                 3 
                 D 
                 STIFF 
                 2.85 
                 1.30 
                 1.00 
                 1.00 
                 1.50 
                 2.85 
                 1.95 
                 1.90 
                 1.30 
                 1.19W 
                 1.19 
                 2 
                 10′ 
               
               
                   
                   
                 SOIL 
               
               
                 4 
                 D 
                 STIFF 
                 2.85 
                 1.30 
                 1.00 
                 1.00 
                 1.50 
                 2.85 
                 1.95 
                 1.90 
                 1.30 
                 1.19W 
                 1.19 
                 2 
                 18′ 
               
               
                   
                   
                 SOIL 
               
               
                 5 
                 C 
                 VERY 
                 2.85 
                 1.30 
                 1.00 
                 1.00 
                 1.30 
                 2.85 
                 1.69 
                 1.71 
                 2.08 
                 1.19W 
                 1.19 
                 2 
                 10′ 
               
               
                   
                   
                 DENSE 
               
               
                   
                   
                 SOIL/ 
               
               
                   
                   
                 SOFT 
               
               
                   
                   
                 ROCK 
               
               
                 6 
                 B 
                 ROCK 
                 2.85 
                 1.30 
                 1.00 
                 1.00 
                 1.00 
                 2.85 
                 1.30 
                 1.90 
                 0.87 
                 1.19W 
                 1.19 
                 2 
                 10′ 
               
               
                   
               
            
           
           
               
            
               
                   1 Refers to Section 1613A.5.2, Table 1613A.5.2 for selection criteria for Site Class and Soil Profile Name of the 2007 CBC. 
               
               
                   2 Based on FIG. 22-3, maximum considered earthquake ground motion for Region 1 or 0.2 sec; Spectral Response acceleration 
               
               
                 (5% of critical damping), Site Class B, pages 214 and 215 of ASCE −05. 
               
               
                   3 Based on FIG. 22-4. Maximum considered earthquake ground motion for region 1 of 1.0 sec spectral response acceleration 
               
               
                 (5% of critical damping), Site Class B, pages 216 and 217 of ASCE 7-05. 
               
               
                   4 Based on Section 1613A.5.3, Table 1613A.5.3(1) of the 2007 CBC. 
               
               
                   5 Based on Section 1613A.5.3, Table 1613A.5.3(2) of the 2007 CBC. 
               
               
                   6 Based on Section 1613A.5.3, Equation 16A-37 of the 2007 CBC. 
               
               
                   7 Based on Section 1613A.5.3, Equation 16A-38 of the 2007 CBC. 
               
               
                   8 Based on Section 1613A.5.4, Equation 16A-39 of the 2007 CBC. 
               
               
                   9 Based on Section 1613A.5.4, Equation 16A-40 of the 2007 CBC. 
               
            
           
         
       
     
       FIG. 7  is a top perspective view in one embodiment of the rebar structure of the reinforced concrete bollards  110  with attached beam support columns  120  of the embodiment of  FIG. 1 . In a preferred embodiment a pair of flanges  710  extends upward from, and integral with, the top portion of the beam support columns  120 . Flanges  710  provide a channel for receiving the “C”-channel support beams  130 . The “C”-channel support beams  130  are preferably fixed by bolts through the flanges  710  into the “C”-channel support beams  130  (pre-drilled or cast holes in flanges  710  not shown). This reduces construction time compared, e.g., to welding. 
       FIG. 8  shows a bottom perspective view in one embodiment of the solar array support structure of the embodiment of  FIG. 1 . A plurality of pairs of oppositely oriented “C”-channels  140  supports a plurality of solar panels, i.e., solar power array  150 . 
       FIGS. 9A and 9B  show a bottom and top perspective view, respectively, in one embodiment of a support assembly of the invention. “C”-channel support beam  130  supports at least two “C”-channels  140 . “C”-channels  140  support a solar power array  150 . 
       FIGS. 10A and 10B  show cross-sectional perspective views in one embodiment of a clip assembly for attaching solar panels to “C”-channels, at the end of and in the middle of the solar canopy array, respectively, in the embodiment of  FIG. 1 .  FIG. 10B  depicts a cross-section of “C”-channels  140 . A clip assembly comprising anchor member  1010  and head member  1020  sandwich edge portions of two solar power panels, i.e., the individual solar panels which make up solar power array  150 .  FIG. 10A  shows a clip assembly sandwiching an edge portion of a single solar panel. This would occur at each end of a solar power array  150 . 
     In both  FIGS. 10A and 10B , anchor member  1010  is supported by “C”-channel  140 . In a preferable embodiment anchor member  1010  is removably attached to “C”-channel  140 , e.g., by a screw or bolt and nut (not shown). 
       FIGS. 11A and 11B  show perspective views of one embodiment of an anchor member for attaching solar panels to “C”-channels in one embodiment of  FIG. 1 . With reference to  FIGS. 10A, 10B, 11A, and 11B , a planar section  1120  of the anchor member rests on the more horizontally oriented portion of the “C”-channel  140 . A riser section  1130  of the anchor member rests against the more vertically oriented portion of the “C”-channel  140 . An angled kick section  1140  rests against the more angled portion of the “C”-channel  140 . Angled hook section  1150  of “C”-channel  140  hooks around the edge portion of the more angled portion of the “C”-channel  140 . The angled hook section  1150  together with riser section  1130  secures the anchor member from movement perpendicularly to the longitudinal axis of “C”-channel  140 . A screw or nut and bolt are preferably installed through both the anchor member and the “C”-channel  140  to prevent any movement along the longitudinal axis of the “C”-channel  140 . 
       FIGS. 12A and 12B  show perspective views in one embodiment of a head member of a clip assembly for attaching solar panels, at a middle section of and at an end section of the solar canopy array, respectively, to “C”-channels in the embodiment of  FIG. 1 . The head member is removably attached, e.g., via bolt or screws to the anchor member, which results in sandwiching the solar panels in between the head member ( 1020  or  1030 ) and anchor members  1140  of the clip assembly. 
       FIGS. 13A and 13B  show perspective views in one preferred embodiment of a clip assembly for attaching solar panels to “C”-channels, at a middle section of and at an end section of the solar canopy array, respectively, in the embodiment of  FIG. 1 .  FIGS. 14A and 14B  show a top perspective view in another embodiment of an anchor member of a clip assembly for attaching solar panels to “C”-channels in the embodiment of  FIG. 1 . With reference to  FIGS. 13A, 13B, 14A, and 14B , a planar section  1420  of the anchor member rests on the more horizontally oriented portion of the “C”-channel  140 . A riser section  1420  of the anchor member rests against the more vertically oriented portion of the “C”-channel  140 . An angled kick section  1430  rests against the more angled portion of the “C”-channel  140 . Angled hook section  1440  of “C”-channel  140  hooks around the edge portion of the more angled portion of the “C”-channel  140 . 
     The angled hook section  1440  together with riser section  1420  secures the anchor member from movement perpendicularly to the longitudinal axis of the “C”-channel  140 . A screw or nut and bolt are preferably installed through both the anchor member and the “C”-channel  140  to prevent any movement along the longitudinal axis of the “C”-channel  140 . In a preferable embodiment a bottom portion of tab sections  1450  are attached to and substantially perpendicular to planar section  1420 . In a preferable embodiment tab section  1450  are integral with planar section  1420 . The two tab sections  1450  along the lateral axis of the anchor member  1310  are for providing proper spacing between the solar panels, i.e., to allow joining of the head member ( 1330  or  1320 ) and anchor member  1310 . The two tab sections  1450  along the longitudinal axis of the anchor member  1310  are for aligning the solar panels by engaging in recesses (not shown) in the bottom of the solar panels as they rest on the “C”-channels  140 . 
       FIGS. 15A and 15B  show perspective views in another embodiment of a head member  1530  or  1520  of a clip assembly for attaching solar panels, at an end section of and at a mid-section of the solar canopy array, respectively, to “C”-channels in the embodiment of  FIG. 1 . 
     The head member  1530  or  1520  is for clamping two solar panels between a bottom portion of the head member  1530  or  1520  and a top portion of the anchor member  1400 . The head member is an elongated form including a plurality of sections. The sections include two substantially vertical planar riser sections  1520 , each having a top end and a bottom end and being substantially parallel to each other. There is also a substantially horizontal joiner section  1530 , for joining the two riser sections, having a left end and a right end, the left end of the joiner section adjoining the bottom end of one riser section, and the right end of the joiner section adjoining the bottom end of the other riser section, thereby forming a U-like assembly. 
     Also, there are two substantially horizontal planar clamping sections  1510 , for clamping solar panels, each having a left end and a right end, the left end of one clamping section adjoining the top end of one riser section  1520 , and the right end of the other clamping section adjoining the top end of the other riser section  1520 ; thereby forming a U-like assembly with flanges extending from the two top portions of the U-like assembly. 
     The head member  1530  or  1520  is removably fixed to the anchor member  1400 , wherein a bottom portion of the solar power arrays rests on a top portion of the planar step section  1410  of the anchor member  1400 , and a bottom portion of the planar clamping sections  1510  of the head member  1530  or  1520  rests on a top portion of the solar power arrays  150  ( FIG. 1 ), thereby clamping the two solar power arrays to the “C”-channel  140  ( FIG. 1 ). 
     The head member  1520  ( FIG. 15B ) or  1530  ( FIG. 15A ) is removably attached, e.g., via bolt or screws to the anchor member through, preferably threaded, hole  1540  in head member  1530  and  1520  and, preferably threaded, hole  1460  in anchor member  1400 , thus sandwiching the solar panels in between the head member ( 1520  or  1530 ) and anchor members  1400  ( FIGS. 14A and 14B ) of the clip assembly. 
     Anchor member  1400 , in one embodiment is comprised of 14 to about 18 gauge sheet metal. Head members  1520  or  1530 , in one embodiment are comprised of 12 to about 14 gauge sheet metal. In addition to sheet metal, either the head member or anchor member may be fabricated by other known materials and fabrication methods such as a cast metal, e.g., cast aluminum. Typical dimensions of the anchor member are from about 3.0″ to about 4.0″ wide, from about 3.5″ to about 4.5″ long, and from about 1″ to about 3″ tall. Typical dimensions of the head member are from about 1″ to about 3″ wide, from about 2″ to about 3″ long, and from about 1″ to about 3″ tall. These dimensions are not meant to limit the invention and the head member and anchor member in various embodiments may be adjusted to fit a wide variety of “C”-channels and solar panels. 
     Other embodiments of the present invention and its individual components will become readily apparent to those skilled in the art from the foregoing detailed description. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the spirit and the scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive. It is therefore not intended that the invention be limited except as indicated by the appended claims.