Patent Description:
In order to facilitate electricity generation, solar photovoltaic (PV) modules can be mounted on various structures such as rooftops, fixed tilt ground mount structures, and active tracking structures that track the location of the sun. PV modules can also be mounted on carports in parking lots or on the tops of parking garages. Further, PV modules can be mounted on structures for pedestrian walkways, bus stops, outdoor train stations, or bike lanes. Such PV modules may be monofacial PV modules that are configured to generate electricity from received light on one side (i.e., the top) of the module or bifacial PV modules that are configured to generate electricity from received light on both sides (i.e., the top and bottom) of the module.

Examples of prior art can be found in, e.g., <CIT>, which discloses methods and apparatus for assembling solar canopy subassemblies, and solar canopies formed with such solar canopy subassemblies.

In this context, the present invention provides a system according to independent claim <NUM> and a method according to independent claim <NUM>. Further embodiments of the claimed invention are described in the dependent claims.

This disclosure includes references to "one embodiment" or "an embodiment. " The appearances of the phrases "in one embodiment" or "in an embodiment" do not necessarily refer to the same embodiment. Particular features, structures, or characteristics may be combined in any suitable manner consistent with this disclosure.

Within this disclosure, different entities (which may variously be referred to as "units," "circuits," other components, etc.) may be described or claimed as "configured" to perform one or more tasks or operations. This formulation-[entity] configured to [perform one or more tasks]-is used herein to refer to structure (i.e., something physical, such as an electronic circuit). More specifically, this formulation is used to indicate that this structure is arranged to perform the one or more tasks during operation. A structure can be said to be "configured to" perform some task even if the structure is not currently being operated. Thus, an entity described or recited as "configured to" perform some task refers to something physical, such as a structure that when constructed implements the task (e.g., a clamp configured to couple to a crossbeam). The term "configured to" is not intended to mean "configurable to.

Reciting in the appended claims that a structure is "configured to" perform one or more tasks is expressly intended not to invoke <NUM> U. § <NUM>(f) for that claim element. Accordingly, none of the claims in this application as filed are intended to be interpreted as having means-plus-function elements. Should Applicant wish to invoke Section <NUM>(f) during prosecution, it will recite claim elements using the "means for" [performing a function] construct.

As used herein, the terms "first," "second," etc. are used as labels for nouns that they precede, and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.) unless specifically stated. For example, references to "first" and "second" purlins would not imply an ordering between the two unless otherwise stated.

As used herein, the term "based on" is used to describe one or more factors that affect a determination. This term does not foreclose the possibility that additional factors may affect a determination. That is, a determination may be solely based on specified factors or based on the specified factors as well as other, unspecified factors. Consider the phrase "determine A based on B. " This phrase specifies that B is a factor is used to determine A or that affects the determination of A. This phrase does not foreclose that the determination of A may also be based on some other factor, such as C. This phrase is also intended to cover an embodiment in which A is determined based solely on B. As used herein, the phrase "based on" is thus synonymous with the phrase "based at least in part on.

Mounting structures for solar photovoltaic (PV) modules allow PV modules to be installed in places such as parking lots, parking garages, bus stops, train stations, pedestrian walkways, and bike lanes. Such mounting structures are configured to secure the PV modules and to elevate them several feet in the air so other activity can occur underneath. For example, a mounting structure might secure PV modules and provide cover for cars parked or people waiting for a bus underneath. Elevated PV modules, being relatively high off the ground, are also less likely to be shaded to the extent that PV modules mounted lower to the ground might be.

In the past, mounting structures were generally used to secure monofacial PV modules that are configured to generate electricity from received light on one side (i.e., the top) of the module. Increasingly, however, there has been interest in bifacial PV modules that are able to generate more electricity (in certain conditions) because they can generate electricity from received light on both sides (i.e., the top and bottom) of the module. Depending on the configuration of the modules, monofacial PV modules and bifacial PV modules may not be mounted in the same way. In some instances, monofacial PV modules may be mounted in a landscape orientation and bifacial PV modules may be mounted in a portrait orientation for any of a number of reasons. For example, monofacial PV modules may be internally wired such that landscape mounting will generate more electricity. In contrast, bifacial PV modules may be wired to be mounted in a portrait orientation. Customers might also have an aesthetic preference for the mounting orientation. For example, if a customer has a large parking lot that already has mounting structures with PV modules installed in a landscape orientation, that customer might demand that additional mounting structure be installed with PV modules oriented the same way to match.

Many PV modules have opaque (typically metal) frames around the encapsuled solar PV cells. Such opaque frames absorb light or reflect it back into space. Because bifacial PV modules are able to generate electricity on both sides of the panel, increasing the amount of light that passes through the mounting structure to be potentially reflected back towards the backside of the bifacial PV modules means that additional electricity may be generated. Additionally, the conditions at a mounting surface might not be uniformly flat or conditions on the ground might differ from a site plan that is provided to a contractor building a mounting structure for PV modules. Further, PV modules have a finite lifespan of about <NUM> to <NUM> years under normal circumstances, and can also be damaged by falling trees or storms, and therefore might need to be replaced before the end of the useful life of the mounting structure beneath. Moreover, a customer might initially install a mounting structure with monofacial PV modules and then later upgrade to bifacial PV modules.

Mounting structures are typically made of metal such as structural steel and steel-reinforced concrete. Because PV modules mounted on a mounting structure are high voltage electrical equipment mounted on metal high in the air, there is a risk that voltage will build up on the mounting structure and result in potentially dangerous discharge. Accordingly, mounting structures employ grounding devices to establish grounding paths that flows from the frames of the PV modules, through the mounting structure, and into the ground via grounding stakes. Such grounding devices are typically installed late in the construction of the mounting structure by skilled electricians.

Accordingly, the inventors identified various issues with prior mounting structures that include, but are not limited to: (<NUM>) a mounting structure should be able to accommodate PV modules installed in landscape or portrait orientation, (<NUM>) a mounting structure should be designed such that either monofacial PV modules or bifacial PV modules may be installed on the mounting structure, (<NUM>) shading should be reduced and reflection of light should be increased to enable more light to be collected by the backside of bifacial PV modules, (<NUM>) the mounting structure should have sufficient adaptability that allows for irregularities at the construction site to be accommodated, (<NUM>) PV modules should be able to be easily replaced after installation on the mounting structure, and (<NUM>) grounding paths should be able to be established as the mounting structure is being built from the ground up by construction personnel and not after the PV modules are installed by more costly electricians. In order to address these issues, the inventors propose a novel PV module mounting structure that allows for installation of PV modules in landscape or portrait orientation and accommodates site irregularities, reduces shading and increases reflected light on the backside of PV modules, allows PV modules to be easily removed from the mounting structure, and establishes grounding paths from the ground up during construction.

<FIG> is a bottom perspective view of a dual-tilt mounting structure <NUM> with photovoltaic (PV) modules <NUM> mounted in portrait orientation <NUM> in accordance with various embodiments. Mounting structure <NUM> is installed over a mounting surface <NUM>. A plurality of column foundations <NUM> extend from the mounting surface <NUM> (and in embodiments, extend below into mounting surface <NUM>). A plurality of columns <NUM> are coupled to the column foundations <NUM>. A plurality of crossbeams <NUM> are coupled to the columns <NUM>. A plurality of purlins <NUM> are coupled to the crossbeams <NUM>. In the embodiment shown in <FIG>, a first set of purlins <NUM> are coupled to a first end of crossbeams <NUM> on the left end of crossbeams <NUM>. A second set of purlins <NUM> are coupled to a second, opposite end of crossbeams <NUM> on the right end of crossbeams <NUM>. A first plurality of PV module support rails <NUM> are coupled to the purlins <NUM>. A second plurality of PV module support rails <NUM> are coupled to the first plurality of PV module support rails <NUM>. PV modules <NUM> are coupled to the PV module support rails <NUM>, <NUM> in a first grid <NUM> and a second grid <NUM>. PV module <NUM> are installed on dual-tilt mounting structure <NUM> in a portrait orientation <NUM>.

In the embodiment shown in <FIG>, dual-tilt mounting structure <NUM> extends along three axes. A first axis (the z-axis shown in <FIG> and <FIG>) extends upward from mounting surface <NUM>. Column foundation <NUM> and columns <NUM> lay at least in part along the first axis. A second axis (the x-axis shown in <FIG> and <FIG>) extends orthogonally from the second axis. Crossbeams <NUM> and PV module rails <NUM> lay at least in part along the second axis. A third axis (the y-axis shown in <FIG> and <FIG>) extends orthogonally from the second and third axes. Purlins <NUM> lay at least in part along the third axis.

Mounting surface <NUM> may be any of a number of surfaces onto which a mounting structure (e.g., mounting structure <NUM>) is installed. In some embodiments, mounting surface <NUM> is a parking lot on the ground or a top level of a parking garage. In such embodiments, dual-tilt mounting structure <NUM> is configured to allow cars and trucks to be installed underneath dual-tilt mounting structure <NUM>. In such embodiments, dual-tilt mounting structure <NUM> may be referred to herein as a "carport. " In other embodiments, however, dual-tilt mounting structure <NUM> (or any mounting structure discussed herein such as mounting structures <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>) are not limited to embodiments in which the mounting structure is a carport installed over a parking lot. In various embodiments, mounting surface <NUM> is a street or a sidewalk and the mounting surface is useable as cover for a pedestrian walkway, bus stop, or bike lane. Alternatively, mounting surface <NUM> may be a train platform and the mounting surface is usable as a cover for a train platform.

Column foundations <NUM> are steel-reenforced concrete pillars that extend into mounting surface <NUM> in various embodiments. In some embodiments, however, column foundation <NUM> may be made of other materials and/or may be secured to mounting surface <NUM> by fasteners such as bolts (not shown). Columns <NUM> are coupled to a top surface of column foundations <NUM> by a plurality of fasteners (e.g., fasteners <NUM> shown in <FIG>). In various embodiments, no column foundation <NUM> is present and column <NUM> is directly fastened to mounting surface <NUM> (e.g., embodiments in which mounting structure is smaller than the embodiments shown in <FIG> and is not used as a carport). In various embodiments, column <NUM> is an I-beam, a square beam (shown in <FIG>), or a tube or other suitable shape. In various embodiments, column <NUM> is made of metal (such as stainless steel) or an electrically conductive composite material. In various embodiments, column <NUM> includes a first flat plate on the bottom with openings configured to accept fasteners to couple the column <NUM> to a column foundation <NUM> (or mounting surface <NUM>) and a second flat plate on the top with openings configured to accept fasteners to couple the column <NUM> to crossbeam <NUM>. In other embodiments, the top of column <NUM> is saddle-shaped and partially surrounds crossbeam <NUM>. The coupling of column <NUM> to crossbeam <NUM> is discussed in additional detail in reference to <FIG>.

Crossbeams <NUM> are coupled to the top ends of columns <NUM>. In various embodiments, crossbeams <NUM> are I-beams, although other suitable shapes may be used (e.g., a square beam). A first set of purlins <NUM> is coupled to first end of crossbeams <NUM> and a second set of purlins <NUM> is coupled to second end of crossbeams <NUM>. In various embodiments, crossbeam <NUM> is made of metal (such as stainless steel) or an electrically conductive composite material. The coupling of crossbeam <NUM> to purlins <NUM> is discussed in additional detail in reference to <FIG>.

In various embodiments, purlins <NUM> are coupled to crossbeams <NUM> at the lateral sides of crossbeams <NUM> as shown in <FIG> (e.g., fasteners <NUM> and brackets <NUM> as discussed in additional detail in reference to <FIG>). In various other embodiments, however, purlins <NUM> could instead rest on top of crossbeams <NUM> and be coupled to the top of crossbeams <NUM> by fasteners that extend downward (i.e., along the first axis) through purlins <NUM> and into crossbeams <NUM>. In various embodiments, purlins <NUM> are I-beams (as shown in <FIG> and <FIG>) but in other embodiments, purlins <NUM> may be T-beams or square beams. In various embodiments, purlins <NUM> define a top flange upon which PV module support rails <NUM> lie and a bottom surface that faces mounting surface <NUM>. In various embodiments, bottom surface defines a flange (e.g., if purlin <NUM> is an I-beam). PV module support rails <NUM> are coupled to purlins <NUM> (e.g., by clamps <NUM> shown in <FIG> and <FIG>). The coupling of purlins <NUM> to PV module support rails <NUM> is discussed in additional detail in reference to <FIG>, <FIG>, and <FIG>.

In the dual-tilt embodiment shown in <FIG> (and in <FIG>) a first set of PV module support rails <NUM> are coupled to purlins <NUM> and a second set of PV module support rails <NUM> are coupled to the first set of PV module support rails <NUM>. In the embodiment shown in <FIG>, the PV module support rails <NUM> and <NUM> are C-shaped beams that define a top surface, an opposing bottom surface, and a middle surface disposed between the top surface and the bottom surface. In various embodiments, PV module support rails <NUM>, <NUM> are made of metal (such as stainless steel) or an electrically conductive composite material. As discussed in further detail in reference to <FIG> and <FIG>, the bottom surface of PV module support rails <NUM> rests on purlins <NUM>. In various embodiments, a clamp (e.g., clamp <NUM> shown in <FIG> and <FIG>) is used to couple the middle surface of PV module support rails <NUM> to the purlins <NUM>. In various embodiments, PV module support rails <NUM> have a similar (or identical) cross-section to PV module support rails <NUM>, but instead of resting on purlins <NUM>, PV module support rails <NUM> are coupled to PV module support rails <NUM> (e.g., by bracket <NUM> shown in <FIG>) and are cantilevered over mounting surface <NUM>. PV modules <NUM> are coupled to PV module support rails <NUM> and PV module support rails <NUM> (e.g., by fasteners <NUM> shown in <FIG> and <FIG>). In various embodiments, blocking rails <NUM> are coupled to the ends of PV module support rails <NUM>, <NUM> to provide lateral support for PV module support rails <NUM>, <NUM>.

The arrangement of PV module support rails <NUM> (and in dual-tilt embodiments the PV module support rails <NUM>) relative to the purlins <NUM> varies depending on the size of the PV modules <NUM> and the orientation (i.e., landscape orientation <NUM> shown in <FIG> versus portrait orientation <NUM>). As discussed in further detail in reference to <FIG> and <FIG>, the spacing of PV module support rails <NUM>, <NUM> relative to each other may differ according to the size and orientation of PV modules <NUM>. In various embodiments in which PV modules <NUM> are installed in portrait orientation <NUM>, PV module support rails <NUM>, <NUM> face the same direction. In various embodiments in which PV modules <NUM> are installed in landscape orientation, however, pairs of PV module support rails <NUM>, <NUM> may face each other (e.g., PV module support rails 112A and 112B shown in <FIG>). In various embodiments, blocking rails <NUM> are disposed between every PV module support rail <NUM>, <NUM>, but in other embodiments blocking rails are only disposed between opposing sets of PV module support rails <NUM>, <NUM> (e.g., as shown in <FIG>).

In the embodiment shown in <FIG>, PV modules <NUM> are disposed in portrait orientation <NUM> in a first grid <NUM> having columns extending along the second axis and rows extending along the third axis. As shown in additional detail in <FIG> and <FIG>, adjacent columns of PV modules <NUM> in first grid <NUM> share a PV module support rail <NUM> between them. Thus, if a first set of PV modules <NUM> are in a first column and second set of PV modules <NUM> are in an adjacent second column, they are secured to a top surface of a same PV module support rail <NUM> disposed between the first column and the second column. Similarly, PV modules <NUM> in dual-tilt embodiments like dual-tilt mounting structure <NUM> are disposed in portrait orientation <NUM> in a second grid <NUM> having columns extending along the second axis and rows extending along the third axis. In various embodiments, adjacent columns of PV modules <NUM> in second grid <NUM> share a PV module support rail <NUM> between them in the same fashion as first grid <NUM>. In various embodiments, the columns of first grid <NUM> and second grid <NUM> are aligned and the rows of the first grid and the second grid are parallel. As shown in <FIG>, first grid <NUM> and second grid <NUM> are disposed on planes that intersect. In various embodiments, first grid <NUM> lies at between a <NUM>- and <NUM>-degree angle relative to mounting surface <NUM> and second grid <NUM> lies at between a -<NUM>- and -<NUM>-degree angle relative to mounting surface <NUM>.

PV modules <NUM> may be any of a number of rectangular-shaped PV modules. In various embodiments, PV modules <NUM> are surrounded by frames made of metal (e.g., steel, aluminum, etc.), composite, or plastic. In such embodiments, PV modules <NUM> are secured to PV module support rails <NUM> by fasteners that pass through the frames of PV modules <NUM> and PV module support rails <NUM> (e.g., as shown in <FIG> and <FIG>) or by clamps that couple to the top side of PV modules <NUM> and are secured to PV module support rails <NUM>. In various embodiments, such frames are opaque. In some embodiments, however, PV modules <NUM> are frameless (e.g., frameless bifacial PV modules) and are mounted to PV module support rails <NUM> by adhesives or clamps that couple to the top side of PV modules <NUM> and are secured to PV module support rails <NUM>. As discussed herein, PV modules <NUM> may be mounted in portrait orientation <NUM> (i.e., the long side of the PV module <NUM> is parallel to PV module support rails <NUM> and crossbeams <NUM>) or in landscape orientation <NUM> (i.e., the long side of the PV module <NUM> is perpendicular to PV module support rails <NUM> as shown in <FIG>.

In various embodiments, PV modules <NUM> are monofacial modules with photovoltaic cells (e.g., monocrystalline silicon photovoltaic cells, polycrystalline silicon photovoltaic cells) arranged on an opaque backing sheet and surrounded by an encapsulant. The photovoltaic cells in a monofacial PV module <NUM> may be front-contact photovoltaic cells arranged individually or in a shingled arrangement in which adjacent photovoltaic cells overlap. Alternatively, photovoltaic cells in a monofacial PV module <NUM> may be interdigitated back contact photovoltaic cells. In other embodiments, PV modules <NUM> are monofacial thin-film photovoltaic modules. In other embodiments, PV modules <NUM> are bifacial modules with photovoltaic cells (e.g., monocrystalline silicon photovoltaic cells, polycrystalline silicon photovoltaic cells) arranged on a transparent backing sheet and surrounded by an encapsulant. In such embodiments, the photovoltaic cells of a bifacial PV module <NUM> are configured to generate electricity that is received from the sun directly on the top surface of the PV module <NUM> that faces the sun and indirectly (i.e., reflected light, ambient light) on the bottom surface of the PV module that faces mounting surface <NUM>. It will be understood that light that is received by a solar cell of a PV module <NUM> causes electricity to be generated, light that passes through a clear encapsulant continues on towards mounting surface <NUM>, and light that impacts an opaque frame or encapsulant is absorbed or reflected.

Thus, in embodiments such as <FIG>, PV modules <NUM> are disposed in portrait orientation <NUM> with the long edges of the frames of PV modules <NUM> lying on top of PV module support rails <NUM> and <NUM>. In embodiments in which PV modules <NUM> are bifacial, this means that fewer shadows are cast on the back side of the bifacial PV modules <NUM> by structural steel such as PV module support rails <NUM> and <NUM>, which would prevent a certain amount of reflected or ambident light from reaching the back side of the bifacial PV modules <NUM>. For example, if a bifacial PV module <NUM> was arranged in landscape orientation <NUM> (e.g., as shown in <FIG> and <FIG> for example) any light reflected from the mounting surface <NUM> onto the bottom surface of the PV module support rails <NUM> and <NUM> that intersect with the long edges of the frames of PV modules <NUM> would not reach the backside of the solar cells of the PV modules <NUM>.

<FIG> is a bottom perspective view of a dual-tilt mounting structure <NUM> with PV modules <NUM> mounted in landscape orientation <NUM> in accordance with various embodiments. In various embodiments, the mounting surface <NUM>, column foundations <NUM>, columns <NUM>, crossbeams <NUM>, and purlins <NUM> are identical to those described above in reference to <FIG>. Indeed, in various embodiments, a dual-tilt mounting structure <NUM> may be reconfigured to become a dual-tilt mounting structure <NUM> shown in <FIG> by reconfiguring the arrangement of PV module support rails <NUM> and <NUM>, blocking rails <NUM>, and PV modules <NUM>. In various embodiments, the PV modules <NUM> installed on dual-tilt mounting structure <NUM> are installed in landscape orientation <NUM>. In various embodiments, such PV modules <NUM> are monofacial PV modules. Accordingly, in various instances the monofacial PV modules <NUM> may be removed from dual-tilt mounting structure <NUM>, the PV module support rails <NUM> and <NUM> and blocking rails <NUM> repositioned, and bifacial PV modules <NUM> installed in portrait orientation <NUM>. Accordingly, the same column foundations <NUM>, columns <NUM>, crossbeams <NUM>, purlins <NUM>, PV module support rails <NUM> and <NUM>, blocking rails <NUM>, and PV modules <NUM> are usable to construct a dual-tilt mounting structure <NUM> with PV modules <NUM> mounted in landscape orientation <NUM> or a dual-tilt mounting structure <NUM> with PV modules <NUM> mounted in portrait orientation <NUM>.

As discussed in additional detail in reference to <FIG> and <FIG>, in various embodiments, the same PV module support rails <NUM> and <NUM> and blocking rails <NUM> may be used to construct dual-tilt mounting structure <NUM>. In various embodiments, however, rather than all of the PV module support rails <NUM> and <NUM> facing the same direction, pairs of PV module support rails <NUM> and <NUM> may face each other. Additionally, blocking rails <NUM> may be installed between pair of facing PV module support rails <NUM> and <NUM> and not between PV module support rails <NUM> and <NUM> that face away from each other. This configuration can be seen more clearly in <FIG> below.

In contrast to portrait orientation <NUM> in which the long sides of the frames of the PV modules <NUM> lay on top of PV module support rails <NUM> and <NUM>, in landscape orientation <NUM>, the long sides of the frames of PV modules <NUM> are perpendicular to PV module support rails <NUM> and <NUM>. As with first grid <NUM> and second grid <NUM> of <FIG>, the landscape-oriented PV module <NUM> in <FIG> are arranged in a first grid <NUM> and a second grid <NUM> in which columns for first grid <NUM> are aligned with columns of second grid <NUM> and first grid <NUM> and second grid <NUM> define planes that intersect.

As shown in <FIG>, landscape orientation <NUM> results in shadows being cast on the backside of the PV modules <NUM>, but if the PV modules <NUM> are monofacial, this will not affect power generation. Moreover, depending on the shading conditions at a particular site (e.g., due to trees or tall buildings) a landscape orientation <NUM> may result in more power generation than portrait orientation <NUM>, even for bifacial PV modules <NUM>. Accordingly, the mounting structures described herein allow for flexibility in both design and construction of the mounting structure without having to use different sets of parts.

<FIG> are cutaway side views of various embodiments of mounting structures in accordance with various embodiments. <FIG> are cutaway side views of embodiments of long span mounting structures in accordance with various embodiments. In various embodiments, each of the mounting structure depicted in <FIG> and <FIG> are constructed over a mounting surface <NUM> and include arrangements of column foundation <NUM> and columns <NUM> as described above.

Referring individually to <FIG>, a side view of a dual-tilt mounting structure <NUM> is shown (although in various embodiments a side view of dual-tilt mounting structure <NUM> would also look like <FIG>). In addition to mounting surface <NUM>, column foundation <NUM>, columns <NUM>, crossbeams <NUM>, purlins <NUM>, and PV module support rails <NUM> and <NUM> discussed above in reference to <FIG> and <FIG>, <FIG> identifies various water management features. A gutter <NUM> is disposed beneath the junction of PV module support rails <NUM> and <NUM> and collects water that flows across first grid <NUM> and second grid <NUM>. Gutter <NUM> drains through pipe <NUM> and into a downspout <NUM> in column <NUM>. In various embodiments, downspout <NUM> discharges water onto mounting surface <NUM> or into a cistern installed on mounting surface <NUM> (not shown), but in other embodiments, downspout <NUM> drains to pipes beneath mounting surface <NUM> (e.g., to a drainage system of a parking garage, to a rainwater sewer, to an underground cistern). As shown in <FIG>, column foundation <NUM> is partially cut away, showing fasteners <NUM> that are buried in column foundation <NUM> and are received by corresponding openings on a flat bottom portion of column <NUM>. Nuts are used to secure column <NUM> to fasteners <NUM> in various embodiments.

<FIG> also includes various dimensions A-E. As shown in <FIG>, the longest dimension is D, the span of the top of mounting structure <NUM>. In various embodiments, D is <NUM> feet, <NUM> inches (approximately <NUM> meters). Dimension E, the extent to which column foundations <NUM> extend above mounting surface <NUM> is between <NUM> feet (approximately <NUM> meters) and <NUM> feet (approximately <NUM> meters). Dimensions B and C are based on Dimension A, which is the minimum clearance under mounting structure <NUM>. In some embodiments, Dimension A is <NUM> feet (approximately <NUM> meter) and Dimension B is <NUM> feet, <NUM> inches (approximately <NUM> meters) and Dimension C is <NUM> feet, <NUM> inches (approximately <NUM> meters). In other embodiments, Dimension A is <NUM> feet, <NUM> inches (approximately <NUM> meters) and Dimension B is <NUM> feet, <NUM> inches (approximately <NUM> meters) and Dimension C is <NUM> feet, <NUM> inches (approximately <NUM> meters). It will be understood, however, that these Dimensions A-E may vary from these numbers (e.g., by <NUM>%, <NUM>%, etc.) and may be changed based on customer requirements (e.g., Dimension A defines a higher minimum clearance for larger vehicles). Further, the mounting structure <NUM> shown in <FIG> is a carport, and the Dimensions A-E may be reduced for applications requiring shorter spans and/or smaller minimum clearances.

Referring now to <FIG>, a single-tilt mounting structure <NUM> is shown. In the single-tilt mounting structure <NUM>, no PV module support rails <NUM> are present, and PV module support rails <NUM> are longer. Additionally, the water management features of <FIG> are not present. In <FIG>, PV modules <NUM> are arranged in a single grid <NUM>. <FIG> also includes various dimensions A-E. As shown in <FIG>, the longest dimension is D, the span of the top of mounting structure <NUM>. In various embodiments, D is <NUM> feet, <NUM> inches (approximately <NUM> meters). Dimension E, the extent to which column foundations <NUM> extend above mounting surface <NUM> is between <NUM> feet (approximately <NUM> meters) and <NUM> feet (approximately <NUM> meters). Dimensions B and C are based on Dimension A, which is the minimum clearance under mounting structure <NUM>. In some embodiments, Dimension A is <NUM> feet (approximately <NUM> meter) and Dimension B is <NUM> feet, <NUM> inches (approximately <NUM> meters) and Dimension C is <NUM> feet, <NUM> inches (approximately <NUM> meters). In other embodiments, Dimension A is <NUM> feet, <NUM> inches (approximately <NUM> meters) and Dimension B is <NUM> feet, <NUM> inches (approximately <NUM> meters) and Dimension C is <NUM> feet, <NUM> inches (approximately <NUM> meters). It will be understood, however, that these Dimensions A-E may vary from these numbers (e.g., by <NUM>%, <NUM>%, etc.) and may be changed based on customer requirements (e.g., Dimension A defines a higher minimum clearance for larger vehicles). Further, the mounting structure <NUM> shown in <FIG> is a carport, and the Dimensions A-E may be reduced for applications requiring shorter spans and/or smaller minimum clearances.

Referring now to <FIG>, a shorter span dual-tilt mounting structure <NUM> is shown. In shorter span dual-tilt mounting structure <NUM>, Dimension D' is shorter than Dimension D in <FIG> and Dimension C' is shorter than Dimension C in <FIG>. Similarly, the crossbeam <NUM> is shorter than crossbeam <NUM>. Referring now to <FIG>, a shorter span single-tilt mounting structure <NUM> is shown. In shorter span single-tilt mounting structure <NUM>, Dimension D' is shorter than Dimension D in <FIG> and Dimension C' is shorter than Dimension C in <FIG>. Similarly, the crossbeam <NUM> is shorter than crossbeam <NUM>. In both shorter span dual-tilt mounting structure <NUM> and shorter span single-tilt mounting structure <NUM> PV module support rails <NUM> are shorter as well.

Referring now to <FIG>, a long span dual-tilt mounting structure <NUM> and a long span single-tilt mounting structure <NUM> are shown, respectively. In mounting structures <NUM> and <NUM>, crossbeams <NUM> may be longer than crossbeams <NUM> and are connected to two sets of column foundations <NUM> and columns <NUM> and PV module support rails <NUM> may be longer. In some embodiments, crossbeams <NUM> and PV module support rails <NUM> in long span mounting structures may be comprised of multiple crossbeams <NUM> or PV module support rails <NUM> that are coupled together end-to-end.

<FIG> relate to embodiments in which PV modules <NUM> are mounted in portrait orientation <NUM>. <FIG> relates to reflected light and relates to bifacial PV modules, which are mounted in portrait orientation <NUM> in some embodiments, but may be mounted in landscape orientation <NUM> as well. Referring now to <FIG>, a bottom perspective partially exploded view of the dual-tilt mounting structure <NUM> with PV modules <NUM> mounted in portrait orientation <NUM> is shown. As discussed herein, though, the mounting of PV modules <NUM> in portrait orientation <NUM> is not limited to mounting structure <NUM> and can be used on the single-tilt, shorter span, and/or longer span embodiments discussed above.

In <FIG>, a set of PV module support rails <NUM> and <NUM>, PV modules <NUM>, and blocking rails <NUM> are exploded of off purlins <NUM>. Clamps <NUM> and fasteners <NUM> and <NUM> are also shown. As shown in <FIG>, clamps <NUM> are used to secure PV module support rails <NUM> to purlins <NUM>, fasteners <NUM> are used to secure PV modules <NUM> to PV module support rails <NUM> and <NUM>, and fasteners are used to secure blocking rails <NUM> to PV modules <NUM>.

As shown in <FIG> and discussed previously, PV module support rails <NUM> and <NUM> are C beams in various embodiments. As shown in <FIG>, a lateral side of the C beam faces the viewer and the open side of the C beam faces away from the viewer. PV module support rails <NUM> and <NUM> include a bottom surface that is coupled to purlins <NUM>. The top surface of PV module support rails <NUM> and <NUM> define a plurality of openings configured to accept fasteners <NUM> to secure PV modules <NUM> to PV module support rails <NUM> and <NUM>. As shown in <FIG>, fasteners <NUM> pass through the long side of the frames of PV modules <NUM>. In various embodiments, fasteners <NUM> include components that establish an electrical grounding path between PV modules <NUM> and PV module support rails <NUM> and <NUM>. Such components may include grounding washers that breach coatings (e.g., paint, reflective coatings <NUM> discussed in connection to <FIG>) to enable the grounding path to be established. Similarly, fasteners <NUM> may also include similar components that establish and electrical grounding path between PV modules <NUM> and blocking rails <NUM>.

As shown in <FIG>, clamps <NUM> couple PV module support rails <NUM> to purlins <NUM>. As shown in <FIG>, clamps <NUM> include a top portion <NUM> and one or more bottom portions <NUM>. In various embodiments, top portions <NUM> are fastened to PV module support rails <NUM> and bottom portions <NUM> are coupled to purlins <NUM>. As discussed in additional detail in reference to <FIG>, clamps <NUM> are not secured to purlins <NUM> by fasteners that pass through purlins <NUM> or by welding. In various embodiments, the top flange of purlins <NUM> do not define any openings at all. Instead, clamps <NUM> pinch a top flange of purlin <NUM> and are held by tension on fasteners that pass through top portions <NUM> and bottom portions <NUM>. In such embodiments, the structural integrity of purlins <NUM> is not diminished by openings. Similarly, because clamps <NUM> attach PV module support rails <NUM> to purlins <NUM> by pinching the top flange and without fasteners having to pass through purlins <NUM>, there is greater flexibility on where PV module support rails <NUM> can be attached. This allows for the variable spacing of PV module support rails <NUM> that is used for portrait orientation <NUM> mounting and landscape orientation <NUM> mounting without having to modify purlins <NUM>. This avoids construction crews having to drill holes in purlins <NUM> in the field, which is difficult to accomplish properly, and also avoids the manufacturer of purlins <NUM> from having to pre-drill holes for both orientations. Additionally, this flexibility also allows for variations at the construction site to be mitigated (e.g., irregular spacing of columns <NUM> due to obstacles on or beneath mounting surface <NUM>).

Similarly, because PV module support rails <NUM> are coupled to purlins <NUM> by clamps <NUM> and not weld points or fasteners, assembly and disassembly of the mounting structure is simplified. Columns of PV modules <NUM> may be removed together by disengaging clamps <NUM> and lifting PV module support rails <NUM> and <NUM> and PV modules <NUM> off of the mounting structure. Similarly, PV modules <NUM> may be attached to PV module support rails <NUM> and <NUM> on the ground and then a subassembly of PV module support rails <NUM> and <NUM> and PV modules <NUM> may be positioned on top of the mounting structure and secured using clamps <NUM>. This may simplify initial construction, as well as enabling PV modules <NUM> to be replaced (e.g., replacing monofacial PV modules <NUM> with bifacial PV modules <NUM>). As discussed in additional detail below in <FIG> and <FIG>, clamps <NUM> aid in establishing an electrical grounding path between PV module support rails <NUM> and purlins <NUM>.

<FIG> is a top view of a set of PV modules <NUM> mounted in portrait orientation <NUM> on a set of three PV module support rails <NUM> and <NUM> in accordance with various embodiments. In <FIG>, purlins <NUM>, PV module support rails <NUM> and <NUM>, and gutter <NUM> are shown in dashed lines because they are obscured by PV modules <NUM>. As can be seen on <FIG>, the long sides of PV modules <NUM> are parallel to and overlap PV modules support rails <NUM> and <NUM>. In the embodiment shown in <FIG>, the long sides of frames of PV modules <NUM> lay on top of PV module support rails <NUM> and <NUM>. Accordingly, PV module support rails <NUM> and <NUM> do not cause shadows across middle of the backside of PV modules <NUM>, which increase the amount of reflected light <NUM> and ambient light <NUM> that can reach the back side of the PV module <NUM>.

<FIG> is a cutaway side view of a PV module <NUM> mounted in portrait orientation <NUM> on a set of PV module support rails <NUM> in accordance with various embodiments. As shown in <FIG>, direct light <NUM> is received by the top of PV module <NUM> and reflected light <NUM> and ambient light <NUM> are received by the back of PV module <NUM>. As shown in <FIG>, very little reflected light <NUM> and ambient light <NUM> is blocked by PV module support rails <NUM> because the PV module support rails <NUM> are parallel to and overlap with the long edges of the frames of PV modules <NUM>. In embodiments in which PV module <NUM> is a bifacial PV module, this increase the amount of energy that can be generated.

<FIG> is a side view of a plurality of mounting structures <NUM> and a mounting surface <NUM> with reflective coatings <NUM> and <NUM>, respectively in accordance with various embodiments. Direct light <NUM> shines from the sun to the tops of PV modules <NUM>. Light that shines between mounting structures <NUM> is reflected by the reflective coating on mounting surface <NUM> as reflected light <NUM> and bounces back up to the backside of PV modules <NUM>. Similarly, ambient light <NUM> bounces off of reflective coatings <NUM> and <NUM>, and some of it reaches the back side of PV modules <NUM> as well. Additionally, in embodiments in which PV modules <NUM> have transparent back sheets and encapsulant, light that passes through the PV modules <NUM> can also bounce off of reflective coatings <NUM> and <NUM> reach the back side of PV modules <NUM>.

In various embodiments, reflective coatings <NUM> for mounting surfaces <NUM> have reflectance values that range from <NUM>% for light-colored coatings to <NUM>% for dark-colored coating. In embodiments in which mounting surface <NUM> is concrete or asphalt, reflective coating <NUM> is formulated accordingly to adhere to the mounting surface <NUM>. Similarly, reflective coatings <NUM> have reflectance values that range from <NUM>% for light-colored coatings to <NUM>% for dark-colored coating in various embodiments. As discussed above, the structural components of the mounting structure are made of metal of composite in various embodiments, and reflective coating <NUM> is formulated accordingly to adhere. Reflective coatings <NUM> and/or <NUM> may include materials such as spheres or flakes of materials like glass, glitter, or crystal that impart a reflective quality. In various embodiments, the columns <NUM>, crossbeams <NUM>, purlins <NUM>, and PV module support rails <NUM> and <NUM> may be coated in reflective coating <NUM> during manufacturing, but in other embodiments may be painted in the field during construction. Similarly, mounting surface <NUM> and column foundations <NUM> may be painted with reflective coating <NUM> during construction of the mounting structure. In various embodiments, substantially all (e.g., <NUM>% or more) of the mounting surface beneath and between mounting structures is painted with reflective coating <NUM> to maximize the amount of reflected light <NUM> and ambient light <NUM>.

<FIG> relate to embodiments in which PV modules <NUM> are mounted in landscape orientation <NUM>. Referring now to <FIG>, a bottom perspective partially exploded view of the dual-tilt mounting structure <NUM> with PV modules <NUM> mounted in landscape orientation <NUM> is shown. As discussed herein, though, the mounting of PV modules <NUM> in landscape orientation <NUM> is not limited to mounting structure <NUM> and can be used on the single-tilt, shorter span, and/or longer span embodiments discussed above.

As shown in <FIG> and discussed previously, PV module support rails <NUM> and <NUM> are C beams in various embodiments. In contrast to <FIG>, in <FIG>, different sets of PV module support rails <NUM> and <NUM> are oriented differently. With PV module support rails 112A and 116A, a lateral side of the C beam faces the viewer and the open side of the C beam faces away from the viewer. With PV module support rails 112B and 116B, a lateral side of the C beam faces away from the viewer and the open side of the C beam faces the viewer. Thus, the open sides of the PV module support rails 112A and 116A shown exploded off purlins <NUM> face the open sides of PV module support rails 112B and 116B exploded off of purlins <NUM>. Blocking rails <NUM> are disposed between the open sides of the PV module support rails 112A and 116A and PV module support rails 112B and 116B. In contrast to <FIG>, however, blocking rails <NUM> are not present between each PV module support rail <NUM> and <NUM>. As shown in <FIG>, blocking rails <NUM>, PV module support rails 112A and 116B, and PV module support rails 112B and 116B form a box, and PV modules <NUM> are coupled on top of the box by fasteners <NUM> and <NUM>. The top surface of PV module support rails 112A, 11B and 116A, 116B define a plurality of openings configured to accept fasteners <NUM> to secure PV modules <NUM> to PV module support rails 112A, 112B and 116A, 116B. In contrast to <FIG>, in <FIG>, fasteners <NUM> pass through the short side of the frames of PV modules <NUM>. In various embodiments, fasteners <NUM> includes components that establish an electrical grounding path between PV modules <NUM> and PV module support rails 112A, 112B and 116A,116B. Such components may include grounding washers that breach coatings (e.g., paint, reflective coatings <NUM> discussed in connection to <FIG>) to enable the grounding path to be established. Similarly, fasteners <NUM> may also include similar components that establish and electrical grounding path between PV modules <NUM> and blocking rails <NUM>.

As with <FIG>, clamps <NUM> attach PV module support rails 112A, 112B to purlins <NUM> without fasteners passing though purlins <NUM> or by weld points. Accordingly, an entire box of blocking rails <NUM>, PV module support rails 112A and 116B, and PV module support rails 112B and 116B may be assembled on the ground, and PV modules <NUM> secured to PV module support rails 112A, 112B and 116A, 116B. Then, the entire subassembly may be lifted onto mounting structure <NUM> and secured with clamps <NUM>. To remove and replace the PV modules, this operation would just need to be done in reverse.

<FIG> is a top view of a set of PV modules <NUM> mounted in landscape orientation <NUM> on a set of PV module support rails 112A, 112B, 116A, 116B in accordance with various embodiments. In <FIG>, purlins <NUM>, PV module support rails 112A, 112B, 116A, and 116B, and gutter <NUM> are shown in dashed lines because they are obscured by PV modules <NUM>. Additionally, a wire tray <NUM> is shown in dashed lines. Various embodiments of mounting structure <NUM>, <NUM>, etc. have wire trays <NUM> that are configured to support electrical wires connected to the PV modules <NUM> in various embodiments. As shown in <FIG>, PV module support rails 112A, 112B, 116A, and 116B cast shadows on the back side of PV modules <NUM>. In embodiments with bifacial PV modules <NUM>, such shadows might reduce power generation, but in embodiments with monofacial PV modules <NUM>, shadows on the back of PV modules <NUM> will have little to no effect on power generation.

<FIG> is a cutaway side view of two monofacial PV modules <NUM> mounted in landscape orientation <NUM> on a set of PV module support rails 112A and 112B in accordance with various embodiments. In the embodiment shown in <FIG>, only direct light <NUM> is shown because the monofacial PV modules <NUM> only generate electricity on the top side.

<FIG> show different views of mounting structures with the PV modules <NUM> removed and focus on the "structural support components" of the mounting structures. As discussed here, the "structural support components" refers to the column foundation <NUM>, columns <NUM>, crossbeams <NUM>, purlins <NUM>, PV module support rails <NUM> and <NUM>, and blocking rails <NUM> as well as the various fasteners and brackets that are used to couple these components together. As discussed above, in various embodiments, after column foundations <NUM> are installed in mounting surface <NUM>, mounting structures described herein may be assembled using only fasteners, brackets, and clamps <NUM> and without any welding.

<FIG> is an exploded top view of a portion of dual-tilt mounting structure <NUM> with the PV modules <NUM> omitted in accordance with various embodiments. Column <NUM> is connected to crossbeam <NUM> by a plurality of fasteners <NUM> (four are shown in <FIG> but more or fewer could be used) that pass through a flat top portion <NUM> of column <NUM>. Crossbeam <NUM> includes a reinforced portion <NUM> that is configured to receive fasteners <NUM> (e.g., with female screw thread installed in reinforced portion <NUM>). In various embodiments, fasteners <NUM> are male threaded screws or bolts. Reinforced portion <NUM> is thicker than other portions of crossbeam <NUM>.

Crossbeam <NUM> is coupled to purlins <NUM> using a pair of brackets <NUM>. In the embodiment shown in <FIG>, brackets <NUM> are L-shaped brackets that are configured to receive a plurality of fasteners <NUM> on both sides of the L. While four fasteners <NUM> are shown in <FIG>, more or fewer fasteners could be used in various embodiments. In some embodiments, fasteners <NUM> pass though brackets <NUM> and into corresponding female threaded components embedded in crossbeam <NUM> and/or purlin <NUM>. In other embodiments holes are drilled through crossbeam <NUM> and/or purlin <NUM> (either during manufacture or in the field) and fasteners are secured using nuts on the other side of crossbeam <NUM> and/or purlin <NUM>. In various embodiments, fasteners <NUM> are male threaded screws or bolts. Thus, in various embodiments purlins <NUM> are coupled to side surfaces of the crossbeams <NUM> (i.e., as opposed to resting on top of the crossbeams <NUM> and being coupled to top flange <NUM>). In various embodiments crossbeam <NUM> includes a top flange <NUM> with helps support the weight of PV module support rails <NUM> and PV modules <NUM>, provides an attachment surface for clamp <NUM>, and provides lateral support along the length of crossbeam <NUM>. In various embodiments, crossbeam <NUM> defines a cutout <NUM> that is useable to run wires (e.g., wires for lighting installed in mounting structure <NUM>, wires connected to PV modules <NUM>) through mounting structure. In some embodiments, crossbeam <NUM> is coped (e.g., has a notch) such that the middle portion of the crossbeam has clearance to fit in a smaller middle section of purlin <NUM>.

Purlins <NUM> are coupled to the PV module support rails <NUM> by clamps <NUM> that couple to top flange <NUM> of purlins <NUM> as discussed previously and in further detail in reference to <FIG>. Purlins <NUM> define a weight-reduction cutout <NUM> at the ends of purlins <NUM> in various embodiments.

As discussed previously, in various embodiments PV module support rails <NUM> and <NUM> are C beams. In such embodiments, PV module support rails <NUM> and <NUM> define a top surface <NUM>, an intermediate surface <NUM>, and a bottom surface <NUM>. In such embodiments, top surface <NUM> define a series of holes (e.g., threaded holes, round and slotted punches) that are configured to receive fasteners <NUM>. In various embodiments, such holes are formed during manufacturing, and the top surface <NUM> of PV module support rails <NUM> and <NUM> includes holes usable to accept fasteners <NUM> to couple PV modules <NUM> in portrait orientation <NUM> or landscape orientation <NUM> (i.e., top surface <NUM> defines sets of holes for both orientations and only one set is used). Intermediate surface <NUM> also defines sets of holes configured to accept fasteners (e.g., fasteners <NUM> shown in <FIG>) to couple top portion <NUM> of clamp <NUM> to the intermediate surface <NUM>. Bottom surface <NUM> is configured to lie on top flange <NUM> when PV module support rails <NUM> are installed. In dual-tilt embodiments, PV module support rails <NUM> and <NUM> define holes <NUM> that are configured to receive fasteners that pass through bracket <NUM> to secure PV module support rails <NUM> to PV module support rails <NUM>. In various embodiments, bracket <NUM> defines four holes: the top two holes are configured to receive fasteners that are received by holes <NUM> and the bottom two holes are configured to receive fasteners to secure gutter <NUM> (not shown in <FIG>) to bracket <NUM>. Blocking rails <NUM> define a pair of holes <NUM> that are configured to receive fasteners that pass through PV module support rails <NUM> and <NUM> and into holes <NUM> to secure blocking rails <NUM> between pairs of PV module support rails <NUM> and <NUM>.

In various embodiments, electrical grounding is facilitated by self-adhesive grounding patches <NUM> that are disposed between various structural support components. A self-adhesive grounding patch <NUM> is disposed between column <NUM> and crossbeam <NUM>, and when fasteners <NUM> are tightened, the self-adhesive grounding patch <NUM> breaks through coatings (e.g., paint, anodization, or oxidation) on column <NUM> and crossbeam <NUM> and establishes an electrical grounding path. Similarly, self-adhesive grounding patches <NUM> are disposed between crossbeams <NUM> and purlins <NUM> such that when crossbeams <NUM> and purlins <NUM> are coupled using bracket <NUM> and fasteners <NUM>, self-adhesive grounding patches <NUM> breaks through coatings (e.g., paint, anodization, or oxidation) on crossbeam <NUM> and purlins <NUM> and establishes an electrical grounding path. In various embodiments, self-adhesive grounding patches <NUM> are disposed between top portion <NUM> of clamp <NUM> and PV module support rails <NUM> such that self-adhesive grounding patches <NUM> breaks through coatings (e.g., paint, anodization, or oxidation) on PV module support rails <NUM> and clamp <NUM> and establishes an electrical grounding path. In some embodiments discussed in additional detail in references to <FIG>, bottom portion <NUM> is able to establish a grounding path between clamp <NUM> and purlin <NUM>. In other embodiments, however, another set of self-adhesive grounding patches <NUM> are disposed between bottom portion <NUM> and purlin <NUM> to establish the grounding path. Finally, in some embodiments, self-adhesive grounding patches <NUM> are disposed between brackets <NUM> and PV module support rails <NUM> and/or <NUM>. Accordingly, though the use of PV module support rails <NUM> and/or clamps <NUM>, an electrical grounding path can be established between columns <NUM>, crossbeams <NUM>, purlins <NUM>, and PV module support rails <NUM> and <NUM> as the structural support components are installed from the ground up. This may allow mounting structures as described herein to be grounded as it is being assembled and not after the PV modules <NUM> have been installed. This approach may reduce the risk of electrical shocks prior to grounding paths being established and allow non-electricians to establish the grounding path, which may subsequently be approved by electricians at lower labor cost.

<FIG> is a top view of the dual-tilt mounting structure <NUM> with the PV modules <NUM> omitted. Similarly, <FIG> is a top view of the dual-tilt mounting structure <NUM> with the PV modules <NUM> omitted. As shown in both <FIG> and <FIG>, with both dual-tilt mounting structure <NUM> and dual-tilt mounting structure <NUM>, column foundation <NUM> and columns <NUM> may be installed at the mounting surface <NUM> in a range labeled G. In various embodiments, this range can be about <NUM> feet (approximate. <NUM> meters), with the column foundation <NUM> and columns <NUM> able to be installed anywhere within that <NUM>-foot range. Moreover, column foundation <NUM> and columns <NUM> are separated by range F, which may range up to <NUM> feet (approximately <NUM> meters) in various embodiments. Thus, a first column foundation <NUM> and first column <NUM> may be <NUM> feet from a second column foundation <NUM> and second column <NUM>, but a third column foundation <NUM> and third column <NUM> are only <NUM> feet from the second column foundation <NUM> and second column <NUM>. Accordingly, column foundation <NUM> and columns <NUM> may be irregularly spaced apart on mounting surface <NUM> to, for example, work around unexpected site conditions that were not known prior to installation. Additionally, referring to <FIG>, gaps <NUM> can be seen showing places in which blocking rails <NUM> are not installed between boxes of blocking rails <NUM>, PV module support rails 112A and 116B, and PV module support rails 112B and 116B discussed previously. It will be understood that while <FIG> and <FIG> show five crossbeams <NUM>, mounting structures constructed according to the techniques described herein may be longer (i.e., having more crossbeams <NUM>) or shorter (i.e., having fewer crossbeams).

<FIG> is a bottom perspective view of dual-tilt mounting structure <NUM> with various water management features highlighted in accordance with various embodiments. In various embodiments, gaskets <NUM> are disposed between PV modules <NUM> that are installed in either landscape orientation <NUM> or portrait orientation <NUM>. This causes water <NUM> to flow down the angled top surface of mounting structure <NUM> and into gutter <NUM>. From gutter <NUM>, water is able to flow through pipe <NUM> and into downspout <NUM>. Thus, mounting structure <NUM> (and other dual-tilt mounting structure described herein) are able to shelter people and objects underneath from precipitation and move water away. In some embodiments, mounting structure <NUM> may have integrated heating elements (e.g., heating elements in PV module support rails <NUM> and <NUM>) that prevent snow and ice from accumulating on PV modules <NUM>.

Referring now to <FIG>, various views of various embodiments of clamp <NUM> are shown. <FIG> is a perspective view of a top portion <NUM> and a bottom portion <NUM> of the clamp <NUM> shown in of <FIG>, <FIG>, and <FIG> in accordance with various embodiments. Top portion <NUM> is an L-shaped bracket having a first top plate <NUM> that defines a pair of holes <NUM> and a second top plate <NUM> defines a pair of holes <NUM>. When installed, first top plate <NUM> is configured to be adjacent to intermediate surface <NUM> of PV module support rails <NUM> and second top plate <NUM> is configured to lie on top flange <NUM> of purlin <NUM>. In the embodiment shown in <FIG>, bottom portion <NUM> is a clamping jaw that defines a first portion <NUM> defining a rounded first top surface <NUM>, a second portion <NUM> defining a flat second top surface <NUM> with a hole <NUM> configured to receive a clamping fastener <NUM>, and a third portion <NUM> defining a rounded third top surface <NUM>. When installed, the rounded first top surface <NUM> abuts top portion <NUM> and rounded third top surface <NUM> abuts the underside of the top flange <NUM> of purlin <NUM>. In various embodiments, the rounded first top surface <NUM> is configured to breach one or more coatings on purlin <NUM> and establish a grounding path between clamp <NUM> and purlin <NUM>.

Referring now to <FIG>, a perspective view of a top portion <NUM> and an alternate bottom portion 504A of an alternative clamp 500A is shown. Alternative bottom portion 504A is S-shaped with a first portion <NUM> defining a hole <NUM> configured to receive clamping fastener <NUM> and a second portion <NUM>. When installed, the first portion <NUM> abuts top portion <NUM> and second portion <NUM> abuts the underside of the top flange <NUM> of purlin <NUM>. In the embodiment shown in <FIG>, a self-adhesive grounding patch <NUM> may be inserted between second portion <NUM> and the underside of top flange <NUM> of purlin <NUM>. Alternatively, a self-adhesive grounding patch <NUM> may be inserted between second top plate <NUM> of top portion <NUM> and the top surface of top flange <NUM>.

Referring now to <FIG>, various views of an installed clamp <NUM> are shown. <FIG>, <FIG> are various views of clamp <NUM> installed with the top portion <NUM> secured to an outer surface of a PV support module support rail <NUM>. <FIG>, <FIG> are various views of clamp <NUM> installed with the top portion <NUM> secured to an inner surface of a PV support module support rail <NUM>. As discussed herein, using clamp <NUM>, PV support module support rail <NUM> are able to be secured to the mounting structure without welding and without having to pass fasteners through purlins <NUM>.

Referring now to <FIG>, a side view of clamp <NUM> installed on a mounting structure is shown. In <FIG>, clamp <NUM> is installed with first top plate <NUM> secured to an outer surface of a PV support module support rail <NUM> by a pair of fasteners <NUM> (e.g., bolts) that extend through holes <NUM> and are secured by bolts <NUM> (see <FIG>). Second top plate <NUM> is secured to the top of top flange <NUM> of purlin <NUM>. Two bottom portions <NUM> are disposed on the bottom side of top flange <NUM>. Clamping fasteners <NUM> (e.g., a bolt) extends through holes <NUM> and holes <NUM> and is secured by nuts <NUM>. Accordingly, tension on the clamping fasteners <NUM> secures second top plate <NUM> and bottom portions <NUM> to purlin <NUM> such that top flange <NUM> is pinched between. <FIG> is a cutaway side view showing clamp <NUM> installed on a mounting structure as described in reference to <FIG>. Similarly, <FIG> is a bottom perspective view showing clamp <NUM> installed on a mounting structure as described in reference to <FIG>. As can be seen in <FIG>, bottom portions <NUM> are disposed between the PV module support rail <NUM> and the end of purlin <NUM> at a distance H from the end of purlin <NUM>.

Referring now to <FIG>, a side view of clamp <NUM> installed on a mounting structure in an alternative manner is shown. In <FIG>, clamp <NUM> is installed with first top plate <NUM> secured to an inner surface of a PV support module support rail <NUM> by a pair of fasteners <NUM> (e.g., bolts) that extend through holes <NUM> and are secured by bolts <NUM> (see <FIG>). Thus, in contrast to <FIG>, <FIG>, top portion <NUM> is disposed inside PV support module support rail <NUM> in some embodiments. Second top plate <NUM> is secured to the inside of bottom surface <NUM> of PV support module support rail <NUM>.

Two bottom portions <NUM> are disposed on the bottom side of top flange <NUM>. Clamping fasteners <NUM> (e.g., a bolt) extends through holes <NUM>, holes through bottom surface <NUM> of PV support module support rail <NUM>, and holes <NUM> and is secured by nuts <NUM>. Accordingly, tension on the clamping fasteners <NUM> secures second top plate <NUM> and bottom portions <NUM> to purlin <NUM> such that bottom surface <NUM> and top flange <NUM> is pinched between. <FIG> is a cutaway side view showing clamp <NUM> installed on a mounting structure as described in reference to <FIG>. Similarly, <FIG> is a bottom perspective view showing clamp <NUM> installed on a mounting structure as described in reference to <FIG>. As can be seen in <FIG>, bottom portions <NUM> are disposed a further distance I from the end of purlin <NUM> compared to distance H in <FIG>. In the embodiment shown in <FIG>, <FIG>, bottom portions <NUM> are disposed beneath PV support module support rail <NUM>.

<FIG> are various views of the self-adhesive grounding patch <NUM> in accordance with various embodiments. <FIG> is a plan view of self-adhesive grounding patch <NUM>. <FIG> is a side view of self-adhesive grounding patch <NUM>. <FIG> is a top perspective view of self-adhesive grounding patch <NUM>. In various embodiments, self-adhesive grounding patch <NUM> includes a plate <NUM> with an adhesive pad <NUM> disposed in the center. In various embodiments, plate <NUM> is made of metal (e.g., stainless steel) and is a square with sides between <NUM> (approximately <NUM> centimeters) and <NUM> inches (approximately <NUM> centimeters) long. In various embodiments, adhesive pad <NUM> is a peel and stick adhesive that is attached to plate <NUM> during manufacture with a peelable top sheet that is removed prior to installation as discussed herein. Cutouts <NUM> are arranged around adhesive pad <NUM> and are bent above and below to form spikes <NUM>. In various embodiments, eight cutouts <NUM> and spikes <NUM> are present and are arranged on the sides and corners of plate <NUM> as shown in <FIG>, but other arrangements can be used (e.g., more cutouts and spikes may be present). Compressive forces on self-adhesive grounding patch <NUM> cause the spikes <NUM> to penetrate coatings on components of the various mounting structure discussed herein, enabling an electrical grounding path to be established between adjacent components. Such compressive forces, for example, result from tension on the fasteners used to secure the structural support components as discussed herein.

<FIG> is flowchart illustrating an embodiment of a PV module support structure construction method <NUM> in accordance with various embodiments. In various embodiments, method <NUM> is performed by construction personnel erecting a mounting structure (e.g., mounting structure <NUM>, <NUM>, etc.) on a mounting surface <NUM>. While method <NUM> proceeds upward from mounting surface <NUM>, it will be understood that the sequence of these steps may be changed in various embodiments (e.g., securing PV modules <NUM> to PV module support rails <NUM> on the ground and then lifting the subassembly and installing it on purlins <NUM> as discussed herein).

A block <NUM>, a plurality of column foundations <NUM> are installed at a mounting surface <NUM> such that column foundations <NUM> are partially embedded in mounting surface <NUM> and extend above mounting surface <NUM>. At block <NUM>, columns <NUM> are coupled to the column foundations <NUM>. At block <NUM>, a plurality of crossbeams <NUM> are coupled to the plurality of columns <NUM>. At block <NUM>, a plurality of purlins <NUM> are coupled to the plurality of crossbeams <NUM>. A first set of purlins <NUM> are coupled to first ends of the plurality of crossbeams <NUM> and a second set of purlins <NUM> are coupled to second ends of the plurality of crossbeams. At block <NUM>, a plurality of PV module support rails <NUM> are coupled to the plurality of purlins <NUM>. The plurality of PV module support rails <NUM> includes a first PV module support rail <NUM>, a second PV module support rail <NUM>, and a third PV module support rail <NUM>. The second PV module support rail <NUM> is disposed between the first PV module support rail <NUM> and the third PV module support rail <NUM>. At block <NUM>, a first set of PV modules <NUM> is coupled, in portrait orientation <NUM>, to the first PV module support rail <NUM> and the second PV module support rail <NUM>. At block <NUM>, a second set of PV modules <NUM> is coupled, in portrait orientation <NUM>, to the second PV module support rail <NUM> and the third PV module support rail <NUM>.

As discussed herein, in various embodiments, clamp <NUM> is used to perform the actions of block <NUM>. Further, in various embodiments, self-adhesive grounding patches <NUM> may be installed between the coupled components as part of performing the actions of blocks <NUM>, <NUM>, and/or <NUM>.

At block <NUM>, a plurality of column foundation <NUM> are installed at a mounting surface <NUM>. At block <NUM>, a plurality of columns <NUM> are coupled to the column foundations <NUM>. At block <NUM>, a plurality of crossbeams <NUM> are coupled to the plurality of columns <NUM>. At block <NUM>, a plurality of purlins <NUM> are coupled to the crossbeams <NUM> at ends of the crossbeams <NUM>. At block <NUM>, a plurality of PV module support rails <NUM> are secured to purlins <NUM> using clamps <NUM>.

As discussed herein, in various embodiments, PV modules <NUM> may be installed on top of PV module support rails <NUM> in portrait orientation <NUM> or landscape orientation <NUM>. Further, clamp <NUM> may be disposed outside of PV module support rails <NUM> as shown in <FIG>, <FIG> or partially inside of PV module support rails <NUM> as shown in <FIG>, <FIG>. Further, in various embodiments, self-adhesive grounding patches <NUM> may be installed between the coupled components as part of performing the actions of blocks <NUM>, <NUM>, <NUM>, and/or <NUM>.

Although specific embodiments have been described above, these embodiments are not intended to limit the scope of the present disclosure, even where only a single embodiment is described with respect to a particular feature. Examples of features provided in the disclosure are intended to be illustrative rather than restrictive unless stated otherwise. The above description is intended to cover such alternatives, modifications, and equivalents as would be apparent to a person skilled in the art having the benefit of this disclosure.

Claim 1:
A system (<NUM>) comprising:
a plurality of columns (<NUM>) extending from a mounting surface (<NUM>) along a first axis, wherein top ends of the plurality of columns (<NUM>) are disposed above the mounting surface (<NUM>);
a plurality of crossbeams (<NUM>) coupled to the top ends of the plurality of columns (<NUM>) and extending along a second axis, wherein individual crossbeams (<NUM>) include a first end and an opposing second end;
a plurality of purlins (<NUM>) coupled to the plurality of crossbeams (<NUM>) and extending along a third axis, wherein a first set of purlins (<NUM>) are coupled to the first ends of the plurality of crossbeams (<NUM>) and a second set of purlins (<NUM>) are coupled to the second ends of the plurality of crossbeams (<NUM>);
a first plurality of photovoltaic (PV) module support rails (<NUM>) extending along the second axis across the plurality of purlins (<NUM>), wherein individual PV module support rails (<NUM>) include a bottom surface coupled to the plurality of purlins and a top surface defining a plurality of openings configured to accept fasteners (<NUM>); and
a plurality of rectangular PV modules (<NUM>) secured to the top surfaces of the first plurality of PV module support rails (<NUM>) by fasteners (<NUM>) that extend through the rectangular PV modules (<NUM>) and the openings configured to accept fasteners (<NUM>);
wherein the plurality of rectangular PV modules (<NUM>) is disposed in portrait orientation (<NUM>) in a first grid having columns extending along the second axis and rows extending along the third axis; and
wherein a first set of rectangular PV modules (<NUM>) in a first column and second set of rectangular PV modules (<NUM>) in an adjacent second column are secured to a top surface of a same PV module support rail (<NUM>, <NUM>) disposed between the first column and the second column.