Patent Application
20250007446
Embodiments disclosed herein generally relate to a vehicle-roof-mountable solar array. More particularly the embodiments disclosed here relate to a combination cargo rack and solar power array for use on/with a vehicle.
The price and availability of solar panels has improved markedly in recent years, as has the prevalence of rechargeable/cordless electric tools and other electronic devices. Also, there is an increased public consciousness to utilize energy resources that are alternative to and/or complementary to fossil-fuel-generated electricity. It may be desirable to provide a source of electrical power for use with portable tools and devices associated with a motor vehicle, as well as for the vehicle itself. Although roof-mounted solar panels on fuel-powered, electric, and hybrid vehicles have been known for many years, there is not a readily-available system that allows a user to have the benefit of both roof-mounted solar panels and cargo-carrying capability. The presently disclosed embodiments are directed to meeting these needs with a system that will be useful for work and/or recreational uses, including to meet a user's desire for electrical energy, cargo-carrying, or both (independent of each other).
A solar power system for a vehicle includes a solar array with at least one solar panel, where the solar array is configured to generate at least 400 watts of electrical power, a roof-mountable cargo-support structure with at least two generally parallel longitudinal rails attached to the solar array and constructed to support a cargo above the solar array and separated from the solar array by a predetermined distance, where at least one cross-member is permanently attached or removably attached to the at least two generally parallel longitudinal rails in a manner permitting support of a load above and separated from the solar array.
Various embodiments are described below with reference to the drawings in which like elements generally are referred to by like numerals. The relationship and functioning of the various elements of the embodiments may better be understood by reference to the following detailed description. However, embodiments are not limited to those illustrated in the drawings. It should be understood that the drawings are not necessarily to scale, and in certain instances details may have been omitted that are not necessary for an understanding of embodiments disclosed herein, such as—for example—conventional fabrication and assembly.
A combined system of solar power and cargo-transport is disclosed, configured for being mounted onto a vehicle or vehicle accessory, where the solar power portion and cargo-transport system are independently useful.
The invention is defined by the claims, may be embodied in many different forms, and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey enabling disclosure to those skilled in the art. As used in this specification and the claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Reference herein to any industry standards (e.g., ASTM, ANSI, IEEE standards) is defined as complying with the currently published standards as of the original filing date of this disclosure concerning the units, measurements, and testing criteria communicated by those standards unless expressly otherwise defined herein.
The terms “about,” “substantially,” “generally,” and other terms of degree, when used with reference to any volume, dimension, proportion, or other quantitative or qualitative value, are intended to communicate a definite and identifiable value within the standard parameters that would be understood by one of skill in the art (equivalent to a solar appliance or automotive accessory engineer with experience in this field), and should be interpreted to include at least any legal equivalents, minor but functionally-insignificant variants, standard manufacturing tolerances, and including at least mathematically significant figures (although not required to be as broad as the largest range thereof), and up to 5% variance unless otherwise specified. The phrase “eye level” refers to a horizontal sightline of a person who is ≤2 m in height, used in reference to a roofline height of a typical full-size pick-up truck, van, box truck, or other vehicle. “Generally parallel” includes completely parallel with variation of up to 15 degrees, but preferably less than 10 degrees. OTHER DEFINITIONS (IF ANY)
One embodiment of a cargo-carrying and solar power system 100 for a vehicle is described with reference to
It should be appreciated that the system may be used on other vehicles with or without accessories including (by way of non-limiting example) at least vans, sport-utility vehicles, cars, camper/RVs, cargo/box trucks, bed-mountable camper units, trailer units (e.g., cargo trailers, camper trailers), and any other vehicle. The system 100 includes a cargo-support structure 200 and a solar array 300. The system 100 may include one or more accessory devices that may be powered by the solar array 300, the vehicle 801, or both. For example, a supplemental brake light 450, one, two, or more spot lights/work-lights 452, and/or other powered accessories may be included on the system 100. The system may also be configured to support any other DC load and/or AC load, including, by way of further non-limiting example, interfacing with a vehicle electrical system (e.g., to charge vehicle battery(ies), to provide alternative and/or supplemental power).
The solar array 300 includes at least one solar panel 302. Preferably, the solar array includes sufficient solar cells in solar panels 302 to generate at least 400 watts of electrical power. In one non-limiting example, the solar array may include four HQST™ 100 W solar panels dimensioned about 36 inches wide by 26 inches long by 1 inch thick, mounted using Renogy™ MTS-ZB brackets. A variety of commercially available solar panel products will be suitable for vehicle mounting including properties of durability, weight, resistance to weather/elements, and a balance of flexibility and rigidity to accommodate vehicle-mounted conditions including at least wind, snow, and dust. The particular dimensions and orientation of the panels 302 can be selected with reference to the type of vehicle and/or vehicle-mountable accessory to which the system 100 will be attached. Accordingly, the example embodiments shown and described here do not limit the number and/or orientation of solar panels used in an array, nor the mounting/framing used for accommodating them. Likewise, those of skill in the art will understand that different wiring configurations may be used within current safety standards.
The bars 362, 364, 366, 368 are shown as being secured together with bolts 371, washers and lock-washers 373, and nuts 375 (which may be lock-nuts) directed through pre-drilled holes. In some embodiments, self-tapping bolts/screws may be used, and it will be appreciated that other connectors can be used to secure these components. Specifically, the components described here may be attached and secured using any conventional structures and methods that will provide for secure, safe connection of the components of the system 100 (with each other, and when mounted to a vehicle and/or vehicle accessory). Bushings 377 are shown as optionally being disposed between the longitudinal angle-bars 362 and the external flat bars 366 (and/or the mounting substrate 803). The illustrated embodiment includes a four-cornered riser support system with materials configured to control sway, vibration, and other less-desirable movement of the system relative to a vehicle and any cargo.
When installed, the external flat bars 366 are disposed on the upper/external surface of the mounting substrate 803 (vehicle roof, vehicle accessory roof, or other mounting platform/element). And, the internal flat bars 368 are disposed on the lower/internal surface of that same substrate 803, aligned longitudinally with the external bars 366 and the longitudinal angle-bars 362. In some embodiments, insulated tape may be installed between one or both flat bars 366, 368 and the substrate 803. Also, it is preferred to seal around the bolts or other fasteners to maintain water-tightness (e.g., using silicone or other sealant material and/or seals such as gaskets, not shown). The term “flat bar” is used here with reference to the illustrated embodiment, which has bars that are laterally-flat, but it is not limited to that embodiment, and bars or other structures (e.g., tubes, curved bars, I-beams, and/or other geometries) may be used to provide the structural support shown and described, within the scope of the claimed invention. It should also be appreciated that these structures will provide weight-distribution, vibration-damping, and resistance to undesirable flex and/or sway of the system.
The solar panel(s) 302 are mounted to the frame 360 using conventional mounting attachments in keeping with the support boundaries and manufacturer recommendations for the selected solar pane(s). The conventional mounting attachments may include, by way of non-limiting example, one or more of bolts, screws, rivets, clips, clamps, adhesive(s), and/or weld(s). The solar array 300 and the cargo-support structure 200 may be configured as being independently and/or mutually attachable to a vehicle roof structure (which includes any vehicle accessory as described elsewhere). When one or both are attached to the roof it/they preferably are securely anchored enough so as not to move relative to the mounting substrate.
In order to provide for transporting cargo that would not span across the rails 202, 204, at least one cross-member 216 is disposed (that is permanently attached or removably attached) transverse to and across/between the longitudinal rails 202, 204. This preferably includes a plurality of cross-members 216. In the drawing figures, the cross-members 216 are attached directly to the inner rails 204, but it should be appreciated that-alternatively or in addition-they may be attached directly to the outer rails 202. The attachment of the cross-member(s) 216 may be permanent or removable. Where the attachment is removable, it should be appreciated that numerous mechanisms exist for attachment/removal without tools, but without sacrificing the secure attachment that one would typically wish to have in a vehicle-mounted cargo-carrying structure. The illustrated embodiment used stained cedar wood for the rails 202, 204 and tubular aluminum cross-members 216, but any other conventional materials may be used to provide a desired appearance, weight, and other characteristics, while remaining within the scope of the claimed embodiments.
The cross-member(s) 216 preferably will be mounted a predetermined distance above the upper surface of the solar array 300. The predetermined distance may be chosen based upon factors including but not limited to the kinds of cargo likely to be carried (e.g., with consideration of how such cargo might rest/ride and minimizing or at least lessening risk of the cargo contacting the solar array in a way that would damage it); allowing light to reach the solar array even when a cargo is disposed on the cross-member(s) 216; air-flow relative to the system 100 and cargo when mounted on a vehicle that is to be in motion; and/or other factors).
It should be appreciated from the description above and the drawing figures that the illustrated embodiment of system 100 is constructed, dimensioned, and positioned such that an upward-facing surface of solar array 300 is obscured from a view of an observer oriented along a longitudinal side at eye-level with the solar power system 100. This provides for aesthetic advantages including that a typical observer at or below the level of at least some embodiments of the system 100 will only see a fairly-typical cargo-carrying assembly instead of the combination solar-power and cargo-transport device actually disclosed here.
Through the past two decades, many different solar power appliances, including for use with vehicles have been developed and are both well known and commercially available. Accordingly, claims of the present disclosure are not directed to particular novel electrical structures and/or functions. Rather, as is diagrammatically depicted in
Those of skill in the art will appreciate that embodiments not expressly illustrated herein may be practiced within the scope of the claims, including that features described herein for different embodiments may be combined with each other and/or with currently-known or future-developed technologies while remaining within the scope of the claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation unless specifically defined by context, usage, or other explicit designation. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting. And, it should be understood that the following claims, including all equivalents, are intended to define the spirit and scope of this invention. Furthermore, the advantages described above are not necessarily the only advantages of the invention, and it is not necessarily expected that all of the described advantages will be achieved with every embodiment. In the event of any inconsistent disclosure or definition from the present application conflicting with any document incorporated by reference, the disclosure or definition herein shall be deemed to prevail.
