WO2018188798A1

WO2018188798A1 - Mounting structure, solar module array and method of assembling a mounting structure

Info

Publication number: WO2018188798A1
Application number: PCT/EP2018/000191
Authority: WO
Inventors: Mirko Dudas
Original assignee: Mirko Dudas
Priority date: 2017-04-12
Filing date: 2018-04-11
Publication date: 2018-10-18

Abstract

A mounting structure (100) for a solar module array is provided wherein the mounting structure comprises at least two posts (101) configured to be connected to a foundation (102); and a rod (105) having at least one bend (106), wherein the rod (105) is connected to a first one of the at least two posts (101) and to a second one of the at least two posts (101).

Description

Mounting Structure, Solar Module Array and Method of Assembling a

Mounting Structure

Technical Field

The invention relates to a mounting structure, a solar module array, in particular to a fixed solar module array, e.g. a fixed solar module field array.

Furthermore, the invention relates to a method of assembling a mounting structure.

Background

Both photovoltaic and solar-thermal energy generation plants are known from the prior art. Both use the incident solar radiation to generate either electrical or thermal energy and supply it to a further consumer. So-called combination modules also exist, which allow a combination of photovoltaic and solar-thermal energy generation.

Typically, such modules are mounted elevated on roofs, flat roofs, free surfaces, or also facades in such a way that they have this optimum orientation toward the sun. A plurality of such solar modules may form a solar module array or arrangement. In addition, solar modules may be arranged in (fixed or tracked) solar module field arrays. In these field arrays or arrangements the solar modules are arranged to groups of (preferably framed) solar modules which are then fixed to a support or mounting structure, formed by a frame structure. In order to further optimize the efficiency, solar energy generation plants are also known, which are actively tracked to the course of the sun, in order to ensure an optimum or at least an improved orientation toward the sun at nearly every time of day. However, such a tracking mechanism used for increasing efficiency is quite complex.

Such frame structures of the mounting structures, for field and roof arrays, typically comprise several posts or poles connected to foundations set to the ground and roof, respectively. To these posts a plurality of rods is fixed which form the actual structures onto which the solar module elements are mounted, e.g. clamped, either directly or via additional mounting rods mounted to the rod attached to the posts. These mounting structures have to be dimensioned to support the complete weight of the solar module elements mounted thereto and additional loads (e.g. wind or snow loads) and to lead the load into the foundation or ground. Thus, the mounting structures have to be sufficient stable leading to the fact that these mounting structures are causing a portion of the costs of a total solar field array.

Summary

Thus, there may be a need to provide a mounting structure, a solar module array, and a method of assembling a mounting structure for a solar module array which may be able to support a high load.

This need may be met by a mounting structure, a solar module array and a method of assembling a mounting structure according to the independent claims. Further exemplary embodiments are described in the dependent claims.

According to an exemplary aspect a mounting structure for a solar module array is provided wherein the mounting structure comprises at least two posts configured to be connected to a foundation; and a rod having at least one bend, wherein the rod is connected to a first one of the at least two posts and to a second one of the at least two posts.

In particular, the rod may be connected or mounted directly to the posts preferably in a fixed manner, i.e. in a way that no or at least no intentional movement, pivoting or tilting is possible at a connecting point. However,

alternatively (some or) all rods may be connected to the posts in a way such that a pivoting, tilting or lateral movement, e.g. along the posts, is possible, e.g. by using articulated or moveable links or joints for the connection.

In particular, the mounting structure may be used for a solar module field array, i.e. a solar module array mounted on the mounting structure arranged on a (flat, bumpy or sloped) field, or may be used on a (flat) roof or any other suitable base. That is, the mounting structure may be used for a field or roof arrangement.

According to an exemplary aspect a solar module array is provided wherein the solar module array comprises at least one mounting structure according to an exemplary aspect and at least one solar module element mounted to the mounting structure. In particular, the solar module array may comprise a plurality of mounting structures and/or a plurality of solar module elements mounted to the plurality of mounting structures.

In particular, the solar module array may comprise four solar module elements mounted to the at least one mounting structure. In particular, the solar module element(s) may be mounted to mounting rod(s) of the mounting structure.

In particular, the solar module (field or roof) array or arrangement may be a fixed or fixedly mounted assembly. That is, no tracking or moving mechanisms are provided. For example, the solar module arrangement may be mounted or fixed to a fixed mounting structure set up on ground. However, it should be noted that the same principle may be used in a moveable or tracked solar module arrangement.

In particular, a single solar module element may be limited or surrounded by a frame structure or framing element, i.e. a frame structure may form the

circumferential or peripheral boundary or a rim of a single solar module element. In such a frame element mounting areas or regions may be formed which are intended to be fixed (e.g. clamped) to a mounting structure, e.g. mounting rods of the mounting structure. Such mounting areas or regions may also be formed or defined in frameless solar module elements.

According to an exemplary aspect a method of assembling a mounting structure for a solar module array is provided wherein the method comprises mounting two posts on foundations; and connecting a rod to a first one of the two posts and to the second one of the two posts, wherein the rod has at least one bend. In particular, the method may optionally further comprise mounting a mounting rod to the rod and/or mounting at least one solar module element to the mounting structure. In particular, mounting rod(s) may be mounted to the rods at the positions of the bend(s) or at least close to the bend(s). In particular, the mounting may be performed by clamping, screwing or another suitable method.

It should be noted that of course a plurality of posts and/or rods may be used to form a single mounting structure and/or a plurality of mounting structures may be assembled in a single solar module array. In particular, the optional mounting rod(s) may be mounted to the rods at the positions of the bend(s). In particular, the mounting rod(s) may be fixed to the rod(s) before the at least one solar module element is mounted to the rods. In particular, the mounting may be performed by clamping, screwing or another suitable method.

It should be noted that the term "rod" or bar may particularly denote any rigid element connected or fixed directly (with optional use of moveable and/or pivotable links, but preferably without the use of further rod-like elements) to posts and used to transfer loads from solar module elements and/or mounting rod(s) to posts, which then transfer the loads into a foundation. Preferably, but not

necessarily, all rods are substantially parallel to each other and/or substantially identical to each other. The term "mounting rods" may particularly denote another group of elements which may be preferably parallel and/or identical to each other, wherein at least some of the mounting rods are rather connected or fixed to rods rather than to posts and/or which are used for mounting or fixing solar module elements onto, irrespective whether directly or indirectly, e.g. by using additional spacers, distance pieces, support structures/elements or compensating elements.

It should be noted that the term "foundation" has to be taken in a broad sense, i.e. as encompassing any element configured to have a (mounting) structure fixed thereto and to transfer loads from the structure into a base, e.g. ground or roof) and may include foundation elements set into ground as well as foundation elements formed in/on roofs or attached to roofs.

The term "bend" may particularly denote any willfully introduced (abrupt) change of a course of an element, e.g. a rod or a mounting rod. In particular, such bends are the result of a bending process, i.e. may form plastic deformations. Such bends or kinks have to be distinguished from dips or sags caused by loads

transferred into the rod (which are generally elastic, i.e. the rod may reassemble the straight course after taking away the load). In particular, such bends may rather represent or form discontinuities in the course of the rod (e.g. sharp bends) while dips may rather form continuous arcs. In particular, the bends may define a bending angle between 1° and 30°, i.e. in a bending step a straight rod may be bent between 1° and 30. In another definition the rod may, after bending, form an angle of 179° to 150° instead of an "angle" of 180° for a straight line. In general, this bending angle may depend on the geometry, e.g. position of the mounting areas of the solar module elements, the inclination of the solar module array. In particular, each bend may form a sharp or slightly rounded kink in the rod. Between bends the rod may be rather straight, i.e. the rod may be imagined as comprising straight portions connected to each other by bends, i.e. rounded or sharp kink portions. Such bends may be formed by a bending process in which a straight rod is bend so that plastic deformations are introduced. However, any other process of introducing such bends into the rods may be used as well.

In particular, the posts for a field arrangement may have a length between 0.5 m and 5.0 m, more particular, between 1.0 m and 3.5 m, e.g. between 2.0 m and 3.0 m, i.e. a height which is large enough to easily access the space below the posts and/or the mounting structure. In case of a (flat) roof arrangement the posts may have a length in the range of centimeters, e.g. 1 to 50 cm, more particularly 5 to 25 cm. Furthermore, it should be noted that the posts may have (substantially) the same length, e.g. only have a difference in length of about 25% or even less than 15%. Therefore, even in case the mounting structures are fixed to a

foundation (e.g. in a field array), the height of the posts may be (substantially) the same. However, it should be noted that the solar module array may as well be arranged on a slopy terrain leading to the fact that the posts are arranged or founded on different heights and that the solar module elements mounted on the mounting structure are inclined, while the actual height of the founded posts (i.e. the clear height) may be the same. Alternatively, the mounting structure may comprise posts of different length and/or height so that rods and/or mounting rods connected thereto may provide an inclined mounting surface/structure for solar module elements (e.g. enabling a southward orientation of the array).

When using a mounting structure comprising rods having willfully introduced bends or kinks it may be possible to enable an effective load/force transfer from the structure into a foundation. In particular, it may be possible that only tensile or compressive forces (and no or at least reduced torsional or bending forces or loads) may work on or affect the rods. The same may be true for the mounting rods in case mounting rods comprising bend(s) are provided in the mounting structure and/or solar module array. Thus, the cross section of the (mounting) rod(s) may be reduced possibly saving material and costs. Furthermore, even these tensile forces (transferred from the rods to the posts) may be cancelled at some of the posts in a solar module array due to the fact that tensile forces having (substantially) the same amount but opposite directions may be transferred to the same post from rods connected to the post at opposite sides, e.g. in the fact of great arrays having a mounting structure comprising a plurality of posts and rods attached or connected thereto. If necessary, some posts may be stabilized by additional stabilizing elements like guy-wires or guy-rods. Such stabilizing elements (e.g. guy-wires) may particularly be useful for posts at the edges or corners of a solar module (field) array and/or may be used additionally for some posts arranged in the inside or interior of the solar module array.

Due to a cancellation or reduction of torsional/bending forces (in particular substantially only tensile forces may be present in the rods and/or transferred to the posts) it may be possible that material may be saved which may reduce the costs of the mounting structure and thus of the whole solar module array.

A gist of an exemplary embodiment may be seen in providing a mounting structure comprising rods having (willfully) introduced bends or kinks, wherein the bends may be at predetermined positions depending on the geometry of the mountings structure and/or solar module (field) array. By providing such rods in mounting structures the overall stability of the mounting structure and/or of the solar module array may be increased or maintained while reducing the necessary material, e.g. reducing the thickness of walls of the rods.

In the following, further exemplary embodiments of the mounting structure for a solar module array will be explained. However, these embodiments also apply to the solar module (field) array and the method of assembling a mounting structure for a solar module (field) array.

According to an exemplary embodiment of the mounting structure the rod is a continuously formed rod.

For example, the rod may be formed by a hollow profile having e.g. a square or substantially square, a rectangular, an annular (circular) or elliptic cross-section. Alternatively, the rod may be formed by an open profile, e.g. a T-profile, C-profile, cap profile or U-profile. In general, the (cross-sectional) profile may be chosen according to the needs, e.g. may be chosen to have a high strength (e.g. can support a high load) while needing not too much material for forming the profile. Such a rod may be formed or manufactured by a forming process or by a pressing process or by extruding manufacturing a substantially straight rod and a subsequent bending step or process forming the bends in the rod. Alternatively, the bend rod may be formed by fixing (e.g. welding) several straight sub-rods (at junction points) to each other wherein the bends are preferably formed at the fixing or junction points of the sub-rods.

According to an exemplary embodiment the mounting structure further comprises at least one mounting rod, wherein the mounting rod is mounted to the rod at the at least one bend.

In particular, the mounting rod(s) may be mounted to the rod(s) in such a way that the application of force is performed close or even at the neutral axis of the rod. It should be noted that "mounting at" may particularly denote that fact that the mounting rod is mounted in close vicinity of the bend position. For example, the middle (axis) of the mounting rod may be arranged at the middle of the bend (wherein the middle/center of the bend may be formed by the center point of the arc forming the bend or bend portion) or at least not farther away than 10 cm, more particularly not farther away than 5 cm. Preferably the mounting rod is laid into the bend and fixed at that position. In particular, the mounting structure may comprise one, two or several mounting rods, wherein one mounting rod is mounted, fixed or connected at a first bend while the other one is mounted, fixed or

connected to a second bend of the same rod. It should be noted that these mounting rods may be substantially identical in shape and geometry. The same may hold true for the rods.

Preferably, the mounting rod is mounted to a single bend of each rod it is passing and at the same time only a single mounting rod is mounted to each bend of a rod. In particular, the mounting rod(s) may be mounted to the rod at an angle being at least 45°, e.g. in the range of 60° to 90°, in particular, between 80° and 90°, preferably about 90°. The mounting rod may be mounted to the rod by screws, clamps hooks or any other suitable manner, i.e. any manner might be chosen ensuring a connection sufficient stable or rigid to convey or transfer loads from the mounting rod into the rods. The mounting(s) may be in such a way that small relative movements between the rod and the mounting rod is still possible, e.g. by using screws or rivets and long holes, or in such a way that such relative movement is impossible or at least greatly reduced in the case of typical loads or forces impinging onto the mounting structure.

In particular, the mounting rod may be formed by a straight element (rod) or may as well comprises one, two or a plurality of bends or kinks. In case of a single bend, the bend may be formed (substantially) in a position corresponding to the middle between two (neighboring) rods the mounting rod is mounted or fixed onto. For example, it may be advantageous to use a straight element as a mounting rod in case the mounting structure is intended to be used in a solar module array having a so-called east-west orientation, while a mounting rod having a single bend or kink (between the mounting points at neighboring rods) may be intended for solar module arrays arranged in a way as described in WO 2010/018195 which is herewith incorporated herein by reference. Furthermore, mounting rods having two bends or kinks may be intended for solar module arrays arranged in a way as described in WO 2016/113131, which is herewith incorporated herein by reference.

According to an exemplary embodiment of the mounting structure the rod has two bends.

In particular, the bends may be arranged symmetrically, i.e. may have the same distance to the middle of the rod and/or one may have a first distance to a first end of the rod while the other one has the same first distance to the other end of the rod. However, the one or more bends may as well be arranged asymmetrical, e.g. in case solar module array is arranged on a slopy terrain.

According to an exemplary embodiment of the mounting structure the rod has four bends.

In particular, each of the four bends may have a mounting rod mounted thereto. For example, the mounting rods may be (substantially) parallel to each other. In particular, each bend may form a kink or a smooth curve of the rod. With such a rod it may be easy to form an array as described in WO 2010/018195. In particular, the four bends of one rod may be two outer bends and two inner bends, wherein the outer bends may be the two bends closer to the posts than the two inner bends (laying both between the outer bends on the rod).

According to an exemplary embodiment of the mounting structure the four bends are two outer bends and two inner bends; and a distance between one outer bend and the neighboring inner bend corresponds to a dimension of a solar module element.

In particular, the distance between each couple of outer and inner bend (on one side of a bend) may be correspond to the distance between two mounting areas determined on the solar module element (i.e. a size or dimension of the solar module element), e.g. the distance between optimal mounting areas, the size of the solar module element (in case of mounting the solar module element at its edges), or the distance between an optimal mounting area and an edge (in case the mounting is performed in a kind of "hybrid mounting", one mounting at an optimum mounting area and one at an edge). For example, in case of a typical solar module element comprising 60 cells, the distance may be in the range of 800 mm to

1300 mm (optimum mounting areas) or between 1600 mm and 1700 mm, corresponding to the length of the solar module element (edge mounting). For a typical solar module element comprising 72 cells, the distance may be in the range of 1000 mm to 1500 mm (optimum mounting areas) or between 1900 mm and 2100 mm, corresponding to the length of the solar module element (edge

mounting).

According to an exemplary embodiment of the mounting structure the at least one bend is formed at a position along the rod, wherein the position is

predetermined. In particular, the position may be determined such that, in case of a moveable joint at the position of the bend of the rod, a total load put to the rod of the mounting structure would provide for an extremum (e.g. minimal or maximal) value of potential/position energy of the mounting structure. It should be noted that this determination has to be understood in a broad sense, i.e. it is also true for a single bend in the rod (where the position and/or angle of the bend is already given by the geometry, i.e. the lengths of the sub-rods), since also in this case it can be said that the potential energy of the determined configuration is at its minimum (or maximum), since its represents the only possible configuration.

Another option to determine the bend position may be to determine the position and/or angle which the bend would assume (in case of a flexible bend) under the total load imposed to the rod. In particular, the total load may be defined by the sum of the weights of the rod(s), mounting rod(s), mounted solar module element(s) and potential additional loads, e.g. expected (maximal and/or average) wind and/or snow loads. That is, the bends may be formed at predetermined positions (along the rods). It should be noted that the actual positions of the bend(s) of course depends on the (expected) loads and the geometry, e.g. the length of the rod(s) and/or mounting rod(s) and/or dimensions of the solar module elements intended to be mounted on the mounting structure. However, with the above given determination methods the position(s) of the bend(s) may be easily and/or uniquely determinable.

By providing the bends at predetermined positions, which are determined according to the manner described above, it may be possible to reduce or even cancel torsial forces and/or torques introduced into the rod(s). Thus, it may be possible to reduce the necessary strength of the mounting structure.

Summarizing, according to an exemplary embodiment a solar module array may be provided comprising a plurality of posts having rods connected there between, wherein each of the rods comprises at least one bend to which a mounting rod is mounted, wherein the bend is formed at a predetermined position and with a predetermined angle wherein the position and/or angle is determined so that the bending forces/moments introduced by the total load (mounting rod, solar module element and additional expected loads) into the rod is minimized. In particular, the bending forces/ moments may be minimized in case the rod simulate (at least at the bend(s) position(s)) the course the rod would adopt under the influence of the total load in case the rod would be flexible (at least at the bend(s) positions). That is, the form or course of the rod(s) may be chosen or determined in such a way that the deformation/twist induced by the total load are already taken into account during the forming of the rods, thus no or at least only reduced bending forces/moments may be introduced into the rods when used in the solar module array.

Brief Description of the Drawings

The aspects defined above and further aspects are apparent from the examples of embodiment to be described hereinafter and are explained with reference to these examples of embodiment. In the drawings, like reference characters generally refer to the same parts throughout the different views. The drawings are not necessarily to scale. Instead emphasis is generally being placed upon illustrating the principles of the invention. In the following description, various exemplary embodiments are described with reference to the following drawings, in which :

Figs. 1A to ID schematically illustrate different steps of assembling a solar module field array according to an exemplary embodiment;

Figs. 2A to 2D schematically illustrate some examples of rods having different arrangements of bends;

Figs. 3A and 3B schematically illustrate two examples of a mounting structure and solar module elements mounted thereto;

Figs. 4A to 4C schematically illustrate embodiments of a mounting structure according to exemplary embodiments;

Figs. 5A to 5E schematically illustrate different mounting rods which can be used in a mounting structure according to an exemplary embodiment; and

Figs. 6A to 6E schematically illustrate some rough sketches of solar module arrays which can be built by using mounting structures according to exemplary embodiments.

Detailed Description of Embodiments

In the following further exemplary embodiments of a solar module field arrangement and a method of assembling a solar module field arrangement will be explained. It should be noted that the description of specific features described in the context of one specific exemplary embodiment may be combined with others exemplary embodiments as well.

Figs. 1A to ID schematically illustrate different steps of assembling a solar module field array or arrangement according to a first exemplary embodiment. In particular, Fig. 1A shows the solar module field array 100 after a first step after setting or founding a plurality of posts 101 on a foundation or ground area 102. As can be seen in Fig. 1A all posts 101 have (substantially) the same length or height after setting into the foundation, so that a (substantially) flat or horizontal

(depending on the slope of the foundation) plane would be defined by the upper ends of the posts 101. For illustration purposes of a rough scale a man 103 is shown in Fig. 1A as well, which indicates that the length of the posts is chosen in the depicted embodiment to be sufficient to easily access the space below the posts.

Fig. IB schematically shows the solar module field array 100 after a further step of assembling. In particular, a plurality of rods 105 are connected or fixed to the posts, wherein one end of the rods is connected to a first post while the other end of the rod is connected to a second post neighboring the first post along a first direction (e.g. x-direction, defined by the direction of the rods). In particular, the rods 105 are (substantially) parallel to each other. As can be seen in Fig. IB each of the rods 105 has or comprises four bends 106. In the embodiment of Fig. 1 these bends 106 are arranged symmetrical to the middle of the rod, i.e. are formed at positions along the rod having the same distance to the middle point or center of the rod. Thus, two inner bends and two outer bends are formed in each rod 105. It should be noted that depending on the circumstances more or less bends may be formed in each rod. For example, in case the rods are extending along an east-west direction only a single bend (in the center or middle of the rod) may be formed (while it may also be possible for east-west orientation to form several bends, e.g. four bends), while the depicted embodiment may be preferred in case of a south facing (in the northern hemisphere) field arrangement. In general, the positions and/or angles of the bends are depending on the geometry of the mounting structure or solar module array and the (expected) load and thus may differ from solar module array to solar module array. It should be noted that in case different loads or forces are imposed to the bends the resulting bends may be different, e.g. have different angles and/or positions. However, the positions may be easily determined for each geometry and corresponding to an expected load which will be explained in more detail after Fig. ID.

Fig. 1C schematically shows the solar module field array 100 after a further step of assembling. In particular, a plurality of mounting rods 110 are mounted to the rods 105. In particular, the mounting rods 110 are as well (substantially) parallel to each other. According to Fig. 1C the mounting rods are mounted to their respective rods (substantially) perpendicular to the rods, i.e. defining (substantially) a y-direction. Furthermore, the mounting rods are mounted to the rods at the positions of the bends 106 of the rod. As can be seen in Fig. 1C also the mounting rods 110 comprise bends 111. In particular, each mounting rod 110 comprises or has at least one bend 111 in the middle between the two points it is mounted to neighboring rods 105. In case the mounting rods are mounted (or passing over) more than two rods (as shown in Fig. 1C) the mounting rods additionally comprises bends 112 at the positions they are passing the rods, which as well can be clearly seen in Fig. 1C. It should be noted that of course the mounting rods may have a length which only corresponds to the distance (in y-direction) between two neighboring rods, so that each mounting rod is only mounted to two (neighboring) rods and only comprises the center bend 111. However, preferably each mounting rod 110 passes over a plurality of rods 105.

Fig. ID schematically shows the solar module field array 100 after a further step of assembling. In particular, a plurality of solar module elements 115 are mounted, e.g. clamped or screwed, to the mounting rods 110. In particular, the solar module elements 115, may be framed solar module elements (as shown in Fig. ID). As can be seen in Fig. ID the solar module elements 115 comprises mounting or clamp areas/regions 116 at which the solar module elements 115 are mounted to the mounting rods 110. The solar module array resulting from the embodiment shown in Fig. 1 may be a solar module array as described in more detail in WO 2010/018195. In general such a solar module assembly or array may comprise at least three solar module elements, which, in the operating state, are situated in an essentially horizontal, planar compound and are each inclined relative to one another to the horizontal H, wherein the side edge peripheral to the solar module assembly is lower or higher relative to the horizontal H than a middle central area formed by the at least three solar module elements. Thus, it may be possible to achieve a high area coverage by using a material efficient mounting structure, possibly leading to a high electrical power output while at the same time potentially using a cost efficient solar module array. It should be noted that the/some rods 105 may be arranged between two neighboring solar module elements (thus it may be possible that the rods extend slightly above the solar module elements) and/or the/some rods 105 may be arranged below the solar module elements. In the following the calculation of the positions and/or angles of the bends of the rods (and for potential bends of the mounting rods as well) will be explained in more detail. Firstly, it is assumed (for the calculation) that the rods are formed by sub-rods connected to each other at the bend positions by pivotable links. For example, for the embodiment shown in Fig. 1 the rod 105 is formed by five

(straight) sub-rods which would be linked (for the calculation) by four pivotable links (at the bend position 106). The distance of the two bends on one side may be determined by the desired positions of the mounting rods which in turns may be determined by the positions of clamping or mounting areas or portions formed in the intended/used solar module elements. The distance between the inner two bends in turn may be determined by the intended distance between the two solar module elements mounted to the left and the right side, respectively, while the position of the outer bends may, on the one hand, determine the distance to the neighboring solar module element of the same posts and may, on the other hand, determine the inclination angle of the mounted solar module element.

Therefore, the positions of the bends depend (uniquely) on the geometry of the intended solar module elements and/or the loads supposed for each bend position during the calculation. The angle of the pivotable links is then calculated.by minimizing the potential/position energy of the "load system" comprising or consisting of the rods, the mounting rods, the solar module elements and additional loads, e.g. average or maximum expected wind loads and/or snow loads. An alternative calculation process of the positions and/or angles may be performed by minimizing the forces/torques transferred or imposed by the "load system" to the rods.Jn general, this second calculation or minimization may be equivalent to calculation by minimizing the potential energy of the load system.

The so determined positions and/or angles of the bends 106 may provide for a minimum load/force/torque imposed or transferred to the rods for a given solar module array.

For the embodiment shown in Fig. 1 some dimensioning numbers concerning the solar module array may be given in the following : In case of solar module elements comprising 60 cells, the two posts to which a single rod is connected (row) may have a distance of (about) 4078 mm. The first bend may be at (about) 343 mm, while the distance to the second bend may be (about) 1428 mm. The two inner bends may have a distance of (about) 577 mm, while the fourth bend is arranged symmetrical to the first bend. Furthermore, the portions of the rods between an outer bend and the neighboring inner bend (i.e. the portions arranged completely under one solar module element) may have an angle (about) 7.02° to the horizontal plane (parallel to the horizontal ground area 102).

In another embodiment, e.g. an east-west oriented solar module array using solar module elements having 60 cells and having a 10° inclination, the numbers may be the following. The distance of the posts may be as well (about) 4078 mm, while the first bend may be at (about) 365 mm (corresponding to the length from the connection point of the rod to the first bend). The distance to the second bend may be as well (about) 1428 mm. The two inner bends may have a distance of (about) 577 mm, while the fourth bend is arranged symmetrical to the first bend. Furthermore, the portions of the rods between an outer bend and the neighboring inner bend (i.e. the portions arranged completely under one solar module element) may have an angle (about) 10.02° to the horizontal plane (parallel to the horizontal ground area).

It should be noted that for safety reasons some posts, in particular the edge and/or corner posts (where no or only reduced cancellation of the loads/forces is achieved) but also some posts inside of the field, may be supported by additional guy-wires or guy-rods. Thus, an efficient overall mounting system may be formed with respect to used material and/or costs compared to the power output of the solar module array. Furthermore, additional support or stiffening elements may be formed between rod(s) and mounting rod(s), e.g. in the form of elements forming a triangular with the respective rod and mounting rod, laying at the edge of the solar module array. Thus, the solar module array may additionally be stiffened.

Figs. 2A to 2D schematically illustrate some examples of rods having different arrangements of bends. In particular, Fig. 2A shows a side view of a mounting structure 200 comprising two posts 201 and a rod 205 connected to the two posts. The rod comprises eight bends 206 to which respective mounting rods are mounted (indicated in Fig. 2A by dots 210). Onto the mounting rods 210 four solar module elements 215 are mounted. In particular, Fig. 2B shows a side view of a mounting structure 220 comprising two posts 221 and a rod 225 connected to the two posts. The rod comprises two bends 226 to which respective mounting rods are mounted (indicated in Fig. 2B by dots 230). In addition, two further mounting rods 230 are mounted on top of the posts. Onto the mounting rods 230 two solar module elements 235 are mounted. It should be noted that Fig. 2B shows a so-called "hybrid clamping", i.e. two of the solar module elements are clamped to the mounting rods at the designed (optimum) mounting areas or regions (the inner one in Fig. 2B) while the outer clamping is performed at a frame of the solar module elements 235 or in the corner of the solar module element (i.e. outside of the optimal mounting areas),.

In particular, Fig. 2C shows a side view of a mounting structure 240 comprising two posts 241 and a rod 245 connected to the two posts. The rod comprises four bends 246 to which respective mounting rods are mounted

(indicated in Fig. 2C by dots 250). Onto the mounting rods 250 two solar module elements 255 are mounted. It should be noted that contrary to Fig. 2B, Fig. 2C shows the "optimum" clamping at all rods, i.e. the clamping or mounting is performed in the mounting areas of the solar module elements 255 (which allow for the highest compression and/or tension loads.

In particular, Fig. 2D shows a side view of a mounting structure 260 comprising two posts 261 and a rod 265 connected to the two posts. The rod comprises one bend 266 to which a respective mounting rod is mounted (indicated in Fig. 2D by dots 270). In addition, two further mounting rods 270 are mounted directly on top of the posts 261. Onto the mounting rods 270 two solar module elements 275 are mounted, e.g. clamped at the frame of the solar module elements or at the solar module elements itself in case of frameless modules.

Figs. 3A and 3B schematically illustrate two examples of a mounting structure and solar module elements mounted thereto. In particular, Fig. 3A shows a dome-like or convex mounting structure 300 in a side view comprising two posts 301 and a rod 305 ("standing rods") connected thereto. The rod comprises two bends 306 close to the center of the rod to which mounting rods 310 are mounted. Two additional mounting rods are mounted on top of the posts. To the four mounting rods two solar module elements 315 are mounted. Such a dome-like mounting structure may be in particular suitable for a solar module array arranged on a (flat) roof and/or for cases no (or at least only small) compression forces/loads (e.g. no snow loads and/or no excessive wind loads) but therefore tension forces/loads (tension/suction forces by winds) has to be expected.

The positions of the bends 306 may correspond to the positions as determined by the above described calculation methods, when the potential energy is maximized, leading to "mirrored" positions of the bends (mirrored with respect to a horizontal line in Fig. 3A) compared to the positions determined by minimizing the potential energy. For these positions of the bends as well forces and/or torques induced into the rods may be reduced so that (substantially) only tensional forces has to be transferred by the rods.

In particular, Fig. 3B shows a concave mounting structure 320 in a side view comprising two posts 321 and a rod 325 ("hanging rods") connected thereto. The rod comprises two bends 326 close to the center of the rod to which mounting rods 330 are mounted. Two additional mounting rods are mounted on top of the posts. To the four mounting rods two solar module elements 335 are mounted. In particular, Fig. 3B shows some kind of horizontally "mirrored case" of the

embodiment of Fig . 3A.

Figs. 4A to 4C schematically illustrate embodiments of a mounting structure according to exemplary embodiments. In particular Fig. 4A shows a mounting structure 400 comprising two posts 401 and a rod 405 connected between these posts. The rod comprises a single bend 406 which is asymmetrical to the middle of the rod. This is a result of the fact that the two posts 401 are arranged on different heights as indicated by dotted line 407. That is, the right post in Fig. 4A is arranged lower than the left one resulting in a displacing of the position of the bend

determined according to the above described methods. In addition, Fig. 4A shows two mounting rods 410 and a solar module element 415 mounted to the mounting rods. Fig. 4A as well demonstrates that it is not necessary that the solar module elements cover the whole rod or the whole space between two posts. The shown embodiment may be in particular useful for an arrangement of the solar module array facing south (southward orientation).

Fig. 4B shows a similar arrangement. However, the rod 425 comprises three bends 426 and in total four mounting rods 430 mounted to top end of the higher post 421 and to the rod at the three bends so that three solar module elements can be mounted to the mounting structure 420. Furthermore, additional spacer or distance elements 428 (or respective formed mounting rods) may be used so that the surface of the solar module elements 435 are laying (substantially) in a common plane.

Fig. 4C schematically shows that it is also possible to omit the spacer of the embodiment of Fig. 4B so that the solar module elements 455 are angled with respect to each other. Alternatively, the height of the spacers may be different so that the solar module elements may be brought out of a common plane, i.e. may be shifted in height and/or inclination with respect to each other.

Figs. 5A to 5E schematically illustrate different mounting rods which can be used in a mounting structure according to an exemplary embodiment. In particular, Fig. 5A schematically illustrate a mounting structure 500 comprising posts 501 and rods 505 comprising four bends (for clarity reasons and due to the scale the bends are not shown in Fig. 5) each having a mounting rod 510 mounted thereto. In the embodiment of Fig. 5A the mounting rods are straight, i.e. do not comprise a specific number of bends. Such straight mounting rods may be in particular useful for east-west arrangements of solar module arrays.

Fig. 5B shows an arrangement 520 similar to the one shown in Fig. 5A comprising posts 521 and rods 530_connected thereto and having bends (not shown). In contrast to the embodiment shown in Fig. 5A the mounting rods 530 comprises a bend 536 in the middle between the mounting points of the mounting rod to the rods, wherein the bend 536 is formed so that the mounting rods 530 extends below the top end of the posts (hanging mounting rods). Such a mounting structure may be in particular useful for solar module arrays having an arrangement as described in WO 2010/018195,

Fig. 5C shows an arrangement similar to the embodiment of Fig. 5B however the bend 556 of the mounting rods 550 mounted to the rods 545 (which in turn are connected to posts 541) are extending above the top end of the posts 541 (standing mounting rods).

Fig. 5D shows an arrangement similar to the embodiment of Fig. 5B (hanging mounting rods) however the additional spacers or distance elements 577 are mounted or fixed to the bends 576 of the mounting rods 570 mounted to the rods 565 (which in turn are connected to posts 561). Thus, the surface of solar module elements (not shown) mounted to the mounting rods and the spacer is

(substantially) leveled again, so that the shown embodiment may as well be suitable for an east-west orientation of a solar module array.

Fig. 5E shows an arrangement similar to the embodiment of Fig. 5B (hanging mounting rods) however every second row of posts 581 is omitted instead an additional supporting structure 598 (e.g. in the form of a triangle) is fixed to the mounting rods 590 having two bends 596. In particular, the additional supporting structure 598 is mounted to its respective mounting rod such that the load transferred from the supporting structure to the mounting rod is introduced at the bends 596 of the mounting rod.

Figs. 6A to 6E schematically illustrate some rough sketches of solar module arrays which can be built by using mounting structures according to exemplary embodiments. In particular, Fig. 6A shows a solar module array of four solar module elements mounted to a mounting structure 600 comprising two "hanging" rods 605 comprising (not shown) bends to which (not shown) "hanging" mounting rods are mounted. According to the embodiment of Fig. 6A the mounting rods comprises a middle bend as indicated by the course of the solar module elements 615.

In particular, Fig. 6B shows a similar solar module array as Fig. 6A but having "standing" mounting rods, while the one depicted in Fig. 6C comprises "hanging" mounting rods but "standing" rods. In the one shown in Fig. 6D the mounting structure comprises "standing" rods and "standing" mounting rods. The one shown in Fig. 6E is as well similar to the one shown in Fig. 6A, i.e. comprises "hanging" rods and "hanging" mounting rods. However, the rods comprise eight bends while the mounting rods would comprise mounting rods similar to the one shown in Fig. 5E, i.e. comprises additional supporting structures.

Summarizing a plurality of embodiments of mounting structures and solar module arrays are described above all comprising rods and/or mounting rods having bends formed at predetermined positions, wherein the positions of the bend preferably depending on the geometry and/or load imposed to the mounting structure. The course and arrangement of the rod(s) and mounting rod(s) may depend on the desired layout of the solar module array, e.g. whether it has a southward facing or east-west orientation, whether the solar module elements shall have an inclined (e.g. about 15° to 25° or even higher) or rather flat (e.g. below 10°) orientation, whether the solar module elements shall be arranged in a close neighborhood (or even abutting) to each other or having an intentional gap (e.g. in a ±x-direction, ±y-direction and/or ±z-direction, according to the coordinate system used above as well) formed between neighboring solar module elements. Such gaps may be advantageous with respect to wind loads since such gaps may enable an air or pressure exchange between the upper side of the solar module elements and the lower side of the same. Such gaps and the advantages of the same are described in more detail in the filed German Patent Application No. 10 2016 004 347.4 which is herewith incorporated herein by reference.

It should also be noted that the term "comprising" does not exclude other elements or features and the "a" or "an" does not exclude a plurality. Also elements described in association with different embodiments may be combined. It should also be noted that reference signs shall not be construed as limiting the scope of the claims. While the invention has been particularly shown and described with reference to specific embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. The scope of the invention is thus indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced. Throughout the whole description the word "exemplary" is used to mean "serving as an example, instance, or illustration". Any embodiment, aspect or design described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments or designs .

Claims

C l a i m s

1. A mounting structure for a solar module array the mounting structure comprising :

at least two posts configured to be connected to a foundation; and

a rod having at least one bend,

wherein the rod is connected to a first one of the at least two posts and to a second one of the at least two posts.

2. The mounting structure according to claim 1, wherein the rod is a

continuously formed rod.

3. The mounting structure according to claim 1 or 2, further comprising at least one mounting rod, wherein the mounting rod is mounted to the rod at the at least one bend.

4. The mounting structure according to any one of the claims 1 to 3, wherein the rod has two bends.

5. The mounting structure according to any one of the claims 1 to 4, wherein the rod has four bends.

6. The mounting rod according to any one of the claims 5,

wherein the four bends are two outer bends and two inner bends; and wherein a distance between one outer bend and the neighboring inner bend corresponds to a size of a solar module element.

7. The mounting structure according to any one of the claims 1 to 6, wherein the at least one bend is formed at a position along the rod, wherein the position is determined such that, in case of a moveable joint at the position of the bend of the rod, a total load would provide for an extremum value of potential energy the mounting structure.

8. A solar module array comprising :

at least one mounting structure according to any one of the claims 1 to 7; and

at least one solar module element mounted to the mounting structure.

9. The solar module array according to claim 8, comprising

a plurality of mounting structures according to any one of the claims 1 to 6; and

a plurality of solar module elements mounted to the plurality of mounting structures.

10. A method of assembling a mounting structure of a solar module array, the method comprising :

mounting two posts on foundations;

connecting a rod to a first one of the two posts and to the second one of the two posts, wherein the rod has at least one bend.

11. The method according to claim 10, further comprising :

mounting a mounting rod to the rod and/or

mounting at least one solar module element to the mounting structure.