DIAGONAL MOUNTING BRACKET FOR A PHOTOVOLTAIC MODULE
A photovoltaic module has a diagonal mounting bracket for structural attachment of the module to a support structure. The photovoltaic module has a back cover with an outer surface and a diagonal mounting bracket is attached to the back cover and extends along at least a portion of a diagonal of the back cover. A method of forming a photovoltaic module with a diagonal mounting bracket is also described.
1 . A photovoltaic module comprising:
a front cover and a back cover;
a plurality of photovoltaic cells between the front and back covers; and
a diagonal mounting bracket attached to the back cover and extending along at least a portion of a diagonal of the back cover.
2 . The module of claim 1 , wherein the diagonal of the back cover has a first length and the diagonal mounting bracket has a second length, wherein the first length is about equal to or greater than the second length.
3 . The module of claim 1 , wherein the diagonal of the back cover has a first length and the diagonal mounting bracket has a second length, wherein the second length is at least about one-third of the first length.
4 . The module of claim 1 , wherein the diagonal of the back cover has a first length and the diagonal mounting bracket has a second length, wherein the second length is between about one-third and about two-thirds of the first length.
5 . The module of claim 1 , wherein the diagonal mounting bracket has longitudinally extending ribs formed on the outer surface of the bracket.
6 . The module of claim 1 , wherein the diagonal mounting bracket has longitudinally extending sidewalls formed at opposite side edges of the bracket.
7 . The module of claim 1 , wherein the diagonal mounting bracket has one or more spaced fasteners for fastening the module to a support structure.
8 . The module of claim 7 , wherein the fasteners are one of bolts and nuts.
9 . The module of claim 1 , wherein the diagonal mounting bracket comprises at least one of aluminum, steel, metal alloy and a polymeric material.
10 . The module of claim 1 , further comprising a first and second corner support clip attached to the front and back covers at respective first and second corners of the module provided at opposite ends of a first diagonal of the module, wherein the first and second corner support clips are each connected to respective first and second opposite ends of the diagonal mounting bracket.
11 . The module of claim 10 , wherein the first and second ends of the diagonal mounting bracket are each spaced a distance in the range of about 10 mm to about 30 mm from the respective first and second corners of the module.
12 . The module of claim 10 , further comprising a third and a fourth corner support clip attached to the front and back covers at respective third and fourth corners of the module provided at opposite ends of a second diagonal of the module.
13 . The module of claim 12 , wherein at least one of the first, second, third and fourth corner support clips further comprises a junction box.
14 . The module of claim 12 , wherein at least one of the first, second, third and fourth corner support clips comprises at least one edge connector for making an electrical connection to said module.
15 . The module of claim 3 , further comprising a first and second corner support clip attached to the front and back covers at respective first and second corners of the module provided at opposite ends of a first diagonal of the module.
16 . The module of claim 15 , further comprising a third and a fourth corner support clip attached to the front and back covers at respective third and fourth corners of the module provided at opposite ends of a second diagonal of the module.
17 . The module of claim 16 , wherein at least one of the first, second, third and fourth corner support clips comprises a junction box.
18 . The module of claim 16 , wherein at least one of the first, second, third and fourth corner support clips comprises at least one edge connector forming an electrical connection to said module.
19 . A method of forming a photovoltaic module comprising the steps of:
providing a front cover and a back cover;
providing a plurality of photovoltaic cells between the front and back covers;
attaching a diagonal mounting bracket to the back cover, the diagonal mounting bracket extending along at least a portion of a diagonal of the back cover between a first and a second corner of the module provided at opposite ends of a first diagonal of the module for structural attachment of the photovoltaic module to a support structure.
20 . The method of claim 19 , wherein the diagonal of the back cover has a first length and the diagonal mounting bracket has a second length, wherein the first length is about equal to or greater than the second length.
21 . The method of claim 19 , wherein the diagonal of the back cover has a first length and the diagonal mounting bracket has a second length, wherein the second length is at least about one-third of the first length.
22 . The method of claim 19 , wherein the diagonal of the back cover has a first length and the diagonal mounting bracket has a second length, wherein the second length is between about one-third and about two-thirds of the first length.
23 . The method of claim 19 , wherein the diagonal mounting bracket has longitudinally extending ribs formed on the outer surface of the bracket.
24 . The method of claim 19 , wherein the diagonal mounting bracket has longitudinally extending sidewalls formed at opposite side edges of the bracket.
25 . The method of claim 19 , wherein the diagonal mounting bracket has one or more spaced fasteners for fastening the module to a support structure.
26 . The method of claim 25 , wherein the fasteners are one of bolts and nuts.
27 . The method of claim 19 , wherein the diagonal mounting bracket comprises at least one of aluminum, steel, metal alloy and a polymeric material.
28 . The method of claim 19 , further comprising the step of attaching a first and a second corner support clip to the front and back covers of the module at respective first and second corners of the module.
29 . The method of claim 19 , wherein the step of attaching the diagonal mounting bracket comprises using one of adhesive and ultrasonic welding.
30 . The method of claim 28 , wherein the first and second opposite ends of the diagonal mounting bracket are each spaced a distance in the range of about 10 mm to about 30 mm from the respective first and second corners of the module.
31 . The method of claim 28 , further comprising the step of attaching a third and a fourth corner support clip to the front and back covers at respective third and fourth corners of the module provided at opposite ends of a second diagonal of the module.
32 . The method of claim 31 , wherein at least one of the first, second, third and fourth corner support clips further comprises a junction box.
33 . The method of claim 31 , wherein at least one of the first, second, third and fourth corner support clips comprises at least one edge connector for making an electrical connection to said module.
34 . The method of claim 21 , further comprising the step of attaching a first and second corner support clip to the front and back covers at respective first and second corners of the module.
35 . The method of claim 34 , further comprising the step of attaching a third and a fourth corner support clip to the front and back covers at respective third and fourth corners of the module provided at opposite ends of a second diagonal of the module.
36 . The method of claim 35 , wherein at least one of the first, second, third and fourth corner support clips comprises a junction box.
37 . The method of claim 35 , wherein at least one of the first, second, third and fourth corner support clips comprises at least one edge connector forming an electrical connection to said module.