Monolithic Bracket for Flat Roof Mounted Photovoltaic Modules

An integral, monolithic mounting bracket for supporting a corner of a photovoltaic (PV) module, the bracket comprising:

• a ballast tray for holding one or more ballast blocks;
• a plurality of monolithic support legs that are disposed at an acute angle from a plane of the ballast tray and that are integral with the ballast tray;
• and
• a plurality of clamp assemblies, each clamp assembly comprising a bolt and a clamp;
• wherein each clamp comprises a plurality of sharp points for piercing a non-conductive coating of a photovoltaic module frame and creating an electrical bonding path;
• wherein each support leg comprises a plurality of integral, monolithic module mounting tabs, wherein each tab defines a hole for receiving a fastener from a clamping assembly.

An integral, monolithic mounting bracket for supporting a corner of a photovoltaic (PV) module, the bracket comprising:

• a ballast tray for holding one or more ballast blocks;
• a plurality of monolithic support legs that are disposed at an acute angle from a plane of the ballast tray and that are integral with the ballast tray;
• and
• five module mounting tabs per support leg, with three tabs being oriented at a shallow angle with respect to a horizontal plane and pointed towards a first end of the bracket, and with two tabs being oriented at the same shallow angle with respect to the horizontal plane and pointed towards a second end of the bracket opposite to the first end of the bracket;
• wherein each support leg comprises a plurality of integral, monolithic module mounting tabs, wherein each tab defines a hole for receiving a fastener from a clamping assembly.

An integral, monolithic mounting bracket for supporting a corner of a photovoltaic module, the bracket comprising:

• a ballast tray for holding one or more ballast blocks defining a plurality of empty spaces;
• and
• a plurality of monolithic support legs, having shapes substantially corresponding to the plurality of empty spaces, that are disposed at an acute angle from a horizontal plane of the ballast tray and that are integral with the ballast tray, wherein the legs lean inwards towards a center of the bracket;
• and
• a plurality of clamp assemblies to clamp the photovoltaic module in place on the support legs, each clamp assembly attached to the support leg with a bolt and a clamp;
• wherein the acute angle ranges from 75-89 degrees;
• wherein the bracket is symmetric across a plane of symmetry that:
• (a) is oriented perpendicular to the plane of the ballast tray, and (b) is located in a middle of the ballast tray;
• wherein two or more brackets are stackable in a nested group;
• wherein the bracket is made of sheet metal;
• and
• wherein each clamp comprises a plurality of sharp points for piercing a non-conductive coating of a photovoltaic module frame and creating an electrical bonding path.

An integral, monolithic mounting bracket for supporting a corner of a photovoltaic module, the bracket comprising:

• a ballast tray for holding one or more ballast blocks;
• and
• a plurality of monolithic support legs that are disposed at an acute angle from a plane of the ballast tray and that are integral with the ballast tray;
• wherein the acute angle is 85 degrees;
• wherein two or more brackets are stackable in a nested group;
• wherein the bracket is made of galvanized steel sheet metal;
• wherein each support leg comprises a plurality of vertical stiffening ribs;
• wherein the ballast tray comprises a plurality of horizontal stiffening ribs;
• further comprising a pair of vertical edges disposed on a perimeter of the ballast tray;
• wherein each support leg comprises a plurality of integral, monolithic module mounting tabs, each tab defining a hole for receiving a fastener from a clamping assembly;
• wherein each module mounting tab is angled at a shallow angle with respect to the plane of the ballast tray, wherein the shallow angle is 5 degrees;
• wherein each module mounting tab is oriented perpendicular to its support leg;
• wherein the ballast tray defines a plurality of leftover empty spaces in the ballast tray corresponding to material that is stamped and bent-up for the support legs;
• further comprising a plurality of clamp assemblies, each clamp assembly comprising a bolt and a clamp;
• wherein each clamp comprises a plurality of sharp points for piercing a non-conductive coating of a PV module frame and creating an electrical bonding path;
• and
• further comprising a side mount support flange disposed vertically on a side of a support leg and oriented perpendicular to said leg.

A method of forming an integral, monolithic mounting bracket for supporting a corner of a photovoltaic module, the method comprising:

• (a) providing a rectangular-shaped sheet of metal, the sheet defining a plane;
• (b) stamping at least two identical sections of metal from the sheet, with each section being cut along three sides, leaving an uncut fourth side remaining, in a pattern that leaves a continuous rim of metal along a perimeter of the sheet;
• and then
• (c) bending-up each section on its remaining uncut fourth side into a near-vertical position to form a ballast tray defining a plurality of empty spaces, whereby each bent-up section forms a monolithic support leg inclined inwards toward another monolithic support leg, having a shape substantially corresponding to one of the plurality of empty spaces, disposed at an acute angle from a plane disposed inside of a ballast tray, and forming the bracket with the ballast tray for holding one or more ballast blocks and mounting tabs angled at a shallow angle with respect to a horizontal plane.

An integral, monolithic mounting bracket for support a corner of a photovoltaic (PV) module, the bracket comprising:

• a ballast tray for holding one or more ballast blocks;
• a plurality of monolithic support legs that are disposed at an acute angle from a plane disposed inside of the ballast tray, and that are integral with the ballast tray, wherein the legs lean inwards towards a center of the bracket;
• and
• a plurality of clamp assemblies, each clamp assembly attached to a support leg with a bolt and a clamp;
• wherein each clamp comprises a plurality of sharp points for piercing a non-conductive coating of a photovoltaic module frame and creating an electrical bonding path;
• and
• wherein a turned-up rim is disposed continuously around an entire ballast tray outside perimeter.

An integral, monolithic mounting bracket for support a corner of a photovoltaic (PV) module, the bracket comprising:

• a ballast tray for holding one or more ballast blocks;
• a plurality of monolithic support legs that are disposed at an acute angle from a horizontal plane disposed inside of the ballast tray, and that are integral with the ballast tray;
• and a plurality of clamp assemblies, each clamp assembly comprising a bolt and a clamp;
• wherein each clamp comprises a plurality of sharp points for piercing a non-conductive coating of a photovoltaic module frame and creating an electrical bonding path;
• wherein a rim is disposed around a ballast tray perimeter;
• and
• wherein each support leg comprises a plurality of integral, monolithic module mounting tabs, and each tab defines a hole for receiving a fastener from one of said clamping assemblies.

An integral, monolithic mounting bracket for support a corner of a photovoltaic (PV) module, the bracket comprising:

• a ballast tray for holding one or more ballast blocks and having a rim disposed around a ballast tray perimeter;
• and
• a plurality of monolithic support legs that are disposed at an acute angle from a horizontal plane disposed inside of the ballast tray, and that are integral with the ballast tray wherein the legs lean inwards towards a center of the bracket;
• wherein each support leg comprises a plurality of integral, monolithic module mounting tabs attached to the support legs, wherein each tab defines a hole for receiving a fastener from a clamping assembly.