Abstract:
In various representative aspects, an assembly for connecting and electrically bonding electronic equipment to solar panel frames is provided. The present invention relates generally to an assembly for supporting junction box structures used in a solar panel frame array. More specifically, the apparatus comprises an adjustable bracket assembly that can mount most sizes and shapes of junction boxes that are then secured virtually to any solar panel frame while being electrically bonded by way of a surface layer penetrating means.

Description:
BACKGROUND OF INVENTION 
     Field of the Invention 
       [0001]    The present invention relates generally to an assembly for securing and installing electrical junction boxes for use with solar panel arrays that are typically installed on roof structures. More specifically, the assembly comprises a bracket assembly that supports an electrical junction box on one end, and is coupled to the frame of a solar panel module. When coupled to the solar panel frame, the bracket can also include an electrical bonding means to electrically bond the junction box to the solar panel frame. A method of installation is also disclosed. 
       Description of the Related Art 
       [0002]    Any discussion of the prior art in the specification should in no way be considered as an admission that the prior art is widely known or forms part of common general knowledge in the field. 
         [0003]    Installing a solar panel array on a roof can be challenging. One difficult aspect of the process is installing a junction box as part of the array so that the junction box has a low profile and requires only a minimum number of parts to complete the installation. A junction box typically provides an enclosed junction where wiring from different components in the solar panel array are combined and grounded. 
         [0004]    There are several types of junction boxes that are typically used. They range in size from a 4″×4″×2″ to a 12″×12″×6″ size box and are made from various materials including PVC plastic and stainless steel. 
         [0005]    There are several ways to install junction boxes as part of the solar panel array. First, the junction box can be installed using a roof-mounted structure as shown in  FIG. 1 . This structure affixes the box  100  with external cable conduit  110  flat on the roof structure  105  and uses screws or glue to secure the box to the roof structure  105 . This is not ideal because it creates unwanted holes into the roof  105 , which may create possible leak points. Furthermore, the box  100  is in plain sight on the roof making it unsightly and unappealing aesthetically. 
         [0006]    A second variation of the junction box installation is a roof-mounted structure with a flashing  130  as shown in  FIGS. 2 and 3 . This assembly is similar to the first example, except that the box  100  is mounted directly to the flashing  130  or is incorporated with the flashing  130 . This variation is limited to flash mounting and may require a proprietary box and proper flashing. It must be mounted directly to the roof  105  as well. 
         [0007]    A third variation of the junction box installation is in the form of a rail mounted box that is mounted to a solar panel rail guide  140  as shown in  FIG. 4 . In this example, the solar panel rail guide  140  is typically mounted to the roof  105  by using a bracket  160  secured with a bolt  165 . The junction box  150  is then coupled to the rail guide  140  using a bolt or similar connecting device. This design can only be installed on solar panel arrays that use rail guides to support the solar panel frames and typically requires extra hardware and brackets to complete the installation. 
         [0008]    A fourth variation is a rail-less mount that is coupled directly to the frames on the solar panel array as shown in  FIG. 5 . The present invention falls under this category of structure. In this variation, the box  155  is secured to the solar panel frame  500  by using a pair of L-shaped brackets  170  that are affixed within a groove of the solar panel frame  500  with the box  155  secured to the extended portions  180  of the brackets  170 . This design limits the installer to use only proprietary module frames with grooves or slots that match the linking hardware. A design that enables junction boxes to be secured to any solar panel frame is and is not limited to any shape or size of junction box. Additionally, a design that can be installed in a rail-less solar panel array to virtually any solar panel frame that is not limited to a particular design of frame is desired. 
       SUMMARY OF THE INVENTION 
       [0009]    The invention is summarized below only for purposes of introducing embodiments of the invention. The ultimate scope of the invention is to be limited only to the claims that follow the specification. 
         [0010]    It is an object of the present invention to provide a bracket mount assembly for securing electrical panels such as an electrical junction box to a solar panel frame. 
         [0011]    It is a further object of the present invention to provide a bracket mount assembly that electrically bonds the junction box to the solar panel frame. 
         [0012]    It is a further object of the present invention for the bracket comprise a clip for securing the bracket to the solar panel frame. 
         [0013]    It is a further object of the present invention for the clip to comprise a raised portion such as a grounding pin to penetrate a surface oxidation layer of the solar panel frame in order to electrically connect the solar panel frame to the junction box. 
         [0014]    It is a further object of the present invention for the clip to be adjustable to fit on varying sizes of solar panel frames. 
         [0015]    It is a further object of the present invention to provide a method for securing the bracket to the solar panel frame. 
         [0016]    It is a further object of the present invention to provide a method for securing the junction box to the bracket. 
         [0017]    A person with ordinary skill in the relevant art would know that any shape or size of the elements described below may be adopted. Any combinations of suitable number, shape, and size of the elements described below may be used. Also, any materials suitable to achieve the object of the current invention may be chosen as well. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures. 
           [0019]      FIG. 1  illustrates a perspective view of a prior art junction box direct roof installation. 
           [0020]      FIG. 2  illustrates a top perspective view of a junction box prior art installation that is secured to a roof with a flashing. 
           [0021]      FIG. 3  is a perspective view of a variation of the junction box installation shown in  FIG. 2  that uses a flashing. 
           [0022]      FIG. 4  illustrates a front view of a junction box prior art installation secured to a solar panel rail guide. 
           [0023]      FIG. 5  illustrates a perspective view of a junction box prior art installation that is connected directly to a solar panel frame. 
           [0024]      FIG. 6  illustrates a perspective view illustrating an exemplary junction box mounting bracket. 
           [0025]      FIG. 7  illustrates a side view of the mounting bracket of  FIG. 6  with an exploded view of an end of the bracket when it is secured to the junction box. 
           [0026]      FIG. 8  illustrates a perspective exploded view of an exemplary junction box that is secured to the mounting bracket of  FIG. 6 . 
           [0027]      FIG. 9  illustrates a perspective view showing the exemplary junction box bracket secured to the junction box prior to being secured to a solar panel frame. 
           [0028]      FIG. 10  illustrates a bottom perspective view of the mounting brackets secured to the solar panel frame with the junction box secured to the mounting brackets. 
           [0029]      FIG. 11  illustrates an alternative exemplary embodiment of the junction box mounting bracket with an adjustable clamp. 
           [0030]      FIG. 12  illustrates a side view of the alternative exemplary mounting bracket of  FIG. 11  with an exploded view of an end of the bracket when it is secured to the junction box. 
           [0031]      FIG. 13  illustrates a perspective exploded view of the junction box that is secured to the alternative exemplary mounting bracket of  FIG. 11 . 
           [0032]      FIG. 14  illustrates a perspective view showing the alternative exemplary junction box mounting bracket secured to the junction box prior to being secured to a solar panel frame. 
           [0033]      FIG. 15  illustrates a top perspective view of a fully installed pair of alternative exemplary mounting brackets secured to the solar panel frame. 
           [0034]      FIG. 16  illustrates a side view of  FIG. 15 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0035]    In the following description, and for the purposes of explanation, numerous specific details are provided to thoroughly understand the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed embodiments may be applied. The full scope of the invention is not limited to the example(s) that are described below. 
         [0036]      FIG. 6  illustrates an exemplary junction box mount comprising a bracket  200  for use with a rail-less solar panel array system. The bracket  200  as generally L-shaped and includes a front side  210  and a rear side  237 . The front side  210  includes several openings or pilot holes  220 . Although one pilot hole would be sufficient, having several pilot holes  220  allows a junction box  300 , as shown in  FIG. 8 , to be secured at various locations along the front side  210  of the bracket  200 . The junction box  300  can be secured to the front side  210  of the bracket  200  with by using fasteners such as standard screws  290  as shown in  FIG. 7 , or slots can be used to interconnect the junction box  300  when necessary. The slots can also use self-driven screws. The advantage of a slot is that allows more location freedom. The bracket  200  can be manufactured in any suitable manner such as extruding it into a single piece. The bracket  200  is typically combined with a second identical bracket to properly secure a wide range of junction box sizes in place along a solar panel frame. 
         [0037]    The rear side  237  of the bracket is better shown in  FIG. 7 . The rear side  237  in this exemplary embodiment illustrates a single-sized clip  235  that is adapted for a single-sized solar panel frame  500 . The clip  235  includes a bottom panel  280 , a rear panel  230 , and a top panel  240 . The bottom panel includes an opening  285 . The opening  285  is typically threaded for receiving a fastener such as an adjustable screw  260 , which in this embodiment is a standard thumb screw  260 , with a threaded shank  270 . The top panel includes at least one grip  250  and may also include a raised portion  255  that can penetrate a surface oxidation layer of a metal object. The thumb screw  260  is used to tighten the grip to the solar panel frame  500  as shown in  FIG. 9 . The thumb screw  260  also serves to electrically bond the bracket  200  to the solar panel frame  500  by penetrating the surface oxidation layer of the solar panel frame  500  when tightened. It is understood that other types of fasteners can be used to secure the clip  235  to the solar panel frame  500  that can penetrate a surface oxidation layer of a metal object. Also pictured is an example of a self-tapping screw  290  in the exploded view of the end of the bracket  200  that shows how the junction box  300  is secured to the bracket  200 . 
         [0038]    A typical junction box  300  is installed as shown using the following steps. First, the junction box is secured to the brackets  200  as shown in  FIG. 8 . The exemplary junction box  300  has a side mount  310  on each side of the box  300  with screw holes  315 . The screws  290  are secured through the screw holes  315  and into at least one of the pilot holes  220  on the front side  210  of the bracket  200 . It is understood by one of ordinary skill in the art that the junction box  300  can be secured to the brackets  200  by using similar fasteners to the screws  290  or by permanently affixing the junction box  300  with adhesive methods. 
         [0039]    Once the junction box  300  is secured to the brackets  200 , the brackets  200  are coupled to the solar panel frame  500  as shown in  FIG. 9 . A typical solar panel frame  500  has a top side  540 , a front side  520  and a bottom side  530 . The clip  235  is inserted over the solar panel frame  500  so that the top panel  240  of the clip  235  contacts the top side  540  of the solar panel. Likewise, the rear panel  230  of the clip  235  contacts the front side  520  of the solar panel frame  500 , and finally the bottom panel  280  of the clip  235  contacts the bottom side  530  of the solar panel frame  500 . 
         [0040]    Once the clip  235  is in place, the brackets  200  are then secured onto the solar panel frame  500  as shown below in  FIG. 10 . This is accomplished by turning the thumb screw  260  until the clip  235  is secured to the solar panel frame  500  and the threaded shank  270  penetrates the surface oxidation layer of the solar panel frame  500 , which creates an electrical conducting path between the junction mount  200  and the solar panel frame  500 . When the brackets  200  are installed, typically, enough clearance should be provided so that the top of the junction box  300  can be lifted at a 90-degree angle with respect to the solar panel frame  500 . 
         [0041]      FIGS. 11 and 12  illustrate an alternate exemplary embodiment showing the bracket  400 . The bracket  400  includes an adjustable mounting clip  435  that allows the bracket  400  to be secured to solar panel frames with varying-sized edges. The clip  435  includes an adjustable portion  430  that comprises a top panel  440 , a rear panel  465 , and a fastener such as an adjustment screw  442  that includes a threaded shank  445 . The clip  435  includes a bottom panel  480 . The adjustable portion  430  includes an aperture  462  that may be threaded for receiving the threaded shank  445 . The top of the bracket  447  also includes an aperture  448  that is typically threaded for receiving the threaded shank  445 . The clip  435  is secured to the solar panel frame by way of adjustment screw  442  as shown and it is understood that other types of fasteners can be used to secure the clip  435 . The adjustable clip  435  also includes a grounding pin  450  on the bottom surface of the top panel for penetrating the surface oxidation layer of the top side  540  of the solar panel frame  500  when the adjustment screw  442  is tightened downward. This enables the bracket  400  to create an electrical connecting path between the junction box  300  and the solar panel frame  500 . An exploded view of one of the pilot holes is also shown in  FIG. 12 . 
         [0042]    The bracket  400  is installed in a similar fashion as the first embodiment of the bracket  200 . First, the junction box  300  is installed onto the brackets as shown in  FIG. 13  such that the side mount  310  is secured to the front side  410  of the bracket  400  by tightening the screws  290  to the openings or pilot holes  420 . Again, it is understood by one of ordinary skill in the art that the junction box  300  can be secured to the brackets  400  by using similar fasteners to the screws  290  or by permanently affixing the junction box  300  with adhesive methods. The clips  435  are then coupled to the solar panel frame  500  as shown in  FIG. 14 . The clip  435  is inserted over the solar panel frame  500  so that the top panel  440  of the clip  435  contacts the top side  540  of the solar panel. Likewise, the rear panel  430  of the clip  435  contacts the front side  520  of the solar panel frame  500 , and finally the bottom panel  480  of the clip  435  contacts the bottom side  530  of the solar panel frame  500 . 
         [0043]    Finally, once the clip  435  is in place the brackets  400  are then secured on to the panel  500  as shown in  FIGS. 15 and 16 . The adjustment screw  442  is then tightened so that the adjustable portion  430  is then lowered and pressed downward onto the top side  540  of the solar panel frame as shown below in  FIG. 16 . Once tightened, the grounding pin  450  penetrates the surface oxidation layer of the top side  540  of the solar panel frame  500  and creates an electrical grounding path between the junction box  300  and the solar panel frame  500 . When the bracket  400  is installed, typically, enough clearance should be provided so that the top of the junction box  300  can be lifted at a 90-degree angle with respect to the solar panel frame  500 .