Abstract:
In various representative aspects, an assembly for connecting and electrically bonding electronic equipment to solar panel frames is provided. More specifically, the present invention relates generally to an assembly for securing and installing micro inverter and power optimizer units for use with solar panel arrays that are typically installed on roof structures. The assembly comprises a bracket assembly that couples micro invertors and power optimizers to solar panel frames.

Description:
BACKGROUND OF INVENTION 
     Field of the Invention 
       [0001]    The present invention relates generally to an assembly for securing and installing electrical panels, and in particular, micro inverter and power optimizer units for use with solar panel arrays that are typically installed on roof structures. More specifically, the assembly comprises a bracket assembly that couples micro invertors and power optimizers to solar panel frames. When coupled to the solar panel frame, the bracket can also include an electrical bonding means to electrically bond the micro invertors and power optimizers 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 micro inventors and power optimizers as part of the array so that these devices have a low profile and require only a minimum number of parts to complete the installation. Micro-invertors and power optimizers are similar module-level electronic devices. A micro-invertor converts a solar panel&#39;s DC current to AC current. A power optimizer conditions a solar panel&#39;s DC current output before sending it to a central inverter. 
         [0004]    There are several micro-invertors and power-optimizers on the market. A standard bracket used to mount either a micro-invertor or power optimizer typically includes one to three slots to accommodate fastening hardware. An example of a micro-inverter  135  is shown below in  FIG. 2  and a power optimizer  100  in  FIG. 1 . 
         [0005]    The power optimizer  100  includes a mounting plate  110  with a guide slot  140 . The power optimizer unit  120  is secured to the mounting plate  110  and provides power to the solar panel array through cables  130 . 
         [0006]    There are two commonly known ways to install micro-invertors and power optimizers. The first is by mounting the apparatus to a rail structure like the micro-inverter  135  as shown in  FIG. 2  that is bolted to the mounting rail  150  on the roof  155  by using the bolt  160 , and the second is to secure the apparatus directly to a solar panel frame. The known prior art does not enable micro-inverters and power optimizers to be both secured directly to solar panel frames and electrically bond them to the solar panel array. The present invention overcomes these limitations and offers a solution that requires minimal parts and is easy to install, use, and manufacture 
       SUMMARY OF THE INVENTION 
       [0007]    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. 
         [0008]    It is an object of the present invention to provide a bracket mount assembly for securing electrical panels such as micro-inverters and power optimizers to a solar panel frame. 
         [0009]    It is a further object of the present invention to provide a bracket mount assembly that electrically bonds the micro-inverter or power optimizer to the solar panel array. 
         [0010]    It is a further object of the present invention for the bracket mount assembly to comprise a flange coupled to a bolt. 
         [0011]    It is a further object of the present invention for the flange to comprise a threaded aperture that receives a threaded shaft on the bolt. 
         [0012]    It is a further object of the present invention for the flange to comprise a raised portion for penetrating a surface oxidation layer on a solar panel frame. 
         [0013]    It is a further object of the present invention for a head of the bolt to comprise at least one serration for penetrating a surface oxidation layer of a metal object such as a bracket. 
         [0014]    It is a further object of the present invention for the flange to be in the shape of a circular disk, a triangle, or an elongated oval. 
         [0015]    It is a further object of the present invention to provide a support bracket that is coupled between the flange and the bolt. 
         [0016]    It is a further object of the present invention to provide a method for securing the power optimizer or the micro inverter to a solar panel frame. 
         [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 power optimizer. 
           [0020]      FIG. 2  illustrates a top view of a perspective view of a prior art micro-inverter secured to a solar panel mounting rail. 
           [0021]      FIG. 3  is a top and bottom perspective view of an exemplary disk/circular-shaped micro-inverter and power optimizer mount. 
           [0022]      FIG. 4  illustrates a top and bottom perspective view of an exemplary triangular-shaped mount. 
           [0023]      FIG. 5  illustrates a top and bottom perspective view of an exemplary elongated oval-shaped mount. 
           [0024]      FIG. 6  is a perspective view illustrating a triangular-shaped mount with a power optimizer. 
           [0025]      FIG. 7  illustrates a bottom perspective view a power optimizer being secured to a solar panel frame. 
           [0026]      FIG. 8  is an exploded top view of a disk/circular-shaped mount being used to secure a power optimizer to a solar panel frame. 
           [0027]      FIG. 9  is an exploded top view of both a triangular-shaped mount and an elongated oval-shaped mount being used to secure a power optimizer to a solar panel frame. 
           [0028]      FIGS. 10A and 10B  illustrate perspective views of the various mounts and perspective views of an L-shaped bracket along with the elongated oval-shaped mount in combination with the L-shaped bracket. 
           [0029]      FIG. 11  illustrates a bottom perspective view of the L-shaped bracket secured to a solar panel frame with the elongated oval-shaped mount. 
           [0030]      FIG. 12  illustrates a bottom perspective view of the power optimizer secured between the L-shaped bracket and the elongated oval-shaped mount. 
           [0031]      FIG. 13  illustrates a cross-sectional view of the L-shaped bracket secured to the solar panel frame using the disk/circular-shaped mount. 
           [0032]      FIG. 14  illustrates a cross sectional view of  FIG. 13  with the power optimizer installed between the L-shaped bracket and the disk/circular-shaped mount. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0033]    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. 
         [0034]      FIG. 1  shows a typical electrical panel as an exemplary power optimizer  100 . As stated previously, a power optimizer conditions a solar panel&#39;s DC current output before sending it to a central inverter. The power optimizer  100  includes a cover  120  to shield the electronic components (not shown) inside the cover  120 . A series of cables  130  interconnect with the electronics inside the cover  120 . The electronic components and cover  120  are typically secured to a mounting bracket  110 . The mounting bracket  110  in this embodiment has an opening such as a guided slit  140  for receiving the threaded portion of a bolt. As shown in  FIG. 2 , a typical solar panel array is secured to a roof  155  by securing each solar panel frame to a mounting rail  150 .  FIG. 2 , an exemplary micro-inverter  135  that includes cables  130  connected to the electronics in the micro inverter. As stated previously, a micro-inverter converts a solar panel&#39;s DC current to AC current. In a typical solar panel array, both the power optimizer  100  and the micro-inverter  135  are secured to the mounting rail  150  by way of a standard nut and bolt  160  through the guided slit  140 . The cables  130  can then be connected to the solar panel array. 
         [0035]      FIGS. 3-5  illustrate exemplary bracket mount assemblies for securing the power optimizers and micro-inverters to individual solar panel frames so that it is unnecessary to connect them to them to the mounting rails separately.  FIG. 3  illustrates an exemplary disk or circular-shaped mount  200 . The mount  200  includes a rounded head flange  210  with a threaded aperture  225  through its middle for receiving a threaded shank  220  of a bolt  230 . The threaded aperture  225  typically extends from a top to a bottom surface of the flange  210 . The bolt  230  includes a serrated portion  240  that is both used to help secure the micro-inverter or power optimizer to a solar panel frame and penetrate a surface oxidation layer of the mounting bracket  110  of the micro inverter or power optimizer. The rounded head flange also includes a raised portion such as a circular tooth  250  on the bottom side of the flange that, when tightened, can penetrate the surface oxidation layer of a metal object such as the solar panel frame or other metal bracket. 
         [0036]    An alternate embodiment of the circular mount is the triangular-shaped mount  300  as shown in  FIG. 4 . The mount  300  includes a triangular-shaped head flange  310  with a threaded aperture  320  through one end for receiving a threaded portion of a bolt  330  and includes a serrated portion  340  that is used to help secure the micro-invertor or power optimizer to the solar panel frame and penetrate the surface oxidation layer of the mounting bracket  110  of the micro-invertor or power optimizer. The arcs  315  on the bottom surface of the triangular-shaped head flange  310  are raised portions that, when tightened, can penetrate the surface oxidation layer of a metal object such as the solar panel frame or other metal bracket. 
         [0037]    Another alternate embodiment of the circular and triangular mounts is the elongated oval-shaped mount  400  as shown in a top and bottom perspective view in  FIG. 5 . The mount  400  includes an elongated oval-shaped head flange  410  with a threaded aperture  420  through one end of the flange  410  for receiving a bolt  430  and includes a serrated portion  440  that is used to help secure the micro-invertor or power optimizer to the solar panel frame and penetrate the surface oxidation layer of the mounting bracket  110  of the micro-invertor or power optimizer. The flange  410  also includes a raised portion such as the circular tooth  435  on the bottom side of the flange  410  on one end that, when tightened, is sufficiently sharp enough to penetrate the surface oxidation layer of a metal object such as the solar panel frame or other metal bracket. The flange  400  can also include a series of grips  450  on the end opposite the threaded aperture  420  to further assist in securing the mounting bracket  110  to the solar panel frame. 
         [0038]    All three mount embodiments can be installed by using the following two-step process. The triangular-shaped mount  300  is used to illustrate the installation process. First, the threaded shaft  220  of the triangular-shaped mount  300  slides through the opening such as the guided slit  140  of the mounting bracket  110  of the micro-invertor or power optimizer as shown below in  FIG. 6 . The second step is to slide the mounting bracket  110  of the micro-invertor or power optimizer on to the lower lip  600  of the solar panel frame as shown below in  FIG. 7 , and then tighten the mount  300  by turning the bolt  330 . As the bolt  330  is tightened, the serrated portion  340  penetrates the surface oxidation layer of the bracket  110  and the arcs  315  penetrate the surface oxidation layer of the solar panel frame  600 . Likewise, if the circular-shaped mount  200  is used, when tightened, the serrated portion  240  will penetrate the surface oxidation layer of the mounting bracket  110  while the circular tooth  250  will penetrate the surface oxidation layer of the solar panel frame  600 . Finally, if the elongated oval-shaped mount is used, the serrated portion  440  will penetrate the surface oxidation layer of the mounting bracket  110 , while the circular tooth  435  will penetrate the surface oxidation layer of the solar panel frame  600 . In all these cases, an electrical connecting path is then created between the bracket and the solar panel frame. 
         [0039]    The circular mount  200  can be installed as shown in  FIG. 8  by utilizing a non-orientation specific installation with the same steps provided above. The triangular and elongated oval-shaped mounts can be installed as shown in  FIG. 9  by using an orientation-specific approach with the same steps as provided above. These two exemplary embodiments automatically adjust to the module leg length and will properly orientate themselves. This occurs because these mounts  300  and  400  will rotate until they encounter the inner module wall. At that time, the mount  300  or  400  stops rotating, but the bolt  330  or  430  keeps tightening and eventually the mount  300  or  400  is secure at proper torque and has clamped the assembly together. 
         [0040]      FIG. 10B  illustrates an alternate exemplary embodiment that comprises the use of a third element, namely a support bracket  500  used in combination with each of the mounts  200 ,  300 , or  400 . The support bracket  500  in this exemplary embodiment is an L-shaped support bracket and includes a perpendicular portion  520  and an open slot  510  that receives the bolts  230 ,  330 , or  430  respectively in each of the mounts  200 ,  300 , or  400 . The use of the bracket  500  can provide additional structural capability to the mounts  200 ,  300 , or  400  and works on virtually any shape of solar panel frame. 
         [0041]    The mounts  200 ,  300 , or  400  with the bracket  500  are installed in two steps. The first step involves assembling the mount  200 ,  300 , or  400  on to the support bracket  500  as shown in  FIG. 11  and then sliding the flange  210 ,  310 , or  410  of the respective mount  200 ,  300 , or  400  into place on the lip  600  of the solar panel frame as shown below in  FIG. 11 . The perpendicular portion  520  of the bracket  500  can optionally rest against the solar panel frame as shown. 
         [0042]    The final step involves sliding the bracket  110  through the opening such as the guided slit  140  of the mounting bracket  110  of either the micro-inverter or the power optimizer into place on the support bracket  500  as shown in  FIG. 12  and then tighten the mounts  200 ,  300 , or  400  to the lower lip  600  of the solar panel frame by rotating the nut  230 ,  330 , or  430  as shown. The support bracket  500  provides additional support to the bottom mounting bracket  110  and, fits most solar panel frame sizes. 
         [0043]    Using the circular mount  200  for example as shown in  FIGS. 13 and 14 , when tightened, the serrated portion  240 ,  340 , or  440  will penetrate the surface oxidation layer of the mounting bracket  110  on the micro-inverter or the power optimizer, and the circular tooth  250  of the circular mount  200 , the tooth  435  of the elongated oval-shaped mount  400 , or the arcs  315  of the triangular-shaped mount  300  will penetrate the surface oxidation layer of the lip  600  of the solar panel frame and create an electrical connected path between the solar panel frame and the bracket  110 .