Abstract:
A wall mount bracket for HVAC Equipment such as a heat pump, AC condensing unit, and preferably the exterior condenser unit of a mini split system. The system can advantageously be used in colder climates to prevent equipment from freezing and keep equipment above the level of the snow, etc. The wall mounts herein employ an offset to space the unit away from the wall of the structure to provide clearance on the rear of the unit. The offset also allows the units to be mounted above the top of the foundation wall without disrupting the exterior siding of the structure.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the priority benefit of U.S. provisional application No. 62/072,507 filed Oct. 30, 2014. The aforementioned provisional is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    The present invention relates generally to a mounting bracket and, more particularly, to a wall mounted bracket for an outdoor appliance such as an outdoor component of a heating and/or cooling system. The bracket herein may advantageously be used in connection with a heating and/or cooling system such as the outdoor condensing unit of a split system, especially a compact or so-called mini split system, and will be described primarily by way of reference thereto. It will be recognized, however, that the present mounting system may be used for all manner of equipment including air conditioning condensers/compressors, electrical transformers, and so forth. 
         [0003]    Mini split air handling systems such as air conditioners or heat pumps locate the compressor and condenser outside the house or other structure to be heated or cooled. Such systems eliminate the need for extensive duct work in the structure by using thin copper tubing to pump a refrigerant to wall mounted blowers inside the structure (ductless) or to compact duct units that allow the evaporator to be hidden while requiring minimal ductwork. 
         [0004]    Commonly, the outdoor condensing units are set on a pad outside the structure, such as a poured concrete slab or a prefabricated pad. In addition to requiring significant site preparation, the use of slabs are commonly very low to the ground, e.g., a few inches above grade, making their use impractical in areas receiving significant snowfall or having a high water table. Units set on a slab or pad are also susceptible to weed/plant growth around the unit, accumulation of leaves, damage from mowers or weed trimmers, and so forth. 
         [0005]    The present disclosure contemplates a new and improved mounting apparatus and method which overcomes the above-referenced problems and others. 
       SUMMARY 
       [0006]    A support apparatus for attaching equipment to a wall of a structure includes first and second of angled bracket arms configured to be mounted side by side in spaced apart relation. Each of the first and second angled bracket arms includes a lower portion configured to be attached to a foundation of the structure; an angled portion extending from the lower portion along a direction angled from an extending direction of the lower portion; and an upper portion extending from the angled portion along a direction generally parallel to the extending direction of the lower portion. 
         [0007]    In one aspect, an equipment support arm is supported on each of the first and second angled bracket arms, the equipment support arm including a horizontal member secured at a generally right angle to a vertical member, wherein the vertical member is removably attached to the upper portion of a respective one of the first and second angled bracket arms. 
         [0008]    In another aspect, an upper support member is attached to the upper portion, the upper support member including a proximal portion extending from the upper portion along a direction parallel to an extending direction of the upper portion and a distal portion extending from the proximal portion along a direction angled from an extending direction of the proximal portion. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0009]    The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention. 
           [0010]      FIG. 1  is an image of a first exemplary wall mounting bracket embodiment, taken generally from the right side and the front. 
           [0011]      FIG. 2  is an image showing an enlarged, fragmentary view of a second exemplary wall mounting bracket embodiment, taken generally from the left side. 
           [0012]      FIG. 3  is an image showing the embodiment appearing in  FIG. 2 , taken generally from the front. 
           [0013]      FIG. 4  is an enlarged, fragmentary view of the horizontal mounting arm showing the elongate hardware slot and exemplary fastener hardware with vibration isolator or dampener. 
           [0014]      FIG. 5  is a partially exploded view of the embodiment appearing in  FIG. 1 . 
           [0015]      FIG. 6  is an image showing a perspective view of a third exemplary wall mounting bracket system herein, configured with upper mounting arms in place of lower mounting arms, taken generally from the front and right side. 
           [0016]      FIG. 7  is a fragmentary side view of a similar bracket embodiment configured for use with the upper mounting arms. 
           [0017]      FIG. 8  is a perspective view of the embodiment appearing in  FIG. 6 , with the upper arms removed and illustrating the adapters. 
           [0018]      FIG. 9  is a perspective view of the upper mounting arms appearing in  FIG. 6  removed from the wall mounted portion, taken generally from the bottom and side. 
           [0019]      FIG. 10  is a perspective view of the upper mounting arms appearing in  FIG. 9  taken generally from the front and bottom. 
           [0020]      FIG. 11  is a perspective view of a further embodiment of the present invention including a roof supported over the wall mounting bracket. 
           [0021]      FIG. 12  is an enlarged front view of the region  12  appearing in  FIG. 11 . 
           [0022]      FIG. 13  shows an exemplary installation on an exterior wall of a building. 
           [0023]      FIG. 14  is a front elevational view of an exemplary wall mounting system herein. 
           [0024]      FIG. 15  is a side elevational view of the wall mounting system appearing in  FIG. 14 . 
           [0025]      FIG. 16  is a top plan view of the wall mounting system appearing in  FIG. 14 . 
           [0026]      FIG. 17  is an exploded view of the wall mounting system appearing in  FIG. 14 . 
           [0027]      FIG. 18  depicts a preferred cross-sectional shape of the horizontal and vertical components of the L-shaped lower mounting arms. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0028]    Referring now to the drawings,  FIGS. 1-5 and 13-17  illustrate a wall mounted bracket system comprising a pair of angled bracket arms  10  mounted side by side and spaced apart any desired width D, which may be selected to accommodate the width of the equipment to be mounted. Although the present invention is described by way of reference to the preferred embodiment wherein two arms  10  are used, it will be recognized that any other number, such as 3, 4, 5, 6, 7, 8, etc., of arms  10  may be employed. The dimensions given in  FIGS. 15 and 16  are exemplary only and are not intended to be limiting. 
         [0029]    The bracket arms  10  are, for example, 2″ or 1¾″ square tubing, preferably steel, although bracket arms formed of other metal or metal alloy are also contemplated. Each bracket arm  10  includes a lower portion  12  for attaching to a foundation wall  11  and an angled portion  14  angled away from the wall. The angle A may be any angle in the range of from about 15 degrees to about 75 degrees and is preferably about 45 degrees). The arm  10  further includes an upper portion  16  which extends in a direction that is generally parallel to the extending direction of the lower portion, i.e., generally vertically from the upper end of the angled portion  14  and is spaced away from wall. 
         [0030]    The bracket arms  10  may be formed by bending the metal tubing. When the lower portions  12  are secured to the exterior side of a foundation wall, the offset portions  14  and  16  can extend above the top of the foundation wall without the need to putting holes in the siding material of the building. The spacing also allows the units to be mounted in accordance with mandatory clearance requirements between the equipment and the building wall, provides room for piping and access for servicing the mounted equipment. 
         [0031]    The lower portion  12  is bolted or anchored to the wall with threaded fasteners  13 . A rigid plate, e.g., metal and preferably steel plate  18  extends along the lower or outward facing surface of the angled portion  14  and in certain embodiments includes a bend  19  to define a proximal portion  18   p  extending along and secured to the angled portion  14  and a distal portion  18   d  extending horizontally a distance from the proximal portion. The distal end of the plate  18   d  extends a distance sufficient to form a rest or shelf for a proximal end of a lower support arm  20 . In certain embodiments, the lower support arms  20  are generally L-shaped and may be formed of bent or roll-formed sheet metal forming a channel with axial extending flanges on either side, i.e., having a generally top-hat shaped cross section. 
         [0032]    As best seen in  FIG. 18 , the support arm vertical and horizontal members  22 ,  24  may be formed of a stock material having parallel axially extending side walls  62  and an axially extending web  64  extending between the parallel axially extending side walls  62 , the parallel axially extending side walls  62  and the axially extending web  64  cooperating to define a channel  60 . In the illustrated preferred embodiment, each of the support arm vertical and horizontal members  22 ,  24  further include axial, outwardly extending flanges  66  on the ends each of the parallel axially extending side walls  62  opposite the web  64 , wherein the parallel axially extending side walls  62 , axially extending web  64 , and outwardly extending axial flanges  66  cooperate to define a structure having a generally top-hat shaped cross sectional shape. 
         [0033]    Each lower support arm  20  has a horizontal member  22  and a vertical member  24  secured at right angles. The lower support arm vertical member  24  has a notch  26  cut out to receive the proximal end of the horizontal member  22 , which extends into the channel defined by the vertical member and rests on the protruding, distal end portion of the bent plate  18 . The proximal end of the plate  18  may be secured to the angled portion  14  via bolts, or, may be permanently secured thereto, e.g., via welding. In the illustrated preferred embodiment, the horizontal member  22  and the vertical member  24  are secured to each other by a welded joint. 
         [0034]    Elongated openings  28  are provided in the upper surface of the horizontal member  22  to accommodate mounting hardware such as bolts  29  to attach the condensing unit to the arms  22 . In the preferred embodiments, vibration absorbing couplings  31  are disposed between the condensing unit (not shown) and the arm horizontal member  22  to absorb vibration and noise emanating from the condenser to prevent or reduce amplification of such noise and vibration by the bracket arms  10  and to prevent or reduce transmission of such noise or vibration to the house of other structure to which the bracket arms  10  are mounted. 
         [0035]    The vibration absorbing coupling members  31  may be formed of a material which is resilient, flexible, compressible, deformable, compliant, and/or elastic, and is preferably a polymeric material. Most preferably, the coupling member  31  is formed of an elastomeric material, such as a synthetic or natural elastomeric or rubber material. Exemplary elastomeric materials which may be used in making the coupling member include, for example, polyurethane, polyisoprene, polybutadiene, neoprene, butadiene-acrylonitrile copolymers, ethylene-butadiene block copolymers, ethylene-propylene based copolymers, natural rubber, polychloroprene rubber, polyisoprene-isobutylene copolymers, silicone rubber, styrene-acrylonitrile copolymers, styrene-butadiene copolymers, styrene-isoprene copolymers, styrene-maleic anhydride copolymers, fluoroelastomers, polyolefins, and so forth. 
         [0036]    The vertical members  24  are bolted to the upper portion  16  of the bracket arms with threaded fasteners  25 . The channel shape of the support arms  20  defines a channel that is sized to receive the upper portion  16  of the bracket arm  10 . 
         [0037]    Although the bracket arms  10  can be adapted for use with any wall of a structure where it is desired to mount equipment, as best seen in  FIG. 13 , the bracket arms  10  support arms  20  are advantageous for supporting equipment E above ground or grade level G, and are particularly advantageous for supporting the equipment E configured for secure attachment to an exterior surface of a foundation wall  11  of a structure or building B without the need to penetrate, remove, or otherwise interfere without exterior siding or wall cladding S applied to the walls of the structure B above the level of the foundation  11 . In addition, the horizontal offset O between the lower portion  12  and the upper offset portion  16  enables the equipment E to be mounted to provide a clearance distance C between the back of the equipment E and the wall of the structure B in accordance with minimum clearance distances as specified by building codes or other regulations. 
         [0038]    Referring now to  FIGS. 6-10  (and continued reference to  FIGS. 1-5 ), upper support arms  30  can be attached to the bracket arms  10 , either in addition to or as an alternative to the lower support arms  20 . The upper support arms  30  include a vertical portion  32  and an angled portion  34 . In certain embodiments, the angled portion extends generally horizontally, e.g., therein the angled portion  34  is configured to support equipment. In other embodiments, the angled portion may be sloped relative to horizontal, e.g., wherein the angled portion  34  is configured to support a roof over equipment beneath the roof. 
         [0039]    An adapter  36  is secured in the open upper end of the bracket upper portion  16 . The adapter  36  may be formed of a segment of steel tubing having an outer diameter that is equal to the inner diameter of the bracket arm  10  and the upper support arm  30 . For example, in the case of a bracket arm  10  and upper support arm  30  formed of square tubing having an outer diameter of 1¾ inches and an inner diameter of 1¼ inches, the adapter is formed of formed of square steel tubing having an outer diameter of 1¼ inches. Other diameter tubing materials are contemplated. The adapter can be bolted in place with threaded fasteners  38 . 
         [0040]    The upper support arms  30  each comprise an inverted L-shaped piece of tubing wherein the lower end is received over the protruding portion of the adapter  36  and bolted in place with the threaded fasteners  38 . The upper arms  30  may be used to support a mini-split condenser or other piece of equipment at a higher elevation than is possible with the lower support arms  20 . Alternatively, the upper support arms  30  could be configured to support a roof or canopy over equipment located between the arms  10 . 
         [0041]    The upper support arms  30  could support a variety of purposes, as follows: 
       Method 1: 
       [0042]    In method 1, the device is used without the lower support arms  20  and the equipment to be mounted is mounted on the upper support arms. 
       Method 2: 
       [0043]    In method 2, the device is used without the lower support arms  20  and the equipment to be mounted is mounted on the ground, e.g., on a concrete slab, prefabricated pad, stand, etc. The upper arms  30  support a roof or canopy over the equipment beneath it. 
       Method 3: 
       [0044]    In method 3, the device is used with the lower support arms  20  and the equipment to be mounted is mounted on the lower support arms. The upper arms  30  support a roof or canopy over the equipment beneath it. 
       Method 4: 
       [0045]    In method 4, the device is used with the lower support arms  20 . A first piece of equipment to be mounted is mounted on the lower support arms and a second piece of equipment is mounted on the upper support arms. 
         [0046]    Referring now to  FIGS. 11 and 12 , there is shown a further embodiment wherein a roof support member  40  is attached to the offset portion  16  with fasteners  48 . Advantageously, the roof support members  40  are secured to the inward facing surface of the respective offset portions. 
         [0047]    Although the embodiment appearing in  FIGS. 11 and 12  is shown with the lower arms  20  attached to the bracket arms  10 , in alternative embodiments the lower arms  20  can be omitted, e.g., wherein the roof support members are provided to support a roof  50  over equipment on the ground, a pad, slab, or stand beneath the roof  50 . 
         [0048]    Each roof support member  40  includes a vertical portion  42  and a roof support portion  44 . The lower and  46  of the roof support member  40  is secured to the offset portion  16  via bolts or other fasteners  48 . In the illustrated embodiment, the transition between the vertical portion  42  and the roof support portion  44  is a radiused bend  43 , although a fastened joint e.g., a welded joint, between the portions  42  and  44  is also contemplated. In the embodiment shown the roof support portion  44  is angled downward by an angle R to allow snow and debris to slide off the roof  50 . In alternative embodiments, a generally horizontal roof may be provided. In certain embodiments one or more transverse support members  60  are provided, which extend between the roof support portions  44  to support the roof and prevent the roof member  50  from sagging. The roof  50  may be formed from any rigid sheet material, including without limitation wood, metal, plastic, and so forth. In certain embodiments, the roof member  50  is formed of twin walled polycarbonate sheet material. 
         [0049]    Each roof support member  40  may be a unitary structure or may comprise two or more segments attached together. In the illustrated embodiment, the roof support member  40  includes a lower straight member  52  and an upper angled member  54 . In this manner, a modular system can be provided wherein straight members  52  of different lengths can be provided wherein the length of the straight members  52  can be selected to support the roof  50  a desired or appropriate height. 
         [0050]    The attachment joint between the straight member  52  and the angled member  54  appears in  FIG. 12  and includes an adapter  56  telescopically received within each of the abutting ends of the adjoining lower straight member  52  and upper angled member  54 , and secured in position with bolts or other threaded fasteners  58 . 
         [0051]    The invention has been described with reference to the preferred embodiment. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.