Bracket mount for securing micro-inverters and power optimizers to solar panel arrays

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.

BACKGROUND OF INVENTION

Field of the Invention

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

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.

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's DC current to AC current. A power optimizer conditions a solar panel's DC current output before sending it to a central inverter.

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-inverter135is shown below inFIG. 2and a power optimizer100inFIG. 1.

The power optimizer100includes a mounting plate110with a guide slot140. The power optimizer unit120is secured to the mounting plate110and provides power to the solar panel array through cables130.

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-inverter135as shown inFIG. 2that is bolted to the mounting rail150on the roof155by using the bolt160, 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

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.

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.

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.

It is a further object of the present invention for the bracket mount assembly to comprise a flange coupled to a bolt.

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.

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.

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.

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.

It is a further object of the present invention to provide a support bracket that is coupled between the flange and the bolt.

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.

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.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1shows a typical electrical panel as an exemplary power optimizer100. As stated previously, a power optimizer conditions a solar panel's DC current output before sending it to a central inverter. The power optimizer100includes a cover120to shield the electronic components (not shown) inside the cover120. A series of cables130interconnect with the electronics inside the cover120. The electronic components and cover120are typically secured to a mounting bracket110. The mounting bracket110in this embodiment has an opening such as a guided slit140for receiving the threaded portion of a bolt. As shown inFIG. 2, a typical solar panel array is secured to a roof155by securing each solar panel frame to a mounting rail150.FIG. 2, an exemplary micro-inverter135that includes cables130connected to the electronics in the micro inverter. As stated previously, a micro-inverter converts a solar panel's DC current to AC current. In a typical solar panel array, both the power optimizer100and the micro-inverter135are secured to the mounting rail150by way of a standard nut and bolt160through the guided slit140. The cables130can then be connected to the solar panel array.

FIGS. 3-5illustrate 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. 3illustrates an exemplary disk or circular-shaped mount200. The mount200includes a rounded head flange210with a threaded aperture225through its middle for receiving a threaded shank220of a bolt230. The threaded aperture225typically extends from a top to a bottom surface of the flange210. The bolt230includes a serrated portion240that 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 bracket110of the micro inverter or power optimizer. The rounded head flange also includes a raised portion such as a circular tooth250on 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.

An alternate embodiment of the circular mount is the triangular-shaped mount300as shown inFIG. 4. The mount300includes a triangular-shaped head flange310with a threaded aperture320through one end for receiving a threaded portion of a bolt330and includes a serrated portion340that 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 bracket110of the micro-invertor or power optimizer. The arcs315on the bottom surface of the triangular-shaped head flange310are 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.

Another alternate embodiment of the circular and triangular mounts is the elongated oval-shaped mount400as shown in a top and bottom perspective view inFIG. 5. The mount400includes an elongated oval-shaped head flange410with a threaded aperture420through one end of the flange410for receiving a bolt430and includes a serrated portion440that 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 bracket110of the micro-invertor or power optimizer. The flange410also includes a raised portion such as the circular tooth435on the bottom side of the flange410on 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 flange400can also include a series of grips450on the end opposite the threaded aperture420to further assist in securing the mounting bracket110to the solar panel frame.

All three mount embodiments can be installed by using the following two-step process. The triangular-shaped mount300is used to illustrate the installation process. First, the threaded shaft220of the triangular-shaped mount300slides through the opening such as the guided slit140of the mounting bracket110of the micro-invertor or power optimizer as shown below inFIG. 6. The second step is to slide the mounting bracket110of the micro-invertor or power optimizer on to the lower lip600of the solar panel frame as shown below inFIG. 7, and then tighten the mount300by turning the bolt330. As the bolt330is tightened, the serrated portion340penetrates the surface oxidation layer of the bracket110and the arcs315penetrate the surface oxidation layer of the solar panel frame600. Likewise, if the circular-shaped mount200is used, when tightened, the serrated portion240will penetrate the surface oxidation layer of the mounting bracket110while the circular tooth250will penetrate the surface oxidation layer of the solar panel frame600. Finally, if the elongated oval-shaped mount is used, the serrated portion440will penetrate the surface oxidation layer of the mounting bracket110, while the circular tooth435will penetrate the surface oxidation layer of the solar panel frame600. In all these cases, an electrical connecting path is then created between the bracket and the solar panel frame.

The circular mount200can be installed as shown inFIG. 8by utilizing a non-orientation specific installation with the same steps provided above. The triangular and elongated oval-shaped mounts can be installed as shown inFIG. 9by 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 mounts300and400will rotate until they encounter the inner module wall. At that time, the mount300or400stops rotating, but the bolt330or430keeps tightening and eventually the mount300or400is secure at proper torque and has clamped the assembly together.

FIG. 10Billustrates an alternate exemplary embodiment that comprises the use of a third element, namely a support bracket500used in combination with each of the mounts200,300, or400. The support bracket500in this exemplary embodiment is an L-shaped support bracket and includes a perpendicular portion520and an open slot510that receives the bolts230,330, or430respectively in each of the mounts200,300, or400. The use of the bracket500can provide additional structural capability to the mounts200,300, or400and works on virtually any shape of solar panel frame.

The mounts200,300, or400with the bracket500are installed in two steps. The first step involves assembling the mount200,300, or400on to the support bracket500as shown inFIG. 11and then sliding the flange210,310, or410of the respective mount200,300, or400into place on the lip600of the solar panel frame as shown below inFIG. 11. The perpendicular portion520of the bracket500can optionally rest against the solar panel frame as shown.

The final step involves sliding the bracket110through the opening such as the guided slit140of the mounting bracket110of either the micro-inverter or the power optimizer into place on the support bracket500as shown inFIG. 12and then tighten the mounts200,300, or400to the lower lip600of the solar panel frame by rotating the nut230,330, or430as shown. The support bracket500provides additional support to the bottom mounting bracket110and, fits most solar panel frame sizes.

Using the circular mount200for example as shown inFIGS. 13 and 14, when tightened, the serrated portion240,340, or440will penetrate the surface oxidation layer of the mounting bracket110on the micro-inverter or the power optimizer, and the circular tooth250of the circular mount200, the tooth435of the elongated oval-shaped mount400, or the arcs315of the triangular-shaped mount300will penetrate the surface oxidation layer of the lip600of the solar panel frame and create an electrical connected path between the solar panel frame and the bracket110.