Mounting bracket protection device

A protective device for a mounting bracket suitable for installation of solar collectors. The device includes a U-shaped polymeric base member having a substantially rectangular bottom joined to two opposed upwardly-projecting side walls, the bottom having at least one aperture adapted to receive a mounting fastener capable of attaching the base member to a substrate. A substantially rectangular polymeric cover having substantially the same dimensions as the base member bottom is attached to the base member's side walls. The protective device also includes a metallic mounting bracket adapted to receive a mounting strap. The base member and cover define a partial enclosure having at least one opening through which the mounting strap or a portion of the metallic mounting bracket can pass, and which can retain and protect sealant placed over the mounting fastener.

BACKGROUND OF THE INVENTION

The present invention relates to an improved method of mounting devices, such as solar collectors, and television and/or satellite antennae, to a support structure which requires a sealed penetration such as a roof. Such devices are commonly mounted using mounting brackets of various materials and designs. However, water damage can occur if the roof penetration for the bracket is poorly sealed and/or if exposed sealant subsequently degrades from exposure to the elements.

Current mounting brackets are typically either metallic or plastic and are directly secured to a roof or support structure using screws or through-bolts. Metallic mounting brackets can suffer corrosion due to exposure to the elements. Even if no leakage occurs, the appearance of the roof can be degraded by streaking due to rusting of a metallic fastening device. Those metallic brackets which are made from two or more dissimilar metals can additionally suffer from galvanic corrosion.

A bracket made entirely of plastic is not inherently as strong as a metallic mounting bracket. Accordingly, the number of plastic mounting brackets required to mount a given device may be greater than the number of required metallic brackets, which increases the number of roof penetrations required to mount the device. A mounting bracket made entirely of plastic may also degrade from ultraviolet exposure over time, thereby weakening and possibly leading to premature failure.

U.S. Pat. No. 2,915,267 disclose a wire holder for holding wires or cables in place along a panel or wall in which the wire is clamped in place between ribs projecting from side walls of a base member and a substantially U-shaped top member adapted to be pressed down upon the base member.

U.S. Pat. No. 4,407,477 discloses a tiedown fastening device adapted to fasten a section of a strap or cord placed between a base of the device and a disengageable cap. The strap is held between confronting surface segments cooperating with one another along a path having a plurality of bends, with at least some of the confronting surface segments having confronting stepped shoulders for gripping the strap segment.

SUMMARY OF THE INVENTION

An advantage of the present invention is that it provides a contained area for sealant placed over the mounting penetration, and thus protects the sealant from ultraviolet damage. The contained area may preferably have one or more drainage channels to facilitate removal of any moisture which may be present either from the elements or condensation.

Another advantage of the present invention is that it includes a metallic mounting bracket which is considerably stronger than a plastic mounting bracket. This, in turn, permits a reduction in the number of mounting penetrations in comparison to a plastic mounting bracket.

Still another advantage of the present invention is that it can include at least one discrete, downwardly-oriented projection (“standoff”) which space the bottom surface of the base member from the substrate, and thus allow a continuous mass of sealant to be injected or otherwise located/formed in the substrate penetration, under the mounting bracket protection device, and extending into the partial enclosure of the mounting protection and over the fastener.

Yet another advantage of the present invention is that it provides an enlarged polymeric base for better sealing and stability without an increase in cost that would normally be associated with a corrosion resistant metal.

These and other advantages are realized by the present invention which, in one aspect, relates to a mounting bracket protection device, comprising

a U-shaped polymeric base member comprising a substantially rectangular bottom joined to two opposed, upwardly-projecting side walls, said bottom having at least one aperture adapted to receive a mounting fastener capable of anchoring said base member to a substrate,

a substantially rectangular polymeric cover having substantially the same dimensions as said substantially rectangular bottom and adapted to be attached to said opposed side walls of said base member, such that the bottom, opposed side walls and cover, when attached in a closed position, define a partial enclosure having at least one opening,

a metallic mounting bracket having at least one aperture adapted to receive said mounting fastener such that said mounting bracket can be fastened to said bottom with said mounting fastener, said metallic mounting bracket being adapted to receive a mounting strap,

such that said partial enclosure has at least one opening which permits passage of either a mounting strap or a portion of the metallic mounting bracket,

such that said partial enclosure is suitable for retaining and protecting sealant placed over said mounting fastener.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The device includes a U-shaped polymeric base member adapted to be securely attached to a support structure which requires a sealed penetration, for example a roof or independent rack. More particularly, the U-shaped base member has a substantially rectangular bottom joined to two opposed, upwardly-projecting side walls, with the bottom having least one aperture adapted to receive a mounting fastener. In one preferred embodiment, the bottom of the U-shaped base member has two apertures to ensure the orientation of the mounting protection device does not change once mounted to a substrate such as a roof. The aperture(s) may be countersunk to ensure the fastener does not interfere with the metallic mounting bracket or mounting strap discussed below.

The U-shaped base member may be manufactured from any suitable polymer such as polyolefin and polyamide. Polypropylene and polyethylene are preferred polyolefins. The base member may be manufactured using conventional techniques well known to those of ordinary skill in the art, such as, for example, injection molding.

A substantially rectangular, polymeric protective cover having substantially the same dimensions as the bottom of the substantially rectangular U-shaped base member is adapted to be attached to the opposed, upwardly-projecting side walls of the base member. The base member and the protective cover form a partial enclosure which can retain and protect sealant placed over a mounting fastener extending through the aperture. The partial enclosure also permits passage of either a mounting strap or a portion of a metallic mounting bracket through at least one end of the mounting bracket protection device.

In one embodiment, the protective cover is pivotably attached to one of the base member's opposed side walls, such that the protective cover can pivot from an open position to the closed position. In the open position, the interior of the base member is exposed, which permits anchoring of the base member onto a substrate such as a roof. The cover may be held in the closed position by conventional fastening techniques. For example, the cover may have one or more pins or tabs which can be inserted into holes located on the opposite side wall of the base member.

In another embodiment, the protective cover can slide from an open position to the closed position by means of opposed, parallel channels located near the top surface of the opposed side walls of the base member. The channels may be open on both ends or, alternatively, may be closed on one end to provide positive location of the cover in the closed position.

In yet another embodiment, the cover has two opposed downwardly-projecting side walls which fit over the upwardly projecting side walls of the base member. The cover may be placed in the closed position by simply pressing it down upon the base member side walls to ensure a friction fit. Alternatively, the cover may be slid into the closed position using by engaging pins or tabs inwardly projecting from the cover side walls and cooperating channels located on the outside of the base member side walls. In still another embodiment, tabs can project outwardly from the side walls, and cooperating holes may be located in the cover's side walls.

The U-shaped base member's bottom is sized so as to permit a suitable metallic mounting bracket to be placed thereon. The mounting bracket has at least one aperture adapted to receive a mounting fastener. Preferably, the base member's aperture has the same diameter as the mounting bracket aperture such that the same mounting fastener can pass through both apertures, and thereby securely attach both the mounting bracket and the base member to an underlying substrate such as a roof.

The metallic mounting bracket is adapted to receive amounting strap which may be used to secure devices such as solar panels and television and/or satellite antenna. Such mounting straps are typically made of flexible metal or plastic, and are well known to those of ordinary skill in the art. For example, galvanized stainless steel strapping having various widths is commercially available from Uline.

In one embodiment, the mounting bracket protection device has a terminal metallic mounting bracket adapted to immobilize one end of the mounting strap in position so that it cannot move. In this terminal metallic mounting bracket embodiment, the partial enclosure has one opening which permits passage of a portion of the metallic mounting bracket.

In another embodiment, the mounting bracket protection device has an intermediate metallic mounting bracket which may or may not immobilize the mounting strap. In this intermediate metallic mounting bracket embodiment, the partial enclosure has two opposed openings which allow the mounting strap to pass through both opposed ends of the mounting bracket protection device. In a “floating” embodiment, the metallic bracket supports but does not immobilize the strap, thereby allowing the strap some freedom of movement. This is especially important when the strap is metallic and subject to significant temperature variation over the course of its service lifetime, which can expand and contract the strap. This freedom of movement also permits convenient removal of the mounting strap by simply pulling it through the mounting bracket. In a “fixed embodiment”, the metallic bracket immobilizes the strap, which can ensure proper tension on the mounting strap is maintained.

The mounting strap may be immobilized by conventional fasteners well known to those of ordinary skill in the art. A strap clamp immobilizes the mounting strap by first looping the strap through an aperture in the mounting bracket and then clamping one section of mounting strap to another by means of a screw. The strap clamp is preferred because it can be reused. Another known mounting strap fastener is an open metal seal, which is placed over two opposed portions of the mounting strap and crimped, thereby immobilizing the mounting strap in place. However, the open metal seal can only be used once. Yet another known mounting strap fastener is a buckle type clamp suitable for plastic mounting straps.

The mounting bracket protection device may be joined to a roof or other structure by conventional fasteners such as screws, bolts or nails which extend through the aperture(s) of the base member. The fastener may include a standoff which maintains a fixed distance or space between the base member and the substrate, and thus allow a continuous mass of sealant to be injected or otherwise located/formed in the substrate penetration, under the mounting bracket protection device, and extending into the partial enclosure of the mounting protection and over the fastener.

FIG. 1illustrates an intermediate mounting embodiment of the mounting bracket protection device of the present invention. U-shaped polymeric base member10comprises a substantially rectangular bottom20joined to two opposed, upwardly-projecting side walls30and40. Substantially rectangular bottom20may optionally have a cut-out25adjacent side wall40, which aids in water drainage and also imparts flexibility to side wall40, which is helpful when closing the cover70of the mounting bracket protection device.

Side wall40has tab45projecting from a portion of its top surface. Base member10has an aperture50which has been countersunk to receive lag bolt60which anchors base member10and bracket65to a substrate (not shown). Mounting bracket65includes rectangular-shaped apertures63adapted to permit passage of a mounting strap therethrough.

One side of substantially rectangular polymeric cover70is joined to side wall30. The opposite side of cover70has side wall80projecting therefrom, with sidewall80having cut-out90extending along the most of its length.

FIG. 2is another plan view of the intermediate mounting bracket protection device ofFIG. 1, further illustrating a portion of a mounting strap100threaded through apertures63of metallic mounting bracket65.

FIG. 3illustrates the intermediate mounting bracket protection device ofFIG. 2in the closed position, in which cover70has been pressed against side40, such that tab45occupies cut-out90of side wall80.

FIG. 4is a cross-section of the intermediate mounting bracket protection device ofFIG. 3taken through line A-A, and illustrates how lag bolt60extends through aperture68of metallic bracket65and aperture50of bottom20to anchor base member10to a substrate (not shown), while mounting strap100passes through apertures63of metallic mounting bracket65.

FIG. 5is a bottom view of the intermediate mounting bracket protection device ofFIG. 3, which illustrates lag bolt60in combination with standoff110.

FIG. 6illustrates a terminal mounting embodiment of the mounting bracket protection device of the present invention. U-shaped polymeric base member110comprises a substantially rectangular bottom120joined to two opposed, upwardly-projecting side walls130and140and upwardly-projecting end wall135. Side walls130and140have tabs145outwardly-projecting from a portion of their top surface distal from end wall135.

One side of substantially rectangular polymeric cover170is joined to end wall135. Opposing sides172and173of cover170each have a side wall180projecting therefrom, with side walls180each having a cut-out190located near opposite edge174of cover170.

FIG. 7is a plan view of the terminal mounting bracket protection device ofFIG. 6in the closed position, in which cover170has been pressed towards side145, and tabs145occupy cut-outs190of side walls180.

FIG. 9is a bottom view of the terminal mounting bracket protection device ofFIG. 7, which illustrates lag bolts160in combination with standoffs205.

As shown inFIGS. 6-9, a portion of metallic mounting bracket165passes through the opening of the partial enclosure formed by the U-shaped base member110and cover170. Mounting strap100does not enter the partial enclosure, as is illustrated inFIGS. 10-13, discussed below.

FIG. 10illustrates the same mounting bracket protection device illustrated inFIG. 7, with the addition of a mounting strap and strap clamp attached thereto. Thus,FIG. 10is a plan view of the terminal mounting bracket protection device ofFIG. 6in the closed position, in which tabs145occupy cut-outs190of side walls180. In addition,FIG. 10illustrates mounting strap100, which has been threaded through mounting bracket165and folded back upon itself. Strap clamp210immobilizes mounting strap100by means of bolt220.

FIG. 11is another plan view of the mounting bracket protection device shown inFIG. 10, and illustrates how mounting strap100passes through aperture163of mounting bracket165and over end164of mounting bracket165.

FIG. 12is a side view of the mounting bracket protection device shown inFIG. 11, and provides additional illustration of the closed terminal mounting bracket protection device with mounting strap100attached by means of strap clamp210. This side view additionally illustrates lag bolts160extending from U-shaped base member110, and how mounting bracket165engages mounting strap100both at aperture163and at end164.

FIG. 13is a cross-section of the mounting bracket protection device shown inFIG. 11, taken along line C-C, and additionally illustrates how mounting strap100is clamped to itself by passage through strap clamp210.

FIGS. 14-16illustrate the “fixed” intermediate embodiment of the mounting bracket protection device, in which the device is used to immobilize a mounting strap. Thus,FIG. 14illustrates the same intermediate mounting bracket protection device illustrated inFIG. 3, with the addition of mounting strap100attached via strap clamp220. As shown therein, mounting strap100passes into and out of the same end of the mounting protection device.

FIG. 15is a side view of the mounting bracket protection device shown inFIG. 14, whileFIG. 16provides more detail as to how mounting strap100passes through both apertures163of mounting bracket165, is bent around one end164of mounting bracket165, and then passes through the first aperture163prior to exiting the device and being clamped by strap clamp210.

Typically, a plurality of spaced-apart brackets will be used to anchor a device such as a solar collector or a television and/or satellite antenna. The location of each mounting bracket is determined by reference to the device and its desired location on the roof or other substrate.

In one preferred embodiment, a hole is drilled into the substrate at each desired location. A mounting bracket base member is placed over the location so that the hole and the base member aperture are aligned. The mounting bracket is then placed over the base member so that the bracket's aperture is aligned with the base member's aperture and the substrate hole. The mounting bracket and the base member are then anchored to the substrate by passing a fastener such as a lag bolt or screw through their apertures into the substrate hole. Preferably, the base member is aligned so that its two opposed openings are directed horizontally rather than vertically, so that rainwater cannot flow through the mounting protection device.

Sealant is applied to and over the fastener after the base and metallic mounting members are secured in the desired position. The sealant may be conveniently any sealant typically used to secure roof mountings, such as RTV silicone, polyurethane, polyester and butyl rubber sealants.

A mounting strap attached to the device to be secured is then threaded through the metallic mounting bracket and clamped into position. The protective cover is then closed, thereby protecting the mounting bracket, the sealant and the underlying fastener from direct exposure to the elements, such as sun, wind, rain, hail and snow. The sealant will not age as quickly due to this protection. Moreover, the aesthetic appearance of a substrate such as a roof is improved in comparison to a plurality of exposed, sealant-covered fasteners, which can discolor due to weathering over time. Moreover, rusting of metallic fasteners due to weathering should be significantly reduced if not eliminated.