Abstract:
A utility bracket for attaching wires or wire bundles to a structure is provided. The utility bracket includes a first portion that supports a product and a second portion for adhering to a support structure. The second portion includes a separation component that separates the second portion from the support structure by a predefined amount. The separation component includes a plurality of ridges or dimples for allowing even application of an adhesive. A nut plate or wire ties secure the product to the first portion. The second portion can include a base plate that is rotatably coupled to the first portion. The bracket can be formed by a molding or extruding process.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates generally to support systems and, more specifically, to utility brackets for securing system components to a structure.  
       BACKGROUND OF THE INVENTION  
       [0002]     Complex systems, such as electrical systems in aircraft, utilize numerous utility brackets for securing many parts, such as electrical wire bundles ( FIG. 1 ). Brackets are currently drilled and riveted to the aircraft structure ( FIG. 2 ). This process requires locating, clamping, drilling the bracket in place, and installing multiple rivets to attach the bracket. There currently exists an unmet need to reduce part count and installation labor costs.  
         [0003]      FIG. 3  illustrates an alternative apparatus to the bolted or riveted utility bracket. A utility bracket  30  is adhesively bonded to a structure  32 . The bracket  30  is an improvement over the drilled and riveted bracket system shown in  FIG. 2 , because the steps required to drill and rivet the bracket are not needed. A person mounting the bracket  30  to the structure  32  simply applies adhesive to the structure  32  or the surface of the bracket  30  that is to be mounted on the structure  32 , and then mates the utility bracket  30  with the structure  32 . However, if too much or not enough pressure is applied when mating the utility bracket  30  to the structure  32 , the amount of adhesive applied may end up being too thin or too thick between the utility bracket  30  and the structure  32 , thereby producing a less than adequate bond.  
         [0004]     The utility bracket  30  utilizes a frame device (not shown) to alleviate this problem by supporting the utility bracket  30  after it is adhesively bonded with the structure  32 . The frame device controls the adhesive bondline thickness between the utility bracket  30  and the structure  32 , but adds an additional expense and requires the extra steps of installation prior to adhesive bonding, and then removing the frame device after the adhesive is cured. Also, the size of the frame device may limit the location freedom of the utility bracket  30  due to interference with nearby structure.  
         [0005]     Therefore, there also currently exists an unmet need to quickly and effectively bond utility brackets to structures by controlling the adhesive bondline thickness, while closely replicating the size and function of the current mechanically attached bracket.  
         [0006]     In addition, the current utility bracket is located in a fixed orientation that dictates the path of all connected components. If wire bundles are attached to the bracket, the wire bundles have a natural tendency to follow a specific path that could cause straining or over-bending of the wire bundles, which could occur because the utility bracket only allows a single axis of rotation. Thus, there currently remains an unmet need to design and manufacture a utility bracket that will swivel to provide multiple rotational axes, whereby components such as wire bundles can follow a general path without undue straining or over-bending.  
       SUMMARY OF THE INVENTION  
       [0007]     The present invention provides a utility bracket for attaching wires or wire bundles to a structure, such as an aircraft. The present invention provides an easy to install bracket with known adhesive capabilities.  
         [0008]     The utility bracket includes a first portion that supports a product and a second portion that adheres to a support structure. The second portion includes a separation component (geometric feature) that separates the second portion from the support structure by a predefined distance. The predefined distance is based on properties of an adhesive that is applied between the second portion and the support structure.  
         [0009]     In one aspect of the invention, the separation component includes a plurality of ridges or dimples.  
         [0010]     In another aspect of the invention, the second portion is a concave surface or an L-shaped surface.  
         [0011]     In a further aspect of the invention, a nut plate secures the product to the first portion.  
         [0012]     In still another aspect of the invention, the second portion includes a base plate and the first portion is rotatably coupled to the base plate. The base plate includes a button and the first portion includes a component for receiving the button.  
         [0013]     In still a further aspect of the invention, the bracket is formed by a molding or extruding process. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     The preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.  
         [0015]      FIG. 1  is a perspective view of a prior art utility bracket application;  
         [0016]      FIGS. 2 and 3  are side views of prior art utility bracket applications;  
         [0017]      FIGS. 4 and 5  are perspective views of a bracket formed in accordance with the present invention;  
         [0018]      FIG. 6  is a side view of a bracket similar to the bracket shown in  FIGS. 4 and 5 ;  
         [0019]      FIG. 7  illustrates a perspective view of a bracket formed in accordance with the present invention;  
         [0020]      FIG. 8  illustrates a side view of a portion of the bracket of  FIG. 7 ;  
         [0021]      FIG. 9  is a perspective view of the bracket of  FIGS. 7 and 8  mounted to a structure and in support of the system component;  
         [0022]      FIG. 10  illustrates a perspective view of a bracket formed in accordance with the present invention;  
         [0023]      FIG. 11  illustrates a perspective view of the bracket of  FIG. 10  mounted to a structure and in support of a system component;  
         [0024]      FIGS. 12 and 14  illustrate side views of various brackets mounted to a structure and formed in accordance with the present invention;  
         [0025]      FIG. 13  illustrates a perspective view of the bracket of  FIG. 12  as mounted to a structure and supporting a system component;  
         [0026]      FIGS. 15 and 17  illustrate side views of a bracket mounted to a structure and formed in accordance with the present invention;  
         [0027]      FIG. 16  illustrates a perspective view of the bracket shown in  FIG. 15  as mounted to a structure and supporting system components;  
         [0028]      FIG. 18  illustrates an exploded view of a swivel bracket formed in accordance with the present invention;  
         [0029]      FIG. 19  illustrates a perspective view of the bracket system shown in  FIG. 18 ;  
         [0030]      FIG. 20  illustrates a perspective view of a base of the swivel bracket shown in  FIGS. 18 and 19 ; and  
         [0031]      FIG. 21  illustrates a perspective view of the swivel bracket of  FIGS. 18-20  that is in support of a system component. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0032]     The present invention provides a utility bracket and a method for attaching the utility bracket to a structure in order to provide a quick and effective bond. Referring now to  FIGS. 4 and 5 , perspective views of an exemplary utility bracket  50  formed in accordance with the present invention are shown. The utility bracket  50  is suitably formed of metal, molded polycarbonate, or some other substance of sufficient thickness to provide suitable rigidity. The utility bracket  50  is bent, extruded, or molded into an approximate L-shape pattern with or without supports as necessary. A section  54  of the utility bracket  50  is stamped or molded with one or more dimples  56 . The dimples  56  protrude from the utility bracket  50  on a convex side of the bracket  50 .  
         [0033]     Referring now to  FIG. 6 , the utility bracket  50  is attached to a support structure by mating the side where the dimples  56  protrude from the utility bracket  50  to the structure  60  after adhesive  62  has been applied to the support structure  60  or the utility bracket  50 . The size of the dimples  56  is determined based on the amount of adhesive  62  that is desired between the utility bracket  50  and the support structure  60 . The amount of desired adhesive is based on the type of adhesive (such as epoxies, acrylics, or polythioethers) and the recommended thickness to apply the adhesive and get the best bond. Thus, after the adhesive  62  has solidified or effected its bond between the utility bracket  50  and the support structure  60 , the recommended thickness for the adhesive  62  will exist between the utility bracket  50  and the support structure  60  because of the size of the dimples  56 .  
         [0034]     Referring now to  FIG. 7 , a bracket  80  formed in accordance with another embodiment of the present invention is shown. The utility bracket  80  includes first and second sides  82  and  84  that are connected to in an approximately parallel relationship to a base  86 . A flange  88  extends from the base  86  and is approximately orthogonal to the first and second sides  82  and  84 . The flange  88  includes one or more thru-holes  90  that are used for bolting on various items that the utility bracket  80  is designed to support, such as without limitation, a wire bundle clamp and holder (not shown). The first and second sides  82  and  84  include inward facing surfaces  92  and  94 , respectively. Each of the inward facing surfaces  92  and  94  include one or more ridges  98 . The gap formed between the first and second sides  82  and  84  receives a support structure.  
         [0035]     Referring now to  FIG. 8 , a side view of a portion of the utility bracket  80  mounted to the support structure  60  is shown. The ridges  98 , formed on the inward surfaces  92  and  94 , are formed of a sufficient thickness or height to allow an adhesive layer of a proper thickness to be applied between the first and second sides  82  and  84  and the support structure  60 . The interior of the cavity that receives the support structure  60  is curved at the point where the inward facing surfaces  92  and  94  meet with the base  86 . The amount of curvature applied is determined based on an amount of gap desired between the base  86  and an end of the support structure  60 . Thus, the curvature sets the gap to be approximately equal to the optimum thickness for the adhesive that will be applied between the support structure  60  and the utility bracket  80 .  
         [0036]     Referring now to  FIG. 9 , the utility bracket  80  mounted and adhesively attached to the support structure  60  is shown. A nut plate attachment  104  is mounted through one of the thru-holes  90 . A bolt (not shown) secures a clamp  106  to the nut plate attachment  104  and thus to the flange  88  of the utility bracket  80 . In this example, the clamp  106  receives a wire bundle  108 .  
         [0037]     Referring now to  FIG. 10 , a utility bracket  100  similar to the bracket  80  ( FIG. 7 ) is shown. The utility bracket  100  is roughly T-shaped with a stem  101  having a first side  102  with one or more ridges  114 . A top portion  116  of the utility bracket  100  includes a first flange  118  that extends from the stem  101  from the first side  102 . The first flange  118  extends a distance approximately equal to the thickness of a support structure that the utility bracket  100  will be adhered to. The top section  116  also includes a second flange  110  having one or more attachment holes  112 .  
         [0038]     Referring now to  FIG. 11 , the utility bracket  100  adhered to the support structure  60  is shown. The flange  118  allows the utility bracket  100  to be quickly positioned on an edge of the frame structure  60 . The ridges  114  maintain a gap between the utility bracket  100  and the support structure  60 .  
         [0039]     Referring now to  FIGS. 12 and 13 , a side-view of a utility bracket  120  that secures a clamp or sleeve device  122  to a support structure  60  is shown. The utility bracket  120  includes an attaching mechanism that is similar to that attaching the bracket  80  to the support structure  60  ( FIGS. 7-9 ). The utility bracket  120  includes an end  124  having one or more thru-holes  126 . One or more wire ties  130  or other securing mechanisms are received through the one or more thru-holes  126 . An edge  136  of the utility bracket  120  opposite the portion that mounts to the support structure  60  is suitably curved to receive a clamp or sleeve  122 . The wire ties  130  secure the clamp or sleeve device  122  to the edge  136 . The edge  136  is formed with a similar radius of curvature as the clamp or sleeve device  122 .  
         [0040]     Referring now to  FIG. 14 , a utility bracket  140  that is similar to the utility bracket  120  ( FIG. 12 ) is shown. The utility bracket  140  includes a similar structure that adheres the utility bracket  100  ( FIG. 10 ) to the support structure  60 . Otherwise, the utility bracket  140  is similar to the utility bracket  120  ( FIG. 12 ).  
         [0041]     Referring now to  FIGS. 15 and 16 , a utility bracket  150  similar to the utility bracket  120  ( FIGS. 12 and 13 ) is shown. An end  152  of the utility bracket  150  that includes the thru-holes extends approximately orthogonal to a portion  156  of the utility bracket  150  that secures the utility bracket  150  to the support structure  60 .  
         [0042]     Referring now to  FIG. 17 , a utility bracket  180  similar to the utility bracket  150  ( FIGS. 15 and 16 ) is shown, except that the utility bracket  180  only includes a single leg  182  and a flange  184  for mating with the support structure  60  (see  FIGS. 10 and 14 ).  
         [0043]     Referring now to  FIGS. 18 and 19 , a swivel bracket system  200  is shown. The swivel bracket system  200  includes a base plate  204  and a utility bracket  206 . The utility bracket  206  is suitably L-shaped and includes a receiving hole  210  on a first portion  212 . A second portion  214  of the utility bracket  206  includes one or more thru-holes  216  for receiving support clamps (not shown). The base plate  204  includes a first surface  220  that is adhesively attached to a support structure (not shown). A second surface  224  opposite the first surface  220  includes a swivel button  226  mounted to approximately the center of the base plate  204 . The swivel button  226  includes two or more flexible leaves  230  that are flanged at a height above the second surface  224  that is approximately equal to or slightly larger than the thickness of the first portion  212 . The swivel button  226  is received through the receiving hole  210  into a convex side of the utility bracket  206 . As the swivel button  226  is received through the receiving hole  210 , the leaves  230  flex inward until the flanged portion of the swivel button  226  passes through the receiving hole  210 . After the swivel button  226  has passed through the receiving hole  210 , the leaves  230  maintain their natural at rest position which places the flanges of the leaves  230  over the surface of the first portion  212  thus attaching the base plate  204  to the utility bracket  206 . Once the base plate  204  is received through the receiving hole  210 , the utility bracket  206  can swivel about the swivel button  226 .  
         [0044]     Referring now to  FIG. 20 , the first surface  220  of the base plate  204  includes one or more posts  240 . The posts  240  are sized to provide a gap between the base plate  204  and a support structure (not shown), such that an optimum amount of adhesive is maintained between the base plate  204  and the support structure. It will be appreciated that the base plate  204  can be formed of metal, an injection-molded plastic, polymer, polycarbonate, or some other similar semi-rigid material.  
         [0045]     Referring now to  FIG. 21 , when the bracket system  200  is used, two axes of rotation allow aligning of wire bundles or other devices connected to the bracket system  200 . The first axis of rotation is about a nut plate  260  that attaches to the bracket  206  through one of the thru-holes  216 . The second axis of rotation is about the swivel button  226 .  
         [0046]     It will be appreciated that the brackets shown in  FIGS. 4-21  may be produced by a various number of manufacturing techniques, such as without limitation, extruding, stamping, or molding performed on various materials, such as without limitation, various metals, alloys, plastics, or polycarbonates.  
         [0047]     While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.