Patent Publication Number: US-2012025038-A1

Title: Mounting Bracket

Description:
FIELD OF INVENTION 
     The invention is an improved mounting bracket for use in structural support applications. The invention is particularly suited for use with ground-mounted solar panel installations and other outdoor installations. 
     BACKGROUND 
     Joining two support beams at angles other than perpendicular presents a number of challenges. A common method involves placing the support beams at the desired angle and attaching the beams with two or more rivets, bolts, nails, screws or other attachment means. This method is suitable for a small number of assemblies, but as the number of assemblies increase, this method becomes less and less efficient. Ensuring that the support beams in each assembly are joined at the correct angle requires measuring the angle each time the beams are joined. 
     Certain assemblies may use pre-drilled holes in the beams for the beams to be at the correct angle. Each such assembly requires placing the beams and their respective holes into alignment and then inserting the attachment means. Where the assemblies do not use pre-drilled holes, the beams must be placed into the correct position and at the correct angle for each assembly. In these scenarios, the positioning of the assembly takes time and effort in order to achieve the desired angle of the assembly. 
     Often the angle of the assembly is desired to be consistent over several separate assemblies. An example of particular importance arises in the installation of ground mounted solar panel arrays. 
     Solar panel arrays in outdoor installations are often comprised of several photoelectric panels supported by channels as is known in the art. The channels provide structural support for the photoelectric panels and also provide spaces for the electric wires running from the panels to external circuitry. 
     For ground mount solar panel arrays, the channels are supported by a series of support posts inserted into the ground, roughly perpendicular to the surface of the ground. The solar energy panels are preferably oriented to face the path of the sun at the location, to maximize the exposure of the solar panels to the rays of the sun. At any given latitude, there is a desired angle of the orientation of a solar panel, as is known to those skilled in the art. The channel supporting the solar panels is usually parallel to the plane of the solar panels, and accordingly is oriented at a particular angle with respect to the support post. 
     While solar panel installations appear to require only exposure to sunlight, in certain climates, solar panel installations cannot rely on optimum weather conditions to exist for every day of operation. Accordingly, the solar panel installation must be able to handle the worst weather conditions in a particular climate. The nature of photoelectric panels requires that the photoelectric panels have a wide surface area, and a solar panel array of photoelectric panels covers wide areas. Accordingly, solar panel arrays are especially susceptible to damage from high winds. It is important that ground-mount installations of solar panel arrays be securely anchored to the ground. Failure to provide sufficient anchoring can result in damage to the solar panel arrays, as well as damage to surrounding property in the event that one or more photoelectric panels becomes dislodged from its ground support. Accordingly, solar panel support structures including the joining of the posts and channels must be sturdy and resistant to the effects of adverse weather conditions. 
     In determining whether to install solar panel arrays, the cost of installation on a per panel basis is weighed against the expected savings in conventional energy sources. Most businesses looking to install solar panel arrays expect a return on the investment after several years. Current efficiency levels of solar energy panels make the cost of installation and maintenance significant factors in implementing solar energy as an alternative to traditional energy sources. Reducing the per panel installation cost can have the effect of increasing the number of installations. For ground-mounted solar panel installations, long-lasting, low maintenance installations are desired. 
     It is a purpose of the invention to provide an improved mounting bracket. 
     It is a further purpose of the invention to provide an improved mounting bracket for use in outdoor applications. 
     It is another purpose of the invention to provide a durable, cost-effective mounting bracket for use in outdoor applications. 
     It is yet another purpose of the invention to provide an improved mounting bracket for use in solar panel installations. 
     SUMMARY OF THE INVENTION 
     The invention is a mounting bracket for attaching two support structures together, such as a support beam or channel to a vertical support post which would be attached at a pre-determined angle. The mounting bracket has a cavity for receiving the vertical support post, the cavity being attached to a side of a support plate at the pre-determined angle. The support plate is attached to the channel, such that the channel is supported from the ground at the desired angle. The invention is designed to be used with installations requiring a consistent angular relationship between the vertical support post and the channel, such as solar panel arrays. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is perspective view of the invention. 
         FIG. 2  is a front end view of the invention. 
         FIG. 3  is side view of the invention, showing a cross section of the cap. 
         FIG. 4  is side view of the invention, being supported by a mounting post and supporting a solar panel array. 
         FIG. 5  is a front view of the invention, being supported by a mounting post and supporting channels and framing for a solar panel array, without the solar panels in place. 
         FIG. 6  is a perspective view of the invention, being supported by a mounting post and supporting a solar panel array. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The invention is a mounting bracket  10  with a support plate  20  and a cap  30  attached to a side of the support plate  20 . 
     Cap  30  has two sides  31 ,  32  which are approximately parallel to each other, and an end plate  33 . The two sides  31 ,  32  do not need to be the same length and preferably are of unequal lengths. The end plate  33  is preferably a wide flat surface. Cap  30  may be U-shaped, with the sides  31 ,  32  and end plate  33  being approximately equal in width, forming a cavity  35 . Slots  34  are provided in sides  31 ,  31  to allow cap  30  to be attached to an additional support structure, as discussed below. Cap  30  is preferably constructed of a rectangular metal plate, bent in two places to form the U-shape. Cavity  35  has an orientation axis  36 , where orientation axis  36  points in a particular direction, preferably perpendicular to end plate  33 . 
     Support plate  20  can be of any dimension and has a longitudinal axis  25  in the direction of the length of the support plate. Support plate  20  is also preferably constructed of metal. Support plate  20  has apertures  22  for use in securing support plate  20  to channel  40 , or another support structure. 
     Cap  30  is attached to a side of support plate  20 , with orientation axis  36  of cavity  35  at an oblique angle θ with respect to the longitudinal axis  25  of support plate  20 . Cap  30  is preferably welded to support plate  20 , or otherwise permanently affixed to support plate  20 , such that oblique angle θ is fixed. Cavity  35  is preferably oriented roughly parallel to the surface plane  21  of support plate  20 . 
     The orientation of cap  30  with respect to support plate  20 , namely the angle θ, is preferably pre-determined based upon the expected use of the invention. The invention is intended for use with installations that require a consistent angle across multiple mounting brackets  10  used for the same installation. Therefore, each cap  30  is preferably welded to each support plate  20  in a manner that angle θ will be the same for each mounting bracket  10 . For solar panel installations in a given location, angle θ will be calculated to maximize the efficiency of the solar panels at such location. 
     Mounting bracket  10  of the present invention is intended for use with ground mounted solar panel installations, as shown in  FIGS. 4-6 . In solar panel installations, the array of solar panels is preferably oriented at a particular angle, based upon the latitude of the installation. As is known in the art, each panel of the array is desired to be at the same angle, regardless of the terrain of the installation location. 
     In the preferred ground-mount solar panel installation, a support post  50  is inserted into the ground. The support post  50  is preferably a metal beam, driven into the ground, or placed into hole  100  in the ground and affixed with footing  100 , such as concrete as is known in the art. Support post  50  preferably has a flat upper end, which allows for the support post to be driven into the ground by force in appropriate conditions, without requiring a previously-prepared hole or footing. 
     Mounting bracket  10  of the present invention is placed on the top of the support post  50 , inserting the top end of the support post into the cavity  35 . Where support post  50  has a flat upper end, having a flat end plate  17  allows the cap to rest on top of the support post. Preferably, the cap  30  is affixed to the support post  50  by post attachment means  37 . Post attachment means  37  may be bolts or other secure attachment means as are known in the art. Slots  34  are provided in the sides  31 ,  32  of cap  30  to allow the cap to be raised or lowered as needed for a desired height. 
     Support plate  20  of mounting bracket  10  is attached to a channel  40  that supports framing  45  which in turn supports one or more solar panels  60 . Preferably, channel  40  is attached to support plate  20  with the longitudinal axis  25  of the support plate parallel to the length of channel  40 . Attachment means  27  are used to attach channel  40  to support plate  20 , and may be bolts or other secure attachment means as are known in the art. Support plate  20  may have holes  24  through which bolts may be passed to secure the channel  40  to support plate  20 . 
     After mounting bracket  10  is attached to support post  50  and channel  40 , channel  40  will be oriented at the desired angle θ with respect to support post  50 . A plurality of assemblies of support post, mounting bracket and channel in a row will support one array of solar panels. Several arrays are commonly used in ground-mount solar panel installations, as is known in the art. 
     While certain novel features of the present invention have been shown and described, it will be understood that various omissions, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing from the spirit of the invention.