Patent Publication Number: US-9853346-B2

Title: High capacity sector mount

Description:
This application claims the benefit of U.S. Provisional Application No. 62/104,898, filed Jan. 19, 2015, which is herein incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a structure, e.g., a metal or steel structure, for supporting radios, antennas and/or similar equipment on a tower. 
     2. Description of the Related Art 
     Background art can be seen in U.S. Pat. Nos. 5,920,291, 7,086,207, 7,113,145, 7,466,286 and U.S. Published Patent Application No. 2007/0261355, each of which is herein incorporated by reference. 
     SUMMARY OF THE INVENTION 
     With increased demand for more wireless communication, the number of radio and antenna units that a tower traditionally supports has increased and is expected to continue to increase. New towers will need to be designed to support greater numbers of antenna and radio units, while existing towers are retrofitted to support more units and effort is made to fully utilize space available on the towers. 
     To meet this increased demand, the Applicant has developed a new high capacity sector frame mount, capable of supporting at least about 1200 lbs. (at least about 300 lbs. per antenna pipe) with a reduced overall EPA (Effective Projected Area) and reduced weight that meets ANSI/TIA 222 G-2. 
     Current antenna mounts are being over loaded with equipment due to increased demand for more bandwidth. More equipment is being mounted on existing structures causing increased stress to tower legs and in some cases sector frame mounting failures. The present invention allows for more equipment weight to be mounted, but offers less EPA, overall weight reduction, fewer parts, and easier installation than other mounts. With reduced weight and EPA, end users can expand their networks without increased tower cost by not having to use more vertical space on the tower to mount additional equipment. 
     The present invention may be applied to existing or new outside towers in the cellular communication field and/or other types of communication fields. Various aspects of the present invention offer advantages over the state of the art, such as one or more of the following: 
     1. The use of two one-piece formed structural tubular frames that eliminate the assembly of multiple parts and attach to a tower leg clamp. 
     2. Face attachment transition angle brackets that selectively attach to the one-piece frame using U-bolts that allow various size face frame antenna mounts to be attached which selectively fix the position for the standoff legs with respect to the frame face. 
     3. The one-piece tubular frame allows reduced overall weight by eliminating additional parts to be assembled in the field, thereby reducing the amount of time required to install the frame structure. 
     4. The one-piece tubular frame with reduced parts has an overall lower EPA and reduces exposure of overall wind loads to the structure, which will allow the customer to install more equipment on the structure. 
     5. The structural tubular frames are attached to an upper and lower structurally welded boxed tower leg clamp, selectively securing the frame attachment to a tower leg bracket with azimuth and taper adjustment. The upper tower leg bracket provides selectively pivotally movable azimuth via a 2 point pivot and taper. 
     Various aspects of the invention provide one or more of the following benefits relative to the state of the prior art in outside wireless telecommunication cell sites:
         A. Capable of supporting higher equipment loading.   B. Reduced EPA.   C. Reduced weight.   D. Reduced parts count and assembly time.   E. Provides azimuth and taper adjustments.   F. Assembly breaks down for compact shipping.       

     Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limits of the present invention, and wherein: 
         FIG. 1  is a front perspective view of an antenna mount, in accordance with a first embodiment of the present invention; 
         FIG. 2  is a rear perspective view of the antenna mount of  FIG. 1 ; 
         FIG. 3  is a close up, rear perspective view of first and second tower mounting brackets of the antenna mount of  FIGS. 1 and 2 ; 
         FIG. 4  is a front perspective view of an antenna frame mounted to the antenna mount of  FIGS. 1 and 2 ; 
         FIG. 5  is a perspective view of three of the antenna frames of  FIG. 4  mounted around a monopole; 
         FIG. 6  is a front perspective view of an antenna mount, in accordance with a second embodiment of the present invention, having the antenna frame mounted thereto; 
         FIG. 7  is a side view of the antenna mount and antenna frame of  FIG. 6 ; 
         FIG. 8  is a close up, top view of a third equipment bracket of the antenna mount of  FIG. 6 ; 
         FIG. 9  is a close up, top view of a first equipment bracket of the antenna mount of  FIG. 6 ; 
         FIG. 10  is a front perspective view of the antenna mount, in accordance with the second embodiment of the present invention, with the antenna frame removed and showing optional cross beams; and 
         FIG. 11  is a rear perspective view of the antenna mount of  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
     Like numbers refer to like elements throughout. In the figures, the thickness of certain lines, layers, components, elements or features may be exaggerated for clarity. Broken lines illustrate optional features or operations unless specified otherwise. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity. 
     As used herein, the singular forms “a”, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.” 
     It will be understood that when an element is referred to as being “on”, “attached” to, “connected” to, “coupled” with, “contacting”, etc., another element, it can be directly on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature. 
     Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper”, “lateral”, “left”, “right” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the descriptors of relative spatial relationships used herein interpreted accordingly. 
       FIG. 1  is a front perspective view of an antenna mount, in accordance with a first embodiment of the present invention.  FIG. 2  is a rear perspective view of the antenna mount of  FIG. 1 . 
     With reference to  FIGS. 1 and 2 , an antenna mount  11  includes a first tower mounting bracket  13  and a second tower mounting bracket  15 . A first one-piece continuous bent tube frame  17  has a first portion  19  attached to the first tower mounting bracket  13  and a second portion  21  attached to the second tower mounting bracket  15 . The “one-piece continuous” aspect of the first tube frame  17  may be created by initially forming the entire first tube frame  17  as a single unitary piece, or alternatively by attaching segments of the first tube frame  17  together, e.g., by welding, slip-fit, or fasteners. 
     A second one-piece continuous bent tube frame  23  has a third portion  25  attached to the first tower mounting bracket  13 , and a fourth portion  27  attached to the second tower mounting bracket  15 . The first portion  19  of the first bent tube frame  17  and the third portion  25  of the second bent tube frame  23  are located side-by-side and are both clamped to the first tower bracket  15  by a same first clamp, such as a first U-bolt  95 , more preferably by two first U-bolts  95 , spaced apart by one or more inches. The second portion  21  of the first bent tube frame  17  and the fourth portion  27  of the second bent tube frame  23  are located side-by-side and are both clamped to the second tower bracket  15  by a same second clamp, such as a second U-bolt  97 , more preferably by two second U-bolts  97 , spaced apart by one or more inches. 
     First and second equipment brackets  29  and  31  are attached to fifth and sixth portions  33  and  35  of the first bent tube frame  17 . Third and fourth equipment brackets  37  and  39  are attached to seventh and eighth portions  41  and  43  of the second bent tube frame  23 . 
     In the embodiment of  FIGS. 1 and 2 , the first bent tube frame  17  presents a first C-shape and the second bent tube frame  23  presents a second C-shape. An opening in the first C-shape of the first bent tube frame  17  exists between the first portion  19  attached to the first tower mounting bracket  13  and the second portion  21  attached to the second tower mounting bracket  15 . An opening in the second C-shape of the second bent tube frame  23  exists between the third portion  25  attached to the first tower mounting bracket  13  and the fourth portion  27  attached to the second tower mounting bracket  15 . 
       FIG. 3  is a close up rear perspective view of the first and second tower mounting brackets  13  and  15 . The first and second tower mounting brackets  13  and  15  clamp onto a common tower leg  100  (See  FIG. 5 ) via first and second tower leg clamps  49  and  51 , respectively. The first tower leg clamp  49  may include a plate  53  with two holes receiving two threaded rods  55  and  57  and two nuts  59  and  61  threaded onto the two threaded rods  55  and  57 . The first and second tower mounting brackets  13  and  15  offer azimuth adjustment via first and second adjustment bolts  45  and  47 , respectively. The first tower mounting bracket  13  may optionally offer upper taper adjustment, via selective placement of mounting bolts  63  into selected apertures from plural apertures  65  in side plates  67 . 
       FIG. 4  shows an antenna frame  69  mounted to equipment faces  93  of the first, second, third and fourth equipment brackets  29 ,  31 ,  37  and  39 . The mounting may be accomplished by first, second, third and fourth equipment bolts  71 ,  73 ,  75 , and  77 , respectively. In a preferred embodiment, each of the first, second, third and fourth equipment bolts  71 ,  73 ,  75 , and  77  may be comprised of two U-bolts. 
       FIG. 5  shows three of the antenna mounts of  FIG. 4 , labeled as  11 - 1 ,  11 - 2  and  11 - 3  in  FIG. 5 , mounted to three tower legs  100 . The three tower legs  100  may be mounted at equally spaced locations, e.g., 120 degrees apart, around a monopole  102 . 
       FIG. 6  is a front perspective view of an antenna mount  11 ′, in accordance with a second embodiment of the present invention.  FIG. 7  is a side view of the antenna mount  11 ′ of  FIG. 6 . Like structures, in the relation to the first embodiment, have been labeled with the same reference numerals. 
     In the embodiment of  FIGS. 6 and 7 , the first bent tube frame  17 ′ is formed as first closed loop, e.g., a D-shaped member, and the second bent tube frame  23 ′ is formed as a second closed loop, e.g., a D-shaped member. The D-shape may assist in enhancing structural rigidity and stability. 
     As illustrated in  FIG. 10 , to further enhance structural rigidity and stability (or as an alternative manner to provide rigidity and stability), an optional first cross beam  79  may connect a ninth portion  81  of the first bent tube frame  17  or  17 ′ to a tenth portion  83  of the first bent tube frame  17  or  17 ′. Further, an optional second cross beam  85  may connect an eleventh portion  87  of the second bent tube frame  23  or  23 ′ to a twelfth portion  89  of the second bent tube frame  23  or  23 ′. 
     As best seen in  FIGS. 8 and 9 , the third and first equipment brackets  37  and  29 , respectively, each have a frame face  91  for attachment to the first bent tube frame  17  or  17 ′ or second bent tube frame  23  or  23 ′ and the equipment face  93  for attachment to equipment, e.g., the antenna frame  69 . The frame face  91  resides in a plane which is orthogonal to a plane containing the equipment face  93 . The frame face  91  extends in a direction D, which intersects the plane containing the equipment face  93  at an angle of approximately 10 to 80 degrees, more preferably at an angle of approximately 25 to 65 degrees, such as at an angle of approximately 45 degrees. 
     Likewise, the second and fourth equipment brackets  31  and  39  each have a frame face  91  for attachment to the first bent tube frame  17  or  17 ′ and second bent tube frame  23  and  23 ′, respectively, and the equipment face  93  for attachment to equipment, e.g., the antenna frame  69 . The frame face  91  is orthogonal to the equipment face  93  and extends in a direction D which intersects a plane containing the equipment face  93  at an angle of approximately 10 to 80 degrees, more preferably at an angle of approximately 25 to 65 degrees, such as at an angle of approximately 45 degrees. 
     As best seen in  FIGS. 10 and 11 , the frame faces  91  of the first and second equipment brackets  29  and  31  are attached to the fifth and sixth portions  33  and  35  of the first frame  17  or  17 ′ by third and fourth U-bolts  105  and  107 , respectively. The frame faces  91  of the third and fourth equipment brackets  37  and  39  are attached to the seventh and eighth portions  41  and  43  of the second frame  23  or  23 ′ by fifth and sixth U-bolts  113  and  115 , respectively. The equipment faces  93  of the first and second equipment brackets  29  and  31  are attached to thirteenth and fourteenth portions  117  and  119  of the first frame  17  or  17 ′ by seventh and eighth U-bolts  121  and  123 , respectively. The equipment faces  93  of the third and fourth equipment brackets  37  and  39  are attached to fifteenth and sixteenth portions  118  and  120  of the second frame  23  or  23 ′ by ninth and tenth U-bolts  122  and  124 , respectively. 
     The fifth portion  33  of the first frame  17  or  17 ′ resides along a first segment  125  of the first frame  17  or  17 ′, which extends along a first axis A 1 . The thirteenth portion  117  of the first frame  17  or  17 ′ resides along a second segment  127  of the first frame  17  or  17 ′, which extends along a second axis A 2 . The first axis A 1  is substantially perpendicular to the second axis A 2 . The sixth portion  35  of the first frame  17  or  17 ′ resides along a third segment  129  of the first frame  17  or  17 ′, which extends along a third axis A 3 . The fourteenth portion  119  of the first frame  17  or  17 ′ resides along the second segment  127  of the first frame  17  or  17 ′, which extends along the second axis A 2 . The third axis A 3  is substantially parallel to the first axis A 1 , and hence substantially perpendicular to the second axis A 2 . 
     The structure and attachments of the third and fourth equipment brackets  37  and  39  and the second frame  23  or  23 ′ may be in the same fashions and orientations, as described in the above paragraphs. 
     Tube diameters of the first and second frames  17 ,  17 ′,  23  or  23 ′ may be between 1 to 3 inches, such as 1.5 to 2.5 inches, more preferably about 1.9 to 2.4 inches. The clamps have been illustrated as U-bolts  95 ,  97 . However, the clamps may be formed in other manners, such as a plate or L-shape member using bolts to apply a frictional clamping force, or a strap which may be tightened to apply a frictional clamping force. The first and second frames  17 ,  17 ′,  23  or  23 ′ in  FIGS. 1-11  have been depicted as tubular frames each with a circular cross-sectional shape. However, the tubular frame may optionally have other cross sectional shapes, such as oval, triangular, rectangular or square. Also, one or more of the advantages of the present invention may be obtained by non-tubular frame members, e.g., L-shaped frame members. 
     The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.