Patent Publication Number: US-2021175842-A1

Title: Tabbed structural bracket

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62944356 filed Dec. 5, 2019 entitled Tabbed Structural Bracket, the entire contents of which are incorporated by reference herein for all purposes. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to structural brackets. More specifically, the present invention relates to a tabbed structural bracket configured to lock rotation of mechanical assemblies and eliminate the need for additional fasteners. 
     BACKGROUND OF THE INVENTION 
     Commercially, there are a numerous number of brackets available in the market, for example, angle brackets and L-shaped brackets. Generally, for heavy industrial use, brackets are fabricated using steel sheet metal having a first leg and a second leg oriented at a desired angle relative to each other. Each leg is a narrow strip with one or more holes for screwing it to other support structures/frames. These brackets are used as support brackets for mounting various types of structures such as solar panels, air conditioners, ventilation systems, and other heavy equipment. 
     A solar module, which is comprised of photovoltaic cells, is an electrical device that converts the energy of light directly into electricity by the photovoltaic effect. Solar cells are the building blocks of photovoltaic modules, otherwise known as solar panels. 
     Solar mounting and racking systems must be installed in sun or light exposed area. Most often, it is desirable to mount solar panels outdoors at an angle from the horizontal so that they will more directly face the sun during peak daylight hours, rather than being mounted flat to the ground or another surface. Many times, many solar panels are mounted together to form a solar panel array, which may utilize hundred or even thousands of solar panels. Mounting and racking systems are a critical cost component in any solar field. 
     A typical solar mount racking system require a very large amount of screws or other types of fasteners to ensure the assembly ha the structural integrity required to last many years in harsh and windy environments. These screws, due to the vast number required, add significant cost to these structures and have an adverse effect on margins. 
     Known mounting brackets or structural bracket are fastened to a mating beam via fasteners such as bolts or heavy duty bolts or screws. The mounting bracket and the mating beam are positioned in such a way to align holes so that treaded bolts together with nuts mount the mounting bracket o the mating beam. Again however, the existing bracket requires a greater number of bolts and nuts to fix a similar mechanical assembly. In addition, it requires more labors and additional assembly time. 
     Therefore, there is a need for an improved design to lock rotation of mechanical assembly and eliminate the need for additional fasteners. 
     SUMMARY OF THE INVENTION 
     To achieve the foregoing and other aspects and in accordance with the purpose of the invention, the subject invention provides a tabbed structural bracket (hereinafter referred as structural bracket). 
     The structural bracket has with a mounting tab and hook to lock rotation of the mechanical assembly and eliminate the need for additional fasteners. 
     The structural bracket is for use with solar mounting assemblies, but may be used in other fields in which fasteners are desirable. 
     In one embodiment, the structural bracket is used for making a connection between two structural members. The structural bracket is fabricated using materials including, but not limited to, steel, aluminum, durable engineering plastic, or other suitable materials. The structural bracket could be galvanized or painted to avoid corrosion due to long-time use or ambient conditions. 
     The the structural bracket comprises a first planar portion and a second planar portion. The first planar portion and the second planar portion may be approximately the same size and shape. In one embodiment, the planar portions are rectangular in shape. In one embodiment, the second planar portion is angularly positioned to the first planar portion at an angle of approximately ninety degrees to form an L-shaped configuration. The second planar portion comprises a mounting tab. In one embodiment, the mounting tab is positioned at a distal end of the second planar portion. In one embodiment, the second planar portion further comprises at least one pre-drilled or pre-tapped aperture. In one embodiment, the aperture is a circular or round through-hole/opening positioned on the surface of the second planar portion. 
     In embodiments, the structural bracket is fastened to the mating beam using the mounting tab and hook. The mating beam comprises one or more pre-punched through-holes or apertures including, a first through-hole and a second through-hole. The mounting tab is configured to snugly fit into the first through-hole and the hook is configured to lock rotation of the mating beam. Further, at least one fastener extends via the second through-hole and the aperture to fasten the mating beam and the structural bracket. The mounting tab locks rotation of the mating beam eliminates the need for a separate fastener to lock rotation. 
     In embodiments, the mounting tab eliminates the need for additional fasteners (e.g., bolts) required to fasten the structural bracket to the mating beam. In one embodiment, the fastener is a threaded bolt or screw having a head, a threaded shaft extends from the screw head, and a threaded nut. The threaded shaft travels through the second through-hole and the aperture to fasten the mating beam and the structural bracket. 
     In embodiments, the structural bracket comprises a first planar portion, and a second planar portion angularly positioned relative to the first planar portion; a mounting tab coupled to the second planer portion proximate a distal end of the second planer portion; a hook extending outwardly from the mounting tab at an angle, wherein the hook is configured to securely lock the structural bracket to a mating beam using an interference fit. 
     In embodiments, a solar mounting system for mounting a solar module of a solar module array is provided. The system comprises a plurality of mounting legs; a frame coupled to the mounting posts, wherein the frame configured to support at least one solar cell, and wherein the frame comprises a plurality of mating beams; a plurality of structural brackets, wherein the structural brackets are configured to be securely fixed to the mating means, wherein the plurality of structural brackets comprise a first planar portion and a second planar portion angularly positioned relative to the first planar portion; a mounting tab coupled to the second planer portion proximate a distal end of the second planer portion; and a hook extending outwardly from the mounting tab at an angle, wherein the hook is configured to securely lock the structural bracket to a mating beam using an interference fit. 
     Other features, advantages, and aspects of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which: 
         FIG. 1  is a perspective view a tabbed structural bracket with a mating beam according to one embodiment of the present invention. 
         FIG. 2  is a perspective view of the structural bracket fastened to the mating beam according to one embodiment of the present invention. 
         FIG. 3  is a front view of the structural bracket according to one embodiment of the present invention. 
         FIG. 4  is a bottom view of the structural bracket according to one embodiment of the present invention. 
         FIG. 5  is a side view of the structural bracket according to one embodiment of the present invention. 
         FIG. 6  is blown up bottom view of the structural bracket according to one embodiment of the present invention. 
         FIG. 7  is a perspective side view the structural bracket according to one embodiment of the present invention. 
         FIG. 8  is an opposite side view of the structural bracket according to one embodiment of the present invention. 
         FIG. 9  is a perspective view of a solar module system utilizing the tabbed bracket in an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention is best understood by reference to the detailed description and examples set forth herein. 
     Embodiments of the invention are discussed below with reference to the examples. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these examples is for explanatory purposes as the invention extends beyond these limited embodiments. For example, it should be appreciated that those skilled in the art will, in light of the teachings of the present invention, recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein, beyond the particular implementation choices in the following embodiments described and shown. That is, there are numerous modifications and variations of the invention that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive. 
     It is to be further understood that the present invention is not limited to the particular methodology, compounds, materials, manufacturing techniques, uses, and applications, described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. Similarly, for another example, a reference to “a step” or “a means” is a reference to one or more steps or means and may include sub-steps and subservient means. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word “or” should be understood as having the definition of a logical “or” rather than that of a logical “exclusive or” unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise. 
     Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Preferred methods, techniques, devices, and materials are described, although any methods, techniques, devices, or materials similar or equivalent to those described herein may be used in the practice or testing of the present invention. 
     Referring now to  FIG. 1 , an exploded view of a tabbed structural bracket (hereinafter referred as structural bracket)  100  is fastened with a mating beam  110 , according to one embodiment of the present invention. The structural bracket  100  is used for fastening at least two structural members of devices, for example, a solar mounting assembly. In one embodiment, the structural bracket  100  is an L-shaped purlin bracket but may be any type of bracket is contemplated herein. The structural bracket  100  is formed by bending a sheet of metal material. The structural bracket  100  may be formed by welding or joining multiple metal pieces together. In some embodiments, the structural bracket  100  is fabricated using materials including, but not limited to, steel, aluminum, durable engineering plastic, or other suitable materials. The structural bracket  100  may be galvanized or painted to avoid corrosion over time. 
     In one embodiment, the structural bracket  100  comprises a first planar portion  102  and a second planar portion  104 . The first planar portion  102  and the second planar portion  104  may have the same size and shape or be dimensioned such that the second planar portion  104  has a bottom portion  148  that is angled inwardly. The second planar portion  104  is angularly joined to the first planar portion  102  at an angle of approximately 90 degrees to form an L-shaped configuration. 
     The second planar portion  104  comprises a mounting tab  106  with a hook portion (shown in  FIGS. 2-8 ) . In one embodiment, the mounting tab  106  is positioned at a distal end of the second planar portion  104 . In one embodiment, the second planar portion  104  further comprises at least one pre-drilled or pre-tapped aperture  108  which is a circular or round through-hole, but may be of any useful shape. While as shown the mounting tab  106  is shown toward the distal or bottom end and the aperture  108  is show above the tab, in optional embodiments, the tab may be located toward the middle or top of the bracket, and the aperture  108  located toward a bottom of distal end. 
     In one embodiment, the mating beam  110  is a C-shaped purlin/beam. The mating beam  110  may be manufactured from a kind of carbon structural steel or high tensile galvanized steel material. The mating beam  110  comprises one or more pre-punched through-holes including a first through-hole  112  and a second through-hole  114 . In one embodiment, the structural bracket  100  is fastened to the mating beam  110  using the mounting tab  106 , hook (shown in  FIGS. 2-8 ), and a fastener  120  such as a bolt or screw and nut. 
     Referring now to  FIG. 2 , the structural bracket  100  fastened to the mating beam  110 , according to one embodiment of the present invention is shown. The structural bracket  100  comprises the first planar portion  102  and the second planar portion  104 . In one embodiment, the second planar portion  104  is angularly positioned relative the first planar portion  102  at an angle of approximately  90  degrees to form the L-shaped configuration. The second planar portion  104  comprises the mounting tab  106  and hook  150  positioned at its distal end. In one embodiment, the second planar portion  104  further comprises at least one pre-drilled or pre-tapped aperture  108 . 
     In operation, the mounting tab  106  and the aperture  108  are configured to fasten the structural bracket  100  to the mating beam  110 . So that it may be used with varying solar mounting equipment, the mating beam  110  comprises one or more pre-punched through-holes including the first through-hole  112  and the second through-hole  114 . In one embodiment, the first through-hole  112  is configured to receive the mounting tab  106  and hook  150 , whereas the second through-hole  114  is configured to align with the aperture  108  to receive the fastener  120  (e.g., bolt and nut). 
     In one embodiment, the structural bracket  100  is fastened to the mating beam  110  using the mounting tab  106 , and the hook  150  is configured to secure the bracket to the mating beam so that the bracket and beam are securely mounted and will not come apart in adverse conditions such as high wind. In this way, the hook  150  acts as a locking mechanism that actuates when the user rotates the bracket  100 . The mounting tab  106  fastens the structural bracket  100  and the mating beam  110  by positioning through first through-hole  112  and the hook  150  acts as a lock based on an interference hit when rotated. In one embodiment, the mounting tab  106  and lock  150  is configured to snugly fit into the first through-hole  112  to prevent the rotation of the mating beam  110  once locked into place with the hook  150 . In one embodiment, the mounting tab  106  eliminates the need for additional fasteners which the fastener  120  fastens the mating beam  110  and the structural bracket  100 . The fastener  120  is a threaded screw having a screw head  122 , a threaded shaft  124  extends from the screw head  122 , and a threaded nut  126 . The threaded shaft  124  of the fastener  120  travels through the second through-hole  114  and the aperture  108  and tightened using the nut  126 , thereby fastening the mating beam  110  and the structural bracket  100 . In one embodiment, the fastener  120  provides structural strength to the assembly such as solar modules. 
     During installation, the structural bracket  100  and the mating beam  110  are fastened or fixed together using the mounting tab  106 , hook  150  and the fastener  120 . In one embodiment, the mounting tab  106  snugly fits into the first through-hole  112  of the mating beam  110 . In one embodiment, the mounting tab  106  is configured to securely fasten to the structural bracket  100  with the mating beam  110  to prevent rotation of the mating beam  110  without the need for additional fasteners. The fastener  120  provides additional structural strength to the assembly. 
     Referring now to  FIG. 3  a front view the bracket  100  is shown. As shown, the second planer portion  104  can be seen together with aperture  108 , and angled portion  148 . As can be seen, the angled portion is inwardly angled at approximate  10 - 15  degrees. This is angle portion or “cut out” allows the user greater ability rotate the bracket in shirt spaces, and further, allows for the mounting tab  106  to be positioned at a distal corner of the second planer portion  104  rather than a distal middle portion of the second planer portion  104 . This placement increases structural integrity of the bracket mounting tab with relation bracket and makes it easier for the user to properly rotate the bracket during installation so that the hook portion  150  locks the bracket in place via interference fit. The mounting tab  106  and hook  150 , as shown, have a L-shaped configuration in relation to each other, though they are formed in one-piece construction but may be two pieces welded to the other so long as the structural integrity is commensurate with the end-use. In optional embodiments, the mounting tab  106  and hook  150  may be coupled via bearing or any type of joint that allows for rotational motion, or a joint that allows for six degrees of freedom. In this embodiment, a lock mechanism is provided to lock the hook into places when the desired angle is reached by the user. 
     Referring now to  FIG. 4 , a bottom view of the bracket  100  is shown for purposes of orientation. As can be seen, the hook  150  has a length that is approximately twice the width of the mounting tab  106  when viewed from the bottom. 
     Referring now to  FIG. 5 , a back view the bracket  100  is shown. As shown, the first planer portion  102  can be seen together with mounting holes  130   a ,  130   b ,  130   c  and  130   d  (n+1). These mounting holes allow the user to use the bracket with any number of designs, or in other embodiments, use all mounting holes to increase structural integrity whilst coupling to another bracket or portion of a structure such as a solar mounting system. For purposes of orientation, the mounting tab  106  and hook  150  can be seen extending from the second planer portion  104 . The hook  150  may extend from the planer portion from the left, right, upwardly or downwardly, the a leftward extension is shown herein. 
     Referring now to  FIG. 6 , a blown-up bottom view of  FIG. 4 . As can be seen, the hook  150  has a length that is approximately twice the width of the mounting tab  106  when viewed from the bottom, and also as a width that is approximately equal to the width of the mounting tab  106  for increased strength. It almost most be dimensioned to fit into the aperture of the elements is mounted to. 
     Referring  FIG. 7 , is a perspective side view the structural bracket according to one embodiment of the present invention is shown. The structural bracket  100  comprises the first planar portion  102  and the second planar portion  104 . The second planar portion  104  comprises the mounting tab  106  and hook  150  positioned at its distal end. In one embodiment, the second planar portion  104  further comprises at least one pre-drilled or pre-tapped aperture  108 . 
     Referring now to  FIG. 8 , an opposite perspective view is shown. As can be seen, the mounting tab  106  extends both downwardly and outwardly from the second planer portion  104 , and the hook extends leftwardly (although may be rightwardly) from the mounting tab  106 . Each of the mounting tab and hook may be of similar thickness to provide appropriate strength. 
     In operation, a user provides the bracket  100  while constructing a solar mount, generally on site. The user inserts the hook  150  into the aperture or mating hole of the mating beam  110 , and during insertion, the bracket is at an angle between  10  and  45  degrees off center. Once the hook  150  is inserted, the user users a twisting motion to insert the mounting tab  106  into hole  122 , at which point the bracket screw hole is aligned with the mating bean hole  114  so that user can fix the top portion of the bracket to the beam. 
     In one embodiment, the mounting tab  106  eliminates the need for additional fasteners, for example, a second fastener used in the conventional structural brackets, to fasten the structural bracket  100  with the support structure, such as the mating beam  110 . In one embodiment, the mounting tab  106  is a rotation-locking tab, which eliminates the need of a ½-13″ serrated flange bolt connection to prevent the rotation. In another embodiment, the structural bracket  100  could be used with any square mechanical assemblies. 
     Referring not to  FIG. 9 , a solar mounting system is shown. The photovoltaic or solar cell  600  is to mounted to frame that supports the cell. The frame is coupled to mounting legs or posts  602 , a mating beam  604  and a slant bean  608 . A plurality of structural brackets  100  are shown which attach the mounting  604  to the slant beam  608 . 
     The advantages of the present invention include, but ae not limited to, eliminating the need for additional mounting holes/apertures and fasteners to mount the structural bracket  100  with the mating beam  110 . The structural bracket  100  eliminates at least 4 connection points per foundation in the solar mounting assembly, for example, approximately 160,000 connectors are replaced with the structural brackets per 100 MW. In addition, the structural bracket  100  maintains the structural integrity of the mounting assembly. Further, the structural bracket  100  reduces part weight and material. The structural bracket  100  is easily latched/connected with the mating beam  110 . Therefore, the structural bracket  100  has reduced assembly time and labor costs. The structural bracket  100  could also be used with square mechanical assemblies or any other mechanical assemblies regardless of fastener count. 
     While the present invention has been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the present invention is not limited to these herein disclosed embodiments. Rather, the present invention is intended to cover all of the various modifications and equivalent arrangements included within the spirit and scope of the appended claims. 
     Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, the feature(s) of one drawing may be combined with any or all of the features in any of the other drawings. The words “including”, “comprising”, “having”, and “with” as used herein are to be interpreted broadly and comprehensively and are not limited to any physical interconnection. Moreover, any embodiments disclosed herein are not to be interpreted as the only possible embodiments. Rather, modifications and other embodiments are intended to be included within the scope of the appended claims.