Bonding Washer Perpendicular Teeth Anodized Aluminum
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Solution Overview
Problem
Existing methods for electrical connection between anodized aluminum components in photovoltaic arrays are inefficient, with small contact areas leading to high resistance and reliability issues, and require multiple connection points and expensive grounding lugs, increasing system costs and installation complexity.
Innovation Solution
A bonding washer with perpendicular metal teeth that embed into the aluminum components during assembly, providing a large surface contact area and ensuring electrical continuity with a short electrical path, eliminating the need for multiple connection points and specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate grounding lug and multiple connection points are used, then electrical connection reliability is improved, but device complexity and installation cost increase
Solution Approach 1:
The bonding washer combines multiple connection functions into a single integrated component. The washer simultaneously provides mechanical fastening (through the central aperture for bolts/screws), electrical bonding (through radially extending teeth that contact both metal pieces), and grounding capabilities. This eliminates the need for separate grounding lugs and multiple connection points, reducing installation complexity while maintaining electrical connection reliability.
Solution Approach 2:
The bonding washer serves multiple functions: it acts as a fastener to mechanically join metal pieces, creates electrical contact through its teeth that embed into the metal surfaces, provides a bonding path for electrical continuity, and serves as a grounding point. This multi-functional design replaces the traditional multi-component approach (grounding lugs, multiple connectors, wiring), simplifying the overall system while ensuring reliable electrical connection.
2Ease of manufacture
If traditional star washers with twisted teeth are used, then ease of manufacture is improved, but electrical connection effectiveness deteriorates due to inability to penetrate anodized coating
Solution Approach 1:
Instead of twisting the teeth to provide spring action (traditional approach), the invention inverts the approach by making the teeth straight and rigid, and relies on the embedding action during tightening. The teeth are oriented radially outward and are forced to embed into the anodized coating and underlying metal when the fastener is tightened, rather than springing back to maintain contact. This inversion enables penetration of the anodized coating while maintaining ease of manufacture through simple forming processes.
Solution Approach 2:
The invention changes the key parameter of tooth orientation from twisted (at an angle to the washer plane) to straight and radial (perpendicular to the washer plane). This parameter change allows the teeth to function as embedding elements that can penetrate the anodized coating when compressed during assembly, while still being manufacturable through conventional forming processes. The straight radial geometry provides a direct path for electrical conduction through the coating and into the metal substrate.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves reliable and efficient electrical bonding with low resistance, reducing installation complexity and costs by integrating the washer into the assembly process and ensuring consistent contact even through anodized coatings.
Implementation Method 1
A bonding washer with perpendicular metal teeth that embed into the aluminum components during assembly
Implementation Method 2
providing a large surface contact area and ensuring electrical continuity with a short electrical path
Data Source
AI summary
A bonding washer for making electrical connection between two metal pieces that are to be mechanically fastened together. The washer, to be interposed between the two metal pieces, may be constructed so as to fasten to one of the pieces before the two pieces are joined. Teeth on the washer, positioned at right angles to the plane of the washer, are forced into each of the two metal pieces when the fastener is tightened, making electrical connection between the two metal pieces.