Cable Clip Structure for Cable Bonding on Coated Metal Rails

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Solution Overview

Problem

Existing technologies fail to efficiently secure and electrically bond electrical cables to metal structures in photovoltaic arrays, necessitating improved cable management and bonding solutions.

Innovation Solution

Cable clips with clamp members, extension members, and spanning members that include penetrating projections to grip and secure cables to metal structures, providing electrical bonding through tooth-like projections that penetrate non-conductive coatings to establish a conductive path.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional cable securing methods are used, then cable management is simple, but electrical bonding and electrical continuity cannot be ensured

Engineering Contradiction:

Improveelectrical bondingVSAvoidcable clip structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cable clip combines two separate functions into a single integrated component: mechanical cable securing (through clamp members) and electrical bonding (through penetrating projections). This merging eliminates the need for separate bonding devices while ensuring both cable management and electrical continuity requirements are met simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cable clip is designed as a multi-functional device that performs both mechanical retention (holding cables to metal structures) and electrical bonding (providing conductive path through penetrating projections). This universal design allows a single component to satisfy multiple requirements that would traditionally need separate solutions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If non-conductive coatings are present on metal structures, then corrosion protection is improved, but electrical bonding becomes difficult

Engineering Contradiction:

Improveelectrical continuityVSAvoidnon-conductive coating interference

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The penetrating projections are designed to penetrate through the non-conductive coating before the cable clip is installed. This preliminary action of breaking through the coating barrier during installation ensures that direct metal-to-metal contact is achieved, establishing the required electrical continuity while the coating remains intact for corrosion protection.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The non-conductive coating, which normally prevents electrical bonding, is converted into a benefit by designing projections that deliberately penetrate it. The coating's presence is acknowledged and worked around - the projections pass through the coating to reach the conductive metal surface, thus converting the coating's protective function into an opportunity for reliable electrical bonding through controlled penetration.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Strength

If clamp members are designed to grip cables securely, then cable retention is improved, but installation complexity increases

Engineering Contradiction:

Improvecable retentionVSAvoidinstallation process

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The cable clip is segmented into distinct functional components: clamp members for cable retention and penetrating projections for bonding. This segmentation allows each component to be optimized for its specific function while maintaining overall simplicity. The clamp members can be designed with simple gripping geometry that provides strong retention without complex mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The clamp members are designed to automatically grip and retain cables through their geometric shape and elastic properties, without requiring additional fastening mechanisms or complex adjustment procedures. The cable insertion triggers the gripping action automatically, making the installation process simple while ensuring strong retention.

Inventive Principle:

Principle #25Self-service

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

Effectively secures and electrically bonds cables to metal structures, ensuring safe electrical continuity and efficient cable management in photovoltaic arrays.

Implementation Method 1

providing electrical bonding through tooth-like projections that penetrate non-conductive coatings to establish a conductive path

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS12548986B2Cable clips

Publication Date: 2026.02.10 HUBBELL INC

AI summary

A cable clip including a pair of clamp members, a pair of extension members, each extension member extending from a clamp member, and a spanning member spanning from one extension member to the other extension member.