PV Bonding Clamp for Electrical Contact Through Anodized Frames

Solution Overview

Problem

The existing methods for securing photovoltaic module frames to rail systems require additional components like grounding lugs or washers to achieve electrical bonding, which increases installation costs and complexity due to the insulating anodized aluminum surfaces preventing direct electrical contact.

Innovation Solution

A bonding clamp with an electrically conductive body, featuring electrical bonding members that pierce through non-conductive coatings and pressure members with offsets to ensure secure mechanical and electrical contact, eliminating the need for separate bonding components by integrating the bonding function into the clamp.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate grounding lugs or washers are installed to achieve electrical bonding, then electrical bonding reliability is improved, but device complexity and installation cost increase

Engineering Contradiction:

Improveelectrical bonding reliabilityVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the mechanical clamping function and electrical bonding function into a single integrated clamp assembly. The clamp body with conductive elements performs both structural support and electrical connection, eliminating the need for separate grounding lugs or washers that would otherwise be required on anodized aluminum surfaces.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The clamp assembly serves multiple functions simultaneously: it provides mechanical support to hold the photovoltaic module, creates electrical bonding through conductive elements that penetrate the anodized coating, and maintains structural integrity. This multi-functional design replaces what would traditionally require multiple separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate grounding lugs or washers are installed to achieve electrical bonding, then electrical bonding reliability is improved, but installation cost increases

Engineering Contradiction:

Improveelectrical bonding reliabilityVSAvoidinstallation cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the mechanical clamping function and electrical bonding function into a single integrated clamp assembly. The clamp body with conductive elements performs both structural support and electrical connection, eliminating the need for separate grounding lugs or washers that would otherwise be required on anodized aluminum surfaces.

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If traditional clamps are used without bonding functionality, then device complexity is reduced, but electrical safety is compromised

Engineering Contradiction:

Improveclamp structure simplicityVSAvoidelectrical safety hazard

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent combines the mechanical clamping function and electrical bonding function into a single integrated clamp assembly. The clamp body with conductive elements performs both structural support and electrical connection, eliminating the need for separate grounding lugs or washers that would otherwise be required on anodized aluminum surfaces.

Inventive Principle:

Principle #5Merging (Combining)

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 bonding clamp provides a reliable and cost-effective electrical bond between photovoltaic module frames and rail systems, enhancing safety and reducing installation costs by eliminating the need for additional bonding components.

Implementation Method 1

electrical bonding members that pierce through non-conductive coatings

Methodology Applied

Scientific EffectMechanical penetration through insulating coating:

Implementation Method 2

pressure members with offsets to ensure secure mechanical and electrical contact

Methodology Applied

Scientific EffectMechanical pressure: Mechanical Force

Implementation Method 3

electrically conductive body

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS9985361B2Bonding clamp

Publication Date: 2018.05.29 HUBBELL INC

AI summary

Bonding clamps used to assembly photovoltaic (PV) arrays and provide an electrical bond between PV module frames forming part of the PV arrays is provided. The bonding clamp includes an electrically conductive body, at least one electrical bonding member extending from the body, and at least one pressure member extending from the body. The bonding clamp may also include one or more spacers to provide a uniform spacing between PV module frames.