PV Bonding Clamp With Piercing Contacts for Grounded Mounting

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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 properties of anodized aluminum frames.

Innovation Solution

The development of 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 is improved, but device complexity and installation cost increase

Engineering Contradiction:

Improveelectrical bondingVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the mechanical fastening function and electrical bonding function into a single clamp assembly. The clamp body with conductive members integrates both structural support and electrical connectivity, eliminating the need for separate grounding lugs or washers that were previously required.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The clamp serves multiple functions simultaneously: it mechanically secures the photovoltaic module to the racking structure while also providing the electrical bonding path through its conductive members. This multi-functional design reduces the total number of components needed in the system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

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

Engineering Contradiction:

Improveelectrical bondingVSAvoidinstallation cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If thread forming screws are used to attach grounding lugs, then electrical bonding is achieved, but mechanical strength is reduced due to limited thread engagement

Engineering Contradiction:

Improveelectrical bondingVSAvoidmechanical strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The clamp is divided into distinct functional components: a clamp body for mechanical fastening, conductive members for electrical bonding, and spacer members for positioning. This segmentation allows each component to be optimized for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conductive members act as intermediaries between the clamp body and the photovoltaic module frame, providing both mechanical connection and electrical conductivity. This intermediary structure enables reliable electrical bonding without relying on limited thread engagement.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This solution provides a cost-effective and efficient method for achieving electrical bonding between photovoltaic module frames and rail systems, enhancing mechanical strength and conductivity while reducing installation complexity and costs.

Implementation Method 1

at least one electrical bonding member extending from the body... The at least one electrical bonding member may have one or more piercing surfaces for cutting through or piercing non-conductive coatings

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Implementation Method 2

at least one pressure member extending from the body... The at least one pressure member may have an offset such that a frame engaging surface of the at least one pressure member lies in a different plane than the bottom surface of the body

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS10270188B2Bonding clamp

Publication Date: 2019.04.23 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.