Solar Panel Rail Bracket Fastening With Integrated Electrical Bonding
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Solution Overview
Problem
Existing solutions for securing solar panel brackets to rail guides are difficult to install and lack an efficient electrical bonding path, requiring special tools and extra bonding components.
Innovation Solution
A nut and bolt combination with a serrated surface and an enlarged 't-bolt' end that penetrates the oxidation layers of both the bracket and rail guide, creating an electrical bonding path and featuring rotational and vertical stabilizing elements for secure installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional nut and bolt combination is used to secure the bracket to the rail guide, then the bracket can be attached to the rail guide, but an additional electrical bonding path cannot be established
Solution Approach 1:
The patent combines the mechanical fastening function and electrical bonding function into a single integrated nut and bolt assembly. The bolt includes both threaded engagement features for mechanical attachment and raised portions that penetrate the oxidation layer to create electrical contact. The nut similarly integrates both mechanical threading and serrated surfaces for electrical bonding. This merging eliminates the need for separate bonding washers or components while establishing both mechanical and electrical connections simultaneously.
2Reliability
If extra bonding washers or bonding components are added to create an electrical bonding path, then electrical bonding can be achieved, but the installation becomes more difficult and time-consuming
Solution Approach 1:
The patent merges multiple functions into single components: the bolt provides both mechanical fastening through threaded engagement and electrical bonding through raised portions that penetrate the oxidation layer. The nut similarly combines mechanical threading with serrated surfaces for electrical contact. This integration eliminates the need for separate bonding washers or components, reducing the number of installation steps and time required while ensuring reliable electrical bonding.
Solution Approach 2:
The raised portions on the bolt and serrated surfaces on the nut are pre-configured during manufacturing to automatically penetrate the oxidation layer and establish electrical contact when the fastening is performed. This preliminary preparation of the bonding surfaces means that the electrical bonding action occurs simultaneously with the mechanical fastening, rather than requiring separate preliminary or follow-up bonding steps.
3Ease of manufacture
If a conventional nut and bolt are used without penetrating features, then the bracket can be attached to the rail guide, but the oxidation layer prevents electrical bonding
Solution Approach 1:
The patent applies local quality by creating specific penetrating features (raised portions on the bolt and serrated surfaces on the nut) at the exact locations where electrical contact is needed. These localized features are designed to penetrate the oxidation layer only at the contact points, while the rest of the fastening components maintain their standard simple fastening function. This allows the majority of the component to remain simple and easy to manufacture while adding only the necessary complexity where electrical bonding is required.
Data Source
AI summary
In various representative aspects, an assembly for securing a support bracket to rail guide used for mounting and installing solar panels is provided. More specifically, the assembly provides a novel and improved nut with a serrated surface in combination with a t-bolt with a serrated surface that is capable of penetrating the respective oxidation surface layers of the bracket and the rail guide when installed. When installed, provides a mechanism for using the bracket to connect the rail guide to a flashing that is typically installed on a roof. An alternate embodiment of the nut also includes rotational and vertical stabilizing features that prevent the nut from moving along the bracket once it is secured. By employing the apparatus at various locations along the roof in a linear fashion, the rail support structure can be properly installed so that an array of solar panel modules to be installed.