U.S. patent application number 14/533703 was filed with the patent office on 2015-06-04 for adjustable bonding washer.
The applicant listed for this patent is Hubbell Incorporated. Invention is credited to Harley Alan Haney.
Application Number | 20150152911 14/533703 |
Document ID | / |
Family ID | 51529120 |
Filed Date | 2015-06-04 |
United States Patent
Application |
20150152911 |
Kind Code |
A1 |
Haney; Harley Alan |
June 4, 2015 |
ADJUSTABLE BONDING WASHER
Abstract
An adjustable bonding washer for placement between two metal
pieces to create an electrical bond between them. The bonding
washer has two metallic parts constrained to slide relative to one
another along an axis. Each part has oppositely directed teeth that
are forcibly embedded into the metal pieces to make electrical
contact with them when they are rigidly clamped together.
Adjustability enables the bonding washer to be mated with metal
pieces having a range of widths and profiles, such as the slotted
rails used to support arrays of photovoltaic panels.
Inventors: |
Haney; Harley Alan; (Gurnee,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hubbell Incorporated |
Shelton |
CT |
US |
|
|
Family ID: |
51529120 |
Appl. No.: |
14/533703 |
Filed: |
November 5, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13844023 |
Mar 15, 2013 |
8888431 |
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14533703 |
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Current U.S.
Class: |
411/539 |
Current CPC
Class: |
F16B 43/00 20130101;
Y02B 10/10 20130101; H02S 20/00 20130101; H01R 9/16 20130101; H01R
43/027 20130101; Y02B 10/12 20130101; H01R 4/26 20130101; Y10T
29/49208 20150115; Y02E 10/50 20130101 |
International
Class: |
F16B 43/00 20060101
F16B043/00 |
Claims
1. An adjustable bonding washer for making an electrical connection
between two metal pieces when the metal pieces are rigidly held
together by a fastener with at least a portion of the bonding
washer disposed between them, the adjustable bonding washer
comprising first and second metallic parts each having a fastener
opening therethrough and at least one pair of oppositely directed
external teeth formed thereon, said parts being slidable relative
to each other along an axis and substantially constrained from
relative off-axis movement by axially extending guide surfaces
formed thereon, whereby, when a fastener extending through said
fastener openings is tightened with said external teeth between the
metal pieces, said external. teeth are forcibly embedded into the
metal pieces to make electrical contact therewith.
Description
FIELD OF THE INVENTION
[0001] The invention relates to the assembly of photovoltaic arrays
and other apparatus requiring electrical connection between metal
parts.
BACKGROUND OF THE INVENTION
[0002] U.S. Pat. No. 8,092,129 to Wiley, et al., which is
incorporated by reference herein in its entirety, discloses a
variety of bonding washer configurations for creating an electrical
bond between metal pieces that are to be mechanically fastened
together, such as photovoltaic panels and their supporting aluminum
rails. Many of these bonding washers and their commercial
counterparts and variants have oppositely directed teeth designed
to penetrate the anodic coatings of the metal pieces when clamped
together. Some have features that retain them in position on one
metal piece to facilitate assembly with another metal piece. In
some embodiments the teeth are positioned to engage the metal
pieces near their fastener holes, while in others the teeth are
positioned to engage the metal pieces near their outer edges.
Typically, these bonding washers are designed to be compatible with
specific metal piece profiles and/or widths.
SUMMARY OF THE INVENTION
[0003] The adjustable bonding washer of the invention has enhanced
versatility afforded by its two relatively movable parts, each of
which carries oppositely directed teeth that engage the metal
pieces when fastened together. The bonding washer of the invention
thus can be mated with metal pieces having a range of widths and
profiles and is especially useful when clamping solar panels to
slotted support rails, which typically retain sliding nuts in their
slots. The invention also covers a method of electrically bonding
two metal pieces using such a bonding washer.
[0004] An adjustable bonding washer (assembly) according to the
invention thus comprises first and second metallic parts each
having at least one pair of oppositely directed external teeth
formed thereon, the parts being slidable relative to each other
along an axis and substantially constrained from relative off-axis
movement by axially extending guide surfaces formed thereon.
[0005] Each part preferably comprises a substantially flat sheet
metal body. The guide surfaces preferably comprise two opposite
edges of the first part and bent edges at two opposite sides of the
second part that lie close to the opposite edges of the first part
when the parts are assembled. Each of the bent edges preferably
comprises a folded-over marginal body portion defining a channel in
which the first part can slide. Each part may have a fastener
opening therethrough for accommodating a fastener that would pass
between the channels. Each pair of external teeth preferably
comprises a pair of substantially aligned, diverging teeth.
[0006] Also preferred is the inclusion of least one protrusion
(e.g., an internal tooth) in each channel formed on at least one of
the parts and adapted to engage the other part when the parts are
assembled. The first part preferably has axially spaced features
such as notches engageable by the protrusion, such features and the
protrusion being configured to resist axial separation of the parts
once they are assembled. Each part may have a bent-out alignment
tab at an axial end thereof, the alignment tabs being disposed at
opposite ends of the bonding washer when the parts are
assembled.
[0007] The method according to the invention of electrically
bonding first and second metal pieces comprises the steps of:
[0008] (a) providing an adjustable bonding assembly comprising
first and second metallic parts slidable relative to each other
along an axis, each part having a primary face with at least one
integral projecting tooth and an opposite secondary face with at
least one integral projecting tooth; [0009] (b) placing the first
part against the first metal piece such that the external
tooth/teeth of the primary side contacts the first metal piece;
[0010] (c) sliding the second part toward the first part so that
the external tooth/teeth of the primary side of the second part
contacts the first metal piece; [0011] (d) placing the second metal
piece against the bonding assembly so that it contacts the
tooth/teeth of the secondary side of each part; and [0012] (e)
clamping the metal pieces together with the bonding assembly
between them so that the teeth are forcibly embedded into the metal
pieces to make electrical contact therewith.
BRIEF DESCRIPTION OF THE DRAWING
[0013] Preferred embodiments of the disclosed invention are
described in detail below purely as examples, with reference to the
accompanying drawing, in which:
[0014] FIG. 1 is a top perspective view of a bonding washer
according to the invention, showing its male and female parts
unmated;
[0015] FIG. 2 is a bottom perspective view of the bonding washer of
FIG. 1;
[0016] FIG. 3 is a top perspective view of the bonding washer of
FIG. 1, showing its parts assembled;
[0017] FIG. 4 is a bottom perspective view of the assembly of FIG.
3;
[0018] FIG. 5 is a side elevational view of the assembly of FIGS. 3
and 4 as it is being installed on a rail;
[0019] FIG. 6 is a partial perspective view of a partially
assembled solar module assembly that includes a bonding washer
according to the invention;
[0020] FIG. 7 is a top perspective view of an alternate embodiment
of the female part of the bonding washer of the invention;
[0021] FIG. 8 is an end elevational view of another alternate
embodiment of the female part of the bonding washer of the
invention; and
[0022] FIG. 9 is a top perspective view of an alternate embodiment
of the male part of the bonding washer of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] As used in this application, terms such as "front," "rear,"
"side," "top," "bottom," "above," "below," "upwardly" and
"downwardly" are intended. to facilitate the description of the
invention and are not to be construed as limiting the structure of
the invention to any particular position or orientation.
[0024] Referring to FIGS. 1 and 2, a bonding washer according to
the invention comprises a male part 10 and a female part. 20, both
preferably made of sheet stainless steel. Male part 10 comprises a
flat body 11 having two integral ears 12 at one end folded up and
back against the body and an integral alignment tab 13 at the same
end bent down perpendicular to the body. The opposite end of the
body has an open-ended recess or notch 14. Each of the ears 12 has
a raised, hollow, circular tooth 15 extending away from the body.
The underside of the body (see FIG. 2) also has two raised, hollow,
circular teeth 16 extending away from the body. Teeth 15 and 16 are
positioned so as to form two sets of aligned, oppositely directed
teeth.
[0025] Female part 20 similarly comprises a flat body 21 having two
ears 22 at one end folded up and back against the body and an
integral alignment tab 23 at the same end bent down perpendicular
to the body. The opposite end of body 21 has an open-ended recess
or notch 24 similar to recess 14 of the male part. Each of the ears
22 has a raised, hollow circular tooth 25 extending away from the
body. The underside of the body also has two raised, hollow,
circular teeth 26 extending away from the body. Teeth 25 and 26 are
positioned so as to form two sets of aligned, oppositely directed
teeth. Teeth 15, 16, 25 and 26 preferably are circular as shown but
may take any form suitable for penetrating anodic coatings, such as
other forms disclosed in U.S. Pat. No. 8,092,129.
[0026] Female part 20 also has an integral flap 27 at each side of
the body 21. Each flap 27 is folded up and back over the body
substantially parallel to but spaced from it, thereby forming a
channel in which the body 11 of male part slides. When mated (see
FIGS. 3 and 4), the two notches 14, 24 merge to form an opening of
adjustable size through which a fastener can extend when the
bonding washer is installed.
[0027] FIGS. 5 and 6 show how the bonding washer of the invention
can be installed on a metal piece, in this case an aluminum rail R
for supporting a photovoltaic panel P. The male and female parts
10, 20 preferably are mated partially before installation with
enough space between their respective alignment tabs 13, 23 to
accommodate the rail. The assembly is then placed atop the rail and
the parts are slid further together until tabs 13, 23 contact the
rail R. The panel is then mounted atop the rail and tightly secured
by a clamp C and a bolt 13, which engages a rail-retained nut N.
The exerted clamping force embeds the tips of teeth 15, 16, 25, 26
in the anodic coatings of the rail and the panel. Should flaps 27
contact any of the superposed components, they will be flattened
against body 11 of male part 10 and not significantly interfere
with the bonding action of the teeth. Nevertheless, it is preferred
that upper teeth 15, 25 extend above flaps 27 prior to any
deformation of the flaps. This arrangement is present but not
easily seen in FIG. 5 due its scale. The same arrangement is
present in all disclosed embodiments and is clearly visible in FIG.
8.
[0028] FIG. 7 shows one alternate configuration of the female part.
In this embodiment, flaps 37 are punched to form rows of integral,
downwardly directed (interior) teeth 38 that engage and scrape
along the body of male part 10 as the parts are telescoped together
during installation. This engagement enhances the electrical bond
between the parts 10, 20 and keeps them from separating. FIG. 7
shows triangular teeth (visible through triangular punched holes in
flaps 37) but they may be of any shape suitable for their intended
purpose. Teeth 38 may be raked away from the mating direction to
enhance their resistance to separation of the parts.
[0029] FIG. 8 shows another alternate configuration for the female
part. In this embodiment, interior scraping teeth 48 are integrally
formed on body 41 and project upward toward flaps 47. As with the
embodiment of FIG. 7, any suitable tooth form and angle is
acceptable. Note that teeth 45 on ears 42 project beyond flaps 47,
which is the same preferred arrangement for all embodiments.
[0030] FIG. 9 shows an alternate configuration for the male part.
In this embodiment, the body 51 includes rows of recesses or
notches 52 that are sequentially engaged by the teeth of the female
part (FIG. 7 or FIG. 8) as the parts are telescoped together. This
arrangement effectively resists separation of the parts and is
especially effective if the teeth on the female part are raked.
[0031] While preferred embodiments have been chosen to illustrate
the bonding washer of the invention, it will be understood by those
skilled in the art that various changes and modifications may be
made without departing from the scope of the invention as defined
by the appended claims.
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