Abstract:
An improved grounding and bonding bracket-type electrical connector is described with improved properties for directionally orienting grounding conductors. The electrical connector has a body with a first and a second clamp area. The second clamp area may be partially formed by a second body member. A frame substrate is connected in the first clamp area, while a grounding conductor is connected in the second clamp area. The grounding conductor may be connected such that the path of the conductor runs parallel, at 45 degrees, or perpendicular as compared to the mounting line of the frame substrate.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/819,140, filed May 3, 2013, which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention is generally directed toward grounding and bonding bracket-type electrical connectors for use with PV modules or cable trays having improved properties for directional placement of associated grounding conductors. 
       BACKGROUND OF THE INVENTION 
       [0003]    Photovoltaic (“PV”) modules, commonly referred to as solar panels, within PV systems/arrays and cable tray components within a cable tray system must be grounded under various electrical codes, e.g., the National Electric Code (NEC), CSA Group, Canadian Electric Code (CEC), and International Electrotechnical Commission (IEC). Electrical connectors are commonly used in PV system and cable tray system applications to mechanically bond and ground individual components within these systems. Many options are available for electrical connectors in PV systems, such as grounding lugs; grounding straps; lay-in lugs; Washer, Electrical Equipment Bonding (“WEEB”) clips; and grounding brackets. Installation of lugs and brackets requires that the anodizing of the PV module be removed in order to achieve electrical connectivity. Although this may be accomplished by star or lock washers, anodizing coating thicknesses vary, and time consuming practices, i.e., grinding or sanding, are often required to ensure electrical connectivity. Lugs also require the installer to disassemble and reassemble the connector bolt, nut, and washers. Installation of WEEB clips (used to bond PV frames to PV mounting racks) requires a particular torque value to ensure proper electrical connectivity by their embossed circular protrusions. However, there are some PV modules on the market that cannot meet the torque requirement, and these PV module frames will collapse before penetration of the anodizing coating by the embossed protrusions. 
         [0004]    Cable tray system components may be bare conductive metal or coated (paint, galvanized, anodized, etc.). Coated cable tray systems require installation of electrical connectors, such as grounding lugs, grounding straps, lay-in lugs, or bracket clamps, which are mechanically bonded to the cable tray components within the cable tray system. The same time consuming process of removing the coating and disassembly/reassembly of bolts/washers can be required for installing these devices in cable tray systems. Furthermore, a disadvantage for all known electrical connectors is that each requires the ground conductor to be run parallel to the frame or frame edge on which it is attached. 
       SUMMARY OF THE INVENTION 
       [0005]    Bracket-type electrical connector clamps comprising two clamping areas for mechanically bonding PV modules within a PV system or cable tray components within a cable tray system are provided. Some embodiments comprise knurled tip fasteners that obviate the need for time consuming removal of protective coatings from PV module frames, mounting racks, and mounting frame, from cable tray components, or from grounding conductors. Some embodiments have a fixed angle construction where the clamping areas cause the connected frame and grounding conductor to form lines approximately perpendicular to one another. In other embodiments, a two-piece design allows for the grounding conductor clamping area to be differentially oriented to allow for lines that are approximately parallel, at a 45° angle, or perpendicular to the connected frame. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    Further advantages of the invention will become apparent by reference to the detailed description of preferred embodiments when considered in conjunction with the drawings: 
           [0007]      FIG. 1  is a perspective view of one embodiment of a PV system or cable tray system electrical connector with opening areas for engaging a frame substrate and a grounding conductor substrate. 
           [0008]      FIG. 2  illustrates the perpendicular orientation feature of the embodiment shown in  FIG. 1  of the present invention. 
           [0009]      FIG. 3A  depicts an embodiment of the present invention bonding and grounding frame substrates (PV module long arm frames) with the grounding conductor  50  running perpendicular to the long arm frame. 
           [0010]      FIG. 3B  is a detail area close up from  FIG. 3A . 
           [0011]      FIG. 4A  is a perspective view of a two-piece embodiment of a PV system or cable tray system electrical connector with an opening area for engaging a frame substrate and a second opening area for directionally orienting a grounding conductor substrate. 
           [0012]      FIGS. 4B and 4C  are top and side views, respectively, of the cable clamp body of a two-piece embodiment of the present invention. 
           [0013]      FIG. 5  illustrates the directional orientation feature of a two-piece embodiment of the present invention. 
           [0014]      FIGS. 6A and 6B  are perspective views of a two-piece embodiment of a PV system or cable tray system electrical connector with an opening area for engaging a frame substrate and a second opening area capable of directionally orienting a grounding conductor substrate approximately at a 45° angle, parallel, or perpendicular to the frame substrate edge. 
           [0015]      FIGS. 6C and 6D  are top and side views of the cable clamp body of a two-piece embodiment of the present invention capable of 45° angle, parallel, and perpendicular orientations. 
           [0016]      FIG. 7  illustrates the directional orientation feature of a two-piece embodiment of the present invention capable of 45° angle, parallel, and perpendicular orientations. 
           [0017]      FIGS. 8A ,  8 B,  8 C, and  8 D show various views (perspective, sides, and top) of a knurled tip hex bolt fastener. 
           [0018]      FIG. 9  is a perspective view of another embodiment of a PV system or cable tray system electrical connector with opening areas for engaging a frame substrate and a grounding conductor substrate. 
           [0019]      FIG. 10  illustrates the perpendicular orientation feature of the embodiment shown in  FIG. 9  of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    The following detailed description is presented to enable any person skilled in the art to make and use the invention. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required to practice the invention. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the invention. The present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest possible scope consistent with the principles and features disclosed herein. 
         [0021]    In one aspect, the present invention provides an electrical connector  10  for electrically connecting a frame substrate (e.g., the frame of a PV module  40 , the mounting rack for a PV module  40 , or the mounting frame of a plurality of PV modules  40 ) to a grounding conductor  50 . The electrical connector  10  of the present invention may also be used for electrically connecting other frame substrates (e.g., cable tray components in a cable tray system) to a grounding conductor  50 . In preferred embodiments, the present invention is used for electrically connecting PV modules  40  to a grounding conductor  50 . The electrical connector body  1  of the present invention may be manufactured by any known or acceptable method(s), e.g., by sheet or plate metal stamping, die casting, extrusion, and/or machining In some embodiments, the electrical connector body  1  is formed by die casting methods and/or a combination of extrusion and machining methods. In preferred embodiments, the electrical connector body  1  is formed by a combination of extrusion and machining methods. 
         [0022]    The electrical connector body  1  of the present invention can be formed from any sturdy and conductive material. In some embodiments, the electrical connector body  1  is formed from aluminum, electrically conductive aluminum alloys, tin-plated copper, or a tin-plated electrically conductive copper alloy. In preferred embodiments, the electrical connector body  1  is formed from aluminum or electrically conductive aluminum alloys. 
         [0023]    The shape of the electrical connector body  1  of the present invention may take any form that allows for mechanical clamping (i.e., bonding) of the substrates to be mechanically clamped (e.g., a PV module  40  frame, mounting rack, or mounting frame, cable tray component, and grounding conductor  50 ) with associated fasteners and also allows for directionally orienting the substrates approximately perpendicular to one another. 
         [0024]    The clamp areas  20 ,  30  of the present invention are formed during the above described manufacturing process(es). The interior of the clamp areas of the present invention should be designed to have openings large enough to adequately contact and hold the substrate being mechanically clamped (i.e., a PV module frame, mounting rack, or mounting frame, and grounding conductor  50 ), but not too large such that wasted material is used in constructing the electrical connector body  1 . Furthermore, the interior of the clamp areas of the present invention may be designed to comprise finished surfaces that are smooth  35  or contain serrations or spike(s)  25  on the side opposite the associated fastener. Serrations and spike(s)  25  can be advantageous in electrical connector design by aiding in gripping the frame substrate being mechanically clamped, or, especially in the case of a spiked surface, for penetrating protective coverings (e.g., insulation) or other coatings (e.g., corrosion) of grounding conductors  50 . In some embodiments, the clamp areas of the present invention have smooth surfaces  35  in both clamp area interiors. In other embodiments, the clamp areas of the present invention have a spiked surface in the grounding conductor clamping area interior and a serrated surface  25  in the frame clamping area interior. In preferred embodiments, the clamp areas of the present invention have a smooth surface  35  in the grounding conductor clamping area interior and a serrated surface  25  in the frame clamping area. 
         [0025]    Any known or acceptable fastener(s) may be employed in the clamp areas  20 ,  30  of the present invention for mechanically bonding the PV modules  40  and/or grounding conductor  50 . The fasteners of the present invention may be formed from any acceptable sturdy and conductive material, e.g., stainless steel, aluminum, electrically conductive aluminum alloys, tin-plated copper, or tin-plated electrically conductive copper alloys. In some embodiments, the fasteners are threadably coupled to the electrical connector body  1 . In preferred embodiments, the threadably coupled fasteners are set screws, bolts, cutting screws, or similar devices. In still further preferred embodiments, the threadably coupled fasteners are set screws. In yet further preferred embodiments, at least one of the threadably coupled fasteners (especially the frame clamp area associated fastener) of the present invention is a stainless steel set screw  33  with a knurled tip  34 . 
         [0026]    In another aspect, the present invention provides an electrical connector  100  for electrically connecting frame substrates (e.g., cable tray components in cable tray systems or the frame of PV modules  40 , the mounting rack for a PV module  40 , or the mounting frame of a plurality of PV modules  40  in a PV system) to a grounding conductor  50 . In preferred embodiments, the present invention is used for electrically connecting frame substrates of cable tray components to a grounding conductor  50 . The electrical connector body  101  and cable clamp body  160  of the present invention may be manufactured by any known or acceptable method(s), e.g., by sheet or plate metal stamping, die casting, extrusion, and/or machining In some embodiments, the electrical connector body  101  is formed by die casting methods and/or a combination of extrusion and machining methods. In preferred embodiments, the electrical connector body  101  is formed by a combination of extrusion and machining methods. In some embodiments, the cable clamp body  160  is formed by die casting methods and/or a combination of extrusion and machining methods. In preferred embodiments, the cable clamp body  160  is formed by a combination of extrusion and machining methods. 
         [0027]    The electrical connector body  101  of the present invention can be formed from any sturdy and conductive material. In some embodiments, the electrical connector body  101  is formed from aluminum, electrically conductive aluminum alloys, tin-plated copper, or tin-plated electrically conductive copper alloys. In preferred embodiments, the electrical connector body  101  is formed from aluminum or electrically conductive aluminum alloys. 
         [0028]    The cable clamp body  160  of the present invention can be formed from any sturdy and conductive material. In some embodiments, the cable clamp body  160  is formed from aluminum, electrically conductive aluminum alloys, tin-plated copper, or tin-plated electrically conductive copper alloys. In preferred embodiments, the cable clamp body  160  is formed from aluminum or electrically conductive aluminum alloys. 
         [0029]    The shape(s) of the electrical connector body  101  and the cable clamp body  160  of the present invention may take any form(s) that allow for mechanical clamping (i.e., bonding) of the substrates to be mechanically clamped (e.g., cable tray component(s) and grounding conductor  50 ) with associated fasteners and also allow for directionally orienting the substrates in one of a plurality of orientations about an axis defined by the cable clamp area fastener. To that end, in some embodiments the cable clamp area  103   a  of the electrical connector body  101  of the present invention is designed to have a plurality of faces to physically engage lips on at least two of the sides of the cable clamp body  160  in order to ensure the orientation of the substrates to be clamped does not substantially deviate from its original orientation. In some embodiments, the orientation of the substrates to be mechanically clamped is an angle between 0-180°, inclusive, to one another. In still further embodiments, the orientation of the substrates to be mechanically clamped is approximately perpendicular, approximately parallel, or approximately at a 45° angle to one another. In preferred embodiments, the orientation of the substrates to be mechanically clamped is approximately perpendicular or approximately parallel to one another. 
         [0030]    The clamp areas  102 ,  103   b  of the present invention are formed during the above described manufacturing process(es). The interior of the clamp areas, especially that of the frame clamping area opening  120 , of the present invention should be designed to have an opening large enough to adequately contact and hold the frame substrate being mechanically clamped (e.g., cable tray component(s) or PV module(s)  40  and grounding conductor  50 ), but not too large such that wasted material is used in constructing the electrical connector body  101 . Furthermore, the interior of the clamp areas of the present invention may be designed to comprise finished surfaces that are smooth  135  or contain serrations or spike(s)  125  on the side opposite the associated fastener. Serrations and spike(s)  125  can be advantageous in electrical connector design by aiding in gripping the substrate being mechanically clamped, or, especially in the case of a spiked surface, for penetrating protective coverings (e.g., insulation) or other coatings (e.g., corrosion) of grounding conductors  50 . In some embodiments, the clamp areas of the present invention have smooth surfaces  135  in both clamp area interiors. In other embodiments, the clamp areas of the present invention have a spiked surface in the grounding conductor clamping area interior and a serrated surface  125  in the frame clamping area interior. In preferred embodiments, the clamp areas of the present invention have a smooth surface  135  in the grounding conductor clamping area  103   a,    103   b  interior and a serrated surface  125  in the frame clamping area  102 . 
         [0031]    Any known or acceptable fastener(s) may be employed in the clamp areas of the present invention for mechanically bonding the cable tray component(s) and/or grounding conductor  50 . The fasteners of the present invention may be formed from any acceptable sturdy and conductive material, e.g., stainless steel, aluminum, electrically conductive aluminum alloys, tin-plated copper, or tin-plated electrically conductive copper alloys. In some embodiments, the fasteners are threadably coupled to the electrical connector body  101 . In preferred embodiments, the threadably coupled fasteners are set screws, bolts, cutting screws, or similar devices. In still further preferred embodiments, the threadably coupled fasteners are set screws or bolts. In yet further preferred embodiments, at least one of the threadably coupled fasteners (especially the frame clamp area associated fastener) of the present invention is a stainless steel set screw or hex bolt  133  with a knurled tip  134 . 
         [0032]    Referring now to the drawings,  FIG. 1  illustrates one embodiment of the electrical connector  10  of the present invention. The electrical connector  10  comprises a one piece electrical connector body  1  preferably formed from extruded aluminum or a conductive aluminum alloy. The electrical connector body  1  of this embodiment is extruded to form one of two clamp areas (the frame clamp area  2  in this embodiment) and machined to form the other clamp area (the grounding conductor clamp area  3  in this embodiment). Each clamp area  2 ,  3  is machined to form threaded holes  28 ,  38  for threadably coupled fasteners  23 ,  33 , respectively. 
         [0033]    The frame clamp area  2  comprises a frame clamp area opening  20  (defined by an upper arm  21  and lower arm  22 ), associated frame clamp area fastener  23  (a hex drive stainless steel set screw with knurled tip  24  in this embodiment, but flat point tip set screws may also be used, especially if the framing substrate has no protective coating or the coating has or will be removed at the mounting location), and serrated surface  25  on the interior of the frame clamp area opening  20  opposite from the side of the associated knurled tip  24  frame clamp area fastener  23 . A flat panel aluminum frame of a PV module  40  (or other suitable frame substrate to be clamped, e.g., a cable tray component) can be inserted into the frame clamp area opening  20  of the frame clamp area  2 , in which it will be mechanically bonded to the electrical connector  10  by engaging the associated frame clamp area fastener  23 . The serrated interior surface  25  of frame clamp area opening  20  serves at least two purposes in this embodiment. First, the serrations aid in holding the electrical connector  10  to the frame substrate prior to mechanical bonding. Second, the serrations may penetrate any protective coating (typically an anodized coating on the aluminum frames of PV modules  40 , mounting racks, and mounting frames, and typically paint, galvanized coating, or similar on cable tray components) of the frame substrate during mechanical bonding. Furthermore, the knurled tip  24  of the associated frame clamp area fastener  23  penetrates into any protective coating of the frame substrate during mechanical bonding and aids in holding the frame substrate securely in various environmental conditions. 
         [0034]    The grounding conductor clamp area  3  comprises a grounding conductor clamp area opening  30  (defined by an upper arm  31  and lower arm  32 ), associated grounding conductor clamp area fastener  33  (a hex drive stainless steel set screw with knurled tip  34  in this embodiment, but flat point tip set screws may also be used, especially if the grounding conductor  50  has no protective coating or the coating has or will be removed at the connecting location), and smooth surface  35  on the interior of the frame clamp area opening  30  opposite from the side of the associated knurled tip  34  frame clamp area fastener  33 . A grounding conductor  50  (typically a bare copper or conductive copper alloy wire) can be inserted into the grounding conductor clamp area opening  30  of the grounding conductor clamp area  3 , in which it will be mechanically bonded to the electrical connector  10  by engaging the associated grounding conductor clamp area fastener  33 . 
         [0035]    The frame clamp area opening  20  and grounding conductor area opening  30  are positioned on the electrical conductor body  1  such that a line defined by a frame substrate  26  and a line defined by a grounding conductor  36  are approximately perpendicular to one another. This can be further visualized in  FIG. 2 . 
         [0036]      FIG. 3  illustrates an embodiment of the present invention in which two PV modules  40  in a PV system/array are bonded and grounded by electrical connectors  10  electrically connected to a grounding conductor  50 . PV modules  40  comprise an anodized aluminum frame  45  having a short side  44  and a long side  43 . The short side  44  has short side flat plate frame member  42 , and the long side  43  has long side flat plate frame member  41 . The electrical connectors  10  of the present invention may be mechanically bonded and grounded to either the short side  44  on short side flat plate frame member  42  or on long side  43  on long side flat plate frame member  41 . The associated frame clamp area fastener  23  with hex drive  27  is engaging the long side flat plate frame member  41  to form a mechanical bond. The associated grounding conductor area fastener  33  with hex drive  37  is engaging the grounding conductor  50  at knurled tip  34  to form a mechanical bond. Note that the long side flat plate frame member  41  and grounding conductor  50  are oriented such that these are approximately perpendicular to one another. 
         [0037]      FIGS. 4-8  illustrate other embodiments of the electrical connector  100  of the present invention. The electrical connector  100  comprises a one piece electrical connector body  1  preferably formed from extruded aluminum, a conductive aluminum alloy, tin-plated copper, or a tin-plated conductive copper alloy. The electrical connector body  101  of this embodiment is extruded to form the frame clamp area  102  and the electrical connector body cable clamp area portion  103   a  of the multidirectional grounding conductor clamp area  103   b  formed by coupling the cable clamp body  160  to the electrical connector body portion  103   a.  Each component  103   a,    122 ,  160  of the clamp areas  102 ,  103   b  is machined to form threaded holes  128 ,  138  for threadably coupled fasteners  123 ,  133 , respectively. 
         [0038]    The frame clamp area  102  comprises a frame clamp area opening  120  (defined by an upper arm  121  and a lower arm  122 ), associated frame clamp area fastener  123  (a stainless steel hex bolt with knurled tip  124  in this embodiment, but flat point tip fastener may also be used, especially if the framing substrate has no protective coating or the coating has or will be removed at the mounting location), and serrated surface  125  on the interior of the frame clamp area opening  120  opposite from the side of the associated knurled tip  124  frame clamp area fastener  123 . A cable tray component frame substrate (or other suitable frame substrate to be clamped, e.g., a flat panel aluminum frame of a PV module  40 ) can be inserted into the frame clamp area opening  120  of the frame clamp area  102 , in which it will be mechanically bonded to the electrical connector  100  by engaging the associated frame clamp area fastener  123 . The serrated interior surface  125  of frame clamp area opening  120  serves at least two purposes in this embodiment. First, the serrations aid in holding the electrical connector  100  to the frame substrate prior to mechanical bonding. Second, the serrations may penetrate any protective coating (typically an anodized coating on the aluminum frames of PV modules  40 , mounting racks, and mounting frames, and typically paint, galvanized coating, or similar on cable tray components) of the frame substrate during mechanical bonding. Furthermore, the knurled tip  124  of the associated frame clamp area fastener  123  penetrates into any protective coating of the frame substrate during mechanical bonding and aids in holding the frame substrate securely in various environmental conditions. 
         [0039]    The cable clamp area  103   b  comprises a cable clamp area opening  130  (defined by an electrical connector body cable clamp area portion  103   a  and cable clamp body  160 ), associated cable clamp area fastener  133  (a stainless steel hex bolt in this embodiment with knurled tip, as shown in  FIG. 8 , but flat point tip fasteners may also be used, especially if the grounding conductor has no protective coating or the coating has or will be removed at the connecting location), and smooth surface  135  on the upper cable clamp area opening  130  opposite from the side of the associated cable clamp area fastener  133 . A grounding conductor  50  (typically a bare copper or conductive copper alloy wire) can be inserted into the cable clamp area opening  130  of the cable clamp area  103   b,  in which it will be mechanically bonded to the electrical connector  100  by engaging the associated grounding conductor clamp area fastener  133 . 
         [0040]    The cable clamp body  160  of this embodiment has two parallel oriented directional cable grooves  163  for seating one or more grounding conductors  50  in cable clamp area opening  130 . The cable clamp body  160  of this embodiment also has four sides  161 ,  162 . Two sides are open sides  162  from which the parallel oriented directional cable grooves  163  run perpendicular. The other two sides  161  form protruding arms  164  designed to engage the electrical connector body portion  103   a  to secure the orientation of the grounding conductor  50  within cable clamp area opening  130 . The cable clamp body  160  can be oriented about the electrical connector body portion  103   a  around an axis defined by the associated cable clamp area fastener in order to differentially orient the frame and grounding conductor  50  to be approximately perpendicular ( FIGS. 4A ,  5 ,  6 A, &amp;  7 ) or approximately parallel ( FIGS. 5 &amp; 7 ). In other embodiments, cable clamp body  160  includes v-cut notches  165  in protruding arms  164  of sides  161 , which allows for an approximately 45° angle orientation ( FIGS. 6B &amp; 7 ). 
         [0041]    The frame clamp area opening  120  and grounding conductor area opening  130  (as further defined by the open sides  162  of the cable clamp body  160 ) are positioned on the electrical conductor  100  such that a line defined by a frame substrate  126  and a line defined by a grounding conductor  136   a,    136   b,  and  136   c  are approximately perpendicular, parallel, or angled at 45° to one another, respectively. This can be further visualized in  FIGS. 5 and 7 . 
         [0042]      FIGS. 9 and 10  illustrate another embodiment of the present invention. For example,  FIG. 9  illustrates an embodiment of the electrical connector  200  of the present invention. The electrical connector  200  comprises a one piece electrical connector body  201  preferably formed from extruded aluminum or a conductive aluminum alloy. The electrical connector body  201  of this embodiment is extruded to form one of two clamp areas (the frame clamp area  202  in this embodiment) and machined to form the other clamp area (the grounding conductor clamp area  203  in this embodiment). Each clamp area  202 ,  203  is machined to form threaded holes  228 ,  238  for threadably coupled fasteners  223 ,  233 , respectively (see  FIG. 10 ). 
         [0043]    The frame clamp area  202  comprises a frame clamp area opening  220  (defined by an upper arm  221  and lower arm  222 ), associated frame clamp area fastener  223  (a hex drive stainless steel set screw with knurled tip  224  in this embodiment, but flat point tip set screws may also be used, especially if the framing substrate has no protective coating or the coating has or will be removed at the mounting location), and serrated surface  225  on the interior of the frame clamp area opening  220  opposite from the side of the associated knurled tip  224  frame clamp area fastener  223 . A flat panel aluminum frame of a PV module  40  (see  FIG. 3A ; or other suitable frame substrate to be clamped, e.g., a cable tray component) can be inserted into the frame clamp area opening  220  of the frame clamp area  202 , in which it will be mechanically bonded to the electrical connector  200  by engaging the associated frame clamp area fastener  223 . The serrated interior surface  225  of frame clamp area opening  220  serves at least two purposes in this embodiment. First, the serrations aid in holding the electrical connector  200  to the frame substrate prior to mechanical bonding. Second, the serrations may penetrate any protective coating (typically an anodized coating on the aluminum frames of PV modules  40 , mounting racks, and mounting frames, and typically paint, galvanized coating, or similar on cable tray components) of the frame substrate during mechanical bonding. Furthermore, the knurled tip  224  of the associated frame clamp area fastener  223  penetrates into any protective coating of the frame substrate during mechanical bonding and aids in holding the frame substrate securely in various environmental conditions. 
         [0044]    The grounding conductor clamp area  203  comprises a grounding conductor clamp area opening  230  (defined by an upper arm  231  and lower arm  232 ), associated grounding conductor clamp area fastener  233  (a hex drive stainless steel set screw with flat point tip  234  in this embodiment, but knurled tip fasteners may also be used, especially if the grounding conductor  50  (see  FIG. 3B ) has a protective coating at the connecting location), and smooth surface  235  on the interior of the frame clamp area opening  230  opposite from the side of the associated flat point tip  234  frame clamp area fastener  233 . A grounding conductor  50  (typically a bare copper or conductive copper alloy wire) can be inserted into the grounding conductor clamp area opening  230  of the grounding conductor clamp area  203 , in which it will be mechanically bonded to the electrical connector  200  by engaging the associated grounding conductor clamp area fastener  233 . Frame clamp area opening  230  has an elongated oval area for seating a grounding conductor  50  closer to frame clamp area  202 . To accommodate the increased the grounding conductor seating area within grounding conductor clamp area  203  the outer lip on upper arm  231  is lengthened accordingly. To facilitate connecting the grounding conductor  50 , the lip on lower arm  232  is removed. As a result, the machining of frame clamp area opening  230  is more efficient than the embodiment shown in  FIGS. 1-3 , decreasing manufacturing costs and time. 
         [0045]    The frame clamp area opening  220  and grounding conductor area opening  230  are positioned on the electrical conductor body  201  such that a line defined by a frame substrate  226  and a line defined by a grounding conductor  236  are approximately perpendicular to one another. This can be further visualized in  FIG. 10 . 
         [0046]    The terms “comprising” and “having,” as used in the claims and specification herein, shall be considered as indicating an open group that may include other elements not specified. The terms “a,” “an,” and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The term “one” or “single” may be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” may be used when a specific number of things is intended. The terms “preferably,” “preferred,” “prefer,” “may,” and similar terms are used to indicate that an item, condition, or step being referred to is an optional (not required) feature of the invention. 
         [0047]    The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures, and techniques other than those specifically described herein can be applied to the practice of the invention as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures, and techniques described herein are intended to be encompassed by this invention. Whenever a range is disclosed, all subranges and individual values are intended to be encompassed. This invention is not to be limited by the embodiments disclosed, including any shown in the drawings or exemplified in the specification, which are given by way of example and not of limitation. 
         [0048]    While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.