Abstract:
A grounding spacer is provided. The grounding spacer comprising a circular body having a top surface, a bottom surface, and a central aperture, and a plurality of radially spaced penetration features, wherein at least one of the penetration features has at least a portion thereof extending from the top surface, and wherein at least one of the penetration features has at least a portion thereof extending from the bottom surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 61/784,847 filed on Mar. 14, 2013, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     Field of the Disclosure 
     The present disclosure relates generally to grounding spacers for making electrical connection between metal pieces that are mechanically joined together. 
     Related Art 
     Solar panels are becoming an increasingly popular energy alternative. Solar panel frames, and the mounting rails to which they are fastened, can be made of aluminum. However, the solar panel frames normally have anodized surface treatment, which insulates the surface from electrical continuity. As a result, the solar panels are not electrically grounded to the mounting rail. There exists a need in the art for a grounding spacer to provide electrical communication between two such mechanical structures that is easy and simple to manufacture. 
     SUMMARY 
     The present disclosure relates to a grounding spacer. More specifically, the present disclosure relates to a single sheet construction of a grounding spacer having a plurality of penetration features radially spaced about the spacer. The penetration features could alternatingly extend in opposite directions, or the penetration features could each have portions thereof that extend in opposite directions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing features of the disclosure will be apparent from the following Detailed Description, taken in connection with the accompanying drawings, in which: 
         FIG. 1  is an exploded view of a solar panel assembly utilizing grounding spacers of the present disclosure; 
         FIG. 2  is an assembled view of the solar panel assembly of  FIG. 1 ; 
         FIG. 3  is a perspective view of a grounding spacer with round penetration features; 
         FIG. 4  is a top view of the grounding spacer of  FIG. 3 ; 
         FIG. 5  is a cross-sectional side view of  FIG. 4 ; 
         FIG. 6  is a top view of another embodiment of a grounding spacer with round penetration features; 
         FIG. 7  is a cross-sectional side view of the grounding spacer of  FIG. 6 ; 
         FIG. 8  is a perspective view of a grounding spacer with elongate penetration features; 
         FIG. 9  is a top view of the grounding spacer of  FIG. 8 ; 
         FIG. 10  is a cross-sectional side view of an elongate penetration feature of  FIG. 9 ; 
         FIG. 11  is a side view of the grounding spacer of  FIG. 8 ; 
         FIG. 12  is a cross-sectional side view of the grounding spacer of  FIG. 9 ; 
         FIG. 13  is a top view of a flat blank grounding spacer with elongate holes; and 
         FIG. 14  is an enlarged view of an elongate hole of the grounding spacer of  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure relates to a grounding spacer, as discussed in detail below in connection with  FIGS. 1-14 . 
       FIG. 1  is an exploded view of a solar panel assembly  8  utilizing grounding spacers (washers)  10  of the present disclosure. As shown, the assembly  8  includes grounding spacers  10 , a solar panel  12  having a top surface  14  and a bottom surface  16 , mounting rails (guard rails)  18  having a top surface  20 , panel clamps  22 , and bolts  24 . The solar panel  12  could have an extruded aluminum frame, such as frames with a T6 surface hardness. The grounding spacer  10  could be made of 300 series stainless steel with a temper, for example, of ½ hardness. However, the material and hardness of the grounding spacer  10  could vary depending on such factors as the material and hardness of the solar panel frame and mounting rails  18 . The grounding spacer  10  can be manufactured from a single sheet of metal. It is noted that although the grounding spacers  10  are used in a solar panel assembly  8 , the spacers  10  could be used in any variety of applications, where mechanical and electrical contact between two materials is desired. 
       FIG. 2  is an assembled view of the solar panel assembly  8  of  FIG. 1 . As shown, each grounding spacer  10  is in direct contact with the bottom surface  16  of the solar panel  12  and the top surface  20  of the mounting rail  20 . When the bolts  24  are tightened, the clamps  22  will push down on the solar panel  12 , and the penetration features of the grounding spacers  10  (discussed in more detail below) will penetrate (e.g., dig into) the aluminum frame of the solar panel  12  and the aluminum mounting rail  18 , piercing the anodized surfaces, thereby providing grounding contact between the solar panel  12  and the mounting rails  18 . 
       FIGS. 3-7  are views of grounding spacers with round penetration features. More specifically,  FIG. 3  is a perspective front view of a grounding spacer  110  with round penetration features  162 ,  164 .  FIG. 4  is a top view of the grounding spacer  110  of  FIG. 3 , and  FIG. 5  is a cross-sectional side view of the grounding spacer  110  of  FIG. 3  taken along line A-A of  FIG. 4 . As shown, the spacer  110  may have a top surface  134 , a bottom surface  136 , a central aperture  132  (e.g., bolt hole), and an outer diameter  130 . Top extending (upstanding) penetration features  162  and bottom extending (downstanding) penetration features  164  alternate around the spacer. It is noted that eight penetration features  162 ,  164  are shown, but any number of penetration features  162 ,  164  could be used. The penetration features  162 ,  164  could be formed by stamping sheet metal. More specifically, a stamping process could be used such that sheet metal is first stamped to remove material, thereby forming the outer diameter  130 , the central aperture  132 , and radial apertures positioned around the central aperture  132 . Then the metal around each of the radial apertures could be pushed (or stamped) to form top extending penetration features  162 , and then pushed (or stamped) a second time to form bottom extending penetration features  164 . 
       FIGS. 6-7  are views of another embodiment of the grounding spacer. More specifically,  FIG. 6  is a top view of a grounding spacer  210  with round holes, and  FIG. 7  is a cross-sectional side view of the grounding spacer taken along line B-B of  FIG. 6 . As shown, compared to the previous embodiment shown in  FIGS. 3-5 , the central aperture  232  is smaller in comparison to the outer diameter  230  of the spacer  210 . Also, the penetration features  264 ,  262  are still round but have smaller individual diameters and are radially spaced farther away from the central aperture  232 . 
       FIG. 8-12  are various views of a grounding spacer with elongate penetration features. More specifically,  FIG. 8  is a perspective view of a grounding spacer  310  with elongate penetration features  340 . The spacer  310  includes a top surface  334 , a bottom surface  336 , an outer diameter  330 , and a central aperture  332 . The spacer  310  is shown as circular but could be of any size, thickness, and/or shape. The spacer  310  may or may not include a central aperture  332  or a slot or other structure to accommodate a bolt. The spacer  310  includes a plurality of penetration features  340 . Although six are shown, any number of penetration features  340  could be used (e.g., four, six, eight, etc.). Each penetration feature  340  includes an oblong hole partially defined by a top extending rim  342  and a bottom extending rim  344 . Separating the two rims  342 ,  344 , and partially defining the oblong hole, is an outer arc  346  positioned toward the outer perimeter of the spacer  310 , and an inner arc  348  positioned toward the central aperture  332 , which are discussed in more detail below. The top extending rim  342  and bottom extending rim  344  extend in opposite directions, and are shown as being generally u-shaped. It is noted that although an elongate penetration feature is shown, any shape could be used. 
       FIG. 9  is a top view of the grounding spacer  310  with elongate penetration features of  FIG. 8 , and  FIG. 10  is a cross-sectional side view of an elongate penetration feature  340  taken along line C-C of  FIG. 9 .  FIG. 10  shows the top rim  342  extending from a top surface  334 , and a bottom rim  344  extending from a bottom surface  336 .  FIG. 11  is a side view of the grounding spacer  310  of  FIG. 8 , and  FIG. 12  is a cross-sectional view of the grounding spacer  310  taken along line D-D of  FIG. 9 . 
       FIGS. 13-14  are views of a flat blank grounding spacer with elongate holes. More specifically,  FIG. 13  is a top view of a flat blank grounding spacer  410  with elongate holes  450 . The flat blank grounding spacer  410  could be formed from a flat piece of sheet metal, and does not have any raised surfaces. A piece of sheet metal could be cut (e.g., stamped) into a desired shape (e.g., circular) with a desired number of elongate holes  450  radially spaced. As shown, the sheet metal could be cut, such as by stamping, into a circular shape having an outer diameter  430  and a central aperture  432 . This is an intermediate step in manufacturing the grounding spacer, prior to creating the raised rims that provide the penetration features of the grounding spacer. 
       FIG. 14  is an enlarged view of an elongate hole of the flat blank grounding spacer  410  of  FIG. 13 . The elongate hole includes a first arc  452 , a second arc  454  opposite thereto, and an inner arc  458  and an outer arc  456  separating the first and second arcs  452 ,  454 . A first portion  463  is defined by the first arc  452  and the bend line  460 , and a second portion  461  is defined by the second arc  454  and the bend line  460 . The first portion  463  and second portions  461  could be formed into rims (such as shown in  FIGS. 8-12 ) by bending or pushing (e.g., stamping) the first portion  463  up, and the second portion  461  down, such as along the bend line  460 . The inner and outer arcs  456 ,  458  facilitate the manufacture of the penetration features and also relieve stress placed on the penetration features when assembled. 
     Having thus described the disclosure in detail, it is to be understood that the foregoing description is not intended to limit the spirit or scope thereof. It will be understood that the embodiments of the present disclosure described herein are merely exemplary and that a person skilled in the art may make any variations and modification without departing from the spirit and scope of the disclosure. All such variations and modifications, including those discussed above, are intended to be included within the scope of the disclosure. What is desired to be protected is set forth in the following claims.