Abstract:
A device for bonding metallic components, providing a mechanical and electrical connection between interfaced components. The bonding device serves as a structural connection between rails, L-feet, module clamps, climbers, and other component connections within a solar mounting system. The invention uses specialized geometry in its construction to penetrate paints, coatings, and other similar materials to provide an electrical connection. The invention provides an advantage of quick and easy installation of hardware components and associated parts, and meets the demand for a single device capable of forming both a mechanical and electrical connection to associated hardware.

Description:
CLAIM OF PRIORITY 
       [0001]    The present application claims priority from Provisional Patent Application No. 62/201,110, filed on Aug. 4, 2015, the disclosure of which is relied upon and incorporated herein by reference. 
     
    
     FIELD OF INVENTION 
       [0002]    This invention relates generally to fastening devices for providing a structural connection. More specifically, the invention relates to a device for providing a mechanical and electrical connection between two parts with flat or substantially flat surfaces of electrically conductive material. 
       BACKGROUND OF THE INVENTION 
       [0003]    Electrically conductive material, such as aluminum and copper, are used in numerous applications in which it is desired to provide both a physical and electrical connection between different structural components. For example, in structural systems and hardware used for solar panels or other photovoltaic arrangements, it is common to employ rails and fastening components (bonding elements) that require both a mechanical and electrical (such as for grounding purposes) connection. 
         [0004]    Solar panels, mounts, and associated structural hardware are commonly installed on roofs or other elevated locations. While working in such locations, installers need to be quick and efficient. Routinely, additional hardware components are used in combination with a bolt, screw, or structural component to provide an electrically interfaced structural connection. These additional hardware components increase the overall cost of mounting systems, while also increasing the time and effort required to install the components. 
         [0005]    Because solar panel mounting systems are subjected to adverse environmental conditions, rails or other structural components may be painted, anodized, treated with a protective coating, or coated with another layer of metal to prevent corrosion and/or to provide for a longer life. To form an adequate electrical connection between parts, it is often necessary to penetrate any non-conductive layers, including dirt, paint and corrosion, or skin of the rail or other structural components to provide the necessary electrical connection to the base metal. 
         [0006]    Hardware bonding elements suitable for fixing together, both mechanically and electrically, a mounting system rail or other associated components without requiring additional hardware are desirable. It is desirable that bonding element be of simple construction and relatively low cost. These attributes have not been found in a single device. 
         [0007]    Thus, a need exists in the industry to address the aforementioned challenges. 
       SUMMARY OF THE INVENTION 
       [0008]    Solar mounting and structural components require appropriate means of bonding and grounding due to regulations. Embodiments of the present invention provide a bonding device for facilitating quick and easy installation of structural components commonly used in solar mounting systems that may also be utilized in any situation where it is desired to achieve both a mechanical and electrical connection between components. 
         [0009]    In an embodiment of the present invention, a bonding device is provided. The bonding device is configured to provide a mechanical and electrical connection to various solar mounting systems. In an aspect, the bonding device includes fixing elements that are configured to create the electrical and mechanical connection to the various components of solar mounting systems. In an exemplary aspect, the fixing elements can comprise protrusions that are configured to penetrate non-conductive layers of the solar mounting systems to create electrical connections with the conductive layers of the components of the solar mounting system. The protrusions can have various structures, including, but not limited to, hemispherical, pyramidal, prismatic, ramp-shaped or any similar structure that serve to penetrate a non-conductive layer on a rail or similar structural connection, such as L-feet, module clamps, climbers, and other component connections within a solar mounting system. In an embodiment, the fixing element is of a material that is stronger than the non-conductive layer and rail material that is also conductive. 
         [0010]    In an aspect, the bonding device can include a T-bolt. In an alternate embodiment of the present invention, a T-bolt is provided that can interface with common bonding hardware including clips, washers, lugs, wires, and any other similar hardware to provide both a mechanically and an electrically bonded arrangement. 
         [0011]    In an alternate embodiment of the present invention, a nut is provided that can interface with common bonding hardware including various bolts and any other similar hardware to provide both a mechanically and an electrically bonded arrangement. 
         [0012]    In another aspect, the bonding device can have a substantially rectangular head. According to an embodiment, this head can have a pair of rounded corners opposite each other. The rounded corners allow the head to be rotated 90 degrees within a slot. Once rotated, the square corners can prevent further rotation. 
         [0013]    Other features and advantages of the invention will become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional features and advantages be included herein within the scope of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0014]      FIG. 1  provides a pre view of a bonding device according to an aspect of the present invention. 
           [0015]      FIG. 1A  provides a close up view of components of  FIG. 1 . 
           [0016]      FIG. 2  illustrates a top plan view of the bonding device of  FIG. 1 . 
           [0017]      FIG. 3  illustrates a side plan view of the bonding device of  FIG. 1 . 
           [0018]      FIG. 4  illustrates a side plan view of the bonding device of  FIG. 1 . 
           [0019]      FIG. 5 . Illustrates a perspective view of a bonding device according to another aspect of the present invention. 
           [0020]      FIG. 5A  provides a close up view of components of  FIG. 5 . 
           [0021]      FIG. 6  provides a perspective view of a bonding device according to another aspect of the present invention. 
           [0022]      FIG. 6A  provides a close up view of components of  FIG. 6 . 
           [0023]      FIG. 7  provides a perspective view of a tightening device that may be used with a bonding device according to an aspect of the present invention. 
           [0024]      FIG. 8  is a top view of rail and structural hardware interfaced with a bonding device and nut combination in accordance with an embodiment of the present invention. 
           [0025]      FIG. 9  provides a cross-sectional view, taken along lines B-B of  FIG. 8 , of rail and structural hardware interfaced with a bonding device and nut combination in accordance with an embodiment of the present invention. 
           [0026]      FIG. 10  is a perspective view of a rail and structural component interfaced with a bonding device and nut according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    Embodiments of the invention will be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
         [0028]    In the following description, numerous specific details are set forth. However, it is to be understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have been shown in detail in order not to obscure an understanding of this description. 
         [0029]    The present invention, as shown in  FIGS. 1-4 , is directed at a bonding device  100 . The bonding device  100  is configured to provide a mechanical and electrical connection to components, including, but not limited to, rails, photovoltaic panels, racking components, wind deflectors, ballast pans, roof anchors, and the like commonly used in solar mounting systems. 
         [0030]    In an aspect, the bonding device  100  comprises a T-bolt  100 . However, the bonding device  100  can comprise other various fasteners known in the art, including, but not limited to, hex bolt, allen bolt, and various other bolts and fasteners used to secure components through a slotted extrusion. The T-bolt  100  includes an elongated fastener  101  with a head  104  featured at a proximal end  102  opposite the distal end  103 . The head  104  itself is elongated, and interfaces the fastener  101  at a substantially 90 degree angle. As most clearly shown in  FIG. 1C , the head  104  has a generally rectangular shape. In an aspect, the generally rectangular shape of the head  104  includes a width that allows the head  104  to be inserted into a mating slots  505 ,  506  (see  FIGS. 9-10 ) of the rail  500  and structural component  503  respectively, discussed in detail below. In this embodiment, two corners of the head  104  may be rounded at opposite edges, which allow the fastener  101  to be rotated into position after insertion in the slots  505 ,  506 . As shown in the attached embodiments, the other two corners of the head  104  are substantially square-shaped, which ensures that the rotation of the fastener  101 , and the head  104 , is limited to approximately 90 degrees with the mating slot  505  of the rail  500 , thereby ensuring that the fixing elements  110  are in the correct position. However, in other aspects, the head  104  of the bonding device  100  can comprise various shapes. But it is preferred that the head  104  have a shape that facilitates ease of securing the bonding device  100  to the components of the solar mounting system. 
         [0031]    In an aspect, the elongated fastener  101  has a cylindrical body  105  that extends from an inner surface  106  of the head  104 . The surface of the fastener  101  may be smooth, or the surface may feature a thread  111  (see  FIG. 8 ). The thread  111  may be a helical structure used to convert between rotational and linear movement (force). In some aspects, the surface of the fastener  101  may be a combination of a partial thread  111  and smooth surface. 
         [0032]    Various embodiments of the bonding device  100 ,  200 ,  300  are illustrated in  FIGS. 1-4  ( 100 ),  5  ( 200 ), and  6  ( 300 ). Each embodiment includes a head  104 ,  204 ,  304  extending from or connected to the proximal end  102 ,  202 ,  302  of the shank or fastener  101 ,  201 ,  301  with the head  104 ,  204 ,  304  having an inner or internal surface  106 ,  206 ,  306  and an outer or external surface  108 ,  208 ,  308 . The fastener  101 ,  201 ,  301  is connected to the head  104 ,  204 ,  304  along the inner surface  106 ,  206 ,  306 . The bonding device/T-bolt  100 ,  200 ,  300  is preferably constructed from a single piece of substantially hard metallic material including carbon steel, stainless steel, titanium, or any other suitable material, such as manufacture by cold forming, turning or forging. However, the head  104 ,  204 ,  304  and the fastener  101 ,  201 ,  301  may be manufactured individually and then bonded together by welding or any other means which provides suitable strength and rigidity. 
         [0033]    The fastener  101 ,  201 ,  301  of the bonding device  100 ,  200 ,  300  is designed to engage a tightening device  400 . In an aspect, the tightening device  400  comprises a nut  400  for tightening purposes. As shown in  FIG. 4 , the nut  400  is preferably constructed from a single piece of substantially hard metallic material including carbon steel, stainless steel, titanium, or any other suitable material. The nut  400  may feature a preferably hexagon shape on its outer portion  401  and a cylindrical inner portion  402 . The surface of the cylindrical inner portion may feature a thread  411  that pairs with a thread  111  around the fastener  101 ,  201 ,  301 . In aspects in which the fastener  101 ,  201 ,  301  is smooth, the tightening device  400  can comprise a push nut fastener (not shown). In other aspects, the tightening device  400  can include, but is not limited to, shaft collars or other retaining element that is designed to secure threaded and non-threaded shafts of the bonding device  100 ,  200 ,  300 . 
         [0034]    The pair of the bonding device  100 ,  200 ,  300  and tightening device  400  can be used to convert torque into linear force. Referring to  FIGS. 1-6 , the rotational movement of the T-bolt  100 ,  200 ,  300  or nut  400  along a fixed axis occurs such that the head  104 ,  204 ,  304  of the T-bolt  100 ,  200 ,  300  moves closer in proximity to the nut  400  (or the nut  400  moves closer to the head  104 ,  204 ,  304  of the bonding device  100 ,  200 ,  300 ). 
         [0035]    It should be recognized by a person of ordinary skill in the art that an embodiment of the present invention could include different bolt designs including eye, set, hex, or any other similar type without departing from the scope of the invention. A person of ordinary skill in the art will also recognize that an embodiment of the present invention may use different nut designs including flanged, slotted, barrel, t-slot, square, wing, or any similar type without departing from the scope of the invention. 
         [0036]    Different embodiments of the bonding device  100 ,  200 ,  300  include fixing elements  110 ,  210 ,  310 . The fixing elements  110 ,  210 ,  310  are configured to be able to penetrate a non-conductive coating or skin of the solar mounting elements to facilitate electrical bonding of mating components such as, but not limited to, rails, L-foot, brackets, etc., discussed in more detail below. The fixing elements  110 ,  210 ,  310 , comprised of a conductive material, can then assist in creating a grounding connection between the bonding device  100 ,  200 ,  300  and any solar mounting system components that are part of the bond path. These components include, but are not limited to, photovoltaic panels, racking components, wind deflectors, ballast pans, roof anchors, and the like. 
         [0037]    As shown in  FIGS. 1-6 , the fixing elements  110 ,  210 ,  310  can comprise protrusions  112 ,  212 ,  312 . The protrusions  112 ,  212 ,  312  can have different polygon or other geometric shapes, such as hemispherical shape, pin shape, ring shape, prismatic shape, ramp shape, cone shape, and pyramidal shape. The protrusions can be convex shaped and have one or more apices. For example, as shown in  FIGS. 1 and 1A , the protrusions  112  are substantially pyramidal shaped or ramp-shaped.  FIGS. 5 and 5A  illustrate the protrusions  212  as substantially prismatic.  FIGS. 6 and 6A  illustrate substantially hemispherical protrusions  312 . As illustrated, the protrusions  112 ,  212 ,  312  can be located on the inner surface  106 ,  206 ,  306  of the head  104 ,  204 ,  304 . Other shapes, such as a circular, trapezoidal, and the like that can pierce the rail  500  and other components  503  could be used in place of the illustrated embodiments. 
         [0038]    In an aspect, the fixing elements  110 ,  210 ,  310  can be positioned equidistant around the inner surface  106 ,  206 ,  306  of the head  104 ,  204 ,  304  of the bonding device  100 ,  200 ,  300 . Referring to  FIG. 2 , the geometric protrusions  112  are positioned proximate the square-shaped corners of the head  104  or centrally located on the head  104  between the corner edge and the curved edge. 
         [0039]    In an aspect, the geometric shaped protrusions  112 ,  212 ,  312  are made from a substantially hard metallic material that can penetrate a non-conductive layer or skin on a rail  500  or similar structural component  503  (as shown in  FIG. 9  and discussed herein). The non-conductive layer  510  may be on a rail  500  or similar structural connection for solar panels, such as L-feet, module clamps, climbers, and other component connections within a solar mounting system. The penetration is achieved by tightening either the associated bonding device (e.g., T-bolt)  100 ,  200 ,  300  or tightening device (e.g., nut)  400  to achieve a sufficient force so that the protrusions will engage and extend through the non-conductive layer. After the non-conductive layer  510  is penetrated, the electrically conductive material of the bolt  100  and nut  400  is in contact with the electrically conductive material of the rail  500  or structural component  503 . The bolt  100  therefore makes an electrical and mechanical connection with the rail  500  or other structural component. 
         [0040]    While the fixing elements  110 ,  210 ,  310  discussed above in relation to  FIGS. 1-6  disclose protrusions  112 ,  212 ,  314  located on the head  104 ,  204 ,  304  of the bonding device  100 ,  200 ,  300 , the fixing elements are not limited to only these forms or locations. For example, the fixing elements can be located along other portions of the bonding device, including the fastener of the bonding device. In such instances, the fixing elements can still comprise protrusions made of a material that is harder than and are still configured to engage the electrically conductive of the material of the rail/structural component, just at a different location, including the interior surface of the slot that receives the bonding device. The fixing elements can take other various forms located at various other locations along the bonding device. However, the fixing elements are configured to create an electrical connection between the bonding device and the other solar system components. 
         [0041]      FIGS. 8-10  illustrate the rail  500  and structural hardware  503  interfaced with a bolt  100  and nut  400  combination in accordance with an embodiment of the present invention.  FIG. 9  provides a cross-sectional view, taken along lines B-B of  FIG. 8 , of rail  500  and structural hardware  503  interfaced with a T-bolt  100  and nut  400  combination, illustrating the geometric protrusion  112  after it has penetrated the non-conductive layer  510  of the rail  500 . 
         [0042]    The t-bolt  100  described herein provides an easier and faster installation, as only one component has to be installed for two functions with use in solar mounting systems. Further, it features fewer parts, thereby resulting in a lower cost for installation. 
         [0043]    Having thus described exemplary embodiments of the t-bolt to provide an electrical and mechanical connection, it should be noted by those skilled in the art that the within disclosures are exemplary only and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Accordingly, the present invention is not limited to the specific embodiments as illustrated herein, but is only limited by the following claims.