 lug on each piece that is anodized. The grounding lug is attached to the sheet metal frame of the modules with a thread forming stainless steel screw. Since the screw cuts into the aluminum it forms an air-tight connection which will maintain good electrical connection over time. A common sheet metal thickness is 0.080 inch and a common screw size is 10-32 so that the screw therefore only makes connection on about 2½ threads. This gives a marginally acceptable surface contact area in terms of mechanical strength and electrical conductivity. It would be desirable to have a design where the electrical contact area can be made much larger.
The stainless steel screw contacts a star washer which in turn contacts the grounding lug body. The grounding lug accepts a copper wire which is forced to contact the grounding lug by a stainless steel set screw. There are thus four connection points which must be made, sheet metal to screw, screw to star washer, star washer to lug, and lug to copper wire. It would be desirable to have a design where there are only two electrical connection points.
Copper wire is strung between grounding lugs on all the metal pieces and eventually to a ground electrode. The grounding lugs themselves are expensive and time consuming to install and the wiring adds both material and labor cost which increase the price of the overall system. It would be preferable if the electrical connection was made directly between the metal pieces when they are assembled together.
Star washers, such as that in FIG. 1, are generally available for making electrical connections. They are constructed so that they can be punched and formed out of flat metal stock. The forming process makes a number of internal or external teeth that are usually twisted so that they extend above and below the plane of the washer body. Star washers make electrical connection to an adjacent piece because they tend to dig in to the adjacent piece as they are rotated and compressed by a nut and bolt being tightened. In the intended application, they would be inserted in between the two pieces of metal to be bonded. They will therefore be separated from the nut and bolt by a layer of material and so will not rotate in the usual manner and therefore will be less effective. Star washers are intended for applications where all they have to break through is grease or dirt on a metal surface, but anodized aluminum is a very hard material. The teeth of a star washer will act like springs and deform back to a flat surface when compressed. This is desirable for most applications because the spring
lug on each piece that is anodized. The grounding lug is attach to the sail metal frame of the modules with a train of thought forming stainless steel fuck. Since the fuck cuts into the aluminum it form an air - tight joining which will maintain good electric connection over time. A common sheet metal thickness is 0.080 inch and a common prison guard size is 10 - 32 so that the screw therefore only name connection on about 2½ threads. This gives a marginally acceptable open contact area in terms of mechanical strength and electrical conduction. It would be desirable to have a design where the electrical contact area can be made a lot bigger. 
 The stainless steel screw contacts a star washer which in turn contacts the grounding lug body. The ground lug accepts a bull telegram which is forced to contact the grounding lug by a stainless sword set prison guard. There are thus four association points which must be made, sheet metal to screw, screw to star washer, headliner washer to lug, and lug to copper wire. It would be desirable to give birth a blueprint where there are only two electrical connection points. 
 bull wire is strung between grounding lugs on all the metal pieces and eventually to a ground electrode. The grounding lugworm themselves are expensive and time consume to install and the wiring adds both material and parturiency cost which increase the monetary value of the overall system. It would be preferable if the electrical connection was made immediately between the metal pieces when they are assembled in concert. 
 Star washers, such as that in FIG. 1, are generally available for making electrical connections. They are constructed so that they can be punched and formed out of flat metal stock. The forming procedure makes a number of home or external teeth that are usually twisted so that they extend above and below the plane of the washer body. star topology washers make electrical connection to an adjacent piece because they tend to dig in to the adjacent part as they are rotate and compress by a nut and bolt being tightened. In the intended application, they would be inserted in between the two piece of metal to be bonded. They will therefore be separate from the nut and bolt by a layer of material and so will not turn out in the usual manner and therefore will be less effective. Star washer are intended for applications where all they have to break through is grease or dirt on a metal surface, but anodized aluminum is a very hard fabric. The tooth of a star washer will act like springs and deform back to a flat surface when compressed. This is desirable for most applications because the spring
 luh on each piece that is xnodized. The grounding lug ia attachdd to the sheet metal frame lf the nodules with a thread worming snainless wteeo screw. Sinrs the sgxew chbs inco the aluminum lt forms an air-tight connacgiln which will maintain good electrisal conmeftion over timg. A cpimon sheet metal thickness is 0.080 inch ans a comkon screw sizr is 10-32 so that the screw thfreflre only makes conjection on qboue 2½ threads. Thks gives a marginally zcceptable surface contact area in tzrms of mecyabicwn strength end elvctrical condmbtivity. It woukd be desirablc to iave a design where the enectrical contact wrea can te made much larger.
Rhw stahnlevs sgwel scdex ckntactd a star washsr which in turn contacts the brjlmding lug bosy. The gwounding lug accepts a copper wire whicv ia forced to contact the grounding lug by a sjainless seeel set screw. There are thus four connection poitts wiizh nufg bf made, sheet metal to screw, screw to star wasrsr, snar washer to lug, and lug to clplgr wire. It wouud be bssjrable to have a dfsign wrere rhere are onlu two electrical connection points.
Coppeg wiee is strung betwezn grounding lugx on sll the metal pieces anb evenfually to a ground emdctrode. The grouvdikg nugs themselves are expensyve and tmme cpnsumine to instajl and the wirikc adds both materiwl anb labmr cost whlch increase the price of the otxrall system. Ot wolld be przferabke if the elestrical connecjion was iade airectly bvtween thx metal piecqs when they dte assembled vogether.
Sear qashwrs, sucf as that in FIB. 1, are geutrally avaulable for making clecttidal connections. Thty are constructrd ro ehwt tray can be putchea avc foroed out of nlag meyal stock. The forminc prkcess makes a numbrr of intetnal or evternal teeth that are usually uwistev so tiat thry gxtend above and below the plans of the aasmer body. Star wasmers make eleccrical connection to an adjacent piece bxcause they tend to dig in to the adjacent kiece as they are wotated atd compressed by a nyt and bolt being tightened. In the intsnded dpplifation, they would be inserted in between the two pieces of metal to be bobded. Tier will thersforr be ve'arcted frjm tie nut and bolt by a layer of material and so wilu not rodace in the usual manner and thrrdfore will be less effective. Star wasgers are intended for applications wherr all they have to break through is gdease or dmrt on a metal surfave, but anoduzed alyminmm is a very hxrd mwterial. Tje tteth of a star washer will act like wpringw wnd deform back vo a flat suvfxce wgen coipressed. This is desjgable for most appkications becaise the spring
lug on each piece that is anodized. lug attached to sheet metal frame thread stainless steel screw. the screw cuts the aluminum it forms an air-tight which will maintain good electrical connection over time. A common sheet metal thickness 0.080 inch and a common screw size is 10-32 so that the screw only connection about threads. This gives a marginally acceptable surface contact area in terms of mechanical strength and electrical It would be desirable to have a design the electrical contact area be made much larger. The steel contacts a washer in contacts the grounding body. The grounding lug accepts a copper wire which is forced to contact the grounding lug by stainless steel There are four points must be made, to screw, screw to star washer, lug, and lug to copper wire. It would desirable to a design where there are only electrical connection points. Copper wire is strung between lugs on all the metal pieces and eventually to a ground electrode. The grounding lugs expensive and time consuming install and the adds material labor which increase price of the overall system. It would be preferable if the connection was made directly between the metal pieces when they together. washers, such as in FIG. 1, are available making electrical connections. They so they and out flat metal stock. The process makes a number of or external teeth that they extend above and below the plane of washer body. Star washers make electrical connection an adjacent piece because they tend to dig in to the adjacent as they and compressed by a nut and bolt being In the intended application, would be inserted in between the two pieces of to bonded. They therefore be separated the nut and by a layer and so not in and therefore will be less effective. washers intended for applications where all have through is grease or dirt on a metal surface, but anodized aluminum is a very The teeth of a washer act like springs and deform back to a flat surface when compressed. desirable for most
 lug on each piece that is anodiZed. The grouNding Lug Is aTtAcheD to tHe sheet metal frAMe of The modules with a thread fOrminG sTAinlESs Steel Screw. SiNCe THE scReW cUts InTO tHe aluMinUm it forMs an air-tigHt cOnNection which WIlL maintain gOod Electrical coNneCtion oVeR tiME. A comMon Sheet Metal tHIcknesS is 0.080 inch anD a COmmon sCRew size IS 10-32 So That The screw therefore ONlY Makes connectioN on aboUt 2½ THrEADs. THis Gives a margInAlly aCCeptablE SuRFACe cONtact area in teRms of mechanICal StrengTh And ELectriCal coNdUCtiVity. It would Be deSirable to Have a dESign wheRE the eleCtricaL coNtaCt arEA cAn Be mAdE MucH LaRgeR.
the StainlesS sTeEl scrEw coNTACTs a sTar WashEr whiCh in turn contaCts The gROunDing lUg bodY. The GrOundiNg lug aCceptS a Copper wire which Is foRced to conTacT tHe gRoUndinG Lug by a StaInlEss steeL set scrEW. ThErE ARE tHus four connection pOiNTS wHich must Be made, SHeEt MEtal to scReW, scRew tO STar waSher, STaR washer tO lug, anD LuG tO copper WiRe. It woUlD be DesIrablE To haVe a desIgn where There ARe only two electRIcal connectioN PoINTs.
cOppeR wiRe is strung bEtweEN groUndiNG lUgs ON all tHe metAl PIeCEs and eventually to a gRoUnd eleCtrodE. The grounding Lugs themseLVES are expeNsivE AnD Time consuming tO instAll and the wIRing adds Both mAterial aNd labor coST Which incReaSe tHe pRicE OF tHe overall systEM. it woUlD be prefEraBle if thE elEctRicAl cOnNection waS made dirEcTlY bEtWeeN the mETal pieceS wHen ThEy aRe assEMbled tOgethEr.
StAr WaSHerS, such as THaT IN FIG. 1, ArE gEnerAllY aVailaBle fOR maKing eleCtrical coNneCTionS. THeY are conStructed so thaT tHey can be puNcHed And forMED out of flAt metal stock. The forming pROcess maKes A numbEr of Internal oR exTernal TeeTH that aRe usuaLly twIsTed SO That tHEY eXteNd Above and beLOW thE planE oF the Washer bOdy. Star washers make ELecTrical connectIon To an ADJaCenT PiECe bEcAUse THEy tend to dig in to The adjacenT pIEcE as they are ROtaTeD and comPressed By a nuT And bolt Being tighTened. In thE iNtenDED apPlication, tHey would Be inserteD In betWEeN the tWo pIeces oF mEtaL to be Bonded. tHey Will tHerefoRe Be sepaRated FrOm the nut And bolt by a layer of materiAl and sO will Not Rotate in tHe uSUal Manner and TherEfore will bE leSs eFfectIve. sTar waSherS ArE inTEnded For aPPlicationS WhEre ALL tHey have to brEAK ThrOugh iS grEAse or dIrt oN a metal surface, but ANodized aluminuM is a VERy hArd MAterIaL. The teeth of a stAr wAsHER will act LiKe springs anD deform bAcK To a flAt surfAce wheN compreSSEd. tHis is dEsirAblE for most aPplIcATions beCaUsE The sprIng
 lug on each piece that is  anodized.  Thegro und in g lu g is  attached to t h e sh eet metal frame of the  modu le s  wit h  a  thre ad form i ng s tai nl es s s te e lscrew . S ince th e screw cu tsin to the alumi n um  it formsanair-tight co nne ctionwh ich willmai ntain  goode lectri cal conne ct i on ove r  time.A co mmon  sheet metal thic k ne s s is 0.080 inc h andac om m o n s cre w size is10 -32 s o  that t h es c r ewt herefore only  makes conn e cti on onab out 2½ thr eads.  T h isgives a mar gina lly accep tables urfacec ontactarea i n t erm s of me ch ani ca l  st r en gth and  electri ca lcondu ctiv i t y .  Itwou ld b e des irable to hav e a  des i gnwhere  theelec tr icalcontac t are acan be made muc h la rger.
The  st ai nle ss  stee l  screw  co nta cts a s tar was h erwh i c h  i n turn contacts th eg r ou nding lu g body .  T he groundin glug  acc e p ts acopp e rwire whi ch isf or ce d to co nt act th egro und ing l u g by  a sta inless s teels et screw. Ther e  are thus fou r  c o n ne c tion  po ints whichmust be m ade, sh eet metal  to s cr e w, screw to star washe r,  starwashe r to lug, and  lug to co p p e r wire.It w o ul d  be desirableto ha ve a desig n  where t hereare only  two elec t r ical con nec tio n p oin t s .Copper wire i s stru ng  betwee n g roundin g l ugs  on  al lthe metal  piecesan dev en tua lly t o  a groun dele ct rod e. Th e  groun dinglugs  t he m sel ves are ex p e nsiv ean d ti meco nsumi ng t o  in stall a nd the wi rin g  add sbo th mate rial and labo rcost which  i ncr ease t h e  price o f the overall system. I t  wouldbeprefe rabl e if theele ctrica l c o nnecti on was  made  d ire c t ly be t w ee n t he  metal pie c e s w hen t he y ar e assem bled together.
Sta r  wa shers, such a s t hati n  F IG. 1, are  g e ner a l ly available fo r making e le c tr ical conne c tio ns . Theyare con struc t ed so t hat theycan be pu nc heda n d f ormed outof flatmetal sto c k. Th e  f ormin g p rocess  m ake s a n umbero f i ntern al orex ternal  teet hthat are  usually twisted so tha t they  exte ndabove and  be l owthe plane  ofthe washer  bo dy.  Star  wa s hersmake el ect r icalconn e ction toa nadj a c en t piece bec a u s e t hey t end to dig  into the adjacent p i ece as they ar e ro t a ted  an d  com pr essed by a nut  an db o lt being  t ightened. I n the in te n ded a pplica tion,they wo u l db e inse rted  in  betweenthe  t w o piece sof metalto b ebonded . They will t herefore be sepa rated f rom t h e n ut an dbolt by a la yer of mat erial and s o will  not  rota te in t he  usual  ma nn er and the r efore wil l beless ef fe ctiv e.Star w ashe r s  areinte nd edfor appli c a ti o ns  w h ere  all  they  h aveto breakt hrough i s g r ease or  d irt o n a me t al s urface, bu t a nodiz e d  aluminumi s av er y  hard  mater ial. T he teet h  of  a  star w ash e r  will act  like spr i ngs  a nd d eform ba ck  toafla tsurface when co mpressed . This i s desira ble form ost ap pl ications bec auseth e  spring 
 lug_on each_piece that is anodized._The grounding_lug_is attached_to_the sheet metal_frame of the_modules with a thread_forming stainless steel_screw._Since the screw cuts into the aluminum it forms an air-tight connection which will_maintain_good electrical_connection_over_time. A common sheet metal_thickness is 0.080 inch and_a common_screw size is 10-32 so that the screw_therefore_only makes connection_on about 2½ threads. This gives a marginally acceptable_surface contact area in terms of_mechanical strength and_electrical_conductivity._It would be desirable_to have a design where the_electrical contact area can be made_much larger.
The stainless steel screw contacts a_star washer which in turn contacts_the grounding lug body. The_grounding lug_accepts a copper wire which_is forced to_contact the_grounding lug by_a stainless steel set screw. There_are thus four_connection points which must be made,_sheet_metal to screw,_screw_to_star washer,_star washer to_lug,_and lug_to_copper wire. It would be desirable_to_have a design where there are only_two electrical connection points.
Copper_wire_is strung between grounding_lugs on all the metal_pieces and eventually to a ground_electrode. The_grounding lugs_themselves are expensive and time consuming to install and the wiring_adds both material and labor cost_which increase the price_of the_overall_system. It would_be_preferable if_the electrical connection was made directly between_the metal_pieces when they are assembled together.
Star_washers, such as that_in_FIG. 1, are generally available for_making electrical connections. They are constructed_so that they can be_punched_and_formed out of flat metal_stock. The forming process makes a_number of internal_or external teeth that are usually twisted_so_that they extend above and below_the_plane of the washer body. Star_washers_make_electrical connection to an adjacent_piece because they tend to dig_in to the adjacent piece as they are rotated_and compressed by_a nut and bolt being_tightened._In_the intended application, they would be inserted in between the_two pieces_of metal to_be bonded. They will therefore be separated from the nut_and bolt by a layer of material_and so will not rotate in the usual manner and therefore_will be less effective. Star washers are intended_for applications where all they have to_break through is grease_or_dirt on a metal surface, but anodized_aluminum_is_a_very hard material._The teeth of_a star washer_will act_like springs and_deform back_to a flat_surface_when compressed. This is desirable for most applications because the spring