Clamp assembly and conductive cushion with molded-in grounding foil

1. An electrically grounding cushioned clamp assembly for clamping a payload and being attachable to an electrically conductive clamp strap, the assembly comprising:

a cushion member with a longitudinal opening extending therethrough, the cushion member having an engaging surface configured to engage the payload; and

an electrically conductive comb strip disposed at least partially in the longitudinal opening of the cushion member, portions of the electrically conductive comb strip being exposed adjacent to the engaging surface to contact the payload and provide a plurality of electrical grounding paths to the payload, wherein the electrically grounding cushioned clamp assembly is configured to removably receive the clamp strap within the longitudinal opening of the cushion member with the electrically conductive comb strip engaging the clamp strap.

2. The clamp assembly of claim 1 wherein the electrically conductive comb strip includes multiple spaced apart teeth exposed adjacent to the engaging surface.

3. The clamp assembly of claim 1 wherein the electrically conductive comb strip is a metal comb strip with a plurality of conductive teeth.

4. The clamp assembly of claim 1 wherein the cushion member is molded from at least two strips of elastomer.

5. The clamp assembly of claim 1 , further comprising a internal conductive member, wherein the opening comprises an open channel, and wherein the clamp assembly is configured to clip onto the internal conductive member with the metal strap disposed within the open channel and in conductive engagement with the electrically conductive comb strip.

6. The clamp assembly of claim 1 wherein the electrically conductive comb strip is bent into a U-shape and extends along a majority of the cushion member, and wherein a portion of the cushion member is positioned within the U-shape of the electrically conductive comb strip.

7. An electrically grounding cushioned clamp assembly for clamping a payload, the assembly comprising:

a cushion member with a longitudinal opening extending therethrough, the cushion member having an engaging surface configured to engage the payload; and

an electrically conductive comb strip disposed at least partially in the longitudinal opening of the cushion member, portions of the electrically conductive comb strip being exposed adjacent to the engaging surface to contact the payload and provide a plurality of electrical grounding paths to the payload, wherein the electrically conductive comb strip includes exposed external surfaces, and wherein the exposed external surfaces are substantially flush with surfaces of the cushion member.

8. The clamp assembly of claim 1 wherein the electrically conductive comb strip is molded into the cushion member.

9. A method for making an electrically grounding cushion assembly comprising the steps of:

bending metal teeth of a metal comb strip to an angle from a connecting strip of the metal comb strip;

inserting the metal teeth into a non-vulcanized elastomer cushion strip;

bending the metal teeth until they are flush with the elastomer cushion strip;

placing the elastomer cushion strip with the comb strip in a mold with at least one additional elastomer cushion strip; and

molding the cushion strips into a cushion assembly.

10. The method of claim 9 wherein molding the cushion strips includes creating an opening along a longitudinal axis of the cushion assembly.

11. The method of claim 10 , further comprising inserting a metal strap into the opening to form an electrically grounding cushioned clamp assembly.

12. The method of claim 9 , further comprising applying a primer to the metal comb strip and bonding the metal comb strip to the first elastomer cushion strip.

13. The method of claim 9 wherein inserting the metal teeth includes supporting the metal teeth during insertion.

14. The method of claim 9 , further comprising perforating the elastomer cushion strip.

15. An electrically grounding cushioned clamp assembly for securing a payload, the clamp assembly comprising:

a cushion assembly, the cushion assembly including:

a cushion member having an opening extending adjacent to a longitudinal axis, the cushion member having an exterior surface that engages the payload, and

a metal comb strip bonded to the cushion member and configured to electrically conductively engage the payload; and

an electrically conductive strap disposed in the opening of the cushion member and in engagement with the metal comb strip to establish an electrical connection to the metal comb strip, wherein the strap is separable from the cushion assembly and is configured to receive a fastener to secure the payload and clamp assembly.

16. The clamp assembly of claim 15 wherein the metal comb strip is U-shaped and includes a connecting strip and multiple spaced apart teeth, and wherein a portion of the cushion member is positioned between the connecting strip and the teeth.

17. The clamp assembly of claim 16 wherein the metal comb strip includes exposed external surfaces, the exposed external surfaces being substantially flush with the exterior surface of the cushion member.

18. The clamp assembly of claim 15 wherein the metal comb strip comprises a metal foil.

19. The clamp assembly of claim 18 wherein the metal foil includes a plurality of teeth, and wherein the cushion assembly includes perforations configured to close around the metal foil with substantially no gap between the metal foil and the cushion member.

20. The clamp assembly of claim 15 wherein the cushion assembly is a first cushion assembly and the electrically conductive strap is a first strap, the clamp assembly further comprising:

a second cushion assembly; and

a second electrically conductive strap, wherein the first and second straps and the first and second cushion assemblies are configured to be clamped around a portion of the payload.