Rail splice for mounting solar panel modules
AssigneeUnirac, Inc.
InventorNeha Avadhoot
Life of this patent
Estimating the term…
Abstract
A rail splice for a mounting system of a solar module that is used to connect the solar module to a surface is described. The rail splice fits in a first end of a first rail and a second end of a second rail to connect the first rail and the second rail together into a single rail having an extended length. The rail splice includes a stop at a middle position of the length of the rail splice to prevent over-insertion of the rail splice into either the first or second rail. The rail splice also includes tabs for providing an electrical connection between the rail splice, first rail, and second rail.
Claims20
A rail system for mounting a solar panel module to a structure, the rail system comprising:
- a first rail component including a first extruded body having a first profile and extending along a first axis, the first rail component defining a first interior passage having a first perimeter defined by a second profile;
- a second rail component including a second extruded body having the first profile and extending along a second axis, the second rail component defining a second interior passage having a second perimeter defined by the second profile;
- and
- a rail splice including:
- a third extruded body having a third profile defining an external perimeter configured to mate with the second profile;
- and
- a stop positioned at a first position along a length of the rail splice, the stop protruding from the third profile and configured to prevent the rail splice from being inserted into the first rail component or the second rail component beyond the stop.
A rail splice comprising:
- an extruded body having an external profile of a cross-section defining a vertical portion and a horizontal portion, the vertical portion extending from an end of the horizontal portion to form an L-shaped profile;
- a stop positioned at a first position along a length of the extruded body including a protrusion extending from a surface of the extruded body;
- and
- an electrical connection positioned at a second position along a length of the extruded body and configured to provide electrical continuity between the rail splice and one or more rail components.
A method of forming a rail splice for connecting adjacent ends of rail components of a solar module mounting system, the method comprising:
- forming an extruded body having an external profile configured to fit within an internal profile of the rail components;
- forming a first opening in a first side wall of the extruded body;
- forming a second opening in a second side wall of the extruded body;
- forming a stop by pressing a first tool through the first opening and deforming a portion of the extruded body away from a center of the extruded body;
- forming an electrical connection by cutting a U-shaped opening opposite the second opening;
- and
- bending the electrical connection away from the center of the extruded body by inserting a second tool through the second opening.
Dependencies are inferred from the claim text.