Solar Panel Rail Guide Splice with Integrated Electrical Bonding
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Solution Overview
Problem
Existing solar panel rail guide assemblies face challenges in securely joining and electrically bonding rail guides, as they often allow movement between components, lack tactile feedback for precise alignment, and require additional parts and tools for assembly.
Innovation Solution
A serrated screw or bonding pins with raised portions are used to penetrate the oxidation layer of rail guides, providing both mechanical and electrical bonding, along with a stop pin for tactile feedback and secure alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a grounding strap is used to electrically connect rail guides, then electrical connectivity is achieved, but the rail guides can still move back and forth along the splice
Solution Approach 1:
The patent combines the electrical bonding function and mechanical securing function into a single integrated splice assembly. The bonding pins serve dual purposes: they provide electrical connectivity between rail guides and simultaneously prevent lateral movement through their rigid structural connection, eliminating the need for a separate grounding strap that only provided electrical connectivity.
Solution Approach 2:
The splice assembly is designed as a multi-functional component that simultaneously achieves electrical bonding, mechanical securing, and alignment functions. The bonding pins with raised portions penetrate the oxidation layer to create both electrical contact and mechanical interlocking, making the splice a universal solution that addresses multiple requirements in one assembly.
2Strength
If a connecting splice is used to join rail guides, then mechanical joining is achieved, but there is no tactile feedback for precise alignment
Solution Approach 1:
The patent incorporates a stop pin with a protrusion that extends outward to provide tactile feedback during assembly. When the rail guide is properly positioned, the protrusion contacts the installer's tool or finger, providing a clear tactile signal that alignment is correct. This feedback mechanism enables precise alignment without requiring complex measurement tools.
Solution Approach 2:
The stop pin acts as an intermediary element between the splice and the rail guide, mediating the alignment process. The protrusion on the stop pin serves as a physical reference point that guides the positioning of the rail guide, ensuring precise alignment before the final securing action is taken.
3Reliability
If a grounding strap with slack is used to connect rail guides, then electrical bonding is achieved, but the rail guides are not fully secured together
Solution Approach 1:
The patent merges the electrical bonding function and mechanical securing function into a single integrated splice assembly. The bonding pins serve dual purposes: they provide electrical connectivity between rail guides and simultaneously prevent lateral movement through their rigid structural connection, eliminating the need for a separate grounding strap that only provided electrical connectivity.
Solution Approach 2:
The raised portions on the bonding pins are designed with specific geometric features that enable them to penetrate the oxidation layer and create both electrical and mechanical contact. The curved or domed shape of the raised portions allows them to concentrate force during installation while maintaining electrical contact, achieving both bonding and securing functions.
4Reliability
If multiple separate components (splice, grounding strap, screws) are used to join and bond rail guides, then both joining and electrical bonding are achieved, but the assembly process requires extra time and parts
Solution Approach 1:
The patent combines the splice, grounding strap, and securing screws into a single integrated bonding pin assembly. Each bonding pin simultaneously provides mechanical joining, electrical bonding, and securing functions, reducing the total number of parts from multiple separate components to a unified assembly that achieves all required functions in one installation step.
Solution Approach 2:
The splice assembly is designed as a multi-functional component that simultaneously achieves electrical bonding, mechanical securing, and alignment functions. The bonding pins with raised portions penetrate the oxidation layer to create both electrical contact and mechanical interlocking, making the splice a universal solution that addresses multiple requirements in one assembly.
Data Source
AI summary
In various representative aspects, an assembly for connecting and electrically bonding two solar panel rail guides is provided. More specifically, the assembly provides a novel and improved inner rail used as a splice that slides within the two solar panel rail guides and includes a serrated screw that is pre-installed within the splice. When installed, the two rail guides are brought together along the splice and meet at the point where the screw is located, the screw can then be tightened so that the serrations penetrate surface treatment layers on each of the rail guides so that the solar panel rail guides are secured and electrically coupled to each other. An alternate embodiment utilizes the inner splice to join two solar panel rail guides by sliding the splice within the inner contour of two solar panel rail guides, and utilizing a pair of bonding pins to electrically bond the splice and the two solar panel rail guides. A stop pin inserted into the splice provides a tactile connection point where the two solar panel guides can be joined together.