Solar Panel Rail Guide Splice with Integrated Spring Bonding Element
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Solution Overview
Problem
Existing methods for connecting and electrically bonding solar panel rail guides are inefficient, often requiring separate components and lacking tactile feedback for proper alignment, which complicates the installation process and does not provide a secure electrical connection.
Innovation Solution
A novel splice assembly that includes a spring element with embedded slots and resilient bands to provide both electrical bonding and tactile feedback, allowing for secure alignment and connection of solar panel rail guides without the need for separate bonding and stop pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate grounding straps and bonding pins are used to electrically bond rail guides, then reliable electrical connection is achieved, but device complexity and installation time increase
Solution Approach 1:
The patent combines multiple separate components (grounding strap, bonding pins, stop pins) into a single integrated splice assembly. The splice includes an inner splice portion that fits within the rail guide hollows and an outer splice portion, with bonding features integrated directly into the splice structure. This merging eliminates the need for separate grounding straps and bonding pins, reducing component count while maintaining reliable electrical connection between rail guides.
Solution Approach 2:
The splice assembly performs multiple functions simultaneously: it mechanically joins the rail guides together, provides electrical bonding through integrated bonding features, and offers alignment guidance through stop features. The inner splice portion fits within the hollows of both rail guides to provide mechanical support, while bonding features on the outer splice portion establish electrical contact with the rail guide surfaces, eliminating the need for dedicated separate components for each function.
2Measurement precision
If traditional splice methods are used without tactile feedback features, then alignment precision is difficult to achieve, but installation simplicity is reduced
Solution Approach 1:
The splice assembly incorporates stop features including stop pins or stop edges that provide tactile feedback during installation. These stop features contact the rail guides at predetermined positions to indicate when proper alignment has been achieved. The installer can feel when the splice is correctly positioned, eliminating the need for complex measurement tools or procedures while ensuring precise alignment.
Solution Approach 2:
The splice is designed with pre-formed bonding features and stop features that are prepared in advance during manufacturing. The bonding features include pre-positioned conductive elements or contact surfaces that will automatically engage with the rail guides when the splice is installed. This preliminary preparation ensures that when installation occurs, the alignment and bonding functions are already configured to work together seamlessly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution simplifies the installation process by providing a secure, efficient, and intuitive method for connecting solar panel rail guides, reducing installation time and ensuring reliable electrical bonding.
Implementation Method 1
The spring both bonds and provides tactile and visual feedback for proper alignment of the splice within the rails that it joins
Implementation Method 2
utilizing an elongated spring element that is embedded within a slot along the length of the splice. The spring both bonds and provides tactile and visual feedback
Implementation Method 3
The spring element includes sharp metal raised portions on its outer surface that penetrate the outer layer, which can be comprised of an oxidation layer, a surface treatment layer or any similar coating that covers the conducting metal material as the two metal rails are joined. By doing so, the splice provides a conducting path to electrically bond the two rails.
Data Source
AI summary
In various representative aspects, an assembly for connecting and electrically bonding two solar panel rail guides. More specifically, the assembly provides a splice that slides within two solar panel rail guides and includes an elongated spring element that is inserted into an elongated slot in the splice and enables the two solar panel rail guides to be electrically bonded together when various bonding techniques are used to allow portions of the spring to penetrate the oxidation layers of the inner surfaces of the rail guides as they are joined together. Another embodiment that utilizes a bonding element that is inserted into an elongated slot of a splice and also enables two solar panel rail guides to be electrically bonded when the rail guides are joined.