Abstract:
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.

Description:
BACKGROUND OF INVENTION 
       [0001]    Field of the Invention 
         [0002]    The present invention relates generally to an assembly for connecting and electrically bonding two solar panel rail guides. More specifically, the apparatus 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. The screw&#39;s serrations are located on the bottom surface of the screw head. When 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. When the surface treatment layers are penetrated by the serrations on the bottom surface of the screw, the serrations not only come in contact with the metal portions of the rail guides, but the screw electrically couples and secures the two rail guides to each other. 
         [0003]    An alternate exemplary embodiment provides a novel and improved splice assembly that includes an inner splice that joins two solar panel rail guides by sliding 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. An optional stop pin inserted into the splice provides a tactile connection point where the two solar panel guides can be joined along the splice. 
         [0004]    Description of the Related Art 
         [0005]    Any discussion of the prior art in the specification should in no way be considered as an admission that the prior art is widely known or forms part of common general knowledge in the field. 
         [0006]    The installation of solar panel arrays on residential roofs can be arduous and time-consuming. Depending on the array design, the components required to install the array can make the installation process even more difficult. This is particularly true when the components must be installed on a roof that links to a rail guide structure for supporting the solar panel array. Within this type of structure, it is desirable to provide electrical connectivity between each rail guides. 
         [0007]    Solar panel arrays typically extend for several feet across a roof. In many cases, several rail guides must be joined together to support the array. Internal bonding splices are often used to couple the rail guides together. And when the rail guides are coupled, they must be electrically connected as well. 
         [0008]    One example of a current assembly for installing rail guides will now be discussed. A typical rail guide is a metallic structure with an oxidation layer that covers its surface. It is also normally hollow inside and extends for a given length. In order to join two rail guides, a connecting splice is often used. A connecting splice is also typically made of an electrical material that is coated with an oxidation layer over its entire surface. The connecting splice generally conforms to the shape of the inner-hollow shape of the rail guide. The splice is inserted into the hollow portions of each respective rail guide and joined together at a given point along the splice. The two rail guides are then electrically connected to each other by using a metallic grounding strap that is secured to each of the rail guides by screwing the ends of the strap to the edges of the rail guides typically no further than approximately an inch apart. 
         [0009]    Although this type of assembly accomplishes the goal of both joining and electrically bonding the rail guides together, it also has several limitations. First, because the grounding strap has a given amount of slack that does not fully secure the rail guides together, the rail guides will always be able to move a small amount back and forth along the splice, which is not desirable. Second, because the splice is never stationary between the two rail guides and provides no tactile feedback where the middle of the splice is located, it is often difficult to align the two rail guides at the midpoint of the splice, which is the most desirable location. Third, it is desirable to electrically connect the two rail guides to the splice. In this assembly, that does not occur. Finally, the use of the strap requires extra time and parts to assemble the rail guides as part of the solar panel array structure. 
         [0010]    Other existing solutions are also inadequate at addressing these concerns. For example, U.S. 2011/0203637 issued to Patton et al, discloses an assembly for joining two solar panel rail guides using a splice, but provides no means to maintain the splice in the desired center location while providing a means to bond the two rail guides with the splice. US 2014/0026946 issued to West et al discloses a splice for joining two solar panel rail guides, but offers no tactile feedback to center the splice where the rail guides are coupled together, nor does it offer any means to secure or electrically bond the rail guides to the splice. US 2014/0260068 issued to Pendley et al also discloses a splice used to connect to guides, but it provides no tactile feedback to center the splice, nor does it offer any means to electrically bond the rail guides to the splice or each other. 
         [0011]    The present invention overcomes these limitations and offers a solution that provides means to use a single screw to both join a pair of rail guides at a central location along a splice, and electrically bond the rail guides and the splice together. In an alternate embodiment, the present invention offers a means for coupling a pair of rail guides at a central point along a splice that also secures and electrically bonds the rail guides and the splice together using a pre-formed insertion points that require minimal parts and no tools that is easy to install, use, and manufacture. 
       SUMMARY OF THE INVENTION 
       [0012]    The invention is summarized below only for purposes of introducing embodiments of the invention. The ultimate scope of the invention is to be limited only to the claims that follow the specification. 
         [0013]    It is an object of this invention to provide an assembly for joining and electrically connecting two solar panel rail guides. 
         [0014]    It is a further object of this invention that the assembly join the rail guides using an internal splice. 
         [0015]    It is a further object of this invention that the splice includes a tactile feedback element for determining a central stopping point where the two rail guides are joined. 
         [0016]    It is a further object of this invention that the tactile feedback element is also a bolt that includes a plurality of raised portions on a flange that extends outward from the head of the bolt is used to join, secure, and electrically couple the rail guides and the splice. 
         [0017]    It is a further object of this invention that alternatively, the splice includes a pair of bonding pins inserted on opposite sides of the tactile feedback means such that the bonding pins each include a raised portion on the head of the bonding pin that is capable of penetrating the oxidation layer of the inner surface of the each of the rail guides. 
         [0018]    It is a further object of the present invention that the raised portions on the bonding pins provide sufficient friction to restrict the rail guides from laterally moving once joined together at the tactile feedback location along the splice. 
         [0019]    A person with ordinary skill in the relevant art would know that any shape or size of the elements described below may be adopted. Any combinations of suitable number, shape, and size of the elements described below may be used. Also, any materials suitable to achieve the object of the current invention may be chosen as well. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures. 
           [0021]      FIG. 1  illustrates a perspective view of an exemplary bolt. 
           [0022]      FIG. 2  illustrates a perspective view of an exemplary solar panel rail guide splice with a prefabricated threaded hole for receiving the bolt shown in  FIG. 1 . 
           [0023]      FIG. 3  is the same as  FIG. 2  showing the bolt inserted into the hole shown in  FIG. 1 . 
           [0024]      FIG. 4  illustrates a perspective view of the bolt and splice shown in  FIG. 3  along with an exemplary solar panel rail guide showing the splice being inserted into the rail guide. 
           [0025]      FIG. 5  illustrates a perspective view of the splice being fully inserted into the rail guide to the point where the bolt is located. 
           [0026]      FIG. 6  illustrates a perspective view of  FIG. 5  with the splice being inserted into a second rail guide. 
           [0027]      FIG. 7  illustrates a perspective view of the two rail guides being joined together where the bolt is located. 
           [0028]      FIG. 8  is a cross-sectional view along point  8  in  FIG. 7  showing the bolt being used to join and secure the splice and the two rail guides together. 
           [0029]      FIG. 9  is a close up view of the encircled portion  8  in  FIG. 8  showing the bolt joining the two rail guides and the splice together and the raised portions on the bottom of the bolt&#39;s extended flange penetrating the surfaces of each of the rail guides. 
           [0030]      FIG. 10  illustrates an exemplary bonding pin. 
           [0031]      FIG. 11  illustrates an exemplary stop pin. 
           [0032]      FIG. 12  illustrates a perspective view of an alternate splice with three prefabricated holes for receiving a pair of the bonding pins and the stop pin shown in  FIGS. 10 and 11  respectively. 
           [0033]      FIG. 13  illustrates a perspective view of the bonding pins and the stop pin fully inserted into the holes of the splice shown in  FIG. 12 . 
           [0034]      FIG. 14  illustrates a perspective view of the splice shown in  FIG. 13  along with an exemplary solar panel rail guide showing the splice being inserted into the rail guide. 
           [0035]      FIG. 15  illustrates a perspective view of the splice being fully inserted into the rail guide to the point where the stop pin is located. 
           [0036]      FIG. 16  illustrates a perspective view of  FIG. 15  with the splice being inserted into a second rail guide. 
           [0037]      FIG. 17  illustrates a perspective view of the two rail guides being joined together where the stop pin is located. 
           [0038]      FIG. 18  is a cross-sectional view along point  9  in  FIG. 17  showing the stop pin being used to maintain separation of the two rail guides. 
           [0039]      FIG. 19  is a close up view of the encircled portion  9  in  FIG. 18  showing the raised portion of one of the bonding pins penetrating the inner surface oxidation layer of the right rail guide. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0040]    In the following description, and for the purposes of explanation, numerous specific details are provided to thoroughly understand the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed embodiments may be applied. The full scope of the invention is not limited to the example(s) that are described below. 
         [0041]      FIG. 1  shows a perspective view of an exemplary embodiment of a screw  110 . The screw  110  is typically made of metal or an electrically conducting material. Other variations of a screw, such as a nut and bolt combination may also suffice. The screw  110  includes a head  115 . The head  115  is typically hexagonally shaped, but it can be any suitable shape that allows it to be rotated. In this embodiment, the head  115  also includes a flange  130 . The flange  130  has a bottom surface that includes a plurality of serrations  140 . It is understood by those skilled in the art that the head  115  and the flange  130  can be separate elements or a singular element where the bottom surface of the flange  130  is simply the bottom surface of the head  115 . The serrations are sufficiently sharp so that when a force, such as a rotational force, is applied to the screw  110 , the serrations can penetrate an oxidation layer of another metal object when they contact each other. The screw  110  also includes a threaded shaft  120  that is typically adapted to be coupled to a threaded aperture  150  as shown in  FIG. 2 . 
         [0042]      FIGS. 2 and 3  show perspective views of a typical splice  100 . The splice  100  shown can be of any suitable shape so long as it conforms to an opening with a similar shape within a solar panel rail guide  200  like the one shown in  FIGS. 4 and 5 , and it can be hollow or solid. The splice is also typically made of a metallic or electrically conducing material with an oxidation or surface treatment layer  160  on its outer surface. The splice  100  includes a threaded aperture  150 . The aperture  150  is typically located in the center of the splice  100 , but it is not limited to that location.  FIG. 2  shows the screw  110  prior to being rotatably coupled to the splice and  FIG. 3  shows the screw  110  fully inserted. One of ordinary skill in the art will also appreciate that the screw  110  could also be rotatably coupled to a splice  100  that does not have a pre-formed threaded aperture  150 . 
         [0043]      FIGS. 4 and 5  show the operational aspects of the assembly. The solar panel rail guide  200  as previously mentioned typically includes a top rail  220  and a side rail  240 . These rails  220  and  240  are used to support additional parts of a solar panel array structure not shown. The solar panel rail guide  200  is also typically comprised of a metallic or electrically conducting material with an oxidation or surface treatment layer  230 . As shown, the solar panel rail guide  200  is hollow inside and the opening  210  of the solar panel rail guide  200  generally conforms to the shape of the splice  100  and can provide a generally snug fit with the splice  100  when the splice  100  is inserted into the opening  210  of the solar panel rail guide  200 .  FIG. 4  shows the splice  100  prior to insertion into the opening  210  with the screw  110  coupled, but not yet tightened, to the splice  100 . As shown in  FIG. 5 , when the splice  100  is fully inserted into the opening  210 , the edge of the solar panel rail guide  200  fits between the flange  130  and the splice  100 . 
         [0044]      FIG. 6  shows the insertion of the opposite end of the splice  100  into a second solar panel rail guide  300  with rails  320  and  340  identical to the rails  220  and  240  of the first solar panel rail guide  200 . The solar panel rail guide  300  is virtually identical in all aspects to those of solar panel rail guide  200 .  FIG. 7  shows the splice  100  fully inserted into rail guides  200  and  300  so that they fit between the flange  130  and the splice  100 . 
         [0045]      FIG. 8  shows a cross-sectional view of point  8  in  FIG. 7  that is looking straight into the first solar panel rail guide  200  and the splice  100  where the screw  110  is now fully tightened into the outer surface of the solar panel rail guides  200  and  300  although only  200  is shown here. The threaded shaft  120  is shown inserted into the splice  100 .  FIG. 9  is a close up view of the area showing how the serrations  140  have penetrated the oxidation layer  230  of the solar panel rail guide  200  so that they contact the conducting portion of the solar panel rail guide  200 . When the solar panel rail guides  200  and  300  are in contact with the threaded shaft  120 , and the screw  110  is fully tightened, the serrations  140  are able to grip the rail guides  200  and  300  so that they are secured and electrically coupled to each other. 
         [0046]    An alternate exemplary embodiment is also shown in  FIGS. 10-19 .  FIGS. 10 and 11  illustrate perspective views a bonding pin  500  and a stop pin that serves as a tactile feedback element  400  respectively. The bonding pin  500  includes a shaft  510  that is typically adapted to fit within pin apertures  170  on the splice  100  as shown in  FIG. 12 . In describing this embodiment, it is presumed that the splice  100  is the same splice described in the previous embodiment of  FIGS. 1-9  except that instead of including a threaded aperture  150 , the splice  100  includes a plurality of pin apertures  170 . Although the pin apertures  170  are all illustrated as being horizontally collinear, a person of ordinary skill in the art would understand that that they can exist anywhere along the length of the splice  100  so long as they are not vertically collinear. The bonding pin  500  also includes a flange  530  and includes a raised portion  520  on the top surface of the flange  530 . The bonding pin  500  is typically comprised of a metallic or electrically conducting material that can form an electrical bond with the splice  100  when it is inserted, and the raised portion  520  is typically sharp enough to penetrate the oxidation or surface treatment layer  230  of the solar panel rail guides  200  and  300 . 
         [0047]    The stop pin or tactile feedback element  400  is similarly structured like that of the bonding pin  500 . The stop pin  400  includes a shaft  410  that is adapted to snap into a pin aperture  170  of the splice, and it also includes a flange  420  with a protrusion  430  that extends outward from the top surface of the flange  420 . 
         [0048]    When inserted into one of the pin apertures  170 , the shaft  510  is typically snapped into the aperture  170  to secure it. It is also understood by one of ordinary skill in the art that the splice  100  can be pre-fabricated with the bonding pins  500  and the stop pin  400  along its length.  FIGS. 12 and 13  show the splice before and after insertion of the stop and bonding pins  400  and  500  respectively. As shown in  FIG. 13 , the pins  400  and  500  have been inserted into the splice  100 . Two differences between the stop pin  400  and the bonding pin  500  are that the stop pin  400  is typically not made of a conducting material, and the protrusion  430  is generally oriented vertically with respect to the edges of the splice  100 , while the raised portions  520  of the bonding pins  500  are generally oriented horizontally with respect to the edges of the splice  100 . This is so that the protrusion  430  is capable of providing a separation distance between the solar panel rail guides  200  and  300  when they are joined together as will be discussed below. The horizontal orientation of the raised portion  520  is primarily so that it not only can penetrate the oxidation layer of the splice  100  and form an electrical bond when the splice  100  is inserted into the solar panel rail guide  200  or  300 , but that the raised portion  520  will provide sufficient resistance to the splice  100  so that it will remain stationary unless a sufficient force is applied to try to move the splice. If the raised portion  520  is oriented vertically, it can cause more-than-necessary oxidation layer to be removed from the inner surface of the rail guides  200  and  300 . 
         [0049]      FIGS. 14 and 15  show the operational aspects of the assembly. Just as with the previous embodiment described in  FIGS. 1-9 , the solar panel rail guide  200  typically includes a top rail  220  and a side rail  240 . These rails  220  and  240  are used to support additional parts of a solar panel array structure not shown. The solar panel rail guide  200  is also typically comprised of a metallic or electrically conducting material with an oxidation or surface treatment layer  230 . As shown, the solar panel rail guide  200  is hollow inside and the opening  210  of the solar panel rail guide  200  generally conforms to the shape of the splice  100  and can provide a generally snug fit with the splice  100  when the splice  100  is inserted into the opening  210  of the solar panel rail guide  200 .  FIG. 14  shows the splice  100  prior to insertion into the opening  210 . As the splice  100  is inserted, the left-most bonding pin  500  is penetrating the oxidation layer (discussed below) of the rail guide  200  and creating an electrical contact between the splice  100  and the rail guide  200 . As shown in  FIG. 15 , when the splice  100  is fully inserted into the opening  210 , the edge of the solar panel rail guide reaches the protrusion  430  and can no longer move. It is presumed that the protrusion extends far enough out to prevent the rail guide  200  from moving passed it during insertion. 
         [0050]      FIG. 16  shows the insertion of the opposite end of the splice  100  into a second solar panel rail guide  300  and the raised portion  520  of the bonding pin  500  having penetrated the oxidation layer of the rail guide  300  and formed an electrical bond between the rail guide  300  and the splice  100 . The solar panel rail guide  300  is virtually identical in all aspects to those of solar panel rail guide  200 .  FIG. 17  shows the splice  100  fully inserted into rail guides  200  and  300  so that they are separated only by the protrusion  430  of the stop pin  400 . 
         [0051]      FIG. 18  shows a cross-sectional view of point  9  in  FIG. 17  that is looking straight into the first solar panel rail guide  200  and the splice  100  where stop pin  400  is snapped into the splice  100  and the protrusion  430  separates the two rail guides  200  and  300 .  FIG. 19  is a close up view of point  10  in  FIG. 17  that is looking straight into the second solar panel rail guide  300  and the splice  100  where the bonding pin  500  is snapped into the splice  100  and the raised portion  520  has penetrated the oxidation layer  310  of the rail guide  300  and formed the electrical bond between the rail guide  300  and the splice  100 . When the solar panel rail guides  200  and  300  are in contact with the bonding pins  500 , the raised portions  520  are able to grip the rail guides  200  and  300  so that they are secured and electrically coupled to each other.