Patent Publication Number: US-2022224280-A1

Title: Rail and Splice Foot Mounting System for Photovoltaic Panels

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority from Provisional Patent Application No. 63/135,968, filed on Jan. 11, 2021, the disclosure of which is relied upon and incorporated herein by reference. 
    
    
     FIELD OF INVENTION 
     This invention generally relates to photovoltaic arrays, and more particularly to a rail system for mounting of photovoltaic (PV) arrays and associated hardware. 
     BACKGROUND OF THE INVENTION 
     A photovoltaic (PV) installation typically includes a collection of photovoltaic modules combined and secured to a support structure that combines each of the photovoltaic components to form a photovoltaic array. Typically, photovoltaic arrays are placed in an outdoor location, commonly rooftops, so that the photovoltaic arrays are exposed to sunlight in order to produce electricity. In most residential settings, the rooftops are sloped roofs. 
     Standard dual rail systems, standard shared rail systems, and standard rail-less systems have been used in various roof installations, ground mount installations, façade installations or installations on floats. However, all three systems have their drawbacks. For example, standard dual and shared rail systems utilize rails of a long length, typically between sixteen (16) to twenty feet (20) each. Rails of such lengths are expensive to ship and cumbersome to manipulate on the roof. In addition, the rails must be cut to length during installations (to fit the roof or the span of PV panels), which can lead to inaccurate cuts or wasted offcuts which cannot be used and are discarded. Further, the aforementioned rail-based systems utilize separate L-feet and splice sections.  FIG. 1  shows a typical standard rail installation with all needed components (rails, L-feet, splices, and PV modules). As shown, the L-feet (labeled as “Roof Attachments” in  FIG. 1 ) are mounted at various rafters of the roof, with splice sections connecting the different portions of rail. Note the large quantities of parts and need for splices and L-feet, leading to a high part count and complicated installation.  FIG. 2  illustrates an installed shared rail system, having fewer rails, L-feet (labeled as “Roof Attachments”), and splices than a standard dual rail system as shown in  FIG. 1 . However, the installation still requires a good number of extra parts, including splices, and still utilizes long rails that must be cut to fit the roof. 
     While rail-less systems eliminate the cumbersome nature of rails, have their own shortcomings as well.  FIGS. 3-5  illustrate typical rail-less attachment components that provide adjustability in height and north/south placement. While the adjustability of such a component may be seen as a benefit, several problems may arise because the sheer number of adjustable components that are installed, leading to the need to adjust each and every one of the components. In addition, splices, as shown in  FIG. 5 , are still needed to join PV modules to form a stiff and rigid structure much like the function of a rail.  FIG. 6  illustrates a typical rail-less system installation, showing rafter locations and the interactions of the attachments and splices. Not only is the layout complicated, but as mentioned above, the individual adjustment of the components and PV modules can be very complicated as well. 
     Therefore, there is a need for a PV mounting system that eliminates the drawbacks of traditional dual and shared rail systems while avoided the complexity found in rail-less PV mounting systems. 
     SUMMARY OF THE INVENTION 
     A PV array short rail and splice foot mounting system for use on support structures such as roofs. In an aspect, the PV array short rail mounting system includes short rails and L-foot connectors. In an aspect, the rails are the length of a span. In another aspect, the mounting system includes splice foot mounts that allow one or two rails to be mounted in a continuous line without the need for a separate splice. 
     In an aspect, the invention is directed to a photovoltaic array rail mounting system for use on a roof that includes at least one rail and a splice foot connector that can support one rail or two rails. In such aspects, the splice foot connector serves as both a mounting bracket and a splice. The splice foot connector can be configured to receive span-length rails to support a photovoltaic array. In an aspect, the splice foot connector can include a roof mount component and a rail mount component forming a substantially 90-degree angle with one another. In an aspect, the splice foot connector can be configured to be mounted on a tile replacement. 
     In an aspect, the rail mount component can include a plurality of apertures that allow connection to one rail or two rails. In such aspects, the plurality of apertures can include elongated apertures to allow for adjustable rail mounting. In other aspects, the roof mount component includes a raised base member to provide horizontal support for the at least one rail. 
     In an aspect, the photovoltaic array rail mounting system can include a cover configured to fit over the one splice foot connector. The photovoltaic array rail mounting system can also include a butyl pad to be placed between the roof mount component and the roof. The photovoltaic array rail mounting system can include a standing seam clamp used to mount the splice foot connector to a standing seam roof. 
     In an aspect, the invention is directed at a method of mounting a photovoltaic ray on a surface that includes mounting a splice foot connector, configured to support one or two rails, onto the surface, mounting the one or two rail onto the splice foot connector using one or more fasteners, and mounting the photovoltaic ray to the one or the two rails. In such methods, the slice foot connector can include a roof mount component and a rail mount component that form a substantially 90-degree angle with one another, with the roof mount component mounted to the surface and the one or two rails mounted to the rail mount component, the rail mount component including a first aperture and a second aperture. In methods in which two rails are mounted, the rails are mounted to the roof mount component by securing a first rail to the first aperture and securing a second rail to the second aperture. In other aspects, the roof mount component includes a base member configured to support the one or two rails. 
     These and other objects and advantages of the invention will become apparent from the following detailed description of the preferred embodiment of the invention. Both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to provide further explanation of the invention as claimed. 
     The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute part of this specification, as well as illustrate several embodiments of the invention that together with the description serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a schematic representation of a photovoltaic (PV) array installation on a roof using a dual rail mounting system known in the prior art. 
         FIG. 2  is a schematic representation of PV array installation on a roof using a shared rail mounting system known in the prior art. 
         FIGS. 3-5  illustrate components of a rail-less PV mounting system known in the prior art. 
         FIG. 6  is a schematic representation of PV array installation on a roof utilizing the rail-less mounting system components of  FIGS. 3-5 . 
         FIGS. 7-8  are perspective elevated views of components of a short rail mounting system according to aspects of the current invention. 
         FIGS. 9-10  are schematic representations of PV array installation on a roof utilizing the short-rail mounting system according to an aspect of the present invention. 
         FIG. 11  is a perspective elevated view of components of a short rail mounting system according to an aspect of the current invention. 
         FIG. 12  is a schematic representation of a PV array installation on a roof utilizing components of the short-rail mounting system shown in  FIG. 11 . 
         FIGS. 13-14  are perspective elevated views of components of a short rail mounting system according to aspects of the current invention. 
         FIG. 15  is a schematic representation of a PV array installation on a roof utilizing components of the short-rail mounting system shown in  FIGS. 13-14 . 
         FIG. 16  is a schematic representation of a PV array installation on a roof utilizing components of the short-rail mounting system shown in  FIGS. 7-8 and 11 . 
         FIGS. 17-24  illustrate an embodiment of the splice foot connector according to an aspect of the present invention. 
         FIGS. 25-27  illustrate an embodiment of the splice foot connector according to an aspect of the present invention. 
         FIGS. 28-28A  illustrate a rail and splice foot connector assembly according to an aspect of the present invention. 
         FIG. 29  illustrates an exploded view of a splice foot connector and rail assembly according to an aspect of the present invention. 
         FIGS. 30-32  illustrate a cover and splice foot connector assembly according to an aspect of the present invention. 
         FIGS. 33-39  illustrate a splice foot connector mounted to various roofing and support structures according to embodiments of the present invention. 
         FIG. 40  illustrate an embodiment of the splice foot XL connector according to an aspect of the present invention. 
         FIG. 41  illustrates a rail and splice foot XL connector assembly according to an aspect of the present invention. 
         FIGS. 42A-42B  illustrate potential rail and splice foot connector assemblies according to an aspect of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments of the invention will be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
     In the following description, numerous specific details are set forth. However, it is to be understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures, and techniques have been shown in detail in order not to obscure an understanding of this description. 
     In an aspect, one embodiment of the present invention, as shown in  FIGS. 7-16 , is directed towards a short rail photovoltaic (PV) array rail mounting system (SPARM)  10 . In an aspect, as illustrated in  FIGS. 7-16 , the SPARM system  10  includes a short rail  100  and an L-foot connector  200  used to provide support and a place to mount solar components  300 . The solar components  300  can include, but are not limited to, PV panels, racking components, wind deflectors, ballast pans, micro-inventers, optimizers, wire management solutions, and the like commonly used in solar panel mounting systems. The SPARM system  10  is configured to allow solar components  300  (e.g., PV panels) to be mounted on roofs. In an aspect, the SPARM system  10  is configured to be used on residential sloped roofs which have rafters  25  spaced at regular intervals. However, the SPARM system  10  can be utilized in other settings that have regularly spaced support portions similar to structural rafters. In an aspect, the SPARM system  10  can include multiple short rails  100  and L-foot connectors  200 ,  1200 ,  2200 , and  3000  as shown in  FIGS. 7-10, 11-12, 13-16, and 17-24  respectively. 
     In an aspect, the rails  100  and the L-foot connectors  200  can be formed from materials that can withstand exposure to environmental elements while meeting the standards of the solar panel industry. Such standards include, but are not limited to, UL 2703 and UL 1703. For example, the short rail  100  and L-foot connectors  200  can be made from, but not limited to, metallic materials (e.g., aluminum, stainless steel, and the like), polymer materials (e.g., plastics and the like), and other materials. In an exemplary aspect, the short rails  100  and L-foot connector  200  are made from aluminums including, but not limited to, AL 6061-T6, 6063-T66, 6005A-T5, 6006A-T61, 6082A-T6 or the equivalent. However, in an aspect, the short rail  100  can include a coating or an anodization. 
     In an aspect, the short rails  100  of the SPARM  10  are configured to have the same characteristics of regular rails, shared and dual, used in PV mounting systems, but without having the same traditional length found in rails (e.g., anywhere between 14 to 20 feet in length). In an aspect, the short rails  100  have a length  110  (See  FIG. 10 ) that is equal to the span-length. In an aspect, span is the distance between attachments to the roof, which is dictated in part by the distance between rafters. The span can be dictated based upon requirements of the SPARM  10  and the spacing between rafters  25 . For example, when the SPARM  10  is going to be in high wind or snow areas, the span is required to be shorter. Likewise, while rafters  25  are typically installed 2 feet apart, in some areas in heavy snow regions, the rafters  25  can be spaced sixteen inches apart from one another. Therefore, the span in California can be 6 feet, whereas in Utah the span can be 4 feet. 
     In an aspect, the span-length can equal six (6) feet, which translate to a length  110  of six (6) feet for the short rails  100  of the SPARM  10 . However, the span length can vary from roof to roof, as discussed above, so the length  110  of the short rails  100  corresponds to the span for various installations, depending on wind loads, snow loads, roof height, and the like. The span lengths will also match up with rafters  25  of the roof (i.e., the span extends over a repeatable number of rafters  25 , allowing the L-foot connectors  200  a secured mounting location). In an aspect, the rails  100  can include various apertures (not shown) that are used to receive fastening devices to be connected to the L-foot connectors  200 . In an aspect, the short rails  100  allow the SPARM  10  to be set up as a dual rail system or a shared rail system. 
     The L-foot connectors  200  of the SPARM  10  are used to mount the short rails  100  to one another as well as to the roof  20 . In an aspect, the L-foot connectors  200  can take the form of a splice foot connector  200  ( FIGS. 7-8 ) that splices (i.e., connect) the short rails  100  to one another as well. In an aspect, the L-foot connectors  200  include a roof mount component  210  and a rail mount component  250 , as shown in  FIGS. 7-8 . The roof mount component  210  of the splice foot connector  200  can take various forms in other embodiments of splice foot mounts  200 , as discussed below. In all aspects, the roof mount component  210  is configured to mount the spice foot connector  200  to the roof or support surface on which the rails are to be mounted. Similarly, the rail mount component  250  of the splice foot connector  200  can take various forms, but will provide a component on which to mount one or two rails together, as discussed in more detail below. 
     In an aspect, the roof mount component  210  includes a base portion  220  that is connected to a vertical portion  230 . The base portion  220  can include a flange  222  with at least one aperture  224  configured to receive a fastener  226 . The fastener  226  can be inserted into the aperture  224  to secure the L-foot connector  200  to the roof at a rafter/joist  25 . In an aspect, flashing  30  can be placed between the L-foot connectors  200  and the roof. By placing the L-foot connector  200  at a rafter  25 , it does not need to be structural, since the rafter  25  is directly underneath to provide support. 
     In an aspect, the base portion  220  and a vertical portion  230  are connected to one another to form the L-foot shape, with the two components  220 ,  230  forming a right angle. In an aspect, the vertical portion  230  can include a T-portion  240 . The T-portion  240  can include a channel  242  that includes flanges  244  extending over the channel  242 . The combination of the flanges  244  and the channel  242  can adjustably retain a fastener used to attach the rail mount component  250 . 
     In an aspect, the rail mount component  250  includes a horizontal portion  260  and a vertical portion  270  that meet to form an L-shape. In, an aspect, the horizontal portion  260  includes at least one aperture  262  configured to receive a fastener  264  which is used to adjustably secure the rail mount component  250  to the T-portion  240  of the roof mount component  210  of the L-foot mount  200 . The fastener  264  can include a nut  266  and a bolt  268 , with the head of the bolt  268  configured to be adjustably received within the channel  242  of the T-portion  240  of the roof mount  210 , with the flanges  244  retaining the head of the bolt  268  in the channel  242 . 
     In an aspect, the vertical portion  270  of the rail mount component  250  includes two apertures  272 ,  274 . In an aspect, the apertures  272 ,  274  are configured to receive fasteners  280  to connect ends of different short rails  100  to the rail mount component  250 . In an aspect, the apertures  272 ,  274  can be configured to allow the fasteners  280 , and the rail  100 , to be adjusted in a vertical direction. Similar to the fastener  264  connecting the T-portion  240  of the roof mount component  210  to the horizontal portion  260  of the rail mount component  250 , the fasteners  280  can include a combination of bolts  282  and nuts  284 . In addition, washers can be used with the fasteners  264 ,  280 . 
       FIGS. 9-10  illustrate the SPARM  10  when utilizing the L-foot connector  200  of  FIGS. 7-8 . As shown, the short rails  100  have a span length  110  and are connected to the L-foot connectors  200  at the rafter locations  25 . PV modules  300  can be mounted on the rails  100 . 
       FIG. 11  illustrates a structural splice L-foot connector  1200  according to an aspect of the present invention. In an aspect, the structural splice L-foot connector  1200  comprises an L-foot mount  1210  and a structural splice  1250 . A structural splice  1250  is strong and stiff enough so that when it is used to join two sections of rail  1100 , the joined rails  1100  have the same or better mechanical characteristics as an un-spliced rail, and roof connections are not increased due to the splice  1250 . In an aspect, the L-foot mount  1210  includes a roof portion  1212  with an aperture  1214  configured to receive a fastener (not shown) for mounting the L-foot mount  1210  to the roof. A vertical portion  1220  can extend from the roof portion  1212 . The vertical portion  1220  can include an aperture  1222  configured to adjustably receive a fastener  1260  to secure the structural splice  1250  (e.g., aperture has a length that allows height to be adjusted). A support member  1230  can extend from the vertical portion  1220 . The support member  1230  is configured to provide support for the structural splice  1250 . The structural splice  1250  can include apertures  1252  (two shown, but can include three) configured to secure the structural splice  1250  to the L-foot mount  1210  (i.e., through the aperture  1222  of the vertical portion  1220 ) with a fastener  1260  and fasteners (not shown) to secure ends of short rails  1100  to the structural splice  1250 . In an aspect, the structural L-foot connectors  1200  can be used in locations that do not coincide with rafters  25  on the roof. Such structure L-foot connectors  1200  can be used when the PV module extends beyond the end of a short rail  1100 , so additional cantilevered rail is needed.  FIG. 12  illustrates a SPARM  1010  utilizing the slice L-foot connector  1200  as discussed above. 
       FIGS. 13-15  illustrate a structural splice L-foot connector  2200  having an L-foot component  2210  and a structural splice  2250  that are configured not to be used with one another. In other words, the L-foot component  2210  is configured to engage only with the rails  100  and not the structural splice  2250 . In an aspect, the L-foot component  2210  and the structural splice  2250  have similar elements as the L-foot component  1210  and the structural splice  1250  of the structural splice L-foot connector  1100  discussed above. That is, the L-foot component  1210  has a roof portion  2212  with an aperture  2214 , a vertical portion  2220  with an aperture  2222  configured to adjustably receive a fastener, and a support member  2230 . Further the structural splice  2250  includes apertures  2252 . However, in an aspect, the structural splice  2250  is configured to be connected only to ends of short rails  100 , and not the L-foot component  2210 . In such cases, the structural splice  2250  can be configured to only have enough apertures  2252  to connect to the rails  100 , and not the L-foot component (i.e., having two apertures v. three apertures).  FIG. 15  illustrates a SPARM  2010  utilizing the separate structural splice  2250  and L-foot component  2110 . 
     In an aspect, a SPARM can utilize a combination of the L-foot connectors  200 ,  1200 ,  2200  discussed above. For example,  FIG. 16  illustrates a SPARM utilizing the L-foot connector  200  of  FIGS. 7-8  with the L-foot connector  1200  of  FIG. 11 . 
     As discussed previously, the L-foot connectors of the present invention can include splice foot connectors. The splice foot mount functions as a roof mount, or part of a roof mount when installed to other roof mounts (e.g., structural tile replacement ( FIG. 33 ), tile hook ( FIG. 34 ), standing seam clamp ( FIGS. 35-36 ) or hanger bolt ( FIG. 37 )), and a rail connector ( FIGS. 28-28A ). The splice foot connectors  3000  are used to secure rails, which can be used for solar panel arrays, on a surface. In an aspect, the splice foot connector is configured for a singular rail mount and a dual rail mount (i.e., when two rails are mounted in a continuous line) or when continuing in a certain angle (e.g., two related parallel roof surfaces in an angle to each other, such as in a roof valley). In the dual rail instance, the use of the splice foot connector eliminates the need for a separate splice. These and other features are discussed below. 
     The splice foot mount  3000  is used on various roofs and structures. For example, the splice foot mount  3000  can be mounted on various roof types, including, but not limited to, slanted, flat, and the like. Similarly, the splice foot mount  3000  can be utilized with various roof coverings, including, but not limited to, composition shingles, tiles, slate, tar paper, saturated felt paper, and the like. In addition, the splice foot mount can be mounted to structural components, including, but not limited to, a roof substrate, any bitumen or asphalt-based roof substrate, any synthetic roof substrate surface (e.g., roof membranes made from polymeric or elastomeric materials), sheet metal surfaces such a various mounted to a surface, including, but not limited to, a roof, substrate, a structural component on a roof, or some other structural component. Along the same lines, the splice foot mount is configured to be mounted to roofs with various coverings, including composition shingles, tiles, standing seam roofs, trapezoidal or corrugated sheet metal, or natural or artificial slate. 
     In some embodiments, the splice foot mount is configured to be attached on top of other structural components attached to the roof surface or to the roof structure. Such structural components include, but are not limited to, tile hooks, structural tile replacements, hanger bolts, clamps for standing seams, or the like. A butyl pad can be placed between the roof mount component of the splice foot connector and the mounting surface. A gasket or any rubber or similar sealant can be placed between the roof mount surface and any other structural component. 
     As discussed above, the splice foot connector  3000 , as shown in  FIGS. 17-39 , includes two main components—a roof mount component  3010  and a rail mount component  3050 . In an aspect, the roof mount component  3010  extends in a substantially horizontal plane and the rail mount component  3050  extends in a substantially vertical plane from the roof mount component  3010 . In an aspect, the rail mount component  3050  intersects the roof mount component  3010  to form a substantially ninety-degree angle with one another. 
     The roof mount component  3010  includes a top surface  3012  and a bottom surface  3014 . In an aspect, the roof mount component  3010  includes a base member  3020  with edges  3022 ,  3024  and flange members  3030 ,  3032  that extend outward from the edges  3022 ,  3024  of the base member  3020 . In such aspects, the flange members  3030 ,  3032  extend in equal lengths from the base member  3020  to provide rigidity and higher resistance against uplift forces. In an aspect, the base member  3020  is thicker than the flange members  3030 ,  3032  to provide rigidity and higher resistance against shear forces along the roof slope. 
     The flange members  3030 ,  3032  include apertures  3040 . The apertures  3040  are configured to receive roof fastening devices  3070  to allow mounting to a roof or other structure. In an aspect, the apertures  3040  are substantially circular, and are sized to receive a roof fastening device  3070  with minimum clearance distance in order to ensure a secure mounting. 
     In an aspect, when the splice foot connector  3000  is mounted to a composition shingle roof (see  FIGS. 18-27 ), or other structure with a substrate, the fastening devices  3070  can include lag screws. In some instances of this aspect, the lag screws  3070  utilize a washer positioned between the head of the lag screw and the top surface  3012  of the roof mount component  3010  to prevent water intrusion. In other instances, the lag screws  3070  include a built-in multi-component flange that includes metal and rubber portions, and functions the same way as the washer member discussed. In other aspects, a butyl pad  3090  (as shown in  FIG. 25 ) can be placed between the bottom surface  3014  of the roof mount member  3010  and the roof/support structure to prevent water intrusion when the splice foot connector  3000  is mounted. The primary purpose of the butyl pad is to prevent water intrusion. In some aspects, the mount is also big enough to cover a pilot hole that misses its intended mark (e.g., rafter). 
     In an aspect, the splice foot connector  3000  can include a single aperture  3040  on each flange member  3030 ,  3032 , as shown in  FIGS. 25-27 . Such splice foot connectors  3000  are utilized when it is possible to attach the splice foot connector  3000  to a rafter or other structural member of the roof structure. In other aspects, the flange members  3030 ,  3032  can include three apertures  3040 , as shown in  FIGS. 17-24 . The apertures  3040  can receive various fasteners, including, but not limited to, lag screws, bolts, tapping screws, and the like. Such an arrangement of three apertures  3040  allows the splice foot connector  3000  to be mounted to roof structures at various locations, based upon the length of the rails. In other words, the three aperture  3040  configuration as shown in  FIGS. 17-24  allows for the splice foot connector  3000  to be attached at a rafter of a roof in three different arrangements—at an outside aperture  3040  (see  FIG. 22 ), the middle aperture  3040  ( FIG. 21 ), and at the other outside aperture  3040  (similar to  FIG. 21 , but opposite aperture  3040 ). Further, the three aperture  3040  arrangement of the splice foot connector  3000  allows for mounting on roofs between rafters, as shown in  FIGS. 18-20 . By having six total apertures  3040 , and hence six fasteners, the splice foot connector  3000  is able to be securely attached. Multiple apertures  3040  on each flange member  3020 ,  3022  allow for various arrangements of the splice foot connector  3000  on a roof, allowing for adjustable mounting of rails. 
     As discussed above, the rail mount component  3050  of the splice foot connector  3000  extends vertically upward from the top surface  3012  of the roof mount component  3010 , as shown in  FIGS. 17-39 . The rail mount component  3050  includes a bottom edge  3052  and a top edge  3054 , with the bottom edge  3052  connected to the roof mount component  3010 . In an exemplary aspect, the bottom edge  3052  is integrally formed (e.g., extrusion forming) with the roof mount component  3010 . While the rail mount component  3050  can be attached/connected to the roof mount component  3010  through various means, including adhesives and welding, an integrated formation provides some structural integrity. In such aspects, the rail mount component  3050  extends upwardly from the base member  3020  of the roof mount component. In some instances of these aspects, the rail mount component  3050  can extend upwardly from one of the edges  3022 ,  3024  of the base member  3020 , which applies uplift loads from the rail symmetrically to the two rows of fasteners in the base member  3020 . In other instances, the rail mount component  3050  extends from the middle of the base member  3020 . 
     In an aspect, the rail mount component  3050  includes two apertures  3060 ,  3062  configured to receive rail securing fasteners  3080 , as shown in  FIGS. 28A and 29 . By having two apertures  3060 ,  3062 , the splice foot connector  3000  can be utilized as a mount for a single rail or as a mount for two rails, as shown in  FIG. 28 . In an aspect, the apertures  3060 ,  3062  are oriented in a substantially parallel fashion with one another. In an aspect, the apertures  3060 ,  3062  are spaced apart from one enough so that in a dual rail implementation, the apertures  3060 ,  3062  allow the connection of two rail ends at the splice foot connector  3000  without overlap of the rails. In an aspect, the apertures  3060 ,  3062  are elongated, allowing for adjustment of the rail securing fasteners  3070  in a vertical direction within the apertures  3060 ,  3062 . By providing elongated apertures  3060 ,  3062 , the height of the rail when mounted can be adjustable. Once the correct height is reached, the rail securing fasteners  3080  can be tightened to hold the rail in place, as shown in  FIGS. 28 and 28A . 
     The securing rail fasteners  3080  can take various forms and are highly dependent on the rail. For example, in rails having channels (see  FIG. 28 ), t-bolt fasteners  3080 , with nuts  3082 , can be utilized. In rails that have apertures, a nut and bolt fastener can be utilized. In aspects in which rails do not have channels or apertures, tapping screws can be used to go through the wall of the rail. 
     In an aspect, the splice foot connector  3000  can include a cover  3100 , as shown in  FIGS. 30-32 . The cover  3100  can be configured to fit over the splice foot connector  3000 . In such aspects, the cover  3100  includes a top surface  3102 , a bottom surface  3104 , a raised middle portion  3110 , a flange portion  3120 , and a slit  3130 . The slit  3130  is shaped to substantially match the shape of the rail mount component  3050  so the cover  3100  can be slid over the rail mount component  3050  of the splice foot connector  3000 . 
     In an aspect, the dimensions of the raised middle portion  3120  of the cover  3100  substantially match those of the roof mounting component  3010  of the splice foot connector  3000 . The arrangement of the raised middle portion  3120  and the flange portion  3130  creates a pocket  3140  on the bottom surface  3104  of the cover  3100  to allow space to receive the roof mounting component  3010  and the fasteners  3070  used to secure the splice foot connector  3000  to the support structure/roof. The cover  3100  can be adhered (e.g., self-adhesive) or welded. In some aspects, the cover  3100  is flexible and therefor can be formed over the raised middle section. Further, the cover  3100  will be a piece of the original roof cover and attached to the roof the same way the pieces of roof covering are attached to each other in most cases welded. 
     As discussed above, the splice foot connector  3000  can be mounted on a variety of different roof types and support structures.  FIG. 33  illustrates the slice foot connector  3000  mounted on a tile replacement  4000 , as shown in the art. As shown, the splice foot connector  3000  is connected via fasteners  3070  through apertures  3040  on the roof mount component  3010 . In such aspects, one aperture  3040   b  on each flange member  3030 ,  3032  is secured via the fasteners  3070 , which are received in corresponding apertures (not shown) in the tile replacement  4000 . 
     The splice foot connector  3000  can also be used on tile roofs without a replacement, but using a tile hook  5000 , as shown in  FIG. 34 . As shown, a fastener  3070  can be inserted into an aperture  3040  of the roof mount component  3010  to secure the splice foot connector  3000  to the tile hook  5000 . 
     The splice foot connector  3000  can also be mounted on standing seam roofs, as shown in  FIGS. 35-36 . In such aspects, the splice foot connector  3000 , via the roof mount component  3010 , is mounted to a standing seam clamp  6000  via fasteners into apertures or into a channel in the top flange of the clamp. Similarly, the splice foot connector  3000  can be mounted to a corrugated fiber cement surface through the use of a hanger bolt/solar fastener  7000 , as shown in  FIG. 37 . In addition, the splice foot connector  3000  can be mounted to a trapezoidal structural skin/sheet metal  8000  in a similar manner used to a composition shingle roof. In this case, self-tapping screws, thread forming screws, or thin sheet screws are used as fasteners, as shown in  FIGS. 38-39 . 
     The splice foot connector does not require metal flashing for it to function (though this is an optional product we will offer). The splice foot connector eliminates the need to pry up shingles and risk damaging them. Further, the splice foot connector prevents the need to pry up roof nails to install a metal flashing. Further, the splice foot connector eliminates the need for a traditional rail connector, as the splice foot connector connects rails. The splice foot connector can be use with the deck attached option (see  FIGS. 18-20 ) to deal with “abnormal” rafter spacing. Sometimes on hipped roofs the rafter will switch from vertical orientation to horizontal. The deck-attached capabilities allow you to install without needing to go into the attic and install an additional support member. On sheet metal roofs the splice foot can be attached to the roof surface directly by screws to the sheet metal surface if the sheet metal is regarded as a structural skin. Or the splice foot is attached to the structure underneath the sheet metal skin e.g., by a hanger bolt. 
     In an aspect, the splice foot connector  9000  may be constructed for larger solar mounts, as depicted in  FIGS. 40-41 and 42A -B. The splice foot connectors  9000  are used to secure rails, which can be used for solar panel arrays, on a surface. In an aspect, the splice foot connector is configured for a singular rail mount and a dual rail mount (i.e., when two rails are mounted in a continuous line) or when continuing in a certain angle (e.g., two related parallel roof surfaces in an angle to each other, such as in a roof valley). In the dual rail instance, the use of the splice foot connector eliminates the need for a separate splice. These and other features are discussed below. 
     As discussed above, the splice foot XL connector  9000  includes two main components—a roof mount component  9010  and a rail mount component  9050 . In an aspect, the roof mount component  9010  extends in a substantially horizontal plane and the rail mount component  9050  extends in a substantially vertical plane from the roof mount component  9010 . In an aspect, the rail mount component  9050  intersects the roof mount component  9010  to form a substantially ninety-degree angle with one another. 
     The roof mount component  9010  includes a top surface  9012  and a bottom surface  9014 . In an aspect, the roof mount component  9010  includes a raised base member  9020  with edges  9022 ,  9024  and flange members  9030 ,  9032  that extend outward from the edges  9022 ,  9024  of the base member  9020 . In such aspects, the flange members  9030 ,  9032  extend in equal lengths from the base member  9020  to provide rigidity and higher resistance against uplift forces. The raised base member  9020  functions as a horizontal support for rails  9100 , similar to the support  2230  of the structural splice L-foot connector  2200 , as shown in  FIG. 13 . In such aspects, the raised base member  9020  is configured to form a hollow interior/channel  9026  running the length of the roof mount component  9010 . In such an aspect, the hollow interior  9026  provides strength and rigidity to the roof mount component  9010  in an economic way by adding less material, and therefore less weight. In an aspect, the base member  9020  is thicker than the flange members  9030 ,  9032  to provide rigidity and higher resistance against shear forces along the roof slope. The flange members  9030 ,  9032  include apertures  9040 . The apertures  9040  are configured to receive roof fastening devices  9070  to allow mounting to a roof or other structure. In an aspect, the apertures  9040  are substantially circular, and are sized to receive a roof fastening device  9070  with minimum clearance distance in order to ensure a secure mounting. 
     In some embodiments, the splice foot mount is configured to be attached on top of other structural components attached to the roof surface or to the roof structure. Such structural components include, but are not limited to, tile hooks, structural tile replacements, hanger bolts, clamps for standing seams, or the like. A butyl pad  9090  can be placed between the roof mount component  9010  of the splice foot connector  9000  and the mounting surface, as shown in  FIG. 40 . A gasket or any rubber or similar sealant can be placed between the roof mount surface and any other structural component. 
     In an aspect, when the splice foot XL connector  9000  is mounted to a composition shingle roof (see  FIGS. 40-41 ), or other structure with a substrate, the fastening devices  9070  can include lag screws. In some instances of this aspect, the lag screws  9070  utilize a washer positioned between the head of the lag screw and the top surface  9012  of the roof mount component  9010  to prevent water intrusion. In other instances, the lag screws  9070  include a built-in multi-component flange that includes metal and rubber portions, and functions the same way as the washer member discussed. In other aspects, a butyl pad  9090  (as shown in  FIG. 40 ) can be placed between the bottom surface  9014  of the roof mount member  9010  and the roof/support structure to prevent water intrusion when the splice foot connector  9000  is mounted. The primary purpose of the butyl pad is to prevent water intrusion. In some aspects, the mount is also big enough to cover a pilot hole that misses its intended mark (e.g., rafter). 
     In an aspect, the splice foot XL connector  9000  can include one, two, or three aperture(s)  9040  on each flange member  9030 ,  9032 , as shown in  FIGS. 40-41 . Such splice foot XL connectors  9000  are utilized when it is possible to attach the splice foot connector  9000  to a rafter or other structural member of the roof structure. In other aspects, the flange members  9030 ,  9032  can include three apertures  9040 ( a - c ), as shown in  FIG. 40 . The apertures  9040  can receive various fasteners, including, but not limited to, lag screws, bolts, tapping screws, and the like. Such an arrangement of three apertures  9040  allows the splice foot XL connector  9000  to be mounted to roof structures at various locations, based upon the length of the rails. In other words, the three aperture  9040  configuration as shown in  FIG. 40  allows for the splice foot XL connector  9000  to be attached at a rafter of a roof in three different arrangements—at an outside aperture  9040  (a or c), the middle aperture  9040 ( b ), and at the other outside aperture  9040 ( a  or  c ), similar to the mountings discussed above for the splice foot connector  3000  as shown in  FIGS. 21-22 . Further, the three aperture  9040  arrangement of the splice foot XL connector  9000  allows for mounting on roofs between rafters, similar to the arrangements discussed above for the splice foot connector  300  as shown in  FIGS. 18-20 . By having six total apertures  9040 , and hence six fasteners, the splice foot XL connector  9000  is able to be securely attached. Multiple apertures  9040  on each flange member  9020 ,  9022  allow for various arrangements of the splice foot connector  9000  on a roof, allowing for adjustable mounting of rails. 
     As discussed above, the rail mount component  9050  of the splice foot XL connector  9000  extends vertically upward from the top surface  9012  of the roof mount component  9010 , as shown in  FIGS. 40-42B . The rail mount component  9050  includes a bottom edge  9052  and a top edge  9054 , with the bottom edge  9052  connected to the roof mount component  9010 . In an exemplary aspect, the bottom edge  9052  is integrally formed (e.g., extrusion forming) with the roof mount component  9010 . While the rail mount component  9050  can be attached/connected to the roof mount component  9010  through various means, including adhesives and welding, an integrated formation provides some structural integrity. In such aspects, the rail mount component  9050  extends upwardly from the raised base member  9020  of the roof mount component. In some instances of these aspects, the rail mount component  9050  can extend upwardly from one of the edges  9022 ,  9024  of the raised base member  9020  (as shown in  FIG. 40 ), which applies uplift loads from the rail symmetrically to the two rows of fasteners in the base member  9020 . In other instances, the rail mount component  9050  extends from the middle of the base member  9020 . 
     In an aspect, the rail mount component  9050  includes two apertures  9060 ,  9062  configured to receive rail securing fasteners  9080 , as shown in  FIGS. 40-41 and 42A -B. By having two apertures  9060 ,  9062 , the splice foot XL connector  9000  can be utilized as a mount for a single rail  9100  or as a mount for two rails  9100 , as shown in  FIGS. 41-42B . In such aspects, utilizing the splice foot XL connector  9000  to mount a single rail  9100  can additionally be used when the PV module extends beyond the end of a short rail  9100 , so additional cantilevered rail is needed. In this aspect the raised base member  9020  acts as a horizontal support similar to the support  2230  of the structural splice L-foot connector  2200 , as shown in  FIG. 13 . In an aspect, the apertures  9060 ,  9062  are oriented in a substantially parallel fashion with one another. In an aspect, the apertures  9060 ,  9062  are spaced apart from one enough so that in a dual rail implementation, the apertures  9060 ,  9062  allow the connection of two rail ends at the splice foot XL connector  9000  without overlap of the rails. In an aspect, the apertures  9060 ,  9062  are elongated, allowing for adjustment of the rail securing fasteners  9070  in a vertical direction within the apertures  9060 ,  9062 . By providing elongated apertures  9060 ,  9062 , the height of the rail when mounted can be adjustable. Once the correct height is reached, the rail securing fasteners  9080  can be tightened to hold the rail in place, as shown in  FIGS. 42A-42B . 
     The securing rail fasteners  9080  can take various forms and are highly dependent on the rail. For example, in rails having channels (see  FIGS. 40-41 and 42A -B), t-bolt fasteners  9080 , with nuts  9082 , can be utilized. In rails that have apertures, a nut and bolt fastener can be utilized. In aspects in which rails do not have channels or apertures, tapping screws can be used to go through the wall of the rail. 
     Having thus described exemplary embodiments of the present invention, it should be noted by those skilled in the art that the disclosures are exemplary only and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Accordingly, the present invention is not limited to the specific embodiments as illustrated herein, but is only limited by the following claims.