Patent Publication Number: US-2023155540-A1

Title: Expandable splice for a solar power system

Description:
BACKGROUND 
     1. Technical Field 
     The present disclosure relates to an expandable splice for a support structure of a solar power system. More particularly, the present disclosure relates to an expandable splice including at least one beveled corner panel and configured to transition between a narrow configuration and an expanded configuration to reinforce the support structure of the solar power system. 
     2. Discussion of Related Art 
     Solar power has long been viewed as an important alternative energy source. To this end, substantial efforts and investments have been made to develop and improve upon solar energy collection technology. Of particular interest are residential-, industrial- and commercial-type applications in which relatively significant amounts of solar energy can be collected and utilized in supplementing or satisfying power needs. One way of implementing solar energy collection technology is by assembling an array of multiple solar modules. 
     Solar modules can employ solar panels made of silicon or other materials (e.g., III-V cells such as GaAs) to convert sunlight into electricity. Solar panels typically include a plurality of photovoltaic (PV) cells interconnected with wiring to one or more appropriate electrical components (e.g., switches, inverters, junction boxes, etc.). 
     Most solar power systems place an array of solar modules at a location where sunlight is readily present. This is especially true for residential, commercial, or industrial applications in which multiple solar modules are desirable for generating substantial amounts of energy. 
     In some arrangements, solar modules are placed side-by-side in an array. Each solar module can be mounted to a rail system further mounted onto a horizontal support structure which is secured to at least a ground-based support structure, such as a solar tracker pile, or a roof-based support structure, such a roof rail or mount. 
     When the array of solar modules is exposed to high winds or rapidly changing winds, the array of solar modules will transfer the wind forces into the rail system and the horizontal support structure, or torque tube. The forces on the structure due to wind can be intensified or concentrated at the connections, joints, and fasteners in the rail system and horizontal support structure potentially resulting in deflection, bending, or failure along a length of the support structure. Any such deflection or bending can cause the array to be less efficient due to lack of total alignment and/or the inability of the torque tube to properly pivot due to the distortion or bending. Additional support may be applied to the array of solar modules or the specific point of attachment, however such support does not necessarily distribute the load or strain sufficiently along a length of the torque tube to prevent distortion or bending. Thus, there remains a continuing need to provide a device configured to and a capable of distributing a load or strain along a length of a support structure of a solar power system or tracker and thereby prevent deflection, bending, or failure of the support structure when exposed to high wind loads. 
     SUMMARY 
     The present disclosure describes an expandable splice configured to reinforce a support structure, such as a torque tube, of a solar power system. The expandable splice is configured to transition between a narrow configuration, which is designed to be easily inserted into a support channel of a support structure of a solar power system, and an expanded configuration, which is designed to provide additional strength to the support structure to prevent warping or bowing of the support structure when exposed to the elements of nature, such as high wind, snow, hail, lightning, etc. The expandable splice includes at least one beveled corner panel. The expandable splice, in the narrow configuration, includes at least one side panel including two points of transition wherein the side panel is bent in at least two places. 
     In some embodiments, the expandable splice described herein includes a top panel, a bottom panel, a first side panel, a second side panel, and at least one beveled corner panel. The first side panel may include a first converging panel attached to a first end of a first median panel and a first diverging panel attached to a second end of the first median panel. The first panel includes at least two points of transition or bend points wherein the first converging and diverging walls meet opposite ends of the first median panel. The second side panel may include a second converging panel attached to a first end of a second median panel and a second diverging panel attached to a second end of the second median panel. The second panel includes at least two points of transition or bend points wherein the second converging and diverging walls meet opposite ends of the second median panel. The first and second side panels may be connected to the top and bottom panels either directly or by the at least one beveled corner panel to form a splice channel therebetween. 
     The at least one beveled corner in the narrow configuration allows the expandable splice to more easily fit within a channel of the support structure or torque tube. The at least one beveled corner in the expanded configuration secures the side panel extending therefrom against a length of the inner surface of the support structure or torque tube thereby distributing any future load or strain along a length of the support structure. 
     In some embodiments, the expandable splices include a plurality of beveled corner panels. In some embodiments, the expandable splices include two, three, or four beveled corner panels. 
     The splices described herein include at least one, if not more than one, beveled corner panel in both the narrow configuration and the expanded configuration. In some embodiments, the splices described herein include two, three, or four beveled corner panels in both the narrow configuration and the expanded configuration. In some embodiments, the number of beveled corner panels remains the same in both the narrow and expanded configurations of the splice. 
     The present disclosure further provides a solar power system, such as a solar tracker, including at least one of the expandable splices described herein. In some embodiments, the system may include at least one support structure, such as a torque tube, including a support channel and at least one expandable splice configured to be positioned within the support channel of the support structure. The expandable splice includes at least a top panel, a bottom, panel, a first and second side panels, and at least one beveled corner panel. In some embodiments, the splice is positioned within the support channel in a narrow configuration, wherein at least one, if not both, of the first and second side panels include a converging panel attached to a first end of a median panel and a diverging panel attached to a second end of the median panel. In some embodiments, the splice is positioned within the support channel in an expanded configuration, wherein at least one, if not both, of the first and second side panels are generally perpendicular to the top and bottom panels and at least one, if not both, of the first and second walls are attached to the top or bottom wall by a beveled corner panel. In some embodiments, the support structure is a torque tube of a solar tracker system. In some embodiments, the support structure is a beam, purlin, or rail of a solar power system. 
     The present disclosure further provides a kit for solar power system including at least one of the expandable splices described herein. The expandable splice including at least a top panel, a bottom, panel, a first and second side panels, and at least one beveled corner panel. In some embodiments, the splice may be in a narrow configuration, wherein at least one, if not both, of the first and second side panels include a converging panel attached to a first end of a median panel and a diverging panel attached to a second end of the median panel. In some embodiments, the kit may include at least one torque tube defining a tube channel and at least one expandable splice as described herein and configured to be positioned within the tube channel of the torque tube. In some embodiments, the kit may further include at least one solar module. In embodiments wherein the kit includes a support structure, the splice may be positioned with the support structure in either the narrow or expanded configuration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various aspects of the present disclosure are described hereinbelow with reference to the drawings, which are incorporated in and constitute a part of this specification, wherein: 
         FIG.  1 A  is a perspective view of an expandable splice in a narrow configuration as described in at least one embodiment herein; 
         FIG.  1 B  is a cross-sectional side view of the expandable splice of  FIG.  1 A  and as described in at least one embodiment herein; 
         FIGS.  2 A- 2 D  are cross-sectional side views of various expandable splice configurations as described in at least one embodiment herein; 
         FIG.  3 A  is a perspective view of a solar tracker suitable for incorporating the expandable splices provided herein as described in at least one embodiment herein; 
         FIG.  3 B  is a side view of the solar tracker of  FIG.  3 A , without the array of solar modules depicted, as described in at least one embodiment herein; 
         FIG.  3 C  is a perspective view of an expandable splice positioned within a support structure of the solar tracker of  FIGS.  3 A and  3 B  as described in at least one embodiment herein; 
         FIG.  4 A  is a cross-sectional side view of an expandable splice in a narrow configuration as described in at least one embodiment herein; 
         FIG.  4 B  is a cross-sectional side view of the expandable splice in  FIG.  4 A  in the expanded configuration as described in at least one embodiment herein; 
         FIG.  4 C  is a schematic cross-sectional side view of the expandable splice in  FIG.  4 A  as described in at least one embodiment herein; 
         FIG.  5    is a perspective view of an expandable splice as described in at least one embodiment herein; and 
         FIG.  6    is a side view of an expandable splice positioned within a tube as described in at least one embodiment herein. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure describes an expandable splice configured to reinforce a support structure, such as a torque tube, of a solar power system. The solar power system may be any type of solar power system, such as a roof-top solar power system, or a solar tracker system, and the like. In particular embodiments, the solar power system is a solar tracker system including at least one ground-based support structure, such as a pile, and an array of solar modules mounted and secured to the ground-based support structure and in particular a rail or torque tube extending generally perpendicular from the support structure (see  FIGS.  3 A- 3 C ). 
     The expandable splice is configured to transition between a narrow configuration (see  FIGS.  1 A- 2 D ) and an expanded configuration (see  FIG.  4 B ). In some embodiments, the expandable splice includes at least one beveled corner panel and at least one side panel including two or more transition points or bend points. 
     Turning now to  FIGS.  1 A and  1 B , the expandable splice  100  described herein includes a top panel  110 , a bottom panel  120 , a first side panel  130 , a second side panel  140 , and at least one beveled corner panel  150   a - d . The top and bottom panels  110 ,  120 , as shown and in some embodiments, may be generally planar and extend along a longitudinal axis (A) of the splice from a proximal end portion  110   a ,  120   a  to a distal end portion  110   b ,  120   b  and in a direction transverse to the longitudinal direction from a first side end portion  110   c ,  120   c  to a second side end portion  110   d ,  120   d . 
     The top panel  110 , bottom panel  120 , first side panel  130 , second side panel  140 , and at least one beveled corner panel  150   a - d  form a closed outer perimeter defining a splice channel  160  therebetween. The expandable splice  100  includes an outer surface  101  and inner surface  102 . The expandable splice  100  is depicted in  FIGS.  1 A and  1 B  in a narrow configuration wherein the expandable splice  100  displays a smaller cross-sectional area than the expanded configuration (see  FIG.  4 B ) and is designed to be slid into a support channel of support structure or torque tube of a solar power system prior to transitioning to the expanded configuration. 
     The first side panel  130  includes a first converging panel  131  attached to a first end  132   a  of a first median panel  132  and a first diverging panel  133  attached to a second end  132   b  of the first median panel  132 . The first panel  130  includes at least two transition points wherein the first converging panel  131  meets the first end  132   a  of the first median panel  132  and the first diverging panel  133  meets the second end  132   b  of the first median panel  132 . The transition points being configured and designed to be the location wherein the first side panel  130  will expand when the splice  100  transitions from the narrow configuration to the expanded configuration. In some embodiments, the transition points are also configured and designed to be the location wherein the first side panel  130  will constrict or retreat when the splice  100  transitions from the expanded configuration to the narrow configuration. 
     The second side panel  140  includes a second converging panel  141  attached to a first end  142   a  of a second median panel  142  and a second diverging panel  143  attached to a second end  142   b  of the second median panel  142 . The second side panel  140  includes at least two transition points wherein the second converging panel  141  meets the first end  142   a  of the second median panel  142  and the second diverging panel  143  meets the second end  142   b  of the second median panel  142 . The transition points of the second side panel being configured and designed to be the location wherein the second side panels will expand when the splice transitions from the narrow configuration to the expanded configuration. In some embodiments, the transition points are also configured and designed to constrict or retreat when the splice transitions from the expanded configuration to the narrow configuration. 
     The first and second median panels  132 ,  142  also include a plurality of splice holes  170  positioned intermittently along a length of the median panels  132 ,  142 . The splice holes  170  are configured to receive a fastener used to secure the splice  100  within the support structure or torque tube. A fastener will also draw the side panels  130 ,  140  of the splice  100  outwardly away from a center C of the splice channel  160 , towards at least one support side wall of the support structure. In some embodiments, the splice holes  170  are preloaded with the fastener, in the narrow configuration, prior to insertion into the support channel of the support structure. In some embodiments, the fastener is added to the splice hole  170  after insertion of the splice  100  into the support channel of the support structure. 
     As further depicted in  FIGS.  1 A and  1 B , the first and second side panels  130 ,  140  are each connected to the top and bottom panels  110 ,  120  by a beveled corner panel  150   a - d  to form a closed outer perimeter of the splice  100  with the channel  160  therebetween. A beveled corner panel is a generally planar wall panel which extends between one of the top or bottom panels of splice and one of the first or second side panels of the splice at an obtuse angle. In some embodiments, a first angle between the beveled corner panel and one of the top or bottom panels is an obtuse angle (a 1 , a 2 , a 3 , a 4 ). In some embodiments, a second angle between the beveled corner panel and one of the first or second side panels is an obtuse angle (b 1 , b 2 , b 3 , b 4 ). In some embodiments, both the first and second angles are obtuse angles. For example, in some embodiments, a beveled corner panel  150   a  may extend from the top panel  110  to the first side panel  130  creating an obtuse angle between the beveled corner panel  150   a  and at least one, if not both, the top panel  110  or the first side panel  130 , and particularly the first converging panel  131 . In another example, in some embodiments, a beveled corner panel  150   b  may extend from the top panel  110  to the second side panel  140  creating an obtuse angle between the beveled corner panel  150   b  and at least one, if not both, the top panel  110  or the second side panel  140 , and particularly the second converging panel  141 . In yet another example, in some embodiments, a beveled corner panel  150   c  may extend from the bottom panel  120  to the first side panel  130  creating an obtuse angle between the beveled corner panel  150   c  and at least one, if not both, the bottom panel  120  or the first side panel  130 , and particularly the first diverging panel  133 . In yet another example, in some embodiments, a beveled corner panel  150   d  may extend from the bottom panel  120  to the second side panel  140  creating an obtuse angle between the beveled corner panel  150   d  and at least one, if not both, the bottom panel  120  or the second side panel  140 , and particularly the second diverging panel  143 . 
     In  FIGS.  1 A and  1 B , in some embodiments, the splice  100  includes a first top beveled corner panel  150   a , a first bottom beveled corner panel  150   b , a second top beveled corner panel  150   b , and a second bottom beveled corner panel  150   d . The first top beveled corner panel  150   a  connects the top end  131   a  of the first converging panel  131  to the first side end portion  110   c  of the top panel  110 . The first bottom beveled corner panel  150   c  connects a bottom end  133   b  of the first diverging panel  133  to a first side end portion  120   c  of the bottom panel  120 . The second top beveled corner panel  150   b  connects the top end  141   a  of the second converging panel  141  to the second side end portion  110   d  of the top panel  110 . The second bottom beveled corner panel  150   d  connects a bottom end  143   b  of the second diverging panel  143  to a second side end portion  120   d  of the bottom panel  120 . 
     In some embodiments, the obtuse angle created between the beveled corner panel and the neighboring panel it connects to, i.e., the top, bottom or side panel, may range from about 95 to 170 degrees. In some embodiments, the obtuse angle created between the beveled corner panel and the neighboring panel it connects to may range from about  100  to 150 degrees. In some embodiments, the angle created between the beveled corner panel and the neighboring panel it connects to may range from about  120  to 140 degrees. 
     As depicted in  FIGS.  2 A- 2 D , the expandable splice  200   a ,  200   b ,  200   c ,  200   d  described herein may include one or more beveled corner panels  250   a - c . In some embodiments, the expandable splices include one, two, three, or four beveled corner panels. 
     As further depicted in  FIGS.  2 A- 2 D , the expandable splice  200   a ,  200   b ,  200   c ,  200   d  described herein include at least 8 vertices. In some embodiments, the expandable splice  200   b ,  200   c ,  200   d  described herein include at least 10 vertices. In some embodiments, the expandable splice  200   b  described herein include at least 12 vertices. 
     In still other embodiments, the expandable splice described herein includes 10-12 vertices. In some embodiments, the expandable splice described herein includes 12 vertices. 
     As illustrated in  FIG.  2 A , in some embodiments, the expandable splice  200   a  may include only one beveled corner panel  250   a  and only one side panel including two transition points  232   a ,  232   b . The splice  200   a  including 8 vertices. 
     In some embodiments, as illustrated in  FIGS.  2 B and  2 C , the expandable splice  200   b ,  200   c  may include only two beveled corner panels  250   a ,  250   b  and two side panels  230 ,  240 , each side panel including two transition points  232   a ,  232   b ,  242   a ,  242   b . In  FIG.  2 B , the expandable splice  200   b  includes a first and second beveled corner panel  250   a ,  250   b  positioned on opposite ends, i.e., one attached to the top panel  210  and one attached to the bottom panel  220 , and opposite sides, i.e., on different first and second side panels  230 ,  240 . In  FIG.  2 C , the expandable splice  200   c  includes a first and second beveled corner panel  250   a ,  250   b  positioned on the same end, i.e., both attached to the bottom panel  220 .  FIG.  2 D  depicts an expandable splice  200   d  including first, second and third beveled corner panels  250   a ,  250   b ,  250   c , and two side panels including at least two points of transition  232   a ,  232   b ,  242   a ,  242   b . The splices  200   b ,  200   c ,  200   c  including 10-12 vertices. 
     Turning to  FIGS.  3 A- 3 B , which depict a solar power system  310 , such as a solar power tracker, including a plurality of solar modules  314  positioned on a plurality of rails  312  extending from a plurality of generally horizontal support structures  312 , i.e., torque tubes. The support structures or torque tubes supported vertically by ground posts  316  which extend vertically from the ground or a base near the ground. 
     As shown in  FIG.  3 C , the expandable splice  300  described herein is configured to be inserted within a support channel of the support structure or torque tube  312  to add strength to the support structure  312  to prevent deflection or warping of the support structure  312 . In  FIG.  3 C , an expandable splice  300  is shown in a narrow configuration and inserted within a support channel of a first torque tube  312   a  and a second torque tube  312   b  (a portion of the second torque tube  312   b  neighboring the first torque tube  312   a  is removed from the figure to allow better access to the expandable splice  300  positioned therein). The splice  300  includes four beveled corner panels 350a-d in the narrow configuration and the splice holes  370  are aligned with the support holes  375  of the torque tubes  312   a ,  312   b  such that a fastener (not shown) can be passed through the support holes  375  and received within the splice holes  370  to secure the splice  300  into a fixed position relative to the torque tubes  312   a ,  312   b . As shown, the torque tubes  312   a ,  312   b  are each generally rectangular including a top support wall  381 , bottom support wall  382 , and two side support walls  383 ,  384  all connected to form a closed outer perimeter. The top and bottom support walls  381 ,  382  being generally parallel to each other and generally perpendicular to the first and second side support walls  381 ,  382  extending therebetween. Other geometric configurations of the torque tube can also be used. 
     In  FIGS.  4 A- 4 C , the expandable splice  400  includes splice holes  470  which are threaded to receive a threaded fastener  495 , such as a screw or bolt. In some embodiments, the hole is simply threaded through the thickness of the sidewall. In some embodiments, the thickness of the sidewall may be increased around the splice hole to accommodate a threaded weld nut or threaded rivet nut configured to receive the fastener. In still other embodiments, the splice hole may be formed by thermal drilling through the splice wall which creates a threaded hole with increased thickness of the wall without having to add or secure the additional material at or around the opening. 
     In some embodiments, the splice holes are not threaded, and the fastener is simply positioned through the splice hole and secured to a nut positioned on an end thereof, the nut being positioned inside the splice channel of the splice. 
     As depicted, in some embodiments, a fastener  495  is passed through the first and second side support walls  483 ,  484 , via support hole  475  and received within threaded splice hole  470 . As the fastener  495  is rotated or tightened, the fastener  495  draws the threaded splice hole  470  away from a center C of the splice channel  426  and towards the inner side  492  of the toque tube  412 . The movement outwardly away from the center C of the splice channel  426  occurs smoothly due to the at least two transition points  232   a ,  232   b ,  242   a ,  242   b  positioned on either side of the splice hole  470 . This transition is complete when the first and second side panels  430 ,  440  are seated against and generally parallel to the first and second support side panels  483 ,  484  and the beveled corner panels  450   a - d  are secured in place. More particularly, in some embodiments, the beveled corner panels  450   a - d  each include a first and second opposite end  451   a ,  452   a ,  451   b ,  452   b ,  451   c ,  452   c ,  451   d ,  452   d , with a generally planar elongate body therebetween. In the expanded configuration, the first end  451   a ,  451   b ,  451   c ,  451   d , of the beveled corner panel  450   a - d  is positioned against one of the top or bottom support walls  481 ,  482  of the torque tube  412  and the second opposite end  452   a ,  452   b ,  452   c ,  452   d , of the beveled corner panel  450   a - d  is positioned abutting against one of the first or second support side walls  483 ,  484  of the torque tube  412 . The beveled corner panel  450   a - d  creates a space 492a-d between a corner of the support structure  412  and the splice  400 . The splice  400  in the expanded configuration does not alter the outer perimeter of the torque tube  412 . Thereby allowing the torque tube to have added strength without increasing in size. 
     As shown in  FIG.  4 C , as the fastener  495  is rotated or tightened, the fastener  495  draws the threaded splice hole  470  away from a center C of the splice channel  426  and towards the toque tube  412  (as indicated by the single arrows pointing towards each other) causing expansion of the splice  400  within the torque tube  412  which generates lines of contact pressure (as indicated by the groups of arrows) that are localized near the corners of the tube  412 . The lines of contact pressure localized near the corners of the torque tube  412  provide: the corner regions of the tube  412  with higher stiffness relative to the flat side walls of a typical closed section tube; more efficient load transfer between tubes via the stiffer regions (i.e. less chance for localized deflections under load); and/or corner regions of the tube that are more efficient at transfer of torsion and bending loads because the corners are the most distant areas from a centroid or neutral axis of the tube. (i.e., lower contact load due to maximum radius). Contact near, but not directly in the corners, is an approach that is more robust because it can accommodate manufacturing tolerances between the torque tubes. In embodiments, the magnitude of the contact pressure will be substantially uniform along the length of engagement reducing overall stresses while increasing joint stiffness compared to alternate designs. 
     Also shown in  FIG.  4 C  are alignment members  425  protruding from the splice  400  and through the top of the tube  412  to center the splice within the tube longitudinally along a length of the tube. 
     In some embodiments, as shown in  FIG.  1 A , an expandable splice  100  as provided herein may include a flat surface or flat edge on or near at least one of the proximal or distal ends  110   a ,  110   b . In some embodiments, as shown in  FIG.  5   , an expandable splice  500  as provided herein may include a curved surface or curved edge  511  on at least one of the proximal or distal ends (specifically shown for example on the proximal end  510   a  in  FIG.  5   ). The curved edge being on at least one of the top panel  510 , the bottom panel  520 , the first side panel  530 , the second side panel  540 . As depicted, the curved surface or edge  511  extends into the panel or wall longitudinally effectively carving out a portion of the panel or wall. The curved surface or edge  511  locally reduces the stiffness and reduces the stress concentration at the ends of the splice  500 . In some embodiments, the curved surface or edge is symmetrical around the perimeter of the end of the splice. In some embodiments, the curved surface or edge is asymmetrical around the perimeter of the end of the splice. 
     In some embodiments, as further shown in  FIG.  5   , expansion of the splice  500  inside the tube  512  generates an area of contact pressure  514  near the corners of the tube  512 , and particularly along a length of the top panel, bottom panel, and/or side panels of the tube  512 , on either side of each corner. 
     In  FIG.  6   , in some embodiments, the expandable splice  600  further include at least one alignment tab  625  protruding outwardly from at least one of the top or bottom non-folded surfaces  610 ,  620  of the splice  600 . The one or more alignment tabs  625  provide automatic longitudinal alignment within the torque tube. In some embodiments, a gap  630  exists between neighboring torque tubes  612   a ,  612   b  and the one or more alignment tabs  625  are configured to fit within, if not fill completely, the gap  630  between the neighboring torque tubes  612   a ,  612   b . During insertion, the expandable splice  600  may be inserted or slid longitudinally through a first tube  612   a  and into a neighboring second tube  612   b  wherein the one or more alignment tabs  625  will include a natural bias to fill the gap  630  between the two tubes as the one or more alignment members  625  exit the first tube  612   a  and before reaching the second tube  612   b . Once the alignment tabs  625  fills the gap  630 , the alignment members  625  may also prevent the splice  600  from being advanced or slid further longitudinally into either tube  612   a ,  612   b . The one or more alignment members  625  may also provide automatic alignment of the splice holes with the support holes  675  of the torque tubes  612   a ,  612   b . The one or more alignment members  625  also may indicate the proper placement of the splice  600 . In embodiments, the one or more alignment members may be centered on the expandable splice. In some embodiments, the one or more alignment members are at least two spaced apart alignment members. 
     The expandable splices provided herein are configured as one-piece structures. The splices can be made from any suitable process, including but not limited to, injection molding, compression molding, extrusion molding, thermoforming, sintering, lamination, die-casting, powder metallurgy, forging, stamping, and the like. The splices may be made from any suitable material including but not limited to hard plastics or metals, including polycarbonate, aluminum, steel, copper, and the like. 
     The support structures provided herein are configured as one-piece structures. The support structures can be made from any suitable process, including but not limited to, injection molding, compression molding, extrusion molding, thermoforming, sintering, lamination, die-casting, powder metallurgy, forging, stamping, and the like. The support structures may be made from any suitable material including but not limited to hard plastics or metals, including polycarbonate, aluminum, steel, copper, and the like. 
     In some embodiments, the splices described herein are configured to be thinner than the support structures. In some embodiments, the splices described herein are configured to be thicker than the support structures. In some embodiments, the splices described herein are configured to have the same thickness as the support structures. 
     In some embodiments, the splices described herein may be part of kit for a solar power system. Such kits may include at least one solar module, at least one support structure including a torque tube; and at least one expandable splice as described herein. In some embodiments, the expandable splice is configured to transition between a narrow configuration and an expanded configuration. In some embodiments, the kit includes an expandable splice including a top panel, a bottom panel, a first side panel including a first converging panel attached to a first end of a first median panel and a first diverging panel attached to a second end of the first median panel, the first panel including two bend points, and a second side panel including a second converging panel attached to a first end of a second median panel and a second diverging panel attached to a second end of the second median panel, the second panel including two bend points, wherein the first and second side panels are connected to the top and bottom panels either directly or by the at least one beveled corner panel to form a channel therebetween. 
     In some embodiments, the kit may include a plurality of framed solar modules, a plurality of support structures, and a plurality of the splices described herein. In addition, the kits described herein may further include additional components commonly associated with the assembly of the solar tracker including, but not limited to, motors, junction boxes, wiring, busbars, ribbons, glass covers, ground support structures, and the like. 
     It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as an exemplification of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure. Such modifications and variations are intended to come within the scope of the following claims.