Systems and Methods for Splicing Solar Panel Racks

Abstract

The invention provides systems and methods for splicing solar panel racks. Solar panel racks may include one, two, or more solar rack sections that may be connected to one another with an internal splice. The internal splice may internally support the adjoining solar racks. The solar rack may be secured to a support surface using one or more feet. The solar panel racks may be configured to support the weight of one or more solar modules. One or more solar module securing component may be used to secure the solar modules to a solar rack surface.

What is claimed is: 
     
         1 . A method for assembling a lightweight solar rack onto a roof structure for supporting one or more solar modules, the method comprising:
 sliding a portion of a hollow internal splice into a first cavity of a first solar rack end, such that a first length of the hollow internal splice is received within the first cavity, and a second length of the hollow internal splice extends from the first solar rack end, wherein the hollow internal splice is formed with a cross-sectional shape that is complementary to a cross-sectional shape of the first cavity, and wherein the first solar rack end includes a side groove and at least one of a top groove and bottom groove;   securing the hollow internal splice to the first solar rack section using at least one fastener;   sliding the second length of the hollow internal splice into a second cavity of a second solar rack end, whereby the second length of the hollow internal splice serves as a self-guiding member to linearly align the first solar rack end relative to the second solar rack end, wherein the cross-sectional shape of the hollow internal splice is complementary to a cross-sectional shape of the second cavity, and wherein the second solar rack end includes another side groove and at least one of another top groove or bottom groove that are linearly aligned with the side groove and the top groove or bottom groove of the first solar rack; and   securing the hollow internal splice to the second solar rack section using at least one of another fastener to provide the lightweight solar rack with an internally spliced end to end connection having a substantially smooth and uninterrupted external surface that may otherwise obstruct a network of footing attachments positioned at fixed structural locations which penetrate the roof structure to secure the lightweight solar rack and modules supported thereon to the roof structure.   
     
     
         2 . The method of  claim 1 , wherein the cross-sectional shape of at least one of the first and second cavities comprises an asymmetric shape. 
     
     
         3 . The method of  claim 1 , wherein the cross-sectional shape of the hollow internal splice comprises an asymmetric shape. 
     
     
         4 . The method of  claim 1 , wherein the hollow internal splice is formed by extrusion. 
     
     
         5 . The method of  claim 1 , wherein the first and second solar rack ends fit flush against each other when respectively secured to the hollow internal splice. 
     
     
         6 . The method of  claim 1 , further comprising:
 providing one or more rack anchors; and   securing the one or more rack anchors to at least one of the first and second solar rack ends using at least one fastener.   
     
     
         7 . The method of  claim 6 , wherein the one or more rack anchors are configured to adjustably elevate the at least one of the first and second solar rack ends at a selected height above a support surface. 
     
     
         8 . The method of  claim 6 , wherein securing the one or more rack anchors comprises inserting a portion of the at least one fastener into the side groove of the at least one of the first and solar rack ends. 
     
     
         9 . The method of  claim 1 , wherein the hollow internal splice is configured to be adjustably received within the first and second cavities, such that a ratio of the first and second lengths is approximately 1:1. 
     
     
         10 . The method of  claim 1 , wherein the plurality of solar racks are arranged in a linear configuration. 
     
     
         11 . The method of  claim 1 , wherein the plurality of solar racks are arranged in a curved, bent, or nonlinear configuration.