U.S. patent application number 12/794311 was filed with the patent office on 2011-12-08 for photovoltaic module connector assemblies having cable strain relief.
This patent application is currently assigned to TYCO ELECTRONICS CORPORATION. Invention is credited to MICHAEL J. SPICER, DAVID T. WILSON.
Application Number | 20110300741 12/794311 |
Document ID | / |
Family ID | 44650717 |
Filed Date | 2011-12-08 |
United States Patent
Application |
20110300741 |
Kind Code |
A1 |
SPICER; MICHAEL J. ; et
al. |
December 8, 2011 |
PHOTOVOLTAIC MODULE CONNECTOR ASSEMBLIES HAVING CABLE STRAIN
RELIEF
Abstract
An electrical connector assembly including a connector housing
having a plurality of sides that define an inner region of the
connector housing and include opposite loading and mating sides.
The connector housing has a cable channel located in the inner
region that extends between the loading and mating sides and a slot
oriented substantially transverse to the cable channel. The slot
extends through the cable channel. The connector assembly also
includes a conductive cable that is received in the cable channel
and extends along a central cable axis. The conductive cable has an
outer surface and is configured to electrically engage the PV
module. The connector assembly also includes a retaining member
that is inserted into the slot. The retaining member surrounds the
conductive cable about the cable axis and grips the outer surface
of the conductive cable.
Inventors: |
SPICER; MICHAEL J.;
(LANCASTER, PA) ; WILSON; DAVID T.; (JACOBUS,
PA) |
Assignee: |
TYCO ELECTRONICS
CORPORATION
BERWYN
PA
|
Family ID: |
44650717 |
Appl. No.: |
12/794311 |
Filed: |
June 4, 2010 |
Current U.S.
Class: |
439/460 |
Current CPC
Class: |
H02S 40/34 20141201;
H01R 13/5808 20130101 |
Class at
Publication: |
439/460 |
International
Class: |
H01R 13/58 20060101
H01R013/58 |
Claims
1. An electrical connector assembly configured to be coupled to a
photovoltaic (PV) module: a connector housing having a plurality of
housing sides and an inner region defined therebetween, the housing
sides including opposite loading and mating sides, the connector
housing having a cable channel located in the inner region that
extends between the loading and mating sides and a slot that is
oriented substantially transverse to the cable channel, the slot
extending through the cable channel; a conductive cable received in
the cable channel and extending along a central cable axis, the
conductive cable having an outer surface and being configured to
electrically engage the PV module; and a retaining member inserted
into the slot, the retaining member surrounding the conductive
cable about the cable axis and gripping the outer surface of the
conductive cable, the retaining member and the slot preventing the
conductive cable from being inadvertently moved with respect to the
connector housing in a direction along the cable axis.
2. The connector assembly in accordance with claim 1, wherein the
retaining member is configured to be inserted into the slot in a
mounting direction that is substantially orthogonal to the cable
axis.
3. The connector assembly in accordance with claim 1, wherein the
retaining member includes an annular portion that extends around
the cable axis and at least one grip element coupled to the annular
portion and projecting radially inward toward the conductive
cable.
4. The connector assembly in accordance with claim 1, wherein the
conductive cable includes an insulative jacket that includes the
outer surface of the conductive cable, the retaining member
piercing or compressing material of the insulative jacket when the
retaining member is inserted into the slot.
5. The connector assembly in accordance with claim 1, wherein the
connector housing includes an aperture that provides access to the
cable channel through the loading side, the conductive cable being
inserted into the cable channel through the aperture.
6. The connector assembly in accordance with claim 5, wherein the
connector housing comprises a single piece of insulative material,
the aperture being completely surrounded about the cable axis by
the insulative material.
7. The connector assembly in accordance with claim 5, wherein the
aperture is sized and shaped to receive a cable seal that surrounds
the conductive cable, the cable seal being compressed against the
outer surface to protect the inner region of the connector housing
from an ambient environment.
8. The connector assembly in accordance with claim 7, wherein the
connector housing includes a housing cap that holds the cable seal
within the aperture.
9. The connector assembly in accordance with claim 1, wherein the
slot includes first and second slot portions that extend radially
away from the cable channel in substantially opposite
directions.
10. The connector assembly in accordance with claim 1, wherein the
conductive cable is a pair of conductive cables and the retaining
member is a pair of retaining members.
11. The connector assembly in accordance with claim 1, wherein the
connector housing includes a mounting surface that extends between
the loading and mating sides, the cable channel opening to the
mounting surface.
12. The connector assembly in accordance with claim 11, further
comprising a cover coupled to the mounting surface, the cover
holding the conductive cable and the retaining member within the
cable channel and the slot, respectively.
13. An electrical connector assembly configured to be coupled to a
photovoltaic (PV) module, the connector assembly comprising: a
plurality of housing sides including opposite loading and mating
sides and a mounting surface extending therebetween; a cable
channel extending between the loading and mating sides along the
mounting surface, the cable channel being sized and shaped to
receive a conductive cable so that the conductive cable extends
along a cable axis when located within the cable channel; and a
slot sized and shaped to have a retaining member inserted therein,
the slot oriented substantially transverse to the cable channel so
that the retaining member extends substantially transverse to the
cable axis, the slot opening to the mounting surface so that the
retaining member is insertable into the slot in a mounting
direction that is orthogonal to the cable axis.
14. The connector assembly in accordance with claim 13 further
comprising a cover that is configured to be mounted to the mounting
surface and hold the conductive cable and the retaining member
within the cable channel and the slot, respectively, when mounted
to the mounting surface.
15. The connector assembly in accordance with claim 13 further
comprising an aperture that provides access to the cable channel
through the loading side, the conductive cable being insertable
into the cable channel through the aperture.
16. The connector assembly in accordance with claim 13 further
comprising a main body formed from a single piece of insulative
material that is shaped to include the housing sides, the cable
channel, and the slot.
17. The connector assembly in accordance with claim 13 further
comprising a housing cap configured to engage the conductive
cable.
18. The connector assembly in accordance with claim 13, wherein the
slot includes first and second slot portions that extend radially
away from the cable channel in substantially opposite
directions.
19. The connector assembly in accordance with claim 13, wherein the
cable channel includes a plurality of cable channels and the slot
includes a plurality of slots.
20. The connector assembly in accordance with claim 13 further
comprising the conductive cable and the retaining member.
Description
BACKGROUND OF THE INVENTION
[0001] The subject matter herein relates generally to electrical
connector assemblies, and more particularly, to electrical
connector assemblies configured to interconnect photovoltaic (PV)
modules to an energy delivery system.
[0002] Photovoltaic (PV) modules include PV cells that convert
light energy (e.g., solar energy) into electrical energy. Several
PV modules may be interconnected to each other in an array. For
example, a building roof or another type of support structure may
hold numerous PV modules arranged side-by-side and interconnected
to each other. The PV modules are generally electrically connected
to an energy system through corresponding electrical connector
assemblies. The electrical connector assemblies may be referred to
as junction boxes. A conventional junction box may include one or
more pairs of foil contacts that electrically engage a
corresponding PV module. The foil contacts are typically located
within a housing and are electrically connected to other connector
assemblies through conductive cables. The conductive cables are
electrically connected to the foil contacts within the housing and
extend through a wall or side to an exterior of the housing.
[0003] It is generally desirable to protect the foil contacts, the
conductive cables, and other internal components from unwanted
moisture or contaminants. During the assembly of some known
junction boxes, the conductive cables are inserted through holes in
a side of the junction box and into an interior of the junction
box. Once located in the junction box, barrels may be compressed or
crimped around corresponding conductive cables. The crimped barrels
effectively increase a diameter of the conductive cables and
prevent the conductive cables from being inadvertently withdrawn or
removed through the same holes of the junction box. However,
crimping barrels around conductive cables inside the junction box
may be costly and require additional steps for assembling the
junction box. In other junction boxes, it may be possible for
internal components, such as conductive cables, to be located
within the junction box through an over-molding process. For
example, the internal components may first be positioned in a
predetermined arrangement with respect to each other and then a
housing material may be molded around the internal components.
However, junction boxes constructed from the above over-molding
process may be susceptible to leaking because a material used in
the over-molding process and the composition of the conductive
cables may not properly bond together to prevent the leaking.
[0004] Accordingly, there is a need for alternative electrical
connector assemblies, such as junction boxes, that protect internal
components from unwanted moisture and contaminants. Furthermore,
there is a need for electrical connector assemblies that are
capable of being constructed in a more simple and/or cost-efficient
manner with respect to known electrical connector assemblies.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In one embodiment, an electrical connector assembly is
provided that is configured to have a photovoltaic (PV) module
mounted thereon. The connector assembly includes a connector
housing that has a plurality of sides that define an inner region
of the connector housing and include opposite loading and mating
sides. The connector housing has a cable channel located in the
inner region that extends between the loading and mating sides and
a slot oriented substantially transverse to the cable channel. The
slot extends through the cable channel. The connector assembly also
includes a conductive cable that is received in the cable channel
and extends along a central cable axis. The conductive cable has an
outer surface, and the conductive cable is configured to
electrically engage the PV module. The connector assembly also
includes a retaining member that is inserted into the slot. The
retaining member surrounds the conductive cable about the cable
axis and grips the outer surface of the conductive cable. The
retaining member prevents the conductive cable from being
inadvertently moved with respect to the connector housing in a
direction along the cable axis.
[0006] Optionally, the connector assemblies may include a plurality
of such conductive cables and retaining members. For example,
embodiments described herein may include one or more pairs of
conductive cables where each conductive cable is held within the
housing by one or more retaining members.
[0007] In another embodiment, an electrical connector assembly that
is configured to be mounted to a photovoltaic (PV) module is
provided. The connector assembly includes a plurality of housing
sides including opposite loading and mating sides and a mounting
surface that extends between the loading and mating sides. The
connector assembly also includes a cable channel that extends
between the loading and mating sides along the mounting surface.
The cable channel is sized and shaped to receive a conductive cable
so that the conductive cable extends along a cable axis when
located within the cable channel. The connector assembly also
includes a slot that is sized and shaped to have a retaining member
inserted therein. The slot is oriented substantially transverse to
the cable channel so that the retaining member extends
substantially transverse to the cable axis. The slot opens to the
mounting surface so that the retaining member is insertable into
the slot in a mounting direction that is orthogonal to the cable
axis. The connector assembly also includes a cover that is
configured to be mounted to the mounting surface. The cover holds
the conductive cable and the retaining member within the cable
channel and the slot, respectively, when mounted to the mounting
surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of an electrical connector
assembly formed in accordance with one embodiment.
[0009] FIG. 2A is a partially exploded view of the connector
assembly of FIG. 1.
[0010] FIG. 2B is an inverted view of the connector assembly shown
in FIG. 2A.
[0011] FIG. 3 is a perspective view of the connector assembly of
FIG. 1 illustrating internal components in greater detail.
[0012] FIG. 4A is a cross-section of the connector assembly of FIG.
1 illustrating a conductive cable held by a retaining member of the
connector assembly.
[0013] FIG. 4B is a cross-section of the connector assembly of FIG.
1 through a power recess of the connector assembly.
[0014] FIG. 5 illustrates the retaining member of FIG. 4A engaged
with the conductive cable.
[0015] FIG. 6 illustrates a retaining member formed in accordance
with another embodiment engaged with a conductive cable.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 1 is a perspective view of an electrical connector
assembly 100 formed in accordance with one embodiment. The
connector assembly 100 is oriented with respect to a longitudinal
axis 190, a lateral axis 191, and a mounting axis 192 that are
mutually perpendicular with respect to each other. The connector
assembly 100 includes a connector housing 102 that has a plurality
of housing sides 104-109. The housing sides 104-109 can include
opposite loading and mating sides 104 and 106, a mounting side 105,
a non-mounting side 107, and opposite walls sides 108 and 109. The
loading side 104 is located opposite to the mating side 106 and is
configured to receive one or more conductive cables 116A and 116B.
The mounting side 105, the non-mounting side 107, and the wall
sides 108 and 109 may extend parallel to the longitudinal axis 190
between the loading and mating sides 104 and 106.
[0017] In the illustrated embodiment, the connector housing 102 may
be assembled from separate components, including a main body 101, a
housing cap 120, a recess plug 306 (FIG. 2B), and a cover 130.
However, in alternative embodiments, one or more of the components
may be integrally formed (e.g., a single part may comprise the main
body 101 and the housing cap 120) or the entire connector housing
102 may be integrally formed (e.g., through an over-molding
process). As shown, the main body 101 may include the wall sides
108 and 109, the non-mounting side 107, and the mating side 106.
Furthermore, the housing cap 120 may include the loading side 104,
and the cover 130 may form a portion of the mounting side 105. Also
shown, the connector housing 102 may include an access window 110
through the non-mounting side 107 that provides access to a power
recess 112 having mating contacts 114A and 114B therein. The recess
plug 306 (FIG. 2B) may be inserted through the access window 110
and coupled to the main body 101. The mating contacts 114A and 114B
are electrically connected to the conductive cables 116A and 116B,
respectively.
[0018] In the exemplary embodiment, the connector assembly 100 is
configured to mate with a photovoltaic (PV) module (not shown)
along the mounting side 105. The PV module is configured to convert
light or solar energy into electric potential or current. When
mounted onto the mounting side 105, the PV module may electrically
connect with the mating contacts 114A and 114B in the power recess
112. Accordingly, in some embodiments, the connector assembly 100
may be referred to as a junction box. The electric potential or
current generated by the PV module is transmitted through the
connector assembly 100 and, more particularly, through the mating
contacts 114A and 114B and respective conductive cables 116A and
116B. Although the connector assembly 100 is shown in FIG. 1 as
including only two conductive cables 116A and 116B and respective
mating contacts 114A and 114B, the connector assembly 100 may
include only one or more than two conductive cables 116 and
respective mating contacts 114. For example, the connector assembly
100 may include one or more pairs of mating contacts 114 and one or
more corresponding pairs of conductive cables 116.
[0019] As described above, the connector housing 102 may be a
single piece of a material. For example, the connector housing 102
may be formed during a molding process where a resin or other
fluid-like material is injected into a mold. In the illustrated
embodiment, the connector housing 102 includes a plurality of
components that are coupled together to form the connector housing
102. Each of the separate components (e.g., the housing cap 120,
the main body 101, the cover 130, the recess plug 306) may comprise
a single piece of material or be constructed from multiple
parts.
[0020] As shown in FIG. 1, the housing cap 120 has the conductive
cables 116A and 116B extending therethrough. The housing cap 120 is
configured to be mounted to the loading side 104. However, in
alternative embodiments, the housing cap 120 may be integrally
formed with the connector housing 102 and include the loading side
104.
[0021] As shown in FIG. 1, the connector housing 102 has a length
L.sub.1, a width W.sub.1, and a height H.sub.1. The connector
housing 102 may have a low-profile such that a larger dimension of
the connector housing 102 (e.g., the length L.sub.1) may extend
along the longitudinal axis 190. A shorter dimension of the
connector housing 102 (e.g., the height H.sub.1) may extend along
the mounting axis 192. For example, the wall sides 108 and 109 may
extend along the height H.sub.1 and be sized to permit the
conductive cables 116A and 116B to be received within the connector
housing 102. The height H.sub.1 may be only slightly larger than an
outer diameter D.sub.1 (shown in FIG. 4A) of the conductive cables
116A and 116B as shown in FIG. 1. The non-mounting side 107 may
comprise a substantially planar surface. More specifically, the
non-mounting side 107 may have a smooth, continuous surface
throughout the non-mounting side 107, except for the access window
110 provided therethrough. When the PV module and the mounting side
105 of the connector assembly 100 are attached, the connector
assembly 100 is moved in a direction along the mounting axis 192
toward the PV module. In alternative embodiments, the PV module may
be moved in a direction along the mounting axis 192 toward the
mounting side 105.
[0022] FIG. 2A is a partially exploded view of the connector
assembly 100. The orientation of the connector assembly 100 in FIG.
2A is upside-down with respect to the orientation of the connector
assembly 100 in FIG. 1. As shown, the connector assembly 100 may
include a first cable connector 122 that is coupled to the
conductive cable 116A and a second cable connector 124 that is
coupled to the conductive cable 116B. The first cable connector 122
may be referred to as a male cable connector and may be configured
to communicatively engage a second cable connector of another
connector assembly, such as a connector assembly that is similar to
the connector assembly 100. The second cable connector 124 may be
referred to as a female cable connector and may be configured to
communicatively engage a first cable connector of another connector
assembly. The connector assembly 100 may be part of an array of
connector assemblies 100 that each electrically engage a
corresponding PV module. For example, an array of PV modules may be
mounted to a roof or other support structure. Each of the PV
modules may be electrically coupled to an energy storage or
delivery system through the corresponding connector assemblies
100.
[0023] As shown in FIG. 2A, the cover 130 may be configured to be
coupled or mounted to a mounting surface 138 of the main body 101.
The mounting surface 138 faces in a direction along the mounting
axis 192. The mounting surface 138 may form a platform or platforms
that surround at least a portion of an opening 132 to an inner
space or region 136 of the connector housing 102. When the cover
130 is mounted to the mounting surface 138, the inner region 136 is
enclosed by the main body 101 and the cover 130 and becomes an
interior 137 (shown in FIG. 4A) of the connector assembly 100. The
cover 130 may be secured to the mounting surface 138 (or the main
body 101) by one or more fastening techniques. For example, the
cover 130 may have a plurality of attachment openings 134 that form
an interference/snap fit with corresponding attachment posts 135 of
the main body 101. Alternatively or in addition to, the main body
101 may have an adhesive or sealant spread along the mounting
surface 138 to facilitate adhering the cover 130 to the mounting
surface 138. For example, the cover 130 may include sealant
channels 366 and 368 that also align with the sealant channels
along the mounting side 105 of the connector housing 102. The
sealant may flow into the sealant channels 366 and 368 when
applied. The sealant secures the connector assembly 100 to the
surface of the PV module and may also facilitate preventing
moisture or other unwanted materials from entering the connector
housing. When the cover 130 is coupled to the mounting surface 138,
a portion of the opening 132 becomes the access window 110 (FIG.
1).
[0024] The opening 132 of the main body 101 provides access to the
inner region 136 of the connector assembly 100. A portion of the
inner region 136 may become the power recess 112 (FIG. 1) after the
cover 130 is coupled to the main body 101. As shown, the main body
101 may have inner surfaces that are shaped to form one or more
features of the inner region 136 of the connector housing 102. For
example, the main body 101 may include cable channels 140A and 140B
in the inner region 136 that extend between the loading and mating
sides 104 and 106. The cable channels 140A and 140B may open in a
direction along the mounting axis 192 toward the cover 130. The
conductive cables 116A and 116B are configured to be received
within the cable channels 140A and 140B, respectively.
[0025] The connector assembly 100 may also include one or more
retaining members 150 and 152. In particular embodiments, the
retaining members 150 and 152 are configured to be inserted into
the main body 101 before the cover 130 is coupled over the inner
region 136 of the connector housing 102. For example, the retaining
members 150 and 152 may be received by the main body 101 when the
retaining members 150 and 152 are moved in a mounting direction M
that is parallel to the mounting axis 192 and inserted into the
main body 101. The retaining members 150 and 152 may be inserted
before the cover 130 is coupled to the mounting surface 138. The
retaining members 150 and 152 are configured to be held by the main
body 101 or the connector housing 102 and may couple to the
respective conductive cables 116A and 116B therein.
[0026] When the cover 130 is coupled to the main body 101, the
conductive cables 116A and 116B and retaining members 150 and 152
are enclosed within the interior 137 (FIG. 4A) of the connector
assembly 100. As such, the retaining members 150 and 152 may
prevent the conductive cables 116A and 116B from being
inadvertently withdrawn from the cable channels 140A and 140B
during the manufacture of the connector assembly 100 and/or during
operation and use of the connector assembly 100. More specifically,
the retaining members 150 and 152 may prevent movement of the
conductive cables 116A and 116B with respect to the connector
housing 102 or the main body 101 in a direction that is along the
longitudinal axis 190. As such, the retaining members 150 and 152
may facilitate providing cable strain relief for the connector
assembly 100.
[0027] Also shown in FIG. 2A, the connector assembly 100 may
include one or more cable seals 154 and 156 that surround
corresponding conductive cables 116A and 116B. The cable seals 154
and 156 are configured to be compressed around the conductive
cables 116A and 116B. The connector housing 102 may include seal
cavities 158 and 160 located proximate to the loading side 104 of
the connector housing 102. For example, the main body 101 may
include the seal cavities 158 and 160. The seal cavities 158 and
160 are sized and shaped to receive and hold the cable seals 154
and 156, respectively, therein. After the cable seals 154 and 156
are inserted into the respective seal cavities 158 and 160, the
housing cap 120 may be coupled to the main body 101. The housing
cap 120 and the main body 101 may be sized and shaped with respect
to each other to form an interference fit therewith.
[0028] FIG. 2B is an exploded perspective view of the connector
assembly 100 showing the non-mounting side 107. As shown, the cover
130 may include a pair of notches 302 and 304. The notches 302 and
304 may receive a portion of the retaining members 152 and 150 when
the cover 130 is attached to the mounting surface 138 (FIG. 2A).
The notches 302 and 304 may facilitate holding the retaining
members 152 and 150 within the interior 137 (FIG. 4A) and
preventing movement of the conductive cables 116B and 116A.
[0029] Also shown in FIG. 2B, the connector assembly 100 may
include a recess plug 306 and a sealing ring 308 (e.g., o-ring).
The sealing ring 308 may be coupled to and surround the recess plug
306. The recess plug 306 may then be inserted through the access
window 110 and attached to the non-mounting side 107 to cover at
least a portion of the access window 110 and enclose the power
recess 112 therein. The recess plug 306 may have a plurality of
conduits 311-313 that provide access to the power recess 112 when
the recess plug 306 is attached to the main body 101. For example,
the conduit 312 may permit injection of a potting material into the
power recess 112 and the conduits 311 and 313 may permit the
displacement of air from the power recess 112 when the potting
material is inserted therein.
[0030] FIG. 3 illustrates in greater detail internal components of
the connector assembly 100. For illustrative purposes, the cover
130 (FIG. 2A) has been removed from FIG. 3. As shown, the
conductive cables 116A and 116B extend along respective central
cable axes 142A and 142B within the cable channels 140A and 140B.
The cable axes 142A and 142B may extend in a direction that is
parallel to the longitudinal axis 190. The cable channels 140A and
140B may be separated from each other by a spacing S.sub.1
therebetween. Also shown, the housing cap 120 is coupled to the
main body 101 proximate to the loading side 104 of the connector
housing 102. The housing cap 120 may comprise a single piece of
insulative material and be configured to form an interference fit
with the main body 101. For example, the housing cap 120 may
include a pair of cap recesses 182 and 184 that are separated by
cap projections 186. The cap recesses 182 and 184 are configured to
receive corresponding housing or body portions 188 and 189 of the
main body 101. The body portions 188 and 189 are formed around the
seal cavities 158 and 160 (FIG. 2A), respectively. The body
portions 188 and 189 receive and hold the cable seals 154 and 156
(FIG. 2A), respectively, within the seal cavities 158 and 160. The
cap projections 186 flex toward each other when engaging the body
portions 188 and 189 and grip the body portions 188 and 189.
[0031] Although the following description is with specific
reference to the conductive cable 116A and the cable channel 140A,
the description may be similarly applied to the conductive cable
116B and the cable channel 140B. The conductive cable 116A includes
an insulative jacket or sleeve 202A and a conductor 204A. The
insulative jacket 202A surrounds the conductor 204A and extends
about the cable axis 142A when the conductive cable 116A is in the
cable channel 140A. As shown, a portion of the insulative jacket
202A has been removed from a distal end of the conductive cable
116A so that the conductor 204A is exposed within the inner region
136 of the connector housing 102.
[0032] Furthermore, the conductive cable 116A may have the mating
contact 114A coupled to the conductor 204A within the connector
housing 102. In particular embodiments, the mating contact 114A may
be coupled to the conductor 204A within the cable channel 140A and
extend from the conductor 204A toward the mating side 106 of the
connector housing 102. As shown, the mating contact 114A may have a
base portion 210A and a mating portion 212A. The base portion 210A
may be crimped or compressed around the conductor 204A so that the
mating contact 114A is coupled thereto. The base portion 210A
extends along the cable channel 140A to the mating portion 212A. As
shown, the mating portion 212A extends toward the mating side 106
and is located within the power recess 112. The mating portion 212A
is configured to electrically engage the PV module. The mating
portion 212A (or the mating contact 114A) may be configured to flex
with respect to the conductor 204A when engaged with the PV
module.
[0033] As shown in FIG. 3, the base portion 210A is crimped around
the conductor 204A and extends therefrom toward the mating side
106. The base portion 210A may also include a coupling bore 214A
that receives a pin or post 216A (shown in FIG. 4A) of the main
body 101. The post may facilitate holding the mating contact 114A
in a predetermined position during the manufacture of the connector
assembly 100. The base portion 210A extends toward the mating side
106 and is shaped into the mating portion 212A. For example, the
mating portion 212A may extend in a direction along the mounting
axis 192 and then extend along the longitudinal axis 190 into the
power recess 112. The mating contacts 114A and 114B may extend a
portion of the cable channels 140A and 140B.
[0034] In addition, the connector housing 102 or the main body 101
may include a plurality of slots 220 and 222 that are configured to
hold the retaining members 150 and 152. As shown, the slots 220 and
222 are oriented substantially transverse to the respective cable
channels 140A and 140B. Each of the slots 220 and 222 extend
through the cable channel 140A and 140B, respectively. More
specifically, the slot 220 is defined by first and second slot
portions 230 and 232 that extend radially away from the cable
channel 140A in substantially opposite directions along the lateral
axis 191. The slot portions 230 and 232 may be extensions of the
cable channel 140A in that the slot portions 230 and 232 define
empty space that extends from the empty space of the cable channel.
More specifically, the slot portions 230 and 232 may open to the
cable channel 140A and face each other across the cable channel
140A. The slot portions 230 and 232 directly oppose each other
across the cable channel 140A so that retaining member 150 is held
substantially transverse to the cable axis 142A. Furthermore, as
shown in FIG. 3, the slot portions 230 and 232 may extend into the
mounting surface 138. The description of slot 220 provided above
may be similarly applied to the slot 222 of the cable channel
140B.
[0035] In the illustrated embodiment, the cable channels 140A and
140B may also include slots 224 and 226. The slots 224 and 226 may
also be oriented substantially transverse to the respective cable
channels 140A and 140B. The slots 224 and 226 may be located closer
to the loading side 104 than the slots 220 and 222. Furthermore,
the slots 224 and 226 may have similar or different dimensions
relative to the slots 220 and 222. In the illustrated embodiment,
the slots 224 and 226 are sized and shaped to hold a smaller
retaining member than the retaining members 150 and 152.
Alternatively, the slots 224 and 226 may be sized and shaped to
hold a retaining member that is equal to or larger than the
retaining members 150 and 152. As such, the connector assembly 100
may be configured to accommodate different sizes of conductive
cables.
[0036] Also shown in FIG. 3, the connector assembly 100 may include
a bypass diode 364 located between the cable conductors 116A and
116B. The bypass diode 364 is configured to be electrically
connected to the mating contacts 114A and 114B. The bypass diode
364 permits current to flow therethrough between the mating
contacts 114A and 114B when the PV module (not shown) is shaded
(i.e., when the PV module is not converting solar energy into
electrical energy).
[0037] The main body 101 may also have a sealant channel or
channels 370 located along an underside of the main body 101 or
mounting side 105. When the cover 130 is attached to the mounting
surface 138, the sealant channels 366 and 368 (FIG. 2A) may align
with one or more sealant channels 370 of the main body 101. The
sealant may facilitate holding the cover 130 to the main body 101
and/or preventing moisture and other contaminants from entering the
interior 137 (FIG. 4A).
[0038] FIG. 4A is a cross-section of the connector assembly 100
after the cover 130 has been coupled to the mounting surface 138 of
the main body 101. Although the following description is with
specific reference to the conductive cable 116A and cable channel
140A, the description may similarly be applied to the conductive
cable 116B and the cable channel 140B (FIG. 2A). In some
embodiments, the connector assembly 100 may be constructed by
providing the main body 101, the cover 130, the housing cap 120,
and a cable assembly 240. The cable assembly 240 may include the
conductive cable 116A, the mating contact 114A coupled to the
conductor 204A, and the cable seal 154 surrounding an outer surface
242 of the insulative jacket 202A. As shown, the main body 101
includes an aperture 244 proximate to the loading side 104 of the
connector housing 102. The aperture 244 may include the seal cavity
158. In particular embodiments, the cable assembly 240 may have the
housing cap 120 coupled thereto. More specifically, the conductive
cable 116A may be inserted through a hole 246 of the housing cap
120.
[0039] In some embodiments, the cable assembly 240 is first
inserted through the aperture 244 of the main body 101. The mating
contact 114A may advance through the aperture 244 followed by the
conductor 204A and the insulative jacket 202A of the conductive
cable 116A. In particular embodiments, the mating contact 114A is
coupled to the connector housing 102 or the main body 101 by
inserting the post 216A through the coupling bore 214A (FIG. 3).
The cable seal 154 may then be advanced along the insulative jacket
202A and inserted into the seal cavity 158 of the aperture 244. The
insulative material of the body portion 188 completely surrounds
the aperture 244 about the cable axis 142A. As shown, the seal
cavity 158 and the cable seal 154 are sized and shaped relative to
each other so an interference fit or a snug fit is formed. Also
shown, the cable seal 154 may be compressed around the outer
surface 242 of the insulative jacket 202A to prevent unwanted
moisture or contaminants from entering the interior 137 of the
connector assembly 100. To this end, the cable seal 154 may have
one or more ribs 250 that are compressed around the insulative
jacket 202A. The housing cap 120 may then be coupled to the main
body 101. In the illustrated embodiment, the housing cap 120
includes the loading side 104. The housing cap 120 may facilitate
holding the cable seal 154 within the seal cavity 158.
[0040] Before, after, or during the insertion of the cable seal 154
into the seal cavity 158 and the coupling of the housing cap 120 to
the main body 101, the retaining member 150 may be inserted into
the slot 220. More specifically, the retaining member 150 may be
moved in a mounting direction M that extends along the mounting
axis 192 (FIG. 1) and is substantially orthogonal to the cable axis
142A. The retaining member 150 may be moved toward the mounting
surface 138 and into the slot 220 to grip the conductive cable
116A. As shown in FIG. 4A, the retaining member 150 may have a
narrow width W.sub.2 measured along the cable axis 142A.
Furthermore, the retaining member 150 may have a height H.sub.2
(FIG. 5) that is slightly greater than the outer diameter D.sub.1
of the conductive cable 116A. The height H.sub.2 is slightly
smaller than the height H.sub.1 (FIG. 1) of the connector housing
102. As such, in particular embodiments, the connector assembly 100
may have a low-profile shape.
[0041] In particular embodiments, after inserting the retaining
member 150 into the slot 220, the cover 130 may be coupled to the
mounting surface 138 (e.g., through interference fit and/or
providing a sealant). The retaining member 150 may be received
within the notch 304 (FIG. 2B). The notch 304 may become a part of
the slot 220 that holds the retaining member 150 therein. As shown
in FIG. 4A, the cover 130 holds the conductive cable 116A and the
retaining member 150 within the cable channel 140A and the slot
220, respectively. The retaining member 150 prevents movement of
the conductive cable 116A with respect to the connector housing 102
in a direction along the cable axis 142A. Furthermore, the cable
seal 154, the main body 101, and the cover 130 prevent movement of
the conductive cable 116A out of the cable channel 140A in a
direction along the mounting axis 192 and/or lateral axis 191 (FIG.
1).
[0042] In the illustrated embodiment, the retaining member 150 is
located between the mating contact 114A and the cable seal 154. In
alternative embodiments, however, the cable seal 154 may be located
between the retaining member 150 and the mating contact 114A.
[0043] FIG. 4B is a cross-section taken along the lateral axis 191
through the power recess 112. As shown, the recess plug 306 may
have opposite latches 360 and 362 that are configured to flex and
grip portions of the main body 101 when the recess plug 306 is
attached thereto. In the illustrated embodiment, the sealing ring
308 may be applied to the recess plug 306 before coupling to the
main body 101. The sealing ring 308 may surround the recess plug
306 and cooperate with the recess plug 306 and the main body 101 to
prevent moisture and contaminants from entering the power recess
112.
[0044] FIG. 5 is a view along the cable axis 142A illustrating the
retaining member 150 inserted into the slot 220 and gripping the
conductive cable 116A. In particular embodiments, the retaining
member 150 is an E-retaining ring or clip. As shown, the retaining
member 150 includes an annular portion 260 that extends around the
outer surface 242 of the conductive cable 116A. The annular portion
260 may also extend around the cable axis 142A. As such, the
annular portion 260 may define a cable-reception region 270 that is
shaped to receive the conductive cable 116A. Also shown, the
retaining member 150 may include at least one grip element 262 that
is configured to grip the insulative jacket 202A. The grip elements
262 are coupled to and project radially inward from the annular
portion 260 toward the cable axis 142A and/or the insulative jacket
202A. In the illustrated embodiment, the retaining member 150
includes three grip elements 262. However, in alternative
embodiments, the retaining member 150 may include only one grip
element, two grip elements, or more than three grip elements. In
addition, the grip elements 262 are not limited to the shapes shown
in FIG. 5, but may have other shapes that facilitate gripping the
insulative jacket 202A. For example, the retaining member 150 may
be bracket-shaped and have grip elements that are similar to the
grip elements 356 and 358 shown in FIG. 6.
[0045] In the illustrative embodiment, the grip elements 262 grip
the conductive cable 116A by piercing material of the insulative
jacket 202A such that a portion of the grip element 262 extends
through the outer surface 242 and is inserted into the insulative
jacket 202A. Accordingly, in the illustrated embodiment, the grip
elements 262 may be shaped to facilitate piercing the insulative
jacket 202A when the retaining member 150 is inserted into the slot
220 in the mounting direction M. For example, the grip elements 262
may have sharp edges capable of piercing the insulative jacket
202A. The grip elements 262 may be substantially evenly distributed
about the cable axis 142A. When the grip elements 262 pierce the
material of the insulative jacket, the grip elements 262 may
provide a grip diameter D.sub.2 that is less than the outer
diameter D.sub.1 of the conductive cable 116A. If a force is
exerted on the conductive cable 116A in a direction that is along
the cable axis 142A, the grip elements 262 prevent the conductive
cable 116A from being moved in the cable channel 140A.
[0046] However, in alternative embodiments, the grip elements 262
do not pierce the insulative jacket 202A. For example, the grip
elements 262 may be shaped to have dull contact points that engage
the insulative jacket 202A. As such, the grip elements 262 may
compress the insulative jacket 202A, but not pierce the outer
surface 242.
[0047] FIG. 6 is a view along a cable axis 342A illustrating a
retaining member 350 of an alternative embodiment inserted into a
slot 320 to grip a conductive cable 316A. As shown, the retaining
member 350 may include separate retaining components 352 and 354.
Each retaining component 352 and 354 includes at least one grip
element 356 and 358, respectively, that is configured to grip an
insulative jacket 302A of the conductive cable 316A. The retaining
components 352 and 354 may be rectangular-shaped parts and the grip
elements 356 and 358 may be edges of the parts. The grip elements
356 and 358 may pierce the insulative material of the conductive
cable 316A. The retaining component 352 may be inserted into the
slot portion 330 and the retaining component 354 may be inserted
into the slot portion 332. The retaining components 352 and 354 may
be inserted separately or simultaneously into the respective slot
portions 330 and 332.
[0048] It is to be understood that the above description is
intended to be illustrative, and not restrictive. In addition, the
above-described embodiments (and/or aspects or features thereof)
may be used in combination with each other. Furthermore, many
modifications may be made to adapt a particular situation or
material to the teachings of the invention without departing from
its scope. Dimensions, types of materials, orientations of the
various components, and the number and positions of the various
components described herein are intended to define parameters of
certain embodiments, and are by no means limiting and are merely
exemplary embodiments. Many other embodiments and modifications
within the spirit and scope of the claims will be apparent to those
of skill in the art upon reviewing the above description. The scope
of the invention should, therefore, be determined with reference to
the appended claims, along with the full scope of equivalents to
which such claims are entitled. In the appended claims, the terms
"including" and "in which" are used as the plain-English
equivalents of the respective terms "comprising" and "wherein."
Moreover, in the following claims, the terms "first," "second," and
"third," etc. are used merely as labels, and are not intended to
impose numerical requirements on their objects. Further, the
limitations of the following claims are not written in
means-plus-function format and are not intended to be interpreted
based on 35 U.S.C. .sctn.112, sixth paragraph, unless and until
such claim limitations expressly use the phrase "means for"
followed by a statement of function void of further structure.
* * * * *