U.S. patent application number 13/362727 was filed with the patent office on 2012-05-24 for external electrical connectors for solar modules.
This patent application is currently assigned to MIASOLE. Invention is credited to Jason Corneille, Michael Meyers.
Application Number | 20120129401 13/362727 |
Document ID | / |
Family ID | 43379409 |
Filed Date | 2012-05-24 |
United States Patent
Application |
20120129401 |
Kind Code |
A1 |
Corneille; Jason ; et
al. |
May 24, 2012 |
EXTERNAL ELECTRICAL CONNECTORS FOR SOLAR MODULES
Abstract
Provided are low profile, water-resistant and touch safe
electrical connectors for solar modules. According to various
embodiments, the electrical connectors include a low-profile
conductive stud, a low-profile sheath that surrounds the stud, and
a socket to mate with the stud. According to various embodiments,
the sheath and socket mate via keyed inter-engageable features.
Also according to certain embodiments, the socket is fastened to
the stud and/or sheath via snap fastening.
Inventors: |
Corneille; Jason; (San Jose,
CA) ; Meyers; Michael; (San Jose, CA) |
Assignee: |
MIASOLE
Santa Clara
CA
|
Family ID: |
43379409 |
Appl. No.: |
13/362727 |
Filed: |
January 31, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13104885 |
May 10, 2011 |
8123565 |
|
|
13362727 |
|
|
|
|
12684278 |
Jan 8, 2010 |
7963802 |
|
|
13104885 |
|
|
|
|
61222012 |
Jun 30, 2009 |
|
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|
61238164 |
Aug 30, 2009 |
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Current U.S.
Class: |
439/627 |
Current CPC
Class: |
H01R 24/66 20130101;
H01R 13/64 20130101; Y02E 10/50 20130101; H01L 31/02008 20130101;
H01R 2101/00 20130101; H01R 24/20 20130101; H01R 11/11
20130101 |
Class at
Publication: |
439/627 |
International
Class: |
H01R 24/28 20110101
H01R024/28 |
Claims
1-20. (canceled)
21. An assembly for a solar module comprising: mateable receiving
and insertion components configured to provide a conductive pathway
from solar cells of a solar module to the exterior of the solar
module, wherein the insertion component includes a flared portion,
the flared portion of the insertion component having a larger
cross-sectional area than a corresponding area of the receiving
component configured to receive the insertion component.
22. The assembly of claim 21, wherein the insertion component
includes a first end configured to be proximal to the exterior of
the solar module and a second end configured to be distal to the
exterior of the module, and wherein the flared portion of the
insertion component is at the first end.
23. The assembly of claim 21, wherein the receiving and insertion
components are lockable.
24. The assembly of claim 21, wherein the receiving and insertion
components can be mated at any radial angle of a plane
perpendicular to the cross-sectional area.
25. The assembly of claim 21, wherein the receiving component
includes one or more protrusions extending from an interior surface
of the receiving component.
26. The assembly of claim 21, wherein at least one of the insertion
and receiving components includes a flexibly resilient
material.
27. The assembly of claim 21, wherein insertion component includes
an insulative portion.
28. The assembly of claim 21, wherein the receiving and insertion
components are mateable via snap fastening.
29. The assembly of claim 21, wherein, when the receiving and
insertion components are mated, the assembly includes no air
gaps.
30. An assembly comprising: mateable receiving and insertion
components configured to provide a conductive pathway from solar
cells of a solar module to the exterior of the solar module,
wherein one or both of insertion and receiving components include
one or more features such that the insertion component has larger
cross-sectional area than a corresponding area of the receiving
component configured to receive the insertion component.
31. The assembly of claim 30, wherein the insertion component
comprises rimmed locking portions.
32. The assembly of claim 31, wherein the corresponding area of the
receiving area is defined by an annular base portion having an
outer and inner diameter, one or more circular ridge portions on a
circumference defined by the outer diameter and one or more
circular ridges on a circumference defined by the inner
diameter.
33. The assembly of claim 30, wherein the receiving and insertion
components are lockable.
34. The assembly of claim 30, wherein the receiving and insertion
components can be mated at any radial angle of a plane
perpendicular to the cross-sectional area.
35. The assembly of claim 30, wherein, when the receiving and
insertion components are mated, the assembly includes no air
gaps.
36. The assembly of claim 30, wherein the receiving component
includes a keyed feature configured to engage with a keyed feature
of the insertion component.
37. The assembly of claim 30, wherein the receiving and insertion
components are mateable via snap fastening.
38. The assembly of claim 30, further comprising a horizontal
connector connected to one of the insertion and receiving
components.
39. The assembly of claim 30, wherein the insertion component is a
stud.
40. The assembly of claim 30, wherein the insertion component is a
socket.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to
U.S. application Ser. No. 13/104,885, filed May 10, 2011, which is
a continuation of U.S. application Ser. No. 12/684,278, now U.S.
Pat. No. 7,963,802, filed Jan. 8, 2010, which claims the benefit of
U.S. Provisional Application No. 61/222,012, filed Jun. 30, 2009,
and U.S. Provisional Application No. 61/238,164, filed Aug. 30,
2009. All of these are incorporated herein by this reference in
their entireties.
BACKGROUND OF THE INVENTION
[0002] Photovoltaic cells are widely used for generation of
electricity, with multiple photovoltaic cells interconnected in
module assemblies. Such modules may in turn be arranged in arrays
and integrated into building structures or otherwise assembled to
convert solar energy into electricity by the photovoltaic effect.
An installation process for a solar module array involves
connecting modules together at the installation site. A string of
live modules connected in series is capable of delivering several
amperes of current at lethal voltages, i.e., greater than 300
V.
SUMMARY OF THE INVENTION
[0003] Provided are low profile, water-resistant and touch safe
electrical connector assemblies for solar modules. According to
various embodiments, the electrical connector assemblies include a
low-profile conductive stud, a low-profile sheath that surrounds
the stud, and a socket to mate with the stud. The socket is further
connected to a cable or other connector for module interconnection.
According to various embodiments, the sheath and socket mate via
keyed inter-engageable features. Also according to certain
embodiments, the electrical connector assemblies are configured
such that the socket is fastenable to the stud and/or sheath via
snap fastening.
[0004] These and other aspects of the invention are described
further below with reference to the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1A shows a plan view of a solar-cell array including a
plurality of solar-cell modules and centrally-mounted junction
boxes in accordance with various embodiments.
[0006] FIG. 1B is a perspective disconnected view of an electrical
connector assembly according to certain embodiments.
[0007] FIG. 2 shows the electrical connector assembly shown in FIG.
1B in an assembled configuration.
[0008] FIG. 3 is a perspective view of the sheath member depicted
in FIGS. 1B and 2.
[0009] FIG. 4 is a perspective view of a sheath member that may be
employed in accordance with certain embodiments.
[0010] FIG. 5 is a perspective disconnected view of an electrical
connector assembly having a shroud-type sheath according to certain
embodiments.
[0011] FIG. 6 is a cross-section view of the electrical connector
assembly depicted in FIG. 5 in an assembled configuration.
[0012] FIG. 7 is a perspective view of the sheath member depicted
in FIGS. 5 and 6.
[0013] FIG. 8 is a perspective disconnected view of a low profile
electrical connector assembly including a keyed low profile sheath
and a keyed socket member according to certain embodiments.
[0014] FIG. 9 is a perspective view of a keyed low profile sheath
and stud assembly disposed on a photovoltaic module according to
certain embodiments.
[0015] FIG. 10 is a cross-sectional view of a low profile
electrical connector assembly including a keyed low profile sheath
and a keyed socket member in an assembled configuration according
to certain embodiments.
[0016] FIG. 11 is a perspective view of a keyed low profile sheath
according to one embodiment of the present invention.
[0017] FIG. 12 is an underneath view of a keyed socket according to
one embodiment of the present invention.
[0018] FIG. 13 is a perspective view of a keyed low profile sheath
according to one embodiment of the present invention.
[0019] FIG. 14 is an underneath view of a keyed socket according to
one embodiment of the present invention.
[0020] FIG. 15 is a perspective disconnected view of an electrical
connector assembly including a circularly keyed low profile sheath
and a circularly keyed socket according to certain embodiments.
[0021] FIG. 16 is a perspective view of a circularly keyed low
profile sheath and conductive stud assembly disposed on a
photovoltaic module according various embodiments.
[0022] FIG. 17 is a perspective view of a circularly keyed socket
in accordance with one embodiment of the present invention.
[0023] FIG. 18 is a perspective view of a circularly keyed low
profile sheath in accordance with one embodiment of the present
invention.
[0024] FIG. 19 is a cross-sectional view of an electrical connector
assembly including a circularly keyed low profile sheath mated with
a circularly keyed socket member in accordance with one embodiment
of the present invention
[0025] FIG. 20 is a cross-sectional view of a circularly keyed low
profile sheath and a mismatched circularly keyed socket disposed
above the sheath.
[0026] FIG. 21 is a perspective view of a circularly keyed lockable
socket in accordance with certain embodiments
[0027] FIG. 22 is a perspective view of a circularly keyed sheath
in accordance with certain embodiments.
[0028] FIG. 23 is a cross-sectional view of an electrical connector
assembly including a circularly keyed low profile sheath and a
circularly keyed locked socket member in accordance with one
embodiment of the present invention.
[0029] FIG. 24 is a perspective view of a circularly keyed lockable
socket in accordance with certain embodiments
[0030] FIG. 25 is a perspective view of a circularly keyed sheath
in accordance with certain embodiments.
[0031] FIG. 26 is a cross-sectional view of an electrical connector
assembly including a circularly keyed low profile sheath and a
circularly keyed locked socket member in accordance with one
embodiment of the present invention.
[0032] FIG. 27 is a cross-sectional view of a circularly keyed low
profile sheath and a mismatched circularly keyed lockable socket
disposed above the sheath.
[0033] FIG. 28 is a cross-sectional view of a circularly keyed low
profile sheath and a mismatched circularly keyed lockable socket
disposed above the sheath.
[0034] FIG. 29 is a cross-sectional view of a portion of a solar
module and electrical connector assembly including an interior seal
disposed between a conductive stud member and an encasing layer of
the module.
DETAILED DESCRIPTION
[0035] Reference will now be made in detail to specific embodiments
of the invention. Examples of the specific embodiments are
illustrated in the accompanying drawings. While the invention will
be described in conjunction with these specific embodiments, it
will be understood that it is not intended to limit the invention
to such specific embodiments. On the contrary, it is intended to
cover alternatives, modifications, and equivalents as may be
included within the spirit and scope of the invention. For example,
while the description below refers chiefly to electrical connector
assemblies and the like for solar modules and solar module
assemblies, they may be used with other electrical devices and
assemblies. One of skill in the art will understand from the
description presented herein how to implement the inventive
electrical connectors and related methods described herein with
other types of devices and assemblies that include electrical
connections. Also, in the following description, numerous specific
details are set forth in order to provide a thorough understanding
of the present invention. The present invention may be practiced
without some or all of these specific details. In other instances,
well known mechanical apparatuses and/or process operations have
not been described in detail in order not to unnecessarily obscure
the present invention.
[0036] Photovoltaic cells are widely used for generation of
electricity, with multiple photovoltaic cells interconnected in
module assemblies. Such modules may in turn be arranged in arrays
and integrated into building structures or otherwise assembled to
convert solar energy into electricity by the photovoltaic effect.
However, a string of live modules connected in series is capable of
delivering several amperes of current at lethal voltages. During
installation of solar module array, individual modules are
interconnected. The present invention provides external electrical
connector assemblies that enable safe and easy installation.
According to various embodiments, the electrical connector
assemblies described herein have one or more of the following
features: low profile, finger safe, keyed, lockable and easy to
install (e.g., without requiring installation tools and/or
alignment).
[0037] Embodiments of the present invention relate to external
electrical connector assemblies for solar modules. According to
various embodiments, the external electrical connector assemblies
described herein provide a connection point for solar modules to an
external grid, battery, etc. In certain embodiments, one or more
external electrical connector assemblies is associated with a solar
module or panel in a solar panel array. An example of solar modules
interconnected via external connector assemblies is shown in FIG.
1A. FIG. 1A shows a plan view 100 of a solar module array 152
including a plurality 160 of solar modules 160a, 160b and 160c.
Each module includes a set of interconnected solar cells 140. The
cells may be any type of photovoltaic cells, including but not
limited to CIS, CIGS, CdTe or silicon photovoltaic cells. The
plurality 160 of solar-cell modules 160a, 160b and 160c are
interconnected via external connector assemblies mounted on the
modules and connected to in-laminate-diode assemblies. For example,
solar-cell module 160b includes a first in-laminate-diode assembly
170, a second in-laminate-diode assembly 171 and a third
in-laminate-diode assembly 172; solar module 160b also includes a
first busbar 174 and a terminating busbar 176 each electrically
coupled with the first, second and third in-laminate-diode
assemblies 170, 171 and 172. Although the figure depicts a specific
in-laminate configuration of interconnected solar cells in which
the cells are arranged in three rows, including in-laminate diode
assemblies, etc., the invention is not limited to any particular
arrangement of interconnected cells within the module, but may be
used with any appropriate arrangement. Other variations are also
within the scope of the invention.
[0038] The solar module 160b further includes first and second
electrical connector assemblies 180b and 182b, mounted on the glass
or other protective structure of the module. The first and second
electrical connector assemblies 180b and 182b are configured to
enable current collection from interconnected solar cells of the
module 160b and to allow interconnection with at least one other
external device, in this case module 160a for electrical connector
assembly 180b, and module 160c for electrical connector assembly
182b. In embodiments of the present invention, the module 160b is
coupled in series with modules 160a and 160c. Solar module 160a
similarly includes external electrical connector assemblies 180a
and 182a and solar module 160c similarly includes external
electrical connector assemblies 180c and 182c. Solar modules 160a
and 160b are intercoupled with interconnector 184 and solar modules
160b and 160c are intercoupled with interconnector 188. According
to various embodiments, the modules may be connected in series,
parallel, series-parallel, etc. The solar panel array may be
mounted on a roof or other surface to absorb solar energy and
convert it to electricity.
[0039] The modules and solar array described above is an example of
solar module, electrical connector and array assemblies within the
scope of the invention. The placement of the electrical connector
assemblies may be varied appropriate on the module--at its center,
edge, etc. Cell wiring schemes, including the presence, absence,
number or arrangement of busbars and diodes may also be varied as
appropriate. The shape of electrical connector assemblies according
to embodiments of the invention may be varied as appropriate. As
discussed further below, in certain embodiments, the electrical
connector assemblies or components thereof have a generally
circular shape to facilitate installation.
[0040] As used herein, the term "electrical connector assembly"
refers to at least one lead or other conductive element configured
to provide a conductive pathway, typically between the cells or
internal circuitry of a solar module and one or more external
cables or devices. In many embodiments, there are two such
electrical connector assemblies per module, one providing a
positive lead and one providing a negative lead. The electrical
connector assemblies described herein may also be referred to as
electrical connection boxes or junction boxes. In certain
embodiments, the electrical connector assemblies described herein
eliminate the need for junction boxes housing both positive and
negative leads.
[0041] In certain embodiments, the electrical connector assemblies
described herein include a conductive element, such as a conductive
stud or pin, that is in electrical communication with the
interconnected solar cells, and that extends from the interior of
the module to the exterior of the module. The electrical connector
assemblies may further include a sheath surrounding the conductive
element, and a socket including a conductive portion to mate with
the stud. In certain embodiments, the socket is configured to
engage with the sheath. The electrical connector assemblies may
further include a connector attached to or connectable to the
socket for interconnection to other modules, etc. According to
various embodiments, the connector assemblies may be in assembled
or unassembled configurations.
[0042] According to various embodiments, the electrical connector
assemblies described have a low profile, as measured as the
greatest distance they extend above a module. Low profile
assemblies facilitate low-cost manufacturing and provide less
interference on the exterior of the module, making the module more
stackable when compared to modules with high profile electrical
connector assemblies. According to various embodiments, the profile
is no more than about 2 inches, 1.9 inches, 1.8 inches, 1.7 inches,
1.6 inches, 1.5 inches, 1.4 inches, 1.3 inches, 1.2 inches, 1 inch,
0.9 inches, 0.8 inches, 0.7 inches, 0.6 inches, 0.5 inches, 0.4
inches, 0.3 inches, 0.2 inches or 0.1 inches.
[0043] In many embodiments, the stud of the low profile connector
assemblies is short and squat. In conventional connectors, the
conductive pin is long and narrow to reduce contact resistance. In
certain embodiments, the studs described herein are squat forms,
such as cylinders, with the contact primarily around their girths,
rather along their lengths. The conductive element may extend above
the module surface a distance of no more than about 1.5 inches, 1.4
inches, 1.3 inches, 1.2 inches, 1 inch, 0.9 inches, 0.8 inches, 0.7
inches, 0.6 inches, 0.5 inches, 0.4 inches, 0.3 inches, 0.2 inches
or 0.1 inches.
[0044] In accordance with various embodiments, studs are provided
including an insulative portion disposed on top of a conductive
portion of the stud. When a sheath of the present invention is
disposed around such a stud of a photovoltaic module, the
non-conductive sheath has no opening sized to allow a finger to
touch a conductive portion of the stud.
[0045] The connector assemblies described herein are finger-safe.
As used herein, the term "finger-safe" refers to an assembly
including a conductive element and sheath surrounding the
conductive element such that there is no manner in which a
finger-shaped object having a diameter of about 4 mm or larger can
contact the conductive portion of the conductive element. In
certain embodiments, finger-safe refers to the finger-safer
requirements specified in Underwriters Laboratory publication
UL-1703, Jun. 30, 2004, which is incorporated by reference
herein.
[0046] In transport, solar modules are unconnected and require
interconnection during installation. According to various
embodiments, a solar module is provided to an installer with a
conductive element and sheath mounted on the module.
Interconnecting solar modules and/or connecting a solar module to
an external battery, grid or other device, involves engaging a
socket as described herein with the conductive element and sheath
disposed on the module. The electrical connector assemblies
described herein are finger-safe prior to, during and after such
installation. An installer cannot contact any conductive part of
the conductive element during installation.
[0047] In certain embodiments, the electrical connection assemblies
are keyed. As used herein, the term "keyed" refers to having one or
mechanical features that prevents connection to an incorrect
component of the same type. As an example, in certain embodiments,
the components of the electrical connector assemblies described
herein are keyed, such that a positive lead from a module may be
connected only to a negative socket and vice-versa. In certain
embodiments, the electrical connector assemblies are lockable, such
that once connected, they cannot be unconnected without the use of
a tool.
[0048] In certain embodiments, the electrical connector assemblies
have one or more features to facilitation easy installation. For
example, in certain embodiments, the electrical connector
assemblies do not require the use of a tool for installation but
may be fit together, e.g., by snapping a socket onto a sheath
and/or conductive elements. Also in certain embodiments, the
electrical connectors do not require alignment prior to connection,
but may be connected at any radial angle. For example, in certain
embodiments, the electrical connector assemblies include a
circularly keyed sheath member and a circularly keyed socket
member. Once the keyed portions of each member are facing each
other, the sheath and socket members can be fastened together at
any relative radial angle due to the circular symmetry of the keyed
inter-engageable features.
[0049] According to various embodiments, assembly of the socket
member to the stud and/or sheath members includes snap fastening.
In certain embodiments, one member includes an insertion component
and another member includes a receiving component configured to fit
around the insertion member and defining an insertion component
receiving area. In certain embodiments, in its unassembled state
the electrical connector assembly includes an insertion component
having a diameter (or other length dimension in the case of
non-cylindrical components) slightly larger than a diameter of the
receiving member. In certain embodiments, one or both of the
insertion component and the receiving component may include a
feature such that the insertion component has a diameter slightly
smaller than a diameter of the receiving component. For example,
according to various embodiments, the insertion component may be
flared slightly, with the flared portion of the insertion component
having a larger area than the corresponding receiving area; the
insertion component may have a ridge or one or more protrusions
around its girth, with the diameter of the insertion component
including the ridged or protruding portions larger than that of the
receiving area; etc. According to various embodiments, the
receiving component includes a narrowed portion and/or a ridge or
one or more protrusions within the receiving area, or other
features that narrow the receiving area so that it has a smaller
diameter than the insertion component. Assembling the interconnect
assembly may involve disposing the socket member over the sheath
and/or stud members disposed on the module and applying a downward
force on the socket member. This force causes one or more of the
insertion component and the receiving components to flex or bend
slightly, thereby allowing the receiving component to fit around
the insertion component, and the insertion component to be inserted
into the receiving area. According to various embodiments, the
insertion component and/or the receiving component may be resilient
such that after fitting, it partially or fully reverts to its
original form. Various examples are presented in the below
description. As indicated, the socket member may fit onto one or
both of the stud (also referred to as conductive element) member
and the sheath member in this fashion. In embodiments wherein the
socket member engages with the stud member in this fashion,
typically, though not necessarily, it is the stud that includes the
insertion component, and the socket the receiving area. In certain
embodiments, the sockets of the electrical connectors described
herein are lockably engageable with a sheath and/or stud
assembly.
[0050] In certain embodiments, once assembled, the electrical
connector assemblies described herein, including conductive element
member (also referred to as stud member or stud assembly), socket
member and sheath member, contain substantially no air gaps. Also
according to certain embodiments, the electrical connector
assemblies include a seal surrounding a portion of the stud on the
interior of the module.
[0051] Examples of electrical connector assemblies according to
various embodiments are described below. FIGS. 1B-3 show various
components of an electrical connector assembly according to certain
embodiments, in which a non-conductive housing disposed over a
conductive stud of a solar module has no opening sized to allow a
finger to touch the stud. In certain embodiments, the housing is
configured to allow detachment of a socket from the stud without
subjecting a person who is performing the detachment to the risk of
contact with the stud.
[0052] First, FIG. 1B is a perspective disconnected view of the
electrical connector assembly, also referred to as a junction box,
including a housing 101, a horizontal connector 103, and a stud 102
disposed on a photovoltaic module 104. Module 104 includes
interconnected solar cells (not shown) and other in-laminate
components, encased by top and bottom encasing layers, the top one
of which is a light transparent layer made of a material including
but not limited to glass, plastic, or fiberglass. The bottom
encasing layer may be made from a material such as glass, plastic,
metal, or fiberglass. Stud 102 is a conductive material, typically
a metal, and provides an electrical connection to the
interconnected solar cells (not shown) within photovoltaic module
104.
[0053] In this embodiment, the stud 102 includes a circular base
portion 102a and a cylindrical portion 102b. Base portion 102a is
within the module glass. Socket member 103 includes a circular base
portion 103a and a vertical nubbin 103b, which allows it to be
fitted onto stud 102 sheathed by housing 101. Socket member 103
further includes attached horizontal connector 103c, which provides
a conductive pathway from stud 102 to another module, battery,
grid, etc. Socket member 103 may also include tool interface
feature 103d for removal.
[0054] The module is delivered with housing 101, also referred to
as a sheath, mounted on the module 104 disposed around the stud
102. Thus, even when socket member 103 including horizontal
connector 103c is disconnected from the stud 102, the housing 101
shields the stud 102 preventing human contact with the stud
102.
[0055] FIG. 2 shows the electrical connector assembly after
connection. In its unconnected state, housing 101 is disposed on
module 104, disposed around stud (not shown), which is in
electrical communication with the cells of the solar module. To
connect the horizontal connector 103c to stud 102, the socket
member is inserted into an opening of housing 101, with the opening
having a middle wide portion 101a, a top narrow portion 101b and a
bottom narrow portion 101c. Circular base portion 103a of the
socket member is inserted via a wide portion 101a of the opening
and vertical nubbin 103b of the socket member is inserted via a
narrow portion 101b of the opening. The socket member is then
pressed onto the stud, with horizontal connector 103c extending
through narrow opening portion 101c of the housing.
[0056] In certain embodiments, socket portion 103b may be fastened
to cylindrical portion 102b via snap fastening. For example
cylindrical portion 102b of stud 102 may be flared slightly at the
end distal to the circular base portion 102a. Socket member 103 may
include a hollow portion (not shown) slightly smaller than the
flared portion of cylindrical portion 102b. On application of
pressure to the vertical nubbin 103b, the socket member 103 is
forced over the flared cylindrical portion 102b, fitting snugly
into place.
[0057] In many embodiments, the socket member 103 including
horizontal connector 103c can be installed without the use of a
tool, but by application of pressure on the socket member 103 after
it is inserted into housing 101. In certain embodiments, an
installer may do this by pressing the socket member 103 with a
hand. Once connected, however, the electrical connector assembly is
configured to prevent easy removal. In certain embodiments, a tool
is necessary for removal, e.g., by prying the socket member 103 off
the stud 102. In the embodiment depicted in FIGS. 1B and 2, both
housing 101 and socket member 103 have tool interface features 101d
and 103d, respectively, allowing safe engagement with such a
tool.
[0058] FIG. 3 is a perspective view of the housing 101, also
referred to as a sheath, depicted in FIGS. 1B and 2. The housing
101 has an outer wall 302 including a round portion 312 and two
opposing substantially flat portions 313, the two opposing
substantially flat portions terminating at a front face 305. As
described above, the front face 305 includes a front face opening
306 sized to allow a horizontal connector to enter the housing 101
and engage with a stud (102 in FIG. 1B) while substantially
preventing a finger from touching the stud. The front face 305
further includes two opposing portions 311 extending inward and
sized to allow a horizontal connector 103 to enter the front face
opening 306 and engage with a stud. The housing 101 further
includes a base portion 303 having a base opening 308. The base
portion 303 includes panels 309 that form a tool opening 310 (tool
interface feature 101d in FIG. 1) configured to allow a tool to
enter to disconnect a horizontal connector. As described above with
respect to FIGS. 1B and 2, the base opening 308 is sized to
surround a socket member 103 including horizontal connector 103c
connected to a stud 102 and is in communication with the front face
opening 306. The housing 101 further includes a ceiling portion 304
having a ceiling opening 307 in communication with the front face
opening 306. As described above, ceiling opening 307 is sized to
allow a horizontal connector 103 including a vertical nubbin to
enter through the front face opening 306.
[0059] FIG. 4 shows a housing 101 according to an alternative
embodiment, in which a ceiling opening 407 is defined by the
ceiling portion 304 and sized to allow a tool to enter to press
down on a socket member to connect a horizontal connector to a
stud. In this embodiment, a socket member would not need a vertical
nubbin, such as nubbin 103b shown in FIG. 1B, as a tool entering
via opening 407 could press down on a base member such as 103b of
socket member 103 shown in FIG. 1B.
[0060] FIGS. 5-7 shows an electrical connector assembly having a
shroud type housing according to another embodiment. First, FIG. 5
is a perspective disconnected view of a shroud-type housing 501,
stud 102 and vertical socket member 503 including a vertical
connector disposed on module 104. FIG. 6 is a cross-sectional view
of a junction box with vertical connector 503 electrically
connected to stud 102. When vertical connector 503 is disconnected
from stud 102, shroud-type housing 501 sheaths stud 102, preventing
human contact with stud 102.
[0061] FIG. 7 is a perspective view of a shroud-type housing 501.
The shroud-type housing 501 includes a side wall 702 and a base
705. The base 705 has a base opening 706 sized to surround a socket
connected to a stud 102. The side wall 702 has a substantially
uniform thickness from the base 705 to the rim 704 formed by the
top of the side wall 702. The diameter of the portion of the side
wall 702 that connects to the base 705 is larger than the diameter
of rim 704. The rim 704 has a rim opening 707 sized to allow a
socket member 503 to engage therein.
[0062] Returning to FIG. 6, socket member 503 includes conductive
portion 503a that is mated with stud 102 to provide an electrical
connection to vertical connector 503c. In certain embodiments,
socket member 503 may be mated with stud 102 via snap fastening.
For example cylindrical portion 102b of stud 102 may be flared
slightly at the end distal to the circular base portion 102a. The
hollow portion of socket member 503 to be fit around stud 102 is
smaller than the flared portion of circular base portion 102a. On
application of pressure to the socket member 503, it is forced over
the flared cylindrical portion 102b, fitting snugly into place.
Once connected, the electrical connector assembly generally
requires a tool for disassembly. As with the electrical connector
assemblies described with reference to FIGS. 1B-4, the module is
generally delivered with stud 102 connected to the solar cells
within the module protective layers, and shroud 501 glued or
otherwise affixed to the glass or other protective layer to thereby
prevent human contact with the stud 102.
[0063] As indicated above, in certain embodiments, the stud members
are flared at the top, allowing the socket members to snap into
place upon application of force. As force is applied, the stud
and/or socket member material flexes or bends sufficiently to allow
the socket member to fit over the stud. In certain embodiments, the
material is resilient such that it flexes or expands back once the
components are mated. In certain embodiments, the socket members
described above may have a lip or protrusions extending inward from
hollow portion of the socket, creating a smaller diameter at the
rim or protrusions. In these embodiments, the stud may or may not
be flared as described above.
[0064] In certain embodiments, a stud of an electrical connector
assembly includes insulation disposed thereon. In certain
embodiments, this feature allows a low profile sheath to be used.
For example, in certain embodiments, a sheath is approximately the
height of the stud. Also, in certain embodiments, sheaths having
features configured to engage with a portion of a socket member are
provided. Furthermore, in certain embodiments, a sheath is keyed to
allow only a mated socket to be engaged thereon. For instance, a
first embodiment of a junction box sheath could be keyed with a
first key configuration that would only allow a socket to be
engaged thereon, wherein this first keyed configuration would only
be disposed on positively charged connectors. Furthermore, a
junction box sheath with a second key configuration which would
only allow a mated socket to be engaged thereon could be employed
on only negatively charged connectors. The use of differentiated
configurations as described above could substantially prevent cross
connection of electrical connectors, thus preventing shorting of
the system or module.
[0065] FIG. 8 is a perspective disconnected view of a keyed low
profile sheath 801, a conductive stud 802 including base conductive
portion 807a, cylindrical conductive portion 807b, and insulated
top portion 806, and a keyed socket member 803. Keyed socket member
803 is configured to engage with the keyed low profile sheath 801
and further connected to a horizontal connector 804. In use, stud
802 is mounted on a solar module surrounded by sheath 801, which is
glued or otherwise affixed to the module. Sheath 801 includes at
least one feature that allows only a socket 803 having
corresponding features to be connected to stud 802. Here, sheath
801 includes a base portion 801a and a raised rim 801b having
indent 801c. Assembled, raised rim 801b surrounds at least the
conductive portion of the stud 802. Indent 801 c is configured to
engage a corresponding tab feature on socket 803. It prevents
sockets having unaligned tab features from connecting to stud 802.
The inner diameter of raised rim 801b is sized to allow a hollow
conductive portion (not shown) of socket member 803 to fit between
the raised rim 801b and stud 802, with the gap between the raised
rim 801b and stud 802 small enough to prevent a human finger from
contacting the conductive portions 807a and 807b of stud 802 when
the socket is not in place. In certain embodiments, the outer
diameter of rim 801b is sized to fit only sockets having a
corresponding groove and preventing sockets having grooves of
different diameters from connecting to stud 802.
[0066] FIG. 9 is a perspective view of a keyed low profile sheath
901 and stud assembly 902 disposed on a photovoltaic module 905.
The keyed low profile sheath 901 provides protection around the
exterior of the stud assembly 902 while the insulator portion 906
of the stud assembly 902 provides protection on the top portion of
the stud assembly 902. As shown, the conductive portion 907 of the
stud assembly 902 is not accessible to human contact, significantly
reducing the risk of electric shock when modules are installed or
when they undergo maintenance.
[0067] FIG. 10 is a cross-sectional view of a keyed electrical
connector assembly according to certain embodiments, including
keyed low profile sheath 1001 and stud assembly 1002 disposed on a
photovoltaic module 1005 and a keyed socket 1003 disposed on and
electrically connected to stud assembly 1002 and engaged on the
keyed low profile sheath 1001. The keyed socket 1003 is further
connected to a horizontal connector 1004 and includes a stud
engaging portion 1008. Stud engaging portion 1008 includes an
electrically conductive portion 1008, which is electrically
integrated with the conductive portion 1007 of the stud assembly
1002. Stud assembly 1002 also includes insulative portion 1006. In
certain embodiments, socket member 1003 mates with stud assembly
1002 via snap fastening. The portion of stud 1002 distal to the
module 1005 may be flared, and have a slightly larger diameter than
that of the hollow portion of socket member 1003, the sidewalls of
which are defined by stud engaging portion 1008. When a downward
force is applied to socket member 1003, the engaging portion 1008
bends or flexes sufficiently such that it fits snugly into the
space between cylindrical portion 1007 of stud 1002 and the inner
diameter of sheath 1001. Once connected, a conductive pathway from
stud 1002 to horizontal connector 1004 is established via the
conductive portion 1009 of stud engaging portion 1008 of socket
member 1003.
[0068] FIG. 11 is a perspective view of a keyed low profile sheath
1101 according to one embodiment of the present invention. The
keyed low profile sheath 1101 has a support portion 1110 having a
first diameter and a torso portion 1111 that has a base 1112 with a
second diameter and ceiling 1113 with a third diameter. The
diameter of the base 1112 of the torso portion 1111 is smaller than
the diameter of the support portion 1110. The diameter of the
ceiling 1113 of the torso portion 1111 is smaller than the diameter
of the base 1112 of the torso portion 1111. The torso portion 1111
further includes a keyed portion 1114 that includes two slots 1115
configured to engage a keyed portion of a keyed socket (see keyed
portion 1216 of keyed socket 1203 in FIG. 12). The low profile
sheath 1101 further includes a center opening 1116 configured to
surround a stud assembly and accommodate an engaging portion of a
keyed socket (see engaging portion 1208 of socket 1203 in FIG.
12).
[0069] FIG. 12 is an underneath view of a keyed socket 1203
connected to a horizontal connector 1204. Keyed socket 1203 is
configured to be mated with a keyed low profile sheath consistent
with the embodiment shown in FIG. 11. The keyed portion 1216 of the
keyed socket 1203 includes two prongs 1217 that are configured to
fit into two slots 1115 disposed on the keyed low profile sheath
1101 shown in FIG. 11. Keyed socket 1203 also includes stud
engaging portion 1208 including conductive portion 1209. A recess
1216 is configured to receive a stud.
[0070] FIG. 13 is a perspective view of a keyed low profile sheath
1301 showing another example of a sheath according to certain
embodiments. The keyed low profile sheath 1301 is similar to the
keyed low profile sheath 1101 of FIG. 11, with the exception that
the keyed portion 1318 includes a single slot 1319 configured to
engage a keyed portion 1420 of a socket 1403 (see FIG. 14).
[0071] FIG. 14 is an underneath view of a keyed socket 1404
connected to a horizontal connecter 1404. The keyed socket 1403 is
configured to be mated with a keyed low profile sheath 1301
consistent with the embodiment shown in FIG. 13. The keyed portion
1420 of the keyed socket 1403 includes one prong 1421 that is
configured to fit into the slot 1319 disposed on the low profile
sheath 1301 shown in FIG. 13.
[0072] The keyed socket 1403 shown in FIG. 14 would not be able to
engage on the keyed low profile sheath 1101 shown in FIG. 11 as the
prong 1421 would not be able to fit into either of the two slots
1115 of the keyed low profile sheath 1101. Similarly, the keyed
socket 1203 shown in FIG. 12 would not be able to engage on the
keyed low profile sheath 1301 shown in FIG. 13 as the two prongs
are spaced too far apart to be able to fit into the slot 1319 of
the keyed low profile sheath 1301.
[0073] In practice, keyed low profile sheaths and their mated
sockets may be used to distinguish positive and negative connectors
to decrease the likelihood of cross connection. It should be noted
that slot features 1115 and 1318 may be on a socket members with
prong features 1217 and 1421 on sheath members. Moreover, the keyed
features are not limited to slots and corresponding prongs, but may
be any type of inter-engageable keyed features. As discussed
further below, in certain embodiments, circular keyed features that
do not require rotational alignment are provided.
[0074] FIG. 15 is a perspective, disconnected view of a circularly
keyed low profile sheath 1501, a conductive stud assembly 1502
including insulating top portion 1506 connected to solar cells
within photovoltaic module 1505, and a circularly keyed socket 1503
configured to be mated with the circularly keyed low profile sheath
1501. The circularly keyed socket is further connected to a
horizontal connector 1504. FIG. 16 is a perspective view of certain
assembled components of an electrical connector assembly including
a circularly keyed low profile sheath 1501 and conductive stud
assembly including conductive portion 1507 and insulative portion
1506, disposed on a photovoltaic module 1505. According to certain
embodiments, the module 1502 is shipped as shown, with sheath 1501
affixed to the module surface and surrounding stud assembly 1502.
The circularly keyed low profile sheath 1501 provides protection
around the exterior of the conductive stud assembly 1502 while the
insulating top portion 1506 of the conductive stud assembly 1502
provides protection on the top portion of the conductive stud
assembly. As shown, the conductive portion 1507 of the conductive
stud assembly is not accessible to human contact, significantly
reducing the risk of electric shock when installing or maintaining
photovoltaic modules.
[0075] FIG. 17 is a perspective view of a circularly keyed socket
1703 (shown sheath- and stud-engaging side up) in accordance with
one embodiment of the present invention. The socket 1703 is further
connected to a horizontal connector 1704. Circularly keyed socket
1703 is configured to be mated with a circularly keyed low profile
sheath 1801 (shown in FIG. 18). Socket 1703 is circularly keyed,
that is the keyed portion 1710 disposed on the base portion 1711
includes a circular protruding shape that is configured to fit in a
circular groove 1812 (FIG. 18) disposed on the circularly keyed low
profile sheath 1801 (FIG. 18). In the depicted in embodiment, there
are no other keyed features such as slots or prongs on socket 1703;
as a result, fitting socket 1703 to sheath 1801 depicted in FIG. 18
does not require any rotational alignment of keyed features.
Rather, once socket 1703 is centered over sheath 1801, it may be
connected at any rotational angle. Circularly keyed socket 1703
further includes a stud engaging portion 1708 including an
electrically conductive portion 1709 which is configured to be
electrically integrated with a conductive portion of a conductive
stud assembly.
[0076] FIG. 18 is a perspective view of a circularly keyed low
profile sheath 1801 according to one embodiment of the present
invention. The keyed low profile sheath 1801 is configured to be
mated with a circularly keyed low profile socket 1703 as shown in
FIG. 17. The circularly keyed low profile sheath 1801 has a base
portion 1813 and a circular groove portion 1812 configured to
engage a keyed portion 1810 of the circularly keyed socket 1703 in
FIG. 17. The circularly keyed low profile sheath 1801 further
includes a center opening 1814 configured to surround a conductive
stud assembly (1902 in FIG. 19) and engage the portion 1708 of the
circularly keyed socket 1703.
[0077] FIG. 19 is a cross-sectional view of an electrical connector
assembly including a circularly keyed low profile sheath 1801 and a
conductive stud 1902 disposed on a photovoltaic module 1905. A
circularly keyed socket 1703 is engaged with circularly keyed low
profile sheath 1801 and conductive stud 1902 and further connected
to a horizontal connector 1704, thereby electrically connecting
conductive stud 1902 and horizontal connector 1704. Stud assembly
1902 includes insulative portion 1906 disposed on top of the
conductive portion 1907 of the stud assembly 1902. The keyed socket
1703 is engaged on the conductive stud assembly 1902 through the
stud engaging portion 1708. As shown, the keyed portion 1710 of the
circularly keyed socket 1703 fits into the circular groove portion
1812 of the circularly keyed low profile sheath 1801 allowing the
stud engaging portion 1708 of the circularly keyed socket 1703 to
engage with the conductive stud assembly 1902. In certain
embodiments, stud engaging portion 1708 of socket 1703 engages with
stud 1902 via snap fastening as described above, with stud 1902 the
insertion component, stud engaging member 1708 (including
conductive portion 1709) the receiving component and the hollow
cylindrical area defined by stud engaging member 1708 (including
conductive portion 1709) and base portion 1711 the receiving area.
As shown in the cross-sectional view in FIG. 19, the assembled
electrical connector assembly contains no air gaps inside the
assembly. This may be advantageous as provides an electrical
connector assembly that does not have any spaces in which
condensation can form and that does not require electrically
insulative potting material to be placed in air gaps.
[0078] FIG. 20 is a cross-sectional view of a circularly keyed low
profile sheath 2001 and a mismatched circularly keyed socket 2003
disposed above the sheath 2001. Because keyed feature (circular
protrusion) 2015 on socket 2003 and keyed feature (circular groove)
2012 on sheath 2001 are not configured to inter-engage, having
different diameters, stud engaging portion 2008 of socket 2003 is
prevented from engaging stud 2002. In certain embodiments, the
conductive portion 2009 of stud engaging portion 2008 is prevented
from contacting the conductive portion 2007 of stud 2002. As
described above, keyed low profile sheaths and their mated snap
fastener sockets as described above could be used to distinguish
positive and negative connectors to decrease the likelihood of
cross connection.
[0079] In certain embodiments, the keyed socket may be configured
to be lockably engageable with a keyed low profile sheath in order
to provide additional security to the electrical connections. FIG.
21 is a perspective view of a circularly keyed lockable socket 2103
in accordance with certain embodiments. Circularly keyed lockable
socket 2103 is configured to be mated with circularly keyed
lockable low profile sheath 2201 (shown in FIG. 22). Circularly
keyed lockable socket 2103 includes a stud engaging portion 2108
including an electrically conductive portion 2109 which is
configured to be electrically integrated with a conductive portion
2307 (shown in FIG. 23) of a conductive stud assembly. Socket 2103
includes a keyed portion disposed on a base portion 2123 of the
circularly keyed lockable socket 2103. The keyed portion 2122
includes a circular ridge having a first diameter that is the same
as the outer diameter of the stud engaging portion 2108 and a
second diameter that is larger than the outer diameter of the stud
engaging portion 2108. The keyed portion 2122 is configured to fit
into a circular opening 2227 defined by circular ridge 2225 of
circularly keyed lockable low profile sheath 2201 (shown in FIG.
22). Circularly keyed lockable socket 2103 further includes rimmed
locking portions 2120 configured to engage with ridged lock
accepting portions 2224 of circularly keyed lockable low profile
sheath 2201 (shown in FIG. 22). Circularly keyed lockable socket
2103 further includes supporting ridges 2121 that are in a
circumferential line with the rimmed locking portions 2120.
[0080] FIG. 22 is a perspective view of a circularly keyed lockable
low profile sheath 2201 in accordance with one embodiment of the
present invention. The circularly keyed lockable low profile sheath
2201 is configured to be mated with circularly keyed lockable
socket 2103 shown in FIG. 21. Circularly keyed lockable low profile
sheath 2201 has an annular base portion 2223 and a circular ridge
2225 that defines a center opening 2227 in sheath 2201. The center
opening 2227 is configured to engage a keyed portion 2122 of
circularly keyed lockable socket 2103 shown in FIG. 21. The
circularly keyed lockable low profile sheath 2201 is further
configured to surround a conductive stud assembly 2301 (shown in
FIG. 23) to provide a barrier to decrease risk of electrical shock.
The circularly keyed lockable low profile sheath 2201 further
comprises ridged lock accepting portions 2224 that are configured
to engage rimmed locking portions 2120 of the circularly keyed
lockable socket 2103 shown in FIG. 21. Ridged lock accepting
portions 2224 are separated by a gap 2230 in this embodiment to
allow a tool to engage and disconnect the socket 2103.
[0081] Socket 2103 may be fastened during assembly to sheath 2201
via snap fastening. In this example, rimmed locking portions 2120
are inserted into an annular receiving area defined by ridged
locked accepting portions 2224, annular base portion 2223 and
circular ridge 2225. Prior to fastening, the outer diameter of
rimmed locking portions 2120 is larger the outer diameter of this
receiving area. During assembly, a force is applied to socket 2103,
causing rimmed locking portions 2120 to flex and slip past ridged
locked accepting portions 2224. Rimmed locking portions 2120 then
flex back into position, snapping into place locked into place
under ridged lock accepting portions 2224.
[0082] FIG. 23 is a cross-sectional view of an assembled electrical
connector assembly including circularly keyed socket 2103 (as
depicted in FIG. 21), circularly keyed lockable low profile sheath
2201 (as depicted in FIG. 22) disposed on a photovoltaic module
2305 with a stud assembly including conductive portion 2307
extending from the interior of module 2305. The shaded areas in
FIG. 23 are included for clarity and are intended to show open
spacing in the assembly. Stud engaging portion 2019 and base
portion 2123 of socket 2103 define a hollow area in which the stud
is received. Circularly keyed lockable socket 2103 is engaged with
the conductive portion 2307 of the stud assembly through the
conductive portion 2109 of stud engaging portion 2108 and is also
engaged with the circularly keyed lockable low profile sheath 2201
through keyed portion 2122. As shown in FIG. 23, rimmed locking
portions 2120 of the circularly keyed lockable socket 2103 are
engaged with the ridged lock accepting portions 2224 of circularly
keyed lockable low profile sheath 2201. The engagement of the
rimmed locking portions 2120 of the of the circularly keyed
lockable socket 2103 with the ridged lock accepting portions 2224
of circularly keyed lockable low profile sheath 2201 provides a
locking mechanism that renders removal of the circularly keyed
lockable socket 2103 impossible or extremely difficult without the
use of a removing tool.
[0083] FIG. 24 is a perspective view of a circularly keyed lockable
socket 2403 in accordance with an alternative embodiment of the
present invention. Circularly keyed lockable socket 2403 is
configured to be mated with a circularly keyed lockable low profile
sheath 2501 (shown in FIG. 25). Circularly keyed lockable socket
2403 includes a stud engaging portion 2408 including an
electrically conductive portion 2409 which is configured to be
integrated with a conductive portion of a conductive stud assembly.
Circularly keyed lockable socket 2403 includes a keyed portion 2427
disposed on a base portion 2423, the keyed portion including a
circular protruding ridge having a first diameter that is larger
that the outer diameter of the stud engaging portion 2408 and a
second diameter that is larger than the first diameter of the keyed
portion 2427. The keyed portion 2427 is configured to fit around a
circular ridge 2529 of the circularly keyed lockable low profile
sheath 2501 show in FIG. 25. Circularly keyed lockable socket 2403
further includes rimmed locking portions 2420 configured to engage
with ridged lock accepting portions 2524 of circularly keyed
lockable low profile sheath 2501 (FIG. 25). Circularly keyed
lockable socket 2403 further includes supporting ridges 2421 that
are in circumferential line with the rimmed locking portions
2420.
[0084] FIG. 25 is a perspective view of a circularly keyed lockable
low profile sheath 2501 in accordance with embodiments of the
present invention. The circularly keyed lockable low profile sheath
2501 is configured to be mated with circularly keyed lockable
socket 2403 (FIG. 24). Circularly keyed lockable low profile sheath
2501 has an annular base portion 2523 and a circular ridge 2529
that defines a center opening 2530 in the center of the sheath
2501. The center opening 2530 is configured to accept a stud
engaging portion 2408 of the circularly keyed lockable socket 2403
and to surround a conductive stud assembly of a photovoltaic module
in order to provide a barrier to decrease risk of electrical shock.
The circularly keyed lockable low profile sheath 2501 further
includes ridged lock accepting portions 2524 that are configured to
engage rimmed locking portions 2420 of the circularly keyed
lockable socket 2403. As with the socket and sheath members
described in FIGS. 21-23, the socket 2403 is fastened to sheath
2501 via snap fastening.
[0085] FIG. 26 is a cross-sectional view of an electrical connector
assembly including a circularly keyed lockable low profile sheath
2501 and a stud assembly including conductive portion 2607 disposed
on a photovoltaic module 2605. The shaded areas in FIG. 26 are
included for clarity and are intended to show open spacing in the
assembly. A circularly keyed lockable socket 2403 is engaged with
the conductive stud assembly portion 2607 through stud engaging
portion 2408 and is also engaged with the circularly keyed lockable
low profile sheath 2501 through keyed portion 2427. As shown in
FIG. 26, when the circularly keyed lockable low profile sheath 2501
and the circularly keyed lockable socket 2403 are engaged with one
another, the circular ridge 2529 of the circularly keyed lockable
low profile sheath 2501 fits between the keyed portion 2427 and the
portion 2408 of the circularly keyed socket 2403. Also as shown in
FIG. 26, rimmed locking portions 2420 of the circularly keyed
lockable socket 2403 are engaged with the ridged lock accepting
portions 2524 of circularly keyed lockable low profile sheath 2501.
The engagement of the rimmed locking portions 2420 of the of the
circularly keyed lockable socket 2403 with the ridged lock
accepting portions 2524 of circularly keyed lockable low profile
sheath 2501 provides a locking mechanism that renders removal of
the circularly keyed lockable socket 2403 impossible or extremely
difficult without the use of a removing tool.
[0086] The circularly keyed lockable sockets 2103 and 2403 (shown
in FIGS. 21 and 24, respectively) and the circularly keyed low
profile sheaths 2201 and 2501 (shown in FIGS. 22 and 25,
respectively) are keyed such that mismatched pairings are not be
able to engage with one another. FIG. 27 is a cross-sectional view
of a circularly keyed lockable low profile sheath 2201 in
accordance with that shown in FIG. 22 disposed on a photovoltaic
module. A mismatched circularly keyed lockable socket 2403 in
accordance with that shown in FIG. 24 is disposed above the sheath
2201. FIG. 27 illustrates that the keyed portion 2427 of the
circularly keyed lockable socket 2403 collides with the circular
ridge 2225 of the mismatched circularly keyed lockable low profile
sheath 2201 if engagement of these two components is attempted,
preventing the connection of the mismatched components. In certain
embodiments, the conductive portions of socket 2403 and stud 2702
are preventing from contacting.
[0087] Similarly, FIG. 28 is a cross-sectional view of a circularly
keyed lockable low profile sheath 2501 in accordance with that
shown in FIG. 25 disposed on a photovoltaic module. A mismatched
circularly keyed lockable socket 2103 in accordance with that shown
in FIG. 21 is disposed above the sheath 2501. FIG. 28 illustrates
that the keyed portion 2122 of the circularly keyed lockable socket
2103 collides with the circular ridge 2529 of the mismatched
circularly keyed lockable low profile sheath 2501, if engagement of
these two components were attempted.
[0088] Also provided are electrical connector assemblies that
include a seal extending around a stud assembly in a module
interior. In certain embodiments, the stud assembly includes a
flange portion extending around the base of a conductive cylinder
portion of the stud. A seal disposed between the flange and the
module glass is formed by coating the flange with a sealant
material. An example is shown in FIG. 29, which shows a
cross-sectional view of an electrical connector assembly for a
photovoltaic module 2905. A conductive stud assembly 2902 includes
a base portion 2932 extending around the stud assembly 2902. A seal
31 is disposed between base portion 2932 and outer layer 2933 of
the photovoltaic module 2905. While some weather-proofing is
provided by a seal 2934 disposed between the circularly keyed
lockable low profile sheath 2901 and the outer layer 2933 of the
photovoltaic module 2905, the inclusion of a seal 2931 between the
base portion 2932 of the conductive stud assembly 2902 and the
outer layer 2933 of the photovoltaic module 2905 provides
additional protection to internal portions of the photovoltaic
module in adverse weather conditions. The seal may comprise a
material that acts as a desiccant to prevent water from entering
the interior of the module, for example a zeolite. Examples of seal
materials that may be used include butyl rubber and silicone. The
seal may also be relatively thick compared to the thickness if the
base portion 2932 of the stud assembly 2902. Example thickness of
the seal range from about 0.5 to 5 mm.
[0089] Although the foregoing invention has been described in some
detail for purposes of clarity of understanding, it will be
apparent that certain changes and modifications may be practiced
within the scope of the invention. For example, while certain
embodiments described above have circular studs, sockets and
sheaths, other shapes may be used. In certain embodiments, a
circularly keyed socket and sheath may be employed, with the base
portions of either of those components shaped as desired. Also, in
certain embodiments, the designs may be modified such that a socket
member connects to any type of cable or other interconnect member
for interconnection between modules. While various types of
inter-engageable keyed and/or locking features have been described
above, the invention is not so limited and may use any type of
inter-engageble features as recognized in the art. The various
conduction paths described may also be altered without departing
from the scope of the invention. There are many alternative ways of
implementing the apparatuses of the present invention. Accordingly,
the present embodiments are to be considered as illustrative and
not restrictive, and the invention is not to be limited to the
details given herein.
* * * * *