U.S. patent application number 14/057105 was filed with the patent office on 2014-02-13 for low leakage electrical joints and wire harnesses, and method of making the same.
The applicant listed for this patent is DEAN SOLON. Invention is credited to DEAN SOLON.
Application Number | 20140041935 14/057105 |
Document ID | / |
Family ID | 43449684 |
Filed Date | 2014-02-13 |
United States Patent
Application |
20140041935 |
Kind Code |
A1 |
SOLON; DEAN |
February 13, 2014 |
LOW LEAKAGE ELECTRICAL JOINTS AND WIRE HARNESSES, AND METHOD OF
MAKING THE SAME
Abstract
Low leakage electrical joints and wire harnesses for simplifying
the electrical infrastructure associated with solar energy
utilities are disclosed. The low leakage electrical joints include
fused wires that have been sealed, encased and configured to plug
into other joints to form wire harnesses. The wire harnesses are
particularly well suited for coupling a plurality of solar
collector junction boxes to a combiner box.
Inventors: |
SOLON; DEAN; (Gallatin,
TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SOLON; DEAN |
Gallatin |
TN |
US |
|
|
Family ID: |
43449684 |
Appl. No.: |
14/057105 |
Filed: |
October 18, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12502395 |
Jul 14, 2009 |
8604342 |
|
|
14057105 |
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Current U.S.
Class: |
174/72A ;
174/84R |
Current CPC
Class: |
H02G 15/18 20130101;
H01R 43/24 20130101; H02S 40/34 20141201; Y10T 29/49194 20150115;
Y10T 29/49195 20150115; H01R 4/70 20130101; H01R 11/28 20130101;
Y02E 10/50 20130101; H01L 31/05 20130101; H01R 31/02 20130101; H02S
40/36 20141201 |
Class at
Publication: |
174/72.A ;
174/84.R |
International
Class: |
H01R 4/02 20060101
H01R004/02 |
Claims
1) A low leakage electrical joint, said joint comprising: a. a
first exposed portion of a first insulated wire welded to a second
exposed portion of a second insulated wire; b. cured synthetic
rubber sealant surrounding said weld; and c. a polypropylene
encasement surrounding said sealant.
2) The joint of claim 1 wherein said first insulated wire includes
copper.
3) The joint of claim 2 wherein said first insulated wire is
capable of carrying DC current up to 1000V.
4) The joint of claim 1 wherein said synthetic rubber sealant is a
silicone based rubber sealant.
5) The joint of claim 1 wherein said encasement includes a UV
stabilization agent.
6) The joint of claim 1 wherein said encasement is molded in a
shape selected from the group consisting of T-shaped, cross-shaped
and Y-shaped.
7) The joint of claim 1 wherein said encasement defines at least
one securing aperture.
8) The joint of claim 1 wherein said encasement defines at least
one channel, said first insulated wire protruding outwardly from
said encasement through said channel.
9) A wire harness, said harness comprising: a. at least one joint
comprising a first exposed portion of a first insulated wire welded
to a second exposed portion of a second insulated wire; cured
synthetic rubber sealant surrounding said weld; and a polypropylene
encasement surrounding said sealant; and b. at least one female
connector attached to said first insulated wire.
10) The wire harness of claim 9 wherein said insulated wire
comprises at least one photovoltaic wire.
11) The wire harness of claim 10 wherein the gauge of said
photovoltaic wire includes at least one gauge selected from the
group consisting of 8, 10, and 12 AWG.
12) The wire harness of claim 9 further comprising at least one
male connector in communication with said second insulated
wire.
13) A method of making an electrical joint comprising the acts of:
a. stripping a portion of insulation off a first insulated wire to
form a first exposed portion; b. stripping a portion of insulation
off a second insulated wire to form a second exposed portion; c.
forming a fused portion by fusing said first exposed portion to
said second exposed portion; d. covering said fused portion, said
first exposed portion and said second exposed portion in sealant;
e. curing said sealant; and f. enclosing said sealant in an
encasement including a plurality of protrusions and defining at
least one securing aperture positioned at the vertex of two of said
protrusions.
14) The method of claim 13 wherein covering said fused portion
includes the act of applying a synthetic rubber sealant.
15) The method of claim 13 wherein enclosing said sealant in an
encasement includes the act of molding said encasement.
16) The method of claim 13 further including the non-sequential act
of attaching a female connector to said first insulated wire.
17) The method of claim 16 further including the non-sequential act
of attaching a male connector to be in communication with said
second insulated wire.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of, and claims
the benefit of, U.S. application Ser. No. 12/502,395, having a
filing date of Jul. 14, 2009.
BACKGROUND
[0002] (1) Field
[0003] The present invention relates generally to electrical
components and, more particularly, to low leakage electrical joints
and wire harnesses for simplifying the electrical infrastructure
associated with solar energy utilities. The low leakage electrical
joints include fused wires that have been sealed, encased and
configured to plug into other joints to form wire harnesses.
[0004] (2) Related Art
[0005] The problems associated with the world's dependence on
non-renewable resources have resulted in increased attention to
so-called alternative energy, such as solar and wind power. As a
result, small-scale production of alternative energy, for example
by installing residential solar heaters or wind turbines, has
become more popular. While these actions may provide psychological
and possible long-term financial benefits, their actual effect on
society's consumption of non-renewable resources is minimal. In
short, permanent and significant changes necessitate the
implementation of alternative energy generation on a large-scale
utility basis.
[0006] Utility scale production of solar energy, however, is often
considered financially imprudent given the high cost of materials,
know-how, and labor. For example, conventionally wiring solar
panels typically requires a qualified electrician to measure, cut,
connect and crimp wires on site, by hand, between each individual
solar panel's junction box and the combiner box, and the combiner
box and master fuse box. In addition, this extensive wiring often
further requires the labor and expense of troubleshooting and
repairing.
[0007] In addition, conventional solar utility infrastructures
often have technical shortcomings that further drive up the price.
For example, conventional wire connections leak precious energy,
thereby decreasing the efficiency, and increasing the price, of the
system.
[0008] Accordingly, the interests of being environmentally
responsible often conflict with the financial realities of building
and maintaining a solar energy plant.
[0009] Thus, there remains a need for components for use in solar
plants that decrease the materials, know-how and/or labor
associated with building and maintaining the electrical
infrastructure.
[0010] There also remains a need for components for use in solar
plants that decrease the cost associated with the materials,
know-how and/or labor in building and maintaining the electrical
infrastructure of a solar plant.
[0011] A need also exists for components that decrease electrical
leakage. Ideally, these low leakage components are relatively
simple, safe and inexpensive to manufacture, transport and use.
[0012] A method of making the aforementioned components is also
needed.
SUMMARY OF THE INVENTIONS
[0013] The present inventions are directed to low leakage
electrical joints and wire harnesses for simplifying the electrical
infrastructure associated with solar energy utilities. The low
leakage electrical joints include insulated photovoltaic wire which
has been partially stripped, with the portion of exposed wire
welded to a portion of exposed wire on another, separate
photovoltaic wire. The section encompassing the exposed wire and
weld is coated in a synthetic rubber sealant and allowed to cure.
After curing, the section of exposed/fused/sealed wire is encased
in a molded polypropylene material including a UV stabilizing
agent. These resulting joints can be shaped as T's, crosses or Y's,
and be fitted with various lengths of insulated wire, female
connectors and/or male connectors for attachment to at least one
other joint. Wire harnesses can be assembled using a plurality of
these joints, usually with lengths of insulated wire there
between.
[0014] The nature of the present inventions will become apparent to
those skilled in the art after reading the following description of
the preferred embodiment when considered with the drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0015] FIG. 1 schematically represents the electrical
infrastructure of a solar energy system;
[0016] FIG. 2 illustrates a wire harness, including enlarged male
and female connectors;
[0017] FIG. 3 is a front view of a tee joint;
[0018] FIG. 4 is a front view of a cross joint;
[0019] FIG. 5 is a front view of a y joint;
[0020] FIG. 6 is a perspective view of a tee joint encasement;
[0021] FIG. 7 is a perspective view of a cross joint
encasement;
[0022] FIG. 8 is a perspective view of a y joint encasement;
and
[0023] FIG. 9 depicts some steps in constructing a tee joint.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] In the following description, like reference characters
designate like or corresponding parts throughout the several views.
It should be understood that the illustrations are for the purpose
of describing a preferred embodiment of the inventions and are not
intended to limit the inventions thereto.
[0025] FIG. 1 provides the general scheme of the electrical
infrastructure of the present inventions. Each solar collector has
junction box, with each junction box wired to a central combiner
box via wire harness 10. The central combiner box bundles the
output into trunk 15, which goes into the master fuse box.
Electricity from the master fuse box travels to the inverter, then
transformer, then power line.
[0026] Referring to FIG. 2, wire harness 10 is constructed of a
plurality of joints, potentially including tee joint 20, cross
joint 22 and/or y joint 24 (not shown in FIG. 2). The joints are
connected one to another via insulated wire 30, and include female
connector 26 or male connector 28 at various junctions. It should
be understood that a multitude of electrical configurations may be
achieved by varying the number and choice of connectors and joint
types, and that FIG. 2 merely represents the preferred
configuration for coupling a plurality of junction boxes to a
combiner box.
[0027] Tee, cross and y joints of FIGS. 3, 4, and 5 respectively
are constructed similarly with respect to each other, but vary
according to shape and function. Using tee joint 20 as an example,
joints comprise spokes 58 protruding from central hub 56,
terminating in female connector 26 or male connector 28. Length of
spokes 58 may be elongated by including longer lengths of insulated
wire 30. Central hub 56 includes external tee encasement 60, which
defines channels 54 (best shown in FIG. 6) through which insulated
wire 30 protrudes outwardly (best shown in FIG. 2). Outwardly
protruding insulated wire 30 may not be visible if connector 26,
28, which is attached to insulated wire 30, abuts channel, as shown
in FIG. 3. External tee encasement 60 preferably defines securing
apertures 52 through which zip ties or other fasteners may be
employed to secure tee joint 20 or wire harness 10 to prevent
unwanted movement during or subsequent to installation. Also,
informational window 45 is preferred for displaying manufacturer,
part number, technical specifications and the like.
[0028] Beneath tee encasement 60 lies sealed wire 38, which
collectively includes segments of exposed wire 34, portions of
which are welded wire 36, covered in sealant 40. This construction
is best exemplified in the scheme set forth in FIG. 9 wherein it
should be understood that encasement 50 is depicted, but similar
construction applies employing tee encasement 60, cross encasement
62 or y encasement 64.
[0029] Referring specifically to FIG. 9A, tee joint 20 is
constructed by taking two separate insulated wires 30, and
stripping off a portion of insulation 32 to reveal exposed wire 34,
as shown in FIG. 9B. Preferably, the trunk wire would be window
stripped to expose an internal section of wire, whereas a branch
wire would be end stripped. Preferably insulated wire 30 includes
copper, and most preferably is a 8, 10 or 12 AWG photovoltaic wire
which is certified by UL and/or TUV for use with solar applications
to carry DC current up to 1000V. A branch wire may be the next
smaller size of wire as it will not carry as much current.
Preferably insulation 32 is constructed of crosslinked polyolefin
copolymer and is 1.7 mm thick. One preferred example of a
commercially available and suitable insulated wire 30 is Betaflam
Solar from Leoni Studer AG of CH-4658 Daniken, Switzerland. As
shown in FIG. 9C, exposed wires are resistance welded to form
welded wire 36, with the end of the branch wire preferably welded
to the center of the trunk wire. Resistance welding is preferably
accomplished by using two copper electrodes which pass a high
current through the joint causing the wires to be fused to form a
solid material at the joint.
[0030] Fused wires 36 and any remaining exposed wires 34 are
completely coated with sealant 40, as shown in FIG. 9D. Preferably
sealant 40 is a synthetic rubber, more preferably a silicone-based
rubber sealant, with Plasti Dip.RTM. multi-purpose rubber coating
from Plasti Dip International of Blaine, Minn. being the most
preferred. Preferably sealant 40 is applied with a small brush, in
a volume adequate to cure at a thickness of approximately 20 mils.
Sealant 40 is permitted to completely cure, preferably at room
temperature for approximately 4 hours. Once cured, the assembly is
placed in a mold according to methods known in the art, and
overmolded to form encasement 50, as shown in FIG. 9E. Encasement
50 is preferably formed using a polypropylene material, most
preferably including a UV stabilization agent. The preferred
polypropylene material is RTP 199 from RTP Imagineering Plastics of
Winona, Minn.
[0031] Slight modifications would be necessary to form cross or y
joints 22 and 24, particularly with respect to stripping and fusing
wire. Moreover, additional steps would be required to secure female
and male connectors 26 and 28 to segments of insulated wire 30.
Namely, the wire will be cut, stripped and terminated with the
applicable terminal, then a rubber boot will be installed to
insulate the terminal. As assembled, all electrically live
components of wire harness 10, including insulated wire 30, exposed
wire 34, sealed wire 38 and connectors 26, 28 are all in electrical
communication one with another.
[0032] In use, an installer would simply select the proper wire
harness 10, preferably based on labeling or packaging, and connect
the appropriate parts (ie female connectors 26 to junction boxes of
solar collectors, and male connector 28 to combiner box). Wire
harnesses of popular specifications can be manufactured in bulk, or
specially assembled in advance if lesser quantities are required,
or constructed on site as required by employing pre-assembled
joints 20, 22, 24, connectors 26, 29 and insulated wire 30.
[0033] In addition to the novel construction and substantial
savings with respect to materials, know-how and labor, the present
inventions provide exceptionally low leakage compared to
conventional solar connectors. Specifically, both the MC Solarline
1 connector from Multi-Contact AG of Stockbrunnenrain, Switzerland,
and the Solarlok connector of Tyco Electronics in Speyer, Germany,
leak 1 mA (milliamp). In contrast, tee, cross and y joints 20, 21
and 24 of the present inventions leak less than 50 nA (nanoamps).
This is well below the maximum industry standard of 50 mA, as set
forth by the solar industry leader.
[0034] Certain modifications and improvements will occur to those
skilled in the art upon a reading of the foregoing description. It
should be understood that all such modifications and improvements
have been deleted herein for the sake of conciseness and
readability but are properly within the scope of the following
claims.
* * * * *