External electrical connectors for solar modules

• US 8,123,565 B2
• Filed: 05/10/2011
• Issued: 02/28/2012
• Est. Priority Date: 06/30/2009
• Status: Expired due to Fees

• Current Assignee: Beijing Apollo Ding Rong Solar Technology Co., Ltd
• Original Assignee: MiaSole Incorporated (Wei Jun Li)
• Inventors: Corneille, Jason, Meyers, Michael
• Primary Examiner(s): Patel, Tulsidas C
• Assistant Examiner(s): NGUYEN, PHUONGCHI T
• Application Number:
  US13/104,885
• Publication Number:
  US 20110277811A1
• Time in Patent Office: 294 Days
• Field of Search: 439/627, 439/855, 439/502, 439/521, 439/522, 439/754, 174/138.F, 136/244
• US Class Current: 439/627
• CPC Class Codes: H01L 31/02008 for solar cells or solar cell modules
• CPC Class Codes: H01R 11/11 End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member H01R11/01 takes precedence
• CPC Class Codes: H01R 13/64 Means for preventing incorrect coupling
• CPC Class Codes: H01R 2101/00 One pole
• CPC Class Codes: H01R 24/20 Coupling parts carrying sockets, clips or analogous contacts and secured only to wire or cable
• CPC Class Codes: H01R 24/66 with pins, blades or analogous contacts and secured to apparatus or structure, e.g. to a wall
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

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.

Claims

1. A solar module, comprising:

a conductive member comprising a conductive base portion and a cylindrical portion having first and second ends with a insulative portion at the second end and a conductive portion extending from the insulative portion to the first end;

a sheath member positioned about said cylindrical portion to surround at least the conductive portion thereof; and

a socket member comprising a base portion and a hollow conductive cylindrical member extending from the base portion and configured to mate with a conductive portion of the conductive member,

wherein said sheath member and said socket member included keyed inter-engageable features.

2. The solar module of claim 1 wherein the profile of an assembly including the conductive member, the sheath member and the socket member when the socket member is mated to the conductive portion of the conductive member is no more than about 1.5 inches.

3. The solar module of claim 1 wherein the cylindrical portion of the conductive member is no more than about 0.5 inches long.

4. The solar module of claim 1 wherein the keyed features of the sheath member form a circle and wherein the keyed features of the socket member form a circle.

5. The solar module of claim 4 wherein keyed features of the sheath member are engageable with the keyed features of the socket member in any rotational position of the socket member in a plane substantially orthogonal to the axis of the cylindrical member.

6. The solar module of claim 1 wherein the keyed inter-engageable features include a circular groove and a raised circular ridge configured to fit into said groove.

7. The solar module of claim 1 wherein the keyed inter-engageable features include at least one slot and at least one prong configured to fit into the at least one slot.

8. The solar module of claim 1 wherein the conductive member extends through an outer layer of the module, and further comprising a seal on the interior of the module disposed between the conductive base portion of the conductive member and the outer layer.

9. The solar module of claim 1 wherein the keyed features of one of the sheath member and the socket member include one or more flexibly resilient members;

further wherein the keyed features of the other of the sheath member and the socket member comprise substantially inflexible locking members configured to engage the flexibly resilient members.

10. The solar module of claim 9 wherein, when the keyed inter-engageable features of the sheath member and the socket member are engaged, the connector is locked.

11. The solar module of claim 10 wherein the keyed inter-engageable features include an aperture for accepting a tool configured to unlock the connector.

12. The solar module of claim 1 wherein said sheath member and said socket member include lockable inter-engageable features.

13. The solar module of claim 12 wherein the lockable features of one of the sheath member and the socket member include one or more rimmed locking portions;

further wherein the lockable features of the other of the sheath member and the socket member include ridged lock accepting portions configured to engage the rimmed locking portion members.

14. The solar module of claim 12 wherein the lockable features of one of the sheath member and the socket member comprise one or more flexibly resilient members;

further wherein the lockable features of the other of the sheath member and the socket member comprise substantially inflexible locking members configured to engage the flexibly resilient members.

15. A solar module, comprising:

a conductive member including a conductive portion;

a sheath member positioned to surround at least the conductive portion of the conductive member and including a first engageable feature; and

a socket member configured to mate with the conductive portion of the conductive member and including a second engageble feature configured to engage with the first engageable feature,

wherein one of the first and second engageable features includes a groove and the other of the first and second engageable feature includes a raised portion configured to mate with the groove.

16. The solar module of claim 15, wherein the first and second engageable features are keyed.

17. The solar module of claim 15 wherein first engageable feature is engageable with the second engageable feature in any rotational position of the socket member in a plane.

18. The solar module of claim 15 wherein the socket member includes a base portion and a hollow conductive cylindrical member extending from the base portion and configured to mate with the conductive portion of the conductive member.

19. The solar module of claim 15 wherein the conductive member includes a conductive base and a cylindrical portion having first and second ends with a insulative portion at the second end and the conductive portion extending from the insulative portion to the first end.

20. The solar module of claim 19 wherein the conductive portion is in contact with the conductive base.

21. The solar module of claim 15 wherein the sheath member includes an annular portion.

22. The solar module of claim 21 wherein the sheath member includes a groove in the annular portion configured to mate with a raised portion of the socket.

23. A solar module, comprising:

a conductive member comprising a an axially oriented cylindrical portion having first and second ends;

a sheath member positioned about said cylindrical portion to surround at least the conductive portion thereof; and

a socket member comprising a base portion, a conductive member engaging portion configured to mate with the cylindrical portion of the conductive member,

wherein when the socket member is not engaged with the conductive member, the sheath member surrounds at least the conductive portion of the conductive member such that an electrical connector assembly including the conductive member, sheath member and socket member is finger safe.

24. The solar module of claim 23 wherein the sheath member comprises:

an outer wall, the outer wall comprising a front face, the front face comprising two opposing portions extending inward and sized to allow a connector to fit between the two opposing portions;

a front face opening in the outer wall; and

a ceiling portion having a ceiling opening.

25. The solar module of claim 23 wherein the ceiling opening is in communication with the front face opening.

26. The solar module of claim 23 wherein the ceiling opening is defined by the ceiling portion and is not in communication with the front face opening.

27. The solar module of claim 23 wherein the socket member comprises a base portion having a hollow cylindrical stud-receiving area formed therein.

28. The solar module of claim 23 wherein the socket member includes a vertical nubbin extending from the circular base portion.

29. The solar module of claim 23 wherein the sheath member includes a side wall having a rim and connected to a base, wherein the base comprises a base opening and wherein the diameter of the portion of the side wall that connects to the base is larger than the diameter of the rim.

30. The solar module of claim 23 wherein the cylindrical portion of the conductive member is flared at one end.

31. The solar module of claim 23 wherein the sheath member and socket member include keyed inter-engageable features.

32. The solar module of claim 31 wherein the keyed inter-engageable features include a groove and a raised ridge configured to fit into the groove.

33. The solar module of claim 32 wherein the grooved and raised ridge are circular.

34. A solar module comprising:

first and second encasing layers;

a plurality of interconnected solar cells disposed between the first and second encasing layers;

a first connector assembly comprising a first conductive member extending through an encasing layer and electrically connected to the plurality of interconnected solar cells and a first keyed sheath member associated with the first conductive member, wherein said first keyed sheath member is configured to mate with a first keyed socket member; and

a second connector assembly comprising a second conductive member extending through an encasing layer and electrically connected to the plurality of interconnected solar cells and a second keyed sheath member associated with the second conductive member wherein said second keyed sheath member is configured to mate with a second keyed socket member;

wherein the first keyed sheath member is configured such that it cannot mate with the second keyed socket member, and further wherein the second keyed sheath member is configured such that it cannot mate with the first keyed socket member.

35. The solar module of claim 34 further comprising the first keyed socket member.

36. The solar module of claim 35 further comprising the second keyed socket member.