Connector and electronic circuit assembly for improved wet insulation resistance

• US 9,398,712 B2
• Filed: 09/29/2011
• Issued: 07/19/2016
• Est. Priority Date: 09/30/2010
• Status: Expired due to Fees

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Reese, Jason A., Teli, Samar R., Keenihan, James R., Langmaid, Joseph A., Maak, Kevin D., Mills, Michael E., Plum, Timothy C., Ramesh, Narayan
• Primary Examiner(s): Barrera, Ramon M
• Application Number:
  US13/821,833
• Publication Number:
  US 20130170149A1
• Time in Patent Office: 1,755 Days
• Field of Search: 136/251
• US Class Current: 1/1
• CPC Class Codes: H01R 13/5202 Sealing means between parts of housing or between housing part and a wall, e.g. sealing rings
• CPC Class Codes: H01R 9/226 comprising a plurality of conductive flat strips providing connection between wires or components H01R9/2425 takes precedence
• CPC Class Codes: H02S 20/25 Roof tile elements
• CPC Class Codes: H02S 40/34 comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
• CPC Class Codes: H02S 40/36 characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
• CPC Class Codes: H05K 7/00 Constructional details common to different types of electric apparatus casings, cabinets, drawers H05K5/00
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

The present invention is premised upon a connector and electronic circuit assembly (130) at least partially encased in a polymeric frame (200). The assembly including at least: a connector housing (230); at least one electrical connector (330); at least one electronic circuit component (430); and at least one barrier element (530).

Claims

1. A photovoltaic device comprising:

a polymeric frame; and

a multi-layered multi-layer laminate structure that includes a connector and electronic circuit assembly;

wherein the connector and electronic circuit assembly is at least partially encased in the polymeric frame and comprises;

a connector assembly comprising;

a connector housing;

at least one electrical connector protruding from the housing;

an electronic circuit component comprising;

at least one bus bar; and

a connection zone where the at least one electrical connector and the at least one bus bar are joined;

wherein the connection zone, the connector housing, or both include at least one elastomeric barrier element; and

wherein the at least one elastomeric barrier element comprises a polyisobutylene tape.

2. The photovoltaic device according to claim 1, wherein the at least one elastomeric barrier element maintains a minimum compression value of 5% to 30% when encased in the polymeric frame.

3. The photovoltaic device according to claim 1, wherein the at least one elastomeric barrier element has a hardness between 20 to 100 Shore A Durometer per ASTM D2240 00.

4. The photovoltaic device according to claim 1, wherein the at least one elastomeric barrier element includes at least one rib structure projecting away from a traverse length of the connector housing.

5. The photovoltaic device according to claim 4, wherein the at least one rib structure has a height ranging between 0.5 mm to 2.5 mm.

6. The photovoltaic device according to claim 1, wherein the at least one elastomeric barrier element maintains an adhesive joint between the connection zone, the connector housing, or both and the polymeric frame between −

40°

C. and 85°

C.

7. The photovoltaic device according to claim 1, wherein the at least one elastomeric barrier element selected from the group consisting of silicone, polychloroprene, butadiene/acrylonitrile copolymer, EPDM rubber, polyurethane, and polyisobutylene.

8. The photovoltaic device of claim 1, wherein the at least one elastomeric barrier element is located between the connection zone and the polymeric frame.

9. The photovoltaic device of claim 8, wherein the polymeric frame is a filled or unfilled moldable plastic.

10. The photovoltaic device of claim 1, wherein the connector and electronic circuit assembly are at least partially encased in the polymeric frame so that the elastomeric barrier element functions to create an adhesive joint between the connection zone, the connector housing, or both.

11. The photovoltaic device of claim 10, wherein the elastomeric barrier element functions to create an adhesive joint between the connection zone, the connector housing, or both and the polymeric frame.

12. The photovoltaic device of claim 11, wherein the connection zone and the connector housing where the elastomeric barrier element extends is encased in the polymeric frame.

13. A photovoltaic device comprising:

a polymeric frame; and

a multi-layered multi-layer laminate structure that includes a connector and electronic circuit assembly;

wherein the connector and electronic circuit assembly is at least partially encased in the polymeric frame and comprises;

a connector assembly comprising;

a connector housing;

at least one electrical connector protruding from the housing;

an electronic circuit component comprising;

at least one bus bar; and

a connection zone where the at least one electrical connector and the at least one bus bar are joined;

wherein the connection zone, the connector housing, or both include at least one elastomeric barrier element; and

wherein the at least one elastomeric barrier element is a tape at room temperature and the tape is wrapped around the connection zone, the connector housing, or both to form the at least one elastomeric barrier element.

14. The photovoltaic device according to claim 13, wherein the elastomeric element material has a Young'"'"'s modulus such that a modulus ratio of the frame material to the modulus to the elastomeric element material at 23°

C. is at least 500;

1, the modulus ratio at −

40°

C. is at least 50;

1, and the modulus ratio at 85°

C. is at least 10000;

1.

15. The photovoltaic device of claim 13, wherein the at least one elastomeric barrier element is an adhesive joint between the connection zone and the polymeric frame.

16. A photovoltaic device comprising:

a polymeric frame; and

a multi-layered multi-layer laminate structure that includes a connector and electronic circuit assembly;

wherein the connector and electronic circuit assembly is at least partially encased in the polymeric frame and comprises;

a connector assembly comprising;

a connector housing;

at least one electrical connector protruding from the housing;

an electronic circuit component comprising;

at least one bus bar; and

a connection zone where the at least one electrical connector and the at least one bus bar are joined;

wherein the connection zone, the connector housing, or both include at least one elastomeric barrier element;

wherein the at least one elastomeric barrier element is located between the connector housing and the polymeric frame; and

wherein the at least one elastomeric barrier element is an adhesive joint between the connector housing and the polymeric frame.

17. The photovoltaic device according to claim 16, wherein the at least one elastomeric barrier element comprises a polyisobutylene tape.

18. The photovoltaic device of claim 16, wherein the at least one elastomeric barrier element is a butyl tape.