Module for electrically connecting conductor wires to circuits of flat surfaces such as solar panels

• US 5,513,075 A
• Filed: 03/02/1994
• Issued: 04/30/1996
• Est. Priority Date: 05/08/1992
• Status: Expired due to Term

• Current Assignee: The Whitaker Corporation (Meggitt PLC)
• Original Assignee: The Whitaker Corporation (Meggitt PLC)
• Inventors: Denovich, Sam, Robertson, James W., Capper, Harry M.
• Primary Examiner(s): SPARKS, DONALD ALAN
• Application Number:
  US08/204,975
• Time in Patent Office: 790 Days
• Field of Search: 361/728, 361/729, 361/730, 361/733, 361/736, 361/740, 361/752, 361/807, 361/809, 361/822, 361/823, 174/52.1, 174/52.2, 174/52.3, 174/52.4, 174/60, 439/122, 439/131, 439/132, 439/142, 439/143, 439/144, 439/151, 439/158, 439/709, 439/711, 439/715, 439/716, 439/717, 439/718, 439/620, 439/389-410, 379/399, 379/442, 379/412, 379/415
• US Class Current: 361/773
• CPC Class Codes: H01R 13/6666 with built-in overvoltage protection
• CPC Class Codes: H01R 4/2441 tube-shaped
• CPC Class Codes: H01R 9/24 Terminal blocks
• CPC Class Codes: H01T 4/06 Mounting arrangements for a plurality of overvoltage arresters
• 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: H04M 1/0293 Terminal boxes for telephone sets
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A connector module (10,100,200) having at least one electrical terminal (24,116,206) therein, adapted to be sealingly mounted to a mounting surface upon being placed thereagainst at a connection site (30,112,204), and simultaneously form electrical connections of each terminal with a circuit (38,152,214) thereat, with the terminal adapted to be thereafter terminated to a discrete conductor wire (60,138,210,212) to interconnect the circuit with the wire. Upstanding lead members (40,160,216) are electrically connected to the circuits and are received into pin-receiving holes (50,172) along the module'"'"'s bottom surface and become engaged with respective terminals. Each terminal is terminated to such a wire upon actuation of an actuator (26,118). A base section (14,104) of the module forms a seal with the mounting surface around the connection site (30,112,204). Such module can easily be mounted to a solar panel (32,110) or circuit board (202). The module can receive thereinto a circuit-bearing element (124) having components (122) mounted thereon upon being mounted to the mounting surface and environmentally seal therearound.

Claims

1. A conductor assembly for connecting at least one discrete conductor to a respective circuit of an article and that is mountable to a generally planar mounting surface of the article defining a connection site, comprising:

a housing module having a base section defining a mounting face adapted to be mounted to said surface at said connection site with adhesive sealing material disposed between said mounting surface and said surface surrounding said connection site, said housing module including at least one housing section for a respective terminal, and an at least one said terminal disposed in a terminal-receiving cavity of a respective said housing section and having at least one conductor-terminating section exposed in a respective conductor-receiving opening of said housing section, with fluid sealing material disposed within said terminal-receiving cavity embedding said terminal, and said housing module further including an actuator adapted to move said terminal from a first unterminated position to a second terminated position upon insertion of an end of a said conductor into said conductor-receiving opening of said housing section;

a lead member affixed to said article in a manner defining an electrical connection thereof to each said circuit of said article to which a said discrete conductor is to be interconnected, each said lead member including a pin section extending orthogonally from a surface of said article to a free end; and

said mounting face of said housing module including a pin-receiving opening orthogonal to the mounting face and associated with each said lead member adapted to receive thereinto said pin section thereof upon mounting said housing module to said article surface, said pin-receiving opening being in communication with said terminal-receiving cavity of a respective said housing section, said terminal-receiving cavity adapted to urge said pin section of a respective said lead member against a surface of a said terminal upon mounting of said housing module to said connection site and during actuation thereof from said first position to said second position,

whereby a sealed connective arrangement is defined upon mounting said housing module to said mounting surface at said connection site.

2. The assembly as set forth in claim 1 wherein said lead member includes a flat, relatively wide base section including a flat surface soldered to a terminus of a circuit.

3. The assembly as set forth in claim 2 wherein said flat surface of said lead member is a bottom of said base section, and said lead member is mounted atop a surface containing said circuit.

4. The assembly as set forth in claim 1 wherein said article is a planar circuit-bearing element and said housing module includes a cavity adapted to receive thereinto said planar circuit-bearing element along said mounting face.

5. The assembly as set forth in claim 4 wherein said planar circuit-bearing element includes electrical or electronic components mounted thereon and electrically connected to at least two said circuits thereof defining a component subassembly, and said cavity is adapted to receive thereinto said component subassembly.

6. The assembly as set forth in claim 5 wherein said housing module includes a fill hole and a corresponding vent hole enabling injection of potting material into said cavity to embed an inwardly facing surface of said component subassembly and seal the electrical connections contained therein.

7. The assembly as set forth in claim 1 wherein said housing module base section includes a mounting flange peripherally therearound including peripheral wall sections extending to a coplanar edge abuttable with said mounting surface and defining a shallow recess therewithin to contain adhesive material for adhering said housing module to said mounting surface.

8. The assembly as set forth in claim 1 wherein said housing module base section includes a shallow recess adjacent each said pin-receiving opening therethrough for receipt thereinto of a base section of a respective said lead during placement of said housing module onto said connection site.

9. A connective arrangement for connecting at least two discrete conductors to respective circuits of an article and that is mountable to a generally planar mounting surface of the article defining a connection site, comprising:

an article containing at least two circuits and including an electrical or electronic component secured thereto in electrical connection with at least two said circuits;

a housing module having a base section defining a mounting face adapted to be mounted to said surface at said connection site with adhesive sealing material disposed between said mounting surface and said surface surrounding said connection site, said housing module including at least one housing section for a respective terminal, an at least one said terminal disposed in a terminal-receiving cavity of a respective said housing section and having at least one conductor-terminating section exposed in a respective conductor-receiving opening of said housing section, with fluid sealing material disposed within said terminal-receiving cavity embedding said terminal, and said housing module further including an actuator adapted to move said terminal from a first unterminated position to a second terminated position upon insertion of an end of a respective said conductor into said conductor-receiving opening of said housing section;

a lead member affixed to said article in a manner defining an electrical connection thereof to each said at least one circuit of said article, said lead member including a pin section extending orthogonally from a surface of said article to a free end; and

said mounting face of said housing module including a pin-receiving opening orthogonal to the mounting face and associated with each said lead member adapted to receive thereinto said pin section thereof upon mounting said housing module to said article surface, said pin-receiving opening being in communication with said terminal-receiving cavity of a respective said housing section, said terminal-receiving cavity adapted to urge said pin section of a respective said lead member against a surface of a said terminal upon mounting of said housing module to said connection site and during actuation thereof from said first position to said second position; and

said housing module includes in communication with said mounting face a cavity adapted to receive thereinto an at least one electrical or electronic component mounted onto said article and electrically connected to at least two said circuits thereof,

whereby a sealed connective arrangement is defined upon mounting said housing module to said mounting surface at said connection site.

10. The connective arrangement as set forth in claim 9 wherein said lead member includes a flat, relatively wide base section including a flat surface soldered to a terminus of a circuit.

11. The connective arrangement as set forth in claim 10 wherein said flat surface of said lead member is a bottom of said base section, and said lead member is mounted atop a surface containing said circuit.

12. The connective arrangement as set forth in claim 9 wherein said article is a planar circuit-bearing element containing said at least one electrical or electronic component defining a component subassembly, and said housing module includes a cavity adapted to receive thereinto said component subassembly along said mounting face.

13. The connective arrangement as set forth in claim 12 wherein said circuit-bearing element includes contact members exposed to permit electrical connections of said at least two circuits thereof with corresponding circuits defined on said mounting surface.

14. The connective arrangement as set forth in claim 13 wherein said housing module is adapted to receive said component subassembly into said cavity while simultaneously receiving said pin sections of said lead members into respective said pin-receiving holes, enabling said contact members to be electrically connected to said corresponding circuits of said mounting surface prior to said housing module being placed over said component subassembly and adhered to said mounting surface and sealing around said component subassembly and exposed electrical connections thereof.

15. The connective arrangement as set forth in claim 9 wherein said housing module includes a fill hole and a corresponding vent hole enabling injection of potting material into said cavity to embed an inwardly facing surface of said component subassembly and seal the electrical connections contained therein.

16. The connective arrangement as set forth in claim 9 wherein said housing module base section includes a mounting flange peripherally therearound including peripheral wall sections extending to a coplanar edge abuttable with said mounting surface and defining a shallow recess therewithin to contain adhesive material for adhering said housing module to said mounting surface.

17. The connective arrangement as set forth in claim 9 wherein said connection site is defined on said article surface surrounding termini of said at least two circuits thereof.

18. The connective arrangement as set forth in claim 9 wherein said article is a planar circuit-bearing element defining said mounting surface.