Dual compressive connector

• US 9,692,164 B2
• Filed: 06/14/2016
• Issued: 06/27/2017
• Est. Priority Date: 05/22/2009
• Status: Active Grant

• Current Assignee: Solaredge Technologies Incorporated
• Original Assignee: Solaredge Technologies Incorporated
• Inventors: Shmukler, Vadim, Gershman, Israel
• Primary Examiner(s): NASRI, JAVAID H
• Application Number:
  US15/181,912
• Publication Number:
  US 20160359254A1
• Time in Patent Office: 378 Days
• Field of Search: 439724, 439439, 439786, 439787, 439788, 439835, 439861
• CPC Class Codes: H01L 31/02002 Arrangements for conducting electric current to or from the device in operations
• CPC Class Codes: H01L 31/0201 comprising specially adapted module bus-bar structures
• CPC Class Codes: H01R 13/2414 conductive elastomers
• CPC Class Codes: H01R 13/2435 with opposite contact points, e.g. C beam
• 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: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing

Abstract

An electrical connector for electrically connecting multiple photovoltaic bus bars. A casing includes first and second opposing walls. An elastic strip is bent into a bent elastic strip with a first leg and a second leg. The bent elastic strip is disposed between the first and second walls of the casing with the first leg pressing against the first wall and the second leg pressing against the second wall. The bent elastic strip is configured to hold at least one of the photovoltaic bus bars between the first leg and the first wall and another of the photovoltaic bus bars between the second leg and the second wall. The bent elastic strip may be formed of resilient spring metal with a thickness and an elastic modulus. The thickness and/or the elastic modulus of the elastic strip is/are configured so that the bus bars are inserted without requiring a tool to open a space and so that the bus bars are removed from the connector without requiring a tool to break the electrical connection.

Claims

1. A photovoltaic panel, comprising:

a circuit board;

a wall; and

an electrical connector, comprising;

a casing, comprising a first casing wall, a second casing wall facing the first casing wall, a third casing wall, a fourth casing wall facing the third casing wall, and an extension portion that extends through the wall and electrically connects to the circuit board, the casing forming a first opening to receive a first bus bar and a second bus bar and a second opening to receive a third bus bar and a fourth bus bar;

a first elastic strip, comprising a first leg configured to hold the first bus bar against the first casing wall, and a second leg configured to hold the second bus bar against the second casing wall; and

a second elastic strip, comprising a third leg configured to hold the third bus bar against the third casing wall, and a fourth leg configured to hold the fourth bus bar against the fourth casing wall.

2. The photovoltaic panel of claim 1, wherein the first leg comprises a protrusion configured to be inserted into and pass through a hole in the first casing wall.

3. The photovoltaic panel of claim 1, wherein the extension portion extends from one end of the first casing wall and the other end of the first casing wall forms the first opening.

4. The photovoltaic panel of claim 1, wherein the extension portion forms a solder hole through which the extension portion is soldered to the circuit board.

5. The photovoltaic panel of claim 1, wherein the extension portion and the first casing wall are integrally formed from a single sheet of metal.

6. The photovoltaic panel of claim 1, wherein the first elastic strip is symmetric such that the first leg and the second leg are substantially equivalent in size and shape.

7. The photovoltaic panel of claim 1, wherein a single bend of the first elastic strip forms the first leg and the second leg.

8. The photovoltaic panel of claim 7, wherein a single bend of the second elastic strip forms the third leg and the fourth leg.

9. An electrical connector, comprising:

a casing, comprising a first wall, a second wall facing the first wall, a third wall, a fourth wall facing the third wall, and an extension portion configured to electrically connect to a circuit board, the casing forming a first opening to receive a first bus bar and a second bus bar and a second opening to receive a third bus bar and a fourth bus bar;

a first elastic strip, comprising a first leg configured to hold the first bus bar against the first wall and a second leg configured to hold the second bus bar against the second wall; and

a second elastic strip, comprising a third leg configured to hold the third bus bar against the third wall and a fourth leg configured to hold the fourth bus bar against the fourth wall.

10. The electrical connector of claim 9, wherein the casing is constructed to receive the first elastic strip through the first opening.

11. The electrical connector of claim 9, wherein the first leg and the second leg are integrally formed by a single bend of metal.

12. The electrical connector of claim 11, wherein the third leg and the fourth leg are integrally formed by a single bend of metal.

13. The electrical connector of claim 9,

wherein the fourth leg of the first elastic strip is slotted longitudinally over a portion thereof to form a fifth leg, and

wherein the fifth leg is configured to hold a fifth bus bar against the fourth wall.

14. The electrical connector of claim 9, wherein the first leg comprises a first protrusion that passes through a first hole in the first wall.

15. The electrical connector of claim 14, wherein the second leg comprises a second protrusion that passes through a second hole in the second wall.

16. The electrical connector of claim 14, wherein the fourth leg comprises a second protrusion that passes through a second hole in the fourth wall.

17. The electrical connector of claim 9, wherein the casing is constructed to provide two holes in the first wall through which two protrusions on the first leg are inserted and two holes in the fourth wall through which two protrusions on the fourth leg are inserted.

18. The electrical connector of claim 9, wherein the first elastic strip is symmetric such that the first leg and the second leg are substantially equivalent in size and shape.

19. A method, comprising:

folding a sheet of metal to form a casing, comprising a first wall, a second wall facing the first wall, a third wall, a fourth wall facing the third wall, and an extension portion configured to electrically connect to a circuit board, wherein the casing forms a first opening to receive a first bus bar and a second bus bar and a second opening to receive a third bus bar and a fourth bus bar; and

inserting a first elastic strip through the first opening between the first wall and the second wall, wherein the first elastic strip comprises a first leg configured to hold the first bus bar against the first wall and a second leg configured to hold the second bus bar against the second wall; and

inserting a second elastic strip through the second opening between the third wall and the fourth wall, wherein the second elastic strip comprises a third leg configured to hold the third bus bar against the third wall and a fourth leg configured to hold the fourth bus bar against the fourth wall.

20. The method of claim 19, further comprising:

inserting the extension portion through a wall;

soldering, through a hole in the extension portion, the extension portion to a solder pad on the circuit board;

inserting, through the first opening, the first bus bar between the first wall and the first leg;

inserting, through the first opening, the second bus bar between the second wall and the second leg;

inserting, through the second opening, the third bus bar between the third wall and the third leg; and

inserting, through the second opening, the fourth bus bar between the fourth wall and the fourth leg.