Mechanical / electrical solar module interface

Abstract

The present invention provides systems, devices, and apparatus for providing both electrical and mechanical connections when solar modules are installed on a torque tube.SOLUTION: The present disclosure describes a system for physically and electrically connecting a solar module to a torque tube. In some implementations, a system includes a bracket and one or more connectors. The bracket includes an electrical interface. The bracket is configured to (i) connect to the solar module and (ii) retain the torque tube within an outer perimeter of the bracket. The one or more connectors are configured to interface with corresponding connectors of the torque tube upon insertion of the torque tube within the outer perimeter of the bracket. Inserting the torque tube within the outer perimeter of the bracket forms both a physical connection and an electrical connection with the torque tube.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 63 / 680,675, filed August 8, 2024. The disclosure of the prior application is considered part of the disclosure of this application and is incorporated by reference into the disclosure of this application. [Background technology]

[0002] Solar panels ("panels") in a solar array (e.g., those at a solar power plant) are often fixed to torque tubes configured to tilt to track the sun and increase the solar power generated by the panels. Typically, the panels are mechanically connected to the torque tubes, and then the electrical connections are made separately. Summary of the Invention [Problem to be solved by the invention]

[0003] The present disclosure includes systems, devices, and apparatus for providing both an electrical connection and a mechanical connection when a solar module is installed in a torque tube. Techniques are described herein for facilitating both the mechanical and electrical connection in a manner that reduces (i) the complexity of the installation, (ii) the time required to install a solar module in a torque tube, (iii) the tools required, and (iv) the skill required by the installer. [Means for solving the problem]

[0004] In some implementations, the system includes a bracket including an electrical interface configured (i) to connect to a solar module and (ii) to hold a torque tube within the periphery of the bracket, and one or more connectors configured to interface with corresponding connectors on the torque tube upon insertion of the torque tube within the periphery of the bracket, such that insertion of the torque tube within the periphery of the bracket forms both a physical connection and an electrical connection with the torque tube.

[0005] The bracket may be shaped to define an interior cavity for receiving the torque tube. One or more connectors may be located on an interior top surface of the bracket.

[0006] One or more connectors can extend away from the inner top surface of the bracket and are configured to engage conductors located on the top surface of the torque tube.

[0007] The bracket may include an access member that is pivotable or rotatable relative to the body of the bracket. The access member may be configured to pivot or rotate between an open position and a closed position.

[0008] The access member can include a rotating member located at an end of the access member and configured to maintain separation between the torque tube and the solar module. The access member can include a locking mechanism configured to secure or lock the access member in the closed position. The locking mechanism can include one or more of a magnet, a latch, and a screw.

[0009] When the bracket is placed on the torque tube, an electrical connection can be made automatically. The electrical connection can be between a conductor located in a recess of the torque tube and a protrusion on the bracket. The one or more connectors can include two or more protrusions laterally offset from one another within the frame. The one or more connectors can include two or more protrusions longitudinally offset from one another within the frame.

[0010] The bracket can be attached to a mounting plate having a width greater than a width of the bracket. The bracket can include an electrical connector configured to electrically connect the bracket to the solar module.

[0011] The solar module may include one or more junction boxes including terminals that facilitate the transfer of power from the solar module, wherein the positive terminal connection of the one or more junction boxes has a different connection configuration than the negative terminal connection of the one or more junction boxes.

[0012] The bracket can include a gap configured to route a cable between the solar module and the torque tube. A first connector of the cable can be attached to the bracket. The torque tube can include a second connector configured to mate with the first connector attached to the bracket. At least one of the first connector and the second connector can include an engagement feature configured to snap into a fixed position upon application of a sufficient amount of force.

[0013] The details of these and other aspects and embodiments of the present disclosure are set forth in the accompanying drawings and the description that follows. Other features, objects, and advantages of the present disclosure will become apparent from the description and drawings, and from the claims. [Brief explanation of the drawings]

[0014] [Figure 1A]FIG. 1 is a diagram of an exemplary system in which both electrical and mechanical connections are made when a solar module is mounted on a torque tube. [Figure 1B] FIG. 1 is a diagram of an exemplary system in which both electrical and mechanical connections are made when a solar module is mounted on a torque tube. [Figure 2A] FIG. 10 is a diagram of another exemplary system in which both electrical and mechanical connections are made when the solar module is mounted on the torque tube. [Figure 2B] FIG. 10 is a diagram of another exemplary system in which both electrical and mechanical connections are made when the solar module is mounted on the torque tube. [Figure 3] FIG. 10 is a diagram of an exemplary system in which two modules are attached to the torque tube by two different brackets. [Figure 4] FIG. 1 illustrates an exemplary system in which brackets are attached to modules. [Figure 5] FIG. 1 is a diagram of an exemplary solar module / panel with connectors. [Figure 6] 1A-1C are diagrams of exemplary brackets that can be connected to a connectorized solar module / panel. [Figure 7] 1 is a diagram of an exemplary torque tube including conductors and configured to facilitate electrical connections between solar modules and other components of a solar power plant installation (e.g., inverters). [Figure 8] 1 is a diagram of an exemplary solar module including a junction box and connectors. [Figure 9] FIG. 10 is a diagram of an exemplary bracket where the electrical interface forms a conduit through which the cables / connectors of the solar module are routed. [Figure 10] FIG. 1 illustrates an exemplary torque tube including a connector housed within the torque tube. [Figure 11] 1 is a diagram of an exemplary solar module including a panel mount connector. [Figure 12]10A-10C are diagrams of an exemplary bracket including a fixed connector at the electrical interface. [Figure 13] 1A and 1B are diagrams of an exemplary torque tube to which a bracket may be attached. [Figure 14] 1A and 1B are diagrams of an exemplary system including a fixed connector. DETAILED DESCRIPTION OF THE INVENTION

[0015] 1A and 1B are diagrams of an exemplary system 100 in which both an electrical connection and a mechanical connection are made when a solar module 102 is mounted on a torque tube 104. In FIG. 1A, the solar module 102 ("module") is connected to a bracket 106 configured to (i) mechanically secure the module 102 to the torque tube 104 and (ii) make an electrical connection to a conductor 107 located within (or on) the torque tube 104. For example, when the bracket 106 is placed on the torque tube 104, the shape of the bracket 106 can prevent the module 102 from becoming dislodged from the torque tube 104. In FIG. 1A, the rear of the bracket 106 (e.g., the portion distal to the connection between the bracket 106 and the module 102) can have an "L" shape, a "C" shape, a "J" shape, a "U" shape, or another similar shape that includes an internal void, such that when the bracket 106 is placed on the torque tube 104, the torque tube 104 is maintained within the outer periphery of the bracket 106. In other words, the bracket 106 is configured to receive the torque tube 104 within the outer periphery of the bracket 106 and to maintain the torque tube 104 within the outer periphery of the bracket 106 .

[0016] In some implementations, the bracket 106 may include a body 108 configured to interact with, connect to, or otherwise secure the bracket 106 to the module 102. In some implementations, the bracket 106 is integrated as part of the frame of the module 102 when the module 102 is manufactured. In some implementations, the bracket 106 may be secured to the module 102 after the module 102 is manufactured using screws, bolts, fasteners, keyholes, or other types of connectors.

[0017] The bracket 106 may include an access member 110 configured to maintain the position of the torque tube 104 within the perimeter of the bracket 106 even when the orientation of the module 102 and bracket 106 changes (e.g., when repositioning the module 102 so that the torque tube 104 tracks the sun). As shown, the access member 110 is shown as a segment of the bracket 106 that is pivotally / rotatably attached to the body 108 of the bracket 106 by fasteners 112. The access member 110 may be attached to the body 108 using a hinge, shoulder bolt, bushing, dowel pin, rotational bearing, or another fastener that allows the access member 110 to rotate relative to the body 108.

[0018] The bracket 106 can be formed from a variety of materials that are strong enough to support the weight of the solar module. Some exemplary materials that can be used to form part or all of the bracket 106 include aluminum, steel (e.g., stainless, galvanized, or coated), and / or zinc alloy. Plastic and rubber can also be used for parts of the bracket, as appropriate.

[0019] FIG. 1A is a diagram of the access member 110 in a closed state. The closed state is a state in which the access member 110 is oriented (or otherwise positioned) to (i) prevent the torque tube 104 from being removed from the interior of the bracket 106 and / or to close (e.g., reduce) access to (i) the interior of the bracket 106 in a specified direction. For example, as shown in FIG. 1A , the access member 110 is oriented such that the inner edges of the access member 110 and the body 108 surround three sides of the torque tube 104, with the module 102 adjacent the last side of the torque tube 104. In this manner, the torque tube 104 is surrounded by the bracket 106 and the module 102 (e.g., on all sides), thereby preventing the torque tube 104 from being removed from the interior of the bracket 106. It should be noted that the torque tube 104 need not be surrounded on all sides, or completely surrounded, in all circumstances, for the access member 110 to be in a closed state. Also, it should be noted that although the module 102 is shown as being offset (e.g., not touching) and the figure shows some space between the torque tube 104 and other components of the system 100 for clarity, the configuration can result in contact between the torque tube 104 and any or all other components.

[0020] FIG. 1B is a diagram of the access member 110 in an open state. The open state is a state in which the access member 110 is oriented (or otherwise positioned) to not prevent or facilitate removal of the torque tube 104 from the interior of the bracket 106 and / or to open (e.g., increase) access to the interior of the bracket 106. For example, as shown, the access member 110 is rotated downward, as indicated by dashed arrow 114, thereby leaving the bottom of the torque tube 104 unconstrained and accessible. In this example, the torque tube 104 can be removed from the interior of the bracket 106 by either lifting the module 102 and / or bracket 106 off the torque tube 104 or by rotating the torque tube 104 to reposition the bottom of the torque tube 104 (as shown in FIG. 1B ), such that gravity causes the module 102 and bracket 106 to slide off the torque tube 104.

[0021] As shown in FIG. 1B , the bracket 106 can include a locking mechanism 116 configured to secure or lock the access member 110 in a closed state. The locking mechanism can be a magnet, a latch (e.g., a latch body or latch bolt), a screw or other mechanical fastener, a snap, or any other mechanism capable of maintaining the access member 110 in a closed state (e.g., by requiring the application of at least a minimal amount of force to remove the access member from the closed state). Examples of magnets that can be used include neodymium magnets (NdFeB), which are often used in magnetic clasp applications, and rare earth magnets such as samarium-cobalt magnets (SmCo), which are resistant to corrosion while providing a strong magnetic connection for magnetic clasp applications. The locking mechanism 116 can be secured to the access member 110 using adhesive or fasteners. Alternatively, the locking mechanism can be embedded in the access member 110 during manufacturing.

[0022] To facilitate securing the access member 110 in a locked state, the torque tube 104 may include a complementary locking mechanism 118, as shown in FIG. 1B . The complementary locking mechanism 118 is configured to engage with the locking mechanism 116 of the access member 110 to maintain the access member 110 in a closed state. For example, the complementary locking mechanism may be a magnet, similar to those described above, or a latch body / latch bolt configured to engage with the latch body / latch bolt of the locking mechanism 116. In situations where the locking mechanism 116 is a screw or bolt, the complementary locking mechanism 118 may be an appropriately sized screw / bolt hole, a nut, or another mechanical device configured to securely receive the screw or bolt.

[0023] As mentioned above, system 100 is configured to facilitate electrical connections to module 102 in addition to the mechanical connections between module 102, bracket 106, and torque tube 104 described above. For example, bracket 106 may include an electrical interface 120 configured to electrically connect module 102 to conductors 107 located on torque tube 104, as shown in FIG. 1B . As shown, conductors 107 are shown as embedded or otherwise housed within torque tube 104. However, conductors 107 may be secured to the outside of torque tube 104 or within an electrical connector secured to torque tube 104. Electrical interface 120 includes at least one pair of conductors (e.g., wires) that connect to module 102 to facilitate the transfer of power from module 102 to conductors 107 of the torque tube.

[0024] In some implementations, the electrical connection between the module 102 and the conductors 107 of the torque tube 104 is made automatically when the bracket 106 is placed on the torque tube 104. For example, as shown, the conductors 107 of the torque tube 104 can be located within recesses in the torque tube 104 (or on raised portions of the torque tube), and the electrical interface 120 of the bracket 106 can have protrusions 122 (or other connection points) configured to engage with the recesses in the torque tube 104 that accommodate the conductors 107, thereby forming an electrical connection between the electrical interface 120 and the conductors 107. To facilitate this automatic electrical connection, the torque tube 104 can be configured with electrical connectors that are complementary to the electrical connectors of the electrical connection interface of the bracket 106. For example, one of the conductors 107 can have a male electrical connector and the other conductor 107 can have a female electrical connector. In this example, the electrical interface 120 of the bracket 106 can have one male electrical connector and one female electrical connector. In this manner, the male electrical connector on the bracket 106 can be connected to the female electrical connector on the torque tube 104, and the female electrical connector on the bracket 106 can be connected to the male electrical connector on the torque tube 104. The various types of electrical connections and the electrical connections to the module 102 are described in more detail with respect to other figures.

[0025] 2A and 2B are diagrams of another exemplary system 200 in which both an electrical connection and a mechanical connection are made when a solar module 102 is attached to a torque tube 104. System 200 is substantially similar to system 100, except that bracket 202 differs from bracket 106 of system 100. Specifically, bracket 202 includes body 108 and access member 110 as described above, but bracket 202 includes a rotating member connected to an end of access member 110. When in an engaged state, rotating member 204 is configured to rotate relative to access member 110 adjacent the side of torque tube 104 closest to module 102. The engaged state of rotating member 204 is when the rotating member is located between module 102 and torque tube 104. For example, when rotating member 204 is positioned within the area defined by body 108, access member 110, and the inner edge of module 102, the rotating member is in an engaged state. However, when the rotating member 204 is not within the area defined by the inner edge of the body and the access member 110 and the module 102, the rotating member is not engaged. FIG. 1A shows the rotating member 204 in an engaged state, and FIG. 1B shows the rotating member 204 in an unengaged, or disengaged, state. The inclusion of the rotating member 204 can further secure the bracket 202 to the torque tube 104 and can provide an offset of the module 102 from the torque tube 204 so that the module 102 is not in direct contact with the torque tube 204. The rotating member 204 can be formed from the same material as the body 108 and / or the access member 110, or the rotating member can be formed from a different material. In some implementations, the rotating member 204 can be formed from or include a damping material that provides a damping interface between the torque tube 104 and the module 102, which can absorb some forces and provide some additional protection against damage to the module 102.

[0026] Aspects of system 200 that are the same as those described above with reference to FIGS. 1A and 1B will not be described again here for the sake of brevity, but it should be understood that the description provided above is equally applicable to FIGS. 2A and 2B.

[0027] FIG. 3 is a diagram of an exemplary system 300 in which two modules 302 and 304 are mounted to a torque tube 306 by two different brackets 308 and 310. More specifically, the diagram in FIG. 3 is a rear view of modules 302 and 304 and illustrates an exemplary location of conductors 312a-312c on torque tube 306. Modules 302 and 304, torque tube 306, and brackets 308 and 310 are similar to those previously described, and therefore the similarities will not be described with reference to FIG. 3. To better illustrate the orientation of conductors 312a and 312b relative to conductor 312c and another conductor on torque tube 306 not shown in this view (i.e., a second conductor located behind conductor 312c in this view), bracket 308 is shown as being wider than bracket 310, as the orientation of conductor 312c and the other conductors not shown is similar to the orientation of conductor 107 in FIGS. 1A and 1B.

[0028] Module 302 is shown attached to (or integral with) bracket 308, which has two conductors 312a and 312b similar to conductor 107 described above. As shown, conductors 312a and 312b are located at different positions along the length of torque tube 306. As used herein, the length of torque tube 306 is the longest dimension of torque tube 306. For example, panels 302 and 304 are shown at different positions along the length of torque tube 306. In this configuration, conductors 312a and 312b can be separated by a specified distance, and electrical interface 314 of bracket 308 can include electrical connectors similarly spaced apart and configured to engage with the connectors of conductors 312a and 312b, thereby forming an electrical connection between module 302 and conductors 312a, 312b. Protrusions of electrical interface 314 of the frame can be laterally offset from one another at positions corresponding to the positions of conductors 312a and 312b. Conductors 312a and 312b may connect to a junction box, an in-line fuse, an inverter, or another component of a solar power plant. Thus, the electrical connection formed by electrical interface 314 of bracket 308 and conductors 312a and 312b is the connection of module 302 to other components of a solar power plant.

[0029] The module 304 is connected to (or integrated with) the bracket 310. With respect to the bracket 310, only one conductor 312c is visible in this view because the other conductor is aligned with conductor 312c and, as a result, is shielded by the presence of conductor 312c. In other words, both conductors in this configuration are located at the same or substantially the same (e.g., within an acceptable threshold distance) position along the length of the torque tube 306. In this configuration, the two conductors of the torque tube 306 are located at different positions along the width of the torque tube 306. As used herein, the width of the torque tube refers to the distance between a first surface of the torque tube closest to the installed module and the opposite surface of the torque tube (e.g., substantially parallel to the first surface). The electrical interface 316 of the bracket 310 is similarly spaced apart from conductor 312c and other electrical conductors (not shown) and can include electrical connectors configured to engage with those conductors' connectors, thereby forming an electrical connection between the module 304 and each of the conductors 312c and the shielded conductors. For example, two or more protrusions of the electrical interface 316 may be longitudinally offset from one another at locations corresponding to the locations of the conductors of the torque tube.

[0030] FIG. 4 is a diagram of an exemplary system 400 in which a bracket 402 is mounted to a module 404. The bracket 402 may be similar to the brackets previously described, specifically brackets 106 and 310. For example, the arrangement of conductors 410 and shielded conductors may be similar to those described above with reference to FIGS. 1A, 1B, and 3. Additionally, the configuration of electrical interface 412 of bracket 402 may be similar to the configuration of electrical interface 316 and electrical interface 120. FIG. 4 also illustrates an alternative configuration of conductors within dashed box 414, which is similar to the configuration of conductors 312a and 312b described with reference to FIG. 3.

[0031] However, as shown in FIG. 4 , the bracket 402 is connected to the module 404 via a mounting plate 406. The mounting plate 406 can be used to help distribute forces exerted on the module 404 by connecting the module to the torque tube 407, while minimizing the amount of material required to manufacture the bracket 402. For example, by using the mounting plate 406 to distribute forces on the module 404, the bracket 402 can have a smaller width (“W”) than would be required to distribute forces otherwise exerted on the module 404 without the use of the mounting plate 406. In some implementations, the mounting plate 406 can be secured to the module 404 by bolts 408. Of course, other fasteners can also be used. An adhesive can also be used to secure the mounting plate 406 to the module 404. The width of the mounting plate 406 can be measured in the same direction as the length of the torque tube 408 when the bracket 402 is installed on the torque tube 408.

[0032] 5 is a diagram of an exemplary connectorized module 500. The connectorized module 500 is a module similar to those described above and includes a connector 502 that enables plug-and-play functionality for the module 500. For example, the connector 502 of the module 500 can be a panel receptacle, a cable coupler, a multi-contact 4 mm ("MC4") connector, or another connector suitable for connecting electrical components of a solar power plant installation. The connector 502 can be configured to connect directly to a corresponding connector on a bracket, such as those described above, or to a cable that connects to the bracket, or to pass through the bracket to connect to the conductors of a torque tube.

[0033] 6 is a diagram of an exemplary bracket 600 that can be connected to a connectorized solar module / panel 500. The bracket 600 is similar to the bracket 106 described with reference to FIGS. 1A and 1B and includes a connector 602 configured to interface (e.g., connect) with the connector 502 of the connectorized module 500. More specifically, when the bracket 602 is attached to the module 500, the connector 602 interfaces (e.g., plugs into and / or is plugged into) with the connector 502 of the module 500 to form an electrical connection between the module 500 and an electrical interface 604 of the bracket 600. The electrical interface 604 may include conduits or other pathways for routing conductors from the connector 602 to two protrusions 606 of the electrical interface 604. While two protrusions are shown, the electrical interface 604 may have one protrusion and one recess and / or one male connector and one female connector. In either case, the protrusions 606 of the electrical interface 604 (or other configuration of the electrical connector) can be configured to interface with (e.g., connect to) the conductors of the torque tube, thereby forming both an electrical connection and a physical connection (e.g., other than a physical connection formed by connecting the conductors). More specifically, the physical connection can be a connection that supports the weight of the module, such as a non-electrical physical contact between the torque tube and one or more of the brackets and / or modules.

[0034] FIG. 7 is a diagram of an example torque tube 700 including conductors 702 and 704 configured to facilitate electrical connection between a solar module and other components of a solar power plant installation (e.g., an inverter). The conductors 702 and 704 may be similar to those previously described with respect to other torque tubes described herein. As shown, the torque tube 700 includes two recesses in which the conductors 702 and 704 can be located. However, the torque tube 700 may have one protrusion and one recess and / or one male connector and one female connector that provide connection points for the conductors 702 and 704. FIG. 7 also illustrates that the torque tube 700 may include two cables (e.g., electrical wires) 706 and 708 housed within the torque tube 700. While two cables 706 and 708 are shown, more cables may be housed within the torque tube 700. Routing cables 706 and 708 through torque tube 700 allows torque tube 700 to act as a conduit for cables 706 and 708, thereby providing protection from damage. Furthermore, configuring the connection between conductors 702 and 704 using connectors that interface with one or more of the brackets (e.g., 600) and / or solar modules also reduces the risk of conductor damage and the risk of electric shock. Furthermore, implementing a plug-and-play configuration reduces installation time.

[0035] 8 is a diagram of an example solar module 800 including junction boxes 802 and 804 and connectors 806 and 808. Junction boxes 802 and 804 include terminals that facilitate the transfer of power from solar module 800 to other components (e.g., an inverter) within a solar power plant. Junction box 802 is connected to connector 806 by cable 810 (e.g., electrical wire), and junction box 804 is connected to connector 808 by cable 812. One of junction boxes 802 or 804 can provide a positive terminal connection, while the other junction box 804 or 802 can provide a negative terminal connection. Thus, connectors 806 and 808 can have different connection configurations (e.g., male vs. female) to maintain connection consistency throughout the system and prevent misconnection of terminals.

[0036] 9 is a diagram of an example bracket 900 in which the electrical interface 902 forms a conduit through which the cables / connectors of the solar module are routed. For example, the electrical interface 902 can include a cavity having an input port 904 and an output port 906. The input port 904 can be an opening through which the connectors 806 and 808 of the module 800 can be inserted into the bracket 900. The output port 906 can be an opening in the electrical interface 902 through which the connectors 806 and 808 exit the electrical interface 902, for example, to connect to the conductors of a torque tube. As shown, the electrical interface of the bracket 900 accommodates the cables 810 and 812, thereby protecting the cables 810 and 812 from damage (e.g., crimping, cutting, or other damage).

[0037] In some implementations, connectors 806 and 808 can be secured to bracket 900, for example as panel-mounted or bulkhead connectors, and can be positioned such that when bracket 900 is placed on a torque tube, such as torque tube 1000 described below, the alignment of connectors 806 and 808 with connectors 1002 and 1004 allows the connectors to mate, such that a force corresponding to the weight of module 800 automatically pushes connectors 806 and 808 into connectors 1002 and 1004, thereby forming an electrical connection between module 800 and torque tube 1000.

[0038] 10 is a diagram of an exemplary torque tube 1000 including connectors 1002 and 1004 for conductors housed within the torque tube 1000. Connector 1002 is a female connector configured to connect to male connector 806 described above, thereby forming an electrical connection between the torque tube 1000 and solar module 800. Connector 1004 is a male connector configured to connect to connector 808 described above, thereby forming an electrical connection between the torque tube 1000 and solar module 800. Connector 1002 is connected to cable (e.g., electrical wire) 1006 housed within the torque tube 1000. Connector 1004 is connected to cable (e.g., electrical wire) 1008 also housed within the torque tube 1000. Cables 1006 and 1008 can be routed through the torque tube 1000 and connected to one or more of other solar modules similar to solar module 800 and / or other solar power plant components, such as an inverter, for example.

[0039] In some implementations, connectors 1002 and 1004 can be panel-mounted or bulkhead connectors configured to mate with connectors 806 and 808, as described above.

[0040] Torque tube 1000 includes protective covers 1010 and 1012 pivotally / rotatably attached to torque tube 1000. Protective covers 1010 and 1012 may be made of plastic, rubber, or another suitable material capable of providing a barrier between connectors 1002 and 1004 and external environmental elements (e.g., water, mud, sand, etc.). Protective covers 1010 and 1012 may include springs that bias protective covers 1010 and 1012 to a protective state when less than a specified amount of force is applied to rotate protective covers 1010 and 1012 to an exposed / accessible state. For example, protective covers 1010 and 1012 may cover connectors 1002 and 1004 in the protected state and leave connectors 1002 and 1004 exposed and accessible for insertion of connectors 806 and 808 in the exposed / accessible state.

[0041] 11 is a diagram of an exemplary solar module 1100 including panel mount connectors 1102 and 1104. As shown, panel mount connector 1102 is a male connector and panel mount connector 1104 is a female connector. In some implementations, panel mount connectors 1102 and 1104 can be integrated into solar module 1100, and corresponding connectors on a mount, such as bracket 1200 described below, can plug into panel mount connectors 1102 and 1104 when bracket 1200 is installed on module 1100. For example, connectors 1102 and 1104 can be positioned on module 1100 at locations where connectors 1202 and 1204 of bracket 1200 will align when bracket 1200 is installed on module 1100. When bracket 1200 is attached to module 1100, connectors 1202 and 1204 mate with connectors 1102 and 1104, thereby forming an electrical connection. Side views with further details of exemplary configurations of connectors 1102 and 1104 are shown at circles 1106 and 1108. The exemplary configuration shown at circle 1108 is a male panel mount connector, and the exemplary configuration shown at circle 1106 is a female bulkhead mount connector. Often, one connector type is used throughout the system, but two different types are shown, and any combination of connector types can be used with any of the connectors described herein.

[0042] FIG. 12 is a diagram of an exemplary bracket 1200 including connectors 1202, 1204, 1206, and 1208 secured within an electrical interface 1210. The secured connectors 1202, 1204, 1208, and 1206 can have a configuration similar to that shown in circles 1106 and / or 1108. The type of connectors used is not important, as long as the same type of connector is used in the connector pair (e.g., intended to be mated). As mentioned above, the connectors 1202 and 1204 can be spaced apart to align with the connectors 1104 and 1102, respectively, when the bracket 1200 is installed on the module 1100. Alternatively, if the bracket 1200 is integrated into the module 1100 during manufacturing, the connectors 1202 and 1204 can be omitted by hard-wiring the connectors 1206 and 1208 into the module 1100.

[0043] The fixed connectors 1206 and 1208 can be placed on the bracket 1200 in positions that align with connectors 1302 and 1304 of a torque tube 1300, which will be described later. In this manner, when the bracket 1200 is placed on the torque tube 1300, the connector 1206 automatically mates with the connector 1302, and the connector 1208 automatically mates with the connector 1304 due to the weight of the bracket 1200 and / or the module 1100 to which the bracket 1200 is attached. In this manner, placing the bracket 1200 on the torque tube 1300 not only forms a physical connection between the torque tube 1300 of FIG. 13 (e.g., the outer structure of the torque tube 1300) and the inner edge of the bracket 1200, but also forms an electrical connection through the mating of the connectors 1206 and 1302 and the mating of the connectors 1208 and 1304.

[0044] Connectors 1206 and 1208 are referred to as fixed connectors because they are fixed in place or otherwise secured to bracket 1200 rather than being free to move independently of bracket 1200 (as pigtail connectors are). Connectors 1206 and 1208 may be fixed, for example, by being molded into bracket 1200 during the manufacturing process or by being inserted into a receptacle with an engagement mechanism (e.g., snap, pressure, etc.) that prevents connector 1206 from moving. Exemplary engagement mechanisms are described below with reference to FIG. 14.

[0045] 13 is a diagram of an exemplary torque tube 1300 to which bracket 1200 can be attached. Torque tube 1300 includes two connectors 1302 and 1304, which can be panel-mount connectors, bulkhead connectors, or other types of electrical connectors. As mentioned above, connectors 1302 and 1304 can be positioned to automatically mate with connectors 1206 and 1208 when bracket 1200 is placed on torque tube 1300.

[0046] FIG. 14 is a diagram of an example system 1400 including fixed connectors 1402 and 1404. Each of the fixed connectors 1402 and 1404 is fixed to a substrate 1406. The substrate 1406 can be a surface of a solar module, a surface of a bracket (e.g., the electrical interface of the bracket), or a surface of a torque tube. In this example, each of the connectors 1402, 1404 includes an engagement mechanism 1408 for securing to the substrate 1406 and is connected to a respective cable (e.g., electrical wire). To prevent movement of the connectors 1402 and 1404, the engagement mechanism 1408 can operate as a “snap-click” type connection where the engagement mechanism 1408 snaps into place when a sufficient amount of force (e.g., a specified threshold amount) is applied and clicks into a receiving area of ​​the substrate 1406 (e.g., a fixed location), holding the engagement mechanism 1408 in place until a sufficient force (e.g., a specified threshold amount of force) is applied to disengage the engagement mechanism 1408.

[0047] Various combinations of connection interfaces can be used, such as bulkhead-to-wire assembly, bulkhead-to-panel mount, panel mount-to-bulhead, panel mount-to-wire assembly, and any other combination of connectors.

[0048] While this specification contains details of many specific implementations, these should not be construed as limitations on the scope of any invention or what may be claimed, but rather as descriptions of features specific to particular embodiments of a particular invention. Certain features described herein in the context of separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, while features may be described above as acting in a particular combination and initially claimed as such, one or more features from a claimed combination may, in some cases, be deleted from that combination, and the claimed combination may be directed to a subcombination or a variation of the subcombination. [Explanation of symbols]

[0049] 100 system, 102 solar module, 104 torque tube, 106 bracket, 107 conductor, 108 body, 110 access member, 112 fastener, 116 locking mechanism, 118 complementary locking mechanism, 120 electrical interface, 122 protrusion, 200 system, 202 bracket, 204 rotating member, 300 system, 302 panel, module, 304 panel, module, 306 torque tube, 308 bracket, 310 bracket, 312 conductor, 314 electrical interface, 316 electrical interface, 400 system, 402 bracket, 404 module, 406 mounting plate, 407 torque tube, 408 torque tube, 408 bolt, 410 conductor, 412 electrical interface, 414 box, 500 panel, module, 502 connector, 600 bracket, 602 Connector, 602, bracket, 604, electrical interface, 606, protrusion, 700, torque tube, 702, conductor, 706, cable, 800, solar module, 802, junction box, 804, junction box, 806, connector, 806, male connector, 808, connector, 810, cable, 812, cable, 900, bracket, 902, electrical interface, 904, input port, 906, output port, 1000, torque tube, 1002, connector, 1004, connector, 1006, cable, 1010, protective cover, 1100, solar module, 1102, panel mount connector, 1104, panel mount connector, 1200, bracket, 1202, connector, 1206, connector, 1208, connector, 1210, electrical interface, 1300, torque tube, 1302, connector, 1304, connector, 1400 System, 1402 connector, 1406 board, 1408 engagement mechanism

Claims

1. a bracket including an electrical interface configured to (i) connect to a solar module and (ii) retain a torque tube within an outer periphery of the bracket; one or more connectors configured to interface with corresponding connectors on the torque tube upon insertion of the torque tube within the periphery of the bracket, wherein insertion of the torque tube within the periphery of the bracket forms both a physical connection and an electrical connection with the torque tube; A system comprising:

2. the bracket is shaped to define an internal cavity for receiving the torque tube; The system of claim 1 , wherein one or more of the connectors are located on an interior top surface of the bracket.

3. The system of claim 2 , wherein one or more of the connectors extend away from the inner top surface of the bracket and are configured to engage conductors located on an upper surface of the torque tube.

4. the bracket includes an access member that is pivotable or rotatable relative to a body of the bracket; The system of claim 3 , wherein the access member is configured to pivot or rotate between an open state and a closed state.

5. The system of claim 4 , wherein the access member includes a rotating member located at an end of the access member and configured to maintain separation between the torque tube and the solar module.

6. The system of claim 4 , wherein the access member includes a locking mechanism configured to secure or lock the access member in the closed position.

7. The system of claim 6 , wherein the locking mechanism is one or more of a magnet, a latch, and a screw.

8. The system of claim 1 , wherein the electrical connection is made automatically when the bracket is placed on the torque tube.

9. 9. The system of claim 8, wherein the electrical connection is between a conductor located within a recess in the torque tube and a protrusion on the bracket.

10. The system of claim 9 , wherein one or more of the connectors comprises two or more protrusions laterally offset from one another within the frame.

11. The system of claim 9 , wherein one or more of the connectors comprises two or more protrusions longitudinally offset from one another within the frame.

12. The system of claim 1 , wherein the bracket is attached to a mounting plate having a width greater than a width of the bracket.

13. The system of claim 1 , wherein the bracket comprises an electrical connector configured to electrically connect the bracket to the solar module.

14. The system of claim 1 , wherein the solar module comprises one or more junction boxes including terminals that facilitate the transfer of power from the solar module.

15. The system of claim 14 , wherein a positive terminal connection of one or more of the junction boxes has a different connection configuration than a negative terminal connection of one or more of the junction boxes.

16. The system of claim 1 , wherein the bracket includes a gap configured to route a cable between the solar module and the torque tube.

17. The system of claim 16 , wherein a first connector of the cable is attached to the bracket.

18. 18. The system of claim 17, wherein the torque tube includes a second connector configured to mate with the first connector mounted to the bracket.

19. 20. The system of claim 18, wherein at least one of the first connector and the second connector includes an engagement mechanism configured to snap into a fixed position upon application of a sufficient amount of force.

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