Improved Electrical Connector

Abstract

To provide an electrical connector for physically preventing improper engagement with another component in an electrical system.SOLUTION: An improved electrical connector 100 includes an electrical connector 110 having an electrical connector body and a collar 150 that surrounds the outer surface of the electrical connector 100 in the circumferential direction. The collar 150 includes a substantially hollow collar body configured to accommodate at least a portion of the electrical connector body, and one or more fingers extend from the free end of the collar body to physically prevent improper engagement with another corresponding component.SELECTED DRAWING: Figure 8

Description

[Technical Field]

[0001] The present invention relates to an improved electrical connector for use in electrical systems and assemblies, and more particularly to an improved electrical connector having a collar to physically prevent improper engagement with other components in the electrical system. [Background technology]

[0002] Electrical components are connected to each other in an electrical system with electrical cables to transfer electrical power. For example, photovoltaic modules (photovoltaic panels, solar shingles, etc.) are connected to each other and / or to other components of a PV system with electrical cables to transfer electrical power. Electrical connectors are used to connect different components and associated electrical cables together to form circuits. For example, MC4 connectors made by Staubli, PV4 connectors made by TE Connectivity, or H4 connectors made by Amphenol may be used to connect photovoltaic modules together.

[0003] Typically, PV modules are connected when an installer installs the PV modules at their intended locations. Proper installation and connection of PV modules is complex, and it takes time to check the connections to ensure that proper connections have been made.

[0004] Arrays of PV modules must be installed in a manner that properly completes an electrical circuit. When there are multiple options for joining electrical connectors together, installers can connect modules together in ways that were not intended, causing the circuit to function improperly. This can create a malfunctioning circuit that requires the roof to be reinstalled, which can be time-consuming and costly. For example, if PV modules are connected improperly, they can short out the circuit, causing damage.

[0005] The potential for improper connections is particularly pronounced in situations where numerous connection options are provided and many connections are made. For example, when installing building-integrated photovoltaic ("BIPV") roofing, many electrical connections are required to connect the individual PV shingles / tiles together to form the intended circuit.

[0006] It is therefore desirable to improve the ease of installation of PV systems and / or reduce the likelihood of improper connections in the electrical circuits of PV systems.

[0007] References made herein to external sources, including patent specifications and other literature, are generally for the purpose of providing background for discussing features of the present invention. Unless otherwise indicated, the citation of such sources should not be construed as an admission in any jurisdiction that such sources are prior art or form part of the common general knowledge in the art. Summary of the Invention [Problem to be solved by the invention]

[0008] It is an object of the present invention to provide an improved electrical connector, electrical connector assembly, or photovoltaic system that overcomes or at least partially ameliorates some of the above-mentioned disadvantages and at least provides the public with a useful choice. [Means for solving the problem]

[0009] According to a first aspect, the present invention generally comprises: an electrical connector having an electrical connector body; a collar circumferentially surrounding an outer surface of the electrical connector; Including, The color is a substantially hollow collar body configured to receive at least a portion of the electrical connector body, the collar body having a cable end and a free end; one or more fingers extending from a free end of the collar body and configured to physically prevent improper engagement with another corresponding component; Includes Improved electrical connectors are included.

[0010] According to another aspect, the collar prevents connection of a corresponding electrical connector that would otherwise be electrically connected if one or more fingers did not obstruct full insertion.

[0011] According to another aspect, the improper engagement that the collar prevents is the connection of components associated with different electrical polarities.

[0012] According to another aspect, the electrical connector is a male or female connector configured to mate with a corresponding electrical connector that is the other of the male or female connector.

[0013] According to another aspect, one or more fingers include an interference surface configured to prevent improper engagement with another component.

[0014] According to another aspect, the interference surface is disposed at the free end of the finger.

[0015] According to another aspect, the electrical connector includes an insertion direction for coaxially engaging a corresponding electrical connector, and the one or more fingers extend substantially parallel to the insertion direction.

[0016] According to another aspect, the one or more fingers extend substantially longitudinally from the collar body.

[0017] According to another aspect, the collar is non-rotatable relative to the electrical connector body.

[0018] According to another aspect, one or more fingers are positioned at or around the periphery of the collar at discrete locations.

[0019] According to another aspect, the collar includes two or more fingers evenly spaced around the circumference of the collar.

[0020] According to another embodiment, the collar includes two fingers spaced 180° apart.

[0021] According to another aspect, the electrical connector includes one or more alignment features configured to align the electrical connector with a corresponding electrical connector in at least one natural connection orientation.

[0022] According to another embodiment, one or more fingers are offset from 0 to 180 degrees in end view in a natural connection orientation.

[0023] According to another aspect, the one or more fingers have a substantially rectangular outline when viewed from the side of the collar.

[0024] According to another embodiment, the collar further comprises one or more visual indicators that represent a positive or negative charge, the visual indicators being colored, imprinted, and / or shaped.

[0025] According to another aspect, the collar body includes an internal notch substantially along the length of the collar body that is complementary to the contour of the exterior surface of the electrical connector body for alignment of the collar to the electrical connector.

[0026] According to another aspect, the collar body and / or the electrical connector body include auxiliary alignment elements that align the components together.

[0027] According to another aspect, the auxiliary alignment features are slots and protrusions.

[0028] According to another aspect, the device further includes a locking mating feature for coupling the collar to the electrical connector.

[0029] According to another aspect, the mating features include tabs on the interior surface of the collar body or the exterior surface of the electrical connector body.

[0030] According to another aspect, the mating features are disposed on an interior surface of the collar body.

[0031] According to another aspect, the tab is a ramp configured to facilitate insertion of the collar into the electrical connector in one direction and prevent disengagement of the collar from the electrical connector in the opposite direction.

[0032] According to another aspect, the inner surface of the collar body or the outer surface of the electrical connector body includes a lip configured to mate with the tab to prevent disengagement of the collar from the electrical connector.

[0033] According to another aspect, the collar comprises a rigid or semi-rigid material.

[0034] According to another aspect, the collar is a separate component from the electrical connector.

[0035] According to another aspect, the collar is detachable from the electrical connector.

[0036] According to another aspect, the electrical connector is a photovoltaic connector.

[0037] According to another embodiment, the photovoltaic connector is a QC4 connector.

[0038] According to another aspect, the electrical connector is a single-pole connector.

[0039] According to another aspect, the collar prevents the improved electrical connector from forming a direct connection and allows the connector to form a parallel connection.

[0040] In another aspect, the invention generally comprises: a male or female electrical connector configured to be coaxially connected to a corresponding electrical connector, the other of the male or female connector, the electrical connector having an electrical connector body; a collar circumferentially surrounding an outer surface of the electrical connector; It encompasses The color is a substantially hollow collar body configured to receive at least a portion of the electrical connector body, the collar body having a cable end and a free end; one or more fingers extending from a free end of the collar body and positioned to permit or prevent physical connection with a corresponding electrical connector; Includes Improved electrical connectors are included.

[0041] In another aspect, the invention generally comprises: a female electrical connector; a male electrical connector; Including, Both the female and male electrical connectors are improved electrical connectors as described in any one of the preceding paragraphs; the female and male electrical connectors being coaxial mating electrical connectors configured to be electrically connected upon full insertion; An electrical connector assembly is included.

[0042] According to another aspect, the collar of each improved electrical connector has the following configuration: an arrangement that allows corresponding male and female electrical connectors to make a full and complete connection upon insertion; an arrangement that prevents full and complete insertion of corresponding male and female electrical connectors, such that one or more fingers are required for the corresponding electrical connectors to achieve full and complete connection; The finger includes one or more fingers that are either of the above.

[0043] According to another aspect, one or more fingers of the female electrical connector mate with one or more fingers of the male electrical connector to prevent a full and complete connection.

[0044] According to another aspect, the corresponding male and female electrical connectors include corresponding alignment features configured to align the connectors in at least one natural connection orientation.

[0045] According to another aspect, one or more fingers of the female connector are positioned such that upon insertion, at least one of the one or more fingers of the female connector aligns with at least one of the one or more fingers of the male connector in the insertion direction to physically prevent full connection, or vice versa.

[0046] According to another aspect, at least one of the one or more fingers of the corresponding female and / or male electrical connectors obstructs full insertion of the electrical connector when the free ends of the connectors are pressed together.

[0047] According to another aspect, at least one of the one or more fingers of the female electrical connector abuts at least one of the one or more fingers of the mating male electrical connector to prevent full insertion of the electrical connectors.

[0048] According to another aspect, female and male electrical connectors are associated with different electrodes.

[0049] According to another aspect, the collar of one or more fingers of the female electrical connector is disposed on one of the fingers of the collar of the corresponding male electrical connector at different locations around the circumference of the collar.

[0050] According to another aspect, one or more fingers of the female electrical connector are arranged as a geometric mirror image of one or more fingers of the corresponding male electrical connector.

[0051] According to another aspect, when the free ends of the connectors are pressed together, one of the fingers of the female electrical connector and the mating male electrical connector does not mate, allowing the electrical connectors to complete insertion.

[0052] According to another aspect, the female and male connectors are associated with the same electrode.

[0053] In another aspect, the invention generally comprises: a female electrical connector having a female natural connection orientation; a male electrical connector having a male natural mating orientation; Including, coaxial mating electrical connectors, the female and male electrical connectors configured to be electrically connected upon full insertion in a natural mating orientation; Each electrical connector includes a collar circumferentially surrounding an outer surface of the electrical connector, the collar being fixed and non-rotatable relative to the electrical connector body; the collar includes one or more fingers extending from the collar body and positioned to permit or prevent physical connection with a corresponding electrical connector upon insertion; An electrical connector assembly is included.

[0054] In another aspect, the invention generally comprises: one or more photovoltaic modules; one or more improved electrical connectors according to any one of the preceding clauses for coupling one or more photovoltaic modules to another component of a photovoltaic system via an electrical cable; The present invention includes a photovoltaic system including:

[0055] According to another aspect, the component to which the photovoltaic cell is connected is one of the following components: another photovoltaic module; A junction box and A solar charge controller; One or more of the following is true:

[0056] In another aspect, the invention generally comprises: a plurality of electrical connectors, each of which is a male or female connector configured to be coaxially connected to a corresponding electrical connector, the other of which is the male or female connector; manufacturing an electrical connector having an electrical connector body; coupling a first collar to a first batch of electrical connectors; Including, the first collar includes a substantially hollow collar body configured to receive at least a portion of the electrical connector and one or more fingers configured to physically prevent, permit, or prevent physical connection with a corresponding electrical connector; A method for manufacturing a plurality of improved electrical connectors is included.

[0057] According to another aspect, the method further includes coupling a second collar to a second batch of electrical connectors, the second collar including a substantially hollow collar body configured to receive at least a portion of the electrical connector and one or more fingers configured to physically prevent, permit, or prevent physical connection with a corresponding electrical connector.

[0058] According to another aspect, the improved electrical connector is the improved electrical connector described in the preceding paragraph.

[0059] According to another aspect, one or more fingers of the first collar are positioned differently from one or more fingers of the second collar.

[0060] According to another embodiment, one or more fingers of the first color are arranged as a geometric mirror image of one or more fingers of the second color.

[0061] According to another embodiment, the first color is associated with a positive polarity and the second color is associated with a negative polarity.

[0062] Other aspects of the present invention will become apparent from the following description, given by way of example only and referring to the accompanying drawings, in which:

[0063] As used herein, the term "and / or" means "and," or "or," or both.

[0064] As used herein, "(s)" following a noun refers to the plural and / or singular form of that noun.

[0065] As used in this specification and claims, "comprising" means "consisting at least in part of." When interpreting statements in the specification and claims that include this term, not all features following this term need be present in each statement, as other features may also be present. Related terms such as "comprise" and "comprised" are to be interpreted in the same manner. [Brief explanation of the drawings]

[0066] The invention will now be described, by way of example only, with reference to the following drawings, in which: [Figure 1] 1 shows a perspective view of an improved electrical connector including an electrical connector and a collar. [Figure 2] FIG. [Figure 3] 1 shows an exploded view of an improved electrical connector. [Figure 4] 1 shows a side view of an electrical connector assembly with male and female connectors associated with different electrodes. [Figure 5] 1 shows a side view of an electrical connector assembly with male and female connectors associated with the same electrode. [Figure 6] 1 shows a side view of an electrical connector assembly with male and female connectors associated with the same electrode fully connected. [Figure 7] FIG. 1 shows a schematic diagram of a photovoltaic system with parallel-connected PV modules. [Figure 8] 1 shows a perspective view of an improved electrical connector. [Figure 9] 1 shows a longitudinal cross-sectional view of an improved electrical connector. [Figure 10] Figures 10(a) through 10(f) show perspective views of various different improved electrical connectors. [Figure 11] Figures 11(a) through 11(f) show various collars for the improved electrical connector of Figures 10(a) through 10(f). [Figure 12]Figures 12(a) through 12(d) show end views of various different improved electrical connectors. DETAILED DESCRIPTION OF THE INVENTION

[0067] In accordance with various aspects of the present invention as illustrated in Figures 1 through 12, there is provided an improved electrical connector 100, electrical connector assembly, and photovoltaic system as will now be described. It will be recognized that these figures illustrate general principles of mechanism and construction, and that the invention is not limited to the precise configurations shown.

[0068] The improved electrical connector 100 is configured for use in an electrical system to connect different components and associated electrical cables together to form a circuit.

[0069] In some preferred configurations, the improved electrical connector 100 is configured for use in photovoltaic (PV) systems to connect PV modules (photovoltaic panels, solar shingles, etc.).

[0070] In some configurations, the PV module 1 may be installed in a building-integrated photovoltaic ("BIPV") roofing, cladding, or wallboard system / product. In these configurations, the solar cells are integrated into the roofing, cladding, wallboard, or other product.

[0071] It is recognized that the improved electrical connector may be used in other electrical applications.

[0072] In a preferred configuration, the improved electrical connector 100 includes an electrical connector 110 and a collar 150 .

[0073] The collar prevents improper engagement with another component (of the PV system), as shown in Figure 1 (collar detached) and Figure 8 (collar attached). Preferably, the collar 150 has physical features that predict the connection that will be made with the electrical connector.

[0074] The collar 150 physically prevents improper mating by preventing full and complete connection of components (e.g., corresponding male and female connectors) that would otherwise be able to form a physical and electrical connection. The collar physically prevents the replacement of the improved electrical connector in the electrical system. Improper mating may be understood to mean an improper, or at least less desirable, connection between the components.

[0075] In a preferred configuration, collar 150 prevents connection of a mating electrical connector that would be electrically connected without the blocking feature provided by the collar. In a most preferred configuration, electrical connector 110 is a male or female connector configured to coaxially mate with a mating electrical connector that is the other of the male or female connector (e.g., a male connector configured to mate with a female connector, or vice versa).

[0076] In the most preferred configuration, the improper mating that the collar 150 prevents is the connection of components associated with different electrical polarities. That is, a positive "+" connector is prevented from connecting with a negative "-" connector. Only connectors with similar / same electrical polarities (i.e., negative to negative, or positive to positive) can be connected together and not interfered with by the collar's features.

[0077] Examples of potential connection errors are: a) Connecting the positive and negative connectors of the same PV module together, resulting in a short circuit of the entire array; b) Connecting the positive and negative connectors of different PV modules together, possibly resulting in inappropriate voltages due to connecting groups of modules in series; Includes.

[0078] In a preferred configuration, collar 150 prevents improper connections between single-pole connectors, which are particularly useful in low voltage, high current applications.

[0079] In electrical systems where male and female polarity connectors are used (such as in PV systems where QC4 connectors and the like are used), modules / components can be connected together in either series or parallel. In some configurations, only parallel connections between modules are envisioned (in these configurations, it is assumed that the series connections are made internal to each module and that the external cable connections between modules are of a common single polarity, i.e., parallel).

[0080] The improved electrical connector 100 preferably physically (and / or otherwise) prevents series connections (improper / unintended connections) and allows only parallel connections (proper / intended connections). In these configurations, an electrical connector that could otherwise be used to form both series and parallel connections is essentially limited to allowing only parallel connections (i.e., only connections between common single-pole connectors having the same polarity are permitted).

[0081] Typically, installers connect arrays of PV modules together on-site, but the multitude of options for joining the electrical components of a PV system together makes connecting and forming the proper electrical circuits difficult.

[0082] Preferably, the critical step of connecting the appropriate collar 150 to the electrical connector is performed at the time of manufacture (or by a qualified person, such as an electrician) at a convenient and / or safe place and time (e.g., prior to installation at the intended location).

[0083] Preferably, an appropriate retrofit electrical connector 100 (with predetermined collars for positive or negative polarity) is connected to the electrical connector prior to installation of the module. Preferably, the appropriate collars are connected to assign polarity prior to installation into a structure such as roofing, cladding, wallboard, etc.

[0084] An installer or electrician need not rely on complex electrical wiring designs to ensure proper connections (when different connection possibilities exist), but can be guided by the physical structure and / or visual indication (coloring) of the connector of the improved electrical connector 100. This can be particularly beneficial when a non-skilled or unqualified person, such as an installer, is completing the final connections between modules.

[0085] 6 shows a schematic diagram of a PV system that uses an improved electrical connector 100 to couple photovoltaic modules 1 in parallel. In these configurations, the voltage of these systems is preferably low for safety reasons and / or because of the relatively small size of each module (such as in configurations where the modules are BIPV roof tiles).

[0086] In some preferred configurations, the improved electrical connector 100 is used in electrical systems of less than approximately 100 volts. In some configurations, the improved electrical connector 100 is used in electrical systems of less than 50 volts. Those skilled in the art will recognize that the improved electrical connector 100 may be used in different voltage ranges as appropriate, depending on the jurisdiction and / or installation method (e.g., the skill level of the person making or preparing the connection).

[0087] The improved electrical connector 180 may be particularly useful for connecting BIPV roof tiles or components in parallel and / or at low voltages (eg, less than approximately 100 volts).

[0088] Furthermore, PV modules are typically installed on roofs or other high, dangerous, or hard-to-reach locations exposed to solar energy. Difficult installation of PV systems compromises the safety of installers. This task becomes even more difficult during poor visibility and / or bad / rainy weather.

[0089] It should be appreciated that in preferred configurations, the present invention can improve the ease and / or proper installation of PV modules by helping to ensure proper connection of electrical connectors. Improving the ease of properly connecting PV system components together allows less skilled installers (who may not have the specialized skills or necessary qualifications) to complete the connection of a PV system. Improved electrical connectors can also help minimize the time required to connect a PV system together and / or reduce the likelihood of having to reinstall / reconnect components due to improper connections.

[0090] Preferably, at least four types of improved electrical connectors 100 are manufactured and available for use in electrical systems: negative male connectors, negative female connectors, positive male connectors, and positive female connectors (FIGS. 10(a), 10(b), 10(d), and 10(e)).

[0091] A plurality of electrical connectors 100 may be manufactured, each being a male or female connector configured to be coaxially connected to a corresponding electrical connector, the other of the male or female connector.

[0092] Preferably, the polarity of the improved electrical connector is established by coupling either a positive or negative type collar 150 to the electrical connector body 111 .

[0093] Preferably, during manufacturing, a first collar (e.g., associated with the positive pole) is bonded to a first batch of electrical connectors 110. Bonding the positive collar to a standard electrical connector forms a positive modified electrical connector.

[0094] Preferably, during manufacturing, a second collar (e.g., associated with the negative pole) is bonded to a second batch of electrical connectors 110. Bonding the negative collar to the standard electrical connector forms a modified negative electrical connector.

[0095] In a preferred embodiment, one or more fingers 152 of a first collar are positioned at different locations than one or more fingers of a second collar.

[0096] In some configurations, one or more fingers of a first color are arranged as a geometric mirror image of one or more fingers of a second color (e.g., Figures 12(a) and 12(c), 12(b) and 12(d)).

[0097] Each type of electrical connector (female 100, male 200, Y-shaped 300, etc. connector) is manufactured from the same components whether the electrical connector is associated with a positive or negative polarity. To distinguish the positive "+" modified electrical connector from the negative "-" modified electrical connector, the collar 150 mated to the electrical connector 110 is different.

[0098] The features associated with the male improved electrical connector 200 are the same as or similar to those described for the female improved electrical connector 100. Therefore, similar features are generally designated with similar numbers, and numbers in the hundreds rather than the hundreds.

[0099] It should be appreciated that collars 150, 250 manufactured separately from the electrical connector can offer advantages such as efficiency, simplicity, and cost savings during manufacturing and quality control.

[0100] Once product requirements are met to ensure they function as expected and are safe to use, PV electrical connectors require validation / inspection for quality control. PV electrical connectors are expected to connect cables to transport power in harsh conditions, including exposure to sun, rain, and wind.

[0101] In a preferred configuration, the connector identification solution (i.e., collar) is attached after the electrical connector 110 (e.g., a QC4 connector) is manufactured. Quality control can be performed on the electrical connector 110 before the collar 150 is attached. Therefore, the process of manufacturing and inspecting the positive and negative polarity electrical connectors is simplified. Because the electrical connector and the polarity identification collar are manufactured first, and then attached after manufacturing and inspection, separate process lines for the positive and negative electrical connectors 110 are not required.

[0102] The improved electrical connector has advantages including the ability to provide an improved electrical connector that is physically prevented from improper mating with other components of a PV system, while significantly improving the efficiency, simplicity, and cost of manufacturing and testing electrical connectors without the need for process and quality control for different electrical connector 110 polarities.

[0103] In a preferred configuration, the electrical connector 110 includes an electrical connector body 111. In the configuration shown, the electrical connector body 111 is substantially cylindrical.

[0104] In a preferred configuration, collar 150 circumferentially surrounds the exterior surface of electrical connector 110. Collar 150 has a substantially hollow collar body 151 that receives at least a portion of electrical connector body 111. Preferably, collar 150 has an open end that passes over electrical connector body 111.

[0105] Preferably, the electrical connector 110 is a photovoltaic connector for a component of a PV system. The improved electrical connector 100 couples one or more photovoltaic modules 1 to another component of a photovoltaic system via an electrical cable 2.

[0106] The improved electrical connector 100 couples PV modules together and / or to other components (e.g., junction boxes 3, solar charge controllers, etc.) to transfer electrical power. A physical and electrical connection is generally established when male and female connectors are mated together.

[0107] In a most preferred configuration, the electrical connector 110 is a coaxial connector configured to mate with a corresponding electrical connector in an insertion direction (arrow shown in Figures 4 and 5) parallel to the longitudinal axis (L) of the connector. Generally, a male electrical connector is configured to mate with a corresponding female electrical connector.

[0108] The electrical connector 110 can be male or female, a Y connector, a T connector, or a straight connector, some examples of which are illustrated in Figures 10(a) to 10(f).

[0109] In the most preferred configuration, the photovoltaic connector is a QC4 connector, as best shown in Figures 1 and 3. A QC4 connector is a single contact, single polarity electrical connector used in PV systems to connect components.

[0110] The improved electrical connector may replace or be modified from other standard electrical connectors known to those skilled in the art, such as MC4, PV4, H4 connectors, and others.

[0111] In a preferred embodiment, collar 150 is an additional / separate component provided on electrical connector 110. Preferably, and with reference to FIG. 9 (described in more detail below), improved electrical connector 100 includes locking mating feature 160 for coupling collar 150 to electrical connector 110.

[0112] In some configurations, the collar 150 is removably attached to the electrical connector 111 .

[0113] In other configurations, collar 150 is modified to be permanently attached to electrical connector body 111. In these configurations, collar 150 is difficult or impossible to sever from connector body 111 without damaging the collar and / or electrical connector, or is not severable without tools (i.e., not manually separable). It should be appreciated that in these configurations, a permanent / semi-permanent collar 150 provides increased safety because the intended use of the connector is not changed or easily changed after manufacture.

[0114] In a PV system, a variety of different modified electrical connectors may be used to connect PV components together to form a predetermined electrical circuit. A variety of different modified electrical connectors are shown in Figures 10(a)-10(f).

[0115] The improved electrical connector shown on the left (Figures 10(a) to 10(c)) is likely to be a negative electrical connector, i.e., an electrical connector associated with and / or connected to / to / from the negative polarity of a component of a PV system.

[0116] The improved electrical connector shown on the right (Figures 10(d)-10(f)) is likely a positive electrical connector, i.e., an electrical connector associated with and / or connected to / to / from the positive polarity of a component of the PV system.

[0117] It should be appreciated that within a PV system, the same type of PV connectors may be used to connect different components together, however, connectors associated with different polarities within a PV system are preferably distinguishable and, when properly connected, form the appropriate / intended electrical circuit (e.g., the partial circuit of FIG. 6).

[0118] Other different colors 150, 250 associated with different polarities and associated with the electrical connectors are an effective way to distinguish between connectors of different polarities.

[0119] Collar 150 may be coupled to electrical connector 110 by one or more of the following: snap fit, press fit, threaded fit, turn lock, adhesive, welding, and the like.

[0120] Preferably, during the manufacture of the improved electrical connector, collar 150 is coupled to electrical connector 110. Alternatively, collar 150 is a separate component that can be coupled to the connector at a later stage.

[0121] In some configurations, the mating of collar 150 and electrical connector 110 produces an audible click that provides positive feedback to confirm that a full / sufficient mating has occurred.

[0122] In some other configurations, the collar 150 is integrated with the electrical connector 110 as a single component during manufacture.

[0123] In a preferred construction, collar 150 comprises a rigid or semi-rigid material. It should be appreciated that the collar can increase the strength of electrical connector 110 and / or protect the connector from damage, such as from physical contact or weathering due to exposure to sun / wind / rain.

[0124] In some configurations, the collar 150 is formed from a hard plastic such as PPE, PA, PC, PBT, etc. It is recognized that other materials known to those skilled in the art may be used with desired physical properties.

[0125] In a preferred configuration, collar 150, best seen in FIG. 2, includes one or more fingers 152 extending from a free end 154 of collar body 151 and configured to physically prevent improper engagement with another component.

[0126] Collar body 151 has a cable end 153 and a free end 152. Collar cable end 153 is configured to be disposed at or toward gland nut 112 of electrical connector 110. Collar free end 152 is disposed toward the free and / or mating end of the connector (i.e., the end of the connector for mating with a corresponding component). One or more fingers 152 of the collar extend from free end 154 and are configured to interfere with a full and complete connection with another component when this would be an undesirable / inappropriate connection to form an electrical circuit.

[0127] Preferably, one or more fingers include an interference surface 155 configured to prevent improper engagement with another component. The interference surface 155 (see FIGS. 2 and 4) is configured to mate with another component and prevent a satisfactory connection. The interference surface 155 is disposed on a free end 156 of the finger.

[0128] In a preferred configuration, collar 150 prevents connection of a corresponding electrical connector that would otherwise be electrically connected if one or more fingers 152 did not obstruct full / full insertion.

[0129] In the illustrated configuration, the improper engagement that collar 150 prevents is the connection of components associated with different electrical polarities (ie, components with positive and negative polarities are prevented from being connected together).

[0130] For example, as shown in Figure 4, the electrical connectors (internal components not including the collars) are mating connectors (i.e., female and male QC4 connectors) that are configured to be fully electrically connectable. However, the female connector has a negative collar 150- and the male connector has a positive collar 250+, which prevents connection.

[0131] In contrast, the female and male counterpart connectors shown in FIG. 6 are modified electrical connectors associated with the same polarity (both associated with positive polarity) and are therefore permitted to form a full and complete connection (unobstructed by one or more fingers 152).

[0132] In the electrical connector assembly, the female and male electrical connectors are preferably coaxial mating electrical connectors configured to be electrically connected upon full insertion. The insertion direction (shown by the arrow in FIG. 5) is parallel to the longitudinal axis of the connectors.

[0133] In a preferred configuration, one or more fingers 152 extend substantially longitudinally from collar body 151 .

[0134] The electrical connector 110 includes an insertion direction for coaxially mating with a corresponding electrical connector. Preferably, one or more fingers 152 extend substantially parallel to the insertion direction (arrow in FIGS. 4 and 5).

[0135] In some configurations, one or more fingers 152 have a substantially rectangular outline when viewed from the side of the collar (as shown in FIG. 4).

[0136] One or more of the fingers 152 may take the form of other contours / shapes that mate and prevent improper / undesirable full and complete connection with a corresponding component. For example, one or more of the fingers 152 may have a square, triangular, tooth / serrated, or wavy contour that prevents or otherwise interferes with improper connection.

[0137] As described above, preferably, one or more fingers 152 are disposed on collar 150 to physically permit connection with another corresponding component or prevent improper engagement.

[0138] The collar 150 of each improved electrical connector 100 is in the following configuration: a) an arrangement of corresponding male and female electrical connectors such that they can make a full and complete connection upon insertion; b) an arrangement that obstructs full and complete insertion of corresponding male and female electrical connectors such that one or more fingers are required for the corresponding electrical connectors to achieve full and complete connection; The finger includes one or more fingers that are either of the above.

[0139] The electrical connector preferably includes one or more alignment features 115, 116 (see FIG. 10(a)) to align the electrical connector 110 with a mating electrical connector in at least one natural mating orientation.

[0140] A natural mating orientation may be defined as the orientation in which an electrical connector is required to align and mate with a mating connector. For a connector with two symmetries (as best illustrated in FIG. 12), the connector has two natural mating orientations (0 and 180°).

[0141] The electrical connector 110 includes one or more alignment features 115, 116 configured to align the electrical connector with a corresponding electrical connector in at least one natural connection orientation.

[0142] 10(a), in some configurations, one of the alignment features is the contour of the mating protrusion 115 of the connector and / or the receiving recess of the mating connector. The contour of the mating protrusion 115 has limited rotational symmetry (not limited to a circle). In the configuration shown, the mating protrusion 115 has two rotational symmetries.

[0143] Referring to FIG. 10(b), in some configurations, one of the alignment features is a complementary corresponding feature (eg, slot 116 and protrusion) on the mating connector to align the connector in a natural mating orientation.

[0144] Preferably, the female electrical connector 100 is non-rotatable relative to the male electrical connector 200 (when the connectors are connected together).

[0145] Preferably, collar 150 is also non-rotatable with respect to electrical connector body 111. This helps ensure that one or more fingers interact (block or pass through other fingers) as desired / expected when aligning corresponding connectors together for connection.

[0146] In a preferred configuration, one or more fingers 152 are disposed at or around the periphery of collar 150 at discrete locations (preferably not a continuous projection).

[0147] In a preferred configuration, the collar 150 has two or more fingers 152. In the configuration shown, the collar 150 has two fingers 152 that physically prevent improper engagement.

[0148] In configurations with two or more fingers 152, the fingers are preferably evenly spaced around the circumference of the collar 150. In the configuration shown, the collar 150 has two fingers 152 spaced 180° apart.

[0149] Preferably, one or more fingers 152 are offset from 0 to 180 degrees in end view in the natural connection orientation.

[0150] When mated, when the female and male electrical connectors 100, 200 are mating electrical connectors and associated with different electrical polarities, the connectors are preferably prevented / impeded from making a full and complete connection.

[0151] At least one of the one or more fingers 152 of the corresponding female and / or male electrical connectors prevents full insertion of the electrical connector when the free ends 154 of the connectors are pressed together.

[0152] Preferably, at least one of the one or more fingers 152 of the female electrical connector (shown as the positive connector in FIG. 4) abuts at least one of the one or more fingers 252+ of the corresponding male electrical connector (shown as the negative connector in FIG. 4) to prevent full insertion of the electrical connectors.

[0153] One or more fingers 152, 252 are positioned so that when the mating ends of the male and female connectors are placed in opposing positions together, the fingers are configured to obstruct a full connection.

[0154] To achieve this, in a preferred configuration, one or more fingers 152 of the female connector are positioned (as shown in FIG. 4) so that at least one of the one or more fingers of the female connector is aligned with at least one of the one or more fingers 252 of the male connector in the insertion direction to physically prevent a full connection upon insertion, or vice versa.

[0155] Preferably, one or more fingers 152 of the female connector are positioned around the circumference of the collar 150 when viewed in end view so as to be offset relative to the fingers of a male counterpart connector of the opposite polarity, or vice versa (e.g., the connectors of Figures 12(a) and 12(d), 12(b) and 12(c)).

[0156] In some configurations, one or more fingers of a female electrical connector (e.g., FIG. 12(b)), such as a connector associated with a different polarity, are arranged as a geometric mirror image of one or more fingers of a corresponding male electrical connector (e.g., FIGS. 12(b), 12(c)).

[0157] In the illustrated configuration, one or more fingers 152 of the female connector are offset by approximately 45° to 90° relative to the male fingers 252 of the corresponding connector of the opposite polarity (best shown in Figures 12(a) and 12(d), and 12(b) and 12(c)).

[0158] When mated, the connectors are preferably permitted to make a full and complete connection when the female and male electrical connectors are mating electrical connectors and associated with the same electrical polarity, i.e., the same electrical polarity does not prevent the connectors from making a complete connection.

[0159] In these configurations, when the free ends of the connectors are pressed together, one of the fingers 152 of the female electrical connector and the corresponding male electrical connector does not mate, allowing the electrical connectors to complete insertion (FIGS. 5 and 6).

[0160] In some configurations, to accomplish this, when viewed in end view (as shown in Figures 12(a) and 12(b), 12(c) and 12(d)), one or more fingers 152 of the female electrical connector are positioned on one of one or more fingers of a corresponding male collar of an electrical connector of the same polarity, at the same location around the circumference of the collar.

[0161] 12 and 5, gaps or openings 157 are preferably provided between the fingers 152 of the collar 150. The gaps 157 are disposed around the periphery of the collar 150.

[0162] As shown in FIG. 5, the gap 157 allows the fingers 252 of the corresponding collar 250 to pass through the open area to allow full / complete connection of the intended mating connector (e.g., a mating connector of the same polarity).

[0163] In a preferred construction, collar 150 further includes one or more visual indicators that represent a positive or negative charge, the visual indicators being colored, engraved, and / or shaped.

[0164] In a most preferred configuration, the polarity of the improved electrical connector 100 may be identified by the coloring of the color 150. The coloring of the color 150 associated with a positive charge should be clearly distinguishable from the coloring of the color associated with a negative charge. For example, the color 150 associated with a positive charge may be red / orange, while the color 150 associated with a negative charge may be blue / black. The difference in coloring or other visual indication is indicated by the colors being in different patterns, as shown in Figures 10 and 11. The color associated with a negative charge has a speckled pattern, while the color associated with a positive charge has a striped pattern, making it visually distinct.

[0165] The clear visual indication (preferably colored) helps the installer identify which connectors should be mated together. This is the primary (visual) indication as to which connectors are to be mated together, while the one or more fingers 152 are an additional / backstop protection (physical obstruction) against improper / incorrect mating coupling of the corresponding electrical connectors.

[0166] It should be recognized that these two features work in concert to provide a dual system of protection against improper connections in the electrical circuitry of a PV system. Again, this improves the ease of connection of PV system components, minimizes the time required to connect a PV system together, reduces the likelihood of improper connections requiring reinstallation, and / or allows electrical connections to be completed by less skilled installers rather than qualified / professional PV electricians.

[0167] 9, the improved electrical connector 100 includes a locking mating feature 160 for coupling the collar 150 to the electrical connector 110. The locking mating feature 160 helps to retain the collar 150 on the electrical connector 110 when the components are joined together to form the improved electrical connector 100.

[0168] Preferably, the locking mating feature 160 makes it more difficult to remove the collar 100 from the electrical connector 110 .

[0169] In some configurations, the mating feature comprises a tab 161 on the inner surface of the collar body (as shown in FIG. 2). Alternatively, the tab 160 is disposed on the outer surface of the electrical connector body 110 (not shown).

[0170] In a preferred configuration, the inner surface of the collar body (when the tab is disposed on the electrical connector body) or the outer surface of the electrical connector body (when the tab is disposed on the inner surface of the collar as shown) includes a lip 162 configured to mate with the tab and prevent disengagement of the collar from the electrical connector (see Figures 2 and 9).

[0171] In a preferred configuration, tab 161 is a sloped portion configured to facilitate insertion of collar 150 into electrical connector 110 in one direction and prevent disengagement of the collar from the electrical connector in the opposite direction. Preferably, sloped tab 161 slopes downward toward the cable end of the electrical connector.

[0172] To align the collar 150 with the electrical connector 110 in the proper orientation, the improved electrical connector has one or more alignment features. The alignment helps to orient the collar 150 in the proper predefined orientation. The predefined orientation of the collar helps to ensure that one or more fingers 152 are positioned to act as a physical interference against improper connection.

[0173] In a preferred configuration, as shown in Figures 12(a)-12(d), the collar body 151 includes an internal notch along a substantial length of the collar body that is complementary to the contour of the outer surface of the electrical connector body for alignment of the collar to the electrical connector.

[0174] In some configurations, the collar body 151 and / or the electrical connector body 111 include auxiliary alignment elements that align the components together.

[0175] Referring to FIG. 8, in one configuration, the auxiliary alignment features are slots 113 and protrusions 114.

[0176] Numerous modifications of the structure and various embodiments and applications of the present invention will suggest themselves to those skilled in the art to which the present invention pertains without departing from the scope of the invention as defined in the appended claims.

[0177] The present invention is generally considered to consist of any or all of the parts, elements, and features referred to or described in the specification of the application, individually or collectively, and any combination of two or more of such parts, elements, or features, and when specific integers having known equivalents in the art to which the invention pertains are referred to herein, such known equivalents are considered to be incorporated into this application as if individually set forth. [Explanation of symbols]

[0178] 1 PV (photovoltaic) module 100 Improved Electrical Connector 110 Electrical Connector 111 Electrical connector body 112 Gland Nut 113 Slots 114 protrusion 115 protrusion 116 Slots 150 colors 152 Finger 153 Cable End 154 Free end 155 Interference Surface 156 Free end of finger 157 Gap 160 Locking Mating Features 161 tabs 162 Lip 200 Improved Electrical Connector 250 colors 252 Finger 300 Improved Electrical Connector

Claims

1. 1. An improved electrical connector comprising: a male or female electrical connector configured to be coaxially connected to a corresponding electrical connector, the other of the male or female connector, the electrical connector having an electrical connector body and one or more alignment features configured to align the electrical connector with the corresponding electrical connector in at least one natural connection orientation; a collar circumferentially surrounding an outer surface of the electrical connector; Including, The color is a substantially hollow collar body configured to receive at least a portion of the electrical connector body, the collar body having a cable end and a free end; one or more fingers integrally formed with the collar, extending from the free end of the collar body and positioned at discrete locations on or around the periphery of the collar, the one or more fingers configured to physically permit connection with the corresponding electrical connector associated with the same electrical polarity and physically prevent improper engagement with the corresponding electrical component associated with a different electrical polarity; encompasses, Improved electrical connectors.

2. 2. The improved electrical connector of claim 1, wherein said collar prevents connection of a mating electrical connector that would be electrically connected if said one or more fingers did not interfere with full insertion.

3. 3. The improved electrical connector of claim 1 or claim 2, wherein said one or more fingers include an interference surface configured to prevent said improper engagement with said corresponding electrical component.

4. 4. The improved electrical connector of claim 3, wherein said interference surfaces are disposed on free ends of said fingers.

5. 5. An improved electrical connector according to any one of claims 1 to 4, wherein the electrical connector includes an insertion direction for coaxially engaging the corresponding electrical connector, and the one or more fingers extend substantially parallel to the insertion direction.

6. The improved electrical connector of any one of claims 1 to 5, wherein the collar is non-rotatable relative to the electrical connector body.

7. An improved electrical connector according to any one of claims 1 to 6, wherein said one or more fingers have a substantially rectangular outline when viewed from the side of said collar.

8. 8. The improved electrical connector of claim 1, wherein the collar further comprises one or more visual indicators representing a positive or negative charge, the visual indicators being colored, engraved, and / or shaped.

9. the collar body and / or the electrical connector body include auxiliary alignment elements that align the corresponding electrical components together; The improved electrical connector of any one of claims 1 to 8, wherein the auxiliary alignment features are slots or protrusions.

10. The improved electrical connector of any one of claims 1 to 9, further comprising a locking mating feature for coupling said collar to said electrical connector.

11. the locking mating feature comprises a tab on an inner surface of the collar body or on the outer surface of the electrical connector body; 11. The improved electrical connector of claim 10, wherein the tab is a ramp configured to facilitate insertion of the collar into the electrical connector in one direction and prevent disengagement of the collar from the electrical connector in an opposite direction.

12. The improved electrical connector of any one of claims 1 to 11, wherein the collar comprises a rigid or semi-rigid material.

13. An improved electrical connector according to any preceding claim, wherein the collar is a separate component from the electrical connector.

14. 14. The improved electrical connector of claim 13, wherein said collar is detachable from said electrical connector.

15. The improved electrical connector of any one of claims 1 to 14, wherein the electrical connector is a photovoltaic connector.

16. 16. The improved electrical connector of claim 15, wherein said photovoltaic connector is a QC4 connector.

17. An improved electrical connector according to any one of claims 1 to 16, wherein the electrical connector is a single pole connector.

18. An improved electrical connector according to any preceding claim, wherein the collar prevents the improved electrical connector from forming a series connection and allows the connector to form a parallel connection.

19. 1. An electrical connector assembly comprising: a female electrical connector; a male electrical connector; It encompasses Both the female and male electrical connectors are the improved electrical connectors according to any one of claims 1 to 18, the female and male electrical connectors being coaxial mating electrical connectors configured to be electrically connected upon full insertion; Electrical connector assembly.

20. The collar of each improved electrical connector has the following configuration: a) an arrangement of corresponding male and female electrical connectors to permit full and complete connection upon insertion; b) the one or more fingers are positioned to prevent full and complete insertion of the corresponding male and female electrical connectors that would otherwise be fully and completely mated; 20. The electrical connector assembly of claim 19, including one or more fingers that are one of:

21. 21. The electrical connector assembly of claim 20, wherein at least one of the one or more fingers of the female connector is positioned such that in an insertion direction for coaxial engagement of the electrical connector with a corresponding electrical connector, at least one of the one or more fingers of the female connector is aligned with at least one of the one or more fingers of the male connector to physically prevent full connection upon insertion, and vice versa.

22. at least one of the one or more fingers of the corresponding female and / or male electrical connectors prevents full insertion of the electrical connectors when the free ends of the electrical connectors are pressed together; 22. The electrical connector assembly of claim 21, wherein at least one of the one or more fingers of the female electrical connector abuts at least one of the one or more fingers of the corresponding male electrical connector to prevent full insertion of the electrical connectors.

23. An electrical connector assembly according to any one of claims 19 to 22, wherein the female and male electrical connectors are associated with different electrodes.

24. An electrical connector assembly as described in any one of claims 19 to 23, wherein the collar of the one or more fingers of the female electrical connector is disposed on one of the one or more fingers of the collar of the corresponding male electrical connector at different positions around the outer periphery of the collar.

25. 25. The electrical connector assembly of claim 24, wherein the one or more fingers of the female electrical connector are arranged as a geometric mirror image of the one or more fingers of the corresponding male electrical connector.

26. 26. The electrical connector assembly of claim 25, wherein one of the one or more fingers of the female electrical connector and the corresponding male electrical connector does not mate when the free ends of the electrical connectors are pressed together, allowing the electrical connectors to complete insertion.

27. An electrical connector assembly according to any one of claims 24 to 26, wherein the female and male electrical connectors are associated with the same electrode.

28. 1. An electrical connector assembly comprising: a female electrical connector having a female natural connection orientation; a male electrical connector having a male natural mating orientation; an electrical connector having an electrical connector body and one or more alignment features configured to align the female electrical connector with the male electrical connector in the natural mating orientation of the female and male; It encompasses the female and male electrical connectors being coaxial mating electrical connectors configured to be electrically connected upon full insertion in the natural mating orientation; Each electrical connector includes a collar circumferentially surrounding an outer surface of the electrical connector, the collar being fixed and non-rotatable relative to the electrical connector body; the collar includes one or more fingers integrally formed with the collar, extending from the collar body and positioned at discrete locations on or around the periphery of the collar, the one or more fingers positioned to physically permit connection with the corresponding electrical connector associated with the same electrical polarity and physically prevent improper engagement with the corresponding electrical connector associated with a different electrical polarity; Electrical connector assembly.

29. one or more photovoltaic modules; one or more improved electrical connectors according to any one of claims 1 to 19, for coupling the one or more photovoltaic modules to another component of a photovoltaic system via an electrical cable; It encompasses The further component of the photovoltaic system to which the photovoltaic cell is connected is one of the following components: a) another photovoltaic module; b) a junction box; c) a solar charge controller; A photovoltaic system, which is one or more of:

30. 1. A method of manufacturing a plurality of improved electrical connectors, comprising: manufacturing a plurality of electrical connectors, each of which is a male or female connector configured to be coaxially connected to a corresponding electrical connector, the other of said male or female connector, said electrical connector having an electrical connector body and one or more alignment features configured to align said electrical connector with the corresponding electrical connector in at least one natural connection orientation; coupling a first collar to the first batch of electrical connectors; Including, the first collar includes a substantially hollow collar body configured to receive at least a portion of the electrical connector; and one or more fingers integrally formed with the first collar and disposed at discrete locations on or about the periphery of the first collar, the one or more fingers configured to physically permit connection with the corresponding electrical connector associated with the same electrical polarity and physically prevent improper engagement with the corresponding electrical connector associated with a different electrical polarity. method.

31. 31. The method of manufacturing a plurality of improved electrical connectors of claim 30, further comprising coupling a second collar to a second batch of the electrical connectors, the second collar comprising a substantially hollow collar body configured to receive at least a portion of the electrical connector and one or more fingers configured to physically prevent, permit, or prevent physical connection with the corresponding electrical connector.

32. A method for manufacturing a plurality of improved electrical connectors according to claim 30 or claim 31, wherein the improved electrical connector is the improved electrical connector according to any one of claims 1 to 19.

33. 33. The method of manufacturing a plurality of improved electrical connectors of claim 32, wherein said one or more fingers of said first collar are positioned differently from said one or more fingers of said second collar.

34. 34. The method of manufacturing a plurality of improved electrical connectors of claim 33, wherein said one or more fingers of said first collar are arranged as a geometric mirror image of said one or more fingers of said second collar.

35. The method of manufacturing a plurality of improved electrical connectors according to any one of claims 30 to 34, wherein the first collar is associated with positive polarity and the second collar is associated with negative polarity.

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