Over-Molded DC Panel Connector With Watertight Shear Bolt Assembly
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Solution Overview
Problem
Existing methods for connecting a solar electrical inverter to a DC feed are time-consuming, require multiple skilled personnel, and can void warranties due to the need to open the electrical inverter.
Innovation Solution
A connector system using a shear bolt connector with a first over-mold section for a panel mount and a second over-mold section for a sealing boot, allowing for a quick, tool-free, and watertight connection of DC voltage cables to the electrical inverter without opening the inverter, utilizing a 'plug and play' mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire connection methods are used, then reliable electrical connection is achieved, but installation time increases and requires multiple skilled personnel
Solution Approach 1:
The connector is divided into separate modular components: a cable connector with lugs that attaches to the cable, and a separate inverter connector that interfaces with the inverter. This segmentation allows pre-assembly of cable connections outside the inverter, reducing on-site installation time while maintaining connection reliability through standardized interfaces.
Solution Approach 2:
The cable connector can be pre-assembled and tested before arriving at the installation site. The lugs are pre-attached to the cable conductors, and the connector housing is pre-formed with the sealing boot already integrated. This preliminary preparation eliminates time-consuming on-site assembly steps while ensuring reliable electrical connections are established before the critical inverter connection phase.
2Reliability
If traditional wire connection methods are used, then reliable electrical connection is achieved, but the process requires multiple skilled personnel
Solution Approach 1:
The connector design incorporates self-aligning features and intuitive assembly mechanisms that allow a single installer to complete the connection without requiring multiple skilled personnel. The cable connector attaches to the cable with simple mechanical fastening, and the sealing boot automatically positions itself during assembly, reducing the skill level and number of personnel needed while maintaining connection reliability.
3Ease of operation
If the electrical inverter is opened for connection, then direct wire access is obtained, but warranty is voided
Solution Approach 1:
The connection interface is extracted from the inverter interior and placed on the exterior through a dedicated access panel or port. The cable connector attaches to the cable outside the inverter, and the sealing boot creates a weatherproof seal at the inverter boundary without requiring the inverter enclosure to be opened. This extraction maintains warranty integrity while providing easy connection access.
4Ease of manufacture
If connector components are exposed, then assembly is simple, but environmental protection is compromised
Solution Approach 1:
The sealing boot is merged with the connector housing to form an integrated weatherproof assembly. The boot is molded as part of the connector structure, creating a seamless seal that protects internal components from environmental factors. This integration maintains assembly simplicity while providing comprehensive environmental protection without requiring separate sealing components.
Solution Approach 2:
The sealing boot is designed to nest over the cable connector and inverter connector components, creating a protective envelope that encloses all exposed electrical elements. This nested configuration allows simple sequential assembly while ensuring that no components remain exposed to environmental factors, effectively combining ease of manufacture with environmental protection.
Data Source
AI summary
A connector for a DC voltage connection to a platform can have i) a first over-mold section for a panel mount and ii) a sealing boot with a second over-mold section. The first over-mold section for the panel mount encases a portion of a first cable and a first section of a shear bolt connector to form a panel mount receptacle. The second over-mold section of the sealing boot encases a portion of a second cable and a second section of the shear bolt connector. The second over-mold section can have a shape and size to slidably fit over the first over-mold section to form a mechanically locked, watertight assembly that covers the shear bolt connector in its entirety and the portions of the first cable and the second cable that are electrically coupled inside the shear bolt connector.