In-Line Fuse Sealing for Combiner-Box-Free PV Wiring
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Solution Overview
Problem
Conventional methods for installing solar power DC wires are labor-intensive, costly, and prone to failed connections, especially with high-wattage solar panels, and require frequent maintenance of combiner boxes due to severe weather exposure.
Innovation Solution
A trunk bus system with a connector hardware design that eliminates combiner boxes by using larger aluminum wires and incorporates a trunk bus feeder/trunk, along with metal material transition connectors and in-line fuses, to facilitate efficient electrical connections and reduce installation costs and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional combiner box wiring methods are used with high-wattage solar panels, then electrical connections can be made, but installation labor and costs increase significantly and connection failures become more frequent
Solution Approach 1:
The patent extracts the combiner box from the system by implementing in-line fuses directly on the DC wiring between solar panels and the inverter. This eliminates the intermediate combiner box component that requires labor-intensive wiring while maintaining circuit protection functionality, thereby improving installation efficiency without compromising connection reliability
Solution Approach 2:
The in-line fuse acts as an intermediary device that combines the functions of circuit protection and wiring termination. By integrating these functions into a single component mounted directly on the DC cable, the system eliminates the need for separate combiner box wiring while ensuring reliable electrical connections
2Ease of operation
If combiner boxes are used in solar power systems, then DC wiring can be managed, but maintenance frequency increases due to severe weather exposure
Solution Approach 1:
The patent removes the combiner box from the system and replaces it with in-line fuses mounted directly on the DC wiring. This eliminates the weather-exposed enclosure that requires frequent maintenance while distributing the wiring management function across multiple inline connection points along the DC cable run
Solution Approach 2:
The system segments the DC wiring into multiple sections with individual in-line fuse protection at each segment. This distributed approach replaces the centralized combiner box, allowing each segment to be independently managed and reducing overall maintenance frequency by eliminating the vulnerable enclosed connection point
3Reliability
If in-line fuses are implemented on DC wiring, then connection failures are reduced, but device complexity increases
Solution Approach 1:
The patent merges the functions of circuit protection, wiring termination, and connection management into a single in-line fuse component. This integration reduces overall system complexity by eliminating multiple separate components (combiner box, individual connectors, wiring harnesses) while improving connection reliability through unified design
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system reduces installation labor and costs, minimizes connection failures, and allows for higher tracker counts in solar farms while maintaining DC loss requirements, enhancing flexibility and reducing maintenance needs.
Implementation Method 1
one or more temperature-activated sealing members, where the one or more temperature-activated sealing members circumferentially surround, and form one or more first seals against, a portion of the first terminal exterior surface of the in-line fuse and a portion of the first insulation sleeve of the first electrical cable
Data Source
AI summary
Techniques and apparatuses for forming electrical connection are presented in which an apparatus may include an in-line fuse having terminals comprising terminal exterior surfaces and terminal recesses, and electrical cables comprising a conductor and a insulation sleeve and having an exposed portion and an unexposed portion. The exposed portion of an electrical cable is at least partially inserted into a respective terminal recess of the in-line fuse. The apparatus may further comprise one or more temperature-activated sealing members that circumferentially surround and form a seal against portions of the terminal exterior surfaces of the in-line fuse and portions of the insulation sleeves of the electrical cables. The apparatus may also comprise an inner mold encapsulating the in-line fuse and at least partially of the one or more temperature-activated sealing members, and an outer mold encapsulating the inner mold.