Insulation Piercing Connector for PV Wiring
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Solution Overview
Problem
Current photovoltaic (PV) systems require combiner boxes and extensive trenching, increasing installation costs due to the need for multiple connections and wiring between PV modules and inverters.
Innovation Solution
An insulation piercing connector (IPC) with a conductive body and set screws is used to connect PV wires directly to larger aluminum power wires, eliminating the need for combiner boxes and reducing wiring by allowing above-ground connections to the inverter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If combiner boxes and trenching are used to connect PV modules to inverters, then reliable electrical connections are achieved, but installation cost and device complexity increase
Solution Approach 1:
The patent extracts and eliminates the combiner box from the PV system architecture. The IPC connector integrates the functions of the combiner box directly into the connector itself, allowing PV module outputs to be combined and connected to inverters without requiring a separate combiner box component, thereby reducing system complexity while maintaining connection reliability
Solution Approach 2:
The IPC connector serves multiple functions: it acts as both a connector for joining conductors and as a combiner for multiple PV module strings. The single-bore design allows multiple PV module outputs to be combined within one connector body, eliminating the need for separate combining devices and reducing overall system complexity
2Reliability
If combiner boxes and extensive trenching are used, then electrical connections are established, but installation cost increases
Solution Approach 1:
The patent eliminates the combiner box component and the associated trenching requirements, directly connecting PV modules to inverters through the IPC connector. This removal of unnecessary components and civil work significantly reduces installation costs while maintaining reliable electrical connections
Solution Approach 2:
The patent enables above-ground wiring as an alternative to traditional trenching by using the IPC connector's design that facilitates surface-mounted connections. The connector's structure allows conductors to be routed above ground level, eliminating the need for expensive trenching and burial work while establishing reliable electrical connections
3Reliability
If multiple connectors and wiring are used for PV connections, then electrical connections are achieved, but the amount of wiring increases
Solution Approach 1:
The patent merges multiple functions into the single IPC connector: it combines the functions of connecting individual PV module conductors, combining multiple strings, and connecting to the inverter output. The single-bore design allows multiple conductors to be terminated within one connector body, reducing the total number of connectors and wiring harnesses required in the system
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 IPC reduces installation costs and complexity by eliminating combiner boxes and minimizing wiring, while ensuring reliable electrical connections for PV systems.
Implementation Method 1
at least one first set screw configured to mate with the at least one threaded hole in communication with the open channel and configured to secure the first electrical conductor within the open channel
Implementation Method 2
a body formed from an electrically conductive material, the body defining an open channel configured to receive a first electrical conductor, at least one first threaded hole transverse to and in communication with the open channel
Implementation Method 3
the electrical connector includes an insulation piercing feature configured to pierce insulation of the first electrical conductor
Data Source
AI summary
An electrical connector, including a body formed from an electrically conductive material, the body defining an open channel configured to receive a first electrical conductor, at least one first threaded hole transverse to and in communication with the open channel, a plurality of bores extending toward the open channel, each bore configured to receive a second electrical conductor, and a second threaded hole associated with each bore transverse to and in communication with the associated bore. At least one first set screw is configured to mate with the at least one first threaded hole in communication with the open channel and configured to secure the first electrical conductor within the open channel. A plurality of second set screws are configured to mate with the second threaded holes in communication with an associated bore and configured to secure the second electrical conductor within the bore.