Material Transition Connectors for Pre-Assembled Solar DC Wiring
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Solution Overview
Problem
Existing methods for installing solar power DC wires are labor-intensive and time-consuming, requiring on-site technicians to pull, cut, and connect wires, which leads to low-quality and inconsistent connections. Additionally, the use of combiner boxes is prone to malfunction and requires extensive maintenance.
Innovation Solution
The proposed apparatus includes a trunk bus system with a metal material transition connector that facilitates electrical connections between different metal materials, using temperature-activated sealing members and molds to ensure secure and reliable connections, thereby eliminating the need for combiner boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wiring methods with combiner boxes are used, then electrical connections can be established, but installation is labor-intensive and connection quality is inconsistent
Solution Approach 1:
The patent merges the functions of multiple separate components (connectors, sealing elements, insulation layers) into an integrated trunk bus assembly. This pre-assembled unit eliminates the need for on-site combination of multiple components, ensuring consistent connection quality while reducing installation labor and time.
Solution Approach 2:
The trunk bus system performs preliminary assembly and testing of electrical connections before deployment. The pre-assembled nature of the trunk bus ensures high-quality connections are established in advance, eliminating the need for on-site connection work that leads to inconsistent quality and labor-intensive installation.
2Reliability
If combiner boxes are used to combine DC feeder lines, then electrical connections are established, but the system requires extensive maintenance and is prone to malfunction
Solution Approach 1:
The patent extracts the combiner box from the system and replaces it with direct trunk bus connections. By removing the combiner box intermediary component, the system eliminates the source of malfunctions and maintenance requirements, achieving higher reliability with no maintenance needed.
Solution Approach 2:
The trunk bus serves as a direct intermediary between solar panels and inverters, replacing the combiner box. This eliminates the need for separate connection points that require maintenance, providing a more reliable system with fewer failure points.
3Adaptability or versatility
If metal material transition connectors are used to connect different metal materials, then electrical connections between aluminum and copper conductors are achieved, but complex sealing and encapsulation processes are required
Solution Approach 1:
The trunk bus employs composite material construction with aluminum and copper sections joined together, allowing direct connection of different metal conductors. The integrated design of the trunk bus incorporates multiple sealing layers and insulation materials in a unified structure, reducing overall complexity despite the multi-material composition.
Solution Approach 2:
The connector structure uses nested sealing members and insulation layers, where smaller sealing elements are placed within larger protective structures. This nested arrangement provides comprehensive protection for the metal transition connection while maintaining a compact and organized structure.
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 solution reduces installation time and costs, improves connection quality, and enhances the reliability of solar array wiring systems by providing a secure and efficient method for connecting solar panels to inverters.
Implementation Method 1
one or more temperature-activated sealing members, wherein the one or more temperature-activated sealing members (a) circumferentially surround, and form a first seal against, at least a portion of the first elongated conductor member
Implementation Method 2
an inner mold, wherein the inner mold encapsulates the metal material transition connector and at least partially encapsulates the one or more temperature-activated sealing members
Data Source
AI summary
In some embodiments, an apparatus for forming an electrical connection comprises a metal material transition connector for a solar array wiring system comprising a first metal portion and a second metal portion. The first metal portion comprises a first metal material and is configured to receive a conductor member comprising the first metal material. The the second metal portion comprises a second metal material and is configured to receive a second conductor member comprising the second metal material. The apparatus further comprises one or more temperature-activated sealing members that circumferentially surround and form a first seal against at least a portion of each of the first conductor member and the second conductor member. The apparatus further comprises an inner mold encapsulating the metal material transition connector and at least partially encapsulating the temperature-activated sealing member(s), and an outer mold encapsulating the inner mold.