PV Module Connector Cable Strain Relief

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Solution Overview

Problem

Conventional electrical connector assemblies for photovoltaic modules are prone to moisture and contaminant ingress, and their assembly processes are often costly and complex, particularly due to the crimping of conductive cables within the junction box.

Innovation Solution

The electrical connector assembly features a connector housing with a cable channel and a retaining member that grips the conductive cable, preventing movement and potential moisture ingress, while allowing for simpler and cost-effective assembly through the use of a cover that secures the cable and retaining member within the housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If barrels are compressed or crimped around conductive cables inside the junction box, then the conductive cables are prevented from being inadvertently removed, but the assembly process becomes costly and complex

Engineering Contradiction:

Improvecable retentionVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cable retention function is segmented from the crimping operation. Instead of crimping barrels directly onto cables inside the junction box, the invention uses separate cable retainers that are inserted into the junction box and independently secure the cables. This segmentation simplifies the assembly process while maintaining cable retention reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Cable retainers serve as intermediary components between the junction box housing and the conductive cables. These retainers mediate the connection by providing a simple insertion mechanism that secures cables without requiring complex crimping operations, thus reducing assembly complexity while ensuring reliable cable retention.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If over-molding process is used to locate internal components within the junction box, then assembly is simplified, but the junction box becomes susceptible to leaking because materials do not properly bond

Engineering Contradiction:

Improveassembly processVSAvoidsealing integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The sealing function is segmented from the over-molding process. Instead of relying on the over-molded material to seal around cables, the invention uses separate cable seals that are inserted into seal cavities within the junction box housing. This segmentation allows for reliable sealing without the bonding issues inherent in over-molding processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Cable seals serve as intermediary components between the housing material and the conductive cables. These seals mediate the sealing function by providing a reliable barrier that prevents moisture and contaminant ingress, overcoming the bonding deficiencies of over-molding while maintaining assembly simplicity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If conductive cables are inserted through holes in the junction box, then assembly is simplified, but internal components become exposed to moisture and contaminants

Engineering Contradiction:

Improveassembly processVSAvoidmoisture and contaminant ingress

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS8083540B1Photovoltaic module connector assemblies having cable strain relief

Publication Date: 2011.12.27 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

An electrical connector assembly including a connector housing having a plurality of sides that define an inner region of the connector housing and include opposite loading and mating sides. The connector housing has a cable channel located in the inner region that extends between the loading and mating sides and a slot oriented substantially transverse to the cable channel. The slot extends through the cable channel. The connector assembly also includes a conductive cable that is received in the cable channel and extends along a central cable axis. The conductive cable has an outer surface and is configured to electrically engage the PV module. The connector assembly also includes a retaining member that is inserted into the slot. The retaining member surrounds the conductive cable about the cable axis and grips the outer surface of the conductive cable.