Photovoltaic In-Line Fuse Connector Assembly

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Solution Overview

Problem

Conventional solar installations with fuses in combiner boxes cause unnecessary shutdown of all panels when one circuit trips, reducing efficiency and requiring multiple combiner boxes, which is costly and complex.

Innovation Solution

A photovoltaic in-line connector assembly with an integral fuse, where the fuse is integrated into the connector or wire harness, providing circuit protection and reducing the need for multiple combiner boxes by allowing individual panel malfunctions to trip only the affected fuse.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fuses are installed in combiner boxes for each array, then circuit protection is provided, but all panels in the array shut down when one circuit trips, reducing overall efficiency

Engineering Contradiction:

Improvecircuit protectionVSAvoidoverall efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention segments the circuit protection function by integrating individual fuses into each panel's connector rather than grouping them in a central combiner box. This allows each panel to be electrically isolated and protected independently, so that when one panel trips, only that specific panel is affected while the rest of the array continues to operate at full capacity.

Inventive Principle:

Principle #1Segmentation

2Reliability

If multiple combiner boxes are used to provide circuit protection, then system reliability is improved, but system complexity and cost increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoidcomponent configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention extracts the fuse function from the combiner box and relocates it directly to the panel connectors. This eliminates the need for multiple combiner boxes and their associated fuses, simplifying the overall system architecture while maintaining comprehensive circuit protection at the panel level.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The connector assembly serves multiple functions: it provides electrical connection, strain relief, and circuit protection through the integrated fuse. By combining these functions into a single component, the system eliminates the need for separate combiner boxes and reduces overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If fuses are integrated into the connector with wire-to-wire connection, then the number of combiner boxes is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvenumber of combiner boxesVSAvoiddouble molding process

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The invention merges the fuse, connector, and wire-to-wire connections into a single integrated assembly through a double molding process. This consolidation reduces the total number of components (eliminating the need for separate combiner boxes) while using automated molding technology to manage the manufacturing complexity of the integrated structure.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10553739B1Photovoltaic in line fuse connector assembly having an integral fuse

Publication Date: 2020.02.04 SHOALS TECHNOLOGIES GROUP LLC

AI summary

A photovoltaic in line connector assembly has an integral fuse, and is double molded to provide electrical insulation, protection and strain relief. The assembly can be integrated with, or added to, a wiring harness for a photovoltaic installation, thereby providing one fuse per solar panel. The assembly may include zero, one, or two connectors that are male, female, or one of each.