Solar Array Lead Assembly Without a Combiner Box
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Solution Overview
Problem
Conventional solar power installations require a combiner box to combine energy from solar arrays before it reaches the inverter, which is cumbersome, prone to damage, and difficult to move without extensive disconnection and reconnection of wiring.
Innovation Solution
A lead assembly that connects solar arrays directly to an inverter via a feeder cable and drop lines, eliminating the need for a combiner box by effectively combining the power from multiple solar arrays into a single feeder cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a combiner box is used to combine energy from solar arrays, then the electrical connection is established, but the device becomes cumbersome, prone to damage, and difficult to move
Solution Approach 1:
The patent divides the combiner box function into separate modular components: individual drop lines with integrated connectors that can be independently connected to each solar array and then combined at a central feeder cable. This segmentation eliminates the need for a single large combiner box, allowing each module to be easily moved and reconfigured while maintaining reliable electrical connections.
Solution Approach 2:
The patent extracts the combining function from the traditional combiner box structure and distributes it across multiple drop lines that each independently connect to solar arrays. The extraction removes the cumbersome housing and internal wiring complexity, leaving only the essential electrical connection elements that can be easily installed and moved.
2Reliability
If a combiner box is used to combine energy from solar arrays, then the electrical connection is established, but extensive disconnection and reconnection of wiring is required for movement
Solution Approach 1:
The patent applies preliminary action by pre-attaching connectors to the drop lines and pre-configuring the electrical connections before field installation. The drop lines come with connectors already attached and positioned, allowing for quick plug-and-play connection to solar arrays without requiring complex wiring assembly during installation or reconfiguration.
Solution Approach 2:
The patent introduces dynamics by designing a flexible system where drop lines can be easily added, removed, or repositioned. The modular connector design allows the system to dynamically adapt to changing configuration needs without requiring complete disassembly and reassembly of the electrical connections.
3Power
If a combiner box is used to combine energy from solar arrays, then the power combination is achieved, but the device is clumsy and requires extensive planning and skill for installation
Solution Approach 1:
The patent applies self-service by designing drop lines with self-aligning and self-latching connectors that automatically establish proper electrical connections when mated. The connectors are designed to guide the connection process and ensure proper alignment, eliminating the need for complex installation procedures or specialized skills while maintaining full power combination capability.
4Reliability
If a combiner box is used to combine energy from solar arrays, then the central connection point is established, but the number of connections increases complexity
Solution Approach 1:
The patent segments the central connection point into multiple distributed connection points along the feeder cable. Instead of all connections converging at a single combiner box, each drop line connects to the feeder cable at its own location, distributing the connection complexity across multiple simple interfaces rather than one complex hub.
Data Source
AI summary
A lead assembly includes a feeder cable, a drop line cable with first and second drop lines, and one or more mold structures disposed about and enclosing a region of electrical interconnection between the feeder cable and the drop line cable. The first drop line terminates at a first drop line connector configured for detachable connection to a wire harness having multiple branches that are each configured to receive electrical power generated by a corresponding PV panel. The second drop line terminates at a second drop line connector. The mold structure(s) are disposed about and enclose a region of electrical interconnection between the feeder cable and the drop line cable. In the region of electrical interconnection, at least a portion of the drop line cable extends along a longitudinal axis that is parallel to a longitudinal axis of at least a portion of the feeder cable.