Low Leakage Solar Wire Harnesses with Sealed Fused Joints

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Solution Overview

Problem

Conventional solar energy utility infrastructure is costly and inefficient due to high labor requirements for wiring, energy leakage, and technical shortcomings, making large-scale alternative energy generation financially imprudent and conflicting with environmental responsibilities.

Innovation Solution

Low leakage electrical joints and wire harnesses are created using insulated photovoltaic wires that are partially stripped, welded, and sealed with synthetic rubber, then encased in UV-stabilized polypropylene, allowing for simple assembly into T, cross, or Y configurations with connectors for efficient electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional wiring methods are used with qualified electricians measuring, cutting, connecting and crimping wires on site, then electrical connections can be made between solar panels, but labor costs and installation time increase significantly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Wire harnesses are pre-assembled, pre-tested, and pre-configured in a controlled manufacturing environment before delivery to the installation site. This preliminary action eliminates on-site measuring, cutting, and crimping operations, reducing installation time while maintaining connection reliability through factory quality control

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The electrical system is divided into modular wire harness segments that can be independently manufactured, tested, and assembled. This segmentation allows parallel manufacturing of multiple harness sections and simplifies on-site assembly through standardized connectors, reducing both labor time and improving reliability

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If conventional wire connections are used in solar infrastructure, then electrical connections can be established, but energy leakage occurs decreasing system efficiency

Engineering Contradiction:

Improvewiring implementation easeVSAvoidenergy leakage

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

Connector housings are made from composite materials with integrated sealing properties, combining mechanical fastening functions with electrical insulation and environmental sealing. This integration eliminates energy leakage paths while maintaining ease of assembly through molded-in features

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Flexible sealing gaskets and thin film barriers are incorporated into connector designs to create conformal seals around wire connections. These flexible sealing elements adapt to manufacturing tolerances and thermal expansion, preventing energy leakage without complicating the assembly process

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If extensive wiring and troubleshooting infrastructure is implemented in solar plants, then complete electrical systems can be built, but material costs and maintenance expenses increase

Engineering Contradiction:

Improvesystem functionalityVSAvoidmaterials required

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

Standardized connector designs serve multiple functions: electrical connection, mechanical support, environmental sealing, and alignment guidance. This multi-functionality reduces the quantity of separate components needed while maintaining system reliability through integrated design

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Multiple functions are merged into single components - for example, connector housings that simultaneously provide structural support, electrical insulation, and environmental protection. This merging reduces material quantity and assembly complexity while preserving system functionality

Inventive Principle:

Principle #5Merging (Combining)

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 significantly reduces materials, labor, and energy leakage, making solar energy infrastructure more cost-effective and efficient, with leakage reduced to less than 50 nA, well below industry standards, while maintaining safety and simplicity in manufacturing and use.

Implementation Method 1

The section encompassing the exposed wire and weld is coated in a synthetic rubber sealant and allowed to cure

Methodology Applied

Scientific EffectSealing:

Implementation Method 2

encased in a molded polypropylene material including a UV stabilizing agent

Methodology Applied

Scientific EffectUV stabilization:

Implementation Method 3

the portion of exposed wire welded to a portion of exposed wire on another, separate photovoltaic wire

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS8604342B2Low leakage electrical joints and wire harnesses, and method of making the same

Publication Date: 2013.12.10 SHOALS TECHNOLOGIES GROUP LLC

AI summary

Low leakage electrical joints and wire harnesses for simplifying the electrical infrastructure associated with solar energy utilities are disclosed. The low leakage electrical joints include fused wires that have been sealed, encased and configured to plug into other joints to form wire harnesses. The wire harnesses are particularly well suited for coupling a plurality of solar collector junction boxes to a combiner box.