Trunk Bus Connector Angled Cable Routing
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Solution Overview
Problem
Conventional methods for connecting solar panels to inverters are labor-intensive, prone to inconsistent quality, and costly due to the need for multiple 90-degree bends in wiring, which leads to wire breaks and increased maintenance, especially with high-wattage solar panels and combiner boxes that malfunction under severe weather conditions.
Innovation Solution
A trunk bus system that allows branch cables from solar panels to connect to a main trunk cable at an angle of 30 to 50 degrees, eliminating the need for 90-degree bends and utilizing larger aluminum wires, reducing material costs and installation complexity by integrating multiple branch lines into a single trunk line without combiner boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wiring methods with multiple 90-degree bends are used to connect branch cables to trunk cables, then electrical connection can be achieved, but wire breaks occur frequently and installation complexity increases
Solution Approach 1:
The patent replaces multiple sharp 90-degree bends with a single gradual curved bend in the branch cable. The cable enters the trunk bus at an angle between 45-90 degrees and curves smoothly to contact the electrical contact, eliminating stress concentration points and reducing wire breaks while simplifying installation procedures
2Reliability
If combiner boxes are used to connect multiple DC feeder lines, then electrical connection can be achieved, but maintenance requirements increase under severe weather conditions
Solution Approach 1:
The patent eliminates the combiner box component entirely by integrating the electrical connection function directly into the trunk bus structure. Branch cables connect directly to the trunk bus through angled entry and curved contact, removing the intermediate combiner box that requires maintenance under severe weather conditions
3Power
If #6AWG copper PV wire is used for high wattage solar panels, then adequate current carrying capacity is achieved, but material costs and Capex increase substantially
Solution Approach 1:
The patent changes the cable configuration parameters (reducing bends, optimizing connection geometry) to reduce resistance and improve current flow efficiency. This allows the use of smaller gauge wires or alternative materials while maintaining adequate current carrying capacity for high wattage panels, reducing material costs
4Productivity
If multiple trackers are installed in a row to better utilize land, then land utilization improves, but DC loss requirements limit the system to 3 or 4 trackers
Solution Approach 1:
The patent creates continuous, low-resistance electrical pathways through the optimized cable routing and direct trunk bus connection. By eliminating bends and intermediate components, the system maintains lower DC losses over longer distances, enabling expansion to 5 or more trackers in a row and improving land utilization
Data Source
AI summary
A trunk bus connector for electrically coupling one or more branch cables to a trunk line. The trunk bus connector containing a junction area, overmold, undermold, and entry pathways arranged so that the branch cables can be coupled to the trunk line without the use of 90-degree bends. The entry of the branch cables relative to the trunk line being approximately 30 to 50 degrees resulting in easier, more reliable installation with less material required.