Abstract:
A low profile PV (LPPV) connector for placement in space restricted areas. The connector includes a plug and receptacle for interconnecting PV solar arrays. The LPPV connector may be a locking connector or a non-locking connector. An extraction tool must be used to unlock an engaged locking connector. The LPPV connector includes a plug and a receptacle that are waterproof when mated.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention is directed to a connector for photovoltaic (PV) systems, and more particularly to a low profile connector in a PV system that provides a solution for space-restricted areas. 
       BACKGROUND OF THE INVENTION 
       [0002]    Photovoltaic (PV) modules, or PV arrays, produce electricity from solar energy. Electrical power produced by PV modules reduces the amount of energy required from non-renewable resources such as fossil fuels and nuclear energy. Significant environmental benefits are also realized from solar energy production, for example, reduction in air pollution from burning fossil fuels, reduction in water and land use from power generation plants, and reduction in the storage of waste byproducts. Solar energy produces no noise, and has few moving components. Because of their reliability, PV modules also reduce the cost of residential and commercial power to consumers. 
         [0003]    PV cells are essentially large-area semiconductor diodes. Due to the photovoltaic effect, the energy of photons is converted into electrical power within a PV cell when the PV cell is irradiated by a light source such as sunlight. PV cells are typically interconnected into solar modules that have power ranges of up to 100 watts (W) or greater. For large PV systems, special PV modules are manufactured with a typical power range of up to several hundred watts. A PV module is the basic element of a (PV) power generation system. A PV module has many solar cells interconnected in series or parallel, according to the desired voltage and current parameters. PV cells are connected and placed between a polyvinyl plate on the bottom and a tempered glass on the top. PV cells are interconnected with thin contacts on the upper side of the semiconductor material. The typical crystalline modules power ranges from several watts to two hundred watts per module. 
         [0004]    In the case of facade or roof systems, the PV system may be installed during construction or added to the building after it is built. Roof systems are generally lower powered systems, e.g., 10 kW, to meet typical residential loads. Roof-integrated PV systems may consist of different module types, such as crystalline and micro-perforated amorphous modules. Roof-integrated PV systems are integrated into the roof such that the entire roof or a portion thereof is covered with PV modules, or they are added to the roof later. PV cells may be integrated with roof tiles or shingles. 
         [0005]    PV modules or arrays require specially designed devices adapted for interconnecting the various PV modules with each other, and with electrical power distribution systems. PV connection systems are used to accommodate serial and parallel connection of PV arrays. In addition to connection boxes, a PV connection system includes connectors that allow for speedy field installation or high-speed manufacture of made-to-length cable assemblies. Connectors or connection boxes may be required to receive specialized cable terminations from PV modules, with power diodes inside for controlling current flow to the load. PV modules may be required in areas with tight space restraints and requirements, requiring the size of the PV module to be minimized. U.S. patent application Ser. No. 11/865,883 entitled “LOW PROFILE PHOTOVOLTAIC (LPPV) BOX”, filed on Oct. 2, 2007, describes a low profile PV junction box for use with PV modules. 
         [0006]    Therefore, there is a need for a low profile PV (LPPV) connector that allows for the placement of PV arrays in compact areas. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is directed to a low profile connector including a plug and a receiver. The plug has a strain relief, a plug body, a male connection and a cable, and the receptacle has a strain relief, a receptacle body and a receiver. The plug is matable with the receptacle to form an electrical connection and when the plug and receptacle are mated, the plug is not removable from the receptacle. The plug and the receptacle have a vertical profile not greater than a width of the cable. 
         [0008]    Another embodiment of the present invention is directed to a low profile connector including a plug and a receptacle. The plug and receptacle mate and form an electrical connection. The plug includes a strain relief, a plug body, a male connection and a cable. The plug body has at least one latch. The receptacle includes a strain relief, a receptacle body and a receiver. The receiver has at least one ledge that engages with the at least one latch. The plug and the receptacle have a vertical profile not greater than a width of the cable. 
         [0009]    An advantage of the present invention is that the low profile PV junction connector allows a PV solar array to be placed in restricted spaces. 
         [0010]    Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  shows a perspective view of a plug and a receptacle of a locking low profile PV connector in an unmated position. 
           [0012]      FIG. 2  shows a side view of the plug and receptacle of  FIG. 1 . 
           [0013]      FIG. 3  shows a cross-sectional view of the plug and receptacle in a mated position. 
           [0014]      FIG. 4  shows a perspective view of the mated connector and an extraction tool. 
           [0015]      FIG. 5  shows a perspective view of a plug and a receptacle of a non-locking low profile PV connector in an unmated position. 
           [0016]      FIG. 6  shows a perspective view of a plug and a receptacle of the non-locking connector in a mated position. 
           [0017]      FIG. 7  shows a cross-sectional view of the non-locking connector. 
           [0018]      FIG. 8  shows a perspective view of a plug and a receptacle of an alternate embodiment of a low profile PV connector. 
           [0019]      FIG. 9  shows the connector of  FIG. 8  in communication with solar arrays. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]      FIGS. 1 ,  2  and  3  show a low profile PV (LPPV) connector  10 . Connector  10  has a plug  12  and a receptacle  14  that are mateable to form an electrical connection. Plug  12  includes a strain relief  16 , a body  18 , locking latches  20 , and a male connection  22 . Strain relief  16  provides a waterproof seal and relieves strain caused by pulling and bending of a cable  24  that extends from plug  12  or receptacle  14 . Strain relief  16  may be manufactured from a flexible and sturdy material such as Santoprene® rubber, or any other suitable material. Cable  24  conducts power from a solar array  26  (see  FIG. 9 ) to plug  12 . While a solar array  26  is described as the source of power conducted by cable  24 , it is appreciated that cable  24  may range from a 14 AWG cable to a 10 AWG cable and may communicate power or data from any source to plug  12  or receptacle  14 . Plug  12  and receptacle  14  are limited in vertical elevation by the width of cable  24  used with connector  10 . A five (5) millimeter cable may be used with connector  10 , however it is appreciated that any cable may be used with connector  10 , including but not limited to, ribbon cable. 
         [0021]    Plug body  18  extends from strain relief  16 , and is manufactured from a rigid plastic material or any other suitable material. Plug  12  may be formed by an overmolding process, or any other suitable manufacturing process. Disposed inside plug body  18  is a contact, or blade  28  for facilitating an electrical connection with receptacle  14 . Blade  28  may be a faston blade or any other suitable blade or contact. Plug body  18  may also include a grip  30  on the top surface to provide a non-slippery surface for a user to grasp plug  12 . Grip  30  may be molded from the same material, or grip  30  may be molded from the same flexible material as strain relief  16 . Disposed on both sides of body  18  are locking latches  20 . Locking latches  20  extend from plug body  18  and bend at an elbow  32  to extend substantially parallel to body  18 . Locking latches  20  have protrusions  34  at the distal end of latch  20 . Protrusions  34  engage with receptacle  14  when plug  12  is mated with receptacle  14 . 
         [0022]    Extending from body  18  is male connection  22 . Male connection  22  mateably connects with receptacle  14 . Sealing ribs  36  are disposed on the outer surface of male connection  22 . The figures show three sealing ribs  36  disposed on the outer surface of male connection  22 , however any suitable number of sealing ribs  36  may be used. Sealing ribs  36  may be formed from a flexible material such as Santoprene® rubber, or any other suitable slightly compressible material. When plug  12  is mated with receptacle  14 , sealing ribs  36  are compressed against receptacle to form a seal between plug  12  and receptacle  14 . Sealing ribs  36  prevent moisture, dust particles or other matter from entering connector  10 . 
         [0023]    Receptacle  14  has a strain relief  16  extending from one end of a receptacle body  40  and a female connection receiver  42  opposite strain relief  16  for receiving plug  12 . Strain relief  16  provides waterproof protection and strain relief to a cable  24  that extends from receptacle  14 . Cable  24  communicates solar power and energy from a solar array  26  (see  FIG. 9 ) to receptacle  14 . While a solar array  26  is described, it is appreciated that cable  24  may communicate power or data from other sources and is not limited to solar arrays. Strain relief  16  may be manufactured from a flexible and sturdy material such as Santoprene® rubber, or any other suitable material. 
         [0024]    Receptacle body  40  extends from strain relief  16 , and is manufactured from a rigid plastic material or any other suitable material. Receptacle  14  may be formed by an overmolding process, or any other suitable manufacturing process. Disposed inside receptacle body  40  is a contact, or blade  28  for facilitating an electrical connection with blade  28  in plug  12 . Blade  28  may be a faston blade or any other suitable blade or contact. Receptacle body  40  may also include a grip  30  on the top surface to provide an abrasive surface for a user to grasp receptacle  14 . Grip  30  may be unitary with receptacle body  40  and molded from the same material, or grip  30  may be molded from the same flexible material as strain relief  16 . 
         [0025]    Extending from receptacle body  40  is receiver  42 . Receiver  42  is unitary with receptacle body  40  and configured to mate with male connection  22  on plug  12 . Disposed on each side surface of receiver  42  are grips  30  to provide an abrasive surface for a user to grasp receptacle  14 . Grip  30  may be molded from the same material as receptacle body  40 , or grip  30  may be molded from the same flexible material as strain relief  16 . Apertures  44  are disposed on opposites sides of receiver  42 . Apertures  44  are configured and disposed to align with protrusions  34  on locking latches  20  when plug  12  is mated with receptacle  14 . Apertures  44  provide access to locking latches  20  when plug  12  is mated with receptacle  14 . Receiver  42  also includes a ledge  46 . Ledge  46  engages locking latch  20  when plug  12  is mated with receptacle  14 . Protrusions  34  engage with ledges  46  and maintain plug  12  engagement with receptacle  14 . When locking latches  20  engage with ledges  46 , an audible and/or tactile signal may notify the user that plug  12  is secured in receptacle  14 . 
         [0026]    As shown in  FIG. 4 , an extraction tool may be used to disengage locking latches  20  from ledges  46 . Extraction tool  48  may be inserted into apertures  44  and contact protrusions  34 , to disengage locking latches  20  from ledges  46 . When extraction tool  48  displaces locking latches  20 , elbow  32  permits movement of locking latches  20  to disengaged protrusions  34  from ledges  46 . Plug  12  may be removed from receptacle  14  when extraction tool  48  has disengaged locking latches  20  from ledges  46 . Both plug  12  and receptacle  14  of connector  10  are configured not to exceed a maximum height of 8 mm. However, connector  10  may be configured within any suitable height requirement. 
         [0027]    In an alternate embodiment shown in  FIGS. 5 ,  6 , and  7 , plug  12  may include at least one engaging latch  50 . Engaging latch  50  extends outward from body  18  of plug  12  and has a projection  52 . Engaging latch  50  is deformable, as plug  12  is mated with receptacle  14 , engaging latch  50  may be displaced inward toward body  18  until projection  52  engages with cavity  54  in receiver  42  in receptacle  14 . When engaging latches  50  engage with receiver  42 , an audible and/or tactile signal may notify the user that plug  12  is secured in receptacle  14 . Once plug  12  is mated with receptacle  14 , plug  12  may be removed from receptacle  14  without the aid of a tool or other device. A normal force of about twenty pounds or greater may be applied to plug  12 , receptacle  14 , or both substantially simultaneously to remove plug  12  from receptacle  14 . Receptacle body  40  of receiver  14  may not include apertures  44  (see, e.g.  FIG. 1 ). An extraction tool  48  ( FIG. 4 ) or other removal device is unnecessary to remove plug  12  from receptacle  14 . 
         [0028]    In another alternate embodiment shown in  FIG. 8 , connector  10  is used with a junction box  54 . Plug  12  is in communication with junction box  54  through cable  24 . Junction box  54  may be an LPPV junction box, or any other suitable junction box and may include a body  58 , strain relief  16 , and a solder pad  60 . An adhesive is used to mount and secure body  58  of junction box  54  to a solar array  26  (see  FIG. 9 ) or other suitable device. Junction box  54  is disposed on solar array  26  ( FIG. 9 ) such that a conductive foil (not shown) on solar array  26  contacts solder pad  60  on junction box  54 . Conductive foil (not shown) is used to provide electrical interconnections between multiple solar arrays  26 . Conductive foil (not shown) may be unitary with, or in communication with solar array  26 , and extend from solar array  26  to enable a connection with junction box  54  or other suitable connection device. Solder pad  60  has a slot  62  for soldering solder pad  60  to a conductive foil (not shown). Once foil (not shown) has been soldered to solder pad  60 , an epoxy or other seal or filling (not shown) is applied to solder pad  60 . The epoxy (not shown) prevents external objects or elements from damaging solder pad  60  and from damaging the soldered connection between solder pad  60  and foil (not shown). Plug  12  may also be a locking plug  12  as described above with reference to  FIGS. 1 ,  2 ,  3  and  4 , above, or plug  12  may be a non-locking plug  12  as described with reference to  FIGS. 5 ,  6 , and  7 , above. 
         [0029]    Receptacle  64  is mateable with plug  12  and may include a body  66 , solder pad  60 , and receiver  42 . An adhesive is used to mount and secure body  66  of receptacle  64  to a solar array  26  (see  FIG. 9 ) or other suitable device. Receptacle  64  is disposed on solar array  26  such that a conductive foil (not shown) on solar array  26  contacts solder pad  60  on receptacle  64 . Solder pad  60  has a slot  62  for soldering solder pad  60  to foil (not shown). Once a solder connection has been made between foil (not shown) and solder pad  60 , an epoxy or other seal or filling (not shown) is applied to solder pad  60 . The epoxy (not shown) prevents external objects or elements form damaging solder pad  60  and from damaging the soldered connection between solder pad  60  and foil (not shown). Receiver  42  receives plug  12  and secures plug  12  in receptacle  64 . Receptacle  64  may be a locking receptacle as described with reference to  FIGS. 1 ,  2 ,  3 , and  4 , above, or receptacle  64  may be a non-locking receptacle as described with reference to  FIGS. 5 ,  6  and  7 , above. 
         [0030]      FIG. 9  shows connector  10  with junction box  54  mounted and secured to solar array  26 . Solar arrays  26  are mounted to a roof  70  or other suitable location, were solar arrays  26  may gather solar energy and power. Junction box  54  is mounted to a first solar array  26  when body  58  is secured to solar array  26  with an adhesive. Receptacle  64  is mounted to a second solar array  26  when body  66  is secured to solar array  26  with an adhesive. A small air gap  72  between roof  70  and connector  10  and solar arrays  26  provide space for a user to access solar arrays  26  and/or connector  10  if necessary. Connector  10  facilitates communication or power transfer between the first and second solar arrays  26 . A plurality of connectors  10  may be used to connect a plurality of solar arrays  26 . 
         [0031]    Both a locking LPPV connector  10  and a non-locking LPPV connector  10  are shown in  FIGS. 1 through 9 . It is appreciated that the locking and non-locking LPPV connectors  10  may be interchanged within applications. It is also appreciated that a locking LPPV connector  10  may be required for certain applications by standards known to those of ordinary skill in the art. 
         [0032]    While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.