Connection interface for a panel and support structure

A connection interface between a panel and a support structure. The panel includes one or more connectors. The support structure supports the panel and is configured to engage with the one or more connectors. The connection interface between the panel and the support structure provides a mechanical connection to secure the panel. The connection interface can also provide for electrical connections between the panel and the support structure and/or between the panel and one or more other panels or remote components.

BACKGROUND

The present application is directed to a connection interface for connecting a panel to a support structure and, more particularly, to a connection interface with a connector that is configured to engage with a receptacle.

Connectors are used in a variety of different applications to connect a first member to a second member. The connectors can be attached to a first member in a variety of different manners. The connectors can be adjustable between a locked position in which the first member is secured to the second member, and an unlocked position in which the first member is not secured to the second member.

The connectors can be positioned on the first member in a manner such that they are not easily accessible. This can occur when the connector is positioned along a back side of the panel in a position that is difficult to access when positioned at the second member. This can make securing the connectors to the second member difficult due to the lack of access. For instance, a connector on the back side of a solar panel may not be accessible to an installer once the solar panel is positioned on the top of a frame. Likewise, a connector on a back of a plywood panel may not be accessible once the panel is placed against wall studs.

SUMMARY

One aspect is directed to an assembly that includes first and second panels. A connector is attached to each of the first and second panels with each of the connectors extending outward from one of the first and second panels. Each of the connectors includes a first shape with a first side and a second side, and a first electrical conductor positioned at the second side. A support structure includes first and second receptacles each including an open side, a bottom side, and walls that extend between the open side and the bottom side. Each of the receptacles has a second shape that complements the first shape and a second electrical conductor positioned at the bottom side. Each of the panels is configured to attach to the support structure as the first shape complements the second shape for each of the first and second connectors to fit within one of the receptacles and each of the first electrical conductors is positioned at and electrically connected to one of the second electrical conductors when the first and second panels are attached to the support member.

In one aspect, the assembly also includes a seal positioned between the first and second receptacles with the seal contacting against each of the panels when the panels are attached to the support member.

In one aspect, the assembly also includes the second electrical conductors at each of the first and second receptacles being electrically connected together.

In one aspect, each of the connectors further includes a first magnetic member positioned at the second side with each of the first and second receptacles further includes a second magnetic member positioned at the bottom side, and for each of the panels the first magnetic member is positioned at the second magnetic member to create a magnetic attraction force that pulls the connector into the receptacle when the panel is attached to the support member.

In one aspect, the first shape is a tapered shape that is wider towards the panel and narrows away from the panel.

In one aspect, the second shape is a tapered shape that is wider at the open side and that narrows towards the closed side.

In one aspect, the first electrical conductor and the first magnetic member are both exposed on the second side of the connector and the second electrical conductor and the second magnetic member are both exposed in the bottom of the receptacle.

In one aspect, each of the connectors includes a base that is positioned towards the panel and first and second arms that extend outward from the base and are spaced apart by a gap with each of the arms comprises an elbow positioned between the base and a tip, and with a width of the gap measured between the arms being greatest at the elbows.

In one aspect, each of the receptacles comprises a first section at the bottom side, a second section at the open side, and a neck section positioned between the closed side and the open side, with a width of the neck section measured between the walls being less than widths of each of the first section and the second section.

One aspect is directed to an assembly that includes a first panel. A first connector is attached to and extends outward from the first panel. The first connector includes a first shape with a first side at the first panel and a second side away from the first panel, and a first electrical conductor positioned at the second side. The assembly includes a second panel and a second connector attached to and extending outward from the second panel. The second connector includes a second shape with a third side at the second panel and a fourth side away from the second panel. The assembly includes a second electrical conductor positioned at the fourth side. The assembly includes a support structure with a first receptacle with a first open side, a first bottom side, and first walls that extend between the first open side and the first bottom side with the first receptacle including a third shape that complements the first shape for the first connector to fit within the first receptacle when the first panel is attached to the support member and with the third receptacle comprising a third electrical conductor positioned at the first bottom side with the third electrical conductor positioned at and electrically connected to the first electrical conductor when the first panel is attached to the support member. The assembly includes a second receptacle with a second open side, a second bottom side, and second walls that extend between the second open side and the second bottom side. The second receptacle includes a fourth shape that complements the second shape for the second connector to fit within the second receptacle when the second panel is attached to the support member with the second receptacle including a fourth electrical conductor positioned at the second closed side, and with the fourth electrical conductor positioned at and electrically connected to the second electrical conductor when the second panel is attached to the support member.

In one aspect, the first shape and the second shape are the same, and the third shape and the fourth shape are the same.

In one aspect, the third and fourth electrical conductors are electrically connected together.

In one aspect, the assembly also includes that each of the first and second connectors has a base and a pair of spaced-apart arms.

In one aspect, the assembly also includes magnetic members in each of the first and second connectors that are attracted to second magnetic members in each of the first and second receptacles with the first and second magnetic members configured to create a magnetic attraction force to pull the first connector into the first receptacle and the second connector into the second receptacle.

One aspect is directed to a method of assembling a panel system. The method includes aligning a first connector on a first panel over a first receptacle in the support member; inserting the first connector into the first receptacle and seating the first connector into the first receptacle with a first connector being shaped to complement the first receptacle; contacting together electrical conductors on the first connector and the first receptacle; aligning a second connector on a second panel over a second receptacle in the support member, the second receptacle being spaced apart from the first receptacle; inserting the second connector into the second receptacle and seating the second connector into the second receptacle with the second connector being shaped to complement the second receptacle; and contacting together electrical conductors on the second connector and the second receptacle.

In one aspect, the method also includes compressing together arms of the first connector while inserting the first connector into the first receptacle and compressing together arms of the second connector while inserting the second connector into the second receptacle.

In one aspect, the method also includes inserting the first connector into the first receptacle and creating a magnetic attraction between the first connector and the support structure by positioning a first magnetic member in the first connector into proximity of a second magnetic member in the support structure.

In one aspect, the method also includes contacting the first panel against a seal positioned in proximity to the first receptacle and contacting the second panel against the seal that is positioned in proximity to the second receptacle.

In one aspect, the method also includes sliding the first connector that has a tapered shaped into the first receptacle that has a complementary tapered shape.

The various aspects of the various embodiments may be used alone or in any combination, as is desired.

DETAILED DESCRIPTION

The present application is directed to a connection interface between a panel and a support structure. As illustrated inFIG. 1, a panel20includes one or more connectors30. A support structure50that supports the panel20is configured to engage with the one or more connectors30to secure the panel20. The connection interface between the panel20and the support structure50provides a mechanical connection to secure the panel20, and can also provide for electrical connections between the panel20and support structure50and/or between the panel20and one or more other panels20or remote components.

FIG. 2illustrates an exploded view of a panel20equipped with connectors30. The support structure50is configured to receive and engage with the panel20and connectors30. The connectors30are positioned along one or more of a bottom side and lateral sides of the panel20to contact against the support structure50. The support structure50can include openings57across which the panels20extend with perimeter edges23and connectors30contacting against the support structure50and the central section of the panel20extending across the opening57.

A variety of different panels20can be attached to the support structure50. As illustrated inFIG. 2, the panels20each include a first side21and a second side22. The sides21,22can each be planar and have a constant thickness measured between the sides21,22. The panels20can also include the sides21,22having different configurations such that the panel20has a varying thickness. The perimeter edges23extend between the sides21,22and can include a variety of shapes such as straight as illustrated inFIG. 2, curved, and various combinations. The panel20can include a variety of different shapes including but not limited to polygonal, circular, and oval.

The panels20can be configured for use in a variety of different environments and for a variety of different purposes. These include but are not limited to solar panels20, wall panels20, glass panels20(e.g., windows, doors), ceiling panels20, and internal building panels20constructed from a variety of materials such as sheetrock, plywood, and fiberglass. One aspect includes a solar panel20configured to obtain usable solar power through photovoltaics. Solar cells can be positioned between the first and second sides21,22and absorb and convert sunlight into electricity. The panel20is also equipped with various electrical contacts and cabling, and various electronic components such as an inverter to change the electric current from DC to AC.

The panels20can include an electrical bus29. The electrical bus29can extend along one or more of the perimeter edges23. The electrical bus29provides for conducting power along the panel20.

Two or more panels20can be connected to the support structure50to form an array100as illustrated inFIG. 3. The panels20are positioned with the first sides21being exposed and facing away from the support structure50. The second sides22face in an opposing direction towards the support structure50. The connectors30are positioned on the panels20to engage with the support structure50when the panels20are inserted onto and/or into the support structure50.

The connectors30extend from the panel20and are configured to engage with the support structure50.FIG. 4illustrates a connector30that is connected to and extends from second side22of the panel20. The connector30includes a body31that is shaped to align and engage with the support structure50. The body31includes an exposed side32and an opposing side33that is attached to the panel20. A centerline C extends along the body31through the sides32,33.

The body31can be attached to the panel20by a variety of means, including but not limited to adhesives and mechanical fasteners. A foam tape90can be positioned between the side33and the panel20. The foam tape90can prevent the ingress of water and/or debris.

FIG. 12includes the body31attached to the panel20by a frame27that wraps around the perimeter edge23of the panel20. A seal28can be positioned between the frame27and the panel20to prevent the ingress of water and/or debris.

The body31can be attached to the panel20by other means. These can include but are not limited adhesives and mechanical fasteners. The body31and panel20can also be integrally made, such as by an injection-molded panel20that includes the body31in the single-piece construction.

As illustrated inFIG. 4, the body31includes a generally tapering shape that is wider at the side33and narrows towards the side32. This tapering shape aligns and engages the panel20relative to the support structure50. The body31includes a first section81formed between sides33. The sides33can be parallel to the centerline C of the body31with a width measured between the sides33being the same throughout the first section81. The body31also includes a second section82formed between sides34. The width of the second section82narrows away from the panel20as the sides34taper towards the centerline C. The sides34can be aligned at various angles relative to the centerline C, including an acute angle as illustrated inFIG. 4. Each of the sides34can be aligned at the same angle providing a symmetrical shape as illustrated inFIG. 4. Alternatively, the sides34can be aligned at different angles relative to the centerline C. A seal28can be positioned between the body31at the perimeter edge23of the panel20.

The shape of the body31can correspond to the shape of the support structure50. As illustrated inFIG. 5, the support structure50includes a receptacle51shape to receive the body31. The receptacle51includes an open side71, and lateral sides53,54that lead to a bottom52. The bottom52includes a shape to match the shape of side32. The bottom can have various shapes, including but not limited to flat and curved. A first section83is formed between sides53and includes a shape and size that corresponds to the first section81. A second section84is formed between sides54and has a tapered shape and size that corresponds to the second section82of the body31of the connector30. The body31can also include a shape that does not correspond to the support structure50.

The complementary tapering shapes of the body31and receptacle51facilitate the engagement of the panel20to the support structure50. As illustrated inFIG. 5, the panel20on the right is being inserted onto the support structure50. The body31contacts against the side54of the receptacle51and is funneled downward towards the bottom52. The panel20on the left is fully seated with the body31in the receptacle51. The side32of the body31is positioned at the bottom52of the receptacle51. Sides33align with sides53and sides34align with sides54.

The connector30and support structure50are configured to create a magnetic attraction force. The magnetic attraction force facilitates seating of the connector30with the support structure50. The magnetic attraction force can also assist in maintaining the connection between the connector30and the support structure50. The magnetic member40can be exposed on the side32, or can be recessed within the body31and spaced a distance from the side32. The magnetic member40can be centered in the body31and extend on both sides of the centerline C.

The magnetic attraction force is created between a magnetic member40positioned in the connector30and a magnetic member58positioned in the support structure50. Each of the magnetic members40,58can include one or more permanent magnets, electromagnets, and ferromagnetic material.FIGS. 4 and 5illustrate the magnetic member40positioned in the connector30including a ferromagnetic core41, with one or more magnets42and ferromagnets43. The interacting magnetic member58is positioned at the bottom52of the receptacle51to create the magnetic attraction force. The magnetic member40can be exposed on the side32, or can be recessed within the body31and spaced a distance from the side32. The magnetic member58can be centered along the bottom52, or can be offset with the positioning configured to align with the magnetic member40. In another design, the support structure50can include the magnetic member with the ferromagnetic core41, with one or more magnets42and ferromagnets43, and the connector30can include the interacting magnetic member.

The connector30can also include a light path39to accommodate light signals that can move along the panels20and/or support structure50. The light path39can be bordered by one or more walls72. The walls72can be formed by the body31, or components of the connector30such as the magnetic member40as illustrated inFIGS. 4 and 5. In the various designs, the number, size, and shape of the one or more walls72may vary. The walls41can also be constructed such that the light signals may be reflected off the walls41when traveling along the light path39. This can occur when the origination and destination points are not within a direct line of sight. The light paths39can include free space as illustrated inFIGS. 4 and 5that allow for the signal transmission. The light paths39can also include optical fiber extending through the free space. As illustrated inFIG. 2, the light paths39provide for the transmission of the light signals. The light paths39can extend between nodes59on the support structure50, between nodes59on the same panel20, between nodes59on different panels20, and various other configurations for directing light signals between points. For example, the light paths39can extend between a transmitter of a first node59and a receiver of a second node59. Light paths, nodes, and electrical components that receive the light signals are disclosed in U.S. application Ser. No. 15/711,773 filed on Sep. 21, 2017 which is hereby incorporated by reference in its entirety.

Electrical conductors60are electrically connected to the bus29and extend in the connector30. The electrical conductors60are positioned to engage with corresponding conductors55in the support structure50. The conductors60can be positioned along the bottom52to engage with and create an electrical connection when the connector30is seated and engaged with the support structure50.

The conductors55in the support structure50engage with and create electrical connections with the one or more panels20. The conductors55can be exposed at the receptacle51to electrically connect with the panels20and extend to a main bus61that extends along the support structure50. The conductors55can extend to other receptacles51to electrically connect together different panels20.

The connectors30can include different configurations to physically and electrically connect to the support structure50.FIG. 6illustrates a connector30that extends outward from the second side22of the panel20. The connector30includes a body31with a first member38shaped to engage with the support structure50. The first member38of the body31includes a base35and a pair of opposing arms36that each terminate at a tip37. Each of the arms36includes an elbow94between the base35and the tip37. The body38is constructed from a flexible material, such as but not limited to metal and plastic. The arms36are configured to flex outward in the direction of arrows A and inward in the direction of arrows B.

The body31can also include an insulating plug70positioned at the base35between the arms36. The insulating plug70is constructed from an insulating material, such as plastic and forms a support for the conductors60. The insulating plug70is attached to the first member38via adhesives and/or mechanical fasteners.

FIG. 7illustrates an exploded view of the support structure50that engages with the connector30. The support structure50includes a support91, a connector92, and a seal93. The support91includes an undulating shape that forms receptacles51to receive a pair of connectors30. Each receptacle51includes an open side71with sides53,54that lead to a bottom52. A first section83formed between sides53includes a tapering shape that increases in width away from the bottom52. A second section84is positioned outward from the first section83and includes a tapering shape that also increases in width away from the bottom52. A neck section85is positioned between the first and second sections83,84and includes a smaller width. An opening86is positioned along the bottom52of each receptacle51.

The support91also includes a receptacle87positioned along a central section between receptacles51. This receptacle87is sized to receive the seal93. The seal93also accommodates changes in the sizing due to thermal heating and cooling.

The connector92is configured to engage with the support91. The connector92includes a base56with a pair of outer arms88and a pair of inner arms89. The outer arms88are sized and shaped to extend through the openings86in the receptacles51. The inner arms89are sized and shape to engage with the support91. Electrical conductors55can extend through the connector92to electrical connect with the panels20. The conductors55can extend through the outer arms88and be exposed within the receptacles51when the connector92is connected to the support91.

The seal93is configured to contact against the panels20and the support91. The seal93can be constructed from a flexible material to deform and create continuous contact between these elements.

FIG. 8illustrates the support91, connector92, and seal93of the attached together to form the support structure50. The inner arms89include tabs that engage with corresponding tabs on the support91. The outer arms88extend through openings86and into the receptacles51. The conductors55can be exposed in the receptacles51to engage with connectors30. The seal93is positioned in the receptacle87between the receptacles51. An exposed edge95is positioned to contact against the second sides22of a pair of panels20. Two or more of the support91, connector92, and seal93can be connected together by snap fit, such as the inner arms89being engaged with the support91. Mechanical fasteners and/or adhesives can also be used for the connection.

FIGS. 8 and 9illustrate the connection of the connector30with the support structure50. As illustrated inFIG. 8, the panel20is positioned with the connector30located at the receptacle51. The panel20is moved towards the support structure50. This movement positions the arms36against the walls54of the second section84of the receptacle51. Specifically, the elbows94slide along the walls of the receptacle51. The tapered shape of the second section84causes the arms36to be forced inward in the direction of arrows B as the panel20moves into engagement. Continued movement causes the arms36to slide along the neck section85.

As illustrated inFIG. 9, further movement causes the elbows85to move beyond the neck section85. This causes the arms36to spring outward in the direction of arrows A and into the first section83. The arms36may not fully spring outward thus the arms36maintain a force against the walls of the first section83to maintain the engagement. Further, the width at the elbows94is greater than the neck section85. The shape of the arms36corresponds to the first section83during the engagement.

The full seating and engagement of the connector30as illustrated inFIG. 9positions the conductors60in contact with the one or more conductors55in the support structure50. This provides for electrical connection between the panel20and the support structure20and/or other panels20or components.

As further illustrated inFIG. 9, legs99form a receptacle98that receives the seal93. The legs99can flex to accommodate thermal expansion between the adjacent panels20.

FIG. 10illustrates a pair of panels20attached to the support structure50. A first panel20is positioned with its connector30engaged with the corresponding receptacle51. This further positions the one or more conductors60in contact with the one or more conductors55in the support member50. A second panel20is likewise positioned with its connector30engaged with its corresponding receptacle51.

Each of the panels20contacts against the seal93. This contact prevents water and/or debris from interfering with the connectors30and potentially preventing the electrical connection between the panels20and the support structure50.

FIG. 11illustrates a panel system10that includes one or more flexible members95positioned between the connectors30and the support structure50. The flexible members95can include various configurations including but not limited to springs and flexible material such as rubber and foam. The different flexible members95can include the same or different configurations. The flexible members95provide for the one or more panels20be elevated above the support structure50. The flexible members95can also provide for the one or more panels20to be flexible relative to the support structure50. In a panel array100, one or more of the panels20can be connected to the support structure with flexible members95, while one or more of the other panels20can be connected without flexible members95.

The system10can include a variety of different combination of elements and configurations. Electrical conductors60may not be included in one or more of the panels20. A seal95may not be positioned between adjacent panels20.

The connectors30and support structure50can include a variety of structures and configurations.FIG. 13aincludes a connector30connected to a panel20. The connector30includes an elongated body31that forms a base35and a pair of opposing arms36. Each of the arms36is shaped with a narrow elbow94that are aligned and tips37. The arms36are constructed to be flexible and flex inward and outward as shown by arrows A and B.

FIG. 13billustrates a pair of panels20each equipped with connectors30as disclosed inFIG. 13a. The support structure50is shaped to correspond to the connectors30. The support structure50includes receptacles51each sized and shaped to connect with one of the connectors30. Each receptacle51includes an enlarged head73and a narrow neck74. As illustrated with the panel20and connector30on the right ofFIG. 13b, the arms36flex outward as illustrated by arrows A as the connector30is being forced onto the receptacle51. The elbow neck94slides over the head forcing the arms36outward. As illustrated with the panel20and connector30on the left ofFIG. 13b, the arms36rebound and flex inward in the direction of arrows B once the necks94have moved beyond the head73. The necks94of the connector30are positioned at the neck74of the support structure50. Electrical conductors55are positioned at the head73to electrically engage with the conductors60in the connector30.

FIG. 14aillustrates a connector30with a pair of indents63and elbows64formed along an outer edge94. A central section between the indents63positions the electrical conductors60. The support structure50includes a pair of receptacles51each configured to connect with one of the connectors30. Each receptacle51includes a pair of arms75that extend outward from a bottom52. The arms75are constructed from a flexible material and are shaped to conform to the outer edge94. As illustrated with the receptacle51on the left ofFIG. 14b, the arms75flex inward in the direction of arrows C when the connector30is being attached to the support structure50. The arms75move beyond a narrow section of the indents and flex outward in the direction of arrows D when the connector30and panel20are connected. When connected, the electrical conductors60on the connectors30are electrically connected to the conductors55in the support structures50.

FIG. 15aillustrates another connector30shaped with an enlarged head76and narrow neck77. The electrical conductors60are positioned at the head76. As illustrated inFIG. 15b, the receptacles51include arms75that extend outward beyond the bottom52. The arms75are constructed from a flexible material to flex outward in the direction of arrows A as illustrated on right-hand connector30ofFIG. 15b. The arms75then flex inward when aligned with the narrow neck77.

FIG. 16awith an open shape having a bottom78and lateral sides79. As illustrated inFIG. 16b, receptacles51on the support structure50include a complementary shape. When the connector30is attached in the receptacle51, the bottom78of the connector30is in proximity for the electrical conductors60to be electrically connected to the electrical conductors55. Magnetic members40in the support structure50are magnetically attracted to magnetic members58in the connectors30to maintain the connection.

The present invention may be carried out in other specific ways than those herein set forth without departing from the scope and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.