Low-cost connectors for inverters and converters and methods of manufacturing and using the same

In some embodiments, systems and methods for connector assembly for use with an AC or DC power interface of a power conversion device, such as a converter and an inverter, are provided. The connector assembly can include a circuit board, a power connector, and a pin. The power connector can have a base configured to be secured relative to the circuit board and define a first channel extending through the power connector along a first channel axis. The first pin can have a first pin body that extends along a first pin axis and a first connection element that extends along the first pin axis from the first pin body to a first terminal end that is skewed relative to the first pin axis.

BACKGROUND

Photovoltaic modules can generate direct current (DC) power based on received solar energy. Photovoltaic modules can include multiple photovoltaic cells that can be electrically coupled to one another to allow the multiple photovoltaic cells to contribute to a combined output power for the photovoltaic module. In some applications, the DC power generated by a photovoltaic module can be converted to alternating current (AC) power through the use of a power inverter, such as a photovoltaic (PV) microinverter. The power inverter can be electrically coupled to an output of the photovoltaic module. Often the power inverter is connected to adapters and intervening wiring.

SUMMARY

In accordance with some embodiments of the disclosed subject matter, systems and methods for establishing electrical connections with power conversion devices (e.g., inverters and converters) are provided.

In accordance with some embodiments of the disclosed subject matter, a connector assembly configured for use with at least one of an AC and a DC power interface of a power conversion device, such as an electronic converter or inverter (e.g., microinverter), is provided. The connector assembly can include a circuit board, a power connector, and a first pin. The circuit board can define a first surface and a second surface spaced apart from the first surface by a thickness. The power connector can have a base configured to be secured relative to the circuit board and define a first channel that extends through the power connector along a first channel axis. The first pin can have a first pin body that extends along a first pin axis and a first connection element that extends along the first pin axis from the first pin body to a first terminal end that is skewed relative to the first pin axis. The first pin can be at least partially seated in the first channel. The terminal end can be configured to electrically engage the circuit board.

Some embodiments include a method for producing a power conversion device, such as an electronic converter or inverter. The method can include providing a printed circuit board that is configured to receive electrical components. The method can include inserting a pin having a connection element into a channel of a power connector. The method can include securing the power connector to the printed circuit board via a securing portion of the power connector. The method can include electrically coupling the connection element to the printed circuit board. The method can include inserting the printed circuit board into an interior volume of a housing that includes a cutout so that the power connector extends through the cutout.

In some embodiments, a power conversion device, such as an electronic converter or an electronic inverter (e.g., a microinverter), is provided. The power conversion device can include a housing, a circuit board, a DC power connector, and an AC power connector. The housing can define an interior volume that includes an exterior surface. The circuit board can be secured within the interior volume. The DC power connector can include a DC power connector body and a DC power pin. The DC power connector body can be engaged with the housing and the DC power pin can extend through the exterior surface of the housing and into the interior volume whereat the DC power pin is coupled to the circuit board. The AC power connector can include an AC power connector body and an AC power pin. The AC power connector body can be engaged with the housing and the AC power pin can be coupled to the circuit board.

DETAILED DESCRIPTION

Also as used herein, unless otherwise specified or limited, directional terms are presented only with regard to the particular embodiment and perspective described. For example, reference to features or directions as “horizontal,” “vertical,” “front,” “rear,” “left,” “right,” and so on are generally made with reference to a particular figure or example and are not necessarily indicative of an absolute orientation or direction. However, relative directional terms for a particular embodiment may generally apply to alternative orientations of that embodiment. For example, “front” and “rear” directions or features (or “right” and “left” directions or features, and so on) may be generally understood to indicate relatively opposite directions or features.

As noted above, inverters, such as microinverters, can be used in photovoltaics. A microinverter can convert direct current (DC) generated by a solar module to alternating current (AC). In general, a single microinverter can be in electrical contact with a single solar module and can have several advantages over conventional inverters. For example, a microinverter can electrically isolate solar modules within an array of modules from one another so that if there is an issue, or even complete failure of a solar module, the output of the array is not disproportionately affected.

In general, AC and DC connectors are among major components in the development and manufacturing of various power conversion devices, such as converters and inverters. These connectors can increase the cost of manufacturing, assembling, and packaging for power conversion systems. For example, AC and DC connectors often contribute a significant portion of the bill-of-materials for the entire converter/inverter. As briefly described above, in the case of a photovoltaic (PV) microinverter, standard systems incorporate two connectors to operate: a DC connector to connect the PV module to the inverter, and an AC connector to connect the inverter to a power grid. Such hardware components can increase the cost of the system. Additionally, AC and DC components can adversely increase the size and weight of individual microinverters. Since a plurality of microinverters may be used in an array of solar modules, it may be useful to reduce the size, weight, and cost of each microinverter, and to enhance the manufacturability of each microinverter by, for example, reducing the cost and the potential failure modes.

Generally, some embodiments of the invention can include a device for establishing electrical connections with power conversion devices, such as inverters and converters. In some embodiments, a connector according to some embodiments of the invention may eliminate the need for standard, and often costly, cumbersome interface connections between AC bus-cables and AC output connectors of inverter/converter structures, such as a microinverter, for example. Additionally, some embodiments of the invention provide methods of manufacturing and using such connectors. While the example embodiments are generally described in the context of a microinverter, one skilled in the art (given the benefit of this disclosure) will appreciate that the scope is not limited to the example microinverter, but is generally applicable to power conversion devices and other contexts that can benefit from the concepts taught herein.

FIG.1illustrates an example of a conventional microinverter100. The microinverter100includes a housing102, a DC power connector assembly104, and an AC power connector assembly106. The DC power connector assembly104can be configured as an adapter and can include DC power cables108and a DC power connector110. Internally within the housing102, though not shown, conventional microinverters often include additional wiring to electrically couple DC power cables, such as the DC power cables108illustrated inFIG.1, to a printed circuit board. As a result, during a manufacturing process of the conventional microinverter100, the DC power connect assembly104may be electrically coupled to the microinverter100after the housing102is assembled and the DC power cables fed through openings (not shown) in the housing102.

Similar to the DC power connector assembly104, the AC power connector assembly106can be configured as an adapter and include an AC power cable112and an AC power connector114. In some conventional microinverters, such as the microinverter ofFIG.1, additional wiring may also be used inside the housing102to electrically couple the AC power cable112to a printed circuit board. Like the DC power connector assembly104, during the manufacturing process of the conventional microinverter100, the AC power connector assembly106is often electrically coupled to the microinverter100after the housing102is assembled. Adhesive sealants are sometimes used in an attempt to establish an environmental barrier where the cables pass into the housing102, with limited reliability and effectiveness.

FIG.2illustrates one example of an electronic inverter, configured as a microinverter120, according to one embodiment of the invention. The microinverter120includes a housing122, a circuit board124, a DC power connector126, and an AC power connector128. In the illustrated embodiment, the housing122includes a body130that defines an interior volume and includes an exterior surface132. The body130further includes a first notch134and a second notch136formed therein. The first notch134includes a first protrusion138that extends along a surface of the first notch134. Similarly, the second notch136includes a second protrusion140that extends along a surface of the second notch136. In the illustrated embodiment, each of the first and second notches134,136are formed in a boss that extends from the exterior surface132generally about the perimeter of the first and second notches134,136.

The housing122also includes a lid142that is dimensioned to engage and be secured to the body130via fasteners144. In the illustrated embodiment, the fasteners144are configured as screws. However, other configurations are possible. For example, other fasteners such as pins, bolts, nuts, adhesives, etc. can be used to secure the lid142to the body130. The lid142includes a pair of mount arms146that extend therefrom. In the illustrated embodiment, the pair of mount arms146are generally coplanar with the lid142. In other embodiments, the housing122can include additional or alternative mounting features, such as mounting brackets that extend from the body130.

Still referring toFIG.2, the circuit board124, which can be configured as a printed circuit board (PCB), includes a top surface152and a bottom surface154. The top surface152and the bottom surface154define a thickness of the circuit board124, which is an orthogonal length between the top surface152and the bottom surface154. In general, the circuit board124is configured to electrically couple a variety of electrical components of the microinverter120. For example, the circuit board124can include conductive tracks, pads, and other features etched from one or more sheet layers of copper laminated onto and/or in between a non-conductive substrate.

Also shown inFIG.2, the DC power connector126includes a DC power connector body160and first and second pins162,164. The DC power connector126can be coupled to a corresponding DC power output. For example, the DC power connector126may be configured to be implemented with a PV panel. In particular, the DC power connector126may be configured to be compatible with industry standard connectors, such as an MC-4 connector type, for example. The AC power connector128includes an AC power connector body170and connector pins172. The AC power connector128may be configured to electrically engage to a corresponding AC power interface (see, for example,FIGS.13and14), which can be used to connect the microinverter120to a power grid. In one embodiment, the first and second pins162,164(and the pins described throughout) may be produced from folded and press-formed copper sheet, or of any other suitable material/process to meet application-specific requirements.

FIGS.3and4illustrate the DC power connector126ofFIG.2. The DC power connector body160includes a first plug176and a second plug178. The first plug176includes a first channel180that defines a first channel axis. The first plug176further includes a pair of arms182that can be resilient and configured as female connector locking tabs that extend from a base184of the first plug176. The first plug176also includes a seal186, which may be configured as an O-ring, proximate to the base184. The second plug178includes a second channel190that defines a second channel axis. The second plug178further includes a pair of connector receptacles192configured as male connector tab receptacles.

Still referring toFIGS.3and4, the DC power connector126includes a connector base196having a flat surface198and a curved surface200that extends around the base196and connects to the flat surface198. The curved surface200includes a profile that is similarly shaped to the first notch134in the housing122, and defines a groove202. The groove202is dimensioned to receive the first protrusion138of the first notch134formed in the body130of the housing122. The engagement of the first protrusion138with the groove202will be described below with reference toFIG.8. In other embodiments, a DC power connector, similar to the DC power connector126, can include a mating feature similar to the groove202that can be dimensioned to engage a corresponding mating feature formed in a lid of a housing, similar to the lid142, to establish a sealing interface completely about the base196.

FIGS.5and6illustrate the first and second pins162,164of the DC power connector126, respectively. With reference toFIG.5, the first pin162includes a pin body208that defines a first pin axis. The pin body208includes an outer surface210and an inner channel212. The outer surface210includes an annular recessed portion214and an annular protruded portion216. The pin body208is generally configured as a female pin dimensioned to receive a corresponding male pin within the inner channel212. The first pin162also includes a first connection element218extending from the pin body208along the first pin axis.

The first connection element218includes a terminal end220. In the illustrated embodiment, the terminal end220is skewed relative to the first connection element218and relative to the first pin axis. In particular, in the illustrated embodiment, the terminal end220is bent approximately 90 degrees relative to the first pin axis. However, in other embodiments, the terminal end220can be skewed at any angle relative to the first pin axis. Additionally, in some embodiments, the terminal end220can be substantially collinear with the first connection element218. In other embodiments, the skew in the first connection element218may occur closer to or further from, for instance, the terminal end220.

With reference toFIG.6, the second pin164includes a pin body224that defines a second pin axis. The pin body224includes an outer surface226having a ramped annular protrusion228and an annular protruded portion230. The pin body224is generally configured as a male pin dimensioned to be received in a corresponding female pin within an inner channel. The second pin164also includes a second connection element232extending from the pin body222along the second pin axis.

The second connection element232includes a terminal end234that is substantially similar to the terminal end220of the first pin162, and therefore will not be described in detail. In general, the gauges of the first and second connection elements218,232illustrated inFIGS.5and6, respectively, are by way of example. A variety of gauges and cross-sections are possible and can be adjusted, varied, or selected based on the use and capabilities of the microinverter120, current and/or voltage ratings, circuit board characteristics such as proximity of electrical components or pre-formed recesses, etc. Therefore, the gauges of the first and second connection elements218,232can be greater or less than the illustrated embodiment, and the form factors can be adapted to address application-specific requirements.

Generally, one of the first pin162and the second pin164can correspond to a positive DC power terminal. Likewise, the other of the first pin162and the second pin164can correspond to a negative DC power terminal.

FIG.7illustrates a cross-sectional view of the DC power connector126according to some embodiments of the invention. As shown, the first pin162can be inserted into the first channel180of the first plug176so that the first channel axis is collinear with the first pin axis of the first pin162. In the illustrated embodiment, the first channel180includes a first portion240and a second portion242separated by a step244. As shown, the first portion240is generally wider in cross section than the second portion242.

When the first pin162is inserted into the first channel180and secured to the DC power connector body160, the annular protruded portion216abuts the step244and the annular recessed portion214is seated within the second portion242of the first channel180. The second portion242may include an annular or partial inward protrusion configured to interface with the recessed portion214of the first pin162to releasably couple the first pin162in the first channel180. The first connection element218extends through the first portion240of the first channel180and outside of the first channel180proximate to the connector base196. The terminal end220is positioned outside the first channel180and generally extends toward the flat surface198of the DC power connector body160. The direction that the terminal end220extends may be dictated by the connection orientation of the DC power connector body160relative to the circuit board124. Therefore, in other embodiments, the terminal end220may extend in different directions than shown inFIG.7, as will be described in detail below.

Still referring toFIG.7, the second pin164can be inserted into the second channel190of the second plug178so that the second channel axis is collinear with the second pin axis of the second pin164. Similar to the first channel180, the second channel190includes a first portion250and a second portion252separated by a step254. As shown, the first portion250is generally wider in cross section than the second portion252.

When the second pin164is inserted into the second channel190and secured to the DC power connector body160, the annular protruded portion230abuts the step254and the ramped annular protrusion228engages a lock member256formed in the second portion252. The ramped annular protrusion228can move past the lock member256in a first direction as the second pin164is inserted into the second channel190, and is inhibited from being unintentionally moved in a second direction out of the second channel190. Similar to the first connection element218and terminal end220, the second connection element232extends through the first portion250of the second channel190and the terminal end234extends toward the flat surface198of the DC power connector body160.

Each of the first and second pins162,164include elements formed on their respective pin bodies208,224that engage the DC power connector body160to axially orient the first and second pins162,164within the respective first and second channels180,190. In some embodiments, each of the first and second pins162,164can include elements formed on their respective pin bodies208,224, such as alignment features, for example, that rotationally orient the pins162,164within the respective channels180,190. In particular, an alignment feature (see, for example,FIG.25) can rotationally orient each terminal end220,234with respect to the DC power connector body160to facilitate electrically coupling the DC power connector126to the circuit board124during a manufacturing process.

FIG.8illustrates the DC power connector126electrically coupled to the circuit board124and secured to the housing122at the first notch134formed in the body130. In an installed configuration, the circuit board124can be secured within the housing122so that the bottom surface154of the circuit board124faces the body130of the housing122. The DC power connector126can be secured within the first notch134so that the first protrusion138is seated within the groove202of the connector base196(e.g., forming a tongue and groove-type fit).

When the DC power connector126is secured to the housing122, the interface between the curved surface200of the connector base196and the first notch134can include one or more of a seal, sealant, or adhesive. The one or more of the seal, sealant, or adhesive can facilitate securing the DC power connector126to the housing122and provide a barrier between the exterior surface132of the body130and the interior volume. Similarly, when the DC power connector126is secured to the housing122, the flat surface198can engage the lid142. The interface between the flat surface198and the lid142can also include one or more of a seal, sealant, or adhesive to facilitate securing the DC power connector126to the housing122and provide a barrier between the exterior surface132and the interior volume of the housing122.

Portions of the first and second connection elements218,232extend beyond their respective first and second channels180,190of the DC power connector body160(see, for example,FIG.7). In an installed configuration, the portions of the first and second connection elements218,232that extend beyond the DC power connector body160extend under the circuit board124proximate to the bottom surface154. The circuit board124includes recesses260that extend through the thickness of the circuit board124. The terminal ends220,234of the first and second pins162,164, respectively, can each extend through a recess260. During a manufacturing process, the terminal ends220,234can be soldered, crimped, or otherwise deformed at the top surface152of the circuit board124to provide electrical coupling between the components of the circuit board124and the DC power connector126. In some embodiments, the terminal ends220,234can be electrically coupled to the circuit board124before the circuit board124is inserted into the housing122, such that the DC power connector126and the circuit board124can be installed into the housing122as an assembly.

In general, the first and second connection elements218,232and their respective terminal ends220,234provide a rigid connection between the DC power connector126and the circuit board124. In some cases, the rigid connection can restrict motion of the first and second pins162,164relative to the circuit board124, which can reduce fatigue failure between the terminal ends220,234and the circuit board124. Additionally, direct connection of the first and second pins162,164from the DC power connector126and the circuit board124can facilitate compact housing compared to some conventional microinverters that employ cables or wires to electrically couple components of a circuit board to a DC power connector. In some cases, eliminating unnecessary wired connections between components within a microinverter can save time and costs (e.g., material and labor costs) during manufacturing processes (e.g., an automated manufacturing process), and reduce potential failure modes while improving reliability.

In the embodiment illustrated inFIG.8, the terminal ends220,234extend through the recesses260of the circuit board124from the bottom surface154to the top surface152. However, in other embodiments, it should be appreciated that various components, such as the DC power connector body160or the first and second pins162,164, could be rotated 180 degrees so that the terminal ends220,234extend through the recesses260of the circuit board124from the top surface152to the bottom surface154. In still other embodiments, portions of the connection elements218,232may extend across a single side of the circuit board124and can be electrically coupled to the circuit board124on that same side.

FIG.9illustrates the AC power connector128of the microinverter120ofFIG.2. The AC power connector body170includes three plug members276. As illustrated, the center plug member276includes an irregular outer surface geometry to facilitate appropriate connection orientation between the AC power connector128and an AC power interface connector. Generally, the three plug members276and their corresponding connector pins172correspond to common AC terminals (e.g., line, neutral, and earth). Each of the plug members276includes a channel278that defines a channel axis. The AC power connector body170also includes a pair of arms280that can be resilient and configured as female connector locking tabs that extend from a base282of the AC power connector body170. The AC power connector128also includes a seal284proximate to the base282.

The base282includes a flat surface286and a curved surface288that extends around the base282, similar to the flat surface198and the curved surface200of the DC power connector126. The curved surface288includes a profile that is similarly shaped to the second notch136in the housing122and defines a groove290. In general, the groove290is dimension to receive the second protrusion140of the second notch136. The engagement of the second protrusion140with the groove290will be described below with reference toFIG.12. In other embodiments, an AC power connector, similar to the AC power connector128, can include a mating feature similar to the groove290that can be dimensioned to engage a corresponding mating feature formed on a lid of a housing, similar to the lid142.

FIG.10illustrates one of the connector pins172of the AC power connector128. Each of the connector pins172can be substantially similar, therefore the description of a single connector pin172below can apply to each of the connector pins172. The connector pin172includes a pin body296that defines a connector pin axis. The pin body296includes an outer surface298and an inner channel300. The outer surface298includes an annular recessed portion302and an annular protruded portion304. The pin body296is generally configured as a female pin dimensioned to receive a corresponding male pin within the inner channel300. The connector pin172also includes a connection element308extending from the pin body296along the first pin axis, similar to the first and second connection elements218,232of the DC power connector126.

Similar to the first and second connection elements218,232, the connection element308includes a terminal end310. In the illustrated embodiment, the terminal end310is skewed relative to the connection element308and relative to the connector pin axis. However, in other embodiments, the terminal end310can be skewed at any angle relative to the connector pin axis. Additionally, in some embodiments, the terminal end310can be substantially collinear with the connection element308. In other embodiments, the skew in the connection element308may occur closer to or further from, for instance, the terminal end310.

FIG.11illustrates a cross-sectional view of the AC power connector128according to some embodiments of the invention. As shown, the connector pins172can be inserted into their respective channels278of the plug members276so that each connector pin axis is collinear with each channel axis. In the illustrated embodiment, each channel278includes a first portion316and a second portion318separated by a step320. As shown, the first portion316is generally wider in cross section than the second portion318.

When each connector pin172is inserted the respective channel278and secured to the AC power connector body170, each annular protruded portion304abuts the respective step320and each annular recessed portion302is seated within the respective second portion318of the channels278. Each of the second portions318may include an annular or partial inward protrusion configured to interface with the recessed portion302of the connector pin172to releasably couple the connector pin172in the respective channels278. Each connection element308extends through the respective first portion316of the channels278and outside of the channels278proximate to the base282. Each terminal end310is positioned outside the respective channel278and generally extends toward the flat surface286of the AC power connector body170. The direction that the terminal ends310extend may be dictated by the connection orientation of the AC power connector body170relative to the circuit board124. Therefore, in other embodiments, the terminal ends310may extend in different directions than shown inFIG.11, as will be described in detail below.

Like the DC power connector126, some embodiments of the AC power connector128can include alignment features. Alignment features can rotationally orient each terminal end310with respect to the AC power connector body170to facilitate electrically coupling the AC power connector128to the circuit board124during a manufacturing process. Such alignment features can include ridges, notches, protrusions, recesses, etc. formed in one or both of the AC power connector body170or the connector pins172.

FIG.12illustrates the AC power connector128electrically coupled to the circuit board124and secured to the housing122at the second notch136formed in the body130. The AC power connector128can be secured within the second notch136so that the second protrusion140is seated within the groove290of the base282(e.g., forming a tongue and groove-type fit). Similar to the DC power connector126, when the AC power connector128is secured to the housing122, the interface between the curved surface288of the base282and the second notch136can include one or more of a seal, sealant, or adhesive. The one or more of the seal, sealant, or adhesive can facilitate securing the AC power connector128to the housing122and provide a barrier between the exterior surface132of the body130and the interior volume. Similarly, when the AC power connector128is secured to the housing122, the flat surface286can engage the lid142, similarly to the flat surface198of the DC power connector126.

Like the DC power connector126, portions of the connection elements308extend beyond their respective channels278. The portions that extend beyond the AC power connector body170extend similarly under the circuit board124and engage recesses260formed in the circuit board124. Details and alternatives described above regarding the electrical coupling of the connection elements218,232of the DC power connector126to the circuit board122can be applied to the connection elements308of the AC power connector128.

As described above, the AC power connector128can be electrically coupled to the circuit board124via the connector pins172and secured to the housing122of the microinverter120. Some embodiments of the invention also include an AC power interface that can be selectively coupled to the AC power connector128. In some embodiments, DC power can be converted via the microinverter120to AC power that can be transferred via contact of the AC power connector128and an AC power interface.

FIGS.13and14illustrate an AC power interface330according to some embodiments of the invention. The AC power interface330includes an interface body332, interface pins334, screw terminals336, terminal plates338, and a back plate340. In general, the AC power connector128can be configured as a female pin connector dimensioned to engage the AC power interface330, which can be generally configured as a male pin connector.

FIG.15illustrates a partially exploded view of the AC power interface330ofFIGS.13and14. The interface body332includes a base344that has a flat surface346and a curved surface348that extends around the base344and connects to the flat surface346. The curved surface348includes a groove350formed therein. The base344also includes notches352formed on lateral sides of the interface body332. The interface body332further includes a receiving portion358that includes channels360and connector receptacles362. The channels360are dimensioned to each receive a respective plug member276of the AC power connector128. The channels360are also configured to centrally receive the interface pins334. The connector receptacles362are configured as male connector receptacles and can receive a pair of arms, such as the arms280of the AC power connector128, for example.

Referring toFIGS.15and16, the back plate340includes notches366that correspond to the notches352formed in the interface body332. As illustrated inFIG.16, when the back plate340is engaged with the interface body332, and the notches352,366are aligned, each of the notches352,366form holes370. Each hole370can be configured as a wire hole. In particular, the holes370can be inlet or outlet wire holes, which may be used to daisy-chain several microinverters in parallel, for instance. The back plate340generally includes a mating profile374that is dimensioned to engage the interface body332proximate to the base344. The back plate340can be secured to the interface body332via an interference fit, fasteners, adhesives, etc. to, in some forms, establish a seal between one or more wires passing through the holes370. The back plate340and the interface body332may be configured to establish sealing engagement, such as through use of a cooperating groove and gasket construction.

FIG.17illustrates the base344of the interface body332with the back plate340removed. In general, the back plate340provides a covering for a portion of the base344of the interface body332. In particular, the back plate340can cover the screw terminals336. The screw terminals336are separated by terminal dividers378that can reduce unwanted electrical contact between electrical components, such as wires.

As illustrated inFIG.18, when the screw terminals336are engaged with the interface body332, the terminal plates338can be sandwiched between the screw terminals336and the interface body332. The screw terminals336include external threads that are dimensioned to extend into the interface pins334within the channels360.

FIG.19illustrates one of the interface pins334of the AC power interface330. Each of the interface pins334can be substantially similar, therefore the description of a single interface pin334can apply to each of the interface pins334. The interface pin334includes a pin body382that defines an interface pin axis. The pin body382includes an outer surface384and an internally threaded channel386. The internally threaded channel386is dimensioned to receive the external threads of the screw terminals336. The outer surface384includes a ridge388that extends parallel to the interface pin axis. The outer surface384also includes a ramped annular protrusion390.

Referring back toFIG.18, the ramped annular protrusion390is configured to engage a lock member394formed within the channel360of the AC power interface330. The ramped annular protrusion390can move past the lock member394in a first direction as the interface pin334is inserted into the channel360. Once inserted, the interface pin334is inhibited from being unintentionally moved in a second direction out of the channel360via the ramped annular protrusion390engaging the lock member394.

In some embodiments, the AC power interface330can be secured to structure, such as a beam or a rail. For example,FIG.20illustrates the microinverter120and the AC power interface330coupled to a rail400. The rail400includes a channel402. The channel402is configured to have wire ran therethrough, which can be electrically coupled to the AC power interface330. The wire may enter or exit the AC power interface330at the holes370and can be electrically coupled to the AC power interface330via the screw terminals336. The microinverter120can then be electrically coupled to the wires via the connection of the AC power connector128and the AC power interface330.

As illustrated inFIG.21, the housing122of the microinverter120can be secured to the rail400via the mount arms146. In general the mount arms146are configured as housing-integrated mounting brackets. The mount arms146include mounting apertures404through which a fastener (e.g., screws, bolts, etc.) can extend to engage with the rail400to secure the housing122to the rail400. In other embodiments, the housing122can include an interface structure that may be clipped, wedged, clamped, etc. to a supporting structure.

Now that embodiments of the microinverter120, including the DC power connector126and the AC power connector128, have been described above, additional embodiments of the invention will be described below. In the following embodiments, various features and aspects described below can be applied to embodiments of the microinverter120, and, in particular, the DC power connector126and the AC power connector128described above. Likewise, features and aspects of the following embodiments below that are substantially similar to those of the microinverter120will be omitted to avoid repetition.

FIG.22illustrates components of a microinverter420according to one embodiment of the invention. The microinverter420, among other components, includes a housing422, a circuit board424, and a DC power connector426. In the illustrated embodiment, the housing422includes a body430having an exterior surface432and a notch434formed therein. The housing422also includes a lid436. Each of the body430and the lid436of the housing422are only partially represented inFIG.22and the housing422is configured to enclose components of the microinverter420, similar to the housing122. The housing422further includes a seal440configured as a gasket that can be seated between the body430and the lid436.

FIGS.23and24illustrate the DC power connector426. Like the DC power connector126, the DC power connector426includes a first plug446and a second plug448that extend from a base450. The base450includes a flat surface452and a curved surface454that extends around the base450and connects to the flat surface452. The curved surface454includes a profile that is similarly shaped to the notch434in the housing422and defines a groove456. The flat surface452includes a channel458that intersects the groove456. The channel458is dimensioned to receive the seal440when the DC power connector426is secured to the housing422and the lid436is secured to the body430.

With reference toFIG.24, the base450also includes a securing portion466that extends from the base450in a direction opposite the first and second plugs446,448. The securing portion466includes protrusions468that extend generally perpendicular from a mate surface470of the securing portion466. The mate surface470is generally parallel to channel axes that are defined by the first and second plugs446,448. In one embodiment, the mate surface470is configured to engage and support a surface of the circuit board424(along with the mechanical interaction of the protrusions468and circuit board424), thus helping accommodate mechanical forces (e.g., stresses) at the interfaces. In the illustrated embodiment, the securing portion466includes a pair of protrusions468. However, in other embodiments, more or fewer protrusions are possible. The protrusions468include a lip472that is configured to create a snap fit with recesses formed in the circuit board424, as will be described in detail below. In one alternative embodiment, the example securing portion466concept may be incorporated into the DC power connector126and the AC power connector128illustrated inFIG.2. For instance, the securing portion466may be integrally molded (e.g., via injection molding) with the overall example DC power connector body160and the AC power connector body170to provide enhanced integrity to the connections between the circuit board124and the DC power connector126and the AC power connector128.

FIG.25illustrates a cross-sectional view of the DC power connector426according to one embodiment of the invention. The DC power connector426includes a tooth480formed in each of the channels defined by the first and second plugs446,448. Each tooth480can be integrally formed with the body of the DC power connector426. Each tooth480is configured as a pin alignment feature and can be dimensioned to engage a corresponding alignment feature formed in a pin (see, for example, notch498inFIG.27). Each tooth480is capable of facilitating a manufacturing process of the microinverter420by correctly orienting pins, such as the first and second pins486,488illustrated inFIG.26, rotationally relative to the circuit board424within the DC power connector426prior to securing the DC power connector426to the circuit board424. For example, the first and second pins486,488may be oriented to facilitate alignment and coupling of respective terminal ends of each of the first and second pins486,488with a desired recess positioned on the circuit board424. The specific form factors of the cooperating pin alignment feature of the connector (e.g., tooth480) and the alignment feature of the pin (e.g., notch498) can take a variety of functional forms, such as arcuate, beveled, angled, tapered, keyed, and the like, with each being configured to establish the desired relative positioning of the pin within the connector.

FIG.26illustrates components of the microinverter420including the circuit board424, the DC power connector426, and the first and second pins,486,488. The first and second pins486,488each include respective pin bodies490,492and respective connection elements494,496. The first and second pins486,488are similar to the first and second pins162,164of the DC power connector126. Likewise, the pin bodies490,492engage the DC power connector426similarly to the DC power connector126, and can be inserted proximate to the base450. In one embodiment, the first and second connection elements494,496provide a solder location when the DC power connector426is coupled to the circuit board424.

FIG.27illustrates the first and second pins486,488seated in the channels formed by the first and second plugs446,448. As briefly described above, each of the first and second pins486,488include a notch498. Each notch498is configured as an alignment feature that can engage each tooth480to rotationally orient the first and second pins486,488within the DC power connector426. Also as illustrated, each of the first and second connection elements494,496extend through the notch434formed in the body430of the housing422. Likewise, the securing portion466extends through the notch434from the exterior surface432to the interior volume of the housing422to support and engage the circuit board424, as well as help orient the first and second pins486,488for electrical coupling to the circuit board424. When the DC power connector426is secured to the housing422, a portion of the notch434is seated in the groove456of the DC power connector426.

FIGS.28and29illustrate a front portion of the microinverter420ofFIG.22. As briefly described above, the curved surface454of the DC power connector426has a similar shaped profile to the notch434formed in the body430of the housing422. The corresponding profiles allow the DC power connector426to engage the housing422. In some embodiments, the DC power connector426sealingly engages the housing422. In some embodiments, the microinverter420can include a seal between the DC power connector426and the housing422to provide a barrier between the exterior surface432of the body430and the interior volume. Also as discussed above, the base450includes a channel458that is dimensioned to receive the seal440so that the flat surface452can sit flush with a portion of the body430and the lid436can engage the body430and the DC power connector426at the flat surface452, as illustrated inFIG.29.

FIGS.30and31illustrate the DC power connector426secured and electrically coupled to the circuit board424.FIG.30in particular illustrates the DC power connector426secured and electrically coupled to the circuit board424and a portion of the lid436secured to the body430, thereby enclosing the circuit board424within the interior volume.FIG.30further illustrates the seal440positioned between the channel458formed in the flat surface452of the DC power connector426and/or the lid436.

FIGS.31and32illustrate the DC power connector426secured to the circuit board424and first and second connection elements494,496electrically coupled to the circuit board424. As briefly described with respect to the first and second pins162,164of the microinverter120, portions of the first and second connection elements218,232can extend under the circuit board124proximate to the bottom surface154of the circuit board. The first and second pins486,488include a similar configuration. Illustrated inFIG.32, portions502and504of the first and second connection elements494,496extend below the circuit board424proximate to a bottom surface506of the circuit board. The first and second connection elements494,496then extend through recesses formed in the circuit board424, as can be seen inFIG.31.

FIG.32further illustrates that when the DC power connector426is secured to the circuit board424, the mate surface470of the securing portion466is engaged with the bottom surface506of the circuit board424and the protrusions468extend through the circuit board424and create a snap fit at the lips472, as shown inFIG.31. In general, the engagement of the circuit board424with the securing portion466of the DC power connector426provides a rigid connection that can be established before the circuit board424is inserted into the housing422.

FIGS.33and34illustrate a connection pin524according to one embodiment of the invention. In some embodiments, the connection pin524can be used with either of the microinverters120,420, for example. The pin524includes a pin body526that defines a pin body axis. A connection element528extends from the pin body526along the pin body axis. The connection element528includes a terminal end530that is skewed relative to the pin body axis. In particular, the terminal end530is bent approximately 90 degrees from the pin body axis. The pin body526includes engagement tabs532that are spaced annularly about the pin body526and fan out radially to create a ramped portion534. The connection pin524can be used with a power connector and the engagement tabs532can provide an engagement feature so that the connection pin524can only be moved through a channel of a power connector in a single direction.

FIGS.35-40illustrate a single DC power connector550according to one embodiment of the invention. The single DC power connector550may be used with a variety of microinverters, such as with the microinverters120and420described above. The single DC power connector550includes a plug552that is similar to the first plug176of the DC power connector126. The single DC power connector550also includes a base554. As illustrated inFIGS.35and36, the base554includes a base surface556. The base surface556can engage and support a circuit board560(see, for example,FIG.40). The base554also includes a slot564that extends into the base554perpendicular to the base surface556.

As illustrated inFIG.37, the single DC power connector550is configured to receive a connection pin, such as the connection pin524, or any other pin described herein or otherwise. The connection pin524, which may define a male or a female coupling structure, can be inserted into a channel (not shown) that extends through the plug552. The single DC power connector550can correspond to either one of a positive DC power terminal or a negative DC power terminal. In some embodiments, a second DC power connector570can correspond to the other of the positive DC power terminal or the negative DC power terminal.

For example,FIG.38illustrates the single DC power connector550and the second single DC power connector570exploded from a housing576. The housing576includes first and second notches578,580that have a profile that corresponds to the bases554of each of the single DC power connectors550,570. When the single DC power connectors550,570are engaged with the housing576, the slot564can engage the corresponding notch578,580to flank a portion of a wall of the housing576. Illustrated for example, inFIG.40, the housing576engages the base554of the single DC power connector550at the slot564. The engagement of the slot564with the notch578in the housing576positions the base surface556at an appropriate height within the housing576so that the circuit board560is supported by the base surface556.

In some embodiments, during a manufacturing process, the terminal end530of the connection pin524may be electrically coupled to the circuit board560(e.g., via solder) and the base surface556can engage and support a bottom surface of the circuit board560. Then the assembly of the circuit board and the DC power connector550can be inserted into and secured to the housing so that the DC power connector550extends outside of the housing576via the notch. In other manufacturing processes, one or more pins are aligned with and seated at least partially within a body of a connector. A securing portion of the connector body is engaged with a circuit board to align and support the circuit board relative to the connector and the one or more pins. The one or more pins are electrically coupled to the circuit board (e.g., via a soldering operation). The completed assembly is then aligned and engaged with a receiving structure defined by a housing.

The discussion herein is presented for a person skilled in the art to make and use embodiments of the invention. Given the benefit of this disclosures, various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention may be not intended to be limited to embodiments shown, but can be to be accorded the widest scope consistent with the principles and features disclosed herein. The detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which may be not necessarily to scale, depict selected embodiments and may be not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.