Abstract:
A low profile photovoltaic connector for placement in space restricted areas. The connector includes a plug and receptacle for interconnecting PV solar arrays. The receptacle is mechanically secured to a solar array. The mechanical connection between the receptacle and the solar array may be a staking process (e.g., ultrasonic, heat). The plug and receptacle may be locking, where only an extraction tool or other similar device may remove the plug from the receptacle. The plug and receptacle may also be non-locking.

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 photovoltaic (LPPV) solar laminate connector. 
       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. Patent application Ser. No. 11/865,883 entitled “LOW PROFILE PHOTOVOLTAIC (LPPV) BOX”, filed on Oct. 2, 2007, describes an LPPV junction box for use with PV modules/arrays. In addition, patent application Ser. No. 12/144,085 entitled “LOW PROFILE PHOTOVOLTAIC CONNECTOR”, filed on Jun. 23, 2008 describes an LPPV connector for use with PV modules/arrays. 
         [0006]    Therefore, there is a need for an LPPV connector that mounts to a PV array mechanically and provides a low profile connection to the PV arrays. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is directed to a low profile connector including a plug and a receptacle. The plug includes a plug body, a male connection and a cable. The receptacle includes a receptacle body and a receiver. The receptacle is secured in electrical contact with a solar array. The plug mates with the receptacle to form an electrical connection and the plug and the receptacle have a vertical profile at least equal to a width of the cable. 
         [0008]    Another embodiment of the present invention includes a low profile connector including a plug and a receptacle. The plug has a plug body, a male connection and a cable and the receptacle has a receptacle body and a receiver. The receptacle is secured to a solar array through a staking process. The plug mates with the receptacle to form an electrical connection and the plug and the receptacle have a vertical profile at least equal to a width of the cable. 
         [0009]    Yet another embodiment of the present invention includes a low profile connector including at least two plugs and at least two receptacles. Each plug of the at least two plugs has a plug body, a male connection and a cable and each receptacle of the at least two receptacles has a receptacle body and a receiver. The at least two receptacles are secured in electrical contact with at least two solar arrays. The at least two plugs are connected by the cable. A first plug of the at least two plugs mates with a first receptacle of the at least two receptacles and a second plug of the at least two plugs mates with a second receptacle of the at least two receptacles. The first receptacle is secured in electrical contact with a first solar array and the second receptacle is secured in electrical contact with a second solar array. The at least two plugs and at least two receptacles are in electrical communication. 
         [0010]    An advantage of the present invention is that the LPPV connector allows a plurality of PV solar arrays to be connected in low profile spaces. 
         [0011]    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 
         [0012]      FIG. 1  shows a perspective view of a plug and receptacle of a LPPV connector in an unmated position. 
           [0013]      FIG. 2  shows a perspective view of the mated connector and an extraction tool. 
           [0014]      FIG. 3  shows a perspective view of a plug and receptacle of a non-locking LPPV connector in an unmated position. 
           [0015]      FIG. 4  shows a perspective view of a plug and receptacle of a non-locking LPPV connector in a mated position. 
           [0016]      FIG. 5  shows perspective view of two plugs and two receptacles of a LPPV connector in  FIG. 1  in a mated position. 
           [0017]      FIG. 6  shows a cross sectional view of a receptacle in  FIG. 1 . 
           [0018]      FIG. 7  shows perspective view of two plugs and two receptacles of a LPPV connector in an unmated position. 
           [0019]      FIG. 8  shows a perspective view of a molded cover that may be used to secure the receptacle to the solar array. 
           [0020]      FIG. 9  shows a side view of a plug and receptacle of  FIG. 7  in an unmated position. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]      FIGS. 1-3  show a low profile Photovoltaic (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  for securing a conductive cable  24  to a body  18 , locking latches  20  projecting from both sides of body  16 , and a male connection  22  at the forward end of body  18 . Strain relief  16  provides a waterproof seal and relieves strain caused by pulling and bending of a cable  24  that extends from plug  12 . Cable  24  conducts power from a solar array  26  (see  FIG. 5 ), to plug  12 . Cable  24  may be any suitable cable having any suitable diameter for electrical communication. For example, cable  24  may be an 18 American Wire Gauge (AWG) cable to a 10 AWG cable, and may communicate power or data from any source to plug  12  or receptacle  14 . Plug  12  has a vertical profile that is at least equal to the diameter of cable  24 . Plug  12  may have a vertical profile that is at least slightly larger than the diameter of cable  24 , e.g. plug  12  has a vertical diameter that is 0.5 mm greater than cable  24 . Strain relief  16  may be manufactured from a flexible and sturdy material such as Santoprene® rubber, or any other suitable material. 
         [0022]    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 terminal  28  (see e.g.  FIG. 6 ) for facilitating an electrical connection with receptacle  14 . Blade terminal  28  may be a FASTON terminal 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 . 
         [0023]    Male connection  22  extends from body  18  and 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, slightly compressible material such as Santoprene® rubber, or any other suitable 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 . 
         [0024]    Receptacle  14  has a receptacle body  40  and a receiver  42 . Receptacle body  40  includes a solder pad  60  for contacting a conductive foil (not shown) from a solar array or solar laminate  26 . The foil (not shown) is attached (e.g., soldered, welded, fastener) to solder pad  60  to create an electrical connection path between solar array  26  and receptacle  14 . 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 electrical connection with solar array  26 , and extend from solar array  26  to enable a connection with a junction box (not shown) or other suitable connection device. Receptacle body  40  may be manufactured from a rigid plastic material or any other suitable material. A contact, or blade terminal  28  is disposed inside receptacle body  40 . The blade terminal  28  provides an electrical connection between solder pad  60  to plug  12 . Blade terminal  28  may be a FASTON terminal or any other suitable blade or contact. Receptacle  14  may also include an aperture  75  (See  FIG. 6 ) for receiving a fastener  74  or other suitable fastening device (e.g. a rivet). Fastener  74  secures receptacle  14  to solar array  26  without the use of adhesive or additional fasteners or devices. 
         [0025]    Receiver  42  extends from receptacle body  40 . Receiver  42  may be unitary with receptacle body  40  and configured to mate with male connection  22  on plug  12 . At least one aperture  44  is disposed on the top surface 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  that engages locking latch  20  when plug  12  is mated with receptacle  14 . Protrusions  34  engage with ledges  46  and prevent plug  12  from easily disconnecting from receptacle  14 . When locking latches  20  engage with ledges  46 , an audible and/or tactile signal may be released, notifying the user that plug  12  has been secured in receptacle  14 . 
         [0026]    As shown in  FIG. 2 , to disengage locking latches  20  from ledges  46 , an extraction tool  48  may be used. Extraction tool  48  is configured to extend into apertures  44  in contact with protrusions  34  thereby displacing locking latches  20 . When extraction tool  48  displaces locking latches  20 , elbow  32  permits movement of locking latches  20  to disengage protrusions  34  from ledges  46 . Plug  12  may be disconnected 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 to a maximum height of 8 mm. However, connector  10  may be configured to any suitable height requirement, for a low profile connector. 
         [0027]    In an alternate embodiment shown in  FIGS. 3 and 4 , plug  12  may include at least one locking latch  50 . Locking latch  50  projects from body  18  of plug  12  and has a raised portion  52 . Locking latch  50  is deformable, as plug  12  is mated with receptacle  14 , locking latch  50  may be displaced inward toward body  18  until raised portion  52  engages with cavity  54  in receiver  42  in receptacle  14 . When locking latches  50  engage with receiver  42 , an audible and/or tactile signal may be released that notifies the user that plug  12  has been 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 greater than 20 lbs. may be applied to plug  12 , receptacle  14 , or both substantially simultaneously to remove plug  12  from receptacle  14 . Receptacle body  40  does not include apertures  44  (See, e.g.  FIG. 1 ). 
         [0028]      FIG. 5  shows two plugs  12  in electrical connection through a cable  24  and mateable with receptacles  14 . Each receptacle  14  is mechanically secured to solar array  26 . Receptacle  14  is mechanically secured to solar array  26  with a fastener  74  or other similar fastening device. Receptacle  14  is disposed on solar array  26  such that a conductive foil (not shown) on solar array  26  contacts solder pad  60 . Solder pad  60  has a slot  62  for allowing the foil (not shown) to extend through and attaching (e.g., soldering, welding, mechanical fastening) 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 damage or external objects or elements from damaging solder pad  60  and from damaging the connection between solder pad  60  and foil (not shown). 
         [0029]      FIG. 6  shows a cross section view of receptacle  14  and solar array  26 . Receptacle  14  may be overmolded with a plastic material and includes blade terminal  28  for electrical connection with plug  12 . Fastener  74  secures receptacle  14  to solar array  26 . Receptacle body  40  partially covers the bottom surface of solder pad  60  and includes an aperture  76  for providing access for conductive foil (not shown) to contact solder pad  60 . Foil (not shown) and solder pad  60  may be attached (e.g., soldered, welded, fastener) to form an electrical connection. Referring back to  FIG. 5  and partially shown in  FIG. 6 , receptacle  14  also includes an edge extension  78  that provides positioning assurance for receptacle  14  on solar array  26 . Edge extension  78  ensures that receptacle  14  is aligned on solar array  26  and positioned to provide a secure connection between solder pad  60  and foil (not shown). 
         [0030]    In another alternate embodiment shown in  FIGS. 7 ,  8  and  9 , receptacle  14  is mechanically secured to solar laminate  26  with a molded cover  80 . Receptacle  14  is disposed on solar array  26  such that a conductive foil (not shown) on solar array  26  contacts solder pad  60 . Solder pad  60  has a slot  62  for attaching (e.g., soldering, welding, mechanical fastening) 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 damage or external objects or elements from damaging solder pad  60  and from damaging the connection between solder pad  60  and foil (not shown). 
         [0031]    Receptacle  14  is mechanically secured to solar array  26  with a cover  80 . Receptacle  14  may be overmolded with plastic and includes solder pad  60  and blade terminal  28  for electrical connection with plug  12 . Receptacle  14  is placed on solar array  26  and aligned with apertures (not shown) in solar array  26 . Cover  80  is aligned with apertures (not shown) in solar array  26  and protrusions  82  on molded cover  80  extend through both solar array  26  and receptacle  14 . A staking process (e.g., ultrasonic, heat) is applied to molded cover  80  to form caps  84  from protrusions  82  and to secure receptacle  14  to solar array  26 . 
         [0032]    Receptacle body  40  partially covers the bottom surface of solder pad  60  and includes an aperture  76  ( FIG. 6 ) for providing access for conductive foil (not shown) to contact the top surface of solder pad  60 . Foil (not shown) and solder pad  60  may be attached (e.g., soldered, welded, fastener) to form an electrical connection. Receptacle  14  also includes an edge extension  78  that provides positioning assurance for receptacle  14  on solar array  26 . Edge extension  78  ensures that receptacle  14  is aligned on solar array  26  and positioned to provide a secure connection between solder pad  60  and foil (not shown). 
         [0033]    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.