Abstract:
A connecting box, gland nut, and electrical connector for the solar connector industry is disclosed. The connecting box, the gland nut, and the electrical connector require a tool to disengage, are being resistant to external environmental stressors, and/or provide the ability to monitor information regarding the connecting box, the gland nut, and/or the electrical connector.

Description:
FIELD OF THE INVENTION 
     The present invention is directed to an electrical connector assembly. In particular, the present invention is directed to a connecting box, a gland nut, and a connector for a solar panel. 
     BACKGROUND OF THE INVENTION 
     Solar panels have a large number of solar cells which are used to convert power from sunlight. Power generated by the solar cells is coupled via electric lines to a rectifier for example, for feeding into the alternating current (AC) network or to a battery. A connecting box with one or more connectors is generally provided for coupling to the solar panel. 
     Connectors typically include a pin housing containing pin contacts mated to a socket housing containing socket contacts. The pin housing and the socket housing are physically mated, which physically and electrically connect the pin and socket contacts to form an electrical connection. 
     Connecting boxes and connectors may be subject to tampering or access by individuals without an adequate understanding of electrical connectors. Most connector assemblies can be unmated without the use of any special skill or tool. To address this, certain industries have promulgated specific requirements for electrical connectors. For instance, under some industry and government standards and regulations, certain electrical connections require a tool in order to unmate any connector assembly carrying an electrical current. 
     Connecting boxes and connectors may be subject to external environmental stressors including rain, snow, floods, and other moisture producing events and temperature extremes. These environmental stressors may decrease the performance of the electrical connection, may damage connecting boxes and/or connectors, and may require increased maintenance. Covering connecting boxes and connectors can prevent some effect of these environmental stressors but covering can be expensive and bulky. As such, under some industry and government standards and regulations, cold impact resistance, flammability resistance, and ultraviolet light resistance requirements have limited the availability of certain modifications for the purpose of providing connecting boxes and connectors for the solar panel industry. 
     Therefore, there is an unmet need to provide a connecting box, connector, and connecting method that requires a tool for access, is resistant to external environmental stressors, is not expensive or bulky, and/or does not cause additional interference. 
     SUMMARY OF THE INVENTION 
     This invention provides a connecting box, a gland nut, and a connector requiring a tool for access, resistant to external environmental stressors without being expensive, bulky, or causing additional interference. 
     According to an embodiment, a connecting box for use with solar panels includes a base housing, a lid, and at least one latch. In the embodiment, the base housing is arranged and disposed to retain a substrate, the base housing being configured to releasably attached to the lid. The latch is arranged and disposed for a tool to be inserted into a latch release thereby disengaging a latch catch permitting the base housing to be released from the lid and the connecting box is arranged and disposed for attaching it to a solar panel. 
     According to another embodiment, a gland nut includes a nut-shaped portion configured to be rotated by a tool, a tapered portion, a generally cylindrical portion including an inner thread, and a cable seal configured to be inserted into a pinch ring. In the embodiment, the pinch ring has a plurality of arms extending from a ring base. The inner thread configured to threadedly engage a connecting box or a connector. The nut-shaped portion, the tapered portion, the generally cylindrical portion, the cable seal, and the pinch ring are configured to circumferentially bound a cable. The plurality of arms of the pinch ring are configured to be forced inward by the tapered portion toward the cable upon the inner thread engaging the connecting box or the connector and forced in the direction of the connecting box or the connector. 
     According to another embodiment, an electrical connector includes a first gland nut and a second gland nut, a pin housing arranged and disposed to threadedly engage the first gland nut, and the socket housing arranged and disposed to threadedly engage the second gland nut. In the embodiment, each gland nut includes a nut-shaped portion configured to be rotated by a tool, a generally cylindrical portion including an inner thread, a tapered portion, a cable seal arranged and disposed to be inserted into a pinch ring, the pinch ring arranged and disposed with a plurality of arms extending from a ring base. In the embodiment, the plurality of arms of the pinch ring are configured to be forced inward by the tapered portion toward a cable upon the inner thread engaging the connecting box or the connector and forced in the direction of the connecting box or the connector. The nut-shaped portion, the generally cylindrical portion, the cable seal, and the pinch ring are configured to circumferentially bound the cable. The pin housing is arranged and disposed to mate with a socket housing and the socket housing is arranged and disposed to mate with the pin housing. The pin housing or the socket housing includes a releasing slot arranged and disposed to require a tool to unmate the pin housing from the socket housing. The electrical connector is arranged and disposed for preventing moisture from entering the electrical connector. 
     An advantage of the present invention is requiring a tool to disengage. 
     Another advantage of the present invention is resistance to external environmental stressors. 
     Yet another advantage of the present invention is the ability to mate two electrical connectors at once. 
     Still yet another advantage of the present invention is the keying of the connectors thereby preventing miswiring. 
     Further aspects of the system and apparatus are disclosed herein. The features as discussed above, as well as other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a perspective view of an exemplary embodiment of a gland nut and connecting box according to the invention. 
         FIG. 2  illustrates an exploded perspective view of an exemplary embodiment of a connector, the gland nut, and the connecting box according to the invention showing the internal portions of the connecting box and the gland nut. 
         FIG. 3  illustrates a perspective view of an exemplary embodiment of a connector, the gland nut, and the connecting box according to the invention showing a substrate positioned inside the base housing of the connecting box. 
         FIG. 4  illustrates a bottom view of an exemplary embodiment of the connector, the gland nut, and the connecting box according to the invention. 
         FIG. 5  illustrates a sectioned view of the gland nut according to the invention. 
     
    
    
     Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. 
     Referring to  FIG. 1 , an exemplary embodiment of a connecting box  100  and a plurality of gland nuts  102  is shown. Connecting box  100  includes a lid  120  and a base housing  122 . Connecting box  100  is a plastic box with two substantially planar surfaces defining the top surface of connecting box  100  and the bottom surface of connecting box  100 . Connecting box  100  further includes four side surfaces connected internally by curved portions generally defining a rectangle. Connecting box  100  is configured to be attached to a solar panel (not shown). In the illustrated embodiment, connecting box  100  is arranged and disposed to be attached to the solar panel on the top of connecting box  100  by lid  120  attached to the solar panel. In another embodiment, connecting box  100  is arranged and disposed to be attached to the solar panel by base housing  122  being attached to the solar panel. As will be appreciated, in other embodiments, connecting box  100  may be attached to other surfaces on either lid  120  or base housing  122 . 
     In the illustrated embodiment, lid  120  includes a plurality of lid tether slots  112 , a lid breather  114 , a plurality of lid text boxes  116 , a plurality of lid tool pictures  118 , and a latch release  113 . In the embodiment, lid tool pictures  118  are positioned proximal to latch release  113  and signify that a screwdriver is required to release lid  120  from base housing  122  by depressing latch release  113  with the screwdriver. Lid tether slots  112  are configured to permit a band or wire or to be inserted into lid tether slots  112  together or independently and wrapped around a portion of base housing  122  or entire base housing  122 . The band or wire in conjunction with lid tether slots  112  substantially prevents base housing  122  from falling upon being released from lid  120 . Lid text boxes  116  permit information to be printed on lid  120 . In the illustrated embodiment, lid  120  is configured to be attached to the side of the solar panel opposite the side of the solar panel configured to convert sunlight into energy. In other embodiments, lid  120  may be attached to other structures near the solar panel. In other embodiments, lid  120  may be attached in other orientations thereby positioning connecting box  100  in other directions. For instance, connecting box  100  may be positioned on side  104 , opposing side  246 , or the other sides of connecting box  100 . Lid  120  may be attached to the solar panel by glue, fasteners, RTV adhesive sealant, or other adhesive. Upon lid  120  being attached to the solar panel, lid tether slots  112 , lid breather  114 , lid text boxes  116 , and lid tool pictures  118  on lid  120  become inaccessible. Due to the inaccessibility of these features, when lid  120  is attached to the solar panel, features on lid  120  may be omitted. These omitted features include lid tether slots  112 , lid breather  114 , lid text boxes  116 , and/or lid tool pictures  118 . As illustrated in  FIG. 2 , lid  120  further includes a latch  115 , which is a flexible piece of plastic integral with the lid  120  and able to be moved slightly as a result of a screwdriver or other tool depressing latch release  113 , which is accessible from base housing  122  of connecting box  100 . In other embodiments with lid  120  attached to the solar panel, breather  114 , text boxes  116 , and tool pictures  118  are included in base housing  122  (see  FIG. 4 ). 
     Referring to  FIGS. 2 and 3 , base housing  122  of connecting box  100  includes a plurality of substrate snaps  232 , a plurality of securing nuts  234 , and breather  114 . Substrate snap  232  is a polycarbonate tab configured to permit a substrate  302  to be properly positioned and releasably attached to base housing  122  (the term substrate includes printed circuit boards and other substrates). In another embodiment, substrate snap  232  may be made of other materials including, but not limited to, other plastics or metals. In other embodiments, substrate snap  232  may be molded into base housing  122 . In yet other embodiments, other features for positioning the board are alternatively or additionally included. Substrate snap  232  permits positioning by allowing for substrate  302  to be aligned with substrate snap  232 . Substrate snap  232  permits substrate  302  to be releasably attached to base housing  122  by extending over the top surface of substrate  302  when substrate  302  is pushed against substrate snap  232 . In the illustrated embodiment, substrate snaps  232  are on opposing ends of base housing  122 . In another embodiment, substrate snap  232  is positioned in conjunction with at least one other substrate snap  232  at various portions of the perimeter of a proper positioning for the substrate  302 . In the illustrated embodiment, securing nuts  234  are configured to threadedly attach other connectors  236  (which may be any connector available) and breather  114  is a membrane configured to permit air to travel in or out of base housing  122  upon a change in temperature or pressure. By permitting air to exit base housing  122  upon a change in temperature or pressure, breather  114  substantially prevents the build up of condensation inside base housing  122 . Breather  114  is comprised of a disc covering a series of concentric holes located on base housing  122 . In the illustrated embodiment, the disc is comprised of porous polytetrafluoroethylene, but the disc could be comprised of any porous material that would substantially prevent moisture from coming into base housing  122 . In another embodiment, a desiccant may be used for the purpose of preventing condensation build up. 
     Referring to  FIGS. 2 and 4 , the base housing  122  includes a latch catch  402 , breather  114 , text boxes  116 , tool pictures  118 , and a plurality of threads  202 . Latch catch  402  is a molded portion of base housing  122  configured to be engaged by latch  115  and disengaged by latch  115  upon a tool depressing latch release  113 . In the embodiment illustrated in  FIG. 2 , latch release  113  is not easily accessible when lid  120  is attached to a surface such as a solar panel. To access latch release  113 , when lid  120  is attached to a surface, connecting box  100  may be modified thereby allowing latch release  113  to be accessed by inserting a screwdriver into latch catch  402  from below. As will be appreciated, latch release  113  may be oriented in several other ways permitting access when lid  120  is attached to a surface. As shown in  FIG. 2 , thread  202  is integral to base housing  122  and protrudes from base housing  122  thereby permitting gland nut  102  to threadedly attach to thread  202 . In the embodiment illustrated by  FIG. 4 , base housing  122  includes light pipe feature  404  comprised of a transparent, semitransparent, translucent, or semi-translucent material. In another embodiment, base housing  122  includes a hole (not shown) with a light pipe  240  (light transmission pipe) inserted into the hole. In yet another embodiment, the base housing includes light pipe feature  404  attached and protruding from base housing  122  and is generally tubular in geometry. In yet further another embodiment, light pipe feature  404  is integrated and protruding from base housing  122 . In one embodiment, base housing  122  is comprised of a transparent, semitransparent, translucent, or semi-translucent material. In another embodiment, light pipe feature  404  is ultrasonically welded to base housing  122 . In still yet another embodiment, light pipe feature  404  is a hole formed by machining, molding, casting, or other similar forming methods. In an additional embodiment, the portion of light pipe feature  404  inside connecting box  100  is configured to releasably receive light pipe  240  by a friction fit. In an additional further embodiment, light pipe  240  is secured to light pipe feature  404  by gluing, thermal welding, or other similar joining method. In yet an additional further embodiment, light pipe  240  is secured directly to base housing  122  or lid  120  by gluing, thermal welding, or other similar joining method. As will be appreciated, in other embodiments, light pipe  240  and/or light pipe feature  404  may be similarly included on lid  120 . Light pipe  240  and/or light pipe feature  404  are generally included on lid  120 , when base housing  122  is to be attached to a surface. Similarly, in yet other embodiments, light pipe  240  and/or light pipe feature  404  may be included on opposing side surfaces  246  of connecting box  100 , when lid  120  and base housing  122  will be attached to surfaces in a manner that would otherwise make seeing illumination from light pipe  240  difficult. 
     Referring to  FIGS. 2 and 4 , light pipe feature  404  may be of any geometry configured to receive the light source corresponding with light pipe feature  404 . The geometry and inside diameter of light pipe feature  404  correspond to the geometry and outside diameter of light pipe  240 . Light pipe  240  may be a fiber optic cable, fiber optic fiber, or other similar light transmission structure as would be appreciated by one of ordinary skill in the art. The light source (not shown), providing light to light pipe  240  and thereby through light pipe feature  404 , may be a light emitting diode (LED), an incandescent light, a fluorescent light, or any other source of light. In one embodiment, the light source may provide more than one light color. In another embodiment, the light source may provide only one light color. In other embodiments with a transparent, semitransparent, translucent, or semi-translucent material comprising base housing  122 , light pipe feature  404  may be omitted and light pipe  240  may illuminate the inside of connecting box  100  or light pipe  240  thereby illuminating connecting box  100 . 
     Referring to  FIGS. 1 and 2 , when threadedly attached, gland nut  102  extends from a side surface  104  of connecting box  100  and other connector  236  extend from an opposing side surface  246  of connecting box  100 . Connecting box  100  may be configured to correspond with connectors beyond other connector  236  shown. In the embodiment illustrated in  FIG. 2 , for transportation purposes, for avoiding damage to contacts, and for weather resistance, a protective plug  238  may be inserted into other connector  236 . Referring to  FIG. 2  again, connecting box  100  is configured so that two gland nuts  102  can threadedly attach to two threads  202  of connecting box  100 . In another embodiment, connecting box  100  is configured so that four gland nuts  102  can threadedly attach to four threads  202  of connecting box  100 . In other embodiments, connecting box  100  may be configured to permit any number of gland nuts  102  to threadedly attach to any number of threads  202  of connecting box  100 . In the embodiment illustrated in  FIG. 2 , connecting box  100  is configured so that two other connectors  236  can attach to connecting box  100  by means of two securing nuts  234  inside of connecting box  100  and a threading on other connectors  236  engaging securing nuts  234 . In another embodiment, connecting box  100  is configured so that four other connectors  236  can threadedly attach to connecting box  100 . In yet another embodiment, connecting box  100  may be configured to permit any number of other connectors  236  to threadedly attach to connecting box  100 . As will be understood by those skilled in the art, in other embodiments, gland nuts  102  and/or other connectors  236  may be attached by other means. 
     Referring to  FIGS. 1 and 5 , gland nut  102  includes a nut-shaped portion  108 , a tapered portion  110 , and a generally cylindrical portion  111  all circumferentially surrounding a cable  106 . Referring to the sectioned view of  FIG. 5 , the interior of gland nut  102  corresponding to generally cylindrical portion  111  includes an inner thread  502  configured to threadedly engage thread  202  of connecting box  100  or to engage threaded portion  222  ( FIG. 2 ) of a corresponding connector. Nut-shaped portion  108  is configured to be rotated by a wrench thereby providing pressure on gland nut  102  in the direction of connecting box  100  by permitting inner thread  502  of gland nut  102  to threadedly engage thread  202  of connecting box  100  or in the direction of the corresponding connector by permitting inner thread  502  of gland nut  102  to threadedly engage threaded portion  222  of the corresponding connector. 
     Referring to  FIG. 2 , a gland nut  210 , a pinch ring  212 , and a cable seal  216  are configured to correspond with a first connector  208  or a second connector  224 . Gland nut  210  is substantially the same as gland nut  102 . Pinch ring  212  is substantially the same as pinch ring  204 . Cable seal  216  is substantially the same as cable seal  206 . Gland nut  102 ,  210  substantially prevents moisture from entering connecting box  100  and/or the connector by providing a tight seal when assembled with pinch ring  204 ,  212  and cable seal  206 ,  216 . Referring to  FIGS. 2 and 5 , in the illustrated embodiment, cable seal  206 ,  216  is a cylindrical body comprised of a thermoplastic elastomer. In other embodiments, cable seal  206 ,  216  is comprised of other flexible plastics, rubbers, or similar materials. Cable seal  206 ,  216  is configured to be inserted into pinch ring  204 ,  212  and circumferentially surround cable  106 . In the illustrated embodiment, pinch ring  204 ,  212  is a cylindrical body comprised of an acetyl resin. In other embodiments, pinch ring  204 ,  212  is comprised of other hard but flexible plastics. Pinch ring  204 ,  212  includes a plurality of arms  242  extending from a ring base  244 . Arms  242  are configured to engage the interior of tapered portion  110  of gland nut  102 . Upon pressure from rotating nut-shaped portion  108  being exerted in the direction of connecting box  100  or the corresponding connector, arms  242  of pinch ring  204 ,  212  are forced inward toward cable  106 . Arms  242  thereby force cable seal  206 ,  216  to tightly and circumferentially seal cable  106  thereby preventing water or other substances from entering connecting box  100  and/or the corresponding connectors. 
     Referring to  FIG. 1 , in the illustrated embodiment, cable  106  extends through nut-shaped portion  108  of gland nut  102  into connecting box  100 . As will be understood by those skilled in the art, cable  106  may be any sort of cable configured to conduct electrical charge including, but not limited to, a solar cable, a coaxial cable, underground service equipment cable, or any other mostly round cable. 
     In embodiment illustrated in  FIG. 2 , first connector  208  is a pin housing with a cylindrical body configured to threadedly engage gland nut  210  by means of threaded portion  222 . Second connector  224  is a socket housing with a cylindrical portion configured to threadedly engage gland nut  210  by means of threaded portion  222 . First connector  208  includes a releasing slot  220  configured to prevent the respective corresponding connector (not shown) from being disconnected without a tool. First connector  208  and second connector  224  are both comprised of plastic but could be comprised of any material configured to prevent moisture from entering the connector. As will be understood by those skilled in the art, first connector  208  and/or second connector  224  may be configured to correspond with other conductive interfaces for electrical connectors including, but not limited to, contacts, sockets, plugs, pins, and receptacles. 
     Referring again to  FIG. 2 , in one embodiment, contact  214  extends from cable  106 . In the illustrated embodiment, contact  214  is comprised of a silver-plated contact. As will be understood by those skilled in the art, the silver-plated contact is used for high conductivity but, in other embodiments, other conductive materials, as are well known by those skilled in the art, may be used. 
     In the embodiment shown in  FIG. 2 , cable  106  extends from second gland nut  210 , which is oriented proximal to gland nut  102 , until cable  106  is split thereby diverging into two contacts. In another embodiment, cable  106  does not split. In yet another embodiment, a plurality of cables  106  are included. In the illustrated embodiment, the nut-shaped portion  108  of second gland nut  210  is located on the end of second gland nut  210  proximal to gland nut  102 . Nut-shaped portion  108  of second gland nut  210  is configured to be tightened thereby providing additional pressure on cable  106 . As shown, upon first connector  208  threadedly engaging second gland nut  210 , first connector  208  and second gland nut  210  enclose second cable seal  216 , second pinch ring  212 , contact  214 , and cable  106 . Similarly, upon second connector  224  threadedly engaging second gland nut  210 , second connector  224  and second gland nut  210  enclose second cable seal  216 , second pinch ring  212 , contact  214 , and cable  106 . In another embodiment, second connector  224  further includes a rubber ring  228  further providing a tighter seal between the first connector  208  and the corresponding electrical connector. 
     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. For instance, the materials disclosed as comprising the embodiments are exemplary and not exhaustive. 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.