Patent Publication Number: US-8523609-B2

Title: Photovoltaic connector assembly

Description:
BACKGROUND OF THE INVENTION 
     The subject matter herein relates generally to photovoltaic connector assemblies. 
     Photovoltaic (PV) modules or 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. 
     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 or greater. For large PV systems, special PV modules are produced with typical power range of up to several 100 W. A photovoltaic module is the basic element of a photovoltaic 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 W to up to 200 W/module. 
     In the case of facade or roof systems, the photovoltaic 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 photovoltaic systems may consist of different module types, such as crystalline and micro-perforated amorphous modules. Roof-integrated photovoltaic systems are integrated into the roof; such that the entire roof or a portion thereof is covered with photovoltaic modules, or they are added to the roof later. PV cells may be integrated with roof tiles or shingles. 
     PV modules/arrays require specially designed devices adapted for interconnecting the various PV modules/arrays 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. Connection or connection boxes may be required to receive specialized cable terminations from PV modules/arrays, with power diodes inside for controlling current flow to the load. PV arrays may be required in areas with tight space restraints and requirements, requiring the size of the PV module to be minimized. 
     What is needed is a photovoltaic connector assembly for a photovoltaic solar array panel that satisfies one or more of these space constraint needs or provides other advantageous features. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one embodiment, a photovoltaic connector assembly is provided having a housing that has a mating end and a cable end. The housing has a securing feature that is configured to secure the housing to another photovoltaic connector assembly. The housing has a cavity that extends between the mating end and the cable end. A terminal is received in the cavity. The terminal is configured to be mated to a corresponding terminal of the other photovoltaic connector assembly. The terminal is configured to be terminated to a cable. A cable locator is configured to be coupled to the cable rearward of the terminal. The cable locator has wings that extend from opposite sides of the cable locator. The cable locator is received in the cavity. The wings engage the housing to position the cable locator within the cavity. 
     In another embodiment, a photovoltaic connector assembly is provided having a housing that has a mating end and a cable end. The housing has a securing feature that is configured to secure the housing to another photovoltaic connector assembly. The housing has a cavity that extends between the mating end and the cable end. A terminal is received in the cavity. The terminal is configured to be mated to a corresponding terminal of the other photovoltaic connector assembly. The terminal is configured to be terminated to a cable. The terminal is one of a blade terminal or a blade receptacle terminal that has a generally wide and short configuration. A cable locator is configured to be coupled to the cable rearward of the terminal. The cable locator has wings that extend from opposite sides of the cable locator. The cable locator is received in the cavity. The wings engage the housing to position the cable locator within the cavity. 
     In a further embodiment, a photovoltaic system is provided including a first solar shingle and a second solar shingle that are configured to be mounted to a substrate. The second solar shingle overlaps a top portion of the first solar shingle such that an overhang space is created immediately above a top edge of the first solar shingle. The overhang space is defined between a base of the second solar shingle, the top edge of the first solar shingle and the substrate. A low profile photovoltaic connector assembly is received in the overhang space. The photovoltaic connector assembly is cable mounted to a cable. The cable is routed through the overhang space. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a photovoltaic (PV) system formed in accordance with an exemplary embodiment. 
         FIG. 2  is a side view of a portion of the PV system shown in 
         FIG. 1 . 
         FIG. 3  is an exploded view of the PV connector assemblies. 
         FIG. 4  is a cross sectional view of the PV connector assemblies in a mated or assembled state. 
         FIG. 5  is another cross sectional view of the PV connector assemblies in the mated or assembled state. 
         FIG. 6  is an exploded view of PV connector assemblies. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  illustrates a photovoltaic (PV) system  100  formed in accordance with an exemplary embodiment. The PV system  100  includes first and second PV connector assemblies  102 ,  104  that are configured to be mated to connect first and second PV components  106 ,  108 . In the illustrated embodiment, the PV connector assemblies  102 ,  104  are cable mounted connector assemblies terminated to ends of cables  110 ,  112 , respectively. The cables  110 ,  112  are terminated to the PV components  106 ,  108 . The PV components  106 ,  108  may be any type of PV components, such as PV modules or arrays that are used to generate electricity, such as solar panels, or other PV components used within the PV system  100  such as power storage devices, sensors, controllers, and the like. In an exemplary embodiment, the PV components  106 ,  108  are solar shingles that may be coupled to a roof of a building. 
     The PV connector assemblies  102 ,  104  may be coupled together to transmit power and/or data along the transmission path between the PV components  106 ,  108 . In the illustrated embodiment, the first PV connector assembly  102  constitutes a plug assembly and the second PV connector assembly  104  constitutes a receptacle assembly that is configured to receive the plug assembly. In an exemplary embodiment, the PV connector assemblies  102 ,  104  are low profile connector assemblies that have a short and wide configuration such that the PV connector assemblies  102 ,  104  have a larger side-to-side dimension as compared to a top-to-bottom dimension. In the illustrated embodiment, the PV connector assemblies  102 ,  104  have a height that is not much taller than a diameter of the cables  110 ,  112 . 
     The low profile aspect of the PV connector assemblies  102 ,  104  allow the PV connector assemblies  102 ,  104  to be positioned within, and routed through, small spaces in which the PV system is utilized. 
       FIG. 2  is a side view of a portion of the PV system  100 .  FIG. 2  shows the first and second PV components  106 ,  108  as solar shingles mounted to a roof  120  of a building. The roof  120  defines a substrate  122  on which the PV components  106 ,  108  are mounted. The first PV component  106  constitutes a first solar shingle, and may be referred to hereafter as a first solar shingle  106 . The second PV component  108  constitutes a second solar shingle, and may be referred to hereafter as a second solar shingle  108 . 
     The second solar shingle  108  overlaps a top portion  124  of the first solar shingle  106  such that an overhang space  126  is created immediately above a top edge  128  of the first solar shingle  106 . The overhang space  126  is defined between a base  130  of the second solar shingle  108 , the top edge  128  of the first solar shingle  106  and the substrate  122 . The base  130  of the second solar shingle  108  is angled downward toward the substrate  122  from the top edge  128  of the first solar shingle  106  such that the overhang space  126  decreases in height between the base  130  and the substrate  122 . The largest height  132  of the overhang space  126  is immediately adjacent the top edge  128 , and the height decreases as you travel away from the top edge  128 . The height  132  is less than or equal to a thickness  134  of the first solar shingle  106 . 
     The PV connector assemblies  102 ,  104  and the cables  110 ,  112  are configured to be routed through the overhang space  126 . The low profile of the PV connector assemblies  102 ,  104  allow the PV connector assemblies  102 ,  104  to fit into the overhang space  126 . In an exemplary embodiment, the PV connector assemblies  102 ,  104  are less than 10 mm tall in order to fit within the overhang space  126 . 
       FIG. 3  is an exploded view of the PV connector assemblies  102 ,  104 . The first PV connector assembly  102  includes a housing  140  extending between a mating end  142  and a cable end  144 . The housing  140  has a securing feature  146  configured to secure the housing  140  to the second PV connector assembly  104 . The housing  140  has a cavity  148  extending between the mating end  142  and the cable end  144 . The housing  140  has opposite sides  150 ,  152  extending between a top  154  and a bottom  156 . The housing  140  has a low profile such that the distance between the top and bottom  154 ,  156  is minimized. Optionally, the top and bottom  154 ,  156  may be planar and parallel to one another. In an exemplary embodiment, the housing  140  is wider from side-to-side  150 ,  152  than from top-to-bottom  154 ,  156 . 
     The first PV connector assembly  102  includes a terminal  160  terminated to a center conductor of the cable  110 . In an exemplary embodiment, the terminal  160  is crimped to the center conductor and to a jacket  162  of the cable  110 . In the illustrated embodiment, the terminal  160  constitutes a blade receptacle terminal having a generally wide and short configuration such that the terminal  160  is wider side-to-side than top-to-bottom. Edges of the blade receptacle terminal  160  are folded over to define a receptacle configured to receive a terminal of the second PV connector assembly  104 . In an exemplary embodiment, the terminal  160  constitutes a Faston® tab, however other types of terminals are possible in alternative embodiments. For example, the terminal may be a pin or a socket terminal, such as the terminal  460  shown in  FIG. 6 , or another type of mating contact. Having the terminal  160  relatively short top-to-bottom, allows the low profile aspect of the PV connector assembly  102  may be maintained. For example, the blade receptacle type terminal may have less height as compared to a conventional pin and socket type terminal, which allows the housing  140 , that holds the terminal  160 , to have a reduced height making the PV connector assembly  102  low profile. 
     The terminal  160  has a mating end  164  and a cable end  166 . The cable end  166  is configured to be crimped to the jacket  162 . In an exemplary embodiment, the cable end  166  may be crimped to a seal  168  in addition to the jacket  162  of the cable  110 . 
     The seal  168  extends around the jacket  162  of the cable  110 . The seal  168  is configured to be received in the cavity  148  of the housing  140  to seal against the housing  140 . The seal  168  also seals against the cable  110 . Optionally, the seal  168  may be a silicon seal. Other types of seals are possible in alternative embodiments. In an exemplary embodiment, the seal  168  prevents movement of the cable  110  by a stiction force created between the seal  168  and the jacket  162 . The seal  168  provides strain relief between the cable  110  and the PV connector assembly  102 . 
     The PV connector assembly  102  includes a cable locator  170  coupled to the cable  110 . Optionally, the cable locator  170  may be crimped to the cable  110  rearward of the seal  168 . The cable locator  170  is coupled to the cable  110  at a predetermined distance from the mating end  164  of the terminal  160 . The cable locator  170  is received in the cavity  148  of the housing  140 . The cable locator  170  is held in position with respect to the housing  140  to position the cable  110  and/or the terminal  160  with respect to the housing  140 . For example, the cable locator  170  may axially position the mating end  164  with respect to the housing  140 . Alternatively, a portion of the terminal  160  may engage the housing  140  to locate the terminal  160  with respect to the housing  140 . 
     The cable locator  170  includes a central bore  172  extending therethrough along a bore axis  174 . The cable locator  170  receives the cable  110  in the central bore  172 , and the cable  110  extends along the bore axis  174 . 
     The cable locator  170  includes wings  176  extending from opposite sides  178  of the cable locator  170 . In an exemplary embodiment, the wings  176  extend radially outward from the cable locator  170  generally perpendicular with respect to the bore axis  174 . The wings  176  do not extend from a top  180  or a bottom  182  of the cable locator  170 . As such, the wings  176  do not add to the overall top-to-bottom height of the cable locator  170 . By only extending from the sides  178 , the cable locator  170  has a low profile and allows the housing  140  to have a low profile. The wings  176  have forward facing surfaces and rear facing surfaces opposite the forward facing surfaces. In an exemplary embodiment, when the cable locator  170  is loaded into the housing  140 , the forward facing surfaces of the wings  176  may engage a wall or shoulder or other portions of the housing  140  to position the cable locator  170  within the cavity  148 . 
     The PV connector assembly  102  includes a cap  184  extending around the cable  110 . For example, the cable  110  extends through a bore  192  extending through the cap  184 . The cap  184  is positioned rearward of the cable locator  170 . The cap  184  is configured to be coupled to the housing  140 . In an exemplary embodiment, the cap  184  engages the back of the cable locator  170  within the housing  140  to hold the cable locator  170  in the cavity  148 . For example, the cap  184  may engage the rear facing surfaces of the wings  176  such that the wings  176  are captured between the housing  140  and the cap  184 . 
     In an exemplary embodiment, the housing  140  has an opening  186  at the cable end  144 . The housing  140  has one or more latching features  188  proximate to the cable end  144 . The cap  184  is received in the opening  186  of the housing  140 . The cap  184  has one or more latching features  190  that engage the latching features  188  of the housing  140  to secure the cap  184  to the housing  140 . In the illustrated embodiment, the latching features  188  constitute receptacles and/or catch surfaces that are engaged by the latching features  190 . The latching features  190  constitute forward extending latches that are configured to engage the latching features  188 . The latching features  190  are deflectable during loading of the cap  184  into the cavity  148  and the latching features  190  snap into place in engagement with the latching features  188  to hold the cap  184  within the housing  140 . 
     In an exemplary embodiment, the latching features  190  are provided along sides  194  of the cap  184 . The latching features  190  do not extend above the top  196  or below the bottom  198 . As such, the latching features  190  add to the side-to-side width of the cap  184 , but do not affect the top-to-bottom height of the cap  184 . Such arrangement of the latching features  190  aids in maintaining the low profile configuration of the PV connector assembly  102 . Optionally, the top  196  may be flush with the top  154 , and the bottom  198  may be flush with the bottom  156 . 
     The second PV connector assembly  104  includes a housing  240  extending between a mating end  242  and a cable end  244 . The housing  240  has a securing feature  246  configured to secure the housing  240  to the first PV connector assembly  102 . The housing  240  has a cavity  248  extending between the mating end  242  and the cable end  244 . The housing  240  has opposite sides  250 ,  252  that extend between a top  254  and a bottom  255 . The housing  240  has a low profile such that the distance between the top and bottom  254 ,  255  is minimized. Optionally, the top and bottom  254 ,  255  may be planar and parallel to one another. In an exemplary embodiment, the housing  240  is wider from side-to-side  250 ,  252  than from top-to-bottom  254 ,  255 . 
     The housing  240  has an embossment  256  at the mating end  242 . The embossment  256  is forward extending and has a reduced height and width as compared to other portions of the housing  240 . The embossment  256  is configured to be received in the cavity  148  of the housing  140 . In an exemplary embodiment, the embossment  256  has a circumferential channel  257  extending around the embossment  256 . A gasket  258  is received in the channel  257  and provides sealing between the housing  240  and the housing  140  when the PV connector assemblies  102 ,  104  are mated. 
     The second PV connector assembly  104  includes a terminal  260  terminated to a center conductor of the cable  112 . In an exemplary embodiment, the terminal  260  is crimped to the center conductor and to a jacket  262  of the cable  112 . In the illustrated embodiment, the terminal  260  constitutes a blade terminal having a generally wide and short configuration such that the terminal  260  is wider side-to-side than top-to-bottom. The blade terminal  260  is configured to be receiving in the blade receptacle terminal  160  of the first PV connector assembly  102 . In an exemplary embodiment, the terminal  260  constitutes a Faston® tab, however other types of terminals are possible in alternative embodiments. For example, the terminal may be a socket or a pin, such as the terminal  462  shown in  FIG. 6 , or another type of mating contact. Having the terminal  260  relatively short top-to-bottom, allows the low profile aspect of the PV connector assembly  104  may be maintained. For example, the blade type terminal may have less height as compared to a conventional pin and socket type terminal, which allows the housing  240 , that holds the terminal  260 , to have a reduced height making the PV connector assembly  104  low profile. 
     The terminal  260  has a mating end  264  and a cable end  266 . The cable end  266  is configured to be crimped to the jacket  262 . In an exemplary embodiment, the cable end  266  may be crimped to a seal  268  in addition to the jacket  262  of the cable  112 . 
     The seal  268  extends around the jacket  262  of the cable  112 . The seal  268  is configured to be received in the cavity  248  of the housing  240  to seal against the housing  240 . The seal  268  also seals against the cable  112 . Optionally, the seal  268  may be a silicon seal. Other types of seals are possible in alternative embodiments. In an exemplary embodiment, the seal  268  prevents movement of the cable  112  by a stiction force created between the seal  268  and the jacket  262 . The seal  268  provides strain relief between the cable  112  and the PV connector assembly  104 . 
     The PV connector assembly  104  includes a cable locator  270  coupled to the cable  112 . Optionally, the cable locator  270  may be crimped to the cable  112  rearward of the seal  268 . The cable locator  270  is coupled to the cable  112  at a predetermined distance from the mating end  264  of the terminal  260 . The cable locator  270  is received in the cavity  248  of the housing  240 . The cable locator  270  is held in position with respect to the housing  240  to position the cable  112  and/or the terminal  260  with respect to the housing  240 . For example, the cable locator  270  may axially position the mating end  264  with respect to the housing  240 . Alternatively, a portion of the terminal  260  may engage the housing  240  to locate the terminal  260  with respect to the housing  240 . 
     The cable locator  270  includes a central bore  272  extending therethrough along a bore axis  274 . The cable locator  270  receives the cable  112  in the central bore  272 , and the cable  112  extends along the bore axis  274 . 
     The cable locator  270  includes wings  276  extending from opposite sides  278  of the cable locator  270 . In an exemplary embodiment, the wings  276  extend radially outward from the cable locator  270  generally perpendicular with respect to the bore axis  274 . The wings  276  do not extend from a top  280  or a bottom  282  of the cable locator  270 . As such, the wings  276  do not add to the overall top-to-bottom height of the cable locator  270 . By only extending from the sides  278 , the cable locator  270  has a low profile and allows the housing  240  to have a low profile. The wings  276  have forward facing surfaces and rear facing surfaces opposite the forward facing surfaces. In an exemplary embodiment, when the cable locator  270  is loaded into the housing  240 , the forward facing surfaces of the wings  276  may engage a wall or shoulder or other portions of the housing  240  to position the cable locator  270  within the cavity  248 . 
     The PV connector assembly  104  includes a cap  284  extending around the cable  112 . For example, the cable  112  extends through a bore  292  extending through the cap  284 . The cap  284  is positioned rearward of the cable locator  270 . The cap  284  is configured to be coupled to the housing  240 . In an exemplary embodiment, the cap  284  engages the back of the cable locator  270  within the housing  240  to hold the cable locator  270  in the cavity  248 . For example, the cap  284  may engage the rear facing surfaces of the wings  276  such that the wings  276  are captured between the housing  240  and the cap  284 . 
     In an exemplary embodiment, the housing  240  has an opening  286  at the cable end  244 . The housing  240  has one or more latching features  288  proximate to the cable end  244 . The cap  284  is received in the opening  286  of the housing  240 . The cap  284  has one or more latching features  290  that engage the latching features  288  of the housing  240  to secure the cap  284  to the housing  240 . In the illustrated embodiment, the latching features  288  constitute receptacles and/or catch surfaces that are engaged by the latching features  290 . The latching features  290  constitute forward extending latches that are configured to engage the latching features  288 . The latching features  290  are deflectable during loading of the cap  284  into the cavity  248  and the latching features  290  snap into place in engagement with the latching features  288  to hold the cap  284  within the housing  240 . 
     In an exemplary embodiment, the latching features  290  are provided along sides  294  of the cap  284 . The latching features  290  do not extend above the top  296  or below the bottom  298 . As such, the latching features  290  add to the side-to-side width of the cap  284 , but do not affect the top-to-bottom height of the cap  284 . Such arrangement of the latching features  290  aids in maintaining the low profile configuration of the PV connector assembly  104 . Optionally, the top  296  may be flush with the top  254 , and the bottom  298  may be flush with the bottom  256 . 
       FIGS. 4 and 5  are horizontal and vertical cross sections, respectively, of the PV connector assemblies  102 ,  104  in a mated or assembled state. During assembly, the seal  168 , cable locator  170  and cap  184  are loaded onto the end of the cable  110 . The end of the cable  110  is stripped exposing a center conductor  300  of the cable  110 . The seal  168  is position proximate to the end of the jacket  162 . A front extension  302  of the seal  168  extends forward from the seal  168 . The front extension  302  at least partially circumferentially surrounds the jacket  162 . Once the seal  168  is positioned on the cable  110 , the terminal  160  is crimped to the cable  110 . A conductor portion  304  of the terminal  160  is crimped to the center conductor  300 . A jacket portion  306  of the terminal  160  is crimped to the jacket  162  and the front extension  302 . Crimping the jacket portion  306  to the front extension  302  holds the seal  168  axially along the cable  110 . Crimping the front extension  302  also compresses the front extension  302  of the seal  168  against the jacket  162  to provide additional sealing between the seal  168  and the jacket  162 . 
     In an exemplary embodiment, the cable locator  170  may be crimped to the cable  110  to secure the axial position of the cable locator  170  on the cable  110 . The cable locator  170  may be secured to the cable  110  by other means in alternative embodiments. The cable locator  170  is positioned rearward of the seal  168 . 
     After the terminal  160  and cable locator  170  are crimped to the cable  110 , the cable  110 , along with the terminal  160 , seal  168 , cable locator  170  are loaded into the cavity  148  through the cable end  144  as a subassembly. The subassembly is loaded into the housing  140  until the wings  176  engage an inner wall  308  of the housing  140  (shown in  FIG. 4 ). The cable locator  170  defines a loading stop for the cable  110  limiting loading of the cable  110  beyond a predetermined position. When the wings  176  engage the inner wall  308 , the mating end  164  of the terminal  160  is positioned at a predetermined location within the housing  140  for mating with the terminal  160 . 
     The cap  184  is loaded into the housing  140  to hold the cable locator  170  in the housing  140 . The cap  184  may be loaded with the subassembly as part of the subassembly or may be loaded after the subassembly is positioned in the housing  140 . The latching features  190  engage the latching features  188  to lock the cap  184  in the housing  140 . A blocking wall  310  of the cap  184  is positioned immediately behind the cable locator  170  to resist rearward movement of the cable locator  170 . The cable locator  170  is captured between the blocking wall  310  and the inner wall  308 . 
     When the PV connector assembly  102  is assembled, the seal  168  provides sealing between the seal  168  and the cable  110 , and also provides sealing between the seal  168  and the housing  140 . The seal  168  has an inner sealing surface  312  and an outer sealing surface  314 . The inner sealing surface  312  engages and provides a seal along the cable  110 . The outer sealing surface  314  engages and provides a seal along cavity walls  316  of the housing  140 . The seal  168  is generally held within the housing  140  by stiction between the outer sealing surface  314  and the cavity walls  316 . The seal  168  is generally held in place with respect to the cable  110  by stiction created between the inner sealing surface  312  and the jacket  162 . The seal  168  is also held in place with respect to the cable  110  by the crimp of the terminal  160  around the front extension  302 . 
     During assembly, the seal  268 , cable locator  270  and cap  284  are loaded onto the end of the cable  112 . The end of the cable  112  is stripped exposing a center conductor  320  of the cable  112 . The seal  268  is position proximate to the end of the jacket  262 . A front extension  322  of the seal  268  extends forward from the seal  268 . The front extension  322  at least partially circumferentially surrounds the jacket  262 . Once the seal  268  is positioned on the cable  112 , the terminal  260  is crimped to the cable  112 . A conductor portion  324  of the terminal  260  is crimped to the center conductor  320 . A jacket portion  326  of the terminal  260  is crimped to the jacket  262  and the front extension  322 . Crimping the jacket portion  326  to the front extension  322  holds the seal  268  axially along the cable  112 . Crimping the front extension  322  also compresses the front extension  322  of the seal  268  against the jacket  262  to provide additional sealing between the seal  268  and the jacket  262 . 
     In an exemplary embodiment, the cable locator  270  may be crimped to the cable  112  to secure the axial position of the cable locator  270  on the cable  112 . The cable locator  270  may be secured to the cable  112  by other means in alternative embodiments. The cable locator  270  is positioned rearward of the seal  268 . 
     After the terminal  260  and cable locator  270  are crimped to the cable  112 , the cable  112 , along with the terminal  260 , seal  268 , cable locator  270  are loaded into the cavity  248  through the cable end  244  as a subassembly. The subassembly is loaded into the housing  240  until the wings  276  engage an inner wall  328  of the housing  240  (shown in  FIG. 4 ). The cable locator  270  defines a loading stop for the cable  112  limiting loading of the cable  112  beyond a predetermined position. When the wings  276  engage the inner wall  328 , the mating end  264  of the terminal  260  is positioned at a predetermined location within the housing  240  for mating with the terminal  260 . 
     The cap  284  is loaded into the housing  240  to hold the cable locator  270  in the housing  240 . The cap  284  may be loaded with the subassembly as part of the subassembly or may be loaded after the subassembly is positioned in the housing  240 . The latching features  290  engage the latching features  288  to lock the cap  284  in the housing  240 . A blocking wall  330  of the cap  284  is positioned immediately behind the cable locator  270  to resist rearward movement of the cable locator  270 . The cable locator  270  is captured between the blocking wall  330  and the inner wall  328 . 
     When the PV connector assembly  104  is assembled, the seal  268  provides sealing between the seal  268  and the cable  112 , and also provides sealing between the seal  268  and the housing  240 . The seal  268  has an inner sealing surface  332  and an outer sealing surface  334 . The inner sealing surface  332  engages and provides a seal along the cable  112 . The outer sealing surface  334  engages and provides a seal along cavity walls  336  of the housing  240 . The seal  268  is generally held within the housing  240  by stiction between the outer sealing surface  334  and the cavity walls  336 . The seal  268  is generally held in place with respect to the cable  112  by stiction created between the inner sealing surface  332  and the jacket  262 . The seal  268  is also held in place with respect to the cable  112  by the crimp of the terminal  260  around the front extension  322 . 
     When the first and second PV connector assemblies  102 ,  104  are mated together, the embossment  256  is received in the cavity  148 . The gasket  258  provides a seal between the housing  140  and the housing  240 . The securing features  146  of the housing  140  engage the securing features  246  of the housing  240  (shown in  FIG. 4 ) to secure the PV connector assemblies  102 ,  104  to one another. In the illustrated embodiment, the securing feature  146  is defined by receptacles and/or catch surfaces and the securing features  246  are defined by latches that engage the catch surfaces. 
     When the first and second PV connector assemblies  102 ,  104  are mated, the terminal  260  is electrically connected to the terminal  160 . For example, the blade of the terminal  260  is received in the blade receptacle of the terminal  160 . Because the terminals  160 ,  260  have a wide and short configuration, the electrical interface between the PV connectors assemblies  102 ,  104  has a low profile, allowing the housing  140 ,  240  to have a low profile. Having wide terminals  160 ,  260  also provides a large surface area on the terminals  160 ,  260  at the mating interfaces to allow voltage or current to be transmitted between the PV connector assemblies  102 ,  104 . 
     Having the various components of the PV connector assemblies  102 ,  104  sacrificially elongated in the width direction (e.g. side-to-side) as opposed to the height direction (e.g. top-to-bottom), such as the terminals  160 ,  260 , the securing features  146 ,  246 , the wings  176 ,  276 , the latching features  188 ,  190 ,  288 ,  290  and the like, the PV connector assemblies  102 ,  104  are able to maintain a low profile. The low profile allows the PV connector assemblies  102 ,  104  to fit in tight spaces, such as the overhang space between two solar shingles. 
       FIG. 6  illustrates alternative PV connector assemblies  402 ,  404  having different types of terminals  460 ,  462 . For example, in the illustrated embodiment, the terminals  460 ,  462  constitute socket and pin terminals. The terminals  460 ,  462  have small diameters, such as diameters that are less than the diameter of the cables. 
     It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.