Patent Abstract:
A connector block assembly that includes two or more input terminals for receiving electrical input voltage, a single electrical conductor output that is electrically connected to two or more input terminals, an insulator base; wherein the plurality of input terminals for receiving electrical input voltage are mounted within the insulator base and the single electrical conductor output are transversely mounted either within the insulator base or to the outside of the outer insulator so that the single electrical conductor output is at an angle of about seventy degrees to about one hundred-ten degrees in relationship to the two or more input terminals with a variation of angles between these two values. The optimal embodiment is being a single electrical conductor output being substantially perpendicular at an angle of about ninety degrees in relationship to the plurality of input terminals.

Full Description:
BACKGROUND OF THE INVENTION 
     Although a number of applications can be used with a collector block assembly with a common, single negative output buss, one of the most valuable is a photovoltaic (PV) power system that utilizes solar cells as a means of alternative energy. The collector block assemblies that have multiple input terminals are typically structured so that each input terminal is electrically connected to a corresponding output terminal. This is shown in collector block assembly  10  of  FIG. 1  with input conductors  12  and an output conductor  14  that extends in parallel to the input conductors  12 . This results in requiring significant space in an electrical panel to bend the output conductor or wiring resulting in a large bend radius for each conductor. 
     In addition, in other situations where a single, common output is desired, a large number of jumper connecting conductors are typically utilized. This is shown with another type of collector block assembly  11  in  FIG. 2  with a jumper connecting conductor  16 . The bend radius of each jumper conductor  16  also becomes an issue with regard to the size of the electrical panel housing the collector block assembly  11 . Moreover, if there are multiple output conductors or jumper conductors, each conductor has the potential to break or lose electrical connection. This will result in a loss of an input voltage or signal. There is also significant troubleshooting time to figure out which specific output conductor is no longer connected. 
     The present invention is directed to overcoming one or more of the problems set forth above. 
     SUMMARY OF INVENTION 
     The present invention is directed to a connector block assembly. This connector block assembly includes two or more input terminals for receiving electrical input voltage, a single electrical conductor output that is electrically connected to the two or more input terminals, and an outer support frame; wherein the two or more input terminals for receiving electrical input voltage and the single electrical conductor output are transversely mounted within the outer support frame so that the single electrical conductor output is at an angle of about seventy degrees to about one hundred-ten degrees in relationship to the two or more input terminals. Preferably, the single electrical conductor output is at an angle of about eighty degrees to about one hundred degrees in relationship to the two or more input terminals and more preferably the single electrical conductor output is at an angle of about eighty-five degrees to about ninety-five degrees in relationship to the two or more input terminals. The optimal embodiment is the single electrical conductor output being substantially perpendicular at an angle of about ninety degrees in relationship to the two or more input terminals. 
     In another aspect of the invention, a connector block assembly is disclosed. This connector block assembly includes two or more input terminals for receiving electrical input voltage, a single electrical conductor output that is electrically connected to the two or more input terminals, and an outer support frame; wherein the two or more input terminals for receiving electrical input voltage and the single electrical conductor output are transversely mounted with the two or more input terminals for receiving electrical input voltage located within the outer support frame and the single electrical conductor output attached to the outside of the support frame with the single electrical conductor output at an angle of about seventy degrees to about one hundred-ten degrees in relationship to the plurality of input terminals. Preferably, the single electrical conductor output is at an angle of about eighty degrees to about one hundred degrees in relationship to the two or more input terminals and more preferably the single electrical conductor output is at an angle of about eighty-five degrees to about ninety-five degrees in relationship to the two or more input terminals. The optimal embodiment is the single electrical conductor output being substantially perpendicular at an angle of about ninety degrees in relationship to the two or more input terminals. 
     Still yet another aspect of the present invention is that a method for utilizing a connector block assembly is disclosed. The method includes utilizing two or more input terminals for receiving electrical input voltage that are located within an outer support frame and a single electrical conductor output that is electrically connected to the two or more input terminals; wherein the two or more input terminals for receiving electrical input voltage and the single electrical conductor output are transversely mounted with the two or more input terminals for receiving electrical input voltage located within the outer support frame so that the single electrical conductor output is at an angle of about seventy degrees to about one hundred-ten degrees in relationship to the plurality of input terminals. Preferably, the single electrical conductor output is at an angle of about eighty degrees to about one hundred degrees in relationship to the two or more input terminals and more preferably the single electrical conductor output is at an angle of about eighty-five degrees to about ninety-five degrees in relationship to the two or more input terminals. The optimal embodiment is the single electrical conductor output being substantially perpendicular at an angle of about ninety degrees in relationship to the two or more input terminals. 
     These are merely some of the innumerable aspects of the present invention and should not be deemed an all-inclusive listing of the innumerable aspects associated with the present invention. These and other aspects will become apparent to those skilled in the art in light of the following disclosure and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       For a better understanding of the present invention, reference may be made to the accompanying drawings in which: 
         FIG. 1  is a side elevational view of a collector block assembly in the prior art having input conductors and an output conductor that are in parallel to each other within an electrical panel; 
         FIG. 2  is a top view of another collector block assembly in the prior art that utilizes jumper conductors; 
         FIG. 3  is a top perspective view of a preferred embodiment of a collector block assembly having input conductors and a single electrical conductor output with connectors located within the collector block assembly; 
         FIG. 4  is a perspective view of a preferred embodiment of a collector block assembly having input conductors and a single electrical conductor output with connectors located within the collector block assembly, as shown in  FIG. 3 ; 
         FIG. 5  is a side elevational view of a preferred embodiment of a collector block assembly having input conductors and a single electrical conductor output with connectors located within the collector block assembly, as shown in  FIGS. 3 and 4 ; 
         FIG. 6  is a cut-way elevational view of the connectors for the single electrical conductor output as shown in  FIGS. 3 through 5 ; 
         FIG. 7  is a top view of a preferred embodiment of a collector block assembly having input conductors and a single electrical conductor output with securing apertures on the bottom portion of the collector block assembly; 
         FIG. 8  is a top perspective view of an alternative embodiment of a collector block assembly having input conductors and a single electrical conductor output with connectors located outside the collector block assembly; 
         FIG. 9  is a perspective view of an alternative embodiment of a collector block assembly having input conductors and a single electrical conductor output with connectors located outside the collector block assembly, as shown in  FIG. 8 ; 
         FIG. 10  is a side elevational view of an alternative embodiment of a collector block assembly having input conductors and a single electrical conductor output with connectors located outside the collector block assembly, as shown in  FIGS. 8 and 9 ; 
         FIG. 11  is a perspective view of an alternative embodiment of a collector block assembly having input conductors and a single electrical conductor output with an exploded view of a connector located outside the collector block assembly, as shown in  FIGS. 8 ,  9  and  10 ; 
         FIG. 12  is a top view of an alternative embodiment of a collector block assembly having input conductors and a single electrical conductor output with securing apertures on the bottom portion of the collector block assembly with connectors located outside the collector block assembly, as shown in  FIGS. 8 ,  9 ,  10  and  11 ; 
         FIG. 13  is a cut-way elevational view of the connectors for the single electrical conductor output as shown in  FIGS. 8 ,  9 ,  10 ,  11  and  12  for the alternative embodiment of a collector block assembly. 
     
    
    
     Reference characters in the written specification indicate corresponding items shown throughout the drawing figures. 
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as to obscure the present invention. 
     The preferred embodiment of a connector block assembly is generally indicated by numeral  20  in  FIGS. 3 and 4 . There is an insulator base  22  that has a bottom portion  24  with a vertical insulator barrier  26 , a vertical insulator barrier middle member  28  and a vertical insulating barrier back member  30  that are all substantially perpendicular to the bottom portion  24 . However, the structure of the insulator base  22  can vary tremendously depending on the number of input terminals, which are generally indicated by numeral  32 , and the number of poles. In  FIGS. 3 and 4 , there is an illustrative first pole  34  and a second pole  36 . The preferred number of poles for the present invention range from one to five poles, however, any number of poles may be utilized. Typically, additional vertical insulator middle members  28  positioned between poles could be utilized to separate the poles. 
     There are a series of input base members  38  that provide numerous input terminals  32 . Preferably, but not necessarily, each input base member  38  is formed of conductive material. The series of input base members  38  preferably, but not necessarily, form a tiered structure with several layers, e.g., three (3), with numerous input terminals  32  and other threaded holes as shown in  FIGS. 5 and 7 . There is a first tier input terminal layer  74 , a second tier input terminal layer  76  and a third tier input terminal layer  78 . 
     Although each input terminal  32  can vary tremendously, the preferred example utilizes threaded holes for securing an input conductor with threaded set screw (not shown). Illustrative, but nonlimiting, examples of input conductors (otherwise known as stings) typically, but not necessarily, include #2 to #14 AWG wire gauge inputs. The illustrative, but nonlimiting, number of input terminals  32  includes twelve (12), twenty-four (24), thirty-six (36), forty-eight (48) and sixty (60) with the illustrative, but nonlimiting, example shown in  FIGS. 3 and 4  depicting twenty-four (24) input terminals  32 . 
     There is a single electrical conductor output  42  that can be a large diameter insulated conductor, solid or multiple strands, as well as an insulated metal, as shown in  FIGS. 3 ,  4  and  5 . A wide variety of conductive material will suffice with the preferred materials being copper or aluminum. An illustrative, but nonlimiting example, of conductor range is between 600 kcmil to #4 AWG conductor gauge. 
     The single electrical conductor output  42  is electrically connected to each of the input terminals  32  transversely at about seventy degrees to about one hundred-ten degrees in relationship to the plurality of input terminals  32 . Preferably, this is at an angle of about eighty degrees to about one hundred degrees in relationship to the plurality of input terminals  32  and more preferably at an angle of about eighty-five degrees to about ninety-five degrees in relationship to the plurality of input terminals  32 . The optimal embodiment is being substantially perpendicular at an angle of about ninety degrees in relationship to the plurality of input terminals  32 , which is illustrated in  FIGS. 3 ,  4 , and  5 . 
     There is an aperture  44  in the vertical insulating barrier  26  of the insulator base  22  that allows the single electrical conductor output  42  to exit the connector block assembly  20  as shown in  FIGS. 3 ,  4 , and  5 . There is a first connector  46  and a second connector  48 , preferably, but not necessarily, one for each pole. The first connector  46  and the second connector  48  clamp and secure the single electrical conductor output  42  and are preferably, but not necessarily, rectangular structures as also shown in  FIGS. 3 ,  4 ,  5  and  7  but literally any geometric shape may suffice if the single electrical conductor output  42  can be physically secured. As best shown in  FIG. 6 , the first connector  46  is positioned between the vertical insulating back barrier  30  and the vertical insulating middle member  28  and includes a first threaded top opening  50  and a first curved support bottom surface  52 . The second connector  48  is positioned between the vertical insulating barrier  26  and the vertical insulating middle member  28  and includes a second threaded top opening  54  and a second curved support bottom surface  56 . 
     A first threaded bolt  66 , having a first hex head threaded opening  70  for clamping, is threadedly received within the first threaded opening  50  in the first pole  34  to secure the single electrical conductor output  42  as shown in  FIGS. 3 ,  4  and  5 . A second threaded bolt  68 , having a second hex head threaded opening  72  for clamping, is threadedly received within the second threaded opening  54  in the second pole  36  to secure the single electrical conductor output  42  as shown in  FIGS. 3 ,  4  and  5 . However, any of a variety of hardware connectors or attachment mechanisms will suffice. The input base members  38  and the first and second connectors  46  and  48 , respectively, are secured within the insulator base  22  by a wide variety of hardware attachment mechanisms or adhesives (not shown). 
     As shown in  FIG. 7 , there is a first aperture  58  and a second aperture  62  that allows hardware to secure the first pole  34  to an electrical panel (not shown) and a third aperture  60  and a fourth aperture  64  to secure the second pole  36  to an electrical panel (not shown). 
     An alternative embodiment of a connector block assembly is generally indicated by numeral  120  in  FIGS. 8 ,  9  and  10 . There is an insulator base  122  that has a bottom portion  124  with an upwardly extending front barrier  126 , an upwardly extending middle barrier  128  and an upwardly extending back barrier  130  that are all substantially perpendicular to the bottom portion  124 . However, the structure of the insulator base  122  can vary tremendously depending on the number of input terminals, which are generally indicated by numeral  132  and the number of poles. In  FIGS. 8 ,  9  and  10 , there is an illustrative first pole  134  and a second pole  136 . The preferred number of poles for the present invention range from one to five poles, however, any number of poles may be utilized. Typically, additional upwardly extending middle barriers  128  positioned between poles could be utilized to separate the poles. 
     There are a series of input base members  138  that provide numerous input terminals  132 . Preferably, but not necessarily, each input base member  138  is formed of conductive material. The series of input base members  138  preferably, but not necessarily, form a tiered structure with several layers, e.g., three (3), with numerous input terminals  132  and other apertures as shown in  FIGS. 10 and 12 . There is a first tier input terminal layer  174 , a second tier input terminal layer  176  and a third tier input terminal layer  178 . 
     Although each input terminal  132  can vary tremendously, the preferred example utilizes threaded apertures for securing a threaded connector attached to an input conductor (not shown). Illustrative, but nonlimiting, examples of input conductors (otherwise known as stings) typically, but not necessarily, include #2 AWG to #14 AWG average wire gauge inputs. The illustrative, but nonlimiting, number of input terminals  132  includes twelve (12); twenty-four (24), thirty-six (36), forty-eight (48) and sixty (60) with the illustrative, but nonlimiting, example shown in  FIG. 9  includes twenty-four (24) input terminals  132 . 
     The single electrical conductor output  142  is electrically connected to each of the input terminals  132  transversely at about seventy degrees to about one hundred-ten degrees in relationship to the plurality of input terminals  132 . Preferably, this is at an angle of about eighty degrees to about one hundred degrees in relationship to the plurality of input terminals  132  and more preferably at an angle of about eighty-five degrees to about ninety-five degrees in relationship to the plurality of input terminals  132 . The optimal embodiment is being substantially perpendicular at an angle of about ninety degrees in relationship to the plurality of input terminals  132 , which is illustrated in  FIGS. 8 ,  9  and  10 . 
     There is a first connector  146  and a second connector  148 , preferably, but not necessarily, one for each pole, which are attached to the outside of the insulator base  122 , as shown in  FIGS. 8 ,  9 , and  10 . The first connector  146  and the second connector  148  hold and secure the single electrical conductor output  142  and are preferably, but not necessarily, rectangular structures, but literally any geometric shape may suffice if the single electrical conductor output  142  can be physically secured. There is an aperture  144  in the second connector  148  that allows the single electrical conductor output  142  to exit the connector block assembly  120 . 
     As best shown in  FIGS. 8 ,  9 ,  10  and  13 , the first connector  146  is positioned between the upwardly extending back barrier  130  and the upwardly extending middle barrier  128  and attached to the outside of the insulator base  122  and includes a first threaded top opening  150  and a first curved support bottom surface  152 . The second connector  148  is positioned between the upwardly extending front barrier  126  and the upwardly extending middle barrier  128  and includes a second threaded top opening  154  and a second curved support bottom surface  156 . 
     The first connector  146  includes a flange member  182  having an aperture  184  that connects a threaded bolt  186  to a base member  188 , shown in  FIG. 11 , which is an integral component thereof or physically attached to the first pole  134  of an input base member  138  as shown in  FIGS. 8 and 11 . There is also a washer  190  and nut  192  for securing the first connector  146  to the base member  188  with the threaded bolt  186 . The second connector  148  includes a flange member  196  having an aperture  198  that connects a threaded bolt  200  to a base member  202 , shown in  FIG. 11 , which is an integral component thereof or physically attached to the second pole  136  of an input base member  138 . There is a washer  204  and nut  206  for securing the second connector  148  to the base member  188  with the threaded post  200 , as shown in  FIGS. 8 and 11 . The hardware utilized above is merely illustrative, with a wide variety of known securing mechanisms that will suffice. 
     There is a first threaded fastener  166 , having a first drive feature threaded opening  170  for clamping, that is threadedly received within the first threaded opening  150  in the first pole  134  to secure the single output connector  142 , as shown in  FIGS. 8 ,  9 , and  10 . There is a second threaded fastener  168 , having a second drive feature threaded opening  172  for clamping, is threadedly received within the second threaded opening  154  in the second pole  136  to secure the single output connector  142 , as shown in  FIGS. 8 ,  9  and  10 . However, any of a variety of hardware connectors or attachment mechanisms will suffice. The input base members  138  and the first connector  146  and second connector  148  are secured to the insulator base  122  by a wide variety of hardware attachment mechanisms or adhesives (not shown). There are apertures  158  and  162  shown in  FIG. 12  for securing the insulator base  122  to an electrical panel or similar type of electrical enclosure. 
     As shown in  FIG. 8 , there is a first screw  212  and a second screw  214  that allows hardware to secure the first pole  134  to the bottom portion  124  of the insulator base  122  and a third screw  216  and a fourth screw  218  to secure the second pole  136  to the bottom portion  124  of the insulator base  122 . However, any of a wide variety of attachment hardware and adhesives will suffice. 
     Furthermore, it should be understood that when introducing elements of the present invention in the claims or in the above description of the preferred embodiment of the invention, the terms “have,” “having,” “includes” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required.” Similarly, the term “portion” should be construed as meaning some or all of the item or element that it qualifies. 
     Thus, there have been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims that follow.

Technology Classification (CPC): 7