US20110300741A1 - Photovoltaic module connector assemblies having cable strain relief - Google Patents
Photovoltaic module connector assemblies having cable strain relief Download PDFInfo
- Publication number
- US20110300741A1 US20110300741A1 US12/794,311 US79431110A US2011300741A1 US 20110300741 A1 US20110300741 A1 US 20110300741A1 US 79431110 A US79431110 A US 79431110A US 2011300741 A1 US2011300741 A1 US 2011300741A1
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- Prior art keywords
- cable
- connector assembly
- slot
- conductive
- retaining member
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 230000000712 assembly Effects 0.000 title description 12
- 238000000429 assembly Methods 0.000 title description 12
- 230000013011 mating Effects 0.000 claims abstract description 49
- 239000000463 material Substances 0.000 claims description 19
- 239000004020 conductor Substances 0.000 description 12
- 239000000565 sealant Substances 0.000 description 11
- 238000000034 method Methods 0.000 description 6
- 239000000356 contaminant Substances 0.000 description 5
- 238000000465 moulding Methods 0.000 description 5
- 230000008878 coupling Effects 0.000 description 4
- 238000010168 coupling process Methods 0.000 description 4
- 238000005859 coupling reaction Methods 0.000 description 4
- 239000011888 foil Substances 0.000 description 4
- 238000007789 sealing Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000004382 potting Methods 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000004146 energy storage Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/58—Means for relieving strain on wire connection, e.g. cord grip, for avoiding loosening of connections between wires and terminals within a coupling device terminating a cable
- H01R13/5804—Means for relieving strain on wire connection, e.g. cord grip, for avoiding loosening of connections between wires and terminals within a coupling device terminating a cable comprising a separate cable clamping part
- H01R13/5808—Means for relieving strain on wire connection, e.g. cord grip, for avoiding loosening of connections between wires and terminals within a coupling device terminating a cable comprising a separate cable clamping part formed by a metallic element crimped around the cable
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the subject matter herein relates generally to electrical connector assemblies, and more particularly, to electrical connector assemblies configured to interconnect photovoltaic (PV) modules to an energy delivery system.
- PV photovoltaic
- PV modules include PV cells that convert light energy (e.g., solar energy) into electrical energy.
- Several PV modules may be interconnected to each other in an array.
- a building roof or another type of support structure may hold numerous PV modules arranged side-by-side and interconnected to each other.
- the PV modules are generally electrically connected to an energy system through corresponding electrical connector assemblies.
- the electrical connector assemblies may be referred to as junction boxes.
- a conventional junction box may include one or more pairs of foil contacts that electrically engage a corresponding PV module.
- the foil contacts are typically located within a housing and are electrically connected to other connector assemblies through conductive cables.
- the conductive cables are electrically connected to the foil contacts within the housing and extend through a wall or side to an exterior of the housing.
- the conductive cables are inserted through holes in a side of the junction box and into an interior of the junction box. Once located in the junction box, barrels may be compressed or crimped around corresponding conductive cables. The crimped barrels effectively increase a diameter of the conductive cables and prevent the conductive cables from being inadvertently withdrawn or removed through the same holes of the junction box.
- crimping barrels around conductive cables inside the junction box may be costly and require additional steps for assembling the junction box.
- the internal components may first be positioned in a predetermined arrangement with respect to each other and then a housing material may be molded around the internal components.
- junction boxes constructed from the above over-molding process may be susceptible to leaking because a material used in the over-molding process and the composition of the conductive cables may not properly bond together to prevent the leaking.
- an electrical connector assembly configured to have a photovoltaic (PV) module mounted thereon.
- the connector assembly includes a connector housing that has a plurality of sides that define an inner region of the connector housing and include opposite loading and mating sides.
- the connector housing has a cable channel located in the inner region that extends between the loading and mating sides and a slot oriented substantially transverse to the cable channel. The slot extends through the cable channel.
- the connector assembly also includes a conductive cable that is received in the cable channel and extends along a central cable axis.
- the conductive cable has an outer surface, and the conductive cable is configured to electrically engage the PV module.
- the connector assembly also includes a retaining member that is inserted into the slot.
- the retaining member surrounds the conductive cable about the cable axis and grips the outer surface of the conductive cable.
- the retaining member prevents the conductive cable from being inadvertently moved with respect to the connector housing in a direction along the cable axis.
- the connector assemblies may include a plurality of such conductive cables and retaining members.
- embodiments described herein may include one or more pairs of conductive cables where each conductive cable is held within the housing by one or more retaining members.
- an electrical connector assembly that is configured to be mounted to a photovoltaic (PV) module.
- the connector assembly includes a plurality of housing sides including opposite loading and mating sides and a mounting surface that extends between the loading and mating sides.
- the connector assembly also includes a cable channel that extends between the loading and mating sides along the mounting surface.
- the cable channel is sized and shaped to receive a conductive cable so that the conductive cable extends along a cable axis when located within the cable channel.
- the connector assembly also includes a slot that is sized and shaped to have a retaining member inserted therein. The slot is oriented substantially transverse to the cable channel so that the retaining member extends substantially transverse to the cable axis.
- the slot opens to the mounting surface so that the retaining member is insertable into the slot in a mounting direction that is orthogonal to the cable axis.
- the connector assembly also includes a cover that is configured to be mounted to the mounting surface. The cover holds the conductive cable and the retaining member within the cable channel and the slot, respectively, when mounted to the mounting surface.
- FIG. 1 is a perspective view of an electrical connector assembly formed in accordance with one embodiment.
- FIG. 2A is a partially exploded view of the connector assembly of FIG. 1 .
- FIG. 2B is an inverted view of the connector assembly shown in FIG. 2A .
- FIG. 3 is a perspective view of the connector assembly of FIG. 1 illustrating internal components in greater detail.
- FIG. 4A is a cross-section of the connector assembly of FIG. 1 illustrating a conductive cable held by a retaining member of the connector assembly.
- FIG. 4B is a cross-section of the connector assembly of FIG. 1 through a power recess of the connector assembly.
- FIG. 5 illustrates the retaining member of FIG. 4A engaged with the conductive cable.
- FIG. 6 illustrates a retaining member formed in accordance with another embodiment engaged with a conductive cable.
- FIG. 1 is a perspective view of an electrical connector assembly 100 formed in accordance with one embodiment.
- the connector assembly 100 is oriented with respect to a longitudinal axis 190 , a lateral axis 191 , and a mounting axis 192 that are mutually perpendicular with respect to each other.
- the connector assembly 100 includes a connector housing 102 that has a plurality of housing sides 104 - 109 .
- the housing sides 104 - 109 can include opposite loading and mating sides 104 and 106 , a mounting side 105 , a non-mounting side 107 , and opposite walls sides 108 and 109 .
- the loading side 104 is located opposite to the mating side 106 and is configured to receive one or more conductive cables 116 A and 116 B.
- the mounting side 105 , the non-mounting side 107 , and the wall sides 108 and 109 may extend parallel to the longitudinal axis 190 between the loading and mating sides 104 and 106 .
- the connector housing 102 may be assembled from separate components, including a main body 101 , a housing cap 120 , a recess plug 306 ( FIG. 2B ), and a cover 130 .
- one or more of the components may be integrally formed (e.g., a single part may comprise the main body 101 and the housing cap 120 ) or the entire connector housing 102 may be integrally formed (e.g., through an over-molding process).
- the main body 101 may include the wall sides 108 and 109 , the non-mounting side 107 , and the mating side 106 .
- the housing cap 120 may include the loading side 104
- the cover 130 may form a portion of the mounting side 105 .
- the connector housing 102 may include an access window 110 through the non-mounting side 107 that provides access to a power recess 112 having mating contacts 114 A and 114 B therein.
- the recess plug 306 ( FIG. 2B ) may be inserted through the access window 110 and coupled to the main body 101 .
- the mating contacts 114 A and 114 B are electrically connected to the conductive cables 116 A and 116 B, respectively.
- the connector assembly 100 is configured to mate with a photovoltaic (PV) module (not shown) along the mounting side 105 .
- the PV module is configured to convert light or solar energy into electric potential or current.
- the connector assembly 100 may be referred to as a junction box.
- the electric potential or current generated by the PV module is transmitted through the connector assembly 100 and, more particularly, through the mating contacts 114 A and 114 B and respective conductive cables 116 A and 116 B.
- the connector assembly 100 may include only one or more than two conductive cables 116 and respective mating contacts 114 .
- the connector assembly 100 may include one or more pairs of mating contacts 114 and one or more corresponding pairs of conductive cables 116 .
- the connector housing 102 may be a single piece of a material.
- the connector housing 102 may be formed during a molding process where a resin or other fluid-like material is injected into a mold.
- the connector housing 102 includes a plurality of components that are coupled together to form the connector housing 102 .
- Each of the separate components e.g., the housing cap 120 , the main body 101 , the cover 130 , the recess plug 306
- the housing cap 120 has the conductive cables 116 A and 116 B extending therethrough.
- the housing cap 120 is configured to be mounted to the loading side 104 .
- the housing cap 120 may be integrally formed with the connector housing 102 and include the loading side 104 .
- the connector housing 102 has a length L 1 , a width W 1 , and a height H 1 .
- the connector housing 102 may have a low-profile such that a larger dimension of the connector housing 102 (e.g., the length L 1 ) may extend along the longitudinal axis 190 .
- a shorter dimension of the connector housing 102 (e.g., the height H 1 ) may extend along the mounting axis 192 .
- the wall sides 108 and 109 may extend along the height H 1 and be sized to permit the conductive cables 116 A and 116 B to be received within the connector housing 102 .
- the height H 1 may be only slightly larger than an outer diameter D 1 (shown in FIG.
- the non-mounting side 107 may comprise a substantially planar surface. More specifically, the non-mounting side 107 may have a smooth, continuous surface throughout the non-mounting side 107 , except for the access window 110 provided therethrough.
- FIG. 2A is a partially exploded view of the connector assembly 100 .
- the orientation of the connector assembly 100 in FIG. 2A is upside-down with respect to the orientation of the connector assembly 100 in FIG. 1 .
- the connector assembly 100 may include a first cable connector 122 that is coupled to the conductive cable 116 A and a second cable connector 124 that is coupled to the conductive cable 116 B.
- the first cable connector 122 may be referred to as a male cable connector and may be configured to communicatively engage a second cable connector of another connector assembly, such as a connector assembly that is similar to the connector assembly 100 .
- the second cable connector 124 may be referred to as a female cable connector and may be configured to communicatively engage a first cable connector of another connector assembly.
- the connector assembly 100 may be part of an array of connector assemblies 100 that each electrically engage a corresponding PV module.
- an array of PV modules may be mounted to a roof or other support structure.
- Each of the PV modules may be electrically coupled to an energy storage or delivery system through the corresponding connector assemblies 100 .
- the cover 130 may be configured to be coupled or mounted to a mounting surface 138 of the main body 101 .
- the mounting surface 138 faces in a direction along the mounting axis 192 .
- the mounting surface 138 may form a platform or platforms that surround at least a portion of an opening 132 to an inner space or region 136 of the connector housing 102 .
- the cover 130 is mounted to the mounting surface 138 , the inner region 136 is enclosed by the main body 101 and the cover 130 and becomes an interior 137 (shown in FIG. 4A ) of the connector assembly 100 .
- the cover 130 may be secured to the mounting surface 138 (or the main body 101 ) by one or more fastening techniques.
- the cover 130 may have a plurality of attachment openings 134 that form an interference/snap fit with corresponding attachment posts 135 of the main body 101 .
- the main body 101 may have an adhesive or sealant spread along the mounting surface 138 to facilitate adhering the cover 130 to the mounting surface 138 .
- the cover 130 may include sealant channels 366 and 368 that also align with the sealant channels along the mounting side 105 of the connector housing 102 . The sealant may flow into the sealant channels 366 and 368 when applied. The sealant secures the connector assembly 100 to the surface of the PV module and may also facilitate preventing moisture or other unwanted materials from entering the connector housing.
- a portion of the opening 132 becomes the access window 110 ( FIG. 1 ).
- the opening 132 of the main body 101 provides access to the inner region 136 of the connector assembly 100 .
- a portion of the inner region 136 may become the power recess 112 ( FIG. 1 ) after the cover 130 is coupled to the main body 101 .
- the main body 101 may have inner surfaces that are shaped to form one or more features of the inner region 136 of the connector housing 102 .
- the main body 101 may include cable channels 140 A and 140 B in the inner region 136 that extend between the loading and mating sides 104 and 106 .
- the cable channels 140 A and 140 B may open in a direction along the mounting axis 192 toward the cover 130 .
- the conductive cables 116 A and 116 B are configured to be received within the cable channels 140 A and 140 B, respectively.
- the connector assembly 100 may also include one or more retaining members 150 and 152 .
- the retaining members 150 and 152 are configured to be inserted into the main body 101 before the cover 130 is coupled over the inner region 136 of the connector housing 102 .
- the retaining members 150 and 152 may be received by the main body 101 when the retaining members 150 and 152 are moved in a mounting direction M that is parallel to the mounting axis 192 and inserted into the main body 101 .
- the retaining members 150 and 152 may be inserted before the cover 130 is coupled to the mounting surface 138 .
- the retaining members 150 and 152 are configured to be held by the main body 101 or the connector housing 102 and may couple to the respective conductive cables 116 A and 116 B therein.
- the retaining members 150 and 152 may prevent the conductive cables 116 A and 116 B from being inadvertently withdrawn from the cable channels 140 A and 140 B during the manufacture of the connector assembly 100 and/or during operation and use of the connector assembly 100 . More specifically, the retaining members 150 and 152 may prevent movement of the conductive cables 116 A and 116 B with respect to the connector housing 102 or the main body 101 in a direction that is along the longitudinal axis 190 . As such, the retaining members 150 and 152 may facilitate providing cable strain relief for the connector assembly 100 .
- the connector assembly 100 may include one or more cable seals 154 and 156 that surround corresponding conductive cables 116 A and 116 B.
- the cable seals 154 and 156 are configured to be compressed around the conductive cables 116 A and 116 B.
- the connector housing 102 may include seal cavities 158 and 160 located proximate to the loading side 104 of the connector housing 102 .
- the main body 101 may include the seal cavities 158 and 160 .
- the seal cavities 158 and 160 are sized and shaped to receive and hold the cable seals 154 and 156 , respectively, therein.
- the housing cap 120 may be coupled to the main body 101 .
- the housing cap 120 and the main body 101 may be sized and shaped with respect to each other to form an interference fit therewith.
- FIG. 2B is an exploded perspective view of the connector assembly 100 showing the non-mounting side 107 .
- the cover 130 may include a pair of notches 302 and 304 .
- the notches 302 and 304 may receive a portion of the retaining members 152 and 150 when the cover 130 is attached to the mounting surface 138 ( FIG. 2A ).
- the notches 302 and 304 may facilitate holding the retaining members 152 and 150 within the interior 137 ( FIG. 4A ) and preventing movement of the conductive cables 116 B and 116 A.
- the connector assembly 100 may include a recess plug 306 and a sealing ring 308 (e.g., o-ring).
- the sealing ring 308 may be coupled to and surround the recess plug 306 .
- the recess plug 306 may then be inserted through the access window 110 and attached to the non-mounting side 107 to cover at least a portion of the access window 110 and enclose the power recess 112 therein.
- the recess plug 306 may have a plurality of conduits 311 - 313 that provide access to the power recess 112 when the recess plug 306 is attached to the main body 101 .
- the conduit 312 may permit injection of a potting material into the power recess 112 and the conduits 311 and 313 may permit the displacement of air from the power recess 112 when the potting material is inserted therein.
- FIG. 3 illustrates in greater detail internal components of the connector assembly 100 .
- the cover 130 FIG. 2A
- the conductive cables 116 A and 116 B extend along respective central cable axes 142 A and 142 B within the cable channels 140 A and 140 B.
- the cable axes 142 A and 142 B may extend in a direction that is parallel to the longitudinal axis 190 .
- the cable channels 140 A and 140 B may be separated from each other by a spacing S 1 therebetween.
- the housing cap 120 is coupled to the main body 101 proximate to the loading side 104 of the connector housing 102 .
- the housing cap 120 may comprise a single piece of insulative material and be configured to form an interference fit with the main body 101 .
- the housing cap 120 may include a pair of cap recesses 182 and 184 that are separated by cap projections 186 .
- the cap recesses 182 and 184 are configured to receive corresponding housing or body portions 188 and 189 of the main body 101 .
- the body portions 188 and 189 are formed around the seal cavities 158 and 160 ( FIG. 2A ), respectively.
- the body portions 188 and 189 receive and hold the cable seals 154 and 156 ( FIG. 2A ), respectively, within the seal cavities 158 and 160 .
- the cap projections 186 flex toward each other when engaging the body portions 188 and 189 and grip the body portions 188 and 189 .
- the conductive cable 116 A includes an insulative jacket or sleeve 202 A and a conductor 204 A.
- the insulative jacket 202 A surrounds the conductor 204 A and extends about the cable axis 142 A when the conductive cable 116 A is in the cable channel 140 A. As shown, a portion of the insulative jacket 202 A has been removed from a distal end of the conductive cable 116 A so that the conductor 204 A is exposed within the inner region 136 of the connector housing 102 .
- the conductive cable 116 A may have the mating contact 114 A coupled to the conductor 204 A within the connector housing 102 .
- the mating contact 114 A may be coupled to the conductor 204 A within the cable channel 140 A and extend from the conductor 204 A toward the mating side 106 of the connector housing 102 .
- the mating contact 114 A may have a base portion 210 A and a mating portion 212 A.
- the base portion 210 A may be crimped or compressed around the conductor 204 A so that the mating contact 114 A is coupled thereto.
- the base portion 210 A extends along the cable channel 140 A to the mating portion 212 A.
- the mating portion 212 A extends toward the mating side 106 and is located within the power recess 112 .
- the mating portion 212 A is configured to electrically engage the PV module.
- the mating portion 212 A (or the mating contact 114 A) may be configured to flex with respect to the conductor 204 A when engaged with the PV module.
- the base portion 210 A is crimped around the conductor 204 A and extends therefrom toward the mating side 106 .
- the base portion 210 A may also include a coupling bore 214 A that receives a pin or post 216 A (shown in FIG. 4A ) of the main body 101 .
- the post may facilitate holding the mating contact 114 A in a predetermined position during the manufacture of the connector assembly 100 .
- the base portion 210 A extends toward the mating side 106 and is shaped into the mating portion 212 A.
- the mating portion 212 A may extend in a direction along the mounting axis 192 and then extend along the longitudinal axis 190 into the power recess 112 .
- the mating contacts 114 A and 114 B may extend a portion of the cable channels 140 A and 140 B.
- the connector housing 102 or the main body 101 may include a plurality of slots 220 and 222 that are configured to hold the retaining members 150 and 152 .
- the slots 220 and 222 are oriented substantially transverse to the respective cable channels 140 A and 140 B.
- Each of the slots 220 and 222 extend through the cable channel 140 A and 140 B, respectively.
- the slot 220 is defined by first and second slot portions 230 and 232 that extend radially away from the cable channel 140 A in substantially opposite directions along the lateral axis 191 .
- the slot portions 230 and 232 may be extensions of the cable channel 140 A in that the slot portions 230 and 232 define empty space that extends from the empty space of the cable channel.
- the slot portions 230 and 232 may open to the cable channel 140 A and face each other across the cable channel 140 A.
- the slot portions 230 and 232 directly oppose each other across the cable channel 140 A so that retaining member 150 is held substantially transverse to the cable axis 142 A.
- the slot portions 230 and 232 may extend into the mounting surface 138 .
- the description of slot 220 provided above may be similarly applied to the slot 222 of the cable channel 140 B.
- the cable channels 140 A and 140 B may also include slots 224 and 226 .
- the slots 224 and 226 may also be oriented substantially transverse to the respective cable channels 140 A and 140 B.
- the slots 224 and 226 may be located closer to the loading side 104 than the slots 220 and 222 .
- the slots 224 and 226 may have similar or different dimensions relative to the slots 220 and 222 .
- the slots 224 and 226 are sized and shaped to hold a smaller retaining member than the retaining members 150 and 152 .
- the slots 224 and 226 may be sized and shaped to hold a retaining member that is equal to or larger than the retaining members 150 and 152 .
- the connector assembly 100 may be configured to accommodate different sizes of conductive cables.
- the connector assembly 100 may include a bypass diode 364 located between the cable conductors 116 A and 116 B.
- the bypass diode 364 is configured to be electrically connected to the mating contacts 114 A and 114 B.
- the bypass diode 364 permits current to flow therethrough between the mating contacts 114 A and 114 B when the PV module (not shown) is shaded (i.e., when the PV module is not converting solar energy into electrical energy).
- the main body 101 may also have a sealant channel or channels 370 located along an underside of the main body 101 or mounting side 105 .
- the sealant channels 366 and 368 may align with one or more sealant channels 370 of the main body 101 .
- the sealant may facilitate holding the cover 130 to the main body 101 and/or preventing moisture and other contaminants from entering the interior 137 ( FIG. 4A ).
- FIG. 4A is a cross-section of the connector assembly 100 after the cover 130 has been coupled to the mounting surface 138 of the main body 101 .
- the connector assembly 100 may be constructed by providing the main body 101 , the cover 130 , the housing cap 120 , and a cable assembly 240 .
- the cable assembly 240 may include the conductive cable 116 A, the mating contact 114 A coupled to the conductor 204 A, and the cable seal 154 surrounding an outer surface 242 of the insulative jacket 202 A.
- the main body 101 includes an aperture 244 proximate to the loading side 104 of the connector housing 102 .
- the aperture 244 may include the seal cavity 158 .
- the cable assembly 240 may have the housing cap 120 coupled thereto. More specifically, the conductive cable 116 A may be inserted through a hole 246 of the housing cap 120 .
- the cable assembly 240 is first inserted through the aperture 244 of the main body 101 .
- the mating contact 114 A may advance through the aperture 244 followed by the conductor 204 A and the insulative jacket 202 A of the conductive cable 116 A.
- the mating contact 114 A is coupled to the connector housing 102 or the main body 101 by inserting the post 216 A through the coupling bore 214 A ( FIG. 3 ).
- the cable seal 154 may then be advanced along the insulative jacket 202 A and inserted into the seal cavity 158 of the aperture 244 .
- the insulative material of the body portion 188 completely surrounds the aperture 244 about the cable axis 142 A.
- the seal cavity 158 and the cable seal 154 are sized and shaped relative to each other so an interference fit or a snug fit is formed.
- the cable seal 154 may be compressed around the outer surface 242 of the insulative jacket 202 A to prevent unwanted moisture or contaminants from entering the interior 137 of the connector assembly 100 .
- the cable seal 154 may have one or more ribs 250 that are compressed around the insulative jacket 202 A.
- the housing cap 120 may then be coupled to the main body 101 .
- the housing cap 120 includes the loading side 104 . The housing cap 120 may facilitate holding the cable seal 154 within the seal cavity 158 .
- the retaining member 150 Before, after, or during the insertion of the cable seal 154 into the seal cavity 158 and the coupling of the housing cap 120 to the main body 101 , the retaining member 150 may be inserted into the slot 220 . More specifically, the retaining member 150 may be moved in a mounting direction M that extends along the mounting axis 192 ( FIG. 1 ) and is substantially orthogonal to the cable axis 142 A. The retaining member 150 may be moved toward the mounting surface 138 and into the slot 220 to grip the conductive cable 116 A. As shown in FIG. 4A , the retaining member 150 may have a narrow width W 2 measured along the cable axis 142 A. Furthermore, the retaining member 150 may have a height H 2 ( FIG.
- the connector assembly 100 may have a low-profile shape.
- the cover 130 may be coupled to the mounting surface 138 (e.g., through interference fit and/or providing a sealant).
- the retaining member 150 may be received within the notch 304 ( FIG. 2B ).
- the notch 304 may become a part of the slot 220 that holds the retaining member 150 therein.
- the cover 130 holds the conductive cable 116 A and the retaining member 150 within the cable channel 140 A and the slot 220 , respectively.
- the retaining member 150 prevents movement of the conductive cable 116 A with respect to the connector housing 102 in a direction along the cable axis 142 A.
- the cable seal 154 , the main body 101 , and the cover 130 prevent movement of the conductive cable 116 A out of the cable channel 140 A in a direction along the mounting axis 192 and/or lateral axis 191 ( FIG. 1 ).
- the retaining member 150 is located between the mating contact 114 A and the cable seal 154 .
- the cable seal 154 may be located between the retaining member 150 and the mating contact 114 A.
- FIG. 4B is a cross-section taken along the lateral axis 191 through the power recess 112 .
- the recess plug 306 may have opposite latches 360 and 362 that are configured to flex and grip portions of the main body 101 when the recess plug 306 is attached thereto.
- the sealing ring 308 may be applied to the recess plug 306 before coupling to the main body 101 .
- the sealing ring 308 may surround the recess plug 306 and cooperate with the recess plug 306 and the main body 101 to prevent moisture and contaminants from entering the power recess 112 .
- FIG. 5 is a view along the cable axis 142 A illustrating the retaining member 150 inserted into the slot 220 and gripping the conductive cable 116 A.
- the retaining member 150 is an E-retaining ring or clip.
- the retaining member 150 includes an annular portion 260 that extends around the outer surface 242 of the conductive cable 116 A.
- the annular portion 260 may also extend around the cable axis 142 A.
- the annular portion 260 may define a cable-reception region 270 that is shaped to receive the conductive cable 116 A.
- the retaining member 150 may include at least one grip element 262 that is configured to grip the insulative jacket 202 A.
- the grip elements 262 are coupled to and project radially inward from the annular portion 260 toward the cable axis 142 A and/or the insulative jacket 202 A.
- the retaining member 150 includes three grip elements 262 .
- the retaining member 150 may include only one grip element, two grip elements, or more than three grip elements.
- the grip elements 262 are not limited to the shapes shown in FIG. 5 , but may have other shapes that facilitate gripping the insulative jacket 202 A.
- the retaining member 150 may be bracket-shaped and have grip elements that are similar to the grip elements 356 and 358 shown in FIG. 6 .
- the grip elements 262 grip the conductive cable 116 A by piercing material of the insulative jacket 202 A such that a portion of the grip element 262 extends through the outer surface 242 and is inserted into the insulative jacket 202 A.
- the grip elements 262 may be shaped to facilitate piercing the insulative jacket 202 A when the retaining member 150 is inserted into the slot 220 in the mounting direction M.
- the grip elements 262 may have sharp edges capable of piercing the insulative jacket 202 A.
- the grip elements 262 may be substantially evenly distributed about the cable axis 142 A.
- the grip elements 262 When the grip elements 262 pierce the material of the insulative jacket, the grip elements 262 may provide a grip diameter D 2 that is less than the outer diameter D 1 of the conductive cable 116 A. If a force is exerted on the conductive cable 116 A in a direction that is along the cable axis 142 A, the grip elements 262 prevent the conductive cable 116 A from being moved in the cable channel 140 A.
- the grip elements 262 do not pierce the insulative jacket 202 A.
- the grip elements 262 may be shaped to have dull contact points that engage the insulative jacket 202 A. As such, the grip elements 262 may compress the insulative jacket 202 A, but not pierce the outer surface 242 .
- FIG. 6 is a view along a cable axis 342 A illustrating a retaining member 350 of an alternative embodiment inserted into a slot 320 to grip a conductive cable 316 A.
- the retaining member 350 may include separate retaining components 352 and 354 .
- Each retaining component 352 and 354 includes at least one grip element 356 and 358 , respectively, that is configured to grip an insulative jacket 302 A of the conductive cable 316 A.
- the retaining components 352 and 354 may be rectangular-shaped parts and the grip elements 356 and 358 may be edges of the parts.
- the grip elements 356 and 358 may pierce the insulative material of the conductive cable 316 A.
- the retaining component 352 may be inserted into the slot portion 330 and the retaining component 354 may be inserted into the slot portion 332 .
- the retaining components 352 and 354 may be inserted separately or simultaneously into the respective slot portions 330 and 332 .
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- Details Of Connecting Devices For Male And Female Coupling (AREA)
Abstract
Description
- The subject matter herein relates generally to electrical connector assemblies, and more particularly, to electrical connector assemblies configured to interconnect photovoltaic (PV) modules to an energy delivery system.
- Photovoltaic (PV) modules include PV cells that convert light energy (e.g., solar energy) into electrical energy. Several PV modules may be interconnected to each other in an array. For example, a building roof or another type of support structure may hold numerous PV modules arranged side-by-side and interconnected to each other. The PV modules are generally electrically connected to an energy system through corresponding electrical connector assemblies. The electrical connector assemblies may be referred to as junction boxes. A conventional junction box may include one or more pairs of foil contacts that electrically engage a corresponding PV module. The foil contacts are typically located within a housing and are electrically connected to other connector assemblies through conductive cables. The conductive cables are electrically connected to the foil contacts within the housing and extend through a wall or side to an exterior of the housing.
- It is generally desirable to protect the foil contacts, the conductive cables, and other internal components from unwanted moisture or contaminants. During the assembly of some known junction boxes, the conductive cables are inserted through holes in a side of the junction box and into an interior of the junction box. Once located in the junction box, barrels may be compressed or crimped around corresponding conductive cables. The crimped barrels effectively increase a diameter of the conductive cables and prevent the conductive cables from being inadvertently withdrawn or removed through the same holes of the junction box. However, crimping barrels around conductive cables inside the junction box may be costly and require additional steps for assembling the junction box. In other junction boxes, it may be possible for internal components, such as conductive cables, to be located within the junction box through an over-molding process. For example, the internal components may first be positioned in a predetermined arrangement with respect to each other and then a housing material may be molded around the internal components. However, junction boxes constructed from the above over-molding process may be susceptible to leaking because a material used in the over-molding process and the composition of the conductive cables may not properly bond together to prevent the leaking.
- Accordingly, there is a need for alternative electrical connector assemblies, such as junction boxes, that protect internal components from unwanted moisture and contaminants. Furthermore, there is a need for electrical connector assemblies that are capable of being constructed in a more simple and/or cost-efficient manner with respect to known electrical connector assemblies.
- In one embodiment, an electrical connector assembly is provided that is configured to have a photovoltaic (PV) module mounted thereon. The connector assembly includes a connector housing that has a plurality of sides that define an inner region of the connector housing and include opposite loading and mating sides. The connector housing has a cable channel located in the inner region that extends between the loading and mating sides and a slot oriented substantially transverse to the cable channel. The slot extends through the cable channel. The connector assembly also includes a conductive cable that is received in the cable channel and extends along a central cable axis. The conductive cable has an outer surface, and the conductive cable is configured to electrically engage the PV module. The connector assembly also includes a retaining member that is inserted into the slot. The retaining member surrounds the conductive cable about the cable axis and grips the outer surface of the conductive cable. The retaining member prevents the conductive cable from being inadvertently moved with respect to the connector housing in a direction along the cable axis.
- Optionally, the connector assemblies may include a plurality of such conductive cables and retaining members. For example, embodiments described herein may include one or more pairs of conductive cables where each conductive cable is held within the housing by one or more retaining members.
- In another embodiment, an electrical connector assembly that is configured to be mounted to a photovoltaic (PV) module is provided. The connector assembly includes a plurality of housing sides including opposite loading and mating sides and a mounting surface that extends between the loading and mating sides. The connector assembly also includes a cable channel that extends between the loading and mating sides along the mounting surface. The cable channel is sized and shaped to receive a conductive cable so that the conductive cable extends along a cable axis when located within the cable channel. The connector assembly also includes a slot that is sized and shaped to have a retaining member inserted therein. The slot is oriented substantially transverse to the cable channel so that the retaining member extends substantially transverse to the cable axis. The slot opens to the mounting surface so that the retaining member is insertable into the slot in a mounting direction that is orthogonal to the cable axis. The connector assembly also includes a cover that is configured to be mounted to the mounting surface. The cover holds the conductive cable and the retaining member within the cable channel and the slot, respectively, when mounted to the mounting surface.
-
FIG. 1 is a perspective view of an electrical connector assembly formed in accordance with one embodiment. -
FIG. 2A is a partially exploded view of the connector assembly ofFIG. 1 . -
FIG. 2B is an inverted view of the connector assembly shown inFIG. 2A . -
FIG. 3 is a perspective view of the connector assembly ofFIG. 1 illustrating internal components in greater detail. -
FIG. 4A is a cross-section of the connector assembly ofFIG. 1 illustrating a conductive cable held by a retaining member of the connector assembly. -
FIG. 4B is a cross-section of the connector assembly ofFIG. 1 through a power recess of the connector assembly. -
FIG. 5 illustrates the retaining member ofFIG. 4A engaged with the conductive cable. -
FIG. 6 illustrates a retaining member formed in accordance with another embodiment engaged with a conductive cable. -
FIG. 1 is a perspective view of anelectrical connector assembly 100 formed in accordance with one embodiment. Theconnector assembly 100 is oriented with respect to alongitudinal axis 190, alateral axis 191, and amounting axis 192 that are mutually perpendicular with respect to each other. Theconnector assembly 100 includes aconnector housing 102 that has a plurality of housing sides 104-109. The housing sides 104-109 can include opposite loading andmating sides mounting side 105, anon-mounting side 107, andopposite walls sides loading side 104 is located opposite to themating side 106 and is configured to receive one or moreconductive cables mounting side 105, thenon-mounting side 107, and thewall sides longitudinal axis 190 between the loading andmating sides - In the illustrated embodiment, the
connector housing 102 may be assembled from separate components, including amain body 101, ahousing cap 120, a recess plug 306 (FIG. 2B ), and acover 130. However, in alternative embodiments, one or more of the components may be integrally formed (e.g., a single part may comprise themain body 101 and the housing cap 120) or theentire connector housing 102 may be integrally formed (e.g., through an over-molding process). As shown, themain body 101 may include the wall sides 108 and 109, thenon-mounting side 107, and themating side 106. Furthermore, thehousing cap 120 may include theloading side 104, and thecover 130 may form a portion of the mountingside 105. Also shown, theconnector housing 102 may include anaccess window 110 through thenon-mounting side 107 that provides access to apower recess 112 havingmating contacts FIG. 2B ) may be inserted through theaccess window 110 and coupled to themain body 101. Themating contacts conductive cables - In the exemplary embodiment, the
connector assembly 100 is configured to mate with a photovoltaic (PV) module (not shown) along the mountingside 105. The PV module is configured to convert light or solar energy into electric potential or current. When mounted onto the mountingside 105, the PV module may electrically connect with themating contacts power recess 112. Accordingly, in some embodiments, theconnector assembly 100 may be referred to as a junction box. The electric potential or current generated by the PV module is transmitted through theconnector assembly 100 and, more particularly, through themating contacts conductive cables connector assembly 100 is shown inFIG. 1 as including only twoconductive cables respective mating contacts connector assembly 100 may include only one or more than two conductive cables 116 and respective mating contacts 114. For example, theconnector assembly 100 may include one or more pairs of mating contacts 114 and one or more corresponding pairs of conductive cables 116. - As described above, the
connector housing 102 may be a single piece of a material. For example, theconnector housing 102 may be formed during a molding process where a resin or other fluid-like material is injected into a mold. In the illustrated embodiment, theconnector housing 102 includes a plurality of components that are coupled together to form theconnector housing 102. Each of the separate components (e.g., thehousing cap 120, themain body 101, thecover 130, the recess plug 306) may comprise a single piece of material or be constructed from multiple parts. - As shown in
FIG. 1 , thehousing cap 120 has theconductive cables housing cap 120 is configured to be mounted to theloading side 104. However, in alternative embodiments, thehousing cap 120 may be integrally formed with theconnector housing 102 and include theloading side 104. - As shown in
FIG. 1 , theconnector housing 102 has a length L1, a width W1, and a height H1. Theconnector housing 102 may have a low-profile such that a larger dimension of the connector housing 102 (e.g., the length L1) may extend along thelongitudinal axis 190. A shorter dimension of the connector housing 102 (e.g., the height H1) may extend along the mountingaxis 192. For example, the wall sides 108 and 109 may extend along the height H1 and be sized to permit theconductive cables connector housing 102. The height H1 may be only slightly larger than an outer diameter D1 (shown inFIG. 4A ) of theconductive cables FIG. 1 . Thenon-mounting side 107 may comprise a substantially planar surface. More specifically, thenon-mounting side 107 may have a smooth, continuous surface throughout thenon-mounting side 107, except for theaccess window 110 provided therethrough. When the PV module and the mountingside 105 of theconnector assembly 100 are attached, theconnector assembly 100 is moved in a direction along the mountingaxis 192 toward the PV module. In alternative embodiments, the PV module may be moved in a direction along the mountingaxis 192 toward the mountingside 105. -
FIG. 2A is a partially exploded view of theconnector assembly 100. The orientation of theconnector assembly 100 inFIG. 2A is upside-down with respect to the orientation of theconnector assembly 100 inFIG. 1 . As shown, theconnector assembly 100 may include afirst cable connector 122 that is coupled to theconductive cable 116A and asecond cable connector 124 that is coupled to theconductive cable 116B. Thefirst cable connector 122 may be referred to as a male cable connector and may be configured to communicatively engage a second cable connector of another connector assembly, such as a connector assembly that is similar to theconnector assembly 100. Thesecond cable connector 124 may be referred to as a female cable connector and may be configured to communicatively engage a first cable connector of another connector assembly. Theconnector assembly 100 may be part of an array ofconnector assemblies 100 that each electrically engage a corresponding PV module. For example, an array of PV modules may be mounted to a roof or other support structure. Each of the PV modules may be electrically coupled to an energy storage or delivery system through the correspondingconnector assemblies 100. - As shown in
FIG. 2A , thecover 130 may be configured to be coupled or mounted to a mountingsurface 138 of themain body 101. The mountingsurface 138 faces in a direction along the mountingaxis 192. The mountingsurface 138 may form a platform or platforms that surround at least a portion of anopening 132 to an inner space orregion 136 of theconnector housing 102. When thecover 130 is mounted to the mountingsurface 138, theinner region 136 is enclosed by themain body 101 and thecover 130 and becomes an interior 137 (shown inFIG. 4A ) of theconnector assembly 100. Thecover 130 may be secured to the mounting surface 138 (or the main body 101) by one or more fastening techniques. For example, thecover 130 may have a plurality ofattachment openings 134 that form an interference/snap fit with corresponding attachment posts 135 of themain body 101. Alternatively or in addition to, themain body 101 may have an adhesive or sealant spread along the mountingsurface 138 to facilitate adhering thecover 130 to the mountingsurface 138. For example, thecover 130 may includesealant channels side 105 of theconnector housing 102. The sealant may flow into thesealant channels connector assembly 100 to the surface of the PV module and may also facilitate preventing moisture or other unwanted materials from entering the connector housing. When thecover 130 is coupled to the mountingsurface 138, a portion of theopening 132 becomes the access window 110 (FIG. 1 ). - The
opening 132 of themain body 101 provides access to theinner region 136 of theconnector assembly 100. A portion of theinner region 136 may become the power recess 112 (FIG. 1 ) after thecover 130 is coupled to themain body 101. As shown, themain body 101 may have inner surfaces that are shaped to form one or more features of theinner region 136 of theconnector housing 102. For example, themain body 101 may includecable channels inner region 136 that extend between the loading andmating sides cable channels axis 192 toward thecover 130. Theconductive cables cable channels - The
connector assembly 100 may also include one ormore retaining members members main body 101 before thecover 130 is coupled over theinner region 136 of theconnector housing 102. For example, the retainingmembers main body 101 when the retainingmembers axis 192 and inserted into themain body 101. The retainingmembers cover 130 is coupled to the mountingsurface 138. The retainingmembers main body 101 or theconnector housing 102 and may couple to the respectiveconductive cables - When the
cover 130 is coupled to themain body 101, theconductive cables members FIG. 4A ) of theconnector assembly 100. As such, the retainingmembers conductive cables cable channels connector assembly 100 and/or during operation and use of theconnector assembly 100. More specifically, the retainingmembers conductive cables connector housing 102 or themain body 101 in a direction that is along thelongitudinal axis 190. As such, the retainingmembers connector assembly 100. - Also shown in
FIG. 2A , theconnector assembly 100 may include one or more cable seals 154 and 156 that surround correspondingconductive cables conductive cables connector housing 102 may includeseal cavities loading side 104 of theconnector housing 102. For example, themain body 101 may include theseal cavities respective seal cavities housing cap 120 may be coupled to themain body 101. Thehousing cap 120 and themain body 101 may be sized and shaped with respect to each other to form an interference fit therewith. -
FIG. 2B is an exploded perspective view of theconnector assembly 100 showing thenon-mounting side 107. As shown, thecover 130 may include a pair ofnotches notches members cover 130 is attached to the mounting surface 138 (FIG. 2A ). Thenotches members FIG. 4A ) and preventing movement of theconductive cables - Also shown in
FIG. 2B , theconnector assembly 100 may include arecess plug 306 and a sealing ring 308 (e.g., o-ring). The sealingring 308 may be coupled to and surround therecess plug 306. Therecess plug 306 may then be inserted through theaccess window 110 and attached to thenon-mounting side 107 to cover at least a portion of theaccess window 110 and enclose thepower recess 112 therein. Therecess plug 306 may have a plurality of conduits 311-313 that provide access to thepower recess 112 when therecess plug 306 is attached to themain body 101. For example, theconduit 312 may permit injection of a potting material into thepower recess 112 and theconduits power recess 112 when the potting material is inserted therein. -
FIG. 3 illustrates in greater detail internal components of theconnector assembly 100. For illustrative purposes, the cover 130 (FIG. 2A ) has been removed fromFIG. 3 . As shown, theconductive cables central cable axes cable channels longitudinal axis 190. Thecable channels housing cap 120 is coupled to themain body 101 proximate to theloading side 104 of theconnector housing 102. Thehousing cap 120 may comprise a single piece of insulative material and be configured to form an interference fit with themain body 101. For example, thehousing cap 120 may include a pair of cap recesses 182 and 184 that are separated bycap projections 186. The cap recesses 182 and 184 are configured to receive corresponding housing orbody portions main body 101. Thebody portions seal cavities 158 and 160 (FIG. 2A ), respectively. Thebody portions FIG. 2A ), respectively, within theseal cavities cap projections 186 flex toward each other when engaging thebody portions body portions - Although the following description is with specific reference to the
conductive cable 116A and thecable channel 140A, the description may be similarly applied to theconductive cable 116B and thecable channel 140B. Theconductive cable 116A includes an insulative jacket orsleeve 202A and aconductor 204A. Theinsulative jacket 202A surrounds theconductor 204A and extends about thecable axis 142A when theconductive cable 116A is in thecable channel 140A. As shown, a portion of theinsulative jacket 202A has been removed from a distal end of theconductive cable 116A so that theconductor 204A is exposed within theinner region 136 of theconnector housing 102. - Furthermore, the
conductive cable 116A may have themating contact 114A coupled to theconductor 204A within theconnector housing 102. In particular embodiments, themating contact 114A may be coupled to theconductor 204A within thecable channel 140A and extend from theconductor 204A toward themating side 106 of theconnector housing 102. As shown, themating contact 114A may have abase portion 210A and amating portion 212A. Thebase portion 210A may be crimped or compressed around theconductor 204A so that themating contact 114A is coupled thereto. Thebase portion 210A extends along thecable channel 140A to themating portion 212A. As shown, themating portion 212A extends toward themating side 106 and is located within thepower recess 112. Themating portion 212A is configured to electrically engage the PV module. Themating portion 212A (or themating contact 114A) may be configured to flex with respect to theconductor 204A when engaged with the PV module. - As shown in
FIG. 3 , thebase portion 210A is crimped around theconductor 204A and extends therefrom toward themating side 106. Thebase portion 210A may also include acoupling bore 214A that receives a pin or post 216A (shown inFIG. 4A ) of themain body 101. The post may facilitate holding themating contact 114A in a predetermined position during the manufacture of theconnector assembly 100. Thebase portion 210A extends toward themating side 106 and is shaped into themating portion 212A. For example, themating portion 212A may extend in a direction along the mountingaxis 192 and then extend along thelongitudinal axis 190 into thepower recess 112. Themating contacts cable channels - In addition, the
connector housing 102 or themain body 101 may include a plurality ofslots members slots respective cable channels slots cable channel slot 220 is defined by first andsecond slot portions cable channel 140A in substantially opposite directions along thelateral axis 191. Theslot portions cable channel 140A in that theslot portions slot portions cable channel 140A and face each other across thecable channel 140A. Theslot portions cable channel 140A so that retainingmember 150 is held substantially transverse to thecable axis 142A. Furthermore, as shown inFIG. 3 , theslot portions surface 138. The description ofslot 220 provided above may be similarly applied to theslot 222 of thecable channel 140B. - In the illustrated embodiment, the
cable channels slots slots respective cable channels slots loading side 104 than theslots slots slots slots members slots members connector assembly 100 may be configured to accommodate different sizes of conductive cables. - Also shown in
FIG. 3 , theconnector assembly 100 may include abypass diode 364 located between thecable conductors bypass diode 364 is configured to be electrically connected to themating contacts bypass diode 364 permits current to flow therethrough between themating contacts - The
main body 101 may also have a sealant channel orchannels 370 located along an underside of themain body 101 or mountingside 105. When thecover 130 is attached to the mountingsurface 138, thesealant channels 366 and 368 (FIG. 2A ) may align with one ormore sealant channels 370 of themain body 101. The sealant may facilitate holding thecover 130 to themain body 101 and/or preventing moisture and other contaminants from entering the interior 137 (FIG. 4A ). -
FIG. 4A is a cross-section of theconnector assembly 100 after thecover 130 has been coupled to the mountingsurface 138 of themain body 101. Although the following description is with specific reference to theconductive cable 116A andcable channel 140A, the description may similarly be applied to theconductive cable 116B and thecable channel 140B (FIG. 2A ). In some embodiments, theconnector assembly 100 may be constructed by providing themain body 101, thecover 130, thehousing cap 120, and acable assembly 240. Thecable assembly 240 may include theconductive cable 116A, themating contact 114A coupled to theconductor 204A, and thecable seal 154 surrounding anouter surface 242 of theinsulative jacket 202A. As shown, themain body 101 includes anaperture 244 proximate to theloading side 104 of theconnector housing 102. Theaperture 244 may include theseal cavity 158. In particular embodiments, thecable assembly 240 may have thehousing cap 120 coupled thereto. More specifically, theconductive cable 116A may be inserted through a hole 246 of thehousing cap 120. - In some embodiments, the
cable assembly 240 is first inserted through theaperture 244 of themain body 101. Themating contact 114A may advance through theaperture 244 followed by theconductor 204A and theinsulative jacket 202A of theconductive cable 116A. In particular embodiments, themating contact 114A is coupled to theconnector housing 102 or themain body 101 by inserting thepost 216A through the coupling bore 214A (FIG. 3 ). Thecable seal 154 may then be advanced along theinsulative jacket 202A and inserted into theseal cavity 158 of theaperture 244. The insulative material of thebody portion 188 completely surrounds theaperture 244 about thecable axis 142A. As shown, theseal cavity 158 and thecable seal 154 are sized and shaped relative to each other so an interference fit or a snug fit is formed. Also shown, thecable seal 154 may be compressed around theouter surface 242 of theinsulative jacket 202A to prevent unwanted moisture or contaminants from entering theinterior 137 of theconnector assembly 100. To this end, thecable seal 154 may have one ormore ribs 250 that are compressed around theinsulative jacket 202A. Thehousing cap 120 may then be coupled to themain body 101. In the illustrated embodiment, thehousing cap 120 includes theloading side 104. Thehousing cap 120 may facilitate holding thecable seal 154 within theseal cavity 158. - Before, after, or during the insertion of the
cable seal 154 into theseal cavity 158 and the coupling of thehousing cap 120 to themain body 101, the retainingmember 150 may be inserted into theslot 220. More specifically, the retainingmember 150 may be moved in a mounting direction M that extends along the mounting axis 192 (FIG. 1 ) and is substantially orthogonal to thecable axis 142A. The retainingmember 150 may be moved toward the mountingsurface 138 and into theslot 220 to grip theconductive cable 116A. As shown inFIG. 4A , the retainingmember 150 may have a narrow width W2 measured along thecable axis 142A. Furthermore, the retainingmember 150 may have a height H2 (FIG. 5 ) that is slightly greater than the outer diameter D1 of theconductive cable 116A. The height H2 is slightly smaller than the height H1 (FIG. 1 ) of theconnector housing 102. As such, in particular embodiments, theconnector assembly 100 may have a low-profile shape. - In particular embodiments, after inserting the retaining
member 150 into theslot 220, thecover 130 may be coupled to the mounting surface 138 (e.g., through interference fit and/or providing a sealant). The retainingmember 150 may be received within the notch 304 (FIG. 2B ). Thenotch 304 may become a part of theslot 220 that holds the retainingmember 150 therein. As shown inFIG. 4A , thecover 130 holds theconductive cable 116A and the retainingmember 150 within thecable channel 140A and theslot 220, respectively. The retainingmember 150 prevents movement of theconductive cable 116A with respect to theconnector housing 102 in a direction along thecable axis 142A. Furthermore, thecable seal 154, themain body 101, and thecover 130 prevent movement of theconductive cable 116A out of thecable channel 140A in a direction along the mountingaxis 192 and/or lateral axis 191 (FIG. 1 ). - In the illustrated embodiment, the retaining
member 150 is located between themating contact 114A and thecable seal 154. In alternative embodiments, however, thecable seal 154 may be located between the retainingmember 150 and themating contact 114A. -
FIG. 4B is a cross-section taken along thelateral axis 191 through thepower recess 112. As shown, therecess plug 306 may haveopposite latches main body 101 when therecess plug 306 is attached thereto. In the illustrated embodiment, the sealingring 308 may be applied to therecess plug 306 before coupling to themain body 101. The sealingring 308 may surround therecess plug 306 and cooperate with therecess plug 306 and themain body 101 to prevent moisture and contaminants from entering thepower recess 112. -
FIG. 5 is a view along thecable axis 142A illustrating the retainingmember 150 inserted into theslot 220 and gripping theconductive cable 116A. In particular embodiments, the retainingmember 150 is an E-retaining ring or clip. As shown, the retainingmember 150 includes anannular portion 260 that extends around theouter surface 242 of theconductive cable 116A. Theannular portion 260 may also extend around thecable axis 142A. As such, theannular portion 260 may define a cable-reception region 270 that is shaped to receive theconductive cable 116A. Also shown, the retainingmember 150 may include at least onegrip element 262 that is configured to grip theinsulative jacket 202A. Thegrip elements 262 are coupled to and project radially inward from theannular portion 260 toward thecable axis 142A and/or theinsulative jacket 202A. In the illustrated embodiment, the retainingmember 150 includes threegrip elements 262. However, in alternative embodiments, the retainingmember 150 may include only one grip element, two grip elements, or more than three grip elements. In addition, thegrip elements 262 are not limited to the shapes shown inFIG. 5 , but may have other shapes that facilitate gripping theinsulative jacket 202A. For example, the retainingmember 150 may be bracket-shaped and have grip elements that are similar to thegrip elements FIG. 6 . - In the illustrative embodiment, the
grip elements 262 grip theconductive cable 116A by piercing material of theinsulative jacket 202A such that a portion of thegrip element 262 extends through theouter surface 242 and is inserted into theinsulative jacket 202A. Accordingly, in the illustrated embodiment, thegrip elements 262 may be shaped to facilitate piercing theinsulative jacket 202A when the retainingmember 150 is inserted into theslot 220 in the mounting direction M. For example, thegrip elements 262 may have sharp edges capable of piercing theinsulative jacket 202A. Thegrip elements 262 may be substantially evenly distributed about thecable axis 142A. When thegrip elements 262 pierce the material of the insulative jacket, thegrip elements 262 may provide a grip diameter D2 that is less than the outer diameter D1 of theconductive cable 116A. If a force is exerted on theconductive cable 116A in a direction that is along thecable axis 142A, thegrip elements 262 prevent theconductive cable 116A from being moved in thecable channel 140A. - However, in alternative embodiments, the
grip elements 262 do not pierce theinsulative jacket 202A. For example, thegrip elements 262 may be shaped to have dull contact points that engage theinsulative jacket 202A. As such, thegrip elements 262 may compress theinsulative jacket 202A, but not pierce theouter surface 242. -
FIG. 6 is a view along acable axis 342A illustrating a retainingmember 350 of an alternative embodiment inserted into aslot 320 to grip aconductive cable 316A. As shown, the retainingmember 350 may includeseparate retaining components component grip element insulative jacket 302A of theconductive cable 316A. The retainingcomponents grip elements grip elements conductive cable 316A. The retainingcomponent 352 may be inserted into theslot portion 330 and theretaining component 354 may be inserted into theslot portion 332. The retainingcomponents respective slot portions - It is to be understood that the above description is intended to be illustrative, and not restrictive. In addition, the above-described embodiments (and/or aspects or features thereof) may be used in combination with each other. Furthermore, 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.
Claims (20)
Priority Applications (5)
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US12/794,311 US8083540B1 (en) | 2010-06-04 | 2010-06-04 | Photovoltaic module connector assemblies having cable strain relief |
EP11168394A EP2393166A1 (en) | 2010-06-04 | 2011-06-01 | Photovoltaic module connector assemblies having cable strain relief |
CA2741899A CA2741899A1 (en) | 2010-06-04 | 2011-06-01 | Photovoltaic module connector assemblies having cable strain relief |
JP2011124569A JP2011258557A (en) | 2010-06-04 | 2011-06-02 | Photovoltaic module connector assemblies having cable strain relief |
CN2011102251689A CN102427089A (en) | 2010-06-04 | 2011-06-03 | Photovoltaic module connector assemblies having cable strain relief |
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US12/794,311 US8083540B1 (en) | 2010-06-04 | 2010-06-04 | Photovoltaic module connector assemblies having cable strain relief |
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US20110300741A1 true US20110300741A1 (en) | 2011-12-08 |
US8083540B1 US8083540B1 (en) | 2011-12-27 |
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US12/794,311 Active 2030-06-17 US8083540B1 (en) | 2010-06-04 | 2010-06-04 | Photovoltaic module connector assemblies having cable strain relief |
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- 2011-06-01 CA CA2741899A patent/CA2741899A1/en not_active Abandoned
- 2011-06-02 JP JP2011124569A patent/JP2011258557A/en not_active Withdrawn
- 2011-06-03 CN CN2011102251689A patent/CN102427089A/en active Pending
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US20110217856A1 (en) * | 2010-03-05 | 2011-09-08 | Vijh Aarohi S | Terminal assembly including a junction box for a photovoltaic module and method of forming |
US8187016B2 (en) * | 2010-03-05 | 2012-05-29 | Xunlight Corporation | Terminal assembly including a junction box for a photovoltaic module and method of forming |
US20120122343A1 (en) * | 2010-09-09 | 2012-05-17 | Dirk Limberg | Junction box for solar module |
US9106066B2 (en) | 2011-12-28 | 2015-08-11 | Sumitomo Wiring Systems, Ltd. | Wire fixing member |
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WO2014169090A1 (en) * | 2013-04-10 | 2014-10-16 | Molex Incorporated | Connector |
US20160056565A1 (en) * | 2013-04-10 | 2016-02-25 | Molex, Llc | Connector |
US9705233B2 (en) * | 2013-04-10 | 2017-07-11 | Molex, Llc | Connector |
US10241289B2 (en) * | 2013-08-23 | 2019-03-26 | CommScope Connectivity Belgium BVBA | Pass-through assembly having an anchor member and a cover |
US10901164B2 (en) | 2013-08-23 | 2021-01-26 | CommScope Connectivity Belgium BVBA | Pass-through assembly having an anchor member and a cover |
US11506856B2 (en) | 2013-08-23 | 2022-11-22 | CommScope Connectivity Belgium BVBA | Pass-through assembly having an anchor member and a cover |
TWI558046B (en) * | 2015-10-07 | 2016-11-11 | 新綠股份有限公司 | Cable fixator |
Also Published As
Publication number | Publication date |
---|---|
US8083540B1 (en) | 2011-12-27 |
CN102427089A (en) | 2012-04-25 |
EP2393166A1 (en) | 2011-12-07 |
CA2741899A1 (en) | 2011-12-04 |
JP2011258557A (en) | 2011-12-22 |
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