WO2021248186A1

WO2021248186A1 - A solar panel electrical system module

Info

Publication number: WO2021248186A1
Application number: PCT/AU2021/050579
Authority: WO
Inventors: Kennedy Theobald
Original assignee: Kennedy Theobald
Priority date: 2020-06-10
Filing date: 2021-06-09
Publication date: 2021-12-16
Also published as: AU2021273573B1

Abstract

A solar panel electrical system comprising a module having an electrical connection socket having at least one DC power contact by which the module is attachable to a rear electrical connection plug of a solar panel in use. The module may comprise at least one spooled retractable power lead electrically connected to the at least one DC power contact for interconnection with an adjacent solar panel in use and/or bypass diodes.

Description

A solar panel electrical system module

Field of the Invention

[0001 ] This invention relates generally to a solar panel electrical systems and, more particularly, to a replaceable module therefor.

Background of the Invention

[0002] Roof mounted solar panels are typically installed adjacently with electrical cabling reticulated therebehind during installation. Cable ties and/or stainless-steel cable clips are commonly used for cable management.

[0003] However, proper running of electrical cables behind solar panels is difficult and time-consuming, especially in that solar panels are typically installed closely adjacently with little or no gap therebetween. As such, installation typically involves anticipating the required length of cable and clipping and/or tying off any excess length to the solar panel frame on ground. Once installed on a roof thereafter, any required final adjustments are made.

[0004] Various solar panel cable management systems exist including US 2018/0076763 A1 (Q FACTORY 33 LLC) 15 March 2018 which discloses a power lead-tensioning system that can be used to maintain tension in power leads extending from components of solar panels, KR 20130068768 A (LG ELECTRONICS INC) 26 June 2013 which discloses a terminal box and a solar cell module to improve convenience by drawing out a cable as long as needed, JP 2016067170 A (KANEKA CORP) 28 April 2016 which discloses a solar cell panel terminal box for drawing cable to the outside and CN 103124036 A (DU PONT APOLLO LTD) 29 May 2013 which discloses a winder and a solar energy junction box.

[0005] The present invention seeks to provide a way which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[0006] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country. Summary of the Disclosure

[0007] There is provided herein a solar panel electrical system comprising a module comprising an electrical socket having at least one DC power contact by which the module is attachable to a rear electrical connection plug of a solar panel in use. [0008] The module may comprise at least one spooled retractable power lead having a terminal plug and which is electrically connected to a respective DC power contact of the socket for interconnection with an adjacent solar panel in use.

[0009] As such, the module may be used for quickly and easily interconnecting adjacent solar panels wherein modules may be attached to installed electrical connection plugs on rear surfaces of solar panels and power leads drawn therefrom to electrically connect to adjacent panels. Pairs of modules each having a respective positive or negative power lead or modules comprising both positive and negative power leads may be used. The rear electrical connection plug may be installed in a variety of locations to allow for a variety of interconnection configurations.

[0010] The module may comprise a housing having respective spools for each power lead. The spools may rotate independently so that the length of each lead may be controlled independently.

[0011 ] Furthermore, the housing may comprise front and rear shell pieces each having a respective spool and a respective port therethrough for the power lead to control the angles of the power leads.

[0012] In embodiments, the module comprises bypass diodes electrically connected to the DC power contacts of the socket. The bypass diodes may be accessibly housed for inspection. Whereas the module may be replaced to replace faulty diodes, in a preferred embodiment, the module comprises a removable bypass diode box electrically connected thereto which may be swapped out to replace faulty bypass diodes.

[0013] Other aspects of the invention are also disclosed. Brief Description of the Drawings

[0014] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[0015] Figure 1 shows a front perspective exploded representation of a solar panel electrical system module in accordance with an embodiment;

[0016] Figure 2 shows a rear perspective view of the module;

[0017] Figure 3 illustrates attachment of the module to a rear of a solar panel in use;

[0018] Figures 4 - 6 illustrate various configurations of the module; and

[0019] Figure 7 illustrates an exploded perspective representation of the module.

Description of Embodiments

[0020] A solar panel electrical system comprises a module 100 comprising an electrical connection socket 101 by which the module 100 is attachable to a rear electrical connection plug 102 of a solar panel 103 in use. The terminology ‘socket’ and ‘plug’ as used herein should not be construed as necessarily being limited to one received within the other, other than they both electrically interconnect. The socket 101 has at least one DC power contact 104 which makes electrical contact with a corresponding power contact 104 with the plug 102 when the socket 101 is connected to the plug 102.

[0021 ] The module 100 may comprise at least one spooled retractable power lead 105 having a terminal plug 106 and which is electrically connected to a respective DC power contact 104. As is illustrated in Figure 3, when the module 100 is attached to the plug 102 on a rear of the solar panel 103, the power lead 105 may be unspooled therefrom to electrically connect to power leads 105 of adjacent solar panels 103. [0022] In one embodiment, the module 100 comprises one power lead 105. In accordance with this embodiment, a pair of modules 100 may be attached to a rear of the solar panel 103 for respective positive or negative power leads 105. These modules 100 may be installed either end of the solar panel 103, either lengthwise or widthwise, so as to allow for series power interconnection of adjacent solar panels [0023] However, in a preferred embodiment, the socket 101 has both positive and negative DC power contacts 104 and the module 100 comprises two spooled retractable power leads 105 respectively electrically connected thereto.

[0024] As such, a single module 100 may be used to interconnect both positive and negative power leads 105 in the manner shown in Figure 3. In the embodiment shown in Figure 3, the module 100 is installed at one end of the solar panel 103 and, during installation, for series interconnection with solar panels 103 adjacent thereto, the positive and negative power leads 105 thereof may be drawn to electrically connect to respective positive and negative power leads 105 of adjacent solar panels 103. The terminal plugs 106 may clip together and, in embodiments, the plugs 106 may comprise male and female MC4-type connector plugs 105. As is further shown in Figure 3, and edge rail 1 17 may be installed which defines an inner channel within which leads 105 may be run.

[0025] The connection plug 102 may be installed on a rear of the solar panel 103, either during manufacture or retrofitted thereto.

[0026] In embodiments, connection plugs 102 may be strategically placed to allow for the attachment of modules 103 at strategic locations. For example, where the module 100 comprises positive and negative power leads 105, plugs 102 may be installed either end of the solar panel so as to allow choice of electrical interconnection from either end thereof.

[0027] Conversely, where the module 100 comprises a single power lead 105, a pair of plugs 102 may be installed at either end of the solar panel 103 so that solar panels 103 can be interconnected lengthwise or alternatively pairs of plugs 102 may be installed at either end of the solar panel 103 for choice of series interconnection from either end of the panel 103.

[0028] The module 100 may comprise a bendable sheath 107 interfacing the power lead 105 to control the bend radius thereof in the manner shown in Figure 6.

[0029] Figure 7 shows an exploded perspective view of the module 100 in accordance with an embodiment wherein the module 100 comprises a housing having respective spools 108 for each power lead 105. Each power lead 105 may be wound around a respective spool 108 which rotates within the housing. A coiled spring may act on the spool 108 to rotate the spool 108 with respect to the housing to retract the power lead 105.

[0030] The housing may comprise a rear shell piece 109A and a front shell piece 109B which enclose the spools 108 therebetween and wherein each spool 108 can rotate independently therein. The spools 108 may rotate on a spindle 110 having a dividing flange 111.

[0031 ] Each shell piece 109 may comprise a port 112 from which the power lead 105 exits the housing. Furthermore, the shell pieces 109 may be rotatable with respect to each other so that the respective positions of the ports 112 are adjustable. As such, as is shown in Figure 5, the power leads 105 may be arranged in parallel but, in the embodiment shown in Figure 4, the power leads 105 may be arranged at an angle. [0032] With reference to figure 7, the module may comprise a backing plate 113 concealing the socket 101. The backing plate 130 may be fixed in position whereas the rear shell piece 109A may be rotatably coupled thereto to allow for controlling the angle of the electrical lead 105 thereof.

[0033] The socket 101 preferably also mechanically secures the module 100 to the rear of the solar panel 103 in use. As shown in Figure 2, a rear of the housing may comprise a planar rear face which lies flat across the rear of the solar panel 103 in use. The backing plate 113 may thermally insulate the module 100 from the rear of the solar panel 103.

[0034] In the embodiment shown, the plug 102 is configured to slide into the socket 101 to mechanically secure and electrically connect the socket 101. As such, the module 100 may slide across the plug 102 installed on the rear of the solar panel 103 for connection and/or disconnection.

[0035] Edges of the socket 101 and the plug 102 may comprise bevelled edges and or rails which mechanically secure the socket 101 and plug 102 together.

[0036] The module 100 may comprise at least one bypass diode 1 14 electrically connected between positive and negative DC power contacts 104 of the socket 101. The diodes 114 may be exposed for inspection and may be concealed beneath a protective cover 115. The cover 115 may be transparent or alternatively removable. [0037] In embodiments, replacement of the diodes 114 may comprise replacement of the module 100. However, in a preferred embodiment, the module 100 comprises a removable bypass diode box 116 having the at least one bypass diode 114 therein. The bypass diode box 116 may expose exterior electrical contacts which make electrical contact with respective electrical contacts of the module 100. As such, to replace a faulty bypass diode 114, the box 116 may be replaced. In embodiments, the diode box 116 may comprise diagnostic circuitry to detect faulty bypass diodes 114. The circuitry may illuminate an LED or the like when detecting a faulty bypass diode thereby allowing for visual inspection of the diode box 116 and replacement if necessary.

[0038] In embodiments, the module 100 may expose electrical testing contacts which are electrically connected to the DC power contacts 104.

[0039] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that specific details are not required in order to practise the invention. Thus, the foregoing descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed as obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the following claims and their equivalents define the scope of the invention.

[0040] The term “approximately” or similar as used herein should be construed as being within 10% of the value stated unless otherwise indicated.

Claims

1 . A solar panel electrical system comprising a module comprising an electrical connection socket having at least one DC power contact by which the module is attachable to a rear electrical connection plug of a solar panel in use.

2. The system as claimed in claim 1 , wherein the system further comprises the solar panel having the connection plug installed on a rear surface thereof.

3. The system as claimed in claim 1 , wherein the module comprises at least one spooled retractable power lead electrically connected to the at least one DC power contact for interconnection with an adjacent solar panel in use.

4. The system as claimed in claim 3, wherein the system further comprises the solar panel having the connection plug installed on a rear surface thereof and wherein connection plugs are installed either end of the solar panel.

5. The system as claimed in claim 4, wherein pairs of connection plugs are installed either end of the solar panel.

6. The system as claimed in claim 3, wherein the socket has positive and negative DC power contacts and wherein the module comprises positive and negative power leads respectively electrically connected thereto.

7. The system as claimed in claim 6, wherein the positive and negative power leads comprise male-type and female-type plugs respectively.

8. The system as claimed in claim 3, wherein the module comprises a bendable sheath interfacing the at least one power lead.

9. The system as claimed in claim 3, wherein the module comprises a housing having at least one spool for the at least one spooled retractable power lead therein.

10. The system as claimed in claim 6, wherein the module comprises a housing having two spools for the positive and negative power leads and wherein the spools are independently rotatable.

11 . The system as claimed in claim 10, wherein the housing comprises respective ports through which the power leads exit the housing and wherein the respective positions of the ports are adjustable with respect to each other.

12. The system as claimed in claim 11 , wherein the housing comprises coaxial rear and front shell pieces each housing a respective spool therein and a respective port therethrough and wherein the front shell piece is rotatable with respect to the rear shell piece to adjust the respective positioning of the ports.

13. The system as claimed in claim 12, wherein the rear shell piece is rotatable with respect to the front shell piece to adjust the respective positioning of the ports.

14. The system as claimed in claim 1 , wherein the socket mechanically secures the module to a rear of the solar panel in use.

15. The system as claimed in claim 14, wherein the module has housing having a planar rear face which lies flat across the rear of the solar panel in use when the socket is connected to the plug.

16. The system as claimed in claim 15, wherein the plug is configured to slide into the socket to mechanically secure and electrically connect the socket.

17. The system as claimed in claim 1 , wherein the socket has positive and negative DC power contacts and wherein the module comprises at least one bypass diode electrically connected therebetween.

18. The system as claimed in claim 17, wherein the module comprises a removeable bypass diode box having the at least one bypass diode therein.

19. A method of interconnecting adjacent solar panels using the system as claimed in claim 3, the method comprising electrically connecting the module to the rear electrical connection plug and drawing the at least one spooled retractable power lead therefrom and electrically connecting the power lead to a respective power lead of an adjacent solar panel.

20. A method of installing solar panel bypass diodes using the system as claimed in claim 17, the method comprising electrically connecting the module to the rear electrical connection plug so that bypass diodes thereof electrically connect between the positive and negative DC power contacts thereof.