Claims:We claim
1. A PV connection system for interconnection of solar arrays in a power distribution system, comprising:
a junction box, a plurality of connectors and a plurality of PV wire wherein the PV wire configured to connect the junction boxes and the connectors, and configured to conduct energy from a solar panels;
the junction box having a box portion with hollow interior for receiving a plurality of contact strips and a plurality of diode(s), wherein the diode(s) are in physical contact with the deformed design feature of the contact strips for electrically connecting the junction box to the solar array;
the connector including a plug and socket design of a male coupling body and a female coupling body connected to each other in the axial direction thereby coupling of PV wire of male and female mating contacts, wherein the PV wire having a tubular bush positioned between a split bush and a silicon bush which encircles the PV wire and facilitates locking and blocking of silicone bush for moisture ingress.

2. The PV connection system according to claim 1, wherein outer surface of said connection system has a machine-readable code containing information.

3. The PV connection system according to claim 1, wherein said connector having locking nut mechanism comprising of connector nut having a plurality of contact elements on the threaded hole and a coupler body having a plurality of resilient receiving elements oriented to define a plane of reception therein, facilitating sliding engagement of said connector nut into said coupler body to facilitate complete pressured engagement and seated securement of said contact elements with said resilient receiving elements.

4. The PV connection system according to claim 3, wherein said plurality of contact elements having an edge thereof formed to provide a contour of insertion of a shape divergent to said plane of reception, whereas said plurality of resilient receiving elements having an accommodation recess with a depth to adequately receive said contour of insertion to form permanent lock.

5. The PV connection system according to claim 3, wherein said plurality of contact elements are formed on threaded hole at near end of the connector nut, whereas said plurality of resilient receiving elements are formed at distant end of externally threaded section defined about an exterior surface on said coupler body.

6. The PV connection system according to claim 3, wherein said contact elements of connector nut engages with said resilient receiving elements of coupler body after complete fastening of nut in body, wherein at least one pair of contacting elements engages simultaneous with said contour of insertion with said plane of reception of said receiving elements in said coupler body.
7. The PV connection system according to claim 1, wherein the connector configured to be coupled to a solar arrays comprising:
a male coupling body at one end; a female coupling body at the other end; a connector claw at a male and a female end; and a connector nut, wherein a connector claw comprising a hollow circular base and an array of projections along the circumference of the circular base, the circular base and the array of projection together form a single unitary piece, the single unitary piece having a first side and a second side, wherein the first side made of a circular profile for allowing the PV wire to flow freely, and the array of projections extending outwardly from the first side having a triangular end forming the second side, the triangular end extending inwardly on the second side facilitates the clamping of the PV wire in order to prevent it from breakage due to an external force and for better ingress protection.

8. The PV connection system according to claim 7, wherein the projections are tangential on the circumference on the second side of base portion of connector claw.

9. The PV connection system according to claim 7, wherein the tubular bush is made of polycarbonate material.

10. The PV connection system according to claim 7, wherein the array of projections has an equally spaced recessed portion in between them to allow a nut cap to facilitate clamping of the cable.
, Description:F O R M 2
THE PATENTS ACT, 1970
(39 of 1970)
The Patent Rule, 2003

COMPLETE SPECIFICATION
(See section 10 and rule 13)

“A PV Connection System”
by
Fancy Fittings Ltd.
145/259, Minerva Industrial Estate, Off Sewri Bunder Road, Sewri, East,
Mumbai 400015

The following specification particularly describes the invention and the manner in which it is to be performed
FIELD OF THE INVENTION
The present invention relates generally to a PV connection system and, more particularly pertains to elements of connection system like junction box, connector for improved performance.
BACKGROUND OF THE INVENTION
Photovoltaic (PV) modules or solar arrays produce electricity from solar energy. Electrical power produced by PV modules reduces the amount of energy required from non-renewable resources such as fossil fuels and nuclear energy. Significant environmental benefits are also realized from solar energy production, for example, reduction in air pollution from burning fossil fuels, reduction in water and land use from power generation plants, and reduction in the storage of waste by products. Solar energy produces no noise, and has few moving components. Because of their reliability, PV modules also reduce the cost of residential and commercial power to consumers in the long term.
Sunlight is converted into electricity within a solar panel, which may be made from a semiconducting material, for example, silicon. When sunlight hits solar panel, the semiconductor absorbs the light, and electrons are “loosened” from the semiconductor atoms causing them to flow and to generate electricity. This conversion of sunlight to electricity is referred to as the “photovoltaic effect.” PV cells are essentially large-area semiconductor diode(s). Due to the photovoltaic effect, the energy of photons is converted into electrical power within a PV cell when the PV cell is irradiated by a light source such as sunlight. PV cells are typically interconnected into solar arrays or PV modules that have power ranges of up to 100 watts or greater. A PV module is the basic element of a photovoltaic power generation system. A PV module has many solar cells interconnected in series or parallel, according to the desired voltage and current parameters.
PV modules require specially designed devices adapted for interconnecting the various PV modules with each other, and with electrical power distribution systems. PV connection systems are used to accommodate serial and parallel connection of PV arrays. A PV connection system includes a junction box with contact strips and diode(s), which is attached to the back of the PV module or solar panel. The diode(s) inside the junction box controls the flow of current and allows unidirectional current flow i.e. from negative to positive. In addition to junction box, a PV connection system includes connectors for connecting the panels in series or arrays. Junction boxes may be required to receive specialized cables from PV modules/arrays. In a junction box, due to lack of contact of diode with the contact strips causes less and inefficient contact conductivity, which is susceptible to mechanical shocks and weather conditions. Thus, junction box generates internal heat, which may affect the internal components and external structures adjacent to the junction box.
Connectors are used for connecting solar modules. Usually in a connector, connector nuts are threaded to ends of male coupler body and female coupler body for tightening the sealing around the wire entry. But existing connectors for connecting solar modules are susceptible to water and dust infiltration because of loosening of connector nut of the connector. Thus, leak points for moisture and dust ingress may be created. Therefore, a need exists for a locking mechanism for connector nut of a connector assembly which prevents loosening of the nut and in turn prevents moisture and dust from penetrating the connector through connector nuts and also simple and robust in design, and inexpensive to manufacture.
Further, one of the largest concerns to PV panel manufacturers is reliability. The junction box with connectors attached to the back of the panel must remain in good working condition for the entire service life of the module. The connectors are however prone to axial pull-out or dislocation from the junction box placing strain on the electrical connection between various conductors carried by the conduits thereby disrupting the flow of energy. When PV wire are subject to repeated physical manipulations that exert bend and strain forces on the PV wire, the PV wire can eventually break or tear. The PV wires used in connection with connector are generally more susceptible to breakage because they are more frequently handled by being bent, pulled, tangled, or wrapped. So the junction box manufacturers have conventionally used strain-relief devices/mechanisms as connector claw to ease the stress burden on PV wire. However, due to increased stress, the teeth of the claw which are straight in shape often break due to movement and friction of the PV wire. Thus, the connector claw shape and structure is important to increase the endurance of the claw’s life to keep the ingress protection effective.
So, there is need for an improved PV connection system having a junction box with improved contact conductivity and a connector with locking mechanism for connector nut, and an improved connector claw for better gripping and intended ingress protection. Further there is also need for a bush in a connector for locking and support for silicon bush to improve product application for IP67 condition. And also need for a machine readable code for identifying technical details, manufacturing date and traceability of solar PV junction box. Further, the connection system should be capable of being constructed in a more simple and/or cost-efficient manner with respect to known connector and junction box.
OBJECTIVE OF THE INVENTION
These objectives are provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This objective are not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
An important objective of the invention aims at providing a compact solution for the shortcomings of the above mentioned systems.
Another objective of the invention is to create contact conductivity between contact strips and diode(s) in a junction box.
Yet another objective of the invention is to provide a locking and supporting for silicon bush to improve product application for standard condition.
Further objective of the current invention is to provide machine readable code on junction box and connector.
Another objective of the invention is to provide a locking mechanism for facilitating facile sliding engagement and seated securement of the contact element and the resilient receiving elements of electrical connector.
Yet another objective of the invention is to prevent axial pull-out/dislocation/damage of the connector claw.
These objectives are achieved by the system according to the invention, which is a PV connection system for interconnection of solar cell arrays in a power distribution system, comprising a junction box, a plurality of connectors and a plurality of PV wires wherein the PV wires configured to connect the junction boxes and the connectors, and configured to conduct energy from solar panels. The junction box has a box portion with hollow interior for receiving a plurality of contact strips (terminals) and a plurality of diode(s), wherein the contact strips are in physical contact with diode(s) for electrically connecting the junction box to the solar cell array. The connector has a plug and socket design having a male coupling body and a female coupling body connected to similar/other coupling body in the axial direction thereby coupling of PV wires of male and female mating contacts, wherein the PV wire having a tubular bush positioned between a split bush and a silicon bush encircles the PV wire and facilitates locking and blocking moisture and dust ingress.
Further, the connector of PV connection system having locking nut mechanism comprising of connector nut having a plurality of contact elements on the threaded hole and a coupler body having a plurality of resilient receiving elements oriented to define a plane of reception therein, facilitating sliding engagement of said connector nut into said coupler body to facilitate complete pressured engagement and seated securement of said contact elements with said resilient receiving elements.
Furthermore, the connector of PV connection system comprising a connector claw having a hollow circular base and an array of projections along the circumference of the circular base, the circular base and the array of projection together form a single unitary piece, the single unitary piece having a first side and a second side, wherein the first side made of a circular profile for allowing a cable to flow freely, and the array of projections extending outwardly from the first side having a triangular end forming the second side, the triangular end extending inwardly on the second side facilitates the clamping of the cable in order to prevent it from breakage, dislocation due to an external force and to continue the intended ingress protection.
In addition, the outer surface of said connection system has a machine-readable code containing information.

BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:
Figure 1 shows a PV connection system, according to an embodiment of the present invention;
Figure 2 shows junction box with improved contact conductivity between contact strips and diode(s), according to an embodiment of the present invention;
Figure 3 shows bush in a connector, according to an embodiment of the present invention;
Figure 4 shows machine readable code engraved on junction box, according to an embodiment of the present invention;
Figure 5 shows an isometric view of connector with locking nut mechanism for engaging connector nut with the coupling body of the connector, according to present embodiment of the invention; and
Figure 6 shows a perspective view of a connector claw of a coupling body, according to an embodiment of the present invention.
Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure.
Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF THE INVENTION
The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
In the claims, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," and the like are to be understood to be open- ended, i.e., to mean including but not limited to. Only the transitional phrases "consisting of and "consisting essentially of," respectively, shall be closed or semi-closed transitional phrases.
To facilitate the understanding of this invention, a number of terms may be defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as "a", "an", and "the" are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the disclosed system or method, except as may be outlined in the claims.
Figure 1 shows a PV connection system, according to an embodiment of the present invention. A PV connection system 10 for interconnection of solar arrays 100 in a power distribution system comprises of a junction box 200, a plurality of connectors 300 and a plurality of PV wires 400 wherein the PV wires 400 configured to connect the junction boxes 200 and the connectors 300, and configured to conduct energy from solar panels. The PV junction box 200 is attached to the back of the solar panel 100 with silicon adhesive. The junction boxes 200 are connected by way of connectors 300 which establish electrical contact between the terminals of various PV wires running through one or more conduits in the junction box 200. With the use of a junction box 200, it becomes easy to connect the solar panel 100 to an array. The solar arrays 100 are generally electrically connected to an energy system through corresponding junction boxes 200. The junction boxes 200 are typically used to electrically connect a number of solar panels 100 to each other and to an electrical power distribution system.
Figure 2 shows junction box with improved contact conductivity between contact strips and diode(s), according to an embodiment of the present invention. The junction box 200 has a box portion with hollow interior for receiving a plurality of contact strips 202 and a plurality of diode(s) 204. The contact strips 202 are in physical contact 206 with diode(s) 204 for electrically connecting the junction box 200 to the solar cell array 100. Physical contact 206 can be established by one or more of a variety of methods, including but are not limited to soldering or joining or fusing. In a particular embodiment, the contact strips can have deformed design feature or profile at their extreme sides or flanks to support the diodes for soldering. The deformed design feature in the contact strips increases the surface area of contact between the contact strips and the diode resulting in better soldering joint.
Figure 3 shows bush in a connector, according to an embodiment of the present invention. The connector 300 has a plug and socket design having a female coupling body 302 and a male coupling body 304 connected to each other in the axial direction thereby coupling of PV wire 400 of male and female mating contacts. A tubular bush 314 is positioned between a split bush 312 and a silicon bush 316 which encircles the PV wire 400 for better locking and supporting of silicon bush 316 to improve product application conditions viz. IP67, IP68, thereby helping in firm anchorage of PV wire. The bush 314 is preferably, but not limited to made of plastic material which offers better chemical resistance. In a particular embodiment of the invention tubular bush is made of polycarbonate material.
Figure 4 shows machine readable code engraved on junction box, according to an embodiment of the present invention. Outer surface of elements of the connection system 10 has machine readable code 500 containing information. The machine readable code 500 containing information can be rapidly and accurately read by a simple scanning device. The machine readable code or merchandising tags 500 can be read by a machine to provide detailed information viz. technical and manufacturing information as to identity the elements of the connection system.
Figure 5 shows an isometric view of connector with locking nut mechanism for engaging connector nut with the coupling body of the connector, according to present embodiment of the invention. Accordingly, a connector 300 with locking nut mechanism 308 consists of connector nut 306 having plurality of contact elements 308a on the threaded hole and a coupler body 302 or 304 with plurality of resilient receiving elements 308b on the threaded end. The resilient receiving elements 308b are oriented to define a plane of reception. During fastening, sliding engagement of said connector nut 306 into said coupler body 302 or 304 facilitate complete pressured engagement and seated securement of said contact elements 308a with said resilient receiving elements 308b.
The contact elements 308a on the connector nut 306 can be formed anywhere on the threaded hole but preferably formed at near end of the connector nut 306. Similarly, resilient receiving elements 308b are formed on the threaded end of coupling body 302 or 304 at corresponding mating position of the contact elements 308a, however, formed preferably at distant end of externally threaded section defined about an exterior surface on said coupler body 302 or 304. Further, plurality of contact elements 308a on the connector nut 306 have an edge thereof formed to provide a contour of insertion of a shape divergent to said plane of reception. Alike, plurality of resilient receiving elements 308b have an accommodation recess with a depth to adequately receive said contour of insertion and said leading portion to form permanent lock.
When the connector nut 306 engages with threads of the coupling body 302 or 304, the contact elements 308a of connector nut 306 engages with said resilient receiving elements 308b of coupler body 302 or 304 to form a tight fit. If contact elements 308a and receiving elements 308b are formed at near end of the connector nut 306 and at distant end of externally threaded section on said coupler body 302 or 304, the contact elements 308a and receiving elements 308b engages after complete fastening of nut in body. In engagement, at least one pair of contacting elements 308a engages simultaneous with said contour of insertion with said plane of reception of said receiving elements 308b in said coupler body 302 or 304. The connector nut 306 engaged with coupler body 302 or 304 of connector 300 according to locking nut mechanism 308 compresses the strain relief or connector claw 310 around the outer jacket of the PV wire 400 and thus, provides water tight sealing. Also when locked, the mating contacts are sealed against ingress of dust and moisture.
Figure 6 shows a perspective view of a connector claw of a coupling body, according to an embodiment of the present invention. Accordingly, a connector claw 310 moulded from polycarbonate material having a first side 310a and a second side 310b, includes a hollow circular base and an array of projections preferably 12, along the circumference of the circular base on the first side 310a. The projections 310c having triangular end forms a second side 310b. The first side 310a and the second side 310b both together form a single unitary piece. The first side 310a includes a circular profile and the array of projections extending outwardly from the first side 310a to allow the PV wire 400 to flow freely through it. The projections 310c having the triangular end extend inwardly on the second side 310b in order to facilitate the clamping of the PV wire 400 through it. The projections 310c along the circumference are tangential to prevent the claw projections 310c from breakage due to an external force. The connector claw 310 to grip the PV wire 400 held to prevent it from any stress by way of friction against the inner walls of the connection and to keep the ingress protection consistent. The projections 310c are equally spaced recession portion 310d in between them to allow a connector nut 306 to expedite clamping of male and female coupling body 302 or 304.
The connector claw 310 be quickly and easily mounts to a connector 300 to accommodate PV wires, cords and cables 400 of varying types, materials, and construction. The connector claw 310 is attached to both ends of the male and the female coupling body of the connector 302 or 304 to facilitate clamping of the PV wire 400 with a connector nut 306.
While the preferred embodiments of the invention has been illustrated and described herein, it is to be understood that the invention is not limited to the precise construction herein disclosed, and the right is reserved to all changes and modifications coming within the scope of the invention.
Although there has been shown and described the preferred embodiments of the present invention, it will be readily apparent to those skilled in the art that modifications may be made thereto which do not exceed the scope of the appended claims. Therefore, the scope of the invention is only to be limited by the following claims.