Lead Assembly For Connecting Solar Panel Arrays To Inverter
Patent No. US12015376 (titled "Lead Assembly For Connecting Solar Panel Arrays To Inverter") was filed by Shoals Technologies Group Llc on Nov 29, 2023.
What is this patent about?
’376 is related to the field of connecting solar panel arrays to inverters, specifically addressing the problem of bulky and unreliable combiner boxes. Traditional solar power systems require combiner boxes to consolidate the DC power from multiple solar panels before feeding it to an inverter. These boxes are prone to damage, require maintenance, and add complexity to the installation process. The patent aims to eliminate the need for a combiner box, simplifying solar power installations and improving reliability.
The underlying idea behind ’376 is to create a lead assembly that directly connects multiple solar panel arrays to an inverter, bypassing the need for a combiner box. This is achieved by using a feeder cable with one or more drop lines connected to it. Each drop line is connected to a wire harness that aggregates the power from a solar panel array. The connection point between the feeder cable and the drop lines is then sealed with a mold structure to protect it from environmental factors.
The claims of ’376 focus on a lead assembly comprising a feeder cable, one or more drop lines, and a mold structure. The drop lines have connectors for detachable connection to wire harnesses from solar panels. The mold structure seals the electrical interconnection between the feeder cable and drop lines, protecting it from the environment. Claim 1 specifically requires two drop lines extending in opposite directions along the feeder cable, while claim 14 specifies current and voltage ratings and parallel extension of the drop line and feeder cable within the mold structure.
In practice, the lead assembly replaces the combiner box by providing a direct connection point for multiple solar panel arrays to the inverter. Each solar panel array connects to a drop line via a wire harness. The drop lines then feed into the feeder cable, which carries the combined power to the inverter. The molded joint ensures a robust and environmentally sealed connection, preventing corrosion and ensuring long-term reliability. The assembly can be customized with varying numbers of drop lines and different spacing to accommodate different solar panel array configurations.
The key differentiation from prior approaches is the elimination of the combiner box. Traditional systems require a separate combiner box to aggregate the power from multiple solar panel arrays. ’376 integrates this functionality into a single, sealed lead assembly, reducing the number of components, simplifying installation, and improving reliability. The use of overmolding and undermolding further enhances the durability and environmental protection of the electrical connections, making the system more robust and less prone to failure compared to traditional combiner box-based systems.
How does this patent fit in bigger picture?
Technical landscape at the time
In the early 2010s when ’376 was filed, solar panel installations were at a time when connecting solar panel arrays to inverters typically involved combiner boxes. At that time, systems commonly relied on dedicated wire harnesses for interconnecting solar panels within an array, rather than integrated or connectorless solutions. Furthermore, overmolding and undermolding techniques were known but applying them to electrical nexus points in lead assemblies presented engineering constraints related to material compatibility and long-term reliability.
Novelty and Inventive Step
The examiner approved the application because prior art references teach some, but not all, of the limitations of the claims. No combination of references, alone or with other art of record, teaches or suggests all the limitations of the amended claims. Therefore, the examiner determined that the claims are clear, free of the prior art, and allowable.
Claims
This patent includes 20 claims, with independent claims numbered 1 and 14. The independent claims are directed to a lead assembly for electrically coupling drop lines to a feeder cable. The dependent claims generally specify details, configurations, or variations of the lead assembly described in the independent claims, and also describe a solar power system that includes the lead assembly.
Key Claim Terms New
Definitions of key terms used in the patent claims.
Patent Family
File Wrapper
The dossier documents provide a comprehensive record of the patent's prosecution history - including filings, correspondence, and decisions made by patent offices - and are crucial for understanding the patent's legal journey and any challenges it may have faced during examination.
Date
Description
Get instant alerts for new documents
US12015376
- Application Number
- US18523464
- Filing Date
- Nov 29, 2023
- Status
- Granted
- Expiry Date
- Sep 9, 2035
- External Links
- Slate, USPTO, Google Patents