Electrical connection system
View Patent ↗A photovoltaic module lead foil connection system includes a wire having a fastener. The system can include a cord plate on a surface of the photovoltaic module where a conductive lead is adjacent to the module at the cord plate. The conductive lead provides external electrical access to the photovoltaic module. The system can include a fastener configured to electrically connect an end of a wire to the conductive lead at a junction mount within the cord plate.
1. A photovoltaic module connection system comprising:
a wire for conducting electricity;
a cord plate configured to be positioned on a surface of the photovoltaic module;
a conductive lead for providing external electrical access to the photovoltaic module;
wherein the cord plate comprises a sidewall extending outward from a surface of the cord plate and defining a compartment on the surface of the cord plate, the surface containing an opening through which the conductive lead extends from beneath the cord plate to a junction mount within the compartment defined by the sidewall; and
a fastener that electrically connects an end of the wire to the conductive lead at the junction mount, the fastener comprising:
a top plate comprising a first side edge, a second side edge, and a bottom surface;
a first side spring finger extending from the first side edge of the top plate to a first terminal edge away from the bottom surface of the top plate;
a second side spring finger extending from the second side edge of the top plate to a second terminal edge away from the bottom surface of the top plate;
a first top gripping extension projecting from the first terminal edge of the first side spring finger toward the bottom surface of the top plate; and
a second top gripping extension projecting from the second terminal edge of the second side spring finger toward the bottom surface of the top plate.
2. The system of claim 1 , wherein the fastener comprises metal.
3. The system of claim 1 , wherein the fastener comprises a galvanized metal sheet.
4. The system of claim 1 , wherein the fastener comprises a conductive material.
5. The system of claim 1 , wherein the fastener comprises a protective coating.
6. The system of claim 1 , wherein the fastener is clamped to the end of the wire.
7. The system of claim 1 , wherein the fastener is crimped to the end of the wire.
8. The system of claim 1 , wherein the fastener is soldered to the end of the wire.
9. The system of claim 1 , wherein the junction mount comprises a terminal attached to the end of the lead configured to connect to the fastener.
10. The system of claim 1 , wherein the junction mount comprises a ledge configured to connect to the fastener to secure the conductive lead.
11. The system of claim 1 , wherein the conductive lead comprises a lead foil and wherein the fastener is configured to secure the lead foil around a portion of the junction mount.
12. The system of claim 1 , wherein the fastener comprises an electrically conductive coating to seal a space between the fastener and the junction mount.
13. The photovoltaic module connection system of claim 12 , wherein the sidewall has an opening and the wire extends through the opening to the junction mount.
14. The photovoltaic module connection system of claim 12 , comprising a plurality of junction mounts and a plurality of conductive leads and wire pairs, each pair connected by a fastener to a separate junction mount.
15. The photovoltaic module connection system of claim 14 , wherein one or more of said junction mounts comprises a ledge within the compartment.
16. The photovoltaic module connection system of claim 15 , wherein said compartment contains a sealant over the junction mount.
17. A photovoltaic module connection system comprising:
a cord plate capable of being on a surface of a photovoltaic module;
a junction mount within a compartment surrounded by a sidewall extending outward from a surface of the cord plate, the surface and compartment including a channel through which a conductive lead extends through the cord plate to the junction mount;
a wire extending through the sidewall to the junction mount; and
a clip that electrically connects an end of a wire to the conductive lead at the junction mount, the clip comprising:
a top plate comprising a first side edge, a second side edge, and a bottom surface;
a first side spring finger extending from the first side edge of the top plate to a first terminal edge away from the bottom surface of the top plate;
a second side spring finger extending from the second side edge of the top plate to a second terminal edge away from the bottom surface of the top plate;
a first top gripping extension projecting from the first terminal edge of the first side spring finger toward the bottom surface of the top plate; and
a second top gripping extension projecting from the second terminal edge of the second side spring finger toward the bottom surface of the top plate.
18. The photovoltaic module connection system of claim 17 , wherein the compartment contains a sealant.
19. A method of electrically connecting a wire to a photovoltaic module comprising:
positioning a cord plate adjacent to a conductive lead extending through a surface of a photovoltaic module;
wherein the cord plate comprises a sidewall extending outward from a surface of the cord plate and defining a compartment on the surface of the cord plate, the surface including an opening configured to allow the conductive lead to extend from beneath the cord plate to a junction mount within the compartment defined by the sidewall; and
electrically connecting an end of a wire to the conductive lead with a fastener at the junction mount, wherein the fastener comprises:
a top plate comprising a first side edge, a second side edge, and a bottom surface;
a first side spring finger extending from the first side edge of the top plate to a first terminal edge away from the bottom surface of the top plate;
a second side spring finger extending from the second side edge of the top plate to a second terminal edge away from the bottom surface of the top plate;
a first top gripping extension projecting from the first terminal edge of the first side spring finger toward the bottom surface of the top plate; and
a second top gripping extension projecting from the second terminal edge of the second side spring finger toward the bottom surface of the top plate.
20. The method of claim 19 , wherein the fastener comprises a metal.
21. The method of claim 19 , wherein the fastener comprises galvanized metal sheet.
22. The method of claim 19 , wherein the fastener comprises a conductive material.
23. The method of claim 19 , wherein the fastener comprises a protective coating.
24. The method of claim 19 , wherein the step of electrically connecting an end of a wire to the conductive lead with a fastener comprises clamping the fastener to the end of the wire.
25. The method of claim 19 , wherein the step of electrically connecting an end of wire to the conductive lead with a fastener comprises crimping the fastener to the end of the wire.
26. The method of claim 19 , wherein the step of electrically connecting an end of a wire to the conductive lead with a fastener comprises soldering the fastener end of the wire.
27. The method of claim 19 , further comprising the step of attaching an end of the conductive lead to the junction mount after positioning the end of the conductive lead adjacent to the junction mount.
28. The method of claim 19 , wherein the junction mount comprises a ledge portion of a cord plate configured to connect to the fastener to secure the conductive lead.
29. The method of claim 19 , wherein the conductive lead comprises a lead foil and wherein the fastener is configured to secure the lead foil around a portion of the junction mount.
30. The method of claim 19 , wherein the fastener comprises an electrically conductive coating to seal a space between the fastener and the junction mount.
31. The method of claim 19 , comprising filling the area with a flowable sealant after electrically connecting the wire and conductive lead.