SELF SUPPORTING SOLAR SOLUTION
An electrical bus system has a trunk bus that includes at least one positive bus line, an equal number of negative bus line, and a ground cable. The trunk bus lines extend through clamping blocks where some of the clamping blocks are coupled to brackets that are themselves coupled to vertical supports. The ground cable is coupled to vertical support using the bracket. Multi-tap shear bolt connectors are used to connect the trunk bus line to photovoltaic wires carrying the output from one or more solar panel arrays, thereby eliminating the need for combiner boxes used in conventional systems.
1 . A ruggedized cable, comprising:
(a) an elongated, cylindrical steel member coated with aluminum, wherein the cylindrical steel member is surrounded by a plurality of conductor strands;
(b) a first insulation layer that encases conductor strands and the cylindrical steel member, wherein the first insulation layer is comprised of cross-linked polyethylene (XLPE); and
(c) a second insulation layer deposited on the first insulation layer, wherein the second insulation layer is comprised of high-density polyethylene (HDPE).
2 . The ruggedized cable of claim 1 , wherein:
(a) the first insulation layer has a thickness from 73 mils to 132 mils; and
(b) the second insulation layer has a thickness from 13 mils to 23 mils.
3 . The ruggedized cable of claim 2 , wherein the cylindrical steel member is surrounded by 7 to 90 conductor strands.
4 . The ruggedized cable of claim 2 , wherein the cylindrical steel member and conductor strands have a combined diameter between 132 mils and 1196 mils.
5 . The ruggedized cable of claim 1 , wherein the first and second insulation layers are formed by simultaneously extruding HDPE over XLPE.
6 . The ruggedized cable of claim 5 , wherein the first and second insulation layers are formed using a single extrusion head that simultaneously extrudes the HDPE over the XLPE.
7 . The cable of claim 1 , wherein the first insulation layer is black and the second insulation layer is comprised of a color additive.
8 . A ruggedized cable, comprising:
(a) an elongated conductive member surrounded by a plurality of conductor strands;
(b) a first insulation layer that disposed over the conductor strands and over the elongated conductive member, wherein the first insulation layer comprises cross-linked polyethylene (XLPE); and
(c) a second insulation layer disposed on the first insulation layer, wherein the second insulation layer comprises high-density polyethylene (HDPE).
9 . The ruggedized cable of claim 8 , wherein the elongated conductive member is formed from steel and coated with aluminum.
10 . The ruggedized cable of claim 8 , wherein the elongated conductive member, the plurality of conductor strands, the first insulation layer, and the second insulation layer have a combined diameter between 304 mils to 1507 mils.
11 . The ruggedized cable of claim 8 , wherein:
(a) the first insulation layer has a thickness from 73 mils to 132 mils; and
(b) the second insulation layer has a thickness from 13 mils to 23 mils.
12 . The ruggedized cable of claim 8 , wherein the first and second insulation layers are formed by simultaneously extruding HDPE over XLPE.
13 . The cable of claim 8 , wherein the first insulation layer is black and the second insulation layer is comprised of a color additive.
14 . A ruggedized cable, comprising:
(a) an elongated conductive member coated with aluminum and surrounded by a plurality of conductor strands;
(b) a first insulation layer that encases the conductor strands and the elongated conductive member; and
(c) a second insulation layer formed over the first insulation layer.
15 . The ruggedized cable of claim 14 , wherein the elongated conductive member is formed from a material comprising steel.
16 . The ruggedized cable of claim 14 , wherein the first insulation layer comprises cross-linked polyethylene (XLPE).
17 . The ruggedized cable of claim 14 , wherein the second insulation layer comprises high-density polyethylene (HDPE).
18 . The ruggedized cable of claim 14 , wherein the first and second insulation layers are formed by simultaneously extruding HDPE over XLPE.
19 . The ruggedized cable of claim 14 , wherein:
(a) the first insulation layer has a thickness from 73 mils to 132 mils; and
(b) the second insulation layer has a thickness from 13 mils to 23 mils.
20 . The ruggedized cable of claim 14 , wherein the elongated conductive member, the plurality of conductor strands, the first insulation layer, and the second insulation layer have a combined diameter between 304 mils to 1507 mils.