AU717353B3

AU717353B3 - Improved flat panel connector

Info

Publication number: AU717353B3
Application number: AU21231/99A
Authority: AU
Inventors: Michael Instance; Walter Reide; Philip Timbrell
Original assignee: Tyco Electronics Pty Ltd
Current assignee: Tyco Electronics Pty Ltd
Priority date: 1999-03-16
Filing date: 1999-03-16
Publication date: 2000-03-23
Anticipated expiration: 2005-03-16

Description

AUSTRALIA

PATENTS ACT 1990

ORIGINAL

COMPLETE SPECIFICATION PETTY PATENT Invention Title: IMPROVED FLAT PANEL CONNECTOR Name of Applicant: UTILUX PTY LIMITED The following statement is a full description of this invention, including the best method of performing it known to me/us: IMPROVED FLAT PANEL CONNECTOR The present invention relates to an improved flat panel connector, and particularly, but not exclusively, to a connector for conductively connecting solar cell panels to electrical conductors.

In the electrical generating industry, it is known to provide solar panels for the generation of electricity for domestic and industrial use. Solar panels usually comprise a series of photovoltaic (solar) cells arranged as a panel (usually a substantially flat panel) to be mounted on a building to receive sunlight and generate electricity. The photovoltaic panels are usually connected to a junction box by wires soldered to the panel on one end and terminated in a terminal block inside the junction box on the other end. They may also be terminated in a crimped connector housed in the junction box.

One type of solar panel that is produced today comprises a thin film or layer which mounts an array of solar cells conductively connected together, mounted on a glass panel. These types of solar panels (known as thin film solar panels) usually provide a conductive pad or a conductive surface within recesses in the glass panel, from which conductive surface or pad conductive connection must be made to connect the solar panels together and take power to a load. Connection of conductors to this arrangement is difficult and presents problems. At present, connections are usually soldered to the conductive surface or pad.

This may be very awkward for a workman to do on installation of the solar panels and is time consuming.

The present invention provides a connector arrangement for a flat panel which includes a recess in the .srface of the panel, a surface within the recess being conductive and being connected to other circuit elements in tne panel, the connector arrangement comprising a bundle of "i 14/12/99\\GHSYDNTI\urs\Speci\300 399\300 349\33765.doc

W

r resilient conductive wire arranged to be placed within the recess in contact with the conductive surface, and a conductive probe arranged to be received by and conductively connect to the wire bundle, whereby to conductively connect the conductive probe and conductive surface, so that electric current can flow between the circuit elements and the probe.

The compression member may comprise a substantially flat member which is pressed down on top of the recess to compress the wire bundle and then is fixed to the solar panel at the edges of the recess. The compression member preferably includes passageway for receiving the probe. Alternatively, the compression member may be integral with the probe and provide a conductive element for another conductor connected on the other side of the compression member from the recess.

The bundle of conductive wire preferably acts resiliently because of its natural "springiness" because it is bundled up.

The probe may also act to further compress the \/ire bundle and may be dimensioned to facilitate this.

The invention is particularly useful for thin film solar panels.

Features and advantages of the present invention will become apparent from the following description of an embodiment thereof, by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a top view of a thin layer solar cell panel suitable for use with an embodiment of the present .'-vention; Fig. 2 is section on line AA of Fig. 1; Fig. 3 is a detail of part B of Fig. 2, illustrating a connector arrangement in accordance with an eismbodiment of the present invention.

14/12 99\\OHSYDNTIuscrs\Speci\300 399\300 349\3765.doc Figs 1 and 2 illustrate a thin layer solar panel 1 which comprises a thin layer 2 of an array of solar cells 3mounted on a substrate 4 of glass. Such thin layer solar panels 1 are known. Each of the solar cells 3 is connected by conductors 5 (shown schematically) and in turn these conductors are connected to a pair of contacts 6. Contacts 6 each comprise a recess in the substrate 4 on the reverse side of th~e panel from the solar cells, a surface or surfaces of the recess including a conductive "land" 8 (in this case conductive land 8 is provided on the surface of the base of the recess 7, but it may provided around the sides of the recess 7).

The contacts 6 are provided so that electric power produced by the solar cells 3 can be conveyed from the solar panel 1. In operation, a number of solar panels 1 may be connected in series, parallel or individually together via the contacts 6 and the connected panels are in turn connected to a further conductor which can convey electrical power from the solar panels 1 to a load.

The nature of the contacts 6 provides difficulties in connecting external conductors to them.

Fig. 3 illustrates schematically an embodiment of tche present invention which facilitates the connection of the contacts 6 to external conductors.

The connector arrangement 10 comprises a resilient conductive medium 11, which in this embodiment is a haphazardly coiled ("spaghetti" bundle) bundle of nickel plated springy wire (other conductive wire may be used).

T"he bundling of the wire and the wires natural elasticity gives it resilience. The wire is seated firmly within the raFcess 7 contacting the conductive land 8. A probe 12 wr!-ch may be a cylindrical metal probe or a relatively rigid piece of wire is inserted into'the bundle of wire 11.

3ttcause the probe 12 takes up space it further compresses ueresilient wire within the recess 7, improving the 14/I 2I99\XGliSYDNTIusrs\Spci3O 399\300 349 1 .33765.doc conductive contact with the conductive layer 8 and also with the conductive probe 12.

Conductive probe 12 extends outwardly of the recess 7, and it may be connected to a further conductor 13 for connection with other solar panels and/or connecting to a load. The probe 12 may in fact be integral with the further conductor 13. Alternatively, it may be crimped to it or otherwise connected.

The connector arrangement. 10 also comprises in this embodiment a compression member 13, which comprises a substantially disk like body which may be of conductive material but may not. The member covers the hole 13 and is mounted by means screws, not shown) to the surface of the solar panel 1. This compression number 13 provides a cover for the contacts 6 and also acts to press down on the resilient wire bundle 11 to further increase compression and therefore further improve the conductive contact between the conductive land 8, wire 7 and probe 12.

The compression member 13 includes a passageway 15 for receiving the probe.

In an alternative embodiment, the probe 12 may be omitted and instead the compression member acts as the conductive contact with the solar cells via the resilient conductive medium 11. A surface on the compression member 14 (on the opposite side from the resilient conductive medium 11) may be provided to enable connection to a conductor 13.

Although the present invention is particularly suited for use with thin solar panels, it may be used with any flat oanel which requires connection to circuit elements within panel. It may also be used with any type of solar panel any flat panel solar device solar windows) and any layered photovoltaic device.

It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to S i\ 14/I299\GHSYDNTI\usfcrSpcci300. 399\300 34933765.doc -6the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

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Claims

2. A connector arrangement in accordance with claim i, further including a compression member being arranged to be mounted to the flat panel over the recess to compress the wire bundle, whereby to improve the conductive contact between the probe, the wire bundle and the conductive surface.
3. A connector arrangement in accordance with claim 1 and substantially as herein described with reference to the accompanying drawings. Dated this 14 th day of January 2000 UTILUX PTY LIMITED By their Patent Attorneys GRIFFITH HACK 14/O1/00JASpeci\300- 399\300 349\3376S.doc