HK1118960A - Connector housing assembly and method for housing a connector contact connecting a wire to a conducting lead in a piece of foil - Google Patents

Description

Connector housing assembly and method for encapsulating connector contacts connecting wires to conductive leads in a piece of foil

Technical Field

The present invention relates to a connector housing assembly for receiving a connector contact for connecting a conductor to a conductive lead embedded in a piece of foil, comprising at least one connector housing part, wherein the at least one connector housing part comprises a recess for receiving at least a portion of the connector contact, a surface of the connector housing part facing a surface of the piece of foil being provided with an opening of the recess, wherein the at least one connector housing part comprises at least one protruding part protruding from the surface of the connector housing part facing the surface of the piece of foil in use, each of the protruding parts being adapted to be inserted through a respective hole in the piece of foil adjacent to the protruding surface.

The invention also relates to a method of connecting a connector for connecting wires to conductive leads embedded in a piece of foil to the foil, comprising: contacting a connector having terminals for connecting wires to the conductive leads to the film; providing a connector housing assembly comprising at least one connector housing part, the at least one connector housing part comprising a recess for accommodating at least a part of the connector contacts, and a face of the connector housing part facing a face of the piece of foil provided with a recess opening; inserting at least one protruding member protruding from a surface of the connector housing part facing the surface of the piece of foil through a respective hole in the piece of foil; and drawing the surface of the connector housing part provided with the recess opening towards the facing surface of the piece of foil.

The invention also relates to an assembly of such a connector housing assembly and a mating connector housing.

Background

Respective examples of such components and such methods are well known. US6568955 discloses an electrical connector which at least partially accommodates a membrane having printed conductors embedded therein, comprising an insulating housing having an insertion opening for the membrane, and at least one membrane connected to contact portions for connecting the printed conductors. To introduce the film, the transmission means embedded in the strand is opened. A Retaining web (Retaining web) on the actuator penetrates the sheet to avoid tension being applied to the sheet. Engaging the locking noses in the holes ultimately fixes the transmission in its installed position.

A problem of the known connector housing assembly is that it can only be connected to a foil of a relatively narrow shape or having a strip-like portion by means of conductive leads embedded in the foil protruding from the edge. This limits the range of applications for such connectors.

Disclosure of Invention

It is an object of the present invention to provide a connector housing assembly and a method of connecting a connector and an assembly as defined in the preceding paragraphs which ensures that the connector housing remains connected to the foil irrespective of the connector contact and which finds a wider range of foil shapes to be used and provides more flexibility in the placement of the connector.

The above object is achieved by a connector housing assembly according to the present invention, which is characterized in that the connector housing assembly is configured to exert a holding force by at least one of the protruding parts pulling a surface of the connector housing part provided with the recess opening towards a facing surface of the piece of foil.

Since the retention force can be applied by at least one of the protruding members inserted through the holes in the piece of foil, the connector housing assembly need not be closed on multiple sides. Thus, the use of the connector housing assembly is not confined to those pieces of foil provided with elongate protruding strips having embedded conductive leads. Likewise, the connector housing assembly can be positioned at or near an edge of the piece of foil parallel to the conductive leads. Since the retention force can be applied by the protruding member, the connection of the connector contact to the piece of foil does not rely on simultaneously holding the connector housing assembly and the piece of foil together. Thus, independence of the connection is obtained, avoiding stress on the embedded conductive leads.

In a preferred embodiment, a first of the two connector housing parts comprises a recess, at least one of the two connector housing parts consisting of one of the at least one connector housing part comprising at least one protruding part, the other of the two connector housing parts being provided with at least one opening for receiving a protruding part inserted through a hole in the piece of foil and protruding towards a surface of the other connector housing part facing the surface of the piece of foil, the other being configured to exert a retaining force pulling the two connector housing parts towards each other by means of the received protruding part.

The two connector housing parts can be adapted to face opposite surfaces of the piece of foil, as the other of the two connector housing parts is provided with at least one opening for receiving a protruding member inserted through a hole in the piece of foil and extending towards the surface of the other connector housing part facing the surface of the piece of foil. A protruding member inserted through an aperture in the piece of foil connects the two connector housing parts together. One of the two connector housing parts is a connector housing part comprising a recess for accommodating at least a part of the connector contacts. Since the connector housing part accommodating the protruding parts is configured to exert a holding force pulling the two connector housing parts towards each other by at least one of the accommodated protruding parts, the connector housing part comprising the recess is close to or against the piece of foil. No additional latches or means for bypassing the diaphragm are required. This means that the two connector housing parts can be adapted to any plane of the piece of foil. More specifically, the position of the connector is not limited to a position near the edge.

In a preferred variant of this embodiment, at least one of the two connector housing parts is provided with a surface opposite to a surface facing, in use, a surface of the piece of foil, the opposite surface being substantially planar and parallel to the surface of the piece of foil, at least when the connector housing part is pulled sufficiently towards the piece of foil.

This variant is used in particular when applied to accommodate connector contacts for connecting wires to conductive leads in a piece of foil further comprising active components interacting with the environment through the surface of the piece of foil. This includes in particular a pellicle plate with a solar part and also a pellicle plate with a light exit part. Because the opposing surfaces are nearly planar and parallel to the pellicle plate surface, shadows or artifacts depending on the angle of incidence to the pellicle plate are prevented.

In a variation of the same embodiment at least one of the two connector housing parts is provided with a recess having an opening in a surface of the connector housing part facing, in use, the surface of the piece of foil, and a surface opposite the surface facing, in use, the surface of the piece of foil, wherein the distance between the opposite surfaces is less than twice the depth of the recess as measured from the opening.

Therefore, at least one of the two connector housing parts should be substantially flat and have as small a height as possible. This variant is also used in particular when applied to a piece of foil which further comprises active elements interacting with the environment through the surface of said piece of foil. In this variant, the occurrence of any form of shadowing and/or obstruction is largely avoided.

In an embodiment of the connector housing assembly, a first of the two connector housing parts comprises said recess, a second of the two connector housing parts comprises a second recess for accommodating at least a part of a received connector contact protruding from a surface of the piece of foil in use, and a surface of the second connector housing part provided with an opening of the second recess.

Thus, when the two connector housing parts are placed on either side of the piece of foil, at least a part of the connector contacts is accommodated in the first recess of the first connector housing part. At least a portion of the connector contacts the pierced membrane sheet, at least a portion of which protrudes from the surface of the membrane sheet, and is thus effectively shielded from environmental influences. This also applies to any component embedded in the piece of foil that is exposed to the environment due to the contact of the connector with the pierced piece of foil.

In an embodiment of the connector housing assembly, at least one surface of the connector housing part provided with the recess opening is configured to engage with the sealing means, adapted to abut a facing surface of the piece of foil over a contact area almost surrounding the recess opening, when the surface of the connector housing part is sufficiently drawn close to the facing surface of the piece of foil.

The sealing means may be formed integrally with the surface of the connector housing part or may be a separate part. Examples in the latter category include sealing rings and or ring seals applied to the surface of the connector housing parts. The present embodiment allows for more effective shielding of the connector contacts from the environment. Which helps to prevent corrosion due to water penetration between the connector housing part and the surface of the piece of foil. An additional benefit is that other components embedded in the piece of foil that are exposed by the act of securing the connector contacts to the conductive leads can also be shielded.

In an embodiment of the connector housing assembly according to the invention, said connector housing part is integrally formed with at least one of said protruding parts it comprises.

This embodiment also has the advantage of being easy to manufacture and assemble, particularly with the final assembly being performed at a location remote from the initial production location. Few components such as screws or rivets are required.

In an embodiment of the connector housing assembly, the connector housing part including the recess comprises a portion provided with a cavity for receiving a terminal of a received connector contact, the cavity opening into the recess near one end of a longitudinal axis thereof, and being provided with an external interface at an opposite end of the longitudinal axis in a direction parallel to the axis, wherein the longitudinal axis intersects a surface of the connector housing part facing, in use, the surface of the piece of foil.

Thus, in use, the wires connected to the embedded conductive leads by the connector contacts are at an angle to the plane of the piece of foil. This embodiment is effectively applied to the case where the pellicle membrane is applied to the support member for the purpose of stabilization. The support member can remain relatively flat with only a small area where the passage for the wires is provided and/or with a portion of the connector housing part where the cavity for receiving the terminal is provided being uneven. It will be appreciated that the longitudinal axis is, in use, substantially perpendicular to the surface of the connector housing part facing the surface of the piece of foil.

In a variation of this embodiment, at least one of the connector housing parts is adapted to engage with a housing of a mating connector, the housing end being connected to a wire of a conductive lead embedded in the piece of foil.

The end of the cavity for receiving the terminal provided with the external interface is preferably closed when engaged with the housing of the mating connector. This will help to shield the recess from external influences such as moisture, since the cavity for accommodating the terminal opens towards the recess near one end of the longitudinal axis of the cavity.

In a further development of the latter of the variations, the connector housing assembly comprises a holding means for maintaining engagement with the housing of the mating connector.

Thus, inadvertent disconnection can be avoided. The elimination of stress on the wire, and more particularly, the elimination of tensile stress (pull relief) is particularly useful for one end of the retention device. This embodiment is actually used to connect the wires to the piece of foil at an angle to the direction of gravity. More specifically, the wires can be suspended from the device with little additional support.

According to another aspect, the method of the invention is characterized in that: on the side of the piece of foil opposite to the connector housing part provided with the protruding part, at least one of the inserted protruding parts is brought into engagement by holding means adapted to exert a holding force pulling the surface of the connector housing part provided with the recess opening towards the facing surface of the piece of foil.

Since the connector housing part containing the recess is pulled towards the surface of the piece of foil so that the surface facing the piece of foil and the surface provided with the opening of the recess are in close proximity, the connection site of the connector contact with the foil can be better protected. At least one protruding member inserted through an aperture in the film is used to apply a force that holds the connector housing parts in close proximity. Thus, there is no or little need for latches or other mechanisms to be mounted for this purpose immediately adjacent the edges of the piece of foil. This provides greater flexibility in terms of the location of installation and the shape of the pellicle membrane used.

In an embodiment of the method, at least one protruding member is inserted through a hole in a conductive lead embedded in said piece of foil.

This embodiment is advantageous when used in connection with a piece of foil in which active elements are embedded for interaction with the environment through a surface of at least one side of the piece of foil. The connector housing part covers almost seldom the surface area where interaction takes place.

An embodiment of the method comprises providing a further connector housing part having an elongated profile, wherein at least one of the two connector housing parts is provided with at least one opening for receiving a protruding member protruding from a surface of the other connector housing part facing a surface of the piece of foil and inserted through an aperture in the piece of foil; further comprising: positioning the further connector housing part over the conductive leads with its longitudinal axis almost parallel to the conductive leads.

This embodiment is also advantageous when used in connection with a piece of foil in which active elements are embedded for interaction with the environment through a surface of at least one side of the piece of foil. The further connector housing part having an elongated profile is advantageously placed on the side of the foil where the interaction takes place. Thus almost rarely covering the surface portions where interaction takes place.

In an embodiment of the invention, a connector housing assembly is provided comprising a connector housing assembly according to the invention.

According to another aspect of the invention, there is provided an assembly comprising a connector housing assembly and a housing of a mating connector, wherein the connector housing assembly comprises a connector housing assembly according to an embodiment of the invention.

Drawings

The invention will now be described in detail with reference to the accompanying drawings, in which:

FIG. 1 is a schematic view of a roll of solar film tape from which pieces of film are cut to form assemblies having connector contacts for connecting wires;

FIG. 2 is a side view, partially in cross-section, of a connector contact folded to a conductive lead embedded in a piece of film;

fig. 3 is a cross-sectional side view of the upper connector housing part of the connector housing assembly in a first embodiment;

FIG. 4 is a cross-sectional side view of the lower connector housing part of the connector housing assembly of the embodiment of FIG. 3;

fig. 5 is a cross-sectional side view of an upper connector housing part of the connector housing assembly in a second embodiment;

fig. 6 is a top plan view of a surface of the lower connector housing part of the second embodiment, which surface is directed towards a surface of the piece of foil in use;

fig. 7 is a cross-sectional side view of the connector housing part shown in fig. 6;

FIG. 8 is a cross-sectional side view of a bushing included in the connector housing assembly of the second embodiment; and

fig. 9 is a cross-sectional side view of a connector housing of a mating connector adapted to mate with the connector housing assembly of the first or second embodiment.

Detailed Description

As shown in fig. 1, a roll of Photovoltaic (PV) film tape 1 includes a plurality of solar cells 2 arranged in a matrix. Each row comprises a number of series-connected solar cells 2 (not shown separately in detail in fig. 1). Two bus bars 3 are embedded in the film. As an example of a method for producing a film roll 1, it is described in detail in WO 01/78156. As an example of a currently manufactured film roll 1, it has a width of about 1.2 meters.

Thin film solar cells, also known as photovoltaic films, generally comprise a support and a photovoltaic layer consisting of a semiconductor material disposed between an electrode located at the front of the film, comprising a Transparent Conductive Oxide (TCO), and an electrode located at the back of the film. The front electrode is transparent so that incident light can reach the semiconductor material where the incident radiation is converted into electrical energy. In this way, light is used to generate an electrical current.

The production of solar cells on a coil 1 has the advantage that they can be cut off from the coil 1 in sheets or strips to provide cells which can generate the desired voltage or power. Preferably, any length of sheet is allowed to be cut to form a unit. To make this possible, the tape roll 1 preferably has an unscheduled division into units. This means that a connection point should be provided to a wire which is connected to conduct the generated current at any position along the length of the roll 1 of foil.

In the configuration shown, the solar cells are connected in series between the bus bars 3. The length of the film piece cut from the roll 1 determines the length of each busbar 3 on the film. The preferred width values of the busbars 3 (in the plane of the film) are in the range of 0.5-1cm, and the preferred thickness values are in the range of 80-100 um. The most suitable material for the bus bar 3 is aluminum, although other electrically conductive materials such as metals or metal alloys are used in other embodiments.

It is not only desirable to allow for the provision of connection points to the conductors at any location along the length of the roll 1 of foil, but this location should also be at a relatively large distance from the longitudinal edges. The next unit is cut from the film roll 1 and placed between the insulating film layers to be laminated to a flat surface, with the bus bar 3 located just short of the edge of the laminated film. This is due to the fact that along each of the edges 4 there must be an electrically insulating edge extending from the edge 4 to the parallel edges of the laminated film.

Fig. 2 shows a connector contact 5 for connecting a wire (not shown) to one of the busbars 3. Fig. 2 shows the subsequent case of connection to a film web cut out from the film roll 1. The connector contact 5 comprises a terminal 6 for connecting a wire to the bus bar 3. In the embodiment shown, the connector contact 5 is a single, integral component. The connector contact 5 is also used in the field of automation and can be obtained by a stamping and subsequent reshaping step. The connector contact 5 in the embodiment may be made of copper, aluminum or an alloy thereof. Optionally, the connector contacts 5 are covered, for example plated. Preferably, the connector contacts are made of plated phosphor bronze to facilitate bending attachment to the piece of foil.

The connector contact 5 comprises a first part 7 comprising an almost plane base 8 with six protruding teeth 9. These teeth 9 form contact members for establishing an electrically conductive connection with the busbar 3 at a desired point in the length direction. The first part 7 has a somewhat elongated shape and is connected at one longitudinal end thereof to a second part 10. The other longitudinal end of which terminates in a connector contact 5. The second part 10 comprises the (female) terminal 6. The terminals 6 are adapted to mate with male terminals (not shown) of a wire connector. In another embodiment, the second portion 10 includes terminals that are directly connected to the wires, such as by soldering or crimping.

It should be noted that the second portion 10 intersects the planar base 8. As shown, its longitudinal axis is substantially perpendicular to the planar base 8. The planar base abuts the surface of the membrane sheet so that the planar base is parallel to the membrane surface. Preferably, the connector contact 5 is attached to the rear surface of the piece of foil, through which the radiation is incident on the piece of foil. This rear face is preferably supported using a bearing surface for the bearing surface, the small passage provided with the connector contact 5 and the connector housing part accommodating it.

When the connector contacts 5 are connected, the teeth 9 are pressed via the film sheet and folded back. The folded portions of the teeth 9 thus project from the opposite face of the piece of foil to which the planar base 8 abuts. In the embodiment shown here, a connector housing assembly of a connector housing part is provided which comprises protruding parts of the guard teeth 9, as will be explained in more detail below.

Fig. 3 and 4 show a first embodiment of a connector housing assembly. The upper connector housing part 11 comprises two pins 12, 13. The pins 12, 13 project from a lower surface 14 of the upper connector housing part 11. In use, the lower face 14 faces the upper face of the piece of foil to which a connector comprising the connector housing assembly is attached. The upper connector housing part 11 protects the part of the tines 9 protruding from the upper surface of the piece of foil which also protects any parts embedded in the piece of foil which would otherwise be exposed by a fracture surface caused by the tines 9 tearing the upper surface. The upper connector housing part 11 is furthermore adapted to exert a retaining force to hold the lower connector housing part 15 (fig. 4) in close contact with the lower surface of the piece of foil. The retention force is applied by pins 12, 13 protruding from the lower surface 14.

In this specification, the term "surface" is used in its geometrical sense to denote the surface of a three-dimensional object as the surface of the object viewed from a particular direction. The lower surface 14 of the upper connector housing part 11 is substantially flush with a plane perpendicular to the direction in which the holding force is applied, except for any protruding parts protruding from the lower surface 14 for transferring the holding force.

The lower connector housing part 15 comprises a main recess 16 for receiving the second portion 10 of the connector contact 5. An opening 17 of the main recess 16 is provided in an upper surface 18 of the lower connector housing part 15. In use, the upper surface 18 faces a lower surface of the piece of foil to which the connector housing parts 11, 15 are attached.

During connection, the pins 12, 13 protruding from the lower surface 14 are inserted from above into the film web through the respective holes. The pins are inserted into the first and second channels 19, 20, respectively. To this end, the first and second channels 19, 20 have openings 21, 22, respectively, provided in the upper surface 17 of the lower connector housing part 15. The lower and upper surfaces 14 and 18 are drawn towards the upper and lower surfaces, respectively, of the piece of film interposed therebetween. When the lower surface 14 and the upper surface 18 are sufficiently close to the opposite upper and lower surfaces of the inserted piece of foil, the pins 12, 13 protrude from the end of the channels 19, 20 opposite the openings 21, 22. The protruding parts of the pins 12, 13 are adapted to exert a holding force in engagement with holding means (not shown). The retention force causes the first and second connector housing parts to abut the membrane. The holding means engaging the pins 12, 13 abut part of the surface of the lower connector housing part around the exit of the channels 19, 20 on the other side of the openings 21, 22.

Some examples of holding devices include tie-wrap and steel-lock. In a further embodiment, the channels 19, 20 comprise at least a threaded portion, and the pins 12, 13 are likewise provided with an external thread. However, resilient clamping means are preferred when the upper and lower connector housing parts 11, 15 are preferably made of plastic, while the pins 12, 13 are formed integrally with the upper connector housing part 11. In principle, it is also possible to melt the parts of the pins 12, 13 which project beyond the channels 19, 20. The elasticity of the material of the pins 12, 13 then provides the holding force. The flared ends of the pins 12, 13 formed by melting can also be considered as a kind of holding means.

In another embodiment, the lower connector housing part 11 comprises pins 12, 13. The pin thus projects from the upper surface 18, on which the opening of the main recess 16 is likewise located. In a first variant, the connector housing assembly comprises only holding means on the side from which the pins 12, 13 protrude when the foil is inserted through the hole. This is useful when the upper surface of the membrane is intact when the connector contacts are connected. In another variant, the upper connector housing part 11 is provided with passages 19, 20 and openings 21, 22. Alternatively, each of the upper and lower connector housing parts 11, 15 may comprise one of the pins 12, 13, while the other is provided with one of the openings 21, 22 for receiving the pin 12, 13 extending thereto from the upper or lower surface of the foil, depending on which surface it faces.

Returning to the embodiment shown in fig. 3 and 4, the upper connector housing part 11 has an upper surface 23, the opposite lower surface 14 of which, in use, faces the upper surface of the piece of foil. The upper surface 23 is almost planar, except for its rounded edges, and also almost horizontal. When the upper connector housing part 11 is sufficiently close to the upper surface of the piece of foil, the upper connector housing part 11 is almost parallel to the upper surface of the piece of foil. The sufficiently close composition is defined by the particular embodiment of the upper connector housing part 11. The distance from the lower surface 14 to the upper surface of the film should be less than a certain distance. At least when the lower surface 14 is most likely to be near the film. In one embodiment, the lower surface 14 may be contiguous. In another embodiment the sealing means between the upper connector housing part 11 and the foil determines the final distance between the lower face 14 and the upper face of the foil.

These sealing means can be provided, for example, along the edge 24 of the second recess 25 of the upper connector housing part 11. The second recess 25 is configured to receive the portion of the teeth 9 protruding above the upper surface of the film. It also covers the area around the protruding part. In particular, when the above-mentioned sealing means are arranged around the edge 24, the fact that the teeth 9 tear the upper surface of the film does not therefore result in a large exposure of the part embedded in the film. For this purpose, the lower surface 14, i.e. the surface opposite to the upper surface of the film in use, is provided with an opening 26 of the second recess 25.

A number of measures are provided to reduce the influence of the upper connector housing part 11 on the ability of the foil to absorb incident radiation in the solar cell 2.

First, the height of the upper connector housing part 11 should be as low as possible. Height in this case refers to the distance from the lower surface 14 to its opposing upper surface 23. Preferably, it should be less than twice the depth of the second groove 25 as measured from the opening 26 of the second groove 25 to its opposing inner wall 27.

Secondly, in a preferred manner of connecting the connector to the film, the pins 12, 13 are inserted through holes punched through the busbar 3. In a practical embodiment, the busbars 3 have a width value in the plane of the film in the range between 0.5 and 1 cm. The punched hole diameter is preferably less than 80% of the width of the bus bar 3 embedded in the film.

Third, as is apparent from fig. 3, the upper connector housing part 11 has an elongated shape. The upper connecting housing part also has an elongated profile when viewed in a direction perpendicular to the lower surface 14 or the upper surface 23 due to its low height. The upper connector housing part also has an elongated shape when viewed in at least one direction perpendicular to the lower face 14. Since the two pins 12, 13 are preferably inserted through punched holes through the bus bar 3, the longitudinal axis of the upper connector housing part 11 is automatically located in a direction almost parallel to the bus bar 3. Thus, a substantial portion of the upper connector housing part 11 covers the bus bar 3 in use and not any solar cells 2.

Fig. 4 most clearly shows further aspects of the lower connector housing part 15. The upper surface 18 of the lower connector housing part 15 is advantageously configured to incorporate sealing means to ensure continuous contact with the foil along a contact area that almost completely surrounds the opening 17. In the embodiment shown, the sealing means are provided in an annular groove 28 and/or along the edges 29, 30 of the openings 21, 22 for receiving the projecting pins 12, 13. Alternatively, ridges, which are an integral part of the lower connector housing part 15, may be used as sealing means. These bumps must be shaped and polished so as to abut the lower surface of the film over a contact area that almost completely surrounds the opening 17 when the upper surface 18 is sufficiently drawn to the lower surface of the film. By "sufficient" it is meant that the distance between the upper surface 18 and the lower surface of the film is less than a minimum value required to ensure proper contact.

The second part 10 of the terminal 6 including the connector contact 5 is accommodated in a cylindrical cavity (enclosure) 31. The cavity 31 opens into the main recess 16 at the upper end of the longitudinal axis 32. An external interface to a connector contact of a mating connector is provided at a lower end of the longitudinal shaft. It should be noted that the longitudinal axis 32 is almost perpendicular to the upper surface 18 of the lower connector housing part 15.

A retention hook (barb)33 is provided as part of a locking mechanism that engages a mating connector housing, as will be described in more detail below.

Fig. 5-8 relate to additional connector housing assemblies. Which has most of the same features as the connector housing assembly discussed previously. The following discussion is limited to repeating the relevant features and discussing the differences between the two components. Reference is made to the foregoing discussion for further details.

The upper connector housing part 34 is disposed over an upper surface of the piece of solar foil. In use, the lower surface 35 faces the upper surface of the piece of foil. The upper surface 36 turns in the opposite direction. Both the upper and lower surfaces 35, 36 are almost planar and parallel. The height of the upper connector housing part 34, i.e. the distance between the lower surface 35 and the upper surface 36, is so low that the upper connector housing part 34 is elongate, as is the case with the upper connector housing part 11 in fig. 3-4.

A projection 37 is formed integrally with the upper connector housing part 34 and projects from the lower surface 35. In use, the projections 37 are inserted through the holes in the piece of foil, as are the pins 12, 13 of the embodiment shown in figures 3-4. The same measures are used to ensure that the upper connector housing part 34 does not cover as much of the surface area of the solar cell 2 as possible.

Fig. 6-7 show the lower connector housing part 38. Which comprises a main recess 39 for receiving the first part 7 of the connector contact 5. An opening 40 of the main recess is provided in an upper surface 41 of the lower connector housing part 38. In use, the upper surface 41 faces the lower surface of the membrane. The projection 37 of the upper connector housing part 34 is received in an extension opening 42 of the opening 40, the opening 42 also being provided in the upper surface 41. A bushing 43 (fig. 8) is received in the lower connector housing part 38. External threads are provided on both the protrusion 37 and the bushing 43 to connect the upper connector housing part 34 and the lower connector housing part 38. Screwing the components together ensures that the upper and lower connector housing parts 34, 38 are drawn towards each other to clamp the piece of foil between the upper surface 41 and the lower surface 35.

The projection 37, when received in the lower connector housing part 38, defines a cavity in a position indicated by reference numeral 44 together with a downwardly extending wall part 45. The longitudinal axis 46 of the cavity is almost perpendicular to the upper surface 41. At the opposite end of the opening 42 in the upper surface 41, the cavity provides an external interface to the terminal 6. The lower connector housing part 38 is adapted to engage a mating connector provided with male contact terminals. To maintain engagement, a locking mechanism is used. The locking mechanism includes a retaining hook 47.

A groove 48 is provided in the upper surface 41 to engage with the sealing means. When the upper and lower connector housing parts 34, 38 are screwed together, a sealing means 38 (not shown) abuts the lower surface of the membrane. The groove 48 completely surrounds the opening 40 of the main recess 39 and the opening 42 for receiving the projection 37. Therefore, the sealing of the main groove 39 with the cavity accommodating the terminal 5 is enhanced.

Fig. 9 shows the mating connector housing 49. Conducting wire(not shown) is received in an elongate channel 50 which terminates in a cavity 51 for receiving a terminal of a male connector contact (not shown) connected to a wire. The male connector contact is adapted to mate with the connector contact 5 shown in fig. 1. In a practical embodiment of the connection to the solar foil, the wires have a diameter in the range of 2.5-6mm²Cross-sectional area between the ranges. A single core wire made of copper or aluminum is used, and an insulating sheath made of polyolefin or polytetrafluoroethylene is coated outside the single core wire. The diameter of the wire core is within the range of 2-3 mm. The outer diameter of the wire is in the range of 5-6 mm. For example, the nominal voltage of the wire is 1000V DC. In an example, its rated current may reach 60A.

The mating connector housing 49 is adapted to engage the lower connector housing part 15 shown in fig. 4 or the lower connector housing part 38 shown in fig. 7. The lower connector housing parts 15, 38 and the mating connector housing 49 are configured such that the longitudinal axis 52 of the elongate passage 50 is almost parallel to the longitudinal axis 32 or 46, respectively, of the cavity accommodating the terminal 5. Thus, when forming an assembly of the mating connector housing 49 and one of the illustrated connector housing assemblies attached to the film, it is ensured that the wires intersect the film plane, preferably perpendicular to the film plane.

The latches 53 engage the retaining hooks 33 or 47, respectively, when the mating connector housing is engaged with the lower connector housing part 15 or 38, respectively. Latch 53 and retaining hook 33 or 47 together form a locking mechanism to provide strain relief to the wire in elongate passage 50.

The annular groove 54 is for engaging a sealing device (not shown). The sealing means ensures that the connection of the mating connector housing 49 to either of the lower connector housing parts 15, 38 is sufficiently water-tight.

The upper and lower connector housing parts 11, 34, 15, 38 in the actual embodiment shown are all made of a polymeric material having good uv resistance. The part is manufactured to withstand thermal changes over a relatively large temperature difference range, for example from-40 ℃ to 85 ℃. The connector housing assembly shown here can be applied directly to the foil, since it provides good protection for the connector contact 5 and the area of the foil adjacent to the connector contact 5. Without the need for additional sealing. Furthermore, the connector housing assembly shown is suitable for use with solar thin film cells that are adhered to a back surface without encapsulation. This is in contrast to the connector housing assembly of a solar array cell, where the solar thin film cell is enclosed in a (rigid) housing. Since the shape of the film sheet and the position to be connected to the connector are not strictly defined, the connection to the connector is easy. Furthermore, since the projections 37 and pins 12, 13 are formed integrally with their respective connector housing parts, there are relatively few component parts, which can be easily installed in remote areas.

The invention is not limited to the embodiments described above, which may be varied within the scope of the appended claims. For example, although only an embodiment having two protruding members for holding the upper and lower connector housing parts together is shown, there may be more protruding members. Each insertable through an aperture in the film held between the upper and lower connector housing parts. The holding means can only engage with a subset of the presented protruding parts.

Claims (15)

1. A connector housing assembly for accommodating a connector contact (5) for connecting a wire to a conductive lead (3) embedded in a piece of foil (1), the connector housing assembly comprising at least one connector housing part (11, 15, 34, 38), wherein the at least one connector housing part (11, 15, 38) comprises a recess (16, 25, 39) for accommodating at least a part of the connector contact (5), a surface of the connector housing part (14, 18, 41) facing a surface of the piece of foil being provided with an opening (17, 26, 40) of the recess (16, 25, 39), wherein the at least one connector housing part (11, 34) comprises at least one protruding part (12, 13, 36) protruding beyond the connector housing part (11) facing the surface of the piece of foil in use, 34) Each of said protruding parts (12, 13, 36) being adapted to be inserted through a respective hole in a piece of foil adjacent to the protruding surface (14, 35), characterised in that:

the connector housing assembly is configured to exert a holding force by at least one of the protruding parts (12, 13, 36) pulling a surface (14, 18, 41) of the connector housing part provided with a recess opening towards a surface of the facing piece of foil.

2. The connector housing assembly of claim 1, wherein:

a first of the two connector housing parts (11, 15, 34, 38) comprises said recess, at least one of the two connector housing parts (11, 15, 34, 38) is composed of one of the at least one connector housing part (11, 34) comprising at least one protruding part (12, 13, 36), the other of the two connector housing parts (11, 15, 34, 38) is provided with at least one opening (21, 22, 42) for receiving a protruding part (12, 13, 36) inserted through a hole in the piece of foil, said protruding part extending towards a surface (18, 41) of said other connector housing part (15, 38) facing a surface of said piece of foil, the other connector housing part is configured to exert a retention force pulling the two connector housing parts towards each other by at least one of the received protruding parts.

3. The connector housing assembly of claim 2, wherein:

at least one of the two connector housing parts (11, 15, 34, 38) is provided with a surface (23, 36) which, in use, is opposite a surface (18, 41) facing the surface of the piece of foil, the opposite surface (23, 36) being substantially planar and parallel to the surface of the piece of foil at least when the connector housing part (11, 34) is drawn sufficiently towards the piece of foil.

4. The connector housing assembly of claim 2 or 3, wherein:

at least one of the two connector housing parts is provided with a recess (25) having an opening (26) in a surface (14) of the connector housing part (11) which in use faces the surface of the piece of foil, and a surface (23) opposite the surface (14) which in use faces the surface of the piece of foil, wherein the distance between the opposite surfaces (14, 23) is less than twice the depth of the recess as measured from the opening (26).

5. The connector housing assembly of any of claims 1-4, wherein:

a first of the two connector housing parts (11, 15) comprises said recess (16), wherein a second of the two connector housing parts (11, 15) comprises a second recess (25) for accommodating at least a portion (9) of a received connector contact (5) protruding from a surface of the piece of foil facing in use, and a surface (14) of the second connector housing part (11) provided with an opening (26) of the second recess (25).

6. The connector housing assembly of any of claims 1-5, wherein:

at least one surface (18, 41) of the connector housing part (15, 38) provided with a recess opening (17, 40) is configured to engage with sealing means adapted to abut the facing piece of foil surface over a contact area substantially surrounding the recess opening when the surface of the connector housing part (15, 38) is sufficiently drawn towards the facing piece of foil surface.

7. A connector housing assembly according to any one of the preceding claims, wherein said connector housing part (11, 34) is integrally formed with at least one of said protruding parts (12, 13, 36) it comprises.

8. A connector housing assembly as claimed in any preceding claim, wherein:

the connector housing part (15, 38) including the recess (16, 39) comprises a portion (45) provided with a cavity (31, 44) accommodating a terminal (6) of a received connector contact (5), the cavity opening into the recess (16, 39) near one end of a longitudinal axis (32, 46) thereof which intersects a surface (18, 41) of the connector housing part (15, 38) facing, in use, the surface of the piece of foil, and being provided with an external interface at an opposite end of the longitudinal axis in a direction parallel to the axis.

9. The connector housing assembly of claim 8, wherein at least one of the connector housing pieces is adapted to engage a housing (49) of a mating connector, the housing end being connected to a wire of a conductive lead embedded in the piece of foil.

10. A connector housing assembly according to claim 9, comprising retaining means (33, 47) for maintaining engagement with the mating connector housing (49).

11. A method of connecting a connector for connecting wires to conductive leads (3) embedded in a piece of foil to the foil, comprising: connecting a connector contact (5) having a terminal (6) for connecting a wire to the conductive lead (3) to the film; providing a connector housing assembly comprising at least one connector housing part (11, 15, 34, 38) comprising a recess (16, 25, 39) for accommodating at least a part of the connector contacts, and a surface (14, 18, 41) of the connector housing part (11, 15, 38) facing the face of the piece of foil, provided with an opening (17, 26, 40) of the recess (16, 25, 39); inserting at least one protruding member (12, 13, 36) protruding from a surface (14, 35) of a connector housing part (11, 34) facing said surface of the piece of foil through a respective hole in said piece of foil; and drawing the surface (14, 18, 41) of the connector housing part (11, 15, 38) provided with the recess opening (17, 26, 40) towards the facing surface of the piece of foil, characterised in that:

-initiating engagement of at least one of said inserted protruding parts (12, 13, 36) on a side of the piece of foil opposite to the connector housing part (11, 34) provided with the protruding part (12, 13, 36) by holding means adapted to exert a holding force pulling a surface (14, 18, 41) of the connector housing part (11, 15, 38) provided with the recess opening towards the facing surface of the piece of foil.

12. A method according to claim 11, wherein at least one protruding member (12, 13, 36) is inserted through a hole in a conductive lead embedded in the piece of foil.

13. The method of claim 11 or 12, comprising:

-providing a further connector housing part (11, 34) having an elongated profile, wherein at least one of the two connector housing parts is provided with at least one opening (21, 22, 42) for receiving a protruding member (12, 13, 36) protruding from a surface (14, 35) of the other connector housing part (11, 34) facing the surface of the piece of foil and inserted through a hole in the piece of foil; further comprising: -positioning the further connector housing part (11, 34) over the conductive leads with its longitudinal axis almost parallel to the conductive leads.

14. The method of any of claims 11-13, wherein the provided connector housing assembly comprises a connector housing assembly of any of claims 1-10.

15. An assembly comprising a connector housing assembly and a housing of a mating connector, wherein the connector housing assembly comprises the connector housing assembly of claim 9 or 10.