HK1130572A - Electrical connection system - Google Patents

Description

Electrical connection system

Technical Field

The present invention relates to an electrical connection system for providing an electrical connection between a first device or component and a second device or component.

Background

The invention has been developed in view of the need to provide electrical connections between adjacent separated photovoltaic cells or tiles, for example the invention may be provided within a solar power panel or on a roof provided with solar cell roof tiles.

The electrical connections between such separate cells or tiles may be formed using conventional methods, such as: welding a lead;

using a connecting block, which generally comprises a block of insulating material housing a conductive tube containing a plurality of wires and screws that can be screwed into the tube to mechanically and electrically engage the wires; and

a matching plug is used.

However, this method of connection is problematic for photovoltaic cells used in tiles because of the need to make connections on the sides of the cells or tiles attached to a support structure such as a roof beam.

Although the invention was originally developed for applications relating to photovoltaic cells and solar shingles, embodiments of the invention may be applied to any application where it is desirable to electrically connect two or more devices or components. For example, embodiments of the present invention may be used to electrically connect rows of one or more sensors to a processor.

It will be understood that, if any prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art, in australia or in any other country.

Disclosure of Invention

An electrical connection system for providing an electrical connection between a first device and a second device, the electrical connection system comprising:

at least one electrically connected post, the or each post having a first end and a second end, the first end being configured to electrically connect with a first device; and

at least one electrically connected tube, the or each said tube having an opening to receive the second end of the respective column and provide an electrical connection thereto, and an end connector at each axial end of the tube, the end connector being configured to be electrically connected with an end connector of an adjacent tube, wherein a second device can be electrically connected with an end connector of the tube and thereby with the first device.

The opening in each tube may comprise a longitudinal groove for receiving the second end of the post, the longitudinal groove leaving at least one end of the tube open.

In one embodiment, the longitudinal grooves are open on both ends of the tube.

The system may further comprise at least one secondary groove extending from the longitudinal groove, the or each secondary groove being configured to receive the second end of a respective post and provide an electrical connection with the second end of a respective post.

Each tube may further include a first conductor extending between the respective end connectors and electrically connected to the first set of secondary slots and a second conductor extending between the respective end connectors and electrically connected to the second set of secondary slots, wherein the first and second conductors are electrically insulated from each other.

In one embodiment of the system, each tube is further provided with a complementary connection at each end to effect a mechanical connection between adjacent tubes.

Drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a schematic representation of an electrical connection post incorporated into an electrical connection system;

FIG. 2 is a perspective view of an electrical connection tube incorporated into the electrical connection system;

FIG. 3 is a plan view of the tube shown in FIG. 2; and

FIG. 4 is a cross-sectional view of the tube shown in FIGS. 2 and 3;

FIG. 5 is a cross-sectional elevation view of a bottom tile incorporated into an embodiment of an electrical connection system according to the present invention;

FIG. 6 is a top elevational view of the bottom tile illustrated in FIG. 5;

FIG. 7 is a bottom elevation view of a cover tile incorporated into an optoelectronic tile assembly;

FIG. 8 is a top elevation view of the overlay tile shown in FIG. 7;

FIG. 9 is a side cross-sectional view of an optoelectronic tile assembly incorporating an electrical connection system, a bottom tile and a cover tile; and

fig. 10 is a lateral side view of the photovoltaic tile assembly shown in fig. 9.

Detailed Description

Referring to the drawings and in particular to fig. 1 and 2, an embodiment of an electrical connection system 10 for providing an electrical connection between a first device and a second device includes one or more electrical connection posts 12 (shown in fig. 1) and one or more electrical connection tubes 14 (shown in fig. 2). Each post 12 has a first end 16 and an opposite second end 18, wherein the first end 16 is configured to be electrically connected to a first device, such as a photovoltaic cell 20. As best seen in fig. 2, each tube 14 has an opening 22 to receive and provide an electrical connection with the second end 18 of a respective post 12. A first end connector 24 and a second end connector 26 are disposed at respective opposite axial ends of the connecting tubes 14 to enable end-to-end electrical connection between adjacent tubes 14. The end connectors 24 and 26 facilitate electrical connection to a second device.

In embodiments described in more detail below, where the electrical connection system 10 is incorporated into a photovoltaic tile assembly (photovoltaic tile assembly), the photovoltaic cell 20 can be considered a first device and the power management system and/or electrical storage device, such as a battery, can be considered a second device. Thus, the connection system 10 can provide an electrical connection between the photovoltaic cells 20 and a management unit or storage device.

Fig. 5-10 illustrate an optoelectronic tile assembly 28 incorporating electrical connection system 10. The tile assembly 28 includes a bottom tile (base tile)30 and one or more cover tiles (cover tiles) 32, each cover tile 32 having one or more PV cells 20.

Although the specific construction of tile assembly 28 is not critical to panel-shaped connection system 10, tile assembly 28 is described to provide context to one particular application of connection system 10. The bottom tile 30 is in the shape and form of a square plate having a flat and substantially continuous upper surface 34, the continuity of which is interrupted only by a series of laterally extending holes 36 into which the posts 12 are inserted. The underside 38 of the bottom tile 30 is formed with a plurality of walls or ribs that divide the underside 38 into a plurality of distinct regions. In this particular embodiment, each of the four corners 40 of the bottom tile 30 is made of a solid material that can be used to receive a mechanical fastener such as a nail or screw.

A pair of parallel walls 42 extend between opposite side edges 44 and 46 of the bottom tile 30 and partially border the solid portion 40. The bottom tile 30 also includes a wall 48 extending perpendicular to the wall 42, the wall 42 also bounding each side of the solid portion 40. The walls 48 extend between respective adjacent side edges 50, 52 of the bottom tile 30 and the nearest wall 42. With this arrangement, the underside 38 of the bottom tile 30 is formed with a compartment 54 adjacent the sides 50 and 52, and a larger central compartment 56 between the walls 42. As best shown in fig. 10, the wall 42 is provided with a recess 58 for receiving the tube 14.

To help provide a watertight connection between adjacent tile assemblies 28, each bottom tile 30 is provided along two longitudinal edges, each longitudinal edge having a laterally extending tongue 60, each tongue 60 being provided with a longitudinally extending rubber seal 62 on their upper and lower surfaces. Two complementary grooves 64 are formed along the remaining two sides of the bottom tile 30 for receiving the tongues 60 of an adjacent bottom tile 30.

Referring specifically to fig. 1, 2, 9 and 10, it can be seen that each post 12 is in the form of a tube and has an opening at its first end 16 for receiving an end cap in the form of a rubber grommet 66. The end cap or snap ring 66 may be made of a resilient material such as rubber and retained in the end 16 by one or both of an interference fit and the use of an adhesive. For example, the snap ring 66 may be provided with a plurality of circumferential ribs that are crushed by inserting the snap ring 66 into the end 16, thereby providing an interference fit. Further, the adhesive may be applied to the ribs or to the inside of the post 12 at the end 16. However, in further variations, if desired, the cap may be formed from a combination of a threaded fastener and a rubber seal and/or washer retained on the shank of the fastener by the head of the fastener, with complementary threads for mating with a fastener formed in the post adjacent the end 16.

The post 12 itself is made of a conductive material, such as steel or stainless steel, so that current can flow between the ends 16 and 18 of the post 12.

In the illustrated embodiment, the post 12 is formed with a pair of circumferentially and axially spaced grooves or recesses 68. The recesses 68 receive corresponding projections formed in the holes 36 in the bottom tile 30, with the posts 12 inserted into the holes 36. The projections cooperate with the grooves or recesses 68 to form a watertight seal between each column 12 and the bottom tile 30.

An electrically conductive spring 70 is electrically and mechanically connected to the end 18 of each post 12. This may be accomplished, for example, by welding or spot welding the spring 70 to the end 18. However, in further variations, the spring 70 may be formed separately from the post 12 and attached to the post 12 after installation thereof. This may be accomplished, for example, by using a screw that may be threadably engaged at end 18 with mating threads formed on the inside of post 12 and a separate spring held on the head of the screw. In this variant, the post 12 may be provided with an external thread, so that the post can be screwed into the substrate or article, instead of being pushed through the hole. In another possible variation, the first end 16 may be formed with an integral cap or head.

As previously described, each tube 14 includes an opening 22 to receive the second end 18 of the post 12 and provide an electrical connection thereto. Each opening 22 includes a longitudinal groove 72 and a plurality of secondary grooves 74 extending from the longitudinal groove 72, the grooves 72 extending the entire length of the tube 14 in this embodiment. The secondary groove 74 includes a first length 76 extending in a circumferential direction, a second length 78 extending in an axial direction, and a circular portion 80, the circular portion 80 configured to function as an electrical contact.

The first end connector 24 may be in the form of a spring loaded or biased pin or plug, while the second end connector 26 may be in the form of a socket. The pin or plug 24 may be withdrawn to be substantially flush with the adjacent end of the tube 14 during connection of the tube 14. In yet another variation, the slots 26 may also be formed to retract linearly under the influence of a biasing mechanism, such as a spring, so that they may extend in an axial direction from the adjacent end of the tube 14. In yet another variation, the first end connector 24 may be in the form of a spring-biased conductive ball that is retained in the adjacent end of the tube 14 and is biased such that a portion of each ball may extend from an axial end of the tube 14 while being retained in the tube 14. In this variation, the second end connector 26 may be in the form of a cup or recess formed in the opposite end of the tube 14 for receiving a corresponding portion of the ball projecting from the adjacent tube 14.

As can be seen from the drawings, in this particular embodiment there are two first end connectors 24 at one end of the tube 14 and two second end connectors 26 at the opposite end of the tube 14. The first conductor 82 connects one of the first end connectors 24 to one of the second end connectors 26 and also provides an electrical connection with a set of secondary slots 74, and in particular with the circular portion 80 at the end of each secondary slot 74. Similarly, the second conductors 84 provide electrical connections between the remaining first and second end connectors 24, 26 and the second set of secondary slots 74 and corresponding circular portions 80. More specifically, conductors 82 and 84 provide electrical connection to alternating circular portions 80 that are electrically connected to positive terminal 86a and negative terminal 86b of PV cell 20. Thus, in effect, the positive terminal 82a of each PV cell 20 is electrically connected to the conductor 82, while the negative terminal 86b of each PV cell 20 is electrically connected to the conductor 84.

Terminals 86a and 86b (hereinafter generally referred to as "terminals 86") are in the form of through holes 87 formed in each of the covering tiles 32 and provided with a conductive surface. Contact between the post 12 and the surface of the hole 87 formed in the cover tile 32 and the outer surface of the post 12 provide an electrical connection. To enhance the electrical connection, the post 12 may also be provided with one or more biased contact surfaces, such as a spring or resilient member 88 near the first end 16. The spring 88 may be in the form of a conventional "banana plug", for example.

Each axial end of the tubes 14 may be provided with some form of mechanical connection to effect connection of the ends of adjacent tubes 14. This may be achieved, for example, by some form of interference fit, or by using a "snap connector" between adjacent tubes 14. The particular form of mechanical connection at each end of the tube 14 is not important to the function or operation of the embodiment of the connection system 10.

The manner in which electrical connection system 10 operates will be described with reference to the process of constructing and installing tile assembly 28 on a structure such as a wooden roof frame. Initially, the post 12 without the corresponding cap or snap ring 66 is pushed into the hole 36 formed in the bottom tile 30 and the second end 18 is pushed through the hole from the surface 34. The post 12 is pushed so that the end 18 and in particular the spring 70 extends into the recess 58. The post 12 is sized such that the first end 16 extends above the surface 34 when the spring 70 is positioned in the recess 58. Once all of the posts 12 are inserted into the holes 36 in the bottom tile 30, each tube 14 may be placed in a respective recess 58 with the end 18 and the spring 70 located within the longitudinal groove 22. This may generally be accomplished by sliding the tube 14 into its corresponding recess 58 so that the spring 70 is located inside the tube 14. The tube 14 is slid to a position where the end 18 of each post 12 and the spring 70 are adjacent the corresponding secondary groove 74. The tube may then be rotated a distance equal to the first length 76 of the channel 74 to place the end 18 adjacent the second length 78 of the secondary channel 74. The tube may then be slid in the axial direction again so that the end 18 is finally placed in the circular portion 80 and the spring 70 bears against the inner surface of the tube 14 around the circular portion 80. Thus, electrical connection is provided from the terminal 86 to the conductors 82 and 84, and thus to the respective first and second end connectors 24 and 26, via the post 12. The bottom tile 30 may be secured in place on the support structure, for example, by driving nails or screws through the solid portion 40 onto the underlying elements of the framework.

A second tile, which has been assembled in the same manner as described above, can then be placed adjacent to the previously placed tile, with the respective tongue and groove portions in engagement with each other. The electrical connection between adjacent tubes 14 is achieved by the interengagement and electrical connection between the first end connector 24 or the second end connector 26 of one tube 14 and the second end connector 26 and the first end connector 24 of the adjacent tube 14. Thereby, an electrical connection path is formed along the adjacent tubes 14 to a second device, such as an electrical energy management unit, or a storage device such as a battery.

Obvious modifications and variations to the electrical connection system 10, which would be apparent to a person of ordinary skill in the art, are considered to be within the scope of the present invention, the nature of which is to be dependent upon the foregoing description and the appended claims.

Such modifications and changes may include, for example, forming the tube 14 to have a square cross-sectional shape rather than a circular cross-sectional shape. In such an embodiment, the groove 72 and the secondary groove 74 would be formed on the same face of the tube. Further, the post 12 may be made primarily of an insulating material such as plastic or rubber, and have an embedded electrical conductor to enable electrical conduction. Other embodiments of electrical connection system 10 may be used in any application where electrical connection of two or more devices or components is desired, not just for photovoltaic tiles.

In the claims of this application and in the description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

It will be understood that, even if the application relates to any prior publication, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art, in australia or in any other country.

Claims (14)

1. An electrical connection system for providing an electrical connection between a first device and a second device, the electrical connection system comprising:

at least one electrically connected post, the or each post having a first end and a second end, the first end being configured to be electrically connected to a first device; and

at least one electrically connected tube, the or each said tube having an opening to receive and provide an electrical connection with the second end of the respective column, and an end connector at each axial end of the tube, the end connector being configured to be electrically connected with an end connector of an adjacent tube, wherein a second device can be electrically connected with an end connector of the tube, and thereby with the first device.

2. The system of claim 1, wherein the opening in each tube comprises a longitudinal groove for receiving the second end of the column, the longitudinal groove leaving at least one end of the tube open.

3. The system of claim 2, wherein the longitudinal groove is open on both ends of the tube.

4. A system as claimed in claim 2 or 3, further comprising at least one secondary groove extending from the longitudinal groove, the or each secondary groove being configured to receive the second end of a respective post and provide an electrical connection with the second end of a respective post.

5. The system of claim 4, wherein the tube further comprises a first conductor extending between the respective end connectors and electrically connected with the first set of secondary slots and a second conductor extending between the respective end connectors and electrically connected with the second set of secondary slots, wherein the first and second conductors are electrically insulated from each other.

6. A system as claimed in any one of claims 1 to 5, wherein the or each end connector comprises a first connector at one end of the tube, the first connector being movable between an extended position and a retracted position.

7. The system of claim 6, wherein the first connector is biased toward the extended position.

8. A system as claimed in claim 6 or 7, wherein the or each end connector comprises a second connector at the opposite end of the tube for receiving a respective first connector.

9. The system of claim 8, wherein the first connector is one of a pin or a ball; and the second connector is a socket.

10. A system as claimed in any one of claims 1 to 9, wherein each tube is further provided with a complementary connection at each end to effect a mechanical connection between adjacent tubes.

11. The system of any one of claims 1 to 10, further comprising a cap for each of the posts, the cap and the first end of the post being configured to mate with each other, the cap having a head extending transversely to the first end of the post.

12. The system of any one of claims 1 to 11, wherein the post forms at least one recess with at least one circumferential groove.

13. The system of any one of claims 1 to 12, wherein at least one of the posts is provided with a first resilient electrical connection at a first end of the post.

14. The system of any one of claims 1 to 13, wherein at least one of the posts is provided with a second resilient electrical connection means at the second end of the post.