US 12,407,295 B2
Lead assembly for connecting solar panel arrays to inverter
Dean Solon, Gallatin, TN (US)
Assigned to Shoals Technologies Group, LLC, Portland, TN (US)
Filed by SHOALS TECHNOLOGIES GROUP, LLC, Portland, TN (US)
Filed on Mar. 21, 2025, as Appl. No. 19/086,937.
Application 19/086,937 is a continuation of application No. 18/739,127, filed on Jun. 10, 2024.
Application 18/739,127 is a continuation of application No. 18/341,655, filed on Jun. 26, 2023, granted, now 12,015,375, issued on Jun. 18, 2024.
Application 18/341,655 is a continuation of application No. 17/301,609, filed on Apr. 8, 2021, granted, now 11,689,153, issued on Jun. 27, 2023.
Application 17/301,609 is a continuation of application No. 14/849,458, filed on Sep. 9, 2015, granted, now 10,992,254, issued on Apr. 27, 2021.
Claims priority of provisional application 62/047,773, filed on Sep. 9, 2014.
Prior Publication US 2025/0219573 A1, Jul. 3, 2025
Int. Cl. H02S 40/30 (2014.01); H01R 4/70 (2006.01); H01R 9/03 (2006.01)
CPC H02S 40/30 (2014.12) [H01R 4/70 (2013.01); H01R 9/03 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A lead assembly for use in a solar energy installation, the lead assembly comprising:
a first feeder cable having a first diameter and a first polarity;
a second feeder cable having a second diameter and a second polarity; and
a plurality of drop lines;
wherein:
each of the first feeder cable and the second feeder cable contains two or more joints;
each joint electrically couples one or more drop lines of the plurality of drop lines to the first or second feeder cable at a nexus;
each drop line has a diameter that is less than the first diameter and less than the second diameter;
each drop line coupled to the first feeder cable is configured to be electrically connected to a wire harness configured to electrically connect to an array of solar panels;
two or more of the plurality of drop lines that are connected to the first feeder cable each includes an in line fuse disposed between the joint and the wire harness; and
each joint has a mold enclosure configured to enclose at least a portion of the nexus;
wherein a first mold enclosure that encloses at least a portion of a first nexus of the first feeder cable includes:
a feeder cable passage that extends completely through the first mold enclosure, the first feeder cable extending through the feeder cable passage along a first longitudinal axis;
a first drop line passage that extends at least partially through the first mold enclosure, a first drop line of the plurality of drop lines extending through the first drop line passage along a second longitudinal axis; and
a second drop line passage that extends at least partially through the first mold enclosure, a second drop line of the plurality of drop lines extending through the second drop line passage along a third longitudinal axis;
the first and second drop lines are part of a single drop line cable and the first and second drop line passages form a drop line cable passage that extends completely through the first mold enclosure.