Material/gauge transition connectors for photovoltaic wiring systems

A wiring harness for forming electrical connections comprising:

• a plurality of multi-terminal metal transition connectors;
• and
• a plurality of electrical cables segments connecting the plurality of multi-terminal metal transition connectors,
• wherein the plurality of electrical cable segments include an electrical cable segment connected between a first multi-terminal metal transition connector and a second multi-terminal metal transition connector, and
• wherein each of the plurality of multi-terminal metal transition connectors comprises:
• a metal transition conductor;
• a terminal portion of a first electrical cable electrically and mechanically coupled to the metal transition conductor;
• a terminal portion of a second electrical cable electrically and mechanically coupled to the metal transition conductor;
• a terminal portion of a third electrical cable electrically and mechanically coupled to the metal transition conductor;
• wherein the metal transition conductor comprises a metal plate,
• wherein at least two of the first electrical cable, second electrical cable, and third electrical cable comprise conductors of different metal materials, and
• wherein at least two of the first electrical cable, second electrical cable, and third electrical cable comprise conductors of different wire gauges;
• and
• a mold structure encasing the metal transition conductor, the terminal portion of the first electrical cable, the terminal portion of the second electrical cable, and the terminal portion of the third electrical cable.

A solar power system, comprising:

• a combiner box;
• at least one row of solar panels, the row comprising a plurality of solar panel strings;
• a positive terminal wiring harness and a negative terminal wiring harness, each electrically connected between the combiner box and the at least one row of solar panels;
• wherein each of the positive and negative terminal wiring harnesses comprises a plurality of connectors, wherein each connector comprises:
• a metal transition conductor;
• a terminal portion of a first electrical cable electrically and mechanically coupled to the metal transition conductor;
• a terminal portion of a second electrical cable electrically and mechanically coupled to the metal transition conductor;
• a terminal portion of a third electrical cable electrically and mechanically coupled to the metal transition conductor;
• wherein the metal transition conductor comprises a metal plate,
• wherein each of the first electrical cable, second electrical cable, and third electrical cable terminates at the metal transition conductor,
• wherein at least two of the first electrical cable, second electrical cable, and third electrical cable comprise conductors of different metal materials, and
• wherein at least two of the first electrical cable, second electrical cable, and third electrical cable comprise conductors of different wire gauges;
• and
• a mold structure encasing the metal transition conductor and the terminal portions of the first, second, and third electrical cables.

A method of manufacturing an apparatus for forming electrical connections, the method comprising the steps of:

• providing a first electrical cable, a second electrical cable, and a third electrical cable, wherein at least two of the electrical cables comprise conductors of different metal materials, and wherein at least two of the electrical cables comprise conductors of different wire gauges;
• electrically and mechanically coupling a terminal portion of the first electrical cable, a terminal portion of the second electrical cable, and a terminal portion of the third electrical cable to a metal transition conductor, such that each cable terminates at the metal transition conductor, wherein the metal transition conductor comprises a metal plate;
• and
• forming a mold structure to encase the metal transition conductor, the terminal portion of the first electrical cable, the terminal portion of the second electrical cable, and the terminal portion of the third electrical cable.