Material/gauge transition connectors for photovoltaic wiring systems

An apparatus for forming electrical connection comprising:

• a metal material transition connector configured for deployment in a solar array wiring system, the metal material transition connector having a first metal portion and a second metal portion welded to the first metal portion at a welded region, the first metal portion comprising a first metal material and including a first recess configured to receive a proximal end of a first elongated conductor member comprising the first metal material, the second metal portion comprising a second metal material different from the first metal material and including a second recess configured to receive a proximal end of a second elongated conductor member comprising the second metal material, wherein the solar array wiring system comprises the first elongated conductor member and the second elongated conductor member,
• wherein the first metal portion of the metal material transition connector is mechanically fastened to and electrically connected with the proximal end of the first elongated conductor member while the proximal end of the first elongated conductor member is positioned in the first recess, and wherein the second metal portion of the metal material transition connector is mechanically fastened to and electrically connected with the proximal end of the second elongated conductor member while the proximal end of the second elongated conductor member is positioned in the second recess;
• one or more temperature-activated sealing members, wherein the one or more temperature-activated sealing members (a) circumferentially surround, and form a first seal against, at least a portion of the first elongated conductor member outside of the first recess while the proximal end of the first elongated conductor member is positioned in the first recess and is fastened to and electrically connected with the first metal portion of the metal material transition connector, and (b) circumferentially surround, and form a second seal against, at least a portion of the second elongated conductor member outside of the second recess while the proximal end of the second elongated conductor member is positioned in the second recess and is mechanically fastened to and electrically connected with the second metal portion of the metal material transition connector;
• an inner mold, wherein the inner mold encapsulates the metal material transition connector and at least partially encapsulates the one or more temperature-activated sealing members while the one or more temperature-activated sealing members circumferentially surround, and form the first seal against, the portion of the first elongated conductor member and circumferentially surround, and form the second seal against, the portion of the second elongated conductor member;
• and
• an outer mold, wherein the outer mold encapsulates the inner mold while the inner mold encapsulates the metal material transition connector and at least partially encapsulates the one or more temperature-activated sealing members.

An apparatus for forming electrical connection comprising:

• a portion of a first trunk cable of a first size;
• a portion of a second trunk cable of a second size smaller than the first size;
• one or more branch cables of a third size smaller than the second size;
• a metal gauge transition connector comprising:
• (1) a first metal material and having a first section and a second section, the first section including a first recess having a first internal diameter and configured to receive a proximal end of a first elongated conductor member comprising the first metal material, the second section including a second recess having a second internal diameter different from the first internal diameter and configured to receive a proximal end of a second elongated conductor member comprising the first metal material, wherein the solar array wiring system comprises the first elongated conductor member and the second elongated conductor member,
• wherein the first section of the metal gauge transition connector is mechanically fastened to and electrically connected with the proximal end of the first elongated conductor member while the proximal end of the first elongated conductor member is positioned in the first recess, and wherein the second section of the metal gauge transition connector is mechanically fastened to and electrically connected with the proximal end of the second elongated conductor member while the proximal end of the second elongated conductor member is positioned in the second recess;
• (2) one or more temperature-activated sealing members, wherein the one or more temperature-activated sealing members (a) circumferentially surround, and form a first seal against, at least a portion of the first elongated conductor member outside of the first recess while the proximal end of the first elongated conductor member is positioned in the first recess and is fastened to and electrically connected with the first section of the metal gauge transition connector, and (b) circumferentially surround, and form a second seal against, at least a portion of the second elongated conductor member outside of the second recess while the proximal end of the second elongated conductor member is positioned in the second recess and is mechanically fastened to and electrically connected with the second section of the metal gauge transition connector;
• (3) an inner mold, wherein the inner mold encapsulates the metal gauge transition connector and at least partially encapsulates the one or more temperature-activated sealing members while the one or more temperature-activated sealing members circumferentially surround, and form the first seal against, the portion of the first elongated conductor member and circumferentially surround, and form the second seal against, the portion of the second elongated conductor member;
• and
• (4) an outer mold, wherein the outer mold encapsulates the inner mold while the inner mold encapsulates the metal gauge transition connector and at least partially encapsulates the one or more temperature-activated sealing members;
• a trunk bus connector comprising a trunk pathway and at least one region of electrical contact, wherein the portion of the second trunk cable passes through the trunk pathway, the one or more branch cables are connected with the at least one region of electrical contact, and the trunk bus connector secures and provides electrical connection between the portion of the second trunk bus cable and the one or more branch cables,
• wherein the portion of the first trunk cable comprises the first metal material and is, as the first elongated conductor member, coupled to the first section of the metal gauge transition connector,
• wherein the portion of the second trunk cable comprises the first metal material and is, as the second elongated conductor member, coupled to the second section of the metal gauge transition connector, and
• wherein each branch cable of the one or more branch cables comprises the first metal material and is electrically coupled with the portion of the second trunk cable via the trunk bus connector.

An apparatus for forming electrical connection comprising:

• a metal gauge transition connector configured for deployment in a solar array wiring system, the metal gauge transition connector comprising a first metal material and having a first section and a second section, the first section including a first recess having a first internal diameter and configured to receive a proximal end of a first elongated conductor member comprising the first metal material, the second section including a second recess having a second internal diameter different from the first internal diameter and configured to receive a proximal end of a second elongated conductor member comprising the first metal material, wherein the solar array wiring system comprises the first elongated conductor member and the second elongated conductor member,
• wherein the first section of the metal gauge transition connector is mechanically fastened to and electrically connected with the proximal end of the first elongated conductor member while the proximal end of the first elongated conductor member is positioned in the first recess, and wherein the second section of the metal gauge transition connector is mechanically fastened to and electrically connected with the proximal end of the second elongated conductor member while the proximal end of the second elongated conductor member is positioned in the second recess;
• one or more temperature-activated sealing members, wherein the one or more temperature-activated sealing members (a) circumferentially surround, and form a first seal against, at least a portion of the first elongated conductor member outside of the first recess while the proximal end of the first elongated conductor member is positioned in the first recess and is fastened to and electrically connected with the first section of the metal gauge transition connector, and (b) circumferentially surround, and form a second seal against, at least a portion of the second elongated conductor member outside of the second recess while the proximal end of the second elongated conductor member is positioned in the second recess and is mechanically fastened to and electrically connected with the second section of the metal gauge transition connector;
• an inner mold, wherein the inner mold encapsulates the metal gauge transition connector and at least partially encapsulates the one or more temperature-activated sealing members while the one or more temperature-activated sealing members circumferentially surround, and form the first seal against, the portion of the first elongated conductor member and circumferentially surround, and form the second seal against, the portion of the second elongated conductor member;
• and
• an outer mold, wherein the outer mold encapsulates the inner mold while the inner mold encapsulates the metal gauge transition connector and at least partially encapsulates the one or more temperature-activated sealing members.

An apparatus for forming electrical connection comprising:

• a first metal material transition connector forming a metal transition connection between a first metal material and a second metal material, the first metal material transition connector having a first terminal configured for connection with a cable comprising the first metal material and a second terminal configured for connection with a cable comprising the second metal material;
• a second metal material transition connector forming a metal transition connection between the first metal material and the second metal material, the first metal material transition connector having a first terminal configured for connection with a cable comprising the first metal material and a second terminal configured for connection with a cable comprising the second metal material;
• a first junction connector comprising the first metal material and having a plurality of terminals including a first terminal, a second terminal, and a third terminal;
• a second junction connector comprising the first metal material and having a plurality of terminals including a first terminal, a second terminal, and a third terminal;
• a first cable of a first size comprising the first metal material and coupled with the first terminal of the first junction connector;
• a second cable of the first size, comprising the first metal material, and coupled with (1) the second terminal of the first junction connector and (2) the first terminal of the first metal material transition connector;
• a first cable of a second size larger than the first size, comprising the second metal material, and coupled with (1) the second terminal of the first metal material transition connector and (2) the second terminal of the second metal material transition connector;
• a third cable of the first size, comprising the first metal material, and coupled with (1) the first terminal of the second metal material transition connector and (2) the first terminal of the second junction connector;
• a fourth cable of the first size, comprising the first metal material and coupled with the second terminal of the second junction connector;
• a fifth cable of the first size, comprising the first metal material, and coupled with the third terminal of the first junction connector;
• and
• a sixth cable of the first size, comprising the first metal material, and coupled with the third terminal of the second junction connector.