Lead assembly for connecting solar panel arrays to inverter

A lead assembly for electrically coupling one or more drop lines to a feeder cable, the lead assembly comprising:

• a feeder cable comprising a conductive core and insulation, wherein the feeder cable has a first diameter;
• a drop line cable comprising at least one drop line, wherein the drop line terminates at a drop line connector, the drop line cable comprises a conductive core and insulation, and the drop line cable has a second diameter that is different than the first diameter;
• and
• a mold structure disposed about and enclosing a region of electrical interconnection between the feeder cable and the drop line cable,
• wherein at least a portion of the drop line cable and at least a portion of the feeder cable extend parallel to one another within the region of electrical interconnection, and the mold structure has distinct openings through which the drop line cable and the feeder cable exit the mold structure.

A lead assembly for electrically coupling one or more drop lines to a feeder cable, the lead assembly comprising:

• a joint where a section of the feeder cable and a section of a drop line cable that includes the one or more drop lines can be electrically coupled at a nexus, the joint including the section of the feeder cable and the section of the drop line cable;
• and
• a mold that encapsulates the nexus, the mold further comprising:
• a feeder pathway extending completely through the mold and configured to allow the feeder cable to extend completely through the mold;
• and
• one or more drop line pathways that each extend at least partially through the mold, and each configured to allow one of the one or more drop lines to extend at least partially through the mold;
• wherein:
• each of the one or more drop lines are configured to be capable of receiving electrical power from a plurality of solar panels for combination at the nexus to the feeder cable;
• the drop line cable includes a section of exposed wire at the nexus;
• the feeder cable includes a section of exposed wire at the nexus;
• and
• at least a portion of the section of exposed wire of the drop line cable is parallel to at least a portion of the section of exposed wire of the feeder cable;
• wherein at least a portion of the feeder cable and at least a portion of the drop line cable extend parallel to one another within the nexus, the mold has distinct openings at ends of the feeder pathway through which the feeder cable exits the mold, and the mold has a distinct opening at at least one end of each of the one or more drop line pathways through which the one or more drop lines exit the mold.

A lead assembly comprising:

• a joint where a section of a feeder cable and a section of a drop line cable are electrically coupled at a nexus, the drop line cable including two drop lines, each of the two drop lines configured to connect to a different wire harness and configured to receive power from a plurality of solar panels;
• a mold that encapsulates the nexus, the mold comprising:
• a feeder pathway configured to allow the feeder cable to extend completely through the mold;
• and
• a drop line cable pathway to allow the drop line cable to extend completely through the mold, the drop line cable pathway including a first drop line pathway through which a first drop line of the two drop lines extends partially through the mold and a second drop line pathway through which a second drop line of the two drop lines extends partially through the mold;
• wherein, in the nexus, at least a portion of the drop line cable extends along a longitudinal axis that is parallel to a longitudinal axis of at least a portion of the feeder cable.

A lead assembly comprising:

• a feeder cable;
• a drop line cable that includes a first drop line and a second drop line, each of the first drop line and the second drop line having an end configured to be connected to a wire harness and configured to receive power from a plurality of solar panels;
• a joint where a section of the feeder cable and a section of the drop line cable are electrically coupled at a nexus to electrically couple each of the first drop line and the second drop line to the feeder cable at the nexus;
• a mold structure that encapsulates the nexus, the mold structure comprising:
• a feeder pathway configured to allow the feeder cable to extend completely through the mold structure;
• and
• a drop line cable pathway configured to allow the drop line cable to extend completely through the mold structure, the drop line cable pathway including a first drop line pathway configured to allow the first drop line to extend partially through the mold structure and a second drop line pathway configured to allow the second drop line to extend partially through the mold structure;
• wherein, in the nexus, at least a portion of the drop line cable extends along a longitudinal axis that is parallel to a longitudinal axis of at least a portion of the feeder cable.