In-line fuse for photovoltaic wiring systems

An apparatus for forming electrical connections comprising:

• a portion of a trunk bus cable of a first size;
• one or more branch cables of a second size smaller than the first size;
• one or more extension branch cables of a third size smaller than the second size;
• a trunk bus connector comprising a trunk pathway and at least one region of electrical contact, wherein the portion of the trunk bus 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 trunk bus cable and the one or more branch cables;
• one or more metal material transition connectors, each metal material transition connector of the one or more metal material transition connectors comprising:
• (1) a first metal portion comprising a first metal material;
• (2) a second metal portion welded to the first metal portion at a welded region, the second metal portion comprising a second metal material different from the first metal material;
• wherein the portion of the trunk bus cable comprises the first metal material,
• wherein each branch cable of the one or more branch cables comprises the first metal material and is coupled to the first metal portion of a corresponding metal material transition connector of the one or more metal material transition connectors;
• and
• wherein each extension branch cable of the one or more extension branch cables comprises the second metal material and is coupled to the second metal portion of a corresponding metal material transition connector of the one or more metal material transition connectors;
• wherein at least one extension branch cable of the one or more extension branch cables is further coupled to an in-line fuse assembly, the in-line fuse assembly comprising:
• an in-line fuse for limiting electrical current along an electrical cable path, the in-line fuse having a first terminal and a second terminal, the first terminal comprising a first terminal exterior surface and a first terminal recess, the second terminal comprising a second terminal exterior surface and a second terminal recess,
• wherein the in-line fuse assembly is configured to couple to a first electrical cable comprising a first conductor and a first insulation sleeve, the first electrical cable having an exposed portion comprising a section of the first conductor not covered by the first insulation sleeve and an unexposed portion comprising a section of the first conductor covered by the first insulation sleeve, wherein the exposed portion of the first electrical cable is at least partially inserted into the first terminal recess of the in-line fuse, and
• wherein the in-line fuse assembly is configured to couple to a second electrical cable comprising a second conductor and a second insulation sleeve, the second electrical cable having an exposed portion comprising a section of the second conductor not covered by the second insulation sleeve and an unexposed portion comprising a section of the second conductor covered by the second insulation sleeve, wherein the exposed portion of the second electrical cable is at least partially inserted into the second terminal recess of the in-line fuse;
• one or more temperature-activated sealing members, wherein the one or more temperature-activated sealing members circumferentially surround, and form one or more first seals against, a portion of the first terminal exterior surface of the in-line fuse and a portion of the first insulation sleeve of the first electrical cable, wherein the one or more temperature-activated sealing members circumferentially surround, and form one or more second seals against, a portion of the second terminal exterior surface of the in-line fuse and a portion of the second insulation sleeve of the second electrical cable,
• an inner mold, wherein the inner mold encapsulates the in-line fuse and at least partially encapsulates the one or more temperature-activated sealing members while the one or more temperature-activated sealing members form the one or more first seals against the portion of the first terminal exterior surface of the in-line fuse and the portion of the first insulation sleeve of the first electrical cable and the one or more second seals against the portion of the second terminal exterior surface of the in-line fuse and the portion of the second insulation sleeve of the second electrical cable;
• and
• an outer mold, wherein the outer mold encapsulates the inner mold while the inner mold encapsulates the in-line fuse 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;
• a sixth cable of the first size, comprising the first metal material, and coupled with the third terminal of the second junction connector;
• a first in-line fuse assembly having a first terminal and a second terminal, wherein the sixth cable of the first size is coupled with the first terminal of the first in-line fuse;
• a second in-line fuse assembly having a first terminal and a second terminal, wherein a seventh cable of the first size is coupled with the first terminal of the second in-line fuse;
• the seventh cable of the first size coupled with the second terminal of the first in-line fuse;
• and
• an eighth cable of the first size coupled with the second terminal of the second in-line fuse;
• wherein each of the first in-line fuse assembly and the second in-line fuse assembly comprises:
• an in-line fuse for limiting electrical current along an electrical cable path, the in-line fuse having a first terminal and a second terminal, the first terminal comprising a first terminal exterior surface and a first terminal recess, the second terminal comprising a second terminal exterior surface and a second terminal recess,
• wherein the in-line fuse assembly is configured to couple to first electrical cable comprising a first conductor and a first insulation sleeve, the first electrical cable having an exposed portion comprising a section of the first conductor not covered by the first insulation sleeve and an unexposed portion comprising a section of the first conductor covered by the first insulation sleeve, wherein the exposed portion of the first electrical cable is at least partially inserted into the first terminal recess of the in-line fuse, and
• wherein the in-line fuse assembly is configured to couple to a second electrical cable comprising a second conductor and a second insulation sleeve, the second electrical cable having an exposed portion comprising a section of the second conductor not covered by the second insulation sleeve and an unexposed portion comprising a section of the second conductor covered by the second insulation sleeve, wherein the exposed portion of the second electrical cable is at least partially inserted into the second terminal recess of the in-line fuse;
• one or more temperature-activated sealing members, wherein the one or more temperature-activated sealing members circumferentially surround, and form one or more first seals against, a portion of the first terminal exterior surface of the in-line fuse and a portion of the first insulation sleeve of the first electrical cable, wherein the one or more temperature-activated sealing members circumferentially surround, and form one or more second seals against, a portion of the second terminal exterior surface of the in-line fuse and a portion of the second insulation sleeve of the second electrical cable,
• an inner mold, wherein the inner mold encapsulates the in-line fuse and at least partially encapsulates the one or more temperature-activated sealing members while the one or more temperature-activated sealing members form the one or more first seals against the portion of the first terminal exterior surface of the in-line fuse and the portion of the first insulation sleeve of the first electrical cable and the one or more second seals against the portion of the second terminal exterior surface of the in-line fuse and the portion of the second insulation sleeve of the second electrical cable;
• and
• an outer mold, wherein the outer mold encapsulates the inner mold while the inner mold encapsulates the in-line fuse and at least partially encapsulates the one or more temperature-activated sealing members.