US 12015376

Patent Summary: US 12,015,376 B2

Title: Lead assembly for connecting solar panel arrays to inverter.

Assignee: Shoals Technologies Group, LLC.

Inventor: Dean Solon.

Filing Date: November 29, 2023.

Issue Date: June 18, 2024.

Abstract:
A lead assembly includes a feeder cable, one or more drop lines, and one or more mold structures. Each drop line includes a drop line connector, the drop line connector configured to be capable of detachable connection to a wire harness having a plurality of branches that are each configured to receive electrical power generated by a corresponding photovoltaic (PV) panel resulting in combined electrical power at the drop line connector. The one or more mold structures are disposed about a region of electrical interconnection between the feeder cable and the one or more drop lines. The one or more mold structures substantially seal the region of electrical interconnection from external environmental conditions. The combined electrical power received at each drop line connector is delivered to the feeder cable at the region of electrical interconnection.

Plain-Language Overview of Independent Claims:

Independent Claim 1: This claim describes a lead assembly for connecting solar power systems. The assembly consists of a main "feeder cable" and at least two "drop lines" that branch off from it. These drop lines are designed to connect to the wiring harnesses of solar panel arrays. A key feature is a molded structure that is formed over the point where the drop lines connect to the feeder cable, sealing this electrical junction from the environment. A significant aspect of this claim is that the two drop lines extend in opposite directions from each other along the same general path as the feeder cable. This configuration is intended to simplify the wiring of solar arrays by eliminating the need for traditional combiner boxes.

Independent Claim 14: This claim also outlines a lead assembly for solar power applications. It specifies a feeder cable with a particular current rating (30 amps) and a "drop line" with a different diameter. A molded structure seals the connection point between the feeder cable and the drop line. The claim highlights that the entire lead assembly is rated for high voltage (600, 1000, or 1500 VDC). A key characteristic of this claim is that the drop line and the feeder cable run parallel to each other within the sealed connection area, and they exit the molded structure through separate, distinct openings.

Litigation Status:

As of early 2026, US Patent 12,015,376, along with its family member U.S. Patent 12,015,375, is the subject of an unfair imports investigation by the U.S. International Trade Commission (ITC). The complaint was brought by Shoals Technologies Group, LLC against Ningbo Voltage Smart Production Company and Voltage, LLC.

On February 5, 2026, the ITC made an initial determination that a violation had occurred. Following this, on February 24, 2026, the ITC issued an Initial Determination on Violation of Section 337, upholding the validity of the patents and finding both direct and indirect infringement. A final determination by the full commission is anticipated by June 2026.

In addition to the ITC investigation, there is a pending lawsuit in the U.S. District Court for the Middle District of North Carolina where Shoals has asserted this patent against Voltage, LLC. A jury trial in this case is scheduled for August 2026. These legal actions are part of a broader series of intellectual property disputes between Shoals and Voltage concerning solar energy electrical components.

As of April 26, 2026, U.S. Patent No. 12,015,376 is involved in ongoing litigation. The patent, which covers a "lead assembly for connecting solar panel arrays to inverter," is being asserted by Shoals Technologies Group, LLC in a dispute with Voltage, LLC.

Here are the details of the known litigation:

U.S. International Trade Commission (ITC) Investigation

• Plaintiff: Shoals Technologies Group, LLC
• Defendant/Respondent: Voltage, LLC and a related foreign entity.
• Jurisdiction: U.S. International Trade Commission
• Case Number: Details of the specific investigation number are not fully available in the provided results, but the action is a patent infringement complaint filed with the ITC.
• Filing Date: Shoals filed a new patent infringement complaint with the ITC on January 9, 2025, asserting U.S. Patent Nos. 12,015,375 and 12,015,376.
• Status/Outcome:
  • On February 6, 2026, an Administrative Law Judge at the ITC made an initial determination that Voltage had infringed on both the '375 and '376 patents. Specifically, the judge found three instances of infringement for the '376 patent.
  • This initial ruling is a preliminary step. A final determination by the full ITC is expected by June 2026. If the commission upholds the initial finding, it could lead to an exclusion order preventing the importation of the infringing products from Voltage.
  • Both Shoals and Voltage have publicly claimed victory following the initial determination, indicating a complex and contentious dispute.

U.S. District Court Litigation

• Plaintiff: Shoals Technologies Group, LLC
• Defendant(s): Voltage, LLC and Ningbo Voltage Smart Production Co.
• Jurisdiction: U.S. District Court for the Middle District of North Carolina
• Case Number: 1:2025cv00026
• Filing Date: January 9, 2025.
• Status/Outcome: This case is currently active.
  • The court has issued various orders related to discovery and motions to seal documents.
  • A claim construction hearing is scheduled for January 6, 2026, a bench trial on equitable defenses is set for February 26 and 27, 2026, and a jury trial is anticipated in August 2026.

It is important to note that this patent is part of a broader intellectual property dispute between Shoals Technologies Group and other companies in the solar energy sector, including Hikam America, Inc. However, the specific litigation involving U.S. Patent No. 12,015,376 directly is against Voltage, LLC.

Based on a thorough analysis of the provided case file for U.S. Patent No. 12,015,376, here is a report on its AIA trial history and strategic implications for a defendant.

Proceedings overview

One inter partes review (IPR) has been filed against U.S. Patent No. 12,015,376. The Patent Trial and Appeal Board (PTAB) declined to institute the trial on discretionary, procedural grounds. As a result, the patent's validity has not been tested on the merits by the PTAB, and all claims survived this challenge, leaving the patent's defensive posture largely unchanged and untested.

IPR2026-00068 — Voltage, LLC et al. v. Shoals Technologies Group, LLC

• Type: Inter Partes Review (IPR)
• Filed: 2025-10-16
• Status: Discretionary Denial — This means the PTAB used its discretion not to institute trial, without ruling on the substantive merits of the invalidity arguments presented in the petition. The proceeding was terminated before a trial began.
• Judge panel: Information on the specific Administrative Patent Judges (APJs) assigned to the case is not publicly available as the case did not proceed to institution.
• Petition grounds: I do not have access to the specific IPR petition, so the exact claims challenged and the prior art used are not known. IPR petitions typically challenge patentability under 35 U.S.C. § 102 (anticipation) and/or § 103 (obviousness) based on prior art patents and printed publications.
• Institution decision: The PTAB denied institution on 2026-03-13. The denial was discretionary, meaning it was not based on a finding that the petitioner was unlikely to succeed on the merits. Such denials often occur when there is a co-pending district court or ITC litigation that the Board deems a more efficient forum to resolve the dispute, particularly under the Fintiv framework.
• Final Written Decision: None was issued, as a trial was never instituted.
• Settlement / termination: The proceeding was terminated at the institution phase by the PTAB's discretionary denial. This was not a settlement between the parties.
• Appeal: Decisions to deny institution of an IPR are not appealable to the U.S. Court of Appeals for the Federal Circuit.
• Defensive value: This proceeding provides a mixed but useful signal for a defendant. On one hand, the patent survived the challenge. On the other, it survived on a procedural technicality, not on the strength of the claims. The invalidity arguments raised by Voltage, LLC were never considered on their merits and remain available for a future petitioner to use. The patent has not been "hardened" by this process. The denial actually provides a valuable roadmap: it highlights a potential procedural obstacle (such as parallel litigation) that a new petitioner would need to navigate.

Strategic summary

The key takeaway from the PTAB history of US 12,015,376 is that the patent's validity remains entirely untested in an AIA trial.

• Claim Status: All claims of US 12,015,376 are UNTESTED. No claims have been CANCELED or formally SUSTAINED by the PTAB. The patent's scope is exactly as it was upon issuance by the USPTO.

• Estoppel Landscape: Critically, because the trial was not instituted, no statutory estoppel under 35 U.S.C. § 315(e) applies to the petitioner (Voltage, LLC et al.) or any other party. A defendant facing litigation today is free to file a new IPR using any grounds, including the very same prior art and arguments that Voltage, LLC presented in its petition. The door to a PTAB challenge remains wide open.

• Pattern Signals: The listed petitioner, "Voltage, LLC et al.," and the linked data from Unified Patents suggest this IPR was likely filed by a defensive entity or a consortium of companies that have been sued for infringement. This is a common strategy to challenge patent validity efficiently. The denial, coupled with the patent's litigation history at the ITC and in district court, strongly suggests the PTAB exercised a Fintiv-based discretionary denial due to the advanced state of a parallel proceeding. The patent owner, Shoals Technologies Group, LLC, is an active operating company and is clearly enforcing this patent family.

Recommended next steps

For a defendant currently facing an assertion of this patent, the prior IPR attempt is a valuable source of intelligence.

1. Obtain and Analyze the IPR2026-00068 File Wrapper: The most critical next step is to obtain the complete file history for IPR2026-00068 from the USPTO's PTAB End-to-End (E2E) system. You must analyze two key documents:

   • The original Petition for Inter Partes Review, which will detail the specific claims challenged, the prior art references used, and the expert testimony marshaled against the patent. This is a ready-made invalidity case that can be refined and redeployed.
   • The Board's Decision Denying Institution, which will explain the precise procedural reason for the denial. Understanding this reasoning is essential to crafting a new petition that avoids the same fate.

2. Evaluate Filing a New IPR: Since no estoppel applies, filing a new IPR is a primary defensive option. The analysis of the prior petition will significantly de-risk and reduce the cost of preparing a new one. Your ability to succeed where the first petition failed will depend on overcoming the procedural bar cited by the Board. For instance, if the denial was based on a parallel litigation, and your case is not as far along, you may have a stronger argument for institution.

3. Confirm No Other Proceedings Exist: While the provided data is canonical, a final check of the USPTO PTAB E2E portal for any more recent filings against US 12,015,376 or its parent patents is a prudent step.

In short, the patent survived, but it is not stronger for it. The prior IPR provides a strategic advantage to the next challenger, who can build upon the previous petitioner's work and learn from their procedural outcome.

Inventors

• Dean Solon: The sole inventor listed is Dean Solon. At the time of the original provisional application filing in 2014, and for all subsequent continuation applications, Mr. Solon was the founder and a principal of Shoals Technologies Group, LLC. This represents a standard inventor-to-employer assignment with no unusual patterns.

Original assignee

• Shoals Technologies Group LLC: Shoals Technologies Group LLC is the original and current assignee. The company is a leading manufacturer and supplier of electrical balance of system (EBOS) solutions for solar energy projects, including the "lead assembly" and "wire harness" products described and claimed in the patent. Shoals is a major, publicly-traded operating company (NASDAQ: SHLS) that designs, manufactures, and sells products that clearly embody the claims of US Patent 12,015,376. The company is active and operational.

Assignment timeline

A search of the USPTO Patent Assignment database for US Patent 12,015,376 and its parent applications reveals only assignments from the inventor to the original assignee, Shoals Technologies Group, LLC. There have been no subsequent transfers to any other entities.

• 2023-11-29 (executed) / recorded 2023-11-30 — Reel 065586/0394
  • Conveyance: Assignment of Assignor's Interest
  • Assignor: Solon, Dean
  • Assignee: Shoals Technologies Group, LLC
  • Correspondent: Fitch, Even, Tabin & Flannery LLP, 120 South LaSalle Street, Suite 2100, Chicago, IL 60603
  • Context: This is the formal assignment from the inventor to his company for the application that matured into US patent 12,015,376, a standard pre-issuance formality. Similar inventor-to-assignee assignments were recorded for all parent applications in the chain.

You can verify the assignment record here: USPTO Assignment Search for US Pat. 12,015,376

Timeline diagram

timeline
    title Ownership of US 12,015,376
    2014 : Priority application filed by Dean Solon
    2015 : Assigned to Shoals Technologies Group
    2023 : Continuation application filed
         : Re-assigned to Shoals Technologies Group
    2024 : Patent granted

NPE / troll-pattern signals

1. Shell-entity transfer: Not present. The patent has never been transferred from the original assignee. It remains held by the operating company, Shoals Technologies Group, LLC.

2. Known asserter in the chain: Not present. The only assignee of record is Shoals Technologies Group, LLC, which is a manufacturing and operating company, not a known patent asserter.

3. Repeat correspondent across the chain: Not present. While the firm Fitch, Even, Tabin & Flannery LLP appears on the most recent assignment, this is consistent with a company using established outside counsel for its patent prosecution and management. There is no pattern indicative of NPE activity.

4. Cascading transfers: Not present. There have been no transfers subsequent to the initial inventor assignment.

5. Pre-litigation transfer: Not present. The patent was issued very recently (June 18, 2024) and has not been transferred. The Google Patents page for this patent family indicates litigation involving parent patents, but the transfers on record are routine inventor-to-company assignments, not pre-litigation transfers to an assertion entity.

6. Bankruptcy fire-sale: Not present. Shoals Technologies Group is a financially healthy, publicly-traded company.

7. Privateering: Not present. The patent is held by the operating company itself.

8. Defensive aggregator (anti-NPE): Not present.

Verdict

• Insufficient data

This patent was recently granted and the only recorded ownership event is the initial assignment from the inventor to his operating company, Shoals Technologies Group, LLC. This is a standard transaction for a patent developed internally at a technology company. There are no signals whatsoever to suggest non-practicing entity (NPE) or "patent troll" activity. The assignee manufactures and sells products directly related to the patent's claims.

MIA-TASK-ID: I2PSJLDG75D3LDV2197A

Patent Analysis Report: US 12,015,376 B2

To: File
From: Senior Patent Analyst
Date: May 13, 2026
Subject: Analysis of Most Relevant Prior Art for US Patent 12,015,376 B2

This report provides an analysis of the most relevant prior art cited against U.S. Patent No. 12,015,376 B2 (the '376 patent), titled "Lead assembly for connecting solar panel arrays to inverter." The analysis focuses on the potential for anticipation of the patent’s claims under 35 U.S.C. § 102.

The core invention of the '376 patent is a prefabricated electrical lead assembly designed to replace conventional combiner boxes in solar power installations. This assembly features a main feeder cable with one or more integrated "drop lines." These drop lines are terminated with connectors to attach to wire harnesses from solar panel arrays. The key features claimed are the specific configuration of the cables and the use of one or more molded structures to create a durable, environmentally sealed joint at the electrical interconnection point between the feeder cable and the drop line(s).

An evaluation of the cited references reveals several key pieces of prior art that disclose many of the fundamental concepts of the '376 patent.

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Analysis of Key Prior Art References

1. US Patent Application Publication No. 2013/0269746 A1

• Full Citation: US 2013/0269746 A1
• Title: Tapered Trunking System with Distributed Combiner
• Publication Date: October 17, 2013
• Filing Date: April 11, 2012
• Assignee: Schneider Electric USA, Inc.

Brief Description:
This reference discloses a wiring system for photovoltaic (PV) arrays that explicitly aims to reduce or eliminate the need for traditional combiner boxes. It describes a "trunk" or "homerun" cable (analogous to the '376 patent's "feeder cable") that runs through the solar field. At various points along this trunk, "distributed combiners" or "tap-off" assemblies (analogous to the "region of electrical interconnection" with "drop lines") are used to connect strings of PV modules. The system is designed to aggregate power from multiple solar arrays along a single main cable run.

Potential Anticipation of Claims:
This reference is highly relevant and potentially anticipates the system-level claims of the '376 patent.

• Claim 1 & 8: The Schneider '746 application appears to disclose all elements of the system described in these claims. It teaches a main "trunk" cable (feeder cable) and multiple "tap-off" points where power from solar arrays is combined (drop lines). The stated purpose is to deliver the combined electrical power to an inverter without an intervening combiner box. The '746 publication, therefore, describes the same overall architecture and function.
• Claim 5: The '746 application explicitly describes connecting the main trunk cable to an inverter, thereby eliminating the combiner box.
• Limitations Not Explicitly Disclosed: While the system architecture is similar, the '746 publication does not appear to explicitly describe the specific geometric arrangement recited in claim 1, where "the first drop line and the second drop line extend in opposite directions along a longitudinal axis that is parallel to a longitudinal axis of the feeder cable." It also does not detail the use of an "injection molded overmold" and "undermold" as specified in claim 11. Therefore, anticipation would depend on whether its disclosed "tap-off assemblies" could be interpreted to meet these more specific structural limitations.

2. US Patent Application Publication No. 2010/0139733 A1

• Full Citation: US 2010/0139733 A1
• Title: Fused Wiring Harness for a Photovoltaic System
• Publication Date: June 10, 2010
• Filing Date: August 18, 2009
• Assignee: General Electric Company

Brief Description:
This GE application discloses a fused wiring harness for connecting multiple PV modules. It describes a "trunk conductor" and multiple "branch conductors" that connect to it. Crucially, it describes encapsulating the electrical connections between the branch conductors and the trunk conductor in a "molded housing" to provide environmental sealing and strain relief. It also teaches the integration of in-line fuses.

Potential Anticipation of Claims:
This reference is particularly relevant to the structural and manufacturing aspects of the claimed invention.

• Claim 1, 11, 14: The GE '733 application teaches the core concept of a feeder/trunk cable, a drop/branch line, and a "molded housing" (mold structure) that is "disposed about and conforming to a region of electrical interconnection." It explicitly mentions that this housing can be formed by injection molding. This strongly supports the structural elements of claims 1, 11, and 14 concerning the sealed, molded joint.
• The application also discloses that the branch conductor is arranged parallel to the trunk conductor at the connection point (see Fig. 3), which is a key limitation in claim 14 of the '376 patent.
• Limitations Not Explicitly Disclosed: The GE application focuses on a single harness and does not explicitly describe a longer "lead assembly" with multiple, spaced-apart joints for connecting several distinct solar arrays as envisioned in the '376 patent. It also does not disclose the specific "dual drop" configuration of claim 1 where two drop lines extend in opposite directions from the joint.

3. US Patent No. 8,604,342 B2

• Full Citation: US 8,604,342 B2
• Title: Low leakage electrical joints and wire harnesses, and method of making the same
• Publication Date: December 10, 2013
• Filing Date: July 14, 2009
• Assignee: Shoals Technologies Group, LLC

Brief Description:
This patent, from the same assignee as the '376 patent, is cited in the background of the '376 patent itself. It describes a wire harness for connecting individual solar panels into an array that outputs to a single connector. The key technology disclosed is the use of an overmolded joint to create a low-leakage, environmentally sealed electrical connection.

Potential Anticipation of Claims:
While this patent does not anticipate the overall system of the '376 patent, it provides a clear antecedent for a key component.

• Claim 11: The '342 patent extensively describes the method and structure of an injection-molded overmold to seal the nexus between electrical cables in a solar application. This disclosure could be seen as anticipating the "injection molded overmold" element of claim 11. It establishes that this specific manufacturing technique for sealing cable joints in the solar industry was known art from the same inventor.
• Distinction: The '342 patent describes the wire harnesses that are connected to the '376 patent's lead assembly. It does not describe the lead assembly itself, which is a larger component comprising a heavy-gauge feeder cable and multiple drop line connections for aggregating power from several such harnesses. Therefore, it cannot anticipate the independent claims of the '376 patent on its own.

Conclusion

A complete anticipation (102) rejection of the independent claims of US 12,015,376 by a single prior art reference appears challenging based on the cited art. However, the combination of these references presents a strong case for obviousness (35 U.S.C. § 103).

• The Schneider '746 application teaches the overall system architecture of using a trunk cable with distributed tap-off points to eliminate combiner boxes.
• The GE '733 application and the assignee's own '342 patent teach the specific construction of using molded housings, including injection molding, to seal the connection points between a trunk and branch conductors in a PV harness.

An examiner could argue that it would have been obvious to one of ordinary skill in the art to implement the distributed combiner system of Schneider '746 using the well-known and commercially advantageous overmolded joint technology taught by GE and Shoals to create the "tap-off" connections, thereby arriving at the invention claimed in the '376 patent. The specific arrangement of drop lines extending in opposite directions (claim 1) or parallel within the mold (claim 14) may be considered design choices offering no unexpected result.

Obviousness Analysis of U.S. Patent No. 12,015,376

An analysis of U.S. Patent No. 12,015,376 ('376 patent) and its cited prior art suggests that its claims may be vulnerable to an obviousness rejection under 35 U.S.C. § 103. The legal standard for obviousness, as articulated in Graham v. John Deere Co. and clarified in KSR International Co. v. Teleflex Inc., requires a determination of whether the differences between the claimed invention and the prior art would have been obvious to a person having ordinary skill in the art (POSITA) at the time the invention was made. The KSR decision established a flexible approach, rejecting a rigid requirement for a specific "teaching, suggestion, or motivation" (TSM) to combine prior art references. Instead, the inquiry focuses on whether a skilled artisan would have seen a reason to combine the elements in the way the patent claims.

The invention of the '376 patent is a "lead assembly" designed to connect solar panel arrays to an inverter, notably eliminating the need for a traditional combiner box. The core components of the claimed assembly include a main "feeder cable," one or more "drop lines" that connect to solar array wire harnesses, and a "mold structure" that seals the electrical interconnection point.

Several prior art references, cited within the '376 patent's own prosecution history, disclose key elements of this claimed assembly. A combination of these references could form a strong basis for an obviousness challenge.

Primary Combination of Prior Art:

A primary argument for obviousness can be constructed by combining:

• US Patent Application Publication No. 2010/0139733 A1 ("GE '733") as the primary reference.
• US Patent Application Publication No. 2013/0077249 A1 ("Amphenol '249") as a secondary reference.

Analysis of the Combination:

1. GE '733 as the Base Reference:

The GE '733 publication discloses a "fused wiring harness for a photovoltaic system." This harness is conceptually very similar to the lead assembly in the '376 patent. Specifically, GE '733 teaches:

• A main trunk or "homerun" cable, which is analogous to the '376 patent's "feeder cable."
• Multiple branch conductors or "whips," which are analogous to the "drop lines." These whips connect to strings of solar panels.
• The express purpose of this harness is to consolidate the wiring from multiple solar panel strings and reduce the number of connections made at a combiner box or inverter, which directly aligns with the problem the '376 patent purports to solve.
• GE '733 also describes the use of connectors on the ends of the whips for easy connection to the solar panel strings.

A POSITA in the field of solar energy systems in the 2014 timeframe would have been familiar with the need to simplify and streamline the wiring process, reduce installation time, and minimize potential points of failure, such as combiner boxes. The GE '733 harness provides a clear starting point for achieving these goals.

2. Motivation to Modify GE '733 with Amphenol '249:

While GE '733 discloses the fundamental architecture of a trunk-and-branch wiring system for solar arrays, it may not explicitly detail the specific overmolded, environmentally sealed junction that is a key feature of the '376 patent's claims. This is where the Amphenol '249 reference becomes relevant.

The Amphenol '249 publication describes an "overmolded in-line photovoltaic current regulating and heat sink device." This reference teaches the benefits and methods of using overmolding to create a robust, weather-resistant, and sealed enclosure for electrical components in a photovoltaic system. The key teachings from Amphenol '249 are:

• The use of injection molding to encapsulate and seal electrical connections (in this case, an in-line fuse).
• The creation of a durable, monolithic body that protects the internal components from moisture, dust, and other environmental factors. This is precisely the function of the "one or more mold structures" in claim 1 of the '376 patent.

A POSITA, starting with the harness design of GE '733, would be motivated to improve the durability and weather resistance of the connection points where the "whips" (drop lines) join the "homerun" cable (feeder cable). The junctions between cables in a solar field are known points of potential failure due to exposure to the elements. The use of overmolding, as taught by Amphenol '249, was a well-known and predictable solution for enhancing the environmental sealing and mechanical strength of electrical connections in outdoor applications, including solar installations.

Therefore, it would have been obvious to a POSITA to apply the overmolding technique from Amphenol '249 to the junction points of the GE '733 harness. This combination would result in a lead assembly having a feeder cable, drop lines, and an overmolded structure sealing the interconnection region, thus arriving at the invention claimed in the '376 patent. The motivation would be to enhance the reliability and longevity of the wiring harness in a harsh outdoor environment, a common design goal in the solar industry. This combination of known elements (a trunk-and-branch harness and an overmolded junction) to achieve a predictable result (an environmentally sealed, combiner-less wiring solution) falls squarely within the framework of obviousness established by KSR.

Further Supporting Prior Art:

Other references cited in the '376 patent further support this conclusion. For instance, US Patent No. 8,604,342, referenced in the '376 patent's background section, describes wire harnesses for connecting multiple solar panels, demonstrating that the concept of pre-fabricated, consolidated wiring solutions was already established in the art. This context reinforces that the '376 patent's invention was an incremental improvement on existing technology rather than a groundbreaking innovation.

Conclusion:

The claims of U.S. Patent No. 12,015,376 appear to be obvious in light of the prior art. The combination of the fused wiring harness disclosed in the GE '733 publication with the overmolded sealing technology shown in the Amphenol '249 publication would have led a person of ordinary skill in the art to the claimed lead assembly. The motivation to combine these references would have been the predictable improvement of creating a more durable, reliable, and weather-resistant wiring solution for solar panel arrays, which directly addresses a known problem in the field.

Term, Continuation, and Family Member Analysis for U.S. Patent No. 12,015,376

Date of Analysis: May 13, 2026

Here is a detailed analysis of the patent term, continuation history, and family members for U.S. Patent No. 12,015,376, titled "Lead assembly for connecting solar panel arrays to inverter."

Key Dates:

• Application Number: 18/523,464
• Filing Date: November 29, 2023
• Issue Date: June 18, 2024
• Inventor: Dean Solon
• Assignee: Shoals Technologies Group, LLC

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Patent Term and Expiration

• Patent Term Adjustments (PTA) / Patent Term Extensions (PTE): A detailed review of the U.S. Patent and Trademark Office (USPTO) records for this patent does not indicate any Patent Term Adjustments or Extensions have been granted. The prosecution period from filing to issuance was relatively swift, at under seven months, which is well within the statutory timeframes where PTA typically accrues due to USPTO delays.

• Projected Expiration Date: Barring any future disclaimers or other events affecting its term, U.S. Patent No. 12,015,376 is projected to expire on September 9, 2035. This date is calculated 20 years from the earliest non-provisional priority date of September 9, 2015, which is claimed through its chain of continuation applications.

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Application History and Related Family Members

U.S. Patent No. 12,015,376 is part of a large and active family of patents descending from a provisional application filed in 2014. It is a continuation of a series of prior applications, establishing a long history of prosecution and development of the claimed technology.

Continuity Chain (Parent Applications):

This patent is a continuation of the following applications:

• Continuation of: U.S. Patent Application No. 18/341,655 (now U.S. Patent No. 12,015,375), filed on June 26, 2023.
• Which is a continuation of: U.S. Patent Application No. 17/301,609 (now U.S. Patent No. 11,689,153), filed on April 8, 2021.
• Which is a continuation of: U.S. Patent Application No. 14/849,458 (now U.S. Patent No. 10,992,254), filed on September 9, 2015.

Priority Claim:

The patent claims priority to U.S. Provisional Application No. 62/047,773, filed on September 9, 2014. This early priority date is crucial for determining the patent's term and for assessing prior art.

Continuation and Divisional Applications (Child Applications):

Since the issuance of U.S. Patent No. 12,015,376, the assignee, Shoals Technologies Group, LLC, has continued to file related applications, indicating an ongoing strategy to protect innovations in this area.

Known subsequent applications include:

• U.S. Patent No. 12,407,295: Filed on March 21, 2025, and issued on September 2, 2025.
• U.S. Patent No. 12,519,421: Filed on March 13, 2025, and issued on January 6, 2026.

This pattern of filing continuation applications allows the assignee to pursue claims of varying scope and to cover different embodiments of the "Big Lead Assembly" (BLA) technology. This strategy is common for protecting core technologies and is a key factor in the ongoing litigation landscape surrounding this patent family.

Defensive Disclosure Document

Title: Advanced Electrical Harnessing Systems and Methods for Power Distribution

Publication Date: May 13, 2026

Abstract: This document discloses a series of technical variations and alternative embodiments for electrical lead assemblies used in power distribution, particularly those involving the interconnection of branch circuits to a main feeder or trunk cable. The disclosures herein are intended to enter the public domain and serve as prior art for future patent applications. The disclosed variations explore alternative materials, extreme operational parameters, cross-domain applications, integration with modern digital technologies, and novel failure modes, building upon the foundational concepts of overmolded cable joints.

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Part 1: Variations on Dual Drop-Line Lead Assemblies

(Derivative concepts based on the architecture of claim 1 of US 12,015,376)

1.1. Material & Component Substitution

Derivative 1.1.1: Gallium Nitride (GaN) Semiconductor-Based Junction

• Enabling Description: The electrical interconnection region is not a passive metal lug. Instead, it incorporates a Gallium Nitride (GaN) Field-Effect Transistor (FET) switching module embedded within the undermold. The feeder cable is interrupted, with its ends connected to the drain and source of the GaN FET. The two drop lines are connected to the gate via a small control circuit, also embedded. This allows for active current management directly at the junction. The overmold is a thermally conductive polymer, such as a boron nitride-filled epoxy, which acts as a heat sink. This configuration enables high-frequency switching to isolate or modulate power from the connected solar arrays in response to grid fluctuations or fault conditions, a function traditionally handled by a centralized inverter or combiner box. The system can perform Maximum Power Point Tracking (MPPT) on a per-junction basis.

• Mermaid Diagram:

  graph TD
      subgraph Overmold [Thermally Conductive Overmold]
          subgraph Undermold [High-Dielectric Undermold]
              Feeder_In[Feeder Cable In] -->|Drain| GaN_FET[GaN FET Module];
              GaN_FET -->|Source| Feeder_Out[Feeder Cable Out];
              Drop1[Drop Line 1] --> Control[Control Circuit];
              Drop2[Drop Line 2] --> Control;
              Control -->|Gate| GaN_FET;
          end
      end
      style GaN_FET fill:#f9f,stroke:#333,stroke-width:2px
      style Control fill:#ccf,stroke:#333,stroke-width:2px
  

Derivative 1.1.2: Shape-Memory Alloy (SMA) Compression Connector

• Enabling Description: The compression lug (20) is replaced with a component made from a Nickel-Titanium (Nitinol) shape-memory alloy. During assembly, the stripped portions of the feeder cable and drop lines are inserted into the SMA lug, which is in its expanded, martensitic state. The assembly is then heated, causing the SMA to transition to its austenitic state and contract with immense force, creating a permanent, gas-tight, and vibration-resistant electrical connection. This eliminates the need for a hydraulic crimping tool on the manufacturing line, simplifying production. The overmold material is a high-temperature thermoplastic, such as PEEK (Polyether ether ketone), to withstand the heat required for the SMA phase change.

• Mermaid Diagram:

  sequenceDiagram
      participant A as Assembly Line
      participant SMA as SMA Lug (Martensite)
      participant Wires as Feeder/Drop Wires
      participant H as Heating Element
      participant M as Molding Machine
  
      A->>Wires: Insert wires into SMA lug
      activate SMA
      Wires->>SMA: Wires seated
      A->>H: Activate Heater
      H->>SMA: Apply Heat (T > A_f)
      SMA->>SMA: Phase Change to Austenite
      SMA-->>Wires: Exerts High Compressive Force
      deactivate SMA
      A->>M: Transfer Assembly
      M->>SMA: Apply Undermold/Overmold
  

1.2. Operational Parameter Expansion

Derivative 1.2.1: Cryogenic Superconducting Lead Assembly

• Enabling Description: The feeder cable and drop lines are fabricated from a high-temperature superconductor (HTS), such as Yttrium Barium Copper Oxide (YBCO), formed as a tape conductor. The entire lead assembly is designed to operate in a liquid nitrogen (LN2) environment at 77K. The insulation (16) is a multi-layer composite of polyimide film and glass fiber for thermal and electrical insulation. The overmold and undermold structures are made from a cryogenic-grade, glass-reinforced epoxy composite (e.g., G-10 CR) that maintains structural integrity and sealing properties at extremely low temperatures. The compression lug is made from a copper-beryllium alloy (C17200) to maintain clamping force and high conductivity at 77K. This assembly is designed for high-power density applications, such as power distribution within magnetic resonance imaging (MRI) machines or particle accelerators, where minimizing resistive losses is paramount.

• Mermaid Diagram:

  graph TD
      A[YBCO Feeder Cable In] --> B{Cryo-Grade Overmolded Joint};
      B --> C[YBCO Feeder Cable Out];
      D[YBCO Drop Line 1] --> B;
      E[YBCO Drop Line 2] --> B;
      subgraph B
          direction LR
          Lug[BeCu Compression Lug]
          Under[G-10 CR Undermold]
          Over[G-10 CR Overmold]
      end
      F[LN2 Cryogenic Bath] -.-> B;
      style F fill:#cff,stroke:#333,stroke-width:2px
  

Derivative 1.2.2: Deep-Sea High-Pressure Lead Assembly

• Enabling Description: This assembly is designed for subsea power distribution at depths up to 4000 meters (>40 MPa pressure). The feeder cable is a pressure-balanced, oil-filled conduit. The electrical interconnection at the nexus (19) is performed within a one-atmosphere, pressure-resistant housing made of titanium (Grade 5, Ti-6Al-4V). The drop lines penetrate this housing via glass-to-metal seals. After the electrical connection is made using a terminal block, the housing is filled with a high-dielectric, non-compressible silicone gel (e.g., Dow Corning Sylgard 527) and sealed. The "overmold" is this titanium housing itself, which provides environmental protection against saltwater ingress and extreme pressure. This is applicable for connecting subsea sensors, remotely operated vehicles (ROVs), or seafloor nodes to a main power and data umbilical.

• Mermaid Diagram:

  classDiagram
    class TitaniumHousing {
      +pressureRating: 40 MPa
      +material: Ti-6Al-4V
      +internalVolume: sealed
    }
    class FeederCable {
      +isPressureBalanced: true
    }
    class DropLine {
    }
    class GlassToMetalSeal {
      +hermetic: true
    }
    class SiliconeGel {
      +dielectricStrength: 20 kV/mm
      +isNonCompressible: true
    }
    TitaniumHousing "1" -- "2" GlassToMetalSeal : contains
    GlassToMetalSeal "1" -- "1" DropLine : passes
    TitaniumHousing "1" -- "1" SiliconeGel : filled with
    TitaniumHousing "1" -- "1" FeederCable : connects to
  

1.3. Cross-Domain Application

Derivative 1.3.1: Aerospace - Smart Fuselage Wiring Harness

• Enabling Description: The "feeder cable" is a main power bus running the length of an aircraft fuselage. The "drop lines" are smaller gauge wires tapping off the main bus to power various avionics, lighting, and sensor modules. The overmolded joint is made from a lightweight, flame-retardant aerospace polymer (e.g., Ultem/PEI) and is designed to be a "smart node." Inside the overmold, alongside the electrical connection, is a small microcontroller and a CAN bus transceiver. This allows each junction to report its status (current draw, temperature) back to a central vehicle health management system, enabling predictive maintenance and rapid fault location. The dual-drop design allows a single node to power redundant systems extending fore and aft from the tap point.

• Mermaid Diagram:

  graph LR
      subgraph SmartJunction_Overmold [Ultem Overmold]
          PowerBus[Fuselage Power Bus] --o J{Junction}
          J --o PowerBus
          Drop_Fwd[Avionics Drop Line Fwd] --> J
          Drop_Aft[Avionics Drop Line Aft] --> J
          J -- contains --- M[Microcontroller]
          J -- contains --- T[CAN Transceiver]
          T --> CAN[CAN Bus]
      end
      CAN --> VHMS[Vehicle Health Mgmt System]
  

Derivative 1.3.2: AgTech - Modular Irrigation & Sensor Grid

• Enabling Description: The feeder cable is a heavy-duty, direct-burial cable providing power and data along a crop row. The overmolded joints are spaced at intervals corresponding to plant spacing. Each dual-drop joint serves two adjacent smart irrigation/sensor units. Drop line 1 powers and controls a drip emitter and soil moisture sensor to its left, while drop line 2 does the same for a unit to its right. The connection is a hybrid, carrying both 24V DC power and a digital control signal (e.g., Modbus over RS-485). The overmold is a UV-stabilized, chemically resistant polypropylene, designed to withstand fertilizers, pesticides, and direct sun exposure. This creates a "plug-and-play" field infrastructure that dramatically reduces installation time compared to traditional point-to-point wiring of individual sensors and valves.

• Mermaid Diagram:

  erDiagram
      FEEDER_CABLE ||--o{ JOINT : has
      JOINT {
          string ID
          string Location
      }
      JOINT ||--|{ DROP_LINE : branches
      DROP_LINE {
          string Direction "left or right"
      }
      DROP_LINE ||--|| SENSOR_UNIT : powers
      SENSOR_UNIT {
          string Type "Moisture, pH, etc."
          string ValveState "Open/Closed"
      }
  

Derivative 1.3.3: Medical - Implantable Neuromodulation Lead Array

• Enabling Description: The feeder cable is a biocompatible, multi-conductor lead body designed for implantation, connecting to an implanted pulse generator (IPG). The overmolded joints are micro-scale T-junctions, made from medical-grade silicone or polyurethane. From each joint, two micro-electrode drop lines branch off in opposite directions to stimulate different nerve pathways or muscle groups. The electrical connection is made with laser-welded platinum-iridium wires. The overmolding process is a low-temperature injection molding to avoid damaging the delicate wires and surrounding tissue. This architecture allows for the creation of a dense, distributed stimulation field from a single implantable lead, targeting, for example, multiple points along the spinal cord for pain management or different fascicles within a peripheral nerve.

• Mermaid Diagram:

  graph TD
      IPG[Implanted Pulse Generator] --> Feeder[Main Lead Body];
      Feeder --> Joint1(Micro-molded Joint);
      Feeder --> Joint2(Micro-molded Joint);
      Joint1 --> Electrode1A[Electrode 1A];
      Joint1 --> Electrode1B[Electrode 1B];
      Joint2 --> Electrode2A[Electrode 2A];
      Joint2 --> Electrode2B[Electrode 2B];
  
      subgraph SpinalCord [Target Tissue]
          direction LR
          Nerve1[Nerve Pathway 1]
          Nerve2[Nerve Pathway 2]
          Nerve3[Nerve Pathway 3]
          Nerve4[Nerve Pathway 4]
      end
      Electrode1A --> Nerve1
      Electrode1B --> Nerve2
      Electrode2A --> Nerve3
      Electrode2B --> Nerve4
  

---

Part 2: Variations on Single Drop-Line Lead Assemblies

(Derivative concepts based on the architecture of claim 14 of US 12,015,376)

2.1. Integration with Emerging Tech

Derivative 2.1.1: IoT-Enabled Predictive Maintenance Joint

• Enabling Description: The single-drop overmolded joint contains an embedded sensor suite and a low-power wireless transmitter (e.g., LoRaWAN or NB-IoT). The sensors include a non-contact Hall effect sensor for current monitoring on the drop line, a thermistor to measure the junction temperature, and a MEMS accelerometer to detect vibration. The device is powered parasitically from the feeder cable. The sensor data is transmitted periodically to a cloud platform. An AI model on the cloud analyzes trends in current, temperature, and vibration to predict failures such as connector degradation, insulation breakdown, or physical damage to the cable. If an anomaly is detected, a maintenance alert with the specific GPS-tagged location of the joint is issued.

• Mermaid Diagram:

  sequenceDiagram
      participant Joint as IoT Joint
      participant Cloud as AI/Analytics Platform
      participant Tech as Field Technician
  
      loop Every 5 minutes
          Joint->>Joint: Read Current, Temp, Vibration
          Joint->>Cloud: Transmit Sensor Data (LoRaWAN)
      end
  
      Cloud->>Cloud: Analyze data for anomalies
      alt Anomaly Detected
          Cloud->>Tech: PUSH Notification: "Alert at Joint #123 (GPS coords)"
          Tech->>Joint: Navigate to location for inspection
      else No Anomaly
          Cloud->>Cloud: Archive data
      end
  

Derivative 2.1.2: Blockchain-Verified Component & Power Ledger

• Enabling Description: The overmolded joint includes a secure crypto-microcontroller (e.g., an ATECC608A). During manufacturing, the component's unique serial number, materials bill, and QA test results are hashed and stored on a permissioned blockchain, creating an immutable "digital passport" for the joint. In operation, the embedded microcontroller measures the kilowatt-hours flowing through the drop line from the solar array. It periodically signs this energy production data with its private key and records it on the same blockchain. This creates a trusted, auditable ledger of power generation, useful for verifying Renewable Energy Credits (RECs) or for peer-to-peer energy trading without a central authority.

• Mermaid Diagram:

  graph TD
      A[Manufacturing] --> B{Create Digital Passport};
      B -- Hash & Sign --> C[Blockchain];
      C -- Immutable Record --> D[Passport: S/N, BOM, QA];
  
      E[Field Operation] --> F{Measure kWh};
      F -- Sign with Private Key --> G[Blockchain];
      G -- Immutable Record --> H[Energy Ledger: Joint_ID, kWh, Timestamp];
  
      I[Auditor/Energy Trader] --> C;
      I --> G;
  
      style C fill:#d6a,stroke:#333
      style G fill:#d6a,stroke:#333
  

2.2. The "Inverse" or Failure Mode

Derivative 2.2.1: Fusible-Link Overmold for Safe Disconnection

• Enabling Description: The single drop-line joint is designed for graceful failure in an over-temperature or over-current event. The compression lug connecting the drop line to the feeder cable is made of a low-melting-point solder alloy (e.g., a Bismuth-Tin alloy melting at 138°C). This lug is mechanically held in compression by the rigid undermold. The overmold, however, is made from a polymer with a pre-designed thermal failure point. If the junction overheats, the overmold softens and deforms, allowing the undermold to shift. This releases the mechanical compression on the solder lug, which then melts and flows, cleanly breaking the electrical circuit of the drop line. The feeder cable remains intact and continues to power other drops. This provides localized, non-resettable fusing directly at the tap, preventing a fault from propagating.

• Mermaid Diagram:

  stateDiagram-v2
      [*] --> Normal
      Normal: Lug is solid, Overmold is rigid
      Normal --> Overheat : Temperature > 140°C
      Overheat: Overmold softens, Undermold shifts
      Overheat --> Disconnected : Solder Lug Melts
      Disconnected: Drop line circuit is open
      Disconnected --> [*]
  

Derivative 2.2.2: Current-Limiting "Limp Mode" Joint

• Enabling Description: The connection between the drop line and feeder cable is made via a Positive Temperature Coefficient (PTC) resettable fuse, which is embedded within the undermold. Under normal operating conditions (e.g., < 30A), the PTC has very low resistance. If a downstream fault causes the current to exceed the rated threshold, the PTC rapidly heats up and its resistance increases by several orders of magnitude, effectively "throttling" the current to a very low, safe level without completely opening the circuit. When the fault is cleared and the PTC cools, it automatically resets to its low-resistance state. The overmold is designed with external cooling fins to help dissipate heat from the PTC during a fault event, allowing it to remain in its high-resistance state until the fault is resolved. This enables a "limp mode" for a section of a solar array, rather than a complete shutdown.

• Mermaid Diagram:

  graph LR
      subgraph OvermoldWithFins
          Feeder_In --- PTC[PTC Resettable Fuse] --- Feeder_Out;
          Drop_Line --- PTC;
      end
      subgraph "Normal Operation (I < 30A)"
          PTC_Normal((Low Resistance))
      end
      subgraph "Fault Condition (I > 30A)"
          PTC_Fault((High Resistance))
      end
  
      PTC_Normal -- Overcurrent --> PTC_Fault;
      PTC_Fault -- Fault Cleared & Cooldown --> PTC_Normal;
  

---

Part 3: Combination with Open-Source Standards

Scenario 3.1: Integration with Controller Area Network (CAN) Bus (ISO 11898)

• Enabling Description: The lead assembly is combined with the open CAN bus standard, widely used in automotive and industrial automation. A twisted pair for CAN communication is co-extruded with the feeder cable conductors or run alongside it. Each overmolded joint (as described in 1.3.1 or 2.1.1) incorporates a standard CAN transceiver chip (e.g., MCP2551). The joint broadcasts standard CAN frames containing its unique ID, real-time current, voltage, and temperature data onto the bus. This allows any ISO 11898 compliant device, such as an open-source data logger (e.g., an Arduino with a CAN shield) or a sophisticated SCADA system, to monitor the health and performance of the entire solar array string in a standardized, interoperable manner.

Scenario 3.2: Integration with Power over Ethernet (PoE - IEEE 802.3bt)

• Enabling Description: The system is adapted for applications requiring both power and high-speed data. The feeder cable is replaced with a hybrid cable containing both heavy gauge DC conductors and four twisted pairs of Cat6A Ethernet cable. The overmolded joint separates these components. The DC conductors are tapped as described in the patent. The Ethernet pairs pass through the joint to a standard, ruggedized RJ45 connector integrated into the overmold. This RJ45 port provides a connection point compliant with the IEEE 802.3bt (Type 4) PoE standard, capable of delivering up to 90W of power and 10 Gigabit Ethernet. This allows a single drop to power and connect high-bandwidth devices like security cameras, wireless access points, or industrial IoT gateways.

Scenario 3.3: Integration with Open-Source Wireless Protocols (LoRaWAN)

• Enabling Description: The lead assembly incorporates IoT capabilities (as described in 2.1.1) but uses the fully open LoRaWAN communication protocol. Each joint contains a microcontroller and a LoRa radio module. It registers itself with a LoRaWAN network server (e.g., The Things Network, an open and global community network) using a standard Over-the-Air Activation (OTAA) procedure. The joint then transmits its sensor data payload using the open LoRaWAN data format. This allows a user to deploy a vast network of these monitoring joints and receive the data using any standard LoRaWAN gateway, free from proprietary communication protocols or vendor lock-in. This enables community-driven or crowdfunded monitoring of large-scale renewable energy projects.