Asymmetrical Integrated Frame for Photovoltaic Module Connectors
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Solution Overview
Problem
Photovoltaic module connectors are prone to damage during manufacturing, installation, and use due to misalignment, bending, and varying roof conditions, leading to mechanical and electrical connection failures.
Innovation Solution
An integrated frame with asymmetrical engagement features is designed to support and align connectors, providing lateral, longitudinal, and rotational support, and featuring pockets and disengagement openings to secure and access the connector clips, ensuring a single configuration installation and protection from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector is provided with a cantilever connection to the active portion, then the connector can be easily attached to the photovoltaic laminate, but the connector becomes prone to bending and damage during manufacturing, installation, and transportation
Solution Approach 1:
The integrated frame is pre-formed with engagement features that will later secure the connector. By preparing the frame structure in advance with built-in support mechanisms, the connector receives immediate structural support upon attachment, preventing bending and damage during subsequent handling and installation processes
Solution Approach 2:
The integrated frame acts as an intermediary structural element between the photovoltaic laminate and the connector. This intermediate component provides mechanical support and protection to the connector, absorbing stresses and preventing direct transmission of bending forces to the connector during installation and transportation
2Manufacturing precision
If the connector has a predetermined attachment location to ensure proper polarity alignment, then electrical connections are correctly aligned, but the connector must be attached in a specific configuration which increases installation complexity
Solution Approach 1:
The integrated frame incorporates asymmetrical engagement features that create a unique geometric configuration. These asymmetric elements allow the connector to be attached in only one correct orientation, automatically ensuring proper polarity alignment while providing visual and tactile guidance to installers, thereby simplifying the installation process despite the precision requirements
3Illumination intensity
If the photovoltaic modules are placed in elevated locations on rooftops or racks, then the photovoltaic array is exposed to optimal sunlight, but the connectors become vulnerable to damage during movement and handling by installers
Solution Approach 1:
The integrated frame is designed and pre-formed with built-in protective structures and engagement features before the photovoltaic module is installed on the rooftop. This preliminary preparation ensures that when installers handle and move the modules during installation, the connectors are already protected by the frame structure, preventing damage from handling and movement
Solution Approach 2:
The integrated frame provides preemptive structural support and protection to the connector, acting as a cushioning mechanism against potential damages. By having this protective structure in place before installation and transportation, the connector is shielded from bending and damage that could occur during handling by installers moving modules to elevated rooftop locations
4Manufacturing precision
If the integrated frame has asymmetrical engagement features, then the connector can only be installed in a single configuration ensuring proper alignment, but the frame design becomes more complex
Solution Approach 1:
The asymmetrical engagement features are integrated directly into the frame structure itself, merging the alignment and securing functions into a single unified component. This integration eliminates the need for separate alignment mechanisms or multiple components, achieving precise single-configuration installation while actually reducing overall design complexity through consolidation
Data Source
AI summary
A photovoltaic module comprising: (a) a photovoltaic laminate including: (i) one or more connectors connected to and extending from the photovoltaic laminate, and (ii) one or more integrated frames each including one or more engagement features, and the one or more integrated frames being in communication with each of the one or more connectors; and wherein the one or more engagement features are asymmetrical so that each of the one or more connectors can only be installed in each of the one or more integrated frames in a single configuration; and wherein each of the one or more integrated frames are connected to the photovoltaic laminate in a location proximate to the one or more connectors so that the one or more integrated frames provide support to the one or more connectors during the manufacturing process, during use, during installation, or a combination thereof.