Biscuit-Shaped Connector Terminal for Solar Panel Macro Motion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional energy transfer systems for solar panels face challenges with macro motion caused by thermal expansion, leading to increased resistance and potential corrosion, especially in outdoor environments like rooftops, where flexible wires are exposed and installation is complicated.
Innovation Solution
A connector system with a biscuit-shaped terminal that includes a nickel-based undercoat and noble metal plating, combined with lubrication, to maintain low resistance and prevent corrosion over thousands of macro motion cycles, ensuring reliable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flexible wires are used to connect solar panels, then installation is simplified, but resistance increases and corrosion occurs after thermal expansion cycles
Solution Approach 1:
The connector is divided into distinct functional layers: a nickel-based undercoat layer providing structural foundation and a noble metal plating layer providing corrosion resistance and low contact resistance. This segmentation allows each layer to optimize its specific function, resolving the contradiction between maintaining low resistance and preventing corrosion over thousands of thermal cycles.
Solution Approach 2:
The connector uses a composite structure combining nickel-based alloy (for mechanical strength and thermal stability) with noble metal plating (for electrical conductivity and corrosion resistance). This composite material approach simultaneously addresses the conflicting requirements of durability through 5000+ thermal cycles and maintaining electrical performance with resistance below 20 milliohms.
2Reliability
If rigid connectors are used to maintain low resistance, then electrical contact is improved, but installation complexity increases due to thermal expansion accommodation
Solution Approach 1:
The connector terminals are designed with altered mechanical parameters including increased flexibility and adjusted hardness to accommodate thermal expansion and contraction. This allows the rigid connector body to maintain low electrical resistance while the modified terminal parameters enable easy installation and movement accommodation during thermal cycles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system maintains resistance below 20 milliohms after 5000 cycles of macro motion, significantly extending the lifespan of the energy transfer system while minimizing corrosion and installation complexities.
Implementation Method 1
a nickel-based undercoat and noble metal plating
Implementation Method 2
prevent corrosion over thousands of macro motion cycles
Implementation Method 3
combined with lubrication, to maintain low resistance
Implementation Method 4
macro motion caused by thermal expansion
Data Source
AI summary
A connector system is configured for macro motion. Two mating terminals are configured so that during macro motion cycles, the resistance between two terminals does not substantially increase. One terminal can have multiple, somewhat spherical-shaped mating surfaces while a mating surface on the other terminal can be flat. The mating terminals can be configured to provide desirable resistance performance after more than 5000 cycles of macro motion.