Compact Solar PV Module With Rotary Junction Box

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Solution Overview

Problem

Existing solar photovoltaic panels are heavy, bulky, and require unsightly mounting structures, making them difficult to install on various surfaces and increasing transportation costs, and are often configured for series connections only, necessitating additional cables and connectors for parallel configurations.

Innovation Solution

A compact solar PV module with a lightweight substrate, concealed wiring, and an integrated rotary junction box that allows for easy configuration in series or parallel connections using a rotary dial, eliminating the need for additional mounting structures and enabling seamless integration with various surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional glass solar photovoltaic panels are used, then they provide reliable solar energy conversion, but they become heavy and bulky requiring special mounting structures

Engineering Contradiction:

Improvesolar energy conversion reliabilityVSAvoidpanel weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The solar panel is segmented into multiple layers including a substrate layer, solar cell layer, and encapsulant layers, allowing each component to be optimized independently for weight and performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite materials including lightweight substrate (such as aluminum alloy or composite panels), encapsulants (EVA, fluoropolymer films), and honeycomb structures to achieve both structural integrity and weight reduction

Inventive Principle:

Principle #40Composite materials

2Strength

If traditional solar panels with bulky frames are used, then they provide structural support, but they require unsightly mounting structures on rooftops

Engineering Contradiction:

Improvestructural supportVSAvoidaesthetic appearance

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent employs thin-film encapsulants and flexible substrate materials that can conform to various surface shapes, eliminating the need for bulky frames and enabling aesthetic integration with building surfaces

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The mounting structure is designed to serve multiple functions: structural support, aesthetic integration, and adaptability to various surfaces (rooftops, walls, fences), replacing the need for separate mounting components

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If traditional heavy solar panels are used, then they provide stable power generation, but they are difficult to transport adding to installation costs

Engineering Contradiction:

Improvepower generation stabilityVSAvoidtransportation difficulty

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The solar panel system is designed as modular segmented units that can be easily transported and assembled, reducing transportation difficulty while maintaining overall system reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Lightweight composite materials and honeycomb structures provide structural integrity for reliable power generation while significantly reducing weight for easier transportation

Inventive Principle:

Principle #40Composite materials

4Device complexity

If solar panels are configured for series connections only, then they simplify the electrical design, but they require additional cables and connectors for parallel configurations increasing setup time

Engineering Contradiction:

Improveelectrical design simplicityVSAvoidinstallation speed

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The junction box incorporates a rotary dial mechanism that dynamically reconfigures electrical connections between series and parallel modes, allowing rapid switching without physical reconfiguration of cables or connectors

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The junction box is designed as a multi-functional component that provides both series and parallel connection capabilities within a single integrated unit, eliminating the need for separate connection configurations

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution results in a lightweight, user-configurable solar module that can be easily mounted on diverse surfaces, reducing installation time and costs while allowing for flexible electrical configurations without additional connectors, enhancing aesthetic integration and operational efficiency.

Implementation Method 1

solar cells laid on an appropriate substrate such as a plastic or metal sheet

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS11025193B2Compact, low-profile, multiply configurable solar photovoltaic module with concealed connectors

Publication Date: 2021.06.01 HELION CONCEPTS

AI summary

A solar module comprising a substrate, a honeycomb structure on the substrate, a solar panel on the honeycomb structure, such that the substrate, honeycomb and solar panel form a sandwich having an exterior perimeter, a rotary junction box configured to be manipulated through the substrate between at least first and second electrical configurations, a plurality of electrical couplers along the exterior perimeter, and a plurality of electrical connectors connecting the solar panel, the rotary junction box, and the electrical couplers; wherein the honeycomb structure defines one or more channels and a pocket, the channels facilitating the electrical connectors and the pocket receiving the rotary junction box.