Diode Connector Layout for Replaceable PV Module Bypass Paths
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Solution Overview
Problem
Conventional photovoltaic modules have high installation costs due to the need for extensive routing and management of junction box cables, and replacing a defective diode often requires replacing the entire module, which is inefficient and costly.
Innovation Solution
The use of diode-included connectors with environmentally-protected housings and strain relief mechanisms, allowing for easy replacement of diodes and reducing the need for internal bus bars, with electrical conductors extending through discrete penetrations for efficient interconnection of photovoltaic laminates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional junction boxes with extensive cable routing are used, then electrical connections can be established, but installation costs increase due to substantial routing and management requirements
Solution Approach 1:
The invention divides the junction box functionality into separate modular connectors, each handling specific electrical connections. This segmentation allows for simplified cable routing while maintaining reliable electrical connections, as each connector is designed for a specific connection task rather than requiring complex internal routing management.
Solution Approach 2:
The invention extracts the diode and electrical connection components from the traditional junction box structure. By placing diodes directly in connectors and simplifying the cable routing structure, the complex routing and management requirements of conventional junction boxes are eliminated while maintaining electrical connection reliability.
2Reliability
If diodes are embedded within the module laminate, then bypass functionality is provided, but replacement of defective diodes requires replacing the entire module
Solution Approach 1:
The invention segments the diode from the module laminate by placing it in an external connector. This allows the diode to maintain its bypass functionality while being independently replaceable. When a diode fails, only the connector containing the diode needs to be replaced, not the entire module, significantly improving ease of repair.
Solution Approach 2:
The invention extracts the diode from the embedded position in the module laminate and relocates it to an external connector. This extraction maintains the bypass functionality while enabling easy replacement of defective diodes without requiring module replacement, as the diode becomes an independently accessible component.
3Reliability
If traditional junction boxes are used, then electrical connections are established, but installation and material costs increase
Solution Approach 1:
The invention segments the junction box into separate modular connectors that can be independently manufactured and installed. This segmentation simplifies the manufacturing process and reduces material costs, as each connector is a simpler, more standardized component compared to a traditional junction box, while maintaining reliable electrical connections.
Solution Approach 2:
The invention extracts the essential electrical connection functionality from the complex junction box structure. By using simplified connectors with direct cable routing, the material costs and installation complexity are reduced while maintaining reliable electrical connections between modules.
Data Source
AI summary
One embodiment relates to a connector that includes a diode. The diode has an anode and a cathode. The connector further includes a first electrical connection which connects to the anode, a second electrical connection which also connects to the anode, and a third electrical connection which connects to the cathode. Another embodiment relates to a photovoltaic laminate which includes a string of photovoltaic cells and three electrical conductors extending out of two discrete penetrations of the laminate. A first electrical conductor is connected to a first end of the string, a second electrical conductor is connected to a second end of the string, and a third electrical conductor is also connected to the second end of the string. The first and third electrical conductors extend out of the first discrete penetration, while the second electrical conductor extends out of the second discrete penetration. Other features and embodiments are also disclosed.