Direct-Output Functional Module Without a Junction Box
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Solution Overview
Problem
The installation of photovoltaic modules on roadways and other surfaces is costly due to the need for a junction box, which requires trenching and filling, increasing labor and material costs.
Innovation Solution
A multilayer stack design that integrates the electrical connection element directly into the functional device, eliminating the need for an intermediate junction box by embedding it within the encapsulating assembly and using a sheath free from halogen elements, ensuring a secure seal and reliability against environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a junction box is used to connect internal flat copper tape to external cables, then electrical connection functionality is achieved, but installation complexity and cost increase due to required trenching and filling
Solution Approach 1:
The patent merges the electrical connection element with the encapsulating assembly by integrating the cable directly into the encapsulation structure. The cable passes through the encapsulating assembly without requiring a separate junction box, combining multiple functions (electrical connection, sealing, and mechanical protection) into a single integrated component.
Solution Approach 2:
The patent extracts the junction box from the system by eliminating this intermediate component. Instead of using a separate junction box for cable connection, the cable is directly integrated into the encapsulating assembly, removing the need for trenching and filling operations while maintaining electrical connection functionality.
2Reliability
If a junction box is embedded in the roadway to enable electrical connections, then electrical functionality is achieved, but installation time and labor costs increase
Solution Approach 1:
The electrical connection element is merged with the encapsulating assembly, allowing the cable to pass directly through the module structure. This integration eliminates the need for separate trenching and junction box installation steps, significantly reducing installation time and labor while maintaining connection stability.
3Reliability
If the electrical connection element uses a halogen-containing sheath, then electrical insulation is achieved, but adhesion to the encapsulating assembly deteriorates causing delamination risk
Solution Approach 1:
The patent changes the chemical composition parameter of the cable sheath by selecting materials free from halogen elements (such as fluoropolymers, chloropolymers, and bromopolymers). This material substitution maintains electrical insulation properties while improving adhesion to the encapsulating assembly, preventing delamination at the cable exit.
Data Source
AI summary
The invention relates to a functional device (100) comprising a multilayer stack comprising, in succession:a first protective film (101), placed on a front side of said device (100),an encapsulating assembly (107),a second protective film (105), placed on the back side of the device,at least one electrically or optically active element (110) embedded in the encapsulating assembly, andan electrical connecting element (160) directly connected to said electrically or optically active element and suitable for transporting electricity from or to said electrically or optically active element, one end (162) of said electrical connecting element exiting directly from said functional device.