Dual Compressive Connector for PV Bus Bars
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Solution Overview
Problem
Existing electrical connectors for photovoltaic panels require tools to insert and remove bus bars, which can be cumbersome and increase the risk of damage.
Innovation Solution
A casing with bent elastic strips made of resilient spring metal, allowing bus bars to be inserted and removed without tools by leveraging the elastic modulus and thickness for secure, tool-free connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional electrical connectors are used, then secure electrical connection is achieved, but tool insertion and removal processes are required which increase complexity and risk of damage
Solution Approach 1:
The elastic strip is designed to be dynamically deformable, allowing it to flex outward when bus bars are inserted and then return to its original shape to secure the connection. This dynamic behavior eliminates the need for tools while maintaining secure electrical connection, directly resolving the contradiction between ease of operation and connection reliability.
Solution Approach 2:
The patent utilizes changes in the physical state of the elastic strip through elastic deformation. By leveraging the elastic properties of the material, the connector can transition between open and closed states without tools, reducing operational complexity while ensuring reliable bus bar retention and minimizing damage risk.
2Ease of operation
If tool-free connection is implemented, then ease of operation is improved, but connection security may be compromised
Solution Approach 1:
The elastic strip is bent into a curved configuration with specific geometry that allows it to flex outward for easy bus bar insertion while maintaining sufficient elastic restoring force to secure the connection. The curved shape enables tool-free operation while preserving connection strength through optimized elastic deformation characteristics.
3Strength
If elastic strip thickness and elastic modulus are increased, then connection strength is improved, but ease of insertion deteriorates
Solution Approach 1:
The patent optimizes the thickness and elastic modulus parameters of the elastic strip to achieve a balance between connection strength and ease of insertion. By carefully selecting these material parameters, the connector provides sufficient holding force for secure electrical connection while remaining flexible enough to allow tool-free bus bar insertion through controlled elastic deformation.
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
Enables easy, tool-free insertion and removal of photovoltaic bus bars, enhancing convenience and reducing the risk of damage while maintaining reliable electrical connections.
Implementation Method 1
The bent elastic strip is formed of resilient spring metal with a thickness and an elastic modulus. The thickness and/or the elastic modulus of the elastic strip is/are configured so that the bus bars are inserted without requiring a tool to open a space between the first leg and the first opposing wall or between the second leg and the second opposing wall.
Data Source
AI summary
An electrical connector for electrically connecting multiple photovoltaic bus bars. A casing includes first and second opposing walls. An elastic strip is bent into a bent elastic strip with a first leg and a second leg. The bent elastic strip is disposed between the first and second walls of the casing with the first leg pressing against the first wall and the second leg pressing against the second wall. The bent elastic strip is configured to hold at least one of the photovoltaic bus bars between the first leg and the first wall and another of the photovoltaic bus bars between the second leg and the second wall. The bent elastic strip may be formed of resilient spring metal with a thickness and an elastic modulus. The thickness and/or the elastic modulus of the elastic strip is/are configured so that the bus bars are inserted without requiring a tool to open a space and so that the bus bars are removed from the connector without requiring a tool to break the electrical connection.