Flat Photovoltaic Connector With Sealed Recesses
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Solution Overview
Problem
Existing photovoltaic connector systems face challenges in providing a space-saving, sealed, and securely latched design for photovoltaic roof tiles that can withstand environmental influences and allow for efficient electrical interconnection of multiple tiles, while ensuring mechanical strength and ease of assembly.
Innovation Solution
A flat electrical connector system with a junction box designed to accommodate multiple socket connectors, featuring a stepped recess with grooves for metallic contact elements, elastic rubber contact bodies for sealing, and latching mechanisms to ensure secure locking and directional energy flow, allowing for interconnection of multiple photovoltaic tiles with machine-weldable contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circular connector design is used, then secure latching and sealing are achieved, but large dimensions and space consumption occur
Solution Approach 1:
The patent transitions from traditional circular connector geometry to a flat planar design. The contact elements are arranged in a substantially planar array rather than radially around a central axis, fundamentally changing the spatial configuration to reduce volume while maintaining connection functionality
Solution Approach 2:
The connector design moves from a three-dimensional circular arrangement to a two-dimensional planar structure. Contact elements are positioned in a flat substantially planar array, utilizing dimensional transformation to achieve compactness without sacrificing latching or sealing capabilities
2Object-affected harmful factors
If rubber seal material is used, then weather and environmental sealing is achieved, but mechanical strength for secure locking is insufficient
Solution Approach 1:
The patent employs a hybrid material system combining rubber seal elements for environmental sealing with rigid plastic or metal structural components for mechanical strength. The housing integrates both flexible sealing portions and rigid locking portions, creating a composite structure that simultaneously achieves weather resistance and secure mechanical interlocking
Solution Approach 2:
Different regions of the connector are assigned different material properties: rubber or elastomeric materials are used specifically in sealing contact areas to provide flexibility and environmental protection, while rigid materials are used in structural and latching areas to provide mechanical strength and dimensional stability
3Volume of moving object
If flat connector design is used, then space-saving and ease of assembly are achieved, but insulating material density and sealing properties are compromised
Solution Approach 1:
The patent incorporates flexible sealing elements such as rubber grommets, O-rings, or elastomeric barriers within the flat connector structure. These flexible sealing components conform to mating surfaces and cable interfaces, providing effective environmental protection despite the reduced overall thickness of the planar design
Solution Approach 2:
Sealing elements are nested within the flat connector housing structure, with rubber seals positioned in recesses or channels that guide them into optimal sealing positions. This nested arrangement maximizes sealing effectiveness within the constrained planar geometry
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 provides a compact, weather-tight, and securely latched connector system that enables efficient electrical interconnection of photovoltaic tiles, ensuring reliable energy transport and easy assembly, while maintaining mechanical strength and environmental durability.
Implementation Method 1
a latching spring (43) which is supported in a non-positive manner on the latching means (24, 31)
Implementation Method 2
preferably elastic plastics are to be used for the seal, in a preferred embodiment rubber materials
Data Source
Figure 1
Figure 2~6
Figure 7
AI summary
The connection box (2) has a flat contact body with two insertion holes (28a,28b), which are mounted on a contact element for a plug-in engagement with a female connecter, where the insertion holes are formed on two opposite recesses (29) of the contact body. The recesses are attached to a guiding unit (30) for guiding the female connecter. An independent claim is included for a female connector for insertion into an insertion hole of a connection box.