Flexible Connector for Photovoltaic Array Thermal Movement
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Solution Overview
Problem
Photovoltaic arrays face challenges due to environmental changes causing stress and strain on connectors, leading to dislocation or breakage, which complicates maintenance and reduces efficiency, as existing connectors are not flexible enough to accommodate thermal expansion and movement without damaging the components.
Innovation Solution
A flexible connector system with a housing and electrical conductors that allows movement within and out of a plane, featuring partial recesses and receptors for secure, quick-release connections, ensuring electrical continuity and easy disconnection without damage to the photovoltaic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid connector is used to electrically connect photovoltaic components, then the electrical connection is stable, but the connector cannot accommodate thermal expansion and movement, leading to dislocation or breakage
Solution Approach 1:
The connector is designed with flexible elements including a flexible circuit board and resilient contact members that can dynamically adjust to accommodate thermal expansion and movement between photovoltaic components while maintaining stable electrical connection. The flexible circuit board allows the connector to bend and flex without breaking, and the resilient contacts can compress and expand to maintain contact pressure despite relative movement between connected components.
Solution Approach 2:
The connector incorporates a flexible circuit board as its core structural element, replacing traditional rigid printed circuit boards. This flexible circuit board can bend and flex to accommodate dimensional changes in connected photovoltaic components due to thermal expansion. The flexible nature of this thin film structure allows the connector to adapt to movement while maintaining electrical connectivity, preventing dislocation and breakage that would occur with rigid connectors.
2Adaptability or versatility
If a flexible connector is used to accommodate movement, then the connector can handle thermal expansion, but the connection may become loose or dislocated
Solution Approach 1:
The connector employs resilient contact members with spring-like properties that dynamically adjust to movement between photovoltaic components. These resilient contacts can compress when components move apart and expand when components are close together, maintaining constant contact pressure and stable electrical connection throughout the range of expected thermal expansion and contraction movements.
Solution Approach 2:
The flexible circuit board acts as a cushioning element that absorbs and accommodates dimensional changes in connected components before these changes can cause connection failure. By incorporating this flexible buffer into the connector design, the system prepares for thermal expansion and movement in advance, allowing the connector to flex and absorb these changes without transmitting excessive stress to the electrical contacts or causing dislocation.
3Reliability
If connectors are designed for secure connection, then the electrical connection is maintained, but maintenance and replacement require excessive manipulation and time
Solution Approach 1:
The connector is designed as a separate, modular component that can be independently installed and removed from photovoltaic components. This segmentation allows the connector to provide secure electrical connection while enabling quick removal and replacement without requiring manipulation of the photovoltaic components themselves. The connector's modular design with distinct connection interfaces at each end facilitates tool-free or minimal-tool installation and removal, significantly reducing maintenance time while maintaining reliable electrical connectivity during operation.
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 flexible connector system maintains electrical connections while allowing for thermal expansion and movement, reducing maintenance time and preventing damage to photovoltaic components, ensuring continuous operation and extended lifespan.
Implementation Method 1
the connector is flexible so that the first end and the second end are movable relative to each other in a plane, out of the plane, or both
Data Source
AI summary
A photovoltaic assembly comprising; (a) at least two photovoltaic components that are adjacent to each other in a first direction, each photovoltaic component comprising (i) a partial recess in communication with the partial recess in an adjacent photovoltaic component and (ii) one or more connector receptors aligned in a second direction which is non-parallel to the first direction; (b) a connector located at feast partially in the partial recess of the photovoltaic component and at least partially in the partial recess of the adjacent photovoltaic component so that the connector connects the photovoltaic component to the adjacent photovoltaic component, the connector comprising: (i) a flexible housing having a first end and a second end; (ii) one or more connection ports at the first end; (iii) one or more connection ports at the second end; and (iv) one more flexible electrical conductors that extend from the one or more connection ports at the first end to the one or more connection ports at the second end; wherein the connector is flexible so that the first end and the second end are movable relative to each other in a plane, out of the plane, or both; wherein the one or more connection ports at the first end and the one or more connection ports at the second end form a connection with the one or more connector receptors of the photovoltaic component and the adjacent photovoltaic component so that the connector electrically connects the photovoltaic component to the adjacent photovoltaic component.