In-Process Electrical Connector for Photovoltaic Modules
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Solution Overview
Problem
The inability to apply an electrical bias to photovoltaic modules until electrical contacts are added limits the ability to perform necessary applications and testing during the manufacturing process, hindering early detection of defects and performance evaluation.
Innovation Solution
A temporary electrical connection apparatus and method that allows for the application of an electrical bias to partially assembled photovoltaic modules using deformable contacts and adjustable spring contacts, enabling in-process testing and performance evaluation before the module is fully assembled.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical contacts are added only near the end of the manufacturing process, then the module structure remains simple and assembly is easier, but the ability to apply electrical bias and perform testing is delayed
Solution Approach 1:
The patent applies preliminary action by installing temporary electrical contacts on the module during intermediate manufacturing stages, before the final electrical contacts are added. This allows electrical bias to be applied and testing to be performed earlier in the process, enabling defect detection before completion while maintaining the simplicity of the final assembly structure.
2Reliability
If temporary electrical contacts are installed during manufacturing, then in-process testing and electrical bias application become possible, but the manufacturing process complexity increases
Solution Approach 1:
The patent employs disposable temporary electrical contacts that are installed during manufacturing for testing purposes and then removed before final assembly. These temporary contacts enable performance evaluation and electrical bias application without permanently complicating the manufacturing process or final product structure, as they are discarded after serving their testing function.
3Productivity
If module testing is performed only after complete assembly, then fewer process steps require modification, but defective modules continue consuming resources through the entire process
Solution Approach 1:
The patent implements preliminary testing by installing temporary contacts and performing electrical bias application and performance evaluation at intermediate manufacturing stages. This allows defective modules to be identified and removed before completing the entire manufacturing process, improving resource efficiency by preventing further processing of non-conforming modules while requiring modifications only to specific process steps rather than the entire manufacturing flow.
Data Source
AI summary
Characteristics of partially assembled photovoltaic modules can be determined using electrical connection apparatuses and methods. By providing deformable electrical contacts against a partially assembled module on an assembly line, an electrical bias can be applied to the module before the module is completely assembled. An electrical connection apparatus for a photovoltaic module may include a first contact configured to engage a first lead on the photovoltaic module, a second contact configured to engage a second lead on the photovoltaic module, and an electrical power source configured to apply an electrical bias between the first contact and the second contact.