Interlockable Shell Connection Box for Photovoltaic Roof Panel Wiring
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Solution Overview
Problem
Existing photovoltaic roof installations require access to the roof substructure for connections, are cumbersome due to multiple types of connectors, and complicate wiring adjustments, making them difficult for installers to accept and assemble efficiently.
Innovation Solution
An electrical connection system featuring interlockable shells with inverse polarity terminals, allowing for easy assembly and wiring of photovoltaic modules by marginal overlapping of panels, with a kit including connection boxes and wires for efficient connection to converters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are placed on the rear side of the covering to avoid damage and preserve aesthetics, then reliability and appearance are improved, but access to the roof substructure is required for connections which increases installation complexity
Solution Approach 1:
The electrical connection system is segmented into male connectors integrated with lower panels and female connectors integrated with upper panels. This segmentation allows connections to be made at the panel level rather than requiring access to the roof substructure, thereby maintaining wire protection while reducing installation complexity.
Solution Approach 2:
The patent introduces intermediary connection elements (male and female connectors) that are integrated into the panel structure itself. These connectors serve as mediators between the photovoltaic modules and the wiring system, enabling connections to be made at the panel level without requiring access to the roof substructure.
2Adaptability or versatility
If multiple types of roofing panels with inverted photovoltaic cell placement and different male/female connectors are used to achieve wiring outlets at the ridge, then adaptability is improved, but device complexity increases substantially
Solution Approach 1:
The patent implements a universal connector system where male connectors are integrated with lower panels and female connectors with upper panels, regardless of the panel's position or orientation in the roof assembly. This universal approach eliminates the need for multiple types of connectors with inverted photovoltaic cell placement, thereby maintaining wiring configuration flexibility while substantially reducing device complexity.
Solution Approach 2:
Instead of inverting the photovoltaic cell placement and using different connector types for different panel positions, the patent inverts the approach by maintaining consistent photovoltaic cell placement and using the same connector types throughout. The male-female connector pairing is systematically applied based on panel position (lower/upper) rather than requiring multiple connector varieties.
3Manufacturing precision
If access to the roof substructure is required for rear-side connections, then manufacturing precision is maintained, but ease of operation deteriorates
Solution Approach 1:
The male and female connectors are pre-integrated into the lower and upper panels respectively during panel manufacturing. This preliminary action ensures that the connectors are precisely positioned and aligned before installation, maintaining manufacturing precision while eliminating the need for access to the roof substructure during assembly, thereby significantly improving ease of operation.
Solution Approach 2:
The panel structure itself provides the connection function through integrated male and female connectors. The panels are self-sufficient with built-in connection capabilities, eliminating the need for separate access to the roof substructure for making connections. This self-service approach maintains precision while dramatically improving assembly ease.
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
Facilitates easy assembly and adjustment of photovoltaic module connections, reduces the complexity of wiring, and allows for efficient electrical connections between panels and converters, improving installer acceptance and reducing installation obstacles.
Implementation Method 1
a central part, which connects the transverse edges, which is covered by at least one pair of columns of photovoltaic modules
Implementation Method 2
a perforation situated in the lower overlap area through which a conducting strip is passed, which connects one of the two electrical poles of the column of photovoltaic modules to one of the two shells of a connection box
Implementation Method 3
the connection box including a first shell and a second shell, one interlockable inside the other
Data Source
AI summary
The present invention provides an electrical connection box for a panel of exterior cladding of a building equipped with at least one photovoltaic module including an electrical pole at one of its longitudinal extremities and an electrical pole of inverse polarity at the other extremity, the connection box including a first shell and a second shell which are interlockable, the first shell including a base including an aperture topped by a sealing chamber, a lateral wall surrounding the base and extending perpendicularly to it, the lateral wall including a removable hatch used as a wire passage, an electrical terminal attached perpendicularly to the base, the second shell including a base, a lateral wall surrounding the base and extending perpendicularly to it, the lateral wall including a wire passage, an electrical terminal of inverse polarity to that of the electrical terminal of the first shell, the electrical terminal being on a perpendicular axis to the base, attached to the base and positioned in such a way that it is plumb with the electrical terminal of the first shell when the first and the second shell are interlocked.The invention further provides a panel of exterior cladding of a building equipped with connection boxes according to the present invention, to the related roof, to the related connection kit and to the related electrical device.