Photovoltaic Junction Box Diode Soldering Stability
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Solution Overview
Problem
The existing photovoltaic junction boxes have weak soldering holding force and reduced current-carrying capacity due to small soldering surface areas of anode pins, leading to instability and reduced performance.
Innovation Solution
The photovoltaic junction box design includes a connection piece that increases the soldering area of the first electrode pins, allowing them to be soldered on adjacent contacts along with their soldering end portions, enhancing the soldering holding force and current-carrying capacity, and optionally features a second electrode pin with a larger soldering surface for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the anode pins are designed with small soldering surfaces to reduce device complexity, then the device complexity is reduced, but the soldering holding force and current-carrying capacity deteriorate
Solution Approach 1:
The anode pin structure is segmented into two functional parts: the original pin body for electrical connection and an extended soldering tail for mechanical attachment. This segmentation allows each part to optimize its function independently - the pin body remains compact while the soldering tail provides extended surface area for robust soldering attachment to the contact.
2Reliability
If the soldering surface area of anode pins is increased to improve soldering holding force, then the soldering stability is improved, but the device complexity increases
Solution Approach 1:
Instead of enlarging the main body of the anode pin (which would increase overall device complexity), the invention inverts the approach by extending a specific functional portion - the soldering tail - backwards from the pin body. This inverted extension provides increased soldering surface area without proportionally increasing the overall device footprint or manufacturing complexity.
3Power
If the soldering surface area of anode pins is increased to improve current-carrying capacity, then the current-carrying capacity is improved, but the device complexity increases
Solution Approach 1:
The invention addresses current-carrying capacity by extending the soldering tail in a dimensional direction perpendicular to the main pin body axis. This dimensional extension provides increased surface area for current distribution without increasing the cross-sectional area of the pin body, thereby improving current-carrying capacity through surface area extension rather than volumetric expansion.
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
This design significantly improves the soldering stability and current-carrying capacity of the first electrode pins while also enhancing heat dissipation through increased soldering areas and larger surface contacts.
Implementation Method 1
The connection piece is configured to be soldered on the one of the two adjacent contacts along with the soldering end portions of the pair of first electrode pins
Data Source
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AI summary
The present disclosure discloses a photovoltaic junction box, including: a housing; at least two contacts provided in the housing; and at least one diode each mounted on two adjacent contacts. Each diode comprises a pair of first electrode pins separated from each other and each having a soldering end portion adapted to be soldered on one of the two adjacent contacts; and a connection piece connected with the soldering end portions of the pair of first electrode pins. The connection piece is configured to be soldered on the one of the two adjacent contacts along with the soldering end portions of the pair of first electrode pins. Therefore, the photovoltaic junction box increases the soldering area of the first electrode pins of the diode, and improves the soldering holding force between the first electrode pins of the diode and the contact and thus the current-carrying capacity and soldering stability of the first electrode pins.