Solar Junction Box Foil Termination via Transition Leg
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Solution Overview
Problem
The existing solar junction boxes face challenges in reliably and efficiently terminating foils from solar panels due to the complexity of manipulating and forming foils into three-dimensional shapes within limited spaces, which can lead to damage and reliability issues.
Innovation Solution
A solar junction box design featuring a housing with a base and cover that includes a contact assembly with a terminal and protection device, where the terminal has a foil contact with a transition leg and mating leg to securely interface with the foil, allowing for effective termination without exposing the foil externally, thus reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the foil is manipulated and formed into three-dimensional shapes within the junction box, then the foil can be terminated to the terminal, but the foil may be damaged due to bending and moving causing fracturing
Solution Approach 1:
Instead of bringing the terminal to the foil and manipulating the foil into complex shapes, the patent inverts the approach by having the foil contact remain flat and stationary while the terminal structure adapts to receive it. The transition leg and mating leg configuration allows the terminal to accommodate the foil in its natural flat state, eliminating the need for complex foil forming operations that cause damage.
Solution Approach 2:
The patent introduces an intermediary structure - the transition leg - that bridges between the mounting wall and the mating leg. This transition leg provides a gradual geometric transition that facilitates foil termination without requiring sharp bends or complex manipulations, thereby protecting the foil from fracturing while still enabling reliable electrical connection.
2Productivity
If the foil is manipulated and formed into three-dimensional shapes, then the foil can interface with the terminal, but the process is time consuming and difficult due to limited accessibility
Solution Approach 1:
The terminal is segmented into distinct functional parts: the mounting wall for structural support, the transition leg for geometric adaptation, and the mating leg for foil contact. This segmentation allows each component to perform its specific function independently, simplifying the overall termination process and improving productivity without requiring complex integrated structures.
Solution Approach 2:
The transition leg is pre-configured with its specific geometry before assembly, creating the optimal pathway for foil termination in advance. This preliminary geometric preparation eliminates the need for complex on-site foil manipulation, allowing for quick and efficient termination operations while maintaining simple device architecture.
3Reliability
If manipulation tools are used within the solar junction box for welding, then the foil can be terminated to the terminal, but it is difficult due to space constraints
Solution Approach 1:
The patent extracts the complex foil manipulation requirements from the junction box assembly process. By designing the terminal with the transition leg and mating leg configuration, the need for complex in-situ foil forming and manipulation tools is eliminated. The foil can be terminated using simpler, more accessible tools that can easily reach into the junction box space.
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 enhances the reliability and efficiency of terminating solar panel foils by minimizing manipulation and exposure, reducing the risk of damage and improving long-term performance.
Implementation Method 1
Due to the photovoltaic effect, the energy of photons is converted into electrical power within a PV cell when the PV cell is irradiated by a light source such as sunlight
Data Source
AI summary
A solar junction box for a solar panel having at least one photovoltaic cell and a foil electrically connected to the at least one cell including a housing having a base and a cover coupled to the base. The base and the cover define a cavity. The base has a mounting wall including a mounting surface configured to be mounted to the solar panel including a foil opening at the mounting surface. A contact assembly is received in the cavity having a terminal including a foil contact configured to be terminated to the foil. The foil contact has a transition leg transitioning into the foil opening to interface with the foil and a mating leg configured to be mated with the foil. The mating leg extends at or beyond the mounting wall.