Low-Profile PV Module Connector With Recessed Safe Contacts
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Solution Overview
Problem
Bulky electrical connectors for photovoltaic modules installed on roofs pose challenges in terms of space efficiency and safety, as they do not prevent access to conductive members, which can lead to electrical contact and safety issues.
Innovation Solution
A low-profile electrical connector system with a first receptacle and a second receptacle, featuring non-conductive openings and conductive members, designed to mate in a way that limits thickness to less than 10 mm and prevents access to the conductive members, ensuring safety compliance with UL 6703 by surrounding the electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bulky electrical connectors are used for photovoltaic modules, then electrical connection is achieved, but the connector thickness increases and safety is compromised due to accessible conductive members
Solution Approach 1:
The conductive members are nested within recessed cavities in the receptacle housing. The first conductive members are received in first recesses and the second conductive members are received in second recesses, creating a nested structure where the conductive elements are contained within the housing rather than exposed on the surface. This nesting approach prevents external access to the conductive members while maintaining electrical connectivity, thereby improving safety without significantly increasing overall connector thickness.
Solution Approach 2:
The conductive members are extracted from the external surface and relocated to recessed positions within the housing. By removing the conductive members from exposed positions and placing them within recesses that prevent access, the design extracts the hazard from the external interface while maintaining the electrical connection function internally.
2Reliability
If traditional electrical connectors are used, then electrical connection is established, but space efficiency is reduced due to increased thickness
Solution Approach 1:
The recessed structure creates a nested arrangement where conductive members are housed within cavities rather than extending outward. This nesting allows the electrical connection components to be contained within a compact volume, reducing the overall thickness and volume of the connector assembly while maintaining reliable electrical contact between mating connectors.
3Ease of operation
If conductive members are made accessible for connection, then electrical connectivity is achieved, but safety hazards increase due to potential electrical contact
Solution Approach 1:
The conductive members are nested within recessed cavities that prevent external access. The recessed structure ensures that even during installation and operation, external objects or persons cannot contact the conductive members, eliminating the electrical contact hazard while the recesses are designed to allow proper mating connectors to engage and establish electrical connectivity.
Solution Approach 2:
The hazard of exposed conductive members is extracted by relocating them to recessed positions within the housing. This extraction removes the safety hazard from the external interface while maintaining the electrical connection capability through the recessed structure that guides proper connector engagement.
Data Source
AI summary
A system, including: a plurality of photovoltaic modules installed above a roof deck, where the plurality of photovoltaic modules includes at least a first photovoltaic module and a second photovoltaic module, where each of the plurality of photovoltaic modules includes: a top surface; a bottom surface opposite the top surface; a plurality of solar cells; a first receptacle on the top surface, where the first receptacle has: a plurality of first non-conductive openings, and a plurality of first conductive members in the plurality of first non-conductive openings; and a second receptacle on the bottom surface, where the second receptacle has: a plurality of second non-conductive openings, and a plurality of second conductive members in the plurality of second non-conductive openings, where at least a portion of the second photovoltaic module overlaps at least a portion of the first photovoltaic module, where the first receptacle of the first photovoltaic module is in mechanical connection with the second receptacle of the second photovoltaic module, and where the first conductive members are in electrical communication with the second conductive members.