Modular Photovoltaic Converter Assembly Without Welding

Solution Overview

Problem

Existing photovoltaic converters for luminescent solar concentrators lack flexibility in assembly, requiring skilled operators for time-consuming welding operations, and are not scalable due to the need for tailor-made components.

Innovation Solution

A modular photovoltaic converter design featuring insertion-connected bridge modules that eliminate the need for welding, allowing for flexible assembly and use of identical modules in various configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If photovoltaic-cell devices are welded on substrates and coupled along the perimeter of the luminescent solar concentrator, then electrical connections are established, but assembly is time-consuming and requires highly skilled operators

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical insertion connection system. The bridge modules feature connectors that insert into corresponding receptacles on the photovoltaic modules, establishing electrical connections through conductive contacts without requiring welding operations. This substitution eliminates the need for skilled welding operators and significantly reduces assembly time while maintaining reliable electrical connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If tailor-made components with multiple photovoltaic cells are pre-assembled on a single support, then assembly is simplified, but production cannot be scaled due to lack of standardization

Engineering Contradiction:

Improveassembly easeVSAvoidproduction scalability

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The patent segments the photovoltaic converter into standardized, modular components: individual photovoltaic modules with integrated connectors and bridge modules. Each module is designed with standard dimensions and connection interfaces, allowing them to be manufactured independently and assembled in various configurations. This segmentation enables both ease of assembly (modular construction) and production scalability (standardized components can be mass-produced and combined in different quantities).

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates universal bridge modules that can connect any photovoltaic module to any other photovoltaic module regardless of position or orientation. The standardized connectors and receptacles provide multi-functional compatibility, allowing the same bridge module design to be used throughout the entire converter assembly. This universality enables scalable production while maintaining assembly ease, as the same standardized components can be used in various configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If welding operations are used to connect photovoltaic cells, then electrical connections are established, but assembly mistakes occur with poorly skilled operators

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly skill requirement

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the welding process (requiring skilled operators) with a mechanical insertion connection system. The bridge modules feature connectors that insert into corresponding receptacles on the photovoltaic modules, establishing electrical connections through conductive contacts without requiring welding operations. This substitution eliminates the need for skilled welding operators and significantly reduces assembly time while maintaining reliable electrical connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If a wide range of tailor-made photovoltaic products is produced to meet various installation needs, then adaptability is improved, but costs and complexity increase due to inefficient scale economies

Engineering Contradiction:

Improveinstallation adaptabilityVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent segments the photovoltaic converter into standardized, modular components: individual photovoltaic modules with integrated connectors and bridge modules. Each module is designed with standard dimensions and connection interfaces, allowing them to be manufactured independently and assembled in various configurations. This segmentation enables both ease of assembly (modular construction) and production scalability (standardized components can be mass-produced and combined in different quantities).

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates universal bridge modules that can connect any photovoltaic module to any other photovoltaic module regardless of position or orientation. The standardized connectors and receptacles provide multi-functional compatibility, allowing the same bridge module design to be used throughout the entire converter assembly. This universality enables scalable production while maintaining assembly ease, as the same standardized components can be used in various configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The modular design simplifies assembly, reduces the risk of defects, and enables cost-effective mass production by using a single type of photovoltaic module in different combinations, while also improving scalability and reducing warehouse management complexity.

Implementation Method 1

containing colour centres and selectively absorbing a portion of the solar spectrum

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Implementation Method 2

The absorbed luminous radiation may be re-emitted in a substantially isotropic manner from the colour centres as a fluorescence radiation

Methodology Applied

Scientific EffectFluorescence: Fluorescence

Implementation Method 3

is partially conveyed towards the perimeter of the slab as a result of total internal reflection

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 4

The fluorescence radiation conveyed towards the perimeter of the luminescent solar concentrator is collected by the photovoltaic cells and converted into electricity, in particular into a current proportional to the incident optical power

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Data Source

PatentUS12323098B2Photovoltaic converter

Publication Date: 2025.06.03 ENI SPA

AI summary

A photovoltaic converter for electric power generating panels includes photovoltaic modules. Each photovoltaic module has a substrate, extending along a main direction from a first end to a second end, and a photovoltaic devices, arranged on the substrate in succession along the main direction. The photovoltaic converter further includes at least a bridge module insertion-connecting a respective upstream photovoltaic module and a respective downstream photovoltaic module.