Modular Solar Box with Standardized Interface
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Solution Overview
Problem
Existing solar boxes are large, inflexible, difficult to maintain, and poorly protected against external influences, leading to issues such as reduced stackability and increased risk of damage during transport and assembly, as well as affecting neighboring solar panels if one fails.
Innovation Solution
A modular solar box design with a multi-part housing that can be operatively connected both mechanically and electrically via a standardized interface, allowing for functional expansion and redesign, featuring self-locking active connection means for durability and improved cooling through an air gap between modules and solar panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a large solar box with cooling fins is used, then cooling performance is improved, but device size increases and stackability is reduced
Solution Approach 1:
The solar box is divided into separate modular components: a connection box housing, an optional expansion module, and a base plate. This segmentation allows the cooling function to be achieved through the base plate design (protruding base) rather than large external fins, reducing overall device size while maintaining cooling effectiveness through convective airflow beneath the module.
Solution Approach 2:
The cooling approach shifts from vertical protrusions (cooling fins extending upward) to horizontal positioning (base plate protruding downward creating an air gap). This dimensional change allows cooling functionality to be achieved without increasing the vertical profile of the device, preserving stackability while maintaining thermal management.
2Ease of manufacture
If a fixed non-modular solar box design is used, then manufacturing is simplified, but adaptability to new requirements is reduced
Solution Approach 1:
The solar box transitions from a static fixed design to a dynamic modular configuration. The connection box can operate independently or be expanded by attaching additional modules via standardized interfaces. This dynamic adaptability allows the system to evolve from a simple connection box to a complex integrated system with additional functions like power optimization or monitoring, while maintaining manufacturing simplicity through standardized component designs.
Solution Approach 2:
The standardized mechanical and electrical interfaces create universal connectivity between modules. The same connection box design can serve multiple functions depending on which modules are attached - basic electrical connection, expanded power optimization, monitoring capabilities, or combinations thereof. This universality enables adaptability without requiring different base designs for different applications.
3Ease of manufacture
If a integrated non-modular solar box is used, then assembly is simplified, but maintainability is reduced
Solution Approach 1:
The solar box is segmented into independently replaceable modules connected via standardized interfaces. If one module fails, only that specific module needs to be detached and replaced rather than replacing the entire integrated unit. The mechanical connection allows quick separation and reattachment, maintaining assembly simplicity while dramatically improving maintainability through modular replacement.
Solution Approach 2:
The modular design enables individual modules to be discarded (removed) and recovered (reused) independently. A failed module can be detached from the healthy connection box and other functional modules, allowing selective replacement rather than total system replacement. This recovers the functional portions of the system while replacing only the defective component.
4Volume of moving object
If a compact solar box design is used, then transport damage risk is reduced, but cooling performance may be compromised
Solution Approach 1:
The cooling strategy moves from vertical space consumption (tall cooling fins) to horizontal air gap creation (protruding base plate). This dimensional shift achieves effective cooling through convective airflow in the horizontal plane beneath the solar module, maintaining a compact vertical profile that reduces transport damage risk while preserving cooling effectiveness.
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
Enables flexible adaptation to new requirements, enhanced durability, improved cooling, and reduced risk of damage, while maintaining compatibility with various solar panels without the need for different connection boxes, thus addressing the limitations of existing solar box technologies.
Implementation Method 1
improved cooling through an air gap between modules and solar panels
Data Source
Figure 1~4
Figure 5~8
Figure 9~10
AI summary
The invention relates to a solar box (1) with a connection box (2) and at least one extension module (3, 20), which can be operatively connected to the connection box (2) via a first and a second connector part (9, 10) of a standardized interface (8). The connection box has a connection shaft (5), into which contacts (7) lead from a shaft wall (11). The contacts (7) and the standardized interface (9) are arranged on the same shaft side.