Multilayer Functional Device With Direct Outputs Without Junction Boxes

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Solution Overview

Problem

The installation of photovoltaic modules on roadways is costly due to the need for trenches to accommodate junction boxes, which are necessary for electrical connections, increasing labor and material expenses.

Innovation Solution

A multilayer stack design integrates the electrical connection element directly into the functional device, eliminating the need for an external junction box by using a sheath free of halogen elements and allowing the connection element to exit directly from the device, ensuring good adhesion and sealing without delamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a junction box is used for electrical connections in photovoltaic modules, then electrical connectivity is ensured, but installation costs increase due to the need for trenches and additional materials

Engineering Contradiction:

Improveelectrical connectivityVSAvoidinstallation cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention extracts and eliminates the junction box component from the photovoltaic module assembly. Instead of using a separate junction box for electrical connections, the patent integrates the electrical connection system directly into the module structure through the backsheet, removing the need for trenches and reducing installation complexity while maintaining electrical connectivity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention merges the electrical connection function with the backsheet layer. The backsheet is designed to incorporate electrical connection elements and conductive pathways directly, combining what were previously separate components (junction box and backsheet) into a single integrated structure that simplifies installation and reduces costs

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a junction box is embedded in the roadway, then electrical connections are protected, but labor and material expenses increase

Engineering Contradiction:

Improveprotection of electrical connectionsVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The invention removes the junction box from the roadway embedding process. By integrating electrical connections into the module itself, the patent eliminates the time-consuming steps of digging trenches, embedding junction boxes, and filling materials, while still providing protection through the integrated backsheet design

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The electrical connection elements are pre-integrated into the backsheet during module manufacturing, before installation. This preliminary integration of protective and connective functions means that during installation, no additional protective structures need to be created on-site, significantly reducing installation time and labor

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If an external junction box is used, then electrical connections can be made, but the device complexity increases

Engineering Contradiction:

Improveelectrical connection capabilityVSAvoidnumber of components

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The invention combines multiple functions into the backsheet: mechanical protection, electrical insulation, and electrical connection pathways. This merging of functions reduces the number of separate components needed while maintaining all necessary electrical connection capabilities

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The backsheet is designed as a multi-functional component that simultaneously provides mechanical protection, electrical insulation, and integrated electrical connection pathways. This universal component replaces what were previously multiple separate components (junction box, cables, connectors), simplifying the overall device structure

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

This design reduces installation costs by eliminating the need for trenches and junction boxes, enhances reliability against environmental factors, and ensures effective sealing and electrical connectivity.

Implementation Method 1

the absence of halogen elements in the outer sheath of the electrical connection element, for example of an electric cable, makes it possible to obtain good adhesion between the encapsulating assembly of the functional device and the outer sheath of the electrical connection element

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentEP4437593B1Functional device with direct electrical outputs and process for fabricating such a functional device

Publication Date: 2025.10.15 COLAS LTD

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AI summary

The invention relates to a functional device (100) comprising a multilayer stack comprising, in succession: - a first protective film (101) placed on a front side of said device (100), - an encapsulating assembly (107), - a second protective film (105) placed on a back side of the device, - at least one electrically or optically active element (110) embedded in the encapsulating assembly, and - an electrical connecting element (160) directly connected to said electrically or optically active element and suitable for transporting electricity from or to said electrically or optically active element, one end (162) of said electrical connecting element exiting directly from said functional device.