Plastic PV Module Connectors for Insulated Rooftop Junctions
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Solution Overview
Problem
Conventional solar photovoltaic module installations on flat rooftops face challenges such as suboptimal sunlight collection due to flat positioning, potential displacement by wind, and the need for complex and costly connection systems that require metal components, increasing installation time and electrical grounding concerns.
Innovation Solution
A photovoltaic module kit with plastic connectors that form insulated junctions, allowing for non-penetrating installation and adjustable tilt angles, reducing the need for additional grounding components and simplifying the installation process by using identically formed connectors for various junction configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal connectors are used to join PV modules, then mechanical strength and rigidity are improved, but electrical grounding concerns and corrosion risks increase
Solution Approach 1:
The connector employs a composite structure combining metal fasteners (for mechanical strength) with a plastic head and body (for electrical insulation). The metal fastener provides the necessary clamping force and structural integrity, while the plastic components electrically isolate the conductive elements, eliminating grounding concerns and preventing corrosion from electrical contact.
Solution Approach 2:
The plastic head and body act as intermediary insulating elements between the metal fasteners and the PV module contact surfaces. This intermediary layer prevents direct electrical contact between metal components and the photovoltaic system, thereby eliminating the need for electrical grounding while maintaining mechanical connection integrity.
2Adaptability or versatility
If multiple different connector types are used to accommodate various junction configurations, then adaptability is improved, but device complexity and installation time increase
Solution Approach 1:
The connector is designed as a universal component that can accommodate all junction configurations (2-module, 3-module, and 4-module junctions) through a single standardized design. The plastic head with its internal fastener mechanism and external geometry works identically regardless of how many modules converge at a junction point, eliminating the need for multiple specialized connector types.
Solution Approach 2:
All connectors in the system use the same homogeneous design - identical plastic heads, identical fastener types, and identical mounting geometries. This uniformity simplifies inventory management, reduces installation training requirements, and allows installers to work with a single connector type across all junction configurations, thereby reducing overall system complexity.
3Reliability
If hand tools are required for connector installation, then connection reliability is improved, but installation time and labor costs increase
Solution Approach 1:
The connector incorporates a self-clamping mechanism where the male and female fasteners automatically engage and secure the PV modules through their complementary geometries. The design allows the connector to self-align and self-lock without requiring external tools for tightening or securing, enabling installers to complete connections by hand without specialized equipment while maintaining reliable mechanical and electrical contact.
Data Source
AI summary
A PV module kit for non-penetrating rooftop installation, including a plurality of PV modules and a plurality of connectors. Each of the PV modules includes a PV laminate and a frame forming a mounting region assembled thereto. The connectors include a male connector having a male fastener extending from a head, and a female connector having a female fastener assembled within a head. The heads are entirely formed of plastic. The kit provides a mounted array state including a junction at which the mounting region of at least two of the PV modules are aligned and interconnected by engagement of the male connector with the female connector. The so-formed junction is substantially electrically insulated. The plurality of connectors can further include a spacer connector including a head forming a bore sized to slidably receive the male fastener, with all of the connector heads being identical.