Integrated Photovoltaic Cable with U-Shape Groove Crimping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing photovoltaic cables face issues with high contact resistance, complex connection processes, poor product consistency, and difficulty in ensuring connection firmness due to the use of copper sheets and screws, which increase direct current resistance and require complex operations.
Innovation Solution
An integrated photovoltaic cable with a connecting terminal featuring U-shape groove sheets and a crimping terminal mode, where the connecting sheet is injection-molded with a housing, and the exposed conductors are crimped into the U-shape groove sheets, reducing contact resistance and improving connection quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper sheet and screw connection is used, then connection firmness is achieved, but contact resistance increases and device complexity increases
Solution Approach 1:
The patent combines the copper sheet and screw into an integrated connecting terminal where the screw is embedded within the copper sheet structure. This merging eliminates the separate components while maintaining connection firmness and reducing contact resistance by creating a more unified electrical contact path.
Solution Approach 2:
The connecting terminal serves multiple functions: it provides mechanical fastening through the screw, electrical connection through the copper sheet, and structural support. By making the terminal multi-functional, the design reduces the number of separate components needed while improving electrical contact.
2Reliability
If copper sheet and screw connection is used, then connection firmness is achieved, but device complexity and operation complexity increase
Solution Approach 1:
The copper sheet and screw are merged into a single integrated connecting terminal component. This reduces device complexity by eliminating the need for separate assembly of multiple parts while maintaining the connection firmness provided by the screw mechanism.
Solution Approach 2:
The connecting terminal is designed with segmented functional zones: an embedded screw portion for mechanical fastening and a copper sheet portion for electrical connection. This segmentation of functions within a unified structure simplifies the overall device while maintaining reliability.
3Reliability
If copper sheet and screw connection is used, then connection is achieved, but manufacturing precision and product consistency deteriorate
Solution Approach 1:
The integrated connecting terminal is manufactured as a single piece using stamping and embedding processes, which ensures consistent geometry and electrical contact properties across all products. This merging eliminates variability introduced by assembling separate components.
Solution Approach 2:
The manufacturing process parameters are optimized for the integrated structure, including the embedding depth of the screw in the copper sheet and the overall terminal geometry. These controlled parameters ensure consistent electrical and mechanical properties across production batches.
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 solution simplifies the production process, enhances connection quality, reduces adapter volume, and ensures a secure and efficient connection with reduced contact resistance, while allowing for expanded connection modes through cross-shaped, T-shaped, or Y-shaped terminal designs.
Implementation Method 1
a plurality of U-shape groove sheets crimped with the photovoltaic cable are integrally formed on the connecting sheet
Implementation Method 2
a housing injection-molded on the connecting terminal
Implementation Method 3
a plurality of anti-skid ribs are provided on an inner surface of each U-shape groove sheet
Implementation Method 4
smearing waterproof glue on a peeled fracture of the photovoltaic cable
Data Source
AI summary
An integrated photovoltaic cable having a connecting terminal and a housing injection-molded on the connecting terminal. The connecting terminal has a connecting sheet, a through hole, and a plurality of U-shape groove sheets. Exposed conductors obtained by peeling front ends of the photovoltaic cable are respectively placed into corresponding U-shape groove sheets and crimped by a crimping plier. A manufacturing method for manufacturing the integrated photovoltaic cable includes three steps of manufacturing a connecting terminal, crimping photovoltaic wires, and injection molding a housing. An improvement of the cable connecting structure simplifies the production, improves the connecting quality, and reduces a volume of an adapter. The conductor end and the U-shape groove are firmly and conveniently connected to ensure the connection quality, reduce a contact resistance of a connecting wire, and cause a smaller volume of the adapter.