PV Connection Box Terminal with Bent Heat Path
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Solution Overview
Problem
Existing connection boxes for photovoltaic modules face challenges in heat management during soldering, leading to potential diode damage, and fail to meet aesthetic and safety requirements due to terminal configuration limitations.
Innovation Solution
A connection box design with a disconnected straight heat conduction path between the bus bar and diode connection regions, utilizing a bending heat conduction path to reduce heat transfer and incorporating deflectable barbs for terminal fixation, allowing for a miniaturized and safer configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If two connection terminals are arranged parallel to each other with a diode connected between them, then the distance between the bus bar soldering point and diode pins is sufficient to prevent heat damage to the diode, but the width size of the connection box body increases
Solution Approach 1:
The connection terminal is designed with a bent structure that extends in multiple directions rather than a straight line. The first connection portion connects to the bus bar in a first direction, while the second connection portion connects to the diode in a second direction that is not collinear with the first direction. This dimensional change allows the heat conduction path to be extended without increasing the width of the connection box, as the bending utilizes spatial arrangement in multiple dimensions rather than simply increasing linear distance.
2Area of stationary object
If two connection terminals and the diode are arranged in the length direction of the connection box, then the width size is reduced, but the length size increases and UL safety specifications cannot be satisfied
Solution Approach 1:
Instead of arranging components solely in the length direction, the connection terminal utilizes multi-directional arrangement by bending in different spatial directions. The first connection portion and second connection portion extend in different directions from the base, allowing compact arrangement that reduces both length and width dimensions while maintaining adequate heat conduction path length for safety compliance.
3Strength
If connection terminals are fixed using molding or adhesive processes, then the terminals are securely attached to the housing, but the manufacturing process becomes complicated and expensive
Solution Approach 1:
The connection terminal incorporates self-fixing barbs that automatically engage with the housing during assembly without requiring external molding or adhesive processes. The barbs are formed as integral parts of the connection terminal structure, allowing the terminal to secure itself to the housing through simple insertion and mechanical interlocking, thereby eliminating complex fixation processes while maintaining secure attachment.
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 design effectively decreases heat conduction to the diode, protecting it from soldering heat and enabling a compact, aesthetically suitable, and safety-compliant connection box while maintaining operational efficiency.
Implementation Method 1
a plurality of deflectable barbs are formed on a bottom of the housing and configured to fix the base
Implementation Method 2
a straight path between the first and second connection regions is disconnected, where a heat conduction path between the first connection region and the second connection region is extended
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
In a connection box for a photovoltaic module, each of the at least one diode is connected between one respective a pair of connection terminals. Each connection terminal comprises: a base mounted on the housing; a first connection portion integrally connected with the base and provided with a first connection region for connecting with the diode; and a second connection portion electrically communicated with the base and provided with a second connection region for connecting with a bus bar, wherein a straight path between the first and second connection regions is disconnected. Heat generated in the second connection region is conducted to the first connection region through a bending heat conduction path. The heat conduction path between the first and second connection regions is extended, thereby heat conduction capability from the second connection region to the first connection region is decreased.