Photovoltaic Connector Layout for Diode Cooling and Cable Flexibility
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional photovoltaic connectors suffer from poor heat dissipation, high production costs, complex assembly processes, and inefficiencies due to junction boxes mounted on the back of modules, leading to performance issues and increased cable costs.
Innovation Solution
A new connector design featuring a socket-type structure with busbar sockets and diodes positioned away from the backplate, allowing for improved heat dissipation using an aluminum frame, simplified assembly, and customizable cable lengths, along with a dust cover for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a junction box is mounted on the back of the photovoltaic module, then the module structure is complete and protected, but the backplate heats up due to heat from the battery panel, affecting diode performance and heat dissipation
Solution Approach 1:
The invention extracts the diode assembly from the traditional junction box mounted on the backplate and relocates it to an independent connector positioned away from the backplate. This separation removes the diode assembly from the heat-generating environment of the backplate, allowing for effective heat dissipation without compromising the protective function of the junction box structure.
2Reliability
If a junction box is mounted on the photovoltaic module, then the module is protected from hot spots, but the assembly process becomes complex with multiple steps including gluing, welding, pouring glue, and mounting box cover
Solution Approach 1:
The invention segments the traditional integrated junction box into separate functional components: the diode assembly is placed in an independent connector that can be separately assembled and connected to the photovoltaic module. This segmentation allows each component to be manufactured and assembled independently, simplifying the overall assembly process while maintaining hot spot protection functionality.
Solution Approach 2:
The invention combines the diode assembly with the connector structure, merging multiple functions (protection, connection, and heat dissipation) into a single integrated connector unit. This eliminates the need for separate junction box assembly steps while maintaining all necessary protective functions.
3Adaptability or versatility
If cables with specific length are configured for the junction box according to different customer requirements, then customer needs are met, but cable costs increase and mounting becomes inconvenient
Solution Approach 1:
The invention employs detachable connectors with standardized interfaces that allow for dynamic configuration of cable lengths. Instead of manufacturing cables in fixed lengths, the system allows cables to be connected and disconnected as needed, enabling flexible adaptation to different installation requirements while using standardized, cost-effective cable specifications.
4Stability of the object's composition
If junction boxes and cables are on the whole module, then the module is complete, but packaging and transportation become difficult and dust-proof effect is poor
Solution Approach 1:
The invention segments the photovoltaic system into modular components where the connector with diode assembly is separated from the main module body. This segmentation allows the module to be packaged and transported more efficiently without the protruding junction box and cables, while maintaining complete functionality through the detachable connector design.
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
Enhances energy conversion efficiency, reduces cable costs, simplifies mounting, and improves current-carrying capacity while allowing on-site maintenance and reducing energy transmission loss.
Implementation Method 1
implements ventilation and heat dissipation using an aluminum frame
Data Source
AI summary
A new connector includes a photovoltaic module, a negative busbar socket, a positive busbar socket, a bypass busbar socket, and a module socket. The negative busbar socket and positive busbar socket are inserted into the module socket. The negative busbar socket is connected to a first busbar cable. The new connector according to the present disclosure achieves a reliable connection, enhances an energy conversion efficiency of modules, implements ventilation and heat dissipation using an aluminum frame, and improves a current-carrying capacity of the connector. In addition, required lengths of cables can be determined according to actual needs of an installation site, and thus costs of the cables are saved.