PV Connector Assembly With Direct PCB Plug-In for Large Current
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Solution Overview
Problem
The mounting of photovoltaic connectors and circuit boards in photovoltaic power generation systems is complex due to limited space and cable bending, leading to disorganization, connection failures, high contact resistance, and heat generation.
Innovation Solution
A connector assembly with a photovoltaic connector and a connecting device that allows for plug-in connections, reducing assembly steps and improving efficiency by eliminating cables and cold-pressed terminals, while ensuring reliable electrical contact and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables and cold-pressed terminals are used to connect photovoltaic connectors to the circuit board, then electrical connection is achieved, but the mounting process becomes complex and mounting efficiency decreases
Solution Approach 1:
The patent integrates the connecting device directly onto the circuit board, merging previously separate components (cables, cold-pressed terminals, and connecting structures) into a unified integrated connection system. This eliminates the need for separate cable routing and terminal installation steps, thereby simplifying the mounting process while maintaining reliable electrical connection.
Solution Approach 2:
The patent extracts and eliminates the cables and cold-pressed terminals from the connection system, replacing them with a direct integrated connecting device that interfaces with the circuit board. This removal of unnecessary intermediate components simplifies the mounting process and improves mounting efficiency while preserving electrical connectivity.
2Power
If multiple cables are used to increase power density, then more photovoltaic connectors can be connected, but the operation space becomes limited and mounting complexity increases
Solution Approach 1:
The patent merges multiple connection functions into a single integrated connecting device structure that can accommodate multiple photovoltaic connectors. By integrating the connecting device directly on the circuit board with optimized layout, it enables high power density connections without requiring separate cable management for each connector, thus reducing mounting complexity despite increased power density requirements.
Solution Approach 2:
The patent optimizes the spatial arrangement of the connecting device and photovoltaic connectors by utilizing vertical and planar dimensions effectively. The connecting device is designed to interface with connectors arranged in specific patterns on the circuit board, enabling high-density connections without increasing linear cable length or requiring excessive operation space.
3Reliability
If cables are routed through limited operation space, then connections can be made, but cables become disorganized and prone to connection failure
Solution Approach 1:
The patent extracts and eliminates the cables from the connection path, replacing them with direct rigid or flexible printed circuit board traces that provide electrical connection. This removal of flexible cables eliminates the problems of cable disorganization, entanglement, and connection failure, while maintaining reliable electrical connectivity between photovoltaic connectors and the circuit board.
Solution Approach 2:
The patent merges the electrical connection function with the circuit board structure itself, integrating conductive pathways directly into the board rather than using separate cables. This integration ensures organized, fixed routing of electrical connections that cannot become disorganized, thereby improving connection reliability and ease of operation.
4Reliability
If multiple contact points are used in the connection circuit, then electrical connection is achieved, but contact resistance increases and heat generation becomes significant
Solution Approach 1:
The patent merges multiple contact points into fewer, larger-area contact interfaces by integrating the connecting device directly with the circuit board. This reduces the total number of contact interfaces from multiple cable-to-terminal and terminal-to-board contacts to a minimized set of direct board-to-connector contacts, thereby reducing cumulative contact resistance and associated heat generation while maintaining reliable electrical connection.
Data Source
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AI summary
Disclosed in the present invention are a connector assembly and a connecting structure. The connector assembly comprises a photovoltaic connector, and a connecting device configured to be fixed to a circuit board and electrically connected to the circuit board, wherein a conductive terminal of the photovoltaic connector is configured to be in plug-in connection with the connecting device. By means of the connector assembly, assembly steps and assembly time required for assembling the photovoltaic connector and the circuit board are reduced, and the installation efficiency of the photovoltaic connector and the circuit board is improved; the probability of problems such as connection failure and poor contact is also reduced, such that the reliability of connection between the photovoltaic connector and the circuit board is improved; connecting points of the whole connecting loop are also reduced, such that the contact resistance and heat generation of the whole connecting structure are reduced, and large current transmission can be realized, which is beneficial to improving the power generation capacity of a photovoltaic power generation system; and wires can also be omitted, such that the cost of the wires can be saved on, and an internal space of an inverter can be saved on, which facilitates the miniaturization design of the inverter.