Integrated External Connectors for PV Module Spacing and Alignment
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Solution Overview
Problem
The existing methods for connecting and packaging photovoltaic (PV) modules are inefficient, leading to increased transportation costs and installation time due to excess material handling and lack of air circulation during the manufacturing process, which affects the curing and alignment of panels.
Innovation Solution
The use of integrated external connectors (IECs) that are moveable and configurable to provide spacing, alignment, and securement between PV frames, allowing for staggered stacking and air circulation, and can be adapted for both horizontal and vertical orientations, reducing waste and enabling efficient panel coupling and rainwater management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional connection methods are used for PV modules, then assembly is simple, but transportation costs increase and installation time increases due to excess material handling
Solution Approach 1:
The connector integrates multiple functions into a single component: it provides structural connection between PV modules, incorporates alignment features through integrated positioning elements, and includes spacing functionality through built-in dimensional design. This merging of connection, alignment, and spacing functions into one integrated connector reduces the number of separate components needed, thereby simplifying assembly while improving installation efficiency by reducing material handling.
2Volume of stationary object
If PV modules are stacked closely for packaging, then space utilization improves, but air circulation is blocked affecting adhesive curing
Solution Approach 1:
The connector design incorporates segmented spacing features that create controlled gaps between adjacent PV modules during stacking. These segmented spacing elements distribute air circulation channels throughout the stacked arrangement, allowing air to flow through multiple pathways rather than requiring large open spaces. This segmentation approach maintains high space utilization while ensuring adequate air circulation for adhesive curing.
Solution Approach 2:
The connector acts as an intermediary element between adjacent PV modules, providing controlled spacing that mediates between the conflicting requirements of compact packaging and air circulation. The connector's dimensional design creates optimal gaps that allow air flow for curing while minimizing the space consumed by the spacing itself, thus enabling efficient packaging without compromising adhesive curing quality.
3Adaptability or versatility
If multiple separate components are used for connection and alignment, then adaptability is high, but device complexity increases
Solution Approach 1:
The connector is designed as a universal multi-functional component that performs connection, alignment, and spacing functions simultaneously. The integrated design incorporates positioning elements and connection features that can adapt to different PV module configurations through its geometric design, providing versatility without requiring multiple specialized components. This multi-functionality reduces device complexity while maintaining adaptability across various installation scenarios.
4Reliability
If excessive materials are used for securement, then reliability of connection improves, but transportation costs increase
Solution Approach 1:
The connector applies securement forces at specific critical locations through locally optimized geometric features rather than distributing material uniformly. The design incorporates localized reinforcement and positioning elements at key connection points where structural integrity is most needed, while minimizing material usage in non-critical areas. This local quality approach maintains connection reliability while reducing overall material consumption and transportation costs.
Data Source
AI summary
Connectors, systems with connectors and processes with connectors are described. These include how connectors can actively hold external portions of two frames or other components together during transport and before final installation, as well as, how the connectors can be repositionable on the frame or other component so as to provide a mechanical connection in one position and not to provide a mechanical connection when moved into a second position. The connectors can also function to provide spacing or alignment or both between frames or other components grouped together using the connectors.