Photovoltaic Jumper Module Structure for Reliable Subarray Connection
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Solution Overview
Problem
There is a need for an effective method to electrically connect subarrays of photovoltaic modules installed on a roof deck, as existing solutions are inadequate for ensuring reliable and efficient energy transmission.
Innovation Solution
A jumper module system comprising electrical bussing encapsulated with a polymer-based encapsulant, a frontsheet, and a backsheet, with junction boxes and side laps for secure connection and installation, allowing for efficient electrical connection between subarrays while being compatible with various installation methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photovoltaic modules are arranged in subarrays on a roof deck, then electrical connection between subarrays is needed for energy transmission, but existing connection methods are inadequate for ensuring reliable and efficient energy transmission
Solution Approach 1:
The jumper module is divided into distinct functional layers: frontsheet with adhesive layer for mechanical attachment, encapsulant layer for electrical insulation and protection, and bussing for electrical connection. This segmentation allows each layer to optimize its specific function while working together as an integrated connection system.
Solution Approach 2:
The jumper module employs a composite structure combining multiple materials: conductive bussing material for electrical connection, polymer encapsulant for insulation and protection, and adhesive frontsheet for mechanical bonding to photovoltaic modules. This composite approach ensures both electrical reliability and mechanical strength.
2Reliability
If a jumper module with encapsulant and frontsheet is used to connect subarrays, then electrical connection and environmental protection are improved, but manufacturing and installation complexity increases
Solution Approach 1:
Multiple protective and functional features are merged into a single jumper module component: the frontsheet provides both mechanical attachment and environmental sealing, the encapsulant provides both electrical insulation and moisture protection, and the bussing provides electrical connection. This consolidation simplifies the overall system while maintaining comprehensive protection.
Solution Approach 2:
The jumper module is designed as a multi-functional component that simultaneously performs electrical connection, environmental sealing, mechanical attachment, and electrical insulation. This universal design reduces the number of separate components needed and simplifies both manufacturing and installation processes.
3Object-affected harmful factors
If electrical bussing is encapsulated with polymer material and covered with frontsheet and backsheet, then protection against moisture and impact is enhanced, but the device structure becomes more complex
Solution Approach 1:
The jumper module uses thin film structures for protection: the frontsheet and backsheet provide environmental sealing and mechanical protection as thin outer layers, while the polymer encapsulant forms a flexible protective shell around the bussing. This layered thin-film approach provides comprehensive protection without excessive structural complexity.
Solution Approach 2:
The protective structure employs composite material layers with distinct functions: the frontsheet and backsheet provide external environmental protection, the polymer encapsulant provides electrical insulation and moisture barrier, and the bussing provides electrical conduction. This composite structure achieves maximum protection with minimal complexity by assigning specific functions to each material layer.
Data Source
AI summary
A system includes a plurality of photovoltaic modules installed on a roof deck in an array and at least one jumper module electrically connecting a first subarray to a second subarray of the array. The jumper module includes at least one electrical bussing and an encapsulant encapsulating the at least one electrical bussing. The jumper module includes a frontsheet juxtaposed with the encapsulant. The frontsheet includes a first layer and a polymer layer attached to the first layer.