Photovoltaic Module Junction Box Mounting in Hollow Frame Profile
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Solution Overview
Problem
Existing photovoltaic modules face challenges in connecting junction boxes without generating shading, reducing energy efficiency, and in producing large-scale panels with complex connections and potential for short circuits, especially when using bifacial modules or connecting multiple modules.
Innovation Solution
The junction boxes are installed inside a support frame with a hollow profile that includes through holes for mounting, providing electrical insulation and easy access, and distributed along the frame to avoid shading, with slots for connecting external lines and intermodule connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If junction boxes are installed on the rear face or edge of photovoltaic modules, then connection functionality is achieved, but shading is generated on photovoltaic cells reducing energy efficiency
Solution Approach 1:
The junction boxes are extracted from the traditional locations (rear face or edge of photovoltaic modules) and relocated to the support frame structure. This extraction eliminates the shading problem on photovoltaic cells while maintaining the electrical connection functionality. The frame acts as a separate carrier for connection components, decoupling the connection function from the module surface.
Solution Approach 2:
The junction boxes are moved from the two-dimensional module surface (rear face or edge) to the three-dimensional support frame structure. This dimensional transition allows connection components to be positioned in spatial locations that do not interfere with light reception by photovoltaic cells, thereby eliminating shading losses.
2Power
If multiple photovoltaic modules are interconnected to form large-scale panels, then power generation capacity is increased, but connection complexity and short circuit risk increase
Solution Approach 1:
The support frame is designed with multi-functionality: it provides structural support for photovoltaic cells, serves as a mounting platform for junction boxes, and acts as an integration platform for intermodule connectors. This universal platform approach simplifies large-scale panel assembly by consolidating multiple functions into a single structure, reducing connection complexity.
Solution Approach 2:
The frame merges the structural support function with the electrical connection function by integrating junction box mounting and intermodule connector placement into the same structure. This merging reduces the number of separate components and simplifies the overall connection system for large-scale photovoltaic panels.
3Ease of operation
If junction boxes are installed on the edge of photovoltaic modules, then connection access is improved, but mechanical strength and protection are reduced
Solution Approach 1:
The junction boxes are extracted from the module edge and relocated to the support frame. This extraction preserves easy connection access (the frame is accessible from the rear) while transferring the mechanical load and protection requirements to the robust frame structure, which provides superior mechanical strength and environmental protection compared to module edges.
4Ease of manufacture
If external connection lines pass through the back protective layer, then electrical connection is achieved, but resistance and insulation requirements increase
Solution Approach 1:
The frame is designed with pre-integrated mounting positions and pathways for external connection lines. This preliminary preparation allows connection lines to be routed through the frame structure itself rather than penetrating the back protective layer, reducing the need for complex insulation measures and maintaining electrical reliability while achieving easy connection.
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
This solution enhances energy efficiency by preventing shading, reduces manufacturing costs, and simplifies the connection process for both individual modules and large-scale panel assembly, while ensuring electrical safety by preventing short circuits.
Implementation Method 1
A photovoltaic module comprises a plurality of photovoltaic cells of the same type of technology, suitable for transforming light radiation from the sun into electrical energy
Implementation Method 2
The junction box comprises a protective rim able to electrically insulate the external connection lines of the profile
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~4
AI summary
The invention relates to a photovoltaic module comprising: - a plurality of photovoltaic cells (111) connected by an internal connection network so as to form several strings of photovoltaic cells (110), - a plurality of external connection lines (113), each connected to at least one string of photovoltaic cells, - at least one junction box (130, 140) adapted for connecting the external connection lines (113), - at least one frame (120) providing support for the photovoltaic cells (111) and comprising at least one profile, at least partially hollow, and having an external wall (120b) comprising at least one through-hole in which the junction box is mounted, said junction box (130, 140) comprising a protective rim (132) capable of electrically isolating the external connection lines (113) from the profile. The invention also relates to a photovoltaic panel comprising at least two interconnected photovoltaic modules.