Photovoltaic Junction Box Venting to Reduce Potting Weight
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Solution Overview
Problem
The existing method of filling the entire empty space inside a distributing box of a solar cell module with potting material increases the weight and manufacturing time of the module, leading to reduced productivity and increased costs.
Innovation Solution
A solar cell module design that includes a distributing box with a residual empty space and an air discharge member, which allows air to flow while preventing water ingress, thereby reducing the need for potting material and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire empty space inside the distributing box is filled with potting material, then sealing and insulation properties are improved, but weight of the distributing box increases
Solution Approach 1:
The patent applies partial action by filling only the necessary space around the circuit board with potting material rather than completely filling the distributing box. The air discharge member creates a controlled empty space, allowing the potting material to be applied partially where it provides protection while avoiding unnecessary weight from over-filling the entire box volume.
2Reliability
If the entire empty space inside the distributing box is filled with potting material, then sealing and insulation properties are improved, but manufacturing time increases
Solution Approach 1:
By implementing partial filling with potting material through the air discharge member structure, the manufacturing process requires less time for material application and coagulation. The controlled empty space allows the potting material to be positioned efficiently without requiring complete filling of the distributing box, thereby reducing manufacturing time while maintaining adequate protection.
3Reliability
If the entire empty space inside the distributing box is filled with potting material, then sealing and insulation properties are improved, but productivity is deteriorated
Solution Approach 1:
The air discharge member enables partial filling of the distributing box with potting material, which streamlines the manufacturing process and improves productivity. By not requiring complete filling of the box, the process becomes faster and more efficient, allowing for higher production rates while still providing adequate sealing and insulation where the potting material is applied.
4Reliability
If the entire empty space inside the distributing box is filled with potting material, then sealing and insulation properties are improved, but manufacturing costs increase
Solution Approach 1:
The patent reduces manufacturing costs by implementing partial filling with potting material through the air discharge member structure. Less potting material is required compared to complete filling of the distributing box, directly reducing material costs while still providing adequate sealing and insulation properties for the circuit board and components.
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 design reduces the weight of the distributing box, improves productivity by eliminating the need for potting material and its associated processes, and maintains effective insulation and protection of the circuit board.
Implementation Method 1
The air discharge member may block supply of water while enabling air to flow by including a membrane having pores.
Data Source
AI summary
A photovoltaic module according to one embodiment of the present invention comprises: a photovoltaic panel; and a junction box electrically connected to the photovoltaic panel and mounted on the rear side of the photovoltaic panel. The junction box comprises: a circuit unit including a circuit board; a case accommodating the circuit unit and having a remaining empty space; and an air discharge member mounted on the case, for allowing air flow inside and outside the case.