PV Module Backplane Integration of Converter and Junction Box
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Solution Overview
Problem
The high production costs of power converters and junction boxes in photovoltaic systems, leading to increased overall system costs.
Innovation Solution
Integration of the power converter box and junction box on the backplane of the photovoltaic module, reducing the length of cables needed and eliminating the need for external connections, thereby lowering production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the power converter and junction box are connected through an external cable, then the system can transmit power from the photovoltaic module to the power converter, but the overall production costs of the power converter and junction box are high
Solution Approach 1:
The patent integrates the power converter and junction box into a single integrated unit mounted on the photovoltaic module backplane. The power converter box includes a power conversion module with input terminals connected to photovoltaic substrings and output terminals connected to an inverter, while the junction box handles electrical connections. This merging eliminates the need for external cables between separate components, reduces the number of connection points, and lowers overall production costs by consolidating multiple functions into one device.
2Loss of energy
If the power converter is of external type, then the power conversion function can be achieved, but the system costs of the photovoltaic system are high
Solution Approach 1:
The power converter is integrated directly onto the photovoltaic module backplane, combining the power conversion function with the module itself. This eliminates the need for separate external power converters and extensive cabling, reducing system costs and simplifying installation. The integrated design allows for direct connection of photovoltaic substrings to the power conversion module within the same housing, reducing the number of installation steps and connection points.
3Ease of manufacture
If the power converter box and junction box are integrated on the backplane, then the cable length is reduced and production costs decrease, but the device structure becomes more complex
Solution Approach 1:
The patent integrates the power converter box and junction box into a single housing mounted on the photovoltaic module backplane. The power converter box contains the power conversion module with input terminals connected to photovoltaic substrings and output terminals connected to an inverter via a cable. The junction box is integrated within the same housing, handling electrical connections between substrings and the power conversion module. This merging reduces cable length and connection points, lowering production costs despite the increased integration complexity.
Solution Approach 2:
The integrated power converter box serves multiple functions: it houses the power conversion module for DC-DC conversion, contains the junction box for electrical connections, and provides mounting structure on the backplane. This multi-functionality consolidates what would traditionally be separate components, reducing the overall number of parts and connection points while maintaining all necessary functions, thereby reducing production costs.
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 integration reduces the length of cables required, decreases production costs, and maintains the functionality of the photovoltaic module by allowing it to operate without an external power converter.
Implementation Method 1
A junction box is attached to a backplane of a solar cell panel (namely, a photovoltaic module)... power generated by the photovoltaic module is connected to an external circuit
Data Source
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AI summary
This application provides a photovoltaic module and a photovoltaic system. A power converter box and at least one junction box are integrated on a backplane of the photovoltaic module as a whole, and there is a cable for connecting the power converter and the junction box. In this case, relative to the conventional technology in which a junction box is independent of a power converter, in this application, a length of a cable used when the junction box and the power converter box are taken as a whole is shorter than a length of a cable used in the conventional technology. Alternatively, only the power converter box is integrated into the backplane of the photovoltaic module, and the power converter box has a connection manner such as a solder ribbon and a circuit board cable. In this case, compared with the conventional technology in which a cable is connected to an independently placed power converter, the power converter in this application only needs to establish a connection relationship by using a solder ribbon, a circuit board cable, and the like with low costs, so that production costs are low.