Photovoltaic Module External Connector for Automated Assembly
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Solution Overview
Problem
Existing photovoltaic (PV) modules lack component interchangeability and efficient manufacturing due to direct connections between in-panel module circuitry and on-panel electronics, which are not easily automated, leading to increased manufacturing time and costs.
Innovation Solution
A PV module with an external electrical connector featuring a permanently bonded metal blade-type contact extending through a plug receptacle, allowing for easy connection to off-panel electronics and improving flexibility and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If direct connections between in-panel module circuitry and on-panel electronics are used, then electrical connectivity is achieved, but manufacturing automation is difficult and manufacturing time increases
Solution Approach 1:
The electrical connection system is segmented into separate modular components: an external electrical connector with contact extending through the module laminate, and a corresponding receptacle on the module frame. This segmentation allows independent manufacturing and assembly of components, enabling automation while reducing connection complexity.
Solution Approach 2:
An external electrical connector serves as an intermediary element between the in-panel module circuitry and the module frame electronics. The contact extends through the module laminate to provide a standardized interface, mediating the connection and enabling automated manufacturing processes.
2Productivity
If direct connections between in-panel module circuitry and on-panel electronics are used, then electrical connectivity is achieved, but manufacturing time and costs increase
Solution Approach 1:
The external electrical connector is pre-assembled with the contact permanently bonded and extending through the module laminate before final module assembly. This preliminary preparation enables faster automated assembly operations and reduces manufacturing time.
Solution Approach 2:
By segmenting the connection system into separate components that can be manufactured independently and assembled through standardized interfaces, the overall manufacturing process becomes more efficient and time-effective.
3Adaptability or versatility
If external electrical connector with permanently bonded contact is used, then component interchangeability is improved, but device complexity increases
Solution Approach 1:
The external electrical connector with the contact extending through the module laminate creates a universal interface that can accommodate different electronics components. This standardized connector design enables interchangeability while the modular nature actually simplifies the overall system architecture.
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
Enables easy interchangeability of on-panel electronics and reduces manufacturing time and costs by automating the routing of electrical connections, enhancing the flexibility and efficiency of PV systems.
Implementation Method 1
Photovoltaic (PV) cells, commonly known as solar cells, are well known devices for converting solar radiation into electrical energy
Implementation Method 2
The contact is electrically connected to the PV cell and extends through the module laminate to an external electrical connector
Data Source
AI summary
A photovoltaic module having an external electrical connector is described. For example, the photovoltaic module may include a plug receptacle mounted on a module laminate, and a contact may extend from a photovoltaic cell within the module laminate into a plug channel of the plug receptacle. The plug receptacle may receive a mating electrical connector, e.g., an electrical plug, of off-panel electronics. Accordingly, the contact may be removably connected to the mating electrical connector, and the photovoltaic cell may be placed in electrical connection with the off-panel electronics.