Photovoltaic Module Isolation Bar Layout for Jumper Wire Short Prevention
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Solution Overview
Problem
The direct contact between jumper wires and interconnection strips in photovoltaic modules leads to electrical connections that adversely affect module operation, causing issues such as short circuits and increased resistance.
Innovation Solution
The implementation of a photovoltaic module design that includes double-sided adhesive isolation bars and L-shaped lead-out wires, along with double-diode junction boxes, to prevent direct contact and manage current flow, reducing resistance and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a jumper wire is used to electrically connect the upper and lower solar cell string groups, then the electrical connection is achieved, but direct contact with interconnection strips causes short circuits and increased resistance
Solution Approach 1:
An isolation bar is introduced as an intermediary component between the jumper wire and the solar cell strings. The isolation bar has a first portion that contacts the jumper wire and a second portion that extends toward the solar cell strings without making direct contact, thereby preventing harmful electrical connections while maintaining the intended electrical connectivity through the jumper wire.
Solution Approach 2:
The isolation bar is positioned in a spatial arrangement where it extends in a direction that prevents contact with the interconnection strips. By utilizing the third dimension (height/depth) rather than just planar positioning, the isolation bar effectively blocks the harmful electrical path without interfering with the functional electrical connections.
2Reliability
If the jumper wire is positioned closer to the solar cell strings to improve electrical connection, then connectivity is enhanced, but the risk of direct contact with interconnection strips increases
Solution Approach 1:
The isolation bar serves as a protective intermediary that allows the jumper wire to be positioned optimally for electrical connection while preventing it from making direct contact with the interconnection strips. The isolation bar physically separates the jumper wire from the solar cell strings, eliminating the harmful contact risk.
3Reliability
If traditional isolation methods are used, then short circuit prevention is achieved, but material consumption and device complexity increase
Solution Approach 1:
The isolation bar is divided into functional portions: a first portion that contacts the jumper wire and a second portion that extends toward the solar cell strings. This segmentation allows the isolation function to be achieved with a simple, lightweight structure rather than a complex multi-component system.
Solution Approach 2:
The isolation bar is implemented as a thin, flexible component that can be easily positioned and secured. This thin-film approach reduces material consumption and structural complexity compared to rigid, bulky isolation structures.
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
The design reduces serial resistance, enhances power output, and minimizes material consumption while ensuring reliable operation and efficient heat dissipation, thus improving the overall performance and efficiency of the photovoltaic module.
Implementation Method 1
a first isolation bar that is double-sided adhesive
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Provided is a photovoltaic module, including a first intermediate busbar having a first lead-out terminal provided at an end thereof; a second intermediate busbar having a second lead-out terminal provided at an end thereof; and a first jumper wire arranged on a first isolation bar; the first lead-out terminal and the second lead-out terminal are located on two opposite sides of the first jumper wire, and the first lead-out terminal and the second lead-out terminal abut against two opposite side surfaces of the first isolation bar or overlap a top surface of the first isolation bar. Compared with the related art, the first isolation bar where the first jumper wire is located is clamped or pressed by the first lead-out terminal and the second lead-out terminal, to prevent short circuit or shielding of the cell caused by free movement of the first jumper wire, the first and second intermediate busbars.