Photovoltaic Module Wiring Assembly for Watertight Roof Installation
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Solution Overview
Problem
Existing photovoltaic systems face challenges in efficient electrical connection and installation on roofing structures, particularly in ensuring reliable and watertight connections while allowing for easy assembly and flexibility in module placement.
Innovation Solution
A photovoltaic module design featuring an encapsulant with openings for electrical bussing, a frontsheet with corresponding openings in fluid communication, and a cover to protect the electrical connections, along with movable electrical connectors that can be easily connected and aligned for efficient installation on a roof deck.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrical connectors are freely extending from the encapsulant, then ease of connection is improved, but reliability of watertight connection deteriorates
Solution Approach 1:
The patent introduces a lead frame as an intermediary component that extends from the encapsulant to receive electrical connectors. The lead frame acts as a mediator between the encapsulant and the connectors, providing a structured interface that maintains watertight integrity while enabling easy connection. The lead frame includes openings that receive connectors and extend outward to facilitate connection without compromising the encapsulant's seal.
2Ease of manufacture
If openings are provided in encapsulant and frontsheet for electrical bussing, then ease of installation is improved, but reliability of watertight integrity deteriorates
Solution Approach 1:
The lead frame serves as an intermediary structure that spans across the openings in the encapsulant and frontsheet. It provides a bridging function that maintains the watertight barrier while allowing electrical bussing to pass through. The lead frame's design enables installation access through openings while its continuous structure preserves the integrity of the encapsulant and frontsheet assembly.
3Reliability
If cover is added to protect electrical connections, then reliability of protection is improved, but device complexity deteriorates
Solution Approach 1:
The cover is merged with the lead frame to form an integrated protective assembly. Rather than being a separate component, the cover is configured to work in conjunction with the lead frame's openings, creating a unified structure that protects electrical connectors while maintaining ease of connection. This integration reduces overall device complexity by combining protective and connective functions in a single assembly.
Data Source
AI summary
A system includes a photovoltaic module including at least one solar cell with electrical bussing, an encapsulant encapsulating the at least one solar cell and having a first surface with a first opening, and a frontsheet juxtaposed with the first surface of the encapsulant. The frontsheet includes a second opening extending from a first surface to a second surface thereof. The second opening of the frontsheet is in fluid communication with the first opening of the encapsulant. The electrical bussing is positioned in the first opening. An electrical wire is connected to the electrical bussing through the first and second openings. A cover is attached to the frontsheet and covers one end of the electrical wire and the first and second openings.