Photovoltaic Panel Socket with Clamping Contact for Solar Element Strips
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Solution Overview
Problem
Existing photovoltaic panel boxes face challenges in connection options, heat balance, internal contacting, and structural design, leading to complex and costly construction, which complicates efficient and cost-effective production and assembly.
Innovation Solution
A tensioning element is attached to the contact carrier, allowing it to be pre-assembled and then moved into a latching position, ensuring reliable electrical contact between the solar panel's contact and the contact carrier, with the clamping element made of electrically conductive material for enhanced reliability and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex construction with stiffening elements and latching means is used for conductor channels, then reliable electrical contact is achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The contact carrier is divided into a base plate and a separately attachable tensioning element. This segmentation allows the simple base plate to provide initial contact while the separate tensioning element enhances reliability without complicating the main contact carrier structure, thereby resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The tensioning element is pre-assembled on the contact carrier in a pre-position before final installation. This preliminary action allows the contact carrier to be prepared in advance with enhanced contact capability, ensuring reliable electrical contact without requiring complex construction during final assembly, thus resolving the contradiction between reliability and device complexity.
2Reliability
If complex embedding of solar element connections is used, then reliable internal contacting is achieved, but ease of manufacture decreases and production becomes less efficient
Solution Approach 1:
The connection system is segmented into the contact carrier with contacts and the separately attachable tensioning element. This allows the contact carrier to be manufactured simply and efficiently, while the tensioning element can be pre-assembled and attached later, improving ease of manufacture without compromising internal contacting reliability.
Solution Approach 2:
The tensioning element is pre-assembled on the contact carrier before final installation on the solar element. This preliminary action simplifies the manufacturing process by allowing standardization and pre-testing of the tensioning mechanism, thereby improving ease of manufacture and production efficiency while maintaining reliable internal contacting.
3Ease of manufacture
If simplified ribbon or flag contacts are used instead of complex conductor channels, then ease of manufacture and production efficiency improve, but contact reliability may be compromised
Solution Approach 1:
The invention merges the simple ribbon or flag contact structure with the separately attachable tensioning element. This combination maintains the manufacturing simplicity of ribbons/flags while adding the reliability-enhancing tensioning mechanism, thereby resolving the contradiction between ease of manufacture and contact reliability.
Solution Approach 2:
The tensioning element is pre-assembled on the contact carrier to create an enhanced contact system that can reliably contact simple ribbon or flag contacts. This preliminary preparation ensures that even simple contact structures achieve reliable electrical contact, resolving the contradiction between ease of manufacture and contact reliability.
4Device complexity
If the contact carrier is designed with integrated tensioning means, then device complexity is reduced, but adaptability and ease of assembly decrease
Solution Approach 1:
The contact carrier is segmented into a simple base plate and a separately attachable tensioning element. This segmentation maintains low device complexity of the base plate while providing adaptability through the separate tensioning element that can be attached as needed, resolving the contradiction between device complexity and adaptability.
Solution Approach 2:
The tensioning element is designed to be pre-assembled on the contact carrier but can be attached or removed flexibly. This preliminary preparation provides adaptability for different assembly scenarios while keeping the base plate structure simple, resolving the contradiction between device complexity and adaptability.
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 solution simplifies assembly, improves electrical contacting, and increases reliability under harsh environmental conditions, while allowing for efficient mass production of clamping elements.
Implementation Method 1
the clamping element (1) exerts a force both on the contact (7) of the solar panel and on the contact (8) of the contact carrier (2), so that the electrical contact reliability is increased
Data Source
Figure 1
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AI summary
The PV junction box has a seal is provided between lower and upper portions of the housing. A connector is provided for connecting cables. A carrier (2) connected with a contact is formed inside a photovoltaic panel. A clamping element (1) is attached to the carrier connected with the contact, and is brought in a latching position from predetermined position.