Photovoltaic Terminal Box Layout for Lead Insulation Protection

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Solution Overview

Problem

Conventional photovoltaic modules with terminal boxes attached on the expanded part of the glass face challenges in fitting the submodule into the outer frame, leading to potential insulation failures and increased manufacturing costs due to thick insulating coatings.

Innovation Solution

A photovoltaic module design where the front surface member is extended to accommodate connection leads, allowing them to be guided into a terminal box without intersecting the outer frame, thus preventing disconnection and insulation failures, and incorporating a resin terminal box with an upright part to enhance insulation and aesthetic appeal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If the terminal box is attached on the expanded part of the glass, then the terminal box can be accommodated without affecting light-collection efficiency, but the submodule cannot be easily fitted into the outer frame due to obstruction

Engineering Contradiction:

Improvelight-receiving areaVSAvoidfitting process

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The terminal box is relocated from the front surface (expanded glass area) to the rear surface of the photovoltaic module. This spatial dimension change allows the terminal box to be accommodated without obstructing the light-receiving area while also eliminating interference with the fitting process of inserting the submodule into the outer frame.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If connection leads are taken out from the edge between front and rear surfaces, then electric current can be output, but the connection leads are subject to damage due to being interposed between substrate and outer frame

Engineering Contradiction:

Improveelectric current outputVSAvoidconnection lead integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The connection leads are extracted from the dangerous zone between the substrate and outer frame by routing them through the rear surface path. The leads are led out from between the extended front surface member and the outmost edge of the rear surface member, then guided into the terminal box on the rear surface, removing them from the compression zone that causes damage.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The extended front surface member acts as an intermediary structure that creates a safe passage for the connection leads. By extending the front surface member beyond the rear surface member's edge, it provides a protected route for the leads to exit the module without being compressed between the substrate and outer frame.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If thick insulating coating is applied to connection leads, then insulation failure is prevented, but manufacturing cost increases

Engineering Contradiction:

Improveinsulation performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of relying on thick insulating coatings as a cushion against damage, the invention provides structural cushioning by routing the connection leads through a protected path on the rear surface. The leads are guided into the terminal box through a channel that prevents compression and mechanical damage, eliminating the need for excessive insulating material.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 design ensures reliable insulation and reduces manufacturing costs by preventing connection lead disconnection and insulation failures, while also improving the module's appearance by hiding the terminal box from the light-receiving surface.

Implementation Method 1

Photovoltaic power generation which converts light energy into electric energy by utilizing the photoelectric conversion effect

Methodology Applied

Scientific EffectPhotoelectric conversion effect: Photoelectric Effect

Data Source

PatentUS7952016B2Photovoltaic module comprising a terminal box attached to the rear surface

Publication Date: 2011.05.31 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

This invention provides a photovoltaic module for preventing insulation failure between an outer frame and connection leads. The photovoltaic module comprises: a photovoltaic submodule including a plurality of solar cells interposed between two light-transmitting substrates through the intermediary of an encapsulant and the connection leads extending from an edge between light-transmitting substrates and outputting generated electric currents; a terminal box attached near an edge of the photovoltaic submodule and housing connected parts between the connection leads and cables for outputting the electric currents to the outside; and an outer frame fitting over peripheral edges of the photovoltaic submodule. A side, of the light-receiving side light-transmitting substrate, from which the connection leads are pulled out, is made large so as to extend outward further than the other light-transmitting substrate. The connection leads are led out from the edge between the two light-transmitting substrates to be guided into the terminal box.