Rotating Electrical Connectors for Photovoltaic Modules
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Solution Overview
Problem
Existing photovoltaic module installations face issues such as cable cutting risks, electrification hazards, moisture penetration leading to degradation, complex and error-prone connection processes, and energy dissipation, which complicate installation and maintenance, and increase the risk of malfunction and fire.
Innovation Solution
A photovoltaic module design featuring rotating electrical connectors that pivot between active and inactive configurations to establish or inhibit electrical connections, integrated within the module frames to simplify installation, reduce moisture ingress, and enhance safety by eliminating direct human contact with live parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standard electrical connectors with cables are used to connect photovoltaic modules, then flexibility and compensation for misalignments are improved, but the risk of cable cutting, electrification hazards, and moisture penetration increases
Solution Approach 1:
The patent extracts the electrical connection function from separate cables and connectors and integrates it directly into the photovoltaic module structure. The connection elements are built-in and fixed to the module, eliminating external cables that are susceptible to cutting, damage, and moisture ingress while maintaining electrical connectivity.
Solution Approach 2:
The patent merges the electrical connection function with the module's structural components. The connection elements are integrated into the module housing or frame, combining mechanical support and electrical connectivity into a single unified structure, thereby eliminating separate cables and reducing failure points.
2Reliability
If connectors are directly connected to photovoltaic modules via cables, then electrical connection is established, but the risk of electrification and electrocution during maintenance increases
Solution Approach 1:
The patent introduces an intermediate mechanical coupling mechanism that mediates between module connection and electrical contact. The connection elements engage mechanically first, and only after proper mechanical engagement do the electrical contacts make connection, providing a safety intermediary that prevents accidental electrification.
Solution Approach 2:
The patent implements preliminary mechanical engagement before electrical contact. The connection elements are designed so that mechanical coupling must be established first, which then enables or completes the electrical connection. This preliminary mechanical action ensures proper alignment and prevents accidental electrical contact during installation or maintenance.
3Reliability
If connection cables are used between photovoltaic modules, then electrical connection is established, but energy dissipation and loss of performance occur
Solution Approach 1:
The patent extracts the electrical connection function from external cables and relocates it to integrated connection elements within the module structure. This eliminates the cable segment that causes energy dissipation through resistance, reducing power loss and improving overall system efficiency.
4Ease of manufacture
If standard connection procedures are used, then photovoltaic modules can be connected, but installation time is increased due to cable connection and storage requirements
Solution Approach 1:
The patent merges the electrical connection function with the module's structural components. The connection elements are integrated into the module housing or frame, combining mechanical support and electrical connectivity into a single unified structure, thereby eliminating separate cables and reducing failure points.
5Reliability
If connectors are crimped on cables during installation, then electrical connection is established, but the risk of inappropriate connection and malfunction increases
Solution Approach 1:
The patent designs connection elements that are self-aligning and self-securing. The integrated connection structures automatically position themselves during module assembly, eliminating the need for manual crimping or complex connector attachment procedures. This self-service mechanism ensures consistent, accurate connections without requiring installer skill or attention.
Data Source
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AI summary
A photovoltaic module (10a) comprises an electrical connector of a first type (12) arranged in such a way as to be able to co-operate with an electrical connector of a second type (13) of a first adjacent photovoltaic module (10b) so as to establish an electrical connection between the photovoltaic modules (10a, 10b). The module (10a) comprises a rotary element (121) whose rotation causes the electrical connector of the first type (12) to pass from an active configuration in which the electrical connector of the first type (12) allows the establishment of an electrical link between the photovoltaic modules (10a, 10b) to an inactive configuration in which the possibility of establishing the electrical link is inhibited.