Single Junction Box Layout for Multi-String PV Module Connections
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Solution Overview
Problem
Existing photovoltaic (PV) modules require multiple junction boxes and increased assembly effort due to separate connection contacts for each cell arrangement, which complicates installation and sealing.
Innovation Solution
A photovoltaic module design featuring a single, elongated junction box housing that covers and contacts all connection contacts along a central line on the back of the module, simplifying assembly and providing additional stabilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate junction boxes are used for each cell arrangement, then each connection contact can be individually protected and contacted, but the assembly effort and complexity increase significantly
Solution Approach 1:
Multiple separate junction boxes for different cell arrangements are merged into a single common junction box that houses all connection contacts from multiple cell arrangements. This consolidation reduces the total number of junction boxes while maintaining individual protection and contact capability for each connection contact, thereby reducing assembly complexity without compromising reliability
2Reliability
If multiple separate junction boxes are used for each cell arrangement, then each connection can be independently managed, but the sealing and mounting effort increases
Solution Approach 1:
Multiple sealing and mounting operations for separate junction boxes are merged into a single sealing and mounting operation for one common junction box. The housing is sealed as a single unit and mounted once to the module rear side, significantly reducing the total sealing and mounting effort while maintaining proper sealing for all connection contacts
3Shape
If connection contacts are arranged at several different positions on the rear side, then the module geometry can be optimized, but the junction box arrangement becomes more complex
Solution Approach 1:
The common junction box is designed with universal capability to accommodate connection contacts from multiple cell arrangements at different positions along the rear side of the module. The housing and contact carrier are configured to receive and contact connection contacts regardless of their specific positions, allowing the module geometry to be optimized while keeping the junction box arrangement simple and unified
4Productivity
If a common junction box is used for all connection contacts, then assembly effort is reduced, but the housing must cover a larger area
Solution Approach 1:
The common junction box housing is segmented into multiple contact areas, each dedicated to specific connection contacts from different cell arrangements. This segmentation allows the housing to cover a larger area efficiently by organizing connection contacts in groups within distinct contact areas, reducing assembly effort while managing the housing area through structured layout
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 2c~3a
AI summary
The invention relates to a photovoltaic module (1) with at least two cell arrangements that can be externally connected to terminal contacts (4). The groups of two terminal contacts (4) assigned to each cell arrangement are arranged along a line on the rear side of the photovoltaic module (1). The photovoltaic module (1) is characterized in that exactly one terminal box (11) is arranged on a rear side (3) of the photovoltaic module (1), which has a housing (111) that has at least one opening towards the rear side (3) for the passage of the terminal contacts (4), the housing (111) covering all terminal contacts (4) of the photovoltaic module (1). The invention further relates to a terminal box (11) for such a photovoltaic module (1), in which the housing (111) has an elongated shape, with all terminal contacts (4) arranged in a line along a longitudinal direction of the housing (111).