Solar Cell Module Interconnection Routing for Water Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Solar cell modules face water ingress issues due to straight output interconnections that allow water to reach the solar cells, compromising their performance and longevity.
Innovation Solution
The design incorporates output interconnections that are routed through insertion slits in the sealing body at an angle orthogonal to the solar cell module's surface, preventing direct passage through the sealing body and allowing water to be diverted and trapped in bent portions, while also using an insulating film and a terminal box with overlapping drawing-in and drawing-out openings for efficient water management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If output interconnections are passed straight through the sealing body from solar cells to the drawing-out opening part, then the interconnection length is short and installation is simple, but water can enter through the drawing-out opening part and reach the solar cells directly
Solution Approach 1:
The patent introduces insertion slits that extend in the thickness direction (Z-axis) of the sealing body, creating a three-dimensional routing path for output interconnections. This dimensional change allows interconnections to enter through side surfaces via insertion slits and exit through the drawing-out opening part, preventing direct water pathways while maintaining electrical connectivity. The insertion slits create a staggered, non-linear arrangement that blocks water ingress routes.
Solution Approach 2:
The patent divides the sealing body into multiple functional regions with separate opening parts: insertion slits for interconnection entry and drawing-out opening parts for interconnection exit. This segmentation creates distinct functional zones that prevent water from traveling in a straight line from the drawing-out opening to the solar cells, as water would need to navigate around the segmented structural features.
2Reliability
If output interconnections are routed through insertion slits at an angle orthogonal to the module surface, then water is prevented from reaching solar cells, but the interconnection length increases
Solution Approach 1:
The insertion slits are configured to extend in the thickness direction of the sealing body, creating a Z-axis component to the interconnection routing path. This three-dimensional routing through the sealing body thickness provides both water protection and controlled interconnection length. The orthogonal angle routing through the sealing body thickness achieves water resistance while the path length is managed by the sealing body dimensions.
3Ease of manufacture
If the drawing-in opening part and drawing-out opening part overlap on the projection plane, then water management is simplified, but the structural complexity increases
Solution Approach 1:
The terminal box serves multiple functions: it houses the output interconnections, provides both drawing-in and drawing-out opening parts for water management, and creates an overlapping configuration that simplifies water drainage. This multi-functional design integrates water management features into the existing terminal box structure, achieving ease of manufacture without proportionally increasing complexity.
Data Source
AI summary
A drawing-out opening part and a first insertion slit formed in a back-surface-side sealing body in a direction almost orthogonal to the principal surface of the solar cell module are designed not to overlap each other on a projection plane in parallel to the principal surface of the solar cell module.