Solar Cell Connecting Device with Clamping Spring Mechanism
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Solution Overview
Problem
Conventional methods for connecting solar cell modules to connection lines, such as soldering, screwing, or using clamps, are complex and costly, and there is a need for a simpler and more cost-effective solution that maintains high-quality and reliable electrical connections.
Innovation Solution
A connecting device with a connector housing featuring a clamping spring mechanism that securely connects foil conductors to connection lines through a pressed screen arrangement, allowing for automated and efficient assembly, and includes features like crimped contact regions and sealing materials for durability and weather resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods (soldering, screwing, clamps) are used to connect foil conductors to connection lines, then reliable electrical connections are achieved, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent combines the connection line, connection element, and clamping mechanism into a single integrated connecting device. The connection element is directly attached to the connection line, forming a unified component that simplifies the manufacturing process while maintaining reliable electrical connections between foil conductors and connection lines.
Solution Approach 2:
The connection element acts as an intermediary component between the foil conductor and the connection line. It provides a standardized interface that simplifies the connection process, enabling automated assembly while ensuring reliable electrical contact through its conductive structure and clamping mechanism.
2Reliability
If conventional connection methods are used, then stable electrical connections are achieved, but production time and cost increase
Solution Approach 1:
The connection element is pre-attached to the connection line during manufacturing, creating a ready-to-use connecting device. This preliminary assembly allows for rapid installation during module production, as the entire connection assembly can be quickly positioned and secured without requiring separate steps for attaching the connection element to the line.
Solution Approach 2:
The clamping mechanism incorporates elastic elements that provide dynamic clamping force, automatically adapting to the foil conductor thickness and ensuring reliable contact. This dynamic adjustment capability maintains connection stability across varying conditions while enabling quick, tool-free installation that improves manufacturing efficiency.
3Ease of manufacture
If simple connection methods are used to reduce cost, then manufacturing becomes more efficient, but connection quality may deteriorate
Solution Approach 1:
The connection element incorporates conductive material with optimized electrical and mechanical properties, and the elastic elements are designed with specific force characteristics. These parameter optimizations ensure that the simple clamping mechanism achieves connection quality comparable to conventional methods, maintaining low contact resistance and stable electrical connection while keeping the manufacturing process simple and cost-effective.
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
The solution enables simple, cost-effective, and reliable electrical connections between solar cell modules and connection lines, facilitating mass production while ensuring high-quality and durable connections that withstand environmental exposure.
Implementation Method 1
an end of the clamping spring is attached to the current conductor region and the other end of the clamping spring is attached to the foil conductor-connection region adjacent to the current conductor region
Data Source
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AI summary
A connecting device (13) connects at least one electrical foil conductor (29) to at least one connection line (25). The connecting device (13) comprises a connector housing (31) having at least one connection line through-hole and at least one foil conductor through-hole (61). Arranged in the connector housing (31) is an intermediate connecting arrangement having at least one intermediate connector, which extends between the connection line through-hole and the foil conductor through-hole (61) and has a connection line-connection region, which is adjacent to the connection line through-hole, for connection to a connection line (25), which is guided through the connection line through-hole into the interior (33) of the connector housing (31), and a current conductor, which extends into the vicinity of the foil conductor through-hole (61) and has a foil conductor-connection region for connection to a foil conductor (29), which is guided through the foil conductor through opening (61) into the interior (33) of the connector housing (31). The current conductor comprises a current conductor region configured for applying a foil conductor-connection region. There is provided a clamping spring (41, 47) configured for resilient attachment to the current conductor region and the foil conductor-connection region adjacent thereto, and for clamping, thereby caused, of the foil conductor-connection region to the current conductor region. A connecting device (13) of this type is suitable for electrical connection of solar cells (19) of a solar cell battery module (11) to external current consumers and may be produced in a particularly simple and beneficial manner.