Solar Module Electrical Connecting Device with Integrated Sheath
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional plug connections for solar modules are not robust or economical enough to withstand environmental and mechanical stresses, particularly in large-scale solar panel installations, and require complex individual connections.
Innovation Solution
An electrical connecting device with a housing and contact element, where the contact element penetrates an insulated conductor, surrounded by a non-conductive sheath, allowing for rapid and simple assembly and reducing the number of connectors needed, with a clamping element for tensile stress relief and water tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug connections are used for solar modules, then individual connections can be made, but the connections are not robust enough to withstand environmental and mechanical stresses
Solution Approach 1:
The patent combines multiple functions into a single integrated connector design. The connector integrates the housing, contact element, sealing structure, and clamping mechanism into one unified component that simultaneously provides electrical connection, environmental protection, and mechanical stress relief, eliminating the need for multiple separate connection elements
Solution Approach 2:
The patent employs composite material structures, particularly the combination of conductive contact elements with non-conductive housing and sealing materials. The connector uses differentiated material properties to achieve both electrical conductivity where needed and insulation/sealing where required, creating a multi-functional composite structure
2Ease of manufacture
If conventional plug connections are used for solar modules, then connections can be established, but they are not economical enough for large-scale installations
Solution Approach 1:
The patent segments the connector into modular components that can be manufactured separately and assembled efficiently. The housing, contact element, and sealing components can be produced through standardized manufacturing processes and then combined, reducing production costs while maintaining reliability through precise modular integration
Solution Approach 2:
The connector design includes self-aligning and self-sealing features that reduce the need for complex assembly procedures and external sealing components. The sealing structure automatically engages with the housing to provide environmental protection, and the contact element self-adjusts to ensure reliable electrical connection, reducing manufacturing and assembly costs
3Productivity
If conventional plug connections are used, then connections can be made, but they require complex individual connections for each solar module
Solution Approach 1:
The patent designs a universal connector that can be used for all solar module connections in the system. The standardized connector interface allows the same component to be used throughout the installation, eliminating the need for different connector types and simplifying inventory management and assembly procedures
Data Source
Figure 1a~2
Figure 3a~4
Figure 5a~5c
AI summary
An electrical connecting device (1) comprises a housing (11, 12) and a contact element (2). A first portion (24) of the contact element (2) is seated in a receiving opening (18) of the housing (11, 12), a second portion (21) of the contact element (2) projects into a receiving channel (3) of the housing (11, 12), which is configured to receive at least one elongate electrical conductor (5), and the second portion (21) of the contact element (2) is configured for contacting the electrical conductor (5). The elongate electrical conductor (5) is received in the receiving channel (3) of the housing (11, 12) and is contacted by the contact element (2). At least one portion of the housing (11, 12) and at least one portion of the contacted electrical conductor (5) are surrounded by a common sheath (6) made of a non-conductive material that forms a uniform bond therebetween.