Solar Panel Interconnector with Detour Structure for Thermal Stress

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Solution Overview

Problem

Existing solar panels face issues with defective electrical connections between photovoltaic cells due to thermal expansion and contraction, leading to stress on the interconnector and reduced durability.

Innovation Solution

The solar panel design incorporates an interconnector with a connection body featuring detours, junctions, and reinforcement portions that deform to absorb thermal changes, maintaining electrical connections and enhancing durability by distributing stress and preventing breakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the connection body is made rigid to maintain stable electrical connections, then electrical connection reliability is improved, but the interconnector becomes prone to breakage due to thermal expansion and contraction stress

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinterconnector durability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The connection body is designed with a flexible structure including detours and reinforcement portions that allow dynamic deformation. This flexibility enables the connection body to adapt to thermal expansion and contraction of the solar panel while maintaining electrical connectivity, thus resolving the contradiction between connection reliability and structural durability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connection body's geometric parameters are optimized with specific detour paths and reinforcement portions. These parameter changes allow the structure to deform in controlled ways under thermal stress, maintaining electrical connection while preventing breakage

Inventive Principle:

Principle #35Parameter changes

2Duration of action of stationary object

If the connection body deforms to absorb thermal changes, then durability is improved, but stress concentration may cause breakage

Engineering Contradiction:

Improvesolar panel durabilityVSAvoidconnection body strength

Core Design Contradiction:

Duration of action of stationary objectVSStrength

Solution Approach 1:

The connection body is segmented into multiple functional portions: detours for deformation, reinforcement portions for stress distribution, and junctions for electrical connection. This segmentation allows each portion to perform its specific function, enabling durability improvement without compromising strength

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the connection body have different structural qualities optimized for their specific functions. The detour portions are designed for flexibility and deformation, while the reinforcement portions are designed for strength and stress distribution, creating local quality variations that resolve the contradiction

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If the interval between photovoltaic cells changes due to thermal expansion, then adaptation to temperature changes is improved, but defective electrical connections occur

Engineering Contradiction:

Improvethermal adaptationVSAvoidelectrical connection reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The connection body's flexible structure allows it to dynamically adjust to changing intervals between photovoltaic cells caused by thermal expansion and contraction. The detour paths enable the connection body to stretch and compress while maintaining electrical connectivity, achieving both thermal adaptability and connection reliability

Inventive Principle:

Principle #15Dynamics

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 effectively limits defective electrical connections and increases the durability of the solar panel by allowing the interconnector to deform with temperature changes, maintaining stable connections and reducing the risk of breakage.

Implementation Method 1

This type of solar panel may be expanded and contracted by changes in the temperature that occur when the solar panel is manufactured or used

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

the connection body deforms to absorb changes in the interval between the first photovoltaic cell and the second photovoltaic cell

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11145775B2Inter-connector and solar panel

Publication Date: 2021.10.12 TOYOTA INDUSTRIES CORP

AI summary

This inter-connector is provided with: a first electrode; a second electrode; and a connecting body which connects the first electrode and the second electrode. The connecting body comprises: a first junction portion connected to the first electrode; a first bypass portion connected with respect to the first junction portion; a first reinforcement portion connected to the first junction portion and the first bypass portion; a second junction portion connected to the second electrode; a second bypass portion connected with respect to the second junction portion; a second reinforcement portion connected to the second junction portion and the second bypass portion; and a connection portion connecting the first bypass portion and the second bypass portion.