Solar Junction Box with Displaceable Contacts
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Solution Overview
Problem
Conventional solar panels face issues with reduced performance and potential damage due to varying sunlight intensities across solar cells, leading to inefficiencies and failures, which existing bypass diodes partially address but with limitations in manufacturing efficiency and storage requirements.
Innovation Solution
A junction box design with displaceable contact elements and diodes that can accommodate different solar module configurations, allowing for efficient electrical connections and reduced storage needs by compensating for manufacturing tolerances, enabling flexible and adaptable solar panel assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional junction boxes with fixed contact elements are used, then manufacturing precision requirements are high, but storage requirements increase and manufacturing efficiency decreases
Solution Approach 1:
The contact elements are designed to be displaceable along the conductor, allowing dynamic adjustment to compensate for manufacturing tolerances. This eliminates the need for high precision fixed positioning and enables a single junction box type to accommodate variations in conductor arrangements.
Solution Approach 2:
The junction box design with displaceable contact elements can accommodate different solar module configurations and conductor arrangements. This universality allows a single junction box type to be used across multiple product variants, reducing storage requirements and improving manufacturing efficiency.
2Adaptability or versatility
If multiple junction box types are stocked to accommodate different solar module configurations, then adaptability is improved, but storage requirements increase
Solution Approach 1:
The junction box incorporates displaceable contact elements that can adapt to different solar module configurations and conductor arrangements. This universal design allows a single junction box type to serve multiple applications, eliminating the need to stock multiple specialized types and thereby reducing storage requirements.
Solution Approach 2:
The contact elements can change their position parameters along the conductor to accommodate different module configurations. This parameter adjustment capability provides adaptability without requiring multiple fixed-design junction box types, reducing inventory complexity.
3Device complexity
If fixed contact elements are used, then device complexity is reduced, but manufacturing tolerances cannot be compensated
Solution Approach 1:
The contact elements are designed with displacement capability along the conductor, providing a simple yet effective mechanism to compensate for manufacturing tolerances. This dynamic feature adds minimal complexity while significantly improving tolerance compensation and overall manufacturing efficiency.
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 enhances manufacturing efficiency, reduces storage requirements, and improves solar panel performance by allowing a single junction box type to fit various solar modules with different conductor arrangements, minimizing rejects and maintaining consistent quality.
Implementation Method 1
at least one diode, which the at least two contact elements electrically contacted
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The wiring box (7) has a housing device (9) arranged on a solar module (3) with an arrangement side (13). The housing device has a supporting unit (11). A contact device (21) is provided, which has two contact elements (23a,23b) and a diode (25), which electrically contacts two contact elements. An independent claim is also included for a method for producing a solar panel.