Solar Module Junction Box Layout Without Internal Cross-Connectors
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Solution Overview
Problem
The manufacturing of solar modules is costly due to the need for manual arrangement and lamination of electrical conductor elements, such as cross-connectors, within the solar module laminate.
Innovation Solution
A junction box semi-finished product and a solar module semi-finished product are designed to be prefabricated separately, with the junction box sub-housings being permanently and weather-resistantly connected to the solar module semi-finished product's housing bases, allowing for electrical interconnection of solar cell strings outside the laminate using box cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical conductor elements (cross-connectors) are arranged and laminated within the solar module laminate, then electrical interconnection of solar cell strings is achieved, but manufacturing complexity and cost increase due to manual arrangement and lamination requirements
Solution Approach 1:
The patent extracts the electrical interconnection function from the solar module laminate structure. Instead of embedding cross-connectors within the laminate, the invention uses the rear element itself to provide electrical connection between solar cell strings through conductive contacts integrated into the rear element structure. This eliminates the separate cross-connector components and their associated manual arrangement and lamination processes.
Solution Approach 2:
The patent merges the electrical connection function with the rear element structure. The rear element is designed to simultaneously serve as the structural back cover and the electrical interconnection medium through integrated conductive contacts. This combination eliminates the need for separate electrical conductor elements and simplifies the manufacturing process by reducing the number of components and assembly steps.
2Reliability
If cross-connectors are manually arranged and laminated within the solar module laminate, then electrical connection is established, but manufacturing cost increases
Solution Approach 1:
The invention extracts the electrical interconnection function from the laminate structure and implements it through the rear element with integrated conductive contacts. This eliminates the need for manual arrangement and lamination of separate cross-connector elements, thereby reducing manufacturing labor costs and material costs associated with additional components.
Solution Approach 2:
By combining the structural and electrical functions into a single rear element component, the patent reduces the total number of parts that need to be manufactured, stored, and assembled. This integration lowers material costs and simplifies the supply chain, while the automated-friendly design reduces labor costs associated with manual lamination processes.
3Reliability
If electrical conductor elements are arranged before lamination, then electrical interconnection is achieved, but spatial arrangement precision must be maintained during lamination
Solution Approach 1:
The patent removes the requirement for pre-arranging separate electrical conductor elements before lamination. Instead, the rear element with integrated conductive contacts is positioned after the solar cell strings are encapsulated in the laminate, eliminating the need to maintain precise spatial arrangements during the lamination process itself.
Solution Approach 2:
The patent inverts the conventional sequence by first completing the solar module laminate encapsulation and then adding the rear element with electrical contacts. This reversal of the assembly sequence eliminates the precision requirements during lamination, as the electrical connection components are installed after the lamination is complete.
Data Source
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AI summary
The invention relates to a connection socket semi-finished product for a solar module, having: - a first and at least one additional connection socket sub-housing (1, 2; 2'), each of which has a contact device (11, 21) with a positive-pole contact element (12, 22) and a negative-pole contact element (13, 23), wherein the connection socket sub-housing (1) and the at least one additional connection socket sub-housing (2, 2') are designed to be structurally separate, - at least one socket cable (31) which produces an electric connection between the first contact device (11) of the first connection socket sub-housing (1) and the additional contact device (21) of the additional connection socket sub-housing (2), and - a first and a second solar module cable (32, 32'), each of which is connected to the first contact device (11) or to the additional contact device or one of the additional contact devices (21). The invention additionally relates to a solar module semi-finished product comprising a first and second housing base (50, 52), which can be connected to the connection socket semi-finished product, and to a solar module, which has the solar module semi-finished product and the connection socket semi-finished product. The invention also relates to a method for producing the solar module.