Solar Module Connecting Element with Resilient Contact
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Solution Overview
Problem
Existing solar modules face challenges in producing connecting elements that are both cost-effective and easy to manufacture, often requiring soldered, clamped, or screwed connections which complicate the production process.
Innovation Solution
A solar module design featuring a resiliently biased contact element, such as a spring contact, that connects electrical wires to the solar element's contact surface without the need for soldered, clamped, or screwed connections, using a connection box housing with preassembled components for automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered, clamped, or screwed connections are used for connecting elements, then reliable electrical contact is achieved, but the production process becomes complex and costly
Solution Approach 1:
The connection box is divided into modular components: a housing, a resilient contact element, and connection sockets. This segmentation allows each component to be manufactured independently and assembled through simple insertion, eliminating the need for complex soldering, clamping, or screwing operations while maintaining reliable electrical contact through the resilient contact element's direct mechanical contact with the solar cell conductor.
Solution Approach 2:
The resilient contact element is designed to automatically establish and maintain electrical contact through its own elastic force. When inserted into the housing, it self-adjusts to press against the solar cell conductor, creating a reliable electrical connection without requiring external fastening operations. The resilient nature provides continuous pressure compensation, ensuring sustained contact reliability.
2Reliability
If traditional connecting elements with fastening operations are used, then secure electrical connection is achieved, but manufacturing time and cost increase
Solution Approach 1:
The resilient contact element is pre-configured within the connection box housing during manufacturing, ready to immediately establish electrical contact upon insertion. This preliminary preparation eliminates the need for time-consuming fastening operations during assembly, as the contact element is already positioned and biased to engage with the solar cell conductor as soon as the connection box is mounted.
Solution Approach 2:
The resilient contact element incorporates elastic deformation capability, allowing it to dynamically adapt to variations in conductor position and maintain optimal contact pressure. This dynamic adjustment ensures secure electrical connection while enabling rapid assembly, as the resilient nature allows for tolerance compensation without requiring precise alignment or additional fastening steps.
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
This design enables easy and cost-effective production of solar modules with reliable electrical contact, simplifying the manufacturing process and eliminating the need for complex connection methods.
Implementation Method 1
The connecting element is connected to the contact surface by a contact element which is resiliently biased against the contact surface of the solar element
Data Source
AI summary
A solar module having a housing and a solar element is described, wherein the housing comprises a connecting element, which is connected to the contact surface of the solar element in an electrically conductive manner. Furthermore the connecting element is connected to electrical connection sockets, by means of which connecting conductors may be connected. A contact element which is biased against the contact surfaces of the solar elements is arranged between the connecting element and the contact surfaces of the solar element as a contact element. As a result of this, soldered, clamped or screwed connections between the solar element and the connecting element are unnecessary. A simple and cost-effective automated production of the solar module is thus made possible.