Solar Module Connector with Integrated Conductor Holding Device
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Solution Overview
Problem
Conventional solar module assembly is time-consuming and prone to mechanical stress due to the high flexibility and sensitivity of thin conductor strips, making automated connection difficult and requiring manual handling.
Innovation Solution
A solar module design with integrated solar module connectors that protrude into the connection-side solar module body, featuring a conductor holding device to secure and protect electrical conductors, allowing for simplified automated electrical contacting without the need for external junction boxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual assembly is used to connect conductor strips to junction box, then connection reliability is improved, but assembly time increases significantly
Solution Approach 1:
The conductor strips are pre-positioned and held in a defined position by the holder element within the solar module connector before the junction box is attached. This preliminary positioning ensures that during automated assembly, the conductors are already in the correct location, enabling reliable automated connection without manual intervention.
Solution Approach 2:
The invention replaces manual mechanical assembly with an automated plug-and-play connection system. The solar module connector with integrated holder element and the junction box form a mechanical system that can be automatically connected and disconnected, eliminating the need for manual conductor strip connection while maintaining connection reliability.
2Reliability
If thin flexible conductor strips are used for electrical connection, then electrical conductivity is improved, but mechanical stability deteriorates
Solution Approach 1:
The holder element acts as an intermediary between the thin flexible conductor strips and the rigid solar module connector. It provides mechanical support and position fixation to the flexible conductors, stabilizing them in a defined position while preserving their electrical conductivity and flexibility for making contact with the junction box.
Solution Approach 2:
The invention utilizes the inherent flexibility of thin conductor strips while providing structural support through the holder element and solar module connector housing. The flexible conductors are contained and guided within the connector structure, allowing them to maintain their flexible nature for electrical contact while being mechanically stabilized by the surrounding rigid structure.
3Ease of operation
If conductor strips are led out of solar module for external connection, then ease of connection is improved, but mechanical stress on conductors increases
Solution Approach 1:
The holder element for the conductor strips is integrated directly into the solar module connector, merging the conductor support function with the connection interface. This integration allows conductors to be easily accessed and connected while the holder element simultaneously provides mechanical protection and reduces stress on the conductor strips throughout the connection process.
Data Source
Figure 1
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Figure 3
AI summary
The module (3) has a solar modular connector (11) with an insertion area (23) into which contact elements of a complementary solar module connector are inserted along an insertion direction (E). Electrical conductors (13a, 13b) are in contact with a solar cell. Conductor holding devices (15a, 15b) are mechanically fixed to the conductors. The electrical conductors extend into a conductor contact section (21a) parallel to the insertion direction. The solar module connector projects into an area of a solar module connection opening (27) in a connection-side solar module body (7). An independent claim is also included for a method for manufacturing a solar module.