Solar Module Frame Routing for Hole-Free Electrical Connection
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Solution Overview
Problem
The routing of electrical connecting cables through holes in solar modules reduces mechanical strength and area available for power generation, and the high temperature of the carrier complicates the integration of electronics in junction boxes, particularly under intense sunlight.
Innovation Solution
A solar module design featuring conductive ribbons connecting solar cells from the front to the back, covered by a layer, eliminating the need for holes and enhancing mechanical stability, combined with a connection system using pins and a potting compound to secure and insulate electrical connections, and integrating module electronics within a recessed frame to manage heat and prevent shading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If holes are formed in the glass pane or plate to route connecting cables, then electrical connection is enabled, but mechanical strength is reduced
Solution Approach 1:
The patent extracts the connecting cables from the interior of the solar module by routing them through the frame structure instead of forming holes in the glass pane. The cables are led through channels in the frame and connection elements, eliminating the need to compromise the integrity of the glass cover while maintaining electrical connectivity functionality
Solution Approach 2:
The frame and its integrated connection elements serve as an intermediary structure that facilitates cable routing without requiring direct penetration of the glass pane. The connection elements with recesses and channels act as mediators that receive and guide cables from the solar cells to the exterior, preserving both mechanical strength and electrical connection capability
2Reliability
If holes are formed in the glass pane or plate to route connecting cables, then electrical connection is enabled, but area available for power generation is reduced
Solution Approach 1:
The patent removes the need for holes in the glass pane by extracting the cable routing function to the frame structure. This eliminates the area loss associated with drilling or punching holes through the glass cover, maximizing the active area available for solar cell placement and power generation while maintaining full electrical connectivity through the frame-integrated connection system
3Ease of manufacture
If junction box is mounted on the back of the carrier, then electrical connection is simplified, but heat management becomes difficult
Solution Approach 1:
The patent extracts the electronics from the high-temperature carrier surface by integrating connection elements and cable routing within the frame structure. The frame serves as a thermally isolated mounting structure that keeps electrical connection components away from the hot carrier surface, simplifying heat management while maintaining ease of electrical connection through the integrated frame design
Solution Approach 2:
The frame acts as an intermediary thermal barrier between the hot carrier and the electrical connection components. By routing cables through frame channels and using frame-integrated connection elements, the system mediates the thermal environment, protecting sensitive electronics from excessive heat while maintaining electrical connectivity functionality
Data Source
AI summary
A solar module includes a plurality of solar cells arranged on the front side of a carrier of the solar module is described, wherein a plurality of conductive ribbons electrically contacts the solar cells and extends from the front side to a rear side of the carrier. The carrier is circumferentially surrounded by a frame of the solar module. A connection system includes the solar module and a connection box, which can further be connected to module electronics via a socket of the connection box in order to form a solar module system.