Solar Module Spacer Assembly for Elevated Plug Connections
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Solution Overview
Problem
Existing solar module systems face challenges with the durability of cable fastening due to plastic clips losing elasticity over time and the risk of electrical insulation faults from water exposure, especially when positive and negative pole plugs are in contact with puddles.
Innovation Solution
A spacer kit with flat parts that can be assembled without tools to create a predetermined distance between the plug connection and the underlying surface, using fixing means to form a plug recess and fastening means like cable ties for secure and UV-stable attachment, preventing direct contact with water and dirt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic clips are used to fasten cables on solar modules, then cable fastening is achieved, but the fastening durability deteriorates over time due to UV exposure causing loss of elasticity
Solution Approach 1:
The invention extracts the cable fastening function from the solar module frame itself and relocates it to a separate plastic housing that is integrated into the junction box. This housing contains recesses specifically designed to receive and secure the cable plugs, thereby separating the fastening function from the structural frame and using a UV-stable integrated solution instead of separate plastic clips.
2Loss of substance
If cables are made shorter to save material, then material usage is reduced, but the ability to fasten cables on the solar module frame is lost
Solution Approach 1:
The invention introduces the plastic housing with integrated cable receiving recesses as an intermediary component between the cable plugs and the solar module frame. This housing acts as a mediator that provides the necessary fastening structure and cable management functionality without requiring the cables to be long enough to reach and attach to the frame directly.
3Ease of operation
If plugs are placed on the underlying surface for permanent mounting, then cable connection is simplified, but electrical insulation is compromised due to water contact
Solution Approach 1:
The invention elevates the plug connection from the ground level (underlying surface) to a higher position within the junction box housing. By integrating the cable plugs into the housing structure that is mounted on the solar module, the plugs are raised above the ground level where they would be exposed to puddles and water, thereby solving the insulation problem while maintaining convenient connection.
Data Source
AI summary
A kit comprising a solar module having a positive-pole cable comprising a positive pole plug, and a negative pole cable comprising a negative-pole plug, a spacer. The spacer comprises a first flat part spanning a first flat part plane together with first flat part outer edges, and a further flat part spanning a further flat part plane together with further flat part outer edges. The first flat part has fixing means and/or the further flat part has further fixing means. The first flat part and the further flat part configured to be mounted on one another such that the first flat part plane is arranged at a fixing angle to the further flat part plane and forms, between the first flat part plane and the further flat part plane, a plug recess located a distance from the first flat part outer edges and the further flat part outer edges.