Solar Panel Mount Contacts With Auto-Engaging Corrosion Sealing

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Solution Overview

Problem

Existing solar panel installations face challenges with corrosion of electrical connections due to exposure to the outside environment, leading to inefficiencies and reliability issues in installation and electrical connectivity.

Innovation Solution

A solar panel mount system with an auto-connecting electrical contact system that includes a plug and receptacle configuration, utilizing elastic materials and biasing forces to facilitate automatic electrical connections between panel and mount contacts, ensuring robust and corrosion-resistant connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If solar panels are installed in exposed outdoor environments to maximize solar energy capture, then energy generation capability is improved, but electrical connections are exposed to corrosion from environmental factors

Engineering Contradiction:

Improvesolar energy captureVSAvoidcorrosion of electrical connections

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The electrical contacts are nested within recesses in the solar panel and mount structures. The panel electrical contact is received within a recess in the solar panel, and the mount electrical contact is received within a recess in the mount, creating a nested configuration that protects contacts from environmental exposure while maintaining electrical connectivity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

A seal acts as an intermediary element between the electrical contacts and the external environment. The seal is configured to seal the electrical contacts from the environment, creating a protective barrier that prevents corrosion while allowing the solar panel to remain exposed for energy capture.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If traditional manual electrical connection methods are used for solar panels, then installation robustness can be achieved, but installation time and efficiency are reduced

Engineering Contradiction:

Improveelectrical connection robustnessVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The electrical contacts are pre-configured in recesses with seals positioned to automatically seal upon insertion. The biasing member is pre-installed to automatically bias the panel electrical contact toward the mount electrical contact, eliminating the need for manual connection steps during installation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The biasing member provides dynamic automatic engagement of electrical contacts. As the solar panel is installed, the biasing member automatically pushes the panel electrical contact into engagement with the mount electrical contact, providing reliable connection without manual intervention.

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If electrical contacts are exposed for easy connection, then connection ease is improved, but corrosion resistance is reduced

Engineering Contradiction:

Improveelectrical connection easeVSAvoidcorrosion resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Electrical contacts are nested within recesses that provide both protection and automatic alignment. The recesses guide the contacts into proper alignment during installation, maintaining ease of connection while the nested configuration provides corrosion protection.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The seal serves as an intermediary that automatically engages when contacts are connected. The seal is positioned to seal the contacts from the environment upon insertion, providing corrosion protection without complicating the connection process.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The system provides quick, efficient, and reliable electrical connections that withstand environmental exposure, enhancing the durability and performance of solar panel installations.

Implementation Method 1

The housing can be formed of an elastic material that exerts a biasing force

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12438504B2Auto-engaging electrical connections for solar panels

Publication Date: 2025.10.07 SARCOS CORP

AI summary

A solar panel and a solar panel mount system for electrically connecting the solar panel to a solar panel mount upon installation of the solar panel within the solar panel mount. The solar panel can comprise a photovoltaic cell, a support structure in support of the photovoltaic cell, and an auto-connecting electrical contact system comprising a panel electrical contact coupled to the support structure. The solar panel mount system can comprise the solar panel, the solar panel mount, and an auto-connecting electrical contact system operable to electrically connect the solar panel with the solar panel mount. The auto-connecting electrical contact system can include a panel electrical contact coupled to the solar panel and a mount electrical contact coupled to the solar panel mount. The panel electrical contact can be operable to electrically connect with the mount electrical contact upon installing the solar panel within the solar panel mount.