Spring-Clip PCB Contact for Solar Panel Junction Boxes
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Solution Overview
Problem
Current junction box systems face issues with fragile electronics, difficulty in replacing components, and inability to dissipate heat in compliance with IEC 61215 standards due to soldered connections and the need for tools or equipment for wire tabbing connections.
Innovation Solution
A printed circuit board with spring clips secured via solderless connections, using a rigid non-conductive material and integral heat sinks, allowing for easy replacement and reduced assembly time, and meeting IEC 61215 temperature standards without requiring tools for wire tabbing connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered connections are used to secure electronics in the junction box, then the electrical connection is strong and reliable, but the electronics become fragile and difficult to replace, and assembly time increases
Solution Approach 1:
The invention separates the connection function into two independent parts: the spring clip provides mechanical retention and electrical contact, while the wire tabbing provides the electrical connection. This segmentation allows the electronics to be easily replaced by simply disconnecting the wire tabbing without damaging the spring clip or PCB, resolving the contradiction between connection reliability and component replaceability.
Solution Approach 2:
The spring clip uses elastic deformation to provide a dynamic, reversible connection. The spring mechanism allows the clip to flex during insertion and removal of wire tabbing, enabling easy replacement of components while maintaining reliable electrical contact during operation. This dynamic connection eliminates the fragility associated with rigid soldered joints.
2Strength
If a second capsule is added around the contact body to provide extra support, then the junction box can withstand the force of inserting wire tabbing, but manufacturing costs and assembly time increase
Solution Approach 1:
The invention extracts the force-withstanding function from the junction box capsule and relocates it to the spring clip itself. The spring clip's elastic properties and geometric design (including reinforcement ribs) provide the necessary strength to withstand insertion forces, eliminating the need for an additional protective capsule and reducing overall structural complexity.
Solution Approach 2:
The spring clip incorporates local reinforcement features such as ribs and optimized cross-sections in specific areas where strength is needed to withstand insertion forces. This localized strengthening provides the necessary mechanical support without requiring a complete redesign of the entire junction box structure or addition of a second capsule.
3Strength
If the junction box is constructed of strong material to withstand insertion force, then structural strength is improved, but tools or equipment are required to make connections, increasing time and cost
Solution Approach 1:
The spring clip is designed to be self-sufficient, providing both the mechanical strength to withstand insertion forces and the electrical connection function in a single component. The elastic spring mechanism automatically engages with the wire tabbing upon insertion, eliminating the need for external tools or equipment to make the connection, thus maintaining ease of operation while providing structural strength.
4Productivity
If solderless connections are used, then assembly time and manufacturing costs are reduced, but the connection strength and reliability may be compromised
Solution Approach 1:
The invention replaces the thermal-mechanical soldering process with a purely mechanical spring-based connection system. The spring clip provides reliable electrical contact through elastic pressure and geometric interlocking features, achieving connection reliability comparable to soldered joints while eliminating the time-consuming soldering process and reducing manufacturing costs.
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 solution reduces manufacturing and maintenance costs, improves junction box performance with enhanced cooling capabilities, allows for easy replacement of components, and provides high retention of wire tabbing without the need for tools or equipment, while meeting IEC 61215 standards.
Implementation Method 1
spring clips (10) secured to the printed circuit board with a solderless connection
Implementation Method 2
integral heat sinks, allowing for easy replacement and reduced assembly time, and meeting IEC 61215 temperature standards
Data Source
AI summary
A spring clip modular assembly for a printed circuit board that has a solderless connection with a junction box. The assembly allows for easier and more efficient removal and replacement of the printed circuit board and electrical components while meeting the IEC 61215 second edition temperature standards. In addition, the spring clip is configured to reduce the amount of normal force applied to the printed circuit board when wire tabbing is inserted into the clips.