Solar Panel Auto-Connecting Contacts With Sealed Corrosion Resistance
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Solution Overview
Problem
Existing solar panel installations face challenges with corrosion and damage to electrical connections due to exposure to the outside environment, and there is a need for quicker and more efficient installation methods with robust and reliable connections.
Innovation Solution
The development of an auto-connecting electrical contact system for solar panels, which includes a plug and receptacle with elastic materials that deform under load to form a seal and ensure a secure, automatic electrical connection upon installation, facilitating multi-axis alignment and sealing to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connections are used for solar panels, then installation is simpler, but the connections are prone to corrosion and damage from environmental exposure
Solution Approach 1:
The patent implements a nested structure where the seal is positioned within the connector housing, and the electrical contacts are nested within the seal cavity. This nested arrangement protects internal components from environmental exposure while maintaining a compact overall structure, directly addressing the corrosion resistance issue without excessive complexity.
Solution Approach 2:
The patent introduces a seal as an intermediary component between the electrical contacts and the external environment. This seal acts as a protective barrier that prevents direct contact between corrosive environmental elements and the electrical connections, thereby improving reliability without requiring fundamental changes to the connection system architecture.
2Productivity
If manual electrical connection methods are used, then connection simplicity is maintained, but installation time and efficiency are reduced
Solution Approach 1:
The patent implements a self-aligning and self-sealing mechanism where the elastic seal automatically deforms to engage with the mating connector and establishes electrical contact without requiring precise manual alignment or additional fastening steps. This self-service capability significantly improves installation efficiency while maintaining operational simplicity.
Solution Approach 2:
The patent employs an elastic seal that dynamically adapts its shape during the connection process. The seal deforms elastically to accommodate slight misalignments and then springs back to create a secure, sealed connection. This dynamic behavior enables faster, more efficient installation without compromising connection reliability or simplicity.
3Reliability
If conventional electrical contacts are used, then manufacturing is simpler, but connection security and reliability under load are insufficient
Solution Approach 1:
The patent utilizes a composite structure combining conductive material for electrical contacts with elastic material for the seal. This composite approach integrates both electrical conductivity and mechanical sealing properties into a single manufactured component or assembly, enhancing connection security under load while maintaining manufacturing feasibility through standard multi-material molding or assembly processes.
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
This solution provides a reliable, efficient, and corrosion-resistant electrical connection system that simplifies the installation process while ensuring the integrity and longevity of solar panel connections.
Implementation Method 1
The housing of the plug can comprise one or more materials configured to deform under an applied load. The material can be an elastic material that exerts a biasing force to bias the housing of the plug to return to an uncompressed state upon removal of the applied load.
Implementation Method 2
The plug can comprise a spring encapsulated in the housing of the plug, wherein the spring supplies a biasing force that biases the electrical contact of the plug into electrical connection with the receptacle electrical contact within the receptacle.
Data Source
AI summary
A solar panel mount system for electrically connecting an installed solar panel including a solar panel, a 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.