Solar Shingle Connector Assembly with Recessed Contacts
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Solution Overview
Problem
The existing methods for electrically coupling solar shingles are unsightly and interfere with the installation and water sealing of shingles, as they require exposed wires and cables, which deter homeowners and complicate the stacking of shingles on roofs.
Innovation Solution
A connector assembly that electrically couples solar shingles by engaging conductive members in recesses of the supporting sections, with a protective cover encasing the contact to prevent exposure and ensure seamless installation and water sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires and cables are used to electrically couple solar shingles, then electrical coupling is achieved, but the wires and cables become exposed above the shingles which is unsightly and interferes with shingle stacking
Solution Approach 1:
The patent extracts the electrical coupling function from the visible exterior by placing contacts and conductive members inside recesses of the shingles. The contacts are received within recesses that extend from upper to lower surfaces, hiding the electrical coupling components beneath the shingle surface while maintaining electrical connectivity between adjacent shingles.
Solution Approach 2:
The patent implements nesting by placing contacts within recesses of the shingles. The contacts are nested inside the recesses rather than protruding outward, allowing the shingles to be stacked or staggered without interference from exposed wiring components while maintaining electrical coupling functionality.
2Reliability
If wires and cables are used for electrical coupling, then electrical connection is established, but the exposed wires prevent proper shingle overlap for water sealing
Solution Approach 1:
The electrical connection components (contacts and conductive members) are extracted from the exterior surface and placed within recesses of the shingles. This extraction allows shingles to overlap properly for water sealing without exposed wires interfering with the waterproofing function.
Solution Approach 2:
The patent moves the electrical coupling components from a two-dimensional surface arrangement to a three-dimensional configuration utilizing the depth of recesses. Contacts are positioned within recesses that extend through the shingle thickness, allowing electrical connection without occupying surface space that would interfere with water sealing overlap.
3Ease of operation
If contacts are placed in recesses of supporting sections, then aesthetic appeal and installation ease are improved, but protective measures are needed to ensure reliable electrical contact
Solution Approach 1:
The patent applies beforehand cushioning by providing a protective cover that receives the contact within the recess. The protective cover prevents damage to the contact and ensures reliable electrical connection by protecting the contact components from environmental factors and installation damage before they are exposed to service conditions.
Solution Approach 2:
The protective cover serves multiple functions: it protects the contact from damage, ensures reliable electrical connection, and maintains the aesthetic appearance by concealing the electrical components. The recess structure itself provides both mechanical support and protective enclosure for the contact.
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 allows for efficient electrical coupling of solar shingles without visible wires, enabling easier installation and maintaining the structural integrity and water-tightness of the shingle system, enhancing aesthetic appeal and functionality.
Implementation Method 1
photovoltaic sections that convert light into electricity
Data Source
Figure 1
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AI summary
A connector assembly (100) for electrically coupling solar shingles (102, 104) is provided. The solar shingles (102, 104) include photovoltaic sections (106) that convert light into electricity and supporting sections (108) having upper surfaces to which additional solar shingles are mounted. The connector assembly (100) includes a contact (300) and a protective cover (308). The contact (300) electrically couples the photovoltaic sections (106) of adjacent solar shingles (102, 104) by engaging conductive members (302, 304) disposed in recesses (114, 116) of the supporting sections (108) of the solar shingles (102, 104). The protective cover (308) is disposed in the recesses (114, 116) of the solar shingles (102, 104). The protective cover (308) encloses the contact (300) between the protective cover (308) and the conductive members (302, 304).