Solar Terminal Box Diode Fixing and Pressure Relief Design
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Solution Overview
Problem
Conventional terminal boxes for solar cell modules face issues with unstable fixing of backflow prevention diodes due to solder spread, risk of adhesive failure under external forces, and difficulties in connecting power cables smoothly, along with challenges in maintaining sealability and releasing internal pressure.
Innovation Solution
The terminal box design includes terminal strips with supporting and pinching parts to secure the backflow prevention diode lead wire, a reinforcing rib for enhanced adhesive stability, and an inclined face to guide power cable insertion, along with a groove-shaped air vent for pressure release and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lead wire of the backflow prevention diode is soldered while placed on the planar terminal strip, then the soldering process is simple, but the solder spreads to other parts and heat may adversely affect other devices, and fixing strength may be insufficient
Solution Approach 1:
The terminal strip is designed with a localized recess portion that creates a confined soldering area. This recess structure concentrates the solder and heat in a specific location, preventing solder spread to other parts while ensuring sufficient fixing strength for the backflow prevention diode lead wire.
Solution Approach 2:
The recess portion acts as an intermediary structure between the lead wire and the planar terminal strip surface. It provides a dedicated space that mediates the soldering process, containing the solder and heat within the recess while maintaining electrical connection.
2Reliability
If the adhesive surface occupies the entire rear face of the main body, then the adhesive coverage is maximized, but external forces can still cause peeling and detachment of the terminal box
Solution Approach 1:
A reinforcing rib is added that extends in the vertical dimension from the adhesive surface toward the opening of the main body. This creates a three-dimensional reinforcement structure that increases resistance to external removal forces by providing additional structural support beyond the two-dimensional adhesive surface.
Solution Approach 2:
The bonding system combines adhesive material with a reinforcing rib structure made of the main body material. This composite approach integrates chemical bonding (adhesive) with mechanical reinforcement (rib structure) to achieve both strong adhesion and high resistance to external forces.
3Reliability
If the terminal box is completely sealed, then sealability is maximized, but internal pressure cannot be released causing potential deformation
Solution Approach 1:
The sealing structure incorporates flexible components that can deform to accommodate pressure changes. The sealing member and air vent design allow the sealed structure to flexibly respond to internal pressure without compromising the overall sealability against water and dust.
Solution Approach 2:
An air vent is provided that allows rapid pressure equalization when internal pressure exceeds a certain threshold. The air vent enables quick release of accumulated pressure while maintaining the sealing function under normal operating conditions, preventing deformation.
4Ease of operation
If the power cable is inserted directly into the main body, then the connection process is straightforward, but the cable may not insert smoothly without guidance
Solution Approach 1:
An inclined face is provided at the opening of the main body that预先 (in advance) guides the power cable into the correct position and orientation before full insertion. This preliminary guiding action prevents misalignment and damage during the insertion process.
Solution Approach 2:
The inclined face provides a curved or angled surface that smoothly directs the cable into the insertion path. This curved guidance surface replaces sharp edges or abrupt transitions, enabling smooth cable insertion without damage.
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 design securely fixes the backflow prevention diode, enhances adhesive strength, simplifies power cable connection, and maintains sealability while allowing pressure release, reducing the risk of terminal box detachment and deformation.
Implementation Method 1
an adhesive surface which is provided on a rear face of the main body and adhesive to the solar cell module
Implementation Method 2
the lead wire is soldered
Data Source
AI summary
A terminal box includes: a main body (101); at least one pair of terminal strips (106) which are connectable to a positive electrode and a negative electrode of a solar cell module; and a backflow prevention diode (118) bridged between the terminal strips (106) to connect the terminal strips (106). The terminal strip (106) and the backflow prevention diode (118) are contained in the main body (101). The terminal strip (106) includes: a supporting part (S) for supporting a lead wire (118a) of the backflow prevention diode (118) in a mounted state; a pinching part (K) for supporting the lead wire (118a) in a pinched state; and a recess (119B) which is provided between the supporting part (S) and the pinching part (K) and configured to position a connecting solder upon connecting the lead wire (118a) and the terminal strip (106).