Solar Cell Terminal Box Conductive Module Design
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Solution Overview
Problem
Traditional solar cell terminal boxes require significant manpower and resources for diode soldering, leading to reduced heat conduction performance and increased risk of damage due to heat generation, as well as structural instability under external forces.
Innovation Solution
An electrically conductive module for a solar cell terminal box featuring an insulation body, two conducting strips with strip-shaped through holes, and a diode chip located inside the insulation body, where the through holes are partially inside and outside the body, forming a connection region that prevents structural damage and facilitates effective heat transfer and busbar soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional diode soldering process is used with independent diode components and multiple soldering steps, then the terminal box can be assembled, but the manufacturing complexity and resource consumption increase significantly
Solution Approach 1:
The patent combines the diode chip and conducting strips into a single integrated assembly where the diode chip is directly mounted on the conducting strips. This merging eliminates the need for separate diode components and multiple independent soldering steps, thereby simplifying the manufacturing process while maintaining the necessary electrical functionality.
Solution Approach 2:
The conducting strips serve multiple functions: they provide electrical connection, structural support for the diode chip, and heat dissipation pathway. This multi-functionality reduces the need for separate components and simplifies the overall structure while maintaining manufacturing efficiency.
2Reliability
If multiple soldering steps are used for diode chip and conducting strips, then the components can be connected, but heat conduction performance deteriorates due to thermal resistance at solder joints
Solution Approach 1:
The diode chip is directly mounted on the conducting strips, creating a direct thermal path from the chip to the strips. This merging eliminates intermediate solder joints that would introduce thermal resistance, thereby improving heat conduction performance while maintaining reliable electrical and thermal connections.
Solution Approach 2:
The conducting strips act as an intermediary that simultaneously provides electrical connection and thermal management. By serving as both the electrical conductor and heat sink, the strips reduce thermal resistance compared to separate mounting arrangements with multiple solder joints.
3Strength
If the insulation body completely encloses the conducting strips, then structural protection is improved, but the ability to withstand external forces deteriorates due to stress concentration
Solution Approach 1:
The insulation body is designed with differential coverage: it encloses the diode chip and portions of the conducting strips for protection, but deliberately leaves exposed the regions that would otherwise concentrate stress. This local quality approach provides protection where needed while maintaining stress resistance in critical load-bearing areas.
Solution Approach 2:
The insulation body is segmented to provide selective enclosure rather than complete envelopment. This segmentation allows the structure to protect sensitive components while maintaining structural integrity and stress distribution in the conducting strips through strategic exposure of certain regions.
4Stability of the object's composition
If the through holes are completely enclosed by the insulation body, then structural integrity is improved, but accessibility for busbar soldering deteriorates
Solution Approach 1:
The insulation body provides selective enclosure of the through holes: portions of the holes are enclosed to maintain structural integrity, while other portions remain exposed to provide accessibility for busbar soldering. This local quality approach resolves the contradiction by providing different properties in different regions of the same structure.
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 enhances structural stability, reduces the risk of damage from external forces, and improves heat conduction by positioning the diode chip centrally for efficient heat transfer and simplifies busbar welding, making the module easier to assemble and replace.
Implementation Method 1
the two conducting strips are electrically connected through the diode chip
Implementation Method 2
improves heat conduction by positioning the diode chip centrally for efficient heat transfer
Data Source
Figure 1~2
Figure 3
AI summary
The present invention discloses an electrically conductive module of a solar cell terminal box. The electrically conductive module comprises an insulation body, conducting strips and a diode chip, wherein there are two and only two conducting strips. The two conducting strips are electrically connected through the diode chip. The diode chip is located inside the insulation body. Each of the two conducting strips is provided with a through hole. The two side edges, which are fixed with the conducting strips, of the insulation body overlap with the through holes. A connection region between the insulation body and each of the conducting strips is only a region between the end portion of the corresponding through hole and the edge of the conducting strip. A part of each through hole is located inside the insulation body, and the remaining part of the through hole is located outside the insulation body and forms an enclosed busbar welding hole together with two side edges of the insulation body. The connection regions between the insulation body and the conducting strips are just the four smaller regions between the end portions of the through holes and the edges of the conducting strips, which can effectively prevent the insulation body from suffering the acting force exerted by the external force through the conducting strips, and avoid the phenomenon that the body is damaged or excessively stressed, etc.