Spring Clip Mechanical Fixation for Solar PV Conductive Sheets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conductive sheets in solar photovoltaic assemblies experience poor electrical contact and high impedance due to rosin joints during soldering, leading to unstable connections and safety risks, as well as complex and difficult soldering processes that hinder maintenance.
Innovation Solution
A spring clip with a main body formed by bending a single spring metal sheet, featuring a gripping portion and an operation portion that allows for easy insertion and removal of conductive sheets, providing a stable mechanical fixation and improving signal transmission by elastically gripping conductive terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect the conductive sheet to the conductive terminal, then electrical connection is achieved, but poor electrical contact and high impedance occur due to rosin joints
Solution Approach 1:
The invention extracts and eliminates the soldering process entirely from the connection method. By using a spring clip with gripping portions that mechanically clamp the conductive sheet to the conductive terminal, the harmful rosin joint contamination is completely removed while maintaining reliable electrical connection through direct metal-to-metal contact.
Solution Approach 2:
The invention replaces the thermal-chemical soldering process with a purely mechanical connection system. The spring clip uses elastic deformation and mechanical clamping force to secure the conductive sheet, substituting the soldering operation with a mechanical fastening mechanism that avoids all associated harmful effects.
2Reliability
If soldering is used to connect the conductive sheet to the conductive terminal, then electrical connection is achieved, but the connection process becomes complicated and difficult to maintain
Solution Approach 1:
The invention segments the connection system into separable components: the spring clip, the conductive terminal, and the conductive sheet. This segmentation allows the conductive sheet to be easily removed and replaced by simply releasing the spring clip's gripping portions, transforming a permanent soldered joint into a modular, maintenance-friendly connection.
Solution Approach 2:
The invention introduces dynamic functionality through the spring clip's elastic properties. The gripping portions can dynamically adjust their clamping force and can be easily opened and closed, enabling the connection to transition between locked and released states. This dynamic capability simplifies maintenance operations compared to static soldered connections.
3Reliability
If the conductive sheet is made very thin, then flexibility and conductivity are improved, but mechanical strength decreases leading to poor contact
Solution Approach 1:
The invention applies counteracting force through the spring clip's elastic gripping portions that clamp onto the thin conductive sheet. This mechanical counterforce compensates for the inherent weakness of thin sheets, providing sufficient contact pressure to ensure reliable electrical connection without requiring the sheet to have high mechanical strength.
Solution Approach 2:
The invention applies local quality enhancement by concentrating the gripping force at specific contact points where the gripping portions clamp the conductive sheet against the conductive terminal. This localized application of force ensures adequate contact pressure exactly where needed for electrical conduction, rather than requiring the entire thin sheet to have high mechanical strength.
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 spring clip enables stable mechanical fixation and improved transmission quality of micro electrical signals, simplifying the connection process and facilitating easy assembly and disassembly, thus enhancing safety and maintenance accessibility.
Implementation Method 1
a spring clip for electrically connecting a conductive sheet to a plate-shaped conductive terminal, comprising a main body formed by bending a single spring metal sheet
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A spring clip 100 for electrically connecting a conductive sheet to a plate-shaped conductive terminal comprises a main body formed by bending a single spring metal sheet, wherein the main body comprises a first arm 1 and a second arm 2. A free end 11 of the first arm extends towards the second arm to form a gripping portion together with a part of the second arm, and a free end of the second arm extends beyond the gripping portion to form an operation portion 21 for expanding the gripping portion. An opening 4 is formed in a connection portion 5 of the first and second arms opposite to the gripping portion, so that an end of the conductive terminal is capable of being inserted into the gripping portion through the opening and elastically gripped by the gripping portion. A stable mechanical fixation between a conductive terminal and a conductive sheet by a simple operation can be achieved, thereby improving transmission stability and quality of a micro electrical signal.