Tool-Locked Solar Connector with Integrated Rear Sealing
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Solution Overview
Problem
Existing connector systems for solar modules to power consumers lack reliable and secure moisture-proof connections, especially in adverse weather conditions, and often require complex sealants and designs to achieve IP 67 or IP 68 standards.
Innovation Solution
A connector system with a housing element and complementary connector featuring a locking device and electrical contact elements, where the locking mechanism can only be unlocked using a tool, ensuring a moisture-tight seal and compact design, achieving IP 67 or IP 68 standards without the need for multiple sealants, and incorporating flexible materials for durability and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connector systems use multiple sealants and complex designs to achieve moisture-proof connections, then moisture protection is improved, but device complexity increases
Solution Approach 1:
The patent integrates the sealing function directly into the connector housing structure itself, merging the sealing element with the housing rather than using separate sealants. This integration achieves IP 67 or IP 68 moisture protection while reducing device complexity by eliminating multiple separate sealing components.
Solution Approach 2:
The connector housing is designed with specific geometric parameters and structural features that inherently provide moisture-proof sealing. By optimizing the housing design parameters, the system achieves high reliability moisture protection without requiring complex additional sealing mechanisms.
2Ease of operation
If the locking mechanism is designed to be tool-free for ease of operation, then ease of operation is improved, but reliability of connection decreases
Solution Approach 1:
The locking mechanism is designed to automatically engage and lock when the connectors are mated, eliminating the need for manual intervention. The system self-secures through its own structural design, achieving both ease of operation and reliable connection security without requiring tools or complex manual locking procedures.
3Ease of manufacture
If the connector design is simplified to reduce device complexity, then ease of manufacture is improved, but moisture protection capability deteriorates
Solution Approach 1:
The sealing function is merged into the housing structure itself, allowing the connector to be manufactured as an integrated component rather than assembling multiple separate sealing parts. This approach simplifies manufacturing while maintaining IP 67 or IP 68 moisture protection capability.
Solution Approach 2:
The housing design incorporates localized sealing features at critical areas where moisture protection is needed, rather than requiring complex sealing throughout the entire connector. This localized approach maintains moisture protection while simplifying overall manufacturing.
4Strength
If the connector system uses rigid materials for structural strength, then strength is improved, but adaptability to assembly variations decreases
Solution Approach 1:
The connector system uses materials and design parameters that provide both structural strength and flexibility. By carefully selecting material properties and dimensional parameters, the system achieves adequate strength while maintaining adaptability to assembly variations and misalignments.
Data Source
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AI summary
The invention relates to a connector system comprising a connector and a complementary connector, the connector comprising a housing element having a locking element and an electrical contact element, said electrical contact element being arranged in a front end section of the housing element and comprising a closing element arranged on the housing element, which closing element envelopes at least the rear end of the housing element and a section of an electrical cable arranged outside the housing element and is intimately connected to the housing element and the electrical cable to such a degree that the interior of the housing element is closed off from the surroundings at the rear end in a moisture-tight manner. The complementary connector comprises corresponding complementary elements. The locking element can only be unlocked by means of a tool.