Universal Solar Junction Box Contact Element
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Solution Overview
Problem
Conventional solar modules face issues with reduced output and potential damage due to varying irradiation intensities across solar cells, leading to inefficiencies and damage from partial shading, which existing bypass diodes partially address but require multiple junction box designs for different assembly methods.
Innovation Solution
A universal junction box with multiple contact configurations allows flexible use across various solar module designs, reducing the need for multiple junction box types and enabling automatic or manual connection options, thereby accommodating different solar panel configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional junction boxes are designed for specific assembly methods, then the connection process is simplified for that method, but multiple junction box designs must be produced and stored for different solar module configurations
Solution Approach 1:
The contact element is designed with multiple contact configurations (first, second, and third contact configurations) that can accommodate different insertion directions and connection methods. This universal design allows a single junction box to be used with various solar module configurations, eliminating the need to produce and store multiple specialized junction box variants while maintaining ease of assembly for different assembly methods
2Device complexity
If a universal junction box design is used, then storage costs and production costs are reduced, but the connection process may become more complex
Solution Approach 1:
The contact element incorporates a clamping device with a resilient clamping contact that automatically engages with the conductor strip when inserted in any of the three insertion directions. The design includes guide surfaces and positioning features that self-align the connection components, eliminating the need for complex manual alignment procedures and making the universal junction box as easy to operate as specialized designs
3Reliability
If bypass diodes are used to prevent damage from partial shading, then solar cell damage is prevented, but the output of shaded solar cell groups is lost
Solution Approach 1:
The junction box provides electrical connection and routing functionality that works in conjunction with bypass diodes. The contact elements and conductor strip connections create reliable electrical pathways that allow bypass diodes to effectively redirect current around shaded solar cell groups, preventing damage while minimizing energy loss through optimized connection geometry and low-contact-resistance design
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 universal junction box reduces storage costs and production costs by allowing a single design to fit multiple solar module configurations, ensuring reliable electrical connections and preventing damage from shading while maintaining efficient energy output.
Implementation Method 1
at least one contact element (11) having a clamping device (13) with a resilient clamping contact (15)
Implementation Method 2
at least one blocking diode (20) arranged in the connection box (1) and electrically connected to the at least two contact elements (11)
Data Source
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AI summary
The invention relates to a socket for a circuit board, comprising: a base having an opening area for introducing an electrical conductor of the circuit board, a contact element for electrically contacting a conductor of the circuit board, and an electrical output electrically connected to the contact element, wherein the contact element comprises a returning connecting contact spring disposed in an introduction area, wherein said spring can be actuated returnably by applying a force along a force direction, such that the electrical conductor can be disposed between a connecting contact area and the connecting contact spring, and wherein each contact element is configured such that the electrical conductor can be brought into contact with the contact element by means of at least two of the three following contact configurations: The at least one electrical conduction - can be introduced along a first insertion direction E1 in the introduction area of the contact element, and can be brought into contact with the contact element by means of the connecting contact spring; - can be inserted in the introduction area of the contact element along the second insertion direction E2, wherein the first and the second direction E1, E2 are different from each other; - can be brought into contact with a contact device of the contact element, wherein the contact device is disposed outside of the insertion area, and a use, a solar panel, a contact element, and a method.