WO2010054841A2 - Photovoltaic components - Google Patents

Abstract

The invention relates particularly to a photovoltaic module (1, 3) that is arranged between a solar panel and a panel socket (5), said module having a housing, wherein the housing is formed from an injection-molded plastic and comprises at least one connection pin (2) having a contact (2.1) corresponding to the panel socket (5) and a contact (2.2) corresponding to a connection strip of the solar panel and the connection pin (2) is surrounded by the injection-molded plastic of the housing with the exception of its contact zones.

Description

 Photovoltaic components

description

The invention relates to photovoltaic components according to the features of the claims of this patent application.

State of the art is the patent application DE10 2007 041 989.0, wherein it is concretely first to photovoltaic panel doses, which make the contacting of the cell assembly of photovoltaic modules to the outside safe, and secondly it is jumpers that a contact of tight allow arranged panel doses of adjacent photovoltaic modules, without the need for a proper connection cable.

The frame conditions or conditions of use formulated in DE 10 2007 041 989.0 apply here as they are. The mating face also described in the prior art (both as a plug and as a socket) with the corresponding specified locking properties to prevent improper handling (only tool-based solvability, TÜV and UL requirement) is taken over unchanged here in terms of plug compatibility.

Photovoltaic panel doses are electrical interfaces between the cell level of photovoltaic modules and their surroundings. In this sense, box boxes must be easily and safely contacted from the outside, in which they outputs either as a plug, as a socket, as a conduit or as a combination of these possibilities for Make available. In addition, panel doses usually serve to accommodate bypass diodes (active or passive).

In current technical implementations, the cell level of the module is guided outwards by means of flexible and inaccurately positioned connecting strips or made electrically contactable. These tapes of the individual solar modules are attached to the contacts of the box sockets by subsequent assembly work, which is not or only to a small extent automatable. This is done either materially by soldering, resistance welding or the like, or indirectly by means of brackets to which these bands are fixed position defined or positioned, and then contacted resiliently.

A manufacturing technical feature of current junction boxes is also that the insulating housing is fitted by subsequent assembly work with the electrical contacts, which is economically as well as technically disadvantageous for a number of reasons.

In addition, the current state of the art does not offer the possibility that electrical and / or optical data signals are transmitted via panel doses or, if appropriate, these can be stored or further processed by integration of corresponding electronics. In this way, additional functions such as the theft protection of modules, the storage or forwarding of module characteristics and other measurement techniques could be realized on the solar module.

The invention relates to photovoltaic panel boxes, which avoid the disadvantages listed above and can optionally provide an added benefit in terms of passing and / or processing of data signals. A conceptual design, the manufacturing technology as well as with regard to the subsequent Mounting the cans on the photovoltaic module would allow a high degree of automation, would be very advantageous in view of the very high volumes produced in photovoltaics.

This object of the invention is achieved by the features described and explained below in general and with reference to the figures.

It is advantageous that the junction boxes according to the invention with plug-in connections (plug or socket) have the same mating face and the same locking as in DE 10 2007 041 989 to ensure compatibility.

Depending on the application, contacting the cell plane or, if appropriate, the connecting strip is realized with the aid of single-pole connection pins or two- or multi-pole connection sockets. The contact surfaces of these connection elements directed towards the photovoltaic module are fastened with conductive adhesive either directly to the corresponding cell arrangement or to the corresponding ribbon and at the same time electrically contacted. Furthermore, these elements perpendicular to the module level form and position-defined flat or round contacts available that are very simple and automatable to contact with corresponding complementary contacts on the side of the panel box, preferably resilient. These elements are preferably formed metallic, but this does not exclude that they can be designed geometrically similar to plastic dome as needed, so that by folding the ribbon over this analog can also be resiliently contacted.

The electrical, preferably stamped contacts of the box sockets are designed in such a way, in particular splash-proof, that they are inserted into the housing tool and can be directly overmoulded. The direct encapsulation of the contacts shown in Figures 7, 9 and 10 is significantly facilitated or even made possible by the contact pin resilient and the contact socket is made rigid. At the contact pin of Figures 9 and 10 also located within the pin located behind the spring blades end face of the correspondingly long-shaped contact protection of Figure 11 serves as a sealing surface in Umspritzwerkzeug. The direct overmoulding has the advantage that the box cans can be manufactured in a very high and reproducible machine quality, without at the same time having the contacts in their holder wobbling phenomena. Likewise, this eliminates a number of possible errors that inevitably occur during assembly work, such. B. additional Maß-, form or position deviations, forgetting parts during assembly, change of part properties due to long intermediate storage, organizational errors, etc. The cost aspect in the form of storage costs, mounting devices, assembly work, etc. is also to be considered. With regard to rationalizability, a direct encapsulation, especially of stamped contacts on the belt, is of course fully automatable. Another advantage is the fact that this type of production allows very high aspect ratios (very slim and geometrically long internal geometries), which are indispensable especially for the very high system voltages from photovoltaics with regard to the required clearances and creepage distances in combination with a compact design. In addition, it comes in an advantageous manner that the effort to produce these internal geometries with expensive and in terms of their life, short-lived tool cores, largely eliminated, since the surfaces to be encapsulated of these contacts or spray mass act shaping.

Optionally, the subject matter of the invention offers the possibility of realizing an electrical or optical data passage through the panel boxes by means of a such passage having corresponding electrical and / or optical connections, such. B. the optical passage shown in Figure 20, is integrated into the panel box. This passage can be made either preferably as an insert for the housing tool of the box box or corresponding to this as a permanently mountable part. In the event that for the purpose of data storage or processing of data, an electronic unit is needed, this in turn can be provided as an integral part of this passage between the terminals.

In Figure 1, a photovoltaic module 1 (hereinafter also referred to as terminal socket) shown with a fixed by a conductive adhesive terminal pin 2, which is here designed unipolar, but can also be designed multi-pole. Such a configuration is in the case of unipolar box doses, where the use of bypass diodes is omitted, as is the case occasionally in the thin-film technology.

FIG. 2 shows a connection pin 2 in a single-pole form, wherein the connection pin 2 is preferably designed as a stamped contact, but can be realized as a turned part or by means of another method. A flat contact 2.1 corresponding to the contact of the junction box is also shown and may alternatively be performed as a round contact or the like. With 2.2, the contact and mounting surface to the corresponding cell level or connecting ribbon of the photovoltaic module 1 is designated. The attachment is preferably carried out with an electrically conductive conductive adhesive, but the attachment is not limited to a conductive adhesive.

FIG. 3 shows a photovoltaic module 3 having a two-pole or multi-pole terminal base 4, which is designed in a planar manner, at least on the underside.

FIG. 4 shows a two-pole or multi-pole terminal base 4 which (not shown in the figure) can also be multi-pole in accordance with the number of photovoltaic module outputs. With 4.1 is a contact carrier made of an insulating material, preferably made of plastic, with the connection pin 4.2 or more connection pins are designated by 4.2. The number, position and orientation of the contacts 4.2 may vary depending on the photovoltaic module and the required alignment of the outputs or the contacts of the junction box. With 4.3 a bypass diode is referred to, which is resiliently or cohesively (soldered, resistance welded and the like) between the corresponding contacts 4.2 is attached. Coding 4.4 to the panel box ensure a clear installation with regard to the respective polarity (plus and minus).

In Figure 5, a terminal pin 4.2 is shown, preferably directly as an insert in an injection moldable, preferably designed as a punching or stamped bending contact, but as an alternative to the punching or stamping process other manufacturing processes such. B. a rotation process can be considered. A flat contact 4.1.1 is designed to correspond to the contact of the panel box and can alternatively be designed as round contact or the like. An insulation displacement contact 4.1.2 is used for fastening and electrical contacting of the bypass diode 4.3, said insulation displacement 4.1.2 may have a correspondingly different shape or geometry with respect to a material-locking attachment. Contact and mounting surface 4.1.3 to the corresponding cell level or to the corresponding terminal strips of the photovoltaic module is also shown in Figure 5, wherein also here the attachment is preferably carried out with an electrically conductive adhesive (conductive adhesive). FIG. 6 shows a photovoltaic panel box 5 with a single-pole socket outlet, wherein 5.1 denotes a housing made of an insulating material, preferably of plastic, again preferably an injection-molded plastic, and the housing 5.1 has a housing opening 5.1.1 for a contact pin. 5.1.2 designates the housing opening for the flat contact 2.1 of the connecting pin 2. As far as possible, these openings should be designed so that the resulting inside the panel box air volume is minimal, so that the formation of condensation within the junction box is kept within negligible limits. In this way, the required use of a pressure compensation membrane can be avoided, which represents an additional cost advantage. This requirement can in turn best be met with directly overmoldable contacts. A latching hook 5.1.3 is used to fix the position on a corresponding connector that can be connected to the junction box. 5.2 designates a socket box socket contact, which is preferably also directly encapsulated directly with a plastic housing. Figure 5.3 shows a seal to the corresponding plug which has been connected to the panel box. A double-sided adhesive pad 5.4, on the one hand ensures the attachment to the photovoltaic module and at the same time ensures the sealing of the contact space to the connection pin, is also shown.

In the simplest embodiment, the photovoltaic module has a flat carrier, in which the at least one connection pin 2 is arranged, in which the photovoltaic module 1 is injection molded from plastic and thereby the contact 2 with the exception of its contact areas of the plastic of the photovoltaic Module 1 is surrounded. After production of this photovoltaic module 1 shown in FIG. 1, it is arranged and fastened on the solar panel, preferably by bonding by means of an adhesive pad. In a further embodiment, the photovoltaic module 3, which is shown in Figure 3, a terminal base 2, which is positively or non-positively connected to the photovoltaic module 3 in connection. The terminal base 2 in this case has a contact carrier 4.1, which consists of plastic and is produced in an injection molding process, wherein there the contacts, with the exception of their contact zones are surrounded by the plastic of the contact carrier.

Overall, with this arrangement, for example, the photovoltaic panel box 5 shown in Figure 6 is realized, which may include the photovoltaic module 1 according to Figure 1 or the photovoltaic module 3 according to Figure 3.

FIG. 7 shows a box-type socket contact which is likewise preferably encapsulated and, in turn, preferably designed as a stamped or stamped bending contact. The Paneldosenbuchsenkontakt is designated by 5.2, wherein a contact surface 5.2.1 corresponding to the resilient blades of the contact pin 6.2 (see Figure 7) and 5.2.2 contact wings corresponding to the flat contact 2.1 of the connection pin 2 are present.

FIG. 8 shows a photovoltaic panel box 6 with a single-pole plug outlet, wherein the box box 6 has a housing 6.1 made of an insulating material, preferably of plastic or injection-molded plastic. The housing 6.1 has a housing opening 6.1.1 for the contact socket and a housing opening 6.1.2 for the flat contact 2.1 of the connection pin 2. As far as possible, these openings should be designed so that the volume of air generated within the junction box is minimal, so that the formation of condensation within the junction box is kept within negligible limits. Again, the effort for a pressure compensation membrane can be avoided in this way again. Reference numeral 6.2 shows the Complete box dowel pin contact, preferably directly molded, consisting of the preferably punched pin contact 6.2.1 and a 6.2.2 Berührschutz (see Figure 9). A double-sided adhesive pad 6.3 ensures, on the one hand, the attachment to the photovoltaic module and, at the same time, the sealing of the contact space to the connection pin 2.

FIG. 9 shows the box dowel pin contact 6.2 completely, preferably directly overmolded, wherein with regard to a splash-tight design, the shank diameter <D1 is slightly smaller, the same or preferably greater than the clear diameter D2, which is defined by the resilient blades 6.2.1.1. The contact blades 6.2.1.1 are formed springs, corresponding to the contact of the socket, which can be connected to the panel box. Contact vanes 6.2.1.2 correspond to the flat contact 2.1 of the connection pin 2. Furthermore, indentations 6.2.1.3 are present on the stamped part 6.2.1, which, in conjunction with the corresponding protrusions 6.2.2.1 on the contact protection 6.2.2, ensure a positive connection of these parts. Due to the high system voltages in photovoltaics, the electrically non-conductive contact protection 6.2.2 is absolutely necessary for safety reasons.

FIG. 10 shows the panel dowel pin contact 6.2 in further detail views analogous to FIG. 9.

FIG. 11 shows the contact protection 6.2.2 in further detail views in the form as used in FIG.

Figure 12 shows a further embodiment of a photovoltaic panel box 7 with a single-pole line output, wherein at the free end of the line either a socket, a plug or a next photovoltaic panel box with identical Power output can be provided. 7.1 designates the housing made of an insulating material with a housing opening 7.1.1 for the flat contact 2.1 of the connection pin 2. Again, these openings should be designed so that the resulting inside the panel box 7 air volume is minimal. A panel box contact 7.2 is in turn preferably directly encapsulated with a plastic housing and preferably designed as a punched contact. A soft Umspritzmasse 7.3, on the one hand seals the housing 7.1 with the overmolded herein unit of line contact 7.2 and 7.5 line to the environment while protecting the line 7.5 against tensile, compressive and bending stresses is also recognizable. By means of a double-sided adhesive pads 7.4 again takes place the attachment and sealing of the photovoltaic module, as already described above.

In Figure 13, the panel box contact 7.2 is shown in further details, wherein contact and joining surfaces 7.2.1 corresponding to the exposed metallic core of the photovoltaic line 7.5 can be seen. This surface is designed in the figure 13 as a soldering or as a welding cup, however, as well as a crimped connection or other connection for the purpose of mechanical connection and electrical contact is conceivable. The still recognizable contact blades 7.2.2 are formed corresponding to the flat contact 2.1 of the connection pin 2.

Another alternative embodiment of a photovoltaic panel box with a two-pole rectified socket output is shown in FIG. Such a junction box works together with a plug socket 4 (see Figure 4) and offers the opportunity if necessary to use bypass diodes 4.3, which are maintenance-technically not interchangeable in this configuration. The box box 8 again has a housing 8.1 made of plastic, with a housing opening 8.1.1 for the contact pin and the housing opening 8.1.2 for the flat contact 2.1 of the connection pin 2. The same applies to the design of these openings, as already said in Figure 12 to the openings 7.1.1. By means of one or more snap hooks 8.1.3 with respect to the corresponding connector this can be connected to the panel box. 8.1.4 and 8.1.5 are codes that ensure the polarity can not be confused. 5.2 is a box can socket contact, preferably directly umspritzbar, and 5.3 a seal to the corresponding connector that can be connected to the panel box 8. 8.2 denotes a double-sided adhesive pad, which on the one hand ensures the attachment of the panel box 8 to the photovoltaic module and at the same time ensures the sealing of the contact space to the terminal pin 2.

FIG. 15 shows a photovoltaic panel box with a two-pole oppositely directed socket output. Such a junction box also works together with a plug socket 4 (see again Figure 4) and provides the use of bypass diodes 4.3, if necessary, and these are also maintenance-technically not interchangeable in this configuration. Such a design allows a relatively direct routing along juxtaposed photovoltaic modules, resulting in a significant saving in terms of the required cable lengths.

FIG. 16 shows a photovoltaic panel box fastened to a photovoltaic module 3 with a mounting opening with a two-pole, oppositely directed socket output, FIG. 3 the photovoltaic module, 4 the connection socket, 10 the photovoltaic panel box with mounting opening with a two-pole opposing socket output and 11 a seal called. FIG. 17 shows the photovoltaic panel box 10 with a mounting opening with a two-pole oppositely directed socket output according to FIG. 16, whereby here too this box box together with the socket 4 functions together and if required allows the use of bypass diodes 4.3, but in this configuration the bypass diodes 4.3 maintenance are interchangeable. In this embodiment of the panel box 10, an undercut 10.1.3 is present, which allows a latching of the seal 11, if necessary. Furthermore, a receptacle 10.1.4 with an axial stop for the seal 11 is present. 10.1.5 denotes a sealing surface corresponding to the seal 11 and 10.1.6 a coding corresponding to the plug socket 4th

FIG. 18 shows with reference to FIG. 17 the seal 11, which is preferably produced as a two-component injection molded part. This consists of a hard and a soft injection molding compound, although also versions of two corresponding assembled plastic parts are conceivable (eg, a hard plastic part with one or more O-rings). The seal 1 1 consists of a hard component 11.1 for fastening purposes with a recess 11.1.1 for tool-bound release of the seal from the photovoltaic panel box 10 for the purpose of replacing the bypass diode 4.3. If necessary, a projection 11.1.2 makes it possible to engage the seal 11 on the undercut 10.1.3, whereby this can of course also be carried out resiliently by means of corresponding shapes. The soft component 11.2 of the seal 11 takes over the sealing purposes.

FIG. 19 shows the embodiment of a photovoltaic panel box with a two-pole, oppositely directed socket output and with an optical data throughput. Such a junction box works together with a connector socket 4 (see Figure 4) and also provides the use of bypass diodes 4.3, if necessary, this maintenance in this configuration not are interchangeable. At the same time optical data signals can be looped through a so-designed panel box, wherein a passage 12.3 for one or more optical fibers is present. Generally, this means that, regardless of the other design, the housing of the photovoltaic panel box has at least one optical waveguide passage 12.3.

Finally, FIG. 20 shows details according to FIG. 19. The optical waveguide passage 12.3 has a center piece 12.3.1 which accommodates an optical waveguide 12.3.2 (FO with waveguide 12.3.2.2 and insulation 12.3.2.1, see detail B), with its two Ends is guided in end pieces 12.3.1.1. The respective end piece 12.3.1.1 has a constriction 12.3.1.2 and a circumferential bead 12.3.1.3. In addition, a corrugated or thread-like section 12.3.1.4 and a section 12.3.1.5 exists. The construction of the optical waveguide passage 12.3 is, as can be seen in FIG. 20, symmetrical. On the ends of the end pieces 12.3.1.1 a fiber optic connector can be plugged, so that a continuous connection is created by means of optical fibers. Alternatively or additionally, it can also be considered that an optical fiber is coupled out or only led to a panel box (and therefore not looped through).

All photovoltaic modules (or the terminal base) are preferably designed flat and are glued by means of an adhesive bond (adhesive pad) on the surface of the solar panel, in the area in which the Kontaktfähnchen (also called ribbon) protrude from the surface of the solar panel , For better installation, it is conceivable that, for example, by the manufacturer of the solar panel, a flat frame positioned exactly around the or the contact flags around on the solar panel and fixed (for example glued) and then the prepared solar panel on a construction site (installation) purpose Production of a solar power plant is delivered. There can then from Fitter exactly the photovoltaic module (or the connection socket) are inserted into the free recess within the frame, with the insertion of the photovoltaic module (or the terminal base) guided in position and fixed in position after the complete insertion and fixed. At the same time, contacting the contact strips of the solar panel with the contact (or the plurality of contacts) of the photovoltaic module, so that a geometrically well-defined and stable contact zone is realized on the solar panel.

Claims

claims 1. photovoltaic module (1, 3), which is arranged between a solar panel and a junction box (5), with a housing, wherein the housing is formed by a molded plastic and at least one connection pin (2) with a contact (2.1) corresponding to the panel box (5) and a contact (2.2) corresponding to a terminal strip of the solar panel and the terminal pin (2) is surrounded by the molded plastic of the housing with the exception of its contact zones. 2. photovoltaic module (1, 3) according to claim 1, characterized in that the contact zones are formed flat. 3. photovoltaic module (1, 3) according to claim 1 or 2, characterized in that corresponding to the number of photovoltaic module outputs two- or multi-pole terminal base (4) has a contact carrier (4.1) made of an insulating material, wherein a terminal pin (4.2) or more connection pins (4.2) are provided. 4. photovoltaic module (1, 3) according to claim 3, characterized in that the contact carrier (4.1) coding (4.4). 5. photovoltaic module (1, 3) according to claim 2 or 3, characterized in that at least one connection pin (4.2) in the contact carrier (4.1) is injected, wherein a flat contact (4.2.1) designed to correspond to a contact of a panel box and at least one insulation displacement contact (4.2.2) for attachment and electrical contacting of a bypass diode (4.3) is formed. 6. Photovoltaic module (1, 3) according to one of the preceding claims, characterized in that the at least one photovoltaic module (1, 3) is part of a junction box (5) with a housing (5.1) and the housing (5.1) at least one housing opening (5.1.1) for a contact pin, wherein the at least one housing opening (5.1.1) is designed such that the inside of the box box (5) resulting air volume is minimal, so that the formation of condensation inside the box box ( 5) is kept within negligible limits. 7. photovoltaic module (1, 3) according to claim 6, characterized in that the one box box (5) of a solar panel has at least one socket box socket (5.2), which is umspritzt in the housing (5.1) arranged and fixed in position, said a contact surface (5.2.1) corresponding to resilient lamellae of a contact pin (6.2) of another panel box (6) of another solar panel is formed and contact blades (5.2.2) corresponding to the flat contact (2.1) of the connection pin (2) are present. 8. photovoltaic module (1, 3) according to one of the preceding claims, characterized in that the one photovoltaic panel box (7) is formed with an at least single-pole line outlet, wherein at the free end of the line (7.5) either a socket, a Plug or a next photovoltaic panel box is provided with identical power output and at least one Paneldosenleitungskontakt (7.2) is molded directly with a plastic housing (7.1), wherein a soft Umspritzmasse (7.3) on the one hand, the housing (7.1) with the herein overmolded unit of line contact (7.2) and line (7.5) seals to the environment while the line (7.5) protects against tensile, compressive and bending stresses. 9. photovoltaic module (1, 3) according to any one of the preceding claims, characterized in that the housing of the photovoltaic panel box has an optical waveguide passage (12.3). 10. Photovoltaic module (1, 3) according to claim 9, characterized in that the optical waveguide passage (12.3) has a center piece (12.3.1) which receives an optical waveguide (12.3.2), with its two ends in end pieces (12.3.2). 12.3.1.1). 11. A method for mounting a photovoltaic module (1) on a solar panel, wherein a planar frame is positioned and secured to the solar panels around the or the Kontaktfähnchen of the solar panel around and then accurately positioned in such a prepared solar panel the photovoltaic module (1 ) is inserted into a free recess within the frame, with the insertion of the photovoltaic module (1) guided in a precise position and fixed in position after the complete insertion and fixed and at the same time contacting the contact strip of the solar panel with the contact or the plurality of contacts Photovoltaic module (1) takes place.