DE102012001589B4 - Junction box, use and method of making a solar panel - Google Patents

Abstract

Connection box (10) for a solar module (4) comprising:
A cover element (22),
- At least one connecting element (8a, 8b) with at least one electrical conductor (9a, 9b), and
- A contact device (12) having at least one conductor connection element (14a, 14b), wherein each of the conductor connection elements (14a, 14b) an associated electrical conductor (9a, 9b) contacts, and at least one contact element (18a-18d), wherein each of the contact elements (18a-18d) is contactable with an electrical conductor (6a-6d) of the solar module (4),
wherein the contact device (12) is freely accessible from an arrangement side (20) of the cover element (22) with which the cover element (22) can be arranged and / or fastened on the solar module (4) and
wherein the junction box (10) with the arrangement side (20) of the cover (22) on the solar module (4) can be arranged such that the contact device (12) at least partially in one of the solar module (4) and the cover (22) formed Contact device receptacle (26) is arranged and that free access to the contact device (12) by the cover (22) is prevented.

Description

The invention relates to a junction box, a use of the junction box and a method for producing a solar panel.

Conventional solar modules for generating electrical energy from sunlight comprise one or more individual solar cells. Depending on the desired voltage and / or current to be provided by the solar module, individual solar cells within the module are connected in parallel and / or in series and thus combined to form solar cell groups. The solar cell groups are combined to form a flat solar module. The electrical connection elements of the solar cell groups of the solar module are led to the outside.

To form a solar panel, a solar module is usually provided with an electrical junction box, which includes other electronic components, such as at least one bypass diode or at least one DC chopper. The solar cells in a solar module are usually connected to each other by flat thin conductor strips. These conductor strips are led out of the solar module as connecting elements, and contacted with an arranged in the junction box electrical contact device. The junction box of the solar panel therefore generally has on the solar module side facing a Anschlußeinführöffnung through which the conductor strips guided, bent and connected, for example, to terminals.

It is understood that the electronic components during manufacture and during many years of outdoor operation must be protected from influences that shorten the life of these components. For example, the electrical components must be protected from corrosion by moisture as well as excessive temperatures that could damage the installed semiconductors.

• – eine Gehäusevorrichtung mit einem Grundelement, einem Kontaktvorrichtungsdeckelement und einem Vergußelement;
• – eine Kontaktvorrichtung mit zumindest einem Leiteranschlußelement und zumindest einem Kontaktelement, wobei jedes der Kontaktelemente mit einem elektrischen Leiter der Leiterplatte kontaktierbar ist;
• – zumindest ein Anschlußelement mit zumindest einem elektrischen Leiter, wobei der elektrische Leiter ein zugeordnetes Leiteranschlußelement der Kontaktvorrichtung kontaktiert,

wobei die Kontaktvorrichtung bereichsweise in einer von dem Grundelement und dem Kontaktvorrichtungsdeckelement ausgebildeten Kontaktvorrichtungsaufnahme angeordnet ist, wobei das Vergußelement als Gußteil ausgebildet ist und eine innige Verbindung mit dem Grundelement, dem Kontaktvorrichtungsdeckelement und dem zumindest einen Anschlußelement aufweist, um das Kontaktvorrichtungsdeckelement mit dem Grundelement zu verbinden und wobei die Kontaktvorrichtungsaufnahme im wesentlichen frei von dem Vergußelement ist.The publication DE 20 2011 002 913 U1 discloses a junction box for a solar module comprising:

• A housing device having a base member, a contactor cover member and a potting member;
• - A contact device with at least one conductor connection element and at least one contact element, wherein each of the contact elements with an electrical conductor of the circuit board is contacted;
• At least one connection element having at least one electrical conductor, wherein the electrical conductor contacts an associated conductor connection element of the contact device,

wherein the contact device is arranged in regions in a formed by the base member and the contactor cover member contactor receptacle, wherein the potting member is formed as a casting and has an intimate connection with the base member, the contactor cover member and the at least one connection element to connect the contact device cover member to the base member and wherein the contactor receptacle is substantially free of the potting element.

• – eine Gehäusevorrichtung, wobei die Gehäusevorrichtung ausgelegt ist, mit einer Anordnungsseite an dem Solarmodul angeordnet zu werden, und die Gehäusevorrichtung zumindest eine Aufnahmeeinrichtung aufweist,
• – zumindest eine Kontaktvorrichtung mit zumindest zwei Kontaktelementen und zumindest einer Diode, welche die zumindest zwei Kontaktelemente elektrisch kontaktiert,

wobei die zumindest eine Kontaktvorrichtung zumindest bereichsweise in der Aufnahmeeinrichtung aufgenommen ist und wobei die Kontaktelemente der Kontaktvorrichtung entlang einer Verlagerungsrichtung V, die mit dem Normalenvektor der Anordnungsseite einen Winkel kleiner 90 Grad einschließt, verlagerbar sind.The publication DE 20 2009 012 176 U1 discloses a junction box for a solar module comprising:

• A housing device, wherein the housing device is designed to be arranged with an arrangement side on the solar module, and the housing device has at least one receiving device,
• At least one contact device having at least two contact elements and at least one diode which electrically contacts the at least two contact elements,

wherein the at least one contact device is received at least partially in the receiving device and wherein the contact elements of the contact device along a displacement direction V, which includes an angle of less than 90 degrees with the normal vector of the arrangement side, are displaced.

It is therefore an object of the invention to provide an electrical connection box, a method for producing a junction box and a use of the junction box, which reliably protects the electrical contacts against moisture and on the other hand allows a simple and cost-effective production of the solar panel.

The object is achieved by a junction box with the features of claim 1, a use of the junction box with the features of claim 8 and a method for producing a solar panel with the features of claim 9. Preferred embodiments are subject of the dependent claims.

Junction box according to one aspect

• – ein Abdeckelement,
• – zumindest ein Anschlußelement mit zumindest einem elektrischen Leiter und
• – eine Kontaktvorrichtung mit zumindest einem Leiteranschlußelement, wobei jedes der Leiteranschlußelemente einen zugeordneten elektrischen Leiter kontaktiert, und zumindest einem Kontaktelement, wobei jedes der Kontaktelemente mit einem elektrischen Leiter des Solarmoduls kontaktierbar ist,

wobei die Kontaktvorrichtung von einer Anordnungsseite des Abdeckelements her frei zugänglich ist, mit welcher das Abdeckelement an dem Solarmodul anordenbar und/oder befestigbar ist und
wobei die Anschlußdose derart mit der Anordnungsseite an dem Solarmodul anordenbar ist, daß die Kontaktvorrichtung zumindest bereichsweise in einer von dem Solarmodul und dem Abdeckelement ausgebildeten Kontaktvorrichtungsaufnahme angeordnet ist und daß ein freier Zugriff auf die Kontaktvorrichtung (12) durch das Abdeckelement (22) verhindert ist.One aspect of the present invention relates to a junction box for a solar module, comprising:

• A cover element,
• - At least one connection element with at least one electrical conductor and
• A contact device having at least one conductor connection element, each of the conductor connection elements contacting an associated electrical conductor, and at least one contact element, each of the contact elements being contactable with an electrical conductor of the solar module,

wherein the contact device is freely accessible from an arrangement side of the cover forth, with which the cover is arranged on the solar module and / or attachable and
wherein the junction box can be arranged on the solar module with the arrangement side such that the contact device is arranged at least in regions in a contact device receptacle formed by the solar module and the cover element and that free access to the contact device ( 12 ) through the cover element ( 22 ) is prevented.

Advantageously, the junction box on only a small number of items, the junction box is simple and inexpensive to manufacture.

The cover member of the junction box has an arrangement side which is designed to be mounted in an arrangement position on the solar module. For this purpose, the arrangement side is at least partially formed as a mounting area. At least one fastening means, for example an adhesive, a thermoplastic polymer or a thermoplastic elastomer can be arranged or arranged on the fastening region. By means of the fastening means, the cover and thus the junction box with the solar module moistureproof connected or attached to the solar module, in particular be glued moisture-proof.

For the purposes of the present application, the term "moisture-proof" is understood as meaning a leak-tightness or a barrier with respect to a fluid, in particular water or water vapor, wherein the flow or displacement of the moisture is prevented. In other words, the solar module and the junction box are moisture-tight connected to each other if a fluid can not penetrate along a (flat) contact area between the solar module and the junction box in the interior of the junction box. In particular, a moisture-proofness can be achieved according to the IP67 standard.

The cover prevents in the arrangement position free access to the contact device, which is arranged in the contact device receptacle, which is formed between the solar module and the cover. In particular, the contact device is sealed moisture-tight in the contactor receptacle.

The at least one conductor connection element of the contact device can in particular comprise a soldering point, a crimping point and / or a cable fastening, but in particular can also be a region of a flat conductor. Each conductor connection element is assigned an electrical conductor of the at least one connection element. Preferably, the at least one connecting element can be designed as a connecting cable, in particular as a single-core connecting cable with exactly one electrical conductor, or as an electrical connector, in particular as a one-pole connector with precisely one electrical connector contact.

Each of the contact elements is arranged such that the contact elements can be contacted with an associated electrical conductor of the solar module, wherein the electrical conductors are preferably fixable by means of at least one fixing element to the contact elements. Preferably, the at least one fixing element is elastically resilient. The fixing element may consist of plastic and / or metal.

The contact device preferably has at least one semiconductor component which electrically connects two conductor connection elements and / or at least two of the contact elements and / or a conductor connection element to one of the contact elements.

The semiconductor component may preferably be a bypass diode which electrically connects two contact elements to one another. More preferably, the semiconductor device may be an overvoltage protection diode, which electrically connects the conductor connection elements with each other. More preferably, the contact device may also comprise circuits comprising semiconductor components such as diodes, transistors and / or integrated circuits (ICs), such as at least one DC-DC converter, a diagnostic circuit, a communication interface, etc ..

The contact device may comprise a printed circuit board (PCB) or at least comprise a metal plate. At least two or more metal plates of the contact device can be connected to one another electrically and / or mechanically by means of a semiconductor component, for example by means of a diode, in particular a diode in SMD design. In particular, the contact device is designed to permanently currents of more than 10 A, preferably more than 15 A from one conductor connection element to the other.

The cover member may include attachment means for securing the cover member to a complementary attachment means of the contactor. For example, the contact device can be glued to the cover and / or screwed. Preferably, the cover is lockable with the contact device. The locking can be done releasably or permanently. For example, the cover may have at least one locking device, which is preferably formed integrally with the cover, wherein the locking device is lockable with an associated complementary locking device of the contact device. For example, the locking device may comprise at least one latching hook and the complementary locking device comprise at least one recess or opening receiving the associated latching hook.

After arranging the contact device to the cover or in a recording of the cover and the optional subsequent locking of the cover and contact device, the contact device is protected by at least one side from free access. The contact device can be inserted at least partially along a contact device insertion direction K into the receptacle of the cover element, for example. However, the contact device remains accessible from the arrangement side, in particular access along the Kontaktvorrichtungseinführrichtung K is possible. The contact device insertion direction K is preferably perpendicular to a flat surface formed on the cover element, which forms the arrangement side or is formed on the arrangement side, so that the flat surface is arranged in the arrangement position on the solar module or terminates substantially gap-free with the solar module , The flat surface of the arrangement side preferably surrounds the region of the receptacle of the cover element in which the contact device can be inserted. In the arrangement position, the solar module and the cover form the contact device receptacle, in which the contact device is at least partially received and in particular fixed. Furthermore, the contact device receptacle, in particular after the attachment of the cover element to the solar module, for example by gluing, is substantially protected against the ingress of moisture in the region of the mechanical contact between cover element and solar module.

Preferably, the junction box comprises at least one potting element, which is designed as a casting, wherein the at least one potting element has an intimate connection with the cover member and / or the at least one connection element to connect them together, and / or wherein the at least one potting element an intimate Has connection with the cover and the contact device to attach the contact device to the cover.

In particular, the interior of the junction box is protected against mechanical action by the intimate connection of the potting with the other elements. In other words, advantageously, the junction box comprising the cover element and the potting element and the at least one connection element and / or the contact device can not be opened or the aforementioned elements can not be separated from each other without the junction box is destroyed. A manipulation of the located inside the junction box electrical or electronic components is thereby advantageously excluded.

Preferably, by the intimate connection of the potting with the at least one connecting element and / or the cover, the junction box at least partially closed moisture-proof. In other words, in particular components which are arranged in the arrangement position in the contact device receptacle can be encompassed by the potting member and the cover member such that these components are advantageously protected from moisture from outside the junction box. Further advantageously, the junction box has a small number of sealing parts, is simple and inexpensive to produce and has an increased resistance to moisture. In particular, by the intimate connection of the Vergusselements with the other elements, such as a lid and the solar module, on which the junction box is arranged in the arrangement position, the interior of the junction box during operational use sealed against moisture in the environment. In other words, it is advantageously possible for substantially no moisture to penetrate the connection box at the at least one conductor connection element, so that electrical or electronic components located in the interior of the connection box are protected against short-circuits and corrosion.

Preferably, the potting consists of a softer or more flexible material than the cover. The cover member may partially from a polymer, preferably made of polyester, such as PBT or glass fiber reinforced polyester exist. The potting element may be made of an elastomer, preferably a thermoplastic elastomer (TPE) or a thermoplastic vulcanizate (TPV).

The melting temperature of the material of the junction box, in particular of the potting element can be about 170 degrees Celsius to about 265 degrees Celsius. Preferably, the melting temperature of the sealing element is below the melting temperature of the cover. Particularly preferably, the covering element may be formed from a PBT having a melting temperature of about 270 degrees Celsius, while the sealing element is formed from a thermoplastic elastomer having a melting temperature of about 170 degrees Celsius to about 210 degrees Celsius. More preferably, the material of the potting element can shrink during cooling or curing. The material of the potting element is thus preferably shrinkable. The term "shrinkable" as used in this application describes a volume change, especially a volume reduction, of between about 0.1% and about 5%, preferably between about 0.2% and about 2%, more preferably between about 0 , 3% and about 0.7%.

The resulting from the shrinkage process mechanical stress acts on the encapsulation element partially enveloped or contacted elements, such as the cover and the at least one connecting element. As a result, a moisture-tight connection between these elements is advantageously produced, without the need for further sealing elements. Advantageously, the components of the contact device or the semiconductor devices arranged on the contact device are decoupled or protected in the contact device receptacle from the mechanical stresses generated by the shrinkage of the potting element by the cover element. Therefore continue to act advantageously advantageously no mechanical stresses generated by the Vergusselement on the contact points or solder joints of the arranged on the contact device components, so that the contact reliability of these components is increased.

In order to form the casting element as a casting, the material of the casting element is liquid applied to the cover or the at least one connecting element, wherein an intimate connection with these is generated by cooling and / or curing of the material of the casting element. Advantageously, the cover prevents the material of the Vergusselements contacted in liquid, hot state, the contact device. In other words, the contact device remains substantially free of the potting element or of the material of the potting element. In this case, "substantially free" means that no electrical component or semiconductor component, which is arranged on the contact device, is mechanically contacted by the potting element. Further, "substantially free" may mean that less than about 10 percent, preferably less than about 5 percent, more preferably less than about 1 percent of the volume of the contactor receptacle is filled with the material of the potting member in the placement position.

Rather, a gas, usually air, remains in a cavity between the contact device or its electrical components and the cover, which is not filled with the material of the Vergusselements. Therefore, heat-sensitive components are advantageously protected from damage by the action of heat. More preferably, the cover comprises a thermally insulating material. In particular, the cover may consist of a thermally insulating material. A thermally insulating material in the sense of the application is characterized in that the thermal conductivity λ of the thermally insulating material is less than 1 Wm ^-1 K ^-1 , in particular about 0.3 Wm ^-1 K ^-1 , preferably less than 0.5 Wm ^-1 K ^-1 , preferably less than 0.1 Wm ^-1 K ^-1 . An exemplary thermally insulating material is foamed polystyrene or polyurethane.

In the arrangement position and after attaching the junction box to the solar module, the junction box is in particular by the intimate connection between the potting and the cover or the at least one connecting element advantageously moisture-proof, in particular according to the specification IP67. Particularly preferably, the junction box meets the fire protection class V-0 and is up to 1000 V voltage electrically insulating.

For the purposes of the application, the term "intimate connection" between two bodies means a direct, direct mechanical contacting in a contact area or a contact area. In particular, the intimate connection can be made by shrinking a peripheral body onto another enclosed body, so that the peripheral body in the contact area exerts a force or mechanical stress on the enclosed body, so that by elastic deformation of the two bodies in the contact area There is essentially no gap between the two bodies. In particular, the two bodies may be fused together in the contact area.

Preferably, the cover member has at least one opening through which an associated one of the conductor connection elements is accessible or through which an associated one of the conductor connection elements, for example in the form of a Lötfahne or a connector, protrudes to be contacted with the electrical conductor of an associated terminal element. Particularly preferably, the connection element comprises a connection cable with at least one electrical conductor, which is electrically contacted with the associated conductor connection element. An insulating jacket of the connecting cable can be intimately connected to the sealing element in order to guide the connection cable moisture-tight out of the junction box. Preferably, the sealing element is at least partially fused with the insulating jacket of the connecting cable. The connection element may alternatively have a connector, preferably a moisture-proof connector, wherein the connector may in particular have a PG screw connection. In particular, when using moisture-tight connectors, it is not necessary to provide one or more encapsulation elements in order to connect the at least one connection element to the cover element in a moisture-tight manner.

Preferably, the junction box has at least one conductor receiving device with a solar module side opening and a mounting opening, wherein the contact elements are arranged in the conductor receiving device, that each of the contact elements can be contacted by an associated electrical conductor of the solar module and the mounting hole is moisture-tight by a lid closed. The solar module side opening is particularly formed on the arrangement side, while the mounting opening is formed on an opposite side.

By or in the solar module side opening, the electrical conductors of the solar module for mounting the junction box can be passed or in it. About the mounting opening hands and / or tools can be introduced at least partially, to electrically connect the electrical conductors with the associated contact elements and optionally fix. After contacting the mounting hole is closed by the moisture-tight cover. Optionally, the conductor receiving device can be cast via the mounting opening and / or a filling opening of the lid with a potting compound. This potting compound may be identical or different to the material of the potting. Preferably, the lid comprises a lid sealing element. More preferably, the lid sealing element may be an O-ring, which is held in particular in a groove of the lid. It is also possible that a substantially liquid sealing material is partially applied to the lid, preferably in a groove of the lid, wherein after the hardening or solidification of the sealing material, the lid sealing element is formed or formed. The lid sealing element can also be manufactured separately and arranged on the lid. For example, an O-ring can be inserted into a groove of the lid. Further preferably, the substantially liquid sealing material can be applied in regions to the edge of the mounting opening of the cover, wherein after the hardening or solidification of the sealing material, the lid sealing element is formed or formed on the cover. The sealing material may be identical or different to the material of the potting element.

Use according to one aspect

One aspect of the present invention relates to the use of a junction box according to the invention and a solar module for providing a solar panel, wherein the cover is attached to the solar module and the electrical conductors of the solar module are contacted with the associated contact elements of the junction box.

Preferably, the at least one electrical conductor of the solar module is inserted substantially force-free in the conductor receiving device. Ie. the electrical conductor must not overcome any mechanical resistance during insertion, for example friction on the conductor receiving device, so that advantageously no mechanical load or deformation takes place on the electrical conductor of the solar module, which may be an electrical conductor strip in particular.

Preferably, the junction box can be attached or glued to the solar module by means of an adhesive. The connection box attached to the solar module and contacted according to the invention can be used to connect the solar module with an electrical power consumer, wherein the electrical connection of the power consumer with the solar module via the at least one contact device of the junction box.

Preferably, the provision of the solar panel comprises the step of: fixing the electrical conductors of the solar module to the associated contact elements by means of at least one fixing element.

The provision of the solar panel preferably comprises the step: providing at least one cover which is designed to close an opening of the conductor receiving device or the mounting opening in a moisture-tight manner. The provision of the lid in particular includes moisture-proof arrangement of the lid at the opening of the conductor receiving device or at the mounting opening.

Preferably, the fixing of the electrical conductors to the associated contact element by closing the lid by means of at least one fixing means arranged on the lid. Optionally, the electrical contacting between the electrical conductors of the solar module and the associated contact elements by means of the fixing agent can be carried out. Furthermore, it may be preferable to arrange the fixing means and place the lid in one step, in particular when the fixing means and the lid are connected to one another when arranged.

Method according to one aspect

• – Anordnen einer Kontaktvorrichtung mit zumindest einem Leiteranschlußelement und zumindest einem Kontaktelement an ein Abdeckelement;
• – Befestigen des Abdeckelements an ein Solarmodul, wobei die Kontaktvorrichtung bereichsweise zwischen dem Solarmodul und dem Abdeckelement eingeschlossen ist und daß ein freier Zugriff auf die Kontaktvorrichtung (12) durch das Abdeckelement (22) verhindert ist; und
• – Kontaktieren zumindest eines elektrischen Leiters zumindest eines Anschlußelements mit dem zugeordneten Leiteranschlußelement der Kontaktvorrichtung.

One aspect of the present invention relates to a method for producing a solar panel comprising the following steps:

• Arranging a contact device with at least one conductor connection element and at least one contact element on a cover element;
• - Attaching the cover to a solar module, wherein the contact device is partially enclosed between the solar module and the cover and that a free access to the contact device ( 12 ) through the cover element ( 22 ) is prevented; and
• - Contacting at least one electrical conductor of at least one connection element with the associated conductor connection element of the contact device.

The arrangement of the contact device to the cover may in particular also comprise a detachable or non-detachable fastening. Before attaching the cover to the solar module, the contact device is still accessible and not moisture-tight enclosed by the cover, which advantageously saves further operations and the necessary material. Only by attaching the cover to the solar module, for example by gluing with a moisture-proof adhesive, a moisture-proof enclosure of the contact device can be formed. It can be assumed that the solar module is moisture impermeable.

• – Ausbilden eines Vergußelements durch ein flüssiges Auftragen einer Gießmasse auf das Abdeckelement und das zumindest eine Anschlußelement, wobei eine innige Verbindung zwischen diesen Elementen ausgebildet wird, um das Abdeckelement mit dem zumindest einen Anschlußelement zu verbinden.

Preferably, the method comprises the step:

• - Forming a Vergusselements by a liquid application of a casting compound on the cover and the at least one connecting element, wherein an intimate connection between these elements is formed to connect the cover to the at least one connecting element.

This step preferably takes place before the step of attaching the cover element to the solar module. However, this step can also take place after fixing or after contacting, wherein the solar module is then thermally stressed and should be temperature insensitive accordingly. The potting element is applied substantially liquid, wherein the formation of the potting element comprises in particular the step of: cooling and / or curing of the liquid-applied material of the potting element. The formation of the potting element can be effected in particular by injection molding by means of an injection mold.

By cooling and / or curing of the potting element, the potting element can preferably shrink and produce an intimate connection with the cover element or the at least one connecting element. Thus, the connection element and cover can be connected or fastened together. In other words, the potting may be formed such that the junction box under operating conditions, d. H. attached to the solar module, for example, by a moisture-proof adhesive, and closed with a lid, is moisture-proof. In other words, the electrical or electronic components of the junction box are sealed against the environment, for example according to the IP67 standard.

The contact device preferably has at least one semiconductor component which electrically connects two conductor connection elements and / or at least two of the contact elements and / or a conductor connection element to one of the contact elements. In particular, none of the semiconductor components comes into contact with the liquid, hot material of the potting element during the formation of the potting element.

Preferably, the casting composition is a thermoplastic. Further preferably, the temperature of the contact device and / or arranged on or on the contact device component or a (semiconductor) component of the contact device during the formation of the Vergusselements by the casting compound does not exceed a temperature of about 150 degrees Celsius, more preferably of about 100 degrees Celsius and in particular of about 70 degrees Celsius.

Preferably, the potting consists of a material or is formed of a material which is softer or more flexible in the solid state than the cover or its materials in the solid state. For the purposes of this application, the terms "more flexible" and "softer" mean that the elastic modulus E _V and / or the shear modulus G _{V of} the potting element is less than the elastic modulus E _K and / or the shear modulus G _{K of} the cover element. More preferably, the ratio E _K / E _V and / or G _K / G _{V is} preferably greater than about 1.5, more preferably greater than about 2, or greater than about 5 or greater than about 10, more preferably greater than about 50 or greater than about 100.

The comparatively hard or rigid cover element may or may, for example, be made of polyester, in particular PBT or glass-fiber reinforced polyester, of polystyrene, in particular foamed polystyrene. The elastic modulus may be about 1 GPa to about 11 GPa, more preferably about 3 GPa or about 10 GPa. The melting temperature of the material of the cover, in particular the polyamides, may be about 250 ° C to about 275 ° C.

The comparatively soft or flexible encapsulation element preferably consists at least partially or completely of a thermoplastic elastomer (TPE) or a thermoplastic vulcanizate (TPV). More preferably, the flexible sealing element consists of a polyolefin. Particularly preferably, the flexible sealing element consists of an α-vinyl copolymer, in particular an ethylene-propylene copolymer. For example, the potting element of ethylene, propylene, thermoplastic rubber (Ethylene Propylene Thermoplastic Rubber, EPTR) exist. The temperature range in which the thermoplastic elastomers can be plastically deformed or melted is preferably below the melting temperature of the material of the cover element or of the contact device (that is to say in particular of polyamides and polystyrene). In particular, the temperature range is about 170 ° C to about 250 ° C.

figure description

Hereinafter, a preferred embodiment of the present invention will be described by way of example with reference to the accompanying drawings. It shows

1 : an exploded view of a solar panel with a junction box;

2 a perspective sectional view of the arranged on the solar panel junction box.

The 1 shows an exploded view of a solar panel 2 , The 2 shows a perspective sectional view of the solar module 4 arranged junction box 10 of in 1 shown solar panels 2 , The following description refers to both 1 and 2 , wherein the same elements in the figures are provided with the same reference numerals.

The solar panel 2 comprises a plate-shaped solar module 4 as a power source with four electrical conductors 6a . 6b . 6c . 6d between which a voltage is applied when the solar module 4 is illuminated. The electrical power is by means of two connection elements 8a . 8b from the solar module 4 derived. The connection elements 8a . 8b are in this embodiment as two connection cables 8a . 8b formed, each having an electrical conductor 9a . 9b exhibit. The connection cables 8a . 8b or their electrical conductors 9a . 9b are by means of a on the solar module 4 arranged junction box 10 with the electrical conductors 6a - 6d of the solar module 4 electrically connected.

The junction box 10 takes the to the operation of the solar panel 2 necessary electrical or electronic components and protects the components from mechanical and chemical effects, such as violence and corrosion. Advantageously, this is achieved in that the junction box 10 mechanically stable and moisture-proof.

The electrical components of the junction box 10 are on a circuit board or board 12 as a preferred contact device 12 arranged. The contact device 12 includes two conductor connection elements 14a . 14b each with an associated electrical conductor 9a . 9b an associated connection cable 8a . 8b is electrically contacted, for example by soldering. Furthermore, the contact device comprises 12 a plurality of contact elements 18a . 18b . 18c . 18d , which in particular the number of electrical conductors 6a - 6d of the solar module 4 equivalent. The outer contact elements 18a . 18d can with the conductor connection elements 14a . 14b be electrically connected.

Two adjacent contact elements 18a - 18d are each by means of a bypass diode 16a . 16b . 16c electrically connected, which optionally a short circuit between the adjacent of the contact elements 18a - 18d generated when connected to these contact elements solar cell group of the solar module 4 is shaded so that the voltage generated falls below a predetermined limit.

To the contact device 12 To protect against mechanical and / or chemical influences, especially moisture, includes the junction box 10 a cover element 22 , The contact device 12 can along a Kontaktvorrichtungseinführrichtung K in a receptacle of the cover 22 be introduced at least in certain areas. After that, the contact device 12 protected from free access by at least one page. The contact device 12 remains however from the arrangement side 20 accessible, in particular access along the Kontaktvorrichtungseinführrichtung K is possible. The contact device insertion direction K is preferably perpendicular to one on the cover 22 trained flat surface, which is the arrangement side 20 forms or on the arrangement side 20 is formed so that the flat surface in the arrangement position on the solar module 4 is arranged or with the solar module 4 completes substantially gap-free.

The cover element 22 has an arrangement page 20 on, which is designed in the arrangement position or during normal use directly to the solar module 4 to be arranged or attached. This is the arrangement page 20 at least partially formed as a mounting area, which at least one fastening means 20a may include, for example, an adhesive, a thermoplastic polymer or a thermoplastic elastomer. The immediate assembly thus does not affect the fastener 20a , For example, the adhesive, in particular part of the arrangement side 20 can be. By means of the fastener 20a can the cover 22 and thus the junction box 10 on the solar module 4 moisture-tight connected or fastened to each other, in particular be glued moisture-tight.

The cover element 22 prevents in the arrangement position free access to the contact device 12 which are in a contactor receptacle 26 is arranged, which between the solar module 4 and the cover member 22 is trained. In other words, there are no further elements of a housing between the contact device 12 and the solar module 4 , whereby a material-saving embodiment of a junction box is provided.

In particular, the contact device 12 moisture-proof in the contactor receptacle 26 locked in. Here is the contact device 12 with the cover 22 screwed. For this purpose, the cover 22 at least one Einschraubbereich (not shown) as a preferred fastening device, in which a screw (not shown) passing through an opening 28 the contact device 12 is performed as a preferred complementary fastening device, can be screwed to the contact device 12 on the cover 22 to fix.

The cover element 22 also has two openings 30 on, by which in each case an associated conductor connection element 14a . 14b is accessible. The as soldering lug 14a . 14b trained conductor connection elements 14a . 14b protrude after arranging the contact device 12 to the cover 22 in these openings 30 into or through and can therefore with the associated electrical conductors 9a . 9b the connection cable 8a . 8b be soldered. It is understood that the electrical contacting of the associated electrical conductors 9a . 9b could also be made by clamping, crimping, or the like.

The junction box 10 further comprises a conductor receiving device 34 with a solar module side opening 36 and a solar module-side opening or mounting opening 38 , Here are the contact elements 18a - 18d such in the conductor receiving device 34 arranged that the contact elements 18a - 18d with an associated electrical conductor 6a - 6d of the solar module 4 are contactable. For contacting the electrical conductors of the solar module side opening 36 in the conductor receiving device 34 introduced and manually or by means of a tool with the associated contact elements 18a - 18d contacted. Hands or tools can at least partially through the mounting hole 38 in the conductor receiving device 34 be introduced. Preferably, the conductors 6a - 6d by means of at least one fixing element 42 at the contact elements 18a - 18d fixed or electrically contacted.

The mounting hole 38 can through a lid 40 be sealed moisture-proof. By means of a locking element 44 of the lid 40 , which is releasably or permanently locked with a complementary locking element, the lid 40 preferably locked such that the lock without at least partially destroying the lid 40 and / or the cover member 22 is insoluble. On the lid 40 can be detachable or non-detachable at least one fixing element 42 be arranged. The arrangement can be made by gluing, fusing, screwing, potting, plugging, clamping, caulking or the like. In particular, this can be at least one fixing element 42 be formed integrally with the lid. Preferably, then, the fixing element 42 and the lid made of plastic.

Each contact element 18a - 18d contacts an associated electrical connector 6a - 6d if the junction box 10 on the solar module 4 is mounted or attached and the junction box 10 or the solar panel 2 is in working condition, especially after the lid 40 is arranged.

The junction box 10 can continue at least one casting element 24a . 24b . 24c exhibit. After arranging or locking cover 22 and contact device 12 is the contact device 12 essentially against the penetration of aufzutragendem liquid, hot material to be formed as a casting Vergußelemente 24a . 24b . 24c protected. A first potting element 24a is at a first of the connection cables 8a and the cover member 22 formed so that an intimate connection of the first Vergusselements 24a with the cover 22 and the first of the connection cables 8a is trained. A second potting element 24b is on a second of the connection cables 8b and the cover member 22 formed, so that an intimate connection of the second Vergusselements 24a with the cover 22 and the second of the connection cables 8b is trained.

A third potting element 24c is at the mounting hole 38 of the cover 22 formed so that an intimate connection of the third Vergusselements 24c with the cover 22 is trained. The third potting element 24c forms a lid sealing element 24c out, so that by closing the lid 40 the mounting hole 38 is sealed moisture-proof. Next, the third sealing element 24c a rest area 43 have, with which a locking element 44 of the lid 40 can lock so that the lid remains closed moisture-tight after locking. The rest area 43 is preferred as around the mounting opening 38 circumferential sealing lip 43 educated. Rest area 43 or sealing lip 43 are advantageously formed simultaneously with the formation of the sealing element, in particular by injection molding. It is understood that the lid 40 alternatively or additionally by means of an O-ring can be closed moisture-proof.

As each of the potting elements 24a . 24b . 24c is formed as a casting, for example by injection molding, an intimate connection of the potting 24a . 24b . 24c generated with the other contacting elements. This allows the junction box 10 be formed moisture-tight, so that in particular the contact device 12 at least partially moisture-proof in the junction box 10 is included. By an arrangement of the cover 22 to the contact device 12 prior to forming the potting elements 24a . 24b . 24c can the contact device 12 essentially free from the liquid, hot material of the potting elements 24a . 24b . 24c stay. The heat-sensitive semiconductor components of the junction box 10 , So in this case, the on the board of the contact device 12 arranged bypass diodes 18a - 18c , Be during injection molding of the potting 24a . 24b . 24c at the completion of the junction box 10 not contacted by the hot casting compound, so that no thermal damage to the components occur and the Committee in the production of junction boxes 10 can advantageously be reduced. In this case, the cover 22 be formed of a thermally insulating material or comprise such a material. For example, foamed polystyrene could be used as the thermal insulating material. Depending on the thermal capacity of the semiconductor devices, the thickness of the thermally insulating material may be selected such that the temperature of the contact device 12 during the formation of the potting elements 24a . 24b . 24c a temperature of about 150 degrees Celsius, preferably not exceeding about 100 degrees Celsius and in particular of about 70 degrees Celsius.

LIST OF REFERENCE NUMBERS

2

solar panel

4

solar module

6a-d

electrical conductor of the solar module

8a, 8b

cable

9a, 9b

electrical conductors

10

junction box

12

contact device

14a, b

Conductor connection element

16a-c

Bypass diode

18a-d

contact element

20

arrangement side

20a

complementary fastener

22

Contact device cover element

24a-c

Vergußelemente

26

Contact assembly receptor

28

opening

30

opening

34

conductor receiving

36

terminal insertion

38

mounting hole

40

cover

42

fixing

43

Latching area, sealing lip

44

locking element

Claims (10)

Junction box ( 10 ) for a solar module ( 4 ) comprising: - a cover element ( 22 ), - at least one connecting element ( 8a . 8b ) with at least one electrical conductor ( 9a . 9b ), and - a contact device ( 12 ) with at least one conductor connection element ( 14a . 14b ), wherein each of the conductor connection elements ( 14a . 14b ) an associated electrical conductor ( 9a . 9b ), and at least one contact element ( 18a - 18d ), each of the contact elements ( 18a - 18d ) with an electrical conductor ( 6a - 6d ) of the solar module ( 4 ) is contactable, wherein the contact device ( 12 ) from a layout page ( 20 ) of the cover element ( 22 ) is freely accessible, with which the cover ( 22 ) on the solar module ( 4 ) can be arranged and / or fastened and wherein the junction box ( 10 ) in such a way with the arrangement side ( 20 ) of the cover element ( 22 ) on the solar module ( 4 ) can be arranged that the contact device ( 12 ) at least partially in one of the solar module ( 4 ) and the cover element ( 22 ) trained Contact device receptacle ( 26 ) and that a free access to the contact device ( 12 ) through the cover element ( 22 ) is prevented. Junction box ( 10 ) according to claim 1, wherein the contact device ( 12 ) with at least one fastening means on the cover element ( 22 ) is attached. Junction box ( 10 ) according to claim 1 or 2, with at least one casting element ( 24a . 24b ), which is designed as a casting, wherein the at least one casting element ( 24a . 24b ) an intimate connection with the cover ( 22 ) and / or the at least one connecting element ( 8a . 8b ) to connect them together and / or wherein the at least one casting element ( 24a . 24b ) an intimate connection with the cover ( 22 ) and the contact device ( 12 ) to the contact device ( 12 ) on the cover element ( 22 ) to fix. Junction box ( 10 ) according to claim 3, wherein the at least one casting element ( 24a . 24b . 24c ) is made of a softer material than the cover element ( 22 ). Junction box ( 10 ) according to one of the preceding claims, wherein the cover element ( 22 ) at least one opening ( 30 ) through which an associated one of the conductor connection elements ( 14a . 14b ) is accessible or through which an associated one of the conductor connection elements ( 14a . 14b ) penetrates to an associated electrical conductor ( 9a . 9b ) of the associated connection element ( 8a . 8b ) to be contacted. Junction box ( 10 ) according to one of the preceding claims, wherein the cover element ( 22 ) at least one conductor receiving device ( 34 ) with a solar module-side opening ( 36 ) and a mounting opening ( 38 ), wherein the contact elements ( 18a - 18d ) in the conductor receiving device ( 34 ) are arranged such that each of the contact elements ( 18a - 18d ) by an associated electrical conductor ( 6a - 6d ) of the solar module ( 4 ) is contactable and the mounting opening ( 38 ) moisture-proof through a lid ( 40 ) is closable. Junction box ( 10 ) according to one of the preceding claims, wherein the contact device ( 12 ) at least one semiconductor device ( 16a . 16b . 16c ), which comprises two conductor connection elements ( 14a . 14b ) and / or at least two of the contact elements ( 18a - 18d ) and / or a conductor connection element ( 14a . 14b ) with one of the contact elements ( 18a - 18d ) electrically connects. Use of a junction box ( 10 ) according to one of claims 1 to 7 and a solar module ( 4 ) for providing a solar panel ( 2 ), wherein the cover element ( 22 ) on the solar module ( 4 ) and the electrical conductors ( 6a - 6d ) of the solar module ( 4 ) with the associated contact elements ( 18a - 18d ) of the junction box ( 10 ) are contacted. Method for producing a solar panel ( 2 ) comprising the following steps: arranging a contact device ( 12 ) with at least one conductor connection element ( 14a . 14b ) and at least one contact element ( 18a - 18d ) to a cover element ( 22 ); - Attaching the cover element ( 22 ) to a solar module ( 4 ), wherein the contact device ( 12 ) partially between the solar module ( 4 ) and the cover element ( 22 ) and free access to the contact device ( 12 ) through the cover element ( 22 ) is prevented; and - contacting at least one electrical conductor ( 9a . 9b ) at least one connection element ( 8a . 8b ) with the associated conductor connection element ( 14a . 14b ) of the contact device ( 12 ). Method according to claim 9, comprising the step: - forming a potting element ( 24a . 24b ) by a liquid application of a casting compound on the cover ( 22 ) and the at least one connecting element ( 8a . 8b ), wherein an intimate connection between these elements is formed to the cover ( 22 ) with the at least one connecting element ( 8a . 8b ) connect to.

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