JP2011518441A - Solar panel connection box - Google Patents

Abstract

A junction box for a solar panel is disclosed. The junction box can have a nested base portion and a cover portion. The base portion has an extending skirt portion, is fixed to the solar cell panel, and can have one or more contacts for electrical connection with the solar cell panel. The electrical components of all other junction boxes can be provided on the top for easy access when connecting with cables or wires and / or when maintaining electrical components. When the cover portion and the base portion are bonded together, the cover portion can have one or more terminals for connection to one or more contacts at the bottom. A terminal can be attached to the cover for connecting to the cable, for connecting to each electrical component, and for dissipating heat from the electrical component.
[Selection] Figure 1

Description

[Related applications]
This application is a continuation of US patent application Ser. No. 12 / 148,088 filed Apr. 16, 2008, which is hereby incorporated by reference as part of this specification. No. 61 / 154,289, filed Feb. 20, 2009, which is incorporated herein by reference as a part thereof.

  The present disclosure is generally directed to a connector for providing an electrical connection from a foil conductor or a flat conductor to a plug connector that can accommodate a cable or wire. In particular, the present disclosure is directed to a junction box for quickly and efficiently electrically connecting to a foil conductor or flat conductor of a solar cell.

  Solar cells convert light energy into electrical energy. Generally, one or more solar cells are sandwiched between plate glasses or between a glass and a laminated substrate to constitute a solar cell panel. Thin and flat metal conductors or foil conductors emanating from the solar cell carry the generated electrical energy. The glass or laminate includes an access region or hole that allows the foil conductor to be connected to a junction box or other electrical connector. Junction boxes typically have contacts for providing an electrical connection between a plug connector and foil conductor that can accommodate wires or cables to allow connection to a solar cell. The plug connector allows a quick, easy and efficient connection to other solar panels, batteries, inverters or power equipment.

  The foil conductor is typically connected to the junction box by a manual process. The attachment of the junction box to the solar cell panel is prevented from being automated because the configuration of the solar cell panel, particularly the method of accessing the foil conductor of the solar cell panel, changes variously. In addition to this drawback, the repair of junction boxes that contain electrical components such as diodes and terminals is generally arranged in areas where the junction boxes are generally inaccessible to the solar panel, and areas where the solar panel is also generally inaccessible ( For example, it may be difficult because it is placed on a roof. Furthermore, the current junction box may not be able to adapt to the increase in current that accompanies an increase in the energy conversion efficiency of the solar cell panel.

  The junction box according to the present disclosure can automate attachment to the solar cell panel and connection to the foil conductor of the solar cell panel. The junction box disclosed herein can also facilitate repair and / or replacement of electrical components housed in the junction box. Moreover, according to this indication, a junction box can respond to a bigger electric current for using with a solar cell panel which has higher efficiency.

  In one aspect of the present disclosure, a solar panel junction box is provided that includes a base module and a cover module. The base module has a substantially flat bottom wall having an outer bottom surface and an inner top surface. The bottom wall has a notch and a plurality of terminals attached to the inner upper surface of the bottom wall. One end of each terminal has a solder terminal extending into the notch, and the opposite end has a clip terminal extending upward from the inner top surface. The base portion has an upright base outer peripheral wall adapted to telescopically fit with the upright cover outer peripheral wall. The cover module has a substantially flat top wall having an outer top surface and an inner bottom surface. The cover module includes an upright base outer peripheral wall, an upright cover outer peripheral wall adapted to be telescopically fitted, and a plurality of main terminals fixed to the inner bottom surface in parallel to each other. The plurality of main terminals have a pair of outer terminals and a pair of inner terminals. Each of the main terminals has a generally rectangular configuration having a first end, a second end, and an intermediate portion. Each intermediate portion has a generally flat rectangular terminal secured to the inner bottom surface and a connection tab extending vertically from the inner bottom surface for connection to a corresponding one of the clip terminals. The first end of each outer terminal and the first end of each inner terminal have a raised tail that provides a plurality of axially aligned contact retaining channels. Each of the paired inner terminals has an opposite raised tail at its second end that provides a pair of axially aligned contact retention channels. A first diode is connected between the first end of one outer terminal and the axially aligned contact holding channel of the first end of the inner terminal adjacent thereto. A second diode is connected between the first end of the other outer terminal and the axially aligned contact holding channel of the first end of the inner terminal adjacent thereto. A third diode is connected between the axially aligned contact retention channels of the second end of the inner terminal. At the second end of each outer terminal is an upright cable connection terminal. The upright cover outer peripheral wall has a pair of cable access openings positioned adjacent to each cable connection terminal to facilitate connection of the electrical cable to the cable connection terminal.

  In another aspect of the present disclosure, a solar panel junction box having a base module and a cover module is provided. The base module has a substantially flat bottom wall having an outer bottom surface and an inner top surface. The bottom wall has a notch and a plurality of terminals attached to the inner upper surface of the bottom wall. One end of each terminal has a solder terminal extending into the notch, and the opposite end has a clip terminal extending upward from the inner top surface. The base module has an upright base outer peripheral wall adapted to telescopically fit with an upright cover outer peripheral wall. The base module has a flanged skirt extending outwardly from the upstanding outer peripheral wall and extending circumferentially in a substantially flush relationship with the bottom wall by at least the same distance as the height of the outer peripheral wall. The cover module has a substantially flat top wall having an outer top surface and an inner bottom surface. The cover module includes an upright base outer peripheral wall and an upright cover outer peripheral wall adapted to fit in a telescopic manner, and a plurality of main terminals fixed to the inner bottom surface. The plurality of main terminals have a pair of outer terminals and a pair of inner terminals. Each of the main terminals has a connection tab extending vertically from the inner bottom surface for connection to a corresponding one of the clip terminals. A plurality of diodes connect the main terminals in series within the cover module. Each outer terminal has an upright cable connection terminal. The upright cover outer peripheral wall has a pair of cable access openings positioned adjacent to each cable connection terminal to facilitate connection of the electrical cable to the cable connection terminal.

  Other aspects, objects and advantages of the present disclosure specifically include the explicit and implicit combination of various features shown herein with the relevant information shown in the attached drawings and examples. Will be understood from the following description according to exemplary embodiments of the present disclosure.

  In the following detailed description, reference will often be made to the following drawings, in which like reference numerals refer to like elements.

1 is a perspective view of one embodiment of a junction box according to the present disclosure fixed to a solar cell panel. FIG. 2 is an exploded view of a junction box and solar cell panel according to the present disclosure. FIG. FIG. 6 is a perspective view of an embodiment of a base portion according to the present disclosure. FIG. 6 is a perspective view of another embodiment of a base portion according to the present disclosure. 1 is a perspective view of one embodiment of a contact according to the present disclosure. FIG. FIG. 6 is a lower perspective view of one embodiment of a junction box according to the present disclosure. It is a front view of the lower side of the base part by this indication. FIG. 7 is a cross-sectional view taken along line 7-7 of the base portion shown in FIG. 6. FIG. 6 is a perspective view of another embodiment of a base portion according to the present disclosure. FIG. 10 is a perspective view of the base portion shown in FIG. 9 fixed to the solar cell panel by a laminated material. It is a perspective view of one embodiment of a cover part by this indication. FIG. 6 is a perspective view of one embodiment of an outer terminal and an inner terminal according to the present disclosure. 1 is a perspective view of one embodiment of a contact connected to a terminal according to the present disclosure. FIG. It is a front view of other embodiments of a cover part by this indication. FIG. 6 is a perspective view of another embodiment of an outer terminal and an inner terminal according to the present disclosure.

  It should be understood that the disclosed embodiments are merely exemplary of the disclosure and may be implemented in various forms. Accordingly, the specific details disclosed herein are not intended to be limiting but merely to variously use the inventive features disclosed herein in substantially any suitable manner and combination. It should be construed as a representative basis for teaching vendors.

  FIG. 1 shows an embodiment of a junction box 10 fixed to a solar cell panel 12. The junction box 10 allows wires or cables 14 to be electrically connected to the foil conductors 16 of the solar panel 12. As shown in FIG. 2, the junction box 10 is generated by the solar cell panel 12 in connection with the contact 18 and the base 18 for contacting the foil conductor 16 via the contact terminal or contact 22. And a cover 20 for transmitting electrical energy to the wire or cable 14 via the cable connection 24.

  FIG. 3 shows an embodiment of the base unit 18. The base portion 18 can be made of any tough, hard and highly durable material such as plastic, plastic alloy, metal, alloy, silicon, glass fiber or the like. It should be understood that if a conductive material such as a metal, alloy or the like is used, an insulating or dielectric material must be placed between the base housing and all electrical contacts or terminals. In one embodiment, the base portion 18 can be made of a dielectric material such as plastic or plastic alloy that can withstand an operating temperature of at least 200 ° C. An example of such a plastic or plastic alloy is Noryl® made by Sabic. The base portion 18 can have a bottom wall 26 and an upstanding wall 28 extending perpendicularly from an inner surface 27 of the bottom wall 26 to form a surrounding region 30. The bottom wall 26 and the upright wall 28 may take other shapes than the rectangular shape depicted in the embodiment of the base portion 18. The upright wall 28 can be spaced from the periphery or edge of the bottom wall 26 to form the shelf 32. On each side surface of the upright wall 28, there may be a column 34 for enhancing and supporting the rigidity of the upright wall 28.

  The bottom wall 26 can have a notch 36 that allows one or more contacts 22 to reach the exposed end 17 of the foil conductor 16 (see FIG. 2). As shown in FIG. 2, a portion of the actual substrate of the panel 12 such as glass or other substrate material or a portion of the laminate 38 of the solar panel 12 provides an access opening 40 that exposes the foil conductor 16. Can be removed. The notches 36 can be large enough to allow access to at least all exposed ends 17. Alternatively, a notch 36 can be provided for each contact 22 to allow access to each exposed end 17. In one embodiment, contact 22 is the only electrical component within base portion 18.

  FIG. 5 illustrates one embodiment of the contact 22. The contact 22 may have a base portion 42, a spring arm 44 extending obliquely downward from the base portion 42, and a contact pad portion 46 at the end of the spring arm 44. One or more spring clips 48 may extend upward from the body portion 42. The contact 22 further includes an opposing front holding arm 50 extending upward from both sides of the main body portion 42 at an end adjacent to the spring arm 44, and a rear holding arm 52 extending upward from the rear portion of the main body portion 42. Can have. Each holding arm 50, 52 may have a platform portion 54, 56 at each end. The contact 22 can be made of any number of conductive materials such as metals and alloys. In one embodiment, contact 22 can be made from a high copper alloy. Contact 22 may also be plated with one or more metals or alloys. In one embodiment, contact 22 is made from Wieland K65 by a known stamping process and may have a nickel plating throughout. The spring clip 48 may have additional silver plating and the contact pad 46 may have additional tin (tin) plating.

  When the base portion 18 is fixed to the panel 12, the contacts 22 are aligned with the upper surface of the bottom wall 26, that is, the contact pad portions 46 of each contact 22 are aligned with the corresponding exposed ends 17. It can be fixed to the inner surface 27. Each holding arm 52, 54 fits into a corresponding mounting wall 58, 60 with a friction or interference fit using a protrusion or hook to bite into one or more of the mounting walls 58, 60. Can be accommodated by. The platform portions 54, 56 cooperate with the mounting walls 58, 60 to prevent the contact 22 from rotating left and right and back and forth. Alternatively, the contacts 22 can be secured to the bottom wall 26 using heat staking.

  In one embodiment, the bottom wall 26 can have a protective wall 61 that surrounds the exposed side of the spring clip 48. As shown in FIG. 4, the protective wall 61 can extend vertically from the inner side surface 27 to at least the height of the spring clip 48 and substantially perpendicular to the inner side surface 27. The protective wall 61 protrudes from the inner surface 27 on both sides of each contact 22 and on the opposite side of the contact pad 46 to prevent inadvertent contact with the contact 22. Such inadvertent contact may cause an electric shock or damage the contact 22 after the contact 22 is electrically connected to the exposed end 17. The protective wall 61 can also prevent arcing between the contacts 22 as will be described in detail later with respect to the terminals attached to the cover portion 20.

  To ensure contact between the contact pad portion 46 and the exposed end 17, a solder fill layer 64 may be pre-deposited on the bottom surface of the contact pad portion 46, as shown in FIGS. it can. After the flux is applied to the exposed end 17, heat is applied by an automatic process or a manual process to melt the solder filling layer 64, and when the solder filling layer 64 solidifies, the exposed end 17 and the contact pad portion 46 are interposed. Provides a secure electrical connection. Alternatively, the solder filling layer 64 may be omitted, and the solder may be attached separately in the soldering process.

  As shown in FIGS. 2 and 6, the contact pad portion 46 can be positioned to enter and extend beyond the notch 36 to contact the exposed end 17. The contact pad portion 46 will be applied to the lower surface 62 as described above, depending on the thickness of the substrate or laminate 38 removed from the solar panel 12 to expose the foil conductor 16. Taking into account the thickness of the adhesive, it can extend beyond the outer surface of the bottom wall 26, ie the lower surface 62, from a fraction of a millimeter to a few millimeters. The spring arm 44 elastically biases the contact pad portion 46 to remain in contact with the exposed end 17, thereby making the contact pad portion 46 an additional distance greater than the thickness of the laminate 38 or substrate. Can be positioned to extend beyond the lower surface 62 only. In other words, since the spring arm 44 allows movement of the contact pad 46, the contact pad is equal to or greater than the thickest stack 38 or substrate to accommodate various solar panel stack 38 thicknesses. It can be positioned to extend beyond the lower surface 62 by a large distance. In one embodiment, the contact pad can be adapted when the distance from the exposed end 17 to the lower surface 62 is about 0.5 to about 2 millimeters.

  The base portion 18 can be fixed to the solar cell panel 12 by a known method such as adhesion. In one embodiment, a double-sided tape 66 may be applied to the lower surface 62 of the bottom wall 26 as shown in FIG. In order to protect the contact pad portion 46 as well, a protective film (not shown) may cover the double-sided tape 66 and the notch 36. As shown in the embodiment of FIG. 8, the solder fill layer 64 can be flush with the tape 66 because the tape 66 is compressible. Alternatively, the contact pad 46 and / or the solder filling layer 64 may protrude beyond the tape 66 to accommodate the thickness of the laminate 38 or substrate as described above.

  To help press the base portion 18 against the solar panel 12, the bottom wall 26 can have an overhanging wall 68 that extends from the inner surface 27 upward and substantially perpendicularly beyond the spring clip 48. . The upper end of the overhanging wall 68 may be substantially flush with the upper surface 70 of the upstanding wall 28 as shown in FIG. In order to facilitate the automatic attachment of the base portion 18 to the solar cell panel 12, the base portion 18 extends upward and substantially perpendicularly from the inner side surface 27, and is an alignment post 72 that is substantially flush with the upper surface 70. , 74. The alignment posts 72, 74 can generally be used with laser, mechanical, or other optical alignment processes.

  In another embodiment shown in FIG. 9, the bottom wall 26 can extend diagonally beyond the shelf 32 to form a skirt 76. The skirt 76 can provide an additional adhesive surface area for securing the base 18 to the solar panel 12. Alternatively, as shown in FIG. 10, a laminated cover 78 may cover the skirt 76 instead of or in addition to an adhesive bond to secure the base portion 18. In one embodiment, the skirt 76 may have a thickness of about 1.3 millimeters near the ledge 32 and a thickness of about 0.6 millimeters at the terminal edge. The lower surface (not shown) of the skirt 76 may be coplanar with the lower surface 62 of the bottom wall 26. In one embodiment, the skirt 76 extends circumferentially beyond the upstanding wall 28 by a distance that is at least as great as the height of the upstanding wall 28 as measured from the inner surface 27. In one embodiment shown in FIG. 3, the bottom wall 26 can have a thickness of about 2.55 mm and the upright wall 28 has a height of about 15.35 mm. Can do. In the embodiment shown in FIG. 9, the base portion 18 can have a width and length of about 126 mm and 98 mm, respectively.

  FIG. 11 shows an embodiment of the cover part 20 of the junction box 10. The cover part 20 can have an upper wall 80 and a protruding wall 82. The protruding wall 82 can extend substantially vertically from the top wall 80 to form a closed region 84. The protruding wall 82 can be spaced from the periphery or edge of the upper wall 80 to form the lip 86. Both sides of the protruding wall 82 can have struts 88 to provide additional rigidity and support to the protruding wall 82. The upper wall 80 and the protruding wall 82 have the rectangular shape illustrated in the embodiment shown in FIG. 11 as long as the upright wall 28 and the protruding wall 82 can be nested with each other to form a housing. Not take other forms. In one embodiment, the protruding wall 82 can be sized to nest within the upstanding wall 28 of the base 18 to form a sealed housing. With respect to the material used to form the cover portion, it should be understood that the above description regarding the material forming the base portion 18 applies equally to the cover portion 20. In one embodiment, the cover portion 20 can be made of the same material as the base portion 18.

  Since the junction box is generally exposed (exposed) to the outdoor environment, a seal that protects the casing formed by fitting the base portion 18 and the cover portion 20 is provided on either the base portion 18 or the cover portion 20. be able to. In the embodiment shown in FIG. 11, the cover portion 20 can have a flexible seal 90 around the protruding wall 82 adjacent to the top surface 92. The seal 90 cooperates with the upright wall 28 to provide a barrier to outdoor elements such as rain and dust. The seal 90 can be made of silicon elastomer, rubber or rubber alloy. In one embodiment, the seal 90 may be a silicon elastomer and can provide an IP67 rating. An interengagement locking member can be provided to join the bottom and the cover. As shown in the embodiment of FIGS. 3 and 11, the base portion 18 has a protruding wall 82 on one of both the lateral sides of the upstanding wall 28 and the longitudinal side of the upstanding wall 28. There may be a locking tab 98 that engages a slot 100 extending from a complementary side. In order to ensure the base 18 and cover 20 are properly oriented, the locking tabs 98 and slots 100 on both lateral sides of the upstanding wall 28 and the protruding wall 82 are positioned off the center of the lateral side. Can be arranged.

  The junction box may be stressed by the rise and fall of temperature. For example, when heated during the day, the air in the junction box expands, and if there is a seal between the base portion and the cover portion, the seal may be damaged. Similarly, when cooled in the night, the air in the junction box contracts, thereby again damaging the seal and allowing air and moisture to enter. Excessive moisture in the junction box can cause the junction box to malfunction and / or fail. If moisture can be prevented from entering the junction box and the pressure in the junction box can be made equal to the atmosphere, the life of the seal and the operability of the junction box can be improved.

  In one embodiment, the junction box 10 may have pressure equalization holes so that air can enter and exit the junction box 10. In the embodiment shown in FIG. 11, the cover part 20 may have a pressure equalizing hole 94 on the upper wall 80 or the protruding wall 82. In order to prevent moisture from entering through the pressure equalizing holes, a moisture-proof material or a moisture-absorbing material may be used. In one embodiment, the pressure equalizing hole 94 can be covered with a moisture-proof thin film cover 96 such as, for example, a Gore-Tex (registered trademark) material.

  In order to pass electrical energy from the base portion 18 of the junction box 10 to the cover portion 20, the cover portion 20 has one or more main terminals for connection to one or more contacts 22 of the base portion 18. Can have. Several factors affect the number and configuration of the terminals, such as the voltage transmitted by the terminals, the number of foil conductors, the incidental heat generated by the terminals and / or other electrical components in the junction box. Since the junction box 10 can be used to connect two or more solar panels in series, the terminals can be made to allow the cumulative voltage generated by the connected solar panels. The greater the voltage and / or current transmitted by the terminal, the more heat is generated. This heat can cause failure of one or more components of the junction box 10, such as the junction box walls, and electrical components and / or terminals such as wire bridges and diodes. Therefore, the size and configuration of the terminals can be determined so as to increase heat dissipation.

  In the embodiment shown in FIG. 11, the cover portion 20 can have four main terminals connected to the four contacts 22 and can accommodate a direct current of about 1000 volts, and later As described in detail, it can serve as a heat sink so that the electrical components connecting the terminals do not exceed about 200 ° C. In one embodiment, the cover part 20 may have two outer terminals 102 and two inner terminals 104. The embodiment of the outer terminal 102 shown in the drawings is the same, but this is not essential. The same is true for the inner terminal 104.

  As shown in FIGS. 11 and 12, one embodiment of each outer terminal 102 may have a front end 106, an opposite rear end 108 and an intermediate portion 110. The front end 106 can have a raised retention channel 112. The intermediate portion 110 can have a large flat rectangular plate 114 and connecting tabs 116 that extend perpendicular to and substantially perpendicular to the rectangular plate 114. The rear end 108 can also include a flat plate 118 and a cable connection member 120 that extends perpendicularly from the flat plate 118 at a substantially right angle.

  The inner terminal 104 can have opposite front ends 122 and rear ends 124. Each front end 122 and rear end 124 may have a raised retention channel 126. The intermediate portion 128 can have a front plate 130 and a rear plate 132 that are partially separated by a connection tab 134 that extends perpendicular to the front plate 130 and the rear plate 132 at a substantially right angle. To do.

  The outer and inner terminals 102 and 104 can be made of any conductive material such as metal or alloy. In one embodiment, the outer and inner terminals 102, 104 can be made of a highly conductive high copper alloy. Also, the terminals 102 and 104 may be plated with one or more metals and alloys. In one embodiment, the terminals 102, 104 are made of a high copper alloy K65 from Willand and may have a nickel plating throughout. The retaining channels 112, 126 and the cable connection member 120 may have additional tin plating. The connection tabs 116, 134 may have additional silver plating. The terminals 102 and 104 can be formed by a known punching process.

  The terminals 102 and 104 can be fixed to the inner surface 81 of the upper wall 80. In one embodiment, the terminals 102, 104 can be secured to the inner surface 81 such that all flat portions of the terminals 102, 104 are in contact with the inner surface 81 to enhance heat dissipation. The terminals 102 and 104 have two or more holes 136 that fit into pillars 138 extending from the inner surface 81, and are heat squeezed in place. Alternative methods may be used to secure the terminal to the cover.

  Safety standards can define the distance that the terminals must be separated from each other as a measure of arcing between the terminals, depending on the transmitted voltage. Such criteria conflicts with the desire for a small junction box. For terminals that carry 1000 volts DC and are exposed to 8000 volts DC pulses, it is recommended that the terminals be spaced about 10 millimeters along the dielectric plane. For example, if the terminals are separated by a specific distance with a straight line extending between two points along the flat surface, by adding a raised surface between the terminals, the distance between the two points can be increased without increasing the distance between the terminals. The distance can be increased. This is because the total distance along the concavo-convex surface is larger than the distance between terminals that are similarly spaced on the flat surface.

  In one embodiment, as shown in FIG. 11, the cover portion 20 can have barriers 144, 146, 148 that extend perpendicularly from the inner surface 81 between the terminals 102, 104 at a substantially right angle. The height and thickness of the barriers 144, 146, 148 can be adjusted so that the distance between adjacent terminals meets safety standards. For example, the distance measured between the outer terminal 102 and the adjacent inner terminal 104 is opposite the distance along the height of one side 150 of the barrier 144 and the distance along the thickness 152 of the barrier 144. And a distance along the side 154 of the terminal, and is greater than or at least equal to the recommended distance for the voltage transmitted by the terminals 102,104. Alternatively, if there is no requirement for miniaturization, the terminals 102 and 104 may be appropriately separated by a recommended security distance along the flat surface without providing a barrier or other such structure.

  The connection tabs 116 and 134 of the terminals 102 and 104 are connected to the spring clips 48 of the contacts 22 when the base portion 18 and the cover portion 20 are brought close to each other, and the base portion 18 and the cover portion 20 are electrically connected. Connect to. This is illustrated in FIG. 13 for the inner terminal 104 and the corresponding contact 22. It should be understood that this also applies to the connection between the other inner terminal 104, each outer terminal 102 and their corresponding contacts 22.

  Terminals 102 and 104 can be electrically connected in series or in parallel to each other by any number of electrical components. In one embodiment, the front retention channel 112 of each outer terminal 102 can be axially aligned with its corresponding front retention channel 126 of the adjacent inner terminal 104. This is to accommodate the corresponding end of the electrical component for electrically connecting the outer terminal 102 to the corresponding adjacent inner terminal 104. The series connection of the terminals 102, 104 is completed by axially aligning the rear retention channel 126 of the inner terminal 104 to accommodate the corresponding ends of the electrical components that electrically connect the inner terminal 104 to each other. Can be made. In this way, the outer terminal 102 can be electrically connected to the corresponding adjacent inner terminal 104, and the inner terminal 104 can be electrically connected to the adjacent inner terminal 104, and the inner terminal 104 can be correspondingly connected thereto. The terminals 102 and 104 can be connected in series by being electrically connected to the adjacent outer terminal 102.

  The particular electrical component that electrically connects the terminals 102, 104 may vary depending on the voltage and current transmitted by the terminals 102, 104. In general, a simple wire bridge can be used for direct currents of 24 volts or less. However, the wire bridge can conduct electricity in either direction. This allows electrical energy to flow to the solar panel from a power source such as a battery, electrical equipment or the like to which the solar panel is connected. In one embodiment, a diode 142 electrically connects the terminals 102, 104. The diode 142 allows electricity to flow in substantially only one direction, thereby preventing back flow from the power source to the solar panel. In a junction box that can accommodate 1000 volts DC, diode 142 can be selected to allow about 9 amps of current. A 9 ampere current through the diode 142 may cause overheating and failure if the heat generated by the diode 142 cannot be removed or dissipated.

The heat sink characteristics of the terminals 102, 104 dissipate the heat generated by the diode 142 in a standard outdoor operating environment and prevent the diode 142 from reaching the recommended maximum temperature of about 200 ° C. In one embodiment, the total area of the outer terminal 102 and the inner terminal 104 in contact with the inner surface 81 of the cover 20 can be about 15 [cm ² ], and the total area of the upper wall 80 is about 65 [cm ² ]. It can be. 14 and 15 show the actual sizes of these embodiments of terminal 102, terminal 104 and top wall 80. FIG. As shown in FIG. 14, the width and length of the upper wall 80 can be about 97 [mm] and 68 [mm] without including the slot 100, respectively. As shown in FIG. 15, the outer terminal 102 may have a width of about 15 mm and a length of about 41 mm without including the raised portion of the front end 106 with the retention channel 112. it can. The inner terminal 104 may have a width of about 15 mm and a length of about 25.5 mm without including the raised portions of the front end 122 and the rear end 124 with retaining channels 126. In both the outer terminal 102 and the inner terminal 104, the retaining channels 112, 126 can be raised by about 7 mm. Each of the connection tabs 116 and 134 may have a height of about 13.3 [mm] and a width of about 5.6 [mm].

  As shown in FIG. 11, the leads 156 on either side of the diode 142 can be received in the raised retention channel of the adjacent terminal. The raised retaining channels 112, 126 can provide a press fit or interference fit connection to the lead 156. As an addition or alternative to the press-fit connection, the lead 156 can be soldered to the raised retention channels 112,126. In order to keep the diode 142 from moving during the assembly or soldering process, the cover portion may include a lead clip 156 extending from the inner surface 81, or as shown with respect to the barriers 146 and 148. A lead clip 160 may be provided at the end of the barrier.

  In order to conduct electricity from the junction box 10, each outer terminal 102 is connected to a cable connection tab 120 so that the outer terminal 102 can be quickly and easily connected to a conductor portion of a wire or cable. The cage clamp 140 can be provided. The cover portion 20 may have an access opening 162 opened in the protruding wall 82 adjacent to each cable connection tab 120 to allow a wire or cable to connect to the outer terminal 102 to enter. A cable sleeve 164 can protrude from the periphery of each access opening 162 and has a tension relief finger 166 at its distal end. As shown in FIG. 3, the upstanding wall 28 of the base portion 18 can have a cable cutout 172 for receiving the cable sleeve 164.

  A collar 166 can be inserted into each cable sleeve 164 so as to be inside the tension relief finger 166 (see FIG. 2). The cable sleeve 164 may have a screw connection 168 that receives the screw cap 170. A cable 14 with a portion of the inner conductor exposed can be inserted into the collar 166 and sleeve 164. The exposed conductor can be connected to the cage clamp 140 and a screw cap 170 can be placed over the cable 14 and fastened to the sleeve 164. A strain relief finger 166 can clamp the cable and provide support and secure connection to the cable 14.

  Although the present disclosure has been described in detail with reference to the above embodiments, other changes and modifications can be further made without departing from the spirit or scope of the disclosure. It should be understood that the present disclosure is not limited by the embodiments described herein. Indeed, the true breadth of the present disclosure is defined by the appended claims including any equivalents given to each element of each claim.

Claims (28)

A solar panel junction box,
A base part, a cover part that engages with the base part to form a housing, a plurality of solar cell panel connection terminals, a plurality of main terminals, and at least one for connecting the plurality of main terminals in series With electrical components,
The base includes a substantially flat bottom wall having an outer surface and an inner surface;
The bottom wall includes at least one notch;
The plurality of solar cell panel connection terminals are attached to the inner surface of the bottom wall, and each of the solar cell panel connection terminals is elastically biased to extend into the at least one notch. A contact end and another end with a clip terminal;
The cover portion includes an upper wall having an outer surface and an inner surface,
The plurality of main terminals are fixed to the inner surface of the upper wall, each of the main terminals having a substantially flat intermediate portion that contacts the first end, the second end, and the inner bottom surface. ,
Each of the plurality of main terminals includes a connection tab for connecting to a corresponding one of the clip terminals,
Two of the plurality of main terminals have cable connection ends;
The cover portion includes a pair of cable access openings, each cable access opening being adjacent to a corresponding one of the cable connection ends to facilitate connection of an electrical cable to the cable connection ends. Solar panel connection box positioned on.   One of the said base part and a cover part is a solar cell panel connection box of Claim 1 containing the sealing gasket for sealing the said housing | casing.   2. The solar cell panel connection box according to claim 1, wherein one of the cover part and the base part includes an opening including a moisture-proof filter that allows passage of air and prevents passage of moisture.   The solar cell panel connection box according to claim 1, wherein the at least one electric component is a diode. The plurality of main terminals include a pair of outer terminals, a pair of inner terminals positioned between the outer terminals,
A first electrical component connected between one of the outer terminals and an adjacent inner terminal;
A second electrical component connected between the other of the outer terminals and the adjacent inner terminal;
A third electrical component connected between the inner terminals,
Each of the said outer side terminal is a solar cell panel connection box of Claim 1 provided with a cable connection end.   The solar cell panel connection box according to claim 5, wherein the first electric component, the second electric component, and the third electric component are diodes.   Each of the connection tabs extends substantially perpendicular to the inner surface of the bottom wall toward the cover portion, and each of the clip terminals faces the inner surface of the upper wall toward the base portion. The solar cell junction box according to claim 6, extending substantially perpendicular to the vertical axis.   The solar cell panel connection box according to claim 7, wherein the connection tab extends from the intermediate portion of the main terminal. A first end of each of the outer terminals and a first end of each of the inner terminals includes a raised portion with a retention channel, the first end retention channels being axially aligned with each other;
The second end of each of the inner terminals includes a raised portion with a retention channel, the retention channels of the second end of the inner terminal being axially aligned with each other;
The solar cell panel connection box according to claim 8, wherein the second end of each of the outer terminals includes the cable connection end.   Leads on both sides of the first diode are housed in a retaining channel at a first end of one of the outer terminals and an inner terminal adjacent thereto, and leads on both sides of the second diode are The other end of the outer terminal and the inner terminal adjacent to the inner terminal are accommodated in the retaining channel of the first terminal, and both leads of the third diode are in the retaining channel of the second end of the inner terminal. The solar cell panel connection box according to claim 9, which is accommodated in a solar cell.   The base portion includes an outer peripheral wall extending substantially perpendicularly from the bottom wall, the cover portion includes an outer peripheral wall extending substantially perpendicularly from the upper wall, and the outer peripheral walls are engaged with each other in a nested manner. The solar cell panel connection box according to claim 10, wherein   The base portion includes a flanged skirt portion extending from a bottom wall of the base portion, the flanged skirt portion comprising a lower surface substantially flush with the outer surface of the bottom wall. Solar panel junction box.   Each of the said solar cell panel connection terminal is a solar cell panel connection box of Claim 1 containing the spring arm which connects the said contact end to a spring clip.   The bottom wall includes the same number of notches as the plurality of solar cell panel connection terminals, and each of the contact ends extends into a corresponding one of the notches. Solar panel junction box.   The solar cell panel connection box according to claim 1, wherein an inner side surface of the upper wall includes a barrier extending from the inner side surface between adjacent main terminals.   The solar cell panel connection box according to claim 15, wherein an inner side surface of the bottom wall includes a protective wall extending from the inner side surface and surrounding each exposed side surface of the clip terminal. A solar panel junction box,
A base module, a cover module, a plurality of connection terminals, a plurality of main terminals, and a plurality of diodes;
The base module comprises a substantially flat bottom wall with an outer bottom surface and an inner top surface;
The bottom wall includes a notch;
The plurality of connection terminals are attached to the inner upper surface of the bottom wall, and each of the plurality of connection terminals extends substantially perpendicular to the contact end extending into the notch and the inner upper surface. With another end with clip terminal,
The base module includes an upright base outer peripheral wall that nests with an upright outer peripheral wall of the cover module;
The base module includes a flanged skirt portion that surrounds the periphery of the base outer peripheral wall and extends outward by at least the same distance as the height of the base outer peripheral wall, and the flanged skirt portion is substantially the same as the outer bottom surface. With a flat bottom surface,
The cover module includes a substantially flat top wall having an outer top surface and an inner bottom surface, the cover module including an upright cover outer wall that nestingly fits with the upright base outer wall,
The plurality of main terminals are fixed to the inner bottom surface, and the plurality of main terminals include a pair of outer terminals and a pair of inner terminals,
Each of the plurality of main terminals includes a connection tab for connecting to a corresponding one of the clip terminals,
The plurality of diodes connect the main terminals in the cover module in series,
Each of the outer terminals includes an upright cable connection terminal;
The upstanding outer peripheral wall of the cover module includes a pair of cable access openings, each of the cable access openings being one of the cable connection terminals to facilitate connection of an electrical cable to the cable connection terminal. A solar panel junction box positioned adjacent to its counterpart.   The solar panel connection according to claim 17, wherein the base module includes a laminated body that covers the flanged skirt portion and extends so as to surround the periphery of the base module. box.   The solar cell panel connection box according to claim 18, wherein one of the base portion and the cover portion includes a sealing gasket for sealing between the base module and the cover module.   20. The solar cell panel connection box according to claim 19, wherein one of the cover module and the base module includes an opening provided with a moisture-proof filter for allowing passage of air and preventing passage of moisture.   18. The solar panel junction box according to claim 17, wherein each of the plurality of main terminals includes a first end, a second end, and a substantially flat intermediate portion in contact with the inner bottom surface.   A first diode is connected between one of the outer terminals and an inner terminal adjacent thereto, and a second diode is connected between the other of the outer terminals and an inner terminal adjacent thereto, The solar cell panel connection box according to claim 17, wherein a third diode is connected between the inner terminals.   The solar cell according to claim 17, wherein the bottom wall includes the same number of notches as the plurality of connection terminals, and each of the contact ends extends into a corresponding one of the notches. Panel connection box. A solar panel junction box,
A base module, a cover module, a plurality of base terminals, a plurality of main terminals, a first diode, a second diode, and a third diode;
The base module comprises a substantially flat bottom wall with an outer bottom surface and an inner top surface;
The bottom wall includes a notch;
The plurality of base terminals are attached to the inner upper surface of the bottom wall, and each of the plurality of base terminals extends substantially perpendicular to the inner upper surface and a solder terminal end extending into the notch. With the opposite end with the clip terminal present,
The base module includes an upright base outer peripheral wall that nests with an upright outer peripheral wall of the cover module;
The cover module includes a substantially flat top wall having an outer top surface and an inner bottom surface, the cover module including an upright cover outer peripheral wall that telescopes with the upright base outer peripheral wall;
The plurality of main terminals are fixed to the inner bottom surface in directions parallel to each other, the plurality of main terminals include a pair of outer terminals and a pair of inner terminals, and each of the plurality of main terminals includes: Comprising a generally rectangular configuration comprising a first end, a second end and an intermediate portion;
Each of the intermediate portions has a substantially flat rectangular terminal with a connection tab secured to the inner bottom surface and extending generally perpendicularly from the intermediate portion for connection to a corresponding one of the clip terminals. ,
A first end of each of the outer terminals and a first end of each of the inner terminals includes a raised tail that provides a plurality of axially aligned contact retention channels;
Each of the pair of inner terminals includes a raised tail at a second end thereof to provide a pair of axially aligned contact retaining channels;
The first diode is connected between the axially aligned contact holding channels of the first end of one of the outer terminals and the first end of the inner terminal adjacent thereto;
The second diode is connected between the axially aligned contact holding channels of the other first end of the outer terminals and the first end of the inner terminal adjacent thereto;
The third diode is connected between the axially aligned contact retention channels of the second end of the inner terminal;
The second end of each outer terminal includes an upright cable connection terminal;
The upstanding outer peripheral wall of the cover module includes a pair of cable access openings positioned adjacent to the corresponding cable connection terminals to facilitate connection of electrical cables to the cable connection terminals. Panel connection box.   25. The solar cell panel connection box according to claim 24, wherein each of the plurality of base terminals includes an elastic spring arm that biases the solder terminal end into the notch.   One of the base module and the cover module includes a sealing gasket for sealing between the base module and the cover module, and one of the cover module and the base module allows passage of air. 25. The solar cell panel connection box according to claim 24, further comprising an opening provided with a moisture-proof filter for preventing passage of moisture.   The base module includes a flanged skirt portion extending from the upright outer peripheral wall of the base portion by a distance larger than the height of the outer peripheral wall, and a lower side of the flanged skirt portion is substantially flush with the outer bottom surface. The solar cell panel connection box according to claim 24, wherein   25. The solar cell of claim 24, wherein the bottom wall includes the same number of notches as the plurality of base terminals, and each of the solder terminals extends into a corresponding one of the notches. Panel connection box.

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