DE102009054087B4 - Junction box housing for solar module - Google Patents

Abstract

Method for mounting a junction box housing (16) on a solar module (10), comprising the steps of: providing a cover element (18) with an opening (44) in a bottom side of the cover element (18), providing a connection device (22) in the cover element ( 18), placing and fastening the junction box housing (16) on the solar module (10), with a contacting unit (46) provided on the solar module penetrating through the opening (44) into the assembled junction box housing (16) and being connected to the connecting device (22 ) is contacted in an electrically conductive manner, the method further comprising the production of a contacting unit (46) on a solar module (10) with the following steps: electrically conductive connection of the solar cells (12) by means of at least one conductor strip (14), providing at least one separate Contact piece (26), electrically conductive contacting of a free end of the conductor strip (14) with a first end (34) of the contact piece (26) by means of a spring element (38) which presses against a surface of the contact piece (26) which is opposite in relation to the contact point between the conductor strip (14) and the contact piece (26),application of a laminating layer (30, 40) such that both the contact point between the conductor strip (14) and the contact piece (26) and the spring element (38) and at least partially the free end of the conductor strip (14) are embedded in a laminating layer (40) and a second end (36 ) of the contact piece (26) protrudes from the laminating layer (40).

Description

The present invention relates to a junction box housing for a solar module and a method for assembling the same.

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 made available by the solar module, individual solar cells are connected in parallel and/or in series within the module and are thus combined into solar cell groups. The solar cell groups are combined to form a flat solar module.

1. (1) Eine (gleichmäßige) Verringerung der Bestrahlungsintensität innerhalb der zusammen geschalteten Solarzellengruppen führt zu einer Leistungsverminderung der jeweiligen Solarzellengruppe.
2. (2) Durch eine partielle Abschattung einer Solarzelle innerhalb einer Solarzellengruppe wirkt diese abgeschattete Solarzelle als Sperrdiode bzw. Widerstand innerhalb des Stromkreises der Solarzellengruppe, was zum einen dazu führen kann, daß die gesamte Solarzellengruppe keine elektrische Energie mehr liefern kann und zum anderen zu einer Beschädigung der abgeschatteten Solarzelle führen kann und damit zum dauerhaften Ausfall der Solarzellengruppe.

The electrical connections of the solar cell groups of the solar module are routed to the outside. If there is a partial reduction in the radiation intensity from sunlight on individual solar cells or solar cell groups, for example due to dirt or shadows, the following effects can occur, among others:

1. (1) A (uniform) reduction in the irradiation intensity within the interconnected solar cell groups leads to a reduction in the output of the respective solar cell group.
2. (2) Partial shading of a solar cell within a solar cell group causes this shaded solar cell to act as a blocking diode or resistor within the circuit of the solar cell group, which can lead to the entire solar cell group no longer being able to supply electrical energy and to damage of the shaded solar cell and thus to the permanent failure of the solar cell group.

In any case, different voltages can be applied between the led-out connections of the solar cell groups of a solar module, depending on the irradiation intensity on the individual solar cells. A series connection of the solar cell groups by appropriate switching of the connections led to the outside leads analogously to the above-mentioned problems.

In order to avoid the problems associated with the different irradiation intensity of the solar cells, so-called bypass diodes are conventionally used, which are electrically connected antiparallel to the solar cell groups. These bypass diodes have the effect that the current flow through the solar module is routed past groups of solar cells that only deliver a low output, i.e. the connections of this group of solar cells of a solar module are short-circuited by the bypass diode and the corresponding group of solar cells is thereby bypassed. Thus, although such a solar cell group no longer contributes to the total output of the solar module, the total current flow through the solar module is essentially unhindered and damage to individual solar cells is prevented.

Solar modules therefore generally include an electrical connection box with a large number of contact devices and a correspondingly adapted number of bypass diodes. Thin, flexible conductor strips, which are electrically connected to the individual solar cell groups, are routed out of the solar module and generally make contact with the contact devices arranged in one junction box, which are electrically connected to one another with bypass diodes.

In order to be able to connect the conductor strips, they are usually introduced from below into the junction box, which has a removable housing cover, and contacted by hand with a contact device present in the junction box.

Such manual assembly is very time-consuming, resulting in the need for automated connection of a solar module. Due to the high flexibility, however, the conductor strips led out of the solar module protrude in a disorderly manner from the back of the solar module. Determining the position of the conductor strips, which is required for automated assembly, is therefore very difficult.

From the DE 10 2007 051 134 A1 a connection and junction box for a solar module is known, which comprises a housing for placing on the solar module. A connection device for the flexible conductor strips is arranged in the housing, the connection device having an electrical contact clamp for producing a clamping contact. A deflection lever bends the flexible conductor strip towards the contact clamp after it has been inserted through an insertion opening into the connecting and junction box, so that the flexible conductor strip can be electrically contacted by means of the contact clamp after bending.

Furthermore, the DE 10 2007 006 433 A1 a connection box for an electrical connection of a solar module and a method for assembly. The connection box has a lower housing part and an upper housing part, with two clamping springs each having a clamping leg for making electrical contact with two connecting lines coming from the solar module, with two connecting elements arranged in the housing Connection of two cables and with two metal parts, via which the connection lines contacted by the clamping springs can be electrically conductively connected to a cable connected by the connection element. The clamping springs, the connection elements and the metal parts are assigned to the lower part of the housing. The two clamping springs can be brought from a first position, in which a connecting line can be inserted between the clamping leg and a contact section of the metal part, into a second position, in which the connecting line is contacted in a clamping manner between the clamping leg and the contact section of the metal part.

the DE 10 2005 053 363 A1 discloses a method for making electrical contact with solar cells.

DE 10 2007 032 603 A1 discloses a connection contact and a method for laminating objects provided with electrical connection contacts with foldable connection contacts, which are folded over during a laminating process by means of a laminate film and are then folded back again.

It is therefore the object of the present invention to simplify a method for producing a solar module.

This object is solved by the independent claims. Preferred embodiments are subject of the dependent claims.

• Bereitstellen eines Deckelelements mit einer Öffnung in einer Bodenseite des Deckelelements,
• Bereitstellen einer Anschlussvorrichtung in dem Deckelelement,
• Aufsetzen und Befestigen des Anschlussdosengehäuses auf dem Solarmodul, wobei beim Aufsetzen eine an dem Solarmodul vorgesehene Kontaktierungseinheit über die Öffnung in das zusammengesetzte Anschlussdosengehäuse eindringt und mit der Anschlussvorrichtung elektrisch leitend kontaktiert wird,
• wobei das Verfahren ferner die Herstellung einer Kontaktierungseinheit an einem Solarmodul mit den folgenden Schritten umfasst:
  • elektrisch leitendes Verbinden der Solarzellen mittels zumindest einem Leiterbands,
  • Bereitstellen von zumindest einem separaten Kontaktstück,
  • elektrisch leitendes Kontaktieren eines freien Endes des Leiterbands mit einem ersten Ende des Kontaktstücks mittels eines Federelements, das gegen eine Fläche des Kontaktstücks drückt, die bezüglich der Kontaktstelle zwischen dem Leiterband und dem Kontaktstück entgegengesetzt liegt,
  • Aufbringen einer Laminierschicht derart, dass sowohl die Kontaktstelle zwischen dem Leiterband und dem Kontaktstück als auch das Federelement und zumindest teilweise das freie Ende des Leiterbands in eine Laminierschicht eingebettet sind und ein zweites Ende des Kontaktstücks aus der Laminierschicht herausragt.

A first aspect of solving the above problem relates to a method for installing a junction box housing on a solar module, comprising the steps:

• providing a lid element with an opening in a bottom side of the lid element,
• providing a connection device in the cover element,
• Placing and fastening the junction box housing on the solar module, with a contacting unit provided on the solar module penetrating through the opening into the assembled junction box housing and being electrically conductively contacted with the connecting device,
• the method further comprising the production of a contacting unit on a solar module with the following steps:
  • electrically conductive connection of the solar cells by means of at least one conductor strip,
  • providing at least one separate contact piece,
  • electrically conductive contacting of a free end of the conductor strip with a first end of the contact piece by means of a spring element which presses against a surface of the contact piece which is opposite to the contact point between the conductor strip and the contact piece,
  • Application of a laminating layer such that both the contact point between the conductor strip and the contact piece and the spring element and at least partially the free end of the conductor strip are embedded in a laminating layer and a second end of the contact piece protrudes from the laminating layer.

The term "connection box housing" according to the present application is used as soon as the connection device is provided in the cover element. The term “providing” includes mounting the connection device before inserting it into the cover element or mounting the connection device in the cover element. The term "opening" refers to a depression in the cover element into which the connection device is inserted. Such an opening or indentation can be delimited on one side by an essentially planar upper side and by edge-like housing elements which emanate from the upper side and which can be connected in one piece to the upper side.

• Bereitstellen eines separaten Bodenelements mit einer Bodenöffnung und
• Einsetzen des Bodenelements in die Öffnung des Deckelelements oder Verbinden des Bodenelements mit dem Deckelelement.

Preferably, the method further comprises the steps:

• providing a separate floor element with a floor opening and
• Inserting the base element into the opening of the cover element or connecting the base element to the cover element.

According to the present application, “separate” means that the cover element and the base element are two separate (not one-piece) parts which, for example, were manufactured separately from one another. A housing that is closed except for the base opening, assembly openings, connection openings, pressure equalization openings, etc. can be formed around the connection device. The edge area of the cover element can be designed in such a way that when the base element is inserted into the opening of the cover element, an essentially flat surface is formed by an edge area of the cover element and the base element. The base element can also be connected to the cover element in such a way that the base element is placed on an edge region and thus in the fully assembled state between between the edge area and the solar module. The connection device, which is otherwise freely accessible via the opening, can be protected and/or shielded and/or fixed in the cover element via the base element.

Furthermore, preferably, after the connection device has been provided in the cover element and before the assembled junction box housing is placed on the solar module, connection cables are inserted into the cover element through connection openings in the cover element and electrically conductively contacted with the connection device.

This has the advantage that when the connection device is installed in the cover element, the connection cables do not yet have to be provided on the connection device. As a result, assembly space can be saved in series production. The junction box housing can be assembled completely or almost completely before the connection cables are contacted.

In a preferred embodiment, the base element has at least two mounting openings through which the connecting cables that have been inserted into the assembled junction box housing are fastened.

According to the present application, the term “fasten” includes both a mechanical and an electrically conductive connection. The assembly openings have the advantage that a junction box housing that is fully assembled without a connecting cable can be provided with the connecting cables at a different production site. In this case, the connecting cables pushed into the junction box housing can be fastened through the assembly openings. The mounting openings, which are provided on the bottom side, can be closed by placing them on the solar module, e.g. together with the bottom opening. Closing or sealing in a separate process step is also possible.

Preferably, a contact surface between the lid member and the bottom member is sealed in the step of inserting the bottom member into the opening of the lid member or connecting the bottom member to the opening of the lid member.

The base element can be sealed relative to the cover element, for example, in particular if a joint between the base element and cover element is not sealed when the junction box housing is subsequently placed on the solar module, for example if the base element is arranged between the cover element and solar module in the fully assembled state, as described above .

Furthermore, the method preferably comprises the steps

Providing a sealing material in the area of a sealing surface of the junction box housing that runs continuously around the opening and/or the bottom opening or a sealing surface of the solar module that corresponds to the sealing surface of the junction box housing, and

Sealing of the interior of the junction box housing from the environment along the sealing surface, the sealing taking place when the junction box housing is placed on the solar module.

A double-sided adhesive pad made of any sealing material, silicone adhesive or any other material that is suitable for sealing can be used as the sealing material. Providing a sealing material in the area of a sealing surface that runs continuously around the opening can include providing an annular provision only in the area of the sealing surface, but also providing the sealing material over the entire surface, for example, on the bottom side.

• eine Vielzahl von Solarzellen, die mit zumindest einem Leiterband elektrisch leitend verbunden sind, wobei die Solarzellen und das Leiterband zumindest teilweise innerhalb einer Laminierschicht angeordnet sind, und
• eine Kontaktierungseinheit mit zumindest einem Kontaktstück, welches separat von dem Leiterband ausgebildet ist und welches innerhalb der Laminierschicht mit dem entsprechenden Leiterband elektrisch leitend verbunden ist, indem ein Federelement gegen eine Fläche des Kontaktstücks drückt, die bezüglich der Kontaktstelle zwischen dem Leiterband und dem Kontaktstück entgegengesetzt liegt, und wobei das Kontaktstück aus der Laminierschicht herausgeführt ist, und
• ein Anschlussdosengehäuse aufweisend ein Deckelelement mit einer Öffnung in einer Bodenseite des Deckelelements und einer Anschlussvorrichtung umfassend elektrische Bauteile zur Konnektierung des Solarmoduls, die in dem Deckelelement angeordnet ist,
• wobei das Anschlussdosengehäuse eine um die Öffnung kontinuierlich umlaufende Dichtungsfläche aufweist, und
• wobei die Kontaktierungseinrichtung über die Öffnung in das Anschlussdosengehäuse hineinragt und mit der Anschlussvorrichtung elektrisch leitend verbunden ist.

A second aspect of the present application relates to a solar module comprising:

• a multiplicity of solar cells which are electrically conductively connected to at least one conductor strip, the solar cells and the conductor strip being at least partially arranged within a laminating layer, and
• a contacting unit with at least one contact piece, which is formed separately from the conductor strip and which is electrically conductively connected within the lamination layer to the corresponding conductor strip, in that a spring element presses against a surface of the contact piece which is opposite in relation to the contact point between the conductor strip and the contact piece , and wherein the contact piece is led out from the lamination layer, and
• a junction box housing having a cover element with an opening in a bottom side of the cover element and a connection device comprising electrical components for connecting the solar module, which is arranged in the cover element,
• wherein the junction box housing has a sealing surface continuously surrounding the opening, and
• wherein the contacting device protrudes into the connection socket housing via the opening and is electrically conductively connected to the connection device.

Electrical components for connecting the solar module can include, among other things, electrical conductors, e.g. printed circuit boards, and/or diodes and/or overvoltage protection elements and/or connection poles for attaching connection cables, etc. These electrical components can be combined as an assembly and made available as a connection device.

Preferably, the junction box housing further includes a separate bottom member that is inserted into the opening of the lid member or connected to the lid member and has a bottom opening.

In a preferred embodiment, the base element has at least two assembly openings at positions that correspond to the attachment points of connection cables with the connection device. The assembly openings can be designed in such a way that they allow access for a tool with which the connection cables are attached to the attachment points of the connection device.

In a further preferred embodiment, the contact surface between the cover element and the separate base element is sealed.

Further modifications of the solar module result from the embodiments of individual components that are described in relation to the junction box housing, the contacting unit or the solar module under the other aspects.

The solar module comprises at least one, ie 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, etc. optionally connected in series voltage-generating solar cell (s) or solar cell group (s), each solar cell preferably two Has conductor strips that form the positive and negative poles of the solar cell and are led out of this at a connection side of the solar module. Consequently, a solar module preferably comprises at least two, i.e. 2, 4, 6, 8, 10, 12, 14, 16, 18, 20 etc. conductor strips. The “connection side or surface” within the meaning of the invention describes a side or surface that is in particular opposite a light-active side or surface. In other words, the light-active side or surface is designed to absorb light or to guide it into the solar module. The "connection side or area" is in particular the rear side of the solar module, by means of which the solar module can be fastened or mounted, for example.

The conductor strip is preferably designed in the form of a strip or flat. In this case, the conductor strip has in particular a ratio of width to thickness of greater than 2, particularly preferably greater than 5, greater than 10, greater than 20, greater than 50 and in particular greater than 100.

The at least one conductor strip is preferably designed as a film conductor, i.e. as a composite of a polymer film with an electrical conductor attached to it, with the attachment being effected in particular by means of vapor deposition or gluing to the polymer film.

The at least one contact piece is made from a material with good electrical conductivity, such as copper or silver. Due to a greater thickness and the choice of material, the contact piece according to the invention is rigid. According to the invention, this property is used so that the contact piece serves as a coupling piece between the conductor strip and a connecting device connected in series. Contacting between the connecting device and the conductor strip is thus significantly simplified by means of the rigid contact piece, the position of which can be clearly determined, as a result of which the manufacturing process can be automated.

According to the application, the term “separate” is understood to mean a separate production of the conductor strip and the contact piece, so that the elements mentioned are separate elements which, for example, are not formed integrally with one another.

The conductor strip preferably runs on a surface of the solar module and a front section of a free end of the conductor strip is bent up essentially perpendicularly to the surface of the solar module. The free end of the conductor strip is thus preferably formed in an L-shape. A “free end of a conductor strip” within the meaning of the invention is to be understood as meaning the section of the conductor strip that is led out of the solar module on the connection side. The front bent-up section of the free end forms the contact point between the contact piece and the conductor strip, this contact being permanently held by means of the laminating layer, in that the contact point is embedded in the laminating layer. The “area of the solar module” is preferably the connection side of the solar module.

Furthermore, the conductor strip preferably has at least one bulge or rib in an area close to the contact piece. Bulges or ribs of this type in the conductor strip are intended to give the individual conductor strip additional length, which is then used if, for example, the conductor strip is accidentally pulled or torn during assembly of the solar module or during maintenance work. The additional distance gained by a bulge or rib makes it possible for the at least one bulge or rib to be smoothed out first, but the contacting between the conductor strip and the contact piece is still ensured. Furthermore, the at least one bulge or rib creates a higher fixing force within the laminating layer.

The solar module preferably also comprises at least one spring element, the spring element pressing the contact piece against the conductor strip at its contact point and preferably having a substantially U-shape. The contact reliability is further improved by means of the additional support provided by the spring element at the contact point between the conductor strip and the contact piece. In particular, the long-term behavior of the spring element, which is preferably made of spring steel, is known, as a result of which permanent contact security can be ensured.

The solar cells are also preferably embedded in a first laminating layer and/or the free end of the conductor strip is at least partially embedded in a second laminating layer.

The solar module preferably also comprises a junction box housing comprising a base element arranged on the solar module and a cover element, the free end of the conductor strip running in at least one opening of the base element on the surface of the solar module.

Furthermore, the second laminating layer is preferably only arranged in the area of the opening in the floor element.

A first end of the contact piece is also preferably arranged essentially perpendicularly to the surface of the solar module and/or parallel to the bent-up section of the conductor strip, and a second end of the contact piece runs essentially parallel to the surface of the solar module.

The contact piece preferably contacts a connection device in an electrically conductive manner.

The method preferably also includes the step of bending the free end of the conductor strips so that the conductor strip runs on a surface of the solar module and a front section of the free end of the conductor strip is bent up essentially perpendicularly to the surface of the solar module.

Advantageously, the method further includes the step of embossing at least one bulge or rib in the conductor strip in an area close to the contact piece.

• Bereitstellen von zumindest einem Federelement;
• Kontaktieren des Federelements mit dem Kontaktstück, so dass das Federelement gegen eine Fläche des Kontaktstücks drückt, die der Kontaktstelle zwischen dem Leiterband und dem Kontaktstück entgegengesetzt ist.

The method further preferably comprises the steps:

• providing at least one spring element;
• Contacting the spring element with the contact piece so that the spring element presses against a surface of the contact piece which is opposite to the point of contact between the conductor strip and the contact piece.

• Aufbringen einer ersten Laminierschicht, in die die Solarzellen eingebettet werden, und/oder
• Aufbringen einer zweiten Laminierschicht, in die das freie Ende des Leiterbands zumindest teilweise eingebettet wird.

Preferably, the laminating step comprises:

• Application of a first laminating layer in which the solar cells are embedded, and/or
• Application of a second laminating layer, in which the free end of the conductor strip is at least partially embedded.

• 1 zeigt eine schematische Vorderansicht eines Solarmoduls;
• 2 zeigt eine perspektivische Ansicht des Anschlussdosengehäuses der zweiten Ausführungsform;
• 3 zeigt eine perspektivische Ansicht des Anschlussdosengehäuses der zweiten Ausführungsform ohne Deckelelement in einem auf einem Solarmodul aufgesetzten Zustand;
• 4 zeigt eine perspektivische Ansicht des Bodenelements des Anschlussdosengehäuses der zweiten Ausführungsform mit der Kontaktierungseinheit, in der die Kontaktstellen zwischen den Leiterbändern und den Kontaktstücken in eine Laminierschicht eingebettet sind;
• 5 zeigt eine perspektivische Ansicht des Bodenelements des Anschlussdosengehäuses der zweiten Ausführungsform mit der Kontaktierungseinheit nach 4 ohne die Laminierschicht;
• 6 zeigt eine Vorderansicht der Kontaktierungseinheit.
• 7 zeigt eine perspektivische Ansicht eines Anschlussdosengehäuses der zweiten Ausführungsform in einem auf einem Solarmodul montierten und kontaktierten Zustand;
• 8 zeigt die perspektivische Ansicht des Anschlussdosengehäuses aus 7 ohne das Solarmodul;
• 9 zeigt eine Vorderansicht des Anschlussdosengehäuses der zweiten Ausführungsform von der dem Solarmodul zugewandten Seite;
• 10 zeigt das Anschlussdosengehäuse aus 9 ohne Bodenelement und ohne Kontaktierungseinheit;

These and other objects, features and advantages of the present invention will become more apparent upon reading the following detailed description of preferred embodiments and accompanying drawings. It should be understood that although embodiments are described separately, individual features thereof can be combined into additional embodiments.

• 1 shows a schematic front view of a solar module;
• 2 Fig. 12 is a perspective view of the junction box body of the second embodiment;
• 3 shows a perspective view of the junction box housing of the second embodiment without a cover element in a state placed on a solar module;
• 4 shows a perspective view of the bottom element of the junction box housing of the second embodiment with the contacting unit in which the contact points between the conductor strips and the contact pieces are embedded in a laminating layer;
• 5 shows a perspective view of the base element of the junction box housing of the second embodiment with the contacting unit 4 without the laminating layer;
• 6 shows a front view of the contacting unit.
• 7 shows a perspective view of a junction box housing of the second embodiment in a state mounted and contacted on a solar module;
• 8th shows the perspective view of the junction box housing 7 without the solar panel;
• 9 shows a front view of the junction box housing of the second embodiment from the side facing the solar module;
• 10 shows the junction box housing 9 without floor element and without contacting unit;

1 shows a front view of a solar module 10 with a multiplicity of solar cells 12 with three solar cell groups connected in parallel, which are connected to one another by means of conductor strips 14 . The two free ends of the conductor strips 14 are routed out of the back of the solar module into a junction box housing 16 (only indicated here) for contacting a connection device 22 .

the 7 until 10 show a junction box housing 16 of a first embodiment. 7 shows a perspective view of the junction box housing 16, which is attached to the back of a solar module 10. The junction box housing 16 comprises a cover element 18 and preferably a separate base element 20. The cover element 18 has an opening 44 in the bottom side, the bottom side of the cover element 18 facing the solar module when the junction box housing 16 is in the assembled state (see 9 ). The term "opening" in the sense of the first embodiment of the junction box housing 16 includes a recess or a passage in the bottom side of the cover element, the recess being surrounded by a peripheral edge 52 (see FIG 9 and 10 ), which serves as a sealing surface in this embodiment, is bordered. The bottom element 20 is manufactured separately from the lid element 18 and has a size and shape corresponding to the opening 44 of the lid element 18, so that the bottom element 20 can close the opening of the lid element 18, preferably completely, once the bottom element 20 is inserted into the opening 44 of the cover element 18 is inserted. The base element 20 preferably has latching lugs 54 which latch or are inserted into recesses (not shown) in the cover element 18 . The inserted base element 20 and the peripheral edge 52 of the cover element 18 preferably form a flat surface.

In the process of assembling the junction box housing 16 , a connecting device 22 is first inserted into the cover element 18 via the opening 44 . The cover element 18 preferably has corresponding recesses for this purpose, so that the connection device 22 can be fitted in and wobbling or slipping of the connection device 22 in the cover element 18 is avoided. The connection device 22 preferably has bypass diodes and/or overvoltage protection diodes and/or at least one connection plate and conducts the current generated by the solar module 10 to the connection cable 24 .

As soon as the connection device 22 is arranged in the cover element 18 , the base element 20 is inserted into the opening 44 of the cover element 22 . Simultaneously with the insertion of the base element 20 into the opening 44 of the cover element 18, the contact surface that exists between the base element 20 and the cover element 18 can be sealed against moisture. However, in this embodiment, where the rim surrounding opening 44 provides a sealing surface, sealing is merely optional.

The term "contact surface" in the sense used above includes the inner peripheral surface of the opening 44 and the outer peripheral surface of the base element 20, which adjoin one another and preferably contact one another mechanically.

The term moisture-proof is used in the context of the present description and the claims in the sense of water protection, which is recorded in DIN EN 60529 (VDE 0470-1) with the title "Types of protection through housing (IP code)". The protection classes IP X1 to IP X9k should be covered by the term moisture-proof.

To produce the above-described moisture-tight connection of the cover element 18 to the base element 18 , a silicone adhesive, for example, is preferably applied to the inner peripheral surface of the opening 44 of the cover element 18 before the base element 20 is inserted.

The two connection cables 24 are then pushed into the closed connection socket housing 16 via connection openings 48 . The connection openings 48 are preferably located in a side wall of the cover element 18 and have a diameter of the Connection cable 24 adapted diameter. The connection cables are inserted into the junction box housing 16 to such an extent that the front ends of the connection cables 24 each reach a position at which the front ends of the connection cables 24 are fastened to the connection device 22 at fastening points. In the present case, the term "fixed" includes both a mechanical and an electrically conductive connection of the connection cable 24 to the connection device 22. For this purpose, contacting lugs are preferably provided at the front ends of the connection cable 24, so that the connection cable 24 can preferably be screwed to the connection device 22 . Since the junction box housing 16 is already closed, the base element 20 has assembly openings 50 corresponding to the number of connecting cables 24 . Such mounting openings 50 are arranged at positions corresponding to the attachment points of the connection cables 24 to the connection device 22 . This allows the user, preferably a robot, to access the attachment point from the outside, despite the closed junction box housing 16. Ie the user can, for example, use a screwdriver, which he inserts into the junction box housing 16 via the assembly openings 50, to attach the connecting cable 24 to the connecting device 22 screw.

In order to further improve the moisture-tightness of the junction box housing 16, the connecting cables 24 can be connected to the cover element 18 in a moisture-tight manner, e.g. screwed.

Only after the junction box housing 16 has been fully assembled is the junction box housing 16 preferably placed and fastened on the back of the solar module 10 . When the junction box housing 16 is placed on the back of the solar module 10, a contacting unit 46, which is arranged on the back of the solar module 10 (described in more detail below), penetrates the junction box housing 16 via a bottom opening 28 (see 9 ) in the floor element 20. The contacting unit 46 penetrates so deeply into the junction box housing 16 that the contacting unit 46 makes electrically conductive contact with the connecting device 22 . The junction box housing 16 and the solar module 10 are preferably also connected to one another in a moisture-tight manner. For this purpose, before being placed on the solar module 10, an adhesive pad can be applied, for example, preferably to the entire surface of the junction box housing that later rests on the back of the solar module. The bottom opening 28 and optionally provided assembly openings can be left out. The adhesive pad offers the advantage that both a moisture-tight connection is established between the junction box housing 16 and the solar module 10 and at the same time the adhesive pad is used to attach the junction box housing 16 to the solar module 10 . As an alternative to an adhesive pad, a silicone adhesive can also be used as the sealing material here, which is applied continuously along the peripheral edge 52 of the cover element 18 and/or to the base element 20 around the base opening 28 before it is placed on the solar module 10, for example. There is also the possibility of applying the silicone adhesive or the adhesive pad to the back of the solar module 10 in advance.

2 14 shows a perspective view of a second embodiment of a junction box housing 16. The junction box housing 16 also includes a cover element 18 and preferably a substantially flat separate base element 20. The cover element 18 also has an opening 44 in the base side. The opening 44 of the cover element 18 is limited by the lower edge of the side walls of the cover element 18 . The base member 20 is sized to completely close the opening 44 and cover the rim of the lid member once the base member 20 is joined to the lid member 18 . The base element 20 preferably does not project beyond the cover element 18 in the lateral direction. The contact surface between the cover element 18 and the base element 20 in the connected state thus forms the lower edge of the side walls of the cover element 18 with the surface of the base element 20 which rests on the lower edge. The contact surface between base element 20 and cover element 18 can be sealed against moisture. In that case, a sealing surface can be provided by areas of the base element 20 which surround the base opening 28 .

In the installed state, the base element 20 preferably rests completely on the rear side of the solar module 10 and, as described above, can be sealed and/or fastened around the base opening 28 . The elements of the junction box housing 16 are preferably injection-moulded from plastic or from a polymer. 2 shows the junction box housing 16 in a state in which the cover element 18 is connected to the base element 20 . As already mentioned with regard to the first embodiment of the junction box housing 16, the cover element 18 of the second embodiment also has individual recesses in the cover element 18, in which, for example, the individual diodes or the contacting unit 46 are accommodated.

3 shows the junction box housing 16 without cover element 18 in a on the Solarmo dul 10 (not shown here) attached state. The connection device 22 to which the connection cables 24 are connected is arranged on the base element 20 in order to discharge the electricity generated by the solar module 10 . The connecting device 22 makes electrically conductive contact with the contacting unit 46, preferably L-shaped contact pieces 26, which as coupling elements connect the connecting device 22 with conductor strips 14 in an electrically conductive manner.

4 also shows a perspective view of the base element 20 of the second embodiment in a state placed on the solar module 10 (not shown here). The base element 20 also preferably has a base opening 28, through which the contacting unit 46 is inserted into the junction box housing 16, in particular the individual conductor strips 14. In the area of the base opening 28, the free ends of the conductor strips 14 are arranged in such a way that they are on the Back or on the back surface of the solar module 10 run. The rear side of the solar module is preferably a first lamination layer 30 in which the individual solar cells are embedded. The first laminating layer could be a weatherproof plastic film, for example.

The base element 20 preferably has assembly openings (not shown here), which also allow the connection cable 24 to be attached to the connection device 22, although the connection socket housing 16 is already closed.

The connection of the base element 20 to the cover element 18 is preferably likewise carried out in a moisture-tight manner, for example by means of a silicone adhesive. Before the base element 20 is connected to the cover element 18, this can be applied continuously to the lower edge of the side walls of the cover element and/or to the base element. Thus, the two elements are firmly and moisture-tightly connected to each other.

After the junction box housing 16 has been completely assembled, the junction box housing is placed on the rear side of the solar module 10 and also preferably connected to the solar module 10 in a moisture-tight manner.

In the contacting unit 46, a front portion 32 of the free ends of the conductor strips 14, as in the 5 and 6 shown, bent essentially perpendicularly to the rear surface 30 of the solar module 10 and serves as a contact surface with the contact piece 26.

The contact piece 26 preferably has an L-shape, with a first end 34 of the contact piece 26 making contact with the front bent-up section 32 of the conductor strip 14 and the second end 36 making contact with the connecting device 22 . The first end 34 of the contact piece 26 is preferably longer than the second end 36 of the contact piece 26. The contact piece 26 is arranged on the front bent-up section 32 in such a way that the first end 34 of the contact piece 26 is essentially perpendicular to the rear surface 30 of the solar module 10 and/or parallel to the front bent-up section 32 of the ladder strip 14 . The second end 36 preferably points backwards in the direction of the ladder strip 14, although an orientation in the other direction is also possible. Furthermore, the contact piece 26 is formed from a material with high electrical conductivity and is essentially rigid.

A surface of the first end 34 of the contact piece 26 is thus in contact with a surface of the front bent-up section 32 of the conductor strip 14 . As in 3 shown, take place in that a raised or upwardly curved surface section 23 of the connection device 22 rests on the upper surface of the second end 36 of the contact piece 26 facing the cover element 18 . The connection can be fixed by screwing, soldering, etc.

The contacting between the conductor strip 14 and the contact piece 26 is preferably supported by a spring element 38, which is preferably made of spring steel. A first end of the spring element 38, which preferably has an essentially U-shape, presses in a prestressed state on a surface of the contact piece 26 which is opposite the contact point between the conductor strip 14 and the contact piece 26. The spring element 38 can preferably be prestressed by a surface (not shown here) against which a second end of the spring element 38 presses. This surface can be formed, for example, in the cover element 18 of the junction box housing 16 so that the spring element 38 is prestressed as soon as the assembled junction box housing 16 is placed on the solar module 10 . Furthermore, the desired preload can be generated by means of an additionally used preload element. For example, an element could be used between two opposing spring elements 38 for this purpose, so that two spring elements 38 are prestressed with one prestressing element. By means of the spring element 38 can be ensured that the electrically lei trend connection between the conductor strip 14 and the contact piece 26 is permanently guaranteed.

As in 4 shown, the contact point between the conductor strip 14 and the contact piece 26 as well as between the contact piece 26 and the spring element 38 is embedded in a second laminating layer 40 and thus firmly connected to one another. The second laminating layer 40 is preferably synthetic resin, which provides particularly good protection against the ingress of moisture, or another preferably weatherproof plastic layer or film. By means of the second laminating layer, as in 4 shown, the free ends of the contact pieces 14 at least partially and the above-described contact points between the conductor strip 14 and the contact piece 26 and between the contact piece 26 and the spring element 38 in the second laminating layer 40 or embedded. Since the second laminating layer 40 is preferably only arranged in the area of the opening 28 in the base element 20 and is therefore arranged directly on the first laminating layer or the solar module 10, the synthetic resin of the second laminating layer 40 acts as an additional adhesive for the contacting unit on the solar module 10 .

In order to further improve the contact reliability between the conductor strip 14 and the contact piece 26, at least one bulge 42 or rib, preferably three, is arranged in a section of the free end of the conductor strip 14, which runs on the solar module 10 and near the contacted contact piece 26 . According to the invention, the term “near” means a distance from the front bent-up section 32 to the first bulge 42 or rib of approximately 1 to 200 mm, preferably of 0.3 mm to 30 mm. The bulges provide protection against accidental disconnection of the contact point by tearing at the conductive strip 14 during assembly or maintenance, since the bulges or ribs allow stretching without disconnecting the electrically conductive contact. Furthermore, the bulges or ribs improve the fixation of the conductor strip in the laminating layer.

The solar module offers the advantage that, on the one hand, automated assembly or assembly of the junction box housing 16 is made possible. The junction box housing 16 can already be completed before it is placed on the solar module 10 and can preferably be closed in a moisture-tight manner. This is possible in particular because the junction box housing 16 is accessible from all sides before it is placed on the solar module 10 . Furthermore, this enables a more space-saving junction box housing. Furthermore, automated contacting or connection of the conductor strips to the connecting device 22 is possible. The position of the contact pieces 26 can be clearly determined by means of the contact pieces 26, which are preferably arranged essentially perpendicularly to the rear side of the solar module 10 and which, in contrast to the conductor strips 14, have rigid properties. Furthermore, the arrangement and shape of the contact pieces 26 offer the advantage that the junction box housing 16 can be simply placed on by means of a robot despite the tight space conditions, and the connection device 22 is thus electrically conductively connected to the contacting unit 44 .

The conductor strips 14 can be bent into their flat position relative to the back of the solar module 10 by simply placing the base element 20 on the back of the solar module 10 . Subsequently or beforehand, individual bulges 42 or ribs can be embossed into the free ends of the conductor tracks 14, which provide additional flexibility for the conductor strips in order to prevent the contact point between the conductor strip 14 and the contact piece 26 from separating. The conductor strips 14 can then be placed on the preferably already pre-positioned contact pieces 26 in such a way that the front bent-up section 32 of the conductor strips 14 is preferably formed automatically. Excess conductor tape can simply be cut off. As soon as the spring elements are arranged in their corresponding positions, the second laminating layer 40 can be applied, as a result of which the individual components are firmly connected to one another or laminated in place.

Reference List

10

solar panel

12

solar cell

14

ladder tape

16

junction box housing

18

cover element

20

floor element

22

connection device

23

raised surface portion of the connecting device

24

connection cable

26

contact piece

28

bottom opening

30

first layer of lamination

32

anterior section

34

first end of contact piece

36

second end of the contact piece

38

spring element

40

second layer of lamination

42

camber

44

Opening in the cover element

46

contacting unit

48

port opening

50

mounting hole

52

peripheral edge of the cover element

54

detent

56

bypass diode

Claims (9)

Method for mounting a junction box housing (16) on a solar module (10), comprising the steps: providing a cover element (18) with an opening (44) in a bottom side of the cover element (18), Providing a connection device (22) in the cover element (18), Placing and fastening the junction box housing (16) on the solar module (10), with a contacting unit (46) provided on the solar module penetrating through the opening (44) into the assembled junction box housing (16) and being electrically conductive with the connecting device (22). is contacted, the method further comprising the production of a contacting unit (46) on a solar module (10) with the following steps: electrically conductive connection of the solar cells (12) by means of at least one conductor strip (14), providing at least one separate contact piece (26), electrically conductive contacting of a free end of the conductor strip (14) with a first end (34) of the contact piece (26) by means of a spring element (38) which presses against a surface of the contact piece (26) which, in relation to the contact point between the conductor strip (14 ) and the contact piece (26) is opposite, Application of a laminating layer (30, 40) in such a way that both the contact point between the conductor strip (14) and the contact piece (26) and the spring element (38) and at least partially the free end of the conductor strip (14) are in a laminating layer (40) are embedded and a second end (36) of the contact piece (26) protrudes from the laminating layer (40). procedure after claim 1 , the method further comprising the steps of: providing a separate base element (20) with a base opening (28) and inserting the base element (20) into the opening (44) of the cover element (18) or connecting the base element (20) to the cover element (18). procedure after claim 1 or 2 , wherein after the connecting device (22) has been provided in the cover element (18) and before the assembled junction box housing (16) is placed on the solar module (10), connecting cables (24) into the cover element (18) through connection openings (48) in the Cover element (18) are introduced and electrically conductively contacted with the connection device (22). procedure after claim 3 , The base element (20) having at least two mounting openings (50) through which the connecting cables (24) that were introduced into the junction box housing (16) are fastened. Procedure according to one of claims 2 until 4 , wherein a contact surface between the lid element (18) and the bottom element (20) in the step of inserting the bottom element (20) into the opening (44) of the lid element (18) or when connecting the bottom element (20) to the opening (44) of the cover element (18) is sealed. A method according to any one of the preceding claims, further comprising the steps Providing a sealing material in the area of a sealing surface of the junction box housing (16) that runs continuously around the opening (44) and/or the bottom opening (28) or a sealing surface of the solar module (10) that corresponds to the sealing surface of the junction box housing (16) and Sealing off the interior of the junction box housing (16) from the environment along the sealing surface, the sealing taking place when the junction box housing (16) is placed on the solar module (10). Solar module (10) comprising: a large number of solar cells (12) which are electrically conductively connected to at least one conductor strip (14), the solar cells (12) and the conductor strip (14) being at least partially arranged within a laminating layer (30, 40). and a contacting unit (46) with at least one contact piece (26) which is formed separately from the conductor strip (14) and which is electrically conductively connected within the lamination layer (40) to the corresponding conductor strip (14) by a spring element ( 38) pressing against a surface of the contact piece (26) which is opposite with respect to the point of contact between the conductor strip (14) and the contact piece (26), and wherein the contact piece (26) is led out of the laminating layer (40), and a junction box housing (16) having a cover element (18) with an opening (44) in a bottom side of the cover element (18) and a connection device (22) comprising electrical components for Connection of the solar module, which is arranged in the cover element (18), wherein the junction box housing (16) has a sealing surface that runs continuously around the opening (44), and wherein the contacting device (46) penetrates the opening (44) into the junction box housing (16 ) protrudes and is electrically conductively connected to the connecting device (22). Solar module (10) after claim 7 wherein the junction box housing (16) further comprises a separate base member (20) inserted into the opening (44) of the cover member (18) or connected to the cover member (18) and having a base opening (28). Solar module (10) after claim 8 , wherein the base element (20) has at least two mounting openings (50) at positions corresponding to the attachment points of connection cables (24) with the connection device (22).

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