DE102021122010A1 - Photovoltaic module and connection arrangement for a photovoltaic module - Google Patents

Abstract

The invention relates to a connection arrangement (10) for a photovoltaic module (1), which has at least one cell arrangement which can be contacted externally at at least two contacts, having at least two connection sockets (11), with connection cables (12) inside the connection sockets (11). the contacts of the photovoltaic module (1) can be connected. The connection arrangement (10) is characterized in that a connecting cable (13), in which a bypass diode (15) is looped, runs between each two of the connection boxes (11). The invention also relates to a photovoltaic module (1) with such a connection arrangement (10).

Description

The invention relates to a connection arrangement for a photovoltaic module (PV module) which has at least one cell arrangement which can be contacted externally at at least two contacts. The connection arrangement comprises at least two connection sockets, within which connection cables can be connected to the contacts of the PV module.

PV modules, e.g. B. for mounting on a house roof or in outdoor systems, usually have a plurality of photovoltaic cells (PV cells), which are connected in series and / or parallel form at least one cell array that can be contacted externally via connecting cables. PV modules often have a number of such cell arrangements which are connected in series within the PV module. In this case, each of the cell configurations is usually led out of the module with its end connections in order to connect a so-called “bypass diode” in parallel with each cell configuration. The bypass diodes direct current past shaded or defective cell arrays. Without the bypass diodes, shading or a defect in one of the cell arrays of the module would reduce the current flow through the entire module, even if the other cell arrays in the module or other modules connected in series with the module are not shaded or defective.

PV modules are known from the prior art in which connections of the existing cell arrangements (usually of three cell arrangements) can be contacted adjacent to one another on a rear side of the PV module in a common connection area. The contacts can, for example, be non-insulated contact strips on the rear side of the PV modules, which is otherwise covered by an insulating layer. A junction box is placed over the contact area, for example glued on, within which the bypass diodes are arranged and make contact with the contact surfaces of the PV module. In addition, two connection cables lead to the junction box mentioned, which are connected to the outer contacts of the series-connected cell arrangements and via which the PV module is connected externally.

A PV module with such a connection arrangement is, for example, in the publication U.S. 2016/0141435 A1 described in an embodiment. In a further exemplary embodiment, the publication describes a PV module in which the contact surfaces of different cell arrangements are not positioned in a common connection area on the rear side of the PV module, but in several different positions. In this case, each of the connection areas is covered with a socket that accommodates a bypass diode. At least two of the boxes function as a connection box, as described above, in that a connection cable for the external connection of the PV module leads to these boxes and is connected to one of the cell arrangements inside the box. A further exemplary embodiment describes that the bypass diodes can also be integrated into the PV module, specifically into the stack of layers of the PV module.

An arrangement of the bypass diodes in one or more of the junction boxes complicates their structure and their assembly. The arrangement of the bypass diodes in the stack of layers of the PV module is advantageous with regard to the design of the junction boxes, but complicates the construction of the PV modules.

It is an object of the present invention to create a connection arrangement for a PV module and a PV module with a connection arrangement in which neither the structure of the PV module itself nor the structure of the junction boxes is complicated by the bypass diodes.

This object is achieved by a connection arrangement for a PV module or a PV module with such a connection arrangement with the respective features of the independent claims. Advantageous refinements and developments are the subject matter of the dependent claims.

A connection arrangement according to the invention of the type mentioned at the outset is characterized in that a connection cable, in which a bypass diode is looped, runs between each two of the connection boxes.

According to the invention, the bypass diode is therefore not arranged in the junction box itself, which complicates its structure, nor is it integrated in the stack of layers of the PV module, which makes its structure more complex. Instead, a connection cable containing the bypass diode is routed externally from the stack of layers of the PV module between two junction boxes. The junction box itself can be designed to be very compact and material-saving, since it only has to accommodate the connection between the connecting cable and, if applicable, the connecting cable and the contact on the back of the PV module. The bypass diode can also be looped into the connecting cable in a compact and space-saving manner, in particular since suitable diodes with axially arranged connections are available, the diameter of which is comparable in size to that of a suitable connecting cable. The diode then provides little more than represents a thickening within the connecting cable. No separate attachment is required for the bypass diode as it is carried by the connecting cable.

If the PV module has a plurality of cell arrangements, the connection arrangement also comprises a plurality of connection sockets which are connected to one another in a chain-like manner via connecting cables, the connection cables being connected to two connection sockets on the outside of the chain.

In an advantageous embodiment of the connection arrangement, the connection boxes each have a contact element that can be connected to the contacts of the PV module. The contacts of the PV module can be exposed contact strips on the back of the PV module, for example. In that case the contact element is, for example, soldered or welded, for example by spot welding, onto the contact strip. A spring contact, in particular a double spring contact, can also be used. The contacts of the PV module can also be (protruding) connection contacts that are already attached to exposed contact strips. In this case, the contact element of the junction box can be a tulip contact or another plug-in contact, for example. A (protruding) connection contact can also be contacted via a spring contact or a welded or soldered contact.

In a further advantageous embodiment of the connection arrangement, the connection sockets have at least one insulation-penetrating contact for connection to the connection cable and/or the connection cable. A connection to the cables can be established easily and in a space-saving manner. In alternative configurations, a connection can also be produced by a crimping, soldering, welding or caulking process with a cable end that is then stripped in each case.

In a further advantageous embodiment of the connection arrangement, the connection cable and a section of the connection cable (or else two sections of two connection cables) are formed by a cable that runs through one of the connection boxes. This configuration is particularly advantageous in connection with the insulation-piercing contact.

In a further advantageous embodiment of the connection arrangement, the at least one bypass diode and adjacent cable ends of sections of the connecting cable are encapsulated with a casting compound. The bypass diode is only a thickening in the connection cable and is protected and arranged in a compact manner. Good cooling of the bypass diode is also ensured if the potting compound is a good heat conductor.

In a PV module according to the invention, the contacts of the at least one cell arrangement are connected to one another and to connection cables via such a connection arrangement. The advantages mentioned in connection with the connection arrangement result.

• 1a, 1b jeweils eine isometrische Darstellung eines PV-Moduls mit Kontaktflächen (1a) bzw. Anschlusskontakten (1b) an seiner Rückseite;
• 2a, 2b eine Gesamtansicht bzw. eine Detailansicht des PV-Moduls gemäß 1b und einer Anschlussanordnung vor dem Montieren der Anschlussanordnung;
• 3a, 3b Darstellungen gemäß den 2a und 2b nach dem Montieren der Anschlussanordnung auf dem PV-Modul; und
• 4a-c verschiedene weitere Ansichten des in 3b dargestellten Bereichs des PV-Moduls.

The invention is explained in more detail below using an exemplary embodiment with the aid of figures. The figures show:

• 1a , 1b an isometric representation of a PV module with contact surfaces ( 1a) or connection contacts ( 1b) at its back;
• 2a , 2 B an overall view or a detailed view of the PV module according to FIG 1b and a terminal assembly before assembling the terminal assembly;
• 3a , 3b Representations according to 2a and 2 B after mounting the terminal assembly on the PV module; and
• 4a-c various other views of the in 3b shown area of the PV module.

In the 1a and 1b a PV module 1 is first shown in an isometric representation. The PV module 1 has a frame 2 and the actual module structure, which is also referred to as a layer structure or layer stack in the context of this application. This module structure is shown in the illustration 1 a and 1 b only one back side 3 can be seen.

The PV module 1 has a plurality of PV cells, which cannot be seen individually here. B. traces are connected to each other. The back 3 is covered with an insulating layer, this insulating layer being uncovered at selected points in order to enable contacting. The 1a shows the PV module 1 with such exposed contact surfaces 4. Four of the contact surfaces 4 are present, each representing the end taps of three cell arrangements connected in series. In other words, two adjacent contact areas 4 are each the end taps of one of the cell arrangements. A first cell arrangement can be contacted, for example, via the two contact surfaces 4 on the left. It is internally connected in series with a second cell arrangement, which can be contacted via the two middle contact surfaces 4 . A third cell arrangement, which is also connected in series with the two cell arrangements, can be contacted via the two right-hand contact surfaces 4 . It will noted that the number of three series-connected cell arrays in the illustrated embodiment is purely exemplary. The connection arrangement presented as part of this application can be used for any number of cell arrangements connected in series with one another. The individual cell arrangements themselves generally have a plurality of cells which are in turn connected to one another in series and/or in parallel.

In the embodiment of 1b are mounted on the contact surfaces 4 connection contacts 5, for example soldered or welded, z. B. in a spot welding process. The connection arrangement described below is designed so that the connection contacts 5 according to the 1 contacted. However, it is also conceivable to design the connection arrangement in such a way that it directly corresponds to the contact surfaces 4 in a PV module 1 according to FIG 1a contacted.

In 2a is the PV module 1 of 1b shown together with a connection arrangement 10 according to the application before the step of mounting the connection arrangement 10 on the PV module 1 . 2 B shows a section 2a in the area of the two left connection contacts 5 of the PV module 1.

In the 3a and 3b is in the same way as in the 2a and 2 B the PV module 1 is shown with the connection arrangement 10 mounted on it.

The connection arrangement 10 comprises four connection sockets 11 which are each plugged onto one of the connection contacts 5 . From the outer two of the connection boxes 11, a connection cable 12 leads away to the outside. This connection cable 12 is shown shortened in the figures. In one implementation, this connecting cable 12 is longer and has a plug connector at its end, with which a connection to an adjacent module or a module connection box or the like is made. can be made.

A connecting cable 13 is arranged between two junction boxes 11 and a diode element 14 is looped into it. The diode element 14 contains a bypass diode that is not visible here (cf. 4b) , which contacted the two cable sections of the connecting cable 13 with their anode or cathode. In the present case, three bypass diodes are each connected antiparallel to each of the three cell arrangements of the PV module 1 .

The connection arrangement 10 can preferably be prefabricated and preassembled, so that it only needs to be placed on the connection contacts 5 during the final assembly of the PV module 1 . In this case, an adhesive sealant is preferably used, with which the junction boxes 11 are glued to the rear side 3 of the PV module 1 in a sealing manner.

4a shows the detail of the back 3 of the PV module 1 with attached connection arrangement 10 again in a top view. In the 4a two cutting lines are given, with the corresponding cuts in Figs 4b and 4c are reproduced.

4b shows a longitudinal section through the in 4a shown part of the connection arrangement 10 along the connection cable 12 and the connecting cable 13. The section also runs lengthwise through the two connection boxes 11, the detailed structure of which thus becomes visible.

The connection boxes 11 have an upper part 111 through which the connection cable or the connection cable 13 leads. There is also a foot 112 with which the junction box 11 rests on the back 3 of the PV module 1 . An outer edge of this foot 112 is suitable as an adhesive and sealing surface for the junction box 11.

Within the junction box 11, a contact element 113 is arranged, the z. B. contacted the connection contact 5 of the PV module 1 in the form of a tulip contact. Electrically connected to the contact element 113 and possibly formed in one piece with it, is an insulation-penetrating contact 114, which points upwards with a tip and penetrates the connecting cable 12 or the connecting cable 13 to form a contact.

By using the insulation-piercing contact 114, an electrical connection to the connecting cable 12 or to the connecting cable 13 can be established in a simple manner and in a space-saving manner within the junction box 11. In addition, the connection cable 12 can be designed in one piece with the corresponding section of the connection cable 13 . The connecting cable 12 and this section of the connecting cable 13 are therefore a continuous piece of cable. The same applies to the two sections of the connection cable 13 in the left in 4b illustrated junction box 11. In alternative configurations, a connection between the connecting cable 12 or the connecting cable 13 and the contact element 113 can also be produced by a crimping, soldering or welding process with a cable end that is then stripped in each case.

In the embodiment shown, the junction box 11 can be designed in one piece be, wherein the continuous connection cable 12 or connection cable 13 is inserted through the upper part 111 and then the combined contact element 113 with the insulation-piercing contact 114 is pressed from below into the connection cable 12 or the connection cable 13 . The connection box 11 preassembled in this way can then be placed onto the connection contact 5 as a whole.

According to the application, the diode element 14 is looped into the connecting cable 13 . In the cross section of 4b It can be seen that the diode element 14 is a bypass diode 15 that makes contact with a cable section of the connecting cable 13 and is integrated into the connecting cable 13 in such a way that it can be mechanically loaded and is electrically insulated, for example by means of a casting compound. The bypass diode 15 or the diode element 14 thus represents little more than a slight thickening in the connecting cable 13. The bypass diode 15 can be contacted with the conductor of the connecting cable 13, for example, by means of a crimping or a soldering point.

The 4c FIG. 1 shows another cross section through one of the junction boxes 11, the penetration of the insulation-penetrating contact 114 into the connecting cable 12 or the connecting cable 13 being clearly visible in this representation.

Reference List

1

Photovoltaic module (PV module)

2

Frame

3

back

4

contact surface

5

connection contact

10

connection arrangement

11

junction box

111

top

112

Foot

113

contact element

114

insulation piercing contact

12

connection cable

13

connection cable

14

diode element

15

bypass diode

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• US20160141435A1 [0004]

Claims (9)

Connection arrangement (10) for a photovoltaic module (1), which has at least one cell arrangement which can be contacted externally at at least two contacts, having at least two connection sockets (11), wherein the connection cable (12) is connected to the contacts of the photovoltaic module inside the connection sockets (11). (1) can be connected, characterized in that a connecting cable (13), in which a bypass diode (15) is looped, runs between each two of the connection boxes (11). Connection arrangement (10) according to claim 1 , In which the junction boxes (11) each have a contact element (113) which can be connected to the contacts of the photovoltaic module (1). Connection arrangement (10) according to claim 2 , in which the contact element (113) is a tulip contact. Connection arrangement (10) according to one of Claims 1 until 3 In which the junction boxes (11) each have an insulation-piercing contact (114) for connection to the connecting cable (12) and/or the connecting cable (13). Connection arrangement (10) according to one of Claims 1 until 4 , in which the connecting cable (12) and a section of the connecting cable (13) are formed by a cable which runs through one of the junction boxes (11). Connection arrangement (10) according to one of Claims 1 until 5 , in which two sections of two connecting cables (13) are formed by a cable that runs through one of the junction boxes (11). Connection arrangement (10) according to one of Claims 1 until 6 Having a plurality of junction boxes (11) which are connected to one another in a chain-like manner via connecting cables (13), the connecting cables (12) being connected to two of the junction boxes (11) on the outside in the chain. Connection arrangement (10) according to one of Claims 1 until 7 In which the bypass diodes (15) and adjacent cable ends of sections of the connecting cable (13) are encapsulated with a casting compound. Photovoltaic module (1) with at least one connection arrangement (10) according to one of Claims 1 until 8th .

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