DE19910532A1 - Photovoltaic solar power generation module in plate form comprises several conductors which are permanently joined to common connection system incorporating multipolar plug connector - Google Patents

Abstract

The module (1) with an outer plate, an inner plate (3) and an intermediate layer with embedded solar cells (6) joined electrically with one another by means of several conductors (8, 9) is characterized by the fact that several such conductors are permanently joined to a common connection system incorporating a multi-polar plug connector (10).

Description

The invention relates to a photovoltaic solar module in plate form, with an outer plate, an inner plate and an intermediate layer of plastic connecting them, in the solar cells are embedded, the solar cells being electrically connected via a plurality of connecting conductors are interconnected and the connecting conductors are each connected to an opening in the inner plate arranged connecting device are electrically connected.  

Photovoltaic solar modules of the aforementioned structure are from a variety of Veröf Publications are known and are increasingly used in practice to Example for photovoltaic facade and roof elements or for charging accumulators Ren. In the case of plate-shaped solar modules that can be flat or curved, there is outer panel facing the sun mostly made of inorganic glass panes; preferably from highly translucent glass with a particularly low iron content, also known as white glass referred to as. The outer plate can also be made of organic glass (plastic) hen. Glass is usually also used for the inner panel for reasons of stability and durability provided discs made of inorganic glass, but other ge for this purpose suitable materials such. B. opaque, if necessary. Metallized plastic films or foils laminates are used.

For the intermediate layer connecting the plates, especially those for the production of Laminated glass panes known materials used, especially in the context of a Ver Bundles of polyvinyl butyral (PVB) or films melted in an autoclave Ethylene vinyl acetate (EVA). Another product and manufacturing variant provides that a low-viscosity liquid monomer mixture inserted between the plates of the solar module brought and polymerized there. The intermediate layer serves in any case, the two between the inner plate and the outer plate arranged solar cells and fix them to be embedded at least on one side.

Individual solar cells are usually made with the help of narrow connecting conductors electrically interconnected and mechanically connected to form so-called cell strings, inserted in the course of the module production together between the panels of the solar module be placed. For the electrical connection of the solar modules with other solar modules, with the power grid or directly with a consumer, it is also necessary that the Ver binding conductors of the individual cell strings each with one after the module completion of externally accessible connection device are electrically connected. To a Cell string usually belong to two connecting conductors. For a solar module are in generally uses several cell strings that are spaced between each other with a small distance be arranged between the plates.  

Tin-plated flat copper conductors are usually used for the connecting conductors in one width of maximum 5 mm.

From practice, a solar module is known in which the ge to eight or ten cell strings listening six connecting conductors each to a hole in the formation of a glass pane th inner plate. In these six holes there are metallic connection sleeves attached, the connection of the connecting sleeves with the individual connecting conductors is produced by soldering or welding. This module connection technology is because of large number of holes technically complex.

From DE 197 12 747 A1 a solar module is known in which the connecting conductor of the Cell strings as a bundle of conductors via an opening made in the inner plate to a be guided outside on this arranged external connection device. Needed though With this module connection technology, only a single opening (hole) in the inside plate. A disadvantage of the protruding connection device over the In plate and the low mechanical strength of the electrical connection (no zu load on the connecting conductors emerging from the solar module). Per Another problem with this solar module is the sealing of the opening on the inside plate to the intermediate layer sensitive to environmental influences. In the case of in Intermediate layers to be polymerized in situ can also contain the liquid monomer Exit the mixture from the opening.

It is therefore an object of the present invention to do away with the known solar module hend to improve that the manufacturing technology is simplified and that the overall height of the So larmoduls can be kept low. The solar module is said to pose no danger to the electrical Connection device can be handled. In addition, a good and easy to manufacture from sealing of the openings to the intermediate layer may be possible.

This object is achieved with a photovoltaic solar module according to claim 1. Advantage adhesive configurations are the subject of the subclaims.  

According to the invention it is provided that several, preferably all, connecting conductors are permanent are connected to a common connection device which has a multi-pole plug connector includes. The multi-pin connector is usually a multiple be formed in the socket as an external connector counterpart several individual plugs having multiple plugs can be inserted. But it can also be used as a multiple plug-trained plug connector or with mixed forms of plug and socket gear be prepared. It is important that the ge in an opening in the inner plate of the solar module Protects arranged connectors enables the solar module to be connected to external ones only when required Connect circuit components, so that until then a problem-free handling with the Solar module is possible until it is installed on site.

Common materials such as silver, gold, Copper, brass or the like can be selected. The distances between the individual contacts (book sen, connector pins) from each other are to be dimensioned so that they are sufficient from each other are insulated and that there is no risk of short circuit when plugging in the connector counterpart consists.

The connecting conductors of the solar module with the individual conductors are preferably one in the intermediate layered embedded contact grid and the individual conductors of the contact grid at their opposite ends with the individual contacts of the multipole gene connector permanently connected. This is best done by the individual contacts of the connector with their foot surfaces facing the inside of the module at least a single conductor of the contact grid are connected by soldering or welding.

Manufacturing technology is particularly advantageous that an industrial prefabrication one Contact grid and existing with this permanently connected connector closing element can be done. The connector of this prefabricated connector is inserted into the opening of the inner panel as part of the solar module production stuck, after which only the connecting conductors of the cell strings with the individual conductors of the Ver contact grids by soldering, welding or other permanent connection technology must be bound.  

The contact grid preferably consists of a thin sheet, in particular of tin tem copper, the individual conductors of which by removing sheet metal sections between the individual conductors, in particular by stamping or etching, formed and separated from one another were. Depending on the length of the contact grid, it can be used for mechanical stabilization be advantageous to initially leave bridges between the individual conductors, which only removed as part of the completion of the solar module depending on the circuit arrangement be, e.g. B. by punching. The thickness of the contact grid is preferably less than about 0.5 mm, especially about 0.2 mm.

The individual conductors of the contact grid run at a mutual distance and normal point parallel over the majority of their longitudinal extent, their to the connector Bend the ends facing the connection surfaces in the contact grid plane, so that the connection surfaces of the individual conductors are congruent with the associated individual con clocking the connector are arranged. The contact grid thus acts in a certain way as an adapter between the arrangement of the connection points of the mostly straight connector conductor and the mostly different arrangement of the individual contacts of the connector binders. The connection of the connecting conductors to the plug connector can be done in this way be considerably simplified compared to a direct connection of the connecting conductors the individual contacts of the connector.

This is particularly the case when a glass plate is used as the inner plate of the solar module Connector receiving opening of the inner plate preferably as a circular hole and the connector as a cylindrical drum with approximately the same diameter guided. Such a circular hole is relatively easy to make in glass. In this case, the individual contacts of the connector are particularly advantageous a circle and substantially equidistant on the cylindrical wall of the connector arranged. This is a particularly effective mutual isolation of the individual contacts possible.  

If a plastic plate or the like is used as the inner plate, then other, e.g. B. rectangular, opening cross-sections and corresponding other connector cross-sections conceivable.

Good sealing and mechanical stability of the connection area of the solar module is essential achievable if the connector with its radial dimensions essentially the Size of the opening in the inner plate corresponds and if the connector is also a on the surface of the inner plate facing the interior of the module preferably has over the entire circumference of the opening extending shoulder that radial dimensions larger than the opening. With such a configuration, be riding a liquid-tight press seal between the übli sufficient for many purposes Usually elastically deformable body material of the connector and the peripheral edge the opening in the inner plate can be achieved. An even better seal against Ga se like water vapor can be reached if between the contact shoulder and the inner plate a (circumferential) seal is arranged. This can be done using a pre-made system shoulder seal ring can be used, or the seal is immediately on sprayed the investment shoulder. For the seal there are double-sided and small ones Height-compensating acrylic-based materials have proven their worth. In the event that Intermediate layer of the solar module in situ by filling and subsequent polyme a low-viscosity liquid monomer mixture is formed, has a Press fit and contact shoulder with circumferential seal made connector lasts. This closes the opening in the gas and liquid-tight manner like a stopper Inner plate. The fact that the contact shoulder of the connector after plugging into the Opening on the surface of the inner plate facing the intermediate layer against this contact shoulder by the monomer mixture introduced during production pressed the inner plate so that an automatic sealing effect is achieved during manufacture becomes. If necessary, this effect can be reinforced with a screw-on counter plate be, which ensures that the system shoulder in the course of the manufacture of the solar module is pressed against the inner plate. After the material has hardened, the counter plate can  be removed again. The width of the contact shoulder should be at least about 1 mm, preferably amount to 4 mm and more.

It is within the scope of the invention to make the connector conical, i. H. outward tapering, design and complementary to the opening in the inner plate ren.

Both the conical design of the connector and the provision of a system shoulder ensures secure mechanical anchoring of the connector on the solar module, so that it absorbs large tear-off forces without damage and dissipates them onto the inner plate can.

The connector is preferably dimensioned so that it is completely in the opening of the Inner plate disappears and the outer surface of the inner plate does not protrude. That's how he is best protected against mechanical stress. You can also rely on this It is better to stack wise solar modules. For this purpose the height of the connector is preferably not more than about 5 mm in total, preferably about 3 mm.

For the subsequent contacting of the solar module, it is advantageous if in the body of the Connector embedded - preferably approximately centrally arranged - threaded socket into which there is a fixing screw for fastening the associated external connector the counterpart is screwed. In this way, an unintentional loosening of the plug connection avoided and a particularly safe and permanent contacting of the plug connector can be reached with its connector counterpart.

With the connection design of the solar module according to the invention, it succeeds more surprisingly wise, a stable and robust connection that can be produced with little manufacturing effort direction with extremely low overall height ready for the electrical connection of solar modules to deliver. The connector consisting of a plug socket and plug part is preferably arrangement designed as a cylindrical drum and has one of the number of required electrical connections corresponding number of socket contacts and contact pins.  

It is understood that the body of the connector is made of an electrically insulating mate rial must exist. The insulation strength of these materials must be up to 150 V be designed. The use of elastically deformable plastic materials is in total all preferred. As suitable materials for the manufacture of the connector body the following plastics have emerged in particular: polycarbonate, acrylonitrile Butadiene styrene (ABS), polyamide, silicone and liquid crystal polymers (LCP). Of these has a liquid crystal polymer based on 4-oxybenzoate-co-6- is particularly suitable oxy-2-naphtoat (73: 27) with 30% by weight glass fiber content (product name Vectra, manufacturer Hoechst Celanese). This material is in the temperature relevant for solar modules sufficiently stable and especially in cases where the intermediate layer of the solar module from an in situ formed, at least one (meth) acrylic acid ester, little least one plasticizer and at least one polymerization initiator art fabric is only compatible with the interlayer material. Such as part of the Erfin Particularly preferred plastic intermediate layers for solar modules are, for example This is the subject of EP 0 683 215 A1.

In the following the invention based on an embodiment and a drawing forth be explained. Show it:

Figure 1 is a plan view of the connection area of a solar module according to the inven tion.

Figure 2 is a sectional view through a solar module with a circuit device according to the invention (not to scale) similar to that of Fig. 1.

Figure 3 is a plan view of an existing made of contact grid and connector connector element.

FIG. 4 shows a partial top view of the underside of the prefabricated connecting element according to FIG. 4; and

Fig. 5 is a perspective view of a cut in the connection area solar module of the invention with an associated connector counterpart.

Fig. 1 shows a schematic representation of the connection area of a solar module 1 according to the invention in plan view of its in the installed state facing away from the sun In nenplatte 3rd In the example shown, the inner plate 3 consists of 4 mm thick float glass. The solar module 1 comprises a large number of individual solar cells 6 , which are grouped together into so-called cell strings. Parts of three such cell strings can be seen in FIG. 1. To a cell string each include two elongated first connection conductors 8 made of tinned copper, which are connected to the solar cells 6 with the aid of a short connecting conductor, not shown. The first connecting conductors 8 connect the individual solar cells 6 to one another electrically and mechanically. They typically have a width of at most about 2 mm in order to get rid of the solar cells 6 as little as possible.

The first connecting conductors 8 , which run into the vicinity of the module edge 5 , are soldered to second connecting conductors 9 , which run approximately parallel to the module edge 5 and connect the cell strings to the connection device of the solar module 1 . This second connection conductor 9 may be wider than the first connection conductor 8 to minimize line losses since they run outside the solar cells 6 . In practice you work e.g. B. with 5 mm wide second connecting conductors 9 . The connection device comprises a multipole connector 10 arranged in a bore 4 in the inner plate 3 , which in the case shown has eight individual contacts 11 designed as sockets. Six of these a single contacts 11 are connected via individual conductors 21 to the second connecting conductors 9 . The middle individual conductors 21 and thus the associated individual contacts 11 of the connector 10 are not used in the exemplary embodiment shown. If necessary, additional cell strings could be connected to them. For a clearer illustration, the plug connector 10 and the individual conductors 21 in FIG. 1 are arranged between the solar cells 6 . In practice, as can be seen in the following FIG. 2, for the best possible use of the module area for energy generation, the solar cells 6 will also be arranged as close as possible to one another in the connection area and the connection device will be positioned above the solar cells 6 from the inner plate 3 .

The individual conductors 21 are in accordance with a more detail below and particularly before ferred embodiment of the invention designed as a welded or soldered 9 separate wires to the second connection conductors. However, it is within the scope of the invention to dispense with such separate conductors and to connect the first connecting conductors 8 and / or the second connecting conductors 9 directly to the individual contacts 11 of the connector 10 .

FIG. 2 shows a cross section of a solar module 1 according to the invention, which is similar to that in FIG. 1, but in which - as already explained - the solar cells 6 are arranged at a smaller distance. To simplify the illustration, the first and second connecting conductors 8 , 9 have also been omitted. Can be recognized in the installation of the sun state facing, also of 4 mm thick float glass existing outer panel 2, the inner panel 3 and the both plates 2, 3 joined and the solar cell 6 embedding intermediate layer 7, the transparen th polymerized in the exemplary embodiment of an in situ Plastic is based on an acrylic acid ester.

In a bore 4 in the inner plate 3 with a diameter of 24 mm, a fastex binder 10 is inserted, the radial dimensions of which are adapted to the diameter of the bore 4 , so that the plug connector 10 is seated in the bore 4 in the manner of an interference fit. The body of the connector 10 , which consists of a liquid crystal polymer (LCP), has a pot shape with a cylindrical wall 14 and with a circular bottom surface 19 . To achieve the desired press fit, the outer diameter of the wall 14 is slightly smaller than the diameter of the bore 4 and are additionally provided over the outer circumference of the wall 14 distributed fitting ribs 15 , which elastically deform when the connector 10 is pressed into the bore 4 and the Fix connector 10 mechanically.

The bottom surface 19 of the connector 10 is extended beyond the wall 14 and forms an approximately 5 mm wide abutment shoulder 17 with which the connector 10 is secured. Due to the press fit mentioned above, this system shoulder 17 , which rests firmly on the surface of the inner plate 3 facing the intermediate layer 7 , can achieve a liquid-tight sealing of the bore 4 that is sufficient for many cases. To improve the seal and to achieve good gas tightness in the illustrated embodiment, however, an additional annular seal 18 is arranged on the acrylic base between the contact shoulder 17 and the inner plate 3 , which is about 250 microns thick and about 3 mm wide when brought to the contact shoulder 17 .

In the vicinity of the wall 14 of the connector 10 embedded in socket jacks 13 , designed as sockets, individual contacts 11 are arranged, which serve for later connection of the solar module 1 with the aid of a multi-connector, sketched in Fig. 5 connector counterpart 25 . The centrally located in the connector 10 , in the body let threaded socket 16 is used in the installed state for fixing this connector counterpart 25 with the help of a fixing screw 26 (see. Fig. 5). Instead of sockets, plugs could also be used as individual contacts 11 of the connector 10 and a connector counterpart designed as a multiple socket. The base surfaces 12 of the individual contacts 11 are permanently connected to a contact grid 20, which is explained in more detail below, preferably by welding or soldering. Between the contact grid 20 and the solar cells 6 , an insulating strip 24 made of the same material and in the same thickness as the seal 18 is arranged, which ensures electrical insulation of the connection device against the solar cells 6 and also acts as a spacer during module production.

As can be clearly seen, the upper edge of the connector 10 is a little way below half the outer surface of the inner plate 3 , so that it is protected when handling the solar module 1 . The solar module 1 not yet connected to the periphery thereby also has a very low overall height and can be stored and transported without problems in the stack. The connector 10 closes with its bottom surface 19, the plant school ter 17 and the seal 18, the bore 4 so tightly in the inner panel 3, that a 7 to Bil the intermediate layer not dung 7 low viscosity monomer mixture used may hinausflie SEN and also that the intermediate layer is well protected against environmental influences in the installed state, in particular against the penetration of water vapor.

Fig. 3 and Fig. 4 show a gebil det of the connector 10 and a contact grid 20 connecting element, which is very preferably used in the context of the invention as a prefabricated, universally applicable component. The connector 10 shown corresponds to that from the previous figures. Clearly than in Fig. 3 can be seen the cylindricity cal wall 14 which is embedded in bushing 13 coats individual contacts (socket) 11, as well as on the outer periphery of the wall 14 respectively to the individual contacts 11 opposite angeord Neten Passungsrippen 15 are.

In Fig. 3 completely and in Fig. 4 is shown in detail from an approximately 200 microns thick tinned copper sheet by punching formed contact grid 20 , which in the exemplary embodiment from eight runs parallel to most of its length individual conductors 21 to. In order to ensure that the connection element can be used as universally as possible, the individual conductors 21 have an overall length which corresponds to the greatest length required in the specific individual case. They are then suitably cut to size before use in the solar module 1. In addition, the individual conductors 21 are first connected to one another at their ends facing away from the plug connector 10 and approximately in the middle by bridge webs 23 , which are also removed as required before use, for example by punching can be, as can be seen in Fig. 1. The individual conductors 21 of the contact grid 20 bend in the area of the connector 10 in the contact grid level, so that their tinned connection surfaces 22 serving for connection to the individual contacts 11 of the multipole connector 10 are congruent with the circularly arranged foot surfaces 12 not shown in these figures Individual contacts 11 come to rest. The contact grid 20 assumes the function of a universal adapter in the solar module 1 according to the invention, which facilitates the connection to the first and / or second connecting conductors 8 , 9 on the plug connector 10 and that the use of the connector 10 and contact grid 20 existing, industrially prefabricated Connection element for a variety of different Solarmodu len 1 permits. The number of individual contacts 11 and individual conductors 21 will be chosen to be as large as possible and, in the specific individual case, as many individual contacts 11 of the connector 10 as required are connected to the solar cells 6 .

Fig. 5 finally shows in perspective view showing the partially cut to circuit area of a solar module 1 according to the invention with a connector 10 positioned over the connector counter-piece 25. The connector counterpart 25 is inserted after plugging into the connector 10 with the help of a fixing screw 26 which is screwed into the threaded socket 16 , so that a permanent good contact of the individual contacts 11 with the individual plugs of the connector counterpart 25 and a fuse against a verse conventional Disconnect is reached. In Fig. 5 is also a circuit board 27 can be seen , which with external circuit elements such. B. diodes, inverters and the same can be provided. For the sake of clarity, further components of the solar module 1, such as solar cells 6 , intermediate layer 7, etc., have been omitted.

The obvious in the above description, in the drawing and in the claims Features of the invention can be used both individually and in any combination the realization of the invention may be essential.  

REFERENCE SIGN LIST

1

Solar panel

2nd

Outer panel

3rd

Inner plate

4th

Opening (hole) in the inner pane

5

Module edge

6

Solar cells

7

Intermediate layer

8th

first connecting conductor

9

second connecting conductor

10th

Connectors

11

Individual contacts (sockets)

12th

Individual contact feet

13

Bushing jacket

14

Wall of the connector

15

Fit ribs

16

Threaded bush

17th

Investment shoulder

18th

poetry

19th

Bottom surface of the connector

20th

Contact grid

21

Individual conductor of the contact grid

22

connector-side connection surfaces

23

Bridges

24th

Insulating strips

25th

Connector counterpart

26

Fixing screw

27

circuit board

Claims (16)

1. Photovoltaic solar module in plate form, with an outer plate ( 2 ), an inner plate ( 3 ) and a connecting intermediate layer ( 7 ) made of plastic, in which solar cells ( 6 ) are embedded, the solar cells ( 6 ) via several connecting conductors ( 8 , 9 ) are electrically interconnected and the connecting conductors ( 8 , 9 ) are each electrically conductively connected to a connection device arranged in an opening in the inner plate ( 3 ), characterized in that several connecting conductors ( 8 , 9 ) are permanently connected are connected to a common Anschlussein direction, which comprises a multi-pin connector ( 10 ). 2. Photovoltaic solar module according to claim 1, characterized in that all Ver connection conductors ( 8 , 9 ) of the solar module ( 1 ) with only one connector ( 10 ) are the verbun. 3. Photovoltaic solar module according to one of the preceding claims, characterized in that the connecting conductors ( 8 , 9 ) with the individual conductors ( 21 ) of an in the inter mediate layer ( 7 ) embedded flat contact grid ( 20 ) are permanently connected and that the individual conductors ( 21 ) of the contact grid ( 20 ) at their opposite ends with their connecting surfaces ( 22 ) with the individual contacts ( 11 ) of the multi-pole plug connector ( 10 ) are permanently connected. 4. A photovoltaic solar module according to claim 3, characterized in that the individual contacts ( 11 ) of the connector ( 10 ) with their base surfaces facing towards the module ( 12 ) are each connected to at least one single conductor ( 21 ) of the contact grid ( 20 ) by soldering or welding are. 5. Photovoltaic solar module according to claim 3 or 4, characterized in that the contact grid ( 20 ) consists of a thin sheet, in particular of tinned copper, with a thickness of less than 0.5 mm, the individual conductors ( 21 ) of which trigger from here Sheet metal sections between the individual conductors ( 21 ), in particular by stamping or etching, were formed and separated from one another. 6. Photovoltaic solar module according to one of claims 3 to 5, characterized in that the individual conductors ( 21 ) of the contact grid ( 20 ) run parallel to one another at a distance from one another and over the majority of their longitudinal extent, their ends facing the plug connector ( 10 ) Bend the connection surfaces ( 22 ) towards the contact grid level so that the connection surfaces ( 22 ) of the individual conductors ( 21 ) are congruent with the associated individual contacts ( 11 ) of the connector ( 10 ). 7. Photovoltaic solar module according to one of the preceding claims, characterized in that the opening ( 4 ) in the inner plate ( 3 ) as a circular bore and that the connector ( 10 ) is designed as a cylindrical drum with approximately the same diameter water. 8. Photovoltaic solar module according to claim 7, characterized in that a single contacts ( 11 ) of the connector ( 10 ) on a circle and substantially equi distant adjacent to the cylindrical wall ( 14 ) of the connector ( 10 ) are angeord net. 9. A photovoltaic solar module is characterized according to any one of the preceding claims, terized in that the connector (10) surfaces, with its radial dimensions in wesentli the size of the opening (4) corresponds to the inner panel (3) and that the plug connector (10) on the inside of the module facing surface of the inner plate ( 3 ) comes to rest against the abutment shoulder ( 17 ), which has larger radial dimensions than the opening ( 4 ). 10. Photovoltaic solar module according to claim 9, characterized in that the contact shoulder ( 17 ) extends over the entire circumference of the opening ( 4 ). 11. A photovoltaic solar module according to claim 10, characterized in that a seal ( 18 ) is arranged between the contact shoulder ( 17 ) and the inner plate ( 3 ). 12. Photovoltaic solar module according to one of the preceding claims, characterized in that the connector ( 10 ) does not protrude beyond the outer surface of the inner plate ( 3 ). 13. Photovoltaic solar module according to one of the preceding claims, characterized in that in the body of the connector ( 10 ) is embedded - preferably approximately centrally - threaded socket ( 16 ) into which a fixing screw ( 26 ) for fastening the associated external connector counterpart ( 25 ) can be screwed in. 14. Photovoltaic solar module according to one of the preceding claims, characterized in that the body of the connector ( 10 ) made of an electrically insulating plastic, preferably made of polycarbonate, acrylonitrile-butadiene-styrene (ABS), polyamide, silicone or a liquid crystal polymer (LCP ), consists. 15. Photovoltaic solar module according to claim 14, characterized in that the body of the connector ( 10 ) consists of a liquid crystal polymer (LCP) stable in the temperature range from -40 ° C to + 120 ° C. 16. Photovoltaic solar module according to one of the preceding claims, characterized in that the intermediate layer ( 7 ) is a transparent polymer layer formed in situ, in particular based on a (meth) acrylic acid ester.