EP2593989A1

EP2593989A1 - Cable connection, in particular for photovoltaic systems

Info

Publication number: EP2593989A1
Application number: EP11746437.0A
Authority: EP
Inventors: Jürgen Feye-Hohmann; Thomas Scheib
Original assignee: Phoenix Contact GmbH and Co KG
Current assignee: Phoenix Contact GmbH and Co KG
Priority date: 2010-07-16
Filing date: 2011-06-27
Publication date: 2013-05-22
Anticipated expiration: 2031-06-27
Also published as: CN103038945B; WO2012007099A1; CN103038945A; DE102010027525A1; JP6012050B2; US20130122733A1; US9083097B2; EP2593989B1; JP2013534705A

Abstract

The subject matter of the invention is a cable connection (1), preferably for photovoltaic systems (100), comprising a contact housing (2) and a connection housing (3). The connection housing (3) can be connected to the contact housing (2) and serves to accommodate a cable (4) which can be configured as required and has a conductor (6). The connection housing (3) is intended to accommodate the cable (4) which is to be connected and has the conductor (6). A contact needle (7) for making contact with the conductor (6) of the cable (4) which is to be connected is arranged on the contact housing (2) and a spring device (8) is intended to radially surround the conductor (6) and the contact needle (7) and to press together said conductor and contact needle in a spring-elastic manner.

Description

Cable connection, in particular for photovoltaic systems

The invention relates to a cable connection, in particular for use in photovoltaic systems. The cable connection according to the invention is used in particular for electrical

Connection of individual solar modules and is suitable to transmit the corresponding currents and voltages safely and permanently. Photovoltaic systems are designed for years of service life of 20 years and more and are often mounted on roofs of houses and industrial plants. They contribute significantly to electricity production. The produced

Strommenge is regularly in the public network

fed and is thus generally available. Even smaller plants in the range of some ten square meters can generate 10,000 kWh and more of electricity annually

to produce . The solar modules mounted on the roofs are installed during assembly e.g. electrically connected to one another via plug connections.

For such applications are connectors and

Cable connections for connecting solar modules become known. The known cable connections work reliably and permanently. In the course of an increasing spread of the installation of photovoltaic systems on roofs and the like do not always do the montages

Specialists in electrical wiring

but increasingly companies that have focused on the installation of photovoltaic modules on roofs.

CONFIRMATION COPY On roofs, installation is often subject to difficult conditions, as many roofs are inclined.

The failure of a single cable connection can lead to a considerable maintenance effort, since all cable connections may have to be examined to find the defective cable connection. Increased maintenance required by the cable connections can be detrimental to the business. That is why it is important to be able to guarantee a long and reliable service life.

Special tools for a wide variety of connections are often not available on site. That's why it is

advantageous if the installation work to be carried out with relatively little special electrical tool can get along, even if the connection cable of individual solar modules flexibly extended or must be assembled freely to adapt to the structural conditions.

The solar modules and the associated cable connections are on the roofs prevailing there

Exposed to ambient conditions. This means that in summer the cable connections can be exposed to high temperatures of over 40 degrees C and in winter temperatures far below zero degrees C, while at the same time moisture in the form of moisture and / or snow affect the cable connections. Under these highly fluctuating conditions, the

Cable connections make long-term and reliable contact over the long planned service life. It is therefore the object of the present invention to provide an electrical cable connection, in particular for use in photovoltaic systems, which permanently produces reliable electrical contact and is relatively easy to assemble.

This object is achieved by the cable connection with the features of claim 1. Preferred developments of the invention are the subject of the dependent claims. Further

Advantages and features arise from the

Embodiment.

An inventive electrical cable connection

in particular for solar cables to photovoltaic systems comprises at least one contact housing and at least one

Connection housing. The connection housing is with the

Contact housing connectable and the terminal housing is provided for receiving at least one cable with a conductor can be assembled freely. The connection housing serves to accommodate the cable to be connected with the conductor. At the contact housing is a contact needle for

Contacting the conductor of the cable to be connected arranged. A spring device is provided to surround the conductor and the contact needle radially at least partially and compress resiliently.

The cable connection according to the invention has many advantages. A significant advantage of the cable connection according to the invention is that the spring means the conductor and the

Contact needle radially surrounds and resilient

compresses. As a result, even after long and long periods of operation a reliable electrical contact between the contact pin and the connected conductor allows.

Another advantage is that a cable which can be freely assembled can be accommodated on the connection housing, as a result of which flexible mounting and flexible extension of

Connecting cables for solar modules is possible. In addition, the cable connection can be made physically small. The spring device is designed in particular as a separate part and surrounds the conductor and the contact needle radially in the connected state. The spring device must not completely surround the contact needle and the conductor radially, but it is sufficient if the

Spring means presses the contact pin and the conductor of two or more sides together to make a reliable and permanent contact.

In a preferred embodiment surrounds the

Spring means the insulating layer of the cable and presses over the insulating layer on the conductor contained therein and the contact needle inserted therein to exert permanent pressure on the conductor and the contact needle. In this case, the insulating layer in particular as a spring elastic

Memory serve.

Such a design uses the elastic

Properties of the insulating layer to permanently exert pressure on the electrical connection of the conductor with the contact needle. Set tion phenomena and the like are compensated by the elastic action of the spring means and the insulating layer, so that a durable

Reliable contacting is possible. In a further preferred embodiment, the spring device surrounds the stripped conductor, in particular directly. A small radial gap in the unconnected state between the stripped conductor and the

Be provided spring device. Such a radial

Gap between the conductor and spring device in the unconnected state ensures that the insertion of the stripped conductor in the spring device is easily possible. When the contact needle is inserted into the conductor, the radial volume of the conductor decreases with the inserted one

Contact needle too. As a result, the radial gap is overcome and the conductor with the inserted contact needle is pressed radially against the spring device, so that the spring device permanently exerts pressure on the conductor with the inserted contact needle.

Such an embodiment, in which the spring device surrounds the stripped conductor, allows particularly long and safe contact times, since the spring device directly in

Contact with the conductor and possibly the contact needle is and thus flow of the insulating layer of the spring device out is not possible. Depending on

Insulating material used may be the softer

Insulating layer due to the close connection between

Spring device and conductor or contact needle

be forced out, which can possibly reduce the contact pressure. With suitable materials and dimensions this can be avoided.

Is the insulation as a spring-loaded memory

used, the insulation in addition to the elastic effect and a sealing function take over because of the applied pressure small and smallest gaps are reliably closed, creating a particularly high impermeability to penetrating

Moisture is achievable.

If the insulating layer of the cable is at least partially or completely removed before the connection and the spring device surrounds the conductor of the cable directly, an additional sealing compound or sealing device may be provided around the spring device in order to more reliably prevent the penetration of moisture.

In all embodiments, it is particularly preferred that the spring device can be installed in the connection housing. In particular, the spring device is in the

Built-in connection housing and there preferably

taken captive. A captive recording of the spring device allows a particularly simple and reliable installation, since the fitter does not have to pay attention to whether the spring device is inserted into the terminal housing or not.

In preferred embodiments, the spring device comprises at least one spring sleeve. The spring sleeve has

preferably a cylindrical receiving area for the head of the cable. Optionally, the spring sleeve may have a funnel-shaped insertion region, which prevents a nudging of the spring sleeve during insertion of the conductor.

The conductor, which consists in particular of a plurality of wires, can in a spring sleeve with a slightly larger inner diameter or a funnel-shaped Insertion area reliable and reproducible in the

Spring sleeve can be inserted without the individual wires on edges or the like nudge and bend. Preferably, the spring device is slotted

executed. It is possible, for example, that parallel to the axis of the spring sleeve, the spring sleeve has a slot, whereby the spring sleeve good elastic and resilient

Features. It is possible that the

Slit ends overlap, leaving the spring sleeve

spirally around a recorded conductor

herstreckt. But it is also possible that the slot ends abut each other or have a certain distance from each other.

Particularly preferred is a helical slot which not only extends in the axial direction but spirally extends around the spring sleeve. This prevents even more reliable that individual wires of the conductor are forced out of the spring sleeve to the outside, whereby the pressing force of the spring sleeve would sink to the head and the contact needle received therein.

Particularly preferably, the spring device is at least partially made of a metal. In particular, the spring device made of a resilient metal and

especially made of spring steel.

It is possible and preferred, however, that the

Spring device consists of a plastic. For example, a fiber composite material is possible. It is also possible that the spring device consists of a viscoelastic plastic. At a

viscoelastic spring device brings either an outer sleeve or, for example, the terminal housing itself the required counterforce to apply the necessary spring force during insertion of the contact needle. A the conductor with the picked up contact needle

Concentrically surrounding spring-loaded spring device with a sleeve arranged concentrically around it or the concentrically provided connection housing can absorb high forces, since the force is applied radially into the sleeve or into the connection housing and because the spring sleeve or the connection housing absorbs and dissipates this force along the circumference ,

In all embodiments, it is preferred that a thread is arranged on the contact housing, which is provided for, with a on the connection housing

cooperate provided thread to screw the contact housing with the terminal housing the

Inserting a contact pin defined from the front into the conductor of the cable. In particular, the contact housing has an internal thread and the connection housing has a

External thread on. The screwing is the

Contact pin pressed into the conductor. Due to the thread pitch, a relatively small rotational force produces a high axial insertion force of the contact needle into the conductor of the connection cable. At the same time a defined immersion in the conductor is ensured by the contact needle, which transmits a high current

Ensures contact surface, which permanently high currents at high applied voltages are transferable. At the same time, a small-sized cable connection can be realized by the chosen construction, whose

Outer diameter is less than three or four times the outer diameter of a solar cable to be connected. As a result, the cable connection can also be laid in narrow channels, profiles and the like, whereby a particularly flexible application of the cable connection for the connection of solar modules of a photovoltaic system

is possible.

Further advantages and features of the present invention will become apparent from the embodiments, which will be explained with reference to the accompanying figures below.

In the figures show:

Fig. 1 is a schematic representation of a

Photovoltaic system whose modules are connected via a cable connection according to the invention;

Fig. 2 shows the cable connection of Fig. 1 in the connected

Status;

3 shows the cable connection according to FIG. 2 during manufacture and when releasing the connection; FIG.

Fig. 4 shows the cable connection of FIG. 2 in one

partially represented cross-section in the unconnected state;

Fig. 5 is a schematic representation of a

perspective view upon penetration of the contact needle in the head;

Fig. 6, the contact needle and the spring sleeve of the

Cable connection according to Fig. 5; Fig. 7 is a schematic cross section of a

Cable connection before immersing the

Contact needle;

Fig. 8 shows a cable connection in the connected state in

Cross-section; and

Fig. 9 shows another embodiment of the

Cable connection in a schematic

Cross section before immersing the contact needle. In Fig. 1 is a highly schematic view of a

Photovoltaic plant 100 shown here in the simple example, three solar modules 101, 102 and 103, which is not shown in detail with photovoltaic cells

are equipped to withstand sunlight in

to convert electricity.

The individual solar modules 101 to 103 of the photovoltaic system 100 are cable 4 designed as a solar cable 5

connected together to make the necessary electrical connection.

The solar cables 5 carry the generated electrical power, but can also be additionally applied with control signals or with sensor signals to the

Photovoltaic system 100 to control suitable.

At light shafts, roofs, windows or other structural features and conditions, the normal distance of a solar module 102 changes to a solar module

103rd

A greater distance of the solar modules 102 and 103 must be bridged over an extension of the connecting cable 4. Since such photovoltaic installations are often done on sloping roof surfaces and there is not always every tool at hand when mounting there, a simple installation without special tools offers significant advantages.

Moreover, it is advantageous if the electric

Cable connection 1 is made small-sized to be performed by profiles, cable ducts or other small spaces.

In this case, it is possible for the cable connection 1 to be connected on one side to a freely configurable cable 4 or on both sides to freely connectable cables 4. With a two-sided connection possibility is

in particular a symmetrical structure advantageous.

Fig. 2 shows the cable connection 1 in a perspective view in the connection state 18, in which the

Contact housing 2 is connected to the terminal housing 3. Not shown here is the solar cable 5

illustrated connection cable 4, which from the

Connection housing 3 emerges. Fig. 3 shows the cable connection 1 in a perspective view, wherein the contact housing 2 and the

Connection housing 3 are partially separated from each other by twisting against each other or when making the connection.

Fig. 4 shows a partially sectioned schematic

Representation of the cable connection 1 before the connection in the open state 20. In the connection housing 3, a cable 4 which can be freely assembled has been inserted so far that the cable 4 or the conductor 6 abuts against the entrance surface 38. The

Terminal housing 3 is designed as a hollow screw and has an external thread 17, which is intended to be screwed into an internal thread 16 of the contact housing 2. Centrally in the hollow cylindrical receiving portion of the contact housing 2, a contact needle 7 is arranged, which defines defined in the manufacture of the compound in the conductor 6 of the recorded on the terminal housing 3 cable 4 axially from the front. By a number of

Revolutions, which can be, for example, between three and ten, depending on the application, the contact needle 7 is defined over virtually their full length or at least a substantial portion thereof inserted into the conductor 6 of the cable 4, so that the contact needle

As centrally as possible is arranged in the conductor 6 and thus can produce a high contact surface to the conductor 6.

At the terminal housing 3, a non-return device 19 is provided, which introduced an inserted into the hollow cylindrical terminal housing cable 4 in front of a

Retracting secures when the contact needle 7 enters the inlet surface 38 of the connection housing 3 axially from the front with the high penetration force. At the entrance and

in particular with increasing admission, the contact needle 7 spreads, so that the axial force on the

inserted cable 4 increases. At the same time, the radial pressure increases because the conductor 6 or its cores 15 spread radially and exert pressure to the outside. Fig. 5 shows a schematic perspective view in which individual parts have been omitted in order to facilitate the overview. Clearly visible is the dipping into the conductor 6 contact needle 7. The conductor 6 is surrounded by a spring means 8 here. The insulating layer 13 of the connecting cable 4 has been removed via a stripped region 11, so that the spring sleeve 9 directly surrounds the stripped conductor 10.

The spring device 8 embodied here as a spring sleeve 9 has a helical slot 21 which ensures high elasticity of the spring sleeve 9 made here of an elastic metal. The annular shaped slot 21 reliably prevents individual wires 15 of the conductor 6 from passing through the slot to the outside.

It is also possible to provide an axially executed slot 21. Optionally, however, can then pass through the slot 21, a core 15 of the conductor 6 radially outward. This must be taken into account in the design, so that the remaining pressure is still sufficient to ensure the connection safely. It is also possible that the spring device 9 as

Spiral spring is executed, the individual turns are close to each other or spaced from each other. Such a spring device 9 also enables the application of the required force to a conductor arranged therein when a contact needle is inserted.

Fig. 6 shows the contact sleeve 9 of FIG. 5 with a schematically inserted contact needle 7 to a possible To show sizing. Here, a spiral annular slot 21 is provided in the contact sleeve 9.

Fig. 7 shows a schematic representation of a

Terminal housing 3 with a recorded therein cable 4, which at a stripped area 11 via a

stripped conductor 10 has. The individual wires 15 of the conductor 6 are stripped over the length of the stripped

Area 11 of a spring device 8 in the form

For example, surrounded by a spring sleeve 9. Here, in the opened state 20, as shown in Fig. 7, a small radial gap between the inner diameter of the spring sleeve 9 and the outer diameter of the conductor 6 with the bundle of wires 15 before. The radial distance may for example be between 5 and 25% of the diameter of the conductor. In any case, the radial distance is such that after immersing a contact needle 7 in the conductor 6, a radial pressure from the contact needle 7 via the conductor 6 is applied to the spring sleeve 9, so that, for example, provided with an axial slot or a ring slot 21 Spring sleeve 9 radially

elastically expands and transmits a corresponding spring force on the conductor 6 and the contact needle 7. Preferably, the spring device 8 or spring sleeve 9 is made in the embodiment of FIG. 7 made of metal. But it is also possible that the spring device 8 consists of an example viscoelastxschen plastic. By inserting the contact needle 7 in the conductor 6, the radial volume is increased there, so that the pressure on the outside viscoelastic spring means

is passed on. The here viscoelastic

Spring device 8 is characterized by the spring device. 8 surrounding terminal housing 3 in its radial extension, so that a corresponding contact force on the conductor 6 and the contact needle 7 arranged therein is exercised.

The outer diameter 35 of the stripped conductor 10 is preferably between twenty and seventy-five percent of the outer diameter 33 of the cable 4. The outer diameter 33 of the cable 4 is preferably in a range

between thirty-three and sixty-six percent or more of the outer diameter 32 of the cable terminal 1, so that a small-sized of the cable terminal 1 is made possible. If the spring device 8 in the exemplary embodiment according to FIG. 7 is formed by a metal part, a radially particularly small-sized cable connection 1 can be realized, since a radially thin spring sleeve 9 can also be used

elastic forces on the conductor 6 and in it

provided contact needle 7 are transferable.

Fig. 8 shows a schematic sectional view of the cable connection 1 in the connection state 18, in which the connection housing 3 is screwed into the contact housing 2 and wherein the not visible here contact pin 7 is immersed in the conductor 6.

Fig. 8 shows two variants. On the one hand, it is possible that a spring device 8, for example, a

viscoelastic material or a metal which

Insulating layer 13 of the connection cable 4 surrounds and exerts elastic pressure from the outside during penetration of the contact needle 7 in the conductor. It is also possible for a stripped region 11 of the conductor 6 to be surrounded by a spring device 24 which is made of a viscoelastic material or of metal

may exist to transmit corresponding forces from the conductor 6 and the contact needle 7. The radially outwardly provided spring device 8 can then

For example, consist of a viscoelastic material or the like and serve as a sealing device 28 of the cable connection 1 to a permanently secure

Connection protected to allow moisture.

Furthermore, in Fig. 8, the reverse safety 19th

shown, which may include a spring means 22 with spring tongues 23, which prevent sliding back after the insertion of the cable 4, since the spring tongues obliquely angled against the insulating layer 13 of the conductor 6 and in the attempt of retraction further into the insulating layer 13 of the cable 4 dig while the outer ends of the spring tongues abut a shoulder 26 in the terminal housing 3.

9 shows, in a schematic cross-section, a further construction of a cable connection 1 in which the cable 4 does not have to be stripped off. The inserted into the terminal housing 3 cable 4 is surrounded by the insulating layer 13 radially from the spring means 8, here

in turn may be formed as a spring sleeve 9. In this case, the spring sleeve 9 may have a slot 21 or the insulating layer 13 completely surrounded. After insertion of the contact needle 7 in the conductor 6 is through the

additional volume of the contact needle 7 causes the conductor 6 radially expanded, whereby the insulating layer 13 as resilient memory 14 is used. Even with mechanical subsidence or the like that is enough

spring-elastic force of the insulating layer, which is supported by the surrounding spring device 8, from, to a permanently tight and reliable connection to

enable .

Overall, the invention provides a reliable

Cable connection 1 available, the permanent and safe electrical contact between a connection cable 4 and a contact needle 7 allows and, for example, designed as a plug connection. The connection can transmit high currents at high voltages and can

maintenance-free operation over long periods of time.

Reference sign list

Electrical cable connection 1

Contact housing 2 Connection housing 3

Cable 4

Solar cable 5

Head 6

Contact needle 7 Spring device 8

Spring sleeve 9

Stripped conductor 10

Stripped area 11 funnel-shaped insertion area 12 insulating layer 13

Spring elastic memory 14

Wire 15

Internal thread 16

External thread 17 connection state 18

Reverse safety 19 opened state 20

Slot 21

Spring device 22 spring tongue 23

Spring device 24

Paragraph 26

Sealing device 28 conical stop surface 29 outer diameter of the connector 32nd

Outer diameter of the cable 33

Outer diameter of the conductor 35

Entrance surface 38

Photovoltaic system 100 solar module 101-103

Claims

claims

1. Cable connection (1) preferably for photovoltaic installations (100) comprising at least one contact housing (2) and at least one connection housing (3),

wherein the connection housing (3) is connectable to the contact housing (2) and serves to receive at least one freely configurable cable (4) with a conductor (6),

characterized,

the connection housing (3) is provided for connecting the cable (4) to be connected to the conductor (6).

and that on the contact housing (2) a contact needle (7) for contacting the conductor (6) of the cable to be connected (4) is arranged, wherein a spring means (8) is provided for the conductor (6) and the contact needle (7 ) radially surrounded and resiliently together to press.

2. Cable connection (1) according to claim 1, wherein the

Spring device (8) surrounds the stripped conductor (10).

3. Cable connection (1) according to claim 1, wherein the

Spring means (8) surrounds the insulating layer (13) of the cable (4).

4. Cable connection (1) according to the preceding claim, claim, wherein the insulating layer (13) as

spring elastic memory (14) is used. Cable connection (1) according to one of the preceding

Claims, wherein the spring means (8) in the

Connection housing (3) is installed.

Cable connection (1) according to one of the preceding

Claims, wherein the spring means (8) a

Spring sleeve (9).

7. Cable connection (1) according to the preceding claim, wherein the spring sleeve (9) has a cylindrical

Receiving area (12) for the conductor (6) of the cable (4) and a funnel-shaped insertion area (12)

having .

Cable connection (1) according to one of the preceding

Claims, wherein the spring means (8) is slotted.

Cable connection (1) according to one of the preceding

Claims, wherein the spring means (8) consists of Met.

10. Cable connection (1) according to one of the preceding

Claims, wherein the spring means (8) of

at least one viscoelastic plastic.

Cable connection (1) according to one of the preceding

Claims, wherein the conductor (6) of the cable (4) consists of a plurality of flexible wires (15).