JP4088272B2 - Terminal box for solar cell module - Google Patents

Description

  The present invention relates to a terminal box for a solar cell module.

The solar power generation system supplies a direct current from a solar cell panel laid on the roof of a house to each electrical appliance via an inverter or the like. A solar cell panel consists of a plurality of solar cell modules, and has a structure in which the electrodes of each solar cell module are connected in series or in parallel via a terminal box.
As a conventional terminal box, as described in Patent Document 1, two terminal plates arranged side by side on the substrate of the box body and connected to the plus electrode and the minus electrode from the back side of the solar cell module respectively A cable having an external connection cable connected to one end of a terminal plate and a reverse load bypass diode bridged between the two terminal plates is known. Here, the box main body is affixed on the back surface of the solar cell module by an adhesive applied to the bottom surface of the substrate.
Japanese Patent Laid-Open No. 9-223538

In the above case, the bottom surface of the substrate is a substantially uniform flat surface, and it is difficult to sufficiently secure the adhesive strength with the adhesive.
The present invention has been completed based on the above-described circumstances, and an object thereof is to increase the bonding strength.

As means for achieving the above object, the invention of claim 1, terminals respectively electrically relay between the cable for external connection corresponding to the positive and negative electrodes and the opposing electrodes of the solar cell module An adhesive layer provided on a bottom surface of the substrate , comprising: a plurality of terminal plates including a plate; a bypass diode connected between adjacent terminal plates via a conductor piece; and a substrate on which the terminal plates are arranged in parallel. In the solar cell module terminal box that can be attached to the solar cell module via a cable, a cable support surface on which the cable is mounted and a terminal plate support surface on which the terminal plate is mounted are provided on the upper surface of the substrate. The board is provided with a bottom-up part that is raised with the bottom surface of the board as a recess, and the upper surface of the bottom-up part constitutes the terminal board support surface. And the terminal board support surface, said together arranged at a position higher than the cable supporting surface, said pin between the said substrate anvil and the horn tip in order to weld the said terminal plate and the conductor pieces An opening for allowing the tip of the amble to enter is provided in the substrate so that the plate and the conductor piece can be sandwiched , and the bottom-up portion defines the opening with respect to the extending direction of the terminal plate. It is characterized in that it is arranged in a region sandwiched between the front and rear.

  According to a second aspect of the present invention, there is provided the adhesive according to the first aspect, wherein the adhesive layer filled in the recess is projected on the inner wall of the recess toward the opening edge side of the recess. It is characterized in that the biting portion is provided.

<Invention of Claim 1>
Since the substrate is provided with a raised portion in the form of being raised while the bottom surface of the substrate is a recess, the adhesive layer provided on the bottom surface of the substrate is also filled in the recess, and the adhesive layer to the substrate The pasting strength of is increased. In addition, since the terminal plate support surface is arranged at a position higher than the cable support surface by raising the bottom raised portion, the terminal plate and the cable can be easily aligned at a height position appropriate for both connections.

<Invention of Claim 2>
Since the inner wall of the recess is provided with a biting portion of the adhesive layer filled in the recess so as to project inward toward the opening edge side, the adhesive layer is filled so as to bite into the recess. Further, the bonding strength to the substrate can be further increased.

  An embodiment of the present invention will be described with reference to FIGS. The terminal box for a solar cell module according to this embodiment is attached to the back side of a solar cell module 90 in which a large number of solar cells connected in series on the front surface are arranged. The box main body 10 and the box main body 10 A large number of terminal boards 30 arranged in parallel with each other and a bypass diode 50 that is bridged between adjacent terminal boards 30 and prevents reverse current flow are configured.

  The box body 10 is formed of a synthetic resin material in a box shape having an open top surface, filled with an insulating resin, and covered with a cover (not shown) from above. Specifically, as shown in FIG. 1, the box body 10 includes a substantially rectangular substrate 11 on which a plurality of terminal plates 30 are placed side by side, and a side plate 12 that is raised from the peripheral edge of the substrate 11 and surrounds the four sides. And a partition wall 13 that is raised from a predetermined position on the substrate 11 and partitions the adjacent terminal plates 30. A plurality of substantially rectangular openings 14 are formed in the substrate 11, and the front end portions of the terminal boards 30 corresponding to the openings 14 face each other. Leads (not shown) connected to both the positive electrode and the negative electrode of the solar cell module 90 are inserted into the openings 14 of the substrate 11, and each inserted lead is soldered to the tip of the terminal plate 30. Can be connected. A long hole-like temporary holding hole 34 is provided at the tip of the terminal plate 30, and a lead end can be inserted into the temporary holding hole 34 from above.

  Further, on the upper surface of the substrate 11, there is provided a locking projection 19 that can be closely fitted into a locked hole 35 provided in the terminal plate 30. The locking projection 19 has a substantially rectangular shape in plan view, and has a tapered notch surface 21 at the peripheral edge of the tip (see FIG. 2). A pair of bendable locking pieces 17 project from two positions on both sides of the substrate 11 with the locking protrusion 19 interposed therebetween. Each locking piece 17 is configured to be vertically raised from the substrate 11 and then folded back inward, and the upper surface of the terminal board 30 is pressed against the substrate 11 at the folded end. (See FIG. 3). The locking pieces 17 are elastically expanded and deformed by sliding contact with both side portions of the corresponding terminal plate 30 in the process in which the terminal plate 30 is placed on the substrate 11, and the terminal plate 30 is placed on the substrate 11. Accordingly, the folded end is brought into contact with both side portions of the upper surface of the terminal board 30, and the terminal board 30 is pressed and fixed to the substrate 11 side.

  Further, notches 20 are provided on both side portions on one end side (the lower side shown in FIG. 1) of the side plate 12, and an external output cable 60 is fitted into the cutout 20 from above. The cable 60 is fixed by being fitted. The partition wall 13 is partitioned and formed along the outer edge shape of the terminal plate 30, and an insulating resin such as silicon resin is filled on the terminal plate 30 in the partition wall 13. That is, the partition wall 13 blocks the resin flow of the insulating resin, and contributes to the saving of the insulating resin by not filling the entire box body 10 with the insulating resin.

  The terminal plate 30 is formed in the shape of a strip that extends long from one end to the other end using a conductive metal plate. Corresponding external connection cables 60 are connected to the terminal boards 30 arranged on both sides of the substrate 11. The core wire 62 is exposed at the end of the cable 60 due to the peeling of the covering 61, and the barrel portion 31 formed at the end of the terminal plate 30 is caulked to the core wire 62, whereby the cable 60 and the terminal plate 30. And are to be connected. A connector portion (not shown) is connected to the end of the cable 60.

  Adjacent terminal plates 30 (excluding the terminal plates 30 arranged on both side portions of the substrate 11) are connected together at one end via a connecting portion 32. One of the terminal plates 30 does not have a contact point with the solar cell module 90 side, is formed shorter than the other terminal plate 30, and is surrounded by the partition wall 13 around the tip. The heat radiation effect of heat generated by the bypass diode 50 is enhanced by the amount of the one terminal board 30 that is detoured. Attached portions 33 are provided on both side edges of the terminal plate 30 so as to protrude sideways, and the leading edge of the attached portion 33 is arranged in an opposing manner between the adjacent terminal plates 30.

A bypass diode 50 is bridged between the adjacent terminal boards 30. In the illustrated case, three bypass diodes 50 are arranged in series across the terminal board 30.
The bypass diode 50 includes a mesa-type bare chip diode (not shown) and a pair of conductor pieces 51. The two conductor pieces 51 are electrically connected to the bare chip diode by sandwiching the bare chip diode between the overlapping regions. ing. And both the conductor pieces 51 are extended in the direction away from a mutual superposition | polymerization area | region, and are connected to the corresponding terminal board 30 by the solder welding, resistance welding, or ultrasonic welding at the extension end side.

  Now, as shown in FIG. 2, each terminal board 30 is disposed at a position one step higher than the surroundings on the upper surface of the substrate 11. In other words, the substrate 11 is provided with a bottom raised portion 15 in the form of being raised with the bottom surface of the substrate 11 as a recess 16, and each terminal is provided on the upper surface of the raised portion 15 (hereinafter referred to as a terminal plate support surface 15A). A plate 30 is supported. The bottom raised portion 15 is provided at a position corresponding to each terminal plate 30 along the extending direction of the terminal plate 30, and each terminal plate 30 is substantially horizontal at a predetermined height position on a flat terminal plate support surface 15 </ b> A. It is placed. As the bottom raised portion 15 is raised, the terminal plate support surface 15A is disposed at a position higher than the cable support surface 11A on which the cable 60 is placed. As a result, the barrel portion 31 of the terminal plate 30 is connected to the core wire 62 of the cable 60. It is easy to connect to the height position.

  By the way, the bottom-up portion 15 is formed along with the formation of the recess 16, and the recess 16 has the same position as the corresponding terminal plate 30 on the bottom surface of the substrate 11 as shown in FIG. 4. It is provided along the formation direction of the terminal board 30. A silicon-based adhesive is applied to the bottom surface of the substrate 11, and the bottom surface of the substrate 11 is attached to the back surface of the solar cell module 90 through an adhesive layer 23 formed by solidifying the adhesive material. The adhesive layer 23 is also filled in the recess 16 by application of the adhesive material to 11.

The side surface of the inner wall of the recess 16 is provided with a reverse taper biting portion 16A that protrudes inward toward the opening edge side of the recess 16, and an adhesive layer 23 is formed inside the bite portion 16A. By entering, the separation of the adhesive layer 23 from the substrate 11 is regulated.
Further, as shown in FIG. 3, the substrate 11 is provided with a through hole 22 that penetrates in the thickness direction. The through hole 22 is filled with an adhesive layer 23 provided on the bottom surface of the substrate 11. The adhesive material flows out from the through hole 22 to the upper surface of the substrate 11, whereby a convex spherical enormous portion 24 is formed around the hole of the through hole 22 on the upper surface of the substrate 11. The substrate 11 is caulked and fixed between the enormous portion 24 and the adhesive layer 23 as the enormous portion 24 is solidified. As shown in FIG. 3, the already-described locking projection 19 is provided at a substantially central portion in the width direction of the terminal plate support surface 15 </ b> A, and the locking piece 17 is formed in the die-cutting hole outward in the width direction of the bottom-up portion 15. The through hole 22 and the enormous portion 24 are provided between the locking piece 17 and the side plate 12.

  Next, the manufacturing method and effects of this embodiment will be described. First, the barrel portion 31 of the terminal plate 30 is caulked to the core wire 62 exposed at the end of the cable 60 to caulk and connect the terminal plate 30 and the cable 60. Subsequently, the terminal plate 30 is placed on the terminal plate support surface 15 </ b> A of the substrate 11 from above. In the process of placing the terminal plate 30 on the terminal plate support surface 15 </ b> A, the locking projection 19 is fitted into the locked hole 35 of the terminal plate 30 and the locking piece 17 is elastically expanded by contact with the terminal plate 30. Then, the locking projection 19 is closely fitted into the locked hole 35 while being loosely restricted, and the terminal plate 30 is supported in a state where the lifting of the locking piece 17 is restricted by lifting the locking piece 17. Press and fix to the surface 15A. With respect to the terminal plates 30 arranged on both sides of the substrate 11, the cable pressing member 65 is attached while covering the cable 60 from above, and the cable 60 is pressed and fixed to the cable support surface 11 </ b> A of the substrate 11. Thereby, as shown in FIG. 2, the terminal board 30 is mounted substantially horizontally in close contact with the terminal board support surface 15A.

  Subsequently, the bypass diode 50 is placed so as to be bridged between the adjacent terminal plates 30, and solder welding, resistance welding, or ultrasonic welding is performed on a portion where both the conductor pieces 51 of the bypass diode 50 overlap the terminal plate 30. The two conductor pieces 51 and the terminal plate 30 are electrically connected. In the case of this embodiment, for example, when ultrasonic welding is performed, the front end of the anvil is made to enter the substrate 11 so that the terminal plate 30 and the two conductor pieces 51 can be sandwiched between the anvil and the horn chip. A permissible opening 29 is formed (see FIG. 2).

  Next, a silicon-based adhesive is applied to the bottom surface of the substrate 11 so as to extend also into the recess 16 to form an adhesive layer 23, and the bottom surface of the substrate 11 is attached to the solar cell module 90 via the adhesive layer 23. Paste and fix to the back side. In the process of attachment, the leads connected to both electrodes of the solar cell module 90 are drawn into the box body 10 through the openings 14 of the substrate 11, and the leads are soldered to the tip of the terminal plate 30.

  As described above, according to the present embodiment, the substrate 11 is provided with the raised portion 15 in the form of being raised while the bottom surface of the substrate 11 is set as the recess 16, so that the adhesion provided on the bottom surface of the substrate 11 is provided. The layer 23 is also filled in the recess 16, and the adhesion strength of the adhesive layer 23 to the substrate 11 is increased. Moreover, since the terminal plate support surface 15A is arranged at a position higher than the cable support surface 11A by raising the bottom raised portion 15, the barrel portion 31 of the terminal plate 30 is easily connected to the core wire 62 of the cable 60 at a height position. Easily aligned.

Further, enormous portions 24 are attached and formed around the through holes 22 on the upper surface of the substrate 11 by an adhesive flowing out from the bottom surface side of the substrate 11 through the through holes 22, and the substrate 11 is caulked and fixed by solidifying the enormous portions 24. Thus, the adhesion strength of the adhesive layer 23 to the substrate 11 is further increased.
Further, since the inner wall of the recess 16 is provided with a biting portion 16A for the adhesive layer 23 filled in the recess 16 so as to project inward toward the opening edge side, the adhesive layer 23 is provided in the recess 16. It will be filled so that it may bite in, and the adhesion strength of the adhesive layer 23 with respect to the board | substrate 11 is raised further.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention, and further, within the scope not departing from the gist of the invention other than the following. Various modifications can be made.
(1) In the above embodiment, the substrate is provided with a through-hole and a bottom-up portion in which the bottom surface of the substrate is raised while being recessed, but in the present invention, the through-hole and the bottom-up portion are provided. Only one of them may be provided.
(2) In the present invention, the formation position of the through hole in the substrate is arbitrary and may be provided at a position where interference with other members can be avoided.
(3) In the embodiment described above, the reverse tapered bite portion is provided on the inner wall of the recess. However, in the present invention, the bite portion projecting inward toward the opening edge side is provided on the inner wall of the recess. What is necessary is just to be reverse-tapered.

The top view of the box body concerning one embodiment of the present invention Side sectional view of the box body attached to the solar cell module Enlarged longitudinal sectional view of the main part of the box body attached to the solar cell module Bottom view of the box body

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Box main body 11 ... Board | substrate 11A ... Cable support surface 12 ... Side board 15A ... Terminal board support surface 16 ... Recess 19 ... Locking protrusion 23 ... Adhesion layer 30 ... Terminal board 31 ... Barrel part 60 ... Cable 90 ... Solar cell module

Claims (2)

A plurality of terminal plate including terminals plate for each electrical relays between the cable for external connection corresponding to the positive and negative electrodes and the opposing electrodes of the solar cell module, the conductor pieces in the adjacent terminal plates For a solar cell module that includes a bypass diode connected via a substrate and a substrate on which the terminal plate is arranged in parallel, and can be attached to the solar cell module via an adhesive layer provided on the bottom surface of the substrate In the terminal box,
The upper surface of the substrate is provided with a cable support surface on which the cable is placed and a terminal plate support surface on which the terminal plate is placed,
The board is provided with a bottom-up portion in the form of being raised with the bottom surface of the board as a recess, and the terminal plate support surface is constituted by the upper surface of the bottom-up portion, and the terminal plate support surface is the cable While being arranged at a position higher than the support surface,
In order to weld the conductor piece and the terminal plate to the substrate, the tip of the anvil is allowed to enter the substrate so that the terminal plate and the conductor piece can be sandwiched between the anvil and the horn chip. A terminal box for a solar cell module, wherein an opening is provided, and the bottom raising portion is arranged in a region sandwiching the opening in the front-rear direction with respect to the extending direction of the terminal plate. The inner wall of the recess is provided with a biting portion of the adhesive layer filled in the recess so as to project inward toward the opening edge side of the recess. The terminal box for solar cell modules as described.

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