JP5053346B2 - Solar cell module connector - Google Patents

Description

  The present invention relates to a connector for connecting a solar cell module, and particularly to a connector provided with a bypass diode.

  Conventionally, in order to obtain a desired voltage, solar cell modules are connected in series at an installation site. A solar cell module connector is used for this connection. Within this connector, a bypass diode may be connected to each module. Various techniques have been developed in order to reduce the thickness of the connector and ensure electrical reliability. One example thereof is disclosed in Patent Document 1, for example.

  In the technique of this Patent Document 1, a relay terminal support plate is disposed in a casing of a terminal box. Two conductive relay terminal connection portions are formed on the relay terminal support plate at intervals. The anode of the pellet-shaped bypass diode is soldered to one conductive relay terminal connecting portion. The cathode of this bypass diode is connected to another conductive middle terminal connection via a lead wire. Two output lead wires are connected to the two relay terminal connection portions, whereby the bypass diode is connected to the solar cell module. Two relay frames are connected to the two relay terminal connection portions. Thereby, the output of the solar cell module is taken out.

JP-A-5-343724

  Such a connection terminal box is used together with a solar cell module in a harsh environment outdoors for a long period of time. Therefore, it is necessary to attach the diode firmly. However, since the above-described pellet-shaped diode is a fragile thin semiconductor pellet, it is vulnerable to vibrations and shocks and easily breaks.

  An object of the present invention is to provide a solar cell module connector having high reliability even in a harsh environment.

  The solar cell module connector of one embodiment of the present invention has an insulating box. This insulating box has a diode zone having one surface opened and a partition wall covering the opening of the diode zone. A plurality of heat sinks are arranged at intervals in the diode zone. A plurality of diodes are mounted on each heat sink. This diode zone is filled with an insulator so as to cover each diode. These diodes have an anode lead and a cathode lead that respectively penetrate the partition. A plurality of connecting means are formed in the partition so as to connect the anode lead and cathode lead of each diode in series. One end of these connection means is a solar cell module lead wire connection terminal, and the other end of the connection means corresponding to both ends of the series circuit of each diode is an output cable connection terminal. Also in this connector, since the diode is covered with an insulator, the characteristics of the diode hardly change even if the temperature and humidity change.

  As described above, in the solar cell module connector according to the present invention, since the diode is covered with the insulator or the module in the diode zone, the reliability of the diode can be improved even in a harsh environment. Further, since the solar cell module lead connection terminal and the output cable connection terminal are not directly connected to the diode, no external force is applied to the diode, and the reliability of the diode is further improved.

It is a front view of the connection tool of the 1st reference example of the present invention, a sectional view which meets a bb line in a front view, a bottom view, and a sectional view which meets a dd line in a front view. It is a front view of the connector of the 2nd reference example of the present invention, a sectional view which meets a bb line of a front view, and a sectional view which meets a cc line of a front view. It is sectional drawing which follows the front view of the connection tool of the 3rd reference example of this invention, and the bb line of a front view. It is a front view of the connecting tool of the 4th reference example of the present invention, a sectional view which meets a bb line of a front view, and a sectional view which meets a cc line of a front view. It is an assembly drawing of the connection tool of one embodiment of the present invention.

  The solar cell module connector of the first reference example of the present invention has an insulating box 2 as shown in FIGS. 1 (a) to 1 (d). The insulating box 2 is formed of an insulator such as an epoxy resin. This insulating box is divided into three zones, that is, a solar cell module lead wire terminal zone 8, a diode heat sink zone 10, and an output cable terminal zone 12 by two partition walls 4, 6 spaced apart from each other. It is partitioned. On both sides of the diode heat dissipation zone 10, a solar cell module lead terminal zone 8 and an output cable terminal zone 12 are positioned.

  A plurality of, for example, four heat sinks 14 are attached to the diode heat sink zone 10 at intervals. These heat sinks 14 are rectangular steel plates having a thickness of, for example, 3 mm, and both end portions thereof are on the partition walls 4 and 6 side, that is, on the solar cell module lead wire terminal zone 8 and the output cable terminal zone 12 side. positioned. The bottom wall of the diode heat sink zone 10 is hollowed out, and a thermally conductive insulating sheet 16 having excellent thermal conductivity is attached to the hollowed portion. The lower surface of each heat sink 14 is bonded. Instead of providing the heat conductive insulating sheet 16, the thickness of the portion where each heat radiating plate 14 is provided and the vicinity thereof can be made thinner than other portions.

  The anode of the diode chip 18 is attached to the upper surface of the heat sink 14 by solder 20 except for one at one end (the left end in FIG. 1A). Further, in these diode chips 18, cathodes are formed so as to face the anodes, and these cathodes are connected to the heat sink 14 adjacent to each other on one side of the heat sink 14 (left side in FIG. 1A) via the leads 22. Soldered (see FIG. 1D). The diode chips 18 are connected in series by such connection between the anode and the cathode.

  The entire area of the diode heat sink zone 10 is filled with an insulator 24 such as an epoxy resin so as to cover each diode chip 18 and the heat sink 14. Since the figures are complicated, the insulator 24 is shown only in FIGS. 1B and 1D. Thus, since each diode chip 18 is protected by the insulator 24, it can withstand temperature change and humidity change, and its reliability is high.

  One end of the solar cell module lead wire connection terminal 26 is soldered to the end of each diode heat sink 14 on the solar cell module lead wire terminal zone 8 side, and penetrates the partition wall 4 to pass through the solar cell module lead wire. It extends to each terminal zone 8 for use. Lead wires of each solar cell module are connected to the tips of these terminals 26. That is, two lead wires of one solar cell module are coupled to the first and second lead wire connecting terminals 26, for example, counted from the left end of FIG. 1A, and the second and third lead wire connecting terminals. Two lead wires of another solar cell module are connected to 26, and two lead wires of another solar cell module are connected to the third and fourth lead wire connection terminals 26. As a result, a plurality of, for example, three solar cell modules are connected in series via each diode chip 18. Cylindrical ribs 28 are formed around the tips of the terminals 26, respectively. After the lead wires are connected to the terminals 26, the ribs 28 are filled with an insulator 29 such as epoxy. Accordingly, these terminals 26 can withstand temperature changes and humidity changes. The insulator 29 is shown only in FIG.

  An output cable connection terminal 30 is soldered to an end portion on the output cable terminal zone 12 side of each of the heat radiating plates 14 on both outer sides. The two connection terminals 30 extend through the partition wall 6 to the output cable terminal zone 12. An output cable is connected to the tips of these output cable connection terminals 30. Thereby, an output voltage is taken out from the both ends of the three solar cell modules connected in series. Note that two ribs 32 are formed in the output cable terminal zone 12 at intervals. An insulator 33 such as epoxy is filled between the ribs 32 and the outer walls of the output cable terminal zone 12 so as to embed the output cable connection terminals 30. As a result, these terminals 30 can withstand temperature changes and humidity changes. The insulator 33 is shown only in FIG.

  These terminals 26 and 30 are not directly connected to the diode chip 18 but are connected to the heat sink 14. Therefore, even if vibration is applied to the terminals 26 and 30, for example, it is not transmitted directly to the diode chip 18, and the vibration resistance of the diode chip 18 can be improved.

  Although not shown in the drawing, lead wires and output cables are inserted into the zones 8 and 12 in the bottom walls of the solar cell module lead wire terminal zone 8 and the output cable terminal zone 12 of the insulation box 2. Through holes may be formed.

  In the connector configured as described above, the heat sink 14 is attached to the diode heat sink zone 10 of the insulating box 2, and the connection terminals 26 and 30 are attached to the heat sinks 14. Next, the diode chip 18 is attached to the heat sink 14 and the lead wire 22 is connected. Then, the insulator 24 is filled. This forms intermediate A. A characteristic test is performed in the state of this intermediate A. If the characteristic test is good, it can be guaranteed that the diode chip 18 can withstand long-term temperature and humidity changes.

  And said intermediate body A is attached to the back surface (surface which does not receive sunlight) of the solar cell panel in which each solar cell module is provided. At this time, it attaches so that the heat conductive insulating sheet 16 may contact the back surface of a solar cell panel. As a result, the solar cell panel functions as a heat sink for the diode chip 18. In this state, the lead wire of each solar cell module is connected to the connection terminal 26, and the intermediate body B is formed. A characteristic test is performed in the state of the intermediate B, and if the test result is satisfactory, the insulator 29 is filled. If the test result is bad, make adjustments to improve it.

  In the intermediate B, an output cable is connected to the connection terminal 30 to form the intermediate C. If the characteristic test is performed in this state and the characteristic test is good, the insulator 33 is filled. If the test result is not good, make adjustments so that it is good.

  In this way, since the quality is confirmed by performing the characteristic test in each of the states of the intermediates A, B, and C, the process loss is less than that in which the test result is defective in the final product. Less.

  The connection tool of the second reference example is shown in FIGS. In the first reference example, the diode chip 18 is mounted on each heat dissipation plate 14, but instead of these, a diode module 40 is used in this embodiment. Since other configurations are substantially the same as those of the connector according to the first embodiment, the same parts are denoted by the same reference numerals and the description thereof is omitted.

  The diode module 40 includes an insulating casing 42, and a plurality of, for example, three diodes are connected in series therein. A heat radiating plate 44 common to these diodes is provided at the lower portion of the housing 42. Connection terminals 46, 48, 50, and 52 are provided on the upper surface of the housing 42. The cathode of the first diode is connected to the connection terminal 46, the anode of the first diode and the cathode of the second diode are connected to the connection terminal 48, and the anode of the second diode and the third diode are connected to the connection terminal 50. And the anode of the third diode is connected to the connection terminal 52.

  The solar cell module lead wire connection terminal 26 is screwed to the connection terminals 46, 48, 50 and 52, and the output cable connection terminal 30 is also screwed to the connection terminals 46 and 52. This connection tool is also assembled in the same manner as the connection tool of the first embodiment. In this reference example, since the diode module 40 is used, the internal diode can sufficiently withstand temperature changes and humidity changes, and the connection terminals 26 and 60 are not directly connected to the diodes. Even if some force is applied, the force is not directly applied to the diode.

  A connector of the third reference example is shown in FIG. In the second reference example, the solar cell module lead wire connection terminal 26 and the output cable connection terminal 30 are separately formed. However, in the connection tool of this reference example, only the solar cell module lead wire is connected. The terminals 48 and 50 are connected to the first terminal, for example, the solar cell module lead dedicated connection terminal 26, and the terminals 46 and 52 connected to both the solar cell module lead wire and the output cable are connected to the terminal 46. , 52 are connected to the solar cell module lead wire terminal zone 8 and the output cable terminal zone 12, respectively, and the solar cell module lead wire and the output cable combined terminal 62 are connected. The dual-purpose terminal 62 is connected to a connector (not shown) in the output cable terminal zone 12. Therefore, the zone 12 is not filled with an insulator. Since other configurations are the same as those of the connection tool of the second reference example, the same parts are denoted by the same reference numerals, and the description thereof is omitted.

  If comprised in this way, since the shared terminal 62 is used, the solar cell module lead wire and the terminal for connecting the output cable can be simultaneously attached to the diode module 40, and the assembly becomes easy.

  A connection tool of a fourth reference example is shown in FIGS. In the connection tool of this reference example, a mold type diode 70 is used instead of the diode chip 18 in the connection tool of the first reference example. In the molded diode 70, a diode chip is embedded in an insulating casing, and an anode of the diode chip is connected to a metal plate provided at a lower portion of the casing, and this metal plate functions as an anode electrode. The cathode of the diode chip is connected in the housing to two cathode electrode pins 72 projecting parallel to the side of the housing. Each mold type diode 70 is disposed on three heat sinks 14, and the anode electrode is fixed in a state where the anode electrode is in contact with the heat sink 14 by a holding metal fitting 74. Each cathode electrode pin 72 is inserted into a socket 76 fixed on the heat sink 14 adjacent to one side. The pins 78 of the sockets 76 are soldered to the heat sink 14. Since the other configuration is the same as that of the connection tool of the first embodiment, the same parts are denoted by the same reference numerals and the description thereof is omitted.

  In this way, the molded diode 70 is used, and the anode is electrically connected and attached to the heat sink 14 by the presser fitting 74, and the cathode is connected by using the socket 76. Is unnecessary, and the mounting and connecting work can be easily performed.

  In addition, the both ends of each heat sink 14 have penetrated into the solar cell module lead terminal zone 8 and the output cable terminal zone 12 beyond the partition walls 4 and 6. Ribs 80 and 82 are respectively formed in the solar cell module lead wire terminal zone 8 and the output cable terminal zone 12, and these reduce the filling amount of the insulators 84 and 86. The diode heat dissipation zone 10 is also filled with an insulator 88.

  A connector according to an embodiment of the present invention is shown in FIG. In this connection tool, the insulating box 100 includes a diode zone, for example, a mount case 102, a partition wall, for example, an insert case 104, and a lid 106. The mount case 102 is formed of an insulator, for example, an epoxy resin, in a flat rectangular parallelepiped shape with one surface, for example, an upper surface opened. An insert case 104 is disposed so as to cover the opening, and a lid 106 is disposed on the insert case 104.

  A plurality of, for example, three heat sinks 108 are attached to the bottom of the mount case 102 at intervals along the longitudinal direction thereof. The bottom of the mount case 102 can be hollowed out in the same manner as in the first reference example described above, and a heat conductive insulating sheet can be adhered, and the heat sink 108 can be adhered thereon, or the heat sink 108 can be attached. It is also possible to make the portion to be formed and the surrounding thickness thinner than other portions.

  Molded diodes 110 are disposed on these heat sinks 108. In the molded diode 110, a cathode electrode 110b and an anode electrode 110c extend upward from one end of a flat rectangular parallelepiped insulator case 110a. A metal plate (not shown) is disposed on the lower surface of the housing 110a, and this is disposed on the heat sink 108.

  The insert case 104 is an insulating flat plate such as an epoxy resin, for example, and is disposed on the opening of the mount case 102. In this insert case 104, three screw insertion holes 112 are formed corresponding to the module type diode 110, and a screw (not shown) inserted through these passes through the housing 110a of the mold type diode 110, The molded diode 110 is fixed to the heat dissipation plate 108 by screwing into a screw hole 114 formed in the heat dissipation plate 108. Although not shown, the mount case 104 is filled with an insulator such as an epoxy resin so as to embed each mold type diode 110.

  The cathode electrode 110 b and the anode electrode 110 c of each molded diode 110 are inserted through the insert case 104. Lead frames 116, 117, 118, and 119 are disposed at these insertion positions, respectively. These lead frames 116, 117, 118, and 119 are embedded in the insert case 104.

  The lead frame 116 is located on one end side of the insert case 104 and extends from one longitudinal edge of the insert case 104 to the other longitudinal edge. In the middle of this, there is an insertion hole for the cathode electrode 110b of the molded diode 110 located on one end side. In this insertion hole, the cathode electrode 110b and the lead frame 116 are coupled by solder or the like.

  Adjacent to the lead frame 116 is a lead frame 117 which extends from one longitudinal edge to the middle of the other longitudinal edge. At the tip of this, there is an insertion hole for the anode electrode 110c of the molded diode 110 located on the one end side described above. In this insertion hole, the anode electrode 110c and the lead frame 117 of the molded diode 110 located on one end side are soldered. The lead frame 117 also has an insertion hole for the cathode electrode 110b of the molded diode 110 located in the middle. In this insertion hole, the anode electrode 110c of the middle mold diode 110 and the lead frame 117 are soldered.

  A lead frame 118 is located on the side of the lead frame 117 and also extends from one longitudinal edge to the middle of the other longitudinal edge. At the tip of this, there is an insertion hole through which the anode electrode of the middle mold type diode 110 is inserted. In this insertion hole, the anode electrode 110c of the middle mold diode 110 and the lead frame 118 are soldered. The leading end of the lead frame 118 also has an insertion hole for the cathode electrode 110b of the molded diode 110 located on the other end side. In this insertion hole, the lead frame 118 and the cathode electrode 110b of the molded diode 110 located on the other end side are soldered.

  A lead frame 119 is located on the side of the lead frame 118, that is, on the other end side of the insert case 104. The lead frame 119 extends from one longitudinal edge of the insert case 104 to the other longitudinal edge. In the middle of the lead frame 119, there is an insertion hole for the anode electrode 110c of the molded diode 110 located on the other end side. In this insertion hole, the lead frame 119 and the anode of the molded diode 110 on the other end side are soldered.

  In this way, the diodes 110 are connected in series using the lead frames 116, 117, 118, and 119.

  One end portion of each lead frame 116, 117, 118, and 119 is exposed to form solar cell module lead wire connection terminals 120, 121, 122, and 123. Further, the end portions on the other longitudinal edge side of the lead frames 116 and 119 are exposed to form output cable connection terminals 124 and 125. A lid 106 is attached on the insert case 104.

  In the connector configured as described above, the lead frames 116, 117, 118, and 119 are embedded in the insert case 104, the solar cell module lead wire connecting terminals 120, 121, 122, and 123, and the output cable connecting terminals 124 and 125. Since it is formed in advance, assembly work becomes easy.

2 Insulating box 4 6 Bulkhead 8 Solar cell module lead wire terminal zone 10 Diode heat sink zone 12 Output cable terminal zone 14 Heat sink 18 Diode chip 26 Solar cell module lead wire connection terminal 30 Output cable connection terminal

Claims (1)

An insulating box having a diode zone open on one side and a partition covering the opening of the diode zone;
A plurality of heat sinks arranged at intervals in the diode zone;
A plurality of diodes mounted on each heat sink, each having an anode lead and a cathode lead penetrating the partition;
An insulator filled in the diode zone to cover the diode;
The anode lead and the cathode lead of each diode are formed in the partition so as to be connected in series, and one end is a solar cell module lead connection terminal, corresponding to both ends of the series circuit of each diode. A plurality of connection means whose other end is an output cable connection terminal,
A solar cell module connector provided.

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