JP5434811B2 - Terminal box for solar cell module - Google Patents

Description

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

Patent Document 1 discloses a conventional terminal box for a solar cell module. This has a plurality of terminal boards and a housing for accommodating each terminal board. The housing is composed of a bottom portion and an outer peripheral portion, and each terminal plate is supported on the bottom portion. Each terminal plate has a pair of cable connection terminals, and both cable connection terminals have a lead connection part to which a lead pulled out from the solar cell module can be connected at one end part, and an external part at the other end part. It has a cable connection part for connection.
A pair of barrel portions is formed in the cable connecting portion, and both the barrel portions are connected by caulking to the end portion of the cable with a mold made of an anvil and a crimper. In assembling, the cable connection terminal is supported on the bottom while being connected to the end of the cable. For this reason, a notch into which the cable is fitted is formed at the edge of the outer periphery, and after the cable is fitted into the notch, a cable pressing member is fitted to cover the cable, and the cable is fixed to the outer periphery. It has come to be.

JP 2006-135246 A

  By the way, since the conventional terminal box is configured to introduce a cable connection terminal to which a cable is connected in advance into the casing, a separate cable pressing member must be prepared after a notch is formed in the outer peripheral portion. However, there is a circumstance that the configuration becomes complicated. On the other hand, for example, if the cable connection terminal is supported on the bottom portion and then the cable is connected to the cable connection portion, it is not necessary to prepare a cable pressing member or the like. In this case, however, a separate mold entry hole into which the mold for connecting the cable to the cable connection part enters must be formed at the bottom, and a separate cover for closing the opening of the mold entry hole. Must be prepared. Therefore, there is a problem that the situation that the configuration is complicated cannot be solved.

  This invention is completed based on the above situations, Comprising: It aims at providing the terminal box for solar cell modules which avoided the structure becoming complicated.

  As means for achieving the above-mentioned object, the invention of claim 1 includes a lead connection part to which a lead drawn out from the solar cell module can be connected, and a terminal having a cable connection part to which a cable for external connection can be connected. In a terminal box for a solar cell module comprising a plate and a support portion for supporting the terminal plate, a window portion is formed in the support portion so that a window portion is opened, and the window portion is a lead inlet for taking in the lead. In addition, the present invention is characterized in that it is a mold entrance into which a mold for connecting the cable to the cable connection portion enters.

According to a second aspect of the present invention, in the first aspect, the lead connection portion and the cable connection portion have a shape protruding forward in the same direction, and face the window portion while being aligned in the width direction. It has the feature in the place arrange | positioned.

According to a third aspect of the present invention, in the first or second aspect, the support portion constitutes a bottom portion of the housing, and an outer peripheral portion of the housing is detachably connected to a peripheral edge of the support portion. The terminal plate supports a rectifying element having a heat generating portion, and the support portion is made of at least one material selected from PBT (polybutylene terephthalate) and PPS (polyphenylene sulfide). Have

<Invention of Claim 1>
A window portion is formed in the support portion, and the window portion is a lead inlet for taking in the leads, and a die entrance into which a die for connecting the cable to the cable connection portion enters. Therefore, the window portion is also used as the lead intake and the mold entrance, and the entire configuration is simplified. Further, since it is not necessary to prepare a separate cable pressing member, cover, etc., the number of parts is reduced, and the work load for assembling is reduced.

<Invention of Claim 2>
Since the lead connection portion and the cable connection portion are projected forward in the same direction and are arranged so as to face the window portion while being aligned in the width direction, the shape of the window portion does not have to be complicated. .

<Invention of Claim 3>
The support portion constitutes the bottom of the housing, the outer periphery of the housing is detachably connected to the periphery of the support portion, the terminal plate supports a rectifying element having a heat generating portion, and the support portion is PBT ( Since it is made of at least one material selected from polybutylene terephthalate) and PPS (polyphenylene sulfide) , the support portion and the outer peripheral portion can be made of different materials. For this reason, for example, the support portion can be made of a material having excellent heat transfer to the solar cell module, and the outer peripheral portion can be made of a material having high weather resistance even if heat resistance is low, thereby expanding the range of material selection. In addition, it is possible to suppress an increase in cost.

It is a top view of the terminal box for solar cell modules concerning Embodiment 1 of the present invention. It is AA sectional drawing of FIG. It is sectional drawing in which the crimping part was formed from the state of FIG. It is sectional drawing in which the sealing material was introduce | transduced in the housing | casing from the state of FIG. It is BB sectional drawing of FIG. It is a top view of an outer peripheral part. It is a top view of a support part. It is a side view of a support part. It is a top view of a housing | casing. It is a top view with which the heat sink was supported in the housing | casing. It is sectional drawing just before a metal mold | die approachs into a window part, and it performs caulking connection.

<Embodiment 1>
A first embodiment of the present invention will be described with reference to FIGS. A terminal box for a solar cell module according to Embodiment 1 (hereinafter simply referred to as a terminal box 10) includes a housing 11, a plurality of terminal plates 60, and a plurality of bypass diodes (hereinafter simply referred to as a diode 80). Composed.

  The casing 11 is made of synthetic resin, has a plate shape as a whole, and includes a support portion 12 and an outer peripheral portion 13 that are detachably connected to each other. The housing 11 is covered with a cover 90 from above (see FIG. 4).

As shown in FIG. 6, the outer peripheral portion 13 has a rectangular frame shape, and includes a pair of left and right side plates 14 and a pair of front and rear plates 15 and 16 that are connected to both front and rear ends of the side plates 14.
A pair of left and right cylindrical cable insertion portions 17 is formed inside the front plate 15 (see FIG. 5). In the cable insertion portion 17, the plus and minus cables 100 are inserted from the front. A front blocking plate 18 is formed on the inner side of the front plate 15 so as to extend in the width direction while continuing to the rear end of the cable insertion portion 17. The front blocking plate 18 has a role of blocking the forward outflow of the sealing material 300 put into the housing 11.

  Inside the both side plates 14, first to third slide receiving pieces 19, 20, 21 are formed extending in the front-rear direction. The first slide receiving piece 19 is positioned below the second slide receiving piece 20, and the second slide receiving piece 20 is positioned below the third slide receiving piece 21. The first slide receiving piece 19 is positioned behind the second and third slide receiving pieces 20 and 21 and extends longer in the front-rear direction than the second and third slide receiving pieces 20 and 21. ing. Further, the second and third slide receiving pieces 20 and 21 have portions overlapping each other in the front-rear direction. First and second slide pieces 30 and 31 (described later) of the support portion 12 are slidably engaged with the first to third slide receiving pieces 19, 20 and 21.

  A pair of left and right locking receiving pieces 22 are formed on the inner side of the rear plate 16 so as to protrude forward. A substantially rectangular locking projection 23 projects from the upper surface of both locking receiving pieces 22. Further, on the inner side of the rear plate 16, an insertion receiving piece 24 is formed between the both locking receiving pieces 22 so as to extend in the left-right direction (width direction). A locking piece 33 (described later) of the support portion 12 is elastically locked to both the locking receiving pieces 22, and an insertion piece 35 (described later) of the supporting portion 12 is provided below the insertion receiving piece 24. It is designed to be slid and engaged. A rear blocking plate 25 is raised at the front end of the insertion receiving piece 24. The rear blocking plate 25 has a role of blocking the backward outflow of the sealing material 300.

  The outer peripheral portion 13 is made of at least one material selected from PPO (polyphenylene oxide), PPE (polyphenylene ether), and PVC (polyvinyl chloride). That is, the outer peripheral part 13 is comprised with the material excellent in the weather resistance and hydrolysis resistance.

  As shown in FIG. 7 and FIG. 8, the support portion 12 has a flat plate shape that constitutes the bottom portion of the housing 11, and its upper surface is a support surface 26 that supports a plurality of terminal plates 60, and its lower surface is It is set as the to-be-attached surface 27 attached to a solar cell module. The support surface 26 and the attachment surface 27 are flat surfaces that are substantially parallel to each other. A plurality of terminal board support regions 28 are formed on the support surface 26 of the support portion 12 in the width direction. Of the support surface 26 of the support portion 12, a partition wall 29 is raised between adjacent terminal plate support regions 28.

  First and second slide pieces 30 and 31 are formed on the outer sides of both side edges of the support portion 12 so as to extend in the front-rear direction. The first slide piece 30 is located behind and below the second slide piece 31 and extends longer in the front-rear direction than the second slide piece 31. The first slide piece 30 can be brought into contact with the first slide receiving piece 19 above the first slide piece 30, and the second slide piece 31 can be brought into contact with the second and third slide receiving pieces 20 and 21 at the lower and upper sides, respectively. Has been.

  A pair of left and right step portions 32 are recessed at the rear edge of the support portion 12, and a pair of left and right locking pieces 33 project into the inner region of the step portion 32 from the back end (front end) of the step portion 32. Is formed. The locking piece 33 can be bent and deformed in the vertical direction with the base side connected to the step portion 32 as a fulcrum, and a substantially rectangular locking hole 34 is formed at the center thereof. An insertion piece 35 is formed on the rear edge of the support portion 12 between the locking pieces 33 so as to extend in the left-right direction (width direction). The insertion piece 35 is disposed below the both locking pieces 33.

  Frame pieces 36 are raised and formed on the front edge, the rear edge, and both side edges of the support portion 12, respectively. The first and second slide portions described above are configured to protrude from the frame pieces 36 at both side edges of the support portion 12, and the above-described insertion pieces 35 are configured to protrude from the frame pieces 36 at the rear edge of the support portion 12. Has been.

  A plurality of convex portions 37 protrude from the support surface 26 of the support portion 12. Each convex portion 37 has a cylindrical shape, and is disposed almost uniformly over the entire support surface 26. Specifically, each of the convex portions 37 is arranged in a plurality in the width direction and separately in the front and rear, and a tapered lead-in portion 38 is formed over the entire circumference at the tip portion. Each convex portion 37 is inserted into a hole 70 (described later) of the terminal board 60, and the insertion operation is guided by the guiding portion 38 at that time. Further, a caulking portion 39 that is caulked by heat after insertion into the hole 70 is formed to bulge at the tip of each convex portion 37 (see FIG. 3). The caulking portion 39 has a brim-like shape having a diameter larger than the diameter on the base side of the convex portion 37, and can be brought into close contact with the opening edge portion of the hole 70 on the surface side of the terminal board 60.

  The support portion 12 is made of at least one material selected from PBT (polybutylene terephthalate) and PPS (polyphenylene sulfide). The support 12 includes a reinforcing material such as glass fiber or talc. Thereby, the heat deformation temperature of the support portion 12 (also the heat deformation temperature of the convex portion 37) is 170 ° C. or higher, and preferably 200 ° C. or higher. That is, the support portion 12 is made of a material having higher heat resistance than the outer peripheral portion 13, and the caulking portion 39 is not deformed by the heat generation of the diode body 81 of the diode 80 (which is a rectifying device body of the present invention and will be described later). Is assured.

  In a state in which the housing 11 is formed by combining the support portion 12 and the outer peripheral portion 13, the frame piece 36 at the front edge of the support portion 12, the front blocking plate 18 of the front plate 15, and the both side plates 14 are partitioned. A substantially rectangular window 50 that is long in the width direction is opened and formed in the inner region. This window part 50 is an inlet for taking in the terminal part of the lead 5 (see FIG. 4) extending from the positive and negative electrodes in the solar cell module, and is connected to the cable connecting part 65 of the cable 100. It is also a mold entrance where molds 400 and 500 for connection enter.

  Each terminal plate 60 has a flat plate shape made of conductive metal, and is arranged in parallel in the width direction while being fitted in the terminal plate support region 28 of the support portion 12. Specifically, as shown in FIG. 10, the terminal plate 60 includes a pair of left and right cable connection terminals 61 that are located at both ends in the width direction and are connected to both the positive and negative external connection cables 100. It is composed of left and right relay connection terminals 62 located between the cable connection terminals 61. A lead connection portion 63 is formed at the front end portion of each terminal plate 60, and an insertion hole 64 into which the terminal portion of the lead 5 can be inserted and connected is formed in the lead connection portion 63. Each terminal plate 60 excluding the relay connection terminal 62 located on the right side in the drawing is a heat radiating plate that supports the diode main body 81 and has a role of radiating heat from the diode main body 81. Among these, the relay connection terminal 62 located on the left side in the figure has the largest surface area, and the other heat sinks also have a larger surface area than the relay connection terminal 62 located on the right side in the figure.

  A lead connection portion 63 and a cable connection portion 65 to which the cable 100 is connected are formed at the front end portions of both cable connection terminals 61 so as to protrude forward in the same direction. The lead connection portion 63 and the cable connection portion 65 are arranged so as to face the window portion 50 while being arranged in the width direction while maintaining a gap therebetween. A pair of left and right open barrel-like barrel pieces 66 are formed at the front end portion of the cable connecting portion 65 so as to protrude upward. Both barrel pieces 66 are caulked to the core wire 101 exposed at the terminal portion of the cable 100, whereby the cable 100 is connected to the cable connection terminal 61 (see FIG. 5). The barrel piece 66 is disposed in front of the front end of the lead connection portion 63 and is opposed to the cable insertion portion 17 at the rear thereof. That is, the cable connection portion 65 and the cable insertion portion 17 are each arranged coaxially with the wiring direction of the cable 100. In addition, a substantially rectangular relief groove 67 into which the locking piece 33 and the locking receiving piece 22 enter is formed in the rear edge of both the cable connection terminals 61.

  A region of the terminal board 60 where the diode 80 is supported (hereinafter referred to as a diode support region 68) is formed so as to be raised from the front and rear regions in a crank shape. As shown in FIG. 2, a cylindrical boss portion 69 protrudes from the lower surface of the diode support region 68, and the tip (lower end) of the boss portion 69 faces the support surface 26 of the support portion 12. The A screw member 200 that passes through an attachment piece 85 (described later) of the diode 80 is screwed to the inner periphery of the boss portion 69. Further, the lead connecting portion 63 is also formed by raising the bottom from the rear region in a crank shape. For this reason, the lead connection portion 63 is configured to straddle the upper side of the frame piece 36 at both side edges of the support portion 12.

  Each terminal board 60 is formed with a plurality of holes 70 at positions corresponding to the convex portions 37. Each hole 70 is circular and has an inner diameter corresponding to the diameter of the base side of each convex portion 37. Specifically, each hole 70 is disposed in a region of the terminal plate 60 before and after sandwiching the diode support region 68 and in a region that can contact the support portion 12 excluding the lead connection portion 63. More specifically, each hole 70 is disposed between the lead connection portion 63 and the cable connection portion 65 and the diode support region 68, and is disposed between the escape groove 67 and the diode support region 68. The relay connection terminals 62 located on the left side are arranged in pairs in the width direction on both the front and rear sides across the diode support region 68. Further, a hole 70 is also formed in the relay connection terminal 62 located on the right side in the drawing behind the lead connection portion 63.

  As shown in FIGS. 1 and 2, the diode 80 includes a diode body 81 in which the chip portion is enclosed in a square block shape with resin, and is connected to the chip portion and protrudes in the width direction from one side surface of the diode body 81. Both the anode side and cathode side connection pins 82 are provided. The diode body 81 is a heat generating portion that is heated up to 170 ° C. to 200 ° C. by the rectifying action of the chip portion. The lower surface (bottom surface) of the diode body 81 is a flat surface that can be in close contact with the support surface 26 of the terminal plate 60.

  Both connection pins 82 are arranged substantially in parallel with each other. The tip of one of the connection pins 82 is soldered and connected to its own terminal board 60 that supports the diode body 81, and the tip of the other connection pin 82. The part is connected to the adjacent terminal board 60 by soldering. A substantially rectangular connection piece 72 on which the tip end portion of the connection pin 82 is placed is formed on the side edge of each terminal plate 60 so as to protrude in the width direction.

  A substantially flat mounting piece 85 is formed in a stepped shape on the diode body 81, and the screw member 200 is passed through and tightened to the mounting piece 85. Further, the screw member 200 is screwed onto the inner periphery of the boss portion 69, whereby the diode main body 81 is sandwiched and fixed between the head portion 201 of the screw member 200 and the terminal plate 60.

The structure of the terminal box 10 according to the present embodiment is as described above. Next, an assembling method and operation effects of the terminal box 10 will be described.
First, when assembling the housing 11, the support portion 12 is slid rearward from the lower front side with respect to the outer peripheral portion 13. In the sliding process, the first slide piece 30 can slide on the lower surface of the first slide receiving piece 19, and the second slide piece 31 can slide between the second and third slide receiving pieces 20, 21. Plugged into. When the slide is completed, as shown in FIG. 9, the insertion piece 35 sinks below the insertion receiving piece 24, and the locking projection 23 of the locking receiving piece 22 is elastically inserted into the locking hole 34 of the locking piece 33. Fit. Thus, the support portion 12 is retained so as to prevent the outer peripheral portion 13 from moving in the vertical direction. Further, as the casing 11 is configured in this manner, the window portion 50 is partitioned and formed.

  Subsequently, the corresponding terminal plates 60 are fitted into the terminal plate support regions 28 of the support portion 12. In the process of fitting, each projection 37 is inserted into the corresponding hole 70 from the back side of the terminal board 60, and when the fitting is completed, the tip of each projection 37 protrudes from the hole 70 as shown in FIG. It faces the surface side of the terminal board 60. Thereby, each terminal board 60 is supported by the support part 12 in the positioning state. Next, a pressing die in a heated state is pressed against the tip portion of each convex portion 37 to apply pressure, and the tip portion of each convex portion 37 is crushed to form a caulked portion 39 at the tip portion of each convex portion 37. Then, the caulking portion 39 comes into close contact with the surface of the terminal plate 60, and the terminal plate 60 is sandwiched and fixed between the caulking portion 39 and the support portion 12 (see FIG. 3). Further, in a state where each terminal plate 60 is caulked and fixed to the support portion 12 in this way, the lead connection portion 63 and the cable connection portion 65 face the window portion 50.

  Subsequently, the diode body 81 is placed on the diode support area 68 of each terminal plate 60, and the diode body 81 is screwed and fixed to each terminal plate 60 by the screw member 200. And the front-end | tip part of each connection pin 82 is soldered and connected to the corresponding connection piece 72. FIG.

  Further, the cable 100 is inserted into the cable insertion portion 17 from the front, and the core wire 101 in the terminal portion of the cable 100 is placed on the bottom surface between the open barrel pieces 66 in the cable connection portion 65. In this state, as shown in FIG. 11, the barrel piece 66 is set in a mold (jig) including an anvil 400 (lower mold) and a crimper 500 (upper mold). At this time, the anvil 400 can enter the housing 11 through the window 50. Then, the crimper 500 is lowered toward the anvil 400, the barrel piece 66 is bent and deformed, and the barrel piece 66 is wound around the core wire 101 of the cable 100. As a result, both the plus and minus cables 100 are caulked and connected to the corresponding cable connection terminals 61 (see FIGS. 1 and 5).

  Thereafter, the attachment surface 27 of the support portion 12 is attached and fixed to the back surface side of the solar cell module with an adhesive, a double-sided tape, a bolt, or the like. At the time of attachment, the lead 5 extending from the solar cell module is drawn into the housing 11 through the window portion 50, and the lead 5 is soldered to the lead connection portion 63 of each terminal plate 60. Further, a sealing material 300 made of an insulating resin such as silicon resin is put into the housing 11. The filling amount of the sealing material 300 is defined by the internal volume defined between the front blocking plate 18, the rear blocking plate 25, and the both side plates 14. In addition, the sealing material 300 enters between the lead connection portion 63 and the terminal plate 60 through a gap between the lead connection portion 63 that has been raised and the upper end of the frame piece 36 at the front edge of the support portion 12. After the sealing material 300 introduced into the housing 11 is cured, the cover 90 is put on the housing 11 to complete the terminal box 10.

  By the way, when the diode body 81 generates heat during use, the heat is radiated from the terminal plate 60 to the solar cell module side via the support portion 12. In this case, there is a concern that the caulking portion 39 is deformed by the heat due to the support portion 12 being made of synthetic resin, and the fixing force to the terminal board 60 becomes weak. However, according to the present embodiment, the support portion 12 is made of a material having excellent heat resistance and heat transfer properties such as PBT (polybutylene terephthalate) containing glass or talc, and the thermal deformation temperature of the convex portion 37 is 170. Since the temperature is set to ℃ to 200 ° C or higher, the above-described thermal deformation of the caulking portion 39 is avoided. As a result, the contact state between the caulking portion 39 and the terminal plate 60 and between the terminal plate 60 and the support portion 12 is maintained, and good heat transfer to the solar cell module is ensured.

  Further, according to the present embodiment, the window portion 50 is formed in the support portion 12 so as to be opened, and the window portion 50 is a lead intake port for taking in the lead 5, and connecting the cable 100 to the cable connecting portion 65. Since the molds 400 and 500 for performing the above are mold entrances, the window 50 is also used as a lead intake port and a mold entrance, and the overall configuration is simplified. Further, since it is not necessary to prepare a separate cable pressing member, cover, etc., the number of parts is reduced, and the work load for assembling is reduced.

  In addition, since the lead connection portion 63 and the cable connection portion 65 are arranged so as to face the window portion 50 while being aligned in the same direction, the shape of the window portion 50 is not complicated.

  Further, the support portion 12 constitutes the bottom portion of the housing 11, the outer peripheral portion 13 of the housing 11 is detachably connected to the periphery of the support portion 12, and the diode 80 having a heat generating portion is supported by the terminal plate 60. And since the support part 12 has heat resistance higher than the outer peripheral part 13, the support part 12 and the outer peripheral part 13 can each be comprised with a different material. For this reason, for example, the material of the outer peripheral portion 13 can be made of a material having high weather resistance even if heat resistance is low, and the range of material selection can be expanded and the increase in cost can be suppressed.

<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.
(1) For example, the caulking portion may be formed with ultrasonic waves by heat-deforming the tip of the convex portion with an ultrasonic oscillator.
(2) The supporting portion (including the convex portion) is adjusted to a heat deformation temperature of 170 ° C. to 200 ° C. or more by containing glass fiber or talc in the raw material having a heat deformation temperature of 170 ° C. to less than 200 ° C. It may be a thing.
(3) Although the terminal board also serves as a heat sink supporting the diode body, the terminal board may be provided separately from the heat sink.
(4) The entire housing including the outer periphery may be made of a material having a heat deformation temperature of 170 ° C. or higher.
(5) The heat dissipation plate may be configured by only both cable connection terminals, and one diode main body may be supported by one of the cable connection terminals.

5 ... Lead 10 ... Terminal box (terminal box for solar cell module)
DESCRIPTION OF SYMBOLS 11 ... Housing 12 ... Support part 13 ... Outer peripheral part 60 ... Terminal board 61 ... Cable connection terminal 63 ... Lead connection part 65 ... Cable connection part 80 ... Diode (rectifier element)
100 ... Cable

Claims (3)

A lead connection part to which a lead drawn from the solar cell module can be connected, and a terminal plate having a cable connection part to which a cable for external connection can be connected;
In a terminal box for a solar cell module provided with a support portion for supporting the terminal plate,
In the support part, a window part is opened and formed,
The solar cell module, wherein the window portion is a lead inlet for taking in the lead, and a die entrance into which a die for connecting the cable to the cable connecting portion enters. Terminal box. 2. The solar cell module terminal according to claim 1, wherein the lead connection portion and the cable connection portion have a shape protruding forward in the same direction, and are arranged to face the window portion while being aligned in the width direction. box. The support portion constitutes a bottom portion of the housing, and an outer peripheral portion of the housing is detachably connected to a peripheral edge of the support portion,
The rectifying element having a heat generating portion is supported on the terminal board, and the supporting portion is made of at least one material selected from PBT (polybutylene terephthalate) and PPS (polyphenylene sulfide). The terminal box for solar cell modules of 2.

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