JP5489544B2 - Terminal box for solar cell module and manufacturing method thereof - Google Patents

Description

  The present invention relates to a terminal box for a solar cell module that constitutes an output part of the solar cell module and a method for manufacturing the terminal box.

  A terminal box constituting the output part of a solar cell module generally includes a circuit part including a terminal block and a bypass diode in an open box on one side. The circuit part is embedded by filling with a filler, and the open part of the box is closed with a lid.

  That is, in a conventional terminal box for a solar cell module, a circuit portion is filled with silicon resin having excellent thermal conductivity, and heat generated by a bypass diode or the like is radiated through the filler. The filling material is filled in the surface of the circuit section and the inner wall surface of the terminal box box without any gaps, and the heat dissipation action prevents disconnection and destruction of the bypass diode, and also allows water and moisture to enter the circuit section. This also prevents dust from adhering (see, for example, Patent Document 1).

JP 2005-019833 A

  In the above conventional terminal box, the procedure for attaching to the solar cell module is that the case of the terminal box is pasted on the laminated module, and after the soldering work to the terminal plate of the output lead wire, The procedure is to fill the filler. In this attachment process, it took a lot of time to solidify the filler, which was a problem, and was a problem.

  The present invention has been made in view of the above, and in the step of attaching to the solar cell module, the solar cell module terminal capable of reducing the solidification time of the filler and improving the production efficiency. An object is to provide a box and a manufacturing method thereof.

  In order to solve the above-described problems and achieve the object, a terminal box for a solar cell module according to the present invention is a terminal box that constitutes an output portion of a solar cell module, and an output lead wire extending from the solar cell module is joined. A circuit body, a box body that stores the circuit section in the circuit storage section, and a filler that fills the circuit storage section. The circuit storage section is connected to the output lead wire and the circuit section by the partition wall. And a second space that does not include a joint portion, and the filler is a joint between the second filler that fills the second space, the output lead wire, and the circuit portion. And a first filler filled in the first space.

  The method for producing a terminal box for a solar cell module according to the present invention includes a circuit unit to which an output lead wire extending from the solar cell module is joined, a box body that stores the circuit unit in the circuit storage unit, and a circuit storage unit. A first box that includes a junction between the output lead wire and the circuit portion by a partition wall, the manufacturing method of the terminal box that constitutes the output portion of the solar cell module And the second space that does not include the joining portion, the second space is filled with the second filler and solidified, the output lead wire and the circuit portion are joined, and then the first space And a mounting step of filling the first space with the first filler.

  According to the present invention, the circuit storage portion is partitioned by the partition wall into the first space including the joint portion between the output lead wire and the circuit portion and the second space not including the joint portion, and the second space is previously provided. By filling and solidifying the second filler, the first space filled with the first filler can be narrowed after joining the output lead wire and the circuit portion. It is possible to shorten the drying time of the filler in the attaching step, and to improve the production efficiency.

FIG. 1 is an exploded perspective view showing a general structure of a terminal box for a solar cell module. FIG. 2 is a plan view of the solar cell module terminal box according to the embodiment of the present invention with the box cover removed. 3 is a cross-sectional view taken along line AA of FIG. 2 of the terminal box attached to the solar cell module. FIG. 4 is a front view of the assembly of the partition wall and the terminal plate. FIG. 5 is a side view of the assembly of the partition wall and the terminal plate. FIG. 6 is a front view showing a state where the assembly of the partition wall and the terminal plate is stored in the box body. FIG. 7 is a front view showing a state in which the second filler is filled. FIG. 8 is a front view showing a state in which the output lead wire is connected to the terminal board.

  DESCRIPTION OF EMBODIMENTS Embodiments of a solar cell module terminal box and a method for producing the same according to the present invention will be described below in detail with reference to the drawings. Note that the present invention is not limited to the embodiments.

Embodiment.
First, the general structure of a terminal box for a solar cell module will be described. FIG. 1 is an exploded perspective view showing a general structure of a terminal box for a solar cell module. The terminal box constituting the output part of the solar cell module 1 is constituted by a box body 2 that houses the circuit part 12 and a box cover 3 that covers the box body 2.

  In the box body 2, a circuit storage portion 6 is defined in an interior separated from the outer wall structure 5 of the four circumferences with a space around. The standing dimension of the circuit storage unit 6 is formed lower than that of the outer wall structure 5, and the circuit storage unit 6 and the inner wall of the outer wall structure 5 are connected by several vertical and horizontal ribs. A circuit unit 12 is stored in the circuit storage unit 6. The circuit unit 12 includes a terminal board 13 and a bypass diode 14. The box body 2 is integrally formed with a resin having high flame retardancy and weather resistance, such as ABS resin or modified PPO resin, in an open rectangular box structure on the side facing the mounting surface 4.

  The box cover 3 covers the open part of the box body 2. The box cover 3 includes an inner cover 16 made of a stainless steel or steel plate having a thickness of about 0.5 mm, and an outer cover 17 formed of a resin having high flame resistance and weather resistance such as ABS resin or modified PPO resin. It consists of.

  The outer cover 17 covers the open portion of the box body 2 so as to cover the inner cover 16. One of the short sides of the outer cover 17 is provided with an engaging portion that is hinge-coupled to the box body 2, so that it can be opened and closed and is detachable. A peripheral edge portion of the outer cover 17 is fitted into a step portion formed in the outer wall structure 5 of the box main body 2 so that watertightness is maintained.

  In the solar cell module terminal box having such a configuration, the terminal box of the present embodiment includes a partition wall that defines the space in the circuit housing portion 6 as a first space and a second space, and the first wall. And a filler filled separately in the second space and the second space.

  FIG. 2 is a plan view showing the solar cell module terminal box according to the embodiment of the present invention with the box cover 3 removed. 3 is a cross-sectional view taken along line AA of FIG. 2 of the terminal box attached to the solar cell module. The terminal box is fixed by fixing the attachment surface 4 of the box body 2 to the back surface of the solar cell module 1 by means such as adhesion (FIG. 3).

  In FIG. 2, the box body 2 has a circuit housing portion 6 defined in the interior separated from the outer wall structure 5 of the four circumferences with a space around the box body 2 as described above. An outlet 9 for the external cable 8 is provided on one surface of the short side of the outer wall structure 5. On the other hand, an insertion opening 2a for inserting an output lead wire (flat copper wire) 7 extending from the solar cell module 1 is formed along the side at the bottom surface of the short side opposite to the outlet 9 of the circuit housing portion 6. Has been.

  A circuit unit 12 is stored in the circuit storage unit 6. The circuit unit 12 is provided with three terminal plates 13 extending in the longitudinal direction of the box body 2, and a solar cell provided between the three terminal plates 13 for the purpose of preventing destruction of the solar cell module due to a backflow current. And a bypass diode 14 for bypassing the reverse load that bypasses the output. An output lead wire 7 extending from the solar cell module 1 is joined to one end (upper end in FIG. 3) of the three terminal boards 13. An external cable 8 extending to a terminal box of another solar cell module is joined to the other end (the lower end in FIG. 3) of the two terminal plates 13 provided on the left and right sides. The external cable 8 extended from the terminal box of another solar cell module is joined to the two terminal plates 13 at the place where the solar cell module is installed).

  The terminal box of the present embodiment is provided with partition walls (ribs) 20 that partition the internal space of the circuit storage unit 6 into two spaces. The partition wall 20 includes the joint space between the output lead wire 7 and the terminal plate 13 (circuit portion 12) and faces the insertion space 2a into which the output lead wire 7 is drawn (opposed). The first space 18 is partitioned into a second space 19 that is a space other than the first space 18. The first space 18 is filled with a first filler 21 so as to completely seal the joint between the output lead wire 7 and the terminal plate 13. The second space 19 is filled with a second filler 22 so as to completely seal the other parts of the circuit unit 12. As the first filler 21 and the second filler 22, a UL94 standard V0 grade two-component mixed silicon filler is suitable in terms of flame retardancy, heat dissipation, and fillability.

  Next, a method for manufacturing the terminal box of this embodiment will be described. FIG. 4 is a front view of the assembly of the partition wall 20 and the terminal plate 13. FIG. 5 is a side view of the assembly of the partition wall 20 and the terminal plate 13. FIG. 6 is a front view showing a state in which the assembly of the partition wall 20 and the terminal plate 13 is housed in the box body. FIG. 7 is a front view showing a state in which the second filler 22 is filled. FIG. 8 is a front view showing a state in which the output lead wire 7 is connected to the terminal board 13. In the terminal box of the present embodiment, the manufacturing process for manufacturing the terminal box and the mounting process for attaching the manufactured terminal box to the solar cell module are performed at different locations.

  The partition wall 20 has an elongated flat plate shape and is formed with a slit-like hole that penetrates the terminal plate 13. As shown in FIGS. 4 and 5, the terminal plate 13, the bypass diode 14 mounted on the terminal plate 13, the external cable 8 joined to the terminal plate 13 on one side, and the partition wall 20 penetrating the terminal plate 13 are shown. Assembled into a simple assembly. Then, the assembly assembled in this way is fixed in the circuit housing portion 6. At this time, the partition wall 20 is positioned by inserting both ends into a guide groove 6a provided on the inner wall of the circuit housing portion 6 (FIG. 6). In this state, the partition wall 20 partitions the inside of the circuit storage unit 6 into a first space 18 and a second space 19. Since the partition wall 20 penetrates the terminal plate 13, the partition wall 20 can be partitioned without a gap including the space between the bottom surface of the circuit storage unit 6 and the terminal plate 13.

  As described above, the first space 18 is a space 18 including the joint portion between the output lead wire 7 and the terminal plate 13 and the insertion opening 2a into which the output lead wire 7 is drawn, and the second space 19 is the first space 19. It is a space other than the space 18. Then, the second space 19 is filled with the second filler 22 (FIG. 7). At this time, the partition wall 20 holds the second filling material 22 before curing in the second space 19 by damming. Thus, the produced intermediate assembly of the terminal box is moved to the process of attaching to the next solar cell module.

  In the attachment process of attaching the terminal box to the solar cell module, the attachment surface 4 of the box body 2 is fixed and fixed to the back surface of the solar cell module 1 by means such as adhesion, and the output lead extending from the solar cell module 1 The wire 7 is drawn from the insertion opening 2 a and soldered to the terminal board 13. After this soldering operation is completed, the first space 18 is filled with the first filler 21 so as to completely seal the joint between the output lead wire 7 and the terminal plate 13.

  According to the present embodiment, the circuit housing portion 6 is divided into the first space 18 including the joint portion between the output lead wire 7 and the terminal plate 13 by the partition wall 20, and the second space 19 not including the joint portion. The second space 19 is filled with the second filler 22 in advance and solidified, so that the first filler 21 is filled after the output lead wire 7 and the terminal plate 13 are joined. Since the 1st space 18 can be narrowed, the drying time of the filler in the attachment process to a module can be shortened, and the effect that improvement in production efficiency can be aimed at can be acquired.

  The partition wall 20 according to the present embodiment is inserted and fixed in the guide groove 6a provided on the inner wall of the circuit storage unit 6. However, the present invention is not limited to this, and the partition wall 20 is formed on the inner surface of the inner cover 16, for example. You may stand up toward the inside. In this case, the terminal plate 13 is not penetrated through the partition wall 20. The partition wall 20 may be detachable without being completely fixed to the box body 2. Then, the partition wall 20 may be removed from the box body 2 after the second filler 22 is cured. That is, the partition wall 20 may be disposed only when the second filler 22 is filled.

  Further, as shown by the phantom line B in FIG. 8, the partition wall 20 may be provided at a position closer to the soldering position of the output lead wire 7 and the terminal plate 13 to narrow the first space to the limit. . By narrowing the first space, the work time of the attachment process can be further shortened. Conversely, the partition wall 20 may be provided at the position indicated by the phantom line C in FIG. 8 so that the time required for curing the filler in the assembly process does not increase.

  As described above, the terminal box for a solar cell module according to the present invention is useful when applied to a terminal box of a solar cell module installed outdoors, and in particular, a solar cell installed in a severe environment. It is suitable for application to a terminal box of a module.

DESCRIPTION OF SYMBOLS 1 Solar cell module 2 Box body 2a Opening 3 Box cover 4 Mounting surface 5 Outer wall structure 6 Circuit storage part 7 Output lead wire 8 External cable 9 Outlet 12 Circuit part 13 Terminal board 14 Bypass diode 16 Inner cover 17 Outer cover 18 1st Space 19 second space 20 partition wall 21 first filler 22 second filler

Claims (3)

A terminal box constituting the output part of the solar cell module,
The terminal box includes a terminal plate to which an output lead wire extending from the solar cell module is joined, a first space including a joint portion between the output lead wire and the terminal plate, and a second space not including the joint portion. An assembly in which the partition wall partitioning the internal space is integrated by passing the terminal plate through the hole of the partition wall;
A circuit housing portion for housing the assembly by having a guide groove for guiding the partition wall on an inner wall, and inserting the partition wall into the guide groove;
With
The second space is filled with a second filler solidified by being dammed to the partition wall ;
The terminal box for a solar cell module, wherein the first space is narrower than the second space, and is filled with a first filler after the solidification and after the joining . 2. The solar cell module terminal box according to claim 1, wherein the first space is a space facing an insertion opening into which an output lead wire is further drawn. An assembly step of forming an assembly in which a terminal plate to which an output lead wire extending from the solar cell module is joined is integrated into a hole formed in advance in the partition wall; and
A storage step of storing the assembly in the circuit storage unit by inserting the partition wall into a guide groove that guides the partition wall of the circuit storage unit on an inner wall;
After the storing step, the partition wall is dammed to a second space, which is an internal space of the circuit storage portion that does not include the planned location for joining the output lead wire and the terminal plate, and is partitioned by the partition wall. and solidifying by filling a second filler,
After the step of solidifying, the step of joining the output lead wire and the terminal plate at the joint planned location,
After the joining step, the first filler is filled in the first space that is narrower than the second space including the planned joining portion and partitioned by the partition wall on the side opposite to the second space. Process,
The manufacturing method of the terminal box for solar cell modules characterized by including.

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