WO2009062326A2 - Junction box for a photovoltaic solar panel - Google Patents
Junction box for a photovoltaic solar panel Download PDFInfo
- Publication number
- WO2009062326A2 WO2009062326A2 PCT/CH2008/000455 CH2008000455W WO2009062326A2 WO 2009062326 A2 WO2009062326 A2 WO 2009062326A2 CH 2008000455 W CH2008000455 W CH 2008000455W WO 2009062326 A2 WO2009062326 A2 WO 2009062326A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- junction box
- solder
- coupling
- zone
- contact
- Prior art date
Links
- 229910000679 solder Inorganic materials 0.000 claims abstract description 106
- 230000008878 coupling Effects 0.000 claims abstract description 62
- 238000010168 coupling process Methods 0.000 claims abstract description 62
- 238000005859 coupling reaction Methods 0.000 claims abstract description 62
- 239000000463 material Substances 0.000 claims description 35
- 238000000034 method Methods 0.000 claims description 16
- 238000005452 bending Methods 0.000 claims description 10
- 238000004519 manufacturing process Methods 0.000 claims description 9
- 239000000853 adhesive Substances 0.000 claims description 7
- 230000001070 adhesive effect Effects 0.000 claims description 7
- 239000011521 glass Substances 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 239000006260 foam Substances 0.000 description 4
- 239000004033 plastic Substances 0.000 description 4
- 229920003023 plastic Polymers 0.000 description 4
- 238000007789 sealing Methods 0.000 description 4
- 238000003466 welding Methods 0.000 description 4
- 230000007423 decrease Effects 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 230000003647 oxidation Effects 0.000 description 3
- 238000007254 oxidation reaction Methods 0.000 description 3
- 239000004417 polycarbonate Substances 0.000 description 3
- 229920000515 polycarbonate Polymers 0.000 description 3
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 2
- 229920004142 LEXAN™ Polymers 0.000 description 2
- 239000004418 Lexan Substances 0.000 description 2
- 238000013005 condensation curing Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 238000004382 potting Methods 0.000 description 2
- 229920002379 silicone rubber Polymers 0.000 description 2
- 239000004945 silicone rubber Substances 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- 229910000906 Bronze Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004831 Hot glue Substances 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 239000010974 bronze Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000007257 malfunction Effects 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/66—Structural association with built-in electrical component
- H01R13/6608—Structural association with built-in electrical component with built-in single component
- H01R13/6641—Structural association with built-in electrical component with built-in single component with diode
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
- H01R11/03—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations
- H01R11/09—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations the connecting locations being identical
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R31/00—Coupling parts supported only by co-operation with counterpart
- H01R31/06—Intermediate parts for linking two coupling parts, e.g. adapter
- H01R31/065—Intermediate parts for linking two coupling parts, e.g. adapter with built-in electric apparatus
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49204—Contact or terminal manufacturing
- Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49204—Contact or terminal manufacturing
- Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
- Y10T29/49222—Contact or terminal manufacturing by assembling plural parts forming array of contacts or terminals
Definitions
- the invention relates to a device for affixing to a photovoltaic solar panel module in order to provide a connection between solar panel modules of a photovoltaic array or a connection between solar panel modules and other devices such as a bus system or cables.
- junction boxes Such devices are also known under the designation junction boxes or connection boxes. Such junction boxes are well known from prior art. Usually said junction boxes provide an electrical contact between contacts of a photovoltaic solar panel and cables which are connected to a further photovoltaic solar panel or to any other device, such as a distribution box or a bus system
- EP 1 501 157 shows an example of such a junction box.
- Contacts of a solar panel extend above the surface on which the junction box is arranged and protrude through openings into the interior of the junction box. Said contacts are received by a contact element that is arranged in the interior of the junction box.
- the junction box comprises openings through which cables can be inserted into the interior of the junction box in order to be received by said contact element.
- the contact element provides an electrical contact between the contacts of a solar panel and the wire.
- Said junction box further comprises an opening in order to provide access to the interior of the box. The opening is sealed by means of a sealing ring and a lid.
- the junction boxes or connecting boxes have weatherproof properties.
- weatherproof properties include the resistance against moisture, water or temperature differences.
- the inflow of water into the interior of such a junction box should be avoided under any circumstances, since it may cause short circuits and/or lead to corrosion of the metallic connection elements.
- the presence of water in the interior of a junction box is not only a result from water that enters through leaky portions of the junction box, but may also be the result of water condensation. However, the presence of water decreases the operational reliability and the lifetime of such a junction box.
- junction boxes are exposed to thermal differences that result in thermal expansion of the junction box itself. Such an expansion can lead to a malfunction of a sealing element, such as the above mentioned sealing ring.
- a further drawback of devices according to prior art is the manufacturing process. Still a high percentage of such a box is manufactured by hand. This leads to high costs. Furthermore quality issues may also arise, since precision and reliability of each craftsman is variable.
- the electrical connection of the electrical contacts between the junction box and the solar panel are designed as a spring contacts.
- Such spring contacts are susceptible to oxidation and mechanical influences. Said negative influences can lower the efficiency of a solar panel arrangement.
- An object of the present invention is to provide a junction box, which does not have the disadvantages of the junction boxes known from prior art.
- the junction box shall be manufactured and/or applied to a solar panel in an automatic manner, while at the same time the electrical connection between elements of the junction box and the solar panel shall be optimized.
- a junction box for a solar panel comprises a housing, a lid, a first connector and a second connector.
- the housing comprises sidewalls and a top wall defining an interior space.
- the first coupling comprises a first contact element and the second coupling comprises a second contact element.
- Said contact elements penetrate at least one of the sidewalls, so that the contact elements provide an electrical contact from external contact elements to internal contact elements, such as solder tails.
- Internal contact elements are arranged at least partially in said interior space.
- the top wall comprises an opening extending only partially in said top wall. Said opening is located such in the top wall that access to said solder tails in a substantially perpendicular direction to the surface of a solar panel for connecting the solder tail to the solar panel is provided.
- the junction box according to the present invention can be mounted in an automatic manner for example in an assembly line.
- the top wall comprises an outer sidewall that extends substantially perpendicular from the top wall and that surrounds substantially the outer circumference of the top wall, so that an overflow space is defined by the top wall and the outer sidewall.
- the opening is substantially surrounded by an inner sidewall which extends substantially perpendicular from said top wall.
- Such a sidewall limits the overflow space to the opening.
- the filling material is preferably a potting compound (pottant) or a foam.
- filling material is injectable into the interior space through said opening, so that the interior space is fully filled with said filling material, and in that the opening is closeable with the lid.
- the filling material is a material that is injected in a liquid state and hardens after being injected.
- the filling material is a pottant or a foam.
- the lid comprises a wall extending substantially perpendicular to the lid and having a shape that fits into the opening in the top surface.
- Such a wall provides a good and easily sealable contact between the opening and the lid.
- the lid comprises further embossments that are arranged such that they extend through the opening into the interior space when being mounted onto the housing. Due to said further embossments filling material is forced to flow through the opening into the overflow space, when said lid is mounted onto the housing when filled fully with filling material.
- the lid Due to that overflow the lid is connected to the housing in tightly sealed manner.
- the embossments are advantageous, since they reduce the volume in the interior space so that filling material and air that may be present is forced out of the interior space. Additionally a closure force is provided.
- a method for manufacturing a junction box according to the present invention comprises the steps of providing the first coupling with a first contact element and the second coupling with a second contact element; connecting the first coupling and the second coupling with the housing; providing each of the contact elements with a solder tail; affixing the diode at the first contact element and at the second contact element.
- junction box With such a method a pre-mounted junction box is provided. Said junction box can be mounted on a solar panel.
- a method for providing a solar panel with a junction box comprises the steps of: - Applying adhesive to the junction box base perimeter or flange; arranging the junction box on a surface of a solar panel module; affixing solder tail to the contacts of a solar panel; filling the interior space of the housing with a filling material; and mounting the lid on the top wall, so that parts of the lid, extend into the interior space of the housing.
- the pre-assembled junction box can be mounted onto a solar panel in an effective and automatic manner.
- the arrangement of the opening giving access to the solder tail is a particular advantage in terms of automatic manufacturing.
- a solder element for providing an electrical connection between a first electrical device and a second electrical device comprises a cylindrically shaped contact zone to be contacted to the first electrical device, a resilient zone and a cylindrically shaped transfer zone having a solder zone to be contacted to the second electrical device.
- the axes of the contact zone and of the transfer zone are axially arranged in alignment of a longitudinal axis.
- the resilient zone enables adjustment of the axial distance between the contact zone and the solder zone.
- Such a solder element is particularly advantageous as the adjustment of the length enables the solder element to be used in a flexible manner.
- the resilient zone is arranged between the contact zone and the solder zone.
- the resilient zone is designed as a bending structure, wherein bending of said bending structure results in said adjustment. This allows an easy adjustment of the length.
- the resilient section comprises at least one, preferably at least two, even more preferably at least three to six, resilient web.
- solder element is produced by a stamping and/or forming process.
- Fig. 1 shows a perspective view of a junction box according to the present invention with a lid according to the present invention
- Fig. 2 shows a bottom view of the junction box of figure 1
- Fig. 3 shows a top view of the junction box of figure 1 ;
- Fig. 4 shows a side view of the junction box of figure 1 ;
- Fig. 5 a-b show a perspective view of the lid for the junction box according to figure 1 ;
- Fig. 6 a-b show the junction box according to figure 1 without a lid;
- Fig. 7 a-b show a connector element that is arranged in the junction box;
- Fig. 8 a-b show the connector element of Fig. 7 with a coupling element;
- Fig. 9 a-d show assembly steps of a junction box according to the present invention;
- Fig. 10 a-c show views of a junction box of a further embodiment according to the present invention;
- Fig. 11 a-d show views of a solder element and
- Fig. 12 a, b show views of a weather cover or junction box according to a further embodiment.
- FIGS 1 to 4 show a junction box according to the present invention.
- a junction box comprises preferably a housing I 5 a lid 2, a first coupling 3 and a second coupling 4.
- the junction box according to the present invention is used to provide an electrical contact between a solar cell of solar panel and external contact elements such as cables etc. or other solar cells.
- solar panels have a typical size of 2200 mm x 2600 mm, but can also be smaller or larger. With such solar panels voltages between 70 V and 500 V and currents between 0.1 amps and 10 amps can be produced.
- the junction box according to the present invention can also be used for solar panels providing higher or lower currents or voltages, respectively.
- the housing 1 comprises sidewalls (here a first sidewall 11 and a second sidewall 12) and a top wall 13.
- the sidewalls 11, 12 extend from the top wall 13.
- An interior space 10 is defined by said sidewalls 11, 12 and said top wall 13.
- Said interior space 10 is provided to accommodate electrical contact elements which are in an electrical contact with a solar cell of a solar panel.
- the interior space 10 shall be sealed off from environmental influences such as water, air etc. to prevent oxidation of the electrical contact elements.
- the terms external and internal will be used.
- the term external or exterior space is to be understood that it comprises everything that is arranged outside of the housing 1, whereas the term internal is to be understood as to comprise everything that is arranged within the interior space 10.
- the housing 1 is made of plastics.
- polycarbonate for example Lexan 940-701, is used to provide the housing.
- the housing 1 is preferably injection molded.
- the housing 1 in that embodiment comprises a bottom wall 14 that is designed as a flange 19. Said flange 19 limits the interior space 10 on a side that is opposite to the top wall 13. When the housing 1 is arranged in the surface of a solar panel, said bottom wall 14 or flange 19 faces the surface of the solar panel either its frontside or its backside.
- the flange 19 extends substantially parallel to the top wall 13 from the sidewalls 11, 12 in the external direction. In that case actually the surface of the solar panel limits the interior space 10, wherein the flange 19 acts as a support element and contact element.
- said sidewalls 11, 12 may comprise a plurality of ribs 18.
- said ribs extend on the external surfaces of the sidewalls 11, 12. Additionally or alternatively said ribs can also be arranged on the internal surfaces of the sidewalls 11, 12 that face the interior space 10. If the sidewalls 1 1, 12 are already stiff enough, the ribs 18 may be omitted.
- the first coupling 3 and the second coupling 4 extend from the housing 1.
- the first coupling 3 comprises a first contact element 5 and the second coupling 4 comprises a second contact element 6.
- Said contact elements 5, 6 penetrate at least one of the sidewalls. Thereby said contact elements 5, 6 provide an electrical contact from the external side to the interior side or interior space 10, respectively. With other words an electrical contact is provided by means of said contact elements 5, 6 from an external contact element to internal contact elements.
- An external contact element can be for example a cable of a bus system linking several solar panels.
- An internal contact element can be a solder tail 7 that is arranged to contact a solder zone of a solar cell.
- solder tail 7 is arranged such that its main parts are arranged in the interior space 10/ whereas some parts extend from the interior space 10 to the external space (e.g. environment).
- first coupling element 3 and the second coupling element 4 are made of plastics such as polycarbonate. This means that said coupling elements 3, 4 can be injection molded.
- the housing 1, the first coupling 3 and the second coupling 4 can be molded in one piece.
- FIG. 2 shows the junction box from the bottom side.
- the bottom wall 14 is designed as flange 19 that extends over the whole length of the sidewalls 11, 12.
- the flange 19 is arranged such that it does not extend into the interior space 10.
- a bottom opening 15 is provided which is limited by the sidewalls 11, 12.
- the flange 19 is glued to the surface of a solar panel by means of hot melt adhesive, such as a dow coming HM2500, which is a reactive hot melt neutral cure adhesive.
- the junction box according to the present invention will be placed on a surface of a solar panel. Preferably the junction box is affixed to said surface by means of an adhesive. Afterwards the solder elements will be connected to the solder zones of a solar cell. After that the junction box according to the present invention is mechanically and electrically connected to a solar panel and the interior space 10 will be filled with a filling material, such as a pottant or potting material.
- the filling material can also be a foam. Said filling material is insertable through the opening 16 that is arranged in the top wall 13. Due to the fill in of the filling material the electrical contacts will be covered by the foam so that oxidation is prevented. Furthermore the filling material may have flame retardant properties.
- the pottant or filling material is a silicone rubber such as an RTV pottant.
- a silicone rubber such as an RTV pottant.
- a memontive (GE) TSE3664 condensation-cure flame retardant RTV can be used.
- TSE 3664 is a two-component condensation cure silicone rubber (RTV)..
- the flange 19 extends from the sidewalls 11, 12 in direction of the interior space 10 as well as in the direction to the external side.
- the bottom opening 15 is limited by the flange 19.
- the surface of the solar panel still limits the interior space 10 in the area of the bottom opening 15.
- the diode 8 is arranged such that it is at least partly visible from the exterior when viewed in a direction perpendicular from the top wall 13. Such an arrangement 'is advantageous for quality checks.
- a diode acts as a security device for bypass protection.
- a silicon diode rated lOOOV/lOA is used.
- Figure 3 shows a top view of the junction box according to the present invention. This figure is mainly used to explain the angular arrangement of the first coupling 3 and the second coupling 4.
- a first axis 100 runs through the first coupling element 3 with the first contact element 5 and a second axis 200 runs through the second coupling element 4 with the second contact element 6. If a plug is connected to said first or second coupling elements 3, 4, it will be inserted in direction of said axis.
- the first axis 100 and the second axis 200 lie in the same plane, which plane is parallel to the surface of a solar panel or to the bottom surface 14 or flange 19, respectively.
- first coupling element 3 and the second coupling element 4 are arranged angular with respect to each other.
- first axis 100 is angular to the second axis 200. This is designated in the figure by means of an angle ⁇ .
- Figure 5a and 5b show the Hd 2 from the front side (Figure 5a) and from the back side ( Figure 5b).
- Said lid 2 has a shape that is substantially congruent with the surface of the top wall 13.
- the Hd comprises further embossments 21.
- Said embossments 21 extend also substantially perpendicular to the bottom surface 2a.
- the embossments 21 are arranged within the wall 20.
- Preferably the embossments 21 have a larger height than the wall 20.
- the Hd comprises indicators 23 and 24.
- Such- indicators 23, 24 indicate which polarity needs to be contacted to the respective coupling'2, 3.
- the lid 2 is made of plastics.
- polycarbonate for example Lexan 940- 701, is being used to provide the housing.
- the lid 2 is preferably injection molded.
- Figures 6a and 6b show the junction box according to the present invention without the lid 2.
- the top wall 13 comprises an opening 16.
- the opening 16 is surrounded by an inner sidewall 171.
- This inner sidewall 171 extends preferably perpendicular from the top wall 13.
- the opening 16 is fully surrounded by the inner sidewall 171.
- An outer sidewall 170 is arranged around the outer boundary of the top wall 13.
- the top wall 13 is folly surrounded by the outer sidewall 170.
- the top wall 13, the outer sidewall 170 and the inner sidewall 171 provide a space which can be designated as overflow space 17.
- the interior space 10 will be fully filled with filling material .
- some parts of the filling material will overflow from the interior space 10 to the overflow space 17 due to the embossments 21 and/or the first wall 20 that are arranged on the inner surface 2a of the lid 2.
- filling material can flow through that gap as the lid is being pushed into position. Hence the filling material is forced to flow through the opening 16 in the top wall 13 into the overflow space 17.
- FIG. 7a and 7b show the contact elements 5, 6 together with the internal contact elements
- the design of the contact elements 5, 6 is such that they can receive an external female or male connector on one end. On the other end the internal contact element here the solder tail 7 is connected to the contact elements 5, 6.
- Figure 9a - 9d illustrate a method for manufacturing a junction box according to the present invention.
- the method for manufacturing a junction box comprises the steps of: providing the first coupling 3 with a first contact element 5 and the second coupling 4 with a second contact element 6; (Fig. 9a) connecting the first coupling 3 and the second coupling 4 with the housing 1 (Fig. 9d). providing each of the contact elements 5, 6 with a solder tail 7; (Fig. 9b) affixing the diode 8 at the first contact element 5 and at the second contact element 6;
- solder tails 7 are preferably welded to the contact elements by means of an automatic resistance welding machine. The same applies to the diode.
- the first coupling 3 and the second coupling 4 are connected to the housing 1 means of an ultrasonic welding procedure.
- the result is a pre-assembled junction box that is ready to be connected to a solar panel.
- junction box is affixed by means of an adhesive as it is described above.
- the opening 16 is arranged such that access to the solder tails 7 is being provided through the opening 16. Access is provided in a direction substantially perpendicular to the surface of the solar panel. This means that parts of a robot in an assembly can enter into the interior space 10 through the opening 16 in order to solder the solder tails 7 to the solder zone of the solar cell.
- Figures 10a - 10c show a further embodiment of a junction box according to the present invention. It is noted that features of this embodiment can be combined with features of other embodiments and vice- versa to further embodiments.
- the junction box 1 comprises sidewalls 1 1 , 12 that are designed stiff enough that the placement of ribs in order to stiffen the sidewalls 1 1, 12 is not necessary. Furthermore the inner sidewall 171 that encompasses the opening 16 in the top wall 13 ' comprises snap-in elements 172 for securing the lid 2.
- solder tail 9 which may also be designated as solder element or solder tag can be used not only with the junction box as described herein, but with every other electrical device. The same applies to the solder tail 7 as it is described above.
- Figure 10b and 10c show that the solder tail 9 is arranged in the same manner as in the previous embodiment. Parts of the solder tails 9 extend by a protruding height having a measure D from the outer surface of the bottom wall 14.
- the measure D is preferably equal to or larger than the thickness of a glass pane of a solar panel, so that the solder tails 9 are able to penetrate through a hole from one side of said glass pane to the other side of said glass pane.
- D is between 1 mm and 10 mm. In other embodiments D is between 3 mm to 5 mm.
- FIGS 11 a to l ib show the solder element 9 in a perspective view.
- the solder element 9 preferably comprises a contact zone 91, a resilient zone 92, a transfer zone 93 and a solder zone 94.
- the solder element 9 comprises a middle axis A along which the length of the solder element 9 is adjustable. The length is considered to be the distance between the contact zone 91 and the solder zone 94.
- the resilient zone or compliant zone 92 comprises at least one, here four, resilient or compliant webs 920.
- the resilient webs 920 are designed such that they are deformable in order to adjust the length of the solder element 9, i.e. the distance between the contact zone 91 and the solder zone 94. Said resilient webs are also designed as a bending structure, as the adjustment of the length of the solder element 9 results in a bending motion to parts of the web 920.
- the resilient webs 920 comprises an upper section 921 and a lower section 922.
- the upper section 921 is connected to the tubular body 910 and extends angular with respect to the middle axis A.
- the solder zone 94 is provided to establish an electrical contact with a second electrical device (e.g. a solar panel). Said solder zone 94 extends from the transfer zone 93. In the present embodiment there is one solder zone 94 arranged but in other embodiments it is also possible to arranged more than one solder zone 94.
- the solder zone 94 here extends angular from the tubular body of the transfer zone 93.
- Figure 11 c shows the solder element 9 according to the present invention in a normal non- compressed state
- Figure Hd shows the solder element 9 in a compressed state
- the length of the solder element 9 in the normal non-compressed state is designated with Ll.
- the elongation of the solder element 9 can be positive or negative. Positive elongation results in a length that is larger than length Ll, whereas negative elongation results in a length that is shorter than length Ll.
- Negative elongation is shown in Figure 1 Id, whereas the length of the solder element 9 is designated with L2. Due to the design of the compliant section 92, the solder element 9 does not return from a compressed state into the non- compressed state as soon as the force F disappears. However, in other embodiments where the compliant section 92 is resilient the solder element 9 does return from a compressed state into the non-compressed state.
Landscapes
- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Electromagnetism (AREA)
- General Physics & Mathematics (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- Computer Hardware Design (AREA)
- Physics & Mathematics (AREA)
- Power Engineering (AREA)
- Photovoltaic Devices (AREA)
- Manufacturing & Machinery (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Coupling Device And Connection With Printed Circuit (AREA)
- Connection Or Junction Boxes (AREA)
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN2008801157671A CN101855732B (en) | 2007-11-12 | 2008-10-30 | Junction box for a photovoltaic solar panel |
US12/742,554 US8500462B2 (en) | 2007-11-12 | 2008-10-30 | Junction box for a photovoltaic solar panel |
EP08849190.7A EP2210281B1 (en) | 2007-11-12 | 2008-10-30 | Junction box for a photovoltaic solar panel |
ES08849190T ES2428885T3 (en) | 2007-11-12 | 2008-10-30 | Connection box for a photovoltaic solar panel |
JP2010533405A JP5395802B2 (en) | 2007-11-12 | 2008-10-30 | Connection box for photovoltaic solar panels |
US13/915,188 US9059350B2 (en) | 2007-11-12 | 2013-06-11 | Junction box for a photovoltaic solar panel |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US98722907P | 2007-11-12 | 2007-11-12 | |
US60/987,229 | 2007-11-12 | ||
EP08405011A EP2058867A3 (en) | 2007-11-12 | 2008-01-16 | Junction box for a photovoltaic solar panel |
EP08405011.1 | 2008-01-16 |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/742,554 A-371-Of-International US8500462B2 (en) | 2007-11-12 | 2008-10-30 | Junction box for a photovoltaic solar panel |
US13/915,188 Division US9059350B2 (en) | 2007-11-12 | 2013-06-11 | Junction box for a photovoltaic solar panel |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2009062326A2 true WO2009062326A2 (en) | 2009-05-22 |
WO2009062326A3 WO2009062326A3 (en) | 2009-07-09 |
Family
ID=40386437
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/CH2008/000455 WO2009062326A2 (en) | 2007-11-12 | 2008-10-30 | Junction box for a photovoltaic solar panel |
Country Status (7)
Country | Link |
---|---|
US (2) | US8500462B2 (en) |
EP (4) | EP2058867A3 (en) |
JP (3) | JP5395802B2 (en) |
CN (1) | CN101855732B (en) |
ES (1) | ES2428885T3 (en) |
TW (1) | TWI453937B (en) |
WO (1) | WO2009062326A2 (en) |
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EP2485275A1 (en) | 2011-02-03 | 2012-08-08 | Multi-Holding AG | Photovoltaic module with junction box |
CN102769052A (en) * | 2011-04-14 | 2012-11-07 | 乐清市信达利实业有限公司 | Junction box with cable connector |
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Also Published As
Publication number | Publication date |
---|---|
EP2637219B1 (en) | 2015-07-08 |
EP2637219A3 (en) | 2014-01-15 |
US9059350B2 (en) | 2015-06-16 |
TW200931673A (en) | 2009-07-16 |
CN101855732A (en) | 2010-10-06 |
JP2013232675A (en) | 2013-11-14 |
EP2210281A2 (en) | 2010-07-28 |
US20120060919A1 (en) | 2012-03-15 |
EP2210281B1 (en) | 2013-07-17 |
EP2058867A2 (en) | 2009-05-13 |
EP2058867A3 (en) | 2009-07-22 |
JP5694454B2 (en) | 2015-04-01 |
JP5395802B2 (en) | 2014-01-22 |
ES2428885T3 (en) | 2013-11-12 |
EP2637218A1 (en) | 2013-09-11 |
EP2637219A2 (en) | 2013-09-11 |
JP2011503884A (en) | 2011-01-27 |
WO2009062326A3 (en) | 2009-07-09 |
JP2013258149A (en) | 2013-12-26 |
US8500462B2 (en) | 2013-08-06 |
CN101855732B (en) | 2012-06-20 |
TWI453937B (en) | 2014-09-21 |
US20130276856A1 (en) | 2013-10-24 |
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