WO2010052207A2

WO2010052207A2 - Connecting device for a photovoltaic solar module

Info

Publication number: WO2010052207A2
Application number: PCT/EP2009/064513
Authority: WO
Inventors: Guenter Feldmeier; Norbert Geister; Heinz Peter Scherer; Andreas Woeber
Original assignee: Tyco Electronics Amp Gmbh
Priority date: 2008-11-07
Filing date: 2009-11-03
Publication date: 2010-05-14
Also published as: DE102008056282A1; WO2010052207A3

Abstract

A connecting device (10, 40) for a photovoltaic solar module (100) for connecting at least one external electrical conductor (2) to an electrical connecting system (3, 104) of the solar module (100) comprises an outer housing (11, 41) which may be arranged on the solar module (100) and current-carrying components (21, 22, 31) which are overmoulded with plastics material (9, 60). The connecting device further comprises a UV-radiation-resistant housing cover (16, 46).

Description

CONNECTING DEVICE FOR A PHOTOVOLTAIC SOLAR MODULE

The present invention relates to a connecting device for a photovoltaic solar module in accordance with the preamble of claim 1.

A photovoltaic solar module typically comprises a panel-like layer arrangement with solar cells, which generate electrical energy by a photovoltaic effect, arranged between the layers. For example, a layer arrangement of such a solar module comprises a planar, radiation-side layer, for example in the form of a glass cover with a low degree of absorption, and a planar second layer, which is arranged on the back of the solar module and, for example, is implemented in the form of a back glass cover. The solar cells are arranged between these layers in an appropriate intermediate space, and are connected to each other within the layer arrangement by an electrical connecting system. Solar module embodiments are known in which the electrical connecting system of the solar cells is connected outwards, for example to a load, on the back of the solar module, remote from the radiation side, by means of electrical conductors, for example in the form of connecting foils. These connecting foils are connected in a connecting device, for example in the form of a connection box or junction box, to one or more electrical conductors of a connecting line, also called a solar connecting line. For this purpose, such a connecting device has a current-carrying arrangement arranged in a connector housing, to which on the one hand one or more connecting foils of the solar module and on the other hand one or more electrical conductors of the one or more connecting cables are connected. Additionally, such a connecting device usually contains one or more diodes, which are provided to prevent equalising currents between solar cells in sunlight and solar cells in shade, which supply different solar currents and solar voltages. With the aid of such so-called bypass diodes, the module can continue to operate even in partial shade and with correspondingly reduced power.

A connecting device for connecting external connecting cables to a solar panel is known, for example from JP 2001 298206 A. The connecting device disclosed therein comprises a connector housing, formed of a plurality of parts and comprising a main housing and a resin moulded part, in which connection plates are moulded which are connected to external connecting cables. An opening is provided in the main body, inside which the connection plates are connected to connecting conductors of the solar module. The module-side ends of the connection plates thus project into the opening in the main housing, the opening being cast in with a resin following connection of said components to one another. The main housing is connected at a side wall to the resin moulded part, in which the connecting cables are embedded.

EP 0 999 601 Al discloses a connecting device in which a plurality of bypass diodes are connected to corresponding connections in the upper housing portion, before the housing portion is attached to the solar panel via the opening in its lower face by way of a lower connection arrangement, through which solar panel the individual conductors of the solar module are led and connected to corresponding connections. When attaching the upper housing portion, its connections are connected to the respective connections of the lower connection arrangement.

The object of the present invention is to provide a connecting device of the aforementioned type which can be produced in a relatively simple and cost effective manner using the simplest components possible.

The present object is achieved by a connecting device according to the features of claim 1.

The connecting device according to the invention, which is constructed for connecting at least one external electrical conductor, for example an external connecting cable, to an electrical connecting system of a photovoltaic solar module, comprises an outer housing which can be arranged on the solar module. The connecting device comprises current-carrying components, which are overmoulded with plastics material, in particular of the outer housing. A current- carrying component is, for example, a conductor rail, a diode component, a circuit board or the like. The connecting device further comprises a UV-radiation-resistant housing cover.

In one embodiment, the connecting device comprises a plurality of conductor rails arranged side by side. The conductor rails comprise at least a first conductor rail having a first contact region for connection to the electrical conductor and a second contact region for connection to the electrical connecting system of the solar module, and a second conductor rail having a contact region for connection to the electrical connecting system of the solar module. At least one diode component which is attached to the conductor rails and interconnects the first and second conductor rails is further provided. At least part of the conductor rails and the diode component are overmoulded with plastics material of the outer housing. At least one opening, which is provided with the housing cover and is in particular able to be sealed, is formed on the outer housing, on a side of the outer housing remote from the solar module, across the contact regions of the first and second contact rails, which are provided for connection to the electrical connecting system of the solar module.

The invention thus offers the advantage that it is possible to make considerable cost savings compared with conventional connecting devices. This is achieved, in particular, by the fact that it is possible for the connecting device according to the invention to be smaller, thus also enabling material savings to be made. It is also possible to use fewer, and therefore simpler components, it also being possible for production and assembly of the parts to be as automated as possible. The invention also makes it possible for the connecting device to be manufactured in a largely automated manner and also to be assembled automatically by the user during installation. Automated handling by the user of the connecting device is thus achieved, in contrast to the previously known handling method.

In particular, in accordance with the invention, substantially identical current-carrying components such as conductor rails may be used, an appropriate number of which can each be assembled individually as required. The conductor rails may be punched, for example, out of a corresponding metal carrier or produced in another manner and correspondingly bent as required, so as to produce the respective contact regions. Depending on the number of solar cells or solar cell strands to be connected, a corresponding number of conductor rails may be used. The connecting device can thus be flexibly adjusted to different requirements.

In one aspect of the invention, according to a first embodiment at least one opening in the outer housing, which opening can be sealed with the housing cover, is filled with a filler material. In particular, the opening of the outer housing is filled with the filler material before the opening is provided with the housing cover. The opening in the outer housing has in particular the purpose of providing access and allowing the user to place the current-carrying components, in particular the conductor rails, in contact with corresponding conductors of the connecting system of the solar module. After the connection of these components, the connection space inside the opening is sealed or filled with the filler material, which is for example formed in such a way that the connection space inside the opening is hermetically sealed or filled by the filler material. A one-component or two-component resin, such as epoxy resin or the like, may for example be used as the filler material. By providing the housing cover, it is further ensured that the filler material can also endure prolonged use during which the connecting device is exposed to UV radiation, since the housing cover protects the filler material provided in the opening from the effects of the UV radiation. This also has the advantage that a material which seals very tightly and has a particular expansion flexibility in relation to temperature variations can be used as a filler material, but the material need not be UV-resistant. In this way, the filler material can be optimised in terms of sealing properties without having to take UV resistance into account at the same time.

In one embodiment of the invention, it is thus provided for only a simple housing cover to be used, which need not seal the opening of the outer housing tightly. In this embodiment, a housing cover is thus provided which is resistant to UV radiation and can be attached to the opening of the outer housing without the use of an additional sealing element. The filler material can thus seal the current-carrying components inside the connecting device against external environmental effects, in such a way that it is not necessary for a separate sealing element to be attached to the opening of the outer housing between the housing opening and the housing cover.

In a further aspect of the invention, the housing cover can be attached to an opening in the outer housing using an additional sealing element in order to seal the opening in the outer housing tightly against environmental effects. This embodiment may for example be used if the opening of the outer housing is not filled with filler material or if the opening is filled with filler material which does not hermetically seal the opening. When overmoulding the current-carrying components, such as at least part of the conductor rails and the diode component, with plasties material, the shape of the outer housing is already created, at least in part, an opening in the outer housing remaining open and ensuring that the contact region of the conductor rails can be accessed and contacted by the connecting conductors of the solar module. By overmoulding the current-carrying components to form a complete connecting housing, better thermal dissipation of the heat produced in the diode components is achieved in such a way that the total amount of lost heat can be conducted towards the exterior of the connecting device in an improved manner.

Overmoulding at least part of the conductor rails and the diode component with a first plastics material to form a functional unit, before the final creation or formation of the outer housing, poses the advantage that the functional unit thus formed can be handled as a unit which can be assembled separately during the production process. By producing the functional unit, a component is created which combines the current-carrying components of the connecting device to form a compact unit which is relatively robust and, owing to these robust properties, can be handled comparatively simply in the production process for the connecting device.

According to one embodiment of the invention, the functional unit forms at least part of an outer face of the connecting device. For example, the functional unit forms at least part of an outer face of the connecting device facing the solar module, which face may be mounted on the solar module, and/or at least part of an outer face of the connecting device remote from the solar module. It is thus possible for the outer housing to be relatively planar.

According to this feature of the invention, the functional unit or the plastics material thereof thus forms part of the outer housing of the connecting device. The outer housing is thus formed of two components and comprises on the one hand the first plastics material which forms the functional unit and on the other hand the second plastics material which forms the entirely finished outer housing. In this regard, different materials may be used as the first and second plastics materials. However, it is also possible to use the same plastics material for both components of the outer housing. It is therefore advantageous to use plastics materials which bond well together so the entire outer housing is configured entirely as a compact unit. For example, the plasties material of the functional unit is formed as an approximately rectangular block which extends transverse to the conductor rails. In this way, a compact unit is formed when producing the functional unit.

In particular, a thermoplastic material may be used as the plastics material of the outer housing. In this case in particular, a housing of a connecting device which surrounds the current-carrying arrangement inside the housing and defines the outer housing of the connecting device is to be understood as the outer housing.

In one embodiment of the invention, the connecting device comprises at least one contact which is formed in a first region for connection to the first contact region of the first conductor rail and which is formed in a second region for connection to the external electrical conductor, the contact being overmoulded by the outer housing in part. In this embodiment, a possibility for connecting the external electrical conductor is provided when forming the outer housing in that the contact is overmoulded in part with the plastics material of the outer housing.

In particular, the contact is formed as part of a plug connection which is arranged between the first conductor rail and the external electrical conductor. In particular, the contact may be part of a plug device which is arranged on a connecting duct of the outer housing in order to cooperate with a corresponding plug device on the external electrical conductor.

In a further embodiment of the invention, the external electrical conductor is overmoulded by the outer housing at least in part. In this way, in this embodiment the external electrical conductor, for example in the form of a connecting cable, or a plurality of conductors or connecting cables of this type is/are already integrated during the forming of the outer housing This provides an extremely robust and compact connecting device for connection to a photovoltaic solar module.

Further advantageous embodiments and developments of the invention are given in the dependent claims. The invention is explained in more detail below with reference to the figures shown in the drawings, which figures illustrate embodiments in relation to the present invention and in which:

Fig. 1 is a schematic cross-sectional view of an exemplary photovoltaic solar module which is connected to a connecting device according to the invention,

Fig. 2 is a schematic perspective view of a first embodiment of a connecting device according to the invention,

Fig. 3 is a schematic illustrative view of components of the first embodiment of a connecting device according to the invention in accordance with Fig. 2,

Figs. 4 and 5 show embodiments of current-carrying components of a connecting device according to the invention in an intermediate production stage,

Fig. 6 is a schematic perspective view of a second embodiment of a connecting device according to the invention,

Fig. 7 is a schematic illustrative view of components of the connecting device according to Fig. 6,

Fig. 8 shows part of a further embodiment of a connecting device according to the invention, in which the current-carrying components are combined to form a functional unit and overmoulded.

Fig. 1 is a schematic cross-section of a photovoltaic solar module, which is provided with a connecting device in the form of a junction box or a connection box. The solar module 100 comprises a layer arrangement with a planar, radiation-side first layer 101, which may be in the form of a glass plate or a foil-type layer. The solar module 100 also comprises a planar second layer 103 which is remote from the radiation side and may also be in the form of a glass plate or a foil-type layer. In this embodiment, the layers 101 and 103 are configured as respective glass plates. Between the two layers 101 and 103, there is at least one solar cell 102 or an arrangement of a plurality of solar cells 102, which supply electrical energy when they are irradiated with light, owing to a photovoltaic effect. The solar cell(s) 102 is/are connected to an electrical connecting system 104. This is only indicated schematically in Fig. 1 and its purpose is, in particular, to interconnect the solar cell(s) and to connect them to the outside world electrically. The electrical connecting system 104 comprises, for example, a copper foil, which on one side is contacted electrically with the back of the solar cell(s) 102, and on the other side merges into one or more electrical conductor(s) 3 of the solar module or is connected to at least one electrical conductor 3 of the solar module, said electrical conductor being, for example, in the form of a connecting foil or connecting ribbon. Via a film conductor 3 of this type, the electrical connecting system 104 of the solar module 100 can be connected to an external connecting line 2, for example in the form of a solar connecting cable.

As also shown in Fig. 1, a connecting device 10 or 40 (as described below) is fixed to the back of the layer 103, which forms an outer face of the solar module, for example by being adhesively bonded by way of an adhesive 107. Furthermore, the layer 103 comprises a throughhole 105, through which the electrical conductor 3, which is in the form of a film conductor for example, may be guided towards the connecting device.

Fig. 2 shows a schematic perspective view of an embodiment of a first variant of a connecting device according to the invention. The composition and individual components thereof are made clear in particular by viewing the combination of Fig. 3, 4 and 5, which show respective embodiments of individual components of the connecting device.

The connecting device 10 comprises an outer housing 11 which may be arranged on the solar module 100 in accordance with Fig. 1. In particular, the outer housing 11 is configured in such a way that a lower face 13 may be applied against one of the layers 101, 103 of the solar module 100 according to Fig. 1 and, for example, may be fixed to the solar module using an adhesive or sealant. An opening (not shown) is provided in the lower face 13 of the outer housing 11, via which opening the film conductors 3 of the electrical connecting system of the solar module may be inserted inside the outer housing 11. The lower face 13 of the outer housing 11 has a substantially planar surface which is suitable for mounting on the solar module 100, which is also planar, and may be adhesively bonded in a correspondingly planar manner. The outer housing is made of the plastics material, which may for example be a thermoplastic or thermoset material.

In the present case, two connecting ducts 12, which are provided with respective plug connection devices 19, are provided in one of the side walls 15 of the outer housing 11, in Fig. 2 and 3 in the side wall pointing forwards, so as to connect the connecting cable 2 (not shown in Fig. 2 and 3) to electricity-carrying components inside the outer housing 11. An opening 18, which can be sealed with a housing cover 16, is formed on the upper face 14 of the outer housing 11, and thus on the side of the outer housing remote from the solar module. The housing opening 18 acts in particular to connect the film conductor 3 of the solar module 100 (Fig. 1) to current-carrying components which are arranged in the outer housing 11, as will be explained in greater detail hereinafter. After these components have been connected, the opening 18 can be filled with a filler material 17, as will be discussed in greater detail hereinafter.

Fig. 4 and 5 show exemplary current-carrying components of a current-carrying arrangement which are arranged inside the outer housing 11. In the present case, the current-carrying arrangement comprises four conductor rails 21 to 24. The arrangement of the conductor rails 21 to 24 should be seen only as an example, and can vary according to requirements. In particular, the number of conductor rails used may also vary according to requirements and may, for example, only include conductor rails 21 and 22. In the present case, the two outer conductor rails 21 and 24 comprise a respective contact region 51 which can be connected to an external electrical conductor. In the embodiment according to Fig. 4, the contact regions 51 of the conductor rails 21 and 24 are connected to an electrical conductor of a respective connecting cable 2. The electrical conductors of the connecting cables 2 may in this case be welded, soldered and/or crimped to the conductor rails 21 and 24 so as to form a corresponding electrical connection. In addition, the conductor rails 21 and 24 comprise a respective second contact region 52 which is provided for connection to the electrical connecting system of the solar module, more precisely to the film conductors 3 thereof. In the present embodiment, the conductor rails 21 and 24 are bent upwards in the second contact region 52 in such a way that a film conductor of the electrical connecting system of the solar module, which conductor leads out from the layer arrangement of the solar module, can be attached to the upwardly bent portion inside the contact region 52. However, the conductor rails may also extend in a straight line in the contact regions 52. As is shown in Fig. 8 in connection with another embodiment, such a film conductor or the like may be arranged on the upwardly curved portion inside the contact region 52 and fixed to a spring member 56, which in this case is in the form of an omega spring. In this regard it is also possible for the respective film conductor to be welded or soldered to the contact region 52 of the conductor rails. The respective film conductor of the connecting system is not shown in Fig. 2 to 8.

The two conductor rails 22 and 23 arranged in the middle are connected at their end regions merely to a corresponding film conductor of the connecting system of the solar module. For this purpose, the conductor rails 22 and 23 comprise contact regions 52 which are configured in accordance with the conductor rails 21 and 24 and are connected to respective film conductors in the same way as described with reference to the conductor rails 21 and 24.

Fig. 5 shows a variant, in accordance with which and in contrast with the embodiment according to Fig. 4, a contact 54 is connected to the respective conductor rails 21 and 24 in the contact regions 51 of the conductor rails 21 and 24. For example, the contact 54 is connected to the conductor rail 21 or 24 by way of a welded, soldered and/or crimped connection. The contact 54 is formed in the region remote from the conductor rails for connection to an external electrical conductor. In particular, the contact 54 is formed as part of the plug connection 19 (shown schematically in Fig. 2 and 3), which is arranged between the conductor rail 21 or 24 and the connecting cable 2. Viewing Fig. 2 and 5 in conjunction, the contact 54 is, in particular, part of a respective plug device 19, which is arranged on one of the connecting ducts 12 of the outer housing 11 and cooperates with a corresponding plug device on the connecting cable 2 (not shown). A connecting cable 2 can thus be connected to the corresponding contact 54 via a simple plug connection at the connecting duct 12, in such a way that the corresponding conductor rail is connected to the connecting cable. It is thus advantageous for the contact 54 to be overmoulded by the outer housing 11.

In contrast, in the embodiment according to Fig. 4 the connecting cable 2 is overmoulded, at least in part by the outer housing, in the region of the connecting ducts 12, in which region the connecting cable 2 is connected to the corresponding conductor rail 21, 24. This type of embodiment is shown in Fig. 6 by way of example, in connection with an embodiment of the invention which is explained in greater detail hereinafter.

As is also shown in Fig. 4 and 5, substantially identical and/or simple conductor rails 21 to 24 are used as current-carrying components, which are made from a metal strip for example and are optionally bent. These conductor rails 21 to 24 are assembled individually in a tool in such a way that the conductor rails 21 to 24 are arranged substantially parallel to one another. A diode component 31 comprises diode connecting wires 35 which are each attached to one of the conductor rails 21, 22 and are electrically connected to the respective conductor rail. In particular, one of the diode connecting wires 35 is attached to the conductor rail 21 and electrically connected to said rail, whilst the other, opposite diode connecting wire 35 of the diode 31 is attached to the second conductor rail 22 and electrically connected to said rail. The first and second conductor rails 21, 22 are thus electrically connected to one another via the diode component 31. A third conductor rail 23 and a fourth conductor rail 24 are arranged beside the conductor rail 22 and are similarly connected to further diode components 32 and 33 which, with their respective diode connecting wires 35, are each attached to one of the conductor rails 22 to 24 and are electrically connected with the respective conductor rail. The diode component 32 thus connects the conductor rails 22 and 23 to one another, whilst the diode component 33 connects the conductor rails 23 and 24 to one another. The diode components 31 to 33 are configured as annular diodes in the present embodiment, the respective diode body being arranged between each of the interconnected conductor rails and in each case extending in a space-saving manner below and above the conductor rails. The conductor rails and diodes can thus be arranged in a space-saving manner.

In one embodiment, it is possible for the contact regions 52 of the conductor rails 21 to 24 to be arranged rotated by 90° in the horizontal direction, in order optionally to be able to connect better to the respective film conductors 3 of the solar module. In addition or alternatively, the contact regions 52 may also be provided with a cut-out if this facilitates the contact.

The diode components 31 to 33 and the conductor rails 21 to 24 are arranged in such a way that the respective diode connection wires 35 lead out of the respective diode component 31 to 33 substantially in a straight line and are also connected to the respective conductor rail in this manner leading out in a straight line. The diode connecting wires as well as the contacts 54 and/or the electrical conductors of the connecting cable 2 may be arranged in corresponding crimps of the conductor rails as preformed contact portions and connected to the respective conductor rail by way of welding, soldering or crimping. In this embodiment, it is not necessary to angle off the diode connecting wires for contact with the respective conductor rails, for example for vertical insertion into a respective conductor rail. Instead, the respective diodes can be applied in the respective contact portion in the state in which they are supplied, with diode connection wires leading out in a straight line, and be connected to the corresponding conductor rail. By way of this arrangement and by way of the arrangement of the diode bodies between the respective conductor rails 21 to 24, said current-carrying parts may be arranged together in a space-saving manner, in such a way that the space taken up by the current-carrying components inside the outer housing of the connecting device can be reduced and this housing may thus be configured so as to be relatively planar. In the embodiment of Fig. 4 and 5, the diode components 31 to 33 are each arranged with the longitudinal extension thereof parallel to the conductor rails 21 to 24, but they may in principle also be arranged perpendicular to the conductor rails 21 to 24.

In a production method for producing a connecting device 10, as shown in Fig. 2, the conductor rails 21 to 24 are arranged beside one another and are connected to the diode components 31 to 33, as described above. In addition, a respective connecting cable 2 or a respective contact 54 are attached in the contact region 51 of the conductor rails 21 and 24, as already explained with reference to Fig. 4 and 5. The current-carrying arrangement thus formed is subsequently overmoulded with a plastics material 9 of the outer housing in such a way that at least part of the conductor rails and the diode components 31 to 33 are surrounded by the plastics material 9. In particular, the conductor rails 21 to 24 and the diode components 31 to 33 are completely overmoulded, merely a region surrounding the contact regions 52 of the conductor rails remaining free, so as to connect the film conductors 3 of the solar module in a subsequent assembly step. Owing to the current-carrying arrangement being overmoulded with plastics material 9, the outer housing 11, as shown in Fig. 2 and 3, is formed in full in such a way that in this embodiment the outer housing 11 is formed from a single plastics material 9 (for example a thermoplastic material). Said outer housing 11 is thus formed in such a way that an opening 18 is formed across the contact regions 52 of the conductor rails 21 to 24 in the side 14 of the outer housing 11 remote from the solar module, which opening ensures that the film conductor can access and contact the conductor rails 21 to 24. The respective plug devices 19 are also formed on the outer housing 11 when forming the outer housing 11. This provides a possibility for connecting appropriate corresponding cable connectors. An extremely robust and compact connecting device is thus obtained by way of the favourable arrangement of the conductor rails.

The connecting device thus formed is, for example, supplied by the manufacturer of the connecting device to a user, who connects the connecting device to the solar module as described above. The module-side contact films are subsequently connected to the free ends of the conductor rails in the contact regions 52 thereof, preferably by welding or soldering or using suitable spring members. The opening 18 formed in the outer face 14 of the outer housing 11 is filled or sealed with a suitable curing material in such a way that the connecting space formed by the opening 18 is hermetically filled by the sealant. A one-component or two- component resin, such as epoxy resin or the like, may for example be used as the sealant. In a further step, the housing opening 18 is sealed by way of the cover 16. The cover provides effective protection against UV radiation, in such a way that the sealant 17 need not be UV- resistant. In a first variant, the housing cover 16 is applied to the opening 18 of the outer housing 11 without using a separate sealing element, since the hermetic seal is produced by the sealant 17. If this sealing is not provided by the sealant 17 or the opening 18 is not sealed with sealant 17, then the housing cover 16 is applied using an additional sealing element (such as a rubber seal) to seal the opening in the outer housing tightly against environmental effects.

If the solar module is shaded in part, the bypass diodes in the form of diode components 31 to 33 provided inside the housing are activated and may heat up considerably. Owing to the overmoulding of the current-carrying components, including the diode components, with plastics material to form the outer housing, the heat thus produced is effectively dissipated, which has a positive effect on the entire system.

Fig. 6 and 7 show a further embodiment of a connecting device according to the invention. This differs from the aforementioned embodiment in particular with regard to the configuration of the outer housing. The connecting device 40 comprises an outer housing 41, which is made of plastics material and is comparable to the connecting device 10 according to Fig. 2, and may comprise a current-carrying arrangement as shown in Fig. 4 and 5. By contrast with the connecting device 10 according to Fig. 2, no plug devices are formed on one of the side walls 45 of the outer housing 41, but the connecting cables 2 are overmoulded by the outer housing 41 in the connecting region, in which they are connected to the corresponding conductor rails. The arrangement according to Fig. 4, for example, is used as a current- carrying arrangement. An opening 48 is formed across the contact regions 52 of the conductor rails 21 to 24 on the upper face 44 of the outer housing 41 remote from the solar module and is sealed with a housing cover 46. In this embodiment, the opening 48 or the connecting space of the outer housing 41, which space is delimited by the opening 48, is not filled with sealant, but instead a housing cover 46 is applied to the opening 48 using a separate sealing element 47, in order to seal the opening in the outer housing tightly against environmental effects. The outer housing 41 is attached to the solar module 100 at the lower face 43, as shown by way of example in Fig. 1.

Fig. 8 shows a further embodiment of a connecting device, in which the current-carrying components in the form of the conductor rails 21 to 24 and the diode components 31 to 33 are overmoulded with a plastics material 60 in such a way that at least part of the conductor rails 21 to 24, are surrounded, in particular completely surrounded or enclosed, in the region of the diode connections and the diode components 31 to 33 by a common housing formed by the plastics material 60, forming a functional unit 5. The diode components 31 to 33 arranged beside one another in a row are thus surrounded by a housing block formed by the plastics material 60, which housing surrounds the diode components 31 to 33 in its longitudinal extension and extends transverse to the conductor rails in said longitudinal extension. The housing block is in this case substantially rectangular, but may, in principle, be shaped otherwise. Also, in this embodiment the conductor rails 21 to 24 are shaped slightly differently from the conductor rails in Fig. 4 and 5, but aligned parallel to one another in a similar manner. Fig. 8 also shows spring elements 56 in the form of omega springs, with which the film conductors of the solar module can be fixed to the conductor rails 21 to 24. These spring elements may in principle also be used in the embodiments of Fig. 4 and 5. The plastics material 60 may, for example, be a thermoplastic or thermoset material, similar to the plastics material according to Fig 2 and according to Fig. 6, and forms part of the outer housing. The housing block formed by the plastics material 60 comprises an upper face 61, a lower face 62 and side walls 64, 65. Owing to the overmoulding of the pre-assembled current-carrying arrangement of conductor rails and diode components, a compact functional unit 5 is obtained which can be handled relatively easily and has a level of mechanical stability which allows the current-carrying arrangement to be handled during the production process with no risk of damage.

A connecting device for a solar module is, for example, produced as follows: Following assembly of the current-carrying arrangement, as explained with reference to Fig. 4 for example, part of the conductor rails 21 to 24 and the diode components 31 to 33 are first overmoulded with the plastics material 60 in such a way that the functional unit 5 is formed, as shown in Fig. 8. In a subsequent production step, the functional unit 5 thus formed is overmoulded with a second plastics material, in particular with the plastics material according to Fig. 2 or Fig. 6, in such a way that the outer housing is formed completely. In this connection, the outer housing may in principle take on the form of the outer housing 11 or the form of the outer housing 41 in accordance with the connecting devices 10 or 40. In one embodiment, it is provided for the functional unit 5 or the plastics material 60 of the housing block to form part of the outer face of the connecting device. For example, it is possible for the upper face 61 of the housing block to form part of the upper face 14 of the outer housing 11 or the upper face 44 of the outer housing 41. It is likewise possible for the lower face 62 of the housing block to form part of the lower face 13 of the outer housing 11 or part of the lower face 43 of the outer housing 41. A planar outer housing is thus obtained. By contrast, the side walls 64 and 65 may be surrounded by the side walls 15 and 45 of the outer housing 11 or 41 respectively.

This embodiment thus provides a connecting device, in which the outer housing is formed of two components, one of these components being configured as a functional unit which can be easily handled during the production process and which in turn is overmoulded with plastics material so as to form the outer housing in full. In this case also, an extremely robust and compact connecting device is obtained by way of the favourable arrangement of the current- carrying components.

Claims

1. Connecting device (10, 40) for a photovoltaic solar module (100) for connecting at least one external electrical conductor (2) to an electrical connecting system (3, 104) of the solar module (100), having:

- an outer housing (11, 41), which may be arranged on the solar module (100), and

- current-carrying components (21, 22, 31) which are overmoulded with plastics material,

characterised in that the connecting device further comprises a UV-radiation-resistant housing cover (16, 46).

2. Connecting device according to claim 1, wherein at least one opening (18) in the outer housing (11), which opening can be sealed with the housing cover, is filled with a filler material (17).

3. Connecting device according to either claim 1 or claim 2, wherein the housing cover (16) can be attached to an opening (18) in the outer housing (11) without using a separate sealing element.

4. Connecting device according to either claim 1 or claim 2, wherein the housing cover (46) can be attached to an opening (48) in the outer housing (41) using an additional sealing element (47) in order to seal the opening in the outer housing tightly against environmental effects.

5. Connecting device according to any one of claims 1 to 4, characterised in that the current-carrying components comprise:

- a plurality of conductor rails (21 to 24) arranged beside one another, comprising at least a first conductor rail (21) having a first contact region (51) for connection to the electrical conductor (2) and a second contact region (52) for connection to the electrical connecting system (3) of the solar module (100), and a second conductor rail (22) having a contact region (52) for connection to the electrical connecting system (3) of the solar module (100), and - at least one diode component (31) which is attached to the conductor rails (21, 22) and connects the first and second conductor rails to one another.

6. Connecting device according to claim 5, wherein at least one opening (18, 48), which is provided with the housing cover (16, 46), is formed in the outer housing (11, 41), on a side of the outer housing remote from the solar module, across the contact regions (52) of the first and second conductor rails (21, 22), which are provided for connection to the electrical connecting system (3) of the solar module (100).

7. Connecting device according to either claim 5 or claim 6, wherein at least part of the conductor rails (21, 22) and the diode component (31) are overmoulded by a first plastics material (60), which surrounds at least part of the conductor rails (21-24) and the diode component (31) and forms a functional unit (5), and the first plastics material (60) is overmoulded, at least in part, by a second plastics material (9) which forms the outer housing (11, 41).

8. Connecting device according to claim 7, wherein the functional unit (5) forms at least part of an outer face (13, 43, 14, 44) of the connecting device.

9. Connecting device according to claim 7, wherein the functional unit (5) forms at least part of an outer face (13, 43) of the connecting device facing the solar module, which face may be mounted on the solar module (100), and/or at least part of an outer face (14, 44) of the connecting device remote from the solar module.

10. Connecting device according to any one of claims 7 to 9, wherein the plastics material (60) of the functional unit (5) is formed as an approximately rectangular block which extends transverse to the conductor rails (21 to 24).

11. Connecting device according to any one of claims 5 to 10, - comprising at least one contact (54) which is formed in a first region for connection to the first contact region (51) of the first conductor rail (21) and which is formed in a second region for connection to the external electrical conductor (2),

- the contact (54) being overmoulded by the outer housing (11, 41).

12. Connecting device according to claim 11, wherein the contact (54) is configured as part of a plug connection (19) which is arranged between the first conductor rail (21) and the external electrical conductor (2), and in particular as part of a plug device (19) which is arranged at a connecting duct (12) of the outer housing (11) so as to cooperate with a corresponding plug device on the external electrical conductor (2).

13. Connecting device according to any one of claims 1 to 12, wherein the external electrical conductor (2) is overmoulded by the outer housing (41) at least in part.