WO2013086265A1 - Solar cell module - Google Patents

Solar cell module Download PDF

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Publication number
WO2013086265A1
WO2013086265A1 PCT/US2012/068359 US2012068359W WO2013086265A1 WO 2013086265 A1 WO2013086265 A1 WO 2013086265A1 US 2012068359 W US2012068359 W US 2012068359W WO 2013086265 A1 WO2013086265 A1 WO 2013086265A1
Authority
WO
WIPO (PCT)
Prior art keywords
box body
solar cell
cell module
junction box
solar panel
Prior art date
Application number
PCT/US2012/068359
Other languages
French (fr)
Inventor
Huaili Qin
Yonghong Ren
Tingliang SHI
Original Assignee
E. I. Du Pont De Nemours And Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by E. I. Du Pont De Nemours And Company filed Critical E. I. Du Pont De Nemours And Company
Publication of WO2013086265A1 publication Critical patent/WO2013086265A1/en

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Classifications

    • 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
    • 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
    • H02S30/00—Structural details of PV modules other than those related to light conversion
    • H02S30/10—Frame structures
    • 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

Definitions

  • the present invention relates to a solar cell module having an improved junction box.
  • solar cell technology has been advancing rapidly, and a great progress has been made for various solar cells in both technological and commercial areas.
  • solar cells can generally be categorized as bulk solar cells and thin film solar cells.
  • Figure 1 schematically shows a typical bulk (normally crystalline silicon) solar cell module, mainly comprising solar panel 1 , frame assembly 2 and junction box 3.
  • the solar panel 1 is normally in a form of laminate, in which an array of solar cells 4 is arranged. Normally, a plurality of solar cells needs to be connected in series to form solar cell strings 6, and then such solar cell strings 6 are connected in series via busbars 8 to provide required output voltage of the cells.
  • a junction box 3 is normally installed in the back of the solar panel 1 , for example, bonded with silicone glue.
  • the junction box 3 contains a positive terminal and a negative terminal.
  • Two output cables 10 from a positive electrode and a negative electrode of the whole solar cell module are connected with the positive and negative terminals and led out from the junction box 3.
  • a connection line is provided between the positive and negative terminals, and two lead wires from the solar cell array formed by the solar cell strings 6 are connected with the connection line in the junction box 3.
  • one or a plurality of switching diodes 12 is connected in series in the connection line to prevent inverse current impulse from occurring in the connection line.
  • the frame assembly 2 surrounds periphery of the solar panel 1 to protect the solar panel.
  • the frame assembly 2 is normally made of corrosion-resistant metal or plastics.
  • the frame assembly 2 can be assembled from frame segments 14 and corner joints 16.
  • a typical thin film solar cell module also mainly comprises a solar panel, a frame assembly and a junction box.
  • the solar panel comprises a layer of thin film solar cells, and the solar cell layer collects electricity via vertical busbars on both sides of the panel, and the vertical busbars are connected with the junction box installed in the back of the solar panel via horizontal busbars.
  • the working temperature of the junction box is high, and heat dissipation in the area where the junction box is attached will be affected because the junction box is attached on the back sheet.
  • This causes an increase of local temperature in the solar cell module i.e., will form hot spots in the solar cell module.
  • power generation efficiency of the solar cell module is reduced with increased temperature, such hot spots will affect overall output efficiency of the solar cell module, and at the same time reduce service life of the solar cell module.
  • junction box A feasible way to solve this problem is to install the junction box on the frame assembly of the solar cell module or integrate it into the frame assembly. In this way, the junction box will not affect heat dissipation of the solar panel, and the heat it generates by itself will not be transferred easily to the solar panel.
  • junction box when the junction box is installed on the frame assembly, it is necessary to make a special modification on structure of the frame assembly so that it is suitable for installation of the junction box. At the same time, installation of the junction box will affect overall shape of the frame assembly.
  • junction box With the integration of the junction box into the frame assembly, the dimension of the frame assembly itself is limited and will result in a narrow operation space in the junction box. It becomes inconvenient to assemble the frame assembly on the solar panel, and it becomes difficult to achieve automated production of the modules on an assembly line. Furthermore, wiring, testing and maintenance of the junction box are also becomes troublesome.
  • the present invention provides a solar cell module having an improved junction box to prevent solar panel hot spots caused by the junction box which would otherwise affect output efficiency of the solar cell module and reduce service life of its components.
  • the invention makes it easier to carry out assembling, wiring, testing and maintenance of the junction box.
  • a solar cell module comprising: a solar panel; a frame assembly assembled around the periphery of the solar panel; a junction box composed of two separate junction box members; and a connection line connected to the solar panel for outputting electricity generated by the solar panel, the connection line extending through the two junction box members; wherein both the junction box members are integrated in the frame assembly; and wherein the connection line comprises an internal line disposed in each of the junction box members and an intermediate line connected between the two internal lines, the intermediate line being arranged along an edge of the solar panel.
  • the frame assembly comprises a plurality of frame segments and corner joints for joining the frame segments together with angles formed there-between, and each junction box member is integrated in a corresponding corner joint and/or a corresponding frame segment.
  • the corner joints are connected with the frame segments in a plug-in manner.
  • the corner joints and/or the frame segments integrated with a junction box member are made of insulative plastics.
  • each junction box member comprises: a box body formed integrally with the corresponding corner joint or frame segment and comprising a bottom wall parallel to the solar panel and vertical side walls extending from the bottom wall, the box body being at least partly open on both the top side which is opposite to the bottom wall and the vertical side proximate to the edge of the solar panel; a side cover assembled to the box body to close the vertical side of the box body; and a top cover assembled to the box body to close the top side of the box body.
  • one of the side cover and the top cover has a locking structure for locking it to the box body, and the other of the side cover and the top cover is locked to the box body by means of the one of the side cover and the top cover.
  • the top cover has the locking structure for locking it to the box body, and the side cover is locked to the box body by means of the top cover.
  • the locking structure comprises a snap-lock structure
  • the box body is provided with a mating structure configured for lockingly engaging the snap-lock structure.
  • the vertical side walls of the box body are provided with opposed vertical slots, and opposite vertical edges of the side cover are inserted into the vertical slots to assemble the side cover to the box body.
  • each junction box member further comprises a sealing member disposed between the side and top covers and the box body.
  • the side cover and the top cover are each made of an insulative material.
  • the solar cell module further comprises wires connected between busbars of the solar panel and the internal lines.
  • each wire is fixed to the box body at its substantially middle portion.
  • each wire comprises a first portion sealed in the box body by the side cover and a second portion extended out from the box body towards the solar panel.
  • the intermediate line is composed of a busbar formed in the solar panel along the edge of the solar panel.
  • At least one of the junction box members comprises at least one bypass diode in its internal line.
  • the solar cell module having a two-member junction box of the present invention preferably, the solar cell module further comprises positive and negative output cables connected to opposite ends of the connection line respectively.
  • the solar cell module having a two-member junction box according to the present invention because two junction box members of the junction box are integrated in the frame assembly, and the
  • the junction box is integrated in the frame assembly, instead of being bonded to the back of the solar panel. Therefore, the junction box will not cause hot spots to occur on the solar cell module, and it will not affect output efficiency of the solar cell module and reduce service life of the components.
  • the junction box is integrated in the frame assembly, which allows the whole frame assembly to maintain an overall smooth and streamlined appearance.
  • a solar cell module comprising a solar panel; a frame assembly assembled around the periphery of the solar panel; and a detachable junction box integrated in the frame assembly.
  • the junction box comprises a box body integrated in a portion of the frame assembly and comprising a bottom wall parallel to the solar panel and vertical side walls extending from the bottom wall, the box body being at least partly open on both the top side which is opposite to the bottom wall and the vertical side proximate to the edge of the solar panel.
  • a side cover is assembled to the box body to close the vertical side of the box body, and a top cover is assembled to the box body to close the top side of the box body.
  • the box body is formed integrally with a portion of the frame assembly; or the box body is separately formed from the frame assembly and then incorporated into a portion of the frame assembly.
  • one of the side cover and the top cover has a locking structure for locking it to the box body, and the other of the side cover and the top cover is locked to the box body by means of the one of the side cover and the top cover.
  • the top cover has the locking structure for locking it to the box body, and the side cover is locked to the box body by means of the top cover.
  • the locking structure comprises a snap-lock structure
  • the box body is provided with a mating structure configured for lockingly engaging the snap-lock structure
  • the vertical side walls of the box body are provided with opposed vertical slots, and opposite vertical edges of the side cover are inserted into the vertical slots to assemble the side cover to the box body.
  • the box body of the junction box is open on both the top side and the vertical side proximate to the edge of the solar panel, and is closed by a dismountable top cover and side cover, assembly and wiring between the junction box and the solar panel become easier.
  • This allows installation of the solar cell module to be accomplished in a simple, fast and cost-effective way to facilitate achieving automated production on an assembly line.
  • the top cover and the side cover can be removed to provide more convenience for operating personnel.
  • the junction box is integrated in the frame assembly, instead of being bonded to the back of the solar panel. Therefore, the junction box will not cause hot spots to occur on the solar cell module, and it will not affect output efficiency of the solar cell module and reduce service life of the components.
  • the junction box is integrated in the frame assembly, which allows the whole frame assembly to still maintain an overall smooth and streamlined appearance.
  • Figure 1 is a diagram of a solar cell module according to a prior art.
  • Figure 2 is a diagram of a solar cell module according to a preferred embodiment of the present invention, wherein the two-member junction box is integrated in the frame assembly.
  • Figure 3 is a diagram of the box body of a detachable junction box member integrated in a corner joint of the frame assembly according to a preferred embodiment of the present invention.
  • Figure 4 and 5 are enlarged diagrams of the top cover and the side cover that can be integrated in the box body as shown in Figure 3.
  • Figure 6 is a diagram of an assembled state of a detachable junction box member integrated in a corner joint according to a preferred embodiment of the present invention.
  • Figure 7 and 8 are diagrams from two different directions showing two corner joints having junction box members integrated with frame segments.
  • Figure 9 is a diagram of the box body of a junction box member according to a preferred embodiment of the present invention, wherein wires are fixed to the box body.
  • Figure 10 is a diagram showing when a side cover is inserted into the box body shown in Figure 9.
  • Figure 1 1 is a diagram showing when a top cover is fixed to the box body shown in Figure 10. Detailed Description
  • the present invention is not only applicable to bulk solar cell (such as crystalline silicon solar cells), but also is applicable to thin film solar cells.
  • examples illustrated in the attached figures are mostly crystalline silicon solar cells.
  • various characteristics related to the crystalline silicon solar cells of the present invention are also considered.
  • a solar cell module (such as a crystalline silicon solar cell module) mainly comprises a solar panel 1 , a frame assembly 2 and a junction box.
  • the solar panel 1 is in a form of a laminate, in which solar cells 4 (e.g., crystal silicon cells) are placed.
  • the solar cells can be made of any materials that have a photoelectric conversion property.
  • the solar cells are made of a crystalline silicon wafer (including monocrystalline silicon and
  • a plurality of solar cells are connected in series via electrically conductive bars to form a solar cell string 6, such as the six solar cell strings as shown in Figure 2 (each solar cell string is constituted by a column of solar cells). Then, a plurality of such solar cell strings 6 are connected in series via busbars 8 in the solar panel to provide required output voltage of the cells. In particular, each solar cell string 6 is connected head-to-tail via the busbars 8. Thus, all the solar cells are connected in series in the solar panel 1 to form a complete solar cell array.
  • the busbar which is connected with the end of the first side (the side proximate to the junction box) of the first solar cell string from the left, and the busbar, which is connected with the end of the first side of the last solar cell string from the left, constitute two output terminals of the solar cell array.
  • the solar cell module also comprises a connection line (as described in detail hereinafter) connected to two output terminals of the solar cell array in the solar panel, for outputting electricity generated by the solar panel.
  • the frame assembly 2 comprises a plurality of frame segments defining an overall outer profile of the frame assembly and corner joints for joining the frame segments together with angles formed there-between.
  • the solar panel 1 has a roughly rectangular shape. Therefore, the frame assembly 2 comprises four frame segments 14 arranged along the four sides of the solar panel and the corner joints 16 for joining the four frame segments together with an angle of 90 degree formed there-between.
  • corner joint 16 and the connected frame segment 14 can be provided with a tenon and a mortise respectively that fit with each other.
  • Each frame segment 14 can be made of suitable metal or plastics.
  • the frame segment can be composed of extruded section bars, thus reducing manufacturing cost of the frame segments.
  • Each corner joint 16 can also be made of suitable metal or plastics. In consideration of insulation, frame segments and corner joints made of insulative plastics are preferred.
  • the frame segments and the corner joint may be molded of polymeric material via injection molding or extrusion molding. Any of these parts may be made of the same or different polymeric material as any other part.
  • the polymeric material suitable for making these parts includes PET (polyethylene terephthalate), PBT (polybutylene
  • PU polyurethane
  • PPO polyphenylene oxide
  • LCP liquid crystal polymers
  • PEI polyether imide
  • PVC polyvinyl chloride
  • Polyesters suitable for use in these parts comprise thermoplastic polyester homopolymers and copolymers.
  • Thermoplastic polyesters are typically derived from one or more dicarboxylic acids and diols.
  • suitable dicarboxylic acids are those selected from the group consisting of terephthalic acid, isophthalic acid, naphthalene dicarboxylic acids, cyclohexane dicarboxylic acids, succinic acid, glutaric acid, adipic acid, sebacic acid, 1 ,12-dodecane dioic acid, fumaric acid, maleic acid, and the derivatives thereof, such as, for example, the dimethyl, diethyl, or dipropyl esters.
  • glycols that can be utilized as the diol component include ethylene glycol, 1 ,3-propylene glycol, 1 ,2- propylene glycol, 2,2-diethyl-1 ,3-propane diol, 2,2-dimethyl-1 ,3-propane diol, 2-ethyl-2-butyl-1 ,3-propane diol, 2-ethyl-2-isobutyl-1 ,3-propane diol, 1 ,3-butane diol, 1 ,4-butane diol, 1 ,5-pentane diol, 1 ,6-hexane diol, 2,2,4- trimethyl-1 ,6-hexane diol, 1 ,2-cyclohexane dimethanol.
  • 1 ,3-cyclohexane dimethanol 1 ,4-cyclohexane dimethanol, 2,2,4,4-tetramethyl-1 ,3- cyclobutane diol, isosorbide, naphthalene glycols, diethylene glycol, triethylene glycol, resorcinol, hydroquinone, and longer chain diols and polyols, such as polytetramethylene ether glycol, which are the reaction products of diols or polyols with alkylene oxides.
  • the dicarboxylic acids comprise one or more of terephthalic acid, isophthalic acid and 2,6-naphthalene dicarboxylic acid, and the diol component comprises one or more of
  • n is an integer of 2 to 10
  • m on average is 1 to 4
  • z an average of about 7 to about 40.
  • (II) and (III) may be a mixture of compounds in which m and z, respectively, may vary and hence since m and z are averages, they do not have to be integers.
  • n is 2, 3 or 4, and/or m is 1 .
  • polyesters include without limitation poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(1 ,4- butylene terephthalate) (PBT), poly(ethylene 2,6-naphthoate) (PEN), and poly(1 ,4-cyclohexyldimethylene terephthalate) (PCT) and copolymers and mixtures of these
  • the preferred thermoplastic polyesters are selected from poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(1 ,4-butylene terephthalate) (PBT), poly(1 ,4- cyclohexyldimethylene terephthalate) (PCT), and copolymers and mixtures of these.
  • a suitable poly(ethylene terephthalate) homopolymer for the invention is commercially available under the tradename Rynite ® poly(ethylene terephthalate) polyester resins from E.I. du Pont de
  • a suitable poly(1 ,4-butylene terephthalate) homopolymer for the invention is commercially available under the tradename Crastin® PBT polyester resins from E.I. du Pont de Nemours and Co., Wilmington, Delaware.
  • Preferred PTT copolymers contain at least about 85 mol%, at least about 90 mol%, at least about 95 mol%, or at least about 98 mol%, of copolymerized units of trimethylene terephthalate.
  • a suitable poly(trimethylene terephthalate) homopolymer for the invention is commercially available under the tradename Sorona® from E.I. du Pont de Nemours and Co., Wilmington, Delaware.
  • a solar cell module junction box is composed of two separate junction box members 18 and 20.
  • the two junction box members are integrated in the frame assembly, corresponding to two output terminals of the solar cell array in the solar panel.
  • each junction box member is integrated in a corresponding corner joint 16 of the frame assembly 2.
  • one of the junction box members can also be integrated in one corner joint 16, and another junction box member can be integrated in the frame segment 14 connected with the corner joint 16.
  • the two junction box members can also be integrated in the same frame segment 14.
  • two junction box members are preferably arranged along the same side of the solar panel, for example, arranged along the same side that both of the two output terminals of the solar cell array in the solar panel are facing, as shown in Figure 2.
  • the present invention does not exclude the situation in which the two junction box members are arranged along different sides of the solar panel.
  • the two output terminals of the solar cell array may be positioned approximately diagonally.
  • the two junction box members can also be arranged approximately diagonally on the two sides of the solar panel.
  • a connection line extends through the two junction box members 18 and 20, and comprises internal lines 22 and 24 disposed respectively in the two junction box members 18 and 20, and an intermediate line 26 connected between the two internal lines 22 and 24.
  • Each internal line can include an inside terminal, an outside terminal and an electric conductor connected between the inside and outside terminals.
  • the two ends of the intermediate line 26 are connected respectively with the inside terminals of the internal lines 22 and 24.
  • the outside terminals of the internal lines 22 and 24 can be connected with the positive and negative output cables 10.
  • the positive and negative output cables 10 can pass through corresponding locations of the frame assembly (for example, pass through the corner joints 16 as shown in Figure 2) and can be led out from the frame assembly, for example, from the two opposite ends of one edge of the frame assembly.
  • bypass diode In the connection line, there is at least one bypass diode connected in series to prevent disconnection or inverse current impulse in the solar cell module.
  • the bypass diode is preferably placed in at least one of the two junction box members 18 and 20.
  • two bypass diodes i.e., the first and the second bypass diodes 28 and 30, are placed in the left-side junction box members 18, and one bypass diode, i.e., the third bypass diode 32, is placed in the right-side junction box member 20.
  • the busbar which is connected with the end of the first side (the side proximate to the junction box) of the first solar cell string from the left, is connected with the internal line 22 on the left side of the first bypass diode 28.
  • the busbar which is connected with the end of the first side of the second and the third solar cell strings from the left, is connected with the internal line 22 on the right side of the first bypass diode 28 (i.e., between the first and the second bypass diodes 28 and 30).
  • the busbar which is connected with the end of the first side of the fourth and the fifth solar cell strings from the left, is connected with the internal line 22 on the right side of the first bypass diode 28, and/or is connected with the internal line 24 on the left side of the third bypass diode 32. It should be point out that the busbar, which is connected with the end of the first side of the fourth and the fifth solar cell strings from the left, can be connected with internal line 22 and/or internal line 24 via a corresponding wire, or connected with internal line 22 and/or internal line 24 via the intermediate line 26 as shown in Figure 2.
  • the busbar which is connected with the end of the first side of the sixth solar cell string from the left, is connected with the internal line 24 on the right side of the third bypass diode 32.
  • the intermediate line 26 is arranged along the edge of the solar panel.
  • the intermediate line 26 is also made in the form of the busbars in the solar panel.
  • the busbars and the intermediate line 26 located on the first side of the solar panel are preferably connected to the internal lines 22 and 24 via a corresponding additional wire 80 (as shown in Figure 9 and as described hereinafter).
  • a junction box is composed of two junction box members separated from each other, and the intermediate line connected between the two junction box members is arranged along the edge of the solar panel (preferably composed of the busbars formed in the solar panel). Therefore, there is no need to set up a separate connection line located outside the solar panel between the two junction box members, thus simplifying operation of wiring between the junction box and the solar panel, and enabling easier and more convenient assembly of the frame assembly having a junction box and solar panel.
  • a solar cell module can have detachable junction box members integrated in the frame assembly.
  • Such detachable junction box members can be made as one or both of the two separate junction box members 18 and 20 as previously described with reference to Figure 2; or, such detachable junction box members can also be made as a single detachable junction box integrated in the frame assembly (corner joints or frame segments).
  • junction box junction box members
  • a detachable junction box member according to one preferred embodiment of the present invention is described below with reference to Figure 3.
  • the detachable junction box member is integrated in one corner joint of the frame assembly of the solar cell module. It is understandable that it can also be integrated in one frame segment of the frame assembly.
  • the detachable junction box member has a box body 40 located in a corner joint (or in a frame segment), and the box body can be formed integrally with the corner joint, for example, made by plastic injection molding.
  • the box body can be made separately relative to the corner joint, and then assembled into the corner joint.
  • the box body can be made of a material different from the corner joint.
  • the box body 40 comprises a bottom wall 42 and a vertical side wall 44 extending from the bottom wall.
  • the bottom wall 42 is parallel to the solar panel.
  • the box body is at least partly open on the top side which is opposite to the bottom wall and on the vertical side proximate to the edge of the solar panel.
  • the top side is completely open and the vertical side is partly open.
  • the vertical side wall 44 comprises a side wall substantially parallel to the adjacent edge of the solar panel and two side walls (end walls) substantially vertical to adjacent edge of the solar panel.
  • the shape of the vertical side wall 44 is not limited to this. For example, vertical side walls of substantially oval shape or with other shapes are also feasible.
  • An accommodation space is defined in the box body 40, and the circuit board 46 bearing an internal line (for example, aforementioned internal line 22 or 24) is placed in the accommodation space, and is preferably supported by the bottom wall 42, so that the obverse side of the circuit board 46 (the side on which the switching diode is mounted) is facing the open top side of the box body.
  • an internal line for example, aforementioned internal line 22 or 24
  • detachable junction box member as shown in Figure 3
  • the top cover 60 as shown in Figure 4 and the side cover 70 as shown in Figure 5 are provided.
  • the vertical side wall 44 of the box body 40 are provided with two vertical slots 48 opposed to each other at the open vertical side, and the left and right two vertical edges 72 of the side cover 70 are inserted into the vertical slots 48.
  • two vertical stopping plates 74 are provided respectively on the left and on the right, extending into the accommodation space, and positioners 76 are also provided along upper edge of the main body of the side cover 70, protruding into the accommodation space.
  • the lower edges of the positioners 76 are higher than the upper edges of the stopping plates 74, and the height difference between the lower edges of the positioners 76 and the upper edges of the stopping plates 74 is approximately equal to thickness of inner edge of the top cover 60.
  • the side cover 70 is firmly fixed on the box body 40 by the top cover 60.
  • the top cover 60 is put on top of the open top side of the box body 40 and is locked here.
  • the inner edge of the top cover 60 is inserted between the lower edges of the positioners 76 and the upper edges of the stopping plates 74.
  • the top cover 60 is provided with a locking structure at the other edges.
  • the top cover 60 is provided with a snap-lock structure 62 and 62' at both end edges and the outer edge
  • the box body 40 is provided with a slot or hole type mating structure 50 and 50' configured for lockingly engaging the snap-lock structure 62 and 62'.
  • other structures or elements for locking the top cover on the box body can also be used, for example, simple fastening screws can be used for locking the top cover on the box body.
  • Figure 6 shows a diagram when such detachable junction box members are assembled.
  • the top cover 60 when the top cover 60 is locked on the box body 40, the top cover 60 can also cover or press the upper edge of the side cover 70, instead of pressing the stopping plates 74 on the side cover 70, and lock the side cover 70 on the box body 40.
  • the locking structure can also be provided on the side cover only, but not on the top cover, and the top cover is locked on the box body by the side cover.
  • both the top cover and the side cover can be provided with respective locking structures to lock them on the box body.
  • Sealing elements can be provided between the side cover and top cover, or between both of them and the box body to prevent foreign matters, especially moisture, from entering the accommodation space of the box body.
  • the lower edges of the stopping plates 74 press against the upper surface (the obverse side) of the circuit board 46 in the accommodation space, to fix the circuit board 46 in the accommodation space in a simple way.
  • other methods can also be used to fix the circuit board 46 in the accommodation space.
  • FIG. 7 and 8 shows part of the frame assembly of the solar cell module according to a preferred embodiment of the present invention from the upper and lower sides, which includes the frame segments 14 and the corner joints 16 assembled at both ends of the frame segments.
  • Each corner joint has a corresponding junction box member 18 or 20 integrated in, and the two junction box members 18 and 20 are assembled to form the junction box of the solar cell module.
  • Figure 8 also clearly shows a solar panel slot 25 formed on back side of various part of the frame assembly (corner joints and frame segments), for the edge of the solar panel to be inserted in.
  • Figure 9 shows details of the box body 40 of a detachable junction box member integrated in the frame assembly according to a preferred embodiment of the present invention.
  • the detachable junction box member is integrated in a corner joint.
  • the detachable junction box member can also be integrated in other parts of the frame assembly.
  • the vertical side of the box body 40 proximate to the edge of the solar panel has a partial side wall 52 extending upwards from the bottom wall 42, and the height of the partial side wall 52 is lower than the height of the vertical side wall 44, so that the vertical side of the box body 40 proximate to the edge of the solar panel is partially open (i.e., the upper part is open, and the lower part is blocked by the partial side wall 52).
  • the upper edge of the partial side wall 52 is
  • the additional wire 80 used for connecting the busbars of the solar panel and the intermediate line with the internal line disposed in the junction box members is fixed on the partial side wall 52.
  • Each additional wire 80 can be in the form of electrically conductive bars as shown in the figure, having a horizontal section 82 extending to the solar panel to be assembled and a vertical section 84 bent from the horizontal section extending substantially upwards.
  • the side cover 70 when the side cover 70 is inserted into the box body 40, the side cover 70 shields the vertical sections of the additional wires inside the accommodation space of the box body 40, so that they can connect with the internal line in the accommodation space, while the horizontal sections 82 are kept outside the accommodation space and are still extending in the direction to the solar panel to be assembled, so that they can connect with the busbars and the
  • Figure 1 1 shows a situation after the top cover 60 is fixed on the box body 40.
  • the vertical sections of the additional wires have been completely enclosed in the accommodation space of the box body 40.
  • the internal end of the corresponding output cable 10 is connected with the internal line in the accommodation space, and the external end of the output cable 10 is exposed outside the corner joints, and part of the output cable 10 is extending inside the corner joint.
  • the external end of the output cable 10 has a plug-in type of connector.
  • the solar panel 1 can be assembled onto the frame assembly, for example, inserted into the solar panel slot 25 on the frame assembly. Then, the horizontal sections 82 of the additional wires are connected (for example, welded) to the busbars of the solar panel and the intermediate line.
  • the box body of the junction box is open on both the top side and the vertical side proximate to the edge of the solar panel, and is closed by a dismountable top cover and a side cover. Therefore, more spacious operation space can be provided for operating personnel, to facilitate assembly and maintenance on circuits in the box body of the junction box. Meanwhile, as long as one of the top cover and the side cover is locked up on the box body, both the top cover and the side cover can be assembled on the box body. Therefore, assembly between the junction box and the solar panel becomes easier, which allows installation of the solar cell module to be accomplished in a simple, fast and cost-effective way to facilitate achieving automated production on an assembly line.
  • junction box integrated in the frame assembly and the detachable junction box integrated in the frame assembly according to the present invention can be used in combination or separately.
  • the junction box is integrated in the frame assembly, instead of being bonded to the back of the solar panel. Therefore, the junction box will not cause hot spots to occur on the solar cell module, and it will not affect output efficiency of the solar cell module and reduce service life of the components.
  • the junction box is integrated in the frame assembly, the whole frame assembly maintains an overall smooth and streamlined appearance.

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Abstract

A solar cell module comprises a solar panel, a frame assembly assembled around the periphery of the solar panel, a junction box composed of two separate junction box members, and a connection line connected to the solar panel for outputting electricity generated by the solar panel. The connection line extends through the two junction box members, wherein both the junction box members are integrated in the frame assembly, and the connection line comprises an internal line disposed in each of the junction box members and an intermediate line connected between the two internal lines. The intermediate line may be arranged along an edge of the solar panel. In such a solar cell module, it is easy to attach and connect the junction box to the solar panel.

Description

TITLE
SOLAR CELL MODULE
Cross Reference to Related Application
This application claims priority from Chinese Application No.
201 1 10405036.4, filed on 8 December 201 1 , which is hereby incorporated herein.
Field of the Invention
The present invention relates to a solar cell module having an improved junction box.
Background
In recent years, solar cell technology has been advancing rapidly, and a great progress has been made for various solar cells in both technological and commercial areas. In terms of cell structure of the solar cells, solar cells can generally be categorized as bulk solar cells and thin film solar cells.
Figure 1 schematically shows a typical bulk (normally crystalline silicon) solar cell module, mainly comprising solar panel 1 , frame assembly 2 and junction box 3.
The solar panel 1 is normally in a form of laminate, in which an array of solar cells 4 is arranged. Normally, a plurality of solar cells needs to be connected in series to form solar cell strings 6, and then such solar cell strings 6 are connected in series via busbars 8 to provide required output voltage of the cells.
A junction box 3 is normally installed in the back of the solar panel 1 , for example, bonded with silicone glue. The junction box 3 contains a positive terminal and a negative terminal. Two output cables 10 from a positive electrode and a negative electrode of the whole solar cell module are connected with the positive and negative terminals and led out from the junction box 3. A connection line is provided between the positive and negative terminals, and two lead wires from the solar cell array formed by the solar cell strings 6 are connected with the connection line in the junction box 3. Moreover, one or a plurality of switching diodes 12 is connected in series in the connection line to prevent inverse current impulse from occurring in the connection line.
The frame assembly 2 surrounds periphery of the solar panel 1 to protect the solar panel. In consideration of impact of sunlight, wind, rain and other weather conditions, the frame assembly 2 is normally made of corrosion-resistant metal or plastics. As shown in Figure 1 , the frame assembly 2 can be assembled from frame segments 14 and corner joints 16.
On the other hand, a typical thin film solar cell module (not shown) also mainly comprises a solar panel, a frame assembly and a junction box. The solar panel comprises a layer of thin film solar cells, and the solar cell layer collects electricity via vertical busbars on both sides of the panel, and the vertical busbars are connected with the junction box installed in the back of the solar panel via horizontal busbars.
In the prior art as described above, in which the junction box is installed in the back of the solar panel, the working temperature of the junction box is high, and heat dissipation in the area where the junction box is attached will be affected because the junction box is attached on the back sheet. This causes an increase of local temperature in the solar cell module, i.e., will form hot spots in the solar cell module. As power generation efficiency of the solar cell module is reduced with increased temperature, such hot spots will affect overall output efficiency of the solar cell module, and at the same time reduce service life of the solar cell module.
A feasible way to solve this problem is to install the junction box on the frame assembly of the solar cell module or integrate it into the frame assembly. In this way, the junction box will not affect heat dissipation of the solar panel, and the heat it generates by itself will not be transferred easily to the solar panel.
Nevertheless, when the junction box is installed on the frame assembly, it is necessary to make a special modification on structure of the frame assembly so that it is suitable for installation of the junction box. At the same time, installation of the junction box will affect overall shape of the frame assembly.
With the integration of the junction box into the frame assembly, the dimension of the frame assembly itself is limited and will result in a narrow operation space in the junction box. It becomes inconvenient to assemble the frame assembly on the solar panel, and it becomes difficult to achieve automated production of the modules on an assembly line. Furthermore, wiring, testing and maintenance of the junction box are also becomes troublesome.
Therefore, it is desired to improve the solar cell module, particularly its junction box, to solve the above-mentioned problems.
Summary
The present invention provides a solar cell module having an improved junction box to prevent solar panel hot spots caused by the junction box which would otherwise affect output efficiency of the solar cell module and reduce service life of its components. In addition, the invention makes it easier to carry out assembling, wiring, testing and maintenance of the junction box.
Therefore, according to one aspect of the present invention, there is provided a solar cell module, comprising: a solar panel; a frame assembly assembled around the periphery of the solar panel; a junction box composed of two separate junction box members; and a connection line connected to the solar panel for outputting electricity generated by the solar panel, the connection line extending through the two junction box members; wherein both the junction box members are integrated in the frame assembly; and wherein the connection line comprises an internal line disposed in each of the junction box members and an intermediate line connected between the two internal lines, the intermediate line being arranged along an edge of the solar panel.
In the solar cell module having a two-member junction box of the present invention, preferably, the frame assembly comprises a plurality of frame segments and corner joints for joining the frame segments together with angles formed there-between, and each junction box member is integrated in a corresponding corner joint and/or a corresponding frame segment.
In the solar cell module having a two-member junction box of the present invention, preferably, the corner joints are connected with the frame segments in a plug-in manner.
In the solar cell module having a two-member junction box of the present invention, preferably, the corner joints and/or the frame segments integrated with a junction box member are made of insulative plastics.
In the solar cell module having a two-member junction box of the present invention, preferably, each junction box member comprises: a box body formed integrally with the corresponding corner joint or frame segment and comprising a bottom wall parallel to the solar panel and vertical side walls extending from the bottom wall, the box body being at least partly open on both the top side which is opposite to the bottom wall and the vertical side proximate to the edge of the solar panel; a side cover assembled to the box body to close the vertical side of the box body; and a top cover assembled to the box body to close the top side of the box body.
In the solar cell module having a two-member junction box of the present invention, preferably, one of the side cover and the top cover has a locking structure for locking it to the box body, and the other of the side cover and the top cover is locked to the box body by means of the one of the side cover and the top cover.
In the solar cell module having a two-member junction box of the present invention, preferably, the top cover has the locking structure for locking it to the box body, and the side cover is locked to the box body by means of the top cover.
In the solar cell module having a two-member junction box of the present invention, preferably, the locking structure comprises a snap-lock structure, and the box body is provided with a mating structure configured for lockingly engaging the snap-lock structure. In the solar cell module having a two-member junction box of the present invention, preferably, the vertical side walls of the box body are provided with opposed vertical slots, and opposite vertical edges of the side cover are inserted into the vertical slots to assemble the side cover to the box body.
In the solar cell module having a two-member junction box of the present invention, preferably, each junction box member further comprises a sealing member disposed between the side and top covers and the box body.
In the solar cell module having a two-member junction box of the present invention, preferably, the side cover and the top cover are each made of an insulative material.
In the solar cell module having a two-member junction box of the present invention, preferably, the solar cell module further comprises wires connected between busbars of the solar panel and the internal lines.
In the solar cell module having a two-member junction box of the present invention, preferably, each wire is fixed to the box body at its substantially middle portion.
In the solar cell module having a two-member junction box of the present invention, preferably, each wire comprises a first portion sealed in the box body by the side cover and a second portion extended out from the box body towards the solar panel.
In the solar cell module having a two-member junction box of the present invention, preferably, the intermediate line is composed of a busbar formed in the solar panel along the edge of the solar panel.
In the solar cell module having a two-member junction box of the present invention, preferably, at least one of the junction box members comprises at least one bypass diode in its internal line.
In the solar cell module having a two-member junction box of the present invention, preferably, the solar cell module further comprises positive and negative output cables connected to opposite ends of the connection line respectively. In the solar cell module having a two-member junction box according to the present invention, because two junction box members of the junction box are integrated in the frame assembly, and the
intermediate line connected between the two junction box members is arranged along an edge of the solar panel, assembly and wiring between the junction box and the solar panel become easier, which allows installation of the solar cell module to be accomplished in a simple, fast and cost-effective way to facilitate achieving automated production on an assembly line.
Furthermore, in the solar cell module having a two-member junction box according to the present invention, the junction box is integrated in the frame assembly, instead of being bonded to the back of the solar panel. Therefore, the junction box will not cause hot spots to occur on the solar cell module, and it will not affect output efficiency of the solar cell module and reduce service life of the components.
Furthermore, in the solar cell module having a two-member junction box according to the present invention, the junction box is integrated in the frame assembly, which allows the whole frame assembly to maintain an overall smooth and streamlined appearance.
According to another aspect of the present invention, there is provided a solar cell module, comprising a solar panel; a frame assembly assembled around the periphery of the solar panel; and a detachable junction box integrated in the frame assembly. The junction box comprises a box body integrated in a portion of the frame assembly and comprising a bottom wall parallel to the solar panel and vertical side walls extending from the bottom wall, the box body being at least partly open on both the top side which is opposite to the bottom wall and the vertical side proximate to the edge of the solar panel. A side cover is assembled to the box body to close the vertical side of the box body, and a top cover is assembled to the box body to close the top side of the box body.
In the solar cell module having a detachable junction box of the present invention, preferably, the box body is formed integrally with a portion of the frame assembly; or the box body is separately formed from the frame assembly and then incorporated into a portion of the frame assembly.
In the solar cell module having a detachable junction box of the present invention, preferably, one of the side cover and the top cover has a locking structure for locking it to the box body, and the other of the side cover and the top cover is locked to the box body by means of the one of the side cover and the top cover.
In the solar cell module having a detachable junction box of the present invention, preferably, the top cover has the locking structure for locking it to the box body, and the side cover is locked to the box body by means of the top cover.
In the solar cell module having a detachable junction box of the present invention, preferably, the locking structure comprises a snap-lock structure, and the box body is provided with a mating structure configured for lockingly engaging the snap-lock structure.
In the solar cell module having a detachable junction box of the present invention, preferably, the vertical side walls of the box body are provided with opposed vertical slots, and opposite vertical edges of the side cover are inserted into the vertical slots to assemble the side cover to the box body.
In the solar cell module having a detachable junction box according to the present invention, because the box body of the junction box is open on both the top side and the vertical side proximate to the edge of the solar panel, and is closed by a dismountable top cover and side cover, assembly and wiring between the junction box and the solar panel become easier. This allows installation of the solar cell module to be accomplished in a simple, fast and cost-effective way to facilitate achieving automated production on an assembly line. Furthermore, during junction box maintenance, the top cover and the side cover can be removed to provide more convenience for operating personnel.
Furthermore, in the solar cell module having a detachable junction box according to the present invention, the junction box is integrated in the frame assembly, instead of being bonded to the back of the solar panel. Therefore, the junction box will not cause hot spots to occur on the solar cell module, and it will not affect output efficiency of the solar cell module and reduce service life of the components.
Furthermore, in the solar cell module having a detachable junction box according to the present invention, the junction box is integrated in the frame assembly, which allows the whole frame assembly to still maintain an overall smooth and streamlined appearance.
Brief Description of the Drawings
Preferred embodiments of the present invention will be described with reference to the attached figures. In the attached figures:
Figure 1 is a diagram of a solar cell module according to a prior art. Figure 2 is a diagram of a solar cell module according to a preferred embodiment of the present invention, wherein the two-member junction box is integrated in the frame assembly.
Figure 3 is a diagram of the box body of a detachable junction box member integrated in a corner joint of the frame assembly according to a preferred embodiment of the present invention.
Figure 4 and 5 are enlarged diagrams of the top cover and the side cover that can be integrated in the box body as shown in Figure 3.
Figure 6 is a diagram of an assembled state of a detachable junction box member integrated in a corner joint according to a preferred embodiment of the present invention.
Figure 7 and 8 are diagrams from two different directions showing two corner joints having junction box members integrated with frame segments.
Figure 9 is a diagram of the box body of a junction box member according to a preferred embodiment of the present invention, wherein wires are fixed to the box body.
Figure 10 is a diagram showing when a side cover is inserted into the box body shown in Figure 9.
Figure 1 1 is a diagram showing when a top cover is fixed to the box body shown in Figure 10. Detailed Description
Various preferred embodiments of the present invention are described with reference to the attached figures.
First of all, it should be pointed out that the present invention is not only applicable to bulk solar cell (such as crystalline silicon solar cells), but also is applicable to thin film solar cells. However, for the sake of convenience in explaining the fundamental principles of the present invention, examples illustrated in the attached figures are mostly crystalline silicon solar cells. However, various characteristics related to the crystalline silicon solar cells of the present invention are also
applicable to other bulk solar cells or thin film solar cells.
As shown in Figure 2, according to a preferred embodiment of the present invention, a solar cell module (such as a crystalline silicon solar cell module) mainly comprises a solar panel 1 , a frame assembly 2 and a junction box.
The solar panel 1 is in a form of a laminate, in which solar cells 4 (e.g., crystal silicon cells) are placed. The solar cells can be made of any materials that have a photoelectric conversion property. For example, in an example of the present invention, the solar cells are made of a crystalline silicon wafer (including monocrystalline silicon and
polycrystalline silicon wafer). In the example , a plurality of solar cells are connected in series via electrically conductive bars to form a solar cell string 6, such as the six solar cell strings as shown in Figure 2 (each solar cell string is constituted by a column of solar cells). Then, a plurality of such solar cell strings 6 are connected in series via busbars 8 in the solar panel to provide required output voltage of the cells. In particular, each solar cell string 6 is connected head-to-tail via the busbars 8. Thus, all the solar cells are connected in series in the solar panel 1 to form a complete solar cell array. The busbar, which is connected with the end of the first side (the side proximate to the junction box) of the first solar cell string from the left, and the busbar, which is connected with the end of the first side of the last solar cell string from the left, constitute two output terminals of the solar cell array.
The solar cell module also comprises a connection line (as described in detail hereinafter) connected to two output terminals of the solar cell array in the solar panel, for outputting electricity generated by the solar panel.
The frame assembly 2 comprises a plurality of frame segments defining an overall outer profile of the frame assembly and corner joints for joining the frame segments together with angles formed there-between. In an example as shown in Figure 2, the solar panel 1 has a roughly rectangular shape. Therefore, the frame assembly 2 comprises four frame segments 14 arranged along the four sides of the solar panel and the corner joints 16 for joining the four frame segments together with an angle of 90 degree formed there-between.
The connection between the corner joint 16 and the frame segment
14 can be in a plug-in manner. Therefore, the corner joint 16 and the connected frame segment 14 can be provided with a tenon and a mortise respectively that fit with each other.
Each frame segment 14 can be made of suitable metal or plastics. For example, the frame segment can be composed of extruded section bars, thus reducing manufacturing cost of the frame segments. Each corner joint 16 can also be made of suitable metal or plastics. In consideration of insulation, frame segments and corner joints made of insulative plastics are preferred.
The frame segments and the corner joint may be molded of polymeric material via injection molding or extrusion molding. Any of these parts may be made of the same or different polymeric material as any other part. The polymeric material suitable for making these parts includes PET (polyethylene terephthalate), PBT (polybutylene
terephthalate), PTT (polytrimethylene terephthalate), PA6
(polycaprolactam), PA66 (polyamides 66), PA46 (polyamides 46), PAR (aromatic polyamides), PC (polycarbonate), ABS (acrylonitrile
/butadiene/styrene copolymer), PU (polyurethane), PPO (polyphenylene oxide), LCP (liquid crystal polymers), PEI (polyether imide), PVC (polyvinyl chloride), and mixtures of these.
Polyesters suitable for use in these parts comprise thermoplastic polyester homopolymers and copolymers. Thermoplastic polyesters are typically derived from one or more dicarboxylic acids and diols.
Among suitable dicarboxylic acids (and their corresponding esters) are those selected from the group consisting of terephthalic acid, isophthalic acid, naphthalene dicarboxylic acids, cyclohexane dicarboxylic acids, succinic acid, glutaric acid, adipic acid, sebacic acid, 1 ,12-dodecane dioic acid, fumaric acid, maleic acid, and the derivatives thereof, such as, for example, the dimethyl, diethyl, or dipropyl esters.
Some representative examples of glycols that can be utilized as the diol component include ethylene glycol, 1 ,3-propylene glycol, 1 ,2- propylene glycol, 2,2-diethyl-1 ,3-propane diol, 2,2-dimethyl-1 ,3-propane diol, 2-ethyl-2-butyl-1 ,3-propane diol, 2-ethyl-2-isobutyl-1 ,3-propane diol, 1 ,3-butane diol, 1 ,4-butane diol, 1 ,5-pentane diol, 1 ,6-hexane diol, 2,2,4- trimethyl-1 ,6-hexane diol, 1 ,2-cyclohexane dimethanol. 1 ,3-cyclohexane dimethanol, 1 ,4-cyclohexane dimethanol, 2,2,4,4-tetramethyl-1 ,3- cyclobutane diol, isosorbide, naphthalene glycols, diethylene glycol, triethylene glycol, resorcinol, hydroquinone, and longer chain diols and polyols, such as polytetramethylene ether glycol, which are the reaction products of diols or polyols with alkylene oxides.
In one preferred type of polyester the dicarboxylic acids comprise one or more of terephthalic acid, isophthalic acid and 2,6-naphthalene dicarboxylic acid, and the diol component comprises one or more of
HO(CH2)nOH (I), 1 ,4-cyclohexanedimethanol, HO(CH2CH2O)mCH2CH2OH (II), and HOiCHsCHsCHsCHsOJzCh Ch Ch Ch OH (III), wherein n is an integer of 2 to 10, m on average is 1 to 4, and is z an average of about 7 to about 40. Note that (II) and (III) may be a mixture of compounds in which m and z, respectively, may vary and hence since m and z are averages, they do not have to be integers. In preferred polyesters, n is 2, 3 or 4, and/or m is 1 . Specific preferred polyesters include without limitation poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(1 ,4- butylene terephthalate) (PBT), poly(ethylene 2,6-naphthoate) (PEN), and poly(1 ,4-cyclohexyldimethylene terephthalate) (PCT) and copolymers and mixtures of these Of these, the preferred thermoplastic polyesters are selected from poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(1 ,4-butylene terephthalate) (PBT), poly(1 ,4- cyclohexyldimethylene terephthalate) (PCT), and copolymers and mixtures of these.
A suitable poly(ethylene terephthalate) homopolymer for the invention is commercially available under the tradename Rynite ® poly(ethylene terephthalate) polyester resins from E.I. du Pont de
Nemours and Co., Wilmington, Delaware. A suitable poly(1 ,4-butylene terephthalate) homopolymer for the invention is commercially available under the tradename Crastin® PBT polyester resins from E.I. du Pont de Nemours and Co., Wilmington, Delaware. Preferred PTT copolymers contain at least about 85 mol%, at least about 90 mol%, at least about 95 mol%, or at least about 98 mol%, of copolymerized units of trimethylene terephthalate. A suitable poly(trimethylene terephthalate) homopolymer for the invention is commercially available under the tradename Sorona® from E.I. du Pont de Nemours and Co., Wilmington, Delaware.
According to one important aspect of the present invention, a solar cell module junction box is composed of two separate junction box members 18 and 20. The two junction box members are integrated in the frame assembly, corresponding to two output terminals of the solar cell array in the solar panel.
As illustrated in an example as shown in Figure 2, each junction box member is integrated in a corresponding corner joint 16 of the frame assembly 2.
Nevertheless, the present invention is not limited to this. According to basic conception of the present invention, one of the junction box members can also be integrated in one corner joint 16, and another junction box member can be integrated in the frame segment 14 connected with the corner joint 16. Alternatively, the two junction box members can also be integrated in the same frame segment 14.
In consideration of wiring cost and convenience, two junction box members are preferably arranged along the same side of the solar panel, for example, arranged along the same side that both of the two output terminals of the solar cell array in the solar panel are facing, as shown in Figure 2. Nevertheless, the present invention does not exclude the situation in which the two junction box members are arranged along different sides of the solar panel. For example, when there are odd numbers of solar cell strings 6 in a solar panel, the two output terminals of the solar cell array may be positioned approximately diagonally. Under such a circumstance, the two junction box members can also be arranged approximately diagonally on the two sides of the solar panel.
A connection line extends through the two junction box members 18 and 20, and comprises internal lines 22 and 24 disposed respectively in the two junction box members 18 and 20, and an intermediate line 26 connected between the two internal lines 22 and 24.
Each internal line can include an inside terminal, an outside terminal and an electric conductor connected between the inside and outside terminals. The two ends of the intermediate line 26 are connected respectively with the inside terminals of the internal lines 22 and 24. The outside terminals of the internal lines 22 and 24 can be connected with the positive and negative output cables 10. The positive and negative output cables 10 can pass through corresponding locations of the frame assembly (for example, pass through the corner joints 16 as shown in Figure 2) and can be led out from the frame assembly, for example, from the two opposite ends of one edge of the frame assembly.
In the connection line, there is at least one bypass diode connected in series to prevent disconnection or inverse current impulse in the solar cell module. The bypass diode is preferably placed in at least one of the two junction box members 18 and 20. For example, in an example as shown in Figure 2, two bypass diodes, i.e., the first and the second bypass diodes 28 and 30, are placed in the left-side junction box members 18, and one bypass diode, i.e., the third bypass diode 32, is placed in the right-side junction box member 20.
The busbar, which is connected with the end of the first side (the side proximate to the junction box) of the first solar cell string from the left, is connected with the internal line 22 on the left side of the first bypass diode 28.
The busbar, which is connected with the end of the first side of the second and the third solar cell strings from the left, is connected with the internal line 22 on the right side of the first bypass diode 28 (i.e., between the first and the second bypass diodes 28 and 30).
The busbar, which is connected with the end of the first side of the fourth and the fifth solar cell strings from the left, is connected with the internal line 22 on the right side of the first bypass diode 28, and/or is connected with the internal line 24 on the left side of the third bypass diode 32. It should be point out that the busbar, which is connected with the end of the first side of the fourth and the fifth solar cell strings from the left, can be connected with internal line 22 and/or internal line 24 via a corresponding wire, or connected with internal line 22 and/or internal line 24 via the intermediate line 26 as shown in Figure 2.
The busbar, which is connected with the end of the first side of the sixth solar cell string from the left, is connected with the internal line 24 on the right side of the third bypass diode 32.
The intermediate line 26 is arranged along the edge of the solar panel. Preferably, the intermediate line 26 is also made in the form of the busbars in the solar panel.
The busbars and the intermediate line 26 located on the first side of the solar panel are preferably connected to the internal lines 22 and 24 via a corresponding additional wire 80 (as shown in Figure 9 and as described hereinafter).
According to the embodiment as shown in Figure 2, a junction box is composed of two junction box members separated from each other, and the intermediate line connected between the two junction box members is arranged along the edge of the solar panel (preferably composed of the busbars formed in the solar panel). Therefore, there is no need to set up a separate connection line located outside the solar panel between the two junction box members, thus simplifying operation of wiring between the junction box and the solar panel, and enabling easier and more convenient assembly of the frame assembly having a junction box and solar panel.
According to another important aspect of the present invention, a solar cell module can have detachable junction box members integrated in the frame assembly. Such detachable junction box members can be made as one or both of the two separate junction box members 18 and 20 as previously described with reference to Figure 2; or, such detachable junction box members can also be made as a single detachable junction box integrated in the frame assembly (corner joints or frame segments).
The term "detachable" used herein means that a junction box (junction box members) has removable components.
A detachable junction box member according to one preferred embodiment of the present invention is described below with reference to Figure 3. The detachable junction box member is integrated in one corner joint of the frame assembly of the solar cell module. It is understandable that it can also be integrated in one frame segment of the frame assembly.
As shown in Figure 3, the detachable junction box member has a box body 40 located in a corner joint (or in a frame segment), and the box body can be formed integrally with the corner joint, for example, made by plastic injection molding.
Alternatively, the box body can be made separately relative to the corner joint, and then assembled into the corner joint. In such a case, the box body can be made of a material different from the corner joint.
In the example as shown in Figure 3, the box body 40 comprises a bottom wall 42 and a vertical side wall 44 extending from the bottom wall. In an assembly state of the solar cell module, the bottom wall 42 is parallel to the solar panel. The box body is at least partly open on the top side which is opposite to the bottom wall and on the vertical side proximate to the edge of the solar panel. In the example as shown in Figure 3, the top side is completely open and the vertical side is partly open. Furthermore, in the example as shown in Figure 3, the vertical side wall 44 comprises a side wall substantially parallel to the adjacent edge of the solar panel and two side walls (end walls) substantially vertical to adjacent edge of the solar panel. Nevertheless, the shape of the vertical side wall 44 is not limited to this. For example, vertical side walls of substantially oval shape or with other shapes are also feasible.
An accommodation space is defined in the box body 40, and the circuit board 46 bearing an internal line (for example, aforementioned internal line 22 or 24) is placed in the accommodation space, and is preferably supported by the bottom wall 42, so that the obverse side of the circuit board 46 (the side on which the switching diode is mounted) is facing the open top side of the box body.
In order to close the open top side and vertical side of the
detachable junction box member as shown in Figure 3, the top cover 60 as shown in Figure 4 and the side cover 70 as shown in Figure 5 are provided.
As shown in Figure 3, the vertical side wall 44 of the box body 40 are provided with two vertical slots 48 opposed to each other at the open vertical side, and the left and right two vertical edges 72 of the side cover 70 are inserted into the vertical slots 48.
On the surface of the main body of the side cover 70 facing the accommodation space, two vertical stopping plates 74 are provided respectively on the left and on the right, extending into the accommodation space, and positioners 76 are also provided along upper edge of the main body of the side cover 70, protruding into the accommodation space. The lower edges of the positioners 76 are higher than the upper edges of the stopping plates 74, and the height difference between the lower edges of the positioners 76 and the upper edges of the stopping plates 74 is approximately equal to thickness of inner edge of the top cover 60.
During assembly of the box body, the left and right vertical edges
72 of the side cover 70 are inserted into the vertical slots 48, and the lower edge of the side cover 70 presses against part of the bottom wall 42, and the top cover 60 presses against the upper edges of the stopping plates 74 of the side cover 70 from the top. In this way, the side cover 70 is firmly fixed on the box body 40 by the top cover 60.
After the side cover 70 is assembled on the box body 40, the top cover 60 is put on top of the open top side of the box body 40 and is locked here. For this purpose, the inner edge of the top cover 60 is inserted between the lower edges of the positioners 76 and the upper edges of the stopping plates 74. Furthermore, the top cover 60 is provided with a locking structure at the other edges. For example, the top cover 60 is provided with a snap-lock structure 62 and 62' at both end edges and the outer edge, and the box body 40 is provided with a slot or hole type mating structure 50 and 50' configured for lockingly engaging the snap-lock structure 62 and 62'. Of course, other structures or elements for locking the top cover on the box body can also be used, for example, simple fastening screws can be used for locking the top cover on the box body.
Figure 6 shows a diagram when such detachable junction box members are assembled.
As an alternative, when the top cover 60 is locked on the box body 40, the top cover 60 can also cover or press the upper edge of the side cover 70, instead of pressing the stopping plates 74 on the side cover 70, and lock the side cover 70 on the box body 40.
It is understandable that the locking structure can also be provided on the side cover only, but not on the top cover, and the top cover is locked on the box body by the side cover. Alternatively, both the top cover and the side cover can be provided with respective locking structures to lock them on the box body.
Sealing elements can be provided between the side cover and top cover, or between both of them and the box body to prevent foreign matters, especially moisture, from entering the accommodation space of the box body.
As a preferred embodiment, when the box body is assembled, the lower edges of the stopping plates 74 press against the upper surface (the obverse side) of the circuit board 46 in the accommodation space, to fix the circuit board 46 in the accommodation space in a simple way. Of course, other methods can also be used to fix the circuit board 46 in the accommodation space.
As described above, the two separate junction box members 18 and 20 as previously described with reference to Figure 2 can be composed of such detachable junction box members of the present invention. Figure 7 and 8 shows part of the frame assembly of the solar cell module according to a preferred embodiment of the present invention from the upper and lower sides, which includes the frame segments 14 and the corner joints 16 assembled at both ends of the frame segments. Each corner joint has a corresponding junction box member 18 or 20 integrated in, and the two junction box members 18 and 20 are assembled to form the junction box of the solar cell module.
Figure 8 also clearly shows a solar panel slot 25 formed on back side of various part of the frame assembly (corner joints and frame segments), for the edge of the solar panel to be inserted in.
Figure 9 shows details of the box body 40 of a detachable junction box member integrated in the frame assembly according to a preferred embodiment of the present invention. In an example as shown in Figure 9, the detachable junction box member is integrated in a corner joint. Of course, the detachable junction box member can also be integrated in other parts of the frame assembly.
It can be seen that the vertical side of the box body 40 proximate to the edge of the solar panel has a partial side wall 52 extending upwards from the bottom wall 42, and the height of the partial side wall 52 is lower than the height of the vertical side wall 44, so that the vertical side of the box body 40 proximate to the edge of the solar panel is partially open (i.e., the upper part is open, and the lower part is blocked by the partial side wall 52). Preferably, the upper edge of the partial side wall 52 is
substantially leveled with the obverse side (the upper surface) of the circuit board placed in the accommodation space.
The additional wire 80 used for connecting the busbars of the solar panel and the intermediate line with the internal line disposed in the junction box members is fixed on the partial side wall 52. Each additional wire 80 can be in the form of electrically conductive bars as shown in the figure, having a horizontal section 82 extending to the solar panel to be assembled and a vertical section 84 bent from the horizontal section extending substantially upwards.
As shown in Figure 10, when the side cover 70 is inserted into the box body 40, the side cover 70 shields the vertical sections of the additional wires inside the accommodation space of the box body 40, so that they can connect with the internal line in the accommodation space, while the horizontal sections 82 are kept outside the accommodation space and are still extending in the direction to the solar panel to be assembled, so that they can connect with the busbars and the
intermediate line on the solar panel.
Figure 1 1 shows a situation after the top cover 60 is fixed on the box body 40. In such a situation, the vertical sections of the additional wires have been completely enclosed in the accommodation space of the box body 40. The internal end of the corresponding output cable 10 is connected with the internal line in the accommodation space, and the external end of the output cable 10 is exposed outside the corner joints, and part of the output cable 10 is extending inside the corner joint.
Preferably, the external end of the output cable 10 has a plug-in type of connector.
In such a situation, the solar panel 1 can be assembled onto the frame assembly, for example, inserted into the solar panel slot 25 on the frame assembly. Then, the horizontal sections 82 of the additional wires are connected (for example, welded) to the busbars of the solar panel and the intermediate line.
When the detachable junction box (junction box members) is used, the box body of the junction box is open on both the top side and the vertical side proximate to the edge of the solar panel, and is closed by a dismountable top cover and a side cover. Therefore, more spacious operation space can be provided for operating personnel, to facilitate assembly and maintenance on circuits in the box body of the junction box. Meanwhile, as long as one of the top cover and the side cover is locked up on the box body, both the top cover and the side cover can be assembled on the box body. Therefore, assembly between the junction box and the solar panel becomes easier, which allows installation of the solar cell module to be accomplished in a simple, fast and cost-effective way to facilitate achieving automated production on an assembly line.
Furthermore, concepts of the two-member junction box integrated in the frame assembly and the detachable junction box integrated in the frame assembly according to the present invention can be used in combination or separately. No matter in what manner they are used, the junction box is integrated in the frame assembly, instead of being bonded to the back of the solar panel. Therefore, the junction box will not cause hot spots to occur on the solar cell module, and it will not affect output efficiency of the solar cell module and reduce service life of the components. Furthermore, because the junction box is integrated in the frame assembly, the whole frame assembly maintains an overall smooth and streamlined appearance.

Claims

CLAIMS What is claimed is:
1 . A solar cell module comprising:
a solar panel having a plurality of solar cells;
a frame assembly assembled around the periphery of the solar panel;
a junction box composed of two separate junction box members; and
a connection line connected to the solar panel for outputting electricity generated by the solar panel, the connection line extending through the two junction box members;
wherein both the junction box members are integrated in the frame assembly; and
wherein the connection line comprises an internal line disposed in each of the junction box members and an intermediate line connected between the two internal lines, the intermediate line being arranged along an edge of the solar panel.
2. The solar cell module of claim 1 , wherein the frame assembly comprises a plurality of frame segments and corner joints for joining the frame segments together with angles formed therebetween, and each junction box member is separately integrated in a corresponding corner joint or a corresponding frame segment.
3. The solar cell module of claim 2, wherein the corner joints are connected with the frame segments in a plug-in manner.
4. The solar cell module of claim 2, wherein the corner joint or the frame segment integrated with a junction box member is made of an insulative plastic.
5. The solar cell module of claim 4, wherein the plastic is selected from the group consisting of polyester terephthalate, polybutylene terephthalate, and polytrimethylene terephthalate.
6. The solar cell module of any one of claims 2 to 5, wherein each junction box member comprises:
a box body formed integrally with the corresponding corner joint or frame segment and comprising a cavity defined by a bottom wall parallel to the solar panel and vertical side walls extending from the bottom wall, the box body being at least partly open on both a top side which is opposite to the bottom wall and a vertical side proximate to the edge of the solar panel;
a side cover attached to the box body to close the vertical side of the box body; and
a top cover attached to the box body to close the top side of the box body.
7. The solar cell module of claim 6, wherein one of the side cover and the top cover has a locking structure for locking it to the box body, and the other of the side cover and the top cover is locked to the box body by means of the one of the side cover and the top cover.
8. The solar cell module of claim 7, wherein the top cover has the locking structure for locking it to the box body, and the side cover is locked to the box body by means of the top cover.
9. The solar cell module of claim 8, wherein the locking structure comprises a snap-lock structure, and the box body is provided with a mating structure configured for lockingly engaging the snap-lock structure.
10. The solar cell module of claim 8, wherein the vertical side walls of the box body are provided with opposed vertical slots, and opposite vertical edges of the side cover are inserted into the vertical slots to assemble the side cover to the box body.
1 1 . The solar cell module of claim 6, wherein each junction box member further comprises a sealing member disposed between the side and top covers and the box body.
12. The solar cell module of claim 6, wherein the side cover and the top cover are each made of an insulative plastic.
13. The solar cell module of claim 6, further comprising wires connected between solar cells of the solar panel and the connection line wherein at least one of said wires connects to the internal line of each junction box member.
14. The solar cell module of claim 13, wherein each junction box member comprises a circuit board detachable attached in the cavity of the box body.
15. The solar cell module of claim 13, wherein each wire comprises a first portion sealed in the cavity of the box body by the side cover and a second portion extended out from the box body towards the solar panel.
16. The solar cell module of any one of claims 1 to 4, wherein the intermediate line comprises a busbar formed in the solar panel along the edge of the solar panel.
17. The solar cell module of any one of claims 1 to 4, wherein at least one of the junction box members comprises at least one bypass diode in its internal line.
18. The solar cell module of any one of claims 1 to 4, further comprising positive and negative output cables connected to opposite ends of the connection line respectively.
19. A solar cell module comprising:
a solar panel;
a frame assembly assembled around the periphery of the solar panel; and a detachable junction box integrated in the frame assembly and comprising:
a box body integrated in a portion of the frame assembly and comprising a cavity having a bottom wall parallel to the solar panel and vertical side walls extending from the bottom wall, the box body being at least partly open;
a junction box circuit board detachably mounted in the cavity of the box body;
a cover attached to the box body to close the cavity of the box body.
20. The solar cell module of claim 19, wherein the box body is formed integrally with the frame assembly; or the box body is separately formed with the frame assembly and then attached to the frame assembly.
21 . The solar cell module of claim 19, wherein the box body is at least partly open on both a top side which is opposite to the bottom wall and a vertical side proximate to the edge of the solar panel, wherein the cover attached to the box body comprises a side cover attached to the box body to close the vertical side of the box body and a top cover attached to box body to close the top side of the box body, and wherein one of the side cover and the topcover has a locking structure for locking it to the box body, and the other of the side cover and the top cover is locked to the box body by means of the one of the side cover and the top cover.
22. The solar cell module of claim 21 , wherein the top cover has the locking structure for locking it to the box body, and the side cover is locked to the box body by means of the top cover.
23. The solar cell module of claim 22, wherein the locking structure comprises a snap-lock structure, and box body is provided with a mating structure configured for lockingly engaging the snap-lock structure.
24. The solar cell module of claim 22, wherein the vertical side walls of the box body are provided with opposed vertical slots, and opposite vertical edges of the side cover are inserted into the vertical slots to assemble the side cover to the box body.
PCT/US2012/068359 2011-12-08 2012-12-07 Solar cell module WO2013086265A1 (en)

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