WO2023006833A1 - Connecteur de borne multi-cœur pour modules photovoltaïques - Google Patents

Connecteur de borne multi-cœur pour modules photovoltaïques Download PDF

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Publication number
WO2023006833A1
WO2023006833A1 PCT/EP2022/071115 EP2022071115W WO2023006833A1 WO 2023006833 A1 WO2023006833 A1 WO 2023006833A1 EP 2022071115 W EP2022071115 W EP 2022071115W WO 2023006833 A1 WO2023006833 A1 WO 2023006833A1
Authority
WO
WIPO (PCT)
Prior art keywords
bundle
wires
connector
photovoltaic module
solar cells
Prior art date
Application number
PCT/EP2022/071115
Other languages
German (de)
English (en)
Inventor
Matthias Köhler
Ronny Bakowskie
Nicole LAMPA
Original Assignee
Hanwha Q Cells Gmbh
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 Hanwha Q Cells Gmbh filed Critical Hanwha Q Cells Gmbh
Publication of WO2023006833A1 publication Critical patent/WO2023006833A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H01L31/0508—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module the interconnection means having a particular shape

Definitions

  • the present invention relates to a photovoltaic module with a multi-wire connection connector for deriving a current from one or more solar cells within the photovoltaic module and a method for electrically contacting solar cells and in particular to multi-wire connection connectors as strain relief elements for bypass elements such as diodes.
  • Photovoltaic modules are often exposed to extreme temperature fluctuations during use. As a result, thermal stresses of considerable magnitude can damage electrical connections within the photovoltaic module over time or even interrupt them completely. In the worst case, this can mean that the entire photovoltaic module can only be used insufficiently due to interrupted electrical connections. There is therefore a need for connectors within a photovoltaic module that can reliably withstand greater thermal stresses.
  • the present invention relates to photovoltaic modules with a plurality of solar cells and at least one multi-wire connection connector for deriving an electric current from a plurality of solar cells within a photovoltaic module.
  • the terminal connector comprises a bundle of wires, the wires forming a braided bundle or a twisted bundle or an untwisted bundle.
  • the bundle is configured to provide the following electrical connection: a component connector having contact to an electrical component of the photovoltaic module.
  • a cross-connector for deriving the current from the solar cells is designed as a current busbar between a cell connector, which has a contact to at least one solar cell, and the component connector.
  • the bundle may be configured to also provide at least one of the following electrical connections:
  • a cross-connector which has a direct contact to a cell connector.
  • connection connector is to be dimensioned in such a way that sufficient current can be derived and the connection connector can be accommodated in a photovoltaic module.
  • the connection connector is therefore advantageously not too thick, but bendable in order to be able to lay the electrical connection flexibly.
  • the electrical component is accommodated, for example, in a junction box from where, for example, the entire current of the photovoltaic module is derived.
  • the electrical component can, for example, switch off or bypass individual solar cells or the entire photovoltaic module automatically or in a targeted manner.
  • the connection connector is intended to be used within the photovoltaic module and not as an external cable which connects the entire photovoltaic module.
  • the wires in the bundle are held together by braiding or weaving or gluing or welding or by holding means. There can be a force-fit or a form-fit connection between the wires.
  • the holding means can, for example, clamps or ring-shaped Include elements that hold the wires together (e.g., mechanical clamps, ferrules, connections by crimping, etc.)
  • the bundle of wires forms a braided flat band in a cross section perpendicular to a direction of flow.
  • the braided band can be as flat as possible so as not to increase the thickness of the photovoltaic module.
  • it can be made as wide as possible in order to enable a sufficient flow of current.
  • the wires within the bundle are at least partially electrically isolated from one another or electrically connected to one another. It will be appreciated that the wires may contact adjacent wires at multiple points along their length, which contact is either electrically conductive or electrically isolated (e.g., where the individual wires are themselves insulated). In addition, it is possible for the entire bundle to be electrically insulated, for example by providing a corresponding coating or sheathing that reliably insulates the current path.
  • the wires of the bundle have a coating of a soft solder and/or a conductive plastic.
  • the coating using a soft solder can be useful in order to enable automatic contacting of various connectors by means of local heating to the melting temperature of the solder. This makes it possible, for example, for the connection connectors to be placed one on top of the other and a reliable electrical connection to be established through targeted heat input. The same effect can be achieved with the conductive plastic, which when melted thermally can also bond and thus create an electrical connection between different connectors.
  • the wires are made of copper or have a copper core.
  • Other possible materials are aluminum, carbon nanotubes, etc.
  • the use of copper offers the advantage that copper has a high level of conductivity and copper wires can also be braided easily, resulting in flat connectors braided or twisted without excessive increase in thickness perpendicular to the module surface.
  • Exemplary embodiments also relate to a photovoltaic module with a number of solar cells and at least one multi-wire connection connector, as previously defined.
  • the photovoltaic module can, for example, have various multi-wire connection connectors that connect, for example, adjacent solar cells in series to form a solar cell chain (these are the cell connectors).
  • cross-connectors can be designed as multi-wire connection connectors in order to collect the current from several solar cell strings.
  • the various multi-core connectors can be of the same type (e.g. as braided ribbons) or of different types.
  • multi-wire terminals may interface with other terminals formed differently (e.g. forming twisted or untwisted bundles of wires).
  • the connectors can be connected to conventional busbars or conventional wires (or conductive pastes).
  • the photovoltaic module has at least one bypass element for dissipating an electrical overvoltage as an electrical component.
  • the at least one bypass element can be electrically contacted by the component connector with the bundle of wires.
  • the bypass element can, for example, comprise a diode or another electrical component which, for example, establishes an electrical connection above a certain voltage value (e.g. in the event of a breakdown voltage) in order to protect the module in this way. This can be advantageous, for example, if the module is partially shaded. In the solar cells that are not exposed to sunlight, the electrical resistance will increase due to the low density of charge carriers, which will result in a high voltage drop. In order to avoid damage, however, it is important that the bypass elements can efficiently dissipate such overvoltages.
  • the photovoltaic module includes a (conventional) busbar for deriving the current from the solar cells and the component connector is seen between the bypass element and the busbar (e.g. the current can routed section by section through the conductor rail).
  • a busbar for deriving the current from the solar cells and the component connector is seen between the bypass element and the busbar (e.g. the current can routed section by section through the conductor rail).
  • the mechanical stresses can occur, for example, as a result of the considerable heat input and endanger or damage the electrical connections.
  • conventional photovoltaic modules there is always a loss of contact with the bypass element, which ultimately leads to damage.
  • exemplary embodiments reliably avoid such damage.
  • thermally induced stresses or mechanical stresses can be reduced in different directions (e.g. strain relief, transverse relief) by appropriately aligning the connectors.
  • a multi-core cross connector can already be connected directly to the bypass element (e.g. the diode).
  • a component connector is not absolutely necessary.
  • connection connectors can be laid flexibly during manufacture without being exposed to the risk of the lines breaking. At the same time, a high current density can be made possible by forming the terminal connectors, for example, as a narrow, wider band.
  • Exemplary embodiments also relate to a method for making electrical contact with solar cells of a photovoltaic module.
  • the procedure includes:
  • the bundle of wires can include any number of wires.
  • the bundle can have 2, 3 or at least 5 or at least 10 or at least 20 wires.
  • At least a portion of the wires of the bundle may have a coating of solder and/or conductive plastic, and the method may optionally further comprise: locally heating the bundle of wires to electrically connect the wires to each other or to a current collection device.
  • connection connectors within photovoltaic modules according to exemplary embodiments.
  • 1B shows an example of a photovoltaic module with the multiplicity of solar cells.
  • 2-9 show exemplary embodiments in which the cross-connectors and/or cell connectors are designed according to exemplary embodiments or conventionally.
  • FIG. 10 shows an exemplary embodiment for a possible contacting of an electrical component within the junction box of a photovoltaic module.
  • FIG. 11 schematically shows a flowchart for a method for electrically contacting solar cells of a photovoltaic module.
  • FIG. 1A shows, by way of example, different possibilities for using connection connectors according to exemplary embodiments within a photovoltaic module 20 .
  • a photovoltaic module 20 is shown as an example in FIG.
  • the photovoltaic module 20 comprises a plurality of solar cells 10 and a connection box 40, with a connection line 50 being provided in order to route the current away from the connection box 40 and to feed it into a public power grid, for example.
  • the multi-wire terminal connectors 100 cannot be seen in FIG. 1B.
  • 1A shows further details of the photovoltaic module 20.
  • the solar cells 10 are arranged in the form of solar cell rows 10a and 10b. The solar cells 10 within each row 10a, 10b, .
  • the cell connectors 100a, 15a are electrically connected to cross-connectors 100b, 15b, which collect the current from a plurality of solar cell rows 10a, 10b and transport it to a junction box 40.
  • a bypass element 60 (or other electrical components such as switches), for example, is accommodated within a junction box 40 and is electrically contacted by a component connector 100c, 15c.
  • the exemplary bypass element 60 does not have to be in the junction box 40; it can also be formed in other positions in the photovoltaic module 20.
  • the exemplary bypass element 60 can also be in the form of a laminated component, for example. In particular, it is intended to switch off individual cells or subgroups of solar cells in the event of shadowing or defects in order to avoid damage to the module.
  • the cell connectors 15a, 100a, the cross-connectors 15b, 100b and the component connectors 15c, 100c can each be conventional (then bear the reference number 15) or be designed according to exemplary embodiments (then bear the reference symbol IOO).
  • the various possibilities are specifically described in the following figures.
  • FIG. 2 shows an exemplary embodiment in which the cross-connectors 110b are designed as a braided bundle, which is electrically contacted by conventional cell connectors 15a.
  • the conventional cell connectors 15a are designed, for example, as so-called busbars or by wires.
  • a plurality of cell connectors 15a are formed on a surface of the solar cell in order to enable the solar cells 10 to discharge electricity evenly.
  • further contact fingers can be formed, which only extend within a solar cell 10 and collect the current (not illustrated in the figure).
  • the enlarged view shows how the cell connectors 15a are routed between two adjacent solar cells 10 from an upper side to a lower side. It is understood that the terminal connectors 110b according to exemplary embodiments can consist of wire bundles that are braided in the manner shown schematically in FIG. 2 .
  • the cell connectors 15a run from an upper side of a first solar cell 10 to an underside of the following solar cell 10 in order to achieve a serial connection of the solar cells 10 in this way.
  • the last (or first) cell connector 15a makes contact with the cross connector 110b, which in turn makes contact with a number of solar cell rows 10a, 10b, . . . (see FIG. 1A).
  • FIG 3 shows a further exemplary embodiment in which both the cell connectors 110a and the cross-connectors 110b are designed as multi-wire connection connectors according to exemplary embodiments.
  • this figure shows two solar cells len io within a row of solar cells, which are connected serially with braided cell connectors noa.
  • the cell connectors noa make contact with the cross-connector nob, both connectors being braided in this exemplary embodiment (see also the enlarged illustration in the lower section).
  • the cell connectors 110a make direct contact with the solar cells 10 or the contact fingers on the solar cells in order to dissipate the current.
  • FIG. 3 A cross-sectional view is again shown on the right-hand side of FIG. 3 , the cross-section running along a vertical direction and along an exemplary cell connector 110a.
  • the solar cells 10 are connected in series, i.e. each solar cell 10 is arranged between two adjacent cell connectors 110a.
  • Fig. 4 shows another embodiment, in which the cross-connector 15b are conventional and the cell connectors 110a are designed as a braided bundle according to Ausure approximately examples.
  • the cross connector 15b is formed, for example, as a bus bar (for example, monolithically made of a metal).
  • a cross-sectional view is also shown on the right, where, starting from the conventional cross-connector 15b, the solar cells 10 are serially connected to one another by means of the cell connectors 110a.
  • FIG. 5 shows another embodiment in which the cell connectors are formed as a twisted bundle 120 while the cross-connector is formed as a braided ribbon 110b.
  • the cross-connector is formed as a braided ribbon 110b.
  • FIG. 5 shows an enlarged view of an exemplary twisted bundle 120 having a plurality of wires twisted into each other along a length. As already explained, however, twisting or twisting is not absolutely necessary.
  • the solar cells 10 are in turn connected to one another in series by the cell connectors 120a being connected from a top side to a first Solar cell 10 are led to a bottom of the second solar cell 10 and so on. This can be seen again in the cross-sectional view on the right in FIG.
  • FIG. 6 shows an exemplary embodiment for the connection connectors within a photovoltaic module 20, in which the cross-connector 15b is again designed conventionally, while the cell connectors 120a are designed as a twisted bundle.
  • FIG. 7 shows an exemplary embodiment for the connection connectors within a photovoltaic module 20, in which the cell connectors 15a are designed conventionally, while the cross-connector 120b is designed as a twisted bundle 120.
  • the twisted bundle 120 of the cross-connector 120b comprises a plurality of wires twisted about one another along its length (see, e.g., the illustration of Figure 5 below).
  • FIG. 8 shows an exemplary embodiment for the connection connectors within a photovoltaic module 20, in which the cell connectors 110a are designed as braided ribbons, while the cross-connector 120b is designed as a twisted bundle 120.
  • FIG. 8 shows an exemplary embodiment for the connection connectors within a photovoltaic module 20, in which the cell connectors 110a are designed as braided ribbons, while the cross-connector 120b is designed as a twisted bundle 120.
  • FIG. 9 shows an exemplary embodiment for the connection connectors within a photovoltaic module 20, in which the cell connectors 120a and the cross-connector 120b are each designed as a twisted bundle 120.
  • FIG. 9 shows an exemplary embodiment for the connection connectors within a photovoltaic module 20, in which the cell connectors 120a and the cross-connector 120b are each designed as a twisted bundle 120.
  • contact is only made from one side (e.g. from the rear) of the solar cells.
  • the bundle 100 of wires e.g. the cell connectors
  • the bundle 100 of wires then does not need to be routed from an upper side to an underside or vice versa. This is the case, for example, for back-contact solar cells or for so-called p-n-p arrangements, where p-type and n-type solar cells are arranged alternately.
  • FIG. 10 shows an exemplary embodiment of a possible contacting of an electrical component 60, which is formed, for example, inside the connection box 40 or elsewhere in the photovoltaic module 20.
  • the electrical component is, for example, a bypass element 60 (e.g. a diode).
  • the current can be routed to the exemplary bypass element 60, for example, by means of one or more conventional busbars 15c.
  • a multi-wire connection connector can be formed as a component connector 110c between the busbar 15c and the bypass element 60 in each case.
  • the multi-wire connection connector can in particular include a braided bundle 110 or a twisted bundle 120 .
  • the electrical component 60 can be offset laterally, so that the current flow changes its direction (see second and fourth illustration from the left).
  • the electrical component 60 can also be in line with the busbars 15 so that the current flow does not have to change its direction (see first and third illustrations from the left).
  • the two illustrations on the right and the two illustrations on the left show views from opposite sides, ie the connection connector 110c can be above or below the busbar 15c be arranged (eg seen from a light incidence side).
  • the overlap between the terminal connectors 100 is advantageously chosen to be sufficiently large so that on the one hand the contact resistance is minimized and on the other hand the risk of detachment is minimized (i.e. even if some wires should detach, reliability is not compromised).
  • FIG. 11 schematically shows a flowchart for a method for electrically contacting solar cells 10 of a photovoltaic module 20.
  • the method includes:
  • the bundles 100 need not be twisted or braided, or not completely, but that the individual wires within the bundle 100 are also held together in some other way.
  • the wires can be glued or soldered to one another at various points, or they can also be connected to one another in a form-fitting or force-fitting manner by holding means. Braiding or weaving, however, represents a special way of forming a durable and reliable conductor.
  • the wires of the bundle 100 can also have a coating of a soft solder and/or a conductive plastic. This offers the advantage that by locally heating the bundle 100, the wires can be electrically connected to one another or to a conventional connector 15b, 15c.
  • Exemplary embodiments overcome the problems of conventional connection connectors, for example through the use of braided wires in a solar module 20, whereby they can be used as busbars, cross-connectors of cell strings or connecting elements for example bypass diode 60 (PPT).
  • Braided wires offer the further advantage that they absorb (elongation) stresses better and thereby reduce the risk of breakage at the edges of the solar cells 10 .
  • connection connectors have a lesser mechanical impact on the edges of the solar cells 10 or on the connections of diodes or other electrical components.
  • the previously used monolithic connectors made of metal exhibit considerable thermal expansion, which leads to stresses during operation. For example, large forces act on the solar cells 10 when they are guided from one side to the opposite side. In addition, these stresses or forces can cause fractures or cracks that can result in significant damage.
  • the terminal connectors comprise a multiplicity of wires (e.g. more than 5 or more than 10 or even 100 or more) which are untwisted, twisted or braided and therefore offer sufficient room for thermal expansion. Even if one or a few of these wires should break, the remaining wires can still carry the current. For this purpose, it can be particularly advantageous if the wires make electrical contact at several points along the current flow, so that any break points can be bridged.
  • wires e.g. more than 5 or more than 10 or even 100 or more
  • the wires can also be provided with an insulating coating, at least in sections (eg to avoid leakage currents).
  • the coating can also be conductive.
  • the entire bundle (or the structure) or individual partial wires can have a copper core with a soft solder coating (eg containing lead or lead-free).
  • wires or parts thereof can have a copper core with a conductive plastic coating (polymers, epoxies, acrylates, silicon cone) have.
  • the soldered or glued connection between different connectors (cell connector 100a, cross connector 100b, component connector io oc) can be achieved simply by local heating above the melting temperature of the solder or the plastic.
  • the component connector is thus replaced by a
  • the component connector can be used to connect an exemplary bypass diode (e.g. in the junction box). This type of contact offers the advantage that it can ensure reliable operation of the exemplary bypass diode, since mechanical stresses can be safely absorbed by the wire bundle or these do not arise in the first place.
  • a wire mesh can therefore advantageously be used there in order to make reliable mechanical cushioning possible.
  • the wire mesh therefore has no negative impact on the electrical resistance in normal operation, since the (high) current is dissipated through the busbar of the cross connector with a low resistance - without the current flowing through the wire bundle of the component connector.

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  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Photovoltaic Devices (AREA)

Abstract

L'invention concerne un module photovoltaïque (20) ayant une pluralité de cellules solaires (10) et ayant au moins un connecteur de borne multi-cœur pour décharger un courant électrique à partir d'une pluralité de cellules solaires (10) à l'intérieur d'un module photovoltaïque (20). Le connecteur de borne comprend un faisceau (100) de fils, les fils formant un faisceau tressé (110) ou un faisceau torsadé (120) ou un faisceau non torsadé (140). Le faisceau (100) est conçu pour assurer la connexion électrique suivante : un connecteur de composant (100c) qui est en contact avec un composant électrique (60) du module photovoltaïque (20). Un connecteur transversal (15b) est conçu sous la forme d'une barre omnibus de courant entre un connecteur de cellule (100a), qui est en contact avec au moins une cellule solaire (10), et le connecteur de composant (100c) pour décharger le courant des cellules solaires (10).
PCT/EP2022/071115 2021-07-29 2022-07-27 Connecteur de borne multi-cœur pour modules photovoltaïques WO2023006833A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102021119776.7 2021-07-29
DE102021119776.7A DE102021119776A1 (de) 2021-07-29 2021-07-29 Mehradriger Anschlussverbinder für Photovoltaikmodule

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WO2023006833A1 true WO2023006833A1 (fr) 2023-02-02

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Citations (3)

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US20180151768A1 (en) * 2015-07-14 2018-05-31 Mitsubishi Electric Corporation Solar battery module and method for manufacturing solar battery module
US20190165189A1 (en) * 2017-11-29 2019-05-30 Miasolé Hi-Tech Corp. Bus bar for use in flexible photovoltaic modules
US20200098943A1 (en) * 2017-03-28 2020-03-26 Kaneka Corporation Solar cell module and manufacturing method thereof

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JPH11177117A (ja) 1997-12-12 1999-07-02 Showa Shell Sekiyu Kk 太陽電池モジュール
JP2001135846A (ja) 1999-11-05 2001-05-18 Honda Motor Co Ltd 太陽電池
JP2001352014A (ja) 2000-06-06 2001-12-21 Canon Inc 半導体装置及び太陽電池モジュール
JP5384164B2 (ja) 2009-03-27 2014-01-08 三洋電機株式会社 太陽電池及び太陽電池モジュール
JP2012232320A (ja) 2011-04-28 2012-11-29 Mitsubishi Cable Ind Ltd 太陽電池用リード線の製造方法および太陽電池用リード線
JP2016219799A (ja) 2015-05-20 2016-12-22 株式会社マイティ タブ電極および太陽電池モジュール
KR101751946B1 (ko) 2015-12-28 2017-06-28 엘지전자 주식회사 태양 전지 모듈

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Publication number Priority date Publication date Assignee Title
US20180151768A1 (en) * 2015-07-14 2018-05-31 Mitsubishi Electric Corporation Solar battery module and method for manufacturing solar battery module
US20200098943A1 (en) * 2017-03-28 2020-03-26 Kaneka Corporation Solar cell module and manufacturing method thereof
US20190165189A1 (en) * 2017-11-29 2019-05-30 Miasolé Hi-Tech Corp. Bus bar for use in flexible photovoltaic modules

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