DE102011001164B3 - Connection box for electrical connection of solar module in photovoltaic system in e.g. roof of building, has cover releasably connected with housing body, and electrical components replaced after loosening cover from front side of module - Google Patents

Abstract

The connection box has an electrical and/or electronic component i.e. electronic circuit board (8), for connecting, protecting or controlling a solar module (2). A housing body (4) and a housing cover (7) are provided at a rear side and a front side of the solar module, respectively. The housing body and the cover overlap a recess/aperture (3) in a disk (1) of the solar module. The housing cover is releasably connected with the body and/or the module. The components are replaced after loosening the cover from the front side. An intermediate element (6) is designed as a connection socket. An independent claim is also included for a method for assembling a connection box.

Description

The invention relates to a junction box, which is provided for solar modules with at least one recess or a breakthrough. The junction box has the advantage that electrical or electronic components can be changed easily from the front of the solar module. It is therefore particularly suitable for solar modules whose backs are not accessible or only with great effort (eg., Installed on rooftops or walls solar modules). With the junction box, a new quality of serviceability is achieved. The method enables an uncomplicated and fully automatic assembly (including contacting) of the junction boxes on the solar modules.

High-quality junction boxes for solar modules are already known from the prior art, which ensure a long life of the protective diodes / power semiconductors used and which allow uncomplicated and possibly fully automatic assembly and assembly.

So z. In DE 10 2006 027 104 B3 and in DE 10 2008 022 297 A1 Junction boxes for solar modules described, which consist of aluminum and in which the protective diodes / power semiconductor with respect to the housing electrically insulated, but are thermally conductively connected thereto, whereby the life of the protective diodes / power semiconductors is sustainably increased.

Furthermore, in DE 10 2008 022 297 A1 discloses a junction box for solar panels, which allows an uncomplicated and possibly fully automatic mounting on the backs of solar modules.

However, the aforementioned and also the other commonly used junction boxes for solar modules are mounted on the backs of the solar modules. While the rear sides of the solar modules are easily accessible in open-field installations, most solar modules that are installed on buildings (roof or house wall) in order to reach the junction boxes must first of all be extensively removed in case of service. As a result, arise in the service case regularly considerable costs, and even if z. B. in the can only relatively inexpensive electronic components are to be exchanged.

Due to the demand of the solar industry for ever more intelligent solutions for increasing the safety and increasing the performance of photovoltaic systems, the junction boxes are being equipped with ever more complex electronic components. The lifetime of the electronic components is, as in the junction boxes very large temperature fluctuations of up to -40 ° C to 85 ° C may occur, experience 8 to 10 years, whereas the expected life of solar modules and accordingly the life of photovoltaic systems over 30 years is estimated.

As a result, it must be assumed that due to failures of the electronic components installed in the junction boxes, the solar modules must be replaced at least three times during their runtime. Due to necessary modernization measures, the corrosion of connections or due to lightning or surges in the network, this value can be even higher.

In the DE 100 50 614 C1 , of the DE 10 2008 051 717 A1 and the DE 100 52 529 A1 are holding devices / junction boxes for solar modules, in the panes breakthroughs are shown. In these junction boxes, the cover is formed by a closure member which cooperates with the case body so that the case body is held by the cover. However, none of the junction boxes in the (in the breakthroughs) installed state from the front of the solar modules allows easy access to the electrical components that are located in the junction boxes.

The invention is based on the object to find a junction box for solar modules, in which the electrical or electronic components contained in it can be replaced from the front of the solar module, so that a lasting improvement in the quality of service is achieved. The method is intended to enable an uncomplicated and fully automatic installation of the junction box on the solar module.

The object of the invention is achieved by the junction box according to claim 1 and the method according to claim 9. Further advantageous embodiments and uses of the invention will become apparent from the claims 2 to 8 and 10th

According to the invention, the junction box, which comprises a housing body with an open side, a housing cover, which serves to close the open side of the housing body, and electrical components, which serve for connection, protection and or control of the solar module, with a Solar module used, the disc has at least one recess or an opening. The junction box is attached to the solar module so that the housing body is located on the back and the housing cover on the front of the solar module, wherein the housing body and the housing cover the Cover recess or breakthrough in the disc completely (a partial overlap is indeed conceivable, but not advantageous). The housing body is glued to the back of the solar module and the housing cover releasably connected to the housing body (and / or the solar module).

After loosening the housing cover can (from the front of the solar module from) electrical components that serve to protect and / or to control the solar module can be easily replaced.

In order to simplify the contacting of the junction box, the terminal strips of the solar module are usually in the recess or the breakthrough (with "in the recess" should also be included levels that are a few millimeters above or below the recess / the breakthrough ) guided.

The preferred embodiment of the junction box according to the invention comprises the housing body, an intermediate element, the housing cover, the electrical components, sealing elements, inner contacting elements, which serve to produce the electrical connection between the electrical components in the junction box, and electrical connection elements, via which the solar module in the photovoltaic system is integrated.

The disc of the solar module is clamped by means of the sealing elements and a detachable connection, which allows subsequent removal of the housing cover, between the housing cover and the housing body. For this purpose, preferably the housing body is waterproof bonded to the back of the disc of the solar module (sealing element here is the adhesive seam) and then the housing cover, the solar module facing side is provided in the edge region with a circumferential seal, bolted to the housing body.

In this way, a waterproof interior is formed, in which the intermediate element is located. The intermediate element presses the terminal strips of the solar module on contact points, which are located inside the housing body. At least two of the contact points are electrically connected to external lines, via which the solar module is connected to the photovoltaic system. To ensure a permanent electrical connection, the connection strips are welded or soldered to the contact points.

The housing body and the housing cover are usually made of metal, preferably of aluminum. In order to avoid electrical short circuits, the housing body is at least partially provided on its inner side with an electrically insulating layer.

Preferably, between the housing cover and the intermediate element, those electrical components are arranged which have a shorter expected operating time, whereas the electrical components are installed on the housing body with a longer expected operating time. The term electrical components is intended to encompass all elements that serve to conduct or regulate electrical current (i.e., all elements from simple electrical connectors to electronic components and circuit boards).

The intermediate element is usually formed as a plastic can having an open side. The open side is turned to the housing cover, whereby a cavity is formed between the intermediate element and the housing cover. It is envisaged that there is at least one electronic board in the plastic can (the cavity between the intermediate element and the housing cover).

On the (at least one) board, optional functions such as bypass diodes, electronic / active bypass solutions, theft protection, protection modules of personal protection modules (in case of fire, rescue, service and installation), monitoring functions (measurement of module performance: current and voltage, detection of Arcs, temperature measurements), performance optimizations / MPP (maximum power point) trackers and a module inverter function be realized.

Power-intensive components, such. As protection diodes, however, are not necessarily implemented on the board, but can also be implemented as individual components and thermally connected to the housing of the junction box.

In contrast, in the case body exclusively (simple) electrical connection elements, such. B. connectors or the contact points are pressed on the connecting strips of the solar modules arranged. The expected service life of these elements is at least 30 years and is therefore just as long, or even longer, than that of the solar modules.

The intermediate element / the plastic can, the housing body and possibly the housing cover can be machined; In particular, they are automatically populated.

Between the electrical components in the housing body and the electrical components in the plastic can (or possibly on Housing cover mounted electrical components) exist on the inner contact elements (spring pins, connectors, etc.) electrical connections that are made automatically during installation of the junction box. In order to enable the electrical connections, breakthroughs are introduced on the side opposite the open side of the plastic can through which the inner contacting elements can engage.

Since the housing cover is detachably connected to the housing body (or the solar module), it can, as soon as an exchange of at least one electronic board (or other installed in the plastic box or on the housing cover components) is required, easily from the front (active side of Solar module) unscrewed and accessed the components.

If the junction box according to the invention is used with a solar module with a breakthrough, the peripheral end edge of the open side of the housing body is glued waterproof with the solar module during their assembly. The solar module facing side of the housing cover is provided with a circumferential seal. Both the edge of the housing body and the peripheral seal are chosen so large and placed so that they completely enclose the opening in the solar module.

If the junction box is used in conjunction with a solar module with a recess, then the peripheral end edge of the open side of the housing body has an increase, which in its geometry adapted to the length of the outwardly open side of the recess and to the thickness of the disc is that it fits exactly in the outwardly open side of the recess, d. h., When mounted junction box, the outwardly open side of the recess is completely filled by the increase of the circumferential edge and the top of the elevation and the front of the disc of the solar module are within the manufacturing tolerances at a height. By the interaction of the recess and the increase, a breakthrough is thus formed, which completely or at least partially releases the open side of the housing body.

The housing body is waterproof connected to the solar module by its adjacent edge to the solar module and the two adjacent to the recess side surfaces are glued. Analogous to the junction box for solar modules with a breakthrough both the end edge of the housing body and the circumferential seal of the housing cover are dimensioned and placed so that they completely surround the breakthrough, formed here by the interaction of recess and elevation in the solar module.

In the method for mounting the junction box according to the invention, the peripheral end edge of the open side of the housing body is first glued (with a recess or a breakthrough), whereby the opening (or through the recess in conjunction with the increase in the end edge the housing body formed breakthrough) is covered by the housing body. When sticking the housing body, the terminal strips of the solar module are guided into the interior of the housing body or care is taken that the ribbon is not bent to the side, but even after sticking still protrude into the housing body.

Subsequently, by the intermediate element (partially or completely) is pushed through the opening in the interior of the housing body, the connecting tapes first bent or bent and then pressed against contact points, which are located in the housing body. In order to achieve a permanent connection between the connection strips and the contact points, they are welded or soldered together fully automatically. To make this possible, the intermediate element is provided with openings, are accessible through the welding or solder joints for the tools provided.

Finally, the housing cover is fastened to the housing body by means of a detachable connection (eg by screws). In this case, contacts between the electrical elements in the junction box are on the one hand produced by means of the inner contacting elements, on the other hand, the disc of the solar module between the housing cover and the housing body clamped and thus the interior formed thereby (which completely surrounds the intermediate element) watertight.

The determination of the power (flashing) of the solar modules is preferably carried out before the closing of the housing cover via the openings in the intermediate element automatically by means of sprung test pins; If the performance determination is to be carried out with the housing cover closed, the contact is realized by means of cables and plugs positioned on a blister pack.

The fact that the disc of the solar module is clamped between the housing cover and the housing body has the manufacturing advantage that not as usual, after the attachment of the housing body has to be maintained until the adhesive has cured, but the assembly can be continued immediately or after a short wait become. Because by the clamping of the disc of the solar module slipping of the housing body, even with still soft adhesive prevented.

The process (and junction box) is suitable for crystalline and thin film solar modules, laminated and glass / glass modules, and modules with or without aluminum frames. Fully automatic assembly in module production is possible.

The invention will be explained in more detail with reference to an embodiment; show:

1 : A junction box mounted on a solar module with a recess in a lateral sectional view,

2 : Front view of a junction box mounted on a solar panel,

3 : Rear view of a connection box mounted on a solar module,

4 : State of installation of a connection box after gluing the housing body,

5 : Mounting state of a junction box after insertion of the intermediate element.

The in the 1 to 3 illustrated junction box, which in one in the disc 1 a solar module 2 introduced recess 3 (or breakthrough 3 ) is installed, consists of the housing body 4 with an open page 5 , as a plastic can 6 executed intermediate element, the housing cover 7 , electrical components, such as, inter alia, the electronic board 8th , Sealing elements for sealing the housing cover 7 (executed as an O-ring 9 ) as well as for sealing the housing body 5 (executed as adhesive seam 10 ), inner contacting elements, designed as a spring connection 11 and electrical connection elements 12 for the electrical integration of the solar module 2 serve in the photovoltaic system.

For mounting the junction box ( 4 and 5 ) first becomes the case body 4 so on the solar module 2 Glued that recess 3 or the breakthrough 3 completely from the housing body 4 is covered. It is important to ensure that in the recess 3 /the break through 3 protruding long 13.1 and short ones 13.2 Connection ribbon of the solar module 2 after gluing the housing body 4 in its interior.

After that, the plastic can 6 in the recess 3 or the breakthrough 3 pressed, with the open side 14 the plastic can 6 from the housing body 5 away (up) points. With the open side 14 the plastic can 6 opposite side 15 while doing the connecting strips 13.1 and 13.2 bent and each on contact points 16 that are in the housing body 4 are pressed. The connecting tapes 13.1 . 13.2 are then with the contact points 16 soldered or welded. To make this possible, are on the open side 14 opposite side 15 breakthroughs 17 introduced, the performing tools for soldering or for welding the connecting tapes 13.1 . 13.2 enable.

Finally, the housing cover 7 by means of the two screws 18 that through in the plastic can 6 molded sleeves 19 be guided, with the housing body 4 screwed, creating the so-formed interior, in which the plastic can 6 and the electronics board mounted on it 8th are watertight.

LIST OF REFERENCE NUMBERS

1

disc

2

solar module

3

Recess / break

4

housing body

5

open side of the housing body

6

Plastic box / intermediate element

7

housing cover

8th

electronic board

9

O-ring

10

adhesive seam

11

spring connection

12

connecting element

13.1

long connection ribbon

13.2

short connection ribbon

14

open side of the plastic can

15

opposite side

16

contact point

17

breakthrough

18

screw

19

shell

Claims (10)

Junction box for solar modules with a housing body ( 4 ) with an open page ( 5 ); a housing cover ( 7 ) used to close the open side ( 5 ) of the housing body ( 4 ) serves; and electrical components used for connection, protection ( 2 ) and / or for controlling the solar module ( 2 ), with a solar module ( 2 ) is used, whose disc ( 1 ) at least one recess ( 3 ) or a breakthrough ( 3 ), wherein at the solar module ( 2 ) mounted junction box of the housing body ( 4 ) on the back side ( 2.2 ) and the housing cover ( 7 ) on the front side ( 2.1 ) of the solar module ( 2 ), and the housing body ( 4 ) as well as the housing cover ( 7 ) the recess ( 3 ) or breakthrough ( 3 ) in the disc ( 1 ) cover, wherein the housing body ( 4 ) on the back of the solar module ( 2 ) and the housing cover ( 7 ) detachable with the housing body ( 4 ) and / or with the solar module ( 2 ), whereby after loosening the housing cover ( 7 ) from the front side of the solar module of electrical components that are used to protect and / or to control the solar module ( 2 ), can be replaced. Junction box according to claim 1, characterized in that it encloses the housing body ( 4 ), an intermediate element ( 6 ), the housing cover ( 7 ), the electrical components, sealing elements ( 9 . 10 ), inner contacting elements ( 11 ), which are used to establish the electrical connection between the electrical components in the junction box, and electrical connection elements ( 12 ), over which the solar module ( 2 ) is integrated into the photovoltaic system, wherein at the solar module ( 2 ) mounted junction box the disc ( 1 ) by means of the sealing elements ( 9 . 10 ) and a detachable connection ( 19 ), the subsequent removal of the housing cover ( 7 ), between the housing cover ( 7 ) and the housing body ( 4 ) is clamped such that a watertight interior is formed, in which the intermediate element ( 6 ), and by means of the intermediate element ( 6 ) the connection strips ( 13.1 . 13.2 ) of the solar module ( 2 ) on contact points ( 17 ) located inside the housing body ( 4 ) are pressed, wherein between the housing cover ( 7 ) and the intermediate element ( 6 ) the electrical components ( 8th ), which have a shorter expected life, and on the housing body ( 4 ) the electrical components are installed with a longer expected life. Junction box according to one of claims 1 and 2, characterized in that by means of the inner contacting elements ( 11 ) between the electrical components in the housing body ( 4 ) and the electrical components in the intermediate element ( 6 ) and the housing cover ( 7 ) formed gap electrical connections that automatically close during installation of the junction box exist. Junction box according to one of claims 1 to 3, characterized in that between the lid ( 7 ) and the intermediate element ( 6 ) at least one electronic board ( 8th ), wherein in the housing body ( 4 ) are arranged exclusively electrical connection elements. Junction box according to one of claims 1 to 4, characterized in that the intermediate element ( 6 ) is designed as a plastic can, the at least one open side ( 14 ), wherein the open side ( 14 ) with installed junction box the housing cover ( 7 ) and in the open side ( 14 ) opposite side ( 15 ) Breakthroughs ( 17 ), which is a penetration of inner contacting elements ( 11 ) enable. Junction box according to one of claims 1 to 5, characterized in that the housing body ( 4 ) and the housing cover ( 7 ) consist of aluminum, wherein at least the housing body ( 4 ) is provided on its inside with an electrically insulating layer, and the housing cover ( 7 ) with the housing body ( 4 ) by means of screws ( 18 ) is releasably connected. Junction box according to one of claims 1 to 6, characterized in that it is provided with a solar module ( 2 ) with a breakthrough ( 3 ) is installed, with mounted junction box, the peripheral end edge of the open side ( 5 ) of the housing body ( 4 ) with the solar module ( 2 ) glued waterproof and the solar module ( 2 ) facing side of the housing cover with a circumferential seal ( 9 ), and both the edge of the housing body and the circumferential seal ( 9 ) the break through ( 3 ) in the disc ( 1 ) of the solar module ( 2 ) completely enclose. Junction box according to one of claims 1 to 6, characterized in that it is provided with a solar module ( 2 ) with a recess ( 3 ), wherein the peripheral end edge of the open side ( 5 ) of the housing body ( 4 ) has an increase in its geometry in such a way to the length of the outwardly open side of the recess ( 3 ) as well as to the thickness of the disc ( 1 ) is adapted, that with mounted junction box, the outwardly open side of the recess is completely filled by the increase of the peripheral edge, wherein the top of the elevation and the front ( 2.1 ) of the solar module ( 2 ) at one level, and the one at the back ( 2.2 ) of the solar module ( 2 ) resting part of the end edge with this and the two adjacent to the recess side surfaces of the increase with the solar module ( 2 ) are glued waterproof, and the solar module ( 2 ) facing side of the housing cover ( 7 ) with a circumferential seal ( 9 ), wherein the circumferential seal ( 9 ) through the recess ( 3 ) and the increase formed breakthrough completely encloses. Method for mounting the junction box according to one of the claims 2 to 8 to solar modules ( 2 ) with a recess ( 3 ) or a breakthrough ( 3 ) that the steps - gluing the circumferential end edge of the open side ( 5 ) of the housing body ( 4 ) on the back ( 2.2 ) of the solar module ( 2 ) such that the breakthrough ( 3 ) or by the recess ( 3 ) in conjunction with the increase of the peripheral edge of the housing body ( 4 ) formed breakthrough completely from the housing body ( 4 ) is covered, wherein the connecting strips ( 13.1 . 13.2 ) of the solar module ( 2 ) in the interior of the housing body ( 4 ), - at least partial insertion of the intermediate element ( 6 ) by the breakthrough in the interior of the housing body ( 4 ), whereby the connecting strips ( 13.1 . 13.2 ) and contact points ( 16 ) located in the housing body ( 4 ), - pressing the housing cover ( 7 ) by a detachable connection ( 18 ) between the housing cover ( 7 ) and the housing body ( 4 ), whereby by means of the inner contacting elements ( 11 ) Contacts made between the electrical elements in the junction box, the disc ( 1 ) of the solar module ( 2 ) between the housing cover ( 7 ) and housing body ( 4 ) and the intermediate element ( 6 ) completely enclosing interior is sealed watertight. Method according to claim 9, characterized in that the connection strips ( 13.1 . 13.2 ), which by means of the intermediate element ( 6 ) to the contact points ( 16 ) in the housing body ( 4 ), with the contact points ( 16 ) are welded or soldered, wherein the tool used by in the intermediate element ( 6 ) breakthroughs ( 17 ) to be led.

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