JP2001250974A - Connection box device for solar battery module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide the connection box device of a solar battery module, where the number of parts is reduced, work processes are reduced and a connection box is miniaturized. SOLUTION: A pair of terminals 21 which are caulking-connected to one end part of each module connection cable 9 are installed. The respective terminals 21 are made in long shapes having the width of not more than the outer diameter of the module connection cable 9 in a caulking state. A connection box 2 is provided with a pair of box bodies 24. The respective box bodies 24 are provided with cable insertion holes 10, frame insertion holes 26, terminal fixing parts and a pair of positioning projecting pieces 28. On a module main body 1a-side, bypass diodes 15 are connected between the lead frames 16. The lead frames 16 in the highest stream side and the lowest stream side of a current circulation direction in the respective lead frames 16 are inserted from the respective frame insertion holes 26, and they are connected to the other ends of the longitudinal direction of the respective terminals 21 which are inserted from the cable insertion holes 10 of the respective box bodies 24 and are restrained to the terminal fixing parts.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a connection box device for a solar cell module used for a solar cell module disposed on a roof of a house or the like.

[0002]

2. Description of the Related Art Conventionally, there is generally known a photovoltaic power generation system in which a plurality of photovoltaic modules are arranged in a matrix on a roof of a house or the like to generate photovoltaic power.

As shown in FIG. 7, a connection box 2 in this type of solar cell module 1 has a solar cell 3 (cell group 4), which is electrically connected in series, and has a solar cell 3 (cell group 4) laid on the surface. A bypass diode, which is provided on the back side of the module main body 1a of the battery module 1 and is housed therein, is connected in a direction opposite to the parallel output voltage of the cell group 3 so as to be in a reverse direction. Cell group 4 (or module 1)
Is bypassed.

The connection box 2 is formed of a synthetic resin or the like, and as shown in FIG. 8, has a box body 7 having a substantially rectangular case structure having an accommodation recess 6 therein and having an open upper surface. It is mainly composed of a plate-shaped lid (not shown) attached to the upper surface side with the accommodation recess 6 closed.

The box body 7 has a plurality of (four in the horizontal direction in the figure) wiring holes 8 as frame insertion holes arranged side by side along one edge of the bottom surface. A cable insertion hole 10 into which a pair of module connection cables 9 are inserted (at both left and right ends in the figure) is formed in the side wall of the edge.

Each wiring hole 8 in the box body 7
A plurality of terminal fixing portions (not shown) are provided in the middle of the cable fitting through-holes 10 so as to protrude from the bottom surface along the left-right direction. Terminal 11 is mounted by thermal crushing. At this time, the projecting portions on both sides of the terminal 11 are arranged along the left-right direction, and the remaining projecting portions are arranged so as to project in the wiring hole 8 direction. In addition, 12 in FIG. 8 is the heat crushed part.

[0007] At the center of the terminals 11 at both ends, connection terminal strips 13 which are caulked to the ends of the module connection cables 9 inserted through the respective cable insertion holes 10 are connected by screws 14. And each adjacent terminal 1
The bypass diodes 15 are soldered between the overhangs.

The ends of each lead frame 16 composed of a bus bar and the like connected to each cell group 4 in the solar cell module 1 are connected to the inside of the connection box 2 through each wiring hole 8 provided on the bottom surface of the connection box 2. And soldered to the corresponding protrusions of the terminals 11.

The connection box 2 has a structure in which the lower surface of the box body 7 is attached to the back surface 17 of the module body 1a with an adhesive. At this time, silicone is filled in the housing recess 6 and the lid is adhered for the purpose of waterproofing, moisture proofing, heat radiation, dew condensation prevention, and the like.

In this solar cell module 1, as shown in FIG. 9, one of the module connection cables 9 of the connection box 2 mounted on the back is connected to the other of the module connection cables 9 of the other solar cell modules 1. The structure is such that a plurality of solar cell modules 1 arranged side by side on a roof or the like can be sequentially connected in series.

When power is extracted from each solar cell module 1, these are electrically connected as shown in the block diagram of FIG. 10 to constitute a solar power generation system 18, and a plurality of solar cells connected in series. The module 1 is connected to an inverter or a junction box 19 and converted into an alternating current,
The structure is taken out.

[0012]

However, according to the structure of the above-described conventional connection box 2, a large number of terminals 11 are attached by thermal crushing, and connection terminal pieces 13 which are caulked to the ends of each module connection cable 9 are connected. Each screw 1
4 and connected to each other.
Need to be inserted into the housing portion 6 and soldered to each terminal 11, and the number of components and the number of working steps are large, which is a troublesome work.

Further, since each bypass diode 15 is also soldered to each terminal 11 and housed in the connection box 2, there is a problem that the connection box 2 itself becomes large.

An object of the present invention is to provide a connection box device for a solar cell module in which the number of parts and the number of working steps are reduced and the connection box is reduced in size.

[0015]

The technical means for solving the above-mentioned problems is to extract the output from the module main body of the solar cell module by connecting the lead frame side connected in parallel by a rectifying element for bypass to the output. In a solar cell module connection box device in which a pair of module connection cables are connected to each other via a terminal, and a connection box having a box body for accommodating the terminal is attached to a module body, the terminal is connected to each of the modules. In a crimped state, each terminal is formed into a slender shape having a width equal to or less than the outer diameter of the module connection cable, and the connection box is configured such that each of the terminals is connected to one end of the connection cable. Are housed and connected to each other on one side The box body includes a pair of the box bodies, each of the box bodies includes a cable insertion hole through which the module connection cable is inserted at one end, and a frame insertion hole into which the lead frame is inserted at the other end. A terminal fixing portion is provided at an intermediate portion where a locking portion provided at an intermediate portion in the longitudinal direction of the terminal is pressed to prevent and lock the terminal, and between each lead frame near an output extraction position from the module main body. The bypass rectifying element is connected to each of the terminals, and the bypass rectifying element is inserted into each cable fitting hole of each of the box bodies, and the bypass rectifying element is attached to the other end in the longitudinal direction of each terminal which is locked to the terminal fixing portion. The lead frames on the most upstream and downstream sides of the connected lead frames in the current flow direction are inserted and connected from the respective frame insertion holes, and are connected. Wherein the scan one side is in a point where the attached to the module body.

Further, a structure may be provided in which the one side surface to which each of the box bodies is connected is provided with an extended plane portion forming the same plane.

Furthermore, a structure may be provided in which a reinforcing rib is provided so as to extend between each of the box bodies and the extended plane portion.

In each of the box bodies, a pair of positioning projections for guiding and holding both sides in the width direction of the terminal are provided for positioning the locking portion and the terminal fixing portion of the terminal housed in the box body. Each of them may be configured to be protruded.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described below with reference to the accompanying drawings. FIGS. 1 to 4 show a connection box 2 as a main part of a solar cell module 1 having the same configuration as the conventional one. The same reference numerals are given to components similar to those in the related art.

That is, the solar cell module 1 has a large number of solar cells 3 (cell group 4) electrically connected in series laid on the surface, and a bypass rectifier for taking out an output from the module body 1a. The lead frame 16 side connected in parallel by a bypass diode 15 as an element and a pair of module connection cables 9 for output extraction are connected to each other via a pair of terminals 21.

At this time, each terminal 21 has an elongated plate piece 21a formed narrower than the outer diameter of the module connection cable 9 and an elongated shape, and one end in the longitudinal direction of the elongated plate piece 21a has both ends in the width direction. A crimping piece 21b of the terminal 21 is crimped to one end of the module connection cable 9. In this crimped state, the terminal 21 is configured to have an elongated shape having a width equal to or less than the outer diameter of the module connection cable 9.

Further, a locking hole 21c as a circular locking portion is formed at an intermediate portion in the longitudinal direction of the elongated plate piece portion 21a.

The connection box 2 is made of a flexible hard synthetic resin or the like.
Are provided with a pair of box bodies 24 each having an accommodation recess 23 in which the box bodies 24 are accommodated.
Are connected to each other on the lower surface as one side surface and arranged in parallel.

At this time, the box bodies 24 are arranged at predetermined intervals, and are connected to each other by an extended plane portion 25 which forms the same plane as the lower surface of each box body 24.

Each box body 24 is provided with a cable insertion hole 10 of substantially the same diameter and circular in which the module connecting cable 9 is inserted on one side surface, and the lead frame 16 is inserted on the lower surface of the other end portion. A rectangular frame insertion hole 26 is provided. Further, a terminal fixing portion 27 having a locking portion 27a for locking and locking the locking hole 21c of the terminal 21 is provided at an intermediate portion of each box body 24.

At this time, as shown in FIG. 4, the retaining locking portion 27a is composed of a pair of bending-deformable locking pieces protruding at a predetermined interval, and both locking pieces are directed upward. When the terminal 21 is pressed downward in a state where the locking hole 21c and the retaining locking portion 27a are vertically aligned with each other, the respective locking pieces are elastically deformed. The locking pieces are fitted into the locking holes 21c, and each locking piece is
It is configured to be locked to the peripheral edge of the lock.

Further, the locking portion 27a and the locking hole 21
When the locking portion 21c of the elongated plate piece 21a is positioned with the locking portion 21c of the terminal 21 and the locking portion 27a of the terminal fixing portion 27, the box body 24 is guided and held on both sides in the width direction of the elongated plate piece 21a. A pair of positioning projections 28 are provided at predetermined intervals from the bottom surface of the projection.

Further, an appropriate number of reinforcing ribs 29 are provided between one side surface of each of the box bodies 24 and the upper surface of the expanded flat portion 25.

In this embodiment, the bypass diodes 15 are connected by soldering between the lead frames 16 in the vicinity of the output take-out position from the module body 1a.

Accordingly, the bypass diode 15 is connected to the other longitudinal end of each terminal 21 which is inserted from each cable fitting hole 10 of each box body 24 and is retained and locked by the terminal fixing portion 27. Each of the lead frames 16 on the most upstream side and the most downstream side in the current flow direction in the lead frame 16 is inserted from each frame insertion hole 26 and connected by soldering, and each box body 24 and the expanded flat portion 25 in the connection box 2 are connected. Is attached to the back surface of the module body 1a with an adhesive. At this time, as in the conventional case, silicone is placed in the housing recess 2 for the purpose of waterproofing, moistureproofing, heat dissipation, prevention of dew condensation, and the like.
3, and a rectangular flat cover 30 is adhered.

As described above, according to the present embodiment, each bypass diode 15 is connected to the module body 1a side.
Since it is structured to be mounted between the lead frames 16 by soldering, the structure on the connection box 2 side can be simplified.

When the connection box 2 is assembled, the terminal 21 is attached to the end of the module connection cable 9 because the elongated plate piece 21a of the terminal 21 is formed to have a width equal to or less than the outer diameter of the module connection cable 9. In the caulked connection state, the end of the module connecting cable 9 is fitted together with the terminal 21 through the cable fitting hole 10 to form the elongated plate piece 2.
The locking hole 21c of the terminal fixing portion 27
If the pushing operation is performed downward from above in a state where the terminal 21 is aligned with the position a, the locking state of the locking hole 21c and the locking portion 27a is obtained, and the terminal 21 can be easily mounted.

In this case, a pair of positioning projections 2
8 are protruded, so that the locking hole 21c and the locking portion 2
The positioning projections 28 serve as guides at the time of the pushing operation when the stopper 21a is locked with the retaining member 7a, so that the mutual positioning can be easily performed, and the displacement during the pushing operation can be effectively prevented. This has the advantage of effectively preventing camera shake.

Further, the lead frame 16 has a structure in which the lead frame 16 is directly soldered to the terminal 21 which is crimped to the module connection cable 9. Compared with a structure in which the connection terminal pieces 13 caulked and connected to the module connection cable 9 are connected by fastening screws 14, the number of parts can be reduced and the number of work steps for assembling can be reduced. The number of lead frames 16 to be inserted from 26 and soldered to the terminals 21 may be two. This also eliminates the need for the four terminals 11 as in the related art, thereby reducing the number of components and the number of soldering operations. it can. Here, the manufacturing cost can be reduced.

By reducing the number of components mounted on the connection box 2 as described above, the size of the connection box 2 can be reduced, and the connection box 2 having a simple shape can be provided without deteriorating the aesthetic appearance.

The module body 1 of the connection box 2
a When bonding to the back surface, since the expansion flat portion 25 is provided, a good bonding area can be secured, and a good bonding state can be obtained.

Further, there is an advantage that the strength of the connection box 2 itself can be improved by each reinforcing rib 29.

FIGS. 5 and 6 show a second embodiment, in which the same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof will be omitted.

That is, in the first embodiment, the two box bodies 24 have a structure separated from each other.
In the present embodiment, the two box bodies 24 are arranged close to each other and integrally formed.
The partition walls between them are omitted, and the extended plane portions 25 are formed on both sides of the box body 24 so as to protrude.

Then, each expansion plane portion 25 and the box body 2
An appropriate number of reinforcing ribs 29 are provided so as to extend between both side surfaces of the reinforcing member 4. The lid 30 is also a single piece.

At this time, the respective lead frames 16 on the most upstream side and the most downstream side in the current flow direction near the output take-out position in the module main body 1a are appropriately bent and arranged close to each other, so that the size of the connection box 2 can be further reduced. Have been. Then, similarly to the first embodiment, the module body 1
a.

The present embodiment configured as described above has the same effects as the first embodiment.

In the present embodiment, the structure in which the frame insertion holes 26 are formed is shown, but a structure in which the frame insertion holes 26 of the respective box bodies 24 are formed continuously and integrally may be used.

[0044]

As described above, according to the connection box device for a solar cell module of the present invention, the terminals are formed in a pair which is caulked to one end of each module connecting cable, and each of the terminals is in a caulked state. The terminal has an elongated shape having a width equal to or less than the outer diameter of the module connection cable, and the connection box includes a pair of box bodies in which the terminals are respectively housed and connected to each other on one side and arranged in parallel. The box body has a cable insertion hole through which the module connection cable is inserted at one end, a frame insertion hole into which the lead frame is inserted at the other end, and a longitudinal middle of the terminal at the middle. A terminal fixing portion is provided, which is locked by pressing a locking portion provided on the portion, and each of the lead holes near an output extraction position from the module body is provided. A bypass rectifying element is connected between each of the arms, and a bypass rectifying element is provided at the other longitudinal end of each terminal which is inserted from each cable fitting hole of each box body and is locked to the terminal fixing portion. The lead frame on the most upstream side and the most downstream side in the current flowing direction of each connected lead frame is inserted and connected from each frame insertion hole, and the one side surface of the connection box is attached to a module main body. There is an advantage that the number of parts can be reduced, the number of working steps can be reduced, and the size of the connection box can be reduced.

Further, if the one side surface to which each box body is connected is provided with an extended plane portion forming the same plane, a good adhesion area to the connection box can be ensured, and a good connection area can be secured. There is an advantage that a bonded state can be obtained.

Further, if a structure is provided in which a reinforcing rib is provided so as to extend between each box body and the expansion plane portion, there is an advantage that the strength of the connection box itself can be improved.

A pair of positioning projections for guiding and holding both sides in the width direction of the terminal are provided on each box body so as to position the locking portion of the terminal accommodated in the box body and the terminal fixing portion. With this structure, when locking the locking part and the terminal fixing part, the positioning between them can be easily performed, and the positional deviation during the pressing operation can be effectively prevented. This has the advantage of effectively preventing camera shake.

[Brief description of the drawings]

FIG. 1 is a plan view of a connection box according to a first embodiment of the present invention.

FIG. 2 is an enlarged cross-sectional view taken along line II-II of FIG.

FIG. 3 is a view of the connection box in FIG. 1 taken along line III-III.

FIG. 4 is an explanatory diagram of attachment of a terminal to a terminal fixing portion.

FIG. 5 is a plan view of a connection box according to a second embodiment.

FIG. 6 is a view taken along line VI-VI of the connection box in FIG. 5;

FIG. 7 is a perspective view of a conventional solar cell module.

FIG. 8 is a plan view of the connection box.

FIG. 9 is a diagram showing a connection state of the solar cell module.

FIG. 10 is a block diagram of a conventional solar power generation system.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Solar cell module 1a Module main body 2 Connection box 9 Module connection cable 10 Cable insertion hole 15 Bypass diode 16 Lead frame 21 Terminal 23 Housing recess 24 Box body 25 Expansion plane part 26 Frame insertion hole 27 Terminal fixing part 28 Positioning protrusion 29 Reinforcement rib

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Masaki Kuwahara 1-14 Nishisuehirocho, Yokkaichi-shi, Mie Sumitomo Wiring Systems, Ltd. F-term (reference) 5F051 BA11 EA01 JA02 JA06 JA07

Claims (4)

[Claims] 1. A lead frame side connected in parallel by a rectifying element for bypass and a pair of module connection cables for output extraction are connected to each other via terminals to extract output from the module main body in the solar cell module. In addition, in a connection box device of a solar cell module in which a connection box having a box body for accommodating the terminal is attached to a module main body, the terminal includes a pair connected to one end of each of the module connection cables by caulking, In the crimped state, each terminal has an elongated shape having a width equal to or less than the outer diameter of the module connection cable, and the connection box accommodates each of the terminals and is connected to each other on one side and arranged in parallel. A pair of box bodies, each box body having one end A cable insertion hole through which the module connection cable is inserted is provided, a frame insertion hole into which the lead frame is inserted is provided at the other end, and a frame insertion hole is provided at an intermediate portion in a longitudinal intermediate portion of the terminal. A terminal fixing portion is provided to which the locking portion is pressed and locked. The bypass rectifying element is connected between each lead frame in the vicinity of an output extraction position from the module main body. The most upstream side and the most downstream side in the current flow direction in each lead frame in which the bypass rectifying element is connected to the other end in the longitudinal direction of each terminal inserted from the cable fitting hole and locked in the terminal fixing portion. The lead frame on the side is inserted and connected from each frame insertion hole, and the one side surface of the connection box is attached to the module body. A connection box device for a solar cell module, comprising: 2. The connection box device for a solar cell module according to claim 1, wherein said one side surface to which each of said box bodies is connected is provided with an expansion plane portion forming the same plane. 3. The connection box device for a solar cell module according to claim 2, wherein a reinforcing rib is provided between the box bodies and the expansion plane portion. 4. A pair of positioning projections for guiding and holding both sides in the width direction of the terminal in order to position the locking portion and the terminal fixing portion of the terminal housed in the box body in each box body. The connection box device for a solar cell module according to any one of claims 1 to 3, wherein each of the connection box devices is protruded.