JPH11135169A - Fitting method of terminal and terminal continuum to be used therein - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fitting method of a terminal, by which the number of parts is decreased and an assembling process is simplified and also cost can be decreased, and to provide a terminal continuum to be used therein. SOLUTION: In the subject fitting method of a terminal, plural bosses 87 are installed projectedly on a resinous connection box main body 67 of a connection box 61 between solar-cell modules and fitting holes are formed respectively on plural relay terminals 63 for connecting by-pass diodes 21, and also the bosses 87 are inserted into the fitting holes, and then the bosses 87 are heated and crushed by pressure, to thereby fix the relay terminals 63. The plural relay terminals 63 are integrally formed in the connected state via the parts to be separated and installed on the connection body 67, after the by-pass diodes 21 have been soldered in the connected state and output cables 11 and 13 are welded and then separated mutually by cutting off the parts to be separated. Metal fittings 97 and 99 are also fixed to bosses 93 and 95 similarly as the relay terminals 63.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a terminal mounting method and a terminal continuum used therefor, and more particularly to a method for mounting a terminal for connecting a bypass diode provided in a connection box between solar cell modules and a terminal used therefor. It is about a continuum.

[0002]

2. Description of the Related Art As shown in FIG. 13, a plurality of solar cell modules (hereinafter, simply referred to as "modules") 1 are arranged in a matrix on a roof of a house or the like, and solar power generation has conventionally been performed. I have. Each module 1 is provided with an inter-module connection box 3. By connecting a plurality of modules 1 in parallel and in series via the connection box 3, the power from each module 1 is converted to an inverter at 140 to 320 V. 5 and converted by an inverter 5 from DC to AC.

As shown in FIG. 14, a module 1 includes a plurality of solar cells (hereinafter simply referred to as “cells”) 7 arranged in a matrix and a connection box 3. The plurality of cells 7 are divided into a plurality of cell groups 9 (see FIG. 15) including at least one cell 7. The connection box 3 is connected to output cables 11 and 13 on the plus side and the minus side for connection to another module 1 or the inverter 5 or the like.
Waterproof connectors 15, 17 for connection to connectors of other cables are connected to the ends of the output cables 11, 13, respectively.

FIG. 15 is a block diagram showing the electrical configuration of a typical module 1. The cells 7 provided in the module 1 are connected in series with each other, and are divided into a plurality of cell groups 9 by a predetermined number from the minus side to the plus side. A bypass diode 21 is connected in parallel to each cell group 9 so as to be in the opposite direction to the output voltage of each cell 7, so that the reverse-biased current of each cell 7 is bypassed by each bypass diode 21. Has become. Thus, when a specific cell 7, for example, the cell 7a is shaded, it is possible to prevent the back electromotive force higher than the withstand voltage from being applied to the cell 7a, thereby preventing the cell 7a from being damaged. .

FIG. 16 is a plan view showing the internal structure of a connection box 3 to which a conventional terminal mounting method provided in a typical module 1 is applied, and FIG. 17 is a sectional view thereof.
The connection box 3 includes a box 35 including a connection box body 31 and a lid 33, a plurality of relay terminals (terminals) 37 provided in the box 35, and a plurality of bypass diodes 21. I have. As shown in FIG. 15, each cell group 9, each bypass diode 21, and output cables 11 and 13 are electrically connected to each other via a plurality of relay terminals 37.

In this connection box 3, the plurality of relay terminals 37 are manufactured in a state where they are separated from each other, and are separately manufactured.
1, the bypass diode 21 is connected to the relay terminal 37 by soldering 38 after the relay terminal 37 is mounted on the connection box main body 31.

Each relay terminal 37 has a screw hole 3 for screw fixing.
7a is provided, and the connection box body 3 is
1 is screwed. A screw 39 is provided at the end of each of the output cables 11 and 13 on the connection box 3 side.
The connection terminal 41 having a screw hole through which is inserted is crimp-connected, and the connection terminal 41 is connected to the relay terminal 37 with the screwing of the relay terminal 37. That is, the screw 39 has a role of fixing the relay terminal 37 to the connection box main body 31 and an electric connection between the relay terminal 37 and the output cables 11 and 13.

Further, a relay cable 43 from each cell group 9 is connected to each relay terminal 37 attached to the connection box main body 37 by soldering 45. Each of the output cables 11 and 13 is drawn into the inside of the box 35 through a through hole 47 provided in a side wall of the connection box main body 31, and inside the connection box main body 31 by a fixing fitting (fixing member) 49. It is fixed to. The fixing bracket 49 is fixed to the connection box main body 31 by screws 51.

[0009]

However, in the conventional terminal mounting method, since the relay terminal 37 is fixed to the connection box main body 31 by screwing, screws 39 and the like for screwing are required. However, there is a problem that the number of components is large and the cost is high, and complicated screwing work is required for each relay terminal 37, which complicates the assembling work.

Further, the connection between the connection terminal 41 of the output cables 11 and 13 and the relay terminal 37 is also made by screwing with the screw 39. It is important to control the torque at the time of screwing, and there is a problem that the man-hour required for the torque control further complicates the assembling work. In addition, the screw 39 may be loosened and a contact failure may occur. There's a problem.

Further, the soldering of the bypass diode 21 to the relay terminal 37 is performed by connecting the junction terminal body 31 of the relay terminal 37.
Since it is carried out in the narrow and complicated connection box main body 31 after fixing to the connection box, it is difficult to perform automation, which hinders cost reduction.

Further, since the fixing bracket 49 for fixing the output cables 11 and 13 to the connection box main body 31 is screwed by the screw 51, the number of parts such as the screw 51 is also reduced. There are problems such as an increase and an increase in the assembly process.

In view of the above problems, the present invention reduces the number of parts, simplifies the assembly process, reduces cost, and improves the reliability of the terminal mounting method and the terminal used therefor. It is intended to provide a continuum.

[0014]

The technical means for achieving the above object is a terminal mounting method for mounting a plurality of terminals for connecting predetermined electric circuits to a resin mounting base. Preparing a terminal continuum formed of a single metal plate in a state where a plurality of terminals are continuously connected via a predetermined separating portion, and a predetermined mounting hole is provided in each of the terminals; At the mounting position of each terminal on the base, a terminal boss portion inserted into the mounting hole of each terminal is integrally provided with the mounting base so as to protrude therefrom. The terminal continuum is installed on the mounting base so that the terminal boss portion at the mounting position is inserted,
The terminals of the terminal continuum are fixed to the mounting table by heating and softening the respective terminal bosses and crushing the terminals, and the cut-off portions between the terminals of the terminal continuum are cut to cut the respective terminals. The terminal is separated.

Preferably, the mounting base is a part of a connection box body for connecting a plurality of photovoltaic cell groups, and the plurality of photovoltaic cell groups are connected to the respective terminals. Connected via a relay cable so as to be connected to each other in series, and the bypass diode of each solar cell group is connected in parallel to each corresponding solar cell group via each terminal. While being connected so as to be connected, an output for extracting an electromotive force from the plurality of photovoltaic cell groups is provided at the most upstream side and the most downstream side of the plurality of terminals in the current flow direction. Cables should be connected respectively.

Preferably, the relay cable, the connection terminal of the bypass diode, and the output cable are welded to the terminal.

Still preferably, each of the bypass diodes is soldered to the terminal of the terminal continuum before the terminal continuum is attached to the mounting base.

[0018] Preferably, mounting holes are provided on both sides of a contact portion of the fixing member for holding and fixing the output cable between the mounting base and the output cable,
A boss portion for a fixing member that is inserted into the mounting hole of the fixing member at a predetermined position of the mounting table is provided integrally with the mounting table, and the output cable is provided between the mounting table and the fixing member. In a state where the boss portion for the fixing member of the mounting base is inserted into the mounting hole of the fixing member so as to be sandwiched,
The output cable is preferably fixed to the mounting base by heating and softening the boss portion for the fixing member and crushing it.

Still preferably, in a terminal continuum used for the terminal mounting method, the terminal continuum is formed of a single metal plate in a state where a plurality of terminals are continuously connected via a predetermined cut-off portion. It is preferable that each terminal is provided with a mounting hole through which the terminal boss protruding from each of the mounting positions of the mounting base is inserted.

In the present invention, "welding" includes welding and soldering.

[0021]

BEST MODE FOR CARRYING OUT THE INVENTION

<Structure> FIG. 1 is a plan view showing an internal structure of a connection box between solar cell modules to which a terminal mounting method according to an embodiment of the present invention is applied, and FIG. 2 is a sectional view thereof. In addition,
The connection box 61 between solar cell modules according to the present embodiment also has the module 1 shown in FIG.
And a plurality of cell groups 9 constituting the module 1, a bypass diode 21 provided in parallel for each cell group 9, and an output cable 1.
The circuit configurations 1 and 13 are the same as those shown in FIG. 15, and the portions corresponding to the connection box 3 shown in FIGS. 16 and 17 are denoted by the same reference numerals, and description thereof will be omitted.

FIG. 3 shows a terminal continuum 6 in which a plurality of relay terminals 63 used in the connection box 61 are continuously connected.
5 is a plan view of the connection box body 67 provided in the connection box 61 in a state before the relay terminal 63 and the like are provided, and FIG. 5 is a VV cross-sectional view thereof. 6 is a sectional view taken along the line VI-VI, FIG. 7 is a sectional view taken along the line VII-VII, FIG. 8 is a sectional view taken along the line VIII-VIII, and FIG. 9 is a side view thereof.

As shown in FIG. 3, the terminal continuum 65 is formed by continuously connecting a plurality of, here four, relay terminals 63 via a narrow cut-off portion 69. It is formed by punching or the like. The relay terminals 63 of the terminal continuum 65 are punched out in a predetermined arrangement corresponding to the attachment position to the connection box main body 67 so as to be continuous in a row at a certain interval here, In this state, attachment to the junction box body 67 is performed. The role that each relay terminal 63 plays in circuit connection in the electric circuit is the same as that of the conventional relay terminal 37, and a detailed description is omitted here.

Of the four relay terminals 63, the middle two
One of the relay terminals 63a has a T-shape, and two of the relay terminals 63b on both sides have a cross shape.
Reference numeral 9 connects the tips of the left and right protruding portions 71 along the continuous direction of the adjacent relay terminals 63.

At the center of each relay terminal 63, a mounting hole 73 for mounting to the junction box body 67 is provided.
A connection hole 77 for the solder connection of the relay cable 43 connected to each cell group 9 is formed in the protrusion 75 on the upper side of each relay terminal 63.
Are provided in the left and right protruding portions 71. The connection holes 7 for solder connection of the connection terminals 21 a of the bypass diodes 21 are provided.
9 are provided, and the lower and upper protruding portions 81 of the relay terminals 63b on both sides (the most downstream side and the most upstream side in the current flow direction) have the positive and negative output cables 11,
13 are connected by welding.

Connection box body (mounting base) 6 which is a resin molded product
7 forms a box body 85 together with a lid 83 mounted on the upper opening. The connection box main body 67 has the same number as the relay terminals 63 of the terminal continuum 65, in this case, four terminal bosses 87, and two cable holding portions 89, 91 extending through the side walls thereof. Also, bosses 93 and 95 for fixing fittings provided in pairs on both sides of the cable holding portions 89 and 91 inside the side wall portion of the connection box body 67 are provided integrally with the connection box body 67.

The four terminal bosses 87 are connected to the terminal continuum 6.
5 are arranged in a row at the center of the bottom of the connection box body 67 in correspondence with the arrangement of the terminals 63, that is, the arrangement of the serially provided relay terminals 63. In FIG. . The cross sections of the two cable holding portions 89 and 91 are U
The output cable 1 has U-shaped grooves 89a and 91a.
1 and 13 are accommodated in the grooves 89a and 91a, and are drawn into the box body 85 through the grooves 89a and 91a. Two pairs of fixing metal bosses 9
3, 95 connect the output cables 11 and 13 to the connection box body 67.
This is for fixing the fixing brackets 97, 99 for fixing the fixing members 97, 99.

The fixing brackets 97 and 99 used for fixing the output cables 11 and 13 are formed by bending a central cable contact portion of a plate-like member in an arc shape along the outer circumference of the output cables 11 and 13. On both sides of the cable abutment portion, boss portions 93 for fixing brackets of the connection box body 67 are provided.
Mounting holes 97a, 99a through which the 95 is inserted (see FIG. 11)
Is provided.

<Assembling Step> The assembling step of the connection box 61 will be described. First, as shown in FIG. 10, the connection holes 7 adjacent to each other of the relay terminals 63 of the terminal continuum 65.
9, connection terminals 21a of three bypass diodes 21
Are connected by soldering 38, and the output cables 11 and 13 are connected to the protruding portions 81 of the relay terminals 63 b at both ends of the terminal continuum 65 by welding 101. At this time,
The three bypass diodes 21 are connected to the output cables 11 and 13 in series via the respective relay terminals 63.

Subsequently, as shown in FIG. 11, the terminal continuum 65 to which the bypass diode 21 and the output cables 11 and 13 are connected is inserted so that the terminal bosses 87 are inserted into the mounting holes 73. It is installed in the junction box body 67. At this time, the output cables 11 and 13 are inserted into the grooves 89a and 91a of the cable holding portions 89 and 91, and the fixing fittings 97 and 99 are inserted from above into the mounting holes 97a and 99.
It is set on the connection box main body 67 so that the fixing metal boss portions 93 and 95 are inserted through the connector box a.

Subsequently, as shown in FIG.
The bosses 87, 93, and 95 are softened by heating and crushed from above, and the relay terminals 63 and the fixing brackets 97 and 99 are fixed to the connection box body 67. As a method of this heat crush,
A method of pressing the heat crushing means heated to a high temperature against the bosses 87, 93, 95 to crush the heat, a method of crushing the bosses 87, 93, 95 while heating and softening the bosses 87, 93, 95 by a predetermined ultrasonic heating means, and the like are used. . In this fixed state, the output cables 11, 13 are connected to the grooves 89 of the cable holding portions 89, 91.
a, 91a and holding fixtures 97, 99 are held and fixed.

Then, as shown in FIG. 1, the cut-off portions 69 between the relay terminals 63 are cut off by predetermined cutting means, and the connection holes 77 of the relay terminals 63 are inserted into the respective cell groups 9.
Is connected by soldering 45, and the lid 83 is attached.

As described above, according to the present embodiment, the terminal boss portion 87 of the connection box body 67 is inserted into the mounting hole 73 provided in the relay terminal 63, and the terminal boss portion 87 is softened by heating. Since the relay terminal 63 is fixed to the connection box body 67 by a simple process of crushing the connection terminal, the screw and the complicated screwing work as in the related art are unnecessary, and the number of parts is reduced. Therefore, there is an advantage that the assembly process can be simplified and the cost can be reduced, and screwing which requires complicated torque management is not required, so that the process of mounting the relay terminal 63 can be easily automated.

The connection box body 6 of the plurality of relay terminals 63
7 is carried out in a continuous state via the separating portion 69, so that a plurality of relay terminals 63 can be connected to the connection box main body 6 at a time.
7, and a terminal boss portion 87 of the connection box body 67 inserted through the mounting hole 73 of each relay terminal 63.
Can be heated and crushed at a time, so that a plurality of relay terminals 63 can be attached at one time, and the working efficiency is very good.

Further, by connecting the output cables 11 and 13 conventionally connected by screwing to the relay terminal 63 by welding 101, the connection between the relay terminal 63 and other circuit parts such as the output cables 11 and 13 is achieved. Connection points by screwing can be completely eliminated from the points, and as a result, the number of parts can be reduced, the assembly process can be simplified and the cost can be reduced, and the reliability of the connection can be improved. In addition, there is an advantage that the connection process of the output cables 11 and 13 can be easily automated.

The solder connection of each bypass diode 21 to each relay terminal 63 is performed before each relay terminal 63 is mounted in the connection box body 67 with poor workability, and the plurality of relay terminals 63 are still disconnected. Not detached, detaching section 69
Therefore, the connection process of the bypass diode 21 can be easily automated, and the automation can greatly reduce the cost of the assembly process.

Further, similarly to the relay terminal 63, fixing metal fittings 97, 99 for fixing the output cables 11, 13 are also provided in the mounting holes 97a, 99a in the metal fitting fixing boss portion 9.
The bosses 93 and 95 can be attached to the connection box body 67 simply by passing the bosses 3 and 95 through and crushing the bosses 93 and 95 by heating. Can be performed in the same process, so that screws and complicated screwing work as in the related art are not required, the number of parts can be reduced, the assembly process can be simplified, and the cost can be reduced.

In this embodiment, the connection box 61 is provided for each module, and the bypass diode 21 is connected in parallel to each cell group 9 in the module 1 via each relay terminal 63 provided in the connection box 61. By this, each cell group 9 provided in a single module 1 is bypassed by each bypass diode 21 of the connection box 61. However, one module 1 is regarded as one cell group 9 and the connection box 61 Is provided for each of the plurality of modules 1, and the bypass diodes 21 are connected in parallel to the respective modules 1 via the respective relay terminals 63 provided in the connection box 61, whereby each bypass diode 21 of the connection box 61 The module 1 may be bypassed.

[0039]

As described above, according to the first to sixth aspects of the present invention, each terminal boss portion of the mounting base is inserted into the mounting hole provided in each terminal, and the terminal boss portion is inserted. The terminal is fixed to the mounting base by heating and softening and crushing, eliminating the need for screws and complicated screwing work as in the past, reducing the number of parts and reducing the assembly process. In addition, there is an advantage that automation can be easily performed because simplification and cost reduction can be achieved, and screwing which requires complicated torque management is unnecessary.

Further, since the fixing of the plurality of terminals to the mounting base is performed in a continuous state through the separating portion, the plurality of terminals can be installed on the mounting base at one time. By heating and crushing each terminal boss portion of the mounting base inserted into the hole at a time, it is possible to mount a plurality of relay terminals at once, which is very efficient.

According to the third aspect of the present invention, the relay cable, the connection terminal of the bypass diode, and the output cable, particularly the output cable conventionally connected by screwing, are connected to the terminal by welding, which is complicated. Connection is performed without using screws that require high torque management, the number of parts can be reduced, the assembly process can be simplified and the cost can be reduced, and the connection reliability can be improved. In addition, there is an advantage that automation is easy.

According to the fourth aspect of the present invention, the soldering connection of each bypass diode to each terminal is performed before each terminal is mounted in the connection box body having poor workability, and a plurality of terminals are still disconnected. Since they are not separated but are positioned and fixed to each other by the separating section, automation is easy, and the automation can greatly reduce the cost of the assembling process.

According to the fifth aspect of the present invention, the fixing member boss of the mounting base is inserted into the mounting hole provided in the fixing base such that the output cable is sandwiched between the mounting base and the fixing base. By heating and softening the boss for the fixing member and crushing it, the output cable is fixed to the mounting base.Therefore, there is no need for screws or the complicated screwing work as in the past, The number of parts can be reduced, and the assembly process can be simplified and the cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a plan view showing an internal configuration of a connection box between solar cell modules to which a terminal mounting method according to an embodiment of the present invention is applied.

FIG. 2 is a sectional view of the junction box of FIG.

FIG. 3 is a plan view of a terminal continuum in which a plurality of relay terminals used in the connection box of FIG. 1 are continuously formed;

FIG. 4 is a plan view showing a state before a relay terminal or the like of a connection box main body provided in the connection box of FIG. 1 is provided;

FIG. 5 is a sectional view taken along line VV of FIG. 4;

FIG. 6 is a sectional view taken along line VI-VI of FIG. 4;

FIG. 7 is a sectional view taken along the line VII-VII of FIG. 4;

FIG. 8 is a sectional view taken along line VIII-VIII of FIG.

FIG. 9 is a side view of FIG. 4;

FIG. 10 is a diagram showing an assembling process of the connection box of FIG. 1;

FIG. 11 is a diagram showing an assembling process of the connection box of FIG. 1;

FIG. 12 is a diagram showing an assembling process of the connection box of FIG. 1;

FIG. 13 is a perspective view showing a state where a solar cell module is installed on a roof of a house.

FIG. 14 is a perspective view of the solar cell module of FIG.

FIG. 15 is a circuit diagram showing an electrical configuration of the solar cell module of FIG.

FIG. 16 is a plan view showing an internal configuration of a connection box to which a conventional terminal mounting method is applied.

FIG. 17 is a sectional view of the junction box shown in FIG. 16;

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 solar cell module 7 solar cell 9 solar cell group 11, 13 output cable 21 bypass diode 43 relay cable 61 connection box between solar cell modules 63 relay terminal 65 terminal continuum 67 connection box main body 69 disconnecting portion 73 mounting hole 87 terminal Boss 93,95 Boss for fixing bracket 97,99 Mounting bracket 97a, 99a Mounting hole

Claims (6)

[Claims] 1. A method of mounting a plurality of terminals for connecting predetermined electric circuits to each other on a resin mounting base, wherein the plurality of terminals are continuously connected via a predetermined cut-off portion. A terminal continuum formed from a single metal plate in a state where each terminal is provided with a predetermined mounting hole is prepared, and the mounting hole of each terminal is provided at a mounting position of the terminal on the mounting base. The terminal boss portion is inserted and protruded integrally with the mounting base, and the terminal continuity is inserted so that the terminal boss portion at each of the corresponding mounting positions is inserted into the mounting hole of each terminal. A body is placed on the mounting base, and each terminal of the terminal continuum is fixed to the mounting base by heating and softening each of the terminal bosses and crushing them. Cut off the disconnecting section and separate each terminal A method for mounting a terminal, comprising: 2. The mounting base is a part of a connection box body for connecting a plurality of solar cell groups, and the plurality of solar cell groups are connected to the respective terminals via the respective terminals. Connected via a relay cable so as to be connected to each other in series, and the bypass diode of each solar cell group is connected in parallel to each corresponding solar cell group via each terminal. The output cable for extracting the electromotive force from the plurality of solar cell groups is connected to the most upstream and the most downstream terminals of the plurality of terminals in the current flow direction. The terminal mounting method according to claim 1, wherein the terminals are connected to each other. 3. The terminal mounting method according to claim 2, wherein the relay cable, the connection terminal of the bypass diode, and the output cable are welded to the terminal. 4. The terminal according to claim 2, wherein each of said bypass diodes is connected by soldering to said terminal of said terminal continuum before said terminal continuum is attached to said mounting base. Mounting method. 5. A fixing member for holding and fixing the output cable to and from the mounting base is provided with mounting holes on both sides of a contact portion with the output cable, and the fixing member is provided at a predetermined position on the mounting base. A boss portion for a fixing member inserted into the mounting hole is provided integrally with the mounting base, and the output cable is sandwiched between the mounting base and the fixing member. In a state where the boss portion for the fixing member of the mounting base is inserted, by heating and softening the boss portion for the fixing member and crushing,
5. The terminal mounting method according to claim 2, wherein the output cable is fixed to the mounting base. 6. A terminal continuum used in the terminal mounting method according to claim 1, wherein a plurality of terminals are continuously connected to each other via a predetermined cut-off portion. A terminal continuum formed of a plate, wherein each terminal is provided with a mounting hole through which the terminal boss protruding from each of the mounting positions of the mounting base is inserted.