Bypass element and photovoltaic module with at least one bypass element

Abstract

The invention relates to a bypass element (13), in particular for a photovoltaic module (1), having a housing (131) in which at least one semiconductor component is arranged, and at least two terminals (132) protruding from the housing. The bypass element (13) is characterized in that the terminals (132) are led out of the housing (131) with one of their surfaces flush with the lower side of the housing (131), and at least one of the terminals (132) is provided with a solder formation (134). The invention also relates to a photovoltaic module (1) having at least one such bypass element (13).

Description

Technical Field

[0001] This invention relates to a bypass element, particularly for use in photovoltaic modules, the bypass element having a housing in which at least one semiconductor component is arranged, and at least two terminals extending from the housing. The invention also relates to a photovoltaic module having at least one bypass element. Background Technology

[0002] In a photovoltaic module (hereinafter referred to as a PV module), the connection points of existing, interconnected individual modules (usually three individual modules) are typically guided to a junction box via contact strips. At least one bypass element is arranged in the junction box. Typically, one bypass element is provided for each individual module, and this bypass element is connected in parallel with the corresponding individual module.

[0003] Without bypass elements, the individual component receiving the least sunlight will determine the total current of the PV module due to the series connection of the individual components. Bypass elements prevent this behavior, resulting in higher efficiency in partially shaded PV modules. Diodes or transistors connected as diodes are used as bypass elements.

[0004] For example, document US2016 / 0141435A1 describes a PV module with a junction box in which bypass diodes are arranged. Contact strips, guided from the individual components to the junction box, are connected to contact elements inside the junction box. The bypass diodes are also connected to these contact elements with their terminals, and connecting cables are also connected to the contact elements. The contact elements must be manufactured, for example, as stamped grids, which results in material and cost incurred. Furthermore, the installation of the contact elements in the junction box, and their connection to the contact strips on one hand and to the bypass diodes and connecting cables on the other, is costly. Summary of the Invention

[0005] One objective of this invention is to provide a bypass element that can be installed in the junction box of a PV module as simply as possible and with as little additional material consumption as possible. Another objective is to describe a PV module having a junction box with at least one bypass element, wherein the junction box can be installed in a manner that minimizes material consumption.

[0006] This task is accomplished by a bypass element and a PV module having the features of the respective independent claims. Advantageous designs and improvements are the subject of the dependent claims.

[0007] The bypass element of the above type according to the invention is characterized in that the terminals extend from the housing with one surface flush with the lower side of the housing, and at least one of the terminals is provided with a solder-formed part.

[0008] Because the bypass element's terminals extend flush with the underside of the housing, the bypass element can be laid flat inside the junction box onto the end of one or more contact strips and directly soldered to them. This eliminates the need for separate contact elements for the contact strips used to contact individual components within the junction box. Another advantage is that the contact strips do not need to be bent upwards or prepared in other costly ways. Instead, their ends can be laid flat on the back of the PV module and soldered to the bypass element's terminals. This reduces the components and installation costs associated with the junction box.

[0009] The connection process itself is simplified by the solder sizing: the junction box is prepared by placing the required number of bypass elements into a preferably prepared receiving portion. The junction box is open downwards, at least in the area of ​​the bypass elements, through which the solder sizing of the bypass elements can be accessed. For installation, the junction box is then placed on the back of the photovoltaic module, which can be done after the back film has been applied to the PV module and then removed again in the connection area. The junction box is placed such that at least one solder sizing is positioned on or above the flat end of the contact strip. Finally, heat (e.g., from the junction box side) is introduced into the contact piece, whereby the solder sizing melts and the bypass elements are soldered to the contact strip. The heat can be introduced, for example, by means of a heated pressure head (in the form of a soldering iron), whereby the contact piece is also uniformly pressed onto the contact strip. Heat can also be induced within the contact piece.

[0010] In an advantageous design of the bypass element, the at least one terminal block includes a crimp contact for connection to a cable (especially a connection cable for a PV module). Preferably, the crimp contact is arranged or constructed at the free end of the terminal block.

[0011] The connecting cable can be positioned in the crimping contact with its stripped insulation section, and crimped there using appropriate tools. Alternatively, it is conceivable to perform the crimping before placing the bypass element into the junction box, i.e., to place the connecting cable together with the bypass element.

[0012] In an advantageous design for a bypass element, the semiconductor component is a diode or transistor, particularly a MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistor). If the semiconductor device is a transistor, it is preferable that the transistor is internally connected to function as a diode. Regardless of whether the semiconductor device is a diode or a transistor, the bypass element typically has two terminals.

[0013] In one design, at least two terminals of the bypass element are provided with crimp contacts for connection to the corresponding cables. Depending on the location of the bypass element in the junction box, typically only one of the two crimp contacts is needed. Even if one or even both crimp contacts of the bypass element are not used, they do not cause further interference. However, this design, with crimp contacts on both terminals, advantageously reduces the variety of parts that need to be stocked.

[0014] The PV module according to the invention has at least one individual component comprising a plurality of solar cells connected in series and / or in parallel. At least one junction box is arranged on the back of the PV module, wherein a metal contact strip is guided along the back from the connection point of the at least one individual component to the at least one junction box. The PV module is characterized in that the junction box has at least one bypass element of the type described above, the bypass element having at least one terminal piece, the at least one terminal piece being welded to at least one contact strip. Preferably, the PV module further has at least one connecting cable connected to a crimp contact, the crimp contact being arranged on or constructed on at least one terminal piece of the at least one bypass element. Particularly preferably, the PV module has at least two individual components connected in series, each individual component having at least one such bypass element connected in parallel.

[0015] The PV module according to the invention eliminates the need for separate contact elements in the junction box for contacting contact strips that contact one or more individual components. Instead, bypass elements are used directly to contact the contact strips and, if possible, also to contact the connecting cables. This reduces the component and installation costs of the junction box and thus the PV module.

[0016] Preferably, the connector protrudes from the underside of the junction box, extending through an opening in the cover layer on the back of the photovoltaic module until it reaches the contact strip. This described mounting method can be used in PV modules where the back cover layer is a back film. With the connector protruding further, it is also possible to use it in PV modules having a glass sheet as the back cover layer. Attached Figure Description

[0017] The present invention will now be described in more detail with reference to the accompanying drawings and embodiments.

[0018] Figure 1 An isometric view of the PV module as seen from its rear, without a junction box.

[0019] Figure 2 Show Figure 1 Enlarged partial view in the image;

[0020] Figure 3 Show Figure 1 A detailed top view of the PV module with the installed junction box.

[0021] Figure 4a , Figure 4b Show respectively according to Figure 3 A perspective view of the junction box housing viewed from its top and bottom sides;

[0022] Figures 5a to 5c Showing according to Figure 3 Different views of the bypass components of the junction box;

[0023] Figure 6 Illustrations showing the connection areas on the back of PV modules with and without positioned bypass elements;

[0024] Figures 7a to 7d Different illustrations show another example of a junction box for a PV module with a bypass element according to the invention; and

[0025] Figures 8a to 8e A different illustration is shown for another example of a junction box for a PV module with a bypass element according to the invention. Detailed Implementation

[0026] In all the accompanying drawings, the same reference numerals denote the same or having the same function. For clarity, not every element is labeled with a reference numeral in every drawing.

[0027] exist Figure 1 The image first depicts a photovoltaic module (PV module) 1 viewed from its rear side in a top view. The PV module 1 has a frame 2 and the actual module structure. The module structure includes a transparent front-facing support substrate, made of, for example, glass or plastic (especially polycarbonate), on which a semiconductor laminate is applied. This laminate is laterally divided into multiple rectangular units 3, wherein adjacent units 3 can be electrically coupled to each other, particularly in series, via applied connecting layers.

[0028] In this PV module 1, the module structure includes one or more individual components 4a-c—specifically three in this case—each having multiple individual components 3 forming a unit.

[0029] The centerline 5 of the PV module 1 extends parallel to its (shorter) lateral side and is centered about its (longer) longitudinal side. The bottom surface of the PV module is rectangular. Each of the individual components 4a-c includes two strips (Streifen) with individual components 3 extending along the longitudinal direction of the PV module 1, wherein half of the individual component 3 in one strip (in Figure 1 In the diagram, the components 4a-c are located above and below the center line 5, respectively. In each individual component 4a-c, the components 3 located above and below the center line 5 are connected in series, forming a string accordingly. Therefore, each individual component 4a-c includes two strings, which are connected in parallel within the region of the center line 5. Consequently, the contact area of ​​the individual components 4a-c is also located within this region of the center line 5.

[0030] exist Figure 1 In China (and in Figure 2 and Figure 3 (See figure). The PV module 1 is shown without a back cover, such as a back film, that serves as insulation and protects the back of the module structure from environmental influences. In PV modules, such a back film (made of, for example, EVA (ethylene-vinyl acetate), PUR (polyurethane), or PA (polyamide)) is typically laminated on, and is interrupted only at selected locations to allow the connection contacts for the monomer components 4a-c to be brought out. Furthermore, Figure 1 and Figure 2 The PV module 1 is shown before the junction box is installed.

[0031] exist Figure 2 It shows Figure 1 A partial view of the area in the centerline 5 and the individual components 4a and 4b.

[0032] In the region of centerline 5, the two halves of the PV module 1 are spaced so far apart that there are strips along centerline 5 without a supporting base of the halves of the halves, and this provides the possibility of positioning contact strips 6 between the two halves of the ...

[0033] In the middle monomer component 4b, two such contact strips 6 extend inward along the center line 5 from the outer edge of the monomer component 4b to the central region 8b located between the two monomer strips forming the monomer component 4b.

[0034] Similarly, in the region of monomer component 4a, a contact strip 6 extends along the center line 5 from the edge region to the central region 8a of monomer component 4a. This central region 8a, similar to central region 8b, is positioned around the intersection of the center line 5 and the two monomer 3 strips forming monomer component 4a. Figure 6 The upper part of the image also zooms in again to show the central area.

[0035] In the PV module 1 shown, the contact strip 6 continues to guide along the centerline 5 until it also extends into the central region 8b of the individual component 4b. Therefore, it extends in sections above the contact strip 6 that guides from the edge of the individual component 4b to the central region 8b. To prevent the two contact strips 6 from contacting each other, they are insulated from each other between the central region 8a of the individual component 4a and the central region 8b of the individual component 4b. For this purpose, an insulating strip 7 is arranged between the two contact strips 6 along the centerline 5. This insulating strip 7 may be provided with a double-sided adhesive layer, thereby securing it both to the lower contact strip 6 and, if possible, to an exposed area of ​​the supporting substrate adjacent to it, to the upper contact strip 6 on its upper side.

[0036] Through the upper contact strip 6, one pole of the single-cell assembly 4a is guided to the central region 8b of the single-cell assembly 4b. The second pole of the single-cell assembly 4a is invisibly connected below the insulating strip 7 to a contact strip of the contact strip 6 disposed on the single-cell assembly 4b. In this way, the two single-cell assemblies 4a and 4b are internally connected in series, while the two poles of each single-cell assembly 4a and 4b can be obtained in the central contact region to allow for the parallel connection of bypass elements. This is explained in more detail below with reference to Figures 4-6.

[0037] In the same manner, the external pole of the individual component 4c is connected to the PV module 1 via the contact strip 6 arranged on the insulating strip 7 (about...). Figure 2 (As shown in the diagram) The connection point on the outer right side leads to the central region 8b of the single component 4b.

[0038] As a result, in the central region 8b of the individual component 4b, the ends of the four contact strips 6 for contacting the individual components 4a-c are present together. Advantageously, the ends of all four contact strips 6 in this central region 8b can be covered by a single junction box, contacted by external connecting cables, and connected to bypass elements.

[0039] Figure 3 A partial view of the back of the PV module 1 with such a mounting junction box 11 is shown.

[0040] Junction box 11 is positioned along centerline 5 above the central region 8b of the intermediate unit 4b. Despite its compact size (narrower than the width of the intermediate unit 4b), junction box 11 still covers the exposed ends of the four contact strips 6 with its housing 111. The insulating back film, which covers and protects the PV module 1 on the back of the module structure except for the ends of the contact strips 6, is not shown in Figure 4, allowing the positioning of junction box 11 on the PV module 1 to be shown. Furthermore, junction box 11 is shown open. In operation, the junction box is closed using a cover and / or potting material to protect it from moisture and dust ingress.

[0041] Connection areas 112 are constructed on the lateral sides of the outer side of the housing 111. The ends of the connecting cables 14 are connected to the connection areas, and the connecting cables carry plugs 15 at their respective free ends. Three bypass elements 13 are installed inside the junction box, and the bypass elements are connected in parallel with each individual component 4a-c.

[0042] The junction box 11 shown does not have individual contact elements, etc., and uses the contact elements to contact the contact strip 6, bypass element 13 and connecting cable 14.

[0043] Instead, the bypass elements 13 are configured to make contact between the contact strip 6 and the connecting cable 14, eliminating the need for separate contact elements 12.

[0044] The arrangement details of the bypass element 13 within the housing 111 of the junction box 11 are as follows: Figure 4a and 4b As can be seen in the figures, these two figures show a junction box 11 equipped with a bypass element 13, which is independent of the PV module 1 and has no connected connecting cable 14.

[0045] A more detailed view of bypass element 13 is in Figure 5a As shown in -c, where, Figure 5a and 5b It shows a stereoscopic view from different perspectives, while Figure 5c A side view is shown.

[0046] Each bypass element 13 has a housing 131 in which a corresponding semiconductor component (e.g., a diode or a MOSFET transistor connected as a diode) is arranged, and terminals 132 extend from the housing on two opposite sides.

[0047] Two terminals 132 form the two electrodes of the bypass element 13. They extend from the housing 131 flush with the lower side of the housing 131. This design of the bypass element 13 facilitates soldering to the contact strip 6 located below.

[0048] In the bypass element 13 of the second embodiment, the terminals 132 transition outward to the crimp contacts 133. In this way, each terminal 132 can be connected to a cable, for example, to the connection cable 14 of the connection assembly 10. In this respect, Figure 4a and 4b As can be seen, from the two external bypass elements 13, one crimp contact 133 extends into the connection area 112, so that the connecting cable 14 inserted there is positioned in the crimp contact 133 with its stripped insulation section, and can be crimped there with the aid of appropriate tools. If possible, crimping can also be performed before the bypass element 13 is inserted into the junction box 11, that is, the connecting cable 14 is inserted together with the bypass element 13.

[0049] To reduce component diversity, the middle bypass element of the three bypass elements 13 also has a crimp contact 133. These crimp contacts are subsequently unused and do not cause any interference. Alternatively, it is conceivable that only the outer bypass elements of the bypass elements 13 have crimp contacts 133, or even that each has only one crimp contact 133. This allows for a smaller junction box 11, but increases the number of different components to be stored.

[0050] In addition, such as Figure 4b and 5b As shown, each terminal block 132 has a solder molded part 134 placed on its underside (i.e., the side flush with the housing 131). (As shown from...) Figure 4b As can be seen, the solder molded parts 134 of the bypass element 13 extend downward from the junction box 11, and in particular from its lower side 114. When the junction box is placed on the back of the PV module, these solder molded parts 134 are positioned on the contact strip 6 and can be soldered to the contact strip 6 located below by heat when the junction box 11 is in place.

[0051] The bypass element 13 is arranged relative to the contact strip 6 located below it. Figure 6 It is shown again in the text. Figure 6 The upper half shows the central region 8b of the middle unit component 4b of the PV module 1, where the contact strips 6 of the three unit components 4a-c terminate. The two middle contact strips are constructed so long that they extend close to the solder mold 134 of the middle bypass element 13.

[0052] exist Figure 6In the lower region, three bypass elements 13 are shown in the absence of the junction box 11, at which they are soldered to the contact strips 6. It can be seen that the left bypass element 13, with its connecting piece 132, contacts the two left contact strips. Correspondingly, the right bypass element 13 contacts the two right contact strips 6. Finally, the middle bypass element 13 contacts the two middle contact strips 6. In this way, the bypass elements 13 achieve connection not only to the contact strips 6 but also to the connecting cable 14 via the solder molding part 134 or the crimp contact 133.

[0053] No additional metal contact elements are required inside junction box 6. Bypass element 13 can be held in junction box 11, for example, by clamping.

[0054] During installation, the junction box 11 is secured to the back of the PV module 1 by means of an adhesive layer disposed on its lower side 114, typically on a previously applied backing film. The adhesive layer can be, for example, a previously applied hot melt adhesive. With the junction box 11 secured, the bypass element 13 can be soldered to the contact strip 6 by introducing heat from above through the junction box 11 onto the contact piece 132. Here, a heated pressure head can be used again, or heat can be introduced via an induction process. The heat melts the solder mold 134, thereby soldering the corresponding contact piece 132 to the contact strip 6 located below. The bypass element 13 is then held in place by the solder in addition to being clamped in the junction box 11. Finally, the junction box 11 can be potted, which protects the bypass element 13 and the contact area located below, while simultaneously securing the junction box 11 to the back of the PV module 1.

[0055] exist Figure 7a Another example of a junction box 11 for use on the back of a PV module is shown in 8d and 8a-e, respectively, with a bypass element 13 according to the invention arranged in the junction box.

[0056] Figure 7a Alternatively, 8a shows the housing 111 of the junction box 11 when viewed from the lower side 114 of the housing 111. Figure 7b Or 8b shows a side view of junction box 11, Figure 7c Or 8c shows a cross-sectional view of the junction box, and Figure 7d Or 8d shows a top view of the upward-opening housing 111.

[0057] Figure 7a -d and 8a-d respectively show junction boxes 11 that are independent of the PV module and have no connecting cables. Junction boxes 11 can be installed on the back of the PV module.

[0058] exist Figure 8e In the example, for one of the two examples, in a similar manner Figure 8c The side sectional view shows the junction box 11, in which the connecting cable 14 is installed. Furthermore, the junction box 11 is closed by a cover 117, at which a retainer 115 for a plug 15 is provided, the plug being located at the end of the connecting cable 14.

[0059] As previously Figure 3 and 4a The junction box 11 shown in b is the same. Figure 7a The junction box 11 of types -d and 8a-e is also characterized by the use of a bypass element 13 according to the invention. The bypass element 13 has a terminal piece 132 extending laterally from the housing 131. A solder mold 134 is arranged on the corresponding downward side of the terminal piece 132 pointing towards the PV module. The solder mold 134 protrudes from the lower side 114 of the housing 111 and can contact the contact strip or other contact element on the back of the PV module. After the junction box 11 is placed and secured to the back of the PV module, for this purpose, the solder mold 134 is melted by inputting heat, and a connection is established with the contact strip or other contact element.

[0060] Similarly, in Figure 3 In the junction box 11 shown in a and b, the connector 132 terminates in a crimp contact 133, which can then connect to the connecting cable (e.g., inside the housing 111) Figure 8e The connecting cable 14 shown is connected. In order to guide the connecting cable, a cable guide 116 is constructed on one lateral side of the junction box 11 shown.

[0061] Unlike the junction box 11 shown previously, in Figure 7a In embodiments -d and 8a-e, only one connecting cable 14 is connected to each junction box 11. To connect the PV module, two such junction boxes 11 are used at different locations on the back of the PV module accordingly.

[0062] Figure 7a The difference between the two illustrated implementations of junction box 11 in -d and 8a-e is that, in Figures 8a-8e In the example, the connector 132 with solder molding 134 is... Figures 7a-7d In the embodiment, it protrudes more significantly from the lower side 114 of the junction box 11. These two junction boxes 11 are designed for different structural types of PV modules: specifically, Figure 8aThe junction box design of -e is for PV modules whose back cover is formed of a glass sheet instead of a (thinner) back film. The thickness of the glass sheet on the back of the PV module is compensated for by a further protruding section of the connector 132, allowing the solder mold 134 to extend through openings in the glass sheet to the contact strips or other contact elements of the PV module, even if the back glass sheet is thick.

[0063] Regardless of the PV module's structure, the junction box can be fixed to the back of the PV module in the same manner as described above, for example, using hot melt adhesive. The corresponding terminals 132 can be soldered to the underlying contact strip or contact element by introducing heat via a heated pressure head or by an induction process to melt the solder mold 134. Afterward, the junction box can be potted and / or as described above. Figure 8e The diagram shows a cover 117 that closes the enclosure.

[0064] List of reference numerals

[0065] 1. Photovoltaic module (PV module)

[0066] 2-framework

[0067] 3 monomers

[0068] 4a-c single-unit component

[0069] 5 center lines

[0070] 6 contact strips

[0071] 7 Insulating strips

[0072] 8a, b central areas

[0073] 10 connection components

[0074] 11 Junction Box

[0075] 111 housing

[0076] 112 connection area

[0077] 114 lower side

[0078] 115 Retainer for plug

[0079] 116 Cable entry section

[0080] 117 cover

[0081] 13 bypass components

[0082] 131 housing

[0083] 132 connector

[0084] 133 crimped contact

[0085] 134 solder forming parts

[0086] 14 Connecting cables

[0087] 15 plugs

Claims

1. A bypass element (13), particularly for a photovoltaic module (1), said bypass element having a housing (131) in which at least one semiconductor component is arranged, and at least two terminals (132) protruding from said housing, characterized in that, The connector (132) extends from the housing (131) with one of its surfaces flush with the lower side of the housing (131), and at least one of the connectors (132) is provided with a solder mold (134).

2. The bypass element (13) according to claim 1, wherein, The solder forming part (134) is arranged on the surface of the at least one terminal piece (132), the surface being flush with the lower side of the housing (131).

3. The bypass element (13) according to claim 1 or 2, wherein, At least one of the connectors (132) includes a crimp contact (133) for connection with a cable.

4. The bypass element (13) according to any one of claims 1 to 3, wherein, The at least two terminals (132) are each provided with a solder forming part (134).

5. The bypass element (13) according to claims 3 and 4, wherein, The at least two connectors (132) each include a crimp contact (133) for connecting to the corresponding cable.

6. The bypass element (13) according to claim 3 or 5, wherein, The crimping contacts (133) are respectively arranged or constructed at the free ends of the connecting pieces (132).

7. The bypass element (13) according to any one of claims 1 to 6, wherein, The semiconductor component is a diode or a transistor.

8. A photovoltaic module (1), the photovoltaic module having at least one single-unit component (4a-c), the single-unit component comprising a plurality of solar cells (3) connected in series and / or in parallel, and the photovoltaic module having at least one junction box (11) disposed on the back of the photovoltaic module (1), wherein, A metal contact strip (6) is guided along the back side from the connection point of the at least one individual component (4a-c) to the at least one junction box (11), characterized in that... The junction box (11) has at least one bypass element (13) according to any one of claims 1 to 7, the bypass element having at least one terminal piece (132) which is welded to at least one of the contact strips (6).

9. The photovoltaic module (1) according to claim 8, wherein, The connector (132) protrudes from the underside of the junction box (11) and extends through an opening in the cover layer on the back of the photovoltaic module (1) to the contact strip (6).

10. The photovoltaic module (1) according to claim 9, wherein, The back cover is a back film or glass sheet.

11. The photovoltaic module (1) according to any one of claims 8 to 10, the photovoltaic module having at least one connecting cable (14) connected to a crimp contact (133), the crimp contact being arranged on or constructed on at least one terminal piece (132) of at least one bypass element (13).

12. The photovoltaic module (1) according to any one of claims 8 to 11, wherein the photovoltaic module has at least two individual components (4a-c) connected in series with each other, and each individual component is connected in parallel with at least one bypass element (13).

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