Connection device

Abstract

A connection device (1) for electrical conductors, in particular for a solar module, comprises a housing (2) and a carrier element (6) with at least one electronic component (10). An insert unit (100) with the carrier element (6) is inserted into an interior space (3) of the housing (2). A solar module with at least one such connection device (1) is provided.

Description

[0001] The invention relates to an insert for a connecting device for electrical conductors, in particular for a solar module, according to the preamble of claim 1.

[0002] Such a connection device is also called a PV box and is used to connect one or more electrical conductors, e.g. a busbar, of a solar module.

[0003] The external electrical connection cables of the solar cell groups of the solar module are combined and connected to power semiconductors in the connection device. These power semiconductors are so-called bypass diodes and serve to bypass, short-circuit, and bridge the current flow around solar cell groups that are defective or produce only a low output compared to other solar cell groups.

[0004] DE 10 2009 049 812 A1 discloses a junction box, in particular for a solar module, comprising: a cover device with a displacement element, a housing device with a functional interior, and a reservoir, wherein the functional interior is hydraulically connectable to the reservoir and wherein, in an arrangement position, the displacement element reduces the interior volume V of the functional interior by a predetermined displacement volume V. A method for producing a solar panel, a cover device, and a use of the cover device are described.

[0005] The existing solutions have proven themselves to be effective. However, there is a constant need for further development, creating greater functionality with increased safety, compact design, and reduced installation time.

[0006] The solution to this problem is the object of the invention.

[0007] This object is achieved with a connecting device according to claim 1.

[0008] The problem is also solved by a solar module according to claim 15.

[0009] A connection device according to the invention for electrical conductors, in particular for a solar module, comprises a housing and a carrier element with at least one electronic component. An insert unit is inserted with the carrier element into an interior of the housing.

[0010] One advantage is that the insert unit allows for quick and easy installation.

[0011] A solar module with at least one such connection device is provided.

[0012] The compact design is advantageous here.

[0013] Further advantageous embodiments of the invention can be found in the remaining subclaims.

[0014] In one embodiment, the insert unit has at least one longitudinal holder, which forms a holder for the carrier element. Thus, the carrier element can be easily inserted into the housing of the connection device, pre-loaded with the electronic component and pre-assembled in the longitudinal holder.

[0015] If the insert unit has two longitudinal holders, this is an advantage as it simplifies handling.

[0016] To achieve an advantageously compact design, the two longitudinal supports are arranged parallel to each other and connected by at least one cross connector. The cross connectors enable an advantageously stable design and simple pre-assembly of the longitudinal supports with the support element.

[0017] In a further design, a recess extending in the longitudinal direction of the corresponding longitudinal holder is formed into each of the two longitudinal holders, each of which forms a receptacle for the long sides of the support element. This is advantageous for simple and quick pre-assembly with or without simple tools.

[0018] In yet another embodiment, the support element rests on a support surface of the at least one cross connector when the insert unit is installed. This results in the advantage of a compact and stable structure.

[0019] In another embodiment, retaining elements are mounted in the housing, which can be connected to the at least one longitudinal holder. This connection is advantageously simple.

[0020] A further advantage arises when the holding elements form clip-like holders into which the insert unit is clipped when assembling the connecting device.

[0021] In yet another embodiment, the retaining elements extend through through-holes in the support element. This is advantageous because it results in a compact and stable structure.

[0022] One embodiment provides that the interior of the housing can be closed with a cover having at least one cover fastening that can be connected, preferably latched, to the at least one longitudinal holder of the insert unit. This provides a further, additional advantageous function of the insert unit.

[0023] In one embodiment, the insert unit forms a displacement volume for a potting compound, with which the interior of the housing of the connection device is potted after assembly. This results in further significant advantages. The volume of potting material in the housing can be reduced by the displacement volume of the insert unit. This, in turn, results in a reduction in the layer thickness or potting height of the potting compound, thus shortening the curing time. This advantageously reduces the overall process time.

[0024] In a further embodiment, the support element has connection sections for a connecting cable or connecting elements in the end areas. This provides an advantageously simple connection option, e.g., with suitable conductor terminals.

[0025] In an alternative advantageous embodiment, the carrier element can be a printed circuit board, a conductor foil, a lead frame, or a combination thereof. Using a printed circuit board or lead foil, i.e., a printed circuit, advantageously simplifies and shortens the assembly / mounting / wiring time of the electronic component(s) and connectors, etc. This also applies to a lead frame, which can be a stamped / bent part and can be connected to the electronic components during the manufacturing process, e.g., by riveting, spot welding, etc.

[0026] In another embodiment, the carrier element has centrally arranged connection sections for the at least one electronic component. This provides, for example, advantageous heat dissipation.

[0027] The connection device according to the invention with the insert unit realizes the following advantageous functions: • Reduction of the volume of potting material in the housing due to the displacement volume of the insert unit. • Reduction of the potting height (layer thickness) of the potting material. • By reducing the thickness of the casting compound, the curing time of the casting compound and thus the overall process time is shortened. • Recording of the lead frame / circuit board with bypass diode / bypass diodes. • Improved heat dissipation from the lead frame / PCB and bypass diode(s). • Fixing the lid. • Easy assembly of the insert unit assembly with support element in the housing of the connection device.

[0028] The invention is explained in more detail using an exemplary embodiment with reference to the accompanying drawings. Fig. 1 is a schematic perspective exploded view of a connecting device according to the invention; and Fig. 2 a schematic perspective top view of the opened connection device according to the invention according to Fig. 1.

[0029] The terms “top”, “bottom”, “left”, “right” refer to the respective arrangements in the figures.

[0030] In Fig. 1 shows a schematic perspective exploded view of a connecting device 1 according to the invention.

[0031] Fig. 2 shows a schematic perspective top view of the opened connection device 1 according to the invention according to Fig. 1

[0032] The connection device 1 forms an electrical connection of cables of a solar module and is arranged on or partially in a solar module.

[0033] The connection device 1 comprises a housing 2, a cover 4 and an insert unit 100.

[0034] The housing 2 is cuboid-shaped with rounded corners and has a base 2a, two side walls 2b, and two end walls 2c, 2d. The base 2a, the side walls 2b, and the end walls 2c, 2d define an interior space 3, which is closed by the cover 4.

[0035] A first end wall 2c has an outwardly projecting cable duct 9 through which a connecting cable (not shown) of the associated solar module, which is not shown, is guided, sealed and strain-relieved.

[0036] The opposite second end wall 2d is provided on its outer side with protruding ribs which are not described in detail.

[0037] On the inner sides of the end walls 2c, 2d, two vertical webs 8 are formed, which protrude into the interior space 3. The webs 8 are spaced apart from one another on the end walls 2c, 2d in the direction of the end walls 2c, 2d.

[0038] On the inside of the base 2a, an upwardly extending retaining element 7 with a retaining lug 7a is attached in each corner area. The retaining elements 7 with their lugs 7a form clip-like holders into which the insert unit 100 is clipped during assembly of the connecting device 1.

[0039] In addition, structural elements 3a (not described in detail) are mounted on the inside of the base 2a, which hold, for example, connection elements such as terminals or the like for the connecting cable (not shown). Furthermore, the structural elements 3a serve as support supports for the insert unit 100.

[0040] The insert unit 100 has two longitudinal holders 5, at least one carrier element 6, and at least one electronic component 10.

[0041] The two longitudinal holders 5 form a support unit and holder for the carrier element 6. The at least one electronic component 10 is fastened to the carrier element 6.

[0042] In the view in Fig. 1, the inner sides of the longitudinal supports 5 face each other. Two cross connectors 5a projecting at right angles are formed on each inner side. Each cross connector 5a is formed with connections V on its end face. The connections V each consist of a protruding pin and a receptacle. In the assembled state, the pins of one longitudinal support 5 are received in the opposite receptacles of the cross connectors of the other longitudinal support 5. The pins and receptacles can be glued and / or locked together.

[0043] A recess 5b extending in the longitudinal direction of each longitudinal holder 5 is formed approximately in the upper quarter of the inner side of the longitudinal holder 5. These recesses 5b form a receptacle for the longitudinal sides of the support element 6, which is thus arranged between the longitudinal holders 5 and additionally rests and is supported on support surfaces 5b of the cross connectors 5a.

[0044] The longitudinal holders 5 also have vertical openings as fastening recesses 5d, 5e. Thus, the fastening recesses 5d arranged in the end regions serve to accommodate the holding elements 7 and to engage with their lugs 7a when installing the insert unit 100 into the interior 3 of the housing 2.

[0045] The fastening recesses 5e located in the middle of the longitudinal holders 5 accommodate cover fastenings 4a, which here also have lugs, for locking and fastening the cover 4 after installation of the insert unit 100 when closing the housing 2.

[0046] In addition, the longitudinal holders 5 are formed with further openings through which a casting compound can spread after installation of the insert unit 100 into the interior 3 of the housing 2 and, after curing, firmly connects the insert unit 100 to the housing 2.

[0047] The longitudinal holders 5 are made, for example, of a material that has high electrical insulation values. This material is, for example, a ceramic material, plastic, or a combination of these materials.

[0048] The carrier element 6 is a printed circuit board and has connection sections 6a and 6b in the end areas for the connecting cable (not shown) or connecting elements, e.g., flat conductors or the like. This will not be explained further here.

[0049] The carrier element 6 can also be a conductor foil or a lead frame or a combination thereof.

[0050] In the center of the carrier element 6, connection sections 6c are provided for the at least one electronic component 10. This at least one component 10 is, for example, a diode that functions as a so-called bypass diode.

[0051] The at least one component 10, here in the form of a power semiconductor, is arranged centrally in the middle of the interior 3 of the housing 2 in the assembled state of the connection device 1, such that the surfaces of this power semiconductor are in intensive contact with the potting compound for advantageous heat dissipation, ie heat conduction and heat radiation during operation. This is in Fig. 2 clearly visible.

[0052] Additional electronic components and functional units can be mounted on the top and / or bottom of the carrier element 6. These can be, for example, functional units with sensors and / or for data communication.

[0053] In the example shown, the support element 6 has through openings 6d for the holding elements 7 in the end regions of the connecting sections 6a, 6b.

[0054] The insert unit 100 is installed in the interior space 3 of the housing 2 in such a way that the longitudinal holders 5 are each arranged parallel to a side wall 2b of the housing 2 in its longitudinal direction.

[0055] The end faces of the connecting sections 6a, 6b of the support element 6 are in contact with the webs 8 of the inner sides of the end faces 2c, 2d of the housing 2 in such a way that a distance is formed between the end faces of the connecting sections 6a, 6b of the support element 6 and the inner sides of the end faces 2c, 2d of the housing 2.

[0056] After the insert unit is installed, the interior space 3 is filled with a potting compound. The potting compound provides electrical insulation and seals the interior space 3 from the outside atmosphere. The seal can, for example, enable protection class IP 67 / 68. The potting compound consists, for example, of a two-component (2K) silicone.

[0057] With the arrangement of all components of the insert unit 100, it is also possible to protect those areas which are not to be cast.

[0058] The insert unit 100 implements the following functions. • Reduction of the volume of potting material in the housing 2 by the displacement volume of the insert unit 100. • Reduction of the potting height (layer thickness) of the potting material. • By reducing the thickness of the casting compound, the curing time of the casting compound and thus the overall process time is shortened. • Recording of the lead frame / circuit board with bypass diode / bypass diodes. • Improved heat dissipation from the lead frame / PCB and bypass diode(s). • Fixing the lid 4. • Simple assembly of the insert unit 100 with support element 6 in the housing 2 of the connection device 1.

[0059] The invention is not limited to the embodiment described above. The invention is modifiable within the scope of the appended claims. Reference symbol 1 connection device 2 housings 2a Floor 2b side wall 2c, 2d front wall 3 Interior 3a Structural elements 4 lids 4a Lid fastening 5 longitudinal holders 5a Cross connector 5b Support surface 5c Recess 5d, 5e mounting recess 6 support element 6a, 6b, 6c connecting section 6d passage opening 7 Holding element 7a Nose 8 bridge 9 Cable entry 10 Component 100 operational units V connection QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2009 049 812 A1

[0004]

Claims

[1] Connection device (1) for electrical conductors, in particular for a solar module, comprising a housing (2) and a carrier element (6) with at least one electronic component (10), characterized by that an insert unit (100) with the carrier element (6) is inserted into an interior space (3) of the housing (2). [2] Connecting device (1) according to claim 1, characterized by that the insert unit (100) has at least one longitudinal holder (5) which forms a holder for the carrier element (6). [3] Connecting device (1) according to claim 2, characterized by that the insert unit (100) has two longitudinal holders (5). [4] Connecting device (1) according to claim 3, characterized by that the two longitudinal holders (5) are arranged parallel to each other and are connected to each other by at least one transverse connector (5a). [5] Connecting device (1) according to claim 3 or 4, characterized bythat the two longitudinal holders (5) each have a recess (5b) formed therein, which extends in the longitudinal direction of the associated longitudinal holder (5) and each forms a receptacle for the longitudinal sides of the support element (6). [6] Connecting device (1) according to one of claims 3 to 5, characterized by that the carrier element (5b) rests on a support surface (5b) of the at least one cross connector (5a) in the installed state of the insert unit (100). [7] Connecting device (1) according to one of claims 2 to 6 characterized by that holding elements (7) are mounted in the housing (2) and can be connected to the at least one longitudinal holder (5). [8] Connecting device (1) according to claim 7, characterized by that the holding elements (7) form clip-like holders into which the insert unit (100) is clipped during assembly of the connecting device (1). [9] Connecting device (1) according to claim 7 or 8, characterized bythat the holding elements (7) extend through through openings (6d) of the carrier element (6). [10] Connecting device (1) according to one of claims 2 to 9, characterized by that the interior (3) of the housing (2) can be closed with a cover (4) which has at least one cover fastening (4a) which can be connected, preferably locked, to the at least one longitudinal holder (5) of the insert unit (100) or the housing 2. [11] Connecting device (1) according to one of the preceding claims, characterized by that the insert unit (100) forms a displacement volume for a casting compound with which the interior (3) of the housing (2) of the connecting device (1) is cast after assembly. [12] Connecting device (1) according to one of the preceding claims, characterized by that the carrier element (6) has connection sections (6a, 6b) for a connection cable or connecting elements in the end regions. [13] Connecting device (1) according to claim 12, characterized by that the carrier element (6) is a printed circuit board, a conductor foil, a lead frame or a combination thereof. [14] Connecting device (1) according to claim 12 or 13, characterized by that the carrier element (6) has connection sections (6c) for the at least one electronic component (10). [15] Solar module with at least one connection device (1) according to one of the preceding claims.

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