DE102008046899A1 - Photovoltaic module for solar power system, has frame for holding solar cell, which is formed by injection molding or foaming of plastic, and has electrical connecting piece - Google Patents

Abstract

The photovoltaic module has a frame for holding a solar cell, which is formed by injection molding or foaming of a plastic, and has an electrical connecting piece (10). The position of the respective electrical connecting piece is fixed in the assigned frame area (2) by a form-fit, force-fit and positive-fit connection to prevent or to reduce displacement of the electrical connecting piece by injection molding or foaming of the plastic. Independent claims are included for the following: (1) a solar power system; and (2) a method for manufacturing a photovoltaic module.

Description

Field of the invention

The The present invention relates generally to electrical contacting of photovoltaic modules or solar cell modules, and in particular arranging electrical contact plugs or sockets within a holding frame made of a plastic such modules.

Background of the invention

WO 2007/045695 A1 discloses a solar power system with a plurality of photovoltaic modules according to the preamble of claim 1, which is described below with reference to 1 to 4b is to be discussed, wherein the manner of mechanical locking and electrical contacting of the photovoltaic modules can in principle also be applied according to the present invention. Of the photovoltaic modules are in the 1 only two holding frames 100 indicated schematically. These are to carry a transparent cover plate and a plurality of solar cells (not shown). According to the 1 . 4a and 4b are in the corner areas of the frame 100 recesses 101 formed into the one in the material of the frame 100 integrated retaining bolt 102 protrudes, without over the side surface of the holding frame 100 protrude. According to the 4a is in at least one corner region of the holding frame 100 on the bottom of a contact plug 112 integrated.

According to the 1 are used to fix the photovoltaic modules locking elements 105 and for connecting adjacent photovoltaic modules, an electrical connection element 109 , wherein the locking elements 105 and the electrical connection element 109 slidable on a mounting bracket or profile 103 are arranged. Several such mounting brackets 103 form a mounting frame, which can be arranged on a house roof, a facade or open space. The mounting bracket 103 are designed as cost-effective endless profile, for example as an aluminum extruded profile. On the long sides of the mounting bracket 103 are two T-slots 104 formed, in which a correspondingly formed T-profile 111 (see. 3c ) of the electrical connection element 109 intervenes. According to the 1 engage around the side walls of a locking element 105 the lateral projections on the top of the mounting bracket 103 ,

The electrical connection element 109 is in the 3a - 3c shown and as a one-piece contact socket with a plurality of contact sockets 110 formed on the top.

The locking element 105 is in the 2a in an open position and in the 2 B shown in a locked position. According to the 2a includes a locking element 105 two rotatably mounted locking claws 106 with an arcuate slot formed therein 107 , To lock a photovoltaic module is first the retaining bolt 102 (see. 1 ) in the in 2a illustrated open position in the slot 107 introduced and on the recess 108 in the side walls of the locking element 105 hung up. By turning the locking claws 106 in the in the 2 B shown locking position, the retaining bolt is then in one of the locking claw 106 and the bottom of the recess 108 formed cage and secured.

For mounting such a solar power system initially several mounting bracket 103 suitably mounted, with the distances between the mounting brackets 103 correspond to the length or the width of the photovoltaic modules to be mounted. Subsequently, for each corner of the photovoltaic modules to be mounted, an electrical connection element 109 at suitable positions along the mounting brackets 103 assembled. Furthermore, the locking elements 105 suitably positioned. Subsequently, the photo voltaic modules on the electrical connection elements 109 put on, so that at the bottom of the holding frame 100 provided connector 112 (see. 4a ) and / or sockets in the on top of the electrical connectors 109 envisaged and correspondingly formed sockets and / or connector plug engage or are arranged directly above them. The retaining bolts arrive 102 in the capture area of the locking claws 106 , By turning the locking claws 106 in their locking position, the photovoltaic modules are fixed in position and at the same time plugged the electrical contact plug and sockets with a predetermined minimum force. For more details of the structure and the installation of such a solar power system is on the WO 2007/045695 A1 the content of which is hereby expressly incorporated by reference.

The not yet revealed German patent application 10 2007 012 239.8 "Electrical connection element", filed March 12, 2007, discloses an electrical connection element having two electrical contact elements arranged on a common carrier, which are electrically connected to one another by means of a flexible electrical connection line. The electrical contact elements are not fixed rigidly with respect to the carrier, but provided with a certain play in the plane parallel to the solar cell modules. This is simplified the assembly of the solar cell modules and ensures a reliable electrical contact.

In order to Photovoltaic modules of the aforementioned type are easily mounted can, is a precise positioning of the individual Connections typically at the corners of the photovoltaic module, important. However, when injection molding or foaming the Plastic frame briefly prevail very high pressures, This can lead to a displacement of the connectors lead in the plastic frame. Such inaccuracies not only increase the assembly effort, but also the effort to seal the connectors to the environment. Furthermore, can such inaccuracies in the production also mechanical stresses be induced in the field.

Summary of the invention

task The present invention is a photovoltaic module of the aforementioned To further develop the type so that the location of the usually in the corners provided plug-in connections simple and reliable can be specified. Further aspects of the present invention further relate to a solar power system having a plurality of such Photovoltaic modules, and a method for producing such Photovoltaic modules.

The The above objects are achieved by a photovoltaic module with the Characteristics according to claim 1, by a solar power system according to claim 12 and a method according to claim 14 solved. Further advantageous embodiments are the subject of the referenced Dependent claims.

at a photovoltaic module according to the present invention Invention is the location of a respective electrical connector in the associated frame area by means of a positive, non-positive or positive locking Connection fixed. Due to the additional fixation, the before injection molding or foaming the frame is made of the plastic material, according to the invention a Displacement of the electrical connector during injection molding or foaming the plastic, d. H. of the frame, prevents or at least significantly reduced. The location of electrical connectors can be specified as precise, which the effort to Installation of solar power systems significantly reduced and also one Sealing the electrical connector allows in a simple manner. The higher precision in the production of an inventive Photovoltaic module also allows a significant reduction of mechanical stresses in ready assembled solar power system.

The at least temporary fixation of the respective electrical Connecting piece is preferably on a prefabricated Frame part, before injection molding or foaming is suitably positioned in a mold. In such a Frame part may preferably be a corner part made of a plastic act, although basically any other profiles, For example, stiffening profiles of a metal or a Material other than plastic, can be used and / or the electrical connector also on others Areas as the corner, for example, on the long sides of the photovoltaic module, can be arranged.

The electrical connector can be attached to such a frame part at least temporarily glued or glued. Even a temporary jamming can for a at least temporary non-positive fixation be enough.

All however, particular preference is given according to the invention positive connections, in particular a form-fitting Locking or latching, the electrical connector in the associated frame area. Preferably, the form-fitting Detachable connection, allowing the connection of frame area and electrical connector, for example, for replacement a defective connector or for inserting a another type of connector, solved again can be before the frame is formed from the plastic.

Preferably, the prefabricated plastic frame part on at least one holding web, which is suitably designed so that the respective electrical connector can be locked or latched with this. Such a prefabricated plastic element can at the same time take on additional functions, in particular precisely specify the position of the solar cells and / or the transparent cover in the mold, serve to fix a retaining bolt to be integrated into the frame (cf. 1 above), or pretend a rear side of the photovoltaic module at least in the region of the electrical plug connection.

According to a further development, the electrical connection piece can be introduced into the holding web or through an opening provided therein in a first rotational position and can be positively locked or latched by turning into a second rotational position with the holding web. For this purpose, a projection or a recess and on the electrical connection piece a corresponding recess or a corresponding projection may be formed on the holding web or in a cylindrical receptacle or socket formed thereon. In the second rotational position is the electric Connecting piece then fixed to the retaining bar.

According to one Further training is on the electrical connector Projection formed, the perpendicular, preferably symmetrical to a longitudinal axis of the electrical connection piece of this in shape protrudes a locking or locking lug. Even at a low Twist of the electrical connector from the first Rotary position can thus prevent a release of the retaining web become.

For An even more reliable latch can be used to hold the locking or locking lug in the second rotational position the holding web or in a cylindrical receptacle formed thereon or Cylinder socket provided a corresponding recess formed be. Preferably, the locking or locking lug has this rounded Edges or even more preferably even domed surface.

For a reliable seal formed on the holding web cylindrical receptacle for receiving the locked or latched Contact plug can be a sealing at the bottom of the contact plug Cap be formed, at least in the second rotational position the bottom of such a cylindrical receptacle completely seals against the environment. Thus, in the mold at Injection molding or foaming of the frame no plastic From the bottom of the recording go into the cylindrical receptacle. Further sealing measures at the front end of such cylindrical receptacle, for example in the form of a circumferential Seal on the back of the aforementioned corner piece can be placed around the cylindrical receptacle, the penetration prevent the plastic in the mold also from the front end.

at a solar power system according to the present Invention, the electrical connection elements for electrical Connecting two photovoltaic modules of the aforementioned type two electrical contact pieces, preferably sockets, on, corresponding to the electrical connectors, prefers the connection plugs, the photovoltaic modules formed are. According to the respective electrical Contact pieces via a flexible electrical Connected together. The contact pieces are thus not rigid with respect to a mounting bracket attached, but with a game, especially in the plane parallel to the photovoltaic modules prevails. Such a flexible electrical connection thus ensures that the electrical Contact pieces are displaceable relative to each other and at the same time an electrical connection is ensured. For An assembly of such a Solarstromsys system, it may therefore be sufficient be roughly pre-positioning the electrical connectors, wherein by the corresponding embodiment of fitting in the frame and contact piece on the mounting bracket (for example, on the roof surface) a certain Selbstzentrierungseffekt is achieved, so as a result, the photovoltaic modules easy only pressed on the electrical connection elements need to be and the side play finally to take the desired position, in which the electrical connector reliable and is formed sealing.

LIST OF FIGURES

following the invention will be described by way of example and with reference are described on the accompanying drawings, from which give further advantages, features and tasks to be solved become. Show it:

1 in a perspective exploded view of a section of a solar power system according to the prior art, wherein basic principles of mounting the same can also be used in a solar power system according to the present invention;

2a and 2 B in a perspective view of a locking element of the solar power system according to the 1 ;

3a - 3c in a plan view, a perspective plan view and a side view of an electrical connection element of the solar power system according to the 1 ;

4a and 4b in a bottom view and a side view of a section of a frame of a conventional photovoltaic module according to the 1 ;

5a the positioning of a contact plug in a corner piece of a photovoltaic module according to the present invention prior to forming the plastic frame;

5b in a schematic plan view from below the positive locking or latching of the contact plug in a cylindrical receptacle of the corner part according to the 5a ;

6 in a perspective view of the electrical contact plug with the corner part according to the 5a and 5b is locked or latched;

7 in a schematic partial section, the locking of the contact plug according to the 6 in the corner part according to the 5a and 5b ;

8th in a schematic partial section, the electrical connection of two photovoltaic modules in a solar power system according to the present invention; and

9 in a schematic partial section, the arrangement of the corner part according to the 5a and 5b with the therein locked contact plug according to 6 in a mold during formation of the plastic support frame of a photovoltaic module according to the present invention.

In the figures denote identical reference numerals identical or essentially equivalent elements.

Detailed description of preferred embodiments

In the frame of a photovoltaic module according to the present invention is a corner part 2 integrated, partly in the 5a and 5b is shown. At the corner part 2 it is a prefabricated plastic element with one in the region of the contact plug 11 flat bottom 3 , protrude from the vertical several webs, which in part only a stiffening of the corner part 2 serve, partly in the form of domes 8th (see. 9 ) for determining the distance between the corner piece 2 and the transparent cover 1 with the solar cells laminated thereon (not shown) and also for receiving a retaining bolt, as exemplified in US Pat 1 is shown. The corner part 2 will, as later by the 9 is described in detail, inserted into a mold, suitably pre-positioned and then encapsulated with a plastic, or foamed, for forming a plastic frame, in which electrical connector and retaining bolts are integrated and which the transparent cover 1 surrounds.

According to the 5a and 5b is in the corner part 2 also a cylindrical receptacle 5 formed vertically from the bottom 3 protrudes. According to the 5b is in the bottom of the cylindrical receptacle 5 a substantially rectangular and diametrically extending recess 6 formed, through which the at the contact plug 11 trained latch nose 12 in the cylindrical receptacle 5 can be introduced, in a first rotational position of the contact plug 11 , By turning the contact plug 11 in the in the 5b shown second rotational position is the Verrastungsnase 12 to the bottom of the cylindrical receptacle 5 turned up and the contact plug 11 fixed in position by the thus accomplished positive locking.

The 6 shows in a schematic perspective view of the contact plug 10 in the corner part according to the 5a and 5b is to fix. At the front end of the contact plug 10 is the cylindrical contact area 11 formed, of which the Verrastungsnase 12 protrudes symmetrically. Below the Verrastungsnase extends a connection socket 13 , which has steps in a pedestal 14 and a sealing cap formed thereunder 15 passes. Below the sealing cap 15 there is a handling section 16 which can be gripped, for example, with two fingers or by a handling tool and rotated in the desired rotational position. That on the contact plug 10 in the area of the handling section 16 emerging connection cable 17 serves for the electrical contacting of the solar cell of the photovoltaic module carried by the cover plate.

The 7 shows a schematic partial section of the contact plug according to the 6 if this is in the corner piece 2 is locked. It can be seen that the height of the connection socket 13 the strength of the bottom of the cylindrical receptacle 5 or the narrowed section formed therein 6 equivalent. For even more reliable locking can be on the recording 5 facing side of the floor 6 a receptacle for receiving the Verrastungsnase 12 of the contact plug 11 be formed and indeed corresponding to Verrastungsnase 12 , One recognizes in the 7 further, that in the locked position of the base 14 close fitting at the lower end of the cylindrical receptacle 5 is included. The cylindrical receptacle 5 is further in the locked position by the sealing cap 15 sealed at the bottom of the contact plug. In the locked position according to the 7 is the contact plug substantially without play präzi se in the cylindrical receptacle 5 of the corner piece 2 positioned. The design of the corner piece 2 in the area of the cylindrical receptacle 5 is chosen so that the contact plug on the one hand in its first rotational position can be easily inserted and on the other hand can be converted by rotation in a locking or Verrastungsstellung that precisely by the design of the cylindrical receptacle 5 is predetermined.

For producing a photovoltaic module according to the present invention, four such corner pieces 2 with therein locked contact plugs in the position according to 7 positioned in a mold that is in the 9 is shown in a schematic partial section. The mold is formed in two parts, with an upper mold 30 and a lower mold 31 , which together form a peripheral channel with the mold closed, which predetermines the holding frame of the photovoltaic module. The transparent cover 1 with the on it ordered solar cells, which are already electrically connected to each other, according to the 9 on the lower mold 31 hung up. On the back of the transparent cover 1 In the corners of the mold, the four corner pieces become 2 applied, with the contact plugs locked therein 10 , Subsequently, the connection cable 17 electrically connected to the solar cells. For sealing the cylindrical receptacle 5 is in the upper mold 30 a circumferential seal 33 taken sufficiently against the bottom 3 of the corner piece 2 pushes to prevent penetration of plastic into the cylindrical receptacle 5 during the injection molding or foaming of the plastic frame to prevent. After closing the mold, press on the corner piece 2 provided dome 8th against the back of the transparent cover 1 , so overall the distance between the bottom 3 of the corner piece 2 and the cover 1 precisely specified. Following the above-described pre-positioning of all essential elements is in the free or cavity 4 of the corner piece 2 and in the circumferential channel (not shown) of the mold, a plastic injected or foamed, which forms after appropriate polymerization and curing, finally, a holding frame, as shown schematically in the 1 is shown. It should be noted that in the corner part 2 injected or foamed plastic or plastic foam in the 9 is shown only partially for simplicity's sake. However, it will be apparent to those skilled in the art that the entire channel in the mold, except for the contact plug sealed by the latched con tact plug, is completely ejected or foamed with the plastic, as shown schematically in FIG 8th is shown.

How to do the synopsis of 5a to 9 can be easily seen, all elements of the photovoltaic module are precisely positioned and fixed during the formation of the holding frame in a method according to the invention. The further assembly of a plurality of photovoltaic modules according to the invention to form a solar power system basically takes place as described above with reference to FIG 1 to 4b described, but according to the invention instead of in the 1 shown, integrally formed electrical connection element 109 Also, an electrical connection element with a flexible electrical connection can be used, as shown in the German patent application 10 2007 012 239.8 The content of this patent application is incorporated by reference in this application. A solar power system using such an electrical connection element is in 8th shown.

In the 8th denotes the reference numeral 7 the plastic retaining frame, in which the corner piece 2 with the contact plug 10 is integrated and the transparent cover 1 encloses or carries with the solar cells provided thereon.

The electrical connection element 20 has two contact sockets 21 on, via a flexible electrical connection cable 22 electrically connected to each other. The electrical connection cable 22 can be encapsulated by a plastic so that this has a certain spring elasticity, so that the electrical connection element 20 in the relaxed state of the connection cable 22 assumes a rest position, starting from the two contact sockets 21 but then can be shifted laterally under a small force to precisely in the cylindrical recordings 5 the photovoltaic modules can be introduced.

According to the 8th is on the outer circumference of the contact sockets 21 a sealing means in the form of a plurality of circumferential and mutually spaced sealing lips 26 made of a resilient plastic, which seals the cylindrical receptacle 5 and the electrical connector against the outside environment close fitting against the inner peripheral wall of the cylindrical receptacle 5 to press. The two contact sockets 21 be of a common or according to the 8th from two separate holding sections 28 worn, in a suitable manner to a mounting bracket 27 be mounted, which may be formed as an endless profile and in particular as in the 1 shown (reference numeral 100 . 103 ), may be formed. On the bottom of the contact sockets 21 extends a cap 23 in a cylindrical extension 25 goes over, from the outer circumference of several elastic scraper ribs 24 protrude radially. The fixation of the electrical connection element 20 at the holding section 28 or the holding sections 28 takes place by introducing the cylindrical extension 25 in a corresponding opening in the holding section 28 and by pushing a retaining clip, not shown. On the mounting bracket 27 in particular in the nature of the in the 1 illustrated mounting bracket 103 may be formed, are also locking elements, as shown schematically in the 1 are shown, slidably disposed, a locking of the in the holding frame 7 integrated retaining bolt (not shown) in the above with reference to the 1 serve described manner. The locking elements are finally on the mounting bracket 27 attached.

Although the invention has been described above with reference to preferred embodiments, it is not limited thereto. In particular, the skilled artisan will recognize in studying the above description that instead of the described contact plug and contact sockets in a corresponding manner, contact sockets and contact plugs or any other electrical connector elements can be used and that instead of the above-described and the form-locking effecting locking elements and any other elements are used can, preferably due to a positive connection, but in principle also serve due to a friction or adhesion of at least temporary fixation of the contact plug to the corner part before injection molding or foaming of the plastic support frame.

1

transparent cover plate

2

corner made of plastic

3

bottom of the corner piece

4

Free- or cavity

5

cylindrical recess

6

constricted section

7

PU foam / holding frame

8th

Haltedom / spacer

10

contact plug

11

contact area

12

latching nose

13

connection socket

14

base

15

sealing cap

16

handling section

17

connection cable

20

electrical connecting element

21

Contact socket

22

electrical connection cable

23

cap

24

elastic Stege

25

cylindrical extension

26

sealing lips

27

Mounting bracket / Profile

28

holding section

29

gap

30

upper mold

31

lower mold

32

vacuum nest

33

poetry

100

frame

101

recess

102

retaining bolt

103

Mounting bracket / Profile

104

longitudinal slot

105

locking element

106

locking pawl

107

slot

108

recess

109

electrical connecting element

110

Contact socket

111

T profile

112

contact plug

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - WO 2007/045695 A1 [0002, 0006]
• - DE 102007012239 [0007, 0038]

Claims (15)

Photovoltaic module with a frame ( 7 ) for holding at least one solar cell, which is formed by injection molding or foaming a plastic, and with at least one electrical connection piece ( 10 ), each in a frame area ( 2 ) within the framework ( 7 ) is arranged and in cooperation with a correspondingly formed electrical contact piece ( 21 ) allows an electrical connection of two photovoltaic modules, characterized in that the position of the respective electrical connector ( 10 ) in the associated frame area ( 2 ) is fixed by means of a positive, non-positive or cohesive connection in order to prevent or at least reduce a displacement of the electrical connection piece during injection molding or foaming of the plastic. Photovoltaic module according to claim 1, wherein the position of the respective electrical connection piece ( 10 ) in the associated frame area ( 2 ) is positively locked or locked. Photovoltaic module according to claim 2, wherein the respective frame portion as a prefabricated plastic element with a holding web ( 2 ) is formed, with which the respective electrical connector ( 10 ) is locked or locked. Photovoltaic module according to claim 3, wherein on the electrical connector ( 10 ) a lead ( 12 ) or a recess and in the retaining web ( 2 ) a corresponding recess ( 6 ) or a corresponding projection is formed so that the electrical connector ( 10 ) in a first rotational position in the retaining web ( 2 ) is insertable and by turning in a second rotational position with the retaining web ( 2 ) is lockable or latched. Photovoltaic module according to claim 4, wherein the projection is perpendicular to a longitudinal axis of the electrical connector ( 2 ) of this projecting locking or latching nose ( 12 ). Photovoltaic module according to claim 5, wherein the locking or latching nose ( 12 ) in the second rotational position in a correspondingly formed recess of the retaining web ( 2 ) is received and locked or locked. Photovoltaic module according to claim 5 or 6, wherein between the locking or latching lug ( 12 ) and a socket ( 14 . 15 ) of the electrical connector ( 10 ) a narrowed section ( 13 ) is formed, which corresponds to the recess ( 6 ) of the retaining bridge ( 2 ) is formed, wherein the distance between the locking or latching lug ( 12 ) and the base ( 14 . 15 ) the strength of the retaining bar ( 2 ) corresponds. Photovoltaic module according to one of claims 3 to 7, wherein the respective electrical connection piece is an electrical contact plug ( 10 ). A photovoltaic module according to claim 8, wherein at the holding web ( 2 ) a cylindrical receptacle ( 5 ) for receiving the locked or latched contact plug ( 10 ) is trained. A photovoltaic module according to claim 9, wherein at a lower end of the contact plug ( 10 ) a sealing cap ( 14 . 15 ) for sealing the cylindrical receptacle ( 5 ) is trained. Photovoltaic module according to one of the preceding claims, wherein in the frame region ( 2 ) further comprises a retaining bolt is received, which in sections and together with the frame portion of the plastic of the frame ( 7 ) is sprayed or foamed over. Solar power system with a plurality of photovoltaic modules according to one of the preceding claims and with electrical connecting elements ( 20 ) for electrically connecting in each case two photovoltaic modules, wherein a respective electrical connecting element ( 20 ) two electrical contact pieces ( 21 ) corresponding to the electrical connection pieces ( 10 ) of the photovoltaic modules are formed and via a flexible electrical connection ( 22 ) are interconnected. Solar power system according to claim 12, wherein on an outer periphery of the two electrical contact pieces ( 21 ) Sealant ( 26 ) are provided to seal the electrical contact between the contact piece and fitting against the environment in cooperation with the respective associated electrical connector. Method for producing a photovoltaic module, in particular according to one of claims 1 to 11, in which method at least one solar cell together with a prefabricated frame region ( 2 ) in a mold ( 30 . 31 ) and in the mold a frame ( 7 ) is injection-molded or foamed from a plastic in which the frame area is integrated, characterized in that at least one electrical connection piece ( 10 ) prior to injection molding or foaming the plastic on the frame area ( 2 ) is positively, positively or materially fixed, to prevent displacement of the electrical connector during injection molding or foaming of the plastic or at least reduce. The method of claim 14, wherein the position of the respective electrical connector ( 10 ) in the associated frame area ( 2 ) is positively locked or locked.