Batteries: thermoelectric and photoelectric – Photoelectric – Panel or array
Reexamination Certificate
2002-02-22
2004-02-24
Diamond, Alan (Department: 1753)
Batteries: thermoelectric and photoelectric
Photoelectric
Panel or array
C136S251000, C136S255000, C136S291000, C257S750000, C257S775000, C257S433000, C257S431000
Reexamination Certificate
active
06696636
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a by-pass rectifier element and a terminal housing for solar battery modules employing a by-pass rectifier element. In particular, the invention relates to a by-pass rectifier element configured such that it can withstand stresses caused by swelling or shrinkage of structural materials, when used under severe climatic conditions.
2. Description of Related Art
As shown in
FIGS. 2 and 6
, a known by-pass diode
100
includes a rectifier laminate
101
essentially formed by laminating, from bottom to top, a base lead plate
103
, a cathode electrode
101
a
, an n-type domain layer
101
b
, a p-type domain layer
101
c
, an anode electrode
101
d
, and a top lead plate
105
. The base lead plate
103
has a rectangular form, one end portion of which is connected to the cathode electrode
101
a
at the bottom of the rectifier laminate
101
by soldering. The top lead plate
105
includes a rectangular portion
105
a
and a head portion
105
b
which extends outward from one side end of the rectangular portion and is connected to the anode electrode
101
d
at the top of the rectifier laminate
101
by soldering. Further, the top lead plate
105
and the base lead plate
103
are arranged parallel to each other, but extend in opposite directions from the rectifier laminate
101
(FIG.
2
).
The above by-pass diode is incorporated into a terminal housing for solar battery modules
110
as shown in FIG.
1
. To mount such a terminal housing, there is first provided a housing
111
, made of e.g. a synthetic resin, including a base and sidewalls, the top being left open. The base carries, in parallel, e.g. four lead-frame receiver terminals
113
a
,
113
b
,
113
c
and
113
d
. A plurality of by-pass diodes
100
are intercalated between the lead-frame receiver terminals
113
a
to
113
d
, such that the base lead plate
103
and top lead plate
105
of each by-pass diode are connected respectively to the adjacent lead-frame receiver terminal
113
a
,
113
b
,
113
c
or
113
d
and soldered thereto. The receiver terminals
113
a
and
113
d
located at both ends of the housing
111
are respectively connected, by clamping, to corresponding module-linking cables
117
a
and
117
d
, which are led into the housing
111
from outside through two fitting holes
115
a
and
115
d
formed in a sidewall of the housing
111
.
The base of the housing
111
is further provided with path holes
121
a
,
121
b
,
121
c
and
121
d
, respectively formed adjacent to the corresponding lead-frame receiver terminals
113
a
to
113
d.
The housing
111
is fitted to a solar battery module (not shown in figures), from which are led out a positive-electrode lead frame
119
a
and a negative-electrode lead frame
119
d
. The positive- and negative-electrode lead frames
119
a
and
119
d
are led into the housing
111
through e.g. respective ones of the path holes
121
a
and
121
d
and connected to the lead-frame receiver terminals
113
a
and
113
d
. The housing
111
is then filled with e.g. silicone (not shown in figures).
As described above, the by-pass diodes
100
are placed in a housing
111
made of e.g. synthetic resin and embedded therein with e.g. silicone. However, the housing
111
and silicone swell and shrink repeatedly, each time they are used under severe conditions caused e.g. by steep temperature changes. Repeated swelling and shrinking imparts excessive stresses to the portions of the by-pass diodes
100
linking the base and top lead plates
103
and
105
to the rectifier laminate
101
. The link portions can then become detached or the rectifier laminate can become delaminated, thereby causing an electrical break.
Such a phenomenon frequently occurs when a plurality of by-pass diodes
100
are mounted in series.
An object of the present invention is therefore to provide stress-resistant by-pass rectifier elements, which may be used in a terminal housing for solar battery modules. In the rectifier elements of the present invention, the portions thereof linking the lead plates to the rectifier laminate cannot be delaminated or detached, even when the elements are used repeatedly under severe climatic conditions.
Another object of the present invention is to provide a connector housing for solar battery modules incorporating the by-pass rectifier element of the present invention.
SUMMARY OF THE INVENTION
To this end, according to one aspect of the present invention, there is provided a by-pass rectifier element including a rectifier laminate having the form of a chip with first and second faces. The by-pass rectifier element further includes a first lead plate and a second lead plate, each having a longitudinal extension with an end portion, the end portions being arranged respectively on the first face and second face of the rectifier laminate. The first lead plate and the second lead plate extend in parallel in opposite directions, respectively from the first face and second face of the rectifier laminate. In the structure of the present invention, the first lead plate is thinner than the second lead plate.
Preferably, the first lead plate includes a zone adjacent to the end portion, and the zone is provided with slits notched alternately in the direction perpendicular to the longitudinal extension along which the first lead plate extends.
Further, at least one of the first and second lead plates includes a rectangular body portion including short sides and long sides, and the end portion of at least one of the first and second lead plates is formed into a head portion extending from one of the short sides of the rectangular body.
The head portion may include a neck portion having a reduced width with respect to the head portion.
Further, the short side of the rectangular body portion may be grooved at both sides of the neck portion along the long side of the rectangular body.
The invention also relates to a by-pass rectifier element including a rectifier laminate having the form of a chip with first and second faces. The by-pass rectifier element further includes a first lead strip and a second lead strip, each having an end portion respectively arranged on the first face and second face of the rectifier laminate. The first lead strip and the second lead strip extend in parallel along opposite directions, respectively from the first face and second face of the rectifier laminate.
At least one of the first and second lead strips may include an elongated rectangular body portion including short sides and long sides.
The end portion of the at least one of the first and second lead strips is formed into a head portion extending from one of the short sides of the elongated rectangular body portion, and the elongated rectangular body portion has a width narrower than that of the head portion and extends therefrom.
Preferably, the first lead strip is thinner than the second lead strip.
The invention further relates to a terminal housing incorporating a by-pass rectifier element for solar battery modules. The by-pass rectifier element includes a rectifier laminate having the form of a chip with first and second faces. The by-pass rectifier element further includes a first lead plate and a second lead plate, each having an end portion arranged on the first face and second face of the rectifier laminate, respectively. The first lead plate and the second lead plate extend in parallel along opposite directions, respectively, from the first face and second face of the rectifier laminate, wherein the first lead plate is thinner than the second lead plate. The housing further includes a container mounted into the solar battery module; a plurality of lead-frame receiver terminals arranged in the container and connected to positive and negative electrode lead frames extending from the solar battery module; a pair of module-linking cables for a power source, one end of which is connected to one of the lead-frame receiver terminals, and the other end of which is drawn towards the outside of the cont
Higashikozono Makoto
Yoshikawa Hiroyuki
LandOfFree
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