Terminal box apparatus for solar cell module

Electrical connectors – With supporting means for coupling part – Outlet box

Reexamination Certificate

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Reexamination Certificate

active

06655987

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a terminal box apparatus for use in a solar cell module disposed on a roof of a house or the like. The present application claims priority to Japanese Application No. 2002-108077, filed on Apr. 10, 2002.
2. Description of Related Art
A solar-electric system for generating electricity by utilizing sunbeams by mounting a plurality of solar cell modules in the shape of a matrix on the roof of a house is known. In the solar-electric system, each solar cell module has a connection terminal box apparatus for connecting the solar cell module to other solar cell modules.
FIG. 15
shows a schematic construction of a conventional solar cell module
1
. The solar cell module
1
has a large number of solar cells
3
(group
4
of cells) arranged oil a surface thereof, with the solar cells
3
electrically connected in series.
A terminal box apparatus
5
is disposed on a rear surface of a body
1
a of the solar cell module
1
. As shown in
FIG. 17
, the terminal box apparatus
5
accommodates bypass diodes
6
serving as a bypass rectifying element. The bypass diodes
6
are connected in a direction reverse to parallel output voltages of the group
4
of cells to bypass the electric current of the inversely biased group
4
(or module
1
) of the cells.
As shown in
FIG. 16
, one of two module connection cables
7
taken out of the terminal box apparatus
5
installed on the rear surface of the solar cell module
1
can be connected to the other of the two module connection cables
7
of the other solar cell module
1
. A plurality of the solar cell modules
1
arranged in parallel on a roof or the like can connected sequentially in series.
In taking out an electric power from each solar cell module
1
, as shown with the block diagram of
FIG. 17
, the solar cell modules
1
are electrically connected to construct a solar-electric system
9
, and a plurality of the solar cell modules
1
connected sequentially in series is connected to an inverter or a connection box
10
to convert a direct current into an alternating current.
As shown in
FIG. 18
, the terminal box apparatus
5
has a box
12
formed by molding a synthetic resin. The box
12
has an approximately rectangular body
12
a
having an accommodation concavity and open on its upper surface. The box
12
also has a plate-shaped cover (not shown) mounted on an upper surface of the body
12
a
to close the accommodation concavity.
With reference to
FIG. 18
, a wiring hole
13
serving as a frame insertion hole is formed on the body
12
a
along one edge of a bottom surface of the body
12
a
. Cable insertion holes (right and left ends in
FIG. 18
)
14
through which a pair of the output take-out module connection cables
7
is inserted respectively are formed on side walls of the body
12
a
at the other side of the bottom surface of the body
12
a.
A plurality of terminal-fixing parts (not shown) is disposed in parallel at a part intermediate between the wiring hole
13
of the body
12
a
and the cable insertion holes
14
, with the terminal-fixing parts (not shown in
FIG. 18
) projecting from the bottom surface of the body
12
a
in a right-to-left direction. A connection terminal
15
approximately T-shaped in a plan view is mounted on each terminal-fixing part by thermal crushing or the like. Side projected parts of the connection terminal
15
are projected in the right-to-left direction, whereas the central projected part thereof is projected toward the wiring hole
13
.
An end of each of a plurality of connection elements (lead frame, not shown) connected to photoelectric conversion elements of the solar cell module
1
is inserted into the box
12
through the wiring hole
13
and soldered to the central projected part of the corresponding connection terminal
15
.
The connection terminal
16
caulked to the end of the module connection cable
7
inserted through the cable insertion hole
14
is fastened to each of the connection terminals
15
at both ends of the box
12
. The bypass diode
6
is soldered to projected parts of the adjacent connection terminals
15
. As the bypass diode
6
, a diode of mold type having a lead pin pulled to the outside is used. The lead pin is soldered to the projected parts. The bypass diodes
6
are connected in the direction reverse to parallel output voltages of the photoelectric conversion elements of each of the solar cell modules
1
. Thereby the bypass diodes
6
have a bypass function.
In recent years, the solar cell
3
tends to be large, and electric current produced by the solar cell
3
also tends to be high. If the solar cell
3
is covered with leaves, the bypass diode
6
of the bypass circuit generates heat and its temperature rises. The higher output current is, the higher the temperature of the bypass diode
6
becomes. Thus, there is a possibility that the bearing life of peripheral component parts decreases.
SUMMARY OF THE INVENTION
The present invention has been made in view of the above-described problem. Accordingly, it is an object of the present invention to provide a terminal box apparatus for a solar cell module having improved durability and reliability for long-term service.
To achieve the object, in various exemplary embodiments, there is provided a terminal box apparatus for a solar cell module having a box mounted on the solar cell module; a plurality of connection terminals disposed inside the box and connected to a plurality of connection elements extending from photoelectric conversion elements of the solar cell module; a pair of output take-out module connection cables having one end thereof connected to one of the connection terminals and other end thereof pulled out of the box respectively; and a plurality of bypass rectifying elements extending across the adjacent connection terminals respectively.
Each of the bypass rectifying elements has a body and a pair of parallel lead plates disposed on an upper and lower surfaces of the body of the rectifying element and extended in opposite directions; each of the lead plates has a wide heat radiation part at an extended side thereof; and each of the heat radiation parts is soldered to a heat radiation part receiving piece projected from each of the connection terminals in a layered state.
In a terminal box apparatus for a solar cell module in various exemplary embodiments, one of the lead plates has a thickness less than 0.1 mm; and in the neighborhood of a portion in which the body of the rectifying element is connected to the other of a pair of the lead plates, a slit-shaped notch is formed in a direction vertical to an extension direction of the lead plate by cutting the lead plate alternately from both side surfaces thereof in the extension direction.
In a terminal box apparatus for a solar cell module in various exemplary embodiments, a heat radiation plate is interposed between the heat radiation part of the lead plate and the heat radiation part receiving piece of the connection terminal.
In a terminal box apparatus for a solar cell module in various exemplary embodiments, the connection terminal has a heat radiation surface part extended to a mounting surface of the box that is mounted on the solar cell module.
In a terminal box apparatus for a solar cell module in various exemplary embodiments, a metal plate is mounted at a portion of a mounting surface of the box, corresponding to a bypass rectifying element-mounting position, to be mounted on the solar cell module.
In a terminal box apparatus for a solar cell module in various exemplary embodiments, a surface of the box in contact with an air layer is made of metal, with the box installed on the solar cell module.
In a terminal box apparatus for a solar cell module in various exemplary embodiments, an entire outer surface of the box is covered with a metal cover.
In a terminal box apparatus for a solar cell module in various exemplary embodiments, the metal has superior heat radiation property.
In various exemplary embodiments, there is provided a termina

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