JP4357972B2 - Solar cell bypass diode module with input / output terminals and manufacturing method thereof - Google Patents

Description

  The present invention relates to an output part structure for a solar cell module, and relates to a bypass diode module with an input / output terminal that can easily and reliably connect the output conductors of a plurality of solar cell modules.

  Conventionally, connecting terminals that can reduce the man-hours, shorten the construction time, and ensure the reliability at the construction site where the solar cell modules connected in series are connected in series to obtain the desired voltage. Realization of the box was desired. In addition, a diode is connected to each module for bypass or backflow prevention, but various technological developments have been made to ensure a thin box structure and electrical reliability. There exists patent document 1 which disclosed the technique about the conventional "output terminal box for solar cell modules."

Japanese Patent Laid-Open No. 5-343724. In "Paragraph 0007" of "Invention Name: Solar Cell Module Output Terminal Box", a solar cell module having a bypass diode is known in the prior art to improve the problem of the solar cell module output drop and cell destruction. It is described.

(Paragraph 0018) “A terminal box for a solar cell module is composed of a relay terminal support plate provided in a casing of the terminal box, a pellet-shaped bypass diode and a pellet-shaped backflow prevention diode provided on the support plate. At least one of them is provided. " (Paragraph 0020) is described as “the step of connecting the bypass diode is illustrated, and FIG. 1D is a cross-sectional view taken along line 1D-1D in FIG. 1C.” The sectional view shown in FIG. 1 (D) is shown in FIG. 3 of this document (the present invention), “the pellet-shaped bypass diode 4a placed on the insulating relay support plate is connected to the conductive relay terminal. Soldered on the portion 13a, one end of the lead wire 25 is connected to the bypass diode 4a, the relay terminal connection portion 13a is provided on the relay terminal support plate, and this connection structure is a terminal It can be housed in a box casing ", but a small, thin pellet-shaped diode chip is soldered to a conductive material.

The solar cell bypass diode module with input / output terminals must be reliable in environmental conditions exposed to harsh weather conditions for a long time outdoors. It is an object of the present invention to create a structure that can guarantee the durability of a semiconductor element incorporated in the module.

The external connection structure of the solar cell bypass diode module with input / output terminals must be reliable in harsh working environment conditions. It is also an object of this invention to create a structure that can ensure electrical connection and electrical insulation.

  The heat dissipation of the diode can be easily achieved, and the diode must be firmly attached. This is a necessary condition for this technology. However, since the above-described pellet-shaped diode is a fragile thin semiconductor pellet, it is vulnerable to vibration and shock and easily breaks. It is possible to manufacture with a process that can guarantee the quality by the technology that eliminates such performance insecurity. For this reason, it must be realized with a product structure that can set a “process separation” that can check the quality between manufacturing processes, is a compact product, and is provided at a low cost with a structure that is easy to install and connect. Was an issue. In order to ensure durability and reliability over a long period of time against changes in temperature and humidity, the problem is that the structure and manufacturing method of the product are systematically incorporated.

With respect to claim 1, in order to solve the above-mentioned problem, a product structure is realized in which a “process delimiter” capable of quality check between manufacturing processes can be set, and a terminal for a solar cell module lead wire A structure in which each zone of the zone, the diode heat sink zone, and the output cable terminal zone is partitioned by a partition wall is formed, and the manufacturing method can check the completeness by a characteristic test for each partition of the manufacturing process.

A plurality of heat sinks with terminal connection means formed in the vicinity of the end are attached to the electrically insulating box frame by fixing or insert molding with an insulation interval, and insulated at the approximate center of the heat sink. A step of connecting the electrodes of the diode in a shape across the interval, a step of filling the diode heat sink zone to which the diode is connected with an insulator to complete the product intermediate, a step of testing the characteristics of the product intermediate, a solar cell Fixing the product intermediate to the back of the module panel, connecting the solar cell module lead wire to the terminal connection means in the module lead wire terminal zone of the heat sink, and performing a performance test at this stage; The process of filling with insulation so as to cover, the process of connecting the output cable to the terminal connection means in the terminal zone for the output cable, and the performance test after this process It was characterized by having a process to obtain a method of manufacturing a solar cell bypass diode module with input and output terminals.

With respect to claim 2, the solar cell module lead wire terminal zone, the diode heat sink zone, and the output cable terminal zone are each formed in an insulating box frame that is partitioned by a partition, and a terminal is provided near the end of the heat sink. A plurality of heat sinks on which connecting means are formed are attached with an insulation interval, and the anode electrode and the cathode electrode of the diode are electrically and mechanically connected in a shape straddling the insulation interval at a substantially central portion of each heat sink. The diode heat sink zone filled with an insulator is used as a product intermediate, and this product intermediate is fixed to the back surface of the solar cell module panel, and the solar cell module lead wire is in the module lead wire terminal zone of the heat sink. After being connected to the terminal connection means, the connection part is filled with an insulating material, etc., and moisture-proof treatment is performed, and the connection to the terminal connection means in the output cable terminal zone is performed. Cable is connected, then was characterized by structure to be moisture-proofed, and a solar cell bypass diode module with input and output terminals.

With respect to claim 3, the solar cell module lead wire terminal zone, the diode heat sink zone, and the output cable terminal zone are each formed of an insulating box frame that is partitioned by partition walls.
A plurality of heat sinks are attached with an insulation interval maintained, terminal connection means are formed in the vicinity of both ends of the heat sink, and a diode electrode is connected in a shape straddling the insulation interval substantially at the center of the heat sink. A product intermediate in which a heat sink zone is filled with an insulator is fixed to the back surface of the solar cell module panel, at least approximately in the center of the heat sink, via a heat conductive electrical insulating plate. A solar cell bypass diode module with an input / output terminal according to claim 2.

4. The input / output terminal according to claim 2, wherein the terminal connecting means formed in the vicinity of both ends of the heat radiating plate is a terminal plate formed of a metal piece to which the lead wire of the module can be soldered. A solar cell bypass diode module with a battery is provided.

The solar cell bypass diode with input / output terminals according to claim 2 or 3, wherein the terminal connecting means formed in the vicinity of both ends of the heat sink is a receptacle terminal having a structure in which the input / output terminals can be inserted and connected. It was a module.

With respect to claim 6, the diode connected in a shape straddling the insulating interval substantially at the center of the heat sink is a finished diode product in which an electrode is connected to the semiconductor chip and the chip part is resin-molded. The solar cell bypass diode module with input / output terminals described in 3 and 4 was used.

This product is fixed to the back surface of the solar cell module panel, and the solar cell module panel acts as a heat radiating fin for the diode.
Since the diode to be connected is a finished product in which the semiconductor chip part is resin-molded, the heat and humidity resistance reliability is confirmed and guaranteed at this stage. As a result of this assembly, the resin filling is further molded into a double moisture-proof construction, so that it is possible to ensure long-term reliability compared to existing products. Furthermore, since the external connection terminal is pulled out so that no force is applied to the semiconductor chip, the construction of the cable connection at the time of installation is easy, so that the completeness of the work is improved and the overall product completeness is increased.

An embodiment according to the present invention will be described with reference to FIG. FIGS. 1A and 1C are plan views, and FIGS. 1B and 1D are side cross-sectional views thereof. The box frame 1 is formed of an insulating material such as an epoxy resin, for example, and each zone of the solar cell module lead wire terminal zone 2, the diode heat sink zone 3, and the output cable terminal zone 4 is divided by a partition wall 12 to A heat radiating plate 9, for example, a copper plate having a thickness of 3 mm, having terminal connecting means 6 and 7 formed in the vicinity of the portion, is fixed to the partition wall 12 by insert molding or adhesive. A plurality of heat sinks 9 are attached with an insulation interval 10 maintained, and the anode electrode and the cathode electrode of the finished diode 8 are soldered in a shape straddling the insulation interval 10 at a substantially central portion of each heat sink. The product intermediate, which is electrically connected in series and the diode heatsink zone 3 is filled with an insulating material such as epoxy resin, is confirmed for quality and reliability in electrical property tests and temperature / humidity environment tests. It becomes a product intermediate and becomes a break of the manufacturing process. The box frame 1 has ribs 5 formed on the bottom 11 of the solar cell module lead wire terminal zone 2 and the bottom 11 of the output cable terminal zone 4 except for the diode heat sink zone 3. In addition to helping to ensure moisture proof reliability when the wire is connected to the terminal and subsequently filling and sealing the connection, it helps to save the required amount of filler. It is also effective to provide a through hole having a size capable of introducing a lead wire of the solar cell module or a cable of an external wiring at the bottom or the side of the frame body of the terminal zones 2 and 4.

The terminal connecting means 6 and 7 formed near the end of the heat sink 9 are receptacle terminals 6 and 7 having a structure in which input / output terminals can be inserted and connected. When making it extremely small, it is preferable to use a screw terminal block having a screw hole structure in which the crimp terminal of the output cable can be screwed. In the case of mass production with a large production scale, it is preferable to use a sheet metal terminal for soldering. 6 is a module lead terminal, and 7 is an output cable terminal.

The finished diode 8 is a diode semiconductor chip fixed to a metal plate, the metal plate is an outer conductor of an anode electrode, and an outer conductor having a cathode connected in parallel to two pins. Parts other than the outer conductor are covered with an electrical insulator, and the humidity resistance reliability of the internal diode chip has been confirmed. The finished diode 8 whose humidity resistance reliability has been confirmed is electrically connected to the heat sink 9 and the chip generates heat during energization. The bottom 11 of the diode heat sink zone 3 is designed to keep the temperature rise low. , (At least at the part where the heat sink 9 is in contact), the thickness is reduced so as to reduce the thermal resistance, for example, the thin plate part 16 is formed to 1 mm or less, or the heat sink as shown in FIG. 9 is formed in a shape that cuts through the bottom 11 part, and a heat conductive insulating sheet (thermal sheet) 13 having excellent heat conductivity is adhered to the heat radiating plate 9 to prevent water from entering, Secured. A panel of the solar cell module is affixed to the outside of this portion, and the panel is made to act as a heat dissipation heat sink. When the bypass current is large, it is important to keep the PN junction temperature of the diode below a specified value by electrically insulating the amount of heat generated by energization with as low a thermal resistance as possible. Compared with the conventional structure in which only the lead wire is transferred, the structure of the present invention in which the tip portion is resin-molded and has a heat transfer effect superior to that of the air has an excellent heat dissipation effect.

The manufacturing method of the embodiment according to the present invention will be described with reference to the manufacturing process diagram shown in FIG. The step of providing the terminal connecting means 6 and 7 on the heat sink 9, the step of forming the insulating box frame 1 to which the heat sink 9 is fixed by insert molding, the box frame is intermediate between the two terminal zones 2 and 4. The diode heat sink zone 3 is formed in the shape. Next, the step of connecting the anode electrode 14 and the cathode electrode 15 of the diode 8 in which the semiconductor chip is insulation molded to the metal heat sink 9 by soldering so as to straddle the insulation interval 10, the diode 8 of the frame 1 The product intermediate A is completed through the process of filling the soldered heatsink zone 3 with an insulator such as an epoxy resin and the above process.

In the product structure and manufacturing process as described above, this product intermediate is in a state where a reliability test such as moisture resistance and vibration resistance can be performed, and therefore, “delimited by process” can be set here. It can be assured that it can withstand long-term changes in temperature resistance and moisture resistance through the product intermediate property test process.

Next, after fixing the above product intermediate to the back surface (shaded surface) of the solar cell panel by bonding or screwing, connect the solar cell module lead wires to the terminal connection means 6 in the terminal zone. After the characteristic test (product intermediate B), the connection part is filled with a moisture-proof insulator.

Connect the output cables of all the modules of the solar cells connected in series to the terminal connection means 7 of the other terminal zone 4 and fill the connection part with moisture-proof insulation after the characteristic test (product intermediate C) To do.

In this way, every time a product intermediate is obtained, process delimiters are provided and quality can be confirmed in the test process. Therefore, there is no process loss compared to the conventional method in which the test result is poor in the final process. Cost is low.

Since the semiconductor chip of the diode is a fragile thin semiconductor pellet, it is vulnerable to vibration and shock and easily breaks. In order to eliminate such performance uncertainties, the diode is made of a metal having a structure in which the portion of the semiconductor chip is molded with an insulator and the force applied to the diode electrode portion for external connection is not directly transmitted to the semiconductor chip. Since it is configured to be fixed to the heat sink, the force applied to the terminals of the terminal box during cable connection work does not affect the semiconductor chip, so the solar cell lead wires and output cables can be easily connected. Since it was realized with a product structure that can set “process separation” that allows quality checks between manufacturing processes, it was possible to provide high reliability with a structure that facilitates installation and wiring work. ， Industry contribution is high.

Structure diagram of one embodiment according to the present invention Manufacturing process diagram of one embodiment according to the present invention Structure diagram of conventional equipment

Explanation of symbols

1 Box frame 2 Terminal zone (for module lead wire)
3 Diode heat sink zone 4 Terminal zone (for output cable)
5 Rib 6 Terminal connection means (terminal for module lead wire)
7 Terminal connection means (terminal for output cable)
8 Completed diode 9 Heat sink 10 Insulation interval 11 Bottom 12 Bulkhead 13 Thermally conductive insulating sheet (thermal sheet)
14 Anode electrode 15 Cathode electrode 16 Thin plate part

Claims (6)

Multiple heatsinks with terminal connection means formed in the vicinity of both ends of an insulating box frame in which the solar cell module lead wire terminal zone, diode heat sink zone, and output cable terminal zone are separated by partition walls The plate is attached by fixing or insert molding with an insulation interval, and the step of connecting the electrode of the diode so as to straddle the insulation interval at the substantially central portion of the heat dissipation plate, the insulator in the diode heat dissipation zone to which the diode is connected To complete the product intermediate, to test the characteristics of the product intermediate, to fix the product intermediate to the back surface of the solar cell module panel, and to attach the solar cell module lead wire to the module lead of the heat sink Connecting to the terminal connection means in the terminal zone for wire and filling the portion covering the connecting portion with an insulator, terminal zone for output cable It was characterized by that the terminal connection unit has the step of connecting the output cable, the manufacturing method of the input and output terminals with the solar cell bypass diode module. A plurality of heat sinks are attached to an insulating box frame in which each zone of a solar cell module lead wire terminal zone, a diode heat sink zone, and an output cable terminal zone is partitioned by a partition wall while maintaining an insulation interval. Terminal connecting means is formed near both ends of the heat sink, the diode electrode is connected across the insulation interval at the approximate center of the heat sink, and the product intermediate in which the diode heat sink zone is filled with an insulator Fixed to the back of the battery module panel, the module lead wire is connected to the terminal connection means in the module lead wire terminal zone of the heat sink, the insulator is filled in the connection site, and the terminal connection in the output cable terminal zone A solar cell bypass diode module with input / output terminals, characterized in that an output cable is connected to the means. A plurality of heat sinks are attached to an insulating box frame in which each zone of a solar cell module lead wire terminal zone, a diode heat sink zone, and an output cable terminal zone is partitioned by a partition wall while maintaining an insulation interval. Terminal connecting means is formed near both ends of the heat sink, the diode electrode is connected across the insulation interval at the approximate center of the heat sink, and the product intermediate in which the diode heat sink zone is filled with an insulator 3. The solar cell bypass diode module with input / output terminals according to claim 2, wherein the solar cell bypass diode module has input / output terminals on the back surface of the battery module panel, and is fixed to at least a substantially central portion of the heat dissipation plate via a heat conductive thin insulating plate. . 4. The solar cell bypass diode module with input / output terminals according to claim 2, wherein the terminal connecting means formed in the vicinity of the end portion of the heat radiating plate is a terminal plate formed of a solderable metal piece. 4. The solar cell bypass diode module with input / output terminals according to claim 2, wherein the terminal connecting means formed in the vicinity of the end of the heat sink is a receptacle terminal having a terminal structure into which the input / output terminals can be inserted and connected. 5. The input / output terminal according to claim 2, 3 or 4, wherein the diode connected in a shape straddling the insulation interval at a substantially central portion of the heat sink is a diode in which an electrode is connected to a semiconductor chip and a chip part is resin-molded. With solar cell bypass diode module.

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