Low Profile Photovoltaic (LPPV) Box

• US 20090084570A1
• Filed: 10/02/2007
• Published: 04/02/2009
• Est. Priority Date: 10/02/2007
• Status: Active Grant

• Current Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Original Assignee: Tyco Electronics Corporation (TE Connectivity Ltd. (United Kingdom))
• Inventors: Duesterhoeft, Scott S., Gherardini, Stephen D.
• Granted Patent: US 8,222,533 B2
• Time in Patent Office: Days
• US Class Current: 174/51
• CPC Class Codes: H02S 40/34 comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
• CPC Class Codes: H02S 40/345 with cooling means associated with the electrical connection means, e.g. cooling means associated with or applied to the junction box cooling means for PV cells H01L31/052, for PV modules H02S40/42
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A low profile photovoltaic connection system for placement in space restricted areas. The connection system includes a connection box, diodes, and heat sinks inside of the connection box. The heat sink element is maintained in contact with the diode element such that the heat sink dissipates heat externally of the junction box and the contacts are arranged with a flat surface parallel to the solar panel to reduce vertical elevation of the junction box when mounted to the solar panel.

Claims

1. A low profile junction box for interconnection of solar cell arrays in a power distribution system, the low profile junction box comprising:

a cover portion having an opening for receiving at least one foil contact from a solar panel,

a plurality of diode elements, each diode element having a heat sink element attached thereto for dissipating heat generated by the diode elements and a plurality of contacts configured to electrically connect to at least one foil contact from a solar panel;

a plurality of cables configured to interconnect a plurality of low profile junction boxes, and configured to conduct the energy from the solar panels; and

wherein the heat sink elements being maintained in contact with the diode elements, such that the heat sinks dissipate heat externally of the junction box and wherein the contacts are arranged with a flat surface parallel to the solar panel to reduce vertical elevation of the junction box when mounted to the solar panel.

2. The junction box of claim 1, wherein the diode element contacts are connected to the foil contacts of the solar panel with a solder connection.

3. The junction box of claim 1, wherein the cover portion is constructed of a substantially rigid, electrical insulating and thermally conductive material.

4. The junction box of claim 3 wherein the cover portion is a single molded piece.

5. The junction box of claim 1 further comprising two diode contact positions.

6. The junction box of claim 1 further comprising three diode contact positions.

7. The junction box of claim 1, wherein at least one diode element of the plurality of diode elements being TO-220 packaged diodes, wherein the TO-220 packaged diodes have heat sink tabs for dissipating heat.

8. The junction box of claim 1, wherein at least one diode element of the plurality of diode elements being TO-220 diodes, wherein the ITO-220 diodes have plastic covered heat sinks to dissipate heat at a rate sufficient to meet the requirements of IEC 61215.

9. The junction box of claim 1, wherein the contacts are a copper alloy.

10. The junction box of claim 9, wherein the contacts are any one of tin plated phos bronze or brass.

11. The junction box of claim 1, further comprising a maximum operating voltage of 45 volts DC for the diode elements.

12. The junction box of claim 1 further comprising a maximum operating current of 15 amps for the diode elements.

13. The junction box of claim 1 wherein the junction box is mounted to a side of a solar panel and secured with an adhesive.

14. The junction box of claim 13 wherein the adhesive is waterproof silicon.

15. A low profile junction box for interconnection of solar cell arrays in a power distribution system, the low profile junction box comprising:

a cover portion having an opening for receiving at least one foil contact from a solar panel,

a diode element having a heat sink element attached thereto for dissipating heat generated by the diode elements and a plurality of contacts configured to electrically connect to at least one foil contact from a solar panel;

a plurality of cables configured to interconnect a plurality of low profile junction boxes, and configured to conduct the energy from the solar panels; and

wherein the heat sink element being maintained in contact with the diode element, such that the heat sink dissipates heat externally of the junction box and wherein the contacts are arranged with a flat surface parallel to the solar panel to reduce vertical elevation of the junction box when mounted to the solar panel.

16. The junction box of claim 15, wherein the cover portion is constructed of a substantially rigid, electrical insulating and thermally conductive material.

17. The junction box of claim 16 wherein the cover portion is a single molded piece.

18. The junction box of claim 15, further comprising two diode contact positions.

19. The junction box of claim 15, further comprising three diode contact positions.

20. The junction box of claim 15, wherein at least one diode element of the plurality of diode elements being TO-220 packaged diodes, wherein the TO-220 packaged diodes have heat sink tabs for dissipating heat.

21. The junction box of claim 15, further comprising a maximum operating voltage of 45 volts, and a maximum operating current of 15 amps for the diode elements.