Abstract:
In order to deliver the current generated by means of photovoltaic solar elements, the invention proposes a connector for a solar module that is accommodated in a connector housing and can be connected to the solar elements. The solar elements are interconnected by means of flat connecting lines and embedding in a translucent sandwich panel. The current is delivered through an opening in one of the sheets of the sandwich panel by means of springable contact elements that are in electric contact with the connecting lines of the solar elements.

Description:
TECHNICAL FIELD 
     The invention pertains to a connector for a solar module that is arranged in a connector housing and serves for connecting an electric service cable to electric connecting lines of the solar module that are arranged with translucent sandwich panels and serve for electrically interconnecting several photovoltaic solar elements. 
     BACKGROUND OF THE INVENTION 
     A connector of this type is required for delivering the solar electricity generated by photovoltaic solar elements in a solar module to a consumer via a service cable. 
     A plate-shaped photovoltaic solar module with an outer plate and an inner plate, as well as a plastic layer with embedded solar cells, is known from EP 1 006 593 A1. The connector of this solar module consists of a plug-and-socket connector that is arranged in an opening in the inner plate and permanently connected to several connecting lines of the solar cells. 
     BRIEF SUMMARY OF THE INVENTION 
     The disadvantage of such an arrangement is that a permanent connection of this type needs to be soldered or welded and is quite complicated and expensive to produce. 
     The invention is based on the objective of developing a connector of the initially described type in such a way that separable electric connections between the connecting lines of solar modules and electric service cables can be easily and inexpensively produced without requiring tools. 
     This objective is attained in that the ends of the connecting lines are partially supported by a reinforcing element, and in that the connecting lines can be respectively contacted by a contact pin in the region of the support realized with the reinforcing element. 
     The advantages attained with the invention can be seen, in particular, in that the contact pins with a pyramid-shaped surface structure make it possible to realize a direct and gas-tight contact with the flat electric connecting lines that are arranged within the solar module and serve for electrically interconnecting the individual photovoltaic solar elements that are embedded in a sandwich panel. 
     The connecting lines are supported by a reinforcing element because they consist of copper and consequently are relatively soft with respect to compressive connection methods. This means that the connecting lines that are additionally placed into a relatively soft plastic layer within the sandwich panel exert a corresponding back pressure upon the contact pin. 
     In this context, it is particularly advantageous that the contact pins are held on a spring element and thusly exert a constant pressure upon the connecting lines such that excessive contact resistances are prevented. 
     The reinforcing elements are also provided with catch elements that are engaged with catch elements of an insulating contact plate. 
     The contact plate contains an integral base plate that is held between the sheets, wherein a collar-shaped connecting part of the contact plate makes it possible to produce a connection with a connector housing in a recess in one of the sheets by attaching the connector housing to the recess. 
     In this case, the contact pins are springably held in the connector housing and pressed against the connecting lines in the sandwich panel. Since the height of the contact plate within the sandwich panel does not exceed the height of the outer sheet or, in the other words, does not protrude over this outer sheet, several sheets with solar modules can be stacked directly on top of one another in order to be stored or transported, namely because only a protective cap initially covers and protects the recess from the admission of dirt and the like. This protective cap is removed after the assembly of the solar module and replaced with the connector housing. 
     However, it is preferred to reduce the total height of the contact plate such that the connector housing with a collar attached thereon can be accommodated in the recess in the sandwich panel in a polarized fashion. 
     The contact pins are connected to a printed circuit board arranged in the connector housing in an electrically conductive fashion, wherein the printed circuit board is electrically connected to a connector plug that advantageously consists of a quick-connector for producing a connection with an external service cable without requiring tools and is realized in the form of a cage strain terminal. 
     The connector housing with the contact pins is advantageously realized in the form of a splash water-proof and dust-proof variation in order to ensure a reliable electric connection between the solar elements and a consumer independently of environmental influences. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       One embodiment of the invention is illustrated in the figures and described in greater detail below. The figures show: 
         FIG. 1 , the installation of a contact plate into a sandwich panel of a solar module; 
         FIG. 2 , a detailed representation of the contact plate; 
         FIG. 3 , a contact plate that is completely installed in the sandwich panel; 
         FIG. 4 , an exploded view of the contact housing; 
         FIG. 5 , a contact housing with contact pins installed on a printed circuit board; 
         FIG. 6 , an exploded view of the connector housing; 
         FIG. 7 , a bottom view of the connector housing; 
         FIG. 8 , a representation of the connector housing installed on the sandwich panel, and 
         FIG. 9 , a section through the connector housing with a connector plug. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  shows a translucent sandwich panel of a solar module that consists of an outer sheet  1  and an inner sheet  3 , between which a plastic layer  2  is arranged. Photovoltaic solar elements (not shown in the figure) are embedded in this plastic layer. 
     Flat connecting lines  4  lead from the solar elements to a central supply terminal, on which a contact plate  10  in the form of a flat housing part is arranged. 
     The connecting lines  4  are inserted into channels  8  in the plastic layer  2  and partially encompassed by reinforcing elements  5  on their ends. 
     The contact plate  10  is realized in the form of a flat, rectangular part and comprises a base plate  12 , on which a structure of different shapes is arranged and surrounded by a collar  18 . 
     The contact plate is placed on the plastic layer  2  above the connecting lines  4 , namely in a depression  7  that corresponds to the base plate. The catch means  6  provided on the reinforcing elements  5  respectively engage on an undercut  16  in the contact plate. 
       FIG. 2  shows an enlarged detail of  FIG. 1 , wherein a reinforcing element  5  is inserted into a rectangular recess  14  in the contact plate  10  and the catch hooks  6  that are cut out along three sides can be respectively engaged on an undercut  16 . In this case, two recesses  14  for the connection of two connecting lines  4  are provided. An additionally provided polarization element  15  is realized in the form of a circular ring with a web attached thereto and contains a threaded bore  17  in its center (see also  FIG. 3 ). 
     The assembly of the sandwich panel is completed after the upper sheet  3  is attached in a precisely fitted fashion to the region in which the contact plate  10  is fixed on the plastic layer  2  with the recess  9 . 
     The recess can be covered with a protective cap or the like in order to prevent the admission of dirt during the transport of the sandwich panel. In this case, it is ensured that the maximum height of the contact plate  10  does not exceed the sheet thickness. The height of the collar is normally smaller than the thickness of the sheet  3  of the sandwich panel. 
       FIG. 3  shows a completely assembled sandwich panel with the contact plate  10 . This figure shows the rectangular recesses  14 , into which the reinforcing elements  5  engage, as well as the polarization  15  with the central threaded bore  17 . The polarization is realized in the form of a circular ring with a narrow web attached thereto such that a connector housing with a corresponding negative polarization can only be inserted in one position. 
       FIG. 4  shows an exploded view of a contact housing  20  that holds contact elements  50 , as well as a cover plate  30  for closing the contact housing and a printed circuit board  35 . The contact element  50  consists of a U-shaped spring element  57 , on the arc section  58  of which a contact pin  52  is fixed. The contact surface  54  is provided with pyramid-shaped points that directly contact the flat connecting lines  4  during the final assembly and serve for delivering the current generated by the solar elements to a consumer. 
     The terminal ends of the spring elements  57  are realized in the form of pin-shaped terminal ends  56  and inserted into bores  36  in the printed circuit board  35 , as well as soldered thereto. 
     The limbs of the spring elements are fixed and guided in longitudinal slots  31  of the cover plate  30 , and the contact pin  52  is held in a guide bore  23  in the contact housing  20 . 
     A negative polarization element  25  referred to the polarization element  15  provided in the contact plate  10  is arranged in the contact housing  20  between the two guide bores  23 . Due to these polarization elements, the contact housing with the contact elements  50  can only be correctly attached to the contact plate  10  in the sandwich panel  1 ,  2 ,  3 . 
     The cover plate  30  also contains outwardly directed catch hooks  33  that engage into openings  26  in the contact housing  20  when the cover plate  30  is installed on the contact housing  20  such that the contact housing  20  with the contact elements  50  and the cover plate  30  form one unit on the printed circuit board  35 . 
     A central bore extends through the entire assembled structure comprising the contact housing  20 , the cover plate  30  and the printed circuit board  35 . When the connector housing is installed on the solar module, it is fixed in position with a screw  43  that extends through the bores  34 ,  32 ,  22  in the printed circuit board  35 , the cover plate  30  and the contact housing  20 . 
       FIG. 5  shows an assembled and interconnected housing  20  that is mounted on a printed circuit board  35 . The contact elements with the contact pins  52  protrude from the contact housing, wherein both elements are able to axially slide in the guide bores  23  independently of one another due to the springable properties of the U-shaped spring element  57 . The printed circuit board is also provided with connecting cables  38  with contacts  37 . Components  39  may also be arranged on the printed circuit board. 
       FIG. 6  shows an exploded view of a rectangular connector housing  40  that consists of a lower housing part  41  and a hinged housing cover  42 . 
     The housing cover  42  is held in a pivoted fashion on the pins  49  with the aid of the limbs  47 , and the limbs  48  in cooperation with the pin  49 ′ cause the cover to be held in position when it is in the open state. 
     The lower housing part contains an opening  46 , into which the contact housing  28  with the printed circuit board  35  is inserted. The contacts  37  need to be simultaneously connected to the connector plug  60 . 
     The lower housing part and the housing cover can be tightly connected to one another by means of a screw  44  that is screwed into a threaded bore  45 , as well as a peripheral seal between the housing and the cover that is not illustrated in greater detail. Due to these measures, the housing is largely protected from environmental influences. 
       FIG. 7  shows a view of the connector housing  40  from the “bottom” that simultaneously forms the installation side to be placed on the contact plate  10  in the sandwich panel. One can ascertain that the contact housing  20  protrudes from the bottom of the connector housing, namely relative to the collar  41 ′ that is integrally formed onto the bottom. The collar polarizes the connector housing in the recess  9  of the upper sheet  3 , and the wall of the contact housing is centered on the contact plate within the collar  18 . 
     The assembly of the connector housing is illustrated in  FIG. 8 . In this case, a double-sided adhesive foil  70  with a recess  72  for the region in which the collar  41 ′ protrudes from the lower housing part, is initially attached to the bottom side of the lower housing part  41 , and the connector housing  40  is subsequently placed on the region of the solar module, in which the contact plate  10  is fixed in the sandwich panel  1 ,  2 ,  3 . 
     The connector housing  40  is initially placed on the sandwich panel without the contact housing  20 . Subsequently, the contact housing is inserted and connected to the contact plate  10  by means of the screw  43 . 
       FIG. 9  shows a section through the open connector housing  40  in a region, in which one of the connector plugs  60  is connected to the connector housing. 
     One can ascertain how the current is supplied to the printed circuit board  35  via the protruding contact pin  52  in the contact housing  20 , then to the contact  37  via the connecting cable  38  and ultimately to the region  63 , in which the connector plug  60  is connected. In the embodiment shown, the connector plug is realized in the form of a cage strain terminal  62  that serves for delivering the current to the service cable  65  fixed in the cage strain terminal. 
     Instead of utilizing the cage strain terminal shown, it would also be conceivable to provide a connector with an axial terminal for bunched conductors in the connector plug  60 .