Photovoltaic junction box and processing method thereof

Abstract

The invention discloses a photovoltaic junction box and a processing method thereof, the photovoltaic junction box comprises a box body, the bottom of the box body is provided with an opening, the box body is covered with a cover plate, the box body is internally provided with two junction metal plates connected with two poles of a photovoltaic panel, and the junction metal plates are connected through a diode. One side of the two wiring metal plates is provided with a ring sleeve sleeved with a conductive pin of the diode, and the wiring metal plates are sleeved with the conductive pin of the diode through the ring sleeve. The upper end or the lower end of the right side of the left wiring metal plate extends rightwards to form a contact lug, the lower end or the upper end of the left side of the right wiring metal plate extends leftwards to form a contact lug, the ring sleeves are arranged at the tail ends of the contact lugs on the two sides, and the diode is perpendicular to a connecting line between the wiring metal plates on the two sides. According to the invention, the structure is compact, the current passing ability is stronger, the high voltage resistance is stronger, and the production cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of connection devices for photovoltaic products, and in particular to a photovoltaic junction box and a processing method thereof. Background Art

[0002] With the shortage of energy and the requirement for environmental protection, the green development is continuously promoted. The photovoltaic industry is becoming more and more popular. Photovoltaic accessories are important products in the new energy photovoltaic industry. Photovoltaic junction boxes are important accessories for connecting various photovoltaic products and important products for connecting photovoltaic panels and wiring harnesses. Diodes need to be set in photovoltaic junction boxes to avoid hot spot effects on photovoltaic panels in a group. The shielded photovoltaic cell assembly in a series branch will be used as a load to consume the energy generated by other illuminated photovoltaic cell assemblies. At this time, the photovoltaic cell group used as a load will generate heat due to hot spot effect. At this time, the parallel bypass diode will work to guide the current through the diode to avoid the hot spot effect.

[0003] Due to the increasing market competition, the size of existing photovoltaic junction boxes tends to be miniaturized to reduce production costs. In order to reduce the size, SMD diodes are usually used in existing photovoltaic junction boxes. However, SMD diodes have low current and voltage bearing capacity and cannot meet the needs of high power and high voltage. In addition, the cost of using SMD diodes is higher. Summary of the invention

[0004] In order to solve the problem of high production cost of photovoltaic junction boxes and the smaller patch diodes with low current and voltage bearing capacity that cannot cope with the current high-power and high-voltage application scenarios in the photovoltaic industry, the present invention provides a photovoltaic junction box with a compact structure and lower production cost and a processing method.

[0005] In order to achieve the above-mentioned invention purpose, the technical scheme adopted by the present invention is as follows: a photovoltaic junction box, comprising a box body, an opening is provided at the bottom of the box body, and a cover plate is provided on the box body, two wiring metal plates are provided in the box body to connect the two poles of the photovoltaic panel, and the wiring metal plates are connected by diodes, and a ring sleeve for sleeve-mounting the conductive pins of the diode is provided on one side of the two wiring metal plates, and the wiring metal plates are sleeved with the conductive pins of the diodes through the ring sleeve. The photovoltaic junction box is connected with the metal plate by the ring sleeve, which improves the connection strength, current bearing and voltage bearing of the diode and the wiring metal plate. A contact ear piece extends to the right at the upper or lower end of the right side wiring metal plate, and a contact ear piece extends to the left at the lower or upper end of the left side wiring metal plate, and the ring sleeve is arranged at the end of the contact ear piece on both sides, and the diode is arranged perpendicular to the connection line between the wiring metal plates on both sides. The diode is arranged perpendicular to the wiring metal plates on both sides, which effectively improves the compactness of the product, and in the case of this scheme, a diode with a larger volume and higher power can be selected according to the width of the shell without affecting the overall volume.

[0006] As a further preferred solution for the photovoltaic junction box: soldering is used to connect the ring sleeve and the diode pin. After the ring sleeve and the diode pin are connected, soldering is performed to improve the contact between the diode pin and the ring sleeve, increase the contact area between the wiring metal plate and the diode, and improve the current flowability.

[0007] As a further preferred solution for the photovoltaic junction box: a heat sink is attached to the lower end surface of the wiring metal plate, a limiting portion for fixing the heat sink is bent at the lower end surface of the wiring metal plate, and a welding spot for welding the wiring harness is provided on the upper end surface of the wiring metal plate. The wiring metal plate can be made of metals with high conductivity such as copper. In order to improve the competitiveness of the product, the thickness of the wiring metal plate must not be too thick. However, while reducing the thickness of the metal material, the wiring metal plate will heat up when a large current or high voltage flows through it. The solution of using a heat sink effectively improves the heat dissipation of the wiring metal plate, and the heat sink is fixed to the heat sink by a limiting portion, which greatly improves the deformation resistance of the wiring metal plate. In order to further fix the wiring metal plate and the heat sink, the limiting portion is a flange folded downward from at least two sides of the wiring metal plate, and the flange is buckled at the edge of the heat sink.

[0008] On the other hand, the flange setting can also improve the product's anti-bending properties.

[0009] As a further preferred solution of the photovoltaic junction box: a positioning column is provided in the middle of the box body, a positioning hole matching the positioning column is provided on the junction metal plate, and a limiting protrusion for limiting the diode is provided in the middle of the box body.

[0010] As a further preferred solution of the photovoltaic junction box: it also includes a threading hole set on the wiring metal plate, and the heat sink avoids the threading hole. The threading hole is set so that the photovoltaic cell harness passes through the threading hole and connects to the wiring metal plate, effectively preventing the photovoltaic cell harness from directly touching the junction box shell and causing the shell to deform.

[0011] Based on the above invention concept, the present application also proposes a method for processing a photovoltaic junction box, comprising the following steps: S1. Prepare the junction box body and cover plate; S2, punching out oppositely arranged sheet-shaped wiring metal strips, wherein the wiring metal strips have contact ears and flanges to be folded; S3, loading the diode between the contact ears of the wiring metal plate strip and fixing the diode, and synchronously punching the contact ears and the conductive pins of the diode to form a ring sleeve to connect and fix the diode to the wiring metal plate; S4, take the heat sink and load it onto the wiring metal plate, stamp and flanging the strip material to fix the heat sink on the wiring metal plate; S5. Assemble the box body, the cover plate, and the wiring metal plate with the heat sink and the diode installed.

[0012] As a preferred solution of the processing method of the photovoltaic junction box, it also includes punching out wire holes in step S2 or S3.

[0013] As a preferred solution for the processing method of the photovoltaic junction box, it also includes using ultrasonic wave to press the junction metal plate and the heat sink. As a preferred solution for the processing method of the photovoltaic junction box, it also includes welding the wire harness to a wiring metal plate and performing tinning treatment on the ring sleeve and the conductive pins of the diode.

[0014] Prepare the junction box body and the cover plate; punch out the oppositely arranged sheet-shaped wiring metal plate strip, which has a contact ear piece in the sheet-shaped wiring metal plate strip; take the diode to feed it between the contact ears of the wiring metal plate strip and fix the diode, and simultaneously punch the contact ear piece and the conductive pin of the diode to form a ring sleeve to fix the diode; also include punching to form threading holes and flanges to be folded; synchronously punch the heat sink and the wiring metal plate to fix the heat sink on the wiring metal plate; assemble the box body, the cover plate, and the wiring metal plate with the heat sink and the diode installed. For the three-body photovoltaic junction box, it is necessary to weld the wiring harnesses of the photovoltaic junction boxes on both sides to connect other lines. Therefore, it is necessary to weld the wiring harness for the above-mentioned photovoltaic junction box. In the conventional production process, the wiring metal plate is usually punched out first, and then the wiring metal plate and the diode are separately fed for positioning welding and assembled as a whole after cooling. In this application, the wiring metal plate and the diode are synchronously connected during stamping to reduce the production process steps.

[0015] The beneficial effects of the present invention are as follows: the wiring metal plate is connected to the diode by a ring sleeve, which effectively improves the connection strength between the wiring metal plate and the diode, and the current and voltage carrying capacity of the contact part; the ring sleeve and the diode are further connected by solder to improve the current flowability; the heat sink is set to effectively reduce the thickness of the wiring metal plate, thereby reducing production costs and improving product competitiveness; the flanging design and the solution of fixing with the heat sink are adopted to improve the deformation resistance and heat dissipation capacity of the wiring metal plate, and further improve the current flowability and pressure resistance of the wiring metal plate; the wiring metal plate is provided with a threading hole to effectively prevent the heating of the line from affecting the product shell. The assembly process is completed simultaneously when the wiring metal plate is stamped, which reduces the production process, improves the product production speed, and reduces the equipment investment cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a stereogram of the present invention.

[0017] Figure 2 It is a schematic diagram of the internal structure of the present invention.

[0018] Figure 3 It is an exploded view of the present invention.

[0019] Figure 4 It is a schematic diagram of the bottom surface structure of the wiring metal plate of the present invention.

[0020] Figure 5 Schematic diagram of the sheet metal strip structure.

[0021] Figure 6 This is a schematic diagram of the diode when it is installed.

[0022] Figure 7 This is the schematic diagram after the diode is connected.

[0023] Among them: 1. Box body; 2. Opening; 3. Cover; 4. Wiring metal plate; 5. Diode; 6. Ring sleeve; 7. Contact ear piece; 8. Heat sink; 9. Solder point; 10. Flanged edge; 11. Positioning column; 12. Positioning hole; 13. Limiting protrusion; 14. Threading hole; 15. Wiring metal plate strip. DETAILED DESCRIPTION

[0024] In order to make the purpose, technical scheme and advantages of the scheme of the present application clearer, the technical scheme in the embodiment of the present application will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the described embodiment is a part of the embodiment of the present application, not all of the embodiments. The listing of all technical features in the dependent claims in an embodiment does not mean that this part is a necessary technical feature. This embodiment is for the purpose of describing the technical scheme simply and clearly. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0025] Embodiment 1: like Figure 1 The three-part photovoltaic junction box is shown in the figure. Its internal structure is similar, and the difference lies in whether the wiring harness is set. Figures 1 to 3As shown: A photovoltaic junction box includes a box body 1, an opening 2 is provided at the bottom of the box body 1, and a cover plate 3 is provided on the box body 1. Two wiring metal plates 4 are provided in the box body 1 to connect the two poles of the photovoltaic panel. The wiring metal plates 4 are connected by diodes 5. A ring sleeve 6 is provided on one side of the two wiring metal plates 4 to sleeve the conductive pins of the diodes 5. The wiring metal plates 4 are sleeved with the conductive pins of the diodes 5 through the ring sleeve 6. A contact ear piece 7 extends to the right from the lower right end of the left wiring metal plate 4, and a contact ear piece 7 extends to the left from the upper left end of the right wiring metal plate 4. The ring sleeve 6 is arranged at the ends of the contact ear pieces 7 on both sides. The diode 5 is arranged perpendicular to the connection line between the wiring metal plates 4 on both sides. The diode 5 is arranged parallel to the width direction of the photovoltaic junction box, which is more compact than the traditional structure arranged parallel to the length direction of the photovoltaic junction box. Similarly, in this application, the contact ear piece 7 extending to the right from the upper right end of the left wiring metal plate 4 corresponds to the contact ear piece 7 extending from the lower left end of the right wiring metal plate 4, which is equivalent, and will not be repeated here.

[0026] In this embodiment, a positioning column 11 is provided in the middle of the box body 1 , a positioning hole 12 matching with the positioning column 11 is provided on the wiring metal plate 4 , and a limiting protrusion 13 for limiting the diode 5 is provided in the middle of the box body 1 .

[0027] Embodiment 2: The present embodiment is an improvement on the embodiment 1. On the basis of the embodiment 1, the ring sleeve 6 is further soldered by tin immersion. The ring sleeve 6 and the pin of the diode 5 are connected by solder. After the ring sleeve 6 and the pin of the diode 5 are connected, the solder connection is performed to improve the contact between the pin of the diode 5 and the ring sleeve 6, increase the contact area between the wiring metal plate 4 and the diode 5, and improve the current flowability.

[0028] Embodiment 3: This embodiment is an improvement based on embodiment 1. Figure 4 As shown, the lower end surface of the wiring metal plate 4 is affixed with a heat sink 8, and the lower end surface of the wiring metal plate 4 is bent with a limiting portion for fixing the heat sink 8, and the upper end surface of the wiring metal plate 4 is provided with a welding point 9 for welding the wiring harness. The wiring metal plate 4 can be made of a metal with high conductivity such as copper. In order to improve the competitiveness of the product, the thickness of the wiring metal plate 4 must not be too thick. However, while reducing the thickness of the metal material, the wiring metal plate 4 will heat up when a large current and high voltage flow through it. The solution of using the heat sink 8 effectively improves the heat dissipation of the wiring metal plate 4, and the heat sink 8 is fixed to the heat sink 8 by a limiting portion, which greatly improves the deformation resistance of the wiring metal plate 4. In order to further fix the wiring metal plate 4 and the heat sink 8, the limiting portion is a flange 10 folded downward from at least two sides of the wiring metal plate 4, and the flange 10 is buckled at the edge of the heat sink 8. On the other hand, the setting of the flange 10 can also improve the anti-bending property of the product.

[0029] Embodiment 4: This embodiment is an improvement on the above embodiment, and further includes a threading hole 14 provided on the wiring metal plate 4, and the heat sink 8 is provided to avoid the threading hole 14. The threading hole 14 is provided so that the photovoltaic cell harness passes through the threading hole 14 and is connected to the wiring metal plate 4, effectively preventing the photovoltaic cell harness from directly touching the junction box housing and causing the housing to deform.

[0030] like Figures 5 to 7 As shown: This embodiment also provides a method for processing the above-mentioned photovoltaic junction box, comprising the following steps: S1, preparing a junction box body 1 and a cover plate 3; S2. Punch out oppositely arranged sheet-shaped wiring metal plate strips 15, wherein the wiring metal plate strips 15 have contact ears 7 and flanges 10 to be folded; the solution of the present application reduces the requirement for the thickness of the wiring metal plates, and can realize metal strip processing, which is more suitable for automated production solutions.

[0031] S3. Take the diode 5 and load it between the contact ear pieces 7 of the wiring metal plate strip 15 and fix the diode. The contact ear pieces 7 and the conductive pins of the diode 5 are synchronously stamped to form a ring sleeve 6, so as to connect and fix the diode 5 to the wiring metal plate 15; the conductive pins of the diode 5 are pressed onto the contact ear pieces 7 and stamped multiple times to form a ring sleeve. The specific method of stamping to form the ring sleeve is a conventional technical means. Ordinary technicians in this field should be aware of the specific technical means and can choose according to needs, which will not be elaborated here.

[0032] S4, take the heat sink 8 and load it onto the connection metal plate strip 15 to punch the flange 10 to fix the heat sink 8 on the connection metal plate 4; when punching, first punch and fold it upward, and then fold it again to set it at the edge of the heat sink 8.

[0033] S5, assembling the box body 1, the cover plate 3, and the connection metal plate 4 with the heat sink 8 and the diode 5 installed thereon.

[0034] In this embodiment, the step S2 or S3 further includes punching to form the threading hole 14. The punching steps of the threading hole 14 are not limited and the order can be adjusted according to specific requirements.

[0035] In this embodiment, in order to increase the contact between the connection metal plate 4 and the heat sink 8, ultrasonic wave is used to press the connection metal plate 4 and the heat sink 8. For some products that require wiring harnesses, the wiring harness is also welded to a wiring metal plate 4, and tinning is performed on the conductive pins of the ring sleeve 6 and the diode 5. For the three-part photovoltaic junction box, it is necessary to weld the wiring harnesses to the photovoltaic junction boxes on both sides to connect other lines. Therefore, welding wiring harnesses is also required for the above-mentioned photovoltaic junction boxes. In the conventional production process, the wiring metal plate 4 is usually punched out first, and then the wiring metal plate 4 and the diode 5 are separately loaded for positioning welding and assembled as a whole after cooling. The present application connects the wiring metal plate 4 and the diode 5 synchronously during stamping to reduce the production process steps.

[0036] It should be noted that, in this application, relational terms such as "left side" and "right side", "upper" and "lower", etc. are only used to distinguish one structure from another structure, and do not necessarily require or imply any such actual relationship between these structures. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element defined by the sentence "comprises a ..." does not exclude the presence of other identical elements in the device including the element.

Claims

1. A photovoltaic junction box, comprising a box body (1), the box body (1) having an opening (2) at the bottom, and a cover plate (3) arranged on the box body (1), the box body (1) having two connection metal plates (4) connected to two poles of a photovoltaic panel, the connection metal plates (4) being connected by diodes (5), characterized in that: A ring sleeve (6) for sleeve-mounting a conductive pin of a diode (5) is provided on one side of the two wiring metal plates (4), and the wiring metal plates (4) are sleeve-connected with the conductive pin of the diode (5) through the ring sleeve (6); a contact ear piece (7) extends to the right from the upper or lower end of the right side of the wiring metal plate (4), and a contact ear piece (7) extends to the left from the lower or upper end of the left side of the wiring metal plate (4); the ring sleeve (6) is arranged at the ends of the contact ear pieces (7) on both sides, and the diode (5) is arranged perpendicular to the connection line between the wiring metal plates (4) on both sides.

2. The photovoltaic junction box according to claim 1, characterized in that: The ring sleeve (6) and the diode (5) are connected by soldering.

3. The photovoltaic junction box according to claim 1, characterized in that: A heat sink (8) is attached to the lower end surface of the wiring metal plate (4), a limiting portion for fixing the heat sink (8) is bent on the lower end surface of the wiring metal plate (4), and a welding point (9) for welding a wiring harness is provided on the upper end surface of the wiring metal plate (4).

4. The photovoltaic junction box according to claim 3, characterized in that: The limiting portion is a flange (10) folded downward from at least two side surfaces of the wiring metal plate (4), and the flange (10) is buckled on the edge of the heat sink (8).

5. The photovoltaic junction box according to any one of claims 1 to 4, characterized in that: A positioning column (11) is provided in the middle of the box body (1), a positioning hole (12) cooperating with the positioning column (11) is provided on the wiring metal plate (4), and a limiting protrusion (13) for limiting the diode (5) is provided in the middle of the box body (1).

6. The photovoltaic junction box according to claim 5, characterized in that: It also includes a wire threading hole (14) arranged on the wiring metal plate (4), and the heat sink (8) is arranged to avoid the wire threading hole (14).

7. The method for processing a photovoltaic junction box according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1. preparing a junction box body (1) and a cover plate (3); S2, punching out oppositely arranged sheet-shaped wiring metal strips (15), wherein the wiring metal strips (15) have contact tabs (7) and flanges (10) to be folded; S3, taking a diode (5) and loading it between the contact ear pieces (7) of the wiring metal plate strip (15) and fixing the diode, and synchronously punching the contact ear pieces (7) and the conductive pins of the diode (5) to form a ring sleeve (6), thereby connecting and fixing the diode (5) and the wiring metal plate (5); S4, taking the heat sink (8), loading it onto the wiring metal plate strip (15), punching and flanging (10) to fix the heat sink (8) on the wiring metal plate (4); S5, assembling the box body (1), the cover plate (3), and the wiring metal plate (4) equipped with the heat sink (8) and the diode (5).

8. The method for processing a photovoltaic junction box according to claim 7, characterized in that: The method further includes punching a threading hole (14) in step S2 or S3.

9. The method for processing a photovoltaic junction box according to claim 7, characterized in that: It also includes using ultrasonic wave to press-connect the connection metal plate (4) and the heat sink (8).

10. The method for processing a photovoltaic junction box according to claim 7, characterized in that: The method also includes welding a wiring harness onto a wiring metal plate (4), and performing tinning treatment on the ring sleeve (6) and the conductive pins of the diode (5).

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