Building-integrated photovoltaic (BIPV) solar junction box

Abstract

This invention discloses a building-integrated photovoltaic (BIPV) solar junction box, comprising a box body, diodes, terminals, and busbars. The box body includes a main body and an extension. The main body is elongated, and the extension extends downward from the bottom of the main body, being sheet-like and perpendicular to the bottom of the main body. The diodes and terminals are located inside the main body. There are two terminals spaced apart along the length of the main body, and the diode is vertically positioned between the two terminals. The two leads of the diode are welded and fixed to the corresponding terminals. There are two busbars, perpendicular to the terminals. One end of the busbar is welded and fixed to the corresponding terminal, and the other end of the busbar extends out of the box body after passing through the extension. This BIPV junction box is easy to install and has strong sealing performance.

Description

Technical Field

[0001] This invention relates to a building-integrated photovoltaic (BIPV) solar junction box, belonging to the field of photovoltaic technology. Background Technology

[0002] A solar junction box is a connector that sits between the solar cell array (composed of solar cell modules) and the solar charging control device, providing users with a combined connection solution for solar panels. Double-glass solar modules consist of two layers of glass on opposite sides and solar cells located between the glass layers. Glass has better insulation than a backsheet, allowing double-glass modules to withstand higher system voltages and offering significant advantages in abrasion resistance, making them suitable for photovoltaic power plants in areas with high levels of acid rain or salt spray. Due to its different structure from backsheet solar modules, it generally uses a separate junction box.

[0003] Chinese patent document CN104821787A discloses a solar photovoltaic junction box, including a cable device and a junction box. The cable device includes a cable and a terminal block. The terminal block includes a terminal body, one end of which is provided with an anti-bending ring, and the other end of which is provided with a multi-ring sealing structure. The junction box includes a box body and a conductive wiring assembly. The conductive wiring assembly is disposed at both ends of the box body. A diode is disposed inside the box body. The conductive wiring assembly includes a conductive wire piece and a lead-out cavity. The conductive wire piece extends from the lead-out cavity into the box body. The diode is connected to the conductive wire piece. This junction box has poor sealing performance and its conductivity decreases after long-term use. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a flexible component junction box that is easy to install and has excellent heat dissipation performance.

[0005] The technical solution provided by this invention to solve the above-mentioned technical problems is as follows: a building-integrated photovoltaic (BIPV) solar junction box, comprising a box body, diodes, terminals, and busbars. The box body includes a main body and an extension. The main body is elongated, and the extension extends downward from the bottom of the main body. The extension is sheet-like and perpendicular to the bottom of the main body. The diodes and terminals are located inside the main body. There are two terminals spaced apart along the length of the main body. The diode is vertically positioned between the two terminals, and its two leads are welded and fixed to the corresponding terminals. There are two busbars, which are perpendicular to the terminals. One end of the busbar is welded and fixed to the corresponding terminal, and the other end of the busbar extends out of the box body after passing through the extension.

[0006] Preferably, during installation, the main body of the box is fitted to the frame of the photovoltaic module, the extension of the box is inserted into the photovoltaic module, the busbar is first welded to the battery cell, and then a lamination process is performed.

[0007] Preferably, the box body extension includes a first support and a second support, the first support and the second support are arranged side by side, the ends of the first support and the second support away from the box body are spaced apart and a gap is formed between them, the ends of the first support and the second support near the box body are connected as one piece, and the bottom of the first support and the second support are provided with a busbar through hole suitable for the busbar to pass through, the busbar through hole extending into the box body.

[0008] Preferably, the housing encapsulates the diode, terminals, and busbar through integrated injection molding.

[0009] Preferably, the device further includes a cable and a connector. The connector includes a wire clamp, a conductive connector, and a housing. The conductive connector is connected to the conductor of the cable. The housing is fitted over the connection between the conductive connector and the cable. The conductive connector is located inside the housing and has a ring of retaining claws that engage and fix it within the housing. A sealing sleeve is fitted over the cable at the connection between the cable and the housing. The wire clamp is fitted over the connection between the housing and the cable, and the sealing sleeve is located inside the wire clamp. The outer surface of the housing has a groove arranged circumferentially thereon. A sealing ring is fitted over the housing and located within the groove. The outer surface of the housing also has... The device has a stop portion that fits into the wire clip. The stop portion facing the wire clip has a first limiting protrusion and a second limiting protrusion. The wire clip has a wire clip slot suitable for insertion of the first limiting protrusion and a wire clip interface that engages with the second limiting protrusion. The stop portion away from the wire clip has a third limiting protrusion and a fourth limiting protrusion. One end of the housing body has a connector interface suitable for insertion of a connector. The connector interface has a housing slot suitable for insertion of the third limiting protrusion and a housing clip interface that engages with the fourth limiting protrusion. When the connector is inserted into the connector interface, the conductive connector is connected to the terminal.

[0010] Preferably, the end of the outer shell away from the wire card is provided with a fifth limiting protrusion arranged along the axial direction of the outer shell, and the main body of the box is provided with a limiting groove that is inserted and cooperates with the fifth limiting protrusion.

[0011] Preferably, the terminal includes a terminal body and a terminal connecting part, the terminal body and the terminal connecting part are integral parts, the terminal body is in the shape of an elongated strip, the two pins of the diode are soldered to the terminal body, the busbar is soldered to the terminal body, the terminal connecting part is cylindrical in shape and has a stepped outer surface, the conductive connector is hollow inside and its shape and size match the terminal connecting part, and the terminal connecting part extends into the outer shell and connects to the conductive connector inside it.

[0012] Preferably, the bottom of the main body of the box is provided with reinforcing blocks arranged at intervals along the length of the box, the reinforcing blocks are in the shape of cuboids, and there are at least six reinforcing blocks.

[0013] Preferably, the downward extension of the box body is at least 19 mm, and the distance between the two busbars is 15 to 50 mm.

[0014] Preferably, the length of the main body of the box is 123 to 130 mm, the height of the main body of the box is 9 to 13 mm, and the width of the main body of the box is 8 to 12 mm.

[0015] This invention has positive effects: (1) The terminals, busbars and diode pins in the photovoltaic building integrated solar junction box of the present invention are all flat, which minimizes the volume of the box, makes the structure compact, reduces the consumption of shell material, and saves costs.

[0016] (2) The connector of the photovoltaic building integrated solar junction box of the present invention is fitted and fixed to the box body. The design is ingenious, the sealing performance is good, and the installation is more convenient.

[0017] (2) The photovoltaic building integrated solar junction box of the present invention has an extension part, which allows the box to be directly inserted into the welding strip on the glass side of the photovoltaic module during installation, and then welded and laminated to form an integral part with the photovoltaic module. Traditional junction boxes are made by manufacturing the photovoltaic module first and then installing the photovoltaic junction box by welding the busbar of the photovoltaic module into the photovoltaic junction box. However, this junction box subverts the traditional process steps. The junction box does not need to be filled with glue but is injection molded as one piece, covering the terminals, busbars and diodes in the box body. The welding of the terminals and busbars is more reliable, which can improve the stability of the junction box operation and extend its service life. Attached Figure Description

[0018] The photovoltaic building-integrated solar junction box of the present invention will be further described below with reference to the accompanying drawings.

[0019] Figure 1 This is a schematic diagram of the assembly structure of the building-integrated photovoltaic solar junction box in Example 1; Figure 2 This is a schematic diagram of the connector layer structure of the photovoltaic building integrated solar junction box in Example 1; Figure 3 This is a schematic diagram of the internal structure of the photovoltaic building-integrated solar junction box in Example 1; Figure 4 This is a schematic diagram of the structure of the building-integrated photovoltaic solar junction box in Example 2.

[0020] The above figures are labeled as follows: Box 1, Box body 11, Box card interface 111, Reinforcing block 112, Box slot 113, Box extension 12, First support 121, Second support 122, Notch 13, Diode 2, Terminal 3, Terminal body 31, Terminal connection part 32, Cable 4, Connector 5, Wire clip 51, Wire clip slot 511, Wire clip interface 512, Conductive connector 52, Fixing buckle 521, Outer shell 53, First limiting protrusion 531, Second limiting protrusion 532, Sealing ring 533, Third limiting protrusion 534, Fourth limiting protrusion 535, Fifth limiting protrusion 536, Sealing sleeve 54, Stop part 55, Busbar 6. Detailed Implementation Example 1

[0021] See Figures 1 to 3 A building-integrated photovoltaic (BIPV) solar junction box includes a box body 1, a diode 2, terminals 3, and busbars 6. The box body 1 includes a main body 11 and a box body extension 12. The main body 11 is elongated, and the box body extension 12 extends downward from the bottom of the main body 11. The box body extension 12 is sheet-shaped and perpendicular to the bottom of the main body 11. The diode 2 and terminals 3 are located inside the main body 11. There are two terminals 3, which are spaced apart along the length of the main body 11. The diode 2 is vertically positioned between the two terminals 3, and the two pins of the diode 2 are welded and fixed to the corresponding terminals 3. There are two busbars 6, which are perpendicular to the terminals 3. One end of the busbar 6 is welded and fixed to the corresponding terminal 3, and the other end of the busbar 6 extends out of the box body 1 after passing through the box body extension 12.

[0022] During installation, the main body 11 of the box fits against the frame of the photovoltaic module, and the extension 12 of the box is inserted into the photovoltaic module. First, the busbar 6 is welded to the solar cell, and then a lamination process is performed.

[0023] The box body extension 12 includes a first support 121 and a second support 122. The first support 121 and the second support 122 are arranged side by side. The ends of the first support 121 and the second support 122 away from the box body 11 are spaced apart and a gap 13 is formed between them. The ends of the first support 121 and the second support 122 close to the box body 11 are connected as one unit. The bottom of the first support 121 and the second support 122 are provided with a busbar through hole suitable for the busbar 6 to pass through. The busbar through hole extends into the box body 11.

[0024] The housing 1 encapsulates the diode 2, terminal 3, and busbar 6 through integrated injection molding.

[0025] It also includes a cable 4 and a connector 5. The connector 5 includes a wire clip 51, a conductive connector 52, and a housing 53. The conductive connector 52 is connected to the conductor of the cable 4. The housing 53 is fitted over the connection between the conductive connector 52 and the cable 4, with the conductive connector 52 located inside the housing 53. The conductive connector 52 has a ring of fixing claws 521, which are engaged and fixed inside the housing 53. A sealing sleeve 54 is fitted over the cable 4 at the connection between the cable 4 and the housing 53. The wire clip 51 is fitted over the connection between the housing 53 and the cable 4, with the sealing sleeve 54 located inside the wire clip 51. The outer surface of the housing 53 has a groove arranged circumferentially thereon. A sealing ring 533 is fitted over the housing 53 and located within the groove. The outer surface of the housing 53 has a groove that corresponds to the wire clip 51. The stop portion 55 has a first limiting protrusion 531 and a second limiting protrusion 532 on the side of the stop portion 55 facing the wire clip 51. The wire clip 51 has a wire clip slot 511 suitable for insertion of the first limiting protrusion 531 and a wire clip interface 512 that engages with the second limiting protrusion 532. The stop portion 55 has a third limiting protrusion 534 and a fourth limiting protrusion 535 on the side away from the wire clip 51. One end of the housing body 11 has a connector interface suitable for insertion of the connector 5. The connector interface has a housing slot 113 suitable for insertion of the third limiting protrusion 534 and a housing clip interface 111 that engages with the fourth limiting protrusion 535. When the connector 5 is inserted into the connector interface, the conductive connector 52 is connected to the terminal 3.

[0026] The end of the outer shell 53 away from the wire clip 51 is provided with a fifth limiting protrusion 536 arranged along the axial direction of the outer shell 53, and the box body 11 is provided with a limiting groove that is inserted and cooperates with the fifth limiting protrusion 536.

[0027] Terminal 3 includes terminal body 31 and terminal connection part 32. Terminal body 31 and terminal connection part 32 are integral parts. Terminal body 31 is in the shape of a long strip. The two pins of diode 3 are soldered to terminal body 31. Busbar 6 is soldered to terminal body 31. Terminal connection part 32 is cylindrical in shape and has a stepped outer surface. The conductive connector 52 is hollow inside and its shape and size match the terminal connection part 32. Terminal connection part 32 extends into outer shell 53 and connects with conductive connector 52 inside it.

[0028] The bottom of the main body 11 of the box is provided with reinforcing blocks 112 arranged at intervals along the length of the box 1. The overall shape of the reinforcing blocks 112 is cuboid, and there are six reinforcing blocks 112.

[0029] The box extension 12 extends downward by 19 mm, and the distance between the two busbars 6 is 15 mm.

[0030] The length of the main body 11 is 123 mm, the height of the main body 11 is 9 mm, and the width of the main body 11 is 8 mm. Example 2

[0031] See Figure 4 The photovoltaic building integrated solar junction box in this embodiment is the same as that in embodiment 1, except that there is no cable 4 and connector 5, and there are five reinforcing blocks 112.

[0032] Obviously, the above embodiments are merely examples to clearly illustrate the embodiments of the present invention, and are not intended to limit the embodiments of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all embodiments here. However, these obvious variations or modifications derived from the spirit of the present invention are still within the protection scope of the present invention.

Claims

1. A building-integrated photovoltaic (BIPV) solar junction box, characterized in that, The device includes a housing (1), a diode (2), a terminal (3), and a busbar (6). The housing (1) includes a housing body (11) and a housing extension (12). The housing body (11) is elongated, and the housing extension (12) extends downward from the bottom of the housing body (11). The housing extension (12) is sheet-shaped and perpendicular to the bottom of the housing body (11). The diode (2) and the terminal (3) are located inside the housing body (11). The terminal (3) has... Two diodes are spaced apart along the length of the main body (11). The diode (2) is vertically positioned between the two terminals (3). The two pins of the diode (2) are welded and fixed to the corresponding terminals (3). There are two busbars (6). The busbars (6) are set perpendicular to the terminals (3). One end of the busbar (6) is welded and fixed to the corresponding terminal (3). The other end of the busbar (6) passes through the extension part (12) of the box and extends out of the box (1).

2. Building integrated photovoltaic solar junction box according to claim 1, characterized in that, During installation, the main body (11) of the box is attached to the frame of the photovoltaic module, and the extension (12) of the box is inserted into the photovoltaic module. The busbar (6) is first welded to the battery cell, and then the lamination process is carried out.

3. The building integrated photovoltaic solar junction box of claim 1, wherein, The box extension (12) includes a first support (121) and a second support (122). The first support (121) and the second support (122) are arranged side by side. The ends of the first support (121) and the second support (122) away from the box body (11) are spaced apart and a gap (13) is formed between them. The ends of the first support (121) and the second support (122) close to the box body (11) are connected as one unit. The bottom of the first support (121) and the second support (122) are provided with a busbar through hole suitable for the busbar (6) to pass through. The busbar through hole extends into the box body (11).

4. The building integrated photovoltaic solar junction box of claim 1, wherein, The housing (1) encloses the diode (2), terminal (3) and busbar (6) through integrated injection molding.

5. Building integrated photovoltaic solar junction box according to any of claims 1 to 4, characterized in that, It also includes a cable (4) and a connector (5). The connector (5) includes a wire clip (51), a conductive connector (52), and a housing (53). The conductive connector (52) is connected to the conductor of the cable (4). The housing (53) is fitted over the connection between the conductive connector (52) and the cable (4). The conductive connector (52) is located inside the housing (53). The conductive connector (52) is provided with a ring of fixing claws (521), which are used to lock and fix the connection. Inside the outer casing (53), a sealing sleeve (54) is provided at the connection between the cable (4) and the outer casing (53) and is fitted onto the cable (4). The wire clip (51) is fitted onto the outside of the connection between the outer casing (53) and the cable (4). The sealing sleeve (54) is located inside the wire clip (51). The outer surface of the outer casing (53) is provided with a groove arranged circumferentially thereon. The sealing ring (533) is fitted onto the outer casing (53) and is located in the groove. The outer surface of the outer casing (53) is provided with a groove arranged circumferentially thereon. The device includes a stop (55) that fits into the cable clip (51). The stop (55) has a first limiting protrusion (531) and a second limiting protrusion (532) on the side facing the cable clip (51). The cable clip (51) has a cable clip slot (511) suitable for insertion of the first limiting protrusion (531). The cable clip (51) has a cable clip interface (512) that engages with the second limiting protrusion (532). The stop (55) has a first limiting protrusion (531) on the side away from the cable clip (51). The three limiting protrusions (534) and the fourth limiting protrusion (535) are provided. One end of the body of the box (11) is provided with a connector interface suitable for the insertion of the connector (5). The connector interface is provided with a box slot (113) suitable for the insertion of the third limiting protrusion (534). The connector interface is provided with a box card interface (111) that engages with the fourth limiting protrusion (535). When the connector (5) is inserted into the connector interface, the conductive connector (52) is connected to the terminal (3).

6. Building integrated photovoltaic solar junction box according to claim 5, characterized in that, The outer shell (53) is provided with a fifth limiting protrusion (536) at the end away from the wire clip (51) along the axial direction of the outer shell (53), and the box body (11) is provided with a limiting groove that is inserted and cooperates with the fifth limiting protrusion (536).

7. The building integrated photovoltaic solar junction box of claim 5, wherein, The terminal (3) includes a terminal body (31) and a terminal connection part (32). The terminal body (31) and the terminal connection part (32) are an integral piece. The terminal body (31) is in the shape of a long strip. The two pins of the diode (3) are welded to the terminal body (31). The bus bar (6) is welded to the terminal body (31). The terminal connection part (32) is cylindrical in shape and has a stepped outer surface. The conductive connector (52) is hollow inside and its shape and size match the terminal connection part (32). The terminal connection part (32) extends into the outer shell (53) and connects with the conductive connector (52) inside it.

8. The photovoltaic building integrated solar junction box according to any one of claims 1 to 4, wherein the bottom of the main body (11) of the box is provided with reinforcing blocks (112) arranged at intervals along the length direction of the box (1), the reinforcing blocks (112) are in the shape of a cuboid, and there are at least six reinforcing blocks (112).

9. Building integrated photovoltaic solar junction box according to any of claims 1 to 4, characterized in that, The length of the box extension (12) extending downward is at least 19 mm, and the distance between the two busbars (6) is 15 to 50 mm.

10. Building integrated photovoltaic solar junction box according to any of claims 1 to 4, characterized in that, The length of the main body (11) is 123 to 130 mm, the height of the main body (11) is 9 to 13 mm, and the width of the main body (11) is 8 to 12 mm.

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