A photovoltaic module connector adaptable to different wire diameters

Abstract

The present invention proposes a photovoltaic module connector that can adapt to different wire diameters, which includes a female plug and a male plug, wherein the female plug includes a female plug sleeve, and the male plug includes a male plug sleeve, and one end of the female plug sleeve and the male plug sleeve is connected to a cable fixing nut through a thread, and an inner claw and a plug plugged with the inner claw are arranged inside; the outer side of the plug is designed as a three-step structure, and the inner claw includes a plug-in portion plugged with the plug and a claw portion, the inner diameter of the plug-in portion is substantially equal to the diameter of the middle portion of the plug, and the outer diameter of the plug-in portion is substantially equal to the diameter of the end of the plug. The connector of the present invention optimizes the structure of the inner claw in the cable fixing nut, uses multiple inner claws and has a step structure, ensures that the waterproof plug is not easily damaged and deformed when the cable is inserted, can be compatible with a wider range of wire diameters, and is more effectively gripped and matched when the product is used and locked, avoiding the waterproof plug from falling off, facilitating construction and completely avoiding the risk caused by misuse of the connector.

Description

Technical Field

[0001] This invention relates to the field of electrical connector technology, and in particular to a photovoltaic module connector that can adapt to different wire diameters. Background Technology

[0002] Solar cells are made of materials that produce the photovoltaic effect, such as silicon, gallium arsenide, and copper indium selenide, which can convert light energy into electrical energy. Currently, photovoltaic modules, composed of multiple solar cells, are widely used as basic photovoltaic power generation units in various building-integrated photovoltaic (BIPV) systems, or as transparent thin-film modules as building facade materials to create energy-efficient and environmentally friendly buildings. To improve power generation efficiency per unit area, various new high-efficiency photovoltaic module structures are constantly being developed and applied; for example, bifacial modules and shingled modules are already in large-scale use.

[0003] The electricity generated by photovoltaic (PV) modules needs to be led out through a junction box, and multiple modules are electrically connected to form a power generation array. Currently, with the increasing prevalence of various new types of modules, especially high-efficiency modules, the power generation capacity of modules is becoming more diverse, and the power generation efficiency of different numbers of modules also has many specifications. Therefore, the specifications of the connectors used for corresponding modules or module arrays are also different, and the cables connected to the connectors also have different wire diameters. To accommodate different cable specifications, the market currently requires different connectors for different cable diameters. Therefore, users need to purchase multiple specifications of connectors, leading to confusion and potential errors in use at the end-user market, resulting in risks. Summary of the Invention

[0004] To meet the diverse needs of customers and address the issue of confusion caused by the large number of photovoltaic module connector models, the purpose of this invention is to propose a novel connector that can simultaneously meet the requirements of wire diameters ranging from 4.7 to 7.5 mm (cross-sectional area 2.5 mm² to 6 mm²), integrating multiple connector specifications into one for convenient use.

[0005] To achieve the objectives of this invention, a photovoltaic module connector adaptable to different wire diameters is provided, comprising a female connector and a male connector. The female connector includes a female connector sleeve and a cable fixing nut threaded to one end of the female connector sleeve. The cable fixing nut has an inner claw and a plug for inserting into the inner claw. A female connector terminal is disposed inside the female connector sleeve and is fixed to the female connector sleeve by a locking buckle. The rear end of the female connector terminal is a riveting part for fixing to the cable. The two sides of the insertion part of the female connector sleeve are provided with hooks for inserting and fixing to the male connector sleeve. The tail end of the insertion part is provided with an annular groove containing an O-ring. The male connector includes a male connector sleeve and a cable fixing nut threaded to one end of the male connector sleeve. The cable fixing nut contains a... The device includes an inner claw and a plug that engages with the inner claw; a male terminal is located inside the male socket and is fixed to the male socket by a latch; the rear end of the male terminal is a riveting part for fixing to a cable; the two sides of the male socket's insertion part are provided with slots for engaging with the hooks on the female socket; wherein, the outer side of the plug is designed with a 3-step structure, including an end 31 with a diameter of Φ1, a head 33 with a diameter of Φ3, and a middle part 32 with a diameter of Φ2 connecting the end 31 and the head 33, wherein Φ1>Φ2>Φ3; the inner claw includes an insertion part and a claw part that engage with the plug, the inner diameter of the insertion part is substantially equal to the diameter of the middle part of the plug, and the outer diameter D1 of the insertion part is substantially equal to the diameter of the end of the plug.

[0006] Preferably, the diameter ratio of Φ3:Φ2 is 9:10-9.7:10, and the ratio of Φ1:Φ2 is 1.1:1-1.2:1.

[0007] Preferably, the inner wall of the head of the plug is provided with raised ribs.

[0008] More preferably, the plug is made of silicone with a hardness between 50 and 55 degrees, a tensile strength ≥7MPa, an elongation at break ≥300%, and a high-temperature compression set of less than 15% (120℃, 2H).

[0009] Preferably, the inner claw has multiple claws arranged evenly at intervals along the circumference, and the claws have a wedge-shaped structure in both the vertical and horizontal directions.

[0010] More preferably, the angle α between one side of the claw and the tangent direction of the circumference is 55°-65°, and the angle β between the other side and the tangent direction of the circumference is 75°-85°.

[0011] More preferably, the claw portion includes a root portion perpendicular to the end face of the insertion portion, a transition portion at an angle to the root portion, and a hook portion extending from the transition portion. A boss is provided on the inner sidewall of the claw portion, adjacent to the hook portion.

[0012] Preferably, the diameter of the circle formed by the inner edge arc of the root of the claw portion is substantially equal to the diameter Φ3 of the head of the plug.

[0013] Preferably, when the plug and the inner claw are assembled, the annular end face of the insertion part of the inner claw is placed on the step between the end and the middle part of the plug, the inner bottom surface of the root of the claw is placed on the step between the middle part and the head of the plug, and the end face of the head of the plug is adjacent to the bottom of the protrusion on the inner sidewall of the claw.

[0014] Preferably, the claw portion has 12 claws.

[0015] The photovoltaic module connector of this invention optimizes the structure of the inner claws inside the cable fixing nut, using multiple inner claws with a stepped structure to ensure that the waterproof plug is not easily damaged or deformed when the cable is inserted. It is compatible with a wider range of wire diameters, provides more effective gripping during product use and locking, and the addition of an internal boss prevents the waterproof plug from falling off. It also meets the functional testing requirements of various environments. It meets the usage needs of modules with different output specifications, eliminates the need for multiple connector models, facilitates construction, and completely avoids the risks caused by misuse of connectors. Attached Figure Description

[0016] The foregoing and other objects, features, and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings. Wherein:

[0017] Figure 1 The diagram shown is an exploded view of the connector of the present invention.

[0018] Figure 2 As shown Figure 1 A three-dimensional structural diagram of the plug of the connector;

[0019] Figure 3 As shown Figure 1 A schematic diagram of the cross-sectional structure of the plug of the connector;

[0020] Figure 4 As shown Figure 1 A three-dimensional structural diagram of the connector's inner claw;

[0021] Figure 5 As shown Figure 4 A top view of the internal claw structure;

[0022] Figure 6 As shown Figure 5 A schematic diagram of the AA section structure of the inner claw.

[0023] The main components and their labels in the diagram are as follows:

[0024] 1-Cable fixing nut 2-Inner claw 3-Plug 4-Female plug sleeve 5-Female plug terminal 6-O-ring 7-Lock 8-Male plug terminal 9-Male plug sleeve Detailed Implementation

[0025] The structural features and advantages of the photovoltaic module connector of the present invention are described in detail below with reference to the accompanying drawings.

[0026] See Figure 1 The exploded structural diagram shown is of the photovoltaic module connector of the present invention, which is adaptable to different wire diameters. The connector includes a female plug and a male plug. The female plug includes a female plug sleeve 4 and a cable fixing nut 1 that is threaded to one end of the female plug sleeve 4. The cable fixing nut has an inner claw 2 and a plug 3 that engages with the inner claw 2. A female plug terminal 5 is disposed inside the female plug sleeve 4 and is fixed to the female plug sleeve 4 by a locking buckle 7. The rear end of the female plug terminal 5 is a riveting part 51 for fixing to the cable. The two sides of the insertion part 41 of the female plug sleeve 4 are provided for engaging with the male plug sleeve. The male plug includes a hook portion 42; the end of the plug portion 1 is provided with an annular groove 43, in which an O-ring 6 is provided; the male plug includes a male plug sleeve 9, and a cable fixing nut 1 connected to one end of the male plug sleeve 9 by a thread, the cable fixing nut being provided with an inner claw 2 and a plug 3 that engages with the inner claw 2; a male plug terminal 8 is provided inside the male plug sleeve 9, which is fixed to the male plug sleeve 9 by a locking buckle 7; the rear end of the male plug terminal 8 is a riveting portion 81 that is fixed to the cable, and the two sides of the plug portion 91 of the male plug sleeve 9 are provided with slots 92 that engage with the hook portion 42 on the female plug sleeve.

[0027] Reference Figure 2 and Figure 3 The plug 3 has a three-step structure on its outer side, including an end portion 31 with a diameter of Φ1, a head portion 33 with a diameter of Φ3, and a middle portion 32 with a diameter of Φ2 connecting the end portion 31 and the head portion 33, wherein Φ1>Φ2>Φ3, and the ratio of Φ3:Φ2 is 9:10-9.7:10, and the ratio of Φ1:Φ2 is 1.1:1-1.2:1. In a preferred embodiment, the inner wall of the head portion 33 is provided with a rib 331, which can improve the strength of the plug under tension. In another preferred embodiment, the plug is made of silicone with a hardness (Shore hardness) between 50-55 degrees, a tensile strength ≥7MPa, an elongation at break ≥300%, and a high-temperature compression set of less than 15% (120℃, 2H).

[0028] Next refer to Figures 4-6The inner claw 2 includes an insertion part 21 that inserts into the plug 3 and a claw part 22. The inner diameter D2 of the insertion part 21 is substantially equal to the diameter Φ2 of the middle part 32 of the plug 3, and the outer diameter D1 of the insertion part 21 is substantially equal to the diameter Φ1 of the end 31 of the plug 3. The term "substantially equal" here not only includes that the relevant values ​​are absolutely equal, but also that there may be slight differences within the allowable design tolerance of the component or the allowable error during processing.

[0029] The inner claw 2 has a plurality of claws 220 on its claw portion 22, which are evenly spaced along the circumference. The claws 220 are wedge-shaped in both the vertical and horizontal directions. Figure 5 In the vertical direction, the angle α between one side of the claw 220 and the circumferential tangent is 55°-65°; the angle β between the other side and the circumferential tangent is 75°-85°. In a preferred embodiment, the claw portion 220 includes a root portion 221 perpendicular to the end face of the insertion portion, a transition portion 222 at an angle to the root portion 221, and a hook portion 223 extending from the transition portion 222. A boss 224 is provided on the inner wall of the claw portion 220, adjacent to the hook portion 223, to improve the mechanical strength of the hook portion 223. To prevent the plug from falling off during cable connection; the diameter D3 of the circle formed by the inner edge arc of the root of the claw portion 220 is substantially equal to the diameter Φ3 of the head 33 of the plug 3; when the plug 3 and the inner claw 2 are assembled, the annular end face of the insertion portion 21 of the inner claw 2 is placed on the step between the end 31 and the middle portion 32 of the plug 3, the inner bottom surface of the root of the claw portion 220 is placed on the step between the middle portion 32 and the head 33 of the plug 3, and the end face of the head 33 of the plug 3 is adjacent to the bottom of the protrusion 224 on the inner sidewall of the claw portion 220.

[0030] In a preferred embodiment, the claw portion has 12 claws.

[0031] The photovoltaic module connector of this invention optimizes the structure of the inner claws within the cable fixing nut, using multiple inner claws with a stepped structure and designing a matching plug. The design requirements for the plug are specified to ensure that the waterproof plug is not easily damaged or deformed during cable insertion. It is compatible with a wider range of wire diameters, provides a more effective grip during product tightening, and the internal boss prevents the waterproof plug from falling off. It also meets various environmental functional testing requirements; satisfying the usage needs of modules with different output specifications; eliminating the need for multiple connector models; facilitating construction; and completely avoiding the risks caused by misuse of connectors.

[0032] This invention is not limited to the embodiments described. Those skilled in the art can make some modifications or changes without departing from the spirit and scope of this invention. Therefore, the scope of protection of this invention is defined by the claims.

Claims

1. A photovoltaic module connector that can adapt to different wire diameters, characterized in that: The connector includes a female plug and a male plug, the female plug includes a female plug sleeve, a cable fixing nut connected to one end of the female plug sleeve by a thread, and an inner claw and a plug plugged with the inner claw are arranged in the cable fixing nut; a female plug terminal is arranged inside the female plug sleeve, and is fixed to the female plug sleeve by a lock; the rear end of the female plug terminal is a riveted part fixed to the cable, and both sides of the plug-in part of the female plug sleeve are provided with plug hook parts plugged and fixed with the male plug sleeve; an annular groove is arranged at the tail end of the plug-in part, and an O-ring is arranged inside; the The male plug includes a male plug sleeve, a cable fixing nut connected to one end of the male plug sleeve by a thread, wherein the cable fixing nut is provided with an inner claw and a plug plugged with the inner claw; a male plug terminal is arranged inside the male plug sleeve, and is fixed to the male plug sleeve by a lock; the rear end of the male plug terminal is a riveted part fixed to the cable, and both sides of the plug-in part of the male plug sleeve are provided with slots plugged with the plug hook part on the female plug sleeve; wherein the outer side of the plug is designed as a 3-step structure, including an end portion 31 with a diameter of Φ1, a diameter of Φ The head 33 of the plug 3 and the middle part 32 of the diameter of Φ2 connected to the end 31 of the plug 3, wherein Φ1>Φ2>Φ3; the inner claw comprises a plug-in portion plugged with the plug and a claw portion, and the inner wall of the head of the plug is provided with convex ribs; the inner diameter of the plug-in portion is substantially equal to the diameter of the middle part of the plug, and the outer diameter of the plug-in portion is substantially equal to the diameter of the end of the plug; the claw portion comprises a root portion perpendicular to the end face of the plug-in portion, a transition portion at an angle to the root, and a transition portion extending from the transition portion. The hook portion that has been protruded is provided with a boss on the inner side wall of the claw portion, adjacent to the hook portion, and the diameter of the circle formed by the arc of the inner edge of the root of the claw portion is substantially equal to the diameter Φ3 of the head of the plug; when the plug and the inner claw are assembled, the annular end face of the plug-in portion of the inner claw is placed on the step between the end and the middle part of the plug, the inner bottom face of the root of the claw portion is placed on the step between the middle part and the head of the plug, and the end face of the head of the plug is adjacent to the bottom of the boss on the inner side wall of the claw portion.

2. A photovoltaic module connector that can adapt to different wire diameters as claimed in claim 1, characterized in that: The above-mentioned diameters Φ3:Φ2 are 9:10-9.7:10, and Φ1:Φ2 are 1.1:1-1.2:

1.

3. A photovoltaic module connector adaptable to different wire diameters as claimed in claim 2, characterized in that: The plug is made of silicone with a hardness between 50 and 55 degrees, a tensile strength of ≥7MPa, an elongation at break of ≥300%, and a high temperature compression set of less than 15% (120°C, 2H).

4. A photovoltaic module connector adaptable to different wire diameters as claimed in claim 3, characterized in that: The claw portion of the inner claw is provided with a plurality of claws which are evenly spaced along the circumferential direction, and the claws are wedge-shaped in both the vertical and horizontal directions.

5. A photovoltaic module connector adaptable to different wire diameters as claimed in claim 4, characterized in that: The included angle α between one side of the clamping claw and the tangent direction of the circle is 55°-65°, and the included angle β between the other side and the tangent direction of the circle is 75°-85°; and there are 12 clamping claw parts.

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