External radiator of photovoltaic junction box

Abstract

The present invention discloses an external radiator of a photovoltaic junction box, comprising a first metal part, the first metal part is provided with a first bending part, a second bending part, a third bending part, a fourth bending part, a fifth bending part and a rounded corner part; the two ends of the second bending part are respectively vertically connected to the upper side surfaces of the first bending part and the third bending part, the lower end surface of the third bending part is connected to the upper end surface of the fourth bending part through the rounded corner part, and one end of the fifth bending part is vertically connected to the lower side surface of the fourth bending part; the outer surfaces of the first bending part, the second bending part, the third bending part, the fourth bending part and the rounded corner part are all wrapped with a shell, and an extended shell integrated with the shell is provided directly below the fifth bending part, the fifth bending part and the extended shell form a slot, and the shell 2 is provided with a U-shaped groove and also includes a heat sink. The radiator of the present invention has low cost and low manufacturing difficulty, and can be used in combination with the original junction box to increase the rated current of the junction box at a minimum cost.

Description

Technical Field

[0001] The invention belongs to the field of photovoltaics, and in particular relates to an external radiator of a photovoltaic junction box. Background Art

[0002] As the power of photovoltaic modules increases, the current becomes larger and larger, thus placing higher and higher requirements on the rated current of photovoltaic junction boxes. However, due to market requirements, the cost requirements are becoming lower and lower.

[0003] There are generally two ways to increase the rated current of existing junction boxes. One is to reduce the heat generated by the components inside the junction box, that is, the heat generated by the diodes inside the junction box. Reducing the heat usually means selecting diodes with better performance. The other is to increase the heat dissipation speed of the junction box. There are many ways to increase the heat dissipation speed. The most common way used in the photovoltaic industry is to increase the area of ​​the conductor in the junction box (usually brass or copper), which also increases the cost of the conductor. In addition, due to the increase in the conductor, the overall volume of the junction box also increases, and more shell materials are required.

[0004] At present, the rated current of existing junction boxes in the photovoltaic industry has been increased from 25A to 30A. Regardless of whether the method used is to improve diode performance or increase the area of ​​the conductor, the cost is more than 120% of the original cost. In addition, improving diode performance also requires redesigning the diode shape and re-molding the diode for production, resulting in huge initial investment and a long cycle. Increasing the heat dissipation area of ​​the conductor will lead to changes in the junction box design, which also requires re-molding, with a large investment, and requires adaptation to the components, with many restrictions. Summary of the invention

[0005] In order to solve the problems existing in the prior art, the present invention aims to provide an external radiator for a photovoltaic junction box. Without changing the existing junction box structure, the heat dissipation efficiency of the junction box is improved by the external radiator, thereby increasing the rated current of the junction box.

[0006] In order to achieve the above technical objectives and effects, the present invention is implemented through the following technical solutions: an external radiator of a photovoltaic junction box, comprising a first metal part, wherein the first metal part is formed by bending a first bending portion, a second bending portion, a third bending portion, a rounded corner portion, a fourth bending portion, and a fifth bending portion in sequence; the first bending portion, the third bending portion, and the fourth bending portion are parallel to each other, and the second bending portion and the fifth bending portion are parallel to each other; the two ends of the second bending portion are respectively vertically connected to the upper side surfaces of the first bending portion and the third bending portion, the lower end surface of the third bending portion and the upper end surface of the fourth bending portion are connected through the rounded corner portion, and the left end surface of the fifth bending portion is connected to the The lower right side surface of the fourth bent portion is vertically connected; the outer surfaces of the first bent portion, the second bent portion, the third bent portion, the fourth bent portion and the rounded corner portion are all wrapped with a shell for heat conduction and insulation, and an extended shell integrated with the shell is arranged directly below the fifth bent portion, and the fifth bent portion and the extended shell form a card slot for clamping with the conductor in the junction box, and the shell is formed with a U-shaped groove for assembly with the junction box in the space enclosed by the first bent portion, the second bent portion, the third bent portion, the rounded corner portion and the fourth bent portion, and the shell also includes a plurality of heat sinks for accelerating the heat dissipation efficiency of the radiator.

[0007] Furthermore, the number of the heat sinks is preferably 9.

[0008] Furthermore, the heat sink is arranged on the left side wall of the shell that wraps the outer surface of the first bending portion, and the heat sink is perpendicular to the left side wall of the shell.

[0009] Furthermore, the distance between two adjacent heat sinks 4 is the same.

[0010] Furthermore, the heat sink and the housing are integrally formed.

[0011] Furthermore, second metal parts corresponding to the heat sinks are arranged on the left side wall of the first bent portion, and each of the second metal parts extends outward into the interior of the corresponding heat sink and is wrapped by the corresponding heat sink.

[0012] Furthermore, the first metal component and the second metal component are integrally formed.

[0013] Furthermore, the U-shaped groove is divided into a connecting groove for clamping with the box wall of the junction box and an avoiding groove for avoiding the box wall of the junction box, and the groove width of the connecting groove is slightly smaller than the thickness of the box wall of the junction box, and the groove width of the avoiding groove is larger than the thickness of the box wall of the junction box.

[0014] Furthermore, the connections between the first bending portion, the second bending portion, the third bending portion, the fourth bending portion and the fifth bending portion are all rounded.

[0015] Furthermore, the width of the slot in the up-down direction is slightly smaller than the thickness of the conductor in the junction box, and the heat sink is connected to the conductor in the junction box through the slot.

[0016] Furthermore, the first metal component and the second metal component are made of the same material, and both are made of aluminum or copper.

[0017] Furthermore, the shell is made of thermally conductive insulating plastic.

[0018] Furthermore, the inner connecting surface of the fourth bending portion vertically connected to the fifth bending portion is not wrapped in the outer shell; the rounded surface of the rounded portion connected to the inner connecting surface of the fourth bending portion is not wrapped in the outer shell.

[0019] The beneficial effects of the present invention are as follows:

[0020] 1. The heat sink of the present invention uses a metal part and a heat-conducting insulating plastic wrapped outside the metal part, which has low cost and low manufacturing difficulty, and prevents electric shock caused by touching the heat sink;

[0021] 2. The heat sink of the present invention adopts the method of adding a plurality of heat sinks on the outer shell to improve the heat dissipation efficiency;

[0022] 3. The radiator of the present invention is connected to the junction box by means of a snap-on external plug-in, thereby increasing the rated power on the basis of the original junction box, thereby reducing the cost of replacing the junction box and facilitating installation and maintenance.

[0023] 4. The heat sink of the present invention is used in combination with the original junction box to increase the rated current of the junction box from 25A to 30A, while the required cost is only increased by 10% relative to the original cost, thereby achieving an increase in the rated current of the junction box at a minimum cost.

[0024] The above description is only an overview of the technical solution of the present invention. In order to more clearly understand the technical means of the present invention and implement it according to the contents of the specification, the following is a detailed description of the preferred embodiments of the present invention in conjunction with the accompanying drawings. The specific implementation of the present invention is given in detail by the following embodiments and their accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0026] Figure 1 It is a schematic diagram of the overall structure of the radiator of the present invention;

[0027] Figure 2 This is a schematic diagram of the structure of the first metal member of the present invention;

[0028] Figure 3 is a schematic diagram of the structure of the second metal member of the present invention;

[0029] Figure 4 It is a schematic diagram of the connection between the radiator and the junction box of the present invention.

[0030] Explanation of the numbers in the figure: 1. first metal part; 2. outer shell; 3. extended shell; 4. heat sink; 5. second metal part; 11. first bending portion; 12. second bending portion; 13. third bending portion; 14. fourth bending portion; 15. fifth bending portion; 16. rounded corner portion. DETAILED DESCRIPTION

[0031] The present invention will be described in detail below with reference to the accompanying drawings and in combination with embodiments.

[0032] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, upper end, lower end, top, bottom...) are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0033] See also Figure 1-2As shown, a first embodiment of the present invention is an external heat sink for a photovoltaic junction box, comprising a first metal member 1, wherein the first metal member 1 is formed by bending a first bending portion 11, a second bending portion 12, a third bending portion 13, a rounded portion 16, a fourth bending portion 14, and a fifth bending portion 15 in sequence; the first bending portion 11, the third bending portion 13, and the fourth bending portion 14 are parallel to each other, and the second bending portion 12 and the fifth bending portion 15 are parallel to each other; the two ends of the second bending portion 12 are respectively vertically connected to the upper side surfaces of the first bending portion 11 and the third bending portion 13, the lower end surface of the third bending portion 13 and the upper end surface of the fourth bending portion 14 are connected through the rounded portion 16, and the left end surface of the fifth bending portion 15 is connected to the lower end surface of the fourth bending portion 14 The outer surfaces of the first bending portion 11, the second bending portion 12, the third bending portion 13, the fourth bending portion 14 and the rounded portion 16 are all wrapped with a shell 2 for heat conduction and insulation, the thickness of the shell 2 is 1 mm, and an extended shell 3 integrated with the shell 2 is arranged directly below the fifth bending portion 15, the fifth bending portion 15 and the extended shell form a card slot for connecting with the conductor in the junction box, the shell 2 is formed with a U-shaped groove for assembly with the junction box in the space surrounded by the first bending portion 11, the second bending portion 12, the third bending portion 13, the rounded portion 16 and the fourth bending portion 14, and the shell 2 also includes a plurality of heat sinks 4 for accelerating the heat dissipation efficiency of the radiator.

[0034] Furthermore, the number of the heat sinks is preferably 9.

[0035] Furthermore, the heat sink 4 is disposed on the left side wall of the housing 2 that wraps the outer surface of the first bent portion 11 , and the heat sink 4 is perpendicular to the left side wall of the housing 2 .

[0036] Furthermore, the distance between two adjacent heat sinks 4 is the same.

[0037] Furthermore, the heat sink 4 and the housing 2 are formed integrally.

[0038] Furthermore, the U-shaped groove is divided into a connecting groove for clamping with the box wall of the junction box and an avoiding groove for avoiding the box wall of the junction box, and the groove width of the connecting groove is slightly smaller than the thickness of the box wall of the junction box, and the groove width of the avoiding groove is larger than the thickness of the box wall of the junction box.

[0039] Furthermore, the connections between the first bending portion 11 , the second bending portion 12 , the third bending portion 13 , the fourth bending portion and the fifth bending portion 15 are all rounded.

[0040] Furthermore, the width of the slot in the up-down direction is slightly smaller than the thickness of the conductor in the junction box, and the heat sink is connected to the conductor in the junction box through the slot.

[0041] Furthermore, the first metal component 1 and the second metal component 5 are made of the same material, and both are made of aluminum or copper.

[0042] Furthermore, the material of the shell 2 is thermally conductive insulating plastic. When in use, the material of the shell 2 is preferably PA or PPE.

[0043] Furthermore, the inner connection surface on the fourth bending portion 14 that is vertically connected to the fifth bending portion 15 is not wrapped in the outer shell 2; the rounded surface of the rounded portion 16 connected to the inner connection surface of the fourth bending portion 14 is not wrapped in the outer shell 2, which reduces the thickness of this part, avoids occupying the space in the junction box, and increases the heat absorption area.

[0044] Figure 3 Yes Figure 2 The first metal member 1 is further improved as shown in FIG. Figure 3 As shown: second metal parts 5 corresponding to the heat sinks 4 are arranged on the left side wall of the first bending portion 11 , and each of the second metal parts 5 extends outward into the interior of the corresponding heat sink 4 and is wrapped by the corresponding heat sink 4 .

[0045] Furthermore, the first metal component 1 and the second metal component 5 are integrally formed.

[0046] Table 1 Experimental data comparison table

[0047]

[0048] See Table 1: When the rated current of the junction box is 30A, different schemes are used, and the bypass diode junction temperature test is used. The test results of different schemes are as follows:

[0049] 1. Conventional junction box (F20-01) + conventional diode (GFMK6045C), the junction temperature of the diode is 226°C.

[0050] 2. Conventional junction box (F20-01) + better performance diode (GFMK8045C), the junction temperature of the diode is 194°C, and the cost increases by 20%.

[0051] 3. Enlarge the junction box (F20-01 002) + conventional diode (GFMK6045C), the junction temperature of the diode is 209°C, and the cost increases by 13%.

[0052] 4. Conventional junction box (F20-01) + conventional diode (GFMK6045C) + external heat sink of the present invention, the junction temperature of the diode is 197°C, and the cost increases by 6%.

[0053] Since the junction temperature of the required diode cannot exceed 200°C when the rated current of the current junction box is 30A, the first and third solutions cannot meet the requirements. The third solution can reduce the junction temperature of the diode by continuously increasing the size of the junction box, but the cost will continue to rise and lead to the increase of the overall device. The second and fourth solutions can both meet the requirements. Although the effect of the second solution is better than that of the third solution, the cost of the second solution is much higher than that of the fourth solution. That is, the fourth solution can achieve the target increase of the rated current of the junction box at the lowest cost.

[0054] The working principle of the present invention is as follows:

[0055] See also Figure 4 When in use, firstly connect the heat sink's slot to the conductor in the junction box. At this time, the lower surface of the fifth bent portion 15 contacts the upper surface of the conductor, and the upper surface of the extended shell 3 of the outer shell 2 contacts the lower surface of the conductor. Then, connect the heat sink's connecting slot to the box wall of the junction box to complete a heat sink assembly. The heat on the conductor is conducted along the metal sheet and the outer shell 2, and finally dissipated through the outer shell 2. In actual use, multiple heat sinks can be assembled as needed to improve the heat dissipation efficiency of the junction box, thereby achieving an increase in the rated current of the junction box.

[0056] To sum up, the radiator of the present invention has low cost and low manufacturing difficulty, and under the premise of ensuring the heat dissipation efficiency of the radiator, it prevents electric shock caused by touching the radiator; in addition, multiple heat sinks are added to the outer shell of the radiator to further improve the heat dissipation efficiency; secondly, the radiator is connected to the junction box in a snap-on manner, which is convenient for assembly and subsequent maintenance and replacement; and the combination of the radiator and the original junction box can increase the rated current of the junction box from 25A to 30A at minimal cost.

[0057] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An external radiator for a photovoltaic junction box, characterized in that: The invention comprises a first metal component (1), wherein the first metal component (1) is formed by bending a first bending portion (11), a second bending portion (12), a third bending portion (13), a rounded corner portion (16), a fourth bending portion (14), and a fifth bending portion (15) in sequence; the first bending portion (11), the third bending portion (13), and the fourth bending portion (14) are parallel to each other, the second bending portion (12) and the fifth bending portion (15) are parallel to each other; the second bending portion The two ends of the first bending portion (11) and the upper side surface of the third bending portion (13) are respectively vertically connected, the lower end surface of the third bending portion (13) and the upper end surface of the fourth bending portion (14) are connected via the rounded corner portion (16), and the left end surface of the fifth bending portion (15) is vertically connected to the lower right side surface of the fourth bending portion (14); the first bending portion (11), the second bending portion (12), and the third bending portion (13) are vertically connected to each other. ), the outer surfaces of the fourth bent portion (14) and the rounded corner portion (16) are all wrapped with a shell (2) for heat conduction and insulation; an extended shell (3) which is integral with the shell (2) is arranged directly below the fifth bent portion (15); the fifth bent portion (15) and the extended shell form a slot for clamping with a conductor in a junction box; the shell (2) is formed with a U-shaped groove for assembly with a junction box in a space surrounded by the first bent portion (11), the second bent portion (12), the third bent portion (13), the rounded corner portion (16) and the fourth bent portion (14); the U-shaped groove is divided into a connecting groove for clamping with a box wall of the junction box and an avoiding groove for avoiding the box wall of the junction box; the groove width of the connecting groove is slightly smaller than the thickness of the box wall of the junction box, and the groove width of the avoiding groove is larger than the thickness of the box wall of the junction box; the shell (2) also includes a plurality of heat sinks (4) for accelerating the heat dissipation efficiency of the heat sink.

2. The external radiator of the photovoltaic junction box according to claim 1, characterized in that: The heat sink (4) is arranged on the left side wall of the shell (2) that wraps the outer surface of the first bent portion (11), and the heat sink (4) is perpendicular to the left side wall of the shell (2).

3. The external radiator of the photovoltaic junction box according to claim 2 is characterized in that: The heat sink (4) and the housing (2) are integrally formed.

4. The external radiator of the photovoltaic junction box according to claim 3 is characterized in that: Second metal parts (5) corresponding one to one with the heat sink (4) are arranged on the left side wall of the first bent portion (11), and each of the second metal parts (5) extends outwardly into the interior of the corresponding heat sink (4) and is wrapped by the corresponding heat sink (4).

5. The external radiator of the photovoltaic junction box according to claim 4, characterized in that: The first metal component (1) and the second metal component (5) are integrally formed.

6. The external radiator of the photovoltaic junction box according to claim 1, characterized in that: The connection points of the first bending portion (11), the second bending portion (12), the third bending portion (13), the fourth bending portion and the fifth bending portion (15) are all rounded.

7. The external radiator of the photovoltaic junction box according to claim 1, characterized in that: The width of the slot in the up-down direction is slightly smaller than the thickness of the conductor in the junction box, and the heat sink is connected to the conductor in the junction box through the slot.

8. The external radiator of the photovoltaic junction box according to claim 5, characterized in that: The first metal component (1) and the second metal component (5) are made of the same material, and both are made of aluminum or copper.

9. The external radiator of the photovoltaic junction box according to any one of claims 1 to 7, characterized in that: The shell (2) is made of heat-conducting insulating plastic.

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