A photovoltaic electrical energy-saving connector

Abstract

The present invention discloses a photovoltaic electrical energy-saving connector, comprising a male plug and a female plug, wherein the male plug and the female plug comprise an outer sheath, wherein one end of the outer sheath is provided with a core protection sleeve, and the other end of the outer sheath is provided with a threaded connection seat, wherein a fixed end cap is threadedly connected to the threaded connection seat, wherein a male plug is inserted into the outer sheath of the male plug, and a female plug is inserted into the outer sheath of the female plug, wherein the male plug and the female plug are plugged in and matched, wherein the core protection sleeve is provided on the outside of the male plug or the female plug, wherein an annular plug-in groove is formed between the core protection sleeve on the male plug and the male plug, and wherein the core protection sleeve on the female plug is plugged in and matched with the annular plug-in groove. The present invention effectively reduces the resistance value of the connector docking position by improving the core structure, thereby improving the safety of the connector and reducing the power loss at the connector position. At the same time, the present invention has good sealing performance, is simple to operate, and is highly reliable, and is worthy of promotion.

Description

Technical Field

[0001] The present invention relates to the technical field of connectors, in particular to a photovoltaic electrical energy-saving connector. Background Art

[0002] Photovoltaic electrical connectors are used in the photovoltaic field to bridge isolated circuits, enabling current flow and enabling the circuits to function as intended. These connectors are unassuming components, but poor quality can pose a significant safety hazard, potentially causing fires and significant losses to power plants. When current flows, the connector's increased resistance causes a temperature rise that exceeds the temperature tolerance of the plastic housing and metal components, potentially causing a fire. Therefore, connector failure and fires are the result of a combination of the plastic housing and metal components.

[0003] A prerequisite for ensuring the proper functioning of connectors. Generally speaking, a connector's contact resistance (R) consists of three components: Rco, the internal resistance of the metal components, and Rcr. Researchers have found that connector burnouts primarily occur in the middle (denoted as Rco) and at the crimping points at both ends (denoted as Rcr).

[0004] 1. Failure analysis of resistor Rco

[0005] Resistance (Rco) is the resistance of the metal-to-metal overlap of a connector after mating. An abnormal increase in Rco can lead to elevated temperatures, potentially causing fires in the connector's center. This abnormal increase in Rco is primarily due to improper installation. To ensure current flow, each company's connectors have a specific overlap length between the A and B segments after mating, ensuring full contact between the two metal parts. If improper installation occurs during connector assembly, the metal parts will not mate properly. Because the actual Rco value exceeds the designed value, the same current generates increased heat in this area, leading to higher temperatures. This condition is further exacerbated by the effects of high temperatures, such as oxidation and aging. This vicious cycle ultimately results in connector burnout.

[0006] 2. Failure analysis of resistor Rcr

[0007] The crimp resistance (Rcr) is primarily related to crimp quality and process. The compression ratio and crimp cross-section can be used to assess crimp quality. A good crimp requires a tight cross-section with no gaps and a regular appearance. For commonly used 4mm² cable crimps, the IEC 2742 / 05 standard requires a contact resistance of less than 0.2mΩ, while IEC 60352-2 stipulates a pull-out force greater than 310N.

[0008] In summary, the key to improving the safety of photovoltaic electrical connectors and reducing power loss at the connector location lies in reducing the resistance of the connector Rco and Rcr. Therefore, it is crucial to develop a safe and energy-saving photovoltaic electrical connector. Summary of the Invention

[0009] The object of the present invention is to provide a photovoltaic electrical energy-saving connector to solve the problems raised in the above background technology.

[0010] To achieve the above object, the present invention provides the following technical solutions:

[0011] A photovoltaic electrical energy-saving connector, comprising a male plug and a female plug, wherein the male plug and the female plug comprise an outer sheath, one end of the outer sheath being provided with a core protection sleeve, the other end of the outer sheath being provided with a threaded connection seat, a fixed end cap being threadedly connected to the threaded connection seat, a male core being inserted into the outer sheath of the male plug, a female core being inserted into the outer sheath of the female plug, the male core being plugged into and mating with the female core, the core protection sleeve being provided on the outer side of the male core or the female core, an annular plugging groove being formed between the core protection sleeve on the male plug and the male core, the female core being inserted into and mating with the male core, The core protection sleeve on the head is plugged into the annular plug-in groove, and the ends of the male and female plugs are provided with crimping ends, which are crimped and connected to the core wires in the cable. The male and female plugs are stamped into a whole copper tube, and the female and male plug-in sections are arranged as cylindrical structures. The male plug-in section is plugged into the inner hole of the female plug-in section, and the male plug-in section is provided with a pair of longitudinal grooves extending to the port, and the port of the male plug-in section is provided with a pair of springs folded toward the axial side of the male plug, and the ends of the springs on both sides are connected by welding.

[0012] Furthermore, a conical fixing clamp is placed between the threaded connection seat and the fixed end cover, and the cable passes through the openings at the ends of the fixing clamp and the fixed end cover. A group of pressure claws are distributed on the fixing clamp, and the ends of the pressure claws extend into the openings of the fixed end cover.

[0013] Furthermore, a conical extrusion groove is provided at the end of the threaded connection seat, and a rubber sealing sleeve is provided between the fixing clamp and the threaded connection seat. The diameter of the rubber sealing sleeve decreases from the middle to both ends, and the rubber sealing sleeve is clamped between the extrusion groove and the fixing clamp.

[0014] Furthermore, a rotating sleeve is rotatably connected to the end face of the inner and outer sheaths of the female plug, a limiting ring is provided on the circumferential inner wall at the port of the rotating sleeve, a group of avoidance grooves are evenly distributed on the limiting ring, and plug-in protrusions are evenly distributed on the circumferential outer wall at the port of the protective core sleeve in the male plug, and the plug-in protrusions are plugged into and matched with the avoidance grooves.

[0015] Furthermore, a pair of limit blocks and a pair of permanent magnet blocks are provided on the end faces of the inner and outer sheaths of the female plug, and a pair of iron blocks are fixedly connected to the circumferential outer wall of the rotating sleeve away from the limit ring, and the iron blocks are located between the limit blocks and the permanent magnet blocks.

[0016] Furthermore, a sealing ring groove is provided on the end surface of the outer sheath in the female plug, a sealing ring is bonded in the sealing ring groove, and the end of the core sheath in the male plug abuts against the sealing ring.

[0017] Furthermore, the surfaces of the male ferrule and the female ferrule are plated with a pure silver layer.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] 1. In the present invention, the male and female ferrules are stamped from a whole copper tube, which is convenient to process, has high structural stability, and has uniform resistance distribution. The longitudinal grooves give the male ferrule good elasticity, which can form a better fit with the female ferrule. The folded springs make the male ferrule elastic for a long time.

[0020] 2. In the present invention, the diameter of the rubber sealing sleeve decreases from the middle to the two ends, which makes it easy to shrink and compress the cable. Compared with traditional sealing sleeves, the contact length is extended and the sealing effect is better.

[0021] 3. In the present invention, after the male plug and the female plug are connected, they are locked by the rotating sleeve and the plug-in protrusion, which has a simple structure, easy operation and high reliability.

[0022] In summary, the present invention effectively reduces the resistance value at the connector docking position by improving the core structure, thereby improving the safety of the connector and reducing the power loss at the connector position. At the same time, the present invention has good sealing, simple operation, and high reliability, and is worthy of promotion. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a schematic diagram of the structure of a photovoltaic electrical energy-saving connector;

[0024] Figure 2 This is a schematic diagram of the structure of a female plug in a photovoltaic electrical energy-saving connector;

[0025] Figure 3 This is a schematic diagram of the structural breakdown of a female plug in a photovoltaic electrical energy-saving connector;

[0026] Figure 4 This is a schematic diagram of the structure of a male plug in a photovoltaic electrical energy-saving connector;

[0027] Figure 5 This is a schematic diagram of the structure of a male and female plug in a photovoltaic electrical energy-saving connector;

[0028] Figure 6 This is a schematic diagram of the structural decomposition of the threaded connection seat and fixed end cover in a photovoltaic electrical energy-saving connector.

[0029] In the figure: 1-male plug, 2-female plug, 3-cable, 4-core wire, 5-crimping end, 6-male ferrule, 7-longitudinal groove, 8-spring, 9-female ferrule, 10-outer sheath, 11-core protection sleeve, 12-threaded connection seat, 13-fixed end cover, 14-fixing clip, 15-rubber sealing sleeve, 16-extrusion groove, 17-annular plug-in groove, 18-plug-in protrusion, 19-rotating sleeve, 20-limiting ring, 21-avoidance groove, 22-iron block, 23-limiting block, 24-permanent magnet block, 25-sealing ring. DETAILED DESCRIPTION

[0030] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0031] Example 1: Please refer to Figures 1 to 5 A photovoltaic electrical energy-saving connector includes a male plug 1 and a female plug 2. The male plug 1 and the female plug 2 include an outer sheath 10. One end of the outer sheath 10 is provided with a core protection sleeve 11. The other end of the outer sheath 10 is provided with a threaded connection seat 12. A fixed end cover 13 is threadedly connected to the threaded connection seat 12. A male core 6 is inserted into the outer sheath 10 of the male plug 1. A female core 9 is inserted into the outer sheath 10 of the female plug 2. The male core 6 is plugged into the female core 9. The core protection sleeve 11 is provided on the outside of the male core 6 or the female core 9. A ring-shaped plug is formed between the core protection sleeve 11 on the male plug 1 and the male core 6. Groove 17, the core protection sleeve 11 on the female plug 2 is plugged into the annular plug-in groove 17, and the ends of the male core 6 and the female core 9 are provided with crimping ends 5, and the crimping ends 5 are crimped and connected with the core wire 4 in the cable 3. The male core 6 and the female core 9 are stamped into a whole copper tube, and the female core 9 and the male core 6 plug-in section are set as a cylindrical structure. The male core 6 plug-in section is plugged into the inner hole of the female core 9 plug-in section, and the male core 6 plug-in section is provided with a pair of longitudinal grooves 7 extending to the port, and the male core 6 plug-in section port is provided with a pair of springs 8 folded toward the axial side of the male core 6, and the ends of the springs 8 on both sides are connected by welding.

[0032] A sealing ring groove is provided on the end surface of the outer sheath 10 in the female plug 2 , a sealing ring 25 is bonded in the sealing ring groove, and the end of the core sheath 11 in the male plug 1 abuts against the sealing ring 25 .

[0033] The surfaces of the male ferrule 6 and the female ferrule 9 are plated with a pure silver layer.

[0034] In the present invention, the male and female ferrules 6 and 9 are stamped from a single copper tube, offering convenient processing, high structural stability, and uniform resistance distribution. A longitudinal groove 7 extending to the port provides excellent elasticity for the male ferrule 6, ensuring a tighter fit with the female ferrule 9. A pair of folded springs 8 form a reset structure at the end of the male ferrule 6, ensuring its long-term elasticity. The surfaces of the male and female ferrules 6 and 9 are plated with a pure silver layer to reduce their resistance. Through these features, the present invention effectively reduces the resistance at the connector's mating point, thereby enhancing connector safety and reducing power loss at the connector's location. A sealing ring 25 ensures a tight seal between the male and female plugs 1 and 2.

[0035] Example 2: Please refer to Figure 6 , a photovoltaic electrical energy-saving connector, which differs from Example 1 in that a conical fixing clamp 14 is placed between the threaded connection seat 12 and the fixed end cover 13, and the cable 3 passes through the openings at the ends of the fixing clamp 14 and the fixed end cover 13. A group of pressure claws are distributed on the fixing clamp 14, and the ends of the pressure claws extend into the openings of the fixed end cover 13.

[0036] A tapered extrusion groove 16 is provided at the end of the threaded connection seat 12, and a rubber sealing sleeve 15 is provided between the fixing clamp 14 and the threaded connection seat 12. The diameter of the rubber sealing sleeve 15 decreases from the middle to both ends, and the rubber sealing sleeve 15 is clamped between the extrusion groove 16 and the fixing clamp 14.

[0037] In this embodiment, as threaded connector 12 and fixed end cap 13 are tightened, the pressure claws of retaining clamp 14 retract to firmly grip cable 3, preventing loosening of the wire at the end of the plug and potentially affecting the connector's service life. During assembly, rubber sealing sleeve 15 is compressed by extrusion groove 16 and retaining clamp 14, ensuring a tight seal at the end of the plug. The rubber sealing sleeve 15's diameter gradually decreases from the center toward the ends, making it easier to retract and compress cable 3. This extends the contact length compared to traditional sealing sleeves, resulting in a more effective seal.

[0038] Example 3: Please refer to Figures 3-4 A photovoltaic electrical energy-saving connector, which differs from Examples 1 and 2 in that a rotating sleeve 19 is rotatably connected to the end face of the outer sheath 10 in the female plug 2, and a limit ring 20 is provided on the circumferential inner wall at the end of the rotating sleeve 19. A group of avoidance grooves 21 are evenly distributed on the limit ring 20, and plug-in protrusions 18 are evenly distributed on the circumferential outer wall at the end of the protective core sleeve 11 in the male plug 1, and the plug-in protrusions 18 are plugged into and matched with the avoidance grooves 21.

[0039] A pair of limit blocks 23 and a pair of permanent magnet blocks 24 are provided on the end surface of the outer sheath 10 of the female plug 2. A pair of iron blocks 22 are fixedly connected to the circumferential outer wall of the rotating sleeve 19 away from the limit ring 20. The iron block 22 is located between the limit block 23 and the permanent magnet block 24.

[0040] In this embodiment, when the male plug 1 of the connector is connected to the female plug 2, the rotating sleeve 19 is first rotated to make the iron block 22 fit the limit block 23, and then the plug-in protrusion 18 is first aligned with the avoidance groove 21, and then the rotating sleeve 19 is inserted into the outer side of the core protective sleeve 11 in the male plug 1. After being inserted into place, the rotating sleeve 19 is rotated again to make the iron block 22 fit the permanent magnet block 24. After the permanent magnet block 24 absorbs the iron block 22, the connector detachment phenomenon caused by the shaking of the rotating sleeve 19 can be avoided.

[0041] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A photovoltaic electrical energy-saving connector, comprising a male plug (1) and a female plug (2), characterized in that: The male plug (1) and the female plug (2) comprise an outer sheath (10), one end of the outer sheath (10) is provided with a core protection sleeve (11), the other end of the outer sheath (10) is provided with a threaded connection seat (12), a fixed end cover (13) is threadedly connected to the threaded connection seat (12), a male plug core (6) is inserted into the outer sheath (10) of the male plug (1), a female plug core (9) is inserted into the outer sheath (10) of the female plug (2), the male plug core (6) and the female plug core (9) are plugged together, the core protection sleeve (11) is provided on the outside of the male plug core (6) or the female plug core (9), an annular plug groove (17) is formed between the core protection sleeve (11) on the male plug (1) and the male plug core (6), the female plug ( 2) is plugged into the annular plug groove (17), the male plug core (6) and the female plug core (9) are provided with a crimping end (5) at the end, and the crimping end (5) is crimped and connected to the core wire (4) in the cable (3), the male plug core (6) and the female plug core (9) are formed by stamping a whole copper tube, the female plug core (9) and the male plug core (6) plug section are set as a cylindrical structure, the male plug core (6) plug section is plugged into the inner hole of the female plug core (9) plug section, the male plug core (6) plug section is provided with a pair of longitudinal grooves (7) extending to the port, the male plug core (6) plug section is provided with a pair of springs (8) folded toward the axial side of the male plug core (6), and the ends of the springs (8) on both sides are connected by welding; A conical fixing clamp (14) is placed between the threaded connection seat (12) and the fixed end cover (13), and the cable (3) passes through the openings at the ends of the fixing clamp (14) and the fixed end cover (13). A group of pressure claws are distributed on the fixing clamp (14), and the ends of the pressure claws extend into the openings of the fixed end cover (13); A rotating sleeve (19) is rotatably connected to the end surface of the outer and inner protective sleeves (10) of the female plug (2), a limiting ring (20) is provided on the circumferential inner wall at the end of the rotating sleeve (19), and a group of avoidance grooves (21) are evenly distributed on the limiting ring (20), and plug-in protrusions (18) are evenly distributed on the circumferential outer wall at the end of the protective sleeve (11) of the male plug (1), and the plug-in protrusions (18) are plugged into and matched with the avoidance grooves (21).

2. The photovoltaic electrical energy-saving connector according to claim 1, characterized in that: A tapered extrusion groove (16) is provided at the end of the threaded connection seat (12), and a rubber sealing sleeve (15) is provided between the fixing clamp (14) and the threaded connection seat (12). The diameter of the rubber sealing sleeve (15) decreases from the middle to both ends, and the rubber sealing sleeve (15) is clamped between the extrusion groove (16) and the fixing clamp (14).

3. The photovoltaic electrical energy-saving connector according to claim 1, characterized in that: A pair of limit blocks (23) and a pair of permanent magnet blocks (24) are provided on the end surfaces of the inner and outer sheaths (10) of the female plug (2), and a pair of iron blocks (22) are fixedly connected to the circumferential outer wall of the rotating sleeve (19) at one end away from the limit ring (20), and the iron block (22) is located between the limit block (23) and the permanent magnet block (24).

4. The photovoltaic electrical energy-saving connector according to claim 3, characterized in that: A sealing ring groove is provided on the end surface of the outer sheath (10) in the female plug (2), a sealing ring (25) is bonded in the sealing ring groove, and the end of the core sheath (11) in the male plug (1) abuts against the sealing ring (25).

5. The photovoltaic electrical energy-saving connector according to claim 4, characterized in that: The surfaces of the male ferrule (6) and the female ferrule (9) are plated with a pure silver layer.

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