Integrated junction box

Abstract

The integrated junction box comprises a junction box main body (1) and a cathode connector (2) installed in the junction box main body (1), the junction box main body (1) is provided with a first inner cavity (1a) and a second inner cavity (1b), a diode (3) is fixedly installed in the first inner cavity (1a) through cold heading, a positive terminal (4) is installed in the second inner cavity (1b), the positive terminal (4) is provided with a first connecting end (4a) and a second connecting end (4b), and the first connecting end (4a) is connected with the second connecting end (4b). The first connection end (4a) is connected to the diode (3) in the first inner cavity (1a) by resistance welding, and the negative connector (2) is connected to the second connection end (4b) in the second inner cavity (1b). Due to the adoption of the integrated design of the junction box and the connector, the transportation cost of the photovoltaic module is reduced, the risk that the connector is in contact with seawater when the photovoltaic module is applied to the sea surface is greatly reduced, the junction box can effectively work for a long time, and compared with an existing structure, the overall production cost is reduced by 30%.

Description

Technical Field

[0001] The invention relates to the field of structural design of junction boxes, and in particular to a photovoltaic junction box with a new structure. Background Art

[0002] Photovoltaic cells are devices that convert solar radiation energy directly into electrical energy. Photovoltaic modules are products made of multiple photovoltaic cells connected and packaged. They are the basic units of the battery array in photovoltaic power generation systems. The photovoltaic module junction box is a key connection device for the solar module system. The function of the junction box is to prevent the hot spot effect when the solar module is partially blocked. If the junction box is damaged or the connection is not secure, the junction box will not work properly. When the solar module is partially blocked, the entire solar module system will not work properly, and the blocked part will emit a lot of heat, which will seriously burn the module. The photovoltaic junction box is an important component used to connect the photovoltaic backplane and the inverter in the solar power generation system. After years of development, the performance and reliability of photovoltaic junction boxes have made great progress. For example, the patent with publication number CN108933566B discloses a horizontal split junction box, including a frame, a cover plate, a nylon bottom plate, a terminal and a diode; the frame is in the shape of a horizontal long strip; the cover plate is detachably fixed to the top of the frame, the nylon bottom plate is detachably fixed to the bottom of the frame, and the terminal is fixed to the nylon bottom plate; the terminal is two horizontally arranged and adjacent metal sheets, one horizontal end of the terminal is provided with a busbar connection part, and the other horizontal end is provided with a diode connection part; the two terminals are staggered and assembled into a horizontal long strip with a gap between them; the busbar connection parts of the two terminals are adjacent to each other horizontally, and the diode connection parts of the two terminals are adjacent to each other horizontally; the diode connects the adjacent diode connection parts. The photovoltaic junction boxes with similar structures mentioned above still have the following shortcomings: 1. Cost problem: The overall cost of the junction box with existing structures is relatively high. 2. Reliability problem: The existing photovoltaic junction boxes cannot work effectively for a long time in some special environments, such as the application of photovoltaic power generation on the sea surface. 3. Product volume problem: The existing structure junction box volume is relatively small. Summary of the invention

[0003] In order to overcome the deficiencies of the prior art, an object of the present invention is to provide an integrated junction box with lower cost and long-term effective operation.

[0004] In order to achieve the above objectives, the present invention provides an integrated junction box, including a junction box body and a negative pole connector installed on the junction box body, the junction box body having a first inner cavity and a second inner cavity, a diode being fixedly installed in the first inner cavity by cold forging, a positive pole terminal being installed in the second inner cavity, the positive pole terminal having a first connecting end and a second connecting end, the first connecting end being connected to the diode in the first inner cavity by resistance welding, and the negative pole connector being connected to the second connecting end in the second inner cavity.

[0005] Preferably, the second connecting end is tubular, a drum spring is arranged inside the second connecting end, the positive terminal has a limiting portion, and the drum spring is limited between the end face of the positive terminal head and the limiting portion.

[0006] Preferably, a first cover plate is installed on the first inner cavity, and a second cover plate is installed on the second inner cavity.

[0007] Preferably, the negative electrode connector includes a connecting end and a mounting end, the connecting end is integrally injection-molded with a negative electrode terminal, the mounting end is integrally injection-molded with a negative electrode cable, the negative electrode terminal is riveted to the end of the negative electrode cable, and the negative electrode terminal is connected to the second connecting end of the positive electrode terminal in the second inner cavity.

[0008] Preferably, an elastic lock is formed on the connecting end, and the negative electrode connector is locked together with the junction box body in the second inner cavity through the elastic lock.

[0009] Preferably, an O-ring is sleeved on the connecting end.

[0010] Preferably, the mounting end is provided with an external thread, and the outside of the negative cable is sequentially sleeved with a T-ring, a cable locking basket and a nut, the nut is screwed onto the external thread of the mounting end, and the T-ring and the cable locking basket are fixedly connected to the first mounting end.

[0011] Preferably, the inner diameter of the T-ring matches the outer diameter of the negative cable, the small end of the T-ring is sleeved in the cable locking basket, and the cable locking basket is sleeved in the nut.

[0012] Preferably, the cable locking basket comprises a body, a front end of the body is provided with a plurality of claw strips arranged in a circle, and elastic seams are provided between the claw strips.

[0013] Preferably, the inner wall of the nut is in an arc shape that gradually contracts toward the central axis. When the nut is tightened, the outer side of the claw of the cable locking basket is compressed, and the inner side of the claw of the cable locking basket gradually contracts inward to bite the negative cable.

[0014] The integrated design of the junction box and connector reduces the transportation cost of photovoltaic modules and greatly reduces the risk of connector contact with seawater when used on the sea surface, ensuring that the junction box can work effectively for a long time. Compared with the existing structure, the overall production cost of the present invention is reduced by 30%. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Attached Figure 1 It is a three-dimensional exploded view of the integrated junction box of the present invention; Attached Figure 2 This is a front view of the integrated junction box of the present invention; Attached Figure 3 is a cross-sectional view of the integrated junction box of the present invention; Attached Figure 4 It is a rear view of the junction box body of the integrated junction box of the present invention; Attached Figure 5 Schematic diagram of the negative electrode connector of the integrated junction box of the present invention. DETAILED DESCRIPTION

[0016] Hereinafter, the terms used in the specification will be briefly described, and the embodiments will be described in detail. All terms including descriptive terms or technical terms used herein should be interpreted as having meanings understood by those of ordinary skill in the art. However, these terms may have different meanings according to the intentions of those of ordinary skill in the art, precedents, or the emergence of new technologies.

[0017] In addition, some terms can be selected by the applicant, and in this case, the meaning of the selected terms will be described in detail in the detailed description of the embodiment. Therefore, the terms used herein must be defined based on the meaning of the terms together with the description in the entire specification. In addition, when a component "includes" or "contains" an element, unless there is a specific description to the contrary, the component may also include other elements without excluding other elements. In the following description, terms such as "component" and "module" indicate a unit for processing at least one function or operation, wherein the unit and module can be implemented as hardware or software or by combining hardware and software and implemented.

[0018] Embodiments will now be described more fully with reference to the accompanying drawings. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. On the contrary, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the embodiments to those of ordinary skill in the art. In the following description, well-known functions or structures are not described in detail because they will obscure the embodiments with unnecessary details, and throughout the specification, the same reference numerals in the drawings represent the same or similar elements.

[0019] Attached Figure 1 The three-dimensional exploded view of the integrated junction box of the present invention is attached. Figure 2 This is a front view of the integrated junction box of the present invention, Figure 3 is a cross-sectional view of the integrated junction box of the present invention, Figure 4 The rear view of the junction box body of the integrated junction box of the present invention is shown in FIG. Figure 5 It is a schematic diagram of the negative electrode connector of the integrated junction box of the present invention; the integrated junction box in this embodiment includes a junction box body 1 and a negative electrode connector 2 installed on the junction box body 1, the junction box body 1 has a first inner cavity 1a and a second inner cavity 1b, a first cover plate 11 is installed on the first inner cavity 1a, and a second cover plate 12 is installed on the second inner cavity 1b.

[0020] A diode 3 is fixedly installed in the first inner cavity 1a by cold heading, and a positive terminal 4 is installed in the second inner cavity 1b. The positive terminal 4 has a first connection end 4a and a second connection end 4b. The first connection end 4a is connected to the diode 3 by resistance welding in the first inner cavity 1a, and the negative connector 2 is connected to the second connection end 4b in the second inner cavity 1b. The second connection end 4b is tubular, and a drum spring 5 is arranged in the second connection end 4b. The positive terminal 4 has a limiting portion 4c, and the drum spring 5 is limited between the end face of the head of the positive terminal 4 and the limiting portion 4c.

[0021] The negative electrode connector 2 includes a connection end 2a and a mounting end 2b. A negative electrode terminal 6 is integrally molded in the connection end 2a, and a negative electrode cable 7 is integrally molded in the mounting end 2b. The negative electrode terminal 6 is riveted to the end of the negative electrode cable 7. The negative electrode terminal 6 is connected to the second connection end 4b of the positive electrode terminal 4 in the second inner cavity 1b. An elastic lock 2c is formed on the connection end 2a, and the negative electrode connector 2 is locked together with the junction box body 1 in the second inner cavity 1b by the elastic lock 2c. An O-ring 13 is sleeved on the connection end 2a.

[0022] The mounting end 2b is provided with an external thread, and the outside of the negative cable 7 is sequentially sleeved with a T-ring 8, a cable locking basket 9 and a nut 10, and the nut 10 is screwed onto the external thread of the mounting end 2b, and the T-ring 8 and the cable locking basket 9 are fixedly connected to the first mounting end 2b. The inner diameter of the T-ring 8 matches the outer diameter of the negative cable 7, and the small end of the T-ring 8 is sleeved in the cable locking basket 9, and the cable locking basket 9 is sleeved in the nut 10. The cable locking basket 9 includes a body, and a plurality of claws are arranged in a circle at the front end of the body, and elastic seams are arranged between the claws. The inner wall of the nut 10 is in an arc shape that gradually shrinks toward the central axis. When the nut 10 is tightened, the outer side of the claw of the cable locking basket 9 is compressed, and the inner side of the claw of the cable locking basket 9 gradually shrinks inward to bite the negative cable 7.

[0023] During the production process, the diode is placed in the first inner cavity of the junction box for cold heading and fixation, the drum spring is inserted into the positive terminal and fixed in the junction box for resistance welding, the negative terminal and the cable are riveted together and placed in the vertical injection molding and the connector body for integral injection molding, the O-ring is inserted into the connector body and inserted into the junction box, the T-ring and the cable locking basket are inserted into the cable, and finally the nut is tightened. The product has a compact appearance and size, and its operation is convenient, fast and reliable, so that workers can install it with simple tools. Due to the integrated design of the junction box and the connector, the transportation cost of the photovoltaic module is reduced, and the risk of the connector contacting with seawater is greatly reduced when used on the sea surface, ensuring that the junction box can work effectively for a long time. Compared with the existing structure, the overall production cost of the present invention is reduced by 30%.

[0024] It should be understood that the embodiments described herein should be considered in a descriptive sense only and not for the purpose of limitation. The description of the features or aspects within each implementation side should generally be considered to be applicable to other similar features or aspects in other embodiments. Although one or more embodiments have been described with reference to the accompanying drawings, it will be understood by those of ordinary skill in the art that various changes in form and detail may be made therein without departing from the spirit and scope defined by the appended claims.

Claims

1. Integrated junction box, characterized by: The invention comprises a junction box body (1) and a negative electrode connector (2) installed on the junction box body (1), wherein the junction box body (1) has a first inner cavity (1a) and a second inner cavity (1b), a diode (3) is fixedly installed in the first inner cavity (1a) by cold heading, a positive electrode terminal (4) is installed in the second inner cavity (1b), the positive electrode terminal (4) has a first connection end (4a) and a second connection end (4b), the first connection end (4a) is connected to the diode (3) in the first inner cavity (1a) by resistance welding, and the negative electrode connector (2) is connected to the second connection end (4b) in the second inner cavity (1b).

2. The integrated junction box according to claim 1, characterized in that: The second connecting end (4b) is tubular, a drum spring (5) is arranged inside the second connecting end (4b), the positive terminal (4) has a limiting portion (4c), and the drum spring (5) is limited between the end surface of the head of the positive terminal (4) and the limiting portion (4c).

3. The integrated junction box according to claim 1, characterized in that: A first cover plate (11) is installed on the first inner cavity (1a), and a second cover plate (12) is installed on the second inner cavity (1b).

4. The integrated junction box according to claim 1, characterized in that: The negative electrode connector (2) comprises a connection end (2a) and a mounting end (2b); a negative electrode terminal (6) is integrally injection-molded in the connection end (2a); a negative electrode cable (7) is integrally injection-molded in the mounting end (2b); the negative electrode terminal (6) is riveted to the end of the negative electrode cable (7); and the negative electrode terminal (6) is connected to the second connection end (4b) of the positive electrode terminal (4) in the second inner cavity (1b).

5. The integrated junction box according to claim 4, characterized in that: An elastic lock buckle (2c) is formed on the connecting end (2a), and the negative electrode connector (2) is locked together with the junction box body (1) in the second inner cavity (1b) via the elastic lock buckle (2c).

6. The integrated junction box according to claim 4, characterized in that: An O-type sealing ring (13) is sleeved on the connecting end (2a).

7. The integrated junction box according to claim 4, characterized in that: The mounting end (2b) is provided with an external thread, and the outside of the negative cable (7) is sequentially sleeved with a T-ring (8), a cable locking basket (9) and a nut (10), the nut (10) being screwed onto the external thread of the mounting end (2b) and fixing the T-ring (8) and the cable locking basket (9) to the first mounting end (2b).

8. The integrated junction box according to claim 7, characterized in that: The inner diameter of the T-ring (8) matches the outer diameter of the negative cable (7), the small end of the T-ring (8) is sleeved in the cable locking basket (9), and the cable locking basket (9) is sleeved in the nut (10).

9. The integrated junction box according to claim 8, characterized in that: The cable locking basket (9) comprises a body, a front end of which is provided with a plurality of claw strips arranged in a circle, and elastic seams are provided between the claw strips.

10. The integrated junction box according to claim 9, characterized in that: The inner wall of the nut (10) is in the shape of an arc that gradually contracts toward the central axis. When the nut (10) is tightened, the outer side of the claw strip of the cable locking flower basket (9) is compressed, and the inner side of the claw strip of the cable locking flower basket (9) gradually contracts inward to engage the negative cable (7).

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