Photovoltaic junction box and manufacturing method thereof

Abstract

The embodiment of the invention provides a photovoltaic junction box and a manufacturing method thereof, the photovoltaic junction box comprises an inner shell, an outer shell, a first colloid layer and a connecting wire group, the inner shell is provided with an accommodating cavity, and the accommodating cavity is used for placing an electronic element; the inner shell is provided with a first through hole; the outer shell is nested outside the inner shell and is provided with a third through hole; the first colloid layer is cured and formed between the inner shell and the outer shell in a glue injection mode, and a second through hole matched with the connecting wire group is formed; one end of the connecting wire group is connected with the electronic element, and the other end of the connecting wire group sequentially penetrates through the first through hole, the second through hole and the third through hole, extends out of the outer shell and is used for being connected with a photovoltaic module. The technical problem that an existing photovoltaic junction box is short in service life is solved.

Description

Technical Field

[0001] The present invention relates to the field of photovoltaics, and in particular to a photovoltaic junction box and a manufacturing method thereof. Background Art

[0002] Photovoltaic power supply systems are increasingly being used, and photovoltaic modules therein usually need to be equipped with photovoltaic junction boxes to be electrically connected to other modules in the photovoltaic power supply system.

[0003] Photovoltaic junction boxes are usually installed outdoors, such as at sea, on mountains, and in forests. Due to the humid outdoor environment, photovoltaic junction boxes are prone to corrosion, aging, and cracking, causing damage to the electronic components inside and the connecting wires between the electronic components and photovoltaic modules, making them unusable, which further affects the normal use of photovoltaic modules. Summary of the invention

[0004] A photovoltaic junction box and a manufacturing method thereof provided in an embodiment of the present invention solve the technical problem that the service life of the existing photovoltaic junction box is short.

[0005] In order to solve the above technical problems, an embodiment of the present invention provides a photovoltaic junction box, comprising an inner shell, an outer shell, a first colloid layer and a connecting wire group, wherein:

[0006] The inner shell has a receiving cavity, and the receiving cavity is used to place electronic components;

[0007] The inner shell has a first through hole;

[0008] The outer shell is nested outside the inner shell and has a third through hole;

[0009] The first colloid layer is solidified and formed between the inner shell and the outer shell by means of glue injection, and forms a second through hole adapted to the connecting wire group;

[0010] One end of the connecting wire group is connected to the electronic component, and the other end passes through the first through hole, the second through hole and the third through hole in sequence, and extends to the outside of the outer shell for connection with the photovoltaic module.

[0011] In order to solve the above technical problems, an embodiment of the present invention further provides a method for manufacturing a photovoltaic junction box, which is used to manufacture the above photovoltaic junction box. The method for manufacturing the photovoltaic junction box includes:

[0012] S101, manufacturing an inner shell and an outer shell, wherein the inner shell has a receiving cavity and a first through hole, and the outer shell has a third through hole;

[0013] S102, placing an electronic component in the accommodating cavity, assembling the inner shell and the outer shell, connecting one end of the connecting wire group to the electronic component, and sequentially passing the other end through the first through hole and the third through hole to extend outside the outer shell;

[0014] S103 , injecting glue between the inner shell and the outer shell, and curing and molding to obtain a first glue layer, wherein the first glue layer has a second through hole adapted to the connecting wire group.

[0015] Beneficial Effects

[0016] A photovoltaic junction box and a manufacturing method thereof provided by an embodiment of the present invention, the photovoltaic junction box includes an inner shell, an outer shell, a first colloid layer and a connecting wire group, the outer shell is nested outside the inner shell, the electronic components are placed in the accommodating cavity of the inner shell, one end of the connecting wire group is connected to the electronic components, and the other end passes through the first through hole of the inner shell, the second through hole of the first colloid layer and the third through hole of the outer shell in sequence, and extends to the outside of the outer shell for connection with the photovoltaic module, the first colloid layer is solidified and formed between the inner shell and the outer shell by means of glue injection, and has a second through hole adapted to the connecting wire group. The present invention forms three layers of protection for the electronic components through the inner shell, the first colloid layer and the outer shell, and the first colloid layer is solidified and formed between the inner shell and the outer shell by means of glue injection, and forms a second through hole adapted to the connecting wire group, and the first colloid layer forms a closed space between the inner shell and the outer shell, further strengthening the protection of the electronic components in the inner shell.

[0017] Other features and corresponding beneficial effects of the present invention are described in the latter part of the specification, and it should be understood that at least part of the beneficial effects become obvious from the description in the specification of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A schematic diagram of a photovoltaic junction box provided in Embodiment 1 of the present invention;

[0019] Figure 2 This is a flow chart of a method for manufacturing a photovoltaic junction box provided in Embodiment 2 of the present invention. DETAILED DESCRIPTION

[0020] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the following is a further detailed description of the embodiments of the present invention through specific implementation methods combined with the accompanying drawings. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0021] Embodiment 1:

[0022] The specific implementation of the present invention is further described in detail below with reference to the accompanying drawings and implementation examples. Figure 1 The photovoltaic junction box includes an inner shell 11, an outer shell 12, a first colloid layer 13 and a connecting wire group 14, the inner shell 11 has a accommodating cavity 111, and the accommodating cavity 111 is used to place an electronic component 15; the inner shell 11 has a first through hole 112; the outer shell 12 is nested outside the inner shell 11 and has a third through hole 121; the first colloid layer 13 is solidified and formed between the inner shell 11 and the outer shell 12 by means of glue injection, and a second through hole (not shown in the figure) adapted to the connecting wire group 14 is formed; one end of the connecting wire group 14 is connected to the electronic component 15, and the other end passes through the first through hole 112, the second through hole and the third through hole 121 in sequence, and extends to the outside of the outer shell 12 for connection with the photovoltaic module.

[0023] In some embodiments, the inner shell 11 may be square, circular, oval or irregular in shape; the inner shell 11 may be made of plastic, metal or other materials; the inner shell 11 may include a first shell body and a first cover body, the first shell body has a receiving cavity 111, or the first shell body and the first cover body are assembled to form the receiving cavity 111, or the first cover body has a receiving cavity 111, the first through hole 112 may be provided on the first shell body, or on the first cover body, or the first shell body and the first cover body are assembled to form the first through hole 112; the aperture of the first through hole 112 depends on the cross-sectional diameter of the connecting wire group 14, preferably, it may be slightly larger than the cross-sectional diameter of the connecting wire group 14, the connecting wire group 14 passes through the first through hole 112, and a gap is left between the connecting wire group 14 and the first through hole 112. The electronic components are placed in the receiving cavity 111.

[0024] In some embodiments, the outer shell 12 may be square, circular, oval or irregular in shape; the shape may be compatible with the inner shell 11 and nested outside the inner shell 11; the outer shell 12 may be made of plastic, metal or other materials; the outer shell 12 may include a second shell body and a second cover body, and the third through hole 121 may be arranged on the second shell body, or on the second cover body, or the second shell body and the second cover body may be assembled together to form the third through hole 121; the aperture of the third through hole 121 depends on the cross-sectional diameter of the connecting wire group 14, and preferably, it may be slightly larger than the cross-sectional diameter of the connecting wire group 14, and the connecting wire group 14 passes through the third through hole 121, and a gap is left between the connecting wire group 14 and the third through hole 121.

[0025] In some embodiments, the photovoltaic junction box further includes electronic components 15 .

[0026] In some embodiments, the first colloid layer 13 can enclose a closed space between the inner shell 11 and the outer shell 12, and the first colloid layer 13 forms a second through hole adapted to the connecting wire group 14 during the injection process, and the second through hole is tightly fitted with the connecting wire group 14, which is not shown in the figure. While the first colloid layer 13 realizes the wire passing, it ensures the sealing and waterproofness of the connection position with the connecting wire group 14. The first colloid layer 13 can be injected with the help of the glue hole reserved on the outer shell 12, or with the help of the third through hole 121 on the outer shell 12.

[0027] In some embodiments, the first colloid layer 13 is at least partially filled in the first through hole 112 and / or the third through hole 121. Since the connecting wire group 14 needs to pass through the first through hole 112 and the third through hole 121, a gap is bound to be left between the connecting wire group 14 and the first through hole 112 and the third through hole 121. The first colloid layer 13 is partially filled in the first through hole 112 and the third through hole 121 to improve the sealing and waterproof properties of the connection position with the connecting wire group 14.

[0028] In some embodiments, the photovoltaic junction box may further include a second colloid layer 16, which is cured and formed in the accommodating cavity 111 by means of glue injection. In some embodiments, an isolation layer is provided between the second colloid layer 16 and the electronic component 15 to prevent the second colloid layer 16 from having an adverse effect on the electronic component 15. The second colloid layer 16 may be made of a water-blocking sealant. The second colloid layer 16 may be injected with glue through the glue hole reserved on the inner shell 11, or may be injected with glue through the first through hole 112 on the inner shell 11.

[0029] In some embodiments, the outer circumferential surface of the outer shell 12 has a groove 122, and the bottom of the groove 122 is provided with the third through hole 121. The photovoltaic junction box may also include a third colloid layer 17, which is solidified and formed on the outer circumferential surface of the outer shell 12 by means of glue injection, and partially fills the groove 122; or partially fills the groove 122 and the third through hole 121. The third colloid layer 17 can seal and waterproof the connection position between the connecting wire group 14 and the third through hole 121. Preferably, the third colloid layer 17 can be solidified and formed by injecting glue into the groove 122. Since the groove 122 has a containing area compared to other places on the outer circumferential surface of the outer shell 12, it is easier to inject glue into the groove 122 than to inject glue into other places on the outer circumferential surface of the outer shell 12. The groove 122 is provided to facilitate glue injection on the one hand, and on the other hand, after the third colloid layer 17 partially fills the groove, the third colloid layer 17 is more firmly attached to the outer peripheral surface of the outer shell 12 to prevent the third colloid layer 17 from falling off.

[0030] In some embodiments, the first colloid layer 13 , the second colloid layer 16 , and the third colloid layer 17 are integrally formed.

[0031] In some embodiments, the first through hole 112 and the third through hole 121 are also used for glue passing during the glue injection process and are used as glue passing holes. For example, glue is injected on the outer peripheral surface of the outer shell 12, so that the colloid flows through the third through hole 121 to the space between the inner shell 11 and the outer shell 12, and then flows through the first through hole 112 to the accommodating cavity 111 in the inner shell 11. After curing, an integrally formed first colloid layer 13, second colloid layer 16 and third colloid layer 17 are obtained. This makes the overall structure of the photovoltaic junction box more compact and more waterproof. In some embodiments, the aperture of the first through hole is larger than that of the third through hole, so that the colloid can flow more easily from between the inner shell 11 and the outer shell 12 into the accommodating cavity in the inner shell 11; in some embodiments,

[0032] In some embodiments, the photovoltaic junction box may include one or more connecting wire groups 14, each connecting wire group 14 includes one or a group of connecting wires, and each connecting wire group 14 is used to connect the electronic components 15 in the accommodating cavity 111 to photovoltaic modules outside the photovoltaic junction box.

[0033] In some embodiments, at least one of the line segment group in the first colloid layer 13, the line segment group in the second colloid layer 16, and the line segment group in the third colloid layer 17 of the connecting line group 14 is in the shape of a spiral spring. Preferably, the connecting line group 14 is made of a hard material, which is convenient for being set in the shape of a spiral spring. When encountering external force damage, the spiral spring-shaped line segment provides a buffer to prevent the connecting line group from being damaged.

[0034] In some embodiments, the line segment group of the connecting line group 14 in the first through hole 112 and / or the line segment group in the third through hole 121 is in the shape of a spiral spring. In some embodiments, the hole wall of the first through hole 112 and / or the third through hole 121 is provided with a spiral groove adapted to the spiral spring-shaped line segment group, for installing and accommodating the spiral spring-shaped line segment group. In some embodiments, the spring hollow part of the spiral spring-shaped line segment group is used for glue during the glue injection process.

[0035] In some embodiments, at least one of the line segments of each connecting line in the connecting line group 14 in the first colloid layer 13, the line segments in the second colloid layer 16, and the line segments in the third colloid layer 17 has a rough outer surface, so that the connecting line group 14 is more firmly attached to the colloid layer and the connection is more waterproof.

[0036] In some embodiments, at least one of the inner shell 11 , the outer shell 12 , and the groove 122 has a rough inner surface, so that the colloid layer adheres more firmly.

[0037] In some embodiments, at least one of the first colloid layer 13, the second colloid layer 16, and the third colloid layer 17 is made of colloid and dopants. The colloid includes but is not limited to water-blocking sealant, and the water-blocking sealant includes but is not limited to butyl rubber, bromobutyl rubber, polyurethane glue, chlorobutyl rubber, epoxy resin glue, etc. The dopants include but are not limited to heat dissipation particles, anti-slip particles, etc.

[0038] The photovoltaic junction box provided in the embodiment of the present invention forms three layers of protection for electronic components through an inner shell, a first colloid layer, and an outer shell, and the first colloid layer is solidified and formed between the inner shell and the outer shell by means of glue injection, and a second through hole adapted to the connecting wire group is formed, and the first colloid layer forms a closed space between the inner shell and the outer shell, further strengthening the protection of the electronic components in the inner shell.

[0039] Embodiment 2:

[0040] The specific implementation of the present invention is further described in detail below in conjunction with the accompanying drawings and implementation examples. The present invention provides a method for manufacturing a photovoltaic junction box, which is used to manufacture the photovoltaic junction box in Example 1, with reference to Figure 2 , the manufacturing method of the photovoltaic junction box includes:

[0041] S101, manufacturing an inner shell and an outer shell, wherein the inner shell has a receiving cavity and a first through hole, and the outer shell has a third through hole;

[0042] S102, placing an electronic component in the accommodating cavity, assembling the inner shell and the outer shell, connecting one end of the connecting wire group to the electronic component, and sequentially passing the other end through the first through hole and the third through hole to extend outside the outer shell;

[0043] S103, injecting glue between the inner shell and the outer shell, and curing and molding to obtain a first glue layer, wherein the first glue layer has a second through hole adapted to the connecting wire group.

[0044] In some embodiments, the inner shell can be square, round, oval or irregular in shape; the inner shell can be made of plastic, metal or other materials; the inner shell can include a first shell body and a first cover body, the first shell body has a receiving cavity, or the first shell body and the first cover body are assembled to form a receiving cavity, or the first cover body has a receiving cavity, the first through hole can be arranged on the first shell body, or on the first cover body, or the first shell body and the first cover body are assembled to form a first through hole; the aperture of the first through hole depends on the cross-sectional diameter of the connecting wire group, preferably, it can be slightly larger than the cross-sectional diameter of the connecting wire group, the connecting wire group passes through the first through hole, and a gap is left between the connecting wire group and the first through hole. The electronic components are placed in the receiving cavity.

[0045] In some embodiments, the outer shell can be square, round, oval or irregular in shape; the shape can be adapted to the inner shell and nested outside the inner shell; the outer shell can be made of plastic, metal or other materials; the outer shell can include a second shell body and a second cover body, and the third through hole can be arranged on the second shell body, or on the second cover body, or the second shell body and the second cover body can be assembled together to form the third through hole; the aperture of the third through hole depends on the cross-sectional diameter of the connecting wire group, and preferably, it can be slightly larger than the cross-sectional diameter of the connecting wire group, and the connecting wire group passes through the third through hole, and a gap is left between the connecting wire group and the third through hole.

[0046] In some embodiments, the photovoltaic junction box may include one or more connecting wire groups, each connecting wire group includes one or a group of connecting wires, and each connecting wire group is used to connect the electronic components in the accommodating cavity to photovoltaic modules outside the photovoltaic junction box.

[0047] In step S102, assembling the inner shell and the outer shell includes nesting the outer shell outside the inner shell. In step S103, the glue can be injected with the help of the glue hole reserved on the outer shell, or with the help of the third through hole on the outer shell. The first colloid layer can enclose a closed space between the inner shell and the outer shell, and the second through hole adapted to the connecting wire group is formed during the injection of the first colloid layer. The second through hole fits tightly with the connecting wire group, realizing the wire passing while improving the sealing and waterproofness of the connection position with the connecting wire group.

[0048] In some embodiments, the first colloidal layer at least partially fills the first through hole and / or the third through hole. Since the connecting wire group needs to pass through the first through hole and the third through hole, a gap is bound to be left between the connecting wire group and the first through hole and the third through hole. Partially filling the first through hole and the third through hole with the first colloidal layer can improve the sealing and waterproofness of the connection position with the connecting wire group.

[0049] In some embodiments, step S101 may further include: making a groove on the outer peripheral surface of the outer shell, and a third through hole is arranged at the bottom of the groove; step S103 may further include: injecting glue on the outer peripheral surface of the outer shell, and curing and molding to obtain a third colloid layer, and the third colloid layer partially fills the groove, or partially fills the groove and the third through hole.

[0050] The photovoltaic junction box may also include a third colloid layer, which can seal and waterproof the connection position between the connecting wire group and the third through hole. Preferably, the third colloid layer can be solidified by injecting glue into the groove. Since the groove has a accommodating area compared to other places on the outer peripheral surface of the outer shell, it is easier to inject glue into the groove than to inject glue into other places on the outer peripheral surface of the outer shell. The provision of the groove is, on the one hand, convenient for glue injection, and on the other hand, after the third colloid layer partially fills the groove, the third colloid layer is more firmly attached to the outer peripheral surface of the outer shell, thereby preventing the third colloid layer from falling off.

[0051] In some embodiments, step S103 may further include injecting glue into the accommodating cavity of the inner shell and curing to obtain a second colloid layer. In some embodiments, step S101 may further include providing an isolation layer around the electronic component to prevent the second colloid layer from having an adverse effect on the electronic component.

[0052] The photovoltaic junction box may further include a second colloid layer and / or an isolation layer. The second colloid layer may be injected with glue by means of the glue holes reserved on the inner shell, or may be injected with glue by means of the first through holes on the inner shell.

[0053] In some embodiments, the first colloid layer, the second colloid layer, and the third colloid layer may be integrally formed.

[0054] In some embodiments, step S103 may include: injecting glue on the outer peripheral surface of the outer shell, allowing the glue to flow between the inner shell and the outer shell through the third through hole, and then flow to the accommodating cavity through the first through hole, and after curing, obtaining an integrally formed first glue layer, second glue layer and third glue layer.

[0055] Preferably, step S103 may include: injecting glue into the groove on the outer peripheral surface of the outer shell, so that the glue flows between the inner shell and the outer shell through the third through hole, and then flows to the accommodating cavity through the first through hole, and after curing, an integrally formed first glue layer, second glue layer and third glue layer are obtained.

[0056] The first through hole and the third through hole are also used for glue passing during the glue injection process and are used as glue passing holes.

[0057] In some embodiments, at least one of the line segments of each connecting line in the connecting line group in the first colloid layer, the line segments in the second colloid layer, and the line segments in the third colloid layer is in the shape of a spiral spring. Preferably, each connecting line in the connecting line group is made of a hard material, which is convenient for being set in the shape of a spiral spring. When encountering external force damage, the spiral spring-shaped line segment provides a buffer to prevent the connecting line group from being damaged.

[0058] In some embodiments, at least one of the line segments of each connecting line in the connecting line group in the first colloid layer, the line segments in the second colloid layer, and the line segments in the third colloid has a rough outer surface, so that the connecting line group is more firmly attached to the colloid layer and the connection is more waterproof.

[0059] In some embodiments, at least one of the inner shell, the outer shell, and the groove has a rough inner surface, so that the colloid layer adheres more firmly.

[0060] In some embodiments, at least one of the first colloid layer, the second colloid layer, and the third colloid layer is made of water-blocking sealant and dopants. The water-blocking sealant includes but is not limited to butyl rubber, bromobutyl rubber, polyurethane glue, chlorobutyl rubber, epoxy resin glue, etc. The dopants include but are not limited to heat dissipation particles, anti-slip particles, etc.

[0061] The manufacturing method of the photovoltaic junction box provided in the embodiment of the present invention forms three layers of protection for electronic components through an inner shell, a first colloid layer, and an outer shell, and the first colloid layer is solidified and formed between the inner shell and the outer shell by means of glue injection, and a second through hole adapted to the connecting wire group is formed, and the first colloid layer forms an enclosed space between the inner shell and the outer shell, further strengthening the protection of the electronic components in the inner shell.

[0062] The above contents are further detailed descriptions of the embodiments of the present invention in combination with specific implementation methods, and it cannot be determined that the specific implementation of the present invention is limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, several simple deductions or substitutions can be made without departing from the concept of the present invention, which should be regarded as falling within the protection scope of the present invention.

Claims

1. A photovoltaic junction box, characterized in that: It includes an inner shell, an outer shell, a first colloid layer and a connecting wire group, wherein: The inner shell has a receiving cavity, and the receiving cavity is used to place electronic components; The inner shell has a first through hole; The outer shell is nested outside the inner shell and has a third through hole; The first colloid layer is solidified and formed between the inner shell and the outer shell by means of glue injection, and forms a second through hole adapted to the connecting wire group; One end of the connecting wire group is connected to the electronic component, and the other end passes through the first through hole, the second through hole and the third through hole in sequence, and extends to the outside of the outer shell for connection with the photovoltaic module.

2. The photovoltaic junction box according to claim 1, characterized in that: The first colloid layer at least partially fills the first through hole and / or the third through hole.

3. The photovoltaic junction box according to claim 1, characterized in that: It also includes a second colloid layer, which is solidified and formed in the accommodating cavity by means of glue injection.

4. The photovoltaic junction box according to any one of claims 1 to 3, characterized in that: The outer peripheral surface of the outer shell has a groove, and the bottom of the groove is provided with the third through hole; It also includes a third colloid layer, which is solidified and formed on the outer peripheral surface of the outer shell by means of glue injection, and partially fills the groove; or partially fills the groove and the third through hole.

5. The photovoltaic junction box according to claim 4, characterized in that: The first colloid layer, the second colloid layer and the third colloid layer are integrally formed.

6. The photovoltaic junction box according to claim 5, characterized in that: The first through hole and the third through hole are also used for glue passing during the glue injection process.

7. A method for manufacturing a photovoltaic junction box, used for manufacturing the photovoltaic junction box according to any one of claims 1 to 6, the method for manufacturing the photovoltaic junction box comprising: S101, manufacturing an inner shell and an outer shell, wherein the inner shell has a receiving cavity and a first through hole, and the outer shell has a third through hole; S102, placing an electronic component in the accommodating cavity, assembling the inner shell and the outer shell, connecting one end of the connecting wire group to the electronic component, and sequentially passing the other end through the first through hole and the third through hole to extend outside the outer shell; S103 , injecting glue between the inner shell and the outer shell, and curing and molding to obtain a first glue layer, wherein the first glue layer has a second through hole adapted to the connecting wire group.

8. The method for manufacturing a photovoltaic junction box according to claim 7, characterized in that: The step S101 further includes: making a groove on the outer peripheral surface of the outer shell, and the bottom of the groove is provided with the third through hole; The step S103 further includes: injecting glue on the outer peripheral surface of the outer shell, and curing and molding to obtain a third glue layer, wherein the third glue layer partially fills the groove, or partially fills the groove and the third through hole.

9. The method for manufacturing a photovoltaic junction box according to claim 8, characterized in that: The step S103 further includes injecting glue into the accommodating cavity and curing and molding to obtain a second colloid layer.

10. The method for manufacturing a photovoltaic junction box according to claim 9, characterized in that: The step S103 includes: injecting glue on the outer peripheral surface of the outer shell, allowing the glue to flow through the third through hole to between the inner shell and the outer shell, and then flow through the first through hole to the accommodating cavity, and after curing, obtaining the first glue layer, the second glue layer and the third glue layer that are integrally formed.

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