Ultra-miniature direct-current connector for photovoltaic system

Abstract

The invention provides an ultra-miniature direct-current connector for a photovoltaic system. The ultra-miniature direct-current connector comprises a male plug and a female plug which are connected in a matched mode. The male plug comprises a positive electrode plastic shell, a positive electrode integrated terminal, a positive electrode plug and a positive electrode nut. The female plug comprises a negative electrode plastic shell, a negative electrode sealing ring, a negative electrode drum spring, a negative electrode integrated terminal, a negative electrode plug and a negative electrode nut. Nut retaining mechanisms are arranged between the nuts and the plastic shell. A terminal retaining mechanism is arranged between each integrated terminal and the plastic shell; a plastic shell retaining mechanism is arranged between the positive pole plastic shell and the negative pole plastic shell; in a plugging state, the length of the photovoltaic ultra-miniature direct current connector does not exceed 100mm, and the diameter of the photovoltaic ultra-miniature direct current connector does not exceed 15mm. The connector is small in size, light in weight, suitable for installation in various application scenes, capable of meeting various installation modes such as suspension and the like, high in connection reliability, safety and sealing performance, capable of reducing the production cost and capable of improving the assembly efficiency and the assembly quality.

Description

Technical Field

[0001] The present invention relates to the field of application equipment for distributed photovoltaic systems, and particularly to a super-miniature DC connector for a photovoltaic system. Background Art

[0002] Currently, the commonly used photovoltaic connectors in the market are mostly used in photovoltaic power stations, with complex structures, large volumes and weights. However, in some cases where the installation space is small, such as the application scenario of rooftop photovoltaics, the commonly sized DC connectors cannot meet the installation requirements. The main problems are as follows: 1. The number of connectors that can be placed in a limited installation space is limited, unable to meet the photovoltaic cable connection requirements, and the commonly sized connectors are not convenient to change angles in a narrow space, greatly increasing the cable laying and installation difficulties; 2. The existing connectors are relatively heavy, which is not conducive to suspension installation. Prolonged suspension is likely to cause cable deformation, cracking, and loosening at the connection due to the pulling force of its own gravity; 3. The existing connectors have large structural volumes and use more production materials, resulting in high production costs; 4. The existing connectors have complex structures and are prone to injection molding stress, leading to potential safety hazards; 5. The existing connectors have complex installation processes and low efficiency, and are prone to situations such as missing installation and incorrect assembly positions, resulting in poor reliability of the connectors during use. Therefore, a super-miniature DC connector for photovoltaics is needed to meet the usage requirements of multiple application scenarios, and while reducing the size, effectively improve the safety and reliability of the connector. Summary of the Invention

[0003] The present invention aims to solve the problems that the existing photovoltaic connectors are large in size and weight, cannot meet the installation requirements such as small spaces and suspension installations, have a narrow application range, and poor safety and reliability, and proposes a super-miniature DC connector for a photovoltaic system.

[0004] To achieve the above object, the present invention adopts the following technical solutions: A super-miniature DC connector for a photovoltaic system, comprising a male plug and a female plug that are cooperatively connected; The male plug includes a positive plastic shell, a positive integrated terminal, a positive plug, and a positive nut; the positive integrated terminal is installed inside the positive plastic shell, the positive plug is installed inside the positive nut, the positive nut is connected to the tail end of the positive plastic shell, a positive cable passes through the positive nut and the positive plug and is connected to the tail end of the positive integrated terminal. When the positive nut is tightened, the positive plug is forced to squeeze and seal and grip the positive cable; The female plug includes a negative plastic shell, a negative sealing ring, a negative drum spring, a negative integrated terminal, a negative plug, and a negative nut; the negative sealing ring is installed at the head end of the negative plastic shell, the negative integrated terminal is installed inside the negative plastic shell, the negative drum spring is installed inside the negative integrated terminal, the negative nut is connected to the tail end of the negative plastic shell, the negative cable passes through the negative nut and the negative plug and is connected to the tail end of the negative integrated terminal, and when the negative nut is tightened, the negative plug is squeezed and sealed by force and grasps the negative cable; A nut stop mechanism is provided between the positive electrode nut and the positive electrode plastic shell, and between the negative electrode nut and the negative electrode plastic shell; a terminal stop mechanism is provided between the positive electrode integrated terminal and the positive electrode plastic shell, and between the negative electrode integrated terminal and the negative electrode plastic shell; a plastic shell stop mechanism is provided between the positive electrode plastic shell and the negative electrode plastic shell; When the male plug is plugged into the female plug, the head end of the positive plastic shell and the head end of the negative plastic shell are plugged and locked with each other, the positive integrated terminal is inserted into the interior of the negative integrated terminal and the drum spring is tightly clamped around the positive integrated terminal, the male plug and the female plug are sealed and connected by the negative sealing ring, and the length of the photovoltaic ultra-micro DC connector in the plugged state does not exceed 100 mm and the diameter does not exceed 15 mm.

[0005] Preferably, the specific structure of the nut anti-retraction mechanism is: a anti-retraction spring piece is arranged at the tail end of the positive plastic shell, and a nut inner groove is arranged correspondingly on the inner side of the positive nut; when the positive nut is screwed at the tail end of the positive plastic shell, the anti-retraction spring piece is in an extruded state; when the positive nut is screwed to a locking position, the anti-retraction spring piece falls into the nut inner groove and bounces up to lock; the nut anti-retraction mechanism structure between the negative nut and the negative plastic shell is the same.

[0006] Preferably, the specific structure of the terminal retaining mechanism is: a terminal step groove is provided on the positive integrated terminal, a clamping ring is fixedly installed in the terminal step groove, and the periphery of the clamping ring is provided with elastic fins that are extended and tilted outward, and the interior of the positive plastic shell is correspondingly provided with a plastic shell inner slot, and when the positive integrated terminal is pushed into the positive plastic shell for installation, the elastic fins around the clamping ring are in an extruded state until the elastic fins of the clamping ring reach the plastic shell inner slot and open and clamp; the structure of the terminal retaining mechanism between the negative integrated terminal and the negative plastic shell is the same.

[0007] Preferably, the clamping ring is pre-installed on the positive integrated terminal and is an integrated structure.

[0008] Preferably, the specific structure of the plastic shell anti-retreat mechanism is as follows: a slot is provided at the head end of the positive plastic shell, and a snap wing is provided at the head end of the negative plastic shell. Before assembly, the snap wings are open. When the positive plastic shell and the negative plastic shell are inserted and assembled, the snap wings are retracted and inserted into the slot until they are locked in position and then opened and locked.

[0009] Preferably, the slot and the snap wings are designed with hollow-out.

[0010] Preferably, the overall structure of the positive plastic shell and the negative plastic shell except for the elastic piece anti-retreat snap is cylindrical with a uniform wall thickness.

[0011] Preferably, both the positive plastic shell and the negative plastic shell are provided with gripping positions, and the gripping positions are concave-convex stripes.

[0012] Preferably, both the positive nut and the negative nut are provided with partial wrench threads at the tail end.

[0013] Preferably, the shape of the positive plug head matches the internal structure of the positive nut, and the shape of the negative plug head matches the internal structure of the negative nut.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: a small-sized ultra-miniature DC connector is designed, which is small in size and light in weight, can be widely applied to various installation scenarios, is not limited by narrow installation spaces and is beneficial to various installation methods such as suspension installation, effectively avoiding problems such as the cable being stretched or even broken and loosened due to the pulling of its own gravity on the cable, and elastic piece anti-retreat snap structures are provided between the plastic shell and the nut, between the connection terminal and the plastic shell, and between the positive plastic shell and the negative plastic shell, avoiding the problem of unreliable assembly and connection of the ultra-miniature DC connector due to its small size. Description of the Drawings

[0015] Figure 1 is a schematic diagram of the overall structure of an assembled ultra-miniature DC connector for a photovoltaic system; Figure 2 is a schematic diagram of the A-A cross-section of an ultra-miniature DC connector for a photovoltaic system; Figure 3 is a schematic diagram of the structure of the male plug; Figure 4 is an exploded view of the male plug; Figure 5 is a schematic diagram of the structure of the female plug; Figure 6 is an exploded view of the female plug; Figure 7 is an exploded view of the integrated terminal; Figure 8 is a schematic diagram of the structure of the threaded anti-retreat mechanism.

[0016] Among them, there are male plug 1 and female plug 2; positive plastic shell 11, positive integral terminal 12, positive plug 13, positive nut 14; negative plastic shell 21, negative sealing ring 22, negative drum spring 23, negative integral terminal 24, negative plug 15, negative nut 26; anti-backlash spring piece 311, inner card slot 312 of the nut; snap ring 321, elastic fin 322, terminal step groove 323, inner card slot 324 of the plastic shell; buckle wing 331, slot 332; gripping position 4, partial wrench thread 5. Specific embodiments

[0017] To further understand the purpose, structure, features, and functions of the present invention, the following is a detailed description in conjunction with embodiments.

[0018] Please refer to Figures 1-8 , the present invention provides a super-miniature DC connector for a photovoltaic system, including a male plug 1 and a female plug 2 that are cooperatively connected; As Figure 3 and Figure 4 shown, the male plug 1 includes a positive plastic shell 11, a positive integral terminal 12, a positive plug 13, and a positive nut 14; the positive integral terminal 12 is installed inside the positive plastic shell 11, the positive plug 13 is installed inside the positive nut 14, the positive nut 14 is connected to the tail end of the positive plastic shell 11, the positive cable passes through the positive nut 14 and the positive plug 13 and is connected to the tail end of the positive integral terminal 12. When the positive nut 14 is tightened, the positive plug 13 is forced to squeeze and grip the positive cable; As Figure 5 and Figure 6 shown, the female plug 2 includes a negative plastic shell 21, a negative sealing ring 22, a negative drum spring 23, a negative integral terminal 24, a negative plug 25, and a negative nut 26; the negative sealing ring 22 is installed at the front end of the negative plastic shell 21, the negative integral terminal 24 is installed inside the negative plastic shell 21, the negative drum spring 23 is installed inside the negative integral terminal 24, the negative nut 26 is connected to the tail end of the negative plastic shell 21, the negative cable passes through the negative nut 26 and the negative plug 25 and is connected to the tail end of the negative integral terminal 24. When the negative nut 26 is tightened, the negative plug 25 is forced to squeeze and grip the negative cable; As Figures 1-8 shown, there are nut anti-backlash mechanisms between the positive nut 14 and the positive plastic shell 11, and between the negative nut 26 and the negative plastic shell 21; there are terminal anti-backlash mechanisms between the positive integral terminal 12 and the positive plastic shell 11, and between the negative integral terminal 24 and the negative plastic shell 21; there is a plastic shell anti-backlash mechanism between the positive plastic shell 11 and the negative plastic shell 21; When the male plug 1 is plugged into the female plug 2, the head end of the positive plastic shell 11 and the head end of the negative plastic shell 21 are plugged and locked with each other, the positive integrated terminal 12 is inserted into the interior of the negative integrated terminal 24 and the drum spring is tightly clamped around the positive integrated terminal 12, and the male plug 1 and the female plug 2 are sealed and connected by the negative sealing ring 22. In the plugged state, the length of the photovoltaic ultra-micro DC connector does not exceed 100 mm and the diameter does not exceed 15 mm.

[0019] The conventional photovoltaic DC connector has a length of 120 mm and a diameter of 19 mm, while the length of the DC connector in the present invention does not exceed 100 mm, specifically 97 mm, and the diameter does not exceed 15 mm, specifically 12.3 mm; after the size is reduced, it can be applied and installed in some narrow areas, such as rooftop photovoltaic installation environments. More connectors can be placed in the same installation space, and the connector can be installed in a variety of ways in the installation space. For example, because of its smaller size and lighter weight, it can effectively avoid problems such as cable stretching or even breakage and loosening caused by its own gravity when suspended during installation.

[0020] Since the overall size of the DC connector is reduced, it is more likely to have problems such as unreliable connection during assembly and it is easy to separate under external force. The photovoltaic ultra-micro DC connector of the present invention has a simpler structure and assembly, and spring-type retaining buckle structures are provided between the plastic shell and the nut, the connecting terminal and the plastic shell, and the positive plastic shell 11 and the negative plastic shell 21. The above structures are structures that can directly affect the reliability and electrical connection effect of the DC connector and are easy to loosen. Conventional-sized connectors are locked by plugging, unplugging, screwing, etc., or a locking structure is provided at a certain location separately. The present invention provides spring-type retaining buckle structures at the above three locations, which can have an effective locking effect and avoid problems such as poor connection reliability caused by improper assembly of small-sized connectors.

[0021] Due to the overall reduction in size and weight of the DC connector, the size and thickness of the positive plastic shell 11 and the negative plastic shell 21 are reduced accordingly. When the size of the photovoltaic cable remains unchanged, the cable passes through the positive plastic shell 11 and the negative plastic shell 21, which makes it easier for the cable to rotate and cause deformation and cracking of the connection between the plastic shell and the nut. The photovoltaic ultra-micro DC connector of the present invention is provided with a plug in the nut. The plug can be made of silicone or rubber. It is assembled with a wire to ensure that the plug does not deform and ensure concentricity, thereby reducing the impact of the cable swing on the nut and the plastic shell, and improving the reliability of the DC connector. In addition, the presence of the positive plug 13, the negative plug 25, and the negative sealing ring 22 facilitates assembly and can effectively ensure the airtightness of the connector.

[0022] In one embodiment, if Figure 8As shown, the specific structure of the nut back-stop mechanism is as follows: a back-stop spring piece 311 is provided at the tail end of the positive plastic shell 11, and a nut inner slot 312 is correspondingly provided on the inner side of the positive nut 14. When the positive nut 14 is screwed at the tail end of the positive plastic shell 11, the back-stop spring piece 311 is in an extruded state. When the positive nut 14 is screwed to the locking position, the back-stop spring piece 311 falls into the nut inner slot 312 and pops up to be fixed. The structure of the nut back-stop mechanism between the negative plastic shell 21 and the negative nut 26 is the same. The back-stop spring piece 311 and the slot are matched to prevent the nut from backing out between the nut and the plastic shell. The operation method is simple and the installation is convenient. It can effectively avoid the problem of insufficient or excessive screwing between the nut and the tail end of the plastic shell, avoid the nut from backing out, and improve the connection reliability between the nut and the plastic shell.

[0023] In one embodiment, if Figure 2 , Figure 4 , Figure 6 , Figure 7 As shown, the specific structure of the terminal retaining mechanism is: a terminal step groove 323 is provided on the positive integrated terminal 12, a clamping ring 321 is fixedly installed in the terminal step groove 323, and the periphery of the clamping ring 321 is provided with an outwardly extended and tilted elastic fin 322, and the interior of the positive plastic shell 11 is correspondingly provided with a plastic shell inner clamping groove 324. When the positive integrated terminal 12 is pushed into the positive plastic shell 11 for installation, the elastic fins 322 around the clamping ring 321 are in an extruded state until the elastic fins 322 of the clamping ring 321 reach the plastic shell inner clamping groove 324 and open and clamp; the structure of the terminal retaining mechanism between the negative integrated terminal 24 and the negative plastic shell 21 is the same. The one-piece terminal is provided with a clamping ring 321. When assembling the one-piece terminal, the fins on the clamping ring 321 are against the inside of the plastic shell in a retracted state until the fins reach the step structure or the slot structure inside the plastic shell and open. The worker senses the bouncing sound of the fins opening, which indicates that the one-piece terminal is fixed in place in the plastic shell. The installation is simple and convenient, the fixing effect is good, and the reliability is high.

[0024] Furthermore, the clamp ring 321 is pre-installed on the positive integrated terminal 12 and is an integrated structure, which is convenient for assembly and avoids missing installation, inadequate assembly position, etc. The elastic fin 322 of the clamp ring 321 is provided with a reinforcing rib at the root, which effectively prevents the elastic fin 322 from breaking or deforming during the assembly process and losing the elastic clamping effect.

[0025] In a preferred embodiment, Figure 1 , Figure 4 and Figure 6As shown in the figure, the specific structure of the plastic shell anti-retreat mechanism is as follows: a slot 332 is provided at the front end of the positive plastic shell 11, and a buckle wing 331 is provided at the front end of the negative plastic shell 21. Before assembly, the buckle wing 331 is open. When the positive plastic shell 11 and the negative plastic shell 21 are inserted and assembled, the buckle wing 331 retracts and inserts into the slot 332 until it reaches the locked position and then opens and locks. The positive plastic shell 11 and the negative plastic shell 21 are inserted and locked with each other, which is convenient for assembly and has a firm connection.

[0026] Furthermore, the slot 332 and the buckle wing 331 are designed with hollow structures, which can reduce the overall weight of the connector, reduce the use of materials, and lower the production cost.

[0027] In one embodiment, the overall structures of the positive plastic shell 11 and the negative plastic shell 21 except for the elastic piece anti-retreat buckle are cylindrical and have a uniform wall thickness. The structure of the connector is complex and the wall thickness is uneven, which is likely to cause shrinkage on the product surface and generate injection molding stress, posing a relatively large safety hazard. However, the connector of the present invention is designed into a simple cylindrical structure, which reduces the production difficulty and has a uniform wall thickness, further improving the product safety.

[0028] In one embodiment, both the positive plastic shell 11 and the negative plastic shell 21 are provided with gripping positions 4. The gripping positions 4 are concave-convex stripes. When assembling the male plug 1 and the female plug 2, the assembly worker can hold on the gripping positions 4 for quick installation. The gripping positions 4 also play a role in positioning to a certain extent. By holding the gripping positions 4 of the positive plastic shell 11 and the negative plastic shell 21 with both hands respectively, the male plug 1 and the female plug 2 can be quickly aligned and connected, improving the assembly efficiency.

[0029] In one embodiment, both the positive nut 14 and the negative nut 26 are provided with local wrench threads 5 at the tail end, retaining their beneficial effects for nut screwing, while simplifying the design, reducing the production cost, reducing the injection molding stress, and improving the safety performance.

[0030] In one embodiment, the shape of the positive plug 13 matches the internal structure of the positive nut 14, and the shape of the negative plug 25 matches the internal structure of the negative nut 26. When the nut is screwed and installed inside the tail end of the plastic shell and the elastic piece anti-retreat buckle is locked, it effectively ensures the airtightness between the male plug 1 and the cable, or between the female plug 2 and the cable. Moreover, the silicone plug or rubber plug has a certain elastic deformation ability, which can play a good buffering and straightening effect when the cable is stressed and swings, improving the reliability of the connection between the connector and the cable.

[0031] In summary, the ultra-miniature DC connector for photovoltaic use of the present invention is small in volume and light in weight. After the structure is simplified, it can be applied to more installation scenarios and installation methods. In specific installation scenarios, such as narrow environments, it is more convenient to install, has better reliability, higher safety, and better waterproof and airtight performance.

[0032] The present invention has been described by the above related embodiments. However, the above embodiments are only examples for implementing the present invention. It must be pointed out that the disclosed embodiments do not limit the scope of the present invention. On the contrary, modifications and refinements made without departing from the spirit and scope of the present invention fall within the scope of patent protection of the present invention.

Claims

1. A super-miniature DC connector for a photovoltaic system, Characterized in that, It includes a male plug and a female plug that are cooperatively connected; The male plug includes a positive plastic shell, a positive integral terminal, a positive plug, and a positive nut; the positive integral terminal is installed inside the positive plastic shell, the positive plug is installed inside the positive nut, the positive nut is connected to the tail end of the positive plastic shell, and the positive cable passes through the positive nut and the positive plug and is connected to the tail end of the positive integral terminal. When the positive nut is tightened, the positive plug is forced to squeeze and seal and grip the positive cable; The female plug includes a negative plastic shell, a negative sealing ring, a negative drum spring, a negative integral terminal, a negative plug, and a negative nut; the negative sealing ring is installed at the head end of the negative plastic shell, the negative integral terminal is installed inside the negative plastic shell, the negative drum spring is installed inside the negative integral terminal, the negative nut is connected to the tail end of the negative plastic shell, and the negative cable passes through the negative nut and the negative plug and is connected to the tail end of the negative integral terminal. When the negative nut is tightened, the negative plug is forced to squeeze and seal and grip the negative cable; There is a nut anti-loosening mechanism between the positive nut and the positive plastic shell, and between the negative nut and the negative plastic shell; there is a terminal anti-loosening mechanism between the positive integral terminal and the positive plastic shell, and between the negative integral terminal and the negative plastic shell; there is a plastic shell anti-loosening mechanism between the positive plastic shell and the negative plastic shell; When the male plug and the female plug are inserted, the head end of the positive plastic shell and the head end of the negative plastic shell are inserted and locked with each other, the positive integral terminal is inserted into the negative integral terminal, and the drum spring is tightly sleeved around the positive integral terminal. The male plug and the female plug are sealed and connected through the negative sealing ring. In the inserted state, the length of the super-miniature DC connector for photovoltaic use does not exceed 100 mm, and the diameter does not exceed 15 mm.

2. The super-miniature DC connector for photovoltaic use according to claim 1, Characterized in that, The specific structure of the nut anti-loosening mechanism is: a anti-loosening elastic piece is arranged at the tail end of the positive plastic shell, and a nut inner card slot is correspondingly arranged on the inner side of the positive nut. When the positive nut is screwed at the tail end of the positive plastic shell, the anti-loosening elastic piece is in a squeezed state. When the positive nut is screwed to the locking position, the anti-loosening elastic piece falls into the nut inner card slot and bounces up and is fixed; the nut anti-loosening mechanism between the negative nut and the negative plastic shell has the same structure.

3. The super-miniature DC connector for photovoltaic use according to claim 1, Characterized in that, The specific structure of the terminal retaining mechanism is as follows: a terminal step groove is provided on the positive integrated terminal, a clamping ring is fixedly installed in the terminal step groove, and the periphery of the clamping ring is provided with elastic fins that are extended and tilted outward, and the interior of the positive plastic shell is correspondingly provided with a plastic shell internal clamping groove. When the positive integrated terminal is pushed into the positive plastic shell for installation, the elastic fins around the clamping ring are in an extruded state until the elastic fins of the clamping ring reach the plastic shell internal clamping groove and open and clamp; the structure of the terminal retaining mechanism between the negative integrated terminal and the negative plastic shell is the same.

4. The photovoltaic ultra-micro DC connector according to claim 3, It is characterized in that The clamping ring is pre-installed on the positive integrated terminal and is an integrated structure.

5. The photovoltaic ultra-micro DC connector according to claim 1, It is characterized in that The specific structure of the plastic shell anti-retraction mechanism is: the front end of the positive plastic shell is provided with a slot, and the front end of the negative plastic shell is provided with snap wings. The snap wings are opened before assembly, and when the positive plastic shell and the negative plastic shell are plugged in and out, the snap wings are retracted and inserted into the slot until they are in the locked position and then opened and locked.

6. The photovoltaic ultra-micro DC connector according to claim 5, It is characterized in that The slot and the buckle wings are hollow designs.

7. The photovoltaic ultra-micro DC connector according to claim 1, It is characterized in that The overall structure of the positive electrode plastic shell and the negative electrode plastic shell, except for the spring retaining buckle, is cylindrical and has uniform wall thickness.

8. The photovoltaic ultra-micro DC connector according to claim 1, It is characterized in that The positive electrode plastic shell and the negative electrode plastic shell are both provided with gripping positions, and the gripping positions are concave-convex stripes.

9. The photovoltaic ultra-micro DC connector according to claim 1, Features: The positive electrode nut and the negative electrode nut are both provided with partial wrench threads at the tail ends.

10. The photovoltaic ultra-micro DC connector according to claim 1, Features: The shape of the positive electrode plug matches the internal structure of the positive electrode nut, and the shape of the negative electrode plug matches the internal structure of the negative electrode nut.

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