A photovoltaic connector end based on copper-aluminum friction welding and gradient plating

Abstract

This invention discloses a photovoltaic connector terminal based on copper-aluminum friction welding and gradient plating, relating to the field of connector technology. It includes a male connector and a female connector. The male connector contains a copper-aluminum male terminal, and the female connector contains a copper-aluminum female terminal. The contact ends of the copper-aluminum male and female terminals are made of copper. A nut is installed at one end of both the male and female connectors. An overheat protection component is installed inside the nut. The overheat protection component includes: multiple sets of elastic clamping elements equidistantly distributed in a circumferential pattern within the nut; and a thermistoric plastic ring, which is annular and surrounds the outer side of the elastic clamping elements. When heated, the thermistoric plastic ring expands and can compress the elastic clamping elements. This invention automatically separates the male and female terminals at high temperatures, reducing the possibility of irreversible damage to the connector and photovoltaic lines due to overheating, reducing edge wear on the connecting wires, and extending the service life of the photovoltaic module.

Description

Technical Field

[0001] This invention relates to the field of connector technology, specifically to a photovoltaic connector end based on copper-aluminum friction welding and gradient plating. Background Technology

[0002] Photovoltaic connectors are used to connect photovoltaic (PV) modules, leading out the positive and negative terminals to transmit electrical energy. PV connectors use male and female connectors to connect the positive and negative terminals of the circuit, forming a cable path. The connectors themselves do not have heat dissipation capabilities. Especially since most photovoltaic equipment is currently outdoor, the connectors themselves are exposed to the elements along with the PV modules. In high-temperature weather, the external high temperature and cable temperature can easily cause overheating failure inside the connector, and may even cause damage to the entire circuitry of the PV module, affecting the lifespan of the equipment. Furthermore, the connecting wires pass directly through both ends of the connector, and the edges of the connector ends are prone to wear and tear on the connecting wires, making them more susceptible to breakage. This also affects the safe use of the PV circuitry and connectors. Especially in adverse outdoor weather conditions, rainwater and other substances adhering to the worn and broken connecting wires can also cause circuit failures. Summary of the Invention

[0003] The technical problem of this invention is to provide a photovoltaic connector end based on copper-aluminum friction welding and gradient plating, so as to enable automatic separation of male and female terminals at high temperatures, reduce the possibility of irreversible damage to the connector and photovoltaic lines due to overheating, reduce wear on the connecting wires at the edges, and improve the service life of photovoltaic modules.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a photovoltaic connector terminal based on copper-aluminum friction welding and gradient plating, comprising a male connector and a female connector, wherein a copper-aluminum male terminal is disposed within the male connector, and a copper-aluminum female terminal is disposed within the female connector. The contact ends of the copper-aluminum male terminal and the copper-aluminum female terminal are made of copper, and the tail end with a riveting wire is made of aluminum, and the two are joined together by friction welding. A nut is installed at one end of both the male connector and the female connector, and an overheat protection component is disposed within the nut. The overheat protection component includes:

[0005] The elastic clamping member is provided in multiple sets and is distributed equidistantly in a circumferential shape inside the nut. The elastic clamping member can surround and conform to the outside of the connecting wire. The lower end of the elastic clamping member is fixedly connected to the riveting end of the copper-aluminum male terminal and the copper-aluminum female terminal.

[0006] A thermosensitive plastic ring, which is circular and surrounds the outer side of the elastic clamping member, expands when heated and can compress the elastic clamping member, thereby driving the elastic clamping member to pull the copper-aluminum male terminal and the copper-aluminum female terminal towards the nut.

[0007] As a further embodiment of the present invention, each nut is fitted with a connecting seat, and the connecting seat has multiple sets of mounting slots on its inner side. The upper end of the elastic clamping member is rotatably connected to the mounting slot via a torsion spring. A transverse partition is fixedly installed at the middle position of the elastic clamping member. The portions of the elastic clamping member on the upper and lower sides of the transverse partition are inclined towards the middle position. A connecting block is fixedly installed at the lower end of each elastic clamping member. The connecting block is fixedly connected to the riveting ends of the copper-aluminum male terminal and the copper-aluminum female terminal.

[0008] As a further embodiment of the present invention, the male connector includes a nut, a plastic claw, a waterproof inner plug, a copper-aluminum male terminal, and a male plastic component. One end of the male plastic component is threadedly connected to the nut, the plastic claw can be engaged with the waterproof inner plug, the waterproof inner plug fills the nut, and the copper-aluminum male terminal is engaged with the male plastic component.

[0009] As a further embodiment of the present invention, the female connector includes a nut, a plastic claw, a waterproof inner plug, a copper-aluminum female terminal and a female plastic, the copper-aluminum female terminal being snapped into the female plastic, and the ends of the female plastic and the male plastic away from the nut being able to snap into each other, with an O-ring filling the contact surfaces between them.

[0010] As a further embodiment of the present invention, stainless steel claws are fixedly installed on the contact ends of both the copper-aluminum male terminal and the copper-aluminum female terminal. The stainless steel claws are welded to the contact ends, and an inner crown spring is provided inside the contact end of the copper-aluminum female terminal.

[0011] As a further embodiment of the present invention, the heat-sensitive plastic rings are respectively fixedly installed in the female plastic and male plastic, and the inner side of the elastic clamping member near the connecting seat is provided with an arc groove.

[0012] As a further embodiment of the present invention, the copper-aluminum male terminal and the copper-aluminum female terminal are provided with three plating layers, namely a 1.3 μm thinnest nickel base layer, a 5 μm thinnest copper layer in the middle, and a 5 μm thinnest bright tin layer on the surface.

[0013] As a further embodiment of the present invention, the riveting ends of both the copper-aluminum male terminal and the copper-aluminum female terminal are fixedly connected to the connecting wire, and the connecting wire passes through the elastic clamping members and leads out to the outside of the nut.

[0014] Compared with the prior art, the beneficial effects of the present invention are:

[0015] 1. In this invention, one end of the elastic clamping member is connected to the riveting end of the copper-aluminum female terminal and the copper-aluminum male terminal. The movement of the elastic clamping member can pull the copper-aluminum female terminal and the copper-aluminum male terminal to move. When the connector is at a high temperature, the thermally sensitive plastic ring expands due to heat and continuously squeezes the elastic clamping member. The squeezing can cause multiple sets of elastic clamping members to converge towards the center and squeeze in the direction of the nut, thereby causing multiple sets of elastic clamping members to change from an open state to a contracted state. Under the action of the squeezing force perpendicular to the direction of the nut, the copper-aluminum female terminal and the copper-aluminum male terminal are driven to move in the direction of the nut, thereby pulling the copper-aluminum female terminal and the copper-aluminum male terminal to separate in opposite directions, avoiding the possibility of irreversible damage to the photovoltaic line caused by the photovoltaic module continuing to work in a high-heat environment.

[0016] 2. In this invention, the connecting wire is surrounded and clamped by multiple sets of elastic clamping members. The elastic clamping members keep the connecting wire centered inside the nut, thereby reducing the contact between the connecting wire and the edge of the connector end, thus reducing the wear of the connecting wire by the connector edge, increasing the service life of the connecting wire, preventing the damaged connecting wire from being exposed outside the connector, and reducing the possibility of accidents caused by rainwater intrusion into the damaged connecting wire. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0019] Figure 2 This is a schematic diagram of the structure of the male connector terminal in this invention;

[0020] Figure 3 This is a schematic diagram of the female connector terminal in this invention;

[0021] Figure 4 This is an exploded view of the male and female connectors in this invention;

[0022] Figure 5 This is a schematic diagram of the structure of the copper-aluminum male terminal and the copper-aluminum female terminal in this invention;

[0023] Figure 6 This is a cross-sectional view of the structure of the present invention;

[0024] Figure 7 This is a schematic diagram of the elastic clamping component in this invention.

[0025] Attached Figures: 1. Nut; 2. Waterproof inner plug; 3. Copper-aluminum male terminal; 4. Male plastic; 5. O-ring; 6. Female plastic; 7. Copper-aluminum female terminal; 8. Plastic claw; 9. Stainless steel claw; 10. Male connector; 11. Female connector; 12. Elastic clamp; 13. Thermosensitive plastic ring; 14. Connecting seat; 15. Mounting groove; 16. Horizontal partition; 17. Connecting block; 18. Inner crown spring; 19. Arc groove. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] Please see Figures 1-7 This invention provides a technical solution: a photovoltaic connector end based on copper-aluminum friction welding and gradient plating, including a male connector 10 and a female connector 11. The male connector 10 contains a copper-aluminum male terminal 3, and the female connector 11 contains a copper-aluminum female terminal 7. The contact ends of the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7 are made of copper, and the tail end with a riveting wire is made of aluminum. The two are joined by friction welding. A nut 1 is installed at one end of both the male connector 10 and the female connector 11. An overheat protection component is provided inside the nut 1. The overheat protection component includes:

[0028] The elastic clamping member 12 is provided in multiple sets and is distributed equidistantly in a circumferential shape inside the nut 1. The elastic clamping member 12 can surround and conform to the outside of the connecting wire. The lower end of the elastic clamping member 12 is fixedly connected to the riveting end of the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7.

[0029] Thermosensitive plastic ring 13 is annular and surrounds the outer side of elastic clamp 12. When heated, the thermosensitive plastic ring 13 expands and can squeeze the elastic clamp 12, driving the elastic clamp 12 to pull the copper-aluminum male terminal 3 and copper-aluminum female terminal 7 to move towards the nut 1.

[0030] During operation, the positive and negative terminals of the circuit in this invention are connected to the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7 respectively via connecting wires. Specifically, the connecting wires pass through the nut 1 and connect to the rivet ends of the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7. When connecting the photovoltaic circuit, the male connector 10 and the female connector 11 are plugged in, allowing the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7 to interlock, thus forming a circuit for the photovoltaic module. In this invention, the connecting wires are surrounded and clamped by multiple sets of elastic clamping members 12. These elastic clamping members 12 keep the connecting wires centered inside the nut 1, thereby reducing contact between the connecting wires and the edge of the connector end, reducing wear on the connecting wires from the connector edge, increasing the service life of the connecting wires, and preventing damaged connecting wires from being exposed outside the connector, thus reducing the possibility of accidents caused by rainwater intrusion into damaged connecting wires. One end of the elastic clamp 12 is connected to the riveting end of the copper-aluminum female terminal 7 and the copper-aluminum male terminal 3. The movement of the elastic clamp 12 can pull the copper-aluminum female terminal 7 and the copper-aluminum male terminal 3 to move. When the connector is at a high temperature, the thermally sensitive plastic ring 13 will expand due to heat and continuously squeeze the elastic clamp 12. The squeezing can cause multiple sets of elastic clamps 12 to converge towards the center and squeeze in the direction of the nut 1, thereby causing multiple sets of elastic clamps 12 to change from an open state to a contracted state. Under the action of the squeezing force perpendicular to the direction of the nut 1, the copper-aluminum female terminal 7 and the copper-aluminum male terminal 3 are driven to move in the direction of the nut 1, thereby pulling the copper-aluminum female terminal 7 and the copper-aluminum male terminal 3 to separate in opposite directions, avoiding the possibility of irreversible damage to the photovoltaic line caused by the photovoltaic module continuing to work in a high-heat environment.

[0031] As a further embodiment of the present invention, each nut 1 is fitted with a connecting seat 14, and multiple sets of mounting grooves 15 are formed on the inner side of the connecting seat 14. The upper end of the elastic clamping member 12 is rotatably connected to the mounting groove 15 by a torsion spring. A transverse partition 16 is fixedly installed in the middle position of the elastic clamping member 12. The portions of the elastic clamping member 12 on the upper and lower sides of the transverse partition 16 are inclined towards the middle position. A connecting block 17 is fixedly installed in the lower end of each elastic clamping member 12. The connecting block 17 is fixedly connected to the riveting end of the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7.

[0032] During operation, the connecting seat 14 is snapped onto the top of the nut 1. Under normal conditions, the transverse partition 16 is snapped into the gap between the male plastic 4 / female plastic 5 and the waterproof inner plug 2. The elastic clamping member 12 provides outward tension, allowing the connecting seat 14 and the elastic clamping member 12 to be stably positioned inside the nut 1. When subjected to compression, the elastic clamping member 12 contracts towards the center, causing the transverse partition 16 to gradually detach from the gap between the male plastic 4 / female plastic 5 and the waterproof inner plug 2. Furthermore, the contraction of the elastic clamping member 12 allows it to be discharged from the end of the nut.

[0033] As a further embodiment of the present invention, the male connector 10 includes a nut 1, a plastic claw 8, a waterproof inner plug 2, a copper-aluminum male terminal 3, and a male plastic 4. One end of the male plastic 4 is threadedly connected to the nut 1, the plastic claw 8 can be engaged with the waterproof inner plug 2, the waterproof inner plug 2 is filled inside the nut 1, and the copper-aluminum male terminal 3 is engaged with the male plastic 4.

[0034] In operation, the male connector 10 of this invention is connected to the nut 1 by threads. The nut 1 is connected and fixed to the copper-aluminum male terminal 3 by the elastic snap-fit ​​member 12. This allows the user to connect the copper-aluminum male terminal 3 simultaneously when assembling the male connector 10 and the nut 1, simplifying the connector assembly process. At the same time, by binding the nut 1 and the copper-aluminum male terminal 3, the problem of the copper-aluminum male terminal 3 being small and easy to lose is reduced.

[0035] As a further embodiment of the present invention, the female connector 11 includes a nut 1, a plastic claw 8, a waterproof inner plug 2, a copper-aluminum female terminal 7, and a female plastic 6. The copper-aluminum female terminal 7 is snapped into the female plastic 6. The ends of the female plastic 6 and the male plastic 4 away from the nut 1 can be snapped into each other, and an O-ring 5 is filled between the snapping contact surfaces.

[0036] During operation, the female plastic 6 and male plastic 4 are more tightly connected by the O-ring 5, and the copper-aluminum female terminal 7 and copper-aluminum male terminal 3 are installed in the same way.

[0037] As a further embodiment of the present invention, stainless steel claws 9 are fixedly installed on the contact ends of both the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7. The stainless steel claws 9 are welded to the contact ends, and an inner crown spring 18 is provided inside the contact end of the copper-aluminum female terminal 7.

[0038] During operation, the stainless steel claw 9 restricts the rotation of the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7 after installation, ensuring the stability of the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7 after insertion. The inner crown spring 18 also makes the connection between the two ends tighter.

[0039] As a further embodiment of the present invention, the heat-sensitive plastic ring 13 is fixedly installed in the female plastic 6 and the male plastic 4 respectively, and the inner side of the elastic clamping member 12 near the connecting seat 14 is provided with an arc groove 19.

[0040] During operation, the circular arc groove 19 of this invention fits against the surface of the connecting wire, reducing wear on the contact surface between the connector and the connecting wire.

[0041] As a further embodiment of the present invention, the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7 are provided with three plating layers, namely a 1.3 μm thinnest nickel base layer, a 5 μm thinnest copper layer in the middle, and a 5 μm thinnest bright tin layer on the surface.

[0042] During operation, this invention uses a three-layer coating to achieve a higher salt spray test level of over 96 hours.

[0043] As a further embodiment of the present invention, the riveting ends of both the copper-aluminum male terminal 3 and the copper-aluminum female terminal 7 are fixedly connected to the connecting wires, and the connecting wires pass through the elastic clamping members 12 and are led out to the outside of the nut 1.

[0044] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A photovoltaic connector terminal based on copper-aluminum friction welding and gradient plating, comprising a male connector (10) and a female connector (11), characterized in that: The male connector (10) is provided with a copper-aluminum male terminal (3), and the female connector (11) is provided with a copper-aluminum female terminal (7). The contact ends of the copper-aluminum male terminal (3) and the copper-aluminum female terminal (7) are made of copper, and the tail end of the riveting wire is made of aluminum. The two are joined together by friction welding. A nut (1) is installed at one end of both the male connector (10) and the female connector (11). An overheat protection component is provided inside the nut (1). The overheat protection component includes: Elastic clamping member (12), the elastic clamping member (12) is provided in multiple sets and is distributed equidistantly in a circumferential shape inside the nut (1), the elastic clamping member (12) can surround and conform to the outside of the connecting wire, and the lower end of the elastic clamping member (12) is fixedly connected to the riveting end of the copper-aluminum male terminal (3) and the copper-aluminum female terminal (7). Thermosensitive plastic ring (13) is annular and surrounds the outer side of the elastic clamp (12). When the thermosensitive plastic ring (13) is heated and expands, it can squeeze the elastic clamp (12) and drive the elastic clamp (12) to pull the copper-aluminum male terminal (3) and copper-aluminum female terminal (7) to move towards the nut (1). The copper-aluminum male terminal (3) and copper-aluminum female terminal (7) are provided with three plating layers, namely a nickel base layer, a copper layer in the middle, and a bright tin layer on the final surface.

2. A photovoltaic connector terminal based on copper-aluminum friction welding and gradient plating according to claim 1, characterized in that: Each nut (1) is fitted with a connecting seat (14). Multiple sets of mounting slots (15) are opened on the inner side of the connecting seat (14). The upper end of the elastic clamping member (12) is rotatably connected to the mounting slot (15) by a torsion spring. A horizontal partition (16) is fixedly installed in the middle position of the elastic clamping member (12). The parts of the elastic clamping member (12) on the upper and lower sides of the horizontal partition (16) are inclined towards the middle position. A connecting block (17) is fixedly installed at the lower end of the elastic clamping member (12). The connecting block (17) is fixedly connected to the riveting end of the copper-aluminum male terminal (3) and the copper-aluminum female terminal (7).

3. A photovoltaic connector terminal based on copper-aluminum friction welding and gradient plating according to claim 2, characterized in that: The male connector (10) includes a nut (1), a plastic claw (8), a waterproof inner plug (2), a copper-aluminum male terminal (3), and a male plastic (4). One end of the male plastic (4) is threadedly connected to the nut (1). The plastic claw (8) can be engaged with the waterproof inner plug (2). The waterproof inner plug (2) fills the nut (1). The copper-aluminum male terminal (3) is engaged with the male plastic (4).

4. A photovoltaic connector terminal based on copper-aluminum friction welding and gradient plating according to claim 2, characterized in that: The female connector (11) includes a nut (1), a plastic claw (8), a waterproof inner plug (2), a copper-aluminum female terminal (7) and a female plastic (6). The copper-aluminum female terminal (7) is snapped into the female plastic (6). The ends of the female plastic (6) and the male plastic (4) away from the nut (1) can snap into each other, and an O-ring (5) is filled between the snapping contact surfaces.

5. A photovoltaic connector terminal based on copper-aluminum friction welding and gradient plating according to claim 4, characterized in that: Stainless steel claws (9) are fixedly installed on the contact ends of the copper-aluminum male terminal (3) and the copper-aluminum female terminal (7). The stainless steel claws (9) are welded to the contact ends. An inner crown spring (18) is provided inside the contact end of the copper-aluminum female terminal (7).

6. A photovoltaic connector terminal based on copper-aluminum friction welding and gradient plating according to claim 5, characterized in that: The heat-sensitive plastic ring (13) is fixedly installed in the female plastic (6) and male plastic (4) respectively, and the elastic clamping member (12) has an arc groove (19) on the inner side of the end near the connecting seat (14).

7. A photovoltaic connector terminal based on copper-aluminum friction welding and gradient plating according to claim 4, characterized in that: The rivet ends of the copper-aluminum male terminal (3) and the copper-aluminum female terminal (7) are fixedly connected to the connecting wires, which pass through the elastic clamps (12) and lead out to the outside of the nut (1).

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