Optical storage inverter cabinet connected by soft copper bars and soft copper bar processing method thereof

Abstract

The invention relates to the technical field of optical storage inverter cabinet installation, and particularly discloses an optical storage inverter cabinet connected with soft copper bars, which comprises a cabinet, a plurality of DCDC modules are connected onto the cabinet in a plugging manner, male heads for electrical connection are arranged on the DCDC modules, female heads matched with the male heads are arranged on the cabinet, and the soft copper bars are arranged on the cabinet. The male head is connected with the female head, and one end, far away from the male head, of the female head penetrates through the cabinet and extends outwards to be connected with a photovoltaic switch; each DCDC module is provided with a PCB (Printed Circuit Board), and the PCB is connected with the male head through a special-shaped thin copper bar; through the above connection mode, the risk of damaging the PCBA circuit board in the DCDC module is reduced, the occupied space in the cabinet is reduced, and the problem of poor heat dissipation is reduced or reduced; the invention further provides a processing method of the soft copper bar, and the processing method of the soft copper bar is suitable for the cabinet.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic storage inverter installation, and in particular to a photovoltaic storage inverter cabinet connected with a soft copper busbar and a processing method of the soft copper busbar. Background Art

[0002] DCDC modules are commonly used in commercial and industrial hybrid inverter cabinets. They feature a withdrawable, front-accessible design and are installed into the cabinet via guide rails. The male copper posts of the DCDC module mate with the female copper posts of the cabinet, establishing electrical continuity. In older cabinets, the electrical connections to the female posts at the rear are made with cables, and the cabinet contains 20 relatively thick cables. However, the use of a large number of thick cables in this structural design increases material costs, especially in large-scale production, where cost pressure increases significantly. In addition, 20 thick cables take up a large amount of space inside the cabinet, which may make it difficult to install other components or cause poor heat dissipation.

[0003] Therefore, there is an urgent need for a photovoltaic storage inverter cabinet connected with a soft copper busbar and a soft copper busbar processing method thereof to solve the above problems. Summary of the Invention

[0004] The main purpose of this application is to provide a photovoltaic storage inverter cabinet connected with a soft copper busbar, aiming to solve the problems of the existing photovoltaic storage inverter cabinet using cable connection, which has high costs and messy cable wiring in the cabinet.

[0005] To achieve the above objectives, the present application provides a photovoltaic storage inverter cabinet connected with a flexible copper busbar, comprising a cabinet, wherein a plurality of DC / DC modules are pluggably connected to the cabinet, wherein a plurality of the DC / DC modules are provided with male connectors for electrical connection, and a female connector is provided on the cabinet that is compatible with the male connector, wherein the male connector is connected to the female connector, and an end of the female connector away from the male connector extends outward through the cabinet and is connected to a photovoltaic switch; Each of the DCDC modules is provided with a PCB board, and the PCB board is connected to the male connector via a special-shaped thin copper busbar.

[0006] As a preferred solution of the present application, the special-shaped thin copper busbar is formed by stacking 5 layers of special-shaped thin copper sheets, and the thickness of each layer of the special-shaped thin copper sheets is 0.5 mm.

[0007] As a preferred solution of the present application, the male connector is composed of several first copper pillars, the female connector is composed of several second copper pillars, and several of the first copper pillars are connected to several of the second copper pillars.

[0008] As a preferred solution of the present application, the special-shaped thin copper busbar is wrapped by a heat shrink tube sleeve, and the heat shrink tube sleeve adopts a halogen-free, environmentally friendly, flame-retardant heat shrink tube.

[0009] To achieve the above-mentioned purpose, the present application also provides a method for processing a soft copper busbar, which is applicable to a photovoltaic storage inverter cabinet connected to the soft copper busbar described above, and comprises the following steps: Use a laser machine to cut out several thin copper sheets according to the selected soft copper busbar drawing; Stack the cut copper sheets and ensure that each stacked copper sheet is aligned; Select one aligned end and use fasteners to fix the stacked thin copper sheets on the tooling sheet metal to form a thin copper bar; Place the thin copper busbar on the sheet metal bending machine and bend both ends to form a special-shaped thin copper busbar; Take out the special-shaped thin copper sheet, remove the tooling sheet metal parts on the special-shaped thin copper bar, and electroplate each special-shaped thin copper sheet with bright nickel; The electroplated special-shaped thin copper sheets are stacked again in an orderly manner to ensure that each special-shaped thin copper sheet is aligned after stacking to form a special-shaped thin copper busbar again; The special-shaped thin copper busbar is manually covered with a heat shrink tube sleeve, which is then heated in an oven so that the heat shrink tube sleeve wraps several layers of thin copper sheets after being heated.

[0010] As a preferred solution of the present application, the fastener is an M6 screw, and the thin copper busbar is fixed to the tooling sheet metal using the M6 screw to ensure the stability of the thin copper busbar during the bending process.

[0011] As a preferred solution of the present application, after the heat shrink tubing is heated, the excess parts at both ends of the tubing are manually trimmed off with a hand knife to ensure a neat appearance of the soft copper busbar.

[0012] As a preferred solution of the present application, the specific value of the difference between the flattened lengths of two adjacent layers of thin copper sheets is two thicknesses of the thin copper sheets.

[0013] As a preferred solution of the present application, after electroplating bright nickel, a 72-hour neutral salt spray test is performed to ensure the corrosion resistance of the electroplating layer.

[0014] As a preferred solution of the present application, the laser machine cutting the thin copper sheet includes processing the mounting holes on the thin copper sheet and cutting the external shape of the thin copper sheet.

[0015] The present application provides a photovoltaic storage inverter cabinet with a flexible copper busbar connection, in which a special-shaped thin copper busbar is used to connect the DC / DC module and its PCBA circuit board. Hardly plugging the male connector on the rear of the DCDC module into the female connector in the photovoltaic storage hybrid inverter cabinet will cause long-term stress. This connection method helps reduce the risk of damaging the PCBA circuit board in the DCDC module. At the same time, because the special-shaped thin copper busbar is composed of five 0.5mm thick special-shaped thin copper sheets and is relatively soft overall, the special-shaped thin copper busbar can be electrically connected with a hard-connected copper busbar (such as a single thick copper plate or a rigid copper busbar). The flexibility of the soft copper busbar can buffer vibration or impact during equipment operation and protect the PCBA circuit board from damage. Furthermore, due to the use of the special-shaped thin copper busbar connection method, the present application is more regular in installation and simple in wiring, which reduces the space occupied in the cabinet and improves the cleanliness and maintainability of the cabinet. The installation is simpler, the wiring workload is reduced, and the installation and maintenance efficiency are improved. It can avoid occupying a large amount of cabinet internal space and reduce or minimize the problem of poor heat dissipation. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a structural diagram of a solar-storage inverter cabinet connected with a flexible copper busbar proposed by the present invention; Figure 2 This is a structural diagram of a DCDC module in a photovoltaic storage inverter cabinet connected with a flexible copper busbar proposed by the present invention; Figure 3 The present invention proposes a kind of soft copper busbar connected to the photovoltaic storage inverter cabinet. Figure 2 An enlarged view of part A on the basis of Figure 4 This is a schematic diagram of the structure of a thin copper busbar in a photovoltaic storage inverter cabinet connected by a soft copper busbar proposed by the present invention; Figure 5 An exploded view of a thin copper busbar in a photovoltaic storage inverter cabinet connected with a flexible copper busbar proposed by the present invention; Figure 6 A schematic diagram of the structure of a special-shaped thin copper busbar in a photovoltaic storage inverter cabinet connected by a soft copper busbar proposed by the present invention; Figure 7 The present invention provides a flowchart of the steps of a method for processing a soft copper busbar.

[0017] Description of reference numerals: 1. Cabinet; 2. DCDC module; 3. Male connector; 4. Female connector; 5. PCB board; 6. Special-shaped thin copper busbar; 7. Heat shrink tubing; 8. Tooling sheet metal; 9. M6 screws; 10. Mounting holes; 11. Thin copper sheet. DETAILED DESCRIPTION

[0018] The embodiments of the present application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present application, and should not be understood as limiting the present application. All other embodiments obtained by ordinary technicians in this field based on the embodiments in the present application without making any creative efforts shall fall within the scope of protection of the present application.

[0019] Furthermore, any references to "first," "second," and the like in this application are for descriptive purposes only (e.g., to distinguish identical or similar elements) and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined as "first" or "second" may explicitly or implicitly include at least one such feature. Furthermore, the technical solutions of various embodiments may be combined with one another, but this must be based on the ability of a person of ordinary skill in the art to implement them. If a combination of technical solutions contradicts or cannot be implemented, such combination of technical solutions shall be deemed non-existent and not within the scope of protection claimed in this application.

[0020] Please refer to Figure 1 , Figure 2 , Figure 3 In one embodiment, the present application provides a photovoltaic storage inverter cabinet 1 connected with a flexible copper busbar, including a cabinet 1, a plurality of DC / DC modules 2 are pluggably connected to the cabinet 1, and the plurality of DC / DC modules 2 are provided with male connectors 3 for electrical connection. The cabinet 1 is provided with a female connector 4 adapted to the male connector 3, and the male connector 3 is connected to the female connector 4. An end of the female connector 4 away from the male connector 3 extends outward through the cabinet 1 and is connected to a photovoltaic switch. Each DCDC module 2 is provided with a PCB board 5 , and the PCB board 5 is connected to the male connector 3 via a special-shaped thin copper bus 6 .

[0021] It should be noted that the male 3 here refers to the male 3 connector, and the female 4 refers to the female 4 connector; For details, please refer to Figure 4 , Figure 5 On the basis of the above embodiment, the special-shaped thin copper busbar 6 is formed by stacking 5 layers of special-shaped thin copper sheets 11, and the thickness of each layer of special-shaped thin copper sheets is 0.5 mm.

[0022] Specifically, based on the above embodiment, the male connector 3 is composed of several first copper pillars, the female connector 4 is composed of several second copper pillars, and the several first copper pillars are connected to the several second copper pillars.

[0023] In summary, it can be understood that the present application provides a kind of photovoltaic storage inverter cabinet 1 connected with a soft copper busbar, in which the DCDC module 2 and its PCBA circuit board adopt a special-shaped thin copper busbar 6 for connection. When the male connector 3 behind the DCDC module 2 is hard-plugged into the female connector 4 in the photovoltaic storage hybrid inverter cabinet 1, there will be a long-term stress problem. The above connection method is conducive to reducing the risk of damaging the PCBA circuit board in the DCDC module 2. At the same time, since the special-shaped thin copper busbar is composed of 5 special-shaped thin copper sheets with a thickness of 0.5 mm, the whole is relatively soft, and the special-shaped thin copper busbar 6 Compared with the use of hard-connected copper busbars (such as a single thick copper plate or a rigid copper busbar) for electrical connection, the flexibility of the soft-connected copper busbar can buffer the vibration or impact during equipment operation and protect the PCBA circuit board from damage. Furthermore, since the present application adopts the connection method of heterogeneous thin copper busbars, the installation is more regular and the wiring is simple, which reduces the space occupied in the cabinet and improves the neatness and maintainability of the interior of the cabinet 1. The installation is simpler, the wiring workload is reduced, the installation and maintenance efficiency are improved, and it can avoid occupying a large amount of internal space of the cabinet 1 and reduce or minimize the problem of poor heat dissipation.

[0024] For details, please refer to Figure 6 On the basis of the above embodiment, the special-shaped thin copper busbar 6 is wrapped by the heat shrink tube 7, and the heat shrink tube 7 adopts a halogen-free, environmentally friendly, flame-retardant heat shrink tube.

[0025] It can be understood that the halogen-free heat shrink tubing has excellent flame retardant properties and a high temperature resistance level. It can adapt to long-term use in high temperature environments, and can suppress the spread of flames under high temperature or open flame conditions, reducing the risk of fire. Even when burning, the halogen-free heat shrink tubing produces little smoke, and the smoke does not contain toxic gases, reducing the harm to the human body and equipment. At the same time, the halogen-free heat shrink tubing can shrink evenly after heating, tightly wrapping the special-shaped thin copper busbar 6 to form a good insulation and protective layer.

[0026] Please refer to Figure 7 To achieve the above purpose, the present application also provides a method for processing a soft copper busbar, which is applicable to the above-mentioned soft copper busbar-connected photovoltaic inverter cabinet 1, comprising the following steps: S1. Cut out a number of thin copper sheets 11 using a laser machine according to the selected soft copper busbar drawing; S2, stacking the cut thin copper sheets 11 and ensuring that each stacked thin copper sheet 11 is aligned; S3, select one end of the alignment and use a fastener to fix the stacked thin copper sheets 11 on the tooling sheet metal part 8 to form a thin copper bar; S4, placing the thin copper busbar on a sheet metal bending machine and performing a bending process at both ends to form a special-shaped thin copper busbar 6; S5, take out the special-shaped thin copper sheets, remove the tooling sheet metal 8 on the special-shaped thin copper bus 6, and electroplate each special-shaped thin copper sheet with bright nickel; S6, stacking the electroplated special-shaped thin copper sheets again in order, ensuring that each stacked special-shaped thin copper sheet is aligned, and forming a special-shaped thin copper bus 6 again; S7. Manually cover the above-mentioned special-shaped thin copper busbar 6 with a heat shrink tube 7, and then heat the heat shrink tube 7 in an oven so that the heat shrink tube 7 wraps several layers of thin copper sheets 11 after being heated.

[0027] Furthermore, in this embodiment, the irregular thin copper busbar 6 is composed of five layers of 0.5mm irregular thin copper sheets 11. The processing technology of the irregular bent soft copper busbar with five layers of 0.5mm thick thin copper sheets 11 stacked with heat shrink tubing significantly reduces the production cost compared to the solution of 25 layers of 0.1mm thick copper foil bent soft copper busbar. The technical solution provided by this application does not require a wire cutting machine or a set of molds for each copper busbar shape to cut the copper foil busbar. The 0.5mm thick copper busbar can be cut using a common laser machine. The two ends of the 25-layer 0.1mm copper foil busbar are then welded together with silver welding rods and polished to a smooth surface. The 5-layer 0.5mm thick laminated soft copper busbar does not require welding. In addition, the 5-layer 0.5mm thick bent laminated soft copper busbar can be plated with bright nickel on each layer separately, while the 25-layer 0.1mm thick copper foil bent soft copper busbar can only be plated as a whole. Therefore, the gaps between each layer of copper foil are difficult to plate, and the plating solution will remain in the gaps between the copper foils, which will corrode the copper foil. Therefore, the salt spray resistance of the 5-layer 0.5mm thick laminated soft copper busbar is much better than that of the 25-layer 0.1mm thick copper foil soft copper busbar. In summary, it can be understood that in the above method, a laser machine is used to cut the thin copper sheet 11 to ensure high cutting accuracy, smooth edges, and reduce burrs and deformation, and then the sheet metal bending machine is used to perform precise bending to form a special-shaped thin copper busbar 6 to meet complex connection requirements; at the same time, the special-shaped thin copper busbar 6 adopts a multi-layer stacking design, which can improve the current-carrying capacity. The conductive cross-sectional area is increased by stacking multiple layers of special-shaped thin copper sheets, thereby improving the current-carrying capacity of the soft copper busbar; the stacking design makes the soft copper busbar flexible and able to adapt to alignment errors and vibrations during the installation process. After bending, bright nickel is electroplated to improve corrosion resistance. The bright nickel layer protects the soft copper busbar from oxidation and corrosion, thereby extending its service life. The nickel layer has good conductivity to ensure the stability of the electrical connection. Finally, it is wrapped with a heat shrink tube to provide insulation protection, prevent short circuits and leakage, and protect the soft copper busbar from mechanical damage and environmental influences. The special-shaped thin copper busbar 6 manufactured by the above processing method has the advantages of high precision, high current carrying capacity, flexibility, corrosion resistance and insulation protection, and has produced a significant improvement in the connection method of the photovoltaic storage inverter.

[0028] For details, please refer to Figure 4Based on the above embodiment, the laser machine cutting of the thin copper sheet 11 includes processing the mounting holes 10 on the thin copper sheet 11 and cutting the external shape of the thin copper sheet 11, providing positioning and stabilization of the mounting holes 10 for the subsequent stacking of the thin copper sheets 11.

[0029] For details, please refer to Figure 4 , Figure 5 On the basis of the above embodiment, the fastener is an M6 screw 9, which is used to fix the thin copper busbar on the tooling sheet metal 8 to ensure the stability of the thin copper busbar during the bending process.

[0030] Specifically, based on the above embodiment, after the heat shrink tubing is heated, the excess parts at both ends of the tubing are manually trimmed off with a hand knife to ensure that the appearance of the soft copper busbar is neat.

[0031] Specifically, based on the above embodiment, the specific value of the difference between the flattened lengths of two adjacent layers of thin copper sheets 11 is the thickness of two thin copper sheets 11 .

[0032] It can be understood that the flattened lengths of two adjacent layers of thin copper sheets 11 differ by the thickness of two thin copper sheets 11 , which means that when stacked, each layer of thin copper sheets 11 will be slightly staggered in the length direction. This staggered design allows the thin copper sheets 11 of each layer to slide relative to each other when the soft copper busbar is bent, thereby forming a flexible connection. The length difference between adjacent thin copper sheets 11 allows the layers to slide freely when the soft copper busbar is bent, reducing internal stress.

[0033] Specifically, based on the above embodiment, after bright nickel electroplating, a 72-hour neutral salt spray test was performed to ensure the corrosion resistance of the electroplating layer.

[0034] It can be understood that the bright nickel layer forms a dense protective film on the surface of the soft copper busbar, which can effectively isolate air, moisture and corrosive substances, and prevent the copper substrate from oxidation or corrosion. A 72-hour neutral salt spray test is carried out after electroplating bright nickel, which is mainly used to verify the corrosion resistance of the soft copper busbar and whether the nickel plating is uniform, without pores or defects, to ensure that it can fully cover the surface of the special-shaped thin copper sheet 11 and ensure its long-term reliability in harsh environments. Through the experiment, the integrity, corrosion resistance and adhesion of the nickel plating can be evaluated, thereby improving product quality, meeting industry standards, and ensuring the stable operation of the photovoltaic inverter cabinet 1.

[0035] It should be noted that, in this document, the terms "comprises," "includes," or any other variations thereof are intended to encompass non-exclusive inclusion, such that a process, apparatus, article, or method comprising a series of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, apparatus, article, or method. In the absence of further limitations, an element defined by the phrase "comprising a ..." does not exclude the presence of other identical elements in the process, apparatus, article, or method comprising the element.

[0036] The above description is only a preferred embodiment of the present application and does not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made using the contents of the present application specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. A solar storage inverter cabinet connected by a flexible copper busbar, characterized in that: The cabinet comprises a plurality of DCDC modules pluggably connected to the cabinet, and the plurality of DCDC modules are provided with male connectors for electrical connection. The cabinet is provided with female connectors adapted to the male connectors, and the male connectors are connected to the female connectors. An end of the female connector away from the male connector extends outward through the cabinet and is connected to a photovoltaic switch. Each of the DCDC modules is provided with a PCB board, and the PCB board is connected to the male connector via a special-shaped thin copper busbar.

2. The solar-storage inverter cabinet connected by a flexible copper busbar according to claim 1, characterized in that: The special-shaped thin copper busbar is formed by stacking 5 layers of special-shaped thin copper sheets, and the thickness of each layer of the special-shaped thin copper sheets is 0.5 mm.

3. The solar-storage inverter cabinet connected by a flexible copper busbar according to claim 1, characterized in that: The male connector is composed of a plurality of first copper pillars, and the female connector is composed of a plurality of second copper pillars, wherein the plurality of first copper pillars are connected to the plurality of second copper pillars.

4. The solar-storage inverter cabinet connected by a flexible copper busbar according to claim 2, characterized in that: The special-shaped thin copper busbar is wrapped by a heat shrink tubing sleeve, and the heat shrink tubing sleeve is a halogen-free, environmentally friendly, flame-retardant heat shrink tubing.

5. A method for processing a soft copper busbar, applicable to a photovoltaic storage inverter cabinet connected to a soft copper busbar as claimed in any one of claims 1 to 4, characterized in that: The following steps are involved: Use a laser machine to cut out several thin copper sheets according to the selected soft copper busbar drawing; Stack the cut copper sheets and ensure that each stacked copper sheet is aligned; Select one aligned end and use fasteners to fix the stacked thin copper sheets on the tooling sheet metal to form a thin copper bar; Place the thin copper busbar on the sheet metal bending machine and bend both ends to form a special-shaped thin copper busbar; Take out the special-shaped thin copper sheet, remove the tooling sheet metal parts on the special-shaped thin copper bar, and electroplate each special-shaped thin copper sheet with bright nickel; The electroplated special-shaped thin copper sheets are stacked again in an orderly manner to ensure that each special-shaped thin copper sheet is aligned after stacking to form a special-shaped thin copper busbar again; The special-shaped thin copper busbar is manually covered with a heat shrink tube sleeve, which is then heated in an oven so that the heat shrink tube sleeve wraps several layers of thin copper sheets after being heated.

6. The method for processing a soft copper busbar according to claim 5, characterized in that: The fasteners are M6 screws, which are used to fix the thin copper busbar to the tooling sheet metal to ensure the stability of the thin copper busbar during the bending process.

7. The method for processing a soft copper busbar according to claim 5, characterized in that: After the heat shrink tubing is heated, the excess parts at both ends of the tubing are manually trimmed with a hand knife to ensure the neat appearance of the soft copper busbar.

8. The method for processing a soft copper busbar according to claim 5, characterized in that: The specific value of the difference between the flattened lengths of two adjacent thin copper sheets is the thickness of two thin copper sheets.

9. The method for processing a soft copper busbar according to claim 5, characterized in that: After bright nickel electroplating, the product passes a 72-hour neutral salt spray test to ensure the corrosion resistance of the electroplating layer.

10. The method for processing a soft copper busbar according to claim 5, characterized in that: The laser cutting of the thin copper sheet includes processing the mounting holes on the thin copper sheet and cutting the outer shape of the thin copper sheet.

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