Corrosion-resistant photovoltaic junction box with sealing structure

Abstract

This invention relates to the field of junction box technology, specifically disclosing a corrosion-resistant photovoltaic junction box with a sealed structure, comprising a lower housing and an upper housing, which are rotatably connected by a hinge. It further includes: a primary sealing mechanism, which is fixedly installed in both the lower and upper housings; and a secondary sealing mechanism, which is fixedly installed on the primary sealing mechanism. The primary sealing mechanism includes an input pipe and an output pipe, each being a separate, independently combined semi-circular ring design. This invention differs from traditional rubber rings. After the lower and upper housings are sealed, the sealing rings achieve self-sealing, significantly reducing the pressure on the rubber surface while ensuring a tight seal. This avoids the problem of rapid deformation and seal failure caused by prolonged pressure in traditional sealing ring structures.

Description

Technical Field

[0001] This invention relates to the field of junction box technology, specifically a corrosion-resistant photovoltaic junction box with a sealed structure. Background Technology

[0002] A photovoltaic junction box is an electrical connection device between a solar photovoltaic module and an external load or inverter, and it plays a crucial role in safely and reliably transmitting the direct current generated by the photovoltaic cells to the outside. Because photovoltaic modules are installed outdoors on rooftops, ground-mounted power stations, or in desert environments for extended periods, junction boxes must withstand harsh conditions such as sun and rain, alternating high and low temperatures, wind and sand erosion, and chemical corrosion.

[0003] Existing photovoltaic junction boxes still have several shortcomings in terms of sealing structure: First, traditional junction boxes typically use rubber sealing rings at the contact surfaces of the lower and upper shells. These rings are tightened with bolts or clips to create elastic deformation, filling the gaps between the shells. However, the rubber sealing rings are under continuous compression. Under the combined effects of thermal and oxidative aging and stress relaxation, their elasticity rapidly decreases, leading to permanent compression deformation. This results in the sealing rings failing to adhere tightly to the shell surface, gradually weakening the sealing effect or even causing complete failure. Moisture then seeps into the box, causing electrical faults. Second, to enhance sealing performance, some designs use multiple sealing rings or increase the tightening force. However, this not only accelerates the deformation rate of the rubber components but also increases the resistance required to open and close the shell, making operation inconvenient. Repeated opening and closing further accelerates damage to the sealing rings. Third, the input and output ports of the junction box are the channels for cables to enter and exit. Traditional designs typically rely solely on a single rubber sheath or potting compound for waterproofing in these areas. Rubber sheaths also age and harden over long-term use, and potting compound cannot be removed without damage during cable repair or replacement, causing significant difficulties for on-site maintenance. If the seal at the port is missing or fails, water can flow directly into the junction box along the cable surface, which is the weakest and most easily overlooked leakage path in traditional structures. Fourth, after the port cables are connected, traditional junction boxes typically use bolts or clips to secure the input and output pipes. These metal fasteners are highly susceptible to corrosion in outdoor environments, making them difficult to loosen during disassembly and maintenance, and may even damage the casing structure due to rust. Summary of the Invention

[0004] (a) Technical problems to be solved This invention provides a corrosion-resistant photovoltaic junction box with a sealed structure, which solves the problems mentioned in the background art.

[0005] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: a corrosion-resistant photovoltaic junction box with a sealed structure, comprising a lower housing and an upper housing, wherein the upper housing and the lower housing are rotatably connected by a hinge, and further comprising: a primary sealing mechanism, wherein the primary sealing mechanism is fixedly installed in the lower housing and the upper housing respectively; and a secondary sealing mechanism, wherein the secondary sealing mechanism is fixedly installed on the primary sealing mechanism; wherein the primary sealing mechanism comprises an input pipe and an output pipe, wherein the input pipe and the output pipe are two separate and independently combined semi-circular rings, and the input pipe and the output pipe are symmetrically inserted and fixedly embedded in the side surfaces of the lower housing and the upper housing respectively, and the input pipe and the output pipe are of the same shape.

[0006] According to one embodiment of the present invention, a closed ring is sleeved on the outer surface of the input tube, and magnets are symmetrically and fixedly embedded on the upper and lower surfaces of the closed ring; a first magnetic strip and a second magnetic strip are elastically and slidably embedded in the wall of the lower housing, wherein the outer surfaces of the first magnetic strip and the second magnetic strip are set as rubber surfaces; the internal structure of the upper housing is the same as that of the lower housing.

[0007] According to one embodiment of the present invention, the secondary sealing mechanism includes a connecting pipe; the connecting pipe is rotatably connected to the side surface of the closing ring, and the cross-sectional view of the connecting pipe is U-shaped, and the connecting pipe is inserted into the input pipe and the output pipe through the U-shaped structure.

[0008] According to one embodiment of the present invention, the inner wall of the input tube is provided with a slot, and the inner diameter of the slot is the same as the inner diameter of the connecting tube, that is, after the connecting tube is inserted into the slot, it combines with the input tube and the output tube to form a complete inner plane.

[0009] According to one embodiment of the present invention, a first groove is formed on the outer surface of the input tube, and a second groove is connected to the inner end of the first groove, wherein the first groove and the second groove are arranged perpendicular to each other, and a sliding strip is symmetrically fixedly connected to the inner surface of the closed ring.

[0010] According to one embodiment of the present invention, a combined pipe is fixedly connected to the inner wall of the connecting pipe, a gap is provided between the combined pipe and the connecting pipe, and an expansion ring is fixedly connected to the side surface of the combined pipe. The expansion ring is made of rubber material, and the end of the expansion ring away from the combined pipe is fixedly connected to the connecting pipe. That is, the connecting pipe, the expansion ring and the combined pipe are finally combined to form a complete inner wall.

[0011] According to one embodiment of the present invention, a sliding tube is elastically slidably inserted into the outer surface of the combined tube, wherein the outer end of the sliding tube is initially protruding from the combined tube.

[0012] To use this junction box, first remove the closed-loop connecting tube, then rotate to open the lower and upper housings and begin connecting the wiring. After the wiring is connected, place the input and output lines into the input and output tubes respectively. Finally, close the lower and upper housings again, and then put the closed-loop back on to lock the input and output tubes, thus completing the sealing of the upper and lower housings. After the closed-loop is put back on the input and output tubes, rotate it. The magnet on the closed-loop will rotate accordingly. As the rotation amplitude increases, the magnet begins to magnetically attract the first and second magnetic strips inside the upper and lower housings. With increasing rotation amplitude, the first and second magnetic strips will move outward inside the lower and upper housings. Finally, the first and second magnetic strips in the lower and upper housings will press and attract each other, and the rubber surface will completely seal the gap between the lower and upper housings. This ensures that the lower and upper housings are completely sealed after installation, thus preventing water from seeping into the junction box and damaging the internal components when used outdoors.

[0013] (III) Beneficial Effects This invention provides a corrosion-resistant photovoltaic junction box with a sealed structure. It offers the following advantages: (i) The corrosion-resistant photovoltaic junction box with a sealed structure is different from the traditional rubber ring. After the sealing lower shell and upper shell of the present invention are closed, the sealing ring achieves self-sealing through rotation. Under the premise of ensuring sealing, the pressure on the rubber surface is greatly reduced, avoiding the problem of rapid deformation and easy sealing failure caused by long-term compression of traditional sealing ring structures.

[0014] (II) This corrosion-resistant photovoltaic junction box with a sealed structure, when the sealing ring is connected to the input and output pipes, the sliding strip on the sealing ring first aligns with the first sliding groove on the input and output pipes. After the sealing ring is inserted into the innermost end, the sliding strip slides along the second sliding groove as the sealing ring rotates. This achieves automatic locking between the sealing ring and the input and output pipes after the sealing ring has rotated, avoiding the problem of the sealing ring easily falling off due to the complex outdoor environment. This not only greatly improves the sealing stability of this junction box, but also has a simple structure, is easy to lock, simplifies outdoor work, and avoids the problem of easy rusting and frequent maintenance required by traditional junction boxes using bolts.

[0015] (III) This corrosion-resistant photovoltaic junction box with a sealed structure, when the sealing ring slides in the first groove, will drive the connecting pipe to gradually insert with the input pipe and the output end, further limiting the input pipe and the output pipe and improving the connection stability. At this time, the outer end of the sliding pipe begins to insert with the slot of the input pipe and the output pipe and generate extrusion force, causing the sliding pipe to begin to contract along the outer wall of the combined pipe, thereby increasing the air pressure in the gap between the combined pipe and the connecting pipe. Under the action of air pressure, the expansion ring begins to expand and release pressure. Finally, the expansion ring is pressed and attached to the outer surface of the wire, automatically achieving a seal on the wire input end and the output end, thereby achieving a complete self-sealing. This solves the problem that the wiring port in the existing junction box cannot be sealed, thus ensuring that the junction box is always kept dry and greatly improving the subsequent use stability. At the same time, the two seals are automatically completed by the insertion and rotation of the sealing ring. Conversely, the seal can also be quickly released during disassembly. This invention avoids the disadvantage of frequent replacement of traditional rubber rings for sealing, and improves the service life of the sealing effect while ensuring the sealing effect. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the closed-loop connecting pipe of the present invention; Figure 3 This is a schematic diagram of the structure of magnetic stripe No. 1 and magnetic stripe No. 2 of the present invention; Figure 4 This is a schematic diagram of the input tube structure of the present invention; Figure 5 This is a schematic diagram of the connecting pipe of the present invention; Figure 6 This is a schematic diagram of the closed ring structure of the present invention; Figure 7 This is a schematic diagram of the expansion ring structure of the present invention; Figure 8 This is a schematic diagram of the combined pipe structure of the present invention.

[0017] In the diagram: 1. Lower housing; 2. Upper housing; 3. Primary sealing mechanism; 31. Input pipe; 32. Output pipe; 33. Closing ring; 34. Magnet; 35. Magnetic strip No. 1; 36. Magnetic strip No. 2; 4. Secondary sealing mechanism; 41. Connecting pipe; 42. Slot; 43. Slide groove No. 1; 44. Slide groove No. 2; 45. Slide bar; 46. Combined pipe; 47. Expansion ring; 48. Sliding pipe. Detailed Implementation

[0018] 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.

[0019] First embodiment: as follows Figures 1 to 8 As shown, the present invention provides a technical solution: a corrosion-resistant photovoltaic junction box with a sealed structure, comprising a lower housing 1 and an upper housing 2, wherein the upper housing 2 and the lower housing 1 are rotatably connected by a hinge, and further comprising: The primary sealing mechanism 3 is fixedly installed in the lower housing 1 and the upper housing 2 respectively; Secondary sealing mechanism 4 is fixedly installed on primary sealing mechanism 3; The primary sealing mechanism 3 includes an input pipe 31 and an output pipe 32. The input pipe 31 and the output pipe 32 are two separate and independently combined semi-circular ring designs. The input pipe 31 and the output pipe 32 are symmetrically inserted and fixedly embedded in the side surfaces of the lower housing 1 and the upper housing 2, and the input pipe 31 and the output pipe 32 are set with the same shape.

[0020] A closing ring 33 is fitted on the outer surface of the input tube 31, and magnets 34 are symmetrically embedded on the upper and lower surfaces of the closing ring 33. A first magnetic strip 35 and a second magnetic strip 36 are elastically and slidably embedded in the wall of the lower housing 1, wherein the outer surfaces of the first magnetic strip 35 and the second magnetic strip 36 are set as rubber surfaces; The internal structure of the upper shell 2 is the same as that of the lower shell 1.

[0021] Second embodiment: as follows Figures 1 to 8 As shown, the secondary sealing mechanism 4 includes a connecting pipe 41; The connecting pipe 41 is rotatably connected to the side surface of the closed ring 33. The cross-sectional view of the connecting pipe 41 is U-shaped. The connecting pipe 41 is inserted into the input pipe 31 and the output pipe 32 through the U-shaped structure.

[0022] The inner wall of the input pipe 31 is provided with a slot 42. The inner diameter of the slot 42 is the same as the inner diameter of the connecting pipe 41. That is, after the connecting pipe 41 is inserted into the slot 42, it combines with the input pipe 31 and the output pipe 32 to form a complete inner plane.

[0023] The outer surface of the input pipe 31 has a first groove 43, and the inner end of the first groove 43 is connected to a second groove 44. The first groove 43 and the second groove 44 are set perpendicular to each other. The inner surface of the closed ring 33 is symmetrically fixed with a slide bar 45.

[0024] A combined pipe 46 is fixedly connected to the inner wall of the connecting pipe 41. A gap is provided between the combined pipe 46 and the connecting pipe 41. An expansion ring 47 is fixedly connected to the side surface of the combined pipe 46. The expansion ring 47 is made of rubber material. The end of the expansion ring 47 away from the combined pipe 46 is fixedly connected to the connecting pipe 41. In this way, the connecting pipe 41, the expansion ring 47 and the combined pipe 46 are finally combined to form a complete inner wall.

[0025] A sliding tube 48 is elastically slidably inserted into the outer surface of the combined tube 46, wherein the outer end of the sliding tube 48 is initially set to protrude from the combined tube 46.

[0026] During operation, when this junction box is needed, first remove the sealing ring 33 and connecting pipe 41. Then, rotate to open the lower housing 1 and upper housing 2 to begin connecting the wiring. After the wiring is connected, place the input and output lines into the input pipe 31 and output pipe 32 respectively. Finally, close the lower housing 1 and upper housing 2 again, and then put the sealing ring 33 back on to limit and lock the input pipe 31 and output pipe 32, thus completing the closure of the upper housing 2 and lower housing 1. After the sealing ring 33 is put back on the input pipe 31 and output pipe 32, rotate it. The magnet 34 on the sealing ring 33 will rotate accordingly. As the rotation amplitude increases, the magnet 34 begins to magnetically attract the first magnetic strip 35 and the second magnetic strip 36 inside the upper housing 2 and lower housing 1. As the rotation amplitude increases, the first magnetic strip 35 and the second magnetic strip 36 move outwards within the lower housing 1 and the upper housing 2. Ultimately, the first magnetic strip 35 and the second magnetic strip 36 in the lower housing 1 and the upper housing 2 press and adhere to each other, completely sealing the gap between the lower housing 1 and the upper housing 2 through the rubber surface. This ensures a complete seal between the lower housing 1 and the upper housing 2 after installation, preventing water seepage into the junction box and damage to internal components during outdoor use. Unlike traditional rubber rings, this invention achieves self-sealing through the rotation of the sealing ring 33 after the lower housing 1 and the upper housing 2 are sealed. This significantly reduces the pressure on the rubber surface while ensuring a tight seal, avoiding the damage caused by prolonged pressure in traditional sealing ring structures. To address the issue of rapid deformation and potential sealing failure in traditional junction boxes, when the sealing ring 33 is connected to the input pipe 31 and output pipe 32, the sliding strip 45 on the sealing ring 33 first aligns with the first sliding groove 43 on the input pipe 31 and output pipe 32. After the sealing ring 33 is inserted to its innermost position, the sliding strip 45 slides along the second sliding groove 44 as the sealing ring 33 rotates. This automatically locks the sealing ring 33 to the input pipe 31 and output pipe 32 after rotation, preventing the sealing ring 33 from easily detaching due to complex outdoor environments. This significantly improves the sealing stability of the junction box, while also offering a simple structure, easy locking, and simplified outdoor work. Furthermore, it avoids the frequent rusting and maintenance issues associated with bolts used in traditional junction boxes. The problem is that when the closed ring 33 slides within the first sliding groove 43, it drives the connecting tube 41 to gradually connect with the input tube 31 and the output end, further limiting the input tube 31 and the output tube 32 and improving connection stability. At this time, the outer end of the sliding tube 48 begins to connect with the slots 42 of the input tube 31 and the output tube 32 and generates a squeezing force, causing the sliding tube 48 to begin to contract along the outer wall of the combined tube 46. This increases the air pressure in the gap between the combined tube 46 and the connecting tube 41. Under the action of air pressure, the expansion ring 47 begins to expand and release pressure. Finally, the expansion ring 47 is pressed and attached to the outer surface of the wire, automatically sealing the wire input and output ends, thus achieving a complete and autonomous seal. This solves the problem that the wiring ports in existing junction boxes cannot be sealed.This ensures the junction box remains dry at all times, significantly improving subsequent operational stability. Simultaneously, the automatic engagement and rotation of the sealing ring 33 creates two seals, which can be quickly released during disassembly. This invention avoids the drawbacks of using traditional rubber rings for sealing, requiring frequent replacements, and extends the lifespan of the seal while ensuring its effectiveness.

[0027] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0028] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A corrosion-resistant photovoltaic junction box with a sealed structure, comprising a lower housing and an upper housing, characterized in that: The upper and lower housings are rotatably connected by a hinge, and the system further includes: A primary sealing mechanism is fixedly installed in the lower housing and the upper housing, respectively. A secondary sealing mechanism, which is fixedly installed on the primary sealing mechanism; The primary sealing mechanism includes an input pipe and an output pipe, which are two separate and independently combined semi-circular rings. The input pipe and the output pipe are symmetrically inserted and fixedly embedded in the side surfaces of the lower housing and the upper housing, and the input pipe and the output pipe are of the same shape.

2. The corrosion-resistant photovoltaic junction box with a sealed structure according to claim 1, characterized in that: The outer surface of the input tube is fitted with a closed ring, and magnets are symmetrically embedded on the upper and lower surfaces of the closed ring. The lower housing has a first magnetic strip and a second magnetic strip that are elastically and slidably embedded in its wall, with the outer surfaces of the first and second magnetic strips being rubber surfaces. The internal structure of the upper shell is the same as that of the lower shell.

3. A corrosion-resistant photovoltaic junction box with a sealed structure according to claim 2, characterized in that: The secondary sealing mechanism includes a connecting pipe; The connecting pipe is rotatably connected to the side surface of the closed ring. The cross-sectional view of the connecting pipe is U-shaped, and the connecting pipe is inserted into the input pipe and the output pipe through the U-shaped structure.

4. A corrosion-resistant photovoltaic junction box with a sealed structure according to claim 3, characterized in that: The inner wall of the input tube is provided with a slot, and the inner diameter of the slot is the same as the inner diameter of the connecting tube. That is, after the connecting tube is inserted into the slot, it combines with the input tube and the output tube to form a complete inner plane.

5. A corrosion-resistant photovoltaic junction box with a sealed structure according to claim 4, characterized in that: The outer surface of the input tube has a first sliding groove, and the inner end of the first sliding groove is connected to a second sliding groove. The first and second sliding grooves are set perpendicular to each other. The inner surface of the closed ring is symmetrically fixed with sliding strips.

6. A corrosion-resistant photovoltaic junction box with a sealed structure according to claim 5, characterized in that: The inner wall of the connecting pipe is fixedly connected to the combined pipe, and a gap is provided between the combined pipe and the connecting pipe. An expansion ring is fixedly connected to the side surface of the combined pipe. The expansion ring is made of rubber material, and the end of the expansion ring away from the combined pipe is fixedly connected to the connecting pipe. Thus, the connecting pipe, the expansion ring and the combined pipe are finally combined to form a complete inner wall.

7. A corrosion-resistant photovoltaic junction box with a sealed structure according to claim 6, characterized in that: The outer surface of the combined tube is elastically slidably connected to a sliding tube, wherein the outer end of the sliding tube is initially set to protrude from the combined tube.

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