A flexible wiring lead-out device for a garden photovoltaic module

Abstract

This invention relates to the field of photovoltaic module technology, specifically a flexible wiring lead-out device for photovoltaic modules in industrial parks. A spiral lead-out mechanism is fixed to one end of a buffered inner wiring mechanism, a bottom support isolation mechanism is disposed on the surface of the buffered inner wiring mechanism, and a sacrificial cover mechanism covers the surface of the bottom support isolation mechanism. The buffered inner wiring mechanism includes a conductive sheet unit, a flexible conductive strip, and a buffer spring. The flexible conductive strip connects to one end of the conductive sheet unit to flexibly connect to the photovoltaic panel welding strip, and the buffer spring connects to the other end of the conductive sheet unit to flexibly connect to the spiral lead-out mechanism. The spiral lead-out mechanism includes a rubber attachment tube and an externally wound, spirally wound, externally connected conductor and a supporting isolation wire, both intermittently distributed spirally along the circumference of the rubber attachment tube. Multi-stage flexible buffering enhances resistance to wind loads, thermal expansion and contraction, and line drag, preventing fatigue fracture of the lead-out wires, extending the service life of the device, and the anti-aging sacrificial outer cover is removable and replaceable to delay internal aging.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module technology, specifically to a flexible wiring lead-out device for photovoltaic modules in industrial parks. Background Technology

[0002] Photovoltaic power generation is a technology that directly converts light energy into electrical energy using the photovoltaic effect at the semiconductor interface. It consists of solar panels, a controller, and an inverter. Its core components are formed by doping silicon atoms to create P-type and N-type semiconductors. When illuminated, a potential difference is generated at the PN junction, forming a current. After being assembled into the solar panels, this current is converted into alternating current by the inverter. As the core power generation unit of a photovoltaic power generation system, the photovoltaic module's rear junction box leads are the key connection structure for realizing the module's power output. They play a crucial role in power transmission and circuit connection. Their structural stability, fatigue resistance, and anti-aging capabilities directly determine the outdoor lifespan and operational safety of the photovoltaic module.

[0003] Currently, most photovoltaic module junction boxes in the industry use straight, rigid cables for their outgoing leads, with the cables rigidly fixed to the junction box outlet. This connection method results in extremely low elastic deformation margins for the cables. While it can meet basic power transmission requirements under static installation conditions, photovoltaic modules operate outdoors under complex conditions year-round, enduring multiple external forces: outdoor wind loads cause continuous low-frequency swaying and vibration of the cables, generating reciprocating bending stress at rigid connection points; diurnal temperature differences cause thermal expansion and contraction deformation of the cables and junction box housing, resulting in alternating thermal stress at the connection interface due to the difference in thermal expansion coefficients between the cable and housing materials; and the installation, maintenance, and accidental dragging of the busbars directly apply instantaneous pull-out loads to the outgoing leads.

[0004] The combined effect of these multiple external factors causes the conductor core and insulation layer at rigid connection points to be under high stress concentration for extended periods, making them highly susceptible to fatigue fracture of the conductor or cracking of the insulation layer. This leads to a decrease in the power generation efficiency of photovoltaic modules and even short-circuit faults in the system. According to industry statistics, problems caused by broken lead wires or damaged insulation account for a high proportion of photovoltaic power plant operation failures, making it one of the main weak links affecting the long-term reliable operation of photovoltaic systems.

[0005] While existing technologies offer some improvements to address the aforementioned issues, such as covering the lead-out wires with flexible sheaths or adding tensile anchors at the junction box outlets, these methods only provide limited protection in specific areas. Relative slippage and stress concentration still exist between the sheath and the cable, failing to fundamentally improve the lead-out wire's fatigue resistance and flexible buffering capacity at the structural level. Furthermore, the added sheaths and anchors increase the number of components and assembly complexity. Therefore, improving the resistance of the lead-out wires and their connection points to multiple external forces by considering the overall structure of the wiring device is a pressing technical problem that needs to be solved in this field. Summary of the Invention

[0006] To overcome the shortcomings of the prior art, this invention provides a flexible wiring lead-out device for photovoltaic modules in industrial parks. By using a buffered internal wiring mechanism to form a flexible connection between the lead-out wire and the photovoltaic panel welding strip, and in conjunction with the spiral elastic deformation of the spiral lead-out mechanism itself, the structural resistance of the lead-out device to multiple external forces such as wind load, thermal expansion and contraction, and dragging by external lines is fundamentally improved, preventing fatigue fracture of the lead-out wire.

[0007] To achieve the above objectives, the present invention employs the following technical solution: A flexible wiring lead-out device for photovoltaic modules in a park includes a buffer-type inner wiring mechanism, a spiral lead-out mechanism, a bottom support isolation mechanism, and a sacrificial cover mechanism. The spiral lead-out mechanism is fixed to one end of the buffer-type inner wiring mechanism, the bottom support isolation mechanism is disposed on the surface of the buffer-type inner wiring mechanism, and the sacrificial cover mechanism covers the surface of the bottom support isolation mechanism. The buffer-type inner wiring mechanism includes a conductive sheet unit, a flexible conductive strip, and a buffer spring. The flexible conductive strip is connected to one end of the conductive sheet unit for flexible connection with the photovoltaic panel welding strip, and the buffer spring is connected to the other end of the conductive sheet unit for flexible connection with the spiral lead-out mechanism. The spiral lead-out mechanism includes a rubber attachment tube, an external conductor, and a supporting isolation wire. The external conductor and the supporting isolation wire are both spirally wound around the surface of the rubber attachment tube and are intermittently distributed spirally along the circumference of the rubber attachment tube.

[0008] Furthermore, the conductive sheet unit includes an inner row of conductive sheets and an outer row of conductive sheets; one end of the buffer spring is fixedly connected to the inner row of conductive sheets; one end of the flexible conductive strip is provided with a connecting piece, and the flexible conductive strip is fixedly connected to the inner row of conductive sheets or the outer row of conductive sheets through the connecting piece; the other end of the flexible conductive strip is provided with a welding piece, and the flexible conductive strip is fixedly connected to the photovoltaic panel welding strip through the welding piece.

[0009] Furthermore, the buffered internal wiring mechanism also includes an insulating inner box; the surface of the insulating inner box is provided with a mounting groove, and the inner row of conductive sheets and the outer row of conductive sheets are both disposed in the mounting groove; the inner wall of the insulating inner box is provided with a wiring port, which is correspondingly disposed with the flexible conductive strip so that the photovoltaic panel welding strip can pass through.

[0010] Furthermore, an isolation sheet is integrally provided on the inner wall of the insulating inner box. The isolation sheet is located between adjacent wiring ports and is used to isolate and insulate the flexible conductive strip and the welding sheet in adjacent wiring ports. The buffered inner wiring mechanism also includes a photovoltaic anti-reverse charging bypass diode, which is fixed between adjacent conductive sheet units.

[0011] Furthermore, the spiral lead mechanism also includes an external insulating head and a conductive post; the external insulating head is fixed to the end of the buffer spring away from the conductive sheet unit; the conductive post is fixed inside the external insulating head, one end of the conductive post is fixed to the buffer spring, and the other end of the conductive post is electrically connected to the external wire.

[0012] Furthermore, the spiral lead mechanism also includes a flexible anti-bending support cylinder; the flexible anti-bending support cylinder is fixedly connected to the surface of the external insulating head, and the inner wall of the flexible anti-bending support cylinder is fixedly connected to the surface of the rubber attachment tube, the surface of the external conductor, and the surface of the supporting isolation line.

[0013] Furthermore, the bottom support isolation mechanism includes a protective base and a circumferential isolation shell; the protective base is disposed on the periphery of the conductive sheet unit, the circumferential isolation shell is fixed to the inside of the protective base, and an isolation space is left between the circumferential isolation shell and the conductive sheet unit.

[0014] Furthermore, the bottom of the protective base is provided with an adhesive application groove and a wiring hole, the wiring hole being provided in correspondence with the wiring port, and the adhesive application groove being used to collect adhesive when the protective base is installed on the surface of the photovoltaic panel; the inner walls on both sides of the protective base are fixed with clips, and the bottom edge of the protective base is integrally provided with a bottom support protrusion ring.

[0015] Furthermore, the sacrificial cover mechanism includes an anti-aging sacrificial outer cover and an inner sealing cover; the inner sealing cover is fixed to the surface of the circumferential isolation shell, the anti-aging sacrificial outer cover covers the surface of the protective base, and the anti-aging sacrificial outer cover is detachably snapped onto the protective base.

[0016] Furthermore, the anti-aging sacrificial outer cover has through holes on both sides, which are engaged with the corresponding locking blocks. Flexible grooves are provided on both sides of the locking holes to improve the flexibility at the locking hole positions. The bottom of the anti-aging sacrificial outer cover has a snap-on groove, and a sealing ring is fixed to the inner wall of the anti-aging sacrificial outer cover. The surface of the sealing ring slides and seals with the surface of the protective base.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. Through the cooperation of the flexible conductive strip and buffer spring in the buffered internal wiring mechanism, an internal flexible connection is formed between the lead wire and the photovoltaic panel welding strip. At the same time, in conjunction with the spiral winding structure in the spiral lead mechanism, the external conductor and the supporting isolation line are spirally and intermittently distributed along the circumference of the rubber attachment tube, so that the lead wire itself has elastic deformation capability. Thus, when the photovoltaic module is subjected to multiple external forces such as wind load, thermal expansion and contraction due to day and night temperature differences, and dragging of external lines, it can achieve multi-level buffering and energy absorption through the bending deformation of the flexible conductive strip, the expansion and contraction deformation of the buffer spring, and the elastic extension and contraction of the spiral winding structure itself. This effectively avoids the concentration of stress at a single rigid connection point, significantly improves the comprehensive resistance to the above-mentioned multiple external forces, and fundamentally prevents fatigue fracture of the lead wire from the structure.

[0018] 2. By combining inner and outer conductive sheets with a flexible conductive strip, a flexible transition connection is formed between the conductive sheet unit and the photovoltaic panel welding strip. Compared with the direct rigid connection between the conductive sheet unit and the photovoltaic panel welding strip, this effectively buffers the relative misalignment caused by temperature changes or mechanical vibration, and avoids brittle fracture at the welding point due to stress concentration. At the same time, by setting connecting pieces and welding pieces at both ends of the flexible conductive strip, which are fixed to the conductive sheet unit and the photovoltaic panel welding strip respectively, the convenience of assembly and the reliability of connection of the flexible conductive strip are ensured.

[0019] 3. Through the cooperation of the buffer spring and the inner row of conductive sheets, an elastic buffer is formed between the conductive sheet unit and the spiral lead mechanism. When relative displacement occurs between the photovoltaic panel solder strip and the lead wire, the buffer spring absorbs the displacement energy through its own deformation, preventing the connection point between the inner row of conductive sheets and the conductive post from breaking due to direct pulling. Together with the flexible conductive strip, it forms a bidirectional flexible buffer at both ends of the conductive sheet unit, which greatly improves the fatigue life of each connection point inside the wiring device.

[0020] 4. The inner and outer rows of conductive sheets are positioned and installed using the mounting grooves on the inner insulating box and its surface, ensuring accurate positioning and electrical isolation of the conductive sheet units inside the protective base and avoiding unintended contact between the conductive sheet units. At the same time, the wiring ports provide a clear path for the photovoltaic panel welding strips and welding operation space, taking into account both the convenience of assembly and the reliability of welding quality.

[0021] 5. By using an integrated insulating sheet on the inner wall of the insulating inner box, the flexible conductive strip and welding sheet in adjacent wiring ports are separated, effectively preventing the risk of creepage or short circuit between adjacent photovoltaic panel welding strips and improving the electrical safety performance of the wiring device; by using photovoltaic anti-reverse charging bypass diodes fixed between adjacent conductive sheet units, a bypass path is provided when the photovoltaic panel is shaded or malfunctions, preventing hot spot effects from damaging the components, thus realizing the integrated design of circuit protection function and wiring structure.

[0022] 6. The conductive post is insulated and supported by an external insulating head, ensuring the insulation safety of the electrical connection transition area from the buffer spring to the external wire; the conductive post is fixed to both the buffer spring and the external wire, forming a complete conductive path from the buffer-type internal wiring mechanism to the spiral lead mechanism, ensuring the continuity of power transmission and the reliability of the connection.

[0023] 7. A flexible anti-bending support tube is fixed to the surface of the external insulating head, and its inner wall is fixed to the surface of the rubber attachment tube, the external conductor, and the supporting isolation line. A flexible stress transition zone is formed between the root of the external conductor and the rigid external insulating head, which effectively avoids fatigue breakage of the root of the external conductor due to stress concentration when it is repeatedly bent, and significantly improves the bending resistance life of the lead wire at the outlet position.

[0024] 8. The conductive sheet unit is supported from the bottom by the protective base, and the circumferential isolation shell is fixed inside the protective base. A double-layer isolation and protection structure is constructed on the outer periphery of the conductive sheet unit. The isolation space between the circumferential isolation shell and the conductive sheet unit can effectively buffer the transmission of external impact to the inner insulating box when the side of the protective base is accidentally damaged. This avoids direct damage to the wiring connections inside the inner insulating box when the side of the protective base is broken, and improves the protection redundancy and reliability of the device under complex outdoor working conditions.

[0025] 9. The adhesive groove at the bottom of the protective base can hold the adhesive when the protective base is installed on the photovoltaic panel surface, increasing the contact area and adhesion between the adhesive and the photovoltaic panel surface, thus improving the installation stability of the device; the corresponding wiring holes and terminals provide a through channel for the photovoltaic panel welding strip, avoiding bending or pressure on the welding strip; the locking block and bottom support protrusion ring respectively achieve locking and limiting of the anti-aging sacrificial cover, ensuring reliable sealing and positioning between the anti-aging sacrificial cover and the protective base.

[0026] 10. The anti-aging sacrificial cover fits snugly onto the surface of the protective base and is removable and snap-fitted. As the outermost protective component, the anti-aging sacrificial cover actively withstands the aging effects of the external environment. By periodically replacing the aged anti-aging sacrificial cover, the overall protective performance of the device is maintained, effectively slowing down the aging rate of the protective base and internal structure, and extending the overall service life of the wiring device. The sealing ring slides and seals with the surface of the protective base, ensuring the airtightness of the protective base and preventing the intrusion of moisture and dust. Through the combination of snap-fit ​​holes, flexible grooves, and snap-fit ​​grooves, quick assembly and disassembly between the anti-aging sacrificial cover and the protective base are achieved, balancing the convenience of replacement operations with the reliability of the snap-fit. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of the present invention.

[0028] Figure 2 This is a schematic diagram of the exploded structure of the present invention.

[0029] Figure 3 This is a schematic diagram of the internal structure of the bottom support isolation mechanism of the present invention.

[0030] Figure 4 This is a cross-sectional view of the location of the bottom support isolation mechanism and the sacrificial cover mechanism of the present invention.

[0031] Figure 5 This is a schematic diagram of the exploded structure at the locations of the bottom support isolation mechanism and the sacrificial cover mechanism of the present invention.

[0032] Figure 6 This is a top-view diagram of the exploded structure at the location of the protective base and the anti-aging sacrificial outer cover of the present invention.

[0033] Figure 7 This is a schematic diagram of the structure at the location of the circumferential isolation shell of the present invention.

[0034] Figure 8 This is a schematic diagram of the exploded structure at the location of the buffer-type internal wiring mechanism of the present invention.

[0035] Figure 9 This is a schematic diagram of the spiral lead wire mechanism of the present invention.

[0036] Figure 10 This is a cross-sectional view of the spiral lead wire mechanism of the present invention.

[0037] Markings in the diagram: 101, Inner row of conductive sheets; 102, Outer row of conductive sheets; 103, Flexible conductive strip; 104, Buffer spring; 105, Photovoltaic anti-reverse charging bypass diode; 106, Connecting piece; 107, Welding piece; 108, Insulating inner box; 109, Mounting groove; 110, Wiring port; 111, Isolating piece; 201, External insulating head; 202, Rubber attachment tube; 203, External wire; 204, Support isolation line; 205, Flexible anti-bending support cylinder; 206, Conductive post; 20 7. Photovoltaic plug; 208. Rubber tensile core; 209. Silicone rubber flame-retardant sponge filler block; 301. Protective base; 302. Circumferential isolation shell; 303. Bottom support protrusion ring; 304. Locking block; 305. Glue application groove; 306. Wiring hole; 307. Support block; 308. Sealing gasket; 309. Inner bolt hole; 401. Anti-aging sacrificial outer cover; 402. Sealing ring; 403. Clip-on groove; 404. Locking hole; 405. Flexible groove; 406. Inner sealing plate; 407. Outer bolt hole. Detailed Implementation

[0038] The embodiments of the present invention are described in detail below. To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. 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.

[0039] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0040] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0041] In the description of this invention, it should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0042] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0043] like Figures 1 to 10 As shown in the illustration, this embodiment provides a flexible wiring lead-out device for photovoltaic modules in a park, including a buffer-type inner wiring mechanism, a spiral lead-out mechanism, a bottom support isolation mechanism, and a sacrificial cover mechanism. The spiral lead-out mechanism is fixed to one end of the buffer-type inner wiring mechanism and is used to connect the photovoltaic panel to the main circuit. The bottom support isolation mechanism is disposed on the surface of the buffer-type inner wiring mechanism to increase the isolation space between the outer periphery of the buffer-type inner wiring mechanism and the outside world. The sacrificial cover mechanism covers the surface of the bottom support isolation mechanism to delay the aging of the buffer-type inner wiring mechanism and the bottom support isolation mechanism. The buffer-type inner wiring mechanism forms a flexible connection between the spiral lead-out mechanism and the photovoltaic panel welding strip. The spiral lead-out mechanism achieves elastic deformation through its own spiral structure. The two work together to effectively improve the device's resistance to multiple external forces such as wind loads, thermal expansion and contraction deformation, and dragging of external lines, preventing fatigue fracture of the lead-out wires.

[0044] like Figure 1 , Figure 2 and Figure 8 As shown, the buffered internal wiring mechanism includes a conductive sheet unit, a flexible conductive strip 103, and a buffer spring 104. The flexible conductive strip 103 is connected to one end of the conductive sheet unit for flexible connection with the photovoltaic panel welding strip. The buffer spring 104 is connected to the other end of the conductive sheet unit for flexible connection with the spiral lead mechanism.

[0045] The conductive sheet unit includes an inner row of conductive sheets 101 and an outer row of conductive sheets 102. The inner row of conductive sheets 101 and the outer row of conductive sheets 102 together constitute the conductive sheet unit, used for welding support of internal circuitry. Both the inner row of conductive sheets 101 and the outer row of conductive sheets 102 are made of copper, possessing good conductivity and welding performance. One end of a buffer spring 104 is fixedly connected to the inner row of conductive sheets 101. The buffer spring 104 is a helical spring made of conductive metal material, possessing both conductive function and elastic expansion capability.

[0046] An insulating layer made of flexible insulating material is fixedly provided on the surface of the flexible conductive strip 103 to cover the exposed part of the flexible conductive strip 103 and prevent short circuits. One end of the flexible conductive strip 103 is provided with a connecting piece 106, through which the flexible conductive strip 103 is fixedly welded to the inner row of conductive sheets 101 or the outer row of conductive sheets 102. The other end of the flexible conductive strip 103 is provided with a welding piece 107, through which the flexible conductive strip 103 is fixedly welded to the photovoltaic panel welding strip. The flexible conductive strip 103 itself has bending deformation capability. When relative displacement occurs between the photovoltaic panel welding strip and the conductive sheet unit, the flexible conductive strip 103 absorbs the displacement energy through its own bending deformation, thereby avoiding stress concentration at the weld point and subsequent breakage.

[0047] The buffered internal wiring mechanism also includes an insulating inner box 108. The insulating inner box 108 is fixedly connected between the protective base 301 and the circumferential isolation shell 302, providing insulating support for the inner row of conductive sheets 101 and the outer row of conductive sheets 102. The insulating inner box 108 is made of insulating material (such as polyphenylene ether PPE or polycarbonate PC), possessing good electrical insulation and heat resistance properties. An installation groove 109 is embedded in the surface of the insulating inner box 108. Both the inner row of conductive sheets 101 and the outer row of conductive sheets 102 are disposed inside the installation groove 109. The contour of the installation groove 109 matches the shape of the inner row of conductive sheets 101 and the outer row of conductive sheets 102 to achieve positioning and installation. A wiring port 110 is provided through the inner wall of the insulating inner box 108. The wiring ports 110 are correspondingly arranged with the flexible conductive strip 103. The number of wiring ports 110 is equal to the number of conductive sheet units, providing welding space between the photovoltaic panel welding strip and the welding sheet 107 for the photovoltaic panel welding strip to pass through. An insulating sheet 111 is integrally provided on the inner wall of the insulating inner box 108. The insulating sheet 111 is located between adjacent wiring ports 110 and is used to isolate and insulate the flexible conductive strip 103 and the welding sheet 107 in the adjacent wiring ports 110, effectively preventing the risk of creepage or short circuit between adjacent photovoltaic panel welding strips.

[0048] The buffered internal wiring mechanism also includes a photovoltaic reverse-charging bypass diode 105. The photovoltaic reverse-charging bypass diode 105 is fixedly installed between adjacent conductive sheet units to provide a bypass path when the photovoltaic panel is shaded or malfunctions, preventing hot spot damage to the module. The two ends of the photovoltaic reverse-charging bypass diode 105 are electrically connected to the adjacent conductive sheet units. When the photovoltaic panel is working normally, the photovoltaic reverse-charging bypass diode 105 is in a reverse cutoff state; when the photovoltaic panel is shaded or malfunctions, the photovoltaic reverse-charging bypass diode 105 is forward-conducting, forming a bypass path to protect the photovoltaic panel.

[0049] The buffered internal wiring mechanism, through the coordinated action of the flexible conductive strip 103 and the buffer spring 104, forms a bidirectional flexible buffer at both ends of the internal wiring mechanism: the flexible conductive strip 103 provides a flexible transition connection between the conductive sheet unit and the photovoltaic panel welding strip; the buffer spring 104 provides elastic buffering between the conductive sheet unit and the spiral lead mechanism. When the photovoltaic module is subjected to multiple external forces such as wind load, thermal expansion and contraction due to day and night temperature differences, and dragging of external lines, the flexible conductive strip 103 absorbs and dissipates external energy through bending deformation, and the buffer spring 104 absorbs and dissipates external energy through expansion and contraction deformation, effectively preventing stress concentration at the connection points at both ends of the conductive sheet unit, thereby significantly improving the fatigue life of the connection points.

[0050] like Figure 1 , Figure 2 , Figure 9 and Figure 10 As shown, the spiral lead mechanism includes an external insulating head 201, a rubber attachment tube 202, an external conductor 203, a support isolation wire 204, a flexible anti-bending support cylinder 205, a conductive post 206, a photovoltaic plug 207, a rubber tensile core 208, and a silicone rubber flame-retardant sponge filling block 209.

[0051] An external insulating head 201 is located at the end of the buffer spring 104 furthest from the inner row of conductive sheets 101. The external insulating head 201 is made of insulating material and is used to provide insulating support for the conductive post 206. The conductive post 206 is fixedly installed inside the external insulating head 201. One end of the conductive post 206 is fixedly welded to one end of the buffer spring 104, achieving electrical and mechanical connection between the buffer spring 104 and the conductive post 206. The other end of the conductive post 206 is electrically connected to the external wire 203. The buffer spring 104 is electrically connected to the external wire 203 through the conductive post 206, thus forming a complete conductive path from the conductive sheet unit → buffer spring 104 → conductive post 206 → external wire 203.

[0052] The rubber attachment tube 202 is fixedly connected to the end of the external insulating head 201 away from the buffer spring 104. The rubber attachment tube 202 is a cylindrical rubber tube made of flexible rubber material, used to support the external conductor 203 and the insulating wire 204. The external conductor 203 is spirally wound around the surface of the rubber attachment tube 202, and the surface of the external conductor 203 is fixedly connected to the surface of the rubber attachment tube 202. One end of the external conductor 203 is fixedly connected to one end of the external insulating head 201. The external conductor 203 is a conductor with a conductive core and an outer insulating layer. Its spiral winding structure gives it elastic deformation capability. When subjected to tension or bending, the spiral structure can absorb deformation through changes in pitch, thereby improving the flexibility and tensile strength of the external conductor 203.

[0053] The supporting insulating wire 204 is also spirally wound on the surface of the rubber attachment tube 202, and the surface of the supporting insulating wire 204 is fixedly connected to the surface of the rubber attachment tube 202. One end of the supporting insulating wire 204 is fixedly connected to one end of the external insulating head 201. The supporting insulating wire 204 and the external conductor 203 are distributed intermittently in a spiral along the circumference of the rubber attachment tube 202, that is, the supporting insulating wire 204 and the external conductor 203 are alternately arranged on the surface of the rubber attachment tube 202, with a predetermined angle between them. The supporting insulating wire 204 is made of tensile fiber material and has high tensile strength. When the external conductor 203 retracts, the supporting insulating wire 204 forms an isolation space through its own rigidity, preventing unintended contact between the turns of the external conductor 203; when the external conductor 203 extends, the supporting insulating wire 204 provides tensile limiting function, preventing the external conductor 203 from being overstretched and damaged. The intermittent spiral distribution of the support isolation line 204 and the external conductor 203 ensures that the external conductor 203 is always constrained and guided by the support isolation line 204 during elastic deformation, thus guaranteeing the deformation stability of the external conductor 203.

[0054] The flexible anti-bending support cylinder 205 is fixedly sleeved on the surface of the external insulating head 201, and the inner wall of the flexible anti-bending support cylinder 205 is fixedly connected to the surfaces of the rubber attachment tube 202, the external conductor 203, and the supporting isolation line 204. The flexible anti-bending support cylinder 205 is a conical cylindrical structure made of flexible rubber material, with its large end sleeved on the surface of the external insulating head 201 and its small end sleeved on the surface of the rubber attachment tube 202. The flexible anti-bending support cylinder 205 forms a flexible stress transition zone at the root of the external conductor 203 (i.e., the connection between the external conductor 203 and the external insulating head 201), preventing the roots of the rubber attachment tube 202, the external conductor 203, and the supporting isolation line 204 from easily breaking due to repeated bending.

[0055] A rubber tensile core 208 is fixedly connected inside the rubber attachment tube 202. The rubber tensile core 208 is a tubular elastic bladder made of tensile rubber material and extends axially along the rubber attachment tube 202. The rubber tensile core 208 is used to improve the tensile strength of the external conductor 203. When the external conductor 203 is subjected to a pulling force, the rubber tensile core 208 absorbs the pulling energy through its own elastic tension, reducing the stress on the external conductor 203. A silicone rubber flame-retardant sponge filler 209 is fixedly installed inside the rubber tensile core 208. The silicone rubber flame-retardant sponge filler 209 is made of flame-retardant silicone rubber sponge material and has the characteristics of being lightweight, flame-retardant, and providing elastic support. The silicone rubber flame-retardant sponge filler block 209 is used to support the rubber tensile core 208 to maintain its expanded state under normal conditions, thereby ensuring that the rubber attachment tube 202 maintains its round shape under normal conditions and preventing the rubber attachment tube 202 from collapsing inward due to its own weight or external force, thus ensuring the stability of the spiral structure of the external wire 203.

[0056] The photovoltaic plug 207 is fixedly connected to the end of the rubber attachment tube 202 away from the external insulating head 201. The photovoltaic plug 207 is fixedly connected to the support isolation line 204, and the photovoltaic plug 207 is electrically connected to the external wire 203 to connect the external wire 203 to the external main circuit.

[0057] like Figures 1 to 8 As shown, the bottom support isolation mechanism includes a protective base 301, a circumferential isolation shell 302, a bottom support protrusion ring 303, a locking block 304, an adhesive application groove 305, a wiring hole 306, a support block 307, a sealing gasket 308, and an inner bolt hole 309.

[0058] The protective base 301 is disposed around the inner row of conductive sheets 101 and the outer row of conductive sheets 102, providing bottom support for the inner row of conductive sheets 101, the outer row of conductive sheets 102, and the insulating inner box 108. The protective base 301 has a rectangular basin-shaped structure and is integrally injection molded from engineering plastics (such as polyphenylene ether, PPE), possessing good mechanical strength and weather resistance. The interior of the protective base 301 forms an accommodating space, within which the insulating inner box 108 and the conductive sheet units are all disposed.

[0059] The circumferential isolation shell 302 is fixedly connected to the inside of the protective base 301. The circumferential isolation shell 302 is a ring-shaped shell structure that surrounds the insulating inner box 108. An isolation space is left between the circumferential isolation shell 302 and the insulating inner box 108. The function of the circumferential isolation shell 302 is as follows: when the side of the protective base 301 is broken due to accidental collision or aging, the circumferential isolation shell 302 acts as a second protective barrier, effectively blocking the transmission of external impacts into the insulating inner box 108. At the same time, the isolation space between the circumferential isolation shell 302 and the insulating inner box 108 plays a buffering and heat insulation role, further increasing the outer circumferential isolation space of the insulating inner box 108, and preventing the breakage of the side of the protective base 301 from directly affecting the wiring connections inside the insulating inner box 108.

[0060] The bottom edge of the protective base 301 is integrally provided with a bottom support protrusion 303, which extends continuously along the circumference of the bottom of the protective base 301 to limit the anti-aging sacrificial outer cover 401. The inner walls of both sides of the protective base 301 are fixedly provided with locking blocks 304, which are protruding structures used to engage with the anti-aging sacrificial outer cover 401. An adhesive application groove 305 is embedded in the bottom of the protective base 301. The adhesive application groove 305 is an annular groove used to collect adhesive when the protective base 301 is installed on the photovoltaic panel surface. The adhesive application groove 305 increases the contact area between the adhesive and the protective base 301 and the photovoltaic panel surface, thereby improving the adhesive adhesion. The bottom of the protective base 301 has a through-hole 306. The through-hole 306 is located on one side of the wiring port 110 and is set to correspond to the wiring port 110. It is used to make way for the welding of the photovoltaic panel welding strip, so that the photovoltaic panel welding strip can pass through the wiring hole 306 and the wiring port 110 from the surface of the photovoltaic panel and enter the interior of the insulating inner box 108 to be welded to the welding piece 107.

[0061] A support block 307 is fixedly connected to the interior of the circumferential isolation shell 302. The support block 307 is a block structure used to form internal bolt holes 309. A sealing gasket 308 is fixedly attached to the surface of the circumferential isolation shell 302. The sealing gasket 308 is an annular elastic washer made of rubber material and is used to seal between the circumferential isolation shell 302 and the inner cover plate 406. The internal bolt holes 309 are threaded holes that are formed between the sealing gasket 308, the circumferential isolation shell 302, and the support block 307. The internal bolt holes 309 are used to install bolts to fix the inner cover plate 406.

[0062] like Figure 1 , Figure 2 and Figures 4 to 7 As shown, the sacrificial cover mechanism includes an anti-aging sacrificial outer cover 401, a sealing ring 402, a snap-on groove 403, a locking hole 404, a flexible groove 405, an inner sealing cover plate 406, and an outer bolt hole 407.

[0063] The anti-aging sacrificial cover 401 is fitted onto the surface of the protective base 301, providing protection for the interior of the protective base 301 through the sacrifice and periodic replacement of the anti-aging sacrificial cover 401. The anti-aging sacrificial cover 401 is a rectangular cover made of a plastic material with moderate weather resistance. As the outermost protective component, it actively withstands the aging effects of the external environment (such as ultraviolet rays, humidity, temperature changes, etc.) during use. By periodically replacing the aged anti-aging sacrificial cover 401, the overall protective performance of the device is maintained, thereby effectively slowing down the aging rate of the protective base 301 and the inner sealing cover plate 406, and extending the overall service life of the wiring device.

[0064] A sealing ring 402 is fixedly connected to the inner wall of the anti-aging sacrificial outer cover 401, and the surface of the sealing ring 402 is slidably connected to the surface of the protective base 301 to seal between the anti-aging sacrificial outer cover 401 and the protective base 301, while simultaneously sealing the inner cover plate 406 to prevent moisture and dust from entering the interior of the protective base 301. A snap-on groove 403 is embedded in the bottom of the anti-aging sacrificial outer cover 401. The snap-on groove 403 is an arc-shaped groove used to provide a force support point when the anti-aging sacrificial outer cover 401 needs to be pried open for replacement. A locking hole 404 is provided through both sides of the anti-aging sacrificial outer cover 401. The locking hole 404 is correspondingly provided with a locking block 304 to engage with the locking block 304 to lock the anti-aging sacrificial outer cover 401. Flexible grooves 405 are provided on both sides of the locking hole 404. Flexible grooves 405 are long strip-shaped through grooves provided on the edge of the locking hole 404. They are used to improve the flexibility at the location of the locking hole 404, so that the anti-aging sacrificial cover 401 is more likely to undergo local elastic deformation during the locking and disassembly process, and it is convenient for the locking block 304 to enter and exit the locking hole 404.

[0065] The inner cover plate 406 is bolted to the surface of the circumferential isolation shell 302 to seal the top of the circumferential isolation shell 302. The inner cover plate 406 is a rectangular plate whose outline dimensions match the opening dimensions of the circumferential isolation shell 302. External bolt holes 407 are formed through the surface of the inner cover plate 406, corresponding to internal bolt holes 309, to accommodate bolts and fix the inner cover plate 406 to the surface of the circumferential isolation shell 302.

[0066] The working principle and process of this invention are as follows: In use, the solder ribbon of the photovoltaic module is first inserted through the wiring hole 306 at the bottom of the protective base 301, and then introduced into the inner insulating box 108 through the wiring port 110. The solder ribbon is then fixedly welded to the welding piece 107 at the end of the flexible conductive strip 103 to achieve electrical connection between the solder ribbon and the conductive sheet unit. The flexible conductive strip 103 is fixedly welded to the inner row of conductive sheets 101 or the outer row of conductive sheets 102 through the connecting piece 106. The other end of the inner row of conductive sheets 101 is fixedly welded to the conductive post 206 in the spiral lead mechanism through the buffer spring 104. The conductive post 206 is electrically connected to the external wire 203. The external wire 203 extends to the photovoltaic plug 207 through the rubber attachment tube 202 and is connected to the external main circuit through the photovoltaic plug 207. This forms a complete conductive path from photovoltaic panel welding strip → welding piece 107 → flexible conductive strip 103 → connecting piece 106 → conductive piece unit (inner row of conductive pieces 101 / outer row of conductive pieces 102) → buffer spring 104 → conductive post 206 → external wire 203 → photovoltaic plug 207 → external main circuit.

[0067] During the operation of photovoltaic modules, when subjected to wind loads, the external conductor 203 sways and vibrates at low frequencies. Because the external conductor 203 has a spiral winding structure, it possesses elastic deformation capabilities and can absorb bending energy through changes in the pitch of the spiral structure, thereby avoiding stress concentration. Simultaneously, the support isolation line 204 and the external conductor 203 are spirally and intermittently distributed, forming an isolation space when the external conductor 203 contracts to prevent unintended contact between coils, and providing tensile limits when the external conductor 203 extends to prevent excessive stretching. The flexible anti-bending support cylinder 205 forms a flexible stress transition zone at the root of the external conductor 203, effectively preventing breakage at the root of the external conductor 203 due to repeated bending.

[0068] When the temperature difference between day and night causes thermal expansion and contraction, the buffer spring 104 absorbs the displacement energy between the conductive sheet unit and the conductive post 206 through its expansion and contraction deformation, preventing the weld joint between the inner conductive sheet 101 and the conductive post 206 from breaking due to tension. At the same time, the flexible conductive strip 103 absorbs the displacement energy between the conductive sheet unit and the photovoltaic panel welding strip through its own bending deformation, preventing the weld joint between the welding piece 107 and the photovoltaic panel welding strip from breaking due to misalignment. The buffer spring 104 and the flexible conductive strip 103 together constitute a bidirectional flexible buffer at both ends of the conductive sheet unit, realizing the displacement dissipation of the internal connection points.

[0069] When an external line is accidentally dragged, the pulling force is transmitted sequentially through the photovoltaic plug 207 → external wire 203 → conductive post 206 → buffer spring 104 → conductive sheet unit → flexible conductive strip 103 → welding piece 107 → photovoltaic panel welding strip. In this path, the spirally wound external wire 203 absorbs some of the pulling energy through the extension of its spiral structure; the rubber tensile core 208 further absorbs the pulling energy through its own elastic stretching; the buffer spring 104 absorbs the subsequently transmitted pulling energy through its expansion and contraction deformation; and the flexible conductive strip 103 absorbs the pulling energy finally transmitted to the welding strip through its bending deformation. This multi-stage buffering and energy-absorbing transmission path effectively avoids the pulling force being concentrated on a single connection point, thus ensuring the reliability of the connection at each point.

[0070] In terms of protection, the protective base 301 provides bottom support for the insulating inner box 108 and the conductive sheet unit, while the circumferential isolation shell 302 forms a second protective barrier inside the protective base 301. The anti-aging sacrificial cover 401, as the outermost protective component, covers the surface of the protective base 301 and is detachably snapped into place, actively bearing the aging effects of the external environment. By periodically replacing the aged anti-aging sacrificial cover 401, the aging rate of the protective base 301 and its internal structure is effectively slowed down, extending the overall service life of the wiring device.

[0071] In this embodiment, the inner conductive sheet 101 and the outer conductive sheet 102 are preferably copper conductive sheets, but other conductive materials, such as aluminum conductive sheets or copper alloy conductive sheets, can also be used. The flexible conductive strip 103 is preferably a multi-strand copper wire wrapped with a flexible insulating sheath, but other flexible conductive materials, such as braided copper strips or flexible circuit boards, can also be used. The buffer spring 104 is preferably a helical spring, but other elastic elements, such as disc springs or wave springs, can also be used.

[0072] The insulating inner box 108 and the protective base 301 are preferably injection molded from polyphenylene oxide (PPE), but other engineering plastics such as polycarbonate (PC), polyamide (PA), or acrylonitrile-butadiene-styrene copolymer (ABS) can also be used. The circumferential isolation shell 302 is preferably integrally injection molded with the protective base 301, but it can also be a separate structure, fixed inside the protective base 301 by snap-fit ​​or welding.

[0073] The external conductor 203 is preferably a copper-core polyvinyl chloride insulated conductor, but a copper-core cross-linked polyethylene insulated conductor or a tin-plated copper-core conductor can also be used. The supporting insulation wire 204 is preferably a polyester fiber wire, but other tensile fiber wires, such as aramid fiber wire or nylon wire, can also be used. The rubber attachment tube 202 and the rubber tensile core 208 are preferably made of silicone rubber, but other elastomer materials, such as ethylene propylene diene monomer (EPDM) rubber or fluororubber (FKM), can also be used. The silicone rubber flame-retardant sponge filler block 209 is preferably a flame-retardant silicone rubber sponge, but other flame-retardant flexible filler materials, such as polyurethane flame-retardant sponge or ceramic fiber cotton, can also be used.

[0074] The anti-aging sacrificial cover 401 is preferably injection molded from polypropylene (PP) material with moderate weather resistance to create a reasonable aging rate gradient between the anti-aging sacrificial cover 401 and the protective base 301. That is, the aging rate of the anti-aging sacrificial cover 401 is faster than that of the protective base 301, thereby achieving the technical effect of protecting the protective base 301 by periodically replacing the anti-aging sacrificial cover 401. However, other plastic materials, such as polyethylene (PE) or polyvinyl chloride (PVC), can also be used.

[0075] The above description is only a part of the specific embodiments of the present invention. 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 flexible wiring lead-out device for photovoltaic modules in a park, characterized in that: It includes a buffer-type internal wiring mechanism, a spiral lead wire mechanism, a bottom support isolation mechanism, and a sacrificial cover mechanism; The spiral lead mechanism is fixed to one end of the buffered inner wiring mechanism, the bottom support isolation mechanism is disposed on the surface of the buffered inner wiring mechanism, and the sacrificial cover mechanism covers the surface of the bottom support isolation mechanism. The buffered internal wiring mechanism includes a conductive sheet unit, a flexible conductive strip (103), and a buffer spring (104). The flexible conductive strip (103) is connected to one end of the conductive sheet unit for flexible connection with the photovoltaic panel welding strip. The buffer spring (104) is connected to the other end of the conductive sheet unit for flexible connection with the spiral lead wire mechanism. The spiral lead mechanism includes a rubber attachment tube (202), an external conductor (203), and a support isolation line (204). The external conductor (203) and the support isolation line (204) are both spirally wound around the surface of the rubber attachment tube (202) and are distributed intermittently in a spiral along the circumference of the rubber attachment tube (202).

2. The flexible wiring lead-out device for photovoltaic modules in a park according to claim 1, characterized in that: The conductive sheet unit includes an inner row of conductive sheets (101) and an outer row of conductive sheets (102). One end of the buffer spring (104) is fixedly connected to the inner row of conductive sheets (101); One end of the flexible conductive strip (103) is provided with a connecting piece (106), and the flexible conductive strip (103) is fixedly connected to the inner row of conductive sheets (101) or the outer row of conductive sheets (102) through the connecting piece (106). The other end of the flexible conductive strip (103) is provided with a welding piece (107), and the flexible conductive strip (103) is fixed to the photovoltaic panel welding strip through the welding piece (107).

3. A flexible wiring lead-out device for photovoltaic modules in a park according to claim 2, characterized in that: The buffered internal wiring mechanism also includes an insulating inner box (108). The surface of the insulating inner box (108) is provided with a mounting groove (109), and the inner row of conductive sheets (101) and the outer row of conductive sheets (102) are both disposed in the mounting groove (109); The inner wall of the insulating inner box (108) is provided with a wiring port (110), which is correspondingly provided with the flexible conductive strip (103) so that the photovoltaic panel welding strip can pass through.

4. A flexible wiring lead-out device for photovoltaic modules in a park according to claim 3, characterized in that: The inner wall of the insulating inner box (108) is integrally provided with an isolation plate (111). The isolation plate (111) is located between adjacent wiring ports (110) and is used to isolate and insulate the flexible conductive strip (103) and the welding piece (107) in adjacent wiring ports (110). The buffered internal wiring mechanism also includes a photovoltaic anti-reverse charging bypass diode (105), which is fixed between adjacent conductive sheet units.

5. A flexible wiring lead-out device for photovoltaic modules in a park according to claim 1, characterized in that: The spiral lead mechanism also includes an external insulating head (201) and a conductive post (206). The external insulating head (201) is fixed to the end of the buffer spring (104) away from the conductive sheet unit; The conductive post (206) is fixed inside the external insulating head (201). One end of the conductive post (206) is fixed to the buffer spring (104), and the other end of the conductive post (206) is electrically connected to the external wire (203).

6. A flexible wiring lead-out device for photovoltaic modules in a park according to claim 5, characterized in that: The spiral lead wire mechanism also includes a flexible anti-bending support cylinder (205). The flexible anti-bending support cylinder (205) is fixed to the surface of the external insulating head (201), and the inner wall of the flexible anti-bending support cylinder (205) is fixed to the surface of the rubber attachment tube (202), the surface of the external wire (203), and the surface of the support isolation line (204).

7. A flexible wiring lead-out device for photovoltaic modules in a park according to claim 3, characterized in that: The bottom support isolation mechanism includes a protective base (301) and a circumferential isolation shell (302). The protective base (301) is disposed on the periphery of the conductive sheet unit, and the circumferential isolation shell (302) is fixed to the inside of the protective base (301). An isolation space is left between the circumferential isolation shell (302) and the conductive sheet unit.

8. A flexible wiring lead-out device for photovoltaic modules in a park according to claim 7, characterized in that: The bottom of the protective base (301) is provided with an adhesive groove (305) and a wiring hole (306). The wiring hole (306) is provided in correspondence with the wiring port (110). The adhesive groove (305) is used to collect adhesive when the protective base (301) is installed on the surface of the photovoltaic panel. The protective base (301) has a locking block (304) fixed to the inner walls on both sides, and a bottom support protrusion ring (303) integrally provided on the bottom edge of the protective base (301).

9. A flexible wiring lead-out device for photovoltaic modules in a park according to claim 8, characterized in that: The sacrificial cover mechanism includes an anti-aging sacrificial outer cover (401) and an inner sealing plate (406). The inner cover plate (406) is fixed to the surface of the circumferential isolation shell (302), the anti-aging sacrificial outer cover (401) covers the surface of the protective base (301), and the anti-aging sacrificial outer cover (401) and the protective base (301) are detachably snapped together.

10. A flexible wiring lead-out device for photovoltaic modules in a park according to claim 9, characterized in that: The anti-aging sacrificial outer cover (401) has through holes (404) on both sides, and the through holes (404) are engaged with the corresponding locking blocks (304). Flexible grooves (405) are provided on both sides of the through holes (404) to improve the flexibility at the position of the through holes (404). The bottom of the anti-aging sacrificial cover (401) is provided with a snap-on groove (403), and the inner wall of the anti-aging sacrificial cover (401) is fixed with a sealing ring (402). The surface of the sealing ring (402) slides and seals with the surface of the protective base (301).

Images