Photovoltaic module junction box

Abstract

The utility model discloses a photovoltaic module junction box. The photovoltaic module junction box comprises a junction box body, the top surface of which is provided with a positioning groove; the junction box diode is fixed in the junction box body; the junction box diode is provided with a riveting hole corresponding to the positioning groove; the bus bar outgoing line is arranged on the junction box diode; the bus bar outgoing line is provided with a lead fixing hole corresponding to the riveting hole; the core-pulling expansion rivet penetrates through the positioning groove and is fixed in the riveting hole; the bottom of the core-pulling expansion rivet is fixed in the riveting hole in an expansion mode, the middle of the core-pulling expansion rivet penetrates through the lead fixing hole, and the top of the core-pulling expansion rivet tightly presses the bus bar outgoing line. According to the application, the bus bar outgoing line is tightly connected with the junction box diode without pseudo soldering, and the situation that the bypass diode is subjected to thermal breakdown damage and even the junction box is burnt due to pseudo soldering heating is avoided.

Description

Technical Field

[0001] The present application relates to the technical field of solar cell manufacturing, and in particular to a photovoltaic module junction box. Background Art

[0002] The junction box of a photovoltaic module is an important component of a photovoltaic module and is an electrical component that integrates circuit design and material application. In the existing junction box of a photovoltaic module, a junction box diode with a conductor material (such as a copper conductor) is provided, and the busbar lead wire is directly welded to the conductor of the junction box diode. There are many cold welds at the connection between the busbar lead wire and the junction box diode in the junction box, resulting in cold welds in the junction box of the photovoltaic module. When the junction box of the photovoltaic module is powered on, the cold weld will heat up. When the heat accumulated at the cold weld exceeds the thermal deformation temperature of the insulating material of the junction box, the junction box will age and deform. The longer the junction box diode is turned on, the greater the risk of deformation and aging of the junction box. When the temperature is greater than the upper limit of the junction temperature of the junction box diode, the high temperature will cause the junction box diode to be damaged by thermal breakdown, or even burn the junction box of the photovoltaic module. Utility Model Content

[0003] The embodiment of the present application provides a photovoltaic module junction box, which can solve the technical problem that there are many cold solder joints at the connection between the bus bar lead wire and the junction box diode in the current junction box, which causes the cold solder joints to heat up. The high temperature will cause the junction box diode to suffer thermal breakdown and damage, or even burn the junction box.

[0004] The present application provides a photovoltaic module junction box, including:

[0005] The junction box body has a positioning groove on its top surface;

[0006] A junction box diode is fixed in the junction box body; the junction box diode is provided with a riveting hole corresponding to the positioning groove;

[0007] A busbar lead wire is arranged on the junction box diode; the busbar lead wire is provided with a lead fixing hole corresponding to the riveting hole;

[0008] A core-pulling expansion rivet passes through the positioning groove and is fixed in the rivet hole; the bottom of the core-pulling expansion rivet is expanded and fixed in the rivet hole, the middle of the core-pulling expansion rivet passes through the lead fixing hole, and the top of the core-pulling expansion rivet presses the busbar lead wire.

[0009] Furthermore, the core-pulling expansion rivet includes a nail rod, a metal tube column and a meson; the meson is connected to the outer side of one end of the metal tube column in a ring shape, one end of the nail rod passes through the metal tube column, and the other end of the nail rod is clamped with the end of the metal tube column away from the meson, and the meson is arranged corresponding to the middle position of the nail rod; the metal tube column can be squeezed and expanded by the nail rod and fixed in the rivet hole, the metal tube column passes through the lead fixing hole, and the meson presses the bus bar lead wire on the junction box diode.

[0010] Furthermore, the positioning groove is rectangular, the riveting hole is runway-shaped, and the width of the riveting hole is smaller than the width of the positioning groove.

[0011] Furthermore, the lead fixing hole is in a racetrack shape, and the width of the lead fixing hole is smaller than the width of the meson.

[0012] Furthermore, the diameter of the metal tube column is 2-6.4 mm, the length of the nail rod is 4-38 mm, and the diameter of the meson is 3.85-12.5 mm.

[0013] Furthermore, the photovoltaic module junction box is provided with two riveting points, the top surface of the junction box body is provided with two positioning grooves, the bus bar lead wires are provided with two, the core-pulling expansion rivets are provided with two, and each bus bar lead wire extends from the end inside the junction box body to the middle.

[0014] Furthermore, the midline point of the rivet hole is 1-15 mm away from the lead fixing hole of the busbar lead wire, and 1-10 mm away from the edge of the junction box diode, and the width of the rivet hole is 1-20 mm.

[0015] Furthermore, the lead fixing hole is located at the head of the busbar lead wire, and the center point of the lead fixing hole is 1-20 mm away from the edge of the busbar lead wire; the length of the lead fixing hole is 1-15 mm, and the width of the lead fixing hole is 1-6 mm.

[0016] Furthermore, the depth of the positioning groove is 1-5 mm, the length of the positioning groove is 1-10 mm, and the width of the positioning groove is 1-10 mm.

[0017] Further, the photovoltaic module junction box further comprises: a diode cable connection port, which is provided at the end of the junction box diode away from the busbar lead wire;

[0018] When the rivet hole is in a racetrack shape, the rivet hole has a long diameter and a short diameter perpendicular to the long diameter, and a bisector perpendicular to the long diameter of the rivet hole bisects the diode connection port.

[0019] The photovoltaic module junction box provided in the embodiment of the present application adopts a core-pulling expansion rivet to fix the lead fixing hole of the bus bar lead wire with the rivet hole of the junction box diode, and the top of the core-pulling expansion rivet presses the bus bar lead wire to make the bus bar lead wire and the junction box diode tightly connected, so as to achieve a tight connection between the bus bar lead wire and the junction box diode without the occurrence of cold solder joints, thereby avoiding thermal breakdown damage to the bypass diode due to heat generated by the cold solder joint, and even burning of the junction box. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The technical solution and other beneficial effects of the present application will be made apparent by describing in detail the specific implementation methods of the present application in conjunction with the accompanying drawings.

[0021] Figure 1 A schematic diagram of the top view of the photovoltaic module junction box provided in one embodiment of the present application.

[0022] Figure 2 A partial structural cross-sectional view of a photovoltaic module junction box provided in one embodiment of the present application.

[0023] Figure 3 A schematic structural diagram of a blind expansion rivet provided in one embodiment of the present application.

[0024] Figure 4 A schematic diagram of the end structure of a busbar lead provided in one embodiment of the present application.

[0025] Figure 5 A schematic diagram of the structure of a riveting machine head provided in one embodiment of the present application.

[0026] Figure 6 A schematic diagram of the structure of installing a blind expansion rivet using a riveting machine head provided in one embodiment of the present application.

[0027] Figure 7 A schematic structural diagram of the corresponding installation positions of the blind expansion rivets provided in one embodiment of the present application.

[0028] Figure 8 A schematic diagram of the comparison structure before and after riveting of a blind expansion rivet installed by a riveting machine head provided in an embodiment of the present application.

[0029] The markings in the figure are as follows: junction box body 1, positioning groove 11, junction box diode 2, rivet hole 21, bus bar lead wire 3, lead fixing hole 31, core-pulling expansion rivet 4, nail rod 41, metal pipe column 42, pion 43, riveting machine head 5, diode cable connection port 6. DETAILED DESCRIPTION

[0030] The technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present application.

[0031] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, an electrical connection, or mutual communication; it can be a direct connection, or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0032] For details, please refer to Figures 1 to 4 An embodiment of the present application provides a photovoltaic module junction box, which includes: a junction box body 1, a junction box diode 2, a bus bar lead wire 3 and a core-pulling expansion rivet 4.

[0033] A positioning groove 11 is provided on the top surface of the junction box body 1; the junction box diode 2 is fixed in the junction box body 1; a rivet hole 21 is provided corresponding to the positioning groove 11 for the junction box diode 2; a bus bar lead 3 is provided on the junction box diode 2; a lead fixing hole 31 is provided corresponding to the rivet hole 21 for the bus bar lead 3; a core-pulling expansion rivet 4 passes through the positioning groove 11 and is fixed in the rivet hole 21; the bottom of the core-pulling expansion rivet 4 is expanded and fixed in the rivet hole 21, the middle of the core-pulling expansion rivet 4 passes through the lead fixing hole 31, and the top of the core-pulling expansion rivet 4 presses the bus bar lead 3.

[0034] It should be noted that the area around the rivet hole 21 is made of a conductive material with conductive properties. After the core-pulling expansion rivet presses the busbar lead wire 3 against the busbar lead wire 3 , the busbar lead wire 3 is electrically connected to the conductive material around the rivet hole 21 .

[0035] The photovoltaic module junction box provided in the embodiment of the present application is provided with a core-pulling expansion rivet 4 to replace the existing tin-adding welding form. The lead fixing hole 31 of the bus lead wire 3 is fixedly connected with the rivet hole 21 of the junction box diode 2 by using the core-pulling expansion rivet 4, and the top of the core-pulling expansion rivet 4 presses the bus lead wire 3 to connect the bus lead wire 3 with the junction box diode 2, thereby achieving a tight connection between the photovoltaic module bus lead wire 3 and the junction box diode 2, avoiding the cold welding phenomenon between the bus lead wire 3 and the junction box, and avoiding the bypass diode from being damaged by thermal breakdown due to heat generated by the cold welding, and even burning the junction box.

[0036] Furthermore, the core-pulling expansion rivet 4 includes a nail rod 41, a metal tube column 42 and a meson 43; the meson 43 is connected to the outer side of one end of the metal tube column 42 in a ring shape, one end of the nail rod 41 passes through the metal tube column 42, and the other end of the nail rod 41 is clamped with the end of the metal tube column 42 away from the meson 43, and the meson 43 is arranged at the middle position corresponding to the nail rod 41; the metal tube column 42 can be squeezed and expanded by the nail rod 41 and fixed in the rivet hole 21, the metal tube column 42 passes through the lead fixing hole 31, and the meson 43 presses the busbar lead 3 on the junction box diode 2.

[0037] In order to facilitate the clamping of the nail rod 41 with the end of the metal tube column 42 away from the meson 43 , a round head is provided at the end of the nail rod 41 , and the diameter of the round head is larger than the inner hole diameter of the metal tube column 42 .

[0038] The material of the core-pulling expansion rivet 4 has high mechanical strength, strong electrical conductivity, is not easy to oxidize and corrode, and is a metal material that is easy to process.

[0039] Furthermore, the positioning groove 11 is rectangular, the rivet hole 21 is runway-shaped, and the width of the rivet hole 21 is smaller than the width of the positioning groove 11. The positioning groove 11 can effectively accommodate the junction box diode 2, and the runway-shaped rivet hole 21 can be adaptively adjusted to avoid dimensional errors, and can adapt to busbar lead wires 3 of different lengths. The width of the rivet hole 21 is smaller than the width of the positioning groove 11 to achieve the placement of the busbar lead wire 3 in the positioning groove 11.

[0040] Furthermore, the lead fixing hole 31 is in a racetrack shape, and the width of the lead fixing hole 31 is smaller than the width of the meson 43. The rivet hole 21 and the lead fixing hole 31 are both in a racetrack-shaped circular hole, and the width of the rivet hole 21 and the lead fixing hole 31 are the same. The width of the rivet hole 21 is the diameter of its inscribed circle, and the width of the lead fixing hole 31 is the diameter of its inscribed circle. This arrangement can achieve the corresponding adaptation of the rivet hole 21 and the lead fixing hole 31, and the corresponding adaptation of the rivet hole 21 and the lead fixing hole 31 can achieve the riveting and fixing of the busbar lead 3 and the junction box diode 2 by the core-pulling expansion rivet 4 in the form of riveting.

[0041] Further, the diameter of the metal column 42 is 2-6.4mm, such as 2mm, 2.8mm, 3mm, 4mm, 5mm, 6mm or 6.4mm. The length of the nail rod 41 is 4-38mm, such as 4mm, 5mm, 15mm, 25mm, 35mm or 38mm. The diameter of the meson 43 is 3.85-12.5mm, such as 4mm, 6mm, 8mm, 10mm, 11mm or 12mm. Preferably, in the implementation, the diameter of the nail rod is 2mm, the length of the nail rod is 38mm, the diameter of the meson 43 is 6mm, the diameter of the metal column 42 is 2.8mm, and the diameter of the round head at the end of the nail rod is 2.8mm.

[0042] Furthermore, the photovoltaic module junction box is provided with two riveting points, the top surface of the junction box body 1 is provided with two positioning grooves 11, two bus bar lead wires 3 are provided, and two core-pulling expansion rivets 4 are provided. Each bus bar lead wire 3 extends from the end inside the junction box body 1 to the middle.

[0043] Further, the midline point of the rivet hole 21 is 1-15mm away from the lead fixing hole 31 of the busbar lead wire 3, such as 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, 11mm, 12mm, 13mm, 14mm or 15mm, etc. The midline point of the rivet hole 21 is 1-10mm away from the edge of the junction box diode 2, such as 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm or 10mm, etc. The width of the rivet hole 21 is 1-20mm, such as 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, 11mm, 12mm, 13mm, 14mm, 15mm, 16mm, 17mm, 18mm, 19mm or 20mm, etc.

[0044] Further, the lead fixing hole 31 is located at the head of the busbar lead wire 3, and the center point of the lead fixing hole 31 is 1-20 mm away from the edge of the busbar lead wire 3, such as 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm or 20 mm. The length of the lead fixing hole 31 is 1-15 mm, such as 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm or 15 mm. The width of the lead fixing hole 31 is 1-6 mm, such as 1 mm, 2 mm, 3 mm, 4 mm, 5 mm or 6 mm. Considering the possibility of position deviation of the lead fixing hole 31, there is a risk of the accuracy of the connection between the busbar lead wire 3 and the lead fixing hole 31 of the junction box, so the length of the lead fixing hole 31 is set to 1-15mm.

[0045] Furthermore, the depth of the positioning groove 11 is 1-5 mm, the length of the positioning groove 11 is 1-10 mm, and the width of the positioning groove 11 is 1-10 mm. Preferably, the size of the positioning groove 11 is larger than the junction box diode 2 and the bus bar lead 3, so that the positioning groove 11 can effectively accommodate the junction box diode 2, and the riveting hole 21 can be adaptively adjusted to avoid dimensional errors, and can adapt to bus bar lead 3 of different lengths, so that the bus bar lead 3 is placed in the positioning groove 11.

[0046] Combination Figure 1 , 6 As shown in FIG. 7 , the photovoltaic module junction box also includes a diode cable connection port 6, and the diode cable connection port 6 is provided at the end of the junction box diode 2 away from the busbar lead 3. The bisector of the rivet hole 21 bisects the diode cable connection port 6. Further, when the rivet hole 21 is in a runway shape, the rivet hole 21 has a long diameter and a short diameter perpendicular to the long diameter, the long diameter may be the diameter of the circumscribed circle of the rivet hole 21, and the short diameter may be the diameter of the inscribed circle of the rivet hole 21. The extension line of the short diameter of the rivet hole 21 bisects the diode connection port 6. The extension line of the short diameter of the rivet hole 21 is perpendicular to the long diameter of the rivet hole 21, that is, the extension line of the short diameter of the rivet hole 21 is the bisector of the rivet hole 21, specifically as shown in FIG. Figure 1 As shown by the dotted line, this arrangement can ensure that the riveting point is centered, and the riveted effect is aesthetically pleasing.

[0047] like Figure 5-Figure 8 As shown, Figure 5 This is a schematic structural diagram of the riveting machine head 5 provided in an embodiment of the present application. Figure 6 A schematic diagram of the structure of installing a blind expansion rivet using a riveting machine head 5 provided in an embodiment of the present application. Figure 7 A schematic structural diagram of the corresponding installation positions of the blind expansion rivets provided in an embodiment of the present application. Figure 8 A schematic diagram of the structure before and after riveting of a blind expansion rivet installed by a riveting machine head 5 provided in an embodiment of the present application.

[0048] The automated riveting equipment is provided with 3-6 riveting heads 5, which can simultaneously rivet and fix 6 rivet positions in the three junction box diodes 2 of the photovoltaic module. Multiple core-pulling expansion rivets 4 are provided corresponding to the multiple rivet positions, which can rivet and fix the busbar lead wire 3 and the junction box diode 2 at multiple points, so as to achieve a tight connection between the photovoltaic module busbar lead wire 3 and the junction box diode 2, and avoid the phenomenon of cold welding between the busbar lead wire 3 and the junction box.

[0049] The automated riveting equipment is provided with a visual inspection system, which is divided into before riveting and after riveting. Before riveting, it is detected whether the runway-shaped lead fixing hole 31 of the busbar lead wire 3 corresponds to the runway-shaped riveting hole 21 of the junction box diode 2. After riveting, the riveting effect of the riveting machine head 5 after riveting is detected.

[0050] The riveting range is wide, the installation is fast, the clamping force is large, the shock resistance is good, the rivet fracture is flat, and the locking capacity is strong. Among them, no tinning welding is required, and the riveting fault tolerance rate is zero.

[0051] The automated riveting method is to send the expansion rivet to the riveting machine head 5 through an automated conveying device. After the visual inspection system determines that the junction box hole is qualified, the riveting machine head 5 inserts the expansion rivet into the runway-shaped lead fixing hole 31 of the bus bar lead wire 3 and the runway-shaped rivet hole 21 of the junction box diode 2. The riveting machine head 5 performs rivet expansion on it, so that the bus bar lead wire 3 and the junction box diode 2 are riveted and fixed at zero distance through force extrusion, and then the riveting effect is identified and detected by the visual inspection system.

[0052] This embodiment rivets the assembly and the junction box by automated riveting, which can replace the existing tinning welding method; the busbar lead 3 and the junction box diode 2 are riveted and fixed by automated riveting equipment, thereby further strengthening the connection between the photovoltaic assembly busbar lead 3 and the junction box diode 2, avoiding the cold soldering between the busbar lead 3 and the junction box, and ensuring the reliability of the current output and bypass between the busbar lead 3 and the junction box.

[0053] Compared with the existing technology, the automatic riveting method of the junction box can replace the existing tinning welding method, greatly reduce the component rework rate, reduce the losses caused by the cold soldering of the busbar lead wires, improve production efficiency, improve product quality, and avoid customer complaints.

[0054] The photovoltaic module junction box provided in the embodiment of the present application adopts core-pulling expansion rivets to fix the bus bar lead wires and the junction box diodes, thereby achieving a tight connection between the bus bar lead wires and the junction box diodes without the occurrence of cold solder joints, thereby avoiding thermal breakdown damage to the bypass diode caused by heat generated by cold solder joints, and even burning of the junction box.

[0055] In the above embodiments, the description of each embodiment has its own emphasis. For parts that are not described in detail in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0056] The above is a detailed introduction to a photovoltaic module junction box provided in an embodiment of the present application. Specific examples are used in this article to illustrate the principles and implementation methods of the present application. The description of the above embodiments is only used to help understand the technical solution and its core idea of ​​the present application. Ordinary technicians in this field should understand that they can still modify the technical solutions recorded in the aforementioned embodiments, or replace some of the technical features therein with equivalents; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A photovoltaic module junction box, characterized in that: include: The junction box body has a positioning groove on its top surface; A junction box diode is fixed in the junction box body; the junction box diode is provided with a riveting hole corresponding to the positioning groove; A busbar lead wire is arranged on the junction box diode; the busbar lead wire is provided with a lead fixing hole corresponding to the riveting hole; A core-pulling expansion rivet passes through the positioning groove and is fixed in the rivet hole; the bottom of the core-pulling expansion rivet is expanded and fixed in the rivet hole, the middle of the core-pulling expansion rivet passes through the lead fixing hole, and the top of the core-pulling expansion rivet presses the busbar lead wire.

2. The photovoltaic module junction box according to claim 1, characterized in that: The core-pulling expansion rivet includes a nail rod, a metal tube column and a meson; the meson is connected to the outer side of one end of the metal tube column in a ring shape, one end of the nail rod passes through the metal tube column, and the other end of the nail rod is clamped with the end of the metal tube column away from the meson, and the meson is arranged at the middle position corresponding to the nail rod; the metal tube column can be squeezed and expanded by the nail rod and fixed in the rivet hole, the metal tube column passes through the lead fixing hole, and the meson presses the bus bar lead wire on the junction box diode.

3. The photovoltaic module junction box according to claim 1, characterized in that: The positioning groove is rectangular, the riveting hole is runway-shaped, and the width of the riveting hole is smaller than the width of the positioning groove.

4. The photovoltaic module junction box according to claim 2, characterized in that: The lead fixing hole is in a racetrack shape, and the width of the lead fixing hole is smaller than the width of the meson.

5. The photovoltaic module junction box according to claim 2, characterized in that: The diameter of the metal tube column is 2-6.4 mm, the length of the nail rod is 4-38 mm, and the diameter of the meson is 3.85-12.5 mm.

6. The photovoltaic module junction box according to claim 1, characterized in that: The photovoltaic module junction box has two riveting points, the top surface of the junction box body is provided with two positioning grooves, the bus bar lead wires are provided with two, the core-pulling expansion rivets are provided with two, and each bus bar lead wire extends from the end inside the junction box body to the middle.

7. The photovoltaic module junction box according to claim 1, characterized in that: The midline point of the rivet hole is 1-15 mm away from the lead fixing hole of the busbar lead wire and 1-10 mm away from the edge of the junction box diode. The width of the rivet hole is 1-20 mm.

8. The photovoltaic module junction box according to claim 1, characterized in that: The lead fixing hole is located at the head of the busbar lead wire, and the center point of the lead fixing hole is 1-20 mm away from the edge of the busbar lead wire; the length of the lead fixing hole is 1-15 mm, and the width of the lead fixing hole is 1-6 mm.

9. The photovoltaic module junction box according to claim 1, characterized in that: The depth of the positioning groove is 1-5 mm, the length of the positioning groove is 1-10 mm, and the width of the positioning groove is 1-10 mm.

10. The photovoltaic module junction box according to claim 1, characterized in that: The photovoltaic module junction box also includes: A diode cable connection port is provided at the end of the junction box diode away from the busbar lead-out line; When the rivet hole is in a racetrack shape, the rivet hole has a long diameter and a short diameter perpendicular to the long diameter, and an extension line of the short diameter of the rivet hole bisects the diode connection port.

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