Photovoltaic module junction box adopting copper-aluminum alloy conductor

Abstract

The utility model discloses a photovoltaic module junction box adopting copper aluminum alloy conductors, which comprises a box body, a box cover, cables, conductors and bypass diodes, the box body is provided with an upper assembly opening, side cable grooves and lower through holes, the box cover fixedly covers the upper assembly opening, the conductors are arranged in the box body, and the bypass diodes are arranged in the side cable grooves. The electric conductor comprises an aluminum alloy substrate and a first copper plate layer rolled on the upper surface of the aluminum alloy substrate, a mounting position is arranged in the middle of the electric conductor, the bypass diode is arranged in the mounting position, two pin ends of the bypass diode are welded on the electric conductor, and one end of the cable extends into the box body and is electrically connected with the electric conductor. According to the utility model, the conductor adopts the composite structure body formed by the aluminum alloy substrate and the first copper plate layer, so that the conductor has more excellent tensile strength, bendability and elongation rate, the conductor does not crack or separate during washing, shearing and bending processing, and in addition, compared with a pure copper conductor, the conductor is lighter in weight and more convenient to use. And the cost is lower.

Description

Technical Field

[0001] The utility model relates to the technical field of photovoltaic junction boxes, in particular to a photovoltaic component junction box using a copper-aluminum alloy conductor. Background Art

[0002] The solar photovoltaic module junction box is a basic component to ensure the efficient and reliable operation of the photovoltaic power generation system. Because it is in the outdoor environment all year round, the product has high requirements for anti-aging, anti-penetration, high temperature resistance, UV resistance, low resistance, low heat generation and other properties to adapt to harsh environmental conditions.

[0003] The photovoltaic junction box will generate a certain amount of heat when working. If the heat accumulates excessively, it may cause thermal runaway or even cause a fire. As a key part of connecting cables and bypass diodes, the conductor is required to have good electrical conductivity, thermal conductivity, corrosion resistance, heat resistance and low contact resistance.

[0004] In addition, the size and current of photovoltaic modules continue to increase, especially for bifacial modules. Under high heat and good light conditions, higher requirements are placed on the rated current of the junction box, so a junction box with a larger current is needed to meet this requirement. To meet the demand for large currents, the first choice is the diode. The chip inside needs to be customized and improved to carry a larger current and reduce the heating temperature. However, the cost of customizing and improving the diode is high. Currently, split junction boxes are generally used, and a set of junction boxes has three diodes. In the case of large usage, the cost increase will be very large. Utility Model Content

[0005] In view of this, the utility model proposes a photovoltaic module junction box using a copper-aluminum alloy conductor, so as to reduce the probability of excessive heat accumulation of the conductor during long-term use.

[0006] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0007] A photovoltaic module junction box using a copper-aluminum alloy conductor comprises a box body, a box cover and a cable, wherein the box body has an upper mounting opening, a side cable groove and a lower through hole, and the box cover is fixedly covered on the upper mounting opening, and further comprises a conductor and a bypass diode, wherein the conductor is fixedly arranged in the box body, the conductor comprises an aluminum alloy substrate and a first copper plate layer rolled on the upper surface of the aluminum alloy substrate, a mounting position is opened in the middle of the conductor, the bypass diode is placed in the mounting position, and two pin ends of the bypass diode are welded to the conductor, and one end of the cable extends into the box body from the side cable groove and is electrically connected to the conductor.

[0008] To better implement the above technical solution, optionally, the thickness of the first copper plate layer is 5%-50% of the thickness of the conductor, and the thickness of the aluminum alloy substrate is 95%-50% of the thickness of the conductor.

[0009] Optionally, a second copper plate layer is rolled on the lower surface of the aluminum alloy substrate.

[0010] Optionally, the thickness of the first copper plate layer is 5%-30% of the thickness of the conductor, the thickness of the aluminum alloy substrate is 90%-40% of the thickness of the conductor, and the thickness of the second copper plate layer is 5%-30% of the thickness of the conductor.

[0011] Optionally, during the process of converting the aluminum alloy substrate from liquid aluminum to solid aluminum, the solid copper plate is rolled on the aluminum alloy substrate by casting rollers at high temperature and high pressure to form a first copper plate layer and a second copper plate layer.

[0012] Optionally, positioning posts are fixedly disposed at each corner of the box body, and the conductor is provided with positioning holes corresponding to the positioning posts one by one, and the positioning posts are inserted and matched with the positioning holes.

[0013] Optionally, a cable pressing block is fixedly provided at the lower opening of the side cable trough.

[0014] Optionally, the box body is filled with sealing heat dissipation glue.

[0015] Optionally, the bypass diode is connected to the first copper plate layer or the second copper plate layer by welding.

[0016] Optionally, the cable is connected to the first copper plate layer or the second copper plate layer by welding.

[0017] Beneficial effects of the utility model:

[0018] The utility model discloses a photovoltaic module junction box using a copper-aluminum alloy conductor. The conductor adopts a composite structure formed by an aluminum alloy substrate and a first copper plate layer, so that the conductor has better tensile strength, bendability and elongation than a pure copper conductor, so that the conductor will not crack or separate during washing, shearing and bending. In addition, the conductor is lighter and has lower cost than a pure copper conductor.

[0019] The utility model discloses a photovoltaic module junction box using a copper-aluminum alloy conductor. During the rolling process of the first copper plate layer and the second copper plate layer, atoms at the interface of the two metals of copper and aluminum mutually penetrate and crystallize to form a conductor with a eutectic copper-aluminum alloy structure. The direct current resistivity of the conductor is lower, and the tensile strength, interface peeling strength and shear strength are better. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1It is a three-dimensional schematic diagram of a photovoltaic module junction box using a copper-aluminum alloy conductor according to an embodiment of the utility model;

[0021] Figure 2 This is an exploded schematic diagram of an angle of a photovoltaic module junction box using a copper-aluminum alloy conductor in an embodiment of the utility model;

[0022] Figure 3 It is a three-dimensional schematic diagram of another angle of a photovoltaic module junction box using a copper-aluminum alloy conductor according to an embodiment of the utility model;

[0023] Figure 4 yes Figure 2 A cross-sectional view of a first structure of a conductive plate;

[0024] Figure 5 yes Figure 2 A cross-sectional view of the second structure of the conductive plate;

[0025] Reference numerals:

[0026] Box body 10, upper assembly port 11, side cable groove 12, lower through hole 13, positioning column 14, box cover 20, cable 30, conductor 40, aluminum alloy substrate 401, first copper plate layer 402, second copper plate layer 403, installation position 41, positioning hole 42, bypass diode 50, cable pressing block 60, sealing heat dissipation glue 70. DETAILED DESCRIPTION

[0027] The technical solution of the utility model is described in detail below in conjunction with the accompanying drawings and specific embodiments, wherein the same components are represented by the same reference numerals.

[0028] See also Figures 1 to 5 The utility model embodiment discloses a photovoltaic module junction box using a copper-aluminum alloy conductor, including a box body 10, a box cover 20, a cable 30, a conductor 40 and a bypass diode 50.

[0029] Among them, the box body 10 is provided with an upper assembly port 11, a side cable 30 groove 12 and a lower through hole 13, the box cover 20 is fixedly covered on the upper assembly port 11, the conductor 40 is fixedly arranged in the box body 10, the conductor 40 includes an aluminum alloy substrate 401 and a first copper plate layer 402 rolled on the upper surface of the aluminum alloy substrate 401, a mounting position 41 is opened in the middle of the conductor 40, the bypass diode 50 is placed in the mounting position 41, and the two pin ends of the bypass diode 50 are welded to the conductor 40, and one end of the cable 30 extends into the box body 10 from the side cable 30 groove 12 and is electrically connected to the conductor 40.

[0030] In the embodiment of the utility model, there are multiple lower through holes 13, and the busbars of the photovoltaic module enter the box body 10 through the lower through holes 13, and the busbars are welded to the conductors 40 respectively by welding.

[0031] In the photovoltaic module junction box of the embodiment of the utility model, the conductor 40 is a composite structure formed by an aluminum alloy substrate 401 and a first copper plate layer 402, so that the conductor 40 has better tensile strength, bendability and elongation than pure copper conductors, so that the conductor 40 does not crack or separate during washing, shearing and bending. In addition, since the density of aluminum is about 2.7g / cm 3 , the density of pure copper is about 8.9g / cm 3 The density of the conductor 40 is about 3-6 g / cm 3 Compared with using pure copper, the cost is more than 30% lower, the weight is more than 20% lighter, and the practicality is higher.

[0032] In an optional embodiment of the present embodiment, the thickness of the first copper plate layer 402 accounts for 5%-50% of the thickness of the conductor 40, and the thickness of the aluminum alloy substrate 401 accounts for 95%-50% of the thickness of the conductor 40. Preferably, the thickness of the conductor 40 is 0.8 mm, the thickness of the aluminum alloy substrate 401 is 0.72 mm, and the thickness of the first copper plate layer 402 is 0.08 mm.

[0033] In an optional embodiment of the present embodiment, a second copper plate layer 403 is rolled on the lower surface of the aluminum alloy substrate 401. Specifically, the thickness of the first copper plate layer 402 accounts for 5%-30% of the thickness of the conductor 40, the thickness of the aluminum alloy substrate 401 accounts for 90%-40% of the thickness of the conductor 40, and the thickness of the second copper plate layer 403 is 5%-30% of the thickness of the conductor 40. Preferably, the thickness of the conductor 40 is 0.8 mm, the thickness of the aluminum alloy substrate 401 is 0.64 mm, the thickness of the first copper plate layer 402 is 0.08 mm, and the thickness of the second copper plate layer 403 is 0.08 mm.

[0034] In an embodiment of the utility model, during the process of converting the aluminum alloy substrate 401 from liquid aluminum to solid aluminum, the solid copper plate is rolled by casting rollers at high temperature and high pressure to form a first copper plate layer 402 and a second copper plate layer 403 on the aluminum alloy substrate 401. Specifically, during the rolling of the first copper plate layer 402 and the second copper plate layer 403, atoms at the interface of the copper and aluminum metals penetrate and crystallize with each other to form a conductor 40 of a eutectic copper-aluminum alloy structure. The conductor 40 has a lower DC resistivity and better tensile strength, interface peeling strength and shear strength.

[0035] In an embodiment of the utility model, when the bypass diode 50 is connected to the conductor 40, the bypass diode 50 is directly welded to the first copper plate layer 402 and, or the second copper plate layer 403. The welding methods include but are not limited to soldering, resistance welding, ultrasonic welding and laser welding. In order to enhance the welding firmness, solder or solder strip for flux can be added to the welding part, which can effectively eliminate electrochemical reactions, reduce resistance, and improve heat dissipation performance, while helping to reduce costs.

[0036] In the embodiment of the utility model, the cable 30 is directly welded to the first copper plate layer 402 or the second copper plate layer 403. The welding methods include but are not limited to soldering, resistance welding, ultrasonic welding, laser welding, etc. In order to enhance the firmness of welding, solder, solder strip, etc. can be added to the welding part. When the crimping method is adopted, tin can be added to the crimping part to enhance the firmness of crimping.

[0037] In the embodiment of the utility model, positioning posts 14 are fixed at each corner of the box body 10, and the conductor 40 is provided with positioning holes 42 corresponding to the positioning posts 14. The positioning posts 14 are inserted and matched with the positioning holes 42. Specifically, the box body 10 is a hollow cubic structure, and there are four positioning posts 14 and four corresponding positioning holes 42. The conductor 40 can be horizontally fixed by the four positioning posts 14 matching the four positioning holes 42. The box body 10 is filled with sealing heat dissipation glue 70. The sealing heat dissipation glue 70 can increase the connection strength of the box body 10, the box cover 20 and the conductor, and has the functions of sealing, waterproofing and heat dissipation. A cable pressing block 60 is fixed at the lower opening of the side cable trough 12. The cable pressing block 60 is welded at the side cable trough 12 of the box body 10 by ultrasonic laser welding. The cable pressing block 60 is provided to protect the connection end of the cable 30 and the conductor 40.

[0038] The technical solution of the utility model is described in detail above in combination with specific embodiments, and the described specific embodiments are used to help understand the concept of the utility model. Derivations and variations made by those skilled in the art based on the specific embodiments of the utility model also fall within the protection scope of the utility model.

Claims

1. A photovoltaic module junction box using a copper-aluminum alloy conductor, comprising a box body (10), a box cover (20) and a cable (30), wherein the box body (10) has an upper assembly opening (11), a side cable groove (12) and a lower through hole (13), and the box cover (20) is fixedly covered on the upper assembly opening (11), characterized in that: It also includes a conductor (40) and a bypass diode (50), wherein the conductor (40) is fixedly arranged in the box body (10), the conductor (40) includes an aluminum alloy substrate (401) and a first copper plate layer (402) rolled on the upper surface of the aluminum alloy substrate (401), a mounting position (41) is opened in the middle of the conductor (40), the bypass diode (50) is placed in the mounting position (41), and two pin ends of the bypass diode (50) are welded to the conductor (40), and one end of the cable (30) extends into the box body (10) from the side cable groove (12) and is electrically connected to the conductor (40).

2. A photovoltaic module junction box using a copper-aluminum alloy conductor according to claim 1, characterized in that: The thickness of the first copper plate layer (402) is 5%-50% of the thickness of the conductor (40), and the thickness of the aluminum alloy substrate (401) is 95%-50% of the thickness of the conductor (40).

3. A photovoltaic module junction box using a copper-aluminum alloy conductor according to claim 2, characterized in that: A second copper plate layer (403) is rolled on the lower surface of the aluminum alloy substrate (401).

4. A photovoltaic module junction box using a copper-aluminum alloy conductor according to claim 3, characterized in that: The thickness of the first copper plate layer (402) is 5%-30% of the thickness of the conductor (40), the thickness of the aluminum alloy substrate (401) is 90%-40% of the thickness of the conductor (40), and the thickness of the second copper plate layer (403) is 5%-30% of the thickness of the conductor (40).

5. A photovoltaic module junction box using a copper-aluminum alloy conductor according to claim 4, characterized in that: During the process of converting the aluminum alloy substrate (401) from liquid aluminum to solid aluminum, the solid copper plate is rolled on the aluminum alloy substrate (401) by casting rollers at high temperature and high pressure to form a first copper plate layer (402) and a second copper plate layer (403).

6. A photovoltaic module junction box using a copper-aluminum alloy conductor according to claim 5, characterized in that: Positioning posts (14) are fixedly arranged at each corner of the box body (10), and the conductor (40) is provided with positioning holes (42) corresponding to the positioning posts (14) one by one, and the positioning posts (14) are inserted and matched with the positioning holes (42).

7. A photovoltaic module junction box using a copper-aluminum alloy conductor according to claim 1, characterized in that: A cable pressing block (60) is fixedly provided at the lower opening of the side cable trough (12).

8. The photovoltaic module junction box using copper-aluminum alloy conductor according to claim 1, characterized in that: The box body (10) is filled with sealing heat dissipation glue (70).

9. The photovoltaic module junction box using copper-aluminum alloy conductor according to claim 3, characterized in that: The bypass diode (50) is connected to the first copper plate layer (402) or the second copper plate layer (403) by welding.

10. A photovoltaic module junction box using a copper-aluminum alloy conductor according to claim 3, characterized in that: The cable (30) is connected to the first copper plate layer (402) or the second copper plate layer (403) by welding.

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