Sealing-enhanced photovoltaic junction box for ultrathin flexible photovoltaic module

Abstract

The utility model belongs to the technical field of photovoltaic power generation, and particularly relates to a photovoltaic junction box for an ultra-thin flexible photovoltaic assembly with enhanced sealing performance, which comprises a box body provided with a sealing bayonet. A clamping groove structure is arranged on the box cover; the positioning column is mounted in the box body, and the height of the box body is flush with that of the positioning column; the glue overflowing opening is formed in the corner of the box body, and the glue overflowing opening is designed to be a flat opening; the positioning column boss is used for riveting the joint with the cable without interfering with the bottom; and the two welding pins are symmetrically designed. The photovoltaic junction box provided by the utility model adopts a novel sealing structure, strengthens the waterproof and dustproof capabilities, improves the reliability and the service life of the assembly, reduces the cost through the thinning design, improves the production efficiency through the weld leg design suitable for laser trepanning and automatic welding, enhances the insulation and protection through the optimization of the glue flow channel, and improves the production efficiency. And through the heat dissipation design of the special-shaped copper plate, the performance is improved, and the cost is reduced at the same time.

Description

Technical Field

[0001] The utility model belongs to the technical field of photovoltaic power generation, and provides a junction box with better sealing and reduced height, in particular to a photovoltaic junction box with enhanced sealing for ultra-thin flexible photovoltaic modules. Background Art

[0002] In the continuous development of the photovoltaic industry, flexible photovoltaic modules have gradually emerged in specific application scenarios due to their unique advantages such as bendability and lightness. However, unlike conventional photovoltaic modules, the photovoltaic junction box of flexible photovoltaic modules is installed on the front of the module, which poses many new challenges to the design of the photovoltaic junction box. In order to meet the special needs of flexible photovoltaic modules, the present invention aims to provide a photovoltaic junction box design scheme with better sealing performance and high thinning. Utility Model Content

[0003] The technical problem to be solved by the present invention is: how to obtain a photovoltaic junction box with better sealing performance and reduced height.

[0004] To achieve the above objectives, the present invention provides the following technical solutions:

[0005] Photovoltaic junction box with enhanced sealing for ultra-thin flexible photovoltaic modules, comprising:

[0006] A box body, wherein a sealing bayonet is provided on the box body;

[0007] A box cover is provided with a card slot structure;

[0008] Positioning column, the positioning column is installed inside the box body, and the box body is flush with the height of the positioning column;

[0009] The overflow port is set at the corner of the box body and adopts a flat port design;

[0010] Positioning column boss, used to ensure that the cable rivet joint does not interfere with the bottom;

[0011] The positive and negative welding feet are symmetrically designed;

[0012] Special-shaped copper plates are used for conducting electricity and dissipating heat. Special-shaped and module diodes are soldered together.

[0013] Glue flow channel, used to improve the glue coverage;

[0014] Among them, the box cover adopts an external wrapping design for sealing and waterproofing, and provides additional creepage distance. The box body and the positioning column are of the same height. The flat mouth design of the overflow port is used to flow out the excess potting glue from the space provided by the box cover. Since the component end adopts laser opening to expose the busbar welding surface, the two welding feet are widened to 4.00mm. Also, because it causes the rivet wire end to shift to the right, in order to ensure the creepage distance of the rivet wire end, the entire box body is lengthened to 76.75mm, and the glue flow channel is widened to 9.25mm to facilitate the flow of potting glue. The special-shaped copper plate has multiple openings for the flow of potting glue and is used to fully seal the potting glue. The flexible component has low power and low current, and uses small module diodes to save costs and heat dissipation. Due to the sealing protection of the potting glue, the special-shaped copper plate welded to the photovoltaic diode module does not need to be electroplated to save costs.

[0015] In some embodiments, optionally, a plurality of reinforcing ribs are provided inside the upper cover of the box lid to provide mechanical strength and accommodate excess potting glue.

[0016] In some embodiments, optionally, welding opening 1, welding opening 2 and rivet opening 3 are opened at the bottom of the box body, which are used for junction boxes that do not require busbar perforations.

[0017] In some embodiments, optionally, the positive and negative electrode welding feet are flush with the bottom surface of the box body, and a cross opening is opened inside to increase the welding strength, and tin blocks are welded on the positive and negative electrode welding feet to facilitate the automated welding needs of the component factory.

[0018] Compared with the existing technology, the beneficial effects of the present invention are as follows: the present invention adopts advanced sealing technology, which greatly improves its sealing performance. This sealing design effectively prevents the intrusion of moisture and dust, thereby protecting the circuits and components inside the photovoltaic module, reducing damage and degradation caused by environmental factors, and significantly improving the reliability and service life of the photovoltaic module;

[0019] By reducing the thickness of the junction box, not only the weight of the module is reduced, but also the overall height of the flexible module is reduced. This design helps reduce the space occupied by photovoltaic modules during storage and logistics, thereby reducing related costs and making photovoltaic modules more economical and efficient.

[0020] The positive and negative welding legs of the junction box have been specially designed and widened to accommodate the laser drilling process for the busbars of flexible photovoltaic modules. In addition, the pre-welded solder block design at the bottom meets the requirements of automated welding, improving production efficiency and welding quality, and ensuring the long-term stable operation of the photovoltaic module.

[0021] The optimized glue flow channel inside the junction box increases the coverage of the potting compound. This design enhances the insulation performance of the junction box, ensuring electrical safety, while also improving the protection performance and providing an additional layer of protection for the photovoltaic modules.

[0022] Using special-shaped copper plates as heat dissipation elements not only improves heat dissipation performance but also provides room for reducing product costs. This heat dissipation design helps lower the operating temperature of photovoltaic modules and improve energy efficiency, while also reducing the risk of performance degradation and damage due to overheating. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the overall structure of the utility model;

[0024] Figure 2 This is a bottom view structural diagram of the present utility model;

[0025] Figure 3 This is a schematic diagram of the box cover structure of the present utility model;

[0026] Figure 4 For the utility model Figure 1 Partial enlarged image.

[0027] In the figure: 1. Box body; 2. Box cover; 3. Special-shaped copper plate; 4. Glue flow channel; 5. Positioning column; 6. Positioning column boss; 7. Glue overflow port; 8. Positive and negative electrode welding feet. DETAILED DESCRIPTION

[0028] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0029] Example 1

[0030] like Figures 1 to 3 As shown, a photovoltaic junction box for an ultra-thin flexible photovoltaic module with enhanced sealing, comprising:

[0031] Box body 1, which is provided with a sealing bayonet;

[0032] The box cover 2 is provided with a card slot structure;

[0033] Positioning post 5, which is installed inside the box body 1, and the box body 1 is flush with the height of the positioning post 5;

[0034] The glue overflow port 7 is arranged at the corner of the box body 1 and adopts a flat-mouth design;

[0035] The positioning column boss 6 is used to ensure that the cable riveting joint does not interfere with the bottom;

[0036] The positive and negative welding pins are 8, and the two welding pins are symmetrically designed;

[0037] Special-shaped copper plate 3, used for conducting electricity and dissipating heat, the special-shaped copper plate and the module diode are soldered;

[0038] Glue flow channel 4, used to improve the glue sealing coverage;

[0039] Specifically, the box cover 2 adopts an external wrapping design for sealing and waterproofing, and provides additional creepage distance. The box body 1 and the positioning column 5 are of the same height. The flat design of the overflow port 7 is used to allow excess potting glue to flow out of the space provided by the box cover 2. Since the component end adopts laser drilling to expose the busbar welding surface, the two welding feet are widened to 4.00mm. Also, since the rivet wire end is shifted to the right, in order to ensure the creepage distance of the rivet wire end, the entire box body 1 is lengthened to 76.75mm, and the glue flow channel 4 is widened to 9.25mm to facilitate the flow of potting glue. The special-shaped copper plate 3 has multiple openings for the flow of potting glue and is used to fully seal the potting glue. The flexible component has low power and low current, and a small module diode is used to save cost and heat dissipation. Due to the sealing protection of the potting glue, the special-shaped copper plate 3 welded to the photovoltaic diode module does not need to be electroplated to save cost;

[0040] The original product PVSM01xy has a solder foot width of 3.5mm, while the patented product PVSM02xy has a solder foot width of 4.0mm, which is an increase of 0.5mm.

[0041] The original product PVSM01xy has a 8.5mm spacing between the four glue flow channels. The patented product PVSM02xy has a 9.25mm spacing between the four glue flow channels, which is an increase of 0.75mm.

[0042] The length of the box body 1 of the original product PVSM01xy is 75mm, and the length of the box body 1 of the current patented product PVSM02xy is 76.75mm, which is increased by 1.75mm.

[0043] In this embodiment, the box body 1 adopts a wrapping design, which provides additional creepage distance and enhances safety. The box body 1 and the positioning column 5 are of the same height, and the flat design of the overflow port 7 helps to smoothly flow out the excess potting glue to avoid accumulation. The widened design of the positive and negative electrode welding feet 8 adapts to the laser-opened busbar welding surface, which improves the reliability of welding. The entire box body 1 is moderately lengthened to provide sufficient creepage distance for the rivet wire end, ensuring the safety performance of the component. The widened design of the glue flow channel 4 is conducive to the flow of potting glue, improves the sealing glue coverage rate, and enhances the insulation and protection performance of the junction box. The multiple openings design of the special-shaped copper plate 3 is not only conducive to the flow of potting glue, but also ensures that the potting glue can be fully sealed, improves the heat dissipation performance, and uses small module diodes to save costs. At the same time, due to the sealing protection of the potting glue, the special-shaped copper plate welded to the photovoltaic diode module does not need to be electroplated, further reducing costs.

[0044] Example 2

[0045] like Figures 1 to 3 As shown, the upper cover of the box lid 2 is provided with a plurality of reinforcing ribs inside, which are used to provide mechanical strength and also to accommodate excess potting glue;

[0046] like Figures 1 to 3 As shown, the bottom of the box body 1 is provided with welding port 1, welding port 2 and rivet port 3, which are used for junction boxes that do not require busbar perforation;

[0047] like Figures 1 to 3 As shown, the positive and negative electrode welding feet 8 are flush with the bottom surface of the box body 1, and a cross opening is opened inside to increase the welding strength. Tin blocks are welded on the positive and negative electrode welding feet 8 to facilitate the automated welding needs of the component factory.

[0048] In this embodiment, the multiple reinforcing ribs arranged inside the box cover 2 not only provide mechanical strength, but also can accommodate excess potting glue, thereby improving the stability and practicality of the structure. The welding port 1, welding port 2 and rivet port 3 opened at the bottom of the box body 1 provide convenience for junction boxes that do not require bus bar perforations, thereby increasing the applicability of the product. The design of the positive and negative electrode welding legs 8 being flush with the bottom surface of the box body 1 and the internal cross openings increase the welding strength and improve the reliability of the component. The tin blocks welded on the positive and negative electrode welding legs 8 meet the requirements of automated welding in the component factory and improve production efficiency.

[0049] The photovoltaic junction box of the present invention has greatly enhanced the sealing performance through the new sealing structure, effectively preventing the intrusion of water vapor, dust, etc., and significantly improving the reliability and service life of the photovoltaic module. The highly thinned design is conducive to reducing the total height of the flexible module, thereby reducing storage and logistics costs. The widened design of the positive and negative electrode welding feet 8 and the design of the pre-welded tin block at the bottom are adapted to the busbar laser opening process of the flexible photovoltaic module and the requirements of automated welding. The optimized glue flow channel 4 improves the coverage rate of the potting glue, further enhancing the insulation and protection performance of the junction box. The use of the special-shaped copper plate 3 for heat dissipation provides space for heat dissipation design and module cost reduction, which is conducive to improving heat dissipation performance and reducing product costs.

[0050] In summary, the photovoltaic junction box of the present invention provides an innovative solution for the development of flexible photovoltaic modules and has broad market application prospects.

[0051] Although the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A photovoltaic junction box for ultra-thin flexible photovoltaic modules with enhanced sealing, characterized in that: include: A box body, wherein a sealing bayonet is provided on the box body; A box cover, wherein the box cover is provided with a slot structure; A positioning post is installed inside the box body, and the box body is flush with the height of the positioning post; The overflow glue port is set at the corner of the box body and adopts a flat mouth design; Positioning column boss, used to ensure that the cable rivet joint does not interfere with the bottom; The positive and negative welding feet are symmetrically designed; Special-shaped copper plate, used for conducting electricity and dissipating heat, said special-shaped plate is soldered to the module diode; Glue flow channel, used to improve the glue coverage; Among them, the box cover adopts an external wrapping design for sealing and waterproofing, and provides additional creepage distance. The box body and the positioning column are of the same height. The flat mouth design of the overflow port is used to flow out the excess potting glue from the space provided by the box cover. Since the component end adopts laser opening to expose the busbar welding surface, the two welding feet are widened to 4.00mm. Also, because it causes the rivet wire end to shift to the right, in order to ensure the creepage distance of the rivet wire end, the entire box body is lengthened to 76.75mm, and the glue flow channel is widened to 9.25mm to facilitate the flow of potting glue. The special-shaped copper plate has multiple openings for the flow of potting glue and is used to fully seal the potting glue. The flexible component has low power and low current, and uses small module diodes to save costs and heat dissipation. Due to the sealing protection of the potting glue, the special-shaped copper plate welded to the photovoltaic diode module does not need to be electroplated to save costs.

2. The photovoltaic junction box for an ultra-thin flexible photovoltaic module with enhanced sealing according to claim 1, characterized in that: A plurality of reinforcing ribs are provided inside the upper cover of the box lid, which are used to provide mechanical strength and accommodate excess potting glue.

3. The photovoltaic junction box for an ultra-thin flexible photovoltaic module with enhanced sealing according to claim 1, characterized in that: The bottom of the box body is provided with a welding port 1, a welding port 2 and a rivet port 3, and is used for a junction box that does not require busbar perforation.

4. The photovoltaic junction box for an ultra-thin flexible photovoltaic module with enhanced sealing according to claim 1, characterized in that: The positive and negative electrode welding feet are flush with the bottom surface of the box body, and a cross opening is opened inside to increase the welding strength. Tin blocks are welded on the positive and negative electrode welding feet to facilitate the automated welding needs of the component factory.

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