Photovoltaic junction box

Abstract

The utility model relates to a photovoltaic junction box. The photovoltaic junction box comprises a box body and a bypass protection module arranged on the box body, the bypass protection module comprises a diode and an electric conductor, the diode comprises a tube body and two pins arranged on the two sides of the tube body, and the pins are provided with flattened welding pin parts; the electric conductor comprises a substrate, a first flanging body and a second flanging body, the first flanging body and the second flanging body are arranged on two adjacent side walls in the substrate, the first flanging body is provided with a protection part exceeding the substrate in the first direction, a gap is formed between one side, facing the protection part, of the second flanging body and the protection part to form a clamping groove for clamping the pin, and a first welding part is arranged on the first surface of the substrate. The first welding part is provided with a plurality of first welding protruding points connected with the welding foot part. By means of the arrangement, limiting of the pins in the diode is enhanced, and it is guaranteed that the pins are located at the set welding positions; the flattened welding foot part in the pin is welded with the plurality of first welding salient points, so that the contact area is small and the heat is concentrated while the welding foot part and the first welding salient points are tightly attached, and the infirm welding is effectively prevented.

Description

Technical Field

[0001] This application relates to the field of photovoltaic power generation technology, and in particular to a photovoltaic junction box. Background Technology

[0002] Photovoltaic power generation is one of the main ways to utilize solar energy. Due to its cleanliness, safety, convenience, and high efficiency, solar photovoltaic power generation has become a new industry of widespread attention and key development in countries around the world. In practical applications, photovoltaic junction boxes are needed to connect the electricity generated by the photovoltaic modules to external loads.

[0003] Currently, the conductors in photovoltaic junction boxes are connected to diodes and cables by resistance welding. During the welding process, the contact area between the conductor and the diode is relatively large, which leads to rapid heat dissipation and is not conducive to heat concentration. This can easily cause incomplete soldering or weak welding, affecting the use of the photovoltaic junction box. Utility Model Content

[0004] Therefore, it is necessary to provide a photovoltaic junction box to address the problem of weak welding in the current resistance welding process between conductors and diodes.

[0005] A photovoltaic junction box includes a box body and a bypass protection module disposed in the box body, wherein:

[0006] The bypass protection module includes a diode and a conductor. The diode includes a tube body and two pins disposed on both sides of the tube body. Each of the two pins is provided with a flattened solder foot.

[0007] The conductor includes a substrate and a first flange and a second flange disposed on adjacent side walls of the substrate. The first flange has a protective portion extending beyond the substrate in a first direction. The side of the second flange facing the protective portion has a gap with the protective portion to form a slot for engaging the pin. A first welding portion is disposed on a first surface of the substrate. A plurality of first welding bumps are disposed on the first welding portion. The first welding bumps are connected to the solder foot portion.

[0008] The aforementioned photovoltaic junction box, by setting a first flange and a second flange in the conductor to form a slot, is used to hold the pins in the diode, which strengthens the limiting of the pin part in the diode and ensures that the pin is located in the set welding position; and by setting the flattened solder foot in the pin to weld with multiple first welding bumps, it ensures that the solder foot and the first welding bumps fit tightly, while the contact area between the two is small and the heat is concentrated, which can effectively prevent the phenomena of incomplete welding and weak welding that exist in the current welding process.

[0009] In one embodiment, the first weld portion protrudes from the first surface.

[0010] In one embodiment, the first surface is further provided with a second welding portion, the second welding portion including a plurality of second welding bumps spaced apart on the first surface, the second welding bumps being connected to a cable.

[0011] In one embodiment, the substrate further includes a second surface disposed opposite to the first surface, and the second surface is further provided with a receiving groove for placing a solder block;

[0012] The substrate is further provided with a first heat dissipation through hole that passes through the first surface and the second surface, and the first heat dissipation through hole is disposed between the receiving groove and the second welding part.

[0013] In one embodiment, the number of the first heat dissipation holes is multiple, and the multiple first heat dissipation holes are spaced apart.

[0014] In one embodiment, the receiving groove is positioned directly opposite the first welding portion.

[0015] In one embodiment, the housing includes a bottom wall and a side wall disposed on the bottom wall. The bottom wall and the side wall form a receiving space for accommodating the bypass protection module. A positioning post is disposed on the bottom wall within the receiving space, and the conductor has a positioning hole adapted to the positioning post.

[0016] In one embodiment, a second heat dissipation hole communicating with the receiving space is also provided on the bottom wall.

[0017] In one embodiment, the box body further includes a partition, the two ends of which are connected to the inner wall of the side enclosure and form a cavity with a top opening with the side enclosure.

[0018] In one embodiment, the outer wall of the partition is provided with a guide member, the guide member including a guide base plate and guide side plates disposed on opposite sides of the guide base plate, the guide base plate having a guide through hole, and the outer wall of the guide side plate being an inclined wall. Attached Figure Description

[0019] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute an undue limitation of this application.

[0020] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is an exploded view of the structure of the photovoltaic junction box provided in this application.

[0022] Figure 2 This is a schematic diagram of the bypass protection module provided in this application.

[0023] Figure 3 for Figure 2 A schematic diagram of the structure of a medium-conducting electron.

[0024] Figure 4 A schematic diagram of the box structure provided in this application.

[0025] in:

[0026] 10. Photovoltaic junction box; a. First direction; 100. Box body; 110. Bottom wall; 111. Second heat dissipation through hole; 112. Combustion hole; 120. Side wall; 130. Reception space; 140. Positioning post; 150. Partition; 160. Cavity; 170. Guide; 171. Guide base plate; 1711. Guide through hole; 172. Guide side plate; 1721. Sloping wall; 200. Bypass protection module; 210. Diode; 211. Tube body; 212. Pin; 2121. Snap-fit ​​section; 2122, Welding section; 2123, Welding foot; 220, Conductor; 221, Substrate; 2211, First surface; 2212, First welding part; 2213, First welding bump; 2214, Second welding bump; 2215, Second surface; 2216, Receiving groove; 2217, Solder block; 2218, First heat dissipation through hole; 222, First flange; 223, Second flange; 224, Protective part; 225, Slot; 226, Positioning hole; 300, Cable; 400, Wire clamp. Detailed Implementation

[0027] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0028] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0029] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0030] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0031] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0032] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0033] See Figure 1 , Figure 2 and Figure 3 As shown, Figure 1 This is an exploded view of the structure of the photovoltaic junction box 10 provided in this application. Figure 2 This is a structural schematic diagram of the bypass protection module 200 provided in this application. Figure 3 for Figure 2 A schematic diagram of the structure of the intermediate conductor 220. An embodiment of this application provides a photovoltaic junction box 10 including a box body 100 and a bypass protection module 200 disposed on the box body 100. The bypass protection module 200 includes a diode 210 and a conductor 220. The diode 210 includes a tube body 211 and two pins 212 disposed on both sides of the tube body 211. In a specific configuration, each pin 212 includes a snap-fit ​​section 2121 and a soldering section 2122 arranged perpendicularly to each other. Each soldering section 2122 of the two pins 212 has a flattened solder foot 2123. Each of the two solder feet 2123 is soldered to a diode 210. Through the above configuration, the pins 212 have an "L"-shaped structure. Compared to the current "I"-shaped pins 212, this avoids the problem of insufficient soldering length and easy desoldering caused by excessively short pins 212, and also avoids the problem of excessively long pins occupying too much space.

[0034] The conductor 220 includes a substrate 221 and a first flange 222 and a second flange 223 disposed on adjacent side walls of the substrate 221. The first flange 222 has a protective portion 224 extending beyond the substrate 221 along a first direction a. The side of the second flange 223 facing the protective portion 224 has a gap with the protective portion 224 to form a slot 225 for engaging the pin 212. In a specific configuration, the slot 225 is used to engage the engaging segment 2121 in the pin 212, strengthening the positioning of the diode 210 and the conductor 220. It should be noted that the length direction of the first flange 222 is the first direction a. Through the above configuration, the first flange 222 becomes a guardrail for the engaging segment 2121 along the first direction a. The second flange 223 is perpendicular to the first direction a in its length direction. On one hand, the second flange 223 acts as a guardrail for the welding section 2122 along its length. On the other hand, the gap on the side of the second flange 223 facing the first flange 223 allows for the formation of a slot 225 to accommodate the snap-fit ​​section 2121, thereby reinforcing the fixation of the pin 212 and preventing displacement during welding. It should be emphasized that, to ensure the protective limiting and snap-fit ​​effect on the snap-fit ​​section 2121, the height dimensions of both the first flange 222 and the second flange 223 are not less than the height dimension of the snap-fit ​​section 2121. To save costs while enhancing heat dissipation of the photovoltaic junction box 10, the conductor 220 is made of copper sheet; therefore, the substrate 221, the first flange 222, and the second flange 223 are also all made of copper sheet.

[0035] The first surface 2211 of the substrate 221 is provided with a first welding portion 2212, and the first welding portion 2212 is provided with a plurality of first welding bumps 2213, which are connected to the solder feet 2123. In specific configuration, the number of first welding bumps 2213 can be 2, 3, 4 or more. The shape of the first welding bumps 2213 is not limited, and can be a circular bump, an elliptical bump, a polygonal bump, a monolithic bump or other irregular shape.

[0036] The photovoltaic junction box 10 described above forms a slot 225 by setting a first flange 222 and a second flange 223 in the conductor 220. The slot 225 is used to hold the pin 212 in the diode 210, which strengthens the limiting of the pin 212 in the diode 210 and ensures that the pin 212 is located in the set welding position. Furthermore, by setting the flattened solder foot 2123 in the pin 212 to weld with multiple first welding bumps 2213, it is ensured that the solder foot 2123 and the first welding bumps 2213 fit tightly while the contact area between the two is small and the heat is concentrated, which can effectively prevent the phenomenon of incomplete welding and weak welding that exists in the current welding process.

[0037] To strengthen the soldering between diode 210 and conductor 220, in one optional embodiment, the first soldering portion 2212 protrudes from the first surface 2211. This arrangement effectively increases the distance between pin 212 and the first surface 2211, reducing heat loss during soldering from the large area of ​​the first surface 2211 and thus preventing cold solder joints caused by uneven heat distribution.

[0038] It should be noted that in actual use, three photovoltaic junction boxes 10 are used. These three junction boxes 10 serve as the positive terminal junction box, the negative terminal junction box, and at least one intermediate junction box. One conductor 220 in both the positive and negative terminal junction boxes is soldered and fixed to the cable 300. (See reference...) Figure 1 To illustrate, when installing cable 300, after passing through the box 100, cable 300 is soldered to conductor 220. To facilitate support for cable 300, a wire clamp 400 is provided at one end of the box 100. The wire clamp 400 allows cable 300 to pass through the middle of the wire clamp 400 and connect to conductor 220 of box 100. It should be emphasized that this embodiment uses a split junction box as an example for illustration; obviously, the structural design of this application is also applicable to single-unit junction boxes.

[0039] To ensure a secure connection between the cable 300 and the conductor 220, in one optional embodiment, the first surface 2211 is further provided with a second welding portion. The second welding portion includes a plurality of second welding protrusions 2214 spaced apart on the first surface 2211, and the second welding protrusions 2214 are connected to the cable 300. With this arrangement, the cable 300 and the second welding protrusions 2214 can be considered as spot welded, resulting in a small contact area and concentrated heat, effectively preventing the phenomena of incomplete soldering and weak welding that exist in current welding processes. Specifically, the number of second welding protrusions 2214 can be two, three, four, or more. The shape of the second welding protrusions 2214 is not limited; they can be circular protrusions, elliptical protrusions, polygonal protrusions, monolithic protrusions, or other irregular shapes.

[0040] It should be noted that the welding of cable 300 to conductor 220 occurs after the bypass protection module 200 is assembled. Currently, in addition to welding conductor 220 to diode 210, the bypass protection module 200 also needs to connect the busbar to conductor 220 via solder block 2217. Therefore, the welding of cable 300 to conductor 220 occurs after the busbar is installed. However, the resistance welding of conductor 220 to cable generates a large amount of heat. This heat is transferred through conductor 220 to solder block 2217, causing solder block 2217 to melt and resulting in the busbar detaching.

[0041] Therefore, to prevent the solder block 2217 from melting due to the heat generated during the welding of the cable 300 and the second solder bump 2214, the substrate 221 specifically includes a second surface 2215 disposed opposite to the first surface 2211. The second surface 2215 also has a receiving groove 2216 for holding the solder block 2217, which is used to connect the busbar. The substrate 221 also has a first heat dissipation through-hole 2218 penetrating the first surface 2211 and the second surface 2215, located between the receiving groove 2216 and the second welding portion. Through this arrangement, the solder block 2217 and the second solder bump 2214 are isolated by the first heat dissipation through-hole 2218, which greatly prevents heat conduction during resistance welding, thereby protecting the solder block 2217 from melting, preventing the busbar from detaching, and significantly improving the production yield.

[0042] To ensure effective heat dissipation without compromising the structural strength of the conductor 220, more specifically, multiple first heat dissipation through-holes 2218 are provided, spaced apart. Specifically, the number of first heat dissipation through-holes 2218 can be two, three, four, or more. With this arrangement, while maintaining the same area ratio of the first heat dissipation through-holes 2218 to the substrate 221 area, the multiple, spaced-apart first heat dissipation through-holes 2218 on the conductor 220, compared to having only one large-area first heat dissipation through-hole 2218, avoid stress concentration around the first heat dissipation through-holes 2218 that could lead to cracking of the conductor 220.

[0043] To accelerate heat dissipation during the welding of cable 300 and the second welding bump 2214, more specifically, the receiving groove 2216 is positioned directly opposite the first welding part 2212. This arrangement also ensures that the receiving groove 2216 is directly opposite the pin 212 of the diode 210. It should be noted that the diode 210 is a heat source, and the pin 212 of the diode 210 is one of the main components for heat dissipation. By positioning the receiving groove 2216 below the pin 212 of the diode 210, the solder block 2217 of the receiving groove 2216 is located below the pin 212 of the diode 210, facilitating the removal of a large amount of heat from the diode 210 pin 212 away from the housing 100 via the busbar on the solder block 2217.

[0044] Combination Figure 4 As shown, Figure 4This is a schematic diagram of the structure of the housing 100 provided in this application. To facilitate the fixing of the conductor 220 within the housing 100, in one optional embodiment, the housing 100 includes a bottom wall 110 and side walls 120 disposed on the bottom wall 110. The bottom wall 110 and the side walls 120 form a receiving space 130 for accommodating the bypass protection module 200. A positioning post 140 is provided on the bottom wall 110 within the receiving space 130, and the conductor 220 has positioning holes 226 adapted to the positioning posts 140. In a specific configuration, each conductor 220 has multiple positioning holes 226 along its own contour edge; the specific number of positioning holes 226 can be two, three, four, or more. With the above configuration, each conductor 220 is installed on multiple positioning posts 140 in the housing 100, which strengthens the fixation of the conductor 220 and also makes the bypass protection module 200 suspended in the housing 100. With this configuration, when the sealant is poured into the housing 100, the sealant can fill both sides of the bypass protection module 200, completely sealing the bypass protection module 200 in the sealant, ensuring the heat dissipation performance of the bypass protection module 200 and the photovoltaic junction box 10. At the same time, the sealant also ensures that the bypass protection module 200 is not damaged by external rainwater.

[0045] To enhance heat dissipation of the photovoltaic junction box 10, a second heat dissipation through-hole 111, communicating with the receiving space 130, is specifically provided on the bottom wall 110. In this configuration, the second heat dissipation through-hole 111 faces the diode 210 to increase heat dissipation from the heat source. It should be noted that the second heat dissipation through-hole 111 is also filled with sealant. This not only increases heat dissipation performance through the through-hole 111 but also ensures that the bypass protection module 200 is not affected by the external environment.

[0046] It is important to emphasize that since the sealant needs to be filled in the box 100, the larger the space, the larger the amount of sealant needed, which can easily lead to increased costs. To reduce production costs, more specifically, the box 100 also includes a partition 150. The two ends of the partition 150 are connected to the inner walls of the side walls 120, forming a cavity 160 with an opening at the top. In a specific configuration, the partition 150 can be a U-shaped structure, but is not limited to the aforementioned U-shape; it can be a semi-circular, elliptical, or other geometric shapes. It should be noted that the bottom of the partition 150 along its height direction is sealed to the side walls 120, so that the partition 150 and the side walls 120 form a cavity 160 with an opening only at the top. Through this configuration, the partition 150 separates the other components in the box 100 from the cavity 160, thus preventing the sealant from flowing into the cavity 160, thereby reducing the amount of sealant used and lowering the cost of raw materials. To facilitate the subsequent accommodating of the circumferential protrusion of the top cover (not shown in the figure) in the housing 100, the height of the partition 150 is lower than the height of the side wall 120. Furthermore, to save costs and ensure good insulation, the partition 150 is made of materials such as plastic and rubber.

[0047] To accelerate the flow of sealant within the housing 100, a guide 170 is further provided on the outer wall of the partition 150. The guide 170 includes a guide base plate 171 and guide side plates 172 disposed on opposite sides of the guide base plate 171. The guide base plate 171 has a guide through hole 1711, and the outer wall of the guide side plate 172 is an inclined wall 1721. Specifically, the guide side plate 172 is a right-angled rectangle, with its right-angled side connected to the outer wall of the partition 150. The inclined side of the guide side plate 172, i.e., the inclined wall 1721, faces away from the partition 150. The angle formed between the inclined wall 1721 and the guide base plate 171 is acute, allowing the inclined wall 1721 to act as a guide, enabling the sealant to flow along the inclined wall 1721 to the periphery of the diode 210, quickly sealing the diode 210 and the conductor 220 connected to the diode 210.

[0048] For ease of manufacturing, the guide base plate 171 is rectangular. However, it should be noted that the guide base plate 171 is not limited to the rectangular structure described above; it can be triangular, polygonal, or other geometric shapes. A guide through-hole 1711 is provided on the side wall of the guide base plate 171 facing away from the outer wall of the partition member 150. That is, the opening end of the guide through-hole 1711 is on the same side as the inclined wall 1721. This arrangement facilitates faster guidance and flow of the sealant, allowing it to flow quickly along the inclined wall 1721 and the guide through-hole 1711 towards the box body 100. This ensures that the entire box body 100 is filled with sealant.

[0049] To facilitate the connection between the reflow tape and the solder block 2217, the bottom wall 110 of the housing 100 is provided with a manifold 112 that communicates with the receiving space 130. This facilitates the connection of the reflow tape to the solder block 2217 through the manifold 112 and also helps to reduce the weight of the housing 100, meeting the market's demand for lightweight design.

[0050] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0051] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A photovoltaic junction box, characterized by, The photovoltaic junction box comprises a box body and a bypass protection module arranged on the box body, wherein: The bypass protection module comprises a diode and a conductor, the diode comprises a tube body and two pins arranged on both sides of the tube body, and flattened soldering leg portions are arranged on the two pins; The conductor comprises a base plate and first and second flange bodies arranged on adjacent two side walls of the base plate, the first flange body has a protection portion which protrudes from the base plate in a first direction, the second flange body has a gap with the protection portion on the side facing the protection portion to form a clamping groove for clamping the pins, a first soldering portion is arranged on a first surface of the base plate, a plurality of first soldering bumps are arranged on the first soldering portion, and the first soldering bumps are connected with the soldering leg portions.

2. The photovoltaic junction box of claim 1, wherein, The first soldering portion protrudes from the first surface.

3. The photovoltaic junction box of claim 1, wherein, A second soldering portion is further arranged on the first surface, the second soldering portion comprises a plurality of second soldering bumps which are arranged on the first surface at intervals, and the second soldering bumps are connected with cables.

4. The photovoltaic junction box of claim 3, wherein, The base plate further comprises a second surface which is arranged opposite to the first surface, and a containing groove for arranging a tin block is arranged on the second surface. The base plate further comprises a first heat dissipation through hole which penetrates through the first surface and the second surface, and the first heat dissipation through hole is arranged between the containing groove and the second soldering portion.

5. The photovoltaic junction box of claim 4, wherein, The first heat dissipation through hole is in a plurality, and the plurality of first heat dissipation through holes are arranged at intervals.

6. The photovoltaic junction box of claim 4, wherein, The containing groove is arranged opposite to the first soldering portion.

7. The photovoltaic junction box of claim 1, wherein, The box body comprises a bottom wall and a side wall arranged on the bottom wall, the bottom wall and the side wall form a containing space for containing the bypass protection module, a positioning column is arranged on the bottom wall in the containing space, and the conductor comprises a positioning hole which is matched with the positioning column.

8. The photovoltaic junction box of claim 7, wherein, A second heat dissipation through hole which is communicated with the containing space is further arranged on the bottom wall.

9. The photovoltaic junction box of claim 8, wherein, The box body further comprises a partition member, two ends of the partition member are connected with inner walls of the side walls and form a cavity with an open top end.

10. The photovoltaic junction box of claim 9, wherein, An outer wall of the partition member is provided with a guide member, the guide member comprises a guide bottom plate and guide side plates arranged on opposite sides of the guide bottom plate, the guide bottom plate comprises a guide through hole, and outer walls of the guide side plates are inclined walls.

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