Integrated junction box

Abstract

The integrated junction box comprises a junction box main body (1) and a cathode connector (2) installed in the junction box main body (1), the junction box main body (1) is provided with a first inner cavity (1a) and a second inner cavity (1b), a diode (3) is fixedly installed in the first inner cavity (1a) through cold heading, a positive terminal (4) is installed in the second inner cavity (1b), the positive terminal (4) is provided with a first connecting end (4a) and a second connecting end (4b), and the first connecting end (4a) is connected with the second connecting end (4b). The first connection end (4a) is connected to the diode (3) in the first inner cavity (1a) by resistance welding, and the negative connector (2) is connected to the second connection end (4b) in the second inner cavity (1b). Due to the adoption of the integrated design of the junction box and the connector, the transportation cost of the photovoltaic module is reduced, the risk that the connector is in contact with seawater when the photovoltaic module is applied to the sea surface is greatly reduced, the junction box can effectively work for a long time, and compared with an existing structure, the overall production cost is reduced by 30%.

Description

Technical Field

[0001] This utility model relates to the field of junction box structural design, and specifically to a new type of photovoltaic junction box. Background Technology

[0002] Photovoltaic cells are devices that directly convert solar radiation energy into electrical energy. Photovoltaic modules are products made up of multiple connected and encapsulated photovoltaic cells, and are the basic unit of the cell array in a photovoltaic power generation system. The photovoltaic module junction box is a key connection device in the solar module system. Its function is to prevent hot spots from forming when the solar module is partially shaded. If the junction box is damaged or the connection is unreliable, it will malfunction, causing the entire solar module system to fail when the solar module is partially shaded. The shaded area will generate a large amount of heat, and in severe cases, it can burn out the module. The photovoltaic junction box is an important component in a solar power generation system used to connect the photovoltaic backsheet and the inverter. After years of development, the performance and reliability of photovoltaic junction boxes have greatly improved. For example, patent CN108933566B discloses a horizontally split junction box, including a frame, a cover plate, a nylon base plate, terminals, and diodes. The frame is horizontally elongated. The cover plate is detachably fixed to the top of the frame, the nylon base plate is detachably fixed to the bottom of the frame, and the terminals are fixed to the nylon base plate. The terminals are two horizontally arranged and adjacent metal pieces. One horizontal end of each terminal has a busbar connection part, and the other horizontal end has a diode connection part. The two terminals are staggered to form a horizontal elongated shape with a gap between them. The busbar connections of each of the two terminals are horizontally adjacent, and the diode connections of each of the two terminals are horizontally adjacent. The diodes are connected to adjacent diode connections. However, photovoltaic junction boxes with similar structures still have the following shortcomings: 1. Cost: The overall cost of existing junction boxes is relatively high. 2. Reliability: Existing photovoltaic junction boxes cannot operate effectively for extended periods in some special environments, such as in offshore photovoltaic applications. 3. Product size issue: The existing junction box structure is relatively large. Summary of the Invention

[0003] In order to overcome the shortcomings of the existing technology, the purpose of this utility model is to provide an integrated junction box that is lower in cost and can work effectively for a long time.

[0004] To achieve the above objectives, this utility model provides an integrated junction box, including a junction box body and a negative connector installed in the junction box body. The junction box body has a first inner cavity and a second inner cavity. A diode is fixedly installed in the first inner cavity by cold forging. A positive terminal is installed in the second inner cavity. The positive terminal has a first connection end and a second connection end. The first connection end is connected to the diode in the first inner cavity by resistance welding. The negative connector is connected to the second connection end in the second inner cavity.

[0005] Preferably, the second connecting end is tubular, and a drum spring is provided inside the second connecting end. The positive terminal has a limiting part, and the drum spring is limited between the end face of the positive terminal head and the limiting part.

[0006] Preferably, a first cover plate is installed on the first inner cavity, and a second cover plate is installed on the second inner cavity.

[0007] Preferably, the negative connector includes a connecting end and a mounting end. The connecting end has a negative terminal integrally injection molded inside, and the mounting end has a negative cable integrally injection molded inside. The negative terminal is riveted to the end of the negative cable, and the negative terminal is connected to the second connecting end of the positive terminal within the second inner cavity.

[0008] Preferably, an elastic latch is formed on the connection end, and the negative connector is locked together with the junction box body in the second inner cavity by the elastic latch.

[0009] Preferably, an O-ring is fitted onto the connecting end.

[0010] Preferably, the mounting end has an external thread, and a T-ring, a cable locking basket, and a nut are sequentially fitted onto the outside of the negative cable. The nut is screwed onto the external thread of the mounting end, and the T-ring and the cable locking basket are fixedly connected to the mounting end.

[0011] Preferably, the inner diameter of the T-ring matches the outer diameter of the negative cable, the small end of the T-ring is fitted into the cable locking basket, and the cable locking basket is fitted into the nut.

[0012] Preferably, the cable locking basket includes a body, the front end of which is provided with a plurality of claw strips arranged in a circle, and elastic slots are provided between the claw strips.

[0013] Preferably, the inner wall of the nut is an arc shape that gradually contracts towards the central axis. When the nut is tightened, the outer side of the claw strip of the cable locking basket is pressed, and the inner side of the claw strip of the cable locking basket gradually contracts inward to engage the negative electrode cable.

[0014] By adopting an integrated design of junction box and connector, the transportation cost of photovoltaic modules is reduced, and the risk of connector contact with seawater is greatly reduced when used on the sea surface, ensuring that the junction box can work effectively for a long time. Compared with the existing structure, the overall production cost of this utility model is reduced by 30%. Attached Figure Description

[0015] Appendix Figure 1 This is a three-dimensional exploded view of the integrated junction box of this utility model;

[0016] Appendix Figure 2 This is a front view of the integrated junction box of this utility model;

[0017] Appendix Figure 3 This is a cross-sectional view of the integrated junction box of this utility model;

[0018] Appendix Figure 4 This is a rear view of the main body of the integrated junction box of this utility model.

[0019] Appendix Figure 5 This is a schematic diagram of the negative connector of the integrated junction box of this utility model. Detailed Implementation

[0020] In the following description, the terminology used in the specification will be briefly described, and embodiments will be described in detail. All terms used herein, including descriptive or technical terms, should be interpreted as having the meaning understood by one of ordinary skill in the art. However, these terms may have different meanings depending on the intent of one of ordinary skill in the art, precedent, or the emergence of new technologies.

[0021] Furthermore, some terms may be chosen by the applicant, and in such cases, the meaning of the chosen terms will be described in detail in the detailed description of the embodiments. Therefore, the terms used herein must be defined based on their meanings in conjunction with the description throughout the specification. Additionally, when a component “comprises” or “contains” an element, the component may also include other elements without excluding them, unless there is a specific description to the contrary. In the following description, terms such as “component” and “module” indicate a unit for performing at least one function or operation, wherein units and modules may be implemented as hardware or software or by combining hardware and software.

[0022] Embodiments will now be described more fully with reference to the accompanying drawings. However, embodiments may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the embodiments to those skilled in the art. In the following description, well-known functions or structures are not described in detail, as they would obscure the embodiments with unnecessary detail, and throughout the specification, the same reference numerals in the drawings denote the same or similar elements.

[0023] Appendix Figure 1 This is a three-dimensional exploded view of the integrated junction box of this utility model, with attached figures. Figure 2 This is a front view of the integrated junction box of this utility model, with attached... Figure 3 This is a sectional view of the integrated junction box of this utility model, attached. Figure 4 This is a rear view of the main body of the integrated junction box of this utility model. Figure 5 This is a schematic diagram of the negative connector of the integrated junction box of this utility model; the integrated junction box in this embodiment includes a junction box body 1 and a negative connector 2 installed on the junction box body 1. The junction box body 1 has a first inner cavity 1a and a second inner cavity 1b. A first cover plate 11 is installed on the first inner cavity 1a and a second cover plate 12 is installed on the second inner cavity 1b.

[0024] A diode 3 is fixedly mounted in the first inner cavity 1a by cold forging. A positive terminal 4 is mounted in the second inner cavity 1b. The positive terminal 4 has a first connecting end 4a and a second connecting end 4b. The first connecting end 4a is connected to the diode 3 in the first inner cavity 1a by resistance welding. The negative connector 2 is connected to the second connecting end 4b in the second inner cavity 1b. The second connecting end 4b is tubular and has a drum spring 5. The positive terminal 4 has a limiting part 4c, and the drum spring 5 is limited between the end face of the head of the positive terminal 4 and the limiting part 4c.

[0025] The negative connector 2 includes a connecting end 2a and a mounting end 2b. A negative terminal 6 is integrally injection-molded within the connecting end 2a, and a negative cable 7 is integrally injection-molded within the mounting end 2b. The negative terminal 6 is riveted to the end of the negative cable 7 and is connected to the second connecting end 4b of the positive terminal 4 within the second inner cavity 1b. An elastic locking buckle 2c is formed on the connecting end 2a, and the negative connector 2 is locked together with the junction box body 1 within the second inner cavity 1b via the elastic locking buckle 2c. An O-ring 13 is fitted onto the connecting end 2a.

[0026] The mounting end 2b has an external thread. A T-ring 8, a cable locking basket 9, and a nut 10 are sequentially fitted onto the outside of the negative cable 7. The nut 10 is screwed onto the external thread of the mounting end 2b, fixing the T-ring 8 and the cable locking basket 9 to the mounting end 2b. The inner diameter of the T-ring 8 matches the outer diameter of the negative cable 7. The small end of the T-ring 8 is fitted inside the cable locking basket 9, which is fitted inside the nut 10. The cable locking basket 9 includes a body, with several claw strips arranged in a circle at the front end, and elastic slots between the claw strips. The inner wall of the nut 10 is an arc shape that gradually contracts towards the central axis. When the nut 10 is tightened, the outer side of the claw strips of the cable locking basket 9 is compressed, and the inner side of the claw strips of the cable locking basket 9 gradually contracts inward to engage the negative cable 7.

[0027] During the production process, the diode is cold-forged and fixed in the first inner cavity of the junction box. A drum spring is inserted into the positive terminal and fixed in the junction box for resistance welding. The negative terminal and cable are riveted together and placed in a vertical injection molding machine, integrally injection molded with the connector body. An O-ring is fitted into the connector body and inserted into the junction box. A T-ring and cable locking loop are fitted onto the cable, and finally, the nut is tightened. The product has a compact size and is easy, quick, and reliable to operate, allowing workers to install it using simple tools. Due to the integrated design of the junction box and connector, the transportation cost of photovoltaic modules is reduced, and the risk of the connector coming into contact with seawater is greatly reduced when used at sea, ensuring the junction box can work effectively for a long time. Compared with existing structures, this invention reduces the overall production cost by 30%.

[0028] It should be understood that the embodiments described herein should be considered in a descriptive sense only and not for limiting purposes. The description of features or aspects within each embodiment should generally be considered applicable to other similar features or aspects in other embodiments. Although one or more embodiments have been described with reference to the accompanying drawings, those skilled in the art will understand that various changes in form and detail may be made therein without departing from the spirit and scope defined by the appended claims.

Claims

1. An integrated junction box, characterized in that: The device includes a junction box body (1) and a negative connector (2) installed in the junction box body (1). The junction box body (1) has a first inner cavity (1a) and a second inner cavity (1b). A diode (3) is fixedly installed in the first inner cavity (1a) by cold forging. A positive terminal (4) is installed in the second inner cavity (1b). The positive terminal (4) has a first connection end (4a) and a second connection end (4b). The first connection end (4a) is connected to the diode (3) in the first inner cavity (1a) by resistance welding. The negative connector (2) is connected to the second connection end (4b) in the second inner cavity (1b).

2. The integrated junction box according to claim 1, characterized in that: The second connecting end (4b) is tubular, and a drum spring (5) is provided inside the second connecting end (4b). The positive terminal (4) has a limiting part (4c), and the drum spring (5) is limited between the end face of the head of the positive terminal (4) and the limiting part (4c).

3. The integrated junction box according to claim 1, characterized in that: A first cover plate (11) is installed on the first inner cavity (1a), and a second cover plate (12) is installed on the second inner cavity (1b).

4. The integrated junction box according to claim 1, characterized in that: The negative connector (2) includes a connecting end (2a) and a mounting end (2b). The connecting end (2a) is integrally injection molded with a negative terminal (6), and the mounting end (2b) is integrally injection molded with a negative cable (7). The negative terminal (6) is riveted to the end of the negative cable (7), and the negative terminal (6) is connected to the second connecting end (4b) of the positive terminal (4) in the second inner cavity (1b).

5. The integrated junction box according to claim 4, characterized in that: An elastic latch (2c) is formed on the connecting end (2a), and the negative connector (2) is locked together with the junction box body (1) in the second inner cavity (1b) by the elastic latch (2c).

6. The integrated junction box according to claim 4, characterized in that: An O-ring (13) is fitted on the connecting end (2a).

7. The integrated junction box according to claim 4, characterized in that: The mounting end (2b) has an external thread. The negative cable (7) is fitted with a T-ring (8), a cable locking basket (9) and a nut (10) in sequence. The nut (10) is screwed onto the external thread of the mounting end (2b) and fixes the T-ring (8) and the cable locking basket (9) to the mounting end (2b).

8. The integrated junction box according to claim 7, characterized in that: The inner diameter of the T-ring (8) matches the outer diameter of the negative cable (7). The small end of the T-ring (8) is fitted inside the cable locking basket (9), which is fitted inside the nut (10).

9. The integrated junction box according to claim 8, characterized in that: The cable locking basket (9) includes a body, the front end of which is provided with several claw strips arranged in a circle, and elastic gaps are provided between the claw strips.

10. The integrated junction box according to claim 9, characterized in that: The inner wall of the nut (10) is an arc shape that gradually contracts toward the central axis. When the nut (10) is tightened, the outer side of the claw bar of the cable locking basket (9) is pressed, and the inner side of the claw bar of the cable locking basket (9) gradually contracts inward to bite the negative cable (7).

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