Repair device for processing cracking of junction box
By installing a repair module on the outer wall of the junction box and filling the gap with sealant, the problem of power-off repair required in the prior art is solved, and a low-cost and easy-to-implement junction box repair effect is achieved.
Patent Information
- Application Number
- CN202423291206.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-31
- Publication Date
- 2026-01-27
- Estimated Expiration
- 2034-12-31
AI Technical Summary
Existing junction box repair devices require power outages at the substation, resulting in high repair costs and complex repair processes.
A repair device is provided, comprising a repair module and a sealant. The repair module is fitted onto the outer wall of the junction box, and the sealant fills the gap between the module and the junction box. The shape of the repair module matches the junction box, and the sealant covers the outer surface of the junction box. The repair process does not require power interruption.
It enables simple and easy junction box repair, reduces repair costs, improves sealing, prevents moisture intrusion, and is suitable for repairing cracks in junction boxes of different shapes.
Smart Images
Figure CN223843744U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of photovoltaic power station technology, and in particular to a repair device for dealing with cracked junction boxes. Background Technology
[0002] Junction boxes are protective devices used in the photovoltaic field to connect and protect solar photovoltaic modules. They connect the electricity generated by solar cells to external lines and conduct the current generated by the photovoltaic modules, making them an important component of the photovoltaic system. Because solar photovoltaic module junction boxes are exposed to the external environment for a long time, they are prone to cracking when subjected to harsh factors such as sun exposure, wind and rain, trampling, and high-pressure washing. Cracks in junction boxes may lead to poor internal electrical connections, resulting in resistive heating, which can affect the power generation efficiency of the photovoltaic system and even cause serious safety hazards. Therefore, timely repair of junction box cracks is crucial.
[0003] Existing junction box repair methods utilize electrical pulses and metal wires, placing the junction box in a repair chamber with a low-oxygen environment. Although the repair effect is good, the repair device has a complex structure and requires the power station to be disconnected beforehand, which results in a large amount of power loss. Furthermore, the existing repair device is expensive, further increasing the repair cost. Utility Model Content
[0004] To address the technical problems of existing junction box repair devices requiring power outages and incurring high repair costs, this invention provides a repair device for handling cracked junction boxes.
[0005] To achieve the above objectives, this utility model provides a repair device for treating cracked junction boxes, comprising a repair module and a sealant; the repair module is fitted onto the outer wall of the junction box, and there is a gap between the side wall of the repair module and the side wall of the junction box, the repair module being used to protect the side wall of the junction box; the sealant is filled in the gap between the repair module and the junction box.
[0006] Optionally, the bottom surface of the repair module is provided with a cut edge, the cut edge being an inclined surface, the inclined surface being inclined from the outer wall of the repair module to the inner wall of the repair module in a direction away from the bottom surface of the repair module.
[0007] Optionally, the sealant covers the cut edge and extends 2-3 mm beyond the cut edge.
[0008] Optionally, the junction box has a protruding structure with an opening on one side, and the repair module has an extension on one side. The extension is fitted onto the outer wall of the protruding structure, and the shape of the extension is adapted to the shape of the protruding structure of the junction box.
[0009] Optionally, the extension has a through hole that matches the opening of the protruding structure, and the bottom surface of the extension is flush with the bottom surface of the repair module.
[0010] Optionally, the side wall of the junction box is provided with an opening, and the side wall of the repair module is provided with a through hole that matches the opening of the side wall of the junction box.
[0011] Optionally, one end of each of the two opposite sidewalls of the repair module is provided with a curved arc that bends inward into the repair module, and the curved arc abuts against the outer sidewall of the junction box.
[0012] Optionally, the length of the longer side of the repair module is not longer than the length of the junction box.
[0013] Optionally, the inner sidewall of the repair module is provided with a protrusion, the size of which is not greater than the gap between the repair module and the junction box.
[0014] Optionally, the protrusion is disposed on two interconnected inner sidewalls of the repair module.
[0015] The above-mentioned technical solution of this utility model has the following advantages compared with the prior art:
[0016] (1) The repair device for treating the cracked junction box of this utility model is directly covered on the side wall of the junction box, and the gap between the repair device and the side wall of the junction box is filled with sealant. The repair device is simple and the repair process is easy to implement. Furthermore, the repair device of this utility model directly repairs the gap on the outer wall of the junction box without disconnecting the power station, which further saves repair costs.
[0017] (2) Adjust the shape of the repair device according to the shape of the junction box so that the shape of the repair device matches the junction box, which can effectively repair the cracks of junction boxes in different shapes.
[0018] (3) A cut edge is designed at the bottom of the repair device. During repair, the sealant will flow along the cut edge to the inner wall of the repair device, thereby effectively covering the entire outer surface of the junction box, improving the sealing performance and preventing water vapor from entering.
[0019] (4) Protrusions are provided on the inner walls of the two sides where the repair devices are connected to each other, which can increase friction during repair installation and prevent the repair from shifting. Attached Figure Description
[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0021] Figure 1 This is a schematic diagram of the structure of the repair device for treating cracked junction boxes according to this utility model;
[0022] Figure 2 This is another structural schematic diagram of the repair device of this utility model for treating cracked junction boxes;
[0023] Figure 3 This is a schematic diagram of the repair device for treating cracked junction boxes with through holes in the side wall, according to this utility model.
[0024] Figure 4 This is a diagram showing the cut edge position of the repair device for treating cracked junction boxes according to this utility model.
[0025] Figure 5 This is a schematic diagram of the structure of the repair device with a side opening for treating cracked junction boxes according to this utility model.
[0026] Instruction manual drawing reference numerals: Repair module-1; Extension-2; Cut edge-3; Curve-4; Protrusion-5; Through hole-6. Detailed Implementation
[0027] To make the above-mentioned objectives, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, not all of them. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of this utility model.
[0028] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.
[0029] Secondly, the term "an embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that excludes other embodiments.
[0030] This utility model is described in detail with reference to the schematic diagrams. When describing the embodiments of this utility model, for ease of explanation, the cross-sectional views illustrating the device structure may be partially enlarged, deviating from the general scale. Furthermore, the schematic diagrams are merely examples and should not limit the scope of protection of this utility model. In actual manufacturing, the three-dimensional spatial dimensions of length, width, and depth should be included.
[0031] Furthermore, in the description of this utility model, it should be noted that the terms "upper," "lower," "left," "right," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are used solely for the convenience of describing this utility model and for simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first," "second," or "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0032] Unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" in this utility model should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integrated connections; similarly, they can refer to mechanical connections, electrical connections, or direct connections, or indirect connections through an intermediate medium, or internal connections between two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.
[0033] Cracks in the junction box of a photovoltaic module can allow moisture to enter, which can damage the internal bypass diodes over time. Once the photovoltaic module loses the protection of the bypass diodes, it will overheat and become damaged, affecting the operation of the entire power station. Therefore, the junction box needs to be repaired.
[0034] The following is for reference. Figures 1-5The present invention describes a repair device for treating cracked junction boxes according to an embodiment of the present invention. The repair device includes a repair module 1 and a sealant (not shown). The repair module 1 is fitted onto the outer wall of the junction box. In this embodiment, the repair module 1 is through-hole on both the top and bottom, and is a hollow ring structure composed of multiple connected side walls. The repair module 1 covers the entire outer wall of the junction box. The front view of the repair module 1 is consistent with that of the junction box. The repair module 1 surrounds the junction box. There is a gap between the inner wall of the repair module 1 and the side wall of the junction box. The sealant is filled in the gap between the repair module 1 and the junction box, so that the sealant covers the entire inner wall of the repair module 1, and then covers the outer wall of the junction box, achieving the effect of repair and sealing. It should be noted that the junction box includes a box body and a cover mounted on the box body. The internal condition of the junction box can be viewed by opening the cover. In addition, the cover is printed with font containing basic information about the junction box. When repairing, the repair module 1 of this utility model is through and hollow, only surrounding the side wall of the junction box. Therefore, it does not affect viewing the contents of the cover or opening the cover. Furthermore, this utility model can repair either side of the junction box.
[0035] It should be noted that the repair module 1 and the junction box of the photovoltaic module can be made of the same material, and the color of the repair module 1 should be consistent with the color of the junction box. The repair module 1 is made of polyphenylene ether (PPO or PPE), which has excellent properties such as high heat resistance, high flame retardancy, good UV resistance, anti-aging, low water absorption, high mechanical strength, good dimensional stability, low temperature resistance, and low dielectric constant. It is an engineering plastic that meets environmental protection requirements.
[0036] Furthermore, the sealant can be a thixotropic paste material. The sealant is white and has strong adhesion to PPO material. Specifically, silicone sealant can be selected. Silicone sealant is prepared by adding reinforcing powder, coupling agent, crosslinking agent, catalyst and other additives. After contact with moisture in the air, it crosslinks and cures into an elastomer at room temperature. When used, the thixotropic paste has high viscosity. After trimming, it can easily fill the gaps and stay in the sealant joint without dripping or running, maintaining a clean and beautiful appearance. As a preferred option, the sealant is packaged in a cylindrical shape, which is convenient to use with a caulking gun and improves the accuracy of the glue application during the repair work.
[0037] In one embodiment, refer to Figure 4The bottom surface of the repair module 1 is provided with a slanted edge 3, which is inclined from the outer wall of the repair module 1 to the inner wall of the repair module 1 and slopes away from the bottom surface of the repair module 1. It should be noted that if the slanted edge 3 is provided on the top surface of the repair module 1, the inclined surface slopes upward from the inner wall of the repair module 1 and extends to the outer wall of the repair module 1. Therefore, the height of the junction between the slanted edge 3 and the gap between the repair module 1 and the junction box is relatively low. During the potting process, the sealant is covered with the slanted edge 3. When the repair module 1 is fitted onto the junction box, the sealant will flow along the inclination of the slanted edge 3 into the gap between the repair module 1 and the junction box and cover the surface of the junction box, thus forming a stable sealing performance with the repair module 1.
[0038] As a preferred method, during the application of sealant, the amount of sealant applied should cover the cut edge 3, and the width of the sealant should extend outwards from the boundary of the cut edge 3 by 2-3 mm, such as 2 mm, 2.4 mm, 2.6 mm, or 3 mm. During repair, the sealant exceeding the cut edge 3 will flow out from the gap between the repair module 1 and the junction box due to compression, filling the gap and ensuring complete coverage of the junction box. Furthermore, after applying the sealant, the repair module 1 and the junction box are placed together and left to stand for 10-20 seconds. After standing, the excess sealant is simply cleaned with a lint-free cloth to keep the surfaces of the repair module 1 and the junction box clean.
[0039] In one embodiment, a protruding structure with an opening is provided on one side of the junction box. In this embodiment, the protruding structure is box-shaped and connected to the side wall of the junction box, and communicates with the interior of the junction box. The top surface of the protruding structure is arc-shaped, and an opening is formed in the middle of the top surface of the protruding structure. (Refer to...) Figure 1 or Figure 2 An extension 2 is provided on the side wall of the repair module 1. The extension 2 is fitted onto the outer wall of the protruding structure. In this embodiment, the extension 2 is connected to the left side wall of the repair module 1. The shape of the extension 2 is adapted to the shape of the left side of the junction box. The design of the extension corresponds to the design of the photovoltaic module junction box, so that the repair module 1 and the extension 2 can cover all the side wall surfaces of the junction box and repair cracks on any side wall surface.
[0040] In one embodiment, a through hole 6 that mates with the junction box is formed at the top of the extension 2, for example in... Figure 1 and Figure 2 In the middle, the top of the two extensions 2 are provided with through holes 6 of different shapes to prevent the sealant from sealing the through holes 6 on the junction box during repair. The bottom surface of the extensions 2 is flush with the bottom surface of the repair module 1 to ensure the uniformity of the sealant coverage.
[0041] In one embodiment, refer to Figure 3Unlike the repair device described above for treating junction box cracks, the side wall of the junction box is provided with an opening, and the side wall of the repair module 1 is provided with a through hole 6 that matches the opening of the side wall of the junction box. The shape of the repair module 1 and the through hole 6 are adaptively adjusted according to the shape and opening of the junction box to further accommodate junction boxes of different shapes.
[0042] In one embodiment, refer to Figure 5 The repair module 1 has an open structure. At one end of each of the two opposite sidewalls of the repair module 1, there is a curved arc 4 that bends inward into the repair module 1. The curved arc 4 abuts against the outer sidewall of the junction box. Since the various outer shells of the junction box only have different protruding structures or openings on the left side of the junction box, the repair module 1 in this embodiment can be used when the left side of the junction box is not cracked. The repair module 1 in this embodiment does not need to distinguish the appearance type of the junction box and is applicable to all appearance types of junction boxes, with a wide range of applications.
[0043] In one embodiment, when the repair module 1 has an opening on one side and the sidewall of the repair module 1 bends inward at the opening to form an inward curved arc 4, the length of the longer side of the repair module 1 is not longer than the length of the junction box, so that the formed inward curved arc 4 forms a hook to be fixed on part of the sidewall of the junction box, so that the protruding part or opening of the junction box is exposed, in order to prevent the repair module 1 from shifting.
[0044] In one embodiment, a protrusion 5 is provided on the inner wall of the repair module 1. The size of the protrusion 5 is not greater than the gap between the repair module 1 and the junction box, so as not to affect the sealant sealing between the repair module and the junction box. Preferably, the protrusion 5 is a wavy protrusion, which can increase friction during repair.
[0045] In one embodiment, protrusions 5 are provided on two interconnected inner sidewalls of the repair module 1 to further solidify the position and prevent displacement.
[0046] The repair device for handling cracked junction boxes proposed in this embodiment of the utility model sets the repair module 1 into various types according to the appearance of the junction box. The principle of this embodiment is as follows: Before starting the repair, the abnormal cracked junction box of the photovoltaic module is cleaned. A handheld vacuum cleaner is used to pre-treat the surface of the junction box, and then a lint-free cloth and brush are used to remove dust from the surface of the junction box. An organic solvent is used to clean the surface of the junction box. When repairing the cracked junction box, if there is a crack on the left side of the junction box, the appropriate repair module 1 is selected according to the appearance type of the junction box. If there is no crack on the left side of the junction box, a repair module 1 with an opening on one side can be selected for repair. After selecting a suitable repair module 1, the cleaned junction box is repaired. Specifically: Place the cylindrical sealant into the caulking gun, align the nozzle of the caulking gun with the cut edge 3 at the bottom of the repair module 1, and apply sealant around the cut edge 3, covering and extending the edge 3 by 2-3mm. After applying the sealant, place the repair module 1 onto the outside of the cleaned junction box and let it stand for 10-20 seconds. After standing, use a lint-free cloth to clean any excess sealant. After cleaning, perform a wet leakage current simulation aging test on the repaired junction box. The repaired junction box can meet the IP68 and wet leakage current tests. The repair device for treating cracked junction boxes provided in this embodiment can achieve a protective function. Furthermore, the repair device for treating cracked junction boxes provided in this embodiment does not require the replacement of all components when repairing cracked junction boxes, and can also reduce repair costs.
[0047] In summary, the above-mentioned technical solution of this utility model has the following advantages compared with the prior art:
[0048] The repair device for treating cracked junction boxes provided in this embodiment directly covers the side wall of the junction box, and the gap between the repair device and the side wall of the junction box is filled with sealant. The repair device is simple, the repair process is easy to implement, and this utility model repair device directly repairs the crack on the outer wall of the junction box without disconnecting the power station, further saving repair costs. The shape of the repair device is adjusted according to the shape of the junction box so that the shape of the repair device matches the junction box, which can effectively repair cracks in junction boxes of different shapes. A cut edge is designed at the bottom of the repair device. During repair, the sealant will flow along the cut edge to the inner wall of the repair device, thereby effectively covering the entire outer surface of the junction box, improving the sealing performance and preventing moisture intrusion. Protrusions are provided on the inner walls of the two sides where the repair device connects to each other, which can increase friction during repair and installation and prevent the repair from shifting.
[0049] Note that the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments. Many other equivalent embodiments may be included without departing from the concept of the present invention, and the scope of the present invention is determined by the scope of the appended claims.
Claims
1. A repair device for treating cracked junction boxes, characterized in that, Includes repair module (1) and sealant; The repair module (1) is fitted onto the outer side wall of the junction box, and there is a gap between the side wall of the repair module (1) and the side wall of the junction box. The repair module (1) is used to protect the side wall of the junction box. The sealant is filled in the gap between the repair module (1) and the junction box.
2. The repair device for treating junction box cracks according to claim 1, characterized in that, The bottom surface of the repair module (1) is provided with a cut edge (3), which is an inclined surface. The inclined surface is inclined from the outer wall of the repair module (1) to the inner wall of the repair module (1) and away from the bottom surface of the repair module (1).
3. The repair device for treating junction box cracks according to claim 2, characterized in that, The sealant covers the cut edge (3) and extends outward from the cut edge (3) by 2-3 mm.
4. The repair device for treating junction box cracks according to claim 2, characterized in that, The junction box has a protruding structure with an opening on one side, and the repair module (1) has an extension (2) on one side. The extension (2) is fitted onto the outer wall of the protruding structure, and the shape of the extension (2) is adapted to the shape of the protruding structure of the junction box.
5. The repair device for treating junction box cracks according to claim 4, characterized in that, The extension (2) has a through hole (6) that matches the opening of the protruding structure, and the bottom surface of the extension (2) is flush with the bottom surface of the repair module (1).
6. The repair device for treating junction box cracks according to claim 1, characterized in that, The junction box has an opening on its side wall, and the repair module (1) has a through hole (6) on its side wall that matches the opening on the side wall of the junction box.
7. The repair device for treating junction box cracks according to claim 1, characterized in that, The repair module (1) has an open structure. One end of each of the two opposite sidewalls of the repair module (1) is provided with a curved arc (4) that bends inward toward the inside of the repair module (1). The curved arc (4) abuts against the outer sidewall of the junction box.
8. The repair device for treating junction box cracks according to claim 7, characterized in that, The length of the longer side of the repair module (1) is not longer than the length of the junction box.
9. The repair device for treating junction box cracks according to claim 1, characterized in that, The inner wall of the repair module (1) is provided with a protrusion (5), the size of which is not greater than the gap between the repair module (1) and the junction box.
10. The repair device for treating junction box cracks according to claim 9, characterized in that, The protrusion (5) is disposed on two interconnected inner sidewalls of the repair module (1).