Function-partitioned integrated photovoltaic junction box

Abstract

The utility model discloses an integrated photovoltaic junction box with function division, and belongs to the technical field of photovoltaic power generation. The junction box comprises a junction box body and a junction box cover, and a conductive metal sheet is arranged in the junction box body; the junction box body comprises a string lead cavity, a hot spot protection cavity and a spacer; a photovoltaic string positive electrode metal pin and a photovoltaic string negative electrode metal pin are arranged in the string lead cavity, and a hot spot protection bypass diode positive electrode metal base, a hot spot protection bypass diode negative electrode metal base and a hot spot protection bypass diode are arranged in the hot spot protection cavity. The positive electrode of the hot spot protection bypass diode is connected with the hot spot protection bypass diode positive electrode metal base, and the negative electrode of the hot spot protection bypass diode is connected with the hot spot protection bypass diode negative electrode metal base. When the hot spot protection bypass diode needs to be replaced, the hot spot protection bypass diode can be rapidly replaced only by opening the box cover of the hot spot protection cavity. The photovoltaic junction box provided by the utility model obviously simplifies the maintenance process, reduces the time and labor cost, and is simple in structure, low in cost and convenient to maintain.

Description

Technical Field

[0001] This utility model belongs to the field of photovoltaic module technology, and in particular relates to the field of photovoltaic module junction boxes, specifically an integrated photovoltaic junction box with functional partitions. Background Technology

[0002] The photovoltaic (PV) junction box is a critical component for connecting and protecting the circuitry of PV modules. It contains a hotspot protection bypass diode. This diode is connected in parallel with the PV string to protect the modules in the event of a hotspot. During module operation, heat is generated at the junction box connection points, causing the string leads to expand. When the module or ambient temperature drops, the string leads contract, creating gaps between the leads and the sealant. This allows moisture to enter the module, causing power degradation. Prolonged thermal expansion and contraction, especially when the hotspot protection bypass diode carries a current of tens of amperes for extended periods, can lead to lead cracking and junction box deformation, ultimately rendering the module unusable.

[0003] Currently, the internal structure of a conventional junction box consists of a hotspot protection bypass diode and the leads connecting the photovoltaic string, all fixed within a single cavity. To protect the module, sealant must be filled inside the cavity. Most photovoltaic modules currently weigh up to 30 kg, have an area of ​​nearly 3 square meters, and are installed at heights exceeding 3 meters. When the hotspot protection bypass diode fails, the photovoltaic module must be manually removed from its support, the junction box opened, and the sealant broken before the damaged diode can be replaced. Furthermore, a soldering iron is required to remove the bypass diode. Since there is no AC power supply near the module, the module must be moved to an area with AC power to remove the hotspot protection bypass diode using a soldering iron, or the entire photovoltaic module must be disassembled and transported to the manufacturer for junction box replacement. This process is not only time-consuming and labor-intensive, posing a risk of damaging the module, but also incurs significant labor and time costs.

[0004] To address this issue, existing patents propose a photovoltaic junction box and module with a pluggable replaceable diode. While this design simplifies the replacement process of the hot spot protection bypass diode, it also presents significant problems: First, the pluggable structure has poor sealing, making it difficult to prevent moisture ingress and increasing the risk of module damage. Second, photovoltaic modules output direct current, and the pluggable structure may loosen after prolonged use, easily causing arcing and combustion at the connection point. During the module's 30-year warranty period, the pluggable device may loosen or fall off multiple times; if not detected in time, this could lead to module failure or even accidents. Finally, the pluggable structure design is complex, increasing the manufacturing cost of the junction box. Utility Model Content

[0005] To overcome the problems of poor sealing and unsuitability for DC output in existing pluggable photovoltaic junction boxes with replaceable diodes, this invention provides an integrated photovoltaic junction box with functional partitions. The integrated functional partition design aims to ensure convenient replacement of the hot spot protection bypass diode while increasing the overall sealing of the junction box, thereby ensuring the safety of the photovoltaic module. Furthermore, this invention adopts an integrated photovoltaic junction box structure with functional partitions, avoiding the loosening problem of pluggable structures and ensuring the long-term stability, safety, and reliability of the junction box.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0007] An integrated photovoltaic junction box with functional partitions includes a junction box body and a junction box cover, the junction box cover being mounted on the junction box body; a conductive metal sheet is disposed inside the junction box body; the junction box body includes a string lead cavity, a hot spot protection cavity, and an isolation plate; an isolation plate is disposed between the string lead cavity and the hot spot protection cavity; the string lead cavity is provided with a positive metal pin and a negative metal pin of the photovoltaic string; the hot spot protection cavity is provided with a positive metal base, a negative metal base, and a hot spot protection bypass diode; the positive terminal of the hot spot protection bypass diode is connected to the positive metal base, and the negative terminal is connected to the negative metal base.

[0008] Furthermore, the junction box cover includes a string lead cavity cover and a hot spot protection cavity cover; the string lead cavity cover is installed on the string lead cavity, and the hot spot protection cavity cover is installed on the hot spot protection cavity.

[0009] Furthermore, the positive and negative metal pins of the photovoltaic string are connected to the positive and negative terminals of the battery string on the photovoltaic module via leads.

[0010] Furthermore, a conductive metal sheet passes through an insulating sheet between the string lead cavity and the hot spot protection cavity.

[0011] Furthermore, one end of the conductive metal sheet located in the string lead cavity is connected to the positive metal pin or negative metal pin of the photovoltaic string through the lead hole, and the other end of the conductive metal sheet located in the hot spot protection cavity is connected to the positive metal base or negative metal base of the hot spot protection bypass diode.

[0012] Furthermore, the conductive metal sheet includes a positive conductive metal sheet and a negative conductive metal sheet. The positive conductive metal sheet is electrically connected to the positive metal pin of the photovoltaic string and the positive metal base of the hot spot protection bypass diode. The negative conductive metal sheet is electrically connected to the negative metal pin of the photovoltaic string and the negative metal base of the hot spot protection bypass diode.

[0013] Furthermore, the string lead cavity, hot spot protection cavity, insulating sheet, and conductive metal sheet are integrally formed.

[0014] Furthermore, the string lead cavity, hot spot protection cavity, and isolation sheet are integrally injection molded from engineering plastics.

[0015] Furthermore, the string lead cavity cover and the hot spot protection cavity cover are provided with sealing rings around the sides facing the inside of the cavity.

[0016] Furthermore, the junction box body and the isolation plate are made of the same material.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] This invention utilizes a functional partitioning design, independently separating the string lead cavity and the hot spot protection cavity. The positive and negative leads of the photovoltaic string are connected to the positive and negative metal pins of the photovoltaic string, respectively, within the string lead cavity, while the hot spot protection bypass diode is housed within the hot spot protection cavity. To protect the module, the string lead cavity is filled with sealant to prevent moisture from entering the module. For easy replacement of the hot spot protection bypass diode, no sealant filling is required inside the hot spot protection cavity. The sealing ring on the junction box cover provides an IP65 dust and water resistance rating for the hot spot protection cavity, which is sufficient for this cavity. When the hot spot protection bypass diode needs replacement, simply opening the cover of the hot spot protection cavity allows for quick replacement. This design significantly simplifies the maintenance process, reduces time and labor costs, and is a simple, low-cost, and easy-to-maintain photovoltaic junction box.

[0019] Furthermore, the electrical connection between the string lead cavity and the hot spot protection cavity is established through two conductive metal plates. These conductive metal plates pass through an insulating sheet between the two cavities, with one end connected via a lead hole to the positive or negative metal pin of the photovoltaic string within the string lead cavity, and the other end soldered to the positive or negative metal base of the hot spot protection bypass diode within the hot spot protection cavity. Moreover, the string lead cavity, hot spot protection cavity, insulating sheet, and conductive metal plates are integrally molded. This integrated design avoids the problems of poor sealing and poor contact inherent in plug-in structures, effectively preventing DC arcing and significantly improving the overall sealing and reliability of the junction box. The integrated functional partition design balances the high overall sealing of the junction box with the ease of removing the hot spot protection bypass diode. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of an integrated photovoltaic junction box with functional partitions according to this utility model.

[0021] Figure 2 This is a schematic diagram of an integrated photovoltaic junction box with functional partitions as described in this utility model when opened.

[0022] Figure 3 This is a schematic diagram of the internal structure of the junction box body in an integrated photovoltaic junction box with functional partitions according to this utility model.

[0023] Figure 4 This is a partially enlarged schematic diagram of the internal structure of the junction box body in an integrated photovoltaic junction box with functional partitions according to this utility model.

[0024] Figure 5 This is a schematic diagram of the junction box cover in an integrated photovoltaic junction box with functional partitions according to this utility model.

[0025] In the diagram, 1-junction box body; 1-1-string lead cavity; 1-1-1-positive metal pin of photovoltaic string; 1-1-2-negative metal pin of photovoltaic string; 1-2-hot spot protection cavity; 1-2-1-positive metal base of hot spot protection bypass diode; 1-2-2-negative metal base of hot spot protection bypass diode; 1-2-3-hot spot protection bypass diode; 1-3-isolation plate; 2-junction box cover; 2-1-string lead cavity cover; 2-2-hot spot protection cavity cover; 3-conductive metal sheet; 3-1-positive conductive metal sheet; 3-2-negative conductive metal sheet; 4-lead hole; 5-sealing ring. Detailed Implementation

[0026] To more clearly illustrate the purpose, effects, and technical solutions of this utility model, the following will provide a more detailed description through embodiments. The specific implementations herein are merely further explanations of this utility model and not intended to limit it.

[0027] like Figures 1 to 5As shown, this embodiment provides an integrated photovoltaic junction box with functional partitions. The junction box adopts a split design, including a junction box body 1 and a junction box cover 2. The junction box body 1 includes a string lead cavity 1-1, a hot spot protection cavity 1-2, and an isolation plate 1-3. The string lead cavity 1-1 contains a positive metal pin 1-1-1 and a negative metal pin 1-1-2 of the photovoltaic string. The positive and negative metal pins 1-1-1 and 1-1-2 are connected to the positive and negative terminals of the battery string on the photovoltaic module via leads. The hot spot protection cavity 1-2 contains a hot spot protection bypass diode positive metal base 1-2-1 and a hot spot protection bypass diode. The diode includes a negative metal base 1-2-2 and a hot spot protection bypass diode 1-2-3. The positive terminal of the hot spot protection bypass diode 1-2-3 is connected to the positive metal base 1-2-1, and the negative terminal of the hot spot protection bypass diode 1-2-3 is connected to the negative metal base 1-2-2 to achieve hot spot protection. The string lead cavity 1-1 and the hot spot protection cavity are separated by an isolation plate 1-3 made of the same material as the junction box body 1, forming two independent functional cavities.

[0028] See Figure 5 The junction box cover 2 includes a string lead cavity cover 2-1 and a hot spot protection cavity cover 2-2; the string lead cavity cover 2-1 is installed on the string lead cavity 1-1, and the hot spot protection cavity cover 2-2 is installed on the hot spot protection cavity 1-2.

[0029] The function of the string lead cavity 1-1 is to realize the electrical connection with the photovoltaic string. Since the string lead cavity 1-1 must have very high sealing performance to prevent moisture from entering the photovoltaic module, the string lead cavity 1-1 is filled with sealant.

[0030] The function of the hot spot protection cavity 1-2 is to protect the photovoltaic module from hot spots. Since the string lead cavity 1-1 is filled with sealant and the insulating sheet 1-3 has separated it from the hot spot protection cavity 1-2, the dustproof and waterproof rating of the hot spot protection cavity 1-2 only needs to reach IP65. The hot spot protection cavity 1-2 is not filled with sealant to facilitate the inspection and replacement of the damaged hot spot protection bypass diode 1-2-3.

[0031] See Figure 3The junction box 1 contains a conductive metal sheet 3 for electrical connection between the string lead cavity 1-1 and the hot spot protection cavity 1-2. The conductive metal sheet 3 passes through the insulating sheet 1-3 between the string lead cavity 1-1 and the hot spot protection cavity 1-2. One end of the conductive metal sheet 3, located within the string lead cavity 1-1, is connected via a lead hole 4 to either the positive metal pin 1-1-1 or the negative metal pin 1-1-2 of the photovoltaic string. The other end, located within the hot spot protection cavity 1-2, is connected to either the positive metal base 1-2-1 or the negative metal base 1-2-2 of the hot spot protection bypass diode.

[0032] The conductive metal sheet 3 includes a positive conductive metal sheet 3-1 and a negative conductive metal sheet 3-2. The positive conductive metal sheet 3-1 realizes the electrical connection between the positive metal pin 1-1-1 of the photovoltaic string and the positive metal base 1-2-1 of the hot spot protection bypass diode. The negative conductive metal sheet 3-2 realizes the electrical connection between the negative metal pin 1-1-2 of the photovoltaic string and the negative metal base 1-2-2 of the hot spot protection bypass diode. The conductive metal sheet 3 is made of conductive materials such as tin-plated copper to ensure its long-term stable and safe operation.

[0033] The string lead cavity 1-1, hot spot protection cavity 1-2, isolation plate 1-3, and conductive metal plate 3 are integrally formed to reduce the amount of moisture or dust in the hot spot protection cavity 1-2 entering the string lead cavity 1-1 through the gap at the connection between the conductive metal plate 3 and the isolation plate 1-3, thus ensuring the stability of the overall structure and the sealing of the two functional cavities.

[0034] The string lead cavity 1-1, hot spot protection cavity 1-2, and isolation plate 1-3 are made of high-strength engineering plastic through integrated injection molding. The engineering plastic has good weather resistance to ensure the structural stability and safety of the junction box during long-term outdoor use. The integrated functional partition design can take into account both the sealing of the two independent functional cavities and the convenience of disassembling and replacing the hot spot protection bypass diode.

[0035] The string lead cavity cover 2-1 and the hot spot protection cavity cover 2-2 are provided with sealing rings 5 ​​around the sides facing the inside of the cavity to reduce the entry of moisture or dust into the cavity. The sealing rings are made of high-temperature resistant and corrosion-resistant single-component or two-component silicone rubber to ensure their dustproof and waterproof capabilities in complex outdoor environments for a long time. The sealing rings 5 ​​enable the cavity to achieve the dustproof and waterproof rating of IP65.

[0036] When the hot spot protection bypass diode 1-2-3 malfunctions and cannot work properly, simply open the hot spot protection chamber cover 2-2 and replace the hot spot protection bypass diode 1-2-3.

[0037] The above description only describes the preferred embodiment of this utility model and should not be construed as limiting the claims. This utility model, through its integrated functional partition design, effectively balances the dust and water resistance of the string lead cavity with the convenience of replacing and maintaining the hot spot protection bypass diode. The use of conductive metal sheets to achieve electrical connection between the two cavities effectively solves the inherent defects of plug-and-play structures. The integrated molding manufacturing method effectively increases the overall dust and water resistance and structural stability of the junction box.

[0038] This utility model proposes a novel photovoltaic junction box that is low in cost, simple to manufacture, yet highly practical and safe. This utility model is not limited to the above embodiments, and variations in its specific structure are permitted. All modifications made within the scope of the independent claims of this utility model are also within the scope of protection of this utility model. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this utility model pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the utility model. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

Claims

1. An integrated photovoltaic junction box with functional zones, characterized in that, The device includes a junction box body (1) and a junction box cover (2), the junction box cover (2) being mounted on the junction box body (1); a conductive metal sheet (3) is disposed inside the junction box body (1); the junction box body (1) includes a string lead cavity (1-1), a hot spot protection cavity (1-2), and an isolation sheet (1-3); an isolation sheet (1-3) is disposed between the string lead cavity (1-1) and the hot spot protection cavity (1-2); the string lead cavity (1-1) is provided with a photovoltaic string positive metal pin (1-1-1) and a photovoltaic string negative metal pin. The hot spot protection cavity (1-2) contains a hot spot protection bypass diode positive metal base (1-2-1), a hot spot protection bypass diode negative metal base (1-2-2), and a hot spot protection bypass diode (1-2-3). The positive terminal of the hot spot protection bypass diode (1-2-3) is connected to the hot spot protection bypass diode positive metal base (1-2-1), and the negative terminal of the hot spot protection bypass diode (1-2-3) is connected to the hot spot protection bypass diode negative metal base (1-2-2).

2. The integrated photovoltaic junction box with functional zones according to claim 1, characterized in that, The junction box cover (2) includes a string lead cavity cover (2-1) and a hot spot protection cavity cover (2-2); the string lead cavity cover (2-1) is installed on the string lead cavity (1-1), and the hot spot protection cavity cover (2-2) is installed on the hot spot protection cavity (1-2).

3. The integrated photovoltaic junction box with functional zones according to claim 1, characterized in that, The positive metal pin (1-1-1) and negative metal pin (1-1-2) of the photovoltaic string are connected to the positive and negative terminals of the battery string on the photovoltaic module respectively via leads.

4. The integrated photovoltaic junction box with functional zones according to claim 1, characterized in that, The conductive metal sheet (3) passes through the insulating sheet (1-3) between the string lead cavity (1-1) and the hot spot protection cavity (1-2).

5. The integrated photovoltaic junction box with functional zones according to claim 4, characterized in that, One end of the conductive metal sheet (3) located in the string lead cavity (1-1) is connected to the positive metal pin (1-1-1) or negative metal pin (1-1-2) of the photovoltaic string through the lead hole (4). The other end of the conductive metal sheet (3) located in the hot spot protection cavity (1-2) is connected to the positive metal base (1-2-1) or negative metal base (1-2-2) of the hot spot protection bypass diode.

6. The integrated photovoltaic junction box with functional zones according to claim 4, characterized in that, The conductive metal sheet (3) includes a positive conductive metal sheet (3-1) and a negative conductive metal sheet (3-2). The positive conductive metal sheet (3-1) is electrically connected to the positive metal pin (1-1-1) of the photovoltaic string and the positive metal base (1-2-1) of the hot spot protection bypass diode. The negative conductive metal sheet (3-2) is electrically connected to the negative metal pin (1-1-2) of the photovoltaic string and the negative metal base (1-2-2) of the hot spot protection bypass diode.

7. The integrated photovoltaic junction box with functional zones according to claim 1, characterized in that, The string lead cavity (1-1), hot spot protection cavity (1-2), isolation sheet (1-3), and conductive metal sheet (3) are integrally formed.

8. The integrated photovoltaic junction box with functional zones according to claim 1, characterized in that, The string lead cavity (1-1), hot spot protection cavity (1-2), and isolation sheet (1-3) are made of engineering plastic through integrated injection molding.

9. The integrated photovoltaic junction box with functional zones according to claim 2, characterized in that, The string lead cavity cover (2-1) and the hot spot protection cavity cover (2-2) are provided with sealing rings (5) around the side facing the inside of the cavity.

10. The integrated photovoltaic junction box with functional zones according to claim 1, characterized in that, The junction box body (1) and the isolation plate (1-3) are made of the same material.

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