Corrosion-resistant photovoltaic module connector with multiple waterproof structures

Abstract

The utility model provides a corrosion-resistant photovoltaic module connector with multiple waterproof structures, which comprises a male plug and a female plug, a plurality of sealing rings are arranged on the plugging part of a male plug body and a female plug body, and a plurality of annular bulges are arranged on the inner wall of a cable fixing plug to form a plurality of sealing structures. According to the connector of the utility model, multiple layers of sealing structures are arranged at the possible gaps of the connector, including the cable fixing part and the plugging part of the male plug and the female plug, so that salt mist, water vapor or seawater can be prevented from entering the connector to cause faults of the connector; the retaining mechanism adopts the ratchet structures which are asymmetrically arranged, so that at least one ratchet structure can be matched with the ratchets to meet the retaining requirement; the male plug and the female plug are provided with the clamping hooks and the clamping grooves, blind plugging operation is supported, a special tool is not needed during plug-in, convenience and rapidness are achieved, a special tool is needed for disassembly during disassembly, and accidental falling of the male plug and the female plug in the use process of the connector can be effectively avoided.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic power generation system technology, and in particular to a connector for photovoltaic modules suitable for marine environments. It has multiple waterproof structures and has excellent corrosion resistance in marine working environments. Background Technology

[0002] Photovoltaic power generation systems require multiple photovoltaic modules to be interconnected via cables to form a photovoltaic module array, which then outputs a large current. This current is then collected and delivered to the user end. Therefore, connectors are essential components in photovoltaic connection systems. Offshore photovoltaic projects face harsh environments, primarily high-salt-spray environments, placing extremely high demands on photovoltaic modules and electronic components. Furthermore, during the operation of offshore photovoltaic power plants, junction boxes and connectors are directly exposed to the air. To withstand strong winds and prevent cable breakage, the connector cables connecting the modules are always longer. With the ebb and flow of tides, connectors may even be submerged in seawater. Therefore, for offshore photovoltaic modules, photovoltaic connectors need to have very strong waterproof performance to withstand harsh corrosive environments and prevent corrosion of internal electronic components. In addition to ensuring excellent water and vapor intrusion resistance, the ease of maintenance of the photovoltaic system must also be considered, making the connection and disconnection of connectors easy. Utility Model Content

[0003] The purpose of this invention is to solve the problems existing in the prior art by proposing a high-voltage, high-current marine connector.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] This utility model discloses a corrosion-resistant photovoltaic module connector with a multi-layer waterproof structure, comprising a male plug and a female plug, the plug ends of which are interlocked. The male plug includes a male plug body with a nut at one end, a cable clip and a plug are provided between the male plug body and the nut, and a metal sleeve is provided inside the male plug body. The female plug includes a female plug body with a nut at one end, a cable clip and a plug are provided between the female plug body and the nut, and a metal pin is provided inside the female plug body. The cables at both ends of the connector are inserted through the nut and fixedly connected to the sleeve and the pin respectively, and the sleeve and the pin are connected to form an electrical connection. The sleeve and the pin are provided with clamping components that cooperate with the stepped portions on the inner walls of the male plug body and the female plug body. A sealing component is provided between the male plug body and the female plug body. The plug end of the male plug body is provided with hooks on both sides, and the female plug body is provided with grooves corresponding to the hooks of the male plug.

[0006] The male connector body has a first annular groove on its insertion part with the female connector body, and a first sealing ring is disposed therein. A second annular groove is disposed adjacent to the first annular groove, and a second sealing ring is disposed therein. The first sealing ring has an O-shaped cross-section and a protruding part, which faces the nut side of the male connector body when the first sealing ring is installed in the first annular groove. The second sealing ring has a rectangular cross-section and a protruding lip structure. The protruding part extends beyond the opening height of the first annular groove, and the lip structure has a height such that the end of the lip structure is higher than the opening height of the second annular groove.

[0007] Preferably, the inner wall of the plug is provided with multiple annular protrusions, which form an interference fit with the cable. When the nut and the male plug body are tightened, the annular protrusions are squeezed and deformed, forming a multi-layer seal with the cable.

[0008] Preferably, the steps on the inner walls of the male and female plug bodies that engage with the clamping feet of the clamping component are right-angled step structures.

[0009] Preferably, the end of the connecting end of the male plug body is provided with an annular groove, in which a third sealing ring is provided. The third sealing ring has a protrusion. During the insertion of the pin and the sleeve, the protrusion of the sealing ring is squeezed and deformed, forming a seal at the connection gap between the connecting end of the male plug body and the internal step of the female plug body.

[0010] Preferably, a backstop structure is provided at the connection between the male connector body and the nut and at the connection between the female connector body and the nut. The backstop structure includes a ratchet structure evenly spaced at the outer end of the nut, adjacent to the internal thread, and at least one pair of spike structures provided at the threaded connection end of the male and female connector bodies, adjacent to the tail of the external thread. The paired spike structures are asymmetrically arranged.

[0011] Preferably, the male connector body has hooks on both sides of the plug end, the upper surface of the hook is a bevel or arc surface, and a groove structure is provided on the upper surface of the hook.

[0012] More preferably, the groove structure is a recess that extends through the width of the hook or two recesses that are symmetrically arranged on the hook.

[0013] Preferably, the sleeve and pin are made of copper, silver-copper alloy, or aluminum with a coating, and the surface of the sleeve and pin is coated with a nano-silver coating.

[0014] This utility model discloses a corrosion-resistant photovoltaic module connector with multiple waterproof structures. Multiple sealing structures are installed at potential gaps in the connector, including cable fixing points and male and female plug connections, to prevent salt spray, moisture, or seawater from seeping into the connector and causing malfunctions. The anti-reverse mechanism uses an asymmetrically arranged ratchet structure, ensuring that at least one ratchet engages with the ratchet teeth to meet the anti-reverse requirement. The male and female plugs are equipped with hooks and slots, supporting blind insertion without the need for special tools, making insertion convenient and quick. Disassembly requires special tools, effectively preventing accidental detachment of the male and female plugs during use. The sockets and pins are plated with a nano-silver coating, effectively reducing contact resistance. Attached Figure Description

[0015] Figure 1 This is a front view of the corrosion-resistant photovoltaic module connector with multiple waterproof structures after insertion, according to an embodiment of the present invention.

[0016] Figure 2 for Figure 1 A schematic diagram of the exploded structure of the connector;

[0017] Figure 3 for Figure 1 A schematic diagram of the internal cross-sectional structure of the connector;

[0018] Figure 4 for Figure 2 Enlarged view of point A in the middle;

[0019] Figure 5 for Figure 2 Enlarged view of point B in the middle;

[0020] Figure 6 for Figure 2 Enlarged view of point C in the middle;

[0021] Figure 7 for Figure 1 A schematic diagram of the connector nut structure;

[0022] Figure 8 for Figure 1 Schematic diagram of the DD cross-sectional structure;

[0023] Figure 9 for Figure 1 A schematic diagram of the male connector body;

[0024] Figure 10 for Figure 1 A schematic diagram of the female connector body. Detailed Implementation

[0025] To provide a better understanding of the purpose, structure, features and functions of this utility model, detailed descriptions are provided below with reference to the embodiments.

[0026] Combination Figure 1 and Figure 2 As shown, this utility model discloses a corrosion-resistant photovoltaic module connector with a multi-layer waterproof structure, including a male plug and a female plug, the plug ends of which are interlocked. The male plug includes a male plug body 5, one end of which is provided with a nut 2. A cable clip 3 and a plug 4 are provided between the male plug body 5 and the nut 2, and a metal sleeve 9 is provided inside the male plug body. The female plug includes a female plug body 12, one end of which is provided with a nut 2. A cable clip 3 and a plug 4 are provided between the female plug body 12 and the nut 2, and a metal sleeve 9 is provided inside the female plug body. The pin 11 and the cables 1 at both ends of the connector are inserted into the nut 2 and fixedly connected to the sleeve 9 and the pin 11 respectively. The sleeve 9 and the pin 11 are plugged in to form an electrical connection. The sleeve 9 and the pin 11 are provided with clamping parts 8 that cooperate with the stepped parts on the inner wall of the male plug body and the female plug body to prevent the sleeve 9 and the pin 11 from being pulled out. A sealing part is provided between the male plug body 5 and the female plug body 12. The two sides of the plug end of the male plug body 5 are provided with hooks 501, and the female plug body 12 is provided with a groove 1201 corresponding to the hooks 501 of the male plug 5.

[0027] A sealing component is provided at the connection between the male connector body 5 and the female connector body 12. Specifically, in conjunction with... Figure 3 as well as Figure 4As shown, a first annular groove 503 is provided on the insertion part of the male connector body 5, and a first sealing ring 6 is disposed therein. Adjacent to the first annular groove 503 is a second annular groove 504, and a second sealing ring 7 is disposed therein. The first sealing ring 6 has an approximately O-shaped cross-section and a protrusion 601. The protrusion 601 faces the nut side of the male connector body 5 when the first sealing ring 6 is installed into the first annular groove 503. The second sealing ring 7 has an approximately rectangular cross-section and a protruding lip structure 701. In a preferred embodiment, the protrusion 601 extends beyond the opening height of the first annular groove 503. The lip structure 701 has a height such that the end of the lip structure 701 is higher than the opening height of the second annular groove 504. Since the sealing ring is generally made of a relatively soft rubber material, when the male plug body 5 and the female plug body 12 are inserted, the inner wall of the female plug body 12 will squeeze the protrusion 601 of the first sealing ring and the lip structure 701 of the second sealing ring, causing them to be squeezed and deformed to tightly abut against the connection between the male plug 5 and the female plug 12, forming a double sealing structure. This prevents external moisture from seeping into the connector from the gap F, thus achieving double protection for the connector and preventing salt spray, water vapor, or seawater from entering the connector and causing connector failure. Compared with the sealing ring body, the smaller size of the protrusion 601 and the lip structure 701 also makes the insertion of the male and female plugs easier and ensures the reliability of the seal. It can also significantly reduce the large stress generated between the male and female plugs due to interference fit, and avoid material deformation caused by stress that reduces the sealing effect.

[0028] In a preferred embodiment, see Figure 4 The step on the inner wall of the male connector body that mates with the clamping foot 801 of the clamping component 8 is a right-angled step structure. In connector manufacturing, both the male and female connector bodies are generally made of plastic material using injection molding. For ease of mold removal, it's not easy to create right-angled step structures on the inner walls of the male and female connector bodies. Therefore, in existing connectors, the steps that mate with the clamping foot 801 of the clamping component 8 are generally inclined step structures. While this type of step structure can also cooperate with the clamping foot 801 to prevent the internal metal conductive terminals (sleeves or pins) from being pulled out, it is clear that the obstruction capability of an inclined step structure is far less than that of a right-angled step structure. Even with a larger external force, there is still a significant possibility of pulling the conductive terminals out of the connector. Therefore, this application improves the molding die of the male and female plug bodies during the connector manufacturing process by using a slider core to form a right-angled step structure on the inner wall. This can significantly improve the blocking ability of the male and female plug bodies against the clamping components, prevent the internal metal conductive terminals from being easily pulled out by external force, and improve the structural reliability of the connector.

[0029] Next refer to Figure 5Taking a male connector as an example, the cable connection end of the male connector body 5 is connected to the nut 2. The cable 1 passes through the nut 2 and enters the male connector body 5, where it is fixedly connected to the metal sleeve. The plug 4 is located inside the connection end of the male connector body 5, and a cable clip 3 is fitted on it. The cable clip 3 has multiple claws. When the nut 2 is tightened to the male connector body 5, the claws will tighten, thereby making the waterproof plug 4 fit tightly against the cable 1, locking the cable and preventing moisture from entering the connector from the end of the connector. In a preferred embodiment, such as Figure 5 As shown, multiple annular protrusions 401 are provided on the inner wall of the plug 4. The annular protrusions 401 form an interference fit with the cable. When the nut 2 and the male plug body 5 are tightened, the annular protrusions 401 are squeezed and deformed, and tightly abut against the cable 1 to form a multi-layer seal. This can provide multi-layer protection for the cable 1. In addition to preventing the cable from loosening from the metal sleeve inside the connector, it can also form a multi-layer sealing structure to prevent seawater from entering the connector from the connector opening.

[0030] Then, in conjunction with references Figure 6 and Figure 9 In a preferred embodiment, the end of the connecting end of the male connector body 5 is provided with an annular groove 505, in which a third sealing ring 10 is provided. The third sealing ring 10 is provided with a protrusion 101. During the insertion of the pin 11 and the sleeve 9, the protrusion 101 of the sealing ring 10 is squeezed and deformed, forming a seal at the connection gap E between the connecting end of the male connector body and the internal step of the female connector body, further preventing salt spray, water vapor or seawater from entering the connector.

[0031] Next refer to Figure 7 and Figure 8 The connector's male and female bodies are equipped with a locking structure at the connection point with the nut to prevent the nut from reversing. Taking the male body 5 and the nut as an example, as follows... Figure 7 As shown, at the outer end of the nut, adjacent to the internal thread, ratchet structures 202 are evenly spaced, corresponding to... Figure 8 and Figure 9As shown, at least one pair of ratchet structures 502 are provided at the threaded connection end of the male connector body 5, adjacent to the tail of the external thread. When the nut 2 is threadedly connected to the male connector body 5, after the nut is screwed in, the ratchet structure 502 enters the recessed structure of the ratchet structure 202. One side of the recessed structure is a bevel to facilitate the ratchet structure 502 screwing in, and the other side is a vertical surface to abut against the ratchet structure 502 to prevent the nut from reversing and achieve the anti-reverse function. In a preferred embodiment, the pair of ratchet structures 502 are asymmetrically arranged. Thus, when the ratchet structure 502 and the ratchet structure 202 are engaged, at least one ratchet structure 502 can be blocked by the vertical surface of the recessed structure of the ratchet structure 202, preventing the nut from reversing. When a pair of symmetrical shank structures 502 are arranged, under normal circumstances, both shank structures 502 will smoothly enter the recessed structure of the ratchet structure 202. However, there is also a possibility that both shank structures 502 will abut against the protrusion 2021 of the ratchet structure 202, thus losing the function of preventing the nut from reversing. Similarly, refer to... Figure 10 At least one pair of thorn structures 1203 are provided at the tail of the external thread 1202 adjacent to the threaded connection end of the female plug body. Their structure and working principle are the same as those of the thorn structure 502 on the male plug body, and will not be described in detail here.

[0032] Next refer to Figure 9 The male connector body has hooks 501 on both sides of its insertion end. The upper surface of the hooks 501 is a bevel or arc surface to facilitate engagement between the hooks 501 and the slots 1201 on the female connector body. In a preferred embodiment, see [reference needed]. Figure 9 A groove structure 5011 is provided on the upper surface of the hook 501. This groove structure 5011 provides a space during connector maintenance, facilitating tool insertion to disengage the hook 501 from the slot 1201, thereby separating the male and female connector parts. In a more preferred embodiment, the groove structure 5011 can be a recess extending through the width of the hook 501, or two grooves can be symmetrically arranged on the hook 501, allowing connector disassembly tools to be inserted from either side of the connector.

[0033] In another preferred embodiment, the metal sleeve 9 and metal pin 11, which serve as conductive terminals in the connector, are made of copper, silver-copper alloy, or aluminum with a plating. A nano-silver coating is applied to the surface of the conductive terminals, which effectively reduces contact resistance. The metal sleeve 9 and metal pin 11 are electrically connected via a drum spring structure. The drum spring is a multi-contact elastic array structure, which increases the contact area by 40% compared to traditional structures.

[0034] During installation, the cables at both ends of the connector are first connected to the socket 9 and pin 11 by automated riveting or welding. After the cables are installed, the socket 9 and pin 11 are assembled into the male plug body 5 and female plug body 12 respectively by positioning claws 8. The first sealing ring 6, the second sealing ring 7, and the third sealing ring 10 are installed into the corresponding sealing ring mounting grooves on the male plug body 5. The plug 4 and the cable clip 3 are fixed to the outer connecting ends of the male plug body 5 and the female plug body 12. The nut 2 is tightened to the male plug body 5 and the female plug body 12. Finally, the assembled male plug 5 and female plug 12 are plugged in to complete the connector installation. During disassembly, a special tool is inserted along the inclined surface of the hook 501 to separate the hook 501 from the slot 1201. The male plug 5 and female plug 12 are pulled outward to disassemble the connector.

[0035] This utility model discloses a corrosion-resistant photovoltaic module connector with multiple waterproof structures. Multiple sealing structures are installed at potential gaps in the connector, including cable fixing points and male and female plug connections, to prevent salt spray, moisture, or seawater from seeping into the connector and causing malfunctions. The anti-reverse mechanism uses an asymmetrically arranged ratchet structure, ensuring that at least one ratchet engages with the ratchet teeth to meet the anti-reverse requirement. The male and female plugs are equipped with hooks and slots, supporting blind insertion without the need for special tools, making insertion convenient and quick. Disassembly requires special tools, effectively preventing accidental detachment of the male and female plugs during use. The socket and pins are plated with a nano-silver coating, effectively reducing contact resistance. The socket connection end features a multi-contact elastic array structure, increasing the contact area by 40% compared to traditional structures.

[0036] This utility model has been described by the above-described embodiments; however, these embodiments are merely examples for implementing this utility model. It must be noted that the disclosed embodiments do not limit the scope of this utility model. Conversely, any modifications and refinements made without departing from the spirit and scope of this utility model are within the scope of patent protection of this utility model.

Claims

1. A corrosion-resistant photovoltaic module connector with multiple waterproof structures, characterized in that, The connector includes a male and a female connector, with their insertion ends interlocked. The male connector includes a male body with a nut at one end, a cable clip and a plug between the male body and the nut, and a metal sleeve inside the male body. The female connector includes a female body with a nut at one end, a cable clip and a plug between the female body and the nut, and a metal pin inside the female body. Cables at both ends of the connector are inserted through the nut and fixedly connected to the sleeve and pin, respectively, forming an electrical connection. The sleeve and pin have clamping components that mate with stepped portions on the inner walls of the male and female connectors. A sealing component is provided between the male and female connectors. Hooks are provided on both sides of the insertion end of the male connector, and grooves corresponding to the hooks of the male connector are provided on the female connector. The male connector body has a first annular groove on its insertion part with the female connector body, and a first sealing ring is disposed therein. A second annular groove is disposed adjacent to the first annular groove, and a second sealing ring is disposed therein. The first sealing ring has an O-shaped cross-section and a protruding part, which faces the nut side of the male connector body when the first sealing ring is installed in the first annular groove. The second sealing ring has a rectangular cross-section and a protruding lip structure. The protruding part extends beyond the opening height of the first annular groove, and the lip structure has a height such that the end of the lip structure is higher than the opening height of the second annular groove.

2. The corrosion-resistant photovoltaic module connector with multiple waterproof structures as described in claim 1, characterized in that, On the inner wall of the plug, there are multiple annular protrusions. The annular protrusions form an interference fit with the cable. When the nut and the male plug body are tightened, the annular protrusions are squeezed and deformed, forming a multi-layer seal with the cable.

3. A corrosion-resistant photovoltaic module connector with multiple waterproof structures as described in claim 1 or 2, characterized in that, The steps on the inner walls of the male and female plug bodies that mate with the clamping feet of the clamping components are right-angled step structures.

4. A corrosion-resistant photovoltaic module connector with multiple waterproof structures as described in claim 1 or 2, characterized in that, The end of the male connector body has an annular groove with a third sealing ring inside. The third sealing ring has a protrusion. During the insertion of the pin and the sleeve, the protrusion of the sealing ring is squeezed and deformed, forming a seal at the connection gap between the male connector body and the internal step of the female connector body.

5. A corrosion-resistant photovoltaic module connector with multiple waterproof structures as described in claim 4, characterized in that, The connector has a backstop structure at the connection between the male body and the nut and at the connection between the female body and the nut. The backstop structure includes a ratchet structure evenly spaced at the outer end of the nut, adjacent to the internal thread, and at least one pair of spike structures adjacent to the tail of the external thread at the threaded connection end of the male body and the female body. The paired spike structures are asymmetrically arranged.

6. A corrosion-resistant photovoltaic module connector with multiple waterproof structures as described in claim 4, characterized in that, The male connector body has hooks on both sides of the plug end. The upper surface of the hook is a bevel or arc surface and a groove structure is provided on the upper surface of the hook.

7. A corrosion-resistant photovoltaic module connector with multiple waterproof structures as described in claim 6, characterized in that, The groove structure is either a recess that extends through the width of the hook or two recesses that are symmetrically arranged on the hook.

8. A corrosion-resistant photovoltaic module connector with multiple waterproof structures as described in claim 4, characterized in that, The socket and pin are made of copper, silver-copper alloy, or aluminum with a coating, and the surface of the socket and pin is coated with a nano-silver coating.

Images