A photovoltaic two-core AC connector

Abstract

This utility model discloses a photovoltaic two-core AC connector, specifically relating to the fields of new energy and photovoltaic related technologies. It includes a male connector body and a female connector body. The male connector body comprises a built-in snap-fit ​​structure, which is completely enclosed within the male connector housing. By completely enclosing the male snap-fit ​​within the housing, this utility model solves the problem of exposed snap-fits being easily deformed and broken by external forces in existing technologies, thus achieving effective protection for the snap-fit ​​and internal components and improving the durability of the connector's mechanical structure. By employing a single-cavity encapsulation process to replace the traditional two-stage injection molding structure, it solves the problem of decreased sealing performance during long-term outdoor use, thereby achieving full encapsulation of the terminal rivet and cable sheath with glue, resulting in long-term reliable waterproof and dustproof performance.

Description

Technical Field

[0001] This utility model relates to the fields of new energy and photovoltaic technology, and more specifically, to a photovoltaic two-core AC connector. Background Technology

[0002] In the photovoltaic power generation industry, photovoltaic two-core AC connectors are mainly used to connect micro-inverters to achieve current transmission. Currently, similar products in the existing technology have the following shortcomings in structural design and performance: First, the male connector's latch is mostly exposed outside the housing. During transportation, installation, or use, the latch is easily deformed or broken by external impacts, which affects the mechanical locking reliability of the male and female connectors and poses a risk of loosening.

[0003] Secondly, traditional overmolded connectors often employ a two-stage injection molding process. This involves first sealing the terminal rivet and inner core wire with glue, and then sequentially wrapping the inner and outer membranes (outer layer). While this process can meet sealing requirements in the short term, under long-term outdoor high-temperature and high-humidity environments, the multi-layered sealing structure is prone to aging and delamination, leading to a decline in sealing performance. Moisture and dust may then penetrate the interior, affecting the safety of the electrical connection.

[0004] Furthermore, most existing overmolded connectors do not have a cable fixing structure. The cable cannot be fixed in position during the overmolding process, which can easily lead to the mold damaging the cable or the finished cable being misaligned. This not only affects the appearance but may also cause poor internal terminal connections due to cable displacement.

[0005] Regarding the aforementioned technologies, the inventors have discovered the following defects: most existing products use a single sealing ring or gasket for sealing, failing to form a fully enclosed sealed cavity. The potting compound only partially fills or does not cover the terminal rivet area, resulting in a waterproof and dustproof rating (IP rating) lower than IP65. In rainy or humid environments, water can easily enter, causing terminal oxidation and short circuits.

[0006] Therefore, a photovoltaic two-core AC connector is proposed to address the above problems. Utility Model Content

[0007] In order to overcome the above-mentioned defects of the prior art, the present invention provides a photovoltaic two-core AC connector to solve the problems mentioned in the background art.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a photovoltaic two-core AC connector, comprising a male connector body and a female connector body, wherein the male connector body includes a built-in snap-fit ​​structure, and the snap-fit ​​structure is completely enclosed inside the male connector shell;

[0009] A sealed cavity is formed between the male connector housing, the sealing ring, and the rubber-coated housing, and the sealed cavity is filled with sealing adhesive;

[0010] A cable fixing clip is provided at the cable inlet end, and the cable fixing clip has a locking hole to accommodate different wire diameters;

[0011] The locking nut and the outer shell are provided with a mutually cooperating anti-rotation structure, which includes an anti-rotation rib and a nut groove.

[0012] Preferably, the built-in snap-fit ​​structure includes a resilient plastic arm and a locking protrusion, which engages with the female connector's slot during mating. The engagement of the locking protrusion with the female connector's slot during mating, along with the deformation of the resilient plastic arm, achieves mechanical locking of the male and female connectors, preventing accidental dislodgement.

[0013] Preferably, the sealing adhesive is a polyurethane potting compound that completely covers the terminal rivet and the cable sheath.

[0014] Preferably, the cable clamp is fixed to the slot structure on the male connector housing by its own snap-fit ​​structure.

[0015] Preferably, the anti-rotation rib of the anti-rotation structure is a radial sawtooth, and the nut groove is a matching annular toothed groove. When the anti-rotation structure is tightened, the anti-rotation rib engages with the groove to prevent the nut from loosening, ensuring the sealing and mechanical fixing effect at the cable inlet.

[0016] Preferably, it also includes a live wire terminal and a neutral wire terminal, wherein the terminals are made of copper alloy by stamping and the surface is tin-plated.

[0017] The technical effects and advantages of this utility model are as follows:

[0018] Compared with existing technologies, this photovoltaic two-core AC connector solves the problem of exposed snap-fits being easily deformed and broken by external forces by completely enclosing the male snap-fit ​​inside the housing. This effectively protects the snap-fit ​​and internal components, thereby improving the durability of the connector's mechanical structure.

[0019] Compared with existing technologies, this photovoltaic two-core AC connector uses a single large cavity potting process to replace the traditional secondary injection molding structure, which solves the problem of decreased sealing performance during long-term outdoor use. This achieves full coverage of the terminal rivet and cable sheath with glue, resulting in long-term reliable waterproof and dustproof performance. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the main structure of this utility model.

[0021] Figure 2 This is a cross-sectional view of the main structure of this utility model.

[0022] Figure 3This is a schematic diagram of the locking nut structure of this utility model.

[0023] Figure 4 This is a schematic diagram of the anti-rotation rib of this utility model.

[0024] Figure 5 This is a schematic diagram of the cable fixing clip and cable connection of this utility model.

[0025] The attached figures are labeled as follows: 1. Male connector body; 101. Built-in snap-fit ​​structure; 101a. Elastic plastic arm; 101b. Locking protrusion; 102. Male connector shell; 2. Female connector body; 201. Rubber-coated shell; 202. Female connector slot; 3. Sealed cavity; 301. Sealing colloid; 4. Cable fixing clip; 5. Locking nut; 501. Anti-rotation structure; 502. Anti-rotation rib; 503. Nut groove; 6. Terminal rivet; 7. Cable sheath; 801a. Live wire terminal; 801b. Neutral wire terminal. Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0027] As attached Figures 1 to 5 The photovoltaic two-core AC connector shown includes a male connector body 1 and a female connector body 2. The male connector body 1 includes a built-in snap-fit ​​structure 101, which is completely wrapped inside the male connector housing 102.

[0028] A sealing cavity 3 is formed between the male connector housing 102, the sealing ring, and the rubber-coated housing 201, and the sealing cavity 3 is filled with sealing adhesive 301;

[0029] A cable fixing clip 4 is provided at the cable inlet end 4, and the cable fixing clip 4 is provided with a clip hole to adapt to different wire diameters;

[0030] The locking nut 5 and the outer shell are provided with a mutually cooperating anti-rotation structure 501, which includes an anti-rotation rib 502 and a nut groove 503.

[0031] The built-in snap-fit ​​structure 101 includes a resilient plastic arm 101a and a locking protrusion 101b, which engages with the female connector slot 202 when the male and female connectors are mated.

[0032] The sealing compound 301 is a polyurethane potting compound that completely covers the terminal rivet 6 and the cable sheath 7.

[0033] The cable clamp 4 is fixed to the slot structure on the male connector housing 102 by its own snap-fit ​​structure.

[0034] The anti-rotation rib 502 of the anti-rotation structure 501 is radially serrated, and the nut groove 503 is a matching annular toothed groove.

[0035] It also includes a live wire terminal 801a and a neutral wire terminal 801b, which are made of copper alloy by stamping and tin-plating.

[0036] Example

[0037] Outdoor connection scenarios for residential distributed photovoltaic systems

[0038] In residential rooftop distributed photovoltaic (PV) systems, two-core AC connectors are primarily used for circuit connections between solar panels and inverters. The specific usage process is as follows:

[0039] First, the male and female connectors are mated together. The built-in snap-fit ​​structure 101 of the male connector body 1 is aligned with the female connector slot 202 of the female connector body 2. The elastic plastic arm 101a in the built-in snap-fit ​​structure 101 has good elastic deformation capability. During mating, as the male connector body 1 is inserted, the locking protrusion 101b gradually engages with the female connector slot 202. When a click is heard, it indicates that the male and female connectors are fully engaged. At this time, the built-in snap-fit ​​structure 101 is completely enclosed inside the male connector housing 102, forming a stable mechanical connection.

[0040] Next, the cable end is installed. The cable leading from the photovoltaic module is inserted through the cable inlet 4. Based on the actual cable diameter (assuming Φ3.5mm), the appropriate locking hole on the cable clamp 4 is selected. The locking hole range is Φ12.0mm and below to meet the needs of various cable specifications. The cable clamp 4 is secured to the slot structure on the inner wall of the male connector housing 102 via the snap-fit ​​structure, thus securing the cable sheath 7 reliably. Tightening the locking nut 5, whose anti-rotation rib 502 is radially serrated, interacts with the annular toothed groove of the nut groove 503 to form an anti-rotation structure 501, preventing the nut from loosening under long-term vibration.

[0041] Since this connection scenario involves outdoor exposure, sealing performance is crucial. The male connector housing 102, sealing ring, and rubber-coated housing 201 mate to form a sealed cavity 3. The sealing compound 301 inside completely covers the terminal rivet 6 and the cable sheath 7, creating a waterproof and dustproof sealing layer. The terminals are copper alloy stamped and tin-plated, with a live wire terminal 801a and a neutral wire terminal 801b, ensuring excellent conductivity.

[0042] The implementation principle of this utility model of a photovoltaic two-core AC connector is as follows:

[0043] First, when the male connector body 1 and the female connector body 2 are inserted, the built-in snap-fit ​​structure 101 inside the male connector deforms the elastic plastic arm 101a to align the locking protrusion 101b with the female connector slot 202. As the insertion is complete, the elastic plastic arm 101a returns to its original position, and the locking protrusion 101b is embedded in the slot to form a mechanical lock, ensuring that the two fit tightly together. The built-in snap-fit ​​structure 101 is completely enclosed in the male connector housing 102 to avoid external factors affecting the locking function, ensure the stability of the connection, and prevent accidental separation due to external forces.

[0044] Secondly, the male connector housing 102, the sealing ring, and the rubber-coated housing 201 are mated to form a sealed cavity 3, which is filled with a sealing compound 301. After the compound cures, it covers the terminal rivet 6 and the cable sheath 7, isolating external pollutants such as moisture and dust, improving the connector's waterproof and dustproof capabilities. The elastic properties of the sealing compound 301 can also buffer vibration, reduce the impact of mechanical stress on the terminal connection, enhance insulation performance, avoid the risk of leakage, and provide long-term environmental protection for the internal electrical structure.

[0045] Next, when the cable is inserted from the cable inlet end 4, the outer sheath is clamped by the cable fixing clip 4, which facilitates subsequent cable management and prevents the main glue inlet from being blocked by messy cables during glue application. This ensures that the cable remains in a suitable position after the glue dries, facilitating the implementation of the next outer layer injection molding process. At the same time, the locking nut 5 and the anti-rotation structure 501 of the outer shell engage with each other. When tightened, the anti-rotation rib 502 and the nut groove 503 lock together, preventing the locking nut 5 from loosening due to vibration. This further strengthens the sealing and mechanical stability at the cable inlet, ensuring reliable cable fixation.

[0046] Next, the live wire terminal 801a and neutral wire terminal 801b inside the connector are made of metal materials with excellent conductivity, and the contact resistance is reduced through surface treatment. When the male and female connectors are mated, the terminals are precisely aligned to form a current conduction channel, ensuring efficient power transmission. The terminals and cables are fixed by crimping, and the sealing colloid 301 wraps the connection part to prevent oxidation or moisture, ensuring long-term conductivity stability and reliability.

[0047] Finally, the male connector housing 102 and the encapsulated housing 201 are injection molded from high-strength, high-temperature resistant, and anti-aging materials, possessing sufficient mechanical strength and environmental tolerance. They can withstand external impacts, temperature changes, and ultraviolet radiation in complex outdoor environments. The various functional modules work together—mechanical locking ensures a stable connection, potting protects against external pollution, the cable fixing structure resists external force, and high-quality terminals ensure conductivity—enabling the connector to work stably for a long time in high humidity, dusty, and strong vibration environments, meeting the reliable operation requirements of photovoltaic systems.

[0048] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0049] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A photovoltaic two-core AC connector, comprising a male connector body (1) and a female connector body (2), characterized in that: The male connector body (1) includes a built-in snap-fit ​​structure (101), which is completely enclosed inside the male connector housing (102); A sealed cavity (3) is formed between the male connector housing (102), the sealing ring and the rubber-coated housing (201), and the sealed cavity (3) is filled with sealing adhesive (301); The male connector body (1) is provided with a cable fixing clip (4) at the cable inlet end, and the cable fixing clip (4) is provided with a card hole to adapt to different wire diameters; The locking nut (5) and the outer shell are provided with a mutually cooperating anti-rotation structure (501), the anti-rotation structure (501) including an anti-rotation rib (502) and a nut groove (503).

2. The photovoltaic two-core AC connector of claim 1, wherein: The built-in snap-fit ​​structure (101) includes a flexible plastic arm (101a) and a locking protrusion (101b), which engages with the female connector slot (202) when the male and female connectors are mated.

3. The photovoltaic two-core AC connector according to claim 1, characterized in that: The sealing colloid (301) is a polyurethane potting compound that completely covers the terminal rivet (6) and the cable sheath (7).

4. The photovoltaic two-core AC connector according to claim 1, characterized in that: The cable clamp (4) is fixed to the slot structure on the male connector housing (102) by its own snap-fit ​​structure.

5. The photovoltaic two-core AC connector according to claim 1, characterized in that: The anti-rotation structure (501) has an anti-rotation rib (502) with radial serrations and a nut groove (503) with matching annular teeth.

6. The photovoltaic two-core AC connector according to claim 1, characterized in that: It also includes a live wire terminal (801a) and a neutral wire terminal (801b), which are made of copper alloy by stamping and tin-plating.

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