A photovoltaic module junction box

Abstract

The utility model relates to photovoltaic technical field, specifically disclose a kind of photovoltaic module junction box. It includes box body, diode module, cable connection panel and two outgoing line panels, diode module includes diode, and the both ends of diode respectively has conducting panel, and two outgoing line panels and two conducting panels one-to-one correspondence;Outgoing line panel and corresponding conducting panel are provided with aligned through-hole, and are collectively fastened in box body by setting second detachable fastener, outgoing line panel and corresponding conducting panel are conducted by surface contact;Cable connection panel and one of conducting panels are provided with aligned through-hole, and are collectively fastened in box body by setting third detachable fastener, cable connection panel and corresponding conducting panel are conducted by surface contact.The utility model dispenses with traditional welding and riveting process, when diode module appears fault, can quickly replace damaged component, and entire junction box does not need to be replaced, improves maintenance efficiency.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic technology, and specifically discloses a photovoltaic module junction box. Background Technology

[0002] The photovoltaic (PV) module junction box is a key component of a solar photovoltaic (PV) power generation system. Its main function is to transmit the electrical energy generated by the PV modules to the external circuit through internal electrical connections. A junction box typically includes a housing, diode modules, lead-out panels, and cable connection panels. The diode modules provide protection within the junction box; when part of the PV module is shaded or malfunctions, the diodes provide a bypass path to prevent hot spot damage to the cells. The lead-out panels and cable connection panels are responsible for transmitting the electrical energy generated by the PV modules to the external circuit, ensuring a stable power output.

[0003] In existing technologies, the junction box and busbar leads are primarily connected using resistance welding or electromagnetic welding, where solder is used to bond the two parts together for current transmission. The diode modules inside the junction box are riveted to the box body using fixing posts. However, if the diode modules fail, the entire junction box needs to be replaced, increasing maintenance costs and reducing efficiency. Furthermore, welding equipment is energy-intensive, which is detrimental to environmental protection and sustainable development. Therefore, developing a photovoltaic module junction box that is simple in structure, easy to install and maintain, and can effectively reduce production costs and energy consumption is of significant practical importance. Utility Model Content

[0004] The purpose of this utility model is to overcome the shortcomings of the existing technology and provide a photovoltaic module junction box.

[0005] This utility model discloses a photovoltaic module junction box, which adopts the following technical solution:

[0006] A photovoltaic module junction box includes a box body, a diode module, a cable connection panel, and two lead-out panels. The diode module includes a diode, each with a conductive panel at both ends. The two lead-out panels correspond one-to-one with the two conductive panels. Each lead-out panel and its corresponding conductive panel has aligned through holes and is secured together within the box body by a second detachable fastener. The lead-out panels and their corresponding conductive panels conduct electricity through surface contact. Each cable connection panel and one of the conductive panels has aligned through holes and is secured together within the box body by a third detachable fastener. The cable connection panel and its corresponding conductive panel conduct electricity through surface contact.

[0007] As an alternative, the photovoltaic module junction box includes a box body, a diode module, a cable connection panel, and two lead-out panels. The diode module includes a diode, and each end of the diode has a conductive panel. The two lead-out panels correspond one-to-one with the two conductive panels. The conductive panels are fixed to the box body by a first detachable fastener. The lead-out panels and their corresponding conductive panels are connected and conductive by conductive adhesive. The cable connection panel and one of the conductive panels have aligned through holes and are fastened together in the box body by a third detachable fastener. The cable connection panel and its corresponding conductive panel conduct electricity through surface contact.

[0008] Preferably, the lead-out panel includes a plug-in section and a bonding section connected together, the box body has a box body lead-out hole for inserting the plug-in section, the conductive panel has a module lead-out hole for inserting the plug-in section, and the bonding section and the corresponding conductive panel are bonded together and fastened together in the box body by the connection of the second detachable fastener.

[0009] Preferably, the cable connection panel includes connected wiring segments and connecting segments. The wiring segments are provided with wire clamps for connecting external cables. The connecting segments are attached to the corresponding conductive panels and are fastened together in the housing by the connection of a third detachable fastener.

[0010] Preferably, the surface roughness Ra of the bonding area between corresponding panels is 0.4 to 0.8 μm.

[0011] Preferably, each detachable fastener is provided in multiple groups.

[0012] Preferably, the first detachable fastener is a first bolt, the conductive panel has a first through hole for the first bolt to pass through, and the housing has a first threaded hole that matches the first bolt; the second detachable fastener is a second bolt, the conductive panel and the lead wire panel both have a second through hole for the second bolt to pass through, and the housing has a second threaded hole that matches the second bolt; the third detachable fastener is a third bolt, the conductive panel and the cable connection panel both have a third through hole for the third bolt to pass through, and the housing has a third threaded hole that matches the third bolt.

[0013] Preferably, the first through hole, the second through hole, and the third through hole have the same size, the first threaded hole, the second threaded hole, and the third threaded hole have the same size, and the first bolt, the second bolt, and the third bolt have the same specifications.

[0014] Preferably, the interior of the housing is divided into a potting area and a heat dissipation area by a partition, the diode module is disposed in the potting area, and the heat dissipation area is located in a part of the edge area of ​​the housing.

[0015] Preferably, the heat dissipation zone comprises several spaced-apart zones.

[0016] Compared with the prior art, the present invention has at least the following beneficial effects:

[0017] This invention employs a panel structure with through holes and uses detachable fasteners to connect and secure the corresponding panels together within the housing. This secures the diode module, cable connection panel, and lead-out panel within the housing. Simultaneously, it allows for surface contact between the conductive panels of the diode module, cable connection panel, and lead-out panel, achieving electrical conductivity. This eliminates the need for traditional welding and riveting processes. Furthermore, when the diode module malfunctions, damaged components can be quickly replaced without replacing the entire junction box, significantly improving maintenance efficiency and reducing costs. This design also reduces reliance on welding equipment, lowers energy consumption, and aligns with environmental protection and sustainable development requirements. Attached Figure Description

[0018] Figure 1 This is a structural disassembly diagram of the photovoltaic module junction box in Example 1;

[0019] Figure 2 This is a schematic diagram of the photovoltaic module junction box with the cover removed, as shown in Example 1.

[0020] Figure 3 for Figure 2 Top view;

[0021] Figure 4 This is a schematic diagram of the junction box structure of the photovoltaic module in Example 1;

[0022] Figure 5 This is a schematic diagram of the diode module structure of the photovoltaic module junction box in Example 1;

[0023] Figure 6 This is a schematic diagram of the lead wire panel structure of the photovoltaic module junction box in Example 1;

[0024] Figure 7 This is a schematic diagram of the cable connection panel structure of the photovoltaic module junction box in Example 1.

[0025] Explanation of icon numbers:

[0026] 1. Housing; 101. First heat dissipation area; 102. Second heat dissipation area; 103. Third heat dissipation area; 104. Potting area; 105. Housing lead-out hole; 2. Diode module; 21. Diode; 22. Conductive panel; 221. Module lead-out hole; 3. Lead-out panel; 31. Plug-in section; 32. Adhesive section; 4. Cable connection panel; 41. Wiring section; 42. Connecting section; 5. Bolt; 6. Housing cover; 7. Cable; 701. Wire; A. First threaded hole; a. First through hole; B. Second threaded hole; b. Second through hole; C. Third threaded hole; c. Third through hole. Detailed Implementation

[0027] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0028] Example 1

[0029] This embodiment discloses a photovoltaic module junction box, referring to... Figure 1-2 It includes a housing 1, a cover 6, a diode module 2, a cable connection panel 4, a cable 7, and two lead-out panels 3. The diode module 2 includes a diode 21 and two conductive panels 22. The two conductive panels 22 are respectively disposed at both ends of the diode 21. The two lead-out panels 3 are electrically connected to the two conductive panels 22 in a one-to-one correspondence. The cable 7 includes a wire 701 that is in electrical contact with the cable connection panel 4.

[0030] Reference Figure 3-5 The conductive panel 22 is fixed to the housing 1 by a first detachable fastener. Specifically, the first detachable fastener can be a first bolt 5. The conductive panel 22 has a first through hole a through which the first bolt 5 passes, and the housing 1 has a first threaded hole A that matches and engages with the first bolt 5. The diode module 2 can be fixed inside the housing 1 using the first bolt 5.

[0031] Reference Figure 4-6 The lead-out panel 3 and the corresponding conductive panel 22 are fastened together in the housing 1 by a second detachable fastener, and conduct electricity through surface contact. Specifically, the second detachable fastener can be a second bolt 5. Both the conductive panel 22 and the lead-out panel 3 are provided with relatively aligned second through holes b, through which the second bolt 5 can pass. The housing 1 is provided with a second threaded hole B that matches and engages with the second bolt 5. The second bolt 5 can be used to fix the lead-out panel 3 and the corresponding conductive panel 22 in the housing 1, so that the lead-out panel 3 and the corresponding conductive panel 22 are tightly fitted and conduct electricity.

[0032] Reference Figure 4-5 and Figure 7The cable connection panel 4 and one of the conductive panels 22 are fastened together in the housing 1 by a third detachable fastener. The cable connection panel 4 and the corresponding conductive panel 22 conduct electricity through surface contact. Specifically, the third detachable fastener can be a third bolt 5. Both the conductive panel 22 and the cable connection panel 4 are provided with relatively aligned third through holes c, through holes c allowing the third bolt 5 to pass through. The housing 1 is provided with a third threaded hole C that matches and engages with the third bolt 5. The third bolt 5 can be used to tightly fit the cable connection panel 4 and the corresponding conductive panel 22 to conduct electricity.

[0033] This solution utilizes a bolt-fixed connection method, eliminating the need for welding. This results in a more secure connection between the diode module 2, lead-out panel 3, and cable connection panel 4 and the housing 1. This not only facilitates assembly but also allows for easier replacement of the diode module 2 in case of diode failure, improving repair efficiency and reducing material costs associated with replacing the entire housing. Furthermore, the use of a panel structure with through holes and a removable fastener system enables surface contact between panels for electrical conductivity, improving the junction box's conductivity stability and operational reliability.

[0034] It should be noted that since both the second and third detachable fasteners can secure the diode module 2 within the housing 1, the first detachable fastener between the diode module 2 and the housing 1 can be omitted in other embodiments. However, in this embodiment, to further improve the installation stability of the diode module 2, a first detachable fastener is preferably provided between the diode module 2 and the housing 1 for fixation. Furthermore, in other embodiments, screws, clips, or other parts can be used instead of bolts for the detachable fasteners. Bolts are preferred due to their advantages of easy production, high versatility, and low cost.

[0035] As a preferred option, refer to Figure 4-6The lead-out panel 3 includes a plug-in section 31 and a mating section 32 connected to each other. The housing 1 has a housing lead-out hole 105 for the plug-in section 31 to be inserted into. The conductive panel 22 has a module lead-out hole 221 for the plug-in section 31 to be inserted into. The housing lead-out hole 105 and the module lead-out hole 221 are aligned. The lead-out panel 3 passes through the housing lead-out hole 105 and the module lead-out hole 221 in sequence. Then, the lead-out panel 3 is bent at 90° so that it is mated with the corresponding conductive panel 22. The second through hole b is opened on the mating section 32. The mating section 32 and the conductive panel 22 are connected by the second bolt 5 and are fastened together in the housing 1. By adopting this structural design, the connection between the lead-out panel 3 and the conductive panel 22 is made tighter, which enhances the reliability of current transmission and avoids power loss and safety hazards caused by poor contact. At the same time, the cooperation between the box lead-out hole 105 and the module lead-out hole 221 optimizes the installation method of the lead-out panel 3 and improves installation efficiency and stability.

[0036] As a preferred option, refer to Figure 7 The cable connection panel 4 includes a connecting segment 41 and a connecting segment 42. The connecting segment 41 is equipped with a clamp for connecting an external cable 7. A third through hole c is formed on the connecting segment 42. The connecting segment 42 is attached to the conductive panel 22 and together they are fastened to the box 1 by a third bolt 5. This design facilitates the connection of the external cable 7, ensures good contact with the conductive panel 22, improves the performance of the entire junction box, and ensures the continuity and stability of current transmission.

[0037] As a preferred embodiment, the surface roughness Ra of the corresponding mating parts of the conductive panel 22, the lead-out panel 3, and the cable connection panel 4 is 0.4–0.8 μm. This surface roughness range ensures the stability of contact resistance and guarantees good conductivity, thereby improving the efficiency and reliability of current transmission.

[0038] As a preferred option, each bolt 5 and its corresponding through hole and threaded hole can be set in multiple groups to improve installation stability and reliability. In this embodiment, it is designed as two groups each, with the two groups of fixing points symmetrically distributed on the conductive panel 22, so that the surface contact between the panels is more sufficient and the conductivity is further improved.

[0039] As a preferred embodiment, the dimensions of the first through hole a, the second through hole b, and the third through hole c are identical; the dimensions of the first threaded hole A, the second threaded hole B, and the third threaded hole C are identical; and the specifications of the first bolt 5, the second bolt 5, and the third bolt 5 are identical. By adopting a uniform hole diameter and bolt specification design, the production process is simplified, production costs are reduced, and standardized production and installation are facilitated. In this embodiment, the bolt 5 is M3 with a length of 4–6 mm. This bolt specification meets the fixing requirements of the junction box's internal structure, ensuring the connection strength and stability between components, while also preventing excessive space occupation due to overly large bolts, thus avoiding impacting the overall structural layout of the junction box.

[0040] As a preferred embodiment, the interior of the housing 1 is divided into a potting area 104 and a heat dissipation area by a partition. The diode module 2 is disposed in the potting area 104, and the heat dissipation area is located in a portion of the edge area of ​​the housing 1. Preferably, the heat dissipation area includes multiple spaced-apart areas, including a first heat dissipation area 101, a second heat dissipation area 102, and a third heat dissipation area 103 in this embodiment. By designing spaced-apart potting sealant, there are still areas without sealant inside the housing 1 after potting, allowing the heat generated by the diode to dissipate in a timely manner. This avoids performance degradation and safety hazards caused by heat accumulation, improving the reliability and service life of the junction box. When the diode module 2 fails, the potting sealant inside the housing 1 is removed, all bolts 5 are removed, the failed diode module 2 is removed, a new diode module 2 is replaced, and the bolts are then installed and secured accordingly.

[0041] In this design, diode 21 is encapsulated within diode module 2. The conductor 701 in cable 7 is crimped with the wire clamp in cable connection panel 4. The internal current transmission direction is: lead-out panel 3 → conductive panel 22 of diode module 2 → cable connection panel 4 → cable conductor 701. During normal operation, the current at both ends of lead-out panel 3 does not flow through diode 21; therefore, diode 21 is inactive, saving energy and reducing unnecessary losses. When hot spots appear on the module surface due to shading, diode 21 utilizes its unidirectional conductivity to provide a bypass path for the faulty battery string. Current flows through diode 21 from both ends of lead-out panel 3, effectively protecting the module and preventing battery damage caused by hot spots, thus improving the safety and stability of the photovoltaic module.

[0042] Example 2

[0043] The only difference between this embodiment and Embodiment 1 is that the lead-out panel 3 and the corresponding conductive panel 22 are connected by conductive adhesive. The diode module 2 and the housing 1 are still fixed by bolts 5. Conductive adhesive is applied to the conductive panel 22 of the diode module 2, and then the lead-out wires are smoothed and bonded to ensure stable current conduction between the two parts. This connection method can also ensure good contact and stable current transmission between the lead-out panel and the conductive panel. The conductive adhesive has a certain degree of flexibility and can buffer external vibrations and impacts to a certain extent. The junction box has good reliability. The use of conductive adhesive in this embodiment provides a solderless alternative to the photovoltaic module junction box.

[0044] The technical solution provided by this utility model has been described in detail above. Specific examples have been used to illustrate the principle and implementation of this utility model. The description of the above embodiments is only for the purpose of helping to understand the method and core idea of ​​this utility model. At the same time, for those skilled in the art, there will be changes in the specific implementation and application scope based on the idea of ​​this utility model. Therefore, the content of this specification should not be construed as a limitation of this utility model.

Claims

1. A photovoltaic module junction box, characterized in that, It includes a housing, a diode module, a cable connection panel, and two lead-out panels. The diode module includes a diode, and each end of the diode has a conductive panel. The two lead-out panels correspond one-to-one with the two conductive panels. The lead-out panel and the corresponding conductive panel are provided with aligned through holes, and are fastened together in the box by a second detachable fastener. The lead-out panel and the corresponding conductive panel conduct electricity through surface contact. The cable connection panel and one of the conductive panels have aligned through holes and are fastened together in the housing by a third detachable fastener. The cable connection panel and the corresponding conductive panel conduct electricity through surface contact.

2. The photovoltaic module junction box according to claim 1, characterized in that, The lead-out panel includes a plug-in section and a bonding section connected together. The box body has a box body lead-out hole for inserting the plug-in section. The conductive panel has a module lead-out hole for inserting the plug-in section. The bonding section and the corresponding conductive panel are bonded together and fastened together in the box body by the second detachable fastener.

3. A photovoltaic module junction box, characterized in that, The device includes a housing, a diode module, a cable connection panel, and two lead-out panels. The diode module includes a diode, and each end of the diode has a conductive panel. The two lead-out panels correspond one-to-one with the two conductive panels. The conductive panel is fixed to the box body by a first detachable fastener. The lead-out panel and the corresponding conductive panel are connected and conduct electricity through conductive adhesive; The cable connection panel and one of the conductive panels have aligned through holes and are fastened together in the housing by a third detachable fastener. The cable connection panel and the corresponding conductive panel conduct electricity through surface contact.

4. The photovoltaic module junction box according to claim 1 or 3, characterized in that, The cable connection panel includes connected wiring segments and connecting segments. The wiring segments are provided with wire clamps for connecting external cables. The connecting segments are attached to the corresponding conductive panels and are fastened together in the box by the connection of a third detachable fastener.

5. The photovoltaic module junction box according to claim 1 or 3, characterized in that, The surface roughness Ra of the bonding area between the corresponding panels is 0.4~0.8μm.

6. The photovoltaic module junction box according to claim 1 or 3, characterized in that, Each detachable fastener is configured as a group.

7. The photovoltaic module junction box according to claim 1 or 3, characterized in that, The interior of the housing is divided into a potting area and a heat dissipation area by a partition. The diode module is located in the potting area, and the heat dissipation area is located in part of the edge area of ​​the housing.

8. The photovoltaic module junction box according to claim 7, characterized in that, The heat dissipation zone comprises several spaced-apart areas.

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