An adapter terminal and an adapter module for connecting an aluminum cable and a copper cable
Patent Information
- Application Number
- CN202522030232.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-22
- Publication Date
- 2026-09-25
- Estimated Expiration
- 2035-09-22
AI Technical Summary
这种铜铝转接端子，虽然可以通过摩擦焊在铜铝界面形成一定厚度的复合金属层，可以很大程度地减少界面腐蚀，但是还是存在明显的缺陷，一是，这种铜铝转接端子在应用时需要根据不同规格的产品定制化生产，比如针对不同线径的电缆来制备相适应的转接端子，加工成本非常高；另外，即使是摩擦焊，由于铜和铝的热膨胀系数不同，且分界面与线缆和转接端子的铆接位置不相关，铜铝界面连接处还是比较容易在应用环境中由于老化、温度冲击等原因发生断裂，导致连接失效
[0015]本实用新型的有益效果是，所述的铜电缆和铝电缆连接用转接端子，使用铜端子作为主体结构，在铜端子的一端内部安装铜铝复合金属套形成铜铝转接结构，通过压接的方式将铜端子、铝铜复合金属套与铝电缆压接固定形成可靠的电连接结构，铜铝界面与压接力的方向呈垂直方向，使连接固定结构不易发生松动，而且，在应用过程中，铜铝界面不存在剪切力，铜铝复合金属套耐环境和抗老化能力更强，不容易出现界面失效进而导致电传输产生问题；另外，转接端子的铜端子可以采用标准件，只需要更换不同厚度的铜铝复合金属套即可适用不同的铝电缆应用，部件的加工更加容易，显著缩减生产成本，适宜在光伏系统中广泛应用。
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Figure CN224804230U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of photovoltaic system connection technology, and in particular to a converter terminal and converter module for connecting aluminum cables and copper cables in a photovoltaic system. Background Technology
[0002] To address climate change, green energy is being used more and more widely around the world. Among green energy sources, solar energy has received particular attention due to its cleanliness and ease of access, leading to the emergence of photovoltaic (PV) power plants. A PV power plant consists of PV modules connected in series and parallel to form a PV array. Through cables, the electricity generated by the PV modules under the action of photovoltaics is fed into an inverter or controller, which then converts this electricity into usable power for the user, either connecting it to the grid or supplying it directly to the user.
[0003] Copper possesses excellent ductility, thermal conductivity, and electrical conductivity, making it the primary material for cables in current photovoltaic (PV) systems. However, as the main connecting cables in PV systems, copper cables are relatively expensive, resulting in higher operating costs. With the continuous expansion of PV power plant scale and the improvement of solar panel conversion efficiency, the amount and diameter of cables used are constantly increasing, leading to higher construction costs for PV systems and hindering their widespread adoption. Therefore, some industries have begun using aluminum cables to replace copper cables. While meeting the same current-carrying requirements, aluminum conductors cost only about one-third the price of copper cables. Consequently, in PV system connections, such as the busbar cables, which are used most extensively, aluminum core cables are now generally being used. However, aluminum core cables encounter a critical problem when used in photovoltaic systems. Currently, the cables used in the junction boxes of photovoltaic modules are copper core cables. When copper core cables are directly connected to aluminum core cables, electro-corrosion will occur at the copper-aluminum contact surface, affecting current conduction and thus electrical transmission performance. Therefore, when connecting photovoltaic systems, the aluminum core cables used for system connection cannot be directly riveted or welded to the connector cables of the module junction boxes. In addition, due to the safety requirements and efficiency of on-site operations, relatively dangerous or complex connection processes are not allowed.
[0004] See Figure 1The commonly used aluminum-copper adapter terminal shown is typically a connection structure with one side made of copper and the other of aluminum. The contact surfaces of the aluminum connector 1 and the copper connector 2 are connected together using special processes such as friction welding. The aluminum connector 1 has a socket 101 for inserting the aluminum core of the aluminum core cable, and the copper connector 2 has a socket 201 for inserting the copper core of the copper core cable. Although this type of copper-aluminum adapter terminal can form a composite metal layer of a certain thickness at the copper-aluminum interface through friction welding, which can greatly reduce interface corrosion, it still has significant drawbacks. First, this type of copper-aluminum adapter terminal needs to be customized for different product specifications, such as preparing adapter terminals for cables of different diameters, which results in very high processing costs. Second, even with friction welding, due to the different coefficients of thermal expansion of copper and aluminum, and the fact that the interface is not related to the riveting position of the cable and the adapter terminal, the copper-aluminum interface connection is still relatively prone to breakage due to aging, temperature shock, etc., in the application environment, leading to connection failure. Therefore, a more reliable adapter terminal for connecting aluminum cables and copper cables needs to be designed. Summary of the Invention
[0005] The purpose of this utility model is to address the shortcomings of existing technologies by proposing an adapter terminal for connecting aluminum cables and copper cables.
[0006] To achieve the above objectives, the present invention adopts the following technical solution: An adapter terminal for connecting aluminum cables and copper cables is disclosed. The adapter terminal includes a first metal body, which includes a first connecting end and a second connecting end. The first connecting end has a first insertion hole, and the second connecting end has a second insertion hole. The first insertion hole and the second insertion hole are not connected. A composite metal sleeve is disposed inside the first insertion hole. The outer layer of the composite metal sleeve is made of the same metal material as the first metal body, while the inner layer of the composite metal sleeve is made of a different material than the outer layer. A cable insertion hole is provided in the middle of the composite metal sleeve. The cable insertion hole connects to a first cable, the core wire of which is made of the same material as the inner layer of the composite metal sleeve. The second insertion hole connects to a second cable, the core wire of which is made of the same material as the first metal body. After the metal core wire of the first cable is inserted into the cable insertion hole, the first connecting end, the composite metal sleeve, and the metal core wire are fixed by crimping. The direction of the pressure applied during crimping forms a non-zero set angle with the axis of the adapter terminal.
[0007] Preferably, the first metal body is a copper body, and the composite metal sleeve is a copper-aluminum composite metal sleeve, with the outer layer being copper and the inner layer being aluminum. The composite metal sleeve is formed by rolling copper-aluminum composite metal sheets into a tube.
[0008] Preferably, the cable plug hole is connected and fixed to the aluminum cable, and the second plug hole is connected and fixed to the copper cable; after the aluminum core wire of the aluminum cable is inserted into the cable plug hole, the first connecting end, the copper-aluminum composite metal sleeve and the aluminum core wire are fixed by crimping, and the direction of the pressure applied during crimping is perpendicular to the axis of the adapter terminal.
[0009] Preferably, the copper-aluminum composite metal sleeve is tightly fitted to the first insertion hole, and the core wire of the aluminum cable is also tightly fitted to the cable insertion hole.
[0010] Preferably, the copper-aluminum composite metal sleeve has a notch.
[0011] Preferably, the inner diameter of the cable socket is larger than the diameter of the second socket.
[0012] Preferably, the inner diameter of the cable socket is 2-3 times the diameter of the second socket.
[0013] According to another objective of this utility model, this utility model also proposes an adapter module for connecting aluminum cables and copper cables. The adapter module includes the aforementioned adapter terminal. The aluminum core wire of the aluminum cable is inserted into the copper-aluminum composite metal sleeve in the adapter terminal, and the first connecting end of the adapter terminal, the copper-aluminum composite metal sleeve, and the aluminum core wire are crimped and fixed by crimping. The copper core wire of the copper cable is fixedly connected to the second socket. The insulating sleeve seals the adapter terminal and the aluminum cable and copper cable into a whole module by injection molding.
[0014] Preferably, the diameter of the copper body of the adapter terminal is greater than or less than the outer diameter of the copper cable and the aluminum cable, and a stepped structure is formed at the connection between the aluminum cable, the copper cable and the adapter terminal.
[0015] The beneficial effects of this utility model are as follows: the adapter terminal for connecting copper and aluminum cables uses a copper terminal as the main structure, and a copper-aluminum composite metal sleeve is installed inside one end of the copper terminal to form a copper-aluminum adapter structure. The copper terminal, the copper-aluminum composite metal sleeve, and the aluminum cable are crimped and fixed to form a reliable electrical connection structure. The copper-aluminum interface is perpendicular to the direction of the crimping force, making the connection and fixing structure less prone to loosening. Moreover, there is no shear force at the copper-aluminum interface during application, and the copper-aluminum composite metal sleeve has stronger environmental resistance and aging resistance, making it less likely to experience interface failure and thus causing problems in electrical transmission. In addition, the copper terminal of the adapter terminal can be a standard part, and only the copper-aluminum composite metal sleeve of different thicknesses needs to be replaced to be suitable for different aluminum cable applications. The processing of the components is easier, significantly reducing production costs, and making it suitable for widespread application in photovoltaic systems. Attached Figure Description
[0016] Figure 1This is a schematic diagram of the structure of an adapter terminal for connecting aluminum cables and copper cables in the prior art; Figure 2 This is a schematic diagram of the structure of an adapter terminal for connecting an aluminum cable and a copper cable according to an embodiment of the present invention; Figure 3 for Figure 2 A cross-sectional structural diagram of the copper body of the adapter terminal; Figure 4 for Figure 2 A schematic diagram of the axial cross-section of the copper-aluminum composite sleeve of the adapter terminal; Figure 5 for Figure 4 A schematic diagram of the radial section of an aluminum-copper composite sleeve; Figure 6 This is a schematic diagram of the adapter module for connecting aluminum cables and copper cables according to this utility model. Figure 7 for Figure 6 An enlarged schematic diagram of part A in the middle. Detailed Implementation
[0017] 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.
[0018] See also Figures 2 to 5 An adapter terminal for connecting aluminum cables and copper cables according to an embodiment of the present invention includes a first metal body 11, which includes a first connecting end 12 and a second connecting end 13. The first connecting end 12 is provided with a first socket 121, and the second connecting end 13 is provided with a second socket 131. The first socket 121 and the second socket 131 are not connected. A composite metal sleeve 120 is provided inside the first socket 121. The outer layer 122 of the composite metal sleeve 120 is made of the same metal material as the first metal body, and the inner layer 122 of the composite metal sleeve 120 is made of the same metal material as the first metal body. The material of 3 is different from that of the outer layer. The composite metal sleeve 120 has a cable insertion hole 124 in the middle. The cable insertion hole 124 is connected to the first cable. The core wire of the first cable is made of the same material as the inner layer 123 of the composite metal sleeve 120. The second insertion hole 131 is connected to the second cable. The core wire of the second cable is made of the same material as the first metal body 11. After the metal core wire of the first cable is inserted into the cable insertion hole 124, the first connecting end 12, the composite metal sleeve 120 and the metal core wire are fixed by crimping. The direction of the pressure applied during crimping is at a non-zero set angle with the axis of the adapter terminal.
[0019] In one embodiment, the first metal body 11 is a copper body, and the composite metal sleeve 120 is a copper-aluminum composite metal sleeve. The outer layer 122 is made of copper, and the inner layer 123 is made of aluminum. The composite metal sleeve 120 is formed by rolling a copper-aluminum composite metal sheet into a tube. The copper-aluminum composite metal sheet is manufactured through a metal composite forming process, forming a reliable atomic doping layer at the copper-aluminum interface. In the following description, this embodiment will be used as an example to illustrate the specific structural features and effects of this application. It should be understood that the first metal body 11 can also be an aluminum body, and the settings of other parts can be changed accordingly according to the spirit of this application.
[0020] like Figures 2 to 4 As shown, the adapter terminal for connecting aluminum cables and copper cables in this embodiment includes a copper body 11, which includes a first connecting end 12 and a second connecting end 13. The first connecting end 12 is provided with a first insertion hole 121, and the second connecting end 13 is provided with a second insertion hole 131. The first insertion hole 121 and the second insertion hole 131 are not connected. A copper-aluminum composite metal sleeve 120 is provided inside the first insertion hole 121. The outer layer 122 of the copper-aluminum composite metal sleeve 120 is copper, and the inner layer 123 is aluminum. A cable insertion hole 124 is provided in the middle of the copper-aluminum composite metal sleeve 120. The cable insertion hole 124 is connected and fixed to the aluminum cable, and the second insertion hole 131 is connected and fixed to the copper cable. After the aluminum core wire of the aluminum cable is inserted into the cable insertion hole 124, the first connecting end 12, the copper-aluminum composite metal sleeve 120, and the aluminum core wire are fixed by crimping. The direction of the pressure applied during crimping is perpendicular to the axis of the adapter terminal.
[0021] In a preferred embodiment, the copper-aluminum composite metal sleeve 120 and the first insertion hole 121 are tightly fitted, that is, the diameter of the copper-aluminum composite metal sleeve 120 is not less than the inner diameter of the first insertion hole 121; in a more preferred embodiment, see... Figure 5 To facilitate the installation of the copper-aluminum composite metal sleeve 120 and the first insertion hole 121 and to form a reliable tight fit, the copper-aluminum composite metal sleeve 120 is provided with a notch 125. This allows the elasticity of the metal material itself to facilitate the assembly of the composite metal sleeve 120 into the first insertion hole 121 and to form a reliable tight fit. It also facilitates the insertion of the aluminum core of the aluminum cable into the cable insertion hole 124 and to form a tight fit with the cable insertion hole 124, thus ensuring reliable contact.
[0022] In this embodiment, the copper-aluminum cable adapter terminal uses a copper terminal as the main structure. A copper-aluminum composite metal sleeve is installed inside one end of the copper terminal, and an aluminum cable is inserted into it. The copper terminal, the copper-aluminum composite metal sleeve, and the aluminum cable are then crimped together to form a reliable electrical connection structure. The copper-aluminum interface is perpendicular to the direction of the crimping force, making the connection structure less prone to loosening and providing stronger environmental resistance and aging resistance. In addition, since the copper cables used in the junction boxes of photovoltaic modules are generally standard parts, when applying aluminum cables of different diameters to the system busbars, the dimensions of the copper terminal (and the aforementioned copper main body 11) can remain unchanged. Only the copper-aluminum composite metal sleeve of different thicknesses needs to be replaced, making the component processing easier and greatly reducing production costs.
[0023] In addition, since the conductivity of aluminum is only about 62% of that of copper, the diameter of aluminum cable needs to be larger than that of copper cable for the same current carrying capacity. Therefore, the inner diameter of cable socket 124 needs to be larger than the diameter of second socket 131. Preferably, the inner diameter of cable socket 124 is 2-3 times the diameter of second socket 131.
[0024] According to another objective of this utility model, see Figure 6 This utility model also proposes an adapter module for connecting aluminum cables and copper cables. The adapter module includes the aforementioned adapter terminal 10. The aluminum core wire 21 of the aluminum cable 20 is inserted into the copper-aluminum composite metal sleeve 12 in the adapter terminal 10 and is crimped and fixed by crimping. The copper core wire of the copper cable 30 is fixedly connected to the second socket 131. The insulating sleeve 40 seals the adapter terminal 10 and parts of the aluminum cable 20 and copper cable 30 into an integral module by injection molding.
[0025] See Figure 6 and Figure 7 In this embodiment, when one end of the adapter terminal 10, the aluminum-copper composite metal sleeve, and the aluminum cable are crimped together, the copper-aluminum interface is perpendicular to the direction of the crimping force (e.g., ...). Figure 7 (The arrow direction in the image) makes the connection and fixing structure less prone to loosening, and enhances its environmental resistance and aging resistance; moreover, the pit 14 formed by pressing on the adapter terminal 10 will be filled by plastic when the insulating material is injection molded to form the insulating sleeve 40, which can improve the bonding force between the insulating sleeve 40 and the adapter terminal and prevent the insulating sleeve from loosening; similarly, in order to further improve the structural strength of the adapter module, the diameter of the copper body 11 of the adapter terminal 10 can be larger or smaller than the outer diameter of the copper cable and the aluminum cable, thus, as Figure 7 As shown, a stepped structure 24 is formed at the connection between the aluminum cable and the adapter terminal 10. When the insulating material is injection molded to form the insulating sleeve 40, the structural strength of the adapter module will also be improved at this point, thus preventing the insulating sleeve from coming loose.
[0026] This utility model discloses a copper and aluminum cable adapter terminal for photovoltaic systems. It uses a copper terminal as the main structure, with a copper-aluminum composite metal sleeve installed inside one end of the copper terminal to form a copper-aluminum adapter structure. The copper terminal, the copper-aluminum composite metal sleeve, and the aluminum cable are crimped together to form a reliable electrical connection. The copper-aluminum interface is perpendicular to the direction of the crimping force, making the connection less prone to loosening. Furthermore, there is no shear force at the copper-aluminum interface during application, and the copper-aluminum composite metal sleeve has stronger environmental resistance and aging resistance, reducing the likelihood of interface failure and subsequent electrical transmission problems. Additionally, the copper terminal of the adapter terminal can be a standard part; only the copper-aluminum composite metal sleeve of different thicknesses needs to be replaced to accommodate different aluminum cable applications. This simplifies component processing and significantly reduces production costs.
[0027] 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. An adapter terminal for connecting aluminum cables and copper cables, characterized in that, The adapter terminal includes a first metal body, which includes a first connecting end and a second connecting end. The first connecting end has a first socket, and the second connecting end has a second socket, which are not connected. A composite metal sleeve is disposed inside the first socket. The outer layer of the composite metal sleeve is made of the same metal material as the first metal body, while the inner layer of the composite metal sleeve is made of a different material than the outer layer. A cable insertion hole is provided in the middle of the composite metal sleeve. A first cable is connected to the cable insertion hole, and the core wire of the first cable is made of the same material as the inner layer of the composite metal sleeve. A second cable is connected to the second socket, and the core wire of the second cable is made of the same material as the first metal body. After the metal core wire of the first cable is inserted into the cable insertion hole, the first connecting end, the composite metal sleeve, and the metal core wire are fixed by crimping. The direction of the pressure applied during crimping forms a non-zero set angle with the axis of the adapter terminal.
2. The adapter terminal for connecting aluminum cable and copper cable as described in claim 1, characterized in that, The first metal body is a copper body, and the composite metal sleeve is a copper-aluminum composite metal sleeve with an outer layer of copper and an inner layer of aluminum. The composite metal sleeve is formed by rolling copper-aluminum composite metal sheets into a tube.
3. The adapter terminal for connecting aluminum cable and copper cable as described in claim 2, characterized in that, The cable plug hole is connected and fixed to the aluminum cable, and the second plug hole is connected and fixed to the copper cable. After the aluminum core wire of the aluminum cable is inserted into the cable plug hole, the first connecting end, the copper-aluminum composite metal sleeve and the aluminum core wire are fixed by crimping. The direction of the pressure applied during crimping is perpendicular to the axis of the adapter terminal.
4. The adapter terminal for connecting aluminum cable and copper cable as described in claim 2, characterized in that, The copper-aluminum composite metal sleeve is tightly fitted to the first insertion hole, and the core wire of the aluminum cable is also tightly fitted to the cable insertion hole.
5. The adapter terminal for connecting aluminum cable and copper cable as described in claim 4, characterized in that, The copper-aluminum composite metal sleeve has a notch.
6. The adapter terminal for connecting aluminum cable and copper cable as described in claim 2, characterized in that, The inner diameter of the cable socket is larger than the diameter of the second socket.
7. The adapter terminal for connecting aluminum cable and copper cable as described in claim 6, characterized in that, The inner diameter of the cable socket is 2-3 times the diameter of the second socket.
8. A converter module for connecting aluminum cables and copper cables, characterized in that, The adapter module includes an adapter terminal as described in any one of claims 2-6. The aluminum core wire of the aluminum cable is inserted into the copper-aluminum composite metal sleeve in the adapter terminal, and the first connecting end of the adapter terminal, the copper-aluminum composite metal sleeve and the aluminum core wire are crimped and fixed by crimping. The copper core wire of the copper cable is fixedly connected to the second socket. The insulating sleeve seals the adapter terminal and the aluminum cable and copper cable into an integral module by injection molding.
9. The adapter module for connecting aluminum cable and copper cable as described in claim 8, characterized in that, The diameter of the copper body of the adapter terminal is greater than or less than the outer diameter of the copper cable and the aluminum cable, and a stepped structure is formed at the connection between the aluminum cable, the copper cable and the adapter terminal.