A photovoltaic connector structure

Abstract

The utility model discloses a photovoltaic connector structure, including base, insulating part, cold pressure needle, contact needle, spring and fuse. The inside of insulating part is equipped with step surface and spring piece, and one end of cold pressure needle is placed in the insulating part and is fixed by both; contact needle is slidably arranged in the base, and the inside of contact needle is respectively provided with big crown spring and small crown spring at both ends, and the aperture of big crown spring is greater than that of small crown spring; spring is contained in the base, and both ends are respectively abutted with contact needle and base; insulating part is clamped with base, and fuse is clamped between cold pressure needle and contact needle, and one end of fuse is interference fit with big crown spring. The design realizes the quick and reliable assembly of cold pressure needle through the cooperation of step surface and spring piece, and the clamping of insulating part and base simplifies the overall assembly process; the continuous pressure provided by spring can automatically compensate the size tolerance, ensures the stable contact resistance, avoids local overheating, and the interference fit of crown spring and fuse realizes the convenient plug -in replacement, and the safety and operation and maintenance efficiency of photovoltaic system are improved obviously.

Description

Technical Field

[0001] This utility model belongs to the field of connector technology, specifically a photovoltaic connector structure. Background Technology

[0002] With the rapid development of the global new energy industry, photovoltaic power plants, as the core form of clean energy utilization, are experiencing continuous expansion in installed capacity, and the application scenarios of distributed and centralized photovoltaic systems are becoming increasingly widespread. Photovoltaic connectors, as key connection components between photovoltaic modules and system circuits, bear the core function of current transmission, and their performance directly affects the operational stability of the entire photovoltaic system. Since photovoltaic systems are mostly deployed in outdoor environments and must withstand complex conditions such as high and low temperature cycles, humidity changes, and ultraviolet radiation for extended periods, the industry has placed stringent requirements on the contact reliability, structural durability, and ease of maintenance of connectors. Simultaneously, the large-scale construction of photovoltaic power plants also demands that connectors possess efficient assembly characteristics to adapt to the batch operation needs of engineering construction.

[0003] Current photovoltaic connectors on the market have significant shortcomings in structural design, making it difficult to balance assembly efficiency and operational stability. Most connectors use bolt-fixed or integrated encapsulation structures, resulting in complex and time-consuming assembly processes. Subsequent maintenance involves cumbersome disassembly and replacement of core components such as fuses, significantly increasing operation and maintenance costs. More critically, existing structures lack effective dimensional tolerance compensation mechanisms, failing to accommodate minor dimensional deviations in fuses and other components during processing and assembly. This directly leads to unstable connector contact pressure, increasing contact resistance and causing localized overheating, which not only reduces electrical contact performance and lifespan but may also trigger overcurrent protection failure, posing a threat to the safe operation of photovoltaic systems and severely hindering the improvement of system operation and maintenance efficiency.

[0004] A photovoltaic connector and photovoltaic system are disclosed in patent application number CN202421215516.3. Although it achieves the assembly of the positive and negative electrode bodies and the base and cover through snap-fit ​​connection, it lacks a dimensional tolerance compensation structure. The mating of the positive and negative copper bodies is easily affected by processing and assembly deviations, resulting in unstable contact pressure, which in turn leads to problems such as increased contact resistance and local overheating, resulting in insufficient contact stability. At the same time, the design does not provide a convenient plug-and-play structure for core components such as fuses. The overall flat structure and snap-fit ​​connection method make the disassembly and replacement of components cumbersome during subsequent maintenance, increasing operation and maintenance costs. In addition, it lacks the ability to adaptively adjust for the dimensional deviations of various components, and cannot adapt to the small dimensional errors in actual applications. Ultimately, this limits its electrical contact reliability and service life, making it difficult to meet the requirements of photovoltaic systems for safe operation and efficient maintenance. Utility Model Content

[0005] The purpose of this utility model is to provide a photovoltaic connector structure to solve the following technical problems mentioned in the background art: Existing photovoltaic connectors suffer from poor contact stability, cumbersome assembly and maintenance, and inability to accommodate component size tolerances, resulting in insufficient system safety and operation and maintenance efficiency.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: A photovoltaic connector structure includes a base, an insulating component, a cold-pressed pin, a contact pin, a spring, and a fuse. The insulating component has a stepped surface and a spring clip inside. One end of the cold-pressed pin is disposed inside the insulating component and fixed by the stepped surface and the spring clip. The contact pin is slidably disposed within the base, and its two ends are respectively provided with a large crown spring and a small crown spring, the large crown spring having a larger aperture than the small crown spring. The spring is housed within the base, with its two ends abutting against the contact pin and the base, respectively. The insulating component is snapped into the base, clamping the fuse between the cold-pressed pin and the contact pin. One end of the fuse is interference-fitted with the large crown spring. A cable connector is also connected to the end of the base.

[0007] Furthermore, a retaining ring is provided inside the base, with a protrusion on the outside of the retaining ring and a hole inside the base; the retaining ring is fixed by the protrusion and the hole on the base; the end face of the retaining ring is aligned with the end face of the contact pin.

[0008] Furthermore, the side of the contact needle closest to the large crown spring tapers inward.

[0009] Furthermore, there are four spring pieces, which are evenly distributed around the circumference of the cold-pressing needle.

[0010] Furthermore, the length of the spring in its free state is greater than its installation space within the base.

[0011] Furthermore, it also includes a protective outer shell; the protective outer shell is fitted onto the outside of the base, and a boss is provided on the inner wall of the protective outer shell, and a corresponding elongated groove is provided on the outer wall of the base. The boss and the elongated groove cooperate to allow the protective outer shell to slide along the axial direction of the base without falling off.

[0012] Furthermore, when the protective housing slides to the first position, it can simultaneously block the first interlocking structure between the base and the cable connector, as well as the second interlocking structure between the base and the insulating component.

[0013] Furthermore, when the protective housing slides to the second position, at least the second interlocking structure between the base and the insulating component is exposed.

[0014] Compared with the prior art, the present invention has the following beneficial effects: This design of the present invention achieves rapid and reliable assembly of the cold-pressed needle through the cooperation of the stepped surface and the spring piece.

[0015] The continuous pressure provided by the spring can automatically compensate for the dimensional tolerances of the fuse and other components, ensuring stable contact resistance and preventing localized overheating.

[0016] The interference fit between the large crown spring and the fuse ensures excellent electrical contact and also enables convenient insertion, removal, and replacement of the fuse.

[0017] The snap-fit ​​connection between the insulator and the base simplifies the overall assembly process. This design ultimately achieves a photovoltaic connector with reliable contact, long lifespan, easy maintenance, and efficient overcurrent protection, significantly improving system safety and operational efficiency. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a cross-sectional view of the present invention; Figure 3 This is a schematic diagram of the retaining ring structure of this utility model; Figure 4 This is a schematic diagram of the structure of the insulating component of this utility model; Figure 5 This is a schematic diagram of the structure of the protective shell of this utility model; Figure 6 This is a schematic diagram of the base structure of this utility model.

[0019] The markings in the diagram are: 1-insulator, 2-protective shell, 3-base, 4-elongated groove, 5-bore, 6-second interlocking structure, 7-retaining ring, 8-first interlocking structure, 9-cable connector, 10-small crown spring, 11-spring, 12-contact pin, 13-large crown spring, 14-fuse, 15-cold-pressed pin, 16-protrusion, 17-stepped surface, 18-spring piece. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings. 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.

[0021] Example: A photovoltaic connector structure includes a base 3, an insulating component 1, a cold-pressed pin 15, a contact pin 12, a spring 11, and a fuse 14. The insulating component 1 has a stepped surface 17 and a spring piece 18 inside. One end of the cold-pressed pin 15 is disposed inside the insulating component 1 and fixed by the stepped surface 17 and the spring piece 18. The contact pin 12 is slidably disposed within the base 3, and its two ends are respectively provided with a large crown spring 13 and a small crown spring 10, the large crown spring 13 having a larger aperture than the small crown spring 10. The spring 11 is housed within the base 3, with its two ends abutting against the contact pin 12 and the base 3, respectively. The insulating component 1 is snapped into the base 3, clamping the fuse 14 between the cold-pressed pin 15 and the contact pin 12. One end of the fuse 14 is interference-fitted with the large crown spring 13. A cable connector 9 is also connected to the end of the base 3.

[0022] In this photovoltaic connector structure, the insulating component 1 serves as the main insulating structure. Its internal stepped surface 17 provides an axial mounting reference and support for the cold-pressed pin 15, while the spring piece 18 applies radial elastic force to assist in fixing the cold-pressed pin 15. The cold-pressed pin 15, as the main conductive connector, is crimped to the cable at one end and directly contacts the fuse 14 at the other end to transmit current. The contact pin 12, as a sliding conductive component, has a large crown spring 13 inside that clamps and fixes the other end of the fuse 14 through an interference fit, achieving electrical connection and mechanical locking. The small crown spring 10 is responsible for forming a low-resistance electrical contact with the pins of the mating connector. The spring 11, housed within the base 3, continuously acts on the contact pin 12, providing stable axial contact pressure for the entire contact system. The fuse 14, as an overcurrent protection element, is connected in series in this conductive circuit. The base 3 serves as the main structure, accommodating and guiding the movement of the contact needle 12 and the spring 11. Through the snap-fit ​​structure with the insulating part 1, the fuse 14 is firmly clamped between the cold-pressed needle 15 and the contact needle 12, forming a complete mechanical assembly and current path.

[0023] This design achieves rapid and reliable assembly of the cold-pressed pin 15 through the cooperation of the stepped surface 17 and the spring piece 18; the continuous pressure provided by the spring 11 automatically compensates for the dimensional tolerances of the fuse 14 and other components, ensuring stable contact resistance and preventing localized overheating; the interference fit between the large crown spring 13 and the fuse 14 ensures excellent electrical contact and facilitates easy insertion, removal, and replacement of the fuse 14; the snap-fit ​​connection between the insulating component 1 and the base 3 simplifies the overall assembly process. This design ultimately achieves a photovoltaic connector with reliable contact, long lifespan, easy maintenance, and efficient overcurrent protection, significantly improving system safety and operational efficiency.

[0024] In a preferred embodiment, a retaining ring 7 is further provided inside the base 3. A protrusion 16 is provided on the outer side of the retaining ring 7, and a hole is provided inside the base 3. The retaining ring 7 is secured to the hole on the base 3 by the protrusion 16. The end face of the retaining ring 7 is aligned with the end face of the contact pin 12. The retaining ring 7 added inside the base 3 is secured by the snap-fit ​​between its outer protrusion 16 and the hole on the base 3. This structure reliably positions the retaining ring 7 inside the base 3. The alignment of the end face of the retaining ring 7 with the end face of the contact pin 12 precisely limits the axial movement of the contact pin 12 within the base 3, preventing the contact pin 12 and the compressed spring 11 from dislodging from the base 3 under counterforce. Simultaneously, it ensures the stability of the pre-compression stroke of the spring 11, continuously providing the designed elastic force to the contact pin 12, thereby ensuring that the fuse 14 remains reliably compressed throughout the entire conductive circuit.

[0025] In a preferred embodiment, the contact pin 12 has an inwardly tapered side near the large crown spring 13. The core function of this inwardly tapered structure on the side of the contact pin 12 near the large crown spring 13 is to mechanically restrain the end of the open spring ring, preventing the large crown spring 13 from dislodging from the contact pin 12 during frequent insertion and removal of the fuse 14, thereby ensuring a stable and reliable interference fit between it and the end cap of the fuse 14. This structure solves the axial fixation problem of the crown spring without significantly affecting its radial elastic deformation capability, ensuring the long-term stability of the electrical connection and the continuity of fuse 14 replacement operations.

[0026] In a preferred embodiment, there are four spring clips 18, evenly distributed circumferentially along the cold-pressing needle 15. The core function of this structure, with four spring clips 18 evenly distributed circumferentially along the cold-pressing needle 15, is to ensure the cold-pressing needle 15 is centrally positioned within the insulating member 1 by forming a symmetrical and balanced radial clamping force, thereby preventing tilting or loosening of the cold-pressing needle 15 due to uneven force on one side. This design significantly increases the fixed contact surface of the cold-pressing needle 15, effectively improving its vibration and torsional resistance, and providing a continuous, stable electrical connection with lower contact resistance between the cold-pressing needle 15 and the fuse 14.

[0027] In a preferred embodiment, the length of spring 11 in its free state is greater than its mounting space within the base 3. This design ensures that spring 11 remains in a pre-compressed state after assembly. This pre-compression force continuously acts on the contact pin 12, pushing it towards the fuse 14, thereby providing continuous and stable axial contact pressure for the entire conductive circuit. Its core function is to automatically compensate for the axial dimensional manufacturing tolerances and accumulated assembly errors of the fuse 14 and other related components, ensuring a tight electrical contact within any tolerance range. This effectively suppresses increased contact resistance and abnormal temperature rise caused by poor contact, significantly improving the reliability and consistency of the connection.

[0028] In a preferred embodiment, a protective housing 2 is further included. The protective housing 2 is fitted onto the outside of the base 3. A boss 5 is provided on the inner wall of the protective housing 2, and a corresponding elongated groove 4 is provided on the outer wall of the base 3. The boss 5 and the elongated groove 4 cooperate to allow the protective housing 2 to slide axially along the base 3 without falling off. Through the sliding engagement between the inner wall boss 5 and the elongated groove 4 of the base 3, the protective housing 2 achieves a unified axial movement freedom and radial anti-fall-off locking on the base 3. This structure allows the protective housing 2 to slide between two predetermined positions according to operational needs: one is a protective position, completely covering the internal interlocking structure to prevent accidental operation; the other is an operational position, exposing a specific interlocking mechanism for connector docking, disassembly, or fuse 14 replacement.

[0029] When the protective housing 2 slides to the first position, it simultaneously blocks the first interlocking structure 8 between the base 3 and the cable connector 9, as well as the second interlocking structure 6 between the base 3 and the insulating component 1. The core function of this design, which allows the protective housing 2 to simultaneously block both interlocking structures when slid to the first position, is to achieve a forced physical safety interlock. This structure ensures that all critical mechanical locking mechanisms are shielded during normal connector use, effectively preventing unintended unlocking of the connector due to accidental impact or contact, and also preventing environmental factors such as dust and moisture from intruding into the internal electrical connection area. More importantly, this design establishes a safety logic that prevents any disassembly operations once the protective housing 2 is moved, forcing maintenance personnel to consciously slide the housing before accessing subsequent operating structures, significantly improving the safety of maintenance operations.

[0030] When the protective housing 2 slides to the second position, at least the interlocking structure 6 between the base 3 and the insulator 1 is exposed. The core function of this second interlocking structure 6, exposed when the protective housing 2 slides to the second position, is to provide a dedicated operating channel for replacing the fuse 14. This design, by selectively exposing specific interlocking structures, allows operators to precisely manipulate the base 3-insulator 1 latch using specialized tools, while ensuring that the interlocking structure of the cable connector 9 remains under controlled concealment.

[0031] Specifically, during use, after all components are installed, the protective shell 2 provides complete shielding of the upper and lower interlocking structures. When it is necessary to replace the fuse (i.e., fuse 14), the protective shell 2 must first be pushed upwards and slid along the elongated slide 4 to the first position, exposing the interlocking structure 8 between the base 3 and the cable connector 9, thereby removing the cable connector 9 and disconnecting the circuit. After the cable connector 9 is removed, the protective shell 2 slides downwards to the second position due to gravity. At this time, the interlocking structure 6 between the base 3 and the insulating component 1 is exposed, and the interlocking structure 6 between the base 3 and the insulating component 1 can be unlocked with a tool, thereby removing the female base 3. Since the female base 3 and the fuse 14 are interference-fitted, they have a certain clamping force, and there is no fixed structure between the fuse 14 and the plate end cold pressing pin 15, the fuse 14 and the female base 3 can be removed simultaneously.

[0032] In the description of this utility model, it should be understood that the terms "coaxial", "bottom", "one end", "top", "middle", "other end", "upper", "side", "top", "inner", "front", "center", "both ends", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0033] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "setting," "connection," "fixing," "screw connection," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Unless otherwise explicitly limited, those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0034] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A photovoltaic connector structure, characterized in that: Includes base (3), insulating part (1), cold pressing needle (15), contact needle (12), spring (11) and fuse (14); The insulating component (1) has a stepped surface (17) and a spring piece (18) inside; one end of the cold-pressed needle (15) is located inside the insulating component (1) and is fixed by the stepped surface (17) and the spring piece (18); the contact needle (12) is slidably located in the base (3), and the two ends of the contact needle (12) are respectively provided with a large crown spring (13) and a small crown spring (10), the diameter of the large crown spring (13) is larger than that of the small crown spring (10); the spring (11) is housed in the base (3), and its two ends abut against the contact needle (12) and the base (3) respectively; the insulating component (1) is snapped into the base (3), and the fuse (14) is clamped between the cold-pressed needle (15) and the contact needle (12), and one end of the fuse (14) is press-fitted with the large crown spring (13); the end of the base (3) is also connected to a cable connector (9).

2. The photovoltaic connector structure according to claim 1, characterized in that: A retaining ring (7) is also provided inside the base (3), and a protrusion (16) is provided on the outside of the retaining ring (7). A hole is provided inside the base (3). The retaining ring (7) is fastened to the hole on the base (3) by the protrusion (16). The end face of the retaining ring (7) is aligned with the end face of the contact pin (12).

3. The photovoltaic connector structure according to claim 1, characterized in that: The side of the contact needle (12) near the large crown spring (13) is tapered inward.

4. A photovoltaic connector structure according to claim 1, characterized in that: There are four spring pieces (18), which are evenly distributed around the cold pressing needle (15).

5. A photovoltaic connector structure according to claim 1, characterized in that: The length of the spring (11) in its free state is greater than its installation space in the base (3).

6. A photovoltaic connector structure according to claim 1, characterized in that: It also includes a protective shell (2); the protective shell (2) is fitted on the outside of the base (3), and a boss (5) is provided on the inner wall of the protective shell (2), and a long groove (4) is correspondingly opened on the outer wall of the base (3). The boss (5) and the long groove (4) cooperate to allow the protective shell (2) to slide along the axial direction of the base (3) without falling off.

7. A photovoltaic connector structure according to claim 6, characterized in that: When the protective housing (2) slides to the first position, it can simultaneously block the first interlocking structure (8) between the base (3) and the cable connector (9) and the second interlocking structure (6) between the base (3) and the insulating component (1).

8. A photovoltaic connector structure according to claim 6, characterized in that: When the protective housing (2) slides to the second position, at least the second interlocking structure (6) between the base (3) and the insulating element (1) is exposed.

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