A photovoltaic connector MC4 copper-aluminum composite conversion joint and a connecting structure thereof

Abstract

The utility model discloses a photovoltaic connector MC4 copper aluminium composite conversion connector, including the electrically conductive connection's aluminium wire harness compression end and copper inner core crimping end, aluminium wire harness compression end and copper inner core crimping end all adopt copper aluminium intercalation formula composite material punch and make, aluminium wire harness compression end is the circular tube structure, and copper inner core crimping end is the variable diameter circular tube structure, aluminium wire harness compression end and copper inner core crimping end are connected MC4 red copper inner core and aluminium wire harness rear partial or all external contour crimping into six prism shape. MC4 copper aluminium composite conversion connection structure, including copper aluminium composite conversion connector, MC4 red copper inner core, one end is inserted in copper inner core crimping end and is mutually compressed tightly and is fixed, and the compressed tightly and fixed place adopts tin soldering electrically conductive connection, aluminium wire harness, tail part is located in aluminium wire harness compression end aluminium wire harness compression end tin soldering electrically conductive connection. The utility model discloses can directly complete the copper of wire harness both ends, aluminium conversion, and the connection wire harness forms the conversion connector, and the connection of wire end is stable and not easy to loosen, is convenient for construction's simultaneously, also has improved product reliability.

Description

Technical Field

[0001] This utility model relates to the field of solar power generation technology, specifically to a photovoltaic connector MC4 copper-aluminum composite conversion connector and its connection structure. Background Technology

[0002] Solar power generation is an important means of implementing the concept of green development and achieving the development of circular and clean energy. Solar energy is a clean and renewable energy source that directly converts light into electricity, and it has broad application prospects.

[0003] Because the positive electrode of the solar panel uses silver, it can only be soldered with copper. This means that the wires coming out of the solar panel must be copper wires. A single solar panel has a voltage of 12VDC, and multiple panels need to be connected in series to reach 600VDC. Then, two wires, one for positive and one for negative terminals, are connected to an inverter, which converts the 600VDC into 380VAC for external transmission.

[0004] Currently, the annual installed capacity of solar power generation is 1 billion kilowatts, and the cost of copper MC4 connecting wires for this scale exceeds 10 billion yuan. At present, very few aluminum wires are used as conductors in the market, mainly because no copper-aluminum conversion connector can meet the 20-25 year service life of solar power generation. Existing Cu+Al conversion connectors use friction welding, which generally has a 5-6% chance of breakage. Aluminum wire ends are bolted, which can loosen over time, easily oxidize, and generate heat, causing danger. For these reasons, aluminum wires are rarely used at present. Utility Model Content

[0005] In view of the above-mentioned defects of the prior art, the purpose of this utility model is to provide a photovoltaic connector MC4 copper-aluminum composite conversion connector and its connection structure, which can directly complete the copper-aluminum conversion at both ends of the wire harness, connect the wire harness to form a conversion connector, and the connection at the wire end is stable and not easy to loosen, which facilitates construction and improves product reliability.

[0006] The objective of this utility model is achieved through the following technical solution:

[0007] A photovoltaic connector MC4 copper-aluminum composite adapter includes an aluminum wire harness crimping end and a copper inner core crimping end for conductive connection; both the aluminum wire harness crimping end and the copper inner core crimping end are made of copper-aluminum interlocking composite material by stamping.

[0008] The aluminum wire harness crimping end is a round tube structure, and the copper inner core crimping end is a variable diameter round tube structure; the aluminum wire harness crimping end and the copper inner core crimping end are respectively connected to the MC4 copper inner core and the aluminum wire harness, and then part or all of the outer contours are crimped into a hexagonal prism shape.

[0009] Furthermore, the minimum outer diameter of the copper inner core crimping end is smaller than the outer diameter of the aluminum wire harness crimping end.

[0010] Furthermore, the aluminum wire harness crimping end is crimped and fixed to the aluminum wire harness and then soldered to form a conductive connection; the copper inner core crimping end is crimped and fixed to the MC4 copper inner core and then soldered to form a conductive connection.

[0011] Furthermore, the outer contour of the aluminum wire harness clamping end after connection with the aluminum wire harness includes:

[0012] The first hexagonal prism, its corresponding circular tube structure is extruded and fixed to the aluminum wire harness inside;

[0013] The spacer section has an aluminum wire harness housed inside its corresponding circular tube structure.

[0014] The second hexagonal prism has its corresponding circular tube structure inside which is extruded and fixed to the aluminum wire harness.

[0015] Furthermore, the outer contour of the aluminum wire harness clamping end after connection with the aluminum wire harness also includes:

[0016] At the head end, located on the front side of the first hexagonal prism directly opposite the copper inner core crimping end, the corresponding round tube structure accommodates the aluminum wire harness; the corresponding round tube structure and the aluminum wire harness are soldered together.

[0017] Furthermore, the aluminum wire harness clamping end structure is a structure with a vertically opening slit.

[0018] Furthermore, the joint between the aluminum wire harness clamping end and the aluminum wire harness after connection is made by soldering.

[0019] A photovoltaic connector MC4 copper-aluminum composite conversion connection structure includes:

[0020] The copper-aluminum composite adapter described above is made of copper-aluminum interlocking composite material and includes an aluminum wire harness crimping end and a copper inner core crimping end for conductive connection.

[0021] The MC4 copper inner core has one end inserted into the copper inner core crimping end, and is crimped and fixed to the copper inner core crimping end. The crimping and fixed connection is made by soldering conductive connection.

[0022] The tail end of the aluminum wire harness is located inside the aluminum wire harness clamping end and is clamped and fixed to the aluminum wire harness clamping end. The tail end is soldered to the aluminum wire harness clamping end for conductive connection.

[0023] Furthermore, the copper inner core crimping end is crimped and then welded to the MC4 copper inner core; the conductive aluminum wire harnesses are crimped and then welded to each other.

[0024] Due to the adoption of the above technical solution, this utility model has the following advantages:

[0025] 1. It can directly convert copper and aluminum at both ends of the wire harness, connect the wire harness to form an adapter, and the connection at the wire end is stable and not easy to loosen, which facilitates construction and improves product reliability.

[0026] 2. The copper-aluminum composite adapter and the MC4 copper core, as well as the copper-aluminum composite adapter and the aluminum wire, are connected by crimping to ensure sufficient contact area. Welding further improves connection stability. The aluminum wire harness end is first crimped using a hexagonal die. The overall crimping section is divided into three parts: the aluminum wire harness end crimping section, the cavity section, and the copper end crimping section. The intermediate space isolates the stress caused by the aluminum wire swinging in the wind, and the copper end is not affected by external stress, increasing the reliability of the device.

[0027] 3. It can reduce the original 4mm diameter of the solar power inverter. 2 6mm copper wire 2 The complete replacement of aluminum wires not only ensures the power generation efficiency of solar panels, but also guarantees reliability and significantly reduces costs, resulting in enormous social and economic value and saving investment costs.

[0028] 4. The copper-aluminum composite material adapter disclosed in this utility model realizes the transformation of MC4 wiring harness from only being able to use copper wire to being completely replaced by aluminum wire, changing the current single mode of copper wire use. While fully meeting the usage requirements and parameters, it reduces the usage cost by more than 50%, saving a lot of investment every year.

[0029] 5. The aluminum ends of the aluminum wire harness and the copper-aluminum composite adapters at both ends, the inner core pressing ends of the copper inner core mother component and the copper ends of the copper-aluminum composite adapters are all connected by crimping to ensure that the contact area meets the requirements, and welding further improves the connection stability and increases the reliability of the electrical connection.

[0030] Other advantages, objectives and features of this invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be taught from the practice of this invention. Attached Figure Description

[0031] The accompanying drawings of this utility model are described below:

[0032] Figure 1 This is a front view schematic diagram of the photovoltaic connector MC4 copper-aluminum composite adapter after connection in the embodiment;

[0033] Figure 2 This is a top view of the photovoltaic connector MC4 copper-aluminum composite adapter after connection in the embodiment.

[0034] In the diagram: 1. MC4 copper inner core; 2. Copper inner core crimp end; 3. Aluminum wire harness crimp end; 4. Aluminum wire harness; 5. Crimping and welding joint between MC4 copper inner core and copper inner core crimp end; 6. Tin welding joint between aluminum wire harness and aluminum wire harness crimp end; 7. First hexagonal prism; 8. Spacing section; 9. Tin welding joint at the aluminum wire harness crimp end; 10. Second hexagonal prism. Detailed Implementation

[0035] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0036] Example:

[0037] like Figures 1 to 2 As shown, a photovoltaic connector MC4 copper-aluminum composite adapter includes an aluminum wire harness crimping end 3 and a copper inner core crimping end 2 for conductive connection; both the aluminum wire harness crimping end 3 and the copper inner core crimping end 2 are made of copper-aluminum interlocking composite material by stamping.

[0038] The aluminum wire harness crimping end 3 is a round tube structure, and the copper inner core crimping end 2 is a variable diameter round tube structure; the aluminum wire harness crimping end 3 and the copper inner core crimping end 2 are respectively connected to the MC4 copper inner core 1 and the aluminum wire harness 4, and then partially or completely of their outer contours are crimped into a hexagonal prism shape.

[0039] The copper-aluminum composite adapter uses patent number ZL2019211264336, named a continuous side-side composite copper-aluminum composite material rolled into a tube shape, forming a copper tube segment and an aluminum tube segment, which respectively correspond to the copper inner core crimping end 2 and the aluminum wire harness crimping end 3.

[0040] In this embodiment, the minimum outer diameter of the copper inner core crimping end 2 is smaller than the outer diameter of the aluminum wire harness crimping end 3.

[0041] In this embodiment, the aluminum wire harness crimping end 3 and the aluminum wire harness 4 are crimped and fixed, and then soldered to form a conductive connection; the copper inner core crimping end 2 and the MC4 copper inner core 1 are crimped and fixed, and then soldered to form a conductive connection.

[0042] Soldering is applied at the crimping welding point 5 between the MC4 copper inner core and the copper inner core crimping end. This seals the gap of the crimping end 2 of the copper inner core rolled into a tube, thus preventing air from contacting the surface of the copper core and oxidizing the copper core. At the same time, it increases the conductive contact surface between the copper core and the aluminum wire harness crimping end 3.

[0043] In this embodiment, the outer contour of the aluminum wire harness clamping end 3 after being connected to the aluminum wire harness 4 includes:

[0044] The first hexagonal prism 7, the inner side of its corresponding circular tube structure is pressed and fixed to the aluminum wire bundle 4;

[0045] The spacer 8 has an aluminum wire bundle 4 housed inside its corresponding circular tube structure.

[0046] The second hexagonal prism 10, the inner side of its corresponding circular tube structure is extruded and fixed to the aluminum wire harness 4.

[0047] The specific shape for extrusion fixing can be any other prismatic structure, as long as extrusion fixing can be achieved.

[0048] In this embodiment, the outer contour of the aluminum wire harness clamping end 3 after being connected to the aluminum wire harness 4 further includes:

[0049] The head end is located on the front side of the first hexagonal prism 7, directly opposite the copper inner core crimping end 2, i.e. Figure 2 The aluminum wire harness is soldered to the aluminum wire harness compression end 6, and the corresponding round tube structure accommodates the aluminum wire harness 4; the inner side of the corresponding round tube structure is soldered to the aluminum wire harness 4. Soldering can seal the exposed part of the end face of the aluminum wire harness 4, prevent the aluminum wire harness 4 from being oxidized by air, and increase the conductive area of ​​the aluminum wire harness 4.

[0050] In this embodiment, the aluminum wire harness clamping end 3 has a structure with a vertical opening slit.

[0051] In this embodiment, the joint between the aluminum wire harness clamping end 3 and the aluminum wire harness 4 is connected by soldering.

[0052] The use of soldering at the joint of the aluminum wire harness clamping end 9 can seal the aluminum wire harness clamping end 3, prevent air from contacting the aluminum wire harness 4, and increase the conductive contact surface between the aluminum wire harness 4 and the aluminum wire harness clamping end 3.

[0053] A photovoltaic connector MC4 copper-aluminum composite conversion connection structure includes:

[0054] The copper-aluminum composite adapter described above is made of copper-aluminum interlocking composite material and includes an aluminum wire harness crimping end 3 and a copper inner core crimping end 2 for conductive connection.

[0055] MC4 copper inner core 1, one end of which is inserted into the copper inner core crimping end 2, and is pressed and fixed together with the copper inner core crimping end 2. The crimping and fixing joint is connected by soldering.

[0056] The tail of the aluminum wire harness 4 is located inside the aluminum wire harness clamping end 3 and is clamped and fixed to the aluminum wire harness clamping end 3. The tail end is soldered to the aluminum wire harness clamping end 3 for conductive connection.

[0057] In this embodiment, the copper inner core crimping end 2 is crimped and then welded to the MC4 copper inner core 1; the conductive aluminum wire harness 4 is crimped and then welded to the aluminum wire harness 4.

[0058] In this embodiment, the copper-aluminum composite material adapter can directly complete the copper-aluminum conversion at both ends of the wire harness, connect the wire harness to form an adapter cable, and the connection at the wire end is stable and not easy to loosen, which facilitates construction and improves product reliability.

[0059] The copper-aluminum composite adapter is crimped to ensure sufficient contact area with the MC4 copper core 1, and the aluminum wire harness 4. Welding further enhances connection stability. These three crimping points ensure effective connection and fixation between the copper-aluminum composite adapter, the MC4 copper core 1, and the aluminum wire harness 4. Specifically, the crimping and fixing points with the MC4 copper core 1 are as follows: Figure 2 The MC4 copper inner core is crimped and welded to the copper inner core at point 5, and the crimping and fixing points with the aluminum wire harness 4 are the first hexagonal prism 7 and the second hexagonal prism 10. An uncompressed area, i.e., a spacer 8, is provided between the first hexagonal prism 7 and the second hexagonal prism 10. This spacer 8 is not compressed with the aluminum wire harness 4, thus forming a cavity structure. This cavity structure can isolate stress when the aluminum wire harness 4 swings in the wind, ensuring the reliability of the connection between the MC4 copper inner core and the copper inner core at point 5 and the MC4 copper inner core 1, thereby increasing the reliability of the electrical connection and ensuring a robust and reliable connection over a 25-year service life.

[0060] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of this technical solution, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. A photovoltaic connector MC4 copper-aluminum composite adapter, characterized in that, It includes an aluminum wire harness crimping end and a copper inner core crimping end with conductive connection; both the aluminum wire harness crimping end and the copper inner core crimping end are made of copper-aluminum interlocking composite material by stamping. The aluminum wire harness crimping end is a round tube structure, and the copper inner core crimping end is a variable diameter round tube structure; the aluminum wire harness crimping end and the copper inner core crimping end are respectively connected to the MC4 copper inner core and the aluminum wire harness, and then part or all of the outer contours are crimped into a hexagonal prism shape.

2. The photovoltaic connector MC4 copper-aluminum composite adapter according to claim 1, characterized in that, The minimum outer diameter of the copper inner core crimping end is smaller than the outer diameter of the aluminum wire harness crimping end.

3. The photovoltaic connector MC4 copper-aluminum composite adapter according to claim 1, characterized in that, The aluminum wire harness crimping end is crimped and fixed to the aluminum wire harness and then soldered to form a conductive connection; the copper inner core crimping end is crimped and fixed to the MC4 copper inner core and then soldered to form a conductive connection.

4. The photovoltaic connector MC4 copper-aluminum composite adapter according to claim 1, characterized in that, The outer contour of the aluminum wire harness clamping end after connection with the aluminum wire harness includes: The first hexagonal prism, its corresponding circular tube structure is extruded and fixed to the aluminum wire harness inside; The spacer section has an aluminum wire harness housed inside its corresponding circular tube structure. The second hexagonal prism has its corresponding circular tube structure inside which is extruded and fixed to the aluminum wire harness.

5. The photovoltaic connector MC4 copper-aluminum composite adapter according to claim 4, characterized in that, The outer contour of the aluminum wire harness clamping end after connection with the aluminum wire harness also includes: At the head end, located on the front side of the first hexagonal prism directly opposite the copper inner core crimping end, the corresponding round tube structure accommodates the aluminum wire harness; the corresponding round tube structure and the aluminum wire harness are soldered together.

6. The photovoltaic connector MC4 copper-aluminum composite adapter according to claim 1, characterized in that, The aluminum wire harness compression end structure has a vertically open slit structure.

7. The photovoltaic connector MC4 copper-aluminum composite adapter according to claim 6, characterized in that, The joint between the aluminum wire harness crimping end and the aluminum wire harness is connected by soldering.

8. A photovoltaic connector MC4 copper-aluminum composite conversion connection structure, characterized in that, include: The copper-aluminum composite adapter as described in any one of claims 1-7 is made of copper-aluminum interlocking composite material and includes an aluminum wire harness crimping end and a copper inner core crimping end that are electrically connected. The MC4 copper inner core has one end inserted into the copper inner core crimping end, and is crimped and fixed to the copper inner core crimping end. The crimping and fixed connection is made by soldering for conductivity. The tail end of the aluminum wire harness is located inside the aluminum wire harness clamping end and is clamped and fixed to the aluminum wire harness clamping end. The tail end is soldered to the aluminum wire harness clamping end for conductive connection.

9. The photovoltaic connector MC4 copper-aluminum composite conversion connection structure according to claim 8, characterized in that, The copper inner core is crimped to the MC4 copper inner core and then welded; the conductive aluminum wire harnesses are crimped to each other and then welded.

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