A photovoltaic connector harness assembly and micro-inverter

Abstract

The utility model discloses a photovoltaic connector wire harness assembly and micro inverter relates to micro inverter technical field, and photovoltaic connector wire harness assembly includes: wire harness, encapsulation spare, and the end of wire harness is covered, and is suitable for wearing and setting in the casing interface of micro inverter, and the outer periphery of encapsulation spare is equipped with annular boss, and annular boss is suitable for with the inner step of casing interface and is matched with each other, sealing ring, the outer periphery of encapsulation spare is covered and is located between annular boss and inner step, fastener, through annular boss fastening on inner step, to with encapsulation spare fixed in casing interface, and through compression sealing ring makes it and encapsulation spare and casing interface closely and is sealed. This photovoltaic connector wire harness assembly is more reliable, and the quality is more stable, and dismounting is more convenient.

Description

Technical Field

[0001] This utility model relates to the field of micro inverter technology, and more specifically, to a photovoltaic connector harness assembly and a micro inverter. Background Technology

[0002] Photovoltaic connector harness assemblies are external interface components of microinverters, used to connect photovoltaic modules to the inverter and enable DC power input. The interface between the harness and the microinverter must have excellent sealing performance to prevent rainwater and dust intrusion, which could cause short circuits, component damage, or decreased photovoltaic system efficiency.

[0003] Currently, the assembly method for photovoltaic connector harness components mostly involves inserting them into slots in the micro-inverter housing and applying sealant to the slots to achieve fixation and sealing. However, this existing technical solution has the following main drawbacks:

[0004] Low sealing reliability: After long-term use, the sealant may experience a decrease in adhesion due to aging and temperature changes, resulting in warping and deformation, which makes it impossible to guarantee the reliability of the seal.

[0005] Poor production quality and low efficiency: The sealant has a certain fluidity, and it is difficult to control the amount and position of the sealant precisely, which can easily lead to poor sealing or overflowing of sealant and pollution, and it is also inefficient.

[0006] Therefore, how to provide a photovoltaic connector harness assembly that can overcome the defects of relying on adhesive coating for production and assembly, making its sealing more reliable, its quality more stable, and its disassembly and assembly more convenient, is a problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0007] In view of this, the purpose of this utility model is to provide a photovoltaic connector harness assembly that has more reliable sealing, more stable quality, and is more convenient to install and disassemble.

[0008] Another objective of this invention is to provide a micro inverter that includes the aforementioned photovoltaic connector harness assembly.

[0009] To achieve the above objectives, this utility model provides the following technical solution:

[0010] A photovoltaic connector harness assembly, comprising:

[0011] wire harness;

[0012] A rubber-coated component is provided to cover the end of the wire harness and is adapted to be inserted into the housing interface of the inverter. The outer periphery of the rubber-coated component is provided with an annular boss, which is adapted to abut against the inner step of the housing interface.

[0013] A sealing ring is fitted around the outer periphery of the rubber-coated part and is located between the annular boss and the inner step;

[0014] Fasteners pass through the annular boss and are fastened to the inner step to fix the rubber-coated part in the housing interface, and compress the sealing ring to make it fit tightly against the rubber-coated part and the housing interface to form a seal.

[0015] Preferably, the annular boss has a mounting hole on the outside of the sealing ring, the fastener is threaded to the mounting hole, and can be screwed through the mounting hole and fastened to the blind hole nut post with the inner step.

[0016] Preferably, the blind hole nut post and the inner step of the housing interface are integrally formed by injection molding, and the end face of the blind hole nut post is flush with the end face of the inner step.

[0017] Preferably, the annular boss has an annular groove, and the sealing ring is embedded in the annular groove, partially exposing the annular groove to press against the inner step.

[0018] Preferably, the wire harness is provided as multiple wires, and the overmolded component has multiple through holes for the multiple wire harnesses to pass through side by side.

[0019] Preferably, the wire harness and the overmolded part are integrally formed by injection molding.

[0020] Preferably, an OT terminal is crimped to one end of the wire harness adjacent to the encapsulated component. The OT terminal is used to fix the wire harness to the PCBA board inside the inverter through a conductive connector to achieve electrical connection.

[0021] Preferably, one end of the wire harness adjacent to the insulated component is soldered to the PCBA board inside the inverter via a dip soldering process.

[0022] Preferably, the other end of the wiring harness away from the overmolded part is connected to a photovoltaic connector plug or socket.

[0023] Preferably, the housing interface is located on the side of the inverter housing.

[0024] A micro inverter comprising the photovoltaic connector harness assembly described in any of the preceding claims.

[0025] The photovoltaic connector harness assembly assembly method provided by this utility model is as follows: The insulated part covering the harness is inserted into the housing interface of the micro-inverter. Fasteners pass through the annular boss of the insulated part and are secured to the inner step of the micro-inverter housing interface. The annular boss can press the sealing ring onto the inner step, compressing the sealing ring to ensure a tight fit with the insulated part and the housing interface, thus forming a seal. Simultaneously, the insulated part is fixed in the housing interface, thereby achieving both fixing and sealing of the harness assembly. This method has the following beneficial effects:

[0026] Firstly, it overcomes the dependence on adhesive application and uses fastener compression sealing rings to achieve sealing, which is superior to the long-term stability and sealing performance of adhesives. It will not fail over time and improves the reliability of the seal.

[0027] Secondly, the specifications of the sealing ring are fixed, and its stable deformation can be controlled by fasteners, overcoming quality defects such as incomplete sealing or glue overflow caused by the adhesive application process, thus improving production quality. Furthermore, the method of using fasteners to tighten and compress the sealing ring is simple and convenient, eliminating the time spent waiting for the adhesive to cure, facilitating assembly, and improving production efficiency.

[0028] Third, when it is necessary to replace or repair the wiring harness assembly, the removal is convenient. Simply remove the fasteners to completely remove the wiring harness assembly without damaging any parts. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the structure of a photovoltaic connector harness assembly provided in this application;

[0031] Figure 2 for Figure 1 A schematic diagram showing the separation of the microinverter and photovoltaic connector harness assembly;

[0032] Figure 3 for Figure 1 An exploded view of the photovoltaic connector harness assembly shown.

[0033] Figure 4 for Figure 1 A partial cross-sectional view of the photovoltaic connector harness assembly shown;

[0034] Figure 5 for Figure 1 A partial sectional view of the structure shown.

[0035] Figure label:

[0036] 1-Inverter; 11-Housing; 12-Housing interface; 13-Inner step; 14-PCBA board;

[0037] 2-Photovoltaic connector wire harness assembly; 21-Wire harness; 22-Insulated part; 23-Annular boss; 24-Sealing ring; 25-Fastener; 26-Mounting hole; 27-OT terminal; 28-Connector;

[0038] 3- Photovoltaic connector. Detailed Implementation

[0039] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0040] The core of this utility model is to provide a photovoltaic connector harness assembly, which has more reliable sealing, more stable quality, and is more convenient to install and disassemble.

[0041] Another core aspect of this invention is to provide a micro inverter that includes the aforementioned photovoltaic connector harness assembly.

[0042] Please refer to Figure 1 This application provides a specific embodiment of a photovoltaic connector harness assembly, which mainly includes two parts: an inverter 1 and a photovoltaic connector harness assembly 2.

[0043] It should be noted that the inverter 1 includes a housing 11 and electronic components housed within the housing 11, and the housing 11 is equipped with a housing interface 12. In a photovoltaic power generation system, the type of inverter 1 needs to be selected based on the system scale and application scenario. In distributed power generation systems, especially in residential and small-scale commercial and industrial scenarios, inverter 1 is a micro-inverter, a miniaturized inverter typically used with a single solar photovoltaic panel or a small number of photovoltaic panels. It enables independent module-level maximum power point tracking control for each module, thereby significantly improving overall efficiency.

[0044] The photovoltaic connector harness assembly 2 is generally installed in the housing interface 12 to connect with electronic components (such as PCBA board 14) inside the housing 11 to achieve a conductive connection between the inverter 1 and the photovoltaic connector 3.

[0045] Please refer to Figure 2 , Figure 3 and Figure 5The photovoltaic connector wiring harness assembly 2 includes a wiring harness 21, an insulated part 22, a sealing ring 24, and a fastener 25. The insulated part 22 covers the end of the wiring harness 21 and is adapted to pass through the housing interface 12 of the inverter 1. The outer periphery of the insulated part 22 is provided with an annular boss 23, which is adapted to abut against the inner step 13 of the housing interface 12. The sealing ring 24 is sleeved on the outer periphery of the insulated part 22 and is located between the annular boss 23 and the inner step 13. The fastener 25 passes through the annular boss 23 and is fastened to the inner step 13 to fix the insulated part 22 in the housing interface 12, and compresses the sealing ring 24 to make it fit tightly against the insulated part 22 and the housing interface 12 to form a seal.

[0046] Specifically, the rubber-coated component 22 covers the end of the wire harness 21 to concentrate and fix the loose ends of the wire harness 21, and serves as a support platform for the fixed installation of the wire harness 21. An annular boss 23 is provided on the outer periphery of the rubber-coated component 22. An inner step 13 is provided inside the housing interface 12 of the inverter 1, and it abuts against the annular boss 23. A sealing ring 24 is placed between the annular boss 23 and the inner step 13. Fasteners 25 can be screws or bolts, passing through the mounting holes 26 on the annular step and fastened into the pre-drilled holes on the inner step 13. By tightening the fasteners 25, the annular boss 23 can be pressed against the inner step 13. Thus, by compressing the sealing ring 24, it can be made to fit tightly against the rubber-coated component 22 and the housing interface 12 to form a seal, while simultaneously fixing the rubber-coated component 22 in the housing interface 12, thereby achieving the fixation and sealing of the wire harness 21 assembly.

[0047] The photovoltaic connector harness assembly 2 in the above embodiments has at least the following effects:

[0048] Firstly, it overcomes the dependence on adhesive application process and uses fastener 25 to compress the sealing ring 24 to achieve sealing, which is superior to the long-term stability and sealing performance of adhesives. It will not fail over time and improves the reliability of the seal.

[0049] Secondly, the specifications of the sealing ring 24 are fixed, and the stable deformation of the sealing ring 24 can be controlled by the fastener 25, overcoming quality defects such as poor sealing or glue overflow pollution caused by the glue application process, thus improving production quality. Moreover, the method of using the fastener 25 to tighten and compress the sealing ring 24 is simple and convenient, saving the time of waiting for the glue to cure, making assembly convenient and improving production efficiency.

[0050] Third, when it is necessary to replace or repair the wire harness 21 assembly, the removal is convenient. Simply remove the fastener 25 to completely remove the wire harness 21 assembly without damaging any parts.

[0051] Based on the above embodiments, as a further preferred option, please refer to... Figure 2 , Figure 3 , Figure 4 and Figure 5 The annular boss 23 is located on the outside of the sealing ring 24 and has a mounting hole 26. The fastener 25 is threaded to the mounting hole 26 and can be screwed through the mounting hole 26 to be fastened to the blind hole nut post provided in the inner step 13.

[0052] Specifically, the annular boss 23 has a mounting hole 26 located outside the sealing ring 24 to prevent damage to the sealing ring 24 during fastener 25 installation. The mounting hole 26 has an internal thread that engages with the external thread of the fastener 25 (such as a bolt or screw). A blind hole nut post is located on the inner step 13 opposite the annular boss 23. The stud hole (equivalent to the aforementioned fastening hole) of the blind hole nut post is coaxial with the mounting hole 26. Thus, when the operator passes the fastener 25 through the mounting hole 26 and screws it into the blind hole nut post, the clamping force of the fastener 25 is directly transmitted to the inner step 13 via the annular boss 23 of the rubber-coated part 22, thereby compressing the sealing ring 24.

[0053] This fastener 25 is threaded to the annular boss 23 and the inner step 13, which allows the tightening force of the fastener 25 to be efficiently converted into a clamping force acting on the annular boss 23 and the inner step 13, thereby fully compressing the sealing ring 24 and ensuring a reliable seal. In addition, the fastener 25 also forms a rigid fastening between the entire rubber-coated part 22 and the housing interface 12, ensuring that the entire wiring harness 21 assembly is firmly installed on the housing interface 12.

[0054] Furthermore, the blind-hole nut post provided in the inner step 13 allows for blind insertion of the fastener 25. The process involves first gently screwing the fastener 25 (such as a screw) into the mounting hole 26, and then simply turning the screw forward to tighten it into the blind-hole nut post, thus completing the installation. This effectively reduces the difficulty of operation and increases the assembly speed.

[0055] Based on the above embodiments, as a further preferred embodiment, the blind hole nut post and the inner step 13 of the housing interface 12 are integrally formed by injection molding, which effectively improves the structural stability of the blind hole nut post, thereby ensuring a stable and reliable connection between it and the fastener 25. Moreover, by pre-installing the blind hole nut post and the inner step 13 of the housing interface 12 into the mold and then injection molding, not only is the process of pressing the blind hole nut post during assembly eliminated, requiring only the tightening of screws for quick assembly, but the use of injection molding can also eliminate the positional deviation caused by manual pressing of the blind hole nut post, for example, effectively ensuring that the end face of the blind hole nut post is flush with the end face of the inner step 13.

[0056] Setting the end face of the blind hole nut post flush with the end face of the inner step 13 ensures that a flat sealing contact surface is formed between the annular boss 23 and the inner step 13. In this way, when the fastener 25 is tightened, the pressure applied by the annular boss 23 will be evenly distributed across the entire contact surface through the sealing ring 24, avoiding poor sealing caused by the blind hole nut post being recessed or protruding.

[0057] It should be noted that the number of fasteners 25, mounting holes 26, and blind hole nut posts is the same, and one or more can be set according to the actual working conditions; the number is not unique.

[0058] Based on the above embodiments, as a further preferred embodiment, the annular boss 23 is provided with an annular groove, and the sealing ring 24 is embedded in the annular groove and partially exposed in the annular groove to press against the inner step 13.

[0059] Thus, before or during the installation of the wire harness 21 assembly on the housing interface 12, the sealing ring 24 can be pre-installed in the annular groove on the annular boss 23 to prevent it from falling off. This allows the sealing ring 24 to eventually move with the annular boss 23 and press against the inner step 13, improving assembly convenience and reliability. Furthermore, the annular groove restricts the initial position of the sealing ring 24, ensuring a quantitative relationship between the compressive force and deformation. The operator can ensure an effective seal by applying a fixed compressive force.

[0060] Based on the above embodiments, as a further preferred option, please refer to... Figure 2 and Figure 3 The wire harness 21 is configured as multiple wires, and the rubber-coated part 22 has multiple through holes for multiple wire harnesses 21 to pass through in parallel.

[0061] The photovoltaic connector harness assembly 2 includes multiple harnesses 21, which are arranged in parallel through multiple through holes in the overlay 22. This allows the loose harnesses 21 to be centrally located and pass together through the overlay 22 into the housing interface 12, facilitating the installation of multiple harnesses 21. Furthermore, the multiple harnesses 21 passing through the housing interface 12 enable electrical connection between the harnesses 21 and the PCBA board 14 (Printed Circuit Board Assembly) inside the housing 11, thereby efficiently transmitting the DC power from the photovoltaic module to the PCBA board 14 for conversion.

[0062] Based on the above embodiments, as a further preferred embodiment, the wire harness 21 and the overmolded part 22 are integrally molded using an injection molding process. This arrangement ensures that the wire harness 21 and the overmolded part 22 are firmly connected together, reducing the risk of the wire harness 21 detaching from the overmolded part 22 due to external force.

[0063] Based on the above embodiments, as a further preferred option, please refer to... Figure 5 One end of the wiring harness 21 adjacent to the insulated part 22 is crimped with an OT terminal 27. The OT terminal 27 is used to fix the PCBA board 14 inside the inverter 1 to achieve electrical connection through a conductive connector 28 (such as a screw).

[0064] It should be noted that the OT terminal 27 is a commonly used tubular terminal block in electrical engineering. It consists of a copper tube and crimping wings. The copper tube is used to insert the wire harness 21, and the crimping wings are used to fix the wire harness 21 by crimping tools.

[0065] Since the insulated component 22 passes through the housing interface 12 and covers the end of the wire harness 21, it is easy to see that one end of the wire harness 21 adjacent to the insulated component 22 extends into the housing 11 through the housing interface 12, where an OT terminal 27 is crimped. The OT terminal 27 can be fixed to the PCBA board 14 with screws. The OT terminal 27 has very low contact resistance and excellent current carrying capacity, efficiently transmitting current. Furthermore, the screw fastening ensures stable electrical connection, making installation simple and quick. It is also removable, facilitating testing and maintenance.

[0066] Based on the above embodiments, as a further preferred embodiment, one end of the wire harness 21 adjacent to the insulated part 22 can also be soldered to the PCBA board 14 inside the inverter 1 via a dip soldering process. That is, the dip-soldered wire harness 21 is directly soldered to the solder holes on the PCBA, forming a continuous, integrated metal conductor. This arrangement eliminates additional contact conductive components (such as the aforementioned OT terminal 27 and screws), which means reduced energy loss, more efficient current transmission, and a very strong weld that is far more resistant to mechanical stress than screw connections, effectively ensuring the long-term stability of the electrical connection.

[0067] Based on the above embodiments, as a further preferred embodiment, the other end of the wire harness 21 away from the overlay 22 is connected to a photovoltaic connector plug or socket. In this way, the operator can complete the electrical connection between the wire harness 21 and the photovoltaic connector 3 without any tools during installation, simply by plugging and unplugging.

[0068] It should be noted that the plug or socket connected to the other end of the wire harness 21 can be a standard plug or socket, which is compatible with most wire harnesses 21 on the market. Moreover, the components such as the rubber-coated part 22, sealing ring 24, and fastener 25 on one end of the wire harness 21 can be produced in modules, which enables the standardized production of the wire harness 21 assembly and makes it compatible with different models of photovoltaic connectors 3.

[0069] Based on the above embodiments, as a further preferred option, please refer to... Figure 2The housing interface 12 is located on the side of the housing 11 of the inverter 1. Compared to having the housing interface 12 located at the top of the housing 11, this side-mounted design prevents rainwater from accumulating in the housing interface 12 due to gravity, effectively reducing the risk of water leakage into the inverter 1. Furthermore, the wiring harness 21 can hang down naturally, avoiding the risk of insulation damage or even loosening and sealing failure caused by the wiring harness 21 forming a U-shaped bend.

[0070] This application also provides a microinverter that includes the photovoltaic connector harness assembly disclosed in the above embodiments.

[0071] It should be noted that in this specification, relational terms such as first and second are used only to distinguish one entity from several other entities, and do not necessarily require or imply any such actual relationship or order between these entities.

[0072] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0073] The photovoltaic connector harness assembly and inverter provided by this utility model have been described in detail above. Specific examples have been used to illustrate the principle and implementation of this utility model. The descriptions of the embodiments above are only for the purpose of helping to understand the method and core idea of ​​this utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made to this utility model without departing from the principle of this utility model, and these improvements and modifications also fall within the protection scope of the claims of this utility model.

Claims

1. A photovoltaic connector harness assembly, characterized in that, include: Wire harness (21); A rubber-coated part (22) is wrapped around the end of the wire harness (21) and is adapted to be inserted into the housing interface (12) of the inverter (1). The outer periphery of the rubber-coated part (22) is provided with an annular boss (23), which is adapted to abut against the inner step (13) of the housing interface (12). A sealing ring (24) is fitted around the outer periphery of the rubber-coated part (22) and located between the annular boss (23) and the inner step (13); Fastener (25) passes through the annular boss (23) and is fastened to the inner step (13) to fix the rubber-coated part (22) in the housing interface (12) and to form a seal by compressing the sealing ring (24) so ​​that it fits tightly with the rubber-coated part (22) and the housing interface (12).

2. The photovoltaic connector harness assembly according to claim 1, characterized in that, The annular boss (23) is located on the outside of the sealing ring (24) and has a mounting hole (26). The fastener (25) is threaded to the mounting hole (26) and can be screwed through the mounting hole (26) and fastened to the blind hole nut post provided in the inner step (13).

3. The photovoltaic connector harness assembly according to claim 2, characterized in that, The blind hole nut post and the inner step (13) of the housing interface (12) are integrally formed by injection molding, and the end face of the blind hole nut post is flush with the end face of the inner step (13).

4. The photovoltaic connector harness assembly according to claim 1, characterized in that, The annular boss (23) is provided with an annular groove, and the sealing ring (24) is embedded in the annular groove and partially exposed to press against the inner step (13).

5. The photovoltaic connector harness assembly according to claim 1, characterized in that, The wire harness (21) is provided as multiple wires, and the overmolded part (22) has multiple through holes for multiple wire harnesses (21) to pass through side by side.

6. The photovoltaic connector harness assembly according to claim 1, characterized in that, The wire harness (21) and the rubber-coated part (22) are integrally formed by injection molding.

7. The photovoltaic connector harness assembly according to claim 1, characterized in that, One end of the wiring harness (21) adjacent to the encapsulated part (22) is crimped with an OT terminal (27), which is used to be fixed to the PCBA board (14) inside the inverter (1) through a conductive connector (28) to achieve electrical connection.

8. The photovoltaic connector harness assembly according to claim 1, characterized in that, The end of the wiring harness (21) adjacent to the overmolded part (22) is soldered to the PCBA board (14) inside the inverter (1) by a dip soldering process.

9. The photovoltaic connector harness assembly according to claim 1, characterized in that, The other end of the wiring harness (21) away from the overlay (22) is connected to a photovoltaic connector plug or socket.

10. The photovoltaic connector harness assembly according to any one of claims 1 to 9, characterized in that, The housing interface (12) is located on the side of the housing (11) of the inverter (1).

11. A micro inverter, characterized in that, Includes the photovoltaic connector harness assembly as described in any one of claims 1 to 10.

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