A photovoltaic connector

Abstract

The utility model discloses a photovoltaic connector, including the casing and the electrically conductive body and temperature detection element of setting in the casing. The surface of temperature detection element is provided with insulating layer, and the outer surface of insulating layer is provided with heat conductor, and heat conductor is used for conducting the heat in casing to temperature detection element. Insulating layer effectively isolates the electrical connection between temperature detection element and electrically conductive body, prevents the occurrence of high voltage breakdown phenomenon, improves the working reliability of temperature detection element under high pressure environment. The heat conductor of insulating layer outer surface setting can gather the heat of each heating site in casing and conduct to temperature detection element, and the response speed of heat conduction efficiency and temperature detection has been improved significantly. While guaranteeing electrical safety, the precise real -time monitoring to the temperature in the connector is realized, can in time early warning and protection before the overheating fault of connector occurs, effectively prevents the equipment damage and safety accident caused by temperature too high.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic power generation technology, and in particular to a photovoltaic connector. Background Technology

[0002] As a key electrical connection component in photovoltaic (PV) power generation systems, PV connectors play a crucial role in electrically connecting PV modules, inverters, and other equipment. During actual operation, PV systems require connectors to withstand significant operating currents. Conductive components generate heat due to resistance losses. Excessive internal temperature can lead to increased contact resistance, aging of insulation materials, and even electrical faults and safety accidents. Existing PV connectors typically lack effective temperature monitoring methods, making real-time monitoring of internal temperatures difficult. This hinders timely warnings and protection against overheating failures, impacting the safe and reliable operation of the PV power generation system. Utility Model Content

[0003] In order to overcome the shortcomings of the existing technology, this utility model provides a photovoltaic connector with temperature monitoring function.

[0004] The technical solution adopted by this utility model to solve its technical problem is:

[0005] A photovoltaic connector includes a housing and a conductor and a temperature sensing element disposed within the housing. The surface of the temperature sensing element is provided with an insulating layer, and the outer surface of the insulating layer is provided with a heat conductor for conducting heat from the housing to the temperature sensing element.

[0006] Furthermore, the temperature sensing element is an NTC thermistor, and the insulating layer is formed on the surface of the NTC thermistor through a potting process.

[0007] Furthermore, the heat conductor covers at least a portion of the outer surface of the insulating layer, and the material of the heat conductor is a metal or a thermally conductive composite material.

[0008] Furthermore, the insulating layer is made of a thermally conductive insulating material, which is a polymer material with added thermally conductive fillers.

[0009] Furthermore, the conductor includes a connection end and a conductive flexible terminal. The connection end is disposed inside the housing. One end of the conductive flexible terminal is electrically connected to the connection end, and the other end extends out of the housing to form a conductive terminal pin. The heat conductor extends to a position adjacent to the conductive flexible terminal for collecting the heat of the conductive flexible terminal and conducting it to the temperature detection element.

[0010] Furthermore, the heat conductor covers the entire outer surface of the insulating layer, forming an integrated heat conduction structure; the bottom of the heat conductor is thermally coupled to the conductive soft terminal, and the top is provided with a through hole for the pins of the temperature sensing element to pass through and extend to the outside of the housing.

[0011] Furthermore, the housing includes a lower shell and an upper shell that cooperate with each other; one end of the lower shell forms a receiving cavity, and the other end forms a fixing tube, with the connecting end disposed inside the fixing tube; the upper shell closes the receiving cavity and is provided with a first channel through which the conductive soft terminal passes and a second channel through which the pin of the temperature sensing element passes.

[0012] Furthermore, the lower shell includes an annular flange extending radially from its outer circumferential surface, and an external threaded section located between the flange and the fixed tube; the mounting nut engages with the external threaded section, and by rotating the mounting nut, it forms an axial clamp with the flange, thereby achieving the fixed installation of the photovoltaic connector.

[0013] Furthermore, the inner wall of the first channel is provided with a first snap-fit ​​portion, and the corresponding position of the conductive flexible terminal is provided with a second snap-fit ​​portion that cooperates with the first snap-fit ​​portion; when the conductive flexible terminal passes through the first channel, the first snap-fit ​​portion and the second snap-fit ​​portion engage with each other to achieve axial positioning of the conductive flexible terminal.

[0014] Furthermore, the first channel and the second channel are located on opposite radial sides of the upper shell; the conductive flexible terminal includes a connecting part, a bending part and an extension part connected in sequence, the connecting part is electrically connected to the connecting end, the extension part extends through the first channel to the outside of the shell; one end of the heat conductor forms a thermal conductive contact with the extension part, and the pin of the temperature sensing element extends through the second channel to the outside of the shell.

[0015] The beneficial effects of this utility model are:

[0016] This utility model discloses a photovoltaic connector, including a housing and a conductor and a temperature sensing element disposed within the housing. An insulating layer is disposed on the surface of the temperature sensing element, and a heat conductor is disposed on the outer surface of the insulating layer. The heat conductor is used to conduct heat from inside the housing to the temperature sensing element. By providing an insulating layer on the surface of the temperature sensing element, the electrical connection between the temperature sensing element and the conductor is effectively isolated, preventing high-voltage breakdown and improving the operational reliability of the temperature sensing element under high-voltage environments. The heat conductor on the outer surface of the insulating layer can quickly collect heat from various heat-generating parts inside the housing and conduct it to the temperature sensing element, significantly improving heat conduction efficiency and temperature detection response speed. While ensuring electrical safety, it achieves accurate real-time monitoring of the connector's internal temperature, enabling timely warning and protection before overheating failures occur, effectively preventing equipment damage and safety accidents caused by excessive temperature. Attached Figure Description

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0018] Figure 1 This is a three-dimensional structural schematic diagram of one embodiment of the present invention;

[0019] Figure 2 yes Figure 1 A frontal view diagram;

[0020] Figure 3 This is a three-dimensional structural schematic diagram of another embodiment of the present invention;

[0021] Figure 4 yes Figure 3 A frontal view diagram;

[0022] Figure 5 yes Figure 1 A cross-sectional view;

[0023] Figure 6 yes Figure 3 A cross-sectional view;

[0024] Figure 7 This is a schematic diagram of the connection structure of the temperature sensing element of this utility model;

[0025] Figure 8 This is a schematic diagram of the temperature detection element of this utility model.

[0026] in,

[0027] 100. Housing; 110. Upper housing; 111. First channel; 1111. First snap-fit ​​part; 112. Second channel; 120. Lower housing; 121. Receiving cavity; 122. Fixing tube; 123. Flange; 124. External thread section;

[0028] 200, Conductor; 210, Connecting end; 220, Conductive flexible terminal; 221, Connecting part; 222, Bending part; 223, Extended part; 2231, Second snap-fit ​​part; 2232, Conductive terminal pin;

[0029] 300. Temperature sensing element;

[0030] 400. Insulation layer;

[0031] 500. Heat conductor;

[0032] 600. Install the nuts. Detailed Implementation

[0033] The following will clearly and completely describe the concept, specific structure, and technical effects of this utility model in conjunction with embodiments and accompanying drawings, so as to fully understand the purpose, features, and effects of this utility model. Obviously, the described embodiments are only a part of the embodiments of this utility model, not all of them. Other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are all within the scope of protection of this utility model. Furthermore, all connections / linkages involved in the patent do not simply refer to direct contact between components, but rather to the ability to form a better connection structure by adding or reducing connecting accessories according to specific implementation conditions. The various technical features in this utility model can be combined interactively without contradicting each other.

[0034] Reference Figure 1-8 This invention provides a photovoltaic connector, which includes a housing 100 and a conductor 200 and a temperature sensing element 300 disposed within the housing 100. The surface of the temperature sensing element 300 is provided with an insulating layer 400, and the outer surface of the insulating layer 400 is provided with a heat conductor 500, which conducts heat from inside the housing 100 to the temperature sensing element 300. By constructing a composite structure of the insulating layer 400 and the heat conductor 500 around the temperature sensing element 300, both the electrical safety of the temperature sensing element 300 and the heat conduction efficiency are significantly improved, thereby achieving accurate real-time monitoring of the internal temperature of the photovoltaic connector.

[0035] During actual operation of the photovoltaic connector, the conductor 200 generates heat due to current carrying capacity. This heat is rapidly transferred to the temperature sensing element 300 via the heat conductor 500. Because the heat conductor 500 has excellent thermal conductivity, it can quickly collect and conduct heat from various heat-generating parts within the housing 100 to the temperature sensing element 300, enabling the temperature sensing element 300 to promptly detect temperature changes inside the connector. Simultaneously, the insulating layer 400 on the surface of the temperature sensing element 300 provides dual protection. On one hand, it isolates the electrical connection between the temperature sensing element 300 and the conductor 200, preventing high-voltage breakdown. On the other hand, by selecting thermally conductive insulating materials, it effectively conducts heat while ensuring insulation performance, ensuring the accuracy of temperature measurement.

[0036] Through the above technical solutions, photovoltaic connectors achieve significant performance improvements in temperature monitoring. The heat conductor 500 greatly enhances the thermal response speed of the temperature sensing element 300, enabling it to respond immediately to changes in the internal temperature of the connector, thus providing timely and accurate temperature information. The insulating layer 400 effectively solves the problem of traditional NTC thermistors being prone to breakdown under high voltage environments. Protected by the insulating layer 400, the temperature sensing element 300 can operate stably within its rated voltage range, avoiding temperature measurement failure due to voltage breakdown.

[0037] In some embodiments, refer to Figure 7-8 The temperature sensing element 300 uses an NTC thermistor, and the insulating layer 400 is formed on the surface of the NTC thermistor through a potting process. The potting process ensures that the insulating layer 400 is tightly bonded to the surface of the NTC thermistor, forming a uniform protective layer. At the same time, the potting material can fill the tiny bumps and depressions on the surface of the NTC thermistor, improving the consistency and reliability of the overall structure.

[0038] In some embodiments, the heat conductor 500 covers at least a portion of the outer surface of the insulating layer 400, and the material of the heat conductor 500 is a metal or a thermally conductive composite material. When using a metal material, metals with excellent thermal conductivity, such as copper, aluminum, or silver, can be selected. These metal materials can quickly conduct heat, ensuring real-time temperature detection. When using a thermally conductive composite material, a polymer matrix material with added thermally conductive fillers such as graphite, boron nitride, or alumina can be selected. These materials have both good thermal conductivity and a certain degree of processing convenience. In practical applications, connectors may need to operate for extended periods in high-temperature outdoor environments. The selection of the material for the heat conductor 500 needs to consider its weather resistance and long-term stability. Although metal materials have excellent thermal conductivity, they require anti-corrosion treatment, while thermally conductive composite materials have better environmental adaptability.

[0039] In some embodiments, the insulating layer 400 is made of a thermally conductive insulating material, which is a polymer material with added thermally conductive fillers. Its thermal conductivity and volume resistivity need to meet specific technical requirements. The setting of the thermal conductivity needs to balance the requirements of thermal conductivity and insulation performance, ensuring sufficient thermal conductivity while maintaining good insulation characteristics. The volume resistivity requirement ensures insulation safety under high-voltage environments, preventing electrical faults caused by insufficient insulation performance.

[0040] In some embodiments, refer to Figure 1-6 The conductor 200 includes a connection end 210 and a conductive flexible terminal 220. The connection end 210 is disposed inside the housing 100. One end of the conductive flexible terminal 220 is electrically connected to the connection end 210, and the other end extends out of the housing 100 to form a conductive terminal pin 2232. The heat conductor 500 extends to a position adjacent to the conductive flexible terminal 220 to collect the heat from the conductive flexible terminal 220 and conduct it to the temperature sensing element 300. The conductive flexible terminal 220 is the main heat-generating component inside the connector. By extending the heat conductor 500 to the vicinity of the conductive flexible terminal 220, the heat generated by the heat source can be directly collected, improving the accuracy and response speed of temperature monitoring.

[0041] In some embodiments, refer to Figure 7 The heat conductor 500 covers the entire outer surface of the insulating layer 400, forming an integrated heat conduction structure. The bottom of the heat conductor 500 is thermally coupled to the conductive flexible terminal 220, and the top has a through hole for the pins of the temperature sensing element 300 to pass through and extend to the outside of the housing 100. By making the heat conductor 500 into an encapsulated structure, the contact area between the heat conductor 500 and the insulating layer 400 is maximized, improving heat conduction efficiency. The thermal coupling between the bottom and the conductive flexible terminal 220 ensures direct thermal contact between the heat source and the heat conductor 500, reducing thermal resistance during heat conduction. The through hole at the top is used for the electrical connection requirements of the pins of the temperature sensing element 300.

[0042] It should be noted that, referring to Figure 5 , 6 The thermal coupling between the bottom of the heat conductor 500 and the conductive flexible terminal 220 can be achieved through various specific connection methods: direct contact thermal coupling, which involves directly attaching the bottom of the heat conductor 500 to the surface of the conductive flexible terminal 220 to form a surface contact heat conduction path, enabling efficient heat transfer through large-area direct contact; mechanical compression thermal coupling, which uses mechanical structures such as springs, clips, or threaded fasteners to press the bottom of the heat conductor 500 against the surface of the conductive flexible terminal 220, forming a high-pressure thermal contact; and welding thermal coupling, which uses processes such as laser welding, ultrasonic welding, or diffusion welding to form a metallurgical bond between the bottom of the heat conductor 500 and the conductive flexible terminal 220, achieving the best heat conduction effect.

[0043] In some embodiments, the housing 100 includes a lower housing 120 and an upper housing 110 that cooperate with each other. One end of the lower housing 120 forms a receiving cavity 121, and the other end forms a fixing tube 122. A connecting end 210 is disposed in the fixing tube 122. The upper housing 110 closes the receiving cavity 121 and has a first channel 111 through which the conductive flexible terminal 220 passes and a second channel 112 through which the pin of the temperature sensing element 300 passes. The receiving cavity 121 of the lower housing 120 provides installation space for the conductive flexible terminal 220, the temperature sensing element 300, and their related structures. The fixing tube 122 is used to accommodate the connecting end 210 and realize mechanical connection with an external conductor. The cooperation between the upper housing 110 and the lower housing 120 needs to form an effective sealing structure to prevent the intrusion of moisture and dust. The first channel 111 and the second channel 112 realize the separation of the conductive function and the temperature monitoring function, avoiding mutual interference between the two functions.

[0044] It should be noted that, Figure 1 , Figure 2 , Figure 5 The structure of the first embodiment is shown. Figure 3 , Figure 4 , Figure 6 The structure of the second embodiment is shown. The two embodiments differ mainly in the structure of the fixing tube 122 and the connecting end 210. Different structural forms can be selected according to actual application requirements.

[0045] In some embodiments, refer to Figure 1-6 The lower housing 120 includes an annular flange 123 extending radially from its outer circumference, and an externally threaded section 124 located between the flange 123 and the fixing tube 122. A mounting nut 600 engages with the externally threaded section 124. By rotating the mounting nut 600, it forms an axial clamp with the flange 123, thus securing the photovoltaic connector. The threaded connection method has good applicability in photovoltaic module installation, adapting to mounting plates of different thicknesses. The different mounting thicknesses can be accommodated by adjusting the screw depth of the mounting nut 600. The annular flange 123 provides an axial positioning reference, ensuring a stable axial position for the connector after installation. In the installation of rooftop distributed photovoltaic systems, this adjustable fixing method can adapt to roofing panels of different thicknesses, improving installation flexibility and convenience.

[0046] In some embodiments, refer to Figure 5 , 6The inner wall of the first channel 111 is provided with a first snap-fit ​​portion 1111, and the corresponding position of the conductive flexible terminal 220 is provided with a second snap-fit ​​portion 2231 that cooperates with the first snap-fit ​​portion 1111. When the conductive flexible terminal 220 passes through the first channel 111, the first snap-fit ​​portion 1111 and the second snap-fit ​​portion 2231 engage with each other, realizing the axial positioning of the conductive flexible terminal 220. The snap-fit ​​positioning ensures the accurate positioning of the conductive flexible terminal 220 during the assembly process, preventing the reliability of the electrical connection from being affected by improper positioning. The snap-fit ​​structure needs to consider the balance between assembly convenience and connection firmness, ensuring both smooth insertion during assembly and a firm connection after assembly. In the manufacturing process of photovoltaic modules, this positioning mechanism can improve assembly efficiency and reduce quality problems caused by human error.

[0047] In some embodiments, continue to refer to Figure 5 , 6 The first channel 111 and the second channel 112 are located on opposite radial sides of the upper shell 110. The conductive flexible terminal 220 includes a connecting portion 221, a bending portion 222, and an extension portion 223 connected in sequence. The connecting portion 221 is electrically connected to the connecting end 210. The extension portion 223 extends through the first channel 111 to the outside of the shell 100. One end of the heat conductor 500 forms a thermal conductive contact with the extension portion 223. The pin of the temperature sensing element 300 extends through the second channel 112 to the outside of the shell 100. The radially opposite layout utilizes the internal space of the connector and avoids mutual interference between functional areas by placing the conductive function and the temperature monitoring function on opposite sides respectively.

[0048] The three-section structure of the conductive flexible terminal 220 takes into account both the reliability of electrical connection and the rationality of spatial layout. The connecting part 221 ensures a firm electrical connection with the connecting end 210, the bending part 222 realizes spatial transformation, and the elongated part 223 undertakes the function of external electrical connection.

[0049] The above is a detailed description of the preferred embodiments of the present utility model. However, the present utility model is not limited to the described embodiments. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present utility model. All such equivalent modifications or substitutions are included within the scope defined by the claims of this application.

Claims

1. A photovoltaic connector, comprising a housing and a conductor and a temperature sensing element disposed within the housing, characterized in that: An insulating layer is provided on the surface of the temperature sensing element, and a heat conductor is provided on the outer surface of the insulating layer. The heat conductor is used to conduct heat from inside the housing to the temperature sensing element.

2. The photovoltaic connector according to claim 1, characterized in that: The temperature sensing element is an NTC thermistor, and the insulating layer is formed on the surface of the NTC thermistor through a potting process.

3. The photovoltaic connector according to claim 2, characterized in that: The heat conductor covers at least a portion of the outer surface of the insulating layer, and the material of the heat conductor is a metal or a thermally conductive composite material.

4. The photovoltaic connector according to any one of claims 2-3, characterized in that: The insulating layer is made of a thermally conductive insulating material, which is a polymer material with added thermally conductive fillers.

5. The photovoltaic connector according to claim 1, characterized in that: The conductor includes a connection end and a conductive flexible terminal. The connection end is disposed inside the housing. One end of the conductive flexible terminal is electrically connected to the connection end, and the other end extends out of the housing to form a conductive terminal pin. The heat conductor extends to a position adjacent to the conductive flexible terminal, for collecting the heat from the conductive flexible terminal and conducting it to the temperature sensing element.

6. The photovoltaic connector according to claim 5, characterized in that: The heat conductor covers the entire outer surface of the insulating layer, forming an integrated heat conduction structure; The bottom of the heat conductor is thermally coupled to the conductive flexible terminal, and the top is provided with a through hole for the pins of the temperature sensing element to pass through and extend to the outside of the housing.

7. The photovoltaic connector according to claim 6, characterized in that: The housing includes a lower shell and an upper shell that fit together. One end of the lower shell forms a receiving cavity, and the other end forms a fixing tube, with the connecting end disposed inside the fixing tube; The upper shell encloses the receiving cavity and has a first channel through which the conductive soft terminal passes and a second channel through which the pin of the temperature sensing element passes.

8. The photovoltaic connector according to claim 7, characterized in that: The lower housing includes an annular flange extending radially from its outer peripheral surface, and an externally threaded section located between the flange and the fixed tube; The mounting nut engages with the external thread section, and by rotating the mounting nut, it forms an axial clamp with the flange, thereby achieving the fixed installation of the photovoltaic connector.

9. The photovoltaic connector according to claim 7, characterized in that: The inner wall of the first channel is provided with a first snap-fit ​​portion, and the corresponding position of the conductive flexible terminal is provided with a second snap-fit ​​portion that cooperates with the first snap-fit ​​portion; When the conductive flexible terminal passes through the first channel, the first locking part and the second locking part engage with each other to achieve axial positioning of the conductive flexible terminal.

10. The photovoltaic connector according to claim 7, characterized in that: The first channel and the second channel are located on opposite radial sides of the upper shell, respectively; The conductive flexible terminal includes a connecting part, a bending part and an extension part connected in sequence. The connecting part is electrically connected to the connecting end, and the extension part extends through the first channel to the outside of the housing. One end of the heat conductor forms a thermal conductive contact with the elongated portion, and the pin of the temperature sensing element extends through the second channel to the outside of the housing.

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