CN104158483A - 电隔离的散热接线盒 - Google Patents
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Abstract
本发明涉及电隔离的散热接线盒。一种用于实现电连接到光伏面板的接线盒。接线盒具有两个室,包括第一室和第二室以及两个室共有将两个室隔离的壁。壁可以适于具有穿过其的电连接。两个盖子适于分别密封两个室。两个盖子位于相对于光伏面板的接线盒的相对侧。使用不同水平的密封性的不同密封工艺,两个盖子可以是可连接的。第一室可以适于接收电路板。接线盒可以包括用于在第一室中安装印刷电路板的支撑物。第二室被配置为用于到光伏面板的电连接。金属散热装置可以被结合在第一室内部。第一室适于接收用于电功率转换的电路板,以及金属散热装置适于耗散电路板生成的热。
Description
本申请是申请日为2010年5月24日,申请号为201080021018.X,发明名称为“电隔离的散热接线盒”的申请的分案申请。
背景
1.技术领域
本发明涉及一种电源的接线盒,以及特别地,涉及一种用于电连接到光伏面板的接线盒。
2.相关技术的描述
光伏模块或光伏面板是光伏电池的成套互连组件,光伏电池也被称为太阳能电池。由于单个光伏模块只能产生有限量的功率,因此商业装置包括多个模块或面板,它们串联和并联互连为光伏阵列。串联设置电连接以达到期望的输出电压和/或并联设置电连接以提供期望量的电流源能力。光伏装置通常包括光伏模块阵列、逆变器、电池和互连线路。
当部分光伏模块被遮挡时,有遮挡的电池不产生与无被遮挡的电池同样多的电流。由于光伏电池被串联连接,则等量的电流必然流过每个串联连接的电池。无遮挡的电池使有遮挡的电池通过更多的电流。有遮挡的电池能够在高电流下工作的唯一途径是在负电压的区域工作,这将导致系统的净电压损耗。电流乘以该负电压得出有遮挡的电池产生的负功率。有遮挡的电池将功率耗散为热并且导致“热斑”。因此,将旁路二极管与光伏模块集成以避免在光伏模块的部分遮挡情况下的电池的过热。
可以将阻塞二极管与电池或模块串联以阻塞反向通过模块的反向漏电流,从而在夜间阻塞电池的电流反向流过模块或者在白天阻塞并联模块的电流反向流向损坏的模块。
可以将执行例如直流(DC)到直流转换的电转换、例如微逆变器的电逆变或者诸如性能监视和/或防窃的其他功能的电子模块与光伏模块集成。
US7291036公开了一种包括具有安装二极管的表面的连接盒的光伏连接系统,二极管安装在连接盒内的印刷电路板上。连接盒可选地包括安装在连接盒的盖子内部的金属平板,作为用于从二极管散热的散热装置。
本文中使用的术语“电缆压盖”指的是用于供电力电缆或电线进入电力装置的设备,用于牢固地固定进入一件电力装置的电力电缆。
本发明的内容中的术语“原位”指的是在零件的制造过程期间例如注塑成型期间的结合或连接,而不是在该零件的制造之后的连接。
发明内容
根据本发明,提供有一种用于实现到光伏面板的电连接的接线盒。接线盒具有两个室,包括第一室和第二室以及两个室共有将两个室隔离的壁。壁可以适于具有穿过其的电连接。两个盖子适于分别密封两个室。两个盖子被配置在相对于光伏面板的接线盒的相对侧。使用不同的密封工艺,两个盖子可以是可连接的。盖子中的一个可以适于密封第一室,以及另一盖子可以以与第一室的密封性水平不同的密封性密封第二室。第一室可以适于接收用于光伏面板的功率输出的电功率转换的电路板。接线盒可以包括用于在第一室中安装印刷电路板的支撑物。第二室被配置为用于到光伏面板的电连接。第二室可以可选地被配置为包括诸如旁路和/或阻塞二极管的二极管。接线盒可以具有安装在第二室内部的电连接端子,用于将电路连接到光伏面板。金属散热装置可以被结合在第一室内部。第一室适于接收用于电功率转换的电路板,以及金属散热装置适于耗散电路板生成的热。在接线盒的制造过程中,散热装置位于注塑模具的内部。散热装置在接线盒的制造的注塑成型工艺过程中被原位铸造。接线盒还可以包括适于在电路板与金属散热装置之间提供热传导和电绝缘的衬垫。金属散热装置可以包括适于防止金属散热装置与接线盒的相互隔离的燕尾榫结构。燕尾榫结构可以是中空的。
根据本发明,提供有一种用于实现到光伏面板的电连接的接线盒。接线盒具有原位结合在第一室内部的金属散热装置。第一室适于接收用于电功率转换的电路板,以及金属散热装置适于耗散电路板生成的热。可选地,接线盒可以具有两个室,包括第一室和第二室,两个室共有将两个室隔离的壁。两个盖子,所述两个盖子适于分别密封所述两个室。金属散热装置可以包括适于防止金属散热装置与接线盒的相互隔离的燕尾榫结构。壁可以具有穿过其的电连接。
附图说明
参考附图,只通过实例的方式在本文中描述了本发明,其中:
图1A和1B示出了根据本发明的实施方式的接线盒的等距图。
图2A示出了图1A中的虚线XX表示的接线盒的截面的细节。
图2B示出了图1A中的虚线表示的接线盒的截面YY的细节。
图3A和3B示出了根据本发明的另一实施方式的散热装置的等距图。
当结合附图考虑时,根据以下详细的描述,以上和/或其他方面将变得明显。
具体实施方式
现在将详细地参考本发明的实施例,附图中示出了本发明的实例,其中整个图示中相同的参考标号指的是相同的元件。以下通过参考图示描述实施例以解释本发明。
通过前言,连接到光伏模块的接线盒内的二极管和/或电子模块耗散热。当使用绝缘接线盒时,热必定主要通过接线盒内部的空气耗散。当使用金属接线盒时,则热可以直接通过接线盒耗散。然而,由于按规定,易碰到的金属表面需要接地并且需要额外布线,因此使用金属接线盒是不方便的。
在详细解释本发明的实施例之前,要理解的是本发明不限于其在以下描述中所述或图示中所示出的部件的设计和配置的细节的应用。本发明能够适于其他实施方式或能够以各种方式实现或执行。并且,要理解的是本文中采用的词语和术语是用于说明目的并且不应被视为限制性的。
现在参照图示,根据本发明的实施方式,图1A示出了接线盒12的等距图10A。示出了接线盒12安装在光伏面板16的背面(或非光伏侧)4。接线盒12具有允许有接线盒12的内部的电缆的端接的电缆压盖130。接线盒12具有外罩壳102和使用盖子106进入接线盒12的入口。
图1B示出了从光伏面板16分离的接线盒12的底面的等距图。该等距图示出了接线盒12的压盖130和两部分A和B。室A由维度Z x X界定且室A被盖子108覆盖。盖子108给出了进入接线盒12的室A的入口。室B是一个用X x Y维度界定的开放部分,以及示出了端子104。旁路二极管110被连接在端子104之间。根据本发明的特征,被移开以进入室B的盖子106和用于进入室A的盖子108位于接线盒12的相对侧。
图2A示出了图1A中的虚线表示的接线盒12的截面XX的细节,示出了本发明的特征。截面XX示出了用卡子216安装在光伏面板16的非光伏侧4上的接线盒12的室部分A和B。接线盒12和光伏面板16之间的、使用卡子216的机械连接使得接线盒12在光伏面板16上是平的并且垫片可以用于密封室B的开口端。
室A包括电路板260、热传导衬垫262、散热装置264、外罩壳102和盖子108。优选地,电路板260被安装在适于接收电路板260的支撑物上。热衬垫262在散热装置264与电路板260之间提供电隔离和热传导。优选地,电路板260的组件侧与热衬垫262接触,使得电路板260的组件产生的热经由热衬垫262被散热装置264耗散。通过使盖子108的一侧涂敷导电屏蔽层108a降低由于电路板260的操作导致的接线盒12的射频干扰(RFI)辐射。屏蔽层108a电连接到散热装置264以形成阻止接线盒12的RFI辐射的法拉第笼。
优选地,通过注塑成型工艺制造根据本发明的一个方面的盖子108。在盖子108的注塑成型工艺的过程中,可以将屏蔽层108a置于原位并且在注塑成型工艺的过程中结合到盖子108。从而,当盖子108被连接到盒室A时,接线盒12被散热装置264和屏蔽层108a电隔离。此外,外罩壳102和盖子108在面板16的背面与接线盒12的外面之间提供散热装置264和屏蔽层108a的非导电隔离。可选地,盖子108被永久性地和/或密封地密封到室A。
室B包括端子104、支撑物214、旁路二极管110、盖子106、汇流条212和壁202。壁202在室部分A和B之间提供了物理隔离。室A中的电路板260与室B中的电连接器104之间的电连接是经由汇流条212。汇流条212被密封在壁202中,采用这样的方式以保护室A的期望的密封性避免例如水或湿气渗入。电连接器104和汇流条212两者都用支撑物214机械地支撑。支撑物214还可以在连接到汇流条212的连接器104的一端与连接到光伏面板16提供的连接点的连接器104的另一端之间提供密封性的密封和/或电隔离。连接到连接器104的旁路二极管110可以位于支撑物214或面板16的背面4之间或者位于支撑物214与盖子106之间。盖子106给出了室B的入口,同时接线盒12被物理连接到光伏面板16而与面板16电隔离。将盖子106连接到接线盒12的优选的机构是使用橡胶垫片配置,以使室B被密封地密封避免例如水/湿气通过盖子106到室B的渗入。
根据本发明的另一实施方式,接线盒12构造有双壁202,以使室A和室B彼此能够隔离且可重新连接。类似的,汇流条212在室A和室B之间可重新连接。在本实施方式中,可以通过用新的电路板260替换室A来修复电路板260的电子器件内的故障,而无需将室B从光伏面板16断开。类似地,电子器件的升级可轻松实现。
优选地,包含罩壳102、盖子108/106、散热装置264和热衬垫262的接线盒12适于符合IEC61215(Ed.2)的温度和绝缘标准或者光伏面板的连接所用的其他可用工业标准。可以通过丙烯腈二乙烯丁二烯(ABS)热塑性塑料、聚对苯二甲酸丁二醇酯(PBT)、聚(苯氧化物)(PPO)或诸如环氧树脂的热固树脂的注塑成型制造接线盒12和盖子108/106。
图2B示出了根据本发明的实施例的图1A中的虚线表示的接线盒12的截面YY的细节。截面YY是安装在光伏面板16的背面4上的室A的截面。截面YY示出了外罩壳102、具有燕尾榫结构264的散热装置264、热传导衬垫262、电路板260和具有电屏蔽层108a的盖子108。
在本发明的一个优选的实施例中,利用注塑成型工艺制造接线盒12的盒室部分A和B。在注塑成型工艺过程中,具有或没有燕尾榫264a的散热装置264位于盒室A的内部,并且由于注塑成型工艺导致其被原位结合到盒室A。
燕尾榫结构264a可以提供散热装置264与盒室A之间的结合的增加强度,燕尾榫结构264a可以作为散热装置264的构成部分。燕尾榫264a的进一步的作用是,当例如接线盒12经受由于室A内部工作的电子部件产生的热应力、接线盒12连接到光伏面板时的高温环境的热量和阳光时,保证散热装置264与室A之间的结合保持完好。在例如螺丝钉的紧固件用于将室A固定到散热装置202的情况下,通常增加燕尾榫结构264a的侧面尺寸以适应紧固件的尺寸。燕尾榫264a的进一步的特征是在燕尾榫264a内的中空结构,其允许燕尾榫264a的变形。燕尾榫264a的变形允许在室A的散热装置264和外壳102之间结合的固化/冷却过程中外壳102和散热装置264/燕尾榫264a的不同的热膨胀率。
现参照图3A和3B,图3A和3B示出了根据本发明的另一实施方式的散热装置264的等距图。散热装置264具有四个孔302。孔302被用来使用螺丝钉将散热装置264连接到接线盒12的室A内。散热装置与室A的连接可以作为接线盒12的注塑成型之后的额外的步骤,或者作为没有被注塑成型的接线盒12之后的额外的步骤。另外的热衬垫可以被置于散热装置264与外壳102之间,以保证在散热装置264被连接到外壳102之后散热装置264与外壳102之间很好的接触。热衬垫的变形特性用于适应由于散热装置264/外壳102的制造偏差导致的散热装置264和外壳102的表面的非均匀性。可选地,热传导粘胶剂或灌封材料可以被置于散热装置264和外壳102之间。
本文中使用的冠词“一个”意思是“一个或多个”,例如“一个散热装置”、“一个电路板”具有“一个或多个”即“一个或多个散热装置”、“一个或多个电路板”的意思。
虽然已经示出并描述了本发明的所选的实施方式,然而要理解的是本发明不限于所述的实施方式。相反地,要理解的是在不脱离本发明的原理和精神下可以对这些实施方式进行修改,本发明的范围由权利要求及其等同物来界定。
Claims (15)
1.一种用于实现电连接到光伏面板的接线盒,所述接线盒包括:
两个室,所述两个室包括第一室和第二室;以及
双壁,所述双壁使得所述第一室和所述第二室是彼此可隔离的且可重新连接的。
2.根据权利要求1所述的接线盒,其中所述接线盒适于连接到所述光伏面板,并且其中所述双壁适于允许所述第一室的彼此隔离和重新连接而无需所述第二室从所述光伏面板断开。
3.根据权利要求1所述的接线盒,其中所述第一室适于安装电路板并且所述第二室适于向所述光伏面板提供电连接器。
4.根据权利要求3所述的接线盒,其中所述双壁包括汇流条且所述第一室中的所述电路板和所述第二室内的所述连接器之间的电连接是经由所述汇流条。
5.根据权利要求4所述的接线盒,其中所述汇流条在所述第一室和所述第二室之间是可重新连接的。
6.根据权利要求4所述的接线盒,其中所述汇流条被密封在所述双壁中,采用这样的方式以保护所述第一室的期望的密封性。
7.根据权利要求4所述的接线盒,其中所述第二室包括支撑物,所述支撑物适于在连接到所述汇流条的所述连接器的一端与连接到由所述光伏面板提供的连接点的所述连接器的另一端之间提供密封性的密封。
8.根据权利要求1所述的接线盒,还包括适于分别密封所述第一室和所述第二室的第一盖子和第二盖子。
9.根据权利要求8所述的接线盒,其中所述第一盖子和所述第二盖子被配置为相对于彼此在所述接线盒的相对侧上。
10.根据权利要求8所述的接线盒,其中所述第一盖子和所述第二盖子通过使用不同密封工艺是可连接的。
11.根据权利要求8所述的接线盒,其中所述第一盖子和所述第二盖子适于以不同水平的密封性分别密封所述第一室和所述第二室。
12.根据权利要求3所述的接线盒,还包括所述电路板,其中所述电路板适于转换来自所述光伏面板的电功率输出。
13.根据权利要求3所述的接线盒,其中所述第二室被配置为包括二极管。
14.一种使用根据权利要求4所述的接线盒的方法,所述方法包括:
将所述接线盒连接到太阳能面板;
将所述第一室内的所述电路板经由所述汇流条电连接到所述连接器,其中所述电路板适于转换来自所述光伏面板的电功率输出;以及
将所述连接器电连接到所述太阳能面板。
15.根据权利要求14所述的方法,还包括:
使用新的第一室替换所述第一室而不将所述第二室从所述光伏面板断开。
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US10686402B2 (en) | 2020-06-16 |
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