CN112994611A - Low-cost large-current split type photovoltaic module junction box - Google Patents
Low-cost large-current split type photovoltaic module junction box Download PDFInfo
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- CN112994611A CN112994611A CN202110264633.3A CN202110264633A CN112994611A CN 112994611 A CN112994611 A CN 112994611A CN 202110264633 A CN202110264633 A CN 202110264633A CN 112994611 A CN112994611 A CN 112994611A
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- 238000003466 welding Methods 0.000 claims abstract description 23
- 238000003825 pressing Methods 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 abstract description 14
- 230000017525 heat dissipation Effects 0.000 abstract description 5
- 238000000034 method Methods 0.000 description 7
- 230000000694 effects Effects 0.000 description 5
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 3
- 238000010248 power generation Methods 0.000 description 2
- 239000000779 smoke Substances 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000005538 encapsulation Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
- H02S40/30—Electrical components
- H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
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Abstract
The invention provides a low-cost large-current split type photovoltaic assembly junction box which comprises a left junction box, a middle junction box and a right junction box, wherein each junction box comprises a box cover, a box body and a conductive terminal module arranged in the box body; the conductive terminal module comprises a first conductive terminal, a second conductive terminal and an axial diode arranged between the first conductive terminal and the second conductive terminal; the first conductive terminal and the second conductive terminal are approximately in an L-shaped structure and are arranged in the junction box body in a staggered mode, and the positive pole bus bar and the negative pole bus bar of the photovoltaic module respectively penetrate through two side edges of the axial diode and then are welded and fixed with the bus bar welding areas on the first conductive terminal and the second conductive terminal respectively. The invention adopts the standardized axial diode as a bypass protection element, and forms a bypass protection conductive terminal module with the conductive terminal, the over-current capability is excellent, the production cost can be greatly reduced, the volume of the junction box is reduced, the heat dissipation performance is excellent, the automatic operation can be adopted, and the production efficiency is improved.
Description
Technical Field
The invention relates to the technical field of solar photovoltaic power generation, in particular to a low-cost large-current split type photovoltaic module junction box suitable for high-power photovoltaic modules.
Background
The solar photovoltaic module is a device for converting solar energy into electric energy, and in the production process of the photovoltaic module, the junction box plays an important role in effectively outputting the photovoltaic electric energy and mainly plays a role in outputting current generated by the photovoltaic module and protecting the solar photovoltaic module. The current generated by each solar panel is relatively small, and a photovoltaic junction box is needed to electrically connect a plurality of solar panels together, so that the currents generated by the plurality of solar panels are converged together and output to form a photovoltaic system reaching a certain power generation capacity.
In practical use, the photovoltaic junction box is generally directly mounted on a corresponding solar panel (also called a photovoltaic module) and electrically connected with a bus bar of the solar panel, and a bypass protection device is arranged in the junction box to avoid hot spot effect caused by damage or local shielding of battery pieces of a photovoltaic module battery string. The photovoltaic module junction box is generally provided with a positive conductive terminal and a negative conductive terminal in a box body, and a bypass protection device is connected between the positive conductive terminal and the negative conductive terminal and is connected in series in a battery string of the module. The existing photovoltaic module is developed towards a high-efficiency high-power module, such as a laminated tile module, a double-glass module, a double-sided module and the like, so that new requirements are brought to a junction box, for example, the overcurrent capacity of the junction box is stronger, and the photovoltaic module is suitable for large-current output; it is desirable to minimize the volume of the assembly, reduce the shading effect on the surface of the assembly, etc.
In view of design standardization and convenience of part management in production, a modularized photovoltaic module bypass element for a junction box is developed, as shown in fig. 1, the modularized photovoltaic module bypass element generally comprises a first conductive terminal 1 and a second conductive terminal 2, a bypass diode is fixed on the first conductive terminal 1 or the second conductive terminal 2 and is electrically connected with the other conductive terminal, then the bypass diode, the first conductive terminal and the second conductive terminal form an integrated module structure through an insulating plastic package block 3, assembly confluence strap through holes 13 are formed in two sides of the insulating plastic package block 3, the confluence straps are respectively welded with a first welding area 12 and a second welding area 22 for a certain depth after penetrating through the through holes 13, soldering tin is pre-filled in the confluence strap through holes, and therefore welding fixation can be conveniently performed during the welding of the confluence straps.
However, when the novel bypass element module is applied, some problems still exist, for example, the bypass element of the photovoltaic module with the modular design is to encapsulate a bypass protection device in an insulating plastic encapsulation block, so that generally only a surface mount type diode can be adopted, and the diode has an obvious disadvantage that the capability of overlarge current is not strong, if the bypass element is applied to a high-power photovoltaic module, a plurality of diode chips are required to be arranged, the requirement of the process is higher, and the size of the module is increased; or a large-sized diode chip is needed, so that the size of the module is different for different application scenarios, and accordingly, the size of the junction box is changed. Like this, to different photovoltaic module, need the terminal box of different models, during production, need prepare many sets of forming die, be unfavorable for reduction in production cost.
Disclosure of Invention
The invention aims to solve the defects in the prior art, and provides the low-cost large-current split type photovoltaic module junction box which is strong in overlarge current capacity; but also can obviously reduce the production cost.
In order to achieve the purpose, the invention adopts the following technical scheme:
a low-cost large-current split type photovoltaic assembly junction box comprises a left junction box, a middle junction box and a right junction box, wherein the left junction box, the middle junction box and the right junction box respectively comprise a box cover, a box body and a conductive terminal module arranged in the box body;
the conductive terminal module comprises a first conductive terminal, a second conductive terminal and an axial diode which is arranged between the first conductive terminal and the second conductive terminal and is fixedly connected with the two conductive terminals; the first conductive terminal and the second conductive terminal are approximately in an L-shaped structure and are arranged in the junction box body in a staggered mode, and the positive pole bus bar and the negative pole bus bar of the photovoltaic module respectively penetrate through two side edges of the axial diode and then are welded and fixed with the bus bar welding areas on the first conductive terminal and the second conductive terminal respectively;
the left part of the left junction box body and the right part of the right junction box body are respectively provided with a cable connecting part which is matched with a cable pressing block to fix a cable and the box body.
Preferably, the box body is internally provided with a rib plate which is arranged between the gaps between the first conductive terminal and the second conductive terminal.
Preferably, the photovoltaic module bus bar penetrates through a gap between the axial diode and the first conductive terminal and the second conductive terminal and then is welded and fixed with the conductive terminals.
Preferably, the bus bars pass through the slots on the first conductive terminal and the second conductive terminal at the positions on two sides of the axial diode, and the photovoltaic module bus bars pass through the slots and then are welded and fixed with the conductive terminals.
Preferably, both sides and/or end parts of the first conductive terminal and the second conductive terminal are provided with flanging structures.
Preferably, the pin of the axial diode is connected with the first conductive terminal and the second conductive terminal by resistance welding, and a convex rib is arranged at the position, welded with the pin of the axial diode, of the first conductive terminal and the second conductive terminal.
Preferably, the conductive terminal and the cable are fixedly connected by resistance welding, and a convex edge is arranged at the position, welded with the cable, of the conductive terminal.
Preferably, the first conductive terminal and the second conductive terminal are provided with folded edges with notch structures adjacent to the fixing positions of the axial diodes, and the two pins of the axial diodes are arranged in the notch structures.
Preferably, the first conductive terminal and the second conductive terminal have the same structure and size.
Preferably, when the conductive terminal module is installed in the box body, the axial direction of the axial diode is perpendicular to the length direction of the box body.
The axial diode standardized in the electronic industry is used as a bypass protection element, and the bypass protection conductive terminal module is formed by the axial diode and a specially designed conductive terminal, so that the excessive current capacity of the axial diode is much better than that of a patch type diode, the axial diode is a standard component, the junction box is favorably made into a product with uniform specification, the junction box is suitable for the use requirements of various application environments, the junction boxes with different specifications are not required to be designed and produced according to different use requirements, the production cost is greatly reduced, and the volume of the junction box is reduced; the flanging structure is designed on the conductive terminal, so that the heat dissipation effect under a heavy-current use scene is facilitated; the axial diode, the bus bar, the cable and the conductive terminal can all adopt a resistance welding process, adopt automatic operation, improve welding efficiency and have no tin smoke pollution.
Drawings
Fig. 1 is a schematic perspective view of a photovoltaic module bypass element module according to the prior art;
fig. 2 is a schematic perspective exploded view of a low-cost high-current split-type photovoltaic module junction box according to an embodiment of the invention;
fig. 3 is an exploded view of the left junction box of the split photovoltaic module junction box of fig. 2;
FIG. 4 is a schematic plan view (with the top cover removed) of the left junction box of FIG. 3;
FIG. 5 is a schematic view (front view) of an assembly structure of the conductive terminals and the axial diode in the junction box of FIG. 3;
FIG. 6 is a schematic view (reverse side) of an assembly structure of the conductive terminals and the axial diode in the junction box of FIG. 3;
FIG. 7 is a plan view of the front view structure of FIG. 6;
FIG. 8 is a schematic plan view (with the top cover removed) of a left junction box according to another embodiment;
fig. 9 is an exploded view of the junction box of the split pv module junction box of fig. 2;
fig. 10 is an exploded view of the right junction box of the split photovoltaic module junction box of fig. 2.
Detailed Description
In order to further understand the objects, structures, features and functions of the present invention, the following embodiments are described in detail.
Referring to fig. 2, the structure of the low-cost high-current split-type photovoltaic module junction box of the invention is schematically shown, and the split-type photovoltaic module junction box comprises a left junction box 10, a middle junction box 20 and a right junction box 30, which respectively comprise a box cover, a box body and a conductive terminal module arranged in the box body.
Referring to fig. 3 to 5, taking the left junction box 10 as an example, it includes a box cover 101, a box body 103, and a conductive terminal module 102 disposed in the box body 103; the conductive terminal module 102 includes a first conductive terminal 1021, a second conductive terminal 1022, and an axial diode 1023 disposed between the first conductive terminal 1021 and the second conductive terminal 1022 and connected and fixed with the two conductive terminals; the first conductive terminal 1021 and the second conductive terminal 1022 are approximately in an L-shaped structure and are arranged in the junction box body in a staggered mode, and positive and negative bus bars of the photovoltaic module respectively penetrate through two side edges of the axial diode 1023 and then are welded and fixed with the bus bar welding areas 1025 on the first conductive terminal 1021 and the second conductive terminal 1022; referring to fig. 4, in a preferred embodiment, the box body 103 is provided with a rib 1033 disposed between the gap between the first conductive terminal 1021 and the second conductive terminal 1022, so as to prevent an arc phenomenon from occurring between the two conductive terminals, and improve the electrical performance of the junction box. In a more preferred embodiment, the top of the rib 1033 abuts the lid.
Referring to fig. 4 and 5, in one embodiment, the photovoltaic module bus bar may be welded and fixed to the conductive terminals after passing through a gap 1024 between the axial diode 1023 and the first conductive terminal 1021 and the second conductive terminal 1022, respectively; alternatively, as shown in fig. 6, in another embodiment, bus bars may be disposed on the first conductive terminal 1021 and the second conductive terminal 1022 at positions on both sides of the axial diode 103 and pass through the slots 1024 ', and the photovoltaic module bus bar may pass through the slots 1024' and then be welded and fixed to the conductive terminals.
With continued reference to fig. 5, the pins of the axial diode and the first and second conductive terminals 1021, 1022 may be connected and fixed by a conventional soldering process, in a preferred embodiment, the pins of the axial diode and the first and second conductive terminals 1021, 1022 are connected by resistance welding, in order to improve the efficiency of resistance welding, a protruding rib 1028 is provided at the position on the first and second conductive terminals 1021, 1022 where the pin of the axial diode is welded, and the protruding direction of the protruding rib 1028 faces the welding surface, for example, as shown in fig. 5, the axial diode 1023 is welded and fixed with the first and second conductive terminals 1021, 1022 from the reverse direction (lower direction, as shown in fig. 6), so that the protruding rib 1028 is protruding downward.
Referring to fig. 6 and 7, the first conductive terminal 1021 and the second conductive terminal 1022 are provided with a folded edge 1031 having a notch structure adjacent to the fixing position of the axial diode 1023, and when the diode is produced, two pins of the axial diode 1023 are placed in the notch structure, so that convenience of assembling the diode can be ensured, positioning of the pins during welding with the conductive terminals can be facilitated, and pin displacement can be avoided.
Similarly, the first conductive terminal of the left terminal box and the second conductive terminal of the right terminal box can be directly and fixedly connected with the cable 40 by a conventional riveting method, and optionally, in order to improve the processing efficiency, the conductive terminal and the cable 40 can also be fixedly connected by resistance welding, in order to improve the efficiency of resistance welding, a convex rib 1027 is arranged at the position on the conductive terminal, which is welded with the cable, and the convex direction of the convex rib 1027 faces to the welding surface, for example, as shown in fig. 4 and 5, the cable is fixedly welded with the first conductive terminal 1021 from the reverse direction (lower direction) of the figure, so that the convex rib 1027 is convex downwards. The ribs 1028 and 1027 may be raised structures with a certain height formed by directly stamping a material with a certain width and length on the conductive terminal by a stamping process. In practical application, for a split junction box, it is not actually necessary to connect cables to two conductive terminals of each junction box, as shown in fig. 2, only the first conductive terminal of the left junction box needs to be connected and fixed to the cable on the left side, and the second conductive terminal of the right junction box needs to be connected and fixed to the cable on the right side, so for the rib 1027, it is only necessary to set the first conductive terminal of the left junction box and the second conductive terminal of the right junction box to meet the use requirement, but from the perspective of standardization of part production, it is an optimal technical solution to set the ribs connected and fixed to the cables on both terminals.
In another preferred embodiment, as shown in fig. 5, since the current passing through the axial diode is relatively large, in order to improve the heat dissipation effect of the junction box, the two sides and/or the ends of the first conductive terminal 1021 and the second conductive terminal 1022 are provided with the flanged structures 1026, which can effectively increase the heat dissipation area of the conductive terminals. The direction of the flange structure 1026 can be vertically upward or vertically downward, and the design can be flexible according to the size and the structure of the box body.
In another preferred embodiment, in order to simplify the production process and reduce the investment of production equipment, the first conductive terminal 1021 and the second conductive terminal 1022 have the same structure, so the conductive terminals in the box bodies of the left, middle and right junction boxes in the split junction box and the conductive terminal modules formed by the axial diodes can be unified structural modules; correspondingly, the main structures of the box bodies 103, 203 and 303 of the left, middle and right junction boxes are also the same (referring to fig. 3, 7 and 8, except that the cable connecting parts 1031 and 3031 are added for the left and right junction boxes to be connected with cables, and the grip part 2031 is added for the middle junction box to be conveniently taken during processing, the shape, the internal structure and the size of the main body part of the box body are the same), so that the processing and manufacturing cost of a forming die can be saved.
In another preferred embodiment, when the conductive terminal module is installed in the box body, the axial direction of the axial diode is perpendicular to the length direction of the box body.
As the left and right junction boxes need to be connected with cables, referring to fig. 2 and 8, the left part of the left junction box body and the right part of the right junction box body are respectively provided with cable connecting parts 1031 and 3031, which are matched with cable pressing blocks 1032 and 2032 to fix the cables and the box body.
It should be understood that, in the present invention, the conductive terminal on the left side in the terminal box in the drawings is referred to as a first conductive terminal, and the conductive terminal on the right side is referred to as a second conductive terminal, which is only for the purpose of clearly describing the embodiments of the present invention, and does not limit the arrangement position of the conductive terminals; in a specific implementation, a user may also set the right conductive terminal as the first conductive terminal and the left conductive terminal as the second conductive terminal in the above embodiment, which should be regarded as an equivalent implementation of the above embodiment.
The axial diode standardized in the electronic industry is used as a bypass protection element, and the bypass protection conductive terminal module is formed by the axial diode and a specially designed conductive terminal, so that the excessive current capacity of the axial diode is much better than that of a patch type diode and is a standard part, the junction box is favorably made into a product with uniform specification, the use requirements of various application environments are met, the junction boxes with different specifications are not required to be designed and produced according to different use requirements, the cost of production equipment (mainly a punch forming die and a plastic forming die) is greatly reduced, the management of parts in the production process is facilitated, the process is simplified, and the volume of the junction box is reduced; the flanging structure is designed on the conductive terminal, so that the heat dissipation effect under a heavy-current use scene is facilitated; the axial diode, the bus bar, the cable and the conductive terminal can all adopt a resistance welding process, adopt automatic operation, improve welding efficiency and have no tin smoke pollution.
The present invention has been described in relation to the above embodiments, which are only exemplary of the implementation of the present invention. It should be noted that the disclosed embodiments do not limit the scope of the invention. Rather, it is intended that all such modifications and variations be included within the spirit and scope of this invention.
Claims (10)
1. A low-cost large-current split type photovoltaic assembly junction box is characterized in that the split type junction box comprises a left junction box, a middle junction box and a right junction box, wherein the left junction box, the middle junction box and the right junction box respectively comprise a box cover, a box body and a conductive terminal module arranged in the box body;
the conductive terminal module comprises a first conductive terminal, a second conductive terminal and an axial diode which is arranged between the first conductive terminal and the second conductive terminal and is fixedly connected with the two conductive terminals; the first conductive terminal and the second conductive terminal are approximately in an L-shaped structure and are arranged in the junction box body in a staggered mode, and the positive pole bus bar and the negative pole bus bar of the photovoltaic module respectively penetrate through two side edges of the axial diode and then are welded and fixed with the bus bar welding areas on the first conductive terminal and the second conductive terminal respectively;
the left part of the left junction box body and the right part of the right junction box body are respectively provided with a cable connecting part which is matched with a cable pressing block to fix a cable and the box body.
2. The low-cost high-current split-type photovoltaic module junction box according to claim 1, wherein the photovoltaic module bus bars respectively penetrate through gaps between the axial diode and the first conductive terminal and the second conductive terminal and then are welded and fixed with the conductive terminals.
3. The low-cost high-current split photovoltaic module junction box as claimed in claim 1, wherein bus bars are arranged on the first conductive terminal and the second conductive terminal at positions on two sides of the axial diode and penetrate through the slots, and the photovoltaic module bus bars penetrate through the slots and are welded and fixed with the conductive terminals.
4. The low-cost high-current split type photovoltaic module junction box according to claim 1, wherein the box body is provided with rib plates arranged between the gaps between the first conductive terminals and the second conductive terminals.
5. The low-cost high-current split-type photovoltaic module junction box according to claim 1, wherein the first conductive terminal and the second conductive terminal are provided with flanging structures at two sides and/or ends.
6. The low-cost high-current split-type photovoltaic module junction box according to claim 1, wherein the pins of the axial diode are connected with the first conductive terminal and the second conductive terminal by resistance welding, and ribs are arranged on the first conductive terminal and the second conductive terminal at positions where the pins of the axial diode are welded.
7. The low-cost high-current split-type photovoltaic module junction box according to claim 1, wherein the conductive terminals and the cables are fixedly connected by resistance welding, and the positions, welded with the cables, of the conductive terminals are provided with ribs.
8. The low-cost high-current split photovoltaic module junction box according to claim 1, wherein when the conductive terminal module is mounted in the box body, the axial direction of the axial diode is perpendicular to the length direction of the box body.
9. The low-cost high-current split photovoltaic module junction box according to claim 1, wherein the first conductive terminal and the second conductive terminal are provided with folded edges having a notch structure adjacent to the fixing position of the axial diode, and two pins of the axial diode are arranged in the notch structure.
10. The low-cost high-current split photovoltaic module junction box according to any one of claims 1 to 9, wherein the first conductive terminal and the second conductive terminal have the same structure and size.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202110179078 | 2021-02-09 | ||
| CN2021101790784 | 2021-02-09 |
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| CN112994611A true CN112994611A (en) | 2021-06-18 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202110264633.3A Pending CN112994611A (en) | 2021-02-09 | 2021-03-11 | Low-cost large-current split type photovoltaic module junction box |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116260388A (en) * | 2023-05-12 | 2023-06-13 | 苏州同泰新能源科技股份有限公司 | Photovoltaic junction box and power management module |
| CN117772895A (en) * | 2024-02-28 | 2024-03-29 | 山西中科安瑞能源科技有限公司 | Assembling equipment for automatic production line of junction box |
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| CN207200665U (en) * | 2017-09-22 | 2018-04-06 | 常熟市冠日新材料有限公司 | A kind of improved high-efficiency photovoltaic terminal box of structure |
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| CN116260388A (en) * | 2023-05-12 | 2023-06-13 | 苏州同泰新能源科技股份有限公司 | Photovoltaic junction box and power management module |
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| CN117772895B (en) * | 2024-02-28 | 2024-05-07 | 山西中科安瑞能源科技有限公司 | Assembling equipment for automatic production line of junction box |
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