CN214203671U - Photovoltaic module bypass element module and split type photovoltaic module junction box with same - Google Patents

Abstract

The utility model provides a photovoltaic module bypass element module, which comprises a first conductive terminal, a second conductive terminal and an insulating plastic package block; the bypass protection device, the first conductive terminal and the second conductive terminal are packaged into a whole by the insulating plastic package block; the first conductive terminal and the second conductive terminal are both provided with a bus bar through hole and a flanging structure through a stamping process, and the side surface of the flanging structure is a welding area welded with the bus bar of the assembly; the assembly bus bar penetrates through the bus bar through hole and then is connected with the bus bar welding area in a resistance welding mode. The utility model discloses still put forward the split type photovoltaic module terminal box of using bypass component module. The utility model discloses a photovoltaic module bypass component module forms the subassembly simultaneously through a stamping process and converges and take perforation and welded structure to can be directly will converge through resistance welding process and take and conductive terminal welded fastening, the structure technology is simplified, and process efficiency is higher also environmental protection more, is fit for the automatic high-efficient production of photovoltaic module terminal box.

Description

Photovoltaic module bypass element module and split type photovoltaic module junction box with same

Technical Field

The utility model relates to a solar photovoltaic power generation technical field especially relates to a photovoltaic module bypass component module that adapts to high-power photovoltaic module and has the split type photovoltaic module terminal box of bypass component module.

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 characterized in that a positive conductive terminal and a negative conductive terminal are arranged 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 with a battery string of a module. Because the types and sizes of the photovoltaic modules are different, the specifications of the junction box are also multiple, and shells, conductive terminals and the like with different specifications need to be produced, so that the production cost of the junction box is increased, the production efficiency is reduced, and cost reduction and efficiency improvement are not facilitated. In addition, 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 this, a modularized photovoltaic module bypass element is developed, as shown in fig. 1, the modularized photovoltaic module bypass element generally includes 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 bus bar through holes 103 are opened at two sides of the insulating plastic package block 3, and the bus bar is respectively welded with a first welding region 102 and a second welding region 202 after passing through the through holes 103; the first welding area 102 and the second welding area 202 are formed by stamping a first conductive terminal 1 and a second conductive terminal 2 to form a pit with a certain depth, and solder is pre-filled in the pit, so that the welding and fixing can be conveniently carried out during the welding of the bus bar.

However, the new bypass component module has problems in application, such as the need to punch through the bus bar and the solder pad separately; solder is required to be stored in the welding area in advance; in addition, the bus bar is generally welded manually, so that the efficiency is low, and tin smoke harmful to human bodies is also generated by soldering; therefore, further improvements are needed for such modular bypass elements.

SUMMERY OF THE UTILITY MODEL

The utility model aims at solving the defects in the prior art, and provides a photovoltaic module bypass element module which is used in a photovoltaic module junction box and has overlarge current capacity; the structure of the conductive terminal is optimized, the welding efficiency of the bus bar and the conductive terminal can be improved, manual welding is not needed, and tin smoke is not generated.

In order to achieve the above purpose, the utility model adopts the following technical scheme:

a photovoltaic module bypass element module comprises a first conductive terminal, an insulating plastic package block and a second conductive terminal, wherein at least one bypass protection device is fixed on the first conductive terminal and/or the second conductive terminal, and the bypass protection device is electrically connected with the other conductive terminal; the insulating plastic package block packages the bypass protection device, the first conductive terminal and the second conductive terminal into a module structure; the first conductive terminal and the second conductive terminal are provided with a first convergence belt through hole, a first folding edge, a second convergence belt through hole and a second folding edge, and the side surfaces of the first folding edge and the second folding edge are welding areas welded with the assembly convergence belt; the assembly bus bar penetrates through the first bus bar through hole and the second bus bar through hole respectively and then is welded with the bus bar welding area.

Preferably, the distance between the first folding edge and/or the second folding edge and the edge of the insulating plastic package block is not less than 0.1 mm.

Still preferably, the distance between the first folding edge and/or the second folding edge and the edge of the insulating plastic package block is 1.5-8 mm.

Still preferably, the distance between the first folded edge and the second folded edge is 1-30 mm.

Still preferably, the distance between the first folded edge and the second folded edge is 8-20 mm.

Still preferably, the height of the first folded edge and the second folded edge is not less than 1 mm.

Still preferably, the height of the first folded edge and the second folded edge is 2.5-15 mm.

Preferably, the distance from the top surfaces of the first folding edge and the second folding edge to the top surface of the insulating plastic package block is 2-15 mm.

Preferably, the distance from the top surfaces of the first folding edge and the second folding edge to the top surface of the insulating plastic package block is 3-8 mm.

Preferably, the first folding edge and the second folding edge are equal in distance and height to the edge of the insulating plastic package block.

Preferably, the angle between the first folding edge and the plane of the conductive terminal is 80-100 degrees.

Preferably, the angle between the first folded edge, the second folded edge and the plane of the conductive terminal is 90 ° ± 3 °.

Preferably, the first conductive terminal and the second conductive terminal are respectively provided with at least one positioning structure, and the shapes of the respective positioning structures are different.

Preferably, the end of the first conductive terminal and/or the second conductive terminal is provided with a resistance welding rib.

Still preferably, the bypass protection device is a diode chip or an integrated circuit module with a bypass protection function.

According to the utility model discloses a further object, the utility model discloses still provide a split type photovoltaic module terminal box, it includes left terminal box, well terminal box and right terminal box, every terminal box all includes box body, lid and sets up as above in the box body photovoltaic module bypass component module.

Preferably, the position, corresponding to the through hole of the bus bar of the photovoltaic module bypass element module, of the box body is provided with a narrow slit through which the bus bar penetrates.

The beneficial effects of the utility model are that, photovoltaic module bypass component module, form the subassembly simultaneously through a stamping process and converge and take perforation and welded structure to can be directly through resistance welding process will converge and take and conductive terminal welded fastening, structural technology simplifies, and the soldering process efficiency is higher before resistance welding process compares in addition, only need can accomplish the welding process about 0.4 seconds through resistance welding equipment, the technology is also environmental protection more, is fit for the automatic high-efficient production of photovoltaic module terminal box.

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 view of a photovoltaic module bypass element module according to an embodiment of the present invention;

fig. 3 is a schematic perspective view of the photovoltaic module bypass element module of fig. 2 from another view direction;

fig. 4 is a schematic plan (top) view of the photovoltaic module bypass element module of fig. 2;

FIG. 5 is a side structural (front) view of the photovoltaic module bypass element module of FIG. 2;

fig. 6 is an exploded view of a split photovoltaic module junction box of the present invention using the photovoltaic module bypass module shown in fig. 2;

fig. 7 is an enlarged schematic structural view of the left junction box in fig. 6.

Main element names and reference numbers in the drawings: 10-a first conductive terminal, 11-a first flange, 112-a first bus bar welding area, 12-a first bus bar perforation hole, 20-a second conductive terminal, 21-a second flange, 212-a second bus bar welding area, 22-a second bus bar perforation hole and 30-an insulating plastic package block.

Detailed Description

In order to further understand the objects, structures, features and functions of the present invention, the following embodiments are described in detail.

Please refer to fig. 2 and fig. 3, which are schematic structural diagrams of a photovoltaic module bypass component module according to the present invention, the photovoltaic module bypass component module includes a first conductive terminal 10, an insulating plastic package block 30 and a second conductive terminal 20, at least one bypass protection device (not shown) is welded on the first conductive terminal 10 and/or the second conductive terminal 20, and the bypass protection device is electrically connected to another conductive terminal; the insulating plastic package block 30 packages the bypass protection device, the first conductive terminal and the second conductive terminal into an integrated module structure; the first conductive terminal 10 and the second conductive terminal 20 are respectively provided with a bus bar through hole (as shown in the figure, a first bus bar through hole 12 and a second bus bar through hole 22) and a folded edge (as shown in the figure, a first folded edge 11 and a second folded edge 21) by a stamping process, and the side surface of the folded edge structure is a welding area (as shown in the figure, a first bus bar welding area 112 and a second bus bar welding area 212) welded with the assembly bus bar; the assembly bus bars are connected to the first bus bar land 112 and the second bus bar land 212 by resistance welding after passing through the first bus bar penetration hole 12 and the second bus bar penetration hole 22, respectively.

The utility model discloses a photovoltaic module bypass component module forms the subassembly simultaneously through a stamping process and converges and take perforation and welded structure to can be directly through resistance welding technology will converge and take and conductive terminal welded fastening, structural technology simplifies, and the soldering process efficiency is higher before resistance welding technology compares in addition, only need 0.4 seconds through resistance welding equipment about can accomplish the welding process, and the technology is also environmental protection more, is fit for automated production.

In a preferred embodiment, referring to fig. 4, the distances d1 and d2 between the first folded edge 11 and the second folded edge 12 and the edge of the insulating plastic block 30 are not less than 0.1 mm; in a more preferred embodiment, the distances d1 and d2 between the first folded edge 11 and the second folded edge 12 and the edge of the insulating and plastic packaging block 30 are 1.5-4 mm. In the embodiment of the present invention shown in fig. 2-4, the bypass element module is basically designed in a bilateral symmetry structure, that is, the bus bar perforation and folding structure of two conductive terminals are distributed on both sides of the insulating plastic package block, and are symmetrically arranged, in this case, in a more preferred embodiment, the distances d1 and d2 between the first folding edge 11 and the second folding edge 12 and the edge of the insulating plastic package block 30 are equal. However, in different embodiments, the insulating plastic package block 30 may not be disposed between the first and second bent edges, or may be disposed on one side of the two bent edges, and only the copper plate structures of the first and second conductive terminals need to be modified, in which case, the distances d1 and d2 between the first and second bent edges 11 and 12 and the edge of the insulating plastic package block 30 are not equal. In order to avoid the mutual influence between the forming and the flanging structures of the insulating plastic package block 30, the flanging structures and the edges of the insulating plastic package block generally cannot be completely overlapped during actual production, the flanging structures and the insulating plastic package block need to be separated by a certain distance, and after actual processing tests, obvious mutual influence cannot be generated when the distance exceeds 0.1 mm. Or, when performing the press forming of the folded edge structure, the folded edge may be performed on a side away from the insulating plastic package block, that is, one side edge of the first folded edge 11 opposite to the second folded edge 21 shown in fig. 4 is subjected to the press folding, which is not limited in this respect, and all of which are considered as the scope of the claimed technical solution.

In addition, when the bypass element module is designed, the bus bars penetrate out of the back of the assembly and then pass through two bus bar through holes to be welded with the welding areas of the folding edges, so that the distance between the first folding edge 11 and the second folding edge 12 is 1-30mm, except for the fact that the first folding edge and the second folding edge can be arranged on one side of the insulating plastic package block or on two sides of the insulating plastic package block respectively as described above, and the distance between the bus bars penetrating out of the assemblies with different specifications is also different, so as to refer to fig. 5; of course, in a preferred embodiment, i.e. when the first and second flanges are respectively disposed on both sides of the insulating plastic block (as shown in fig. 2-5), the distance L between the first and second flanges 11, 12 is 8-20 mm.

In the technical scheme of the application, a part of material of the copper plate terminal is punched and bent to form a welding surface for resistance welding of the bus bar, so that the height of the flanging structure needs certain requirements for facilitating the implementation of the resistance welding and the reliability of the welding, and referring to fig. 5, according to a test structure, when the height H of the flanging structure reaches about 1mm, the resistance welding can be realized; in a preferred embodiment, the height H of the first folding edge 11 and the second folding edge 12 is 2.5-15 mm; in a more preferred embodiment, the height H of the first and second folded edges 11 and 12 is 4-8 mm. In addition, when the folding structure is formed by bending on the side far away from the insulating plastic package block, at this time, the welding part of the welding equipment is located above the insulating plastic package block, and in order to avoid collision between the welding equipment and the insulating plastic package block, in a preferred embodiment, the distance from the top surface of the first folding edge 11 and the second folding edge 12 to the top surface of the insulating plastic package block 30 is 2-15mm, and preferably, the distance from the top surface of the first folding edge 11 and the second folding edge 12 to the top surface of the insulating plastic package block 30 is 3-8 mm. Therefore, the size of the photovoltaic module bypass element module, the efficient and smooth performance of the welding process by using the resistance welding equipment, the electrical performance of the module and the like can be considered at the same time.

In another preferred embodiment, the angles between the first and second folded edges 11 and 21 and the plane of the conductive terminal are 80-100 °; preferably, the angles between the first folded edge 11, the second folded edge 21 and the plane of the conductive terminal are 90 ° ± 3 °.

In another preferred embodiment, referring to fig. 2, the first conductive terminal 10 and the second conductive terminal 20 are respectively provided with at least one positioning structure 14 and 24, so that the photovoltaic module bypass element module can be quickly and accurately positioned in the box body when the junction box is produced; in a preferred embodiment, the positioning structure 13 of one of the conductive terminals, for example, the first conductive terminal 10, is a circular hole, and the positioning structure 24 of the other conductive terminal, for example, the second conductive terminal 20, is a rectangular slot, and a corresponding shaped bump (see the positioning structures 3014 and 3024 in fig. 6) is provided in the assembly junction box, so that the assembly junction box can achieve a quick and fool-proof effect during installation, and prevent the module from being installed reversely.

In another preferred embodiment, when the photovoltaic module bypass element module is welded with the cable, a connection mode of resistance welding is adopted, and the cable is directly connected and fixed with the end part of the first conductive terminal and/or the second conductive terminal by resistance welding; in order to enhance the effect of resistance welding, the end parts of the first conductive terminal and the second conductive terminal are provided with convex ribs 40, and the convex ribs are raised structures with certain height which are formed by directly stamping materials with certain width and length at the end parts of the conductive terminals by adopting a stamping process. In practical application, in order to meet different application requirements, for example, for a split junction box, it is not necessary to connect cables to two conductive terminals of each photovoltaic module bypass element module, the protruding edge 40 may be disposed at an end of any one of the first conductive terminal and the second conductive terminal, or disposed at both ends of the first conductive terminal and the second conductive terminal, which is not limited in the present invention; it is a preferred solution to provide said ribs on both terminals, only from the viewpoint of standardization of the production of the components.

It should be understood that, in the present invention, the conductive terminal on the left side in the photovoltaic module bypass element module in the drawings is referred to as the first conductive terminal, and the conductive terminal on the right side is referred to as the second conductive terminal, which is only for the purpose of clearly describing the embodiments of the present invention, and is not for limiting the position where the bypass protection element is disposed; 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.

In addition, it should be understood that the bypass protection device of the present invention may adopt a diode chip as the protection device of the modularized bypass element, and may also adopt an integrated circuit module having a bypass protection function as the protection device, such as a MOS transistor, and the present invention is not limited thereto.

The utility model adopts the integrated packaging technology of the conductive terminal and the diode, avoids secondary switching, enhances the conductivity of the diode, simplifies the process and reduces the volume of the photovoltaic bypass element module; the assembly bus bar through hole and the welding area can be formed by a simple stamping process, an electric resistance welding process is applied in the aspect, an automatic process is adopted, the welding efficiency is improved, and tin smoke pollution is avoided.

According to another object of the present invention, referring to fig. 5, the present invention further provides a split type photovoltaic module junction box, which comprises a box body (as shown in the figure, a left box body 301, a middle box body 302 and a right box body 303), a box cover 100 and the photovoltaic module bypass element module 200 disposed in the box body as described above. As shown in the figure, the split junction box includes a left junction box, a middle junction box and a right junction box, the internal structure of the box body of each junction box is the same, referring to fig. 6, taking the left junction box as an example, narrow slits 3011 through which the bus bars pass are arranged in the box body 301 corresponding to the positions of the bus bar through holes 12 and 22 of the photovoltaic module bypass element module 200, and the module bus bars pass through the narrow slits 3011 and then the bus bar through holes 12 and 22 after passing through the module, and then are resistance welded to the welding areas of the folded edges; positioning posts 3014 and 3024 with different end shapes are arranged in the box body corresponding to the positioning structures 14 and 24 of the bypass element module 200; cable lead-out structures are arranged at the left end of the left junction box body and the right end of the right junction box body and are matched with the cable pressing block 403 to fix the cables and the box bodies.

It should be understood that, when the utility model discloses a when bypass component module 200 is applied to the split type terminal box of the combination use that comprises left box body, well box body, right box body, although as shown in fig. 5, only the second conductive terminal on the right side of left first conductive terminal and right terminal box in the left terminal box needs to be connected fixedly with the cable conductor 400 that is connected with connector 501, 502, but in preferred embodiment, can install the photovoltaic module bypass component module of the same structure in left box body, well box body, right box body, thereby can adopt a structure to be applied to in different box bodies, satisfy the installation demand, avoid producing the conductive terminal of multiple structure when the terminal box adds man-hour, save the input of extra stamping die, and make things convenient for the management of spare part in the production process, save cost, raise the efficiency.

The present invention has been described in relation to the above embodiments, which are only examples for implementing the present invention. It should be noted that the disclosed embodiments do not limit the scope of the invention. On the contrary, all changes and modifications which do not depart from the spirit and scope of the present invention are deemed to fall within the scope of the present invention.

Claims (17)

1. The bypass element module of the photovoltaic module is characterized by comprising a first conductive terminal, an insulating plastic package block and a second conductive terminal, wherein at least one bypass protection device is fixed on the first conductive terminal and/or the second conductive terminal and is electrically connected with the other conductive terminal; the insulating plastic package block packages the bypass protection device, the first conductive terminal and the second conductive terminal into a module structure; the first conductive terminal and the second conductive terminal are provided with a first convergence belt through hole, a first folding edge, a second convergence belt through hole and a second folding edge, and the side surfaces of the first folding edge and the second folding edge are welding areas welded with the assembly convergence belt; the assembly bus bar penetrates through the first bus bar through hole and the second bus bar through hole respectively and then is welded with the bus bar welding area.

2. The photovoltaic module bypass element module according to claim 1, wherein the first flange and/or the second flange is spaced from the edge of the insulating plastic block by a distance of not less than 0.1 mm.

3. The photovoltaic module bypass element module according to claim 2, wherein the first and/or second flange is spaced from the edge of the insulating plastic block by a distance of 1.5-8 mm.

4. The photovoltaic module bypass element module defined in claim 1, wherein the first flange is spaced from the second flange by a distance of 1-30 mm.

5. The photovoltaic module bypass element module according to claim 4, wherein the first flange and the second flange are spaced apart by 8-20 mm.

6. The photovoltaic module bypass element module defined in claim 1, wherein the first and second flanges are not less than 1mm high.

7. The photovoltaic module bypass element module defined in claim 6, wherein the first and second flanges have a height of 2.5-15 mm.

8. The photovoltaic module bypass element module according to claim 1, wherein the distance from the top surface of the first and second flanges to the top surface of the insulating plastic block is 2-15 mm.

9. The photovoltaic module bypass element module according to claim 8, wherein the distance from the top surface of the first and second flanges to the top surface of the insulating plastic block is 3-8 mm.

10. The photovoltaic module bypass element module according to claim 1, wherein the first and second flanges are spaced apart from and are substantially equal in height to the edges of the insulating plastic block.

11. The photovoltaic module bypass element module according to claim 1, wherein the angle between the first and second flanges and the plane of the conductive terminal is 80-100 °.

12. The photovoltaic module bypass element module according to claim 11, wherein the angle between the first and second flanges and the plane of the conductive terminal is 90 ° ± 3 °.

13. The photovoltaic module bypass element module according to claim 1, wherein the first conductive terminal and the second conductive terminal are respectively provided with at least one positioning structure, and the shapes of the respective positioning structures are different.

14. The photovoltaic module bypass element module according to claim 1, wherein the first conductive terminal and/or the second conductive terminal is provided with an electric resistance welding rib at an end thereof.

15. The photovoltaic module bypass element module according to claim 1, wherein the bypass protection device is a diode chip or an integrated circuit module having a bypass protection function.

16. A split pv junction box comprising a left junction box, a middle junction box, and a right junction box, each junction box comprising a box body, a box cover, and the pv bypass element module of any of claims 1-15 disposed in the box body.

17. The split pv module junction box of claim 16 wherein said box body has slots formed therein through which the bus bars pass at locations corresponding to the bus bar perforations of the pv module bypass modules.

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