WO2016145639A1 - 一种直接注塑成型的接线盒 - Google Patents

一种直接注塑成型的接线盒 Download PDF

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Publication number
WO2016145639A1
WO2016145639A1 PCT/CN2015/074544 CN2015074544W WO2016145639A1 WO 2016145639 A1 WO2016145639 A1 WO 2016145639A1 CN 2015074544 W CN2015074544 W CN 2015074544W WO 2016145639 A1 WO2016145639 A1 WO 2016145639A1
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Prior art keywords
junction box
diode
cable
conductor
electric conductor
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PCT/CN2015/074544
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English (en)
French (fr)
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许建明
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常熟市福莱德连接器科技有限公司
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Priority to PCT/CN2015/074544 priority Critical patent/WO2016145639A1/zh
Publication of WO2016145639A1 publication Critical patent/WO2016145639A1/zh

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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
    • 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

Definitions

  • the invention relates to the technical field of solar photovoltaic modules, and in particular to a junction box for direct injection molding.
  • a junction box structure of the prior art is assembled by using a plurality of plastic parts, for example, a photovoltaic junction box according to the invention of the invention of the invention of the publication No. CN 203708192U, the disclosure of which is incorporated herein by reference.
  • a diode module and a circuit board are disposed in the casing body, and the outer surface of the casing is inlaid with a heat sink.
  • the diode module located in the casing is attached to the back of the heat sink and electrically connected to the copper conductor on the circuit board.
  • the junction box with multiple plastic parts assembly methods has many problems during the assembly process: the installation is cumbersome and the assembly is not in place. In the course of use, cracking of the casing may occur, and the sealing property may be poor.
  • the invention application of the application No. 201010505274.8, the application date of September 28, 2010 provides an integral injection junction box and a method of manufacturing the same
  • the body injection junction box includes: a cover, a box body, a diode, a conductive sheet and a cable, the diode is soldered on the conductive sheet, and is wrapped with the conductive sheet by plastic injection; the cable is connected at the terminal of the conductive sheet, And the conductive sheet and the diode wrapped together are molded integrally with the box body by plastic injection molding, and formed in the box body.
  • the above invention saves the installation labor cost of the junction box, in practical applications, since the junction box will withstand higher temperatures, the plastic formed by the overmolding may be delaminated, resulting in a decrease in the strength of the junction box. The structure is deformed and the sealing property is lowered.
  • the technical problem solved by the invention is that the junction box of the double injection molding is difficult to control due to the injection molding condition, the junction box is not easily melted into one body, and in the process of use, under the action of high temperature, the two layers of plastic of the junction box may be Layering, this will result in reduced strength, structural deformation, and reduced sealability of the junction box.
  • a direct injection molding junction box comprising a diode, an electric conductor, a cable, a box body, a cover, the diode is mounted on the electric conductor, and the cable is connected to the electric conductor, the box
  • the structure of the body is one injection molding, and the casing is provided with a connection cavity, and the casing encloses a connection between the electric conductor and the cable, and the diode is located in the connection cavity.
  • the diode, the electric conductor and the cable are connected and integrated into the bottom mold, and after the mold is closed, the box body is injection molded at one time, a connection cavity is formed on the box body, and the connection between the electric conductor and the cable is wrapped in the box body.
  • the free end of the cable protrudes from the housing, and the diode and a portion of the electrical conductor are located within the connection cavity.
  • a bus bar is inserted into the connecting cavity to refill the glue, and then the cover is fastened on the connecting cavity to form a complete photovoltaic junction box.
  • the technical solution can solve the technical problem that the junction box body is easy to crack and the sealing property is poor during use; and the junction box after multiple injection molding is avoided, the junction box may be layered under the action of high temperature during use. risks of.
  • the direct injection molding junction box of the invention not only simplifies the production process of the junction box, improves the production efficiency, completely solves the problem of consistent safety risk caused by the assembly of the ordinary parts, and improves the protection level of the junction box. And guarantee the long-term effectiveness of the degree of protection.
  • the electrical conductor is a unitary structure.
  • the diode is connected to both ends of the conductor, so that the diode can still function to protect the solar cell module.
  • the electric conductor is provided with a protruding portion, the protruding portion is provided with a card slot, and the two ends of the diode are provided with a connecting portion, and the connecting portion is tightly engaged in the card slot.
  • the design ensures the connection between the diode and the conductor, and eliminates the trouble of using the welding method in the prior art, which is advantageous for streamlining the processing steps and saving cost.
  • the electrical conductor is provided with protruding ends, and the cable is connected to the electrical conductor through both ends.
  • the edge of the connecting cavity is provided with a protruding buckle
  • the edge of the cover is provided with a card slot, and the protruding buckle is engaged in the card slot.
  • FIG. 1 is a schematic structural view of a direct injection molding junction box of the present invention
  • Figure 2 is a schematic view showing the structure of the junction box viewed from the front in Figure 1;
  • FIG. 3 is a schematic structural view of the junction box of FIG. 1 as viewed from the right side;
  • FIG. 4 is an exploded perspective view of the diode, the conductor, and the cable connected together in FIG. 1;
  • Figure 5 is a schematic view showing the structure of the cover of the present invention.
  • a direct injection molded junction box includes a diode 10, a conductor 20, a cable 30, a case 40, and a cover 50.
  • the diode 10 is provided with a connecting portion 11 at both ends.
  • the conductor 20 is of a unitary structure.
  • the electric conductor 20 is provided with a protruding portion 21, and the protruding portion 21 is provided with a card slot 210, and the electric conductor 20 is provided with two end portions 22.
  • the connecting portion 11 is tightly engaged in the card slot 210 of the electrical conductor 20.
  • the cable 30 is connected to the electrical conductor 20 through both end portions 22 of the electrical conductor 20.
  • the structure of the casing 40 is one-shot injection molding, and the casing 40 is provided with a connection cavity 400.
  • the edge of the connection cavity 400 is provided with a protruding buckle 401.
  • the case 40 encloses the junction of the conductor 20 and the cable 30, and the diode 10 is located within the connection cavity 400.
  • the edge of the cover 50 is provided with a card slot 501, and the protruding buckle 40 1 is engaged in the card slot 501.
  • the diode 10 is engaged with the conductor 20, and the cable 30 is connected to the conductor 20. Thereafter, the diode 10, the conductor 20, and the cable 30 are integrally buried in the bottom mold. Thereafter, the casing 40 is injection molded once, and the casing 40 wraps the joint of the conductor 20 with the cable 30, and the casing 40 forms a joint cavity 400. Thereafter, a bus bar is inserted into the connecting cavity 400 and refilled, and the cover 50 is mounted on the connecting cavity 400 by the engagement of the protruding buckle 401 and the card slot 501. Thus, the complete junction box is processed.

Abstract

一种直接注塑成型的接线盒，包括二极管(10)、导电体(20)、电缆(30)、盒体(40)、盒盖(50)，所述二极管(10)安装在导电体(20)上，所述电缆(30)与导电体(20)连接，所述盒体(40)的结构为一次注塑成型，所述盒体(40)设有连接腔(400)，所述盒体(40)包裹导电体(20)与电缆(30)的连接处，所述二极管(10)位于连接腔(400)内。一次注塑成型接线盒不仅简化了接线盒的生产过程，解决了通常散件组装而带来的一致安全风险问题，而且提升了接线盒的防护等级，并保证了防护等级的长期有效性。

Description

一种直接注塑成型的接线盒 技术领域
本发明涉及太阳能光伏组件技术领域，具体而言，涉及一种直接注塑成型的接线盒。
背景技术
太阳能光伏接线盒在太阳能组件中的地位非常重要，其主要作用是将太阳能电池产生的电力与外部线路进行连接。随着光伏行业日新月异的发展，越来越多的目光转向了接线盒身上，因为其不仅能将太阳电池产生的电力方便的传输到外部电路中去，同时还能对太阳电池组件起到有效的保护作用。
现有技术中的接线盒结构采用多个塑料件组装的方式，例如，授权公告号CN 203708192U，授权公告日2014年7月9日的发明所述的一种光伏接线盒，包括有盒体，盒体内设有二极管模组和线路板，所述的盒体外表面镶嵌有散热器，位于盒体内的二极管模组贴附于散热器背面，并与线路板上的铜导体电连接。采用多个塑料件组装方式的接线盒，在组装过程中产生诸多问题：安装繁琐，组装不到位。在使用过程中也可能产生盒体开裂，密封性差等问题。
针对上述技术问题，申请号201010505274.8，申请日2010年9月28日的发明申请提供了一种整体式注塑接线盒及其制造方法，所述整 体式注塑接线盒包括：盒盖、盒体、二极管、导电片和电缆线，二极管焊接在导电片上，并与导电片用塑胶注塑的方式包裹在一起；电缆线连接在导电片的接线端子处，并与包裹在一起的导电片和二极管再次用塑胶注塑的方式与盒体一体成型，并形成在盒体内。虽然上述发明申请节省了接线盒的安装人工费用，但是，在实际应用中，由于接线盒将承受较高的温度，二次注塑形成的塑胶可能出现分层的现象，导致接线盒的强度降低、结构变形、密封性下降。
发明内容
本发明所解决的技术问题：采用二次注塑成型的接线盒，由于注塑条件较难控制，接线盒不易熔为一体，在使用过程中，在高温的作用下，接线盒的两层塑胶可能会分层，如此将导致接线盒的强度降低、结构变形、密封性下降。
本发明提供如下技术方案：一种直接注塑成型的接线盒，包括二极管、导电体、电缆、盒体、盒盖，所述二极管安装在导电体上，所述电缆与导电体连接，所述盒体的结构为一次注塑成型，所述盒体设有连接腔，所述盒体包裹导电体与电缆的连接处，所述二极管位于连接腔内。
按上述技术方案，二极管、导电体、电缆连接后一体埋入底模中，合模后，一次注塑成型盒体，盒体上形成连接腔，导电体与电缆的连接处被包裹在盒体内，电缆的自由端突出盒体，二极管和部分导电体位于连接腔内。在所述连接腔中插入汇流条，再灌胶，之后，盒盖扣盖在所述连接腔上，形成完整的光伏接线盒。通过本发明 所述的技术方案，可解决接线盒体在使用过程中易开裂、密封性差的技术问题；也避免了经多次注塑成型的接线盒在使用过程中，在高温作用下接线盒可能出现分层的风险。本发明所述的直接注塑成型的接线盒，不仅简化了接线盒的生产过程，提高了生产效率，彻底解决了通常散件组装而带来的一致安全风险问题，而且提升了接线盒的防护等级，并保证了防护等级的长期有效性。
作为本发明的进一步改进，所述导电体为一体结构。二极管连接导电体的两端，如此，二极管仍可起到保护太阳电池组件的作用。作为进一步改进，所述导电体上设有突出部，所述突出部上开设有卡槽，所述二极管两端设有连接部，所述连接部紧密地卡接在卡槽中。如此设计，既保证了二极管与导电体之间的连接，又免去了现有技术采用焊接方式的麻烦，有利于精简加工步骤，节约成本。作为进一步改进，所述导电体设有突出的两端部，所述电缆通过两端部与导电体连接。
作为本发明的进一步改进，所述连接腔的边缘设有突出卡扣，所述盒盖的边缘开设有卡槽，所述突出卡扣卡合在卡槽中。
附图说明
下面结合附图对本发明做进一步的说明：
图1为本发明一种直接注塑成型的接线盒的结构示意图；
图2为图1中从正后方观察所述接线盒所得的结构示意图；
图3为图1中从右侧观察所述接线盒被剖后所得的结构示意图；
图4为图1中连接在一起的二极管、导电体、电缆的分解示意图；
图5为本发明所述盒盖的结构示意图。
图中符号说明：
10－二极管；11－连接部；
20－导电体；21－突出部；210－卡槽；22－端部；
30－电缆；
40－盒体；400－连接腔；401－突出卡扣；
50－盒盖；501－卡槽。
具体实施方式
如图1、图2、图5所示，一种直接注塑成型的接线盒，包括二极管10、导电体20、电缆30、盒体40、盒盖50。
如图4所示，所述二极管10两端设有连接部11。
如图4所示，所述导电体20为一体结构。所述导电体20上设有突出部21，所述突出部21上开设有卡槽210，所述导电体20设有两端部22。
如图1所示，所述连接部11紧密地卡接在导电体20的卡槽210中。
所述电缆30通过导电体20的两端部22与导电体20连接。
如图1～3所示，所述盒体40的结构为一次注塑成型，所述盒体40设有连接腔400，所述连接腔400的边缘设有突出卡扣401。所述盒体40包裹导电体20与电缆30的连接处，所述二极管10位于连接腔400内。
如图5所示，所述盒盖50的边缘开设有卡槽501，所述突出卡扣40 1卡合在卡槽501中。
实际操作中，二极管10卡合在导电体20上，电缆30与导电体20连接。之后，二极管10、导电体20、电缆30一体埋入底模中。之后，一次注塑成型盒体40，盒体40包裹导电体20与电缆30的连接处，盒体40上形成连接腔400。之后，在所述连接腔400中插入汇流条，再灌胶，盒盖50通过突出卡扣401和卡槽501的卡合安装在所述连接腔400上，至此，完整的接线盒加工完成。
以上内容仅为本发明的较佳实施方式，对于本领域的普通技术人员，依据本发明的思想，在具体实施方式及应用范围上均会有改变之处，本说明书内容不应理解为对本发明的限制。

Claims (5)

  1. 一种直接注塑成型的接线盒，包括二极管(10)、导电体(20)、电缆(30)、盒体(40)、盒盖(50)，所述二极管(10)安装在导电体(20)上，所述电缆(30)与导电体(20)连接，其特征在于：所述盒体(40)的结构为一次注塑成型，所述盒体(40)设有连接腔(400)，所述盒体(40)包裹导电体(20)与电缆(30)的连接处，所述二极管(10)位于连接腔(400)内。
  2. 如权利要求1所述的一种直接注塑成型的接线盒，其特征在于：所述导电体(20)为一体结构。
  3. 如权利要求2所述的一种直接注塑成型的接线盒，其特征在于：所述导电体(20)上设有突出部(21)，所述突出部(21)上开设有卡槽(210)，所述二极管(10)两端设有连接部(11)，所述连接部(11)紧密地卡接在卡槽(210)中。
  4. 如权利要求3所述的一种直接注塑成型的接线盒，其特征在于：所述导电体(20)设有两端部(22)，所述电缆(30)通过两端部(22)与导电体(20)连接。
  5. 如权利要求1所述的一种直接注塑成型的接线盒，其特征在于：所述连接腔(400)的边缘设有突出卡扣(401)，所述盒盖(50)的边缘开设有卡槽(501)，所述突出卡扣(401)卡合在卡槽(501)中。
PCT/CN2015/074544 2015-03-18 2015-03-18 一种直接注塑成型的接线盒 WO2016145639A1 (zh)

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Cited By (2)

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Publication number Priority date Publication date Assignee Title
CN112848060A (zh) * 2021-03-26 2021-05-28 青岛波瑞特工程材料有限公司 一种可埋入金属件的一次性注塑模具及使用方法
CN115664337A (zh) * 2022-11-07 2023-01-31 江苏通灵电器股份有限公司 浇注封装一体机

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CN202004021U (zh) * 2011-03-08 2011-10-05 莱尼电气线缆（常州）有限公司 一种太阳能接线盒
CN102394252A (zh) * 2011-11-24 2012-03-28 人和光伏科技有限公司 太阳能电池接线盒
CN102420544A (zh) * 2010-09-28 2012-04-18 无锡尚德太阳能电力有限公司 整体式注塑接线盒及其制造方法

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US4460232A (en) * 1982-05-24 1984-07-17 Amp, Incorporated Junction box for solar modules
CN2909650Y (zh) * 2006-05-10 2007-06-06 苏州快可光伏电子有限公司 透明薄型建筑光伏接线盒
CN102420544A (zh) * 2010-09-28 2012-04-18 无锡尚德太阳能电力有限公司 整体式注塑接线盒及其制造方法
CN102097508A (zh) * 2010-11-11 2011-06-15 苏州快可光伏电子股份有限公司 一种一体式快速连接光伏接线盒
CN202004021U (zh) * 2011-03-08 2011-10-05 莱尼电气线缆（常州）有限公司 一种太阳能接线盒
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112848060A (zh) * 2021-03-26 2021-05-28 青岛波瑞特工程材料有限公司 一种可埋入金属件的一次性注塑模具及使用方法
CN115664337A (zh) * 2022-11-07 2023-01-31 江苏通灵电器股份有限公司 浇注封装一体机
CN115664337B (zh) * 2022-11-07 2023-08-11 江苏通灵电器股份有限公司 浇注封装一体机

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