Connecting box for a solar panel

A connecting box for connecting to a solar panel includes a housing and a terminal assembly. The housing has an opening for introducing an electrical connecting element of the solar panel. The terminal assembly is disposed in the housing, which includes a first terminal having a first contact portion for contacting and applying an elastic force to the electrical connecting element and a first releasing portion extending from the first contact portion. The first releasing portion is non-obstructedly arranged in the housing to be operable to release the elastic force without assistance of any tools when the solar panel is inserted into or extracted from the connecting box.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a connecting box, and more particularly to a connecting box for connection to a solar panel.

2. Description of Related Art

Solar panels have a large number of solar cells that are used to convert power from sunlight. The power generated by the solar cells is conveyed via electric lines for feeding into an alternative current (AC) network or to a battery. A connecting box is generally provided for electrical connection between the solar panel and the AC network or the battery.

U.S. Pat. No. 7,134,883 B2 discloses a connecting box having a housing and a number of terminal assemblies arranged side by side in the housing. The housing is provided with an opening for introducing the electrical lines of the solar panel to one ends of the terminal assemblies, and a cable connected to the other ends of the terminal assemblies for output the converted power to the AC network or the battery. A number of diodes each connects two neighbouring terminal assemblies to establish an electrical connection therebetween. As shown inFIG. 5of the drawings of the patent, an elastic contact10for connection to the electrical lines of the solar panel is encircled within the contact base13. A suitable tool is required to extend through an opening defined on the top of the contact base to operate the elastic contact to allow a user to insert or extract the electrical lines of the solar panel. However, the suitable tool is not always available to the user when the solar panel is damaged and need to be replaced, in such situation, it is quite difficult for the user to implement the replacement. In addition, the terminal assembly has a relatively complex structure thereby making manufacture both time and cost inefficient.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide a connecting box that is convenient to allow insertion or extraction of the electrical lines of the solar panel.

It is another object of the present invention to provide a connecting box having a relatively simple contact assembly.

In order to achieve afore-mentioned objects, there is provided, according to one aspect of the invention, a connecting box for connecting to a solar panel includes a housing and a terminal assembly. The housing has an opening for introducing an electrical connecting element of the solar panel. The terminal assembly is disposed in the housing, which includes a first terminal having a first contact portion for contacting and applying an elastic force to the electrical connecting element and a first releasing portion extending from the first contact portion. The first releasing portion is non-obstructedly arranged in the housing to be operable to release the elastic force without assistance of any tools when the solar panel is inserted into or extracted from the connecting box.

According to another aspect of the invention, there is provided a connecting box for connecting between a solar panel and a cable to convey power converted by the solar panel from sunlight. The connecting box includes a housing and a terminal assembly. The housing has an opening for introducing an electrical connecting element of the solar panel. The terminal assembly includes a terminal base disposed in the housing, a first terminal disposed in the terminal base for connecting the electrical connecting element of the solar panel, and a second terminal disposed in the terminal base for connecting the cable. The first and second terminals are substantially identical in structure to enhance the common usage of the contacts thereby making manufacture both time and cost efficient.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 to 5show a connecting box100for a solar panel in accordance with one preferred embodiment of the present invention. The connecting box includes an insulating housing1, a lid2covered on the housing1, four terminal assemblies assembled in the housing1, and a pair of cables6connecting to two opposite ones of the terminal assemblies.

The housing1has a base board11and peripheral side walls13. A number of ribs (not labeled) are disposed between the base board11and the side walls13to reinforce the connection therebetween. The base board11is provided with an opening14adjacent to one longitudinal side wall thereof for introducing electrical connecting elements of a solar panel, which will be described in detail hereinafter with reference toFIGS. 5 and 6. Four retaining frames12are arranged on the base board11parallel to one another along a lateral direction. Each retaining frame12includes two pairs of locking arms121,122symmetrically disposed at both lateral sides of the frame12. Each locking arm121,122extends upright from the base board11and is formed with a hook portion at the top thereof for retaining the terminal assembly. Two cable openings15are arranged on the other longitudinal side wall14of the housing1for being extended through by a pair of cables6. Person skilled in the art will recognize that the cables are used to output the power converted from sunlight to an AC network or a battery, and the two cables respectively form a positive and a negative poles of a power supply. As shown inFIG. 1, after inserted in the housing1, each cable6is connected to a corresponding terminal assembly via a contacting means, and then a nut (not shown) is screwed onto threaded grooves151formed outside of the opening15to fasten the cable6therein. In respect of the connection of the cable to the terminal assembly, it will be fully described hereinafter.

Referring toFIG. 1, a pair of spaced protrusions132is formed on one of the longitudinal side walls14, and at the opposite side wall14, a pair of blocks131is provided and each defines a passageway (not labeled) therethrough. Also referring toFIG. 2, the lid2may include a cover plate21, a pair of latches23and a pivot22respectively disposed at opposite longitudinal edges of the cover plate21. The lid2may be rotatable around the pivot22to open or close relative to the housing1, and in close state, the latches23of the lid2engage with the protrusions132to secure the lid2onto the housing1.

In present embodiment, the four terminal assemblies are essentially identical in construction, for reasons of simplification, below only one terminal assembly is described. With reference toFIG. 4, the terminal assembly includes a terminal base3, and a first, second, third elastic terminals41,42,43retained in the terminal base4. It will be noted that the terminal base or the elastic terminals may be stamped from a metallic plate. The terminal base3is composed of a generally rectangular bottom plate31, a vertical plate32extending upwardly from a longitudinal rear end of the bottom plate31, and a top plate33extending rearward from a top end of the vertical plate32. On both lateral sides of the bottom plate31, a pair of first side plates34extends upright and each defines a first receiving slot341arranged vertically at a top thereof. The first side plate34and the bottom plate31together defines a second receiving slot342arranged longitudinally therebetween. A pair of second side plates35extends rearward from both lateral sides of the vertical plate32. Each second side plate35defines a third receiving slot351extending longitudinally therein. The first, second, third receiving slots341,342,351are used to receive the first, second, third spring terminals41,42,43respectively. The first, second, third receiving slots341,342,351are substantially identical in construction. Each of them is formed narrowly at opening thereof and gradually widening toward the bottom thereof.

A pair of guiding grooves322,323extends upwardly and obliquely from the top of the vertical plate32, and a hole332is defined in the top plate33. Referring now toFIG. 4in conjunction withFIG. 5, the terminal base3defines a first, second, and third contact regions311,331,321on the bottom plate31, the vertical plate32, and the top plate33opposing the first, second, and third terminals41,42,43respectively. To enhance the contact stability between the terminal base3and the terminal41,42,43, each contact region is formed with a friction enhancing structure. In present embodiment, the friction enhancing structure consists of a number of indentations formed on the surface of the terminal base3. It would be apparent to those skilled in the art that the friction enhancing structure may also take the form of a variety of well-known structures such as embossments, strips, or coated abrasive formed the surface of the terminal base3.

Referring toFIG. 4, in present embodiment, the first, second, and third terminals41,42,43are substantially identical in structure, herein only the first terminal41is exemplified. The first terminal41which includes a first retaining portion411, a first contact portion412extending from and bending forwardly relative to the first retaining portion411, and a first releasing portion413extending from and bending forwardly relative to the first contact portion412. It should be noted that an external force F (as indicated inFIGS. 5 and 6) will be frequently exerted to the first releasing portion413, if the force exertion is so frequent or so large that exceeds the elastic instability of the elastic terminal, a permanent deformation will be generated and not resume to its original position. To avoid the permanent deformation, the first terminal41further includes a reverse bend portion located between the first retaining portion411and the first contact portion412to improve the elastic stability of the terminal. Furthermore, the first releasing portion411of the first terminal41also includes a reverse bend section (not labeled) for being conveniently operated when the user applying the force F. It should be noted that the terms “forwardly” and “reversely” are used herein to refer to a movement in opposite directions, just like in present embodiment, the term “forwardly” indicates bending anticlockwise, whilst the term “reversely” indicates bending clockwise. It would be apparent that the indication of the two terms can also be interchanged, in other words, “forwardly” indicates bending clockwise while “reversely” indicates bending anticlockwise. The first retaining portion413has a pair of ear sections415and a pair of wing sections416projected at both lateral sides thereof for engaging to the first receiving slot341of the terminal base3.

Referring toFIG. 4, as the arrows indicated, the first terminal41is inserted into the terminal base3vertically, and the second, third terminals42,43are inserted into the terminal base3horizontally, and in the mean time, the first, second, and third retaining portions411,421,431snugly fitted into the first, second, and third receiving slots341,342,351to retain the terminals in the terminal base3, in which the wing sections415,425,435of the terminals411,421,431are positioned at the narrower regions of the receiving slots341,342,351respectively, and the ear portions426,436of the second, third retaining portions421,431are positioned at the wider regions of the second, third receiving slots342,351, and the ear portion416of the first retaining portion411abuts against a pair of protrusions (not labeled) extending from the top of first side wall34. Also referring toFIG. 5, the first, second, and third contact portions412,422,432of the terminals elastically press on the first, second, and third contact regions311,331,321of the terminal base3. The first releasing portion413extends beyond the top of the first side wall34. The second releasing portion423and the second reverse bend portion424are located below the top wall33. The third releasing portion433and the third reverse bend portion434are located below the top of the first side wall34. Referring back toFIGS. 1 to 3, each terminal assembly is assembled in the corresponding retaining frame, and the locking arms121,122hook the first side wall34and the top wall33of the terminal base3. An electrical component is connected between the two neighbouring terminal assemblies3to establish an electrical path therebetween.

Referring now toFIG. 5, in present embodiment, the electrical component is a diode with two connection leads extending downwardly, and the cable6has an electrical conductor61, and the electrical connecting element of the solar panel is an electrical line7with an electrical conductor71. Along the insertion directions as the arrows indicated, the two leads51of the diode5are inserted through two guiding grooves322,323respectively defined in two neighbouring terminal bases3and pressed against the third contact region321by the third contact portion432of the third terminal43. The cable6extends through the cable opening5with the electrical conductor61pressed against the second contact region331by the second contact portion422of the second terminal42. The electrical line7passes through the opening14with the conductor71pressed against the first contact region311by the first contact portion412of the first terminal41. It should be noted that the first releasing portion413of the first terminal41is disposed non-obstructedly in the housing1, by this arrangement, it is convenient for a user to operate the first terminal413by user fingers directly pressing on the first releasing portion413to release the elastic force applied on the first contact region311by the first contact portion412, thereby actuating the first terminal41to move from the position in broken line to the position in real line to allow the insertion of the conductor71. It will be apparent that such arrangement also makes the manual withdrawn of the conductor71convenient for the reason of user fingers direct operation. With respect to the second or third terminals42,43, in present embodiment, a suitable tool is still required to actuating the second or third releasing portion423,433to allow the insertion or extraction of the conductor61of the cable6or the lead51of the diode5.

FIG. 6illustrates an alternative embodiment of the terminal assembly similar to that ofFIG. 5with the cable and the electrical wire of the solar panel as only elements that are different in present embodiment. Accordingly, the other elements are labeled with identical reference numerals. In present embodiment, the cable6and the electrical wire7of the solar panel each employs a board62,72with golden fingers instead of conductor as described in above embodiment. It will be apparent to those skilled in the art that various other alternatives to the cable or electrical wire may be employed, such as employing the contacts to replace the boards with golden fingers of present embodiment or the conductors of the previous embodiment.

As one advantage of the connecting box described previously, the elastic terminal for electrical elements of the solar panel has the releasing portion non-obstractedly arranged in the housing. This arrangement facilitates the operation of the insertion or extraction of the electrical elements of the solar panel because no tool is required and the operator can perform it only by using finger. Moreover, the contacts for connecting the solar panel, the cable, and the diodes are substantially identical in structure, which enhances the common usage of the contacts thereby making manufacture both time and cost efficient. Furthermore, the terminal base is formed with friction enhancing structures at regions where the conductors of the solar panel and the cable, and leads of the diodes positioned to enhance contact stability therebetween.

While the description as set forth is only a preferred embodiment of the present invention, it can also achieved by other various embodiments, for example, the first, second, third terminals may integrally formed with the terminal base just ensure the releasing portion of the first terminal extending beyond the terminal base. In addition, since the diodes are seldom disassembled from the terminal base after assembling, the leads of the diodes may connect to the terminal base via a permanent connection means, such as soldering means, in this case, the third terminal can be omitted and the manufacture expense is reduced. Any equivalent modifications made by a person skilled in the art according to the teaching of the present invention should be construed to be included within the scope or spirit of the appended claims as defined in the present invention.