High Performance Photovoltaic Connector

Stable contact force in electrical connectors is the key to controlling power loss. Due to the deterioration of the contact interface, only increasing the contact resistance by 100mΩ will result in power loss (½kW-hr/day per panel per day, or up to 5% of the power output).

Thermal runaway and fire are also the result of high electrical resistance at the contact interface. The effective contact design and the performance of the contact alloy make the design engineer full of confidence that the junction box connector will provide the performance and reliability required by the application.

Photovoltaic connector application requirements

  • 25-40 years of stable electrical performance
  • 1000 DC; 35 one
  • Ambient temperature 85℃; maximum heating up 30℃
  • Contact resistance is less than 50 mΩ·increase
  • Resistant to multiple insertion and permanent deformation
  • The minimum contact force of silver plate is 1n; the minimum contact force of tin plate is 3n

For photovoltaic technology to realize its promised benefits, every component must perform flawlessly. In particular, the connector must provide a stable electrical path with minimal power loss and controlled insertion force. The use of high-performance copper alloy contact springs ensures that the connector is fully competent and reliable under almost any environmental conditions.

Advantages of high performance copper alloy contacts with performance alloys

The contact design is combined with the mechanical properties of the electroplated contact spring to provide stable resistance at the connector interface. Copper alloy contact spring alloy must provide:

  • High fatigue strength
  • High and stable contact force
  • Resistant to fretting
  • Minimum deformation after buckling
  • Minimum temperature rise and power loss
  • Stability at high temperature
  • Compatible with two-piece design
  • Effective and reliable design miniaturization ability

Specifically, the alloy properties that control the connector performance are:

  • Strength-produces contact force, low power loss and resistance to fretting wear
  • Conductivity-Minimize resistance heating
  • Stress relaxation resistance-provides mechanical stability at high temperatures

The performance alloy beryllium copper alloy provides the highest strength of all copper alloys. They have a conductivity of 50% of pure copper and have excellent thermal stress relaxation resistance at 150°C for more than 10,000 hours.

What kind of brush performance alloy provides advantages for photovoltaic connector design

  • More choices of high-performance copper alloy products
  • Small dimensional tolerance
  • Authentication attributes of each order
  • Design assistance
  • Global technical support
  • Products compliant with RoHS standards

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