Curb and Cap Junction Box with Removable Panel
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Solution Overview
Problem
Existing solutions for protecting exterior electrical conductor connections from the elements, such as solar panel systems, fail to provide adequate protection while maintaining easy accessibility for maintenance and monitoring.
Innovation Solution
A curb and cap junction box assembly that includes a planar flashing portion, a central housing with top and bottom openings, a plate member with knockout sections for conductor apertures, a ground block for electrical grounding, a pan member for circuit board mounting, and a cap member with a gasket for sealing, designed to secure electrical conductors while allowing easy access and protection from water and weather.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealed enclosure is used to protect electrical connections from water and weather, then protection from elements is improved, but accessibility for maintenance deteriorates
Solution Approach 1:
The enclosure is divided into a permanent curb member that remains installed and a removable cap member that can be detached for maintenance access. This segmentation allows the sealed enclosure to maintain weather protection while enabling easy access to electrical connections by simply removing the cap portion.
2Ease of manufacture
If knockout sections are made removable to allow conductor access, then ease of installation is improved, but structural integrity deteriorates
Solution Approach 1:
The knockout sections are pre-formed as integral parts of the plate member during manufacturing, maintaining full structural integrity of the plate. During installation, these pre-formed knockout sections can be easily removed to create conductor access openings without compromising the overall strength of the plate member or requiring additional reinforcement.
Data Source
AI summary
A curb and cap junction box assembly protecting joined electrical conductors includes a curb member with a planar flashing and central housing extending upwardly from the flashing, forming an enclosed space. The central housing has top and bottom openings. A plate, secured over the bottom opening has a knockout section and a mounting pan for circuit boards. A cap member has a planar top and peripheral edge extending downward. The cap member reversibly fastens over the top opening of the central housing. The junction box assembly is secured to a structure by the flashing and receives an electrical conductor from the structure through the knockout aperture in the plate member. The electrical conductor extends through the top opening of the central housing and under the downward extending peripheral edge of the cap member and outside the junction box assembly. The junction box provides enclosure for high voltage applications.