Hook-Jaw Clamp Structure for Solar Junction Box Positioning
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Solution Overview
Problem
The existing methods for bonding a junction box to a solar panel using silicone adhesive are prone to shifting during the long curing process, which can loosen the connection between the conductive ribbon and the junction box, compromising power transmission and the service life of the solar panel.
Innovation Solution
A clamp structure with a base plate and jaws, where the second jaws form a hook-shaped configuration with arcs of varying curvatures, securely engaging with the junction box recesses to prevent shifting and enhance connection stability during bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicone adhesive is used to bond the junction box to the solar panel, then the connection stability is improved, but the curing time is extended to half a day to a day
Solution Approach 1:
The clamp structure is applied before the adhesive curing process to preliminarily secure the junction box in the correct position. The clamping action prevents shifting during the extended curing period, ensuring proper alignment is maintained from the start until the adhesive fully cures.
Solution Approach 2:
The clamp structure acts as an intermediary device that temporarily maintains the positional relationship between the junction box and solar panel during the curing process. It mediates the bonding process by providing mechanical support while the adhesive develops its bonding strength.
2Reliability
If the junction box and solar panel are bonded with adhesive, then the connection stability is enhanced, but the components may shift during the long curing process
Solution Approach 1:
The clamp structure applies preliminary counter-action to prevent the harmful effect of shifting during curing. By clamping the junction box firmly in position before and during the initial stages of curing, it counteracts external forces and gravity that would otherwise cause misalignment.
Solution Approach 2:
The clamp structure is applied in advance to secure the positioning before the adhesive fully cures. This preliminary mechanical fixation ensures that the junction box maintains its correct position relative to the solar panel throughout the curing process.
3Ease of operation
If a simple clamp structure is used to secure the junction box, then the installation is simplified, but the engagement with the junction box may cause damage
Solution Approach 1:
The second jaws have different curvature radii at different locations - a first curvature radius near the jaw opening and a second curvature radius away from the opening. This local variation in geometry allows the clamp to adapt to the junction box surface, providing secure engagement at the contact point while distributing stress to prevent damage.
Solution Approach 2:
The second jaws are designed with curved surfaces featuring different radius of curvature. This spherical/curved geometry allows the clamp to engage smoothly with the junction box recesses, reducing stress concentration and preventing damage while maintaining secure holding.
Data Source
AI summary
A clamp structure includes a base plate, a pair of first jaws, and a pair of second jaws. The first jaws extend respectively from two sides of the base plate in a face-to-face manner and form a first jaw opening at their ends. The first jaws are also formed with a pair of cutouts that face each other. The second jaws extend respectively from the pair of cutouts towards the base plate and form a second jaw opening at their ends. Each second jaw has a hook-shaped configuration composed of a first arc near the second jaw opening and a second arc away from the base plate, wherein the first arc has a greater curvature than the second arc. A junction box and a solar panel which are bonded together can be inserted into and thus clamped by the clamp structure so as to be secured against lateral shifting.