Solar Junction Box Cable Sealing via Gel Chamber and Over-molding
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Solution Overview
Problem
Conventional solar photovoltaic junction boxes face challenges in preventing water leakage and cable loosening, leading to potential short circuits and open circuits, respectively, due to complex fastening structures that complicate assembly and are not adequately sealed.
Innovation Solution
A solar photovoltaic junction box design featuring a housing with over-molded structures to securely fasten and seal the cable, using a chamber filled with gel to prevent water ingress and a ring clamp with embedded wings to maintain cable tension, along with a ring recess and protrusion for a solid seal and a drain channel to prevent water accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gel is applied locally and special fasteners are used to fix the cable, then water leakage prevention and cable loosening prevention are improved, but the fixing structure becomes complicated and assembly operation becomes difficult
Solution Approach 1:
The patent combines the cable fixing function and water sealing function into a single integrated cable entry structure. The housing body includes a through hole with an integrated design that secures the cable while preventing water ingress, eliminating the need for separate fasteners and local gel application. This merging of functions simplifies the overall structure while maintaining reliability.
Solution Approach 2:
The cable entry structure serves multiple functions simultaneously: it mechanically secures the cable to prevent loosening, seals the interface to prevent water leakage, and provides structural support. This multi-functional design replaces multiple specialized components with a single universal structure that accomplishes all necessary tasks.
2Reliability
If special fasteners are used to fix the cable, then cable loosening prevention is improved, but assembly operation becomes difficult
Solution Approach 1:
The cable fixing mechanism is integrated into the housing body structure itself, combining the fastening function with the housing. This eliminates the need for separate fasteners and simplifies the assembly process to a single operation of inserting and securing the cable through the through hole, maintaining reliability while improving ease of operation.
3Ease of manufacture
If conventional fastening methods are used, then cable fixation is achieved, but water sealing and cable tension maintenance are insufficient in severe weather conditions
Solution Approach 1:
The patent merges the fastening construction with water sealing features in the cable entry structure. The through hole design integrates both mechanical fixation and waterproof sealing capabilities, achieving simple manufacturing while ensuring reliable waterproof performance in severe weather conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design provides a simple, effective solution for preventing water leakage and cable loosening, ensuring reliable electrical connections and improved waterproof performance by securely fastening the cable and sealing the junction box, thus enhancing the operational stability of solar photovoltaic systems.
Implementation Method 1
a chamber for filling gel therein is formed between the terminal and a joint of the cable with the housing body
Data Source
AI summary
The invention discloses a solar photovoltaic junction box assembly having a housing having a housing body and a housing cover, a cable extending into the housing body and joined to the housing body, and an electrical connector disposed in the housing body and including at least a metal piece electrically connected to a solar cell and a terminal electrically connected to the cable, wherein a chamber for filling gel therein is formed between the terminal and the joint of the cable with the housing body. A part of the cable extending into the housing is fixed to and sealed in the housing by filling gel in the chamber, and first and second over-molded structures can further prevent the cable from being loosened relative to the housing of the junction box, and further prevent water from entering into the housing of the junction box.