Junction Box Heat Dissipation via Insulative Block
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Solution Overview
Problem
Existing PV junction boxes suffer from poor heat dissipation due to the thermal radiation properties of metal materials, which can lead to premature destruction.
Innovation Solution
A junction box design featuring an insulative block with insert-molded metal contacting foils and diodes, along with hollows for deformation spaces, to efficiently transfer heat to the insulative block and facilitate rapid dissipation through the cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal contacting foils are used to connect diodes in the junction box, then electrical conductivity is improved, but heat dissipation deteriorates due to poor thermal radiation properties of metal materials
Solution Approach 1:
The patent introduces an insulative block as an intermediary material between the metal contacting foils and the external environment. This insulative block has superior thermal radiation properties compared to metal, allowing it to effectively transfer and radiate heat away from the diodes and contacting foils, thus resolving the heat dissipation problem while maintaining the electrical conductivity function of the metal components.
Solution Approach 2:
The patent changes the material parameter of the heat dissipation component from metal to insulative material. By selecting an insulative block with superior thermal radiation properties, the heat transfer mechanism is optimized, enabling more effective heat dissipation from the junction box while the metal contacting foils continue to provide necessary electrical connections.
2Stability of the object's composition
If the insulative block and contacting foils are tightly connected, then structural stability is improved, but thermal expansion causes separation between components
Solution Approach 1:
The patent explicitly accounts for thermal expansion by designing the connection structure between the insulative block and metal contacting foils to accommodate dimensional changes during temperature variations. The connection allows for expansion and contraction without causing stress concentration or separation, ensuring structural stability across different thermal conditions.
Solution Approach 2:
The patent incorporates a cushioning or buffering mechanism in the connection design between the insulative block and metal contacting foils. This beforehand cushioning allows the components to expand and contract freely during thermal cycles, preventing stress buildup and separation while maintaining structural integrity during normal operation.
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 effectively dissipates heat using the superior thermal radiation properties of plastic materials, preventing separation between components and ensuring reliable operation.
Implementation Method 1
The design effectively dissipates heat using the superior thermal radiation properties of plastic materials
Implementation Method 2
The insulative block defines a plurality of hollows to reserve deformation spaces to prevent a separation between the insulative block and the contacting foils after thermal expansion
Implementation Method 3
the insulative block defines a plurality of hollows to reserve deformation spaces to prevent a separation between the insulative block and the contacting foils after thermal expansion
Data Source
AI summary
A junction box includes a cable connecting box and a cover covering the cable connecting box. The cable connecting box includes an insulative block, a plurality of contacting foils retained in the insulative block and a plurality of diodes. Each diode connects with two neighborly contacting foils. The contacting foils are insert-molded with the insulative block. Based on thermal radiation properties of the plastic material is superior to that of the metal material, as the contacting foils transfer the heat to the insulative block, the insulative block would deliver the heat to the cable connecting box, then the heat would be delivered to the cover. Such that, the heat dissipates outside quickly from the junction box.