Roof Junction Box Flashing With Water Diverter and Captive Lid Fastener
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Solution Overview
Problem
Existing junction boxes are not well-suited for outdoor use, as they can deteriorate due to water and heat exposure, and they often require multiple fasteners for installation, which can be lost or time-consuming to secure.
Innovation Solution
A junction box with integral flashing and a water diverter, where the flashing extends from the junction box base and is oriented to sit under shingle flashings, and a single captive fastener is used for lid security, reducing material usage and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple fasteners are used to secure the box lid, then the lid is securely fastened, but installation time increases and fasteners may be lost
Solution Approach 1:
The patent combines multiple fastening functions into a single integrated captive fastener system. The captive fastener is retained within the junction box structure, eliminating the need for multiple separate fasteners while maintaining secure lid attachment. This merging approach reduces installation time and prevents fastener loss while ensuring reliable lid security.
Solution Approach 2:
The captive fastener is designed to be self-retaining within the junction box, automatically securing the lid without requiring external fasteners that could be lost. The fastener system serves itself by being captured within the box structure, eliminating the need for additional fastening components and simplifying the installation process.
2Adaptability or versatility
If junction box is partially sealed for outdoor use, then it can be installed on exterior surfaces, but moisture builds up around the box increasing damage risk
Solution Approach 1:
The patent introduces flashing as an intermediary component between the junction box and the roof structure. The flashing extends from the base of the junction box and is configured to direct water away from the box, serving as a mediator that prevents moisture accumulation while allowing the box to remain installed on exterior surfaces. This intermediary element resolves the conflict between outdoor installation capability and moisture protection.
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 junction box with flashing and water diverter effectively directs water away from the junction box, reducing moisture damage, and the simplified fastening mechanism speeds up installation while minimizing the risk of lost fasteners.
Implementation Method 1
includes a water diverter that continuously extends from a lateral side of the junction box base and is shaped to direct water flow away from the junction box base
Data Source
AI summary
A junction box comprising a base configured to mount to a roof, the base including an enclosed bottom, an open end opposite the enclosed bottom, a first side extending from the enclosed bottom to the open end, a second side opposite of the first side, a third side extending from the first side to the second side, and a fourth side opposite the third side, a wall extending from the first side to the second, a high point disposed along the wall, the high point having an angle within a range of 90 degrees and 180 degrees, a lid sized to seal against and hingedly connect to the base, and a flashing that extends from a portion of the first side of the base, from a portion of the second side of the base, and from the wall, in a direction away from the base.