Photovoltaic Junction Box Structure for Replaceable Bottom Plate Assembly
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Solution Overview
Problem
The existing junction boxes for photovoltaic modules require the replacement of both the housing and the bottom plate when the electronic element is replaced, leading to increased manufacturing costs.
Innovation Solution
A junction box design where the housing and the bottom plate are separately arranged, allowing only the bottom plate to be replaced when the electronic element is changed, without the need to replace the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the housing and bottom plate are integrated, then the structural strength is improved, but the manufacturing cost increases when electronic elements need replacement
Solution Approach 1:
The junction box is divided into separate components: the housing and the bottom plate assembly. The bottom plate can be detached from the housing, allowing the electronic elements mounted on the bottom plate to be replaced without replacing the entire housing. This segmentation resolves the contradiction by enabling cost-effective maintenance while maintaining structural integrity through proper connection design between the housing and bottom plate.
2Stability of the object's composition
If the housing and bottom plate are integrated, then the structural stability is improved, but the ease of repair deteriorates
Solution Approach 1:
The bottom plate is designed as a separate removable component from the housing. This allows the bottom plate with mounted electronic elements to be easily detached and replaced, significantly improving ease of repair. The structural stability is maintained through proper connection mechanisms between the housing and bottom plate that ensure stable assembly while allowing disassembly for repair purposes.
3Ease of repair
If the housing and bottom plate are separately arranged, then the ease of repair is improved, but the device complexity increases
Solution Approach 1:
The junction box is segmented into housing and bottom plate components, improving ease of repair. However, the complexity is controlled by using simple connection mechanisms such as snap-fits, clips, or standardized fasteners that require minimal assembly/disassembly steps. The bottom plate may include integrated mounting structures for electronic elements, reducing the need for additional separate components and keeping the overall device complexity manageable.
Solution Approach 2:
The bottom plate combines multiple functions: it serves as a structural support, a mounting platform for electronic elements, and a removable module for repair. By merging these functions into a single integrated bottom plate component, the design improves ease of repair without proportionally increasing device complexity, as the bottom plate itself becomes a multi-functional module rather than adding separate components for each function.
Data Source
AI summary
A junction box and a method for mounting a junction box. The junction box includes a housing and an assembly module. The housing is hollow inside to form an accommodation space. The accommodation space passes through two sides of the housing along a thickness direction of the junction box. The assembly module includes a bottom plate and an electronic element. Along the thickness direction of the junction box, the bottom plate is mounted on one side of the housing, the bottom plate and the housing define an accommodation cavity, the electronic element is mounted on the bottom plate, and at least part of the electronic element is located in the accommodation cavity. The housing and the bottom plate are separately arranged and connected to each other.