Rail-Mountable Junction Box With Clamp Mounting and Hinged Lid
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Solution Overview
Problem
Electrical junction boxes attached directly to outside surfaces face challenges in being easily relocated, replaced, or reoriented without causing damage, and traditional attachment methods compromise the integrity of weather-resistant surfaces.
Innovation Solution
A rail-mountable junction box design featuring a base that mounts to photovoltaic component mounting rails, equipped with a clamp mechanism and a hinging lid that allows for easy installation, removal, and relocation, while maintaining a weather-resistant seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical junction boxes are attached directly to outside surfaces using traditional methods (screws, nails, glue, epoxy), then the junction boxes can be securely fixed in place, but the attachment methods compromise the integrity of weather-resistant surfaces and make relocation difficult
Solution Approach 1:
The patent introduces a rail mounting system as an intermediary between the junction box and the mounting surface. The rail attaches to the photovoltaic array frame without penetrating or damaging the weather-resistant surface, while the junction box then attaches to the rail. This mediator resolves the contradiction by providing secure fixation without direct attachment to the protected surface.
Solution Approach 2:
The mounting system is divided into separate components: a rail that attaches to the photovoltaic array frame and a junction box that attaches to the rail. This segmentation allows the rail to bear the mechanical load of secure fixation while leaving the weather-resistant surface intact, resolving the contradiction between secure attachment and surface preservation.
2Reliability
If electrical junction boxes are attached directly to outside surfaces, then they can be fixed in place, but they cannot be easily relocated, replaced, or reoriented without causing damage
Solution Approach 1:
The rail mounting system provides a dynamic attachment solution where the junction box can be easily moved along the rail or removed and reattached to different locations. The clamp mechanism allows for quick release and repositioning while maintaining stable attachment when installed, resolving the contradiction between stable fixation and relocation capability.
Solution Approach 2:
By separating the mounting function into a removable rail-junction box assembly rather than permanent surface attachment, the system enables easy relocation and reconfiguration. The segmented design allows the junction box to be detached from the rail and repositioned without damaging the underlying surface.
3Ease of manufacture
If chemicals and adhesives are used to attach junction boxes to outside surfaces, then attachment can be achieved, but the chemicals may cause damage to the surface and degrade over time requiring routine application of additional chemicals
Solution Approach 1:
The patent replaces chemical attachment methods (adhesives, epoxy) with a mechanical clamp-based mounting system. The clamp applies mechanical force to secure the junction box to the rail without chemical substances that could degrade or damage the surface. This mechanical system is durable, maintenance-free, and eliminates the problems of chemical degradation and surface damage.
Data Source
AI summary
A junction box includes a body configured to mount to a solar panel mounting rail, and a lid sized to seal against the body and to hingedly connect with the body when at a first angle that is less than a detaching angle. The lid is configured to separate from the body when at a second angle that is greater than the detaching angle.