Modular Solar Junction Box With Replaceable Diode Block

Solution Overview

Problem

Existing solar panel installations face high costs and inefficiencies when a solar module becomes defective, as the entire module often needs to be replaced, and manufacturers must customize output specifications for different coupling assemblies.

Innovation Solution

A universal solar junction box with multiple sub-assemblies, including a replaceable diode block and an open-IP plug sub-assembly, allowing for cost-effective replacement of defective components and flexibility in adapting to various output coupling wiring specifications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the entire solar module is replaced when a component becomes defective, then the system reliability is maintained, but the cost and loss of time increase significantly

Engineering Contradiction:

Improvesystem reliabilityVSAvoidreplacement time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The junction box is divided into separate replaceable modules: a base assembly, a diode block, and an expansion module. This segmentation allows the diode block to be replaced independently without replacing the entire junction box, reducing replacement time and cost while maintaining system reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design enables selective replacement of only the defective diode block while recovering and retaining the functional base assembly and other components. This partial replacement approach reduces material waste and installation time compared to replacing the entire junction box.

Inventive Principle:

Principle #34Discarding and recovering

2Reliability

If the entire solar module is replaced when a component becomes defective, then the system reliability is maintained, but the cost increases significantly

Engineering Contradiction:

Improvesystem reliabilityVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The junction box is divided into separate replaceable modules: a base assembly, a diode block, and an expansion module. This segmentation allows the diode block to be replaced independently without replacing the entire junction box, reducing replacement time and cost while maintaining system reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design enables selective replacement of only the defective diode block while recovering and retaining the functional base assembly and other components. This partial replacement approach reduces material waste and installation time compared to replacing the entire junction box.

Inventive Principle:

Principle #34Discarding and recovering

3Adaptability or versatility

If solar module manufacturers customize output specifications for different coupling assemblies, then the adaptability to various wiring specifications is improved, but the device complexity increases

Engineering Contradiction:

Improveadaptability to wiring specificationsVSAvoidjunction box complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The base assembly is designed as a universal platform that can accommodate different diode blocks and expansion modules through standardized interfaces. This universality allows the same base assembly to support various wiring configurations and output specifications without increasing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The junction box is divided into separate replaceable modules: a base assembly, a diode block, and an expansion module. This segmentation allows the diode block to be replaced independently without replacing the entire junction box, reducing replacement time and cost while maintaining system reliability.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP3304729B1Apparatus of a universal module junction box

Publication Date: 2025.03.05 JA SOLAR USA

Figure 1A~1B
Figure 2A~2B
Figure 3

AI summary

Embodiments of the present disclosure are directed to a universal junction box for solar modules that comprises multiple sub-assemblies with a replaceable diode black and an open-IP plug sub-assembly. The universal junction box includes a first sub-assembly (junction box platform), a second sub-assembly (a replaceable diode block), and a third sub-assembly (an open sub-assembly or plug sub-assembly). If the electronics in the diode block becomes defective, a new replaceable diode block can be used to substitute into the defective diode black without having to replace the entire junction box. The open-IP plug sub-assembly provides the flexibility to couple a variety of cable sub-assembly or IMEs to the universal junction box as long as a particular selected cable sub-assembly fits with the dimension of the open-IP plug sub-assembly.