Solar Junction Box Multi-Direction Foil Termination
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Solution Overview
Problem
Conventional solar junction boxes are limited in accepting foils from various directions, making termination of foils to terminals difficult and time-consuming, as they are designed to receive foils from a single direction, and the assembly process is hindered by the need for adhesive curing, which adds to overall assembly time.
Innovation Solution
A solar junction box design featuring a contact assembly with exposed terminals and a cover that allows foils to be terminated from multiple directions, eliminating the need for sidewalls and enabling faster access and assembly, with a housing that provides environmental protection after termination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional junction boxes with enclosed terminals are used, then environmental protection is provided, but access to terminals for foil termination is limited and time-consuming
Solution Approach 1:
The junction box is divided into two functional parts: a base that provides environmental protection and encloses the terminals, and a removable cover that can be taken off to allow access to the terminals for foil termination. This segmentation allows both environmental protection during operation and easy access during assembly.
Solution Approach 2:
The cover is designed to be removable rather than fixed, transforming the static enclosed structure into a dynamic one that can open during assembly and close during operation. This dynamic feature enables quick access to terminals without compromising the sealed environment when assembled.
2Device complexity
If junction boxes with single-direction foil acceptance are used, then terminal structure is simple, but versatility in accepting foils from different directions is limited
Solution Approach 1:
The terminal structure is designed with multiple foil acceptance surfaces and orientations, allowing the same terminal to receive foils from different directions (front, side, top). This universal design enables a single junction box model to accommodate various foil routing configurations without requiring directional-specific models.
Solution Approach 2:
The terminal design incorporates three-dimensional foil acceptance capabilities, allowing foils to approach from multiple spatial dimensions rather than being restricted to a single linear direction. This multi-dimensional approach increases versatility while maintaining structural simplicity.
3Strength
If adhesive curing is required to seal junction box to solar panel, then secure mounting is achieved, but assembly time is increased due to waiting for cure
Solution Approach 1:
The cover is designed to be attached to the base using mechanical fasteners (screws, clips, or snap-fits) that provide immediate secure mounting without requiring adhesive curing time. This preliminary mechanical attachment allows the junction box to be securely mounted while eliminating the waiting period for adhesive to cure.
4Object-affected harmful factors
If enclosed terminal design is used, then environmental protection is provided, but ease of operation for foil termination is reduced
Solution Approach 1:
The junction box is segmented into a protective base and an removable cover, allowing operators to easily remove the cover for foil termination and then replace it to restore environmental protection. This segmentation provides both protection and operational ease.
Solution Approach 2:
The cover is extracted from the permanent structure, allowing it to be temporarily removed during foil termination operations and then returned to its protective position. This extraction enables easy access to terminals while maintaining the enclosed protective design when needed.
Data Source
Figure 1~4
Figure 2
Figure 3
AI summary
A solar junction box (102) for a solar panel (106) includes a contact assembly (120) having a base (124) configured to be mounted to a solar panel and a terminal (150) held by the base. The base has at least one foil opening (160) configured to receive a foil (116). The terminal has a protection device contact (170) configured to be terminated to a protection device (154). The terminal has a foil contact (174) configured to be terminated to the foil. The terminal has a terminating contact (172) configured to be electrically connected to a terminating assembly (104). The solar junction box includes a cover (122) covering the contact assembly. The cover has walls (134) defining a cavity (140) receiving the terminal of the contact assembly. The walls are configured to be mounted directly to the solar panel.