Universal Junction Box for Solar Panel Accessory Swapping

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Solution Overview

Problem

Existing solar panel systems require permanent attachment of accessory modules to individual panels, making it impractical to optimize individual panels due to the need for replacement or swapping, especially when panels or modules are damaged, and seasonal sunlight changes.

Innovation Solution

A universal junction box that can be affixed to solar panels and allows for easy, reversible engagement and disengagement of accessory modules, enabling their replacement without moving the panel, using a standard engagement interface compatible with preexisting modules.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If accessory modules are permanently affixed to solar panels, then structural stability is improved, but adaptability and ease of replacement deteriorate

Engineering Contradiction:

Improvestructural stabilityVSAvoidadaptability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The system is divided into two distinct segments: a permanently affixed junction box attached to the solar panel, and a separately replaceable accessory module. This segmentation allows the junction box to remain stably attached while the accessory module can be independently replaced, resolving the contradiction between structural stability and adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The junction box serves as an intermediary component between the solar panel and the accessory module. It provides a stable mounting interface while enabling modular replacement of the accessory module through its engagement interface, thus mediating between the need for permanent attachment and the need for easy replacement.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If accessory modules are hard wired to panels, then electrical connection reliability is improved, but ease of repair and replacement deteriorate

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidease of repair

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The electrical connection system is segmented into permanent wiring within the junction box and removable electrical connectors at the accessory module interface. This allows reliable electrical connections to be maintained through standardized connectors that can be easily disconnected and reconnected, resolving the contradiction between connection reliability and ease of repair.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The junction box acts as an intermediary that houses the electrical connection infrastructure, allowing accessory modules to be connected and disconnected without affecting the permanent wiring to the solar panel. This mediates between maintaining reliable electrical connections and enabling easy repair through modular replacement.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If entire panel assemblies are replaced when modules are damaged, then system reliability is improved, but loss of time and productivity deteriorate

Engineering Contradiction:

Improvesystem reliabilityVSAvoidloss of time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system is segmented so that only the damaged accessory module needs to be replaced rather than the entire panel assembly. The junction box remains attached to the panel while the accessory module is independently replaced, significantly reducing replacement time while maintaining system reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The junction box serves as a stable intermediary platform that remains in place during accessory module replacement. This allows damaged modules to be swapped out quickly without disturbing the permanent panel installation, reducing downtime while ensuring reliable system operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Adaptability or versatility

If standardized engagement interfaces are used, then adaptability and ease of operation are improved, but manufacturing precision requirements worsen

Engineering Contradiction:

ImproveadaptabilityVSAvoidmanufacturing precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The junction box employs a universal engagement interface that can accommodate multiple types of accessory modules through standardized mechanical and electrical connections. This universal design enables adaptability across different module types while using conventional manufacturing tolerances, resolving the contradiction between versatility and manufacturing precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10720879B2Solar panel junction box capable of integrating with a variety of accessory modules, and method of use

Publication Date: 2020.07.21 SHOALS TECHNOLOGIES GROUP LLC

AI summary

A junction box is affixed to, and electrically coupled with, a solar panel. The junction box is configured to releasably engage and disengage accessory modules, thereby allowing accessory modules to be replaced or exchanged easily. Accessory modules are electrically coupled with other accessory modules in the solar panel string. The furthest downstream accessory module is connected to a wire harness, which is connected to a central combiner box.