US 11,888,440 B2 · Apparatus and method of a universal module junction box

Abstract

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.

Claims29

Dependent claims

A universal solar module box mounted on a solar module, comprising:

a junction box platform having a base plate, a blade block, and a cover;
a singular modular diode block coupled electrically and mechanically to the junction box platform via the blade block, the singular modular diode block serving as a replaceable modular unit;
and
a plug sub-assembly having a plug block and a cable block, attachable to the junction box platform and the singular modular diode block, the plug sub-assembly providing a protective covering to weatherize the singular modular diode block, the blade block, and the cable block, the cable block attachable mechanically to the plug block, the cable block securing mechanically and electrically to one or more output cables.

1 more element

A universal solar module box mounted on a solar module, comprising:

a junction box platform having a base plate, a blade block, a cover, and a cage;
a singular modular diode block coupled electrically and mechanically to the junction box platform via the blade block, the singular modular diode block serving as a replaceable singular modular unit, including:
a first diode having a first end and a second end,
a second diode having a first end and a second end,
a third diode having a first end and a second end,
a first spring connector connecting to the first end of the first diode,
a first electrical conducting blade connector disposed between the second end of the first diode and the first end of the second diode,
a second electrical conducting blade connector disposed between the second end of the second diode and the first end of the third diode;
a second spring connector connecting to the second end of the third diode;
and
a plug sub-assembly having a plug block and a cable block, attachable to the junction box platform and the singular modular diode block, the plug sub-assembly providing a protective covering to weatherize the singular modular diode block, the blade block, and the cable block, the cable block attachable mechanically to the plug block, the cable block securing mechanically and electrically to one or more output cables.

8 more elements

A universal solar module box mounted on a solar module, comprising:

(a) a junction box platform having a base plate, a blade block, and a cover, the base plate having a structure for attaching to one of a plurality of plug sub-assemblies dependent on a selection of a particular plug sub-assembly, the selected plug sub-assembly including electronics that optimize or invert a solar module output power for the solar module;
(b) a modular diode block (30) coupled electrically and mechanically to the junction box platform via the blade block, the entirety of the modular diode block serving as a singularly, independent, and replaceable modular unit that is inserted into the base plate with a cover for covering over a cavity of the base plate, the based plate is attached to the solar module, including:
a first diode having a first end and a second end,
a second diode having a first end and a second end,
a third diode having a first end and a second end,
a first spring connector connecting to the first end of the first diode,
a first electrical conducting blade connector disposed between the second end of the first diode and the first end of the second diode,
a second electrical conducting blade connector disposed between the second end of the second diode and the first end of the third diode;
a second spring connector connecting to the second end of the third diode;
and
(c) a plug sub-assembly having a plug block and a cable block, attachable to the junction box platform and the modular diode block, the plug sub-assembly providing a protective covering to weatherize the modular diode block, the blade block, and the cable block, the cable block attachable mechanically to the plug block, the cable block securing mechanically and electrically to one or more output cables,
wherein the modular diode block is replaced by another modular diode block if the singular modular diode block becomes defective, without having to replace the entirety of universal solar module box.

9 more elements

Dependencies are inferred from the claim text.

Apparatus and method of a universal module junction box

Life of this patent

Apparatus and method of a universal module junction box

Life of this patent

Abstract

Claims29