Terminal assembly including a junction box for a photovoltaic module and method of forming

A terminal assembly including a junction box for a photovoltaic module, comprising:

• a terminal connector which extends through a first surface of a photovoltaic module;
• a junction box attached to the first surface of the photovoltaic module with an adhesive, wherein the junction box comprises a first portion and a second portion, and wherein the first portion is positioned over the terminal connector and the second portion has an aperture;
• a power cable attached to the terminal connector and extending from the junction box first portion and through the second portion aperture, wherein the power cable comprises an inner conductive core and an outer insulating sheath;
• and
• a gasket composed of insulating materials which is attached to the power cable outer sheath and housed between the first surface of the photovoltaic module and the junction box, wherein the gasket comprises an epoxy and butyl rubber.

A method of forming a terminal assembly for a photovoltaic module, comprising:

• providing a terminal connector;
• attaching a power cable to the terminal connector;
• attaching a second gasket material to the terminal cable;
• attaching a junction box to the photovoltaic module, wherein a portion of the terminal connector, a portion of the terminal cable and the second gasket material are housed within a cavity of the junction box;
• filling the junction box cavity with a first gasket material;
• and
• curing the first gasket material to form a seal about an end portion of the power cable.