Patent Description:
The present invention relates generally to solar technologies and, more particularly, to a solar junction box assembly for providing electronics to solar panels.

Solar power industry has grown rapidly over the past decade, as more environmentally-conscious countries are advancing renewal energy and conserving earthly resources to combat against global warming and climate change. The urgency to scale back on carbon emissions cannot be overstated, statement which was promulgated in the gathering of leaders around the globe during the <NUM> United Nations Climate Change Conference, COP <NUM> or CMP <NUM>, in Paris, France. The increased use of solar energy is a centerpiece strategy to reduce the reliance on petroleum, along with several other solar initiatives that have been launched.

Constructions of solar farms and solar projects, plus installations of solar panels at offices and residential homes, provide an energy efficient mechanism to absorb the sun rays as a source of energy for generating electricity or heating. A solar module or a photovoltaic (PV) module is a packaged and connected assembly with a matrix of solar cells. Each solar module is rated by its direct current (DC) output power under a set of test conditions. One industrial leading company designing and manufacturing solar cells and solar modules is JA Solar, www.

Most solar panel installations contain an array of solar modules to supply a greater aggregate amount of power. Like any electrical product, there is a life cycle to electronic circuitry, or sometimes there is a failure in an electrical component. When a solar module becomes defective due to an electrical failure, one current solution is to replace the entire module with a new solar module. Such approach can be expensive, either singularly as a solar module or cumulatively for multiple solar modules. The current "in-module" electronics (IME) is quite fractured and difficult to implement, representing a risk for solar cell and module companies to incorporate IME into their solar modules. Another shortcoming of the conventional solution is that the solar module manufactures are required to customize the output specification of the solar modules depending on the choice of the coupling assembly to the solar modules.

In one conventional solution as described in <CIT>, with a U. counterpart Application No. <CIT>, the solar box includes a connection box operatively connected to an optional extension module. Inserted between a junction box and an expansion module, the optional extension module has an electronic circuit for controlling a connected solar panel, and transmits power from the junction box to the expansion module.

Accordingly, it is desirable to have a solar junction box with cost-effective design for replacement of a solar module when the solar junction box becomes defective, as well as flexibility to adapt the solar module to various output coupling wiring specifications.

Aspects of the present invention are set out in the claims.

Embodiments of the present disclosure are directed to a universal junction box for solar modules that comprises multiple sub-assemblies with a replaceable diode block 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 become defective, a new replaceable diode block can be used to substitute into the defective diode block without having to replace the entire junction box. The open-IP plug sub-assembly provides the flexibility to couple a variety of cable sub-assemblies 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.

A universal solar module box mounted on a solar module comprises (i) a junction box platform having a base plate, a blade block, and a cover, the blade block having a first blade and a second blade; (ii) a modular diode block electrically and mechanically coupleable to the junction box platform via the blade block. The modular diode block has a first connector and a second connector. The first blade of the blade block extends through the base plate and protruding through the first connector of the modular diode block for establishing an electrical connection between the first blade of the blade block and the first connector of the modular diode block. The second blade of the blade block extends through the base plate and protruding through the second connector of the modular diode block for establishing an electrical connection between the second blade of the blade block and the second connector of the modular diode block. The universal solar module box further includes (iii) a plug sub-assembly that has a plug block and a cable block, attachable to the junction box platform and the modular diode block. The plug sub-assembly provides a protective covering to weatherize the diode block, the blade block, and the cable block. The cable block is attachable mechanically to the plug block. The cable block secures mechanically and electrically to one or more output cables.

Broadly stated, 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 modular diode block coupled electrically and mechanically to the junction box platform via the blade block; and 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 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.

Advantageously, the claimed disclosure provides a universal junction box design that has an open-IP plug sub-assembly suitable for coupling with different types of cable assemblies, thereby reducing the costs and the necessity to have different types of junction box designs specific to a particular cable assembly specification. The claimed disclosure also provides the flexibility to couple to various IME components regardless of the functionality and size of the IME. In addition, the claimed disclosure provides a universal junction box design that minimizes or avoids the solar module manufacturers from liability or warranty claims.

The structure and methods of the present invention are disclosed in the detailed description below. This summary does not purport to define the invention. The present invention contains different embodiments, which may be applied to various different environments. Variations upon and modifications to these embodiments are provided for by the present invention, which is limited only by the claims. These and other embodiments, features, aspects, and advantages of the invention are better understood with regard to the following description, appended claims, and accompanying drawings.

The disclosure is described with respect to specific embodiment thereof, and reference will be made to the drawing, in which:.

A description of structural embodiments and methods of the present invention is provided with reference to <FIG>. It is to be understood that there is no intention to limit the invention to the specifically disclosed embodiments but that the invention may be practiced using other features, elements, methods, and embodiments. Like elements in various embodiments are commonly referred to with like reference numerals. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide an understanding of various embodiments of the inventive subject matter. It will be evident to those skilled in the art, however, that embodiments of the inventive subject matter may be practiced without these specific details. In general, well-known instruction instances, protocols, structures, and techniques have not been shown in detail.

The following definitions apply to the elements and steps described herein. These terms may likewise be expanded upon.

<FIG> is a structural diagram illustrating a universal solar junction box <NUM>, which is attached to a solar panel <NUM> for providing electrical connections to the solar panel and for providing placement of electronics inside the universal solar junction box <NUM>. The main constituents (or parts) of the universal solar junction box <NUM> are depicted in <FIG>. The universal solar junction box <NUM> includes three main sub-assemblies: a junction box platform <NUM> (also referred to as "a first sub-assembly"), a diode block <NUM> (also referred to as "a diode sub-assembly" or "a second sub-assembly"), and a plug sub-assembly <NUM> (also referred to as "an open-IP sub-assembly" or "an open-IP plug sub-assembly" or "a third sub-assembly"). In the first sub-assembly <NUM>, the junction box platform <NUM> includes a base plate <NUM>, a blade block <NUM>, and a cover for base plate <NUM>. The diode block <NUM> or the second sub-assembly <NUM> includes one or more diodes for controlling the electrical current supplied to the universal solar junction box <NUM>, and thus serves to prevent short circuiting in the associated solar panel. In the third sub-assembly <NUM>, the open-IP plug sub-assembly includes a plug block <NUM> and a cable block <NUM>. A sample solar panel <NUM> is illustrated on <FIG> and <FIG>, with the front side <NUM> of the solar panel as shown in <FIG> and the back side <NUM> of the solar panel as shown in <FIG>.

<FIG> is a structural diagram illustrating the first embodiment of a universal solar junction box in a second perspective, which is attached to a solar panel for providing electrical connections to the solar panel and providing placement of electronics inside the universal solar junction box. <FIG> is a structural diagram illustrating the constituents of the universal solar junction box in the second perspective with three sub-assemblies assemblies: the junction box platform, the diode block, and the open-IP plug sub-assembly. The universal solar junction box <NUM> includes the junction box platform <NUM>, which can be coupled to the diode block <NUM>, which in turn can be coupled to the plug sub-assembly <NUM>. In the first sub-assembly <NUM>, the junction box platform <NUM> comprises the blade block <NUM>, which can be inserted and coupled (or attached) to the base plate <NUM> with the cover for base plate <NUM>. The diode block <NUM> or the second sub-assembly <NUM> includes one or more diodes for controlling the electrical current supplied to the universal solar junction box <NUM>, and thus serves to prevent short circuiting in the associated solar panel. In the third sub-assembly <NUM>, the open-IP plug sub-assembly includes the plug block <NUM> and the cable block <NUM>.

<FIG> is a structural diagram illustrating the constituents of the junction box platform <NUM> and the diode block <NUM>. The blade block <NUM> is inserted into the base plate <NUM>, with the cover <NUM>, for coupling (or attaching) to the diode block <NUM>. A combined sub-assembly of the junction box platform <NUM> and the diode block <NUM>, collectively, are referred to as a junction box/diode block sub-assembly <NUM>.

<FIG> is a structural diagram illustrating the constituents of the open-IP plug sub-assembly <NUM>, which includes the plug block <NUM> and the cable block <NUM>. The concept of the open-IP plug sub-assembly is to provide a greater flexibility to manufacturers that have different specifications for plugging into the universal solar junction box <NUM>. The various manufactures may have a block to mount onto the universal solar junction box <NUM>, such as a micro inverter or solar module optimization box, as well as different number of cables, such as one cable (like an AC wire), two cables, four cables, etc. A manufacture can provide an inverter box for mounting onto the frame of the solar panel <NUM>, and connectable to the open-IP plug sub-assembly <NUM>, for converting direct current (DC) to alternating current (AC) to the solar module <NUM>. A manufacturer can provide the solar module optimization box, to mount the open-IP plug sub-assembly <NUM>, as a mechanism to monitor the solar module <NUM> and make adjustments to optimize the efficiency of the solar module <NUM> (or a plurality of solar modules). The concept of the open-IP plug sub-assembly is to provide a common interface (or platform) for various manufacturers that offers the flexibility to tailor their block (e.g., electrical/mechanical block with one or more wires) that is pluggable to the open-IP plug sub-assembly <NUM>. Without the common interface, a solar module will have to provide a wide range of product lines to fit and operate with each external communication box to the solar module. The cable block <NUM> has one or more open gaps for wires or cables to extend between the inside and outside of the cable block <NUM>. In an alternate embodiment, the inverter or the solar module optimization box can be integrated into the open-IP sub-assembly <NUM>. After inserting the cable block into the plug block <NUM> in the open-IPB sub-assembly <NUM>, the resulting combination of the open-IP plug sub-assembly is shown in <FIG>.

<FIG> is a structural diagram illustrating a combined sub-assembly of the junction box platform <NUM> with the diode block, the plug block <NUM>, and the cable block <NUM>. The junction box platform <NUM> (or the first sub-assembly) has assembled the base plate <NUM>, the blade <NUM>, and the cover <NUM> into one sub-assembly. The diode block <NUM> (or the second sub-assembly) is not shown in this figure. On the other end, the open-IP sub-assembly (or the third sub-assembly) is illustrated with the plug block <NUM> and the cable block <NUM>.

<FIG> is a structural diagram illustrating the junction box platform <NUM> (the first sub-assembly), the diode block (the second sub-assembly), and the open-IP plug sub-assembly <NUM> (the third sub-assembly). The junction box platform <NUM> has been assembled into one sub-assembly in this figure to include the base plate <NUM>, the blade <NUM>, and the cover <NUM>. The open-IP sub-assembly <NUM> has been assembled into one sub-assembly in this figure to include the plug block <NUM> and the cable block <NUM>. The diode block <NUM> ("the replaceable diode block"), which is a modular unit that can be removed and singularly replace the defective diode block <NUM>, rather than the entire solar junction box <NUM>, is shown to be placed between the junction box platform <NUM> and the open-IP sub-assembly <NUM>.

<FIG> is a structural diagram illustrating the junction box platform <NUM> (the first sub-assembly), the diode block <NUM> (the second sub-assembly), and the open-IP plug sub-assembly <NUM> (the third sub-assembly) coupled with a cable sub-assembly <NUM>. The cable sub-assembly <NUM> plugs into the cable block <NUM> and the plug block <NUM> in the open-IP plug sub-assembly <NUM>. In one embodiment, the cable sub-assembly <NUM> has a pair of cables that serve the solar module output with positive polarity and negative polarity. The cables or wires in the cable sub-assembly <NUM> are also replaceable and can be removed or unplugged from the open-IP sub-assembly for replacement, servicing, or testing of functions. After servicing or testing, the existing cable sub-assembly <NUM>, if the part is operational, a new cable sub-assembly <NUM>, is plugged back in to the cable sub-assembly <NUM>. In another embodiment, the cables on the cable sub-assembly <NUM> can be one or more DC cables or AC cables that operate as one or more micro-converters used to convert DC power to AC power. The cable sub-assembly <NUM> can be constructed from various embodiments to tailor to a specific device that will be plugged into the universal solar junction box <NUM>.

<FIG> is a structural diagram illustrating a first perspective of the base plate <NUM>, the replaceable diode block <NUM>, and an output cable sub-assembly <NUM>. In one embodiment, the base plate <NUM> is attached to the backside of the solar module <NUM>. As an example of attachment, the base plate <NUM> is glued to the backside of the solar module <NUM>. The output cable sub-assembly <NUM> includes the open-IP sub-assembly and one or more cables <NUM>. <FIG> shows another perspective of the same components of the base plate <NUM>, the replaceable diode block <NUM>, and the output cable sub-assembly <NUM>. <FIG> is a structural diagram illustrating the base plate <NUM> with a cage <NUM>, the replaceable diode block <NUM>, and the output cable sub-assembly <NUM> with a box cover <NUM>. The box cover <NUM> can be placed over the cage <NUM> for assembling the base plate <NUM>, the replaceable diode block <NUM>, and the output cable sub-assembly <NUM>.

<FIG> is a structural diagram illustrating a horizontal embodiment of one or more locking latches 42a and 42b for affixing with the blade block <NUM>. The base plate <NUM> is attached (such as glued) to the frame module and affixed (such as screwed) to the module frame <NUM> for additional strength to allow larger IME to be plugged. For example, the IME includes electronics such as inverters, DC-DC optimizers, etc. Optionally, an aluminum bar can also be inserted as part of the cage <NUM> for grounding. The blade block <NUM> extends through one or more slots 64a, 64b, 64c and 64d in the base plate <NUM> one or more electrical conducting blades 62a and 62b. Each of the electrical conducting blades 62a and 62b is inserted through a corresponding one of the slots 64a and 64b. Alternatively, a vertical embodiment with one or more locking latches for affixing with a vertical blade block <NUM> is illustrated in <FIG>.

<FIG> is a structural diagram illustrating the vertical locking latch embodiment for affixing with the replaceable diode block <NUM>. The replaceable diode block <NUM> includes one or more blade connectors 32a and 32b for plugging into the base plate <NUM>. When the diode block <NUM> becomes defective, it can be easily unplugged from the base plate <NUM> and replaced with a new diode block <NUM>. The modularity of the replaceable diode block <NUM> mitigates the expensive and cumbersome approach of having to replace the entire solar module when one of the diodes, which is sealed to a solar junction box, becomes defective. The reliability and life cycle of a diode can be a weak point in the solar module. If one of the diodes in a traditional sealed diode block is short circuited, the solution is relatively expensive in having to replace the entire solar module instead of just a diode block.

<FIG> is a structural diagram illustrating the replaceable diode block <NUM> with spring connectors 36a and 36b for receiving and affixing to vertical locking latches <NUM>. In this embodiment, the replaceable diode block <NUM> includes three diodes 34a, 34b and 34c, that are pre-assembled in one block, as well as spring connectors 36a and 36b, electrical conducting blade connectors 32a and 32b, and one or more wires <NUM>. The spring connector 36a is electrically connected to the diode 34a via a wire, which is electrically connected to the electrical conducting blade connection 32a via a wire 38a, which is electrically connected to the diode 34a via a wire 38b, which is electrically connected to the electrically conducting blade connector <NUM> via a wire 38c, which is electrically connected to the diode 34c via a wire 38d, and which is electrically connected to the spring connector 36b via a wire 38e. Each of the diodes 34a, 34b and 34c produce heat when active. The replaceable diode block <NUM> can include an optional heat dissipating silicone 31a within a cavity 31b of the replaceable diode block <NUM>, thereby reducing or preventing overheating caused to one of the diodes. The heat dissipating silicone 31a can be filled throughout the entire cavity 31b of the replaceable diode block <NUM>, or surrounding the exterior areas of the diodes 34a, 34b and 34c. Other types of heat dissipating materials that are suitable to operate with diodes can also be used.

<FIG> is a structural diagram illustrating a first embodiment of the output cable sub-assembly <NUM> with a cover <NUM> for attaching to a pair of wires 92a and 92b. The cover <NUM> in the output cable sub-assembly <NUM> can be used to mechanically and electrically coupled to operate with any types of IMEs to service their customers. One benefit from this type of design is the allocation of warranties. While a first company, such as JA Solar, provides a solar module, including a junction box, and the associated warranty for the solar module, the second company who provides an IME for coupling to the cover <NUM> of the output cable sub-assembly <NUM> would provide the warranty for that portion of the electronics and part. This effectively reduces the warranty exposure and liability of the solar module company. In an alternative embodiment, <FIG> is a structural diagram illustrating a second embodiment of the output cable sub-assembly with a single wire 92c that is mechanically and electrically coupled to the cover of the output <NUM> cable sub-assembly <NUM>.

<FIG> is a structural diagram illustrating a horizontal assembly embodiment with the junction box platform <NUM>, the diode block <NUM>, and the output cable sub-assembly <NUM> (or open-IP plug sub-assembly <NUM> with the pair of cables 92a and 92b). In this horizontal assembly embodiment, the junction box platform <NUM> incudes the horizontal blade block <NUM>, which has one or more horizontal blades that extend horizontally to the replaceable diode block <NUM>. The open-IP plug sub-assembly <NUM> also has a horizontal construction for coupling to the replaceable diode block <NUM>. <FIG> is a structural diagram illustrating a vertical assembly embodiment with the junction box platform <NUM>, the diode block <NUM>, and the output cable sub-assembly <NUM> (or the open-IP plug sub-assembly <NUM> and the pair of cables 92a and 92b). In this vertical assembly embodiment, the junction box platform <NUM> incudes the vertical blade block <NUM>, which has one or more vertical blades that extend vertical to the replaceable diode block <NUM>. The open-IP plug sub-assembly <NUM> also has a vertical construction for coupling to the replaceable diode block <NUM>.

<FIG> is a structural diagram illustrating an embodiment of the universal solar junction box <NUM> attached to a solar module frame <NUM> of the solar module <NUM>. Additional views of the universal solar junction box <NUM> are shown in <FIG>. <FIG> is a structural diagram illustrating a second embodiment of the universal solar junction box <NUM> with a DC-to-DC optimizer <NUM> that can be plugged directly into the base plate <NUM> without the diode. Other alternative interface boxes can also be used in place of the DC-to-DC optimizer <NUM> or the replaceable diode block <NUM> for mechanically coupling between the junction box platform <NUM> and the open-IP sub-assembly. <FIG> is a structural diagram illustrating a third embodiment of the universal solar junction box <NUM> with a micro-inverter <NUM> that can be plugged directly into the replaceable diode block <NUM> and coupling between the junction box platform <NUM> and the open-IP sub-assembly.

A hardware module may also comprise programmable logic or circuitry (e.g., as encompassed within a general-purpose processor <NUM> or other programmable processor) that is temporarily configured by software to perform certain operations. It will be appreciated that the decision to implement a hardware module mechanically, in dedicated and permanently, configured circuitry, or in temporarily configured circuitry (e.g., configured by software) may be driven by cost and time considerations.

Accordingly, the term "hardware module" should be understood to encompass a tangible entity, be that an entity that is physically constructed, permanently configured (e.g., hardwired) or temporarily configured (e.g., programmed) to operate in a certain manner and/or to perform certain operations described herein. Considering embodiments in which hardware modules are temporarily configured (e.g., programmed), each of the hardware modules need not be configured or instantiated at any one instance in time. For example, where the hardware modules comprise a general-purpose processor configured to using software, the general-purpose processor may be configured as respective different hardware modules at different times. Software may accordingly configure a processor, for example, to constitute a particular hardware module at one instance of time and to constitute a different hardware module at a different instance of time.

Modules can provide information to, and receive information from, other modules. For example, the described modules may be regarded as being communicatively coupled. Where multiples of such hardware modules exist contemporaneously, communications may be achieved through signal transmission (e.g., over appropriate circuits and buses) that connect the modules. In the embodiments where multiple modules are configured or instantiated at different times, communications between such modules may be achieved. For example, communications may occur through the storage and retrieval of information in memory structures where the multiple modules have access. For example, one module may perform an operation and store the output of that operation in a memory device to which it is communicatively coupled. A further module may, at a later time, access the memory device to retrieve and process the stored output. Modules may also initiate communications with input or output devices, and can operate on a resource (e.g., a collection of information).

The various operations of example methods described herein may be performed, at least partially, by one or more processors that are temporarily configured (e.g., by software, code, and/or instructions stored in a machine-readable medium) or permanently configured to perform the relevant operations. Whether temporarily or permanently configured, such processors may constitute processor-implemented (or computer-implemented) modules that operate to perform one or more operations or functions. The modules referred to herein may, in some example embodiments, comprise processor-implemented (or computer-implemented) modules.

For example, some embodiments may be described using the term "connected" to indicate that two or more elements are in direct physical or electrical contact with each other. In another example, some embodiments may be described using the term "coupled" to indicate that two or more elements are in direct physical or electrical contact. The term "coupled", however, may also mean that two or more elements are not in direct contact with each other, but yet still co-operate or interact with each other.

As used herein, the terms "comprises", "comprising", "includes", "including", "has", "having" or any other variation thereof, are intended to cover a non-exclusive inclusion.

The terms "a" or "an", as used herein, are defined as at least one. The term "plurality", as used herein, is defined as two or more than two. The term "another", as used herein, is defined as at least a second or more.

Claim 1:
A universal solar module box (<NUM>) mounted on a solar module (<NUM>), comprising:
a junction box platform (<NUM>) having a base plate (<NUM>), a blade block (<NUM>), and a cover (<NUM>),
the blade block (<NUM>) having a first electrical conducting blade (62b) and a second electrical conducting blade (62a);
a modular diode block (<NUM>) electrically and mechanically coupleable to the junction box platform via the blade block, the modular diode block (<NUM>) having a first spring connector (36a) and a second spring connector (36b), the first blade (62b) of the blade block extending
through the base plate and protruding through the modular diode block (<NUM>) for establishing an electrical connection between the first blade (62b) of the blade block and the first spring
connector (36a) of the modular diode block (<NUM>), the second blade (62a) of the blade block
extending through the base plate and protruding through the modular diode block (<NUM>) for establishing an electrical connection between the second blade (62a) of the blade block and
the second spring connector (36b) of the modular diode block (<NUM>); and
a plug sub-assembly (<NUM>) having a plug block (<NUM>) and a cable block (<NUM>), attachable to the junction box platform and the modular diode block (<NUM>), 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 (<NUM>).