Patent ID: 12255445

DETAILED DESCRIPTION

Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims.

The following disclosure relates to a rail-mountable junction box. In one example, the rail-mountable junction box includes a housing sized and shaped for at least partially enclosing electrical components, cable routing into a structure, etc. A lid can be positioned over the housing to provide a secure, protective top covering. In some embodiments, the housing includes an exterior surface or mounting sidewall with mounting brackets (e.g., that are integrally connected to the mounting sidewall). These mounting brackets can include a low profile, sturdy hook (such as an L-shaped protrusion) for receiving a rail mount. In certain implementations, the mounting brackets also include a retention mechanism (e.g., a curled portion) for retaining the rail mount in place within the mounting bracket.

A rail mount can include a variety of attachment mechanisms insertable into the mounting brackets. In particular embodiments, a rail mount includes an adjustable clamp. Upon adjustment, the rail mount can attach the rail-mountable junction box to a solar array rail structure (e.g., a crossbar, support member, etc.) that mounts solar panels to a roof or wall structure. In the rail-attached position, the rail-mountable junction box can hang or suspend over a structure (e.g., a roof structure) by virtue of the cantilevered connection to the solar array rail structure.

As will be described in more detail below, the mounting brackets and the rail mount together can form a universal fit for myriad different solar array rail structures. Where conventional junction boxes are only compatible with a specific model or type of rail structure, the disclosed junction box is universally compatible with most, if not all, rail structures. Thus, the disclosed junction box can provide significant compatibility improvements over conventional junction boxes.

These and other embodiments are discussed below with reference toFIGS.1-20D. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to the figures is for explanatory purposes only and should not be construed as limiting. Furthermore, as used herein, a system, a method, an article, a component, a feature, or a sub-feature including at least one of a first option, a second option, or a third option should be understood as referring to a system, a method, an article, a component, a feature, or a sub-feature that can include one of each listed option (e.g., only one of the first option, only one of the second option, or only one of the third option), multiple of a single listed option (e.g., two or more of the first option), two options simultaneously (e.g., one of the first option and one of the second option), or combination thereof (e.g., two of the first option and one of the second option).

FIGS.1-2respectively illustrate a top perspective view and a bottom perspective view of an example rail-mountable junction box (hereafter “junction box”) in accordance with one or more embodiments of the present disclosure. As shown, a junction box100includes a lid102, a housing104, and mounting brackets108. Each is discussed in turn.

The lid102comprises a covering sized and shaped to at least partially enclose an interior portion within the housing104. In some embodiments, the lid102comprises a weather resistant lid (e.g., rain, snow, ice, wind, and/or ultraviolet ray resistant). In other embodiments, the lid102is completely weatherproof (e.g., impervious to rain, snow, ice, wind, and/or UV rays). In these or other embodiments, the lid102forms a rigid, protective casing over the housing104, thereby also protecting the internal volume of the housing104from exposure to debris, bugs, or even incidental foot trampling. Additional details of the lid102are discussed further below in relation toFIGS.3-4andFIGS.12-16.

The housing104comprises a partial enclosure (e.g., for housing electrical components in transmission of solar array power). In particular, the housing104comprises sidewalls106a-106d. The sidewalls106aextend upwards from (e.g., substantially perpendicular to) an exterior bottom surface110of the housing104. Specifically, the sidewalls106a-106dextend upwards from the exterior bottom surface110along a periphery112(i.e., perimeter edge) of the housing104. Like the lid102, the sidewalls106a-106dand the exterior bottom surface110can form a rigid, protective barrier around an internal volume of the housing104against the outside environment.

Together, the lid102and the housing104can mate or otherwise attach to each other—forming a protective seal or complete enclosure around the internal volume of the housing104. For example, the lid102can be oriented parallel to the exterior bottom surface110and positioned on a top portion of each of the sidewalls106a-106d. In such a position, the lid102and the housing104can be joined or fastened together (as will be explained below).

At least one of the sidewalls106a-106dis a mounting sidewall with an exterior mounting surface. Such a mounting sidewall can mount to a solar array rail structure that supports a solar array and/or affixes a solar array to a roof structure. The mounting sidewall (in this case, the sidewall106c) comprises the mounting brackets108. Via the mounting brackets108, the junction box100can attach to and suspend from a solar array rail structure. In particular, the mounting brackets108are sized and shaped to receive a rail mount (i.e., an attachment mechanism, not shown) that can removably attach the junction box100to a solar array rail structure. In some embodiments, the mounting brackets108are removably or permanently attached to the mounting sidewall. In other embodiments, the mounting brackets108are integrally formed with or tooled into the mounting sidewall as a continuous extension of the mounting sidewall. Further details of the mounting brackets108are provided below in relation to at leastFIGS.5-6.

In a rail-mounted position, the exterior bottom surface (and the junction box100as a whole) is raised above the roof structure—thereby avoiding direct contact with the roof structure. In this manner, the junction box100in a rail-mounted position can advantageously avoid or limit exposure to, for instance, rainwater that runs down a sloped roof structure or the wedging buildup of snow and ice.

In these or other embodiments, the junction box100can comprise one or more of a variety of materials. These materials can withstand the environmental elements, as well as the duration of use (e.g., 20+ years). In some embodiments, the junction box100comprises a rigid, stiff material (e.g., metal). Additionally or alternatively, the junction box100comprises a flexible or soft material (e.g., elastomer, rubber, rubber with saturated polymer backbones, ethylene propylene diene monomer rubber, etc.). In at least some examples, the junction box100comprises a non-conductive material or a UV-resistant material. In particular embodiments, the junction box100comprises a plastic material, a polycarbonate material, a polyvinyl chloride (PVC) material, an acrylonitrile butadiene styrene (ABS) material, acrylonitrile styrene and polycarbonate blend (ASA+PC) material, a polycarbonate and ABS blend (PC+ABS) material, etc. In another example, the junction box100comprises an acrylic material, a high density polyethylene material, polyamide-imide material, a polyvinylidene fluoride material, or a hydroxyphenyl benzotriazole material.

The junction box100can also be manufactured in a variety of different ways. In some embodiments, the junction box100is formed via molding, tooling, 3D-printing, casting, forging, or machining methods. In particular embodiments, the junction box100can be formed utilizing injection molding techniques. Additionally, in certain implementations, multiple versions of the junction box100can be formed simultaneously. For example, two or more of the junction box100can be injection molded utilizing multi-cavity tooling.

Further, the junction box100can be formed with a variety of strength-enhancing features. For example, the junction box100can include rounded corners, fillets, etc. that can reduce stress concentrations and improve rigidity/strength. To illustrate, the joint between the sidewalls106a-106dand the exterior bottom surface can include a fillet.

Likewise, the junction box100can be formed with a variety of manufacturing enhancement features. For example, in some embodiments, the sidewalls106a-106dare not perfectly perpendicular relative to the exterior bottom surface. Instead, the sidewalls106a-106dare positioned at least a half degree off 90 degrees to allow easier retraction or withdrawal of the injection molding tooling. As another example, the junction box100includes a built-in flashing without additional (or excess) material extending away from the housing104. For example, a portion of the interior bottom surface306(described below) surrounding a seal groove can help block or shed water from entering inside the housing104. Such example configurations can advantageously reduce material consumption.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown inFIGS.1-2can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown inFIGS.1-2.

Various example features of the lid102and the housing104will now be discussed in relation toFIGS.3-4. In particular,FIGS.3-4respectively illustrate top and bottom exploded views of the junction box100in accordance with one or more embodiments of the present disclosure.

As shown, the lid102comprises lid holes302, and the housing104comprises housing holes304. The lid holes302and the housing holes304are alignable to receive a fastener that, when fastened, secures the lid102and the housing104together. In some embodiments, at least one of the lid holes302or the housing holes304are threaded to engage a correspondingly threaded fastener (e.g., bolt or screw). In some embodiments, at least one of the lid holes302or the housing holes304are threadless. In certain implementations, at least one of the lid holes302or the housing holes304are self-tapping holes, subject to the tapping threads of a fastener. Still, in other embodiments, one of the lid holes302or the housing holes304can include captive fasteners that are positionally bound within the hole. Further, other embodiments of the lid102include a snap-on lid, an interference-fit lid, or a slide-on lid.

The housing104also includes an interior bottom surface306that opposes the exterior bottom surface110. Together with the sidewalls106a-106d, the interior bottom surface306bounds an internal volume of the housing104. In particular, the interior bottom surface306spans between a periphery308(e.g., an internal perimeter) of the housing104. The interior bottom surface306comprises a variety of features (e.g., for mounting electrical components, drilling thru-holes, evacuating water condensation, and/or positionally orienting an installer).

To illustrate, the interior bottom surface306comprises a drill zone310. The drill zone310corresponds to an area that can be drilled, punctured, or knocked out (e.g., for providing access to a cable or conduit). The drill zone310can be sized and shaped for at least one drill-hole. In particular embodiments, the drill zone310is sized and shaped to accommodate multiple 1-inch drill holes. Moreover, as will be described below in relation toFIG.9, the drill zone310can be sized and shaped to correspond with (e.g., fit inside of) a seal groove406in the exterior bottom surface.

The interior bottom surface306further comprises a DIN rail clip-in312. The DIN rail clip-in312comprises one or more elements to secure a DIN rail to the interior bottom surface306. In particular, the DIN rail clip-in312comprises elements that can secure a DIN rail to the interior bottom surface306without the use of fasteners. To illustrate, the DIN rail clip-in312includes a first portion (not shown) that secures a first DIN rail end and a second portion that secures a second DIN rail end. Further aspects of the DIN rail clip-in312are described below in relation toFIGS.10-11.

Although illustrated in a particular orientation (e.g., front-to-back or north-to-south), those of ordinary skill in the art will appreciate that the DIN rail clip-in312can be arranged in a variety of different orientations and configurations. For example, the DIN rail clip-in312can be oriented side-to-side (east-to-west) or diagonally toward opposing corners. As another example, the DIN rail clip-in312can be positioned off-center on the interior bottom surface306. Similarly, in some embodiments, the interior bottom surface306can include multiple DIN rail clip-ins (e.g., the DIN rail clip-in312as shown plus an additional DIN rail clip-in running side-to-side perpendicular to the DIN rail clip-in312).

In at least some embodiments, a DIN rail is also positionable on top of a DIN rail support structure322. For example, a bottom surface of a DIN rail can physically rest (e.g., contact or abut) the DIN rail support structure322. As shown, the DIN rail support structure322comprises one or more blocks, ribs, or raised protrusions that extend upward from the interior bottom surface306. In particular embodiments, the DIN rail support structure322has a height of about 1 millimeter to about 10 millimeters, as may be desired. Thus, the DIN rail support structure322can advantageously suspend a DIN rail above the interior bottom surface306to reduce or eliminate trapped moisture on the interior bottom surface306. Instead of moisture pooling around the DIN rail, moisture can freely pass underneath the suspended DIN rail and out of weep holes316discussed below.

The housing104also includes weep holes316. The weep holes316can promote the evacuation of condensation inside the housing104. Additionally or alternatively, the weep holes316can vent air or otherwise facilitate air exchange into and out of the housing104(thereby drying out condensation). In some embodiments, the weep holes316are positioned within the interior bottom surface306(and the exterior bottom surface) and the sidewalls106a-106d. That is, the weep holes316can comprise thru-holes that extend from the interior bottom surface306to the exterior bottom surface and extend upwards along a portion of the sidewall106a. By extending upwards along the sidewall106a, condensation can be evacuated notwithstanding the different possible orientations or angles of the junction box100(whether suspended over a roof structure or side-mounted on the side of a house).

The weep holes316can be arranged in various different ways and locations. In particular embodiments, the weep holes316are located adjacent to bottom corners of the sidewall106a. In this position, the sloped suspension of the junction box100and the effect of gravity can draw condensation out of the weep holes316in the sidewall106a. In other embodiments, the weep holes316are located in a central portion of one or more of the sidewalls106a-106dat the periphery308and the periphery112. Still, in other embodiments, the weep holes316are interspaced along the periphery308and the periphery112.

The housing104also includes standoffs318positioned on the interior bottom surface306. The standoffs318can define a recess for receiving fasteners. Protruding up from the interior bottom surface306, the standoffs318can specifically include a recess sized and shaped to provide engagement with the fasteners, yet prevent the fasteners from penetrating the interior bottom surface306. In particular embodiments, the standoffs318can be used to attach grounding bars, grounding lugs, DIN rails, or other suitable element within the internal volume of the housing104. The standoffs318can be positioned in a variety of different configurations, as may be desired. In particular implementations, however, the standoffs318are positioned in pairs adjacent to the sidewall106c.

The housing104further includes a boss320positioned within the interior bottom surface306. The boss320includes a thru-hole or a knock-out for creating a thru-hole. Fasteners can be inserted through the boss320to secure the housing104to a roof structure or a wall structure (e.g., for non-rail mounted positions of the junction box100). Although not shown inFIG.3, the housing104can include multiple bosses320(e.g., four bosses interspaced across the interior bottom surface306).

The housing104also includes drilling boundary indicators314. The drilling boundary indicators314comprise a visual or tactile indication where sidewall drilling is permitted (i.e., in a central area between a pair of the drilling boundary indicators314on a given sidewall). Outside of the drilling boundary indicators314toward a corner area, there is potentially less room (or insufficient room) for a housing-internal conduit fitting to secure a conduit positioned inside the sidewalls106a-106d. In at least some embodiments, the drilling boundary indicators314are positioned on select sidewalls, (e.g., three sidewalls not abutting a solar array rail structure, such as the sidewalls106a,106b,106d). In other embodiments, the drilling boundary indicators314are positioned on each of the sidewalls106a-106d.

The drilling boundary indicators314can, in certain implementations, include an indented groove, a raised rib, etc. In some embodiments, the drilling boundary indicators314can include laser markings or other indicia. Additionally or alternatively, portions of the sidewalls106a-106don opposite sides of the drilling boundary indicators314can include different colors, indicia, or visual/tactile patterns. Further detail of the drilling boundary indicators314are discussed below in relation toFIGS.15-16.

As shown inFIG.4, the underside of the lid102further includes a gasket channel402defined by a gasket wall404and a flange405. Specifically, the gasket channel402is positioned between the gasket wall404and the flange405. The gasket wall404includes raised rib, surface protrusion, or jutted lip that runs around the perimeter of the lid102. The gasket wall404is parallel to the flange405and circumscribes the lid holes302. In addition, the gasket wall404is sized and shaped to retain a gasket against the flange405. The flange405comprises the side portion of the lid102, including the portion of the lid102which envelops an outer perimeter of the housing104.

A variety of different gaskets (not shown) can be positioned inside of the gasket channel402, such as an O-ring, a formed in place (FIP) gasket, or a cure in place (CIP) gasket. In these or other embodiments, the gasket can be pliable so as to conform to the gasket channel402. For example, in response to positioning (and securing) the lid102in place over the housing104, the gasket can compress against the lid102. In so doing, the gasket can form a seal against the gasket wall404and the flange405. In certain implementations, the formed seal comprises a hermetic seal, waterproof seal, etc.

FIG.4further shows the housing104comprises a seal groove406. The seal groove406can be particularly advantageous for non-rail mounted positions of the junction box100(e.g., when the junction box100is directly fastened to a roof structure or wall structure instead of suspended from a solar array rail structure). In some embodiments, the seal groove406comprises a sealant guide for applying sealant, adhesive, tape, or a gasket to the housing104. The seal groove406can include a partial perimeter around the exterior bottom surface. In other embodiments, the seal groove406can include an entire perimeter around the exterior bottom surface. In some examples, the seal groove406is sized and shaped to encompass the drill zone310(as will be described more below in relation toFIG.9). Additionally, in some examples, the seal groove406is shaped to include a leading vertex or corner (whether rounded or pointed). With such geometry, the sealant positioned along the seal groove406can more easily shed or divert water away from (or at least around) the housing104.

As just mentioned, the seal groove406can include a partial perimeter around the exterior bottom surface. This partial perimeter can form a gap408. The gap408can advantageously allow the area between the exterior bottom surface and a supporting structure (e.g., a wall structure or roof structure) to breathe and/or evacuate condensation. In particular embodiments, the housing104comprises additional weep holes410formed in the exterior bottom surface. The additional weep holes410can be located in a variety of locations. However, in some embodiments, the additional weep holes410are positioned at areas corresponding to the DIN rail clip-in312, as will be described more below in relation toFIGS.10-11. Thus, fluid or condensation can be evacuated from the additional weep holes410and out through the gap408. In this manner, the gap408can be in fluid communication with the additional weep holes410.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown inFIGS.3-4can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown inFIGS.3-4.

Additional detail regarding the mounting brackets108is now provided. In particular,FIGS.5-6respectively illustrate top and perspective views of the mounting brackets108in accordance with one or more embodiments of the present disclosure. As shown, the mounting brackets108includes a first bracket wall502, a second bracket wall504, and a retaining edge506. The first bracket wall502is connected to the sidewall106c(i.e., the mounting sidewall). In some embodiments, the connection between the first bracket wall502and the mounting sidewall comprises a reinforced connection514. The reinforced connection514can include additional material (e.g., an increased thickness of material). Additionally or alternatively, the reinforced connection514can include a fillet (as opposed to sharp corner).

At the reinforced connection514, the first bracket wall502can extend substantially perpendicularly away from the mounting sidewall. The second bracket wall504then connects to the opposing end of the first bracket wall502(e.g., in a substantially perpendicular fashion). The second bracket wall504extends away from the first bracket wall502in manner substantially parallel to the mounting sidewall. The retaining edge506further connects to the second bracket wall504. The retaining edge506comprises a curved portion oriented toward the mounting sidewall.

The various members of the mounting brackets108just described can be attached together in a variety of ways. In some embodiments, each of the first bracket wall502, the second bracket wall504, and the retaining edge506can be integrally (or inseparably) formed together as a continuous, unibody bracket. For example, the first bracket wall502, the second bracket wall504, and the retaining edge506can be molded, tooled, 3D-printed, cast, forged, or machined as a single piece. In other examples, at least one of the first bracket wall502, the second bracket wall504, or the retaining edge506can be attached (whether permanently or non-permanently). For instance, at least one of the first bracket wall502, the second bracket wall504, or the retaining edge506can be bonded, adhered, fastened, press fit, or interlocked together.

In these or other embodiments, the various members of the mounting brackets108define an interior portion510accessible by a clearance distance512. In particular embodiments, the interior portion510is sized and shaped to receive a rail mount (seeFIGS.19-20D). For example, the interior portion510is sized and shaped to receive a clamp, zip tie, Velcro® strip, bailing wire, rope, string, or tape.

Likewise, the clearance distance512can be sized to permit convenient, quick access into the interior portion510for certain types of rail mounts. Additionally or alternatively, the clearance distance512can be sized to retain a rail mount within the interior portion510(e.g., such that a rail mount does not slip or fall out of the interior portion510). That is, the retaining edge506curves inward to form a choke point—which having the clearance distance512—can be sufficiently small to help prevent a rail mount from slipping out of the mounting brackets108. To illustrate, the clearance distance512can range from 0.1 inches to 0.75 inches.

In a particular use case, as will be described below in relation toFIGS.20A-20D, the retaining edge506defining the clearance distance512can even retain a rail mount that has yet to be tightened or fastened to a solar array rail structure. Advantageously, this can allow an installer to handle the junction box100without worry or hassle of a rail mount falling out of the mounting brackets108.

In certain implementations, the mounting brackets108can further include an optional mounting plate508. In particular embodiments, the optional mounting plate508abuts the surface of the mounting sidewall (the sidewall106c) in a parallel fashion. In addition, the optional mounting plate can adjoin the first bracket wall502(e.g., at the reinforced connection514). In these or other embodiments, the optional mounting plate can provide increased stability or rigidity for the mounting brackets108. In particular embodiments, the optional mounting plate can provide increased resistance to an applied bending moment (discussed more below in relation toFIG.9) by spreading the transferred load across the surface of the optional mounting plate. Alternatively, in some embodiments, the optional mounting plate can be omitted from the mounting brackets108.

In some embodiments, the mounting brackets108can be attached to the mounting sidewall (the sidewall106c) in various ways. For example, the mounting brackets108can be integrally (or inseparably) formed as part of the mounting sidewall (e.g., via molding, tooling, 3D-printing, casting, forging, or machining methods). As another example, the mounting brackets108can be permanently or removably attached to the mounting sidewall. For instance, the mounting brackets108can be fastened, bonded, adhered, or interlocked with the mounting sidewall.

In at least one embodiment, the mounting brackets108are slidably attached to the mounting sidewall (the sidewall106c). For example, the mounting brackets108and the mounting sidewall can include one or more corresponding geometries or mating structures (e.g., tongue and groove, T-slots, lap joints, dovetail joints, box joints, dado joints, lap joints, butt joints, mortise and tenon joints, birdsmouth joints, bridle joints, pocket-hole joints, etc.) To illustrate, the mounting sidewall can include a slotted region sized and shaped to slidably receive at least one of the reinforced connection514or the optional mounting plate508. In such an example, the mounting brackets108are held within the slotted region via overhanging portions on the mounting sidewall, thereby creating an interference fit with the mounting brackets108. Optionally, the slotted region can include one or more caps or stops to prevent the mounting brackets108from incidental withdrawal out of the slotted region.

Those of ordinary skill in the art will appreciate that the mounting brackets108can include other configurations. For example, the mounting brackets108can include a closed-loop bracket as shown inFIG.7. In this figure, a mounting bracket700comprises the same or similar elements as the mounting brackets108. However, instead of the retaining edge506, the mounting bracket700comprises a third bracket wall702at least partially enclosing the interior portion510. In particular, the third bracket wall702connects the second bracket wall504and the mounting sidewall (the sidewall106c). In doing so, the third bracket wall702is formed parallel to the first bracket wall502, and perpendicular to both of the second bracket wall504and the mounting sidewall. Together, the first bracket wall502, the second bracket wall504, and the third bracket wall702form a closed loop.

In this example configuration, a rail mount can be threaded through the interior portion510to engage the mounting brackets108(as opposed to entering and exiting the interior portion510via the clearance distance512). Without the clearance distance512, the mounting bracket700can, in certain instances, more easily retain a rail mount. Additionally or alternatively, the third bracket wall702can provide increased strength and rigidity for the mounting bracket700. For instance, the third bracket wall702can approximately halve the bending load that the mounting brackets108undergoes at the reinforced connection514(e.g., by splitting the bending moment transferred through connections of the first bracket wall502and the third bracket wall702to the mounting sidewall).

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown inFIGS.5-7can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown inFIGS.5-7.

Some additional detail regarding the housing104is now presented. In particular,FIGS.8-9respectively illustrate top and bottom views of the housing104in accordance with one or more embodiments of the present disclosure. In particular,FIG.8illustrates a drill zone boundary800around the drill zone310. In some embodiments, the drill zone boundary800comprises a tactile or visual groove defined by the interior bottom surface306. In other embodiments, the drill zone boundary800comprises a laser marking, raised protrusion, patterned or colored indicia, etc. In this manner, the drill zone boundary800can provide visual and/or tactile feedback for easily and conveniently locating the drill zone310within the interior bottom surface306.

In these or other embodiments, the drill zone boundary800can be sized and shaped for a variety of configurations. Indeed, as mentioned above, the drill zone310(and therefore the drill zone boundary800) can be sized and shaped to accommodate multiple thru-holes (e.g., with one-inch fittings). In particular embodiments, the drill zone310(and therefore the drill zone boundary800) can be sized and shaped to accommodate a particular positional arrangement of thru-holes, as may be desired based on cable entry location.

Moreover, as shown inFIG.9, the drill zone boundary800is sized and shaped to fit inside of the seal groove406defined by the exterior bottom surface. In these or other embodiments, the drill zone boundary800is positionally offset from the seal groove406(e.g., to provide a buffer region for incidental error in either sealant application or drilling). For example, the drill zone boundary800is positionally offset from the seal groove406by a range of 0.1 inches to 3 inches, and in particular implementations, by 0.5 inches. Thus, sealant applied along the seal groove406can help prevent water infiltration into a thru-hole positioned within the drill zone310(i.e., on or inside of the drill zone boundary800), as well as any corresponding holes into a roof or wall structure to route a cable or wire.

Those of ordinary skill in the art will appreciate that sealant can include myriad different types of seals. For example, sealant can include a gel-type sealant, a caulk-type sealant, a foam sealant, a rubber seal, a tar seal, a tape seal (e.g., Butyl seal, peel-and-stick seal), a compression seal, an expansion seal, etc. Additionally or alternatively, sealant can include a seal formed by way of chemical reaction, change of state (e.g., liquid to solid), or change in size (to name a few examples).

FIGS.8-9further show an arrangement of the standoffs318and the bosses320discussed above. As shown, the bosses320comprise four knock-outs or thru-holes interspaced in a rectangular fashion across the interior bottom surface306(albeit other configurations are herein contemplated). In some embodiments, the bosses320are positioned outside of the drill zone310. Thus, the bosses320do not reduce the useable footprint of the drill zone310. Additionally, in particular embodiments, the bosses320are positioned inside of the seal groove406(as shown inFIG.9). In this manner, sealant applied along the seal groove406can help prevent water infiltration into the bosses320, as well as water infiltration into corresponding holes into a roof or wall structure to engage a fastener.

In addition,FIG.8shows a first end portion802and a second end portion804of the DIN rail clip-in312. Together, the first end portion802and the second end portion804can secure a DIN rail inside the housing104. In particular, the first end portion802can secure a first end of a DIN rail, and the second end portion804can secure a second end of a DIN rail. The particular aspects of the first end portion802and the second end portion804are discussed below in relation toFIGS.10-11, respectively.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown inFIGS.8-9can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown inFIGS.8-9.

FIG.10illustrates the first end portion802in accordance with one or more embodiments of the present disclosure. As, shown, the first end portion802comprises guide posts1000. The guide posts1000include opposing arms that protrude upwardly (e.g., substantially perpendicularly) from the interior bottom surface306. In particular, the guide posts1000are spaced apart a distance1001. The distance1001can correspond to a DIN rail width (as measured between opposing shoulders or rails on a DIN rail). In particular embodiments, the distance1001is between 25 millimeters and 50 millimeters.

Further, the first end portion802comprises an end holder1002. The end holder1002includes a base1004and a lip1006. The base1004connects the end holder1002to the interior bottom surface306and juts upwardly (e.g., substantially perpendicularly) from the interior bottom surface306. The lip1006then integrally connects to the base1004and extends perpendicularly away from the base1004(e.g., toward the second end portion804of the DIN rail clip-in312, not shown). In these or other embodiments, the base1004and the lip1006form an L-shaped protrusion or riser oriented toward the guide posts1000. In particular, the underside of the lip1006is positioned at a height1005above the interior bottom surface306. The height1005can correspond to a DIN rail wall thickness. For example, the height1005can range from 0.5 millimeters to 5 millimeters.

Together, the guide posts1000and the end holder1002can secure an end portion of a DIN rail. For example, a DIN rail can be slid between the guide posts1000, thereby ensuring the DIN rail is properly aligned. In some embodiments, the guide posts1000contact the DIN rail, which can also provide support or stability to the DIN rail. In other embodiments, the guide posts1000do no contact the DIN rail. Rather, the guide posts1000can be for visual aid purposes. In addition, the DIN rail can be slid toward the end holder1002such that a bottom edge of the DIN rail slides underneath the lip1006. Once underneath the lip1006, the corresponding portion of the DIN rail can be pivotably anchored in place. That is, once one end of the DIN rail is positioned between the guide posts1000and inside the end holder1002, the opposite portion of the DIN rail can be pivoted toward the second end portion804for locking into place (as will be described in relation toFIG.11).

FIG.11illustrates the second end portion804in accordance with one or more embodiments of the present disclosure. As shown, the second end portion804comprises locking posts1102. The locking posts1102include arms1101that extend upwardly (e.g., substantially perpendicularly) from the interior bottom surface306. In certain embodiments, the locking posts1102are flexible. The locking posts1102further include a ramped surface1104positioned apart at an interference distance1105. The interference distance1105can correspond to an interference fit for DIN rail shoulders. For example, the interference distance1105can range from 15 millimeters to 30 millimeters. In particular implementations, the interference distance1105is 25 millimeters (+/−2 millimeters). Additionally, the ramped surface1104includes an angled surface that extends to a locking edge1106.

The locking edge1106defines a surface that juts outwardly from the arms1101. In addition, the locking edge1106is positioned at a height1107that corresponds to a DIN rail height (as measured from the bottom surface to the top-most flange surface of a DIN rail). For example, the height1107ranges from 5 millimeters to 10 millimeters. In particular implementations, the height1107is 7.5 millimeters (+/−1 millimeter).

The second end portion804further includes a stop1108. The stop1108comprises a block, riser, or protrusion extending above the interior bottom surface306. In some embodiments, the stop1108comprises an engagement face1110. In some embodiments, the engagement face1110is a flat face (e.g., for perpendicularly engaging or abutting a DIN rail).

Together, the locking posts1102and the stop1108can secure a second end of the DIN rail. For example, DIN rail shoulders can be rested on each ramped surface1104of the locking posts1102. The DIN rail can then be pressed downward such that the DIN rail shoulders and flange slide down the ramped surface1104toward the interior bottom surface306. As the DIN rail moves down the ramped surface1104, the locking posts1102can flex or bias (e.g., move outwardly away from each other). With sufficient downward pressure on the DIN rail, the DIN rail flange can be locked into position underneath the locking edge1106. In this locked position, the locking edge1106can prevent incidental upward movement of the DIN rail flange. Additionally, in this locked position, the locking posts1102have returned back to their unbiased position.

Further, in the locked position, the DIN rail can abut or be in close proximity to the engagement face1110of the stop1108. In some embodiments, the engagement face1110abuts the DIN rail such that the other end of the DIN rail cannot incidentally withdraw from the end holder1002of the first end portion802(not shown).

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown inFIGS.10-11can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown inFIGS.10-11.

FIGS.12-13respectively illustrate top and bottom views of the lid102in accordance with one or more embodiments of the present disclosure. In particular, the lid102can have a variety of different shapes and/or cross-sectional profiles. For instance, in some embodiments, the lid102is triangular shaped, square shaped, pentagonal shaped, etc. As shown, however, the lid102comprises a rectangular shape (e.g., that coincides with a rectangular shape of the housing104, not shown). Specifically, the lid102comprises a lid width1200and a lid length1202. The lid width1200is less than the lid length1202, thereby forming the rectangular shape of the lid102.

In some examples, the lid width1200ranges from 3 inches to 15 inches. In particular implementations, the lid width1200is between 5 inches and 6 inches. Similarly, the lid length1202ranges from 4 inches to 20 inches. In particular embodiments, the lid length1202is between 7 inches and 10 inches. Of course, other sizes (e.g., larger sizes for different roof types or solar-install applications) can be implemented.

InFIG.13, the gasket channel402is in plain view. The gasket channel402is defined by the gasket wall404(discussed above) and the flange405(which defines the curved portion of the lid102that is extendable around the housing104). In particular, the gasket channel402comprises a channel width1302measured from the flange405to the gasket wall404. The channel width1302can be sized to fit an O-ring, FIP gasket, CIP gasket, or other suitable seal.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown inFIGS.12-13can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown inFIGS.12-13.

FIGS.14-16respectively illustrate a profile view, an opposing profile view, and a side profile view of the junction box100in accordance with one or more embodiments of the present disclosure. As shown, the lid102comprises a lid height1400. The lid height1400can range from 0.25 inches to 4 inches. In particular embodiments, the lid height1400is between 0.5 inches and 1.5 inches. In some embodiments, the lid height1400is sized such that the lid102is positionable to abut or be within close proximity of a top portion of the mounting brackets108of the housing104(e.g., when the lid102is positioned over the housing104).

InFIG.15, the drilling boundary indicators314are shown on the housing104. As described above, the drilling boundary indicators314comprise a visual or tactile indication where sidewall drilling through the housing104is permitted. In some embodiments, the drilling boundary indicators314are spaced apart by a distance1500. Compared to a housing length1502(which ranges from 4 inches to 20 inches), the distance1500ranges from 50% to 95% of the housing length1502. In particular implementations, the distance1500is between 70% and 85% of the housing length1502. For instance, the distance1500is between 6 inches and 8 inches. Thus, a majority of the sidewall106acomprises a drillable portion for access into the housing104.

Further shown inFIG.15, the weep holes316extend upward into the sidewall106a. In some embodiments, the weep holes316comprise a weep hole height1504measured from the exterior bottom surface. In some embodiments, the weep hole height1504corresponds to the transition height where the sidewall106acurves or transitions to the exterior bottom surface. Additionally or alternatively, the weep hole height1504is relative to a housing height1506of the housing104. For example, in some embodiments, the weep hole height1504ranges from 2% to 15% of the housing height1506. In these or other embodiments, the housing height1506is between 2 inches and 10 inches. By extending upwards along the sidewall106ato the weep hole height1504, condensation can be evacuated from inside the housing104notwithstanding the different possible orientations or angles of the junction box100(whether suspended over a roof structure or side-mounted on the side of a house).

The weep holes316can also be spaced apart according to a variety of distances. In particular embodiments, the weep holes316are spaced apart by the distance1500, as with the drilling boundary indicators314. In alternative embodiments, the weep holes316are interspaced at a different distance than the distance1500.

InFIG.16, the drilling boundary indicators314are shown on a different sidewall, namely the sidewall106d. In this example, the drilling boundary indicators314are spaced apart by a distance1600. The distance1600, similar to the distance1500, can be dependent on the dimensions of the sidewall106d. For example, compared to a housing width1604(which ranges from 4 inches to 20 inches), the distance1600ranges from 50% to 95% of the housing width1604. In particular implementations, the distance1600is between 70% and 85% of the housing width1604. For instance, the distance1600is between 2 inches and 10 inches. Thus, a majority of the sidewall106d(and likewise the opposing sidewall106b, not shown) comprises a drillable portion for access into the housing104.

As mentioned above, the lid102can be positioned adjacent to or abutting the mounting brackets108. In so doing, the lid102can at least partially enclose a top end of the interior portion510of the mounting brackets108. Specifically,FIG.16shows the flange405of the lid102comprises a thickness1602. In certain implementations, the thickness1602of the lid102extends a portion of the clearance distance512. For example, the thickness1602extends a majority of the clearance distance512. In these or other embodiments, thickness1602of the lid102can help secure a rail mount (not shown) within the mounting brackets108. For example, the lid102can wedge the rail mount against the mounting brackets108inside the interior portion510.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown inFIGS.14-16can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown inFIGS.14-16.

FIGS.17-18respectively illustrate a top profile view and a bottom profile view of the junction box100in accordance with one or more embodiments of the present disclosure. As shown, the lid102is positioned over the housing104. In this enclosed position, these figures also show the lid102protruding outwardly over the mounting brackets108(e.g., to partially cover a top side of the interior portion510) as described above.

In addition,FIG.18shows the junction box100comprises a center of gravity1802—a point where a downward force from the weight of the junction box100can be modeled as passing through (into and out of the page). The junction box100further comprises a moment arm1804measured from the center of gravity1802to the mounting brackets108(namely the outermost portion of the mounting brackets108, the exterior surface of the second bracket wall504).

A combination of the moment arm1804and the junction box weight through the center of gravity1802define a bending moment1806. In particular, the bending moment1806is equivalent to the junction box weight multiplied by the moment arm1804. In these or other embodiments, the bending moment1806(or a portion thereof) acts through the point of connection between the mounting brackets108and the sidewall106c(i.e., the reinforced connection514). For example, one half of the bending moment1806acts through the reinforced connection514for a first mounting bracket, and the other half of the bending moment1806acts through the reinforced connection514for the other mounting bracket.

In at least some implementations, the bending moment1806comprises a reduced bending moment compared to the bending moments of conventional junction boxes that are configured for rail mounting. To illustrate, some contributing factors are as follows. For example, the junction box100is composed of a lightweight, durable material that weighs less than other conventional junction boxes. Additionally, the junction box100can be rectangular shaped, thereby reducing the moment arm1804by positioning the center of gravity1802closer to the point of contact between the mounting brackets108and a solar array rail structure. Similarly, the mounting brackets108can be low profile (e.g., not overextending beyond the mounting sidewall), which also contributes to a smaller moment arm1804. These and other contributing factors can reduce the bending moment1806compared to conventional junction boxes. In at least some embodiments, this improvement can correspondingly improve the durability and lifetime of the junction box100compared to conventional junction boxes.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown inFIGS.17-18can be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown inFIGS.17-18.

As mentioned above, the junction box100can include a rail mount.FIGS.19and20A-20Dillustrate a rail-mountable system comprising the junction box100with a rail mount1900in accordance with one or more embodiments of the present disclosure. As shown, the rail mount1900comprises an adjustable clamp (or clamp) with an adjustment mechanism adjustment mechanism1902. Alternatively to a clamp, the rail mount1900can include zip ties, Velcro® strips, bailing wire, rope, string, or tape.

The junction box100can include multiple rail mounts1900(e.g., at least two rail mounts, as shown). In other embodiments, the junction box100includes only a single rail mount1900.

Each rail mount1900can be positioned inside the mounting brackets108for securing the junction box100to a solar array rail structure1904. To illustrate, the rail mount1900can tighten or loosen in response to actuation (e.g., twisting or screwing) of the adjustment mechanism1902. Specifically, actuation of the adjustment mechanism1902can drive a worm gear in the adjustment mechanism1902to engage slots or teeth defined in the band of the rail mount1900— thereby translating the rail mount1900to form a larger or smaller diameter. In some embodiments, the number of slots or teeth defined in the band of the rail mount1900can define an adjustment range for the rail mount1900. In certain examples, more slots or teeth in the rail mount1900can be added to extend the adjustment range and/or the adjustment resolution of the rail mount1900. With sufficient tightening of the adjustment mechanism1902, the rail mount1900can bind the mounting brackets108to the solar array rail structure1904such that the mounting brackets108abuts the solar array rail structure1904.

In these or other embodiments, the solar array rail structure1904corresponds to one or more members for supporting and mounting a solar array (e.g., solar panels) to a roof or wall structure. Those of ordinary skill in the art will appreciate that the solar array rail structure1904can be formed with a variety of sizes, materials, thickness (or gauge), etc. Indeed, the solar array rail structure1904can be circular shaped, oval shaped, rectangular shaped, square shaped, or shaped with another polygonal profile. Similarly, the solar array rail structure1904can include a variety of different cross-sectional profiles having a variety of sizes, materials, extrusions, surface recesses, hollow regions, etc.

Unfortunately, conventional junction boxes are only compatible with a specific model or type of rail structure. For example, some conventional junction boxes include mounting features that engage corresponding mounting features on the rail structure. By contrast, the rail mount1900and the mounting brackets108can universally fit a host of different rail structures, regardless of size, material, available mounting features, etc. Specifically, the rail mount1900and the mounting brackets108can mount to these and/or other rail structures known to those of ordinary skill in the art. Advantageously, the universal fit afforded by the rail mount1900and the mounting brackets108provides significant compatibility improvements over conventional junction boxes. Accordingly, the junction box100is mountable with the myriad different rail structures.

FIGS.20A-20Dillustrate an example process of attaching a junction box100to the solar array rail structure1904via the rail mount1900in accordance with one or more embodiments. In a first set of steps, the rail mount1900can be inserted into the mounting brackets108and positioned around the solar array rail structure1904. A particular order of inserting the rail mount1900into the mounting brackets108versus positioning around the solar array rail structure1904is not required. For example, at least one rail mount1900is positioned around the solar array rail structure1904prior to inserting the rail mount1900into the mounting brackets108. In other embodiments, however, at least one rail mount1900is not positioned around the solar array rail structure1904prior to inserting the rail mount1900into the mounting brackets108.

Such flexibility in mounting steps can provide increased convenience for technicians (e.g., installers or repair personnel). To illustrate, the junction box100can be mounted to the solar array rail structure1904at an end portion (allowing at least one of the rail mount1900to be slid onto the solar array rail structure1904post-insertion into the mounting brackets108). In other examples, the junction box100is mounted to the solar array rail structure1904at non-end portions. In such a case, the rail mount1900can be unthreaded and opened to first mount to the solar array rail structure1904prior to insertion into the mounting brackets108.

Moreover, as shown inFIG.20A, each rail mount1900is positioned toward the mounting brackets108(e.g., in the direction of arrows2000). However, as depicted, the curvature of the rail mount1900can interfere or otherwise inhibit insertion of the rail mount1900into the mounting brackets108.

FIG.20Bshows the process to insert the rail mount1900into the mounting brackets108. For example, the rail mount1900is compressed against the junction box100(e.g., in the direction of the arrows2002). By compressing the rail mount1900in this manner, the curvature of the rail mount1900becomes compatible with inserting into the mounting brackets108(e.g., by slipping through the clearance distance512past the retaining edge506of the mounting brackets108).

InFIG.20C, the rail mount1900rebounds within the mounting brackets108after the compressive forces are released. Once rebounded, the rail mount1900in its non-compressed state is wedged between the mounting sidewall of the junction box100and the mounting brackets108. In particular, the curvature of the rail mount1900(when non-compressed) inhibits incidental withdrawal of the rail mount1900from the mounting brackets108. Thus, a technician can freely move around or adjust the junction box100with the rail mount1900, but without fear of the rail mount1900falling out.

InFIG.20D, the adjustment mechanism1902is actuated to fasten the junction box100to the solar array rail structure1904. In particular, a screw or bolt of the adjustment mechanism1902is turned clockwise in the direction of arrows2004. In so doing, the rail mount1900reduces its diameter. In some cases, the rail mount1900at least partially conforms to the mounting brackets108and/or the solar array rail structure1904. In turn, the rail mount1900draws the mounting brackets108(and therefore the junction box100) into intimate contact with the solar array rail structure1904. In this fastened position, the junction box100is securely mounted to the solar array rail structure1904.

Any of the features, components, and/or parts, including the arrangements and configurations thereof shown inFIGS.19and20A-20Dcan be included, either alone or in any combination, in any of the other examples of devices, features, components, and parts shown in the other figures described herein. Likewise, any of the features, components, and/or parts, including the arrangements and configurations thereof shown and described with reference to the other figures can be included, either alone or in any combination, in the example of the devices, features, components, and parts shown inFIGS.19and20A-20D.

The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed.

It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings. Indeed, various inventions have been described herein with reference to certain specific aspects and examples. However, they will be recognized by those skilled in the art that many variations are possible without departing from the scope and spirit of the inventions disclosed herein. Specifically, those inventions set forth in the claims below are intended to cover all variations and modifications of the inventions disclosed without departing from the spirit of the inventions. The terms “including” or “includes” as well as “having” or “have” as used in the specification and claims shall have the same meaning as the term “comprising.” Further, the term “substantially” or “about” should be interpreted as +/−10% of a given value. For example, substantially perpendicular is equivalent to 90 degrees+/−9 degrees (which is 10% of 90 degrees) relative to a reference datum.