U.S. patent application number 12/424106 was filed with the patent office on 2010-10-21 for junction box for photovoltaic modules.
Invention is credited to Mark Edwin Lauermann, Daniel Eugene Stahl.
Application Number | 20100263714 12/424106 |
Document ID | / |
Family ID | 42980070 |
Filed Date | 2010-10-21 |
United States Patent
Application |
20100263714 |
Kind Code |
A1 |
Lauermann; Mark Edwin ; et
al. |
October 21, 2010 |
JUNCTION BOX FOR PHOTOVOLTAIC MODULES
Abstract
A junction box is provided for electrically connecting a
photovoltaic (PV) module to a power distribution system having a
mating connector. The junction box includes a housing having a
mounting side configured to be mounted on the PV module. The
housing includes a mating interface and an opening extending into
the housing through the mounting side. The housing is configured to
mate with the mating connector of the power distribution system at
the mating interface. An electrical contact is held by the housing.
The electrical contact includes an integrally formed, one-piece
body. The body of the electrical contact includes a base, a mating
end extending from the base, and a PV module end extending from the
base. The base of the body of the electrical contact is held within
the opening of the housing such that the mating end extends along
the mating interface for engagement with the mating connector. The
PV module end of the body extends outwardly from the opening on the
mounting side of the housing for engagement with foil of the PV
module.
Inventors: |
Lauermann; Mark Edwin;
(Harrisburg, PA) ; Stahl; Daniel Eugene;
(Middletown, PA) |
Correspondence
Address: |
ROBERT J. KAPALKA;TYCO TECHNOLOGY RESOURCES
4550 NEW LINDEN HILL ROAD, SUITE 140
WILMINGTON
DE
19808
US
|
Family ID: |
42980070 |
Appl. No.: |
12/424106 |
Filed: |
April 15, 2009 |
Current U.S.
Class: |
136/251 ;
439/76.1 |
Current CPC
Class: |
Y02E 10/50 20130101;
H02S 40/34 20141201 |
Class at
Publication: |
136/251 ;
439/76.1 |
International
Class: |
H01L 31/048 20060101
H01L031/048; H01R 13/00 20060101 H01R013/00 |
Claims
1. A junction box for electrically connecting a photovoltaic (PV)
module to a power distribution system having a mating connector,
said junction box comprising: a housing having a mounting side
configured to be mounted on the PV module, the housing comprising a
mating interface and an opening extending into the housing through
the mounting side, the housing being configured to mate with the
mating connector of the power distribution system at the mating
interface; and an electrical contact held by the housing, the
electrical contact comprising an integrally formed, one-piece body,
the body of the electrical contact comprising a base, a mating end
extending from the base, and a PV module end extending from the
base, the base of the body of the electrical contact being held
within the opening of the housing such that the mating end extends
along the mating interface for engagement with the mating
connector, the PV module end of the body extending outwardly from
the opening on the mounting side of the housing for engagement with
foil of the PV module.
2. The junction box according to claim 1, wherein the PV module end
of the body of the electrical contact comprises an approximately
planar tab.
3. The junction box according to claim 1, wherein at least a
portion of the PV module end of the body of the electrical contact
extends outwardly from the opening of the housing past the mounting
side of the housing.
4. The junction box according to claim 1, wherein the body of the
electrical contact is stamped from a single sheet of material.
5. The junction box according to claim 1, wherein the PV module end
of the body of the electrical contact comprises at least one of a
non-planar structure, a flexible structure, and a resilient
structure.
6. The junction box according to claim 1, wherein the mounting side
of the housing comprises a mounting surface configured to face a
dielectric substrate of the PV module, at least a portion of the PV
module end of the body of the electrical contact being offset from
the mounting surface of the housing in a direction away from the
housing.
7. The junction box according to claim 1, wherein the mounting side
of the housing comprises a mounting surface configured to face a
dielectric substrate of the PV module, the PV module end of the
body of the electrical contact comprising an approximately planar
tab having an engagement surface configured to engage the foil of
the PV module, the engagement surface extending approximately
parallel with the mounting surface of the housing.
8. The junction box according to claim 1, wherein the mating end of
the body of the electrical contact comprises a pin.
9. The junction box according to claim 1, wherein the mating
interface of the housing comprising a mating receptacle that
extends within the housing and communicates with the opening of the
housing, the base of the body of the electrical contact held within
the opening of the housing such that the mating end of the body
extends within the mating receptacle.
10. The junction box according to claim 1, further comprising a
contact retainer engaged with the electrical contact and the
housing for holding the electrical contact by the housing.
11. The junction box according to claim 1, wherein the electrical
contact is a first electrical contact, the junction box comprising
a second electrical contact held by the housing, the junction box
further comprising a diode electrically connecting the first and
second electrical contacts.
12. The junction box according to claim 1, wherein the housing
comprises an exterior side, the opening within the housing
extending through the exterior side, a cover received within the
opening at the exterior side for closing the opening at the
exterior side.
13. A junction box and photovoltaic (PV) module assembly
comprising: a PV module comprising a plurality of PV cells
interconnected by a foil; and a junction box comprising: a housing
having a mounting side mounted on the PV module, the housing
comprising a mating interface and an opening extending into the
housing through the mounting side, the housing being configured to
mate with a mating connector at the mating interface; and an
electrical contact held by the housing, the electrical contact
comprising an integrally formed, one-piece body, the body of the
electrical contact comprising a base, a mating end extending from
the base, and a PV module end extending from the base, the base of
the body of the electrical contact being held within the opening of
the housing such that the mating end extends along the mating
interface for engagement with the mating connector, the PV module
end of the body extending outwardly from the opening on the
mounting side of the housing, the PV module end of the body being
engaged with the foil of the PV module.
14. The junction box and PV module assembly according to claim 13,
wherein the PV module end of the body of the electrical contact
comprises an approximately planar tab.
15. The junction box and PV module assembly according to claim 13,
wherein at least a portion of the PV module end of the body of the
electrical contact extends outwardly from the opening of the
housing past the mounting side of the housing.
16. The junction box and PV module assembly according to claim 13,
wherein the body of the electrical contact is stamped from a single
sheet of material.
17. The junction box and PV module assembly according to claim 13,
wherein the mating end of the body of the electrical contact
comprises a pin.
18. The junction box and PV module assembly according to claim 13,
further comprising a contact retainer engaged with the electrical
contact and the housing for holding the electrical contact by the
housing.
19. The junction box and PV module assembly according to claim 13,
wherein the electrical contact is a first electrical contact, the
junction box comprising a second electrical contact held by the
housing, the junction box further comprising a diode electrically
connecting the first and second electrical contacts.
20. A junction box for electrically connecting a photovoltaic (PV)
module to a power distribution system having a mating connector,
said junction box comprising: a housing having a mounting side and
an exterior side, the mounting side being configured to be mounted
on the PV module, the housing comprising a mating interface and an
opening extending through the mounting side and the exterior side,
the housing being configured to mate with the mating connector of
the power distribution system at the mating interface; an
electrical contact held by the housing, the electrical contact
comprising a mating end and a PV module end, the mating end
extending along the mating interface for engagement with the mating
connector, the PV module end extending outwardly from the opening
on the mounting side of the housing for engagement with foil of the
PV module; a cover received within the opening of the housing at
the exterior side for closing the opening at the exterior side; and
an o-ring engaged between the housing and the cover for sealing the
cover with the housing.
Description
BACKGROUND OF THE INVENTION
[0001] The subject matter described and/or illustrated herein
relates generally to photovoltaic (PV) modules, and, more
particularly, to a junction box for interconnecting PV modules with
a power distribution system.
[0002] To produce electricity from solar energy, PV modules include
a plurality of PV cells interconnected in series and/or parallel,
according to the desired voltage and current parameters. PV cells
are essentially large-area semiconductor diodes. Due to the
photovoltaic effect, the energy of photons is converted into
electrical power within a PV cell when the PV cell is irradiated by
a light source, such as sunlight. Within a PV module, the PV cells
are typically sandwiched between a transparent panel and a
dielectric substrate. The PV cells within the PV module are
typically interconnected by an electrically conductive foil, such
as a metallic foil. A plurality of PV modules that are mechanically
and electrically connected together is sometimes referred to as a
PV panel.
[0003] A plurality of PV modules and/or PV panels is often
interconnected, in series and/or parallel, to create a PV array.
Junction boxes are typically used to electrically connect the PV
modules and/or PV panels to each other and to an electrical power
distribution system. Each junction box includes a housing that is
mounted on the dielectric substrate of the corresponding PV module.
The housing holds electrical contacts that engage the foil that
interconnects the PV cells through the dielectric substrate to
electrically connect the PV module to the junction box. The
junction box is electrically connected to the power distribution
system via cables that are terminated by connectors that
electrically connect to the electrical contacts of the junction
box. The foil of the PV module is electrically connected to the
junction box by bending the foil up through an opening within the
dielectric substrate and into the junction box housing. The foil is
then wrapped around the electrical contacts of the junction box
within the housing to electrically connect the PV module to the
electrical contacts. Bending the foil through the opening of the
dielectric substrate and wrapping the foil around the electrical
contacts within the housing may increase a difficulty, a time,
and/or a cost of connecting the junction box to the PV module.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one embodiment, a junction box is provided for
electrically connecting a photovoltaic (PV) module to a power
distribution system having a mating connector. The junction box
includes a housing having a mounting side configured to be mounted
on the PV module. The housing includes a mating interface and an
opening extending into the housing through the mounting side. The
housing is configured to mate with the mating connector of the
power distribution system at the mating interface. An electrical
contact is held by the housing. The electrical contact includes an
integrally formed, one-piece body. The body of the electrical
contact includes a base, a mating end extending from the base, and
a PV module end extending from the base. The base of the body of
the electrical contact is held within the opening of the housing
such that the mating end extends along the mating interface for
engagement with the mating connector. The PV module end of the body
extends outwardly from the opening on the mounting side of the
housing for engagement with foil of the PV module.
[0005] In another embodiment, a junction box and photovoltaic (PV)
module assembly includes a PV module having a plurality of PV cells
interconnected by a foil, and a junction box. The junction box
includes a housing having a mounting side mounted on the PV module.
The housing includes a mating interface and an opening extending
into the housing through the mounting side. The housing is
configured to mate with a mating connector at the mating interface.
An electrical contact is held by the housing. The electrical
contact includes an integrally formed, one-piece body. The body of
the electrical contact includes a base, a mating end extending from
the base, and a PV module end extending from the base. The base of
the body of the electrical contact is held within the opening of
the housing such that the mating end extends along the mating
interface for engagement with the mating connector. The PV module
end of the body extends outwardly from the opening on the mounting
side of the housing. The PV module end of the body is engaged with
the foil of the PV module.
[0006] In another embodiment, a junction box is provided for
electrically connecting a photovoltaic (PV) module to a power
distribution system having a mating connector. The junction box
includes a housing having a mounting side and an exterior side. The
mounting side is configured to be mounted on the PV module. The
housing includes a mating interface and an opening extending
through the mounting side and the exterior side. The housing is
configured to mate with the mating connector of the power
distribution system at the mating interface. An electrical contact
is held by the housing. The electrical contact includes a mating
end and a PV module end. The mating end extends along the mating
interface for engagement with the mating connector. The PV module
end extends outwardly from the opening on the mounting side of the
housing for engagement with foil of the PV module. A cover is
received within the opening of the housing at the exterior side for
closing the opening at the exterior side. An o-ring is engaged
between the housing and the cover for sealing the cover with the
housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a partially exploded perspective view of an
exemplary embodiment of a junction box and photovoltaic (PV) module
assembly.
[0008] FIG. 2 is a perspective view of an exemplary embodiment of a
junction box of the assembly shown in FIG. 1.
[0009] FIG. 3 is another perspective view of the junction box shown
in FIG. 1 viewed from a different angle than FIG. 2.
[0010] FIG. 4 is a perspective view of an exemplary embodiment of a
contact retainer of the junction box shown in FIGS. 2 and 3.
[0011] FIG. 5 is a partially exploded perspective view of the
junction box shown in FIGS. 2 and 3 illustrating an exemplary
embodiment of an electrical contact of the junction box.
[0012] FIG. 6 is another partially exploded perspective view of the
junction box shown in FIGS. 2, 3, and 5 illustrating an exemplary
embodiment of a cover of the junction box.
[0013] FIG. 7 is a partially exploded perspective view of a portion
of an exemplary alternative embodiment of a junction box having an
exemplary alternative embodiment of a cover.
[0014] FIG. 8 is another partially exploded perspective view of the
junction box shown in FIG. 7 viewed from a different angle than
FIG. 7.
[0015] FIG. 9 is a partially exploded perspective view of a portion
of another exemplary alternative embodiment of a junction box
having another exemplary alternative embodiment of a cover.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 1 is a partially exploded perspective view of an
exemplary embodiment of a junction box and photovoltaic (PV) module
assembly 10. The assembly 10 includes a PV module 12 and a junction
box 14. Only a portion of the PV module 12 is shown herein. The PV
module 12 includes a dielectric substrate 16, a transparent panel
18, and a plurality of PV cells 20 held between the dielectric
substrate 16 and the transparent panel 18. When irradiated by a
light source (such as, but not limited to, sunlight and/or the
like), the PV cells 20 convert the energy of photons into
electrical power. Each PV cell 20 may be any type of PV cell 20,
such as, but not limited to, a thin film PV cell and/or the like.
The PV cells 20 of the PV module 12 are electrically interconnected
with each other, in series and/or parallel, by an electrically
conductive foil 22, such as, but not limited to, a metallic foil
and/or the like. The foil 22 of the PV module is exposed through an
opening 26 within the dielectric substrate 16. In the exemplary
embodiment, the foil 22 includes two electrical contact portions
22a and 22b that are exposed through the opening 26.
[0017] The junction box 14 is mounted on the PV module 12 for
electrically connecting the PV module 12 to a power distribution
system (not shown). The power distribution system distributes
electrical power generated by the PV module 12 to an electrical
load (not shown), an electrical storage device (not shown), and/or
the like. The junction box 14 may also electrically connect the PV
module 12 to other PV modules (not shown). For example, a plurality
of PV modules may be mechanically and electrically interconnected,
in series and/or parallel, to create a PV panel (not shown).
Moreover, a plurality of PV modules and/or PV panels may be
electrically interconnected to create a PV array.
[0018] The transparent panel 18 of the PV module 12 is transparent
to light emitted from the light source. The transparent panel 18
may be transparent to any wavelengths of electromagnetic radiation
from any light source. In the exemplary embodiment, the transparent
panel 18 includes only a single layer. However, alternatively the
transparent panel 18 includes any number of layers greater than
one. Each layer of the transparent panel 18 may be fabricated from
the same or different material(s) from other layers of the
transparent panel 18. Similarly, although shown as including only
one layer, the dielectric substrate 16 may include any number of
layers. Each layer of the dielectric substrate 16 may be fabricated
from the same or different material(s) from other layers of the
dielectric substrate 16.
[0019] FIG. 2 is a perspective view of an exemplary embodiment of
the junction box 14. The junction box 14 includes a housing 28 and
an optional cover 30. The housing 28 has an exterior side 32 and a
mounting side 34. In the exemplary embodiment, the housing 28 of
the junction box 14 includes a pair of mating interfaces 36. The
housing 28 is configured to mate with a corresponding mating
connector (not shown) of the power distribution system (not shown)
at each of the mating interfaces 36. Each of the mating connectors
of the power distribution system terminates a corresponding
electrical wire or cable of the power distribution system. As will
be described below, mating of the housing 28 with the mating
connectors establishes an electrical connection between the
junction box 14 and the wires and/or cables of the power
distribution system. At an end (not shown) opposite the mating
connector, each wire or cable of the power distribution system may
be electrically connected to an electrical load (not shown), an
electrical storage device (not shown), the junction box (not shown)
of another PV module (not shown), another component of the power
distribution system, and/or the like.
[0020] In the exemplary embodiment, each mating interface 36 of the
housing 28 includes a mating receptacle 38 that receives a plug
(not shown) of the corresponding mating connector therein. In
addition or alternative to the mating receptacle 38, each mating
interface 36 of the housing 28 may include a plug (not shown) that
is received within a receptacle (not shown) of the corresponding
mating connector. Although the housing 28 includes two mating
interfaces 36 in the exemplary embodiment, the housing 28 may have
any number of mating interfaces 36 for mating with any number of
mating connectors.
[0021] FIG. 3 is another perspective view of the junction box 14
viewed from a different angle than FIG. 2. Specifically, FIG. 2
illustrates the exterior side 32 of the junction box 14, while FIG.
3 illustrates the mounting side 34 of the junction box 14. In FIG.
3, the cover 30 (FIGS. 2 and 6) has been removed from the junction
box 14. The mounting side 34 of the housing 28 is configured to be
mounted on the dielectric substrate 16 (FIG. 1) of the PV module 12
(FIG. 1). In the exemplary embodiment, the mounting side 34 of the
housing 28 includes a mounting surface 40 that faces the dielectric
substrate 16 when the housing 28 is mounted on the dielectric
substrate 16. The housing 28 may be mounted on the dielectric
substrate 16 using any suitable method, process, means, structure,
connection type, and/or the like. In the exemplary embodiment, the
housing 28 is mounted on the dielectric substrate 16 using an
adhesive (not shown), such as, but not limited to, room temperature
vulcanizing (RTV) silicone and/or the like. In some embodiments,
the adhesive seals the housing 28 to the dielectric substrate 16.
The mounting surface 40 includes an optional groove 42 that may
accommodate excess adhesive during mounting of the housing 28 on
the dielectric substrate 16. In some embodiments, the mounting
surface 40 of the housing 28 engages the dielectric substrate 16
when the housing 28 is mounted on the dielectric substrate 16.
However, it should be understood that when adhesive is used to
mount the housing 28 on the dielectric substrate 16, a portion or
all of the mounting surface 40 may not engage the dielectric
substrate 16, but rather the adhesive may space a portion or all of
the mounting surface 40 from the dielectric substrate 16.
[0022] The housing 28 includes an opening 44 that extends into the
housing 28 through the mounting side 34. In the exemplary
embodiment, the opening 44 also extends through the exterior side
32. The housing 28 holds a plurality of electrical contacts 46.
Each electrical contact 46 is held by the housing 28 using a
contact retainer 50 that engages both the housing 28 and the
corresponding electrical contact 46. As will be described below,
each the electrical contact 46 establishes an electrical connection
between a corresponding one of the electrical contact portions 22a
and 22b (FIG. 1) of the foil 22 (FIG. 1) of the PV module 12 and a
corresponding one of the mating connectors. Although two electrical
contacts 46 are shown, the junction box 14 may include any number
of electrical contacts 46 for electrical connection to any number
of the electrical contact portions 22a and 22b and for electrical
connection with any number of mating connectors.
[0023] FIG. 4 is a perspective view of an exemplary embodiment of a
contact retainer 50. Each contact retainer 50 includes a body 52
having a mounting side 54 that engages the housing 28 (FIGS. 1-3,
5, and 6) of the junction box 14 (FIGS. 1-3, 5, and 6). In the
exemplary embodiment, the mounting side 54 of the contact retainer
body 52 includes a base engagement surface 56, a contact alignment
surface 58, a plurality of housing connectors 60, and a plurality
of contact connectors 62. When the contact retainer 50 is mounted
on the junction box housing 28, the base engagement surface 56
engages a base 64 (FIG. 5) of the corresponding electrical contact
46 (FIGS. 3, 5, and 6), and the contact alignment surface 58
engages a stem 67 (FIG. 5) of the corresponding electrical contact
46. In the exemplary embodiment, the contact alignment surface 58
includes an arcuate shape that is complementary to the exemplary
stem 67 of the corresponding electrical contact 46, and the base
engagement surface 56 includes an approximately planar shape that
is complementary to the exemplary base 64 of the corresponding
electrical contact 46. In addition or alternative to the arcuate
shape, the contact alignment surface 58 may include any other shape
for engagement with any shaped stem 67. Similarly, in addition or
alternative to the approximately planar shape, the base engagement
surface 56 may include any other shape for engagement with any
shaped base 64.
[0024] The housing connectors 60 extend on the mounting side 54 of
the contact retainer body 52 for engagement with the junction box
housing 28. In the exemplary embodiment, each housing connector 60
includes a leg 68 extending outwardly on the mounting side 54 of
the contact retainer body 52. Each leg 68 is configured to be
received within a corresponding connector opening 70 (FIG. 5) of
the junction box housing 28. In the exemplary embodiment, each leg
68 engages the corresponding connector opening 70 of the junction
box housing 28 with an interference fit to connect the contact
retainer body 52 to the housing 28. In addition or alternative to
the legs 68 and/or the interference fit thereof, the contact module
body 52 may be connected to the junction box housing 28 using any
other structure, means, connector, and/or the like, such as, but
not limited to, using an interference fit and/or the like. Although
four legs 68 are shown, the contact retainer body 52 may include
any number of the legs 68 for reception within any number of
connector openings 70.
[0025] The contact connectors 62 extend on the mounting side 54 of
the contact retainer body 52 for engagement with the base 64 of the
corresponding electrical contact 46. In the exemplary embodiment,
each contact connector 62 includes an extension 72 extending
outwardly on the mounting side 54 of the contact retainer body 52.
Each extension 72 is configured to be received within a
corresponding contact opening 74 (FIG. 5) of the corresponding
electrical contact 46. In the exemplary embodiment, each extension
72 engages the corresponding contact opening 74 of the
corresponding electrical contact 46 with a clearance fit to connect
the contact retainer body 52 to the corresponding electrical
contact 46. The contact module body 52 may be connected to the
corresponding electrical contact 46 using any other structure,
means, connector, and/or the like in addition or alternative to the
extension 72 and/or the clearance fit thereof, such as, but not
limited to, using an interference fit and/or the like. In the
exemplary embodiment, the contact retainer body 52 includes two
extensions 72. However, the contact retainer body 52 may include
any number of the extensions 72 for reception within any number of
contact openings 74.
[0026] FIG. 5 is a partially exploded perspective view of the
junction box 14. In FIG. 5, the cover 30 (FIGS. 2 and 6) has been
removed from the junction box 14. Each electrical contact 46
includes a body 48. The body 48 of each electrical contact 46
includes the base 64, the stem 67 extending outwardly from the base
64, a mating end 66 extending outwardly from the stem 67, and a PV
module end 76 extending outwardly from the base 64. The base 64
includes the contact openings 74. Although two contact openings 74
are shown, the base 64 may include any number of the contact
openings 74. In the exemplary embodiment, the base 64 includes an
approximately planar shape. Additionally or alternatively, the base
64 may include any other shape. The mating end 66 extends outwardly
from the base 64 for engagement with a corresponding mating contact
(not shown) of the corresponding mating connector (not shown). In
the exemplary embodiment, the mating end 66 includes a pin 78 that
is configured to be received within a socket (not shown) of the
corresponding mating contact. The mating end 66 of the electrical
contact body 48 may include, in addition or alternative to the pin
78, any other structure, means, shape, geometry, and/or the like
for electrically connecting to the corresponding mating contact,
such as, but not limited to, a socket (not shown) that receives a
pin (not shown) of the corresponding mating contact therein, and/or
the like.
[0027] The PV module end 76 of the electrical contact body 48
extends outwardly from the base 64 for engagement with a
corresponding one of the electrical contact portions 22a and 22b
(FIG. 1) of the foil 22 (FIG. 1) of the PV module 12 (FIG. 1). In
the exemplary embodiment, the PV module end 76 includes an
approximately planar tab 80 that includes an engagement surface 82
that engages the corresponding electrical contact portion 22a or
22b. As shown herein, the tab 80, and thus the engagement surface
82, extends approximately parallel with the base 64. However, the
tab 80 and/or the engagement surface 82 may extend at any other
angle relative to the base 64, such as, but not limited to, an
acute or obtuse angle relative to the base 64, and/or the like.
Moreover, the engagement surface 82 of the tab 80 may or may not
extend approximately parallel to some or all portions of the foil
22.
[0028] In addition or alternative to the approximately planar tab
80, the PV module end 76 may include any other structure, means,
shape, geometry, and/or the like for electrically connecting to the
corresponding electrical contact portion 22a or 22b of the foil 22
of the PV module 12, such as, but not limited to, a hook shape, any
other non-planar shape, a flexible structure, a resilient
structure, and/or the like. Forming at least a portion of the PV
module end 76 with a flexible and/or resilient structure (such as,
but not limited to, a flexible and/or resilient beam, a flexible
and/or resilient hook, and/or the like) may facilitate
accommodating different thicknesses of the dielectric substrate 16
(FIG. 1). In embodiments wherein the PV module end 76 includes
other structures, means, shapes, geometries, and/or the like in
addition or alternative to the tab 80, some or all portions of such
other structures, means, shapes, geometries, and/or the like may or
may not extend approximately parallel to some or all portions of
the foil 22.
[0029] The body 48 of the electrical contact 46 may be formed using
any suitable process, means, method, structure, and/or the like,
such as, but not limited to, any stamping process, any cutting
process, any forming process, and/or the like. In some embodiments,
the electrical contact body 48 is an integrally formed, one piece
body. For example, the base 64, the mating end 66, and the PV
module end 76 are optionally formed integrally as one piece. In
some embodiments, the entirety of the electrical contact body 48 is
stamped and formed out of a single sheet of material.
[0030] When held by the junction box housing 28 using the
corresponding contact retainer 50, the base 64 of each electrical
contact 46 is held within the opening 44 of the housing 28.
Specifically, the base 64 is engaged with the base engagement
surface 56 (FIG. 4) of the corresponding contact retainer 50 such
that the base 64 is held between the mounting side 54 of the
corresponding contact retainer 50 and the housing 28. The
extensions 72 (FIG. 4) of the contact connectors 62 are received
within the contact openings 74 of the electrical contact base 64 to
connect the contact retainer 50 to the base 64. Each leg 68 of the
contact retainer 50 is received within the corresponding connector
opening 70 of the housing 28 to connect the contact retainer 50 to
the housing 28. When the base 64 is held by the housing 28 using
the corresponding contact retainer 50, the mating end 66 of the
electrical contact 46 extends along a corresponding one of the
mating interfaces 36 of the housing 28 for engagement with the
corresponding mating contact of the corresponding mating connector.
Specifically, the mating end 66 extends within a corresponding one
of the mating receptacles 38 of the housing 28. Extension of the
mating end 66 within the mating receptacle 38 is best seen in FIG.
6.
[0031] Referring again to FIG. 3, the junction box 14 optionally
includes a diode 84 that electrically connects the electrical
contacts 46 of the junction box 14 together. The diode 84 may
enable electrical power generated by another PV module (not shown)
that is electrically connected to the junction box 14 to bypass the
PV module 12. In the exemplary embodiment, the diode 84 is engaged
with, and thereby electrically connected to, the base 64 of each of
the electrical contacts 46. Alternatively, the diode 84 is engaged
with, and thereby electrically connected to, any other portion of
the body 48 of each of the electrical contacts 46. The diode 84 may
be engaged with and electrically connected to each electrical
contact 46 using any suitable method, process, structure,
connector, means, and/or the like, such as, but not limited to,
being welded to the electrical contacts 46, being soldered to the
electrical contacts 46, being brazed to the electrical contacts 46,
and/or the like.
[0032] FIG. 6 is another partially exploded perspective view of the
junction box 14. When held by the junction box housing 28 using the
corresponding contact retainer 50 (FIGS. 3-5), the PV module end 76
of each electrical contact 46 extends outwardly from the opening 44
of the junction box housing 28 on the mounting side 34 thereof. The
tab 80 of the PV module end 76 extends outwardly from the opening
44 of the housing 28 past the mounting surface 40 of the housing
28. Specifically, the engagement surface 82 of the tab 80 is offset
from the mounting surface 40 in a direction away from the housing
28 by a distance D. In some embodiments, the distance D is
approximately equal to a thickness T (FIG. 1) of the dielectric
substrate 16 (FIG. 1) of the PV module 12 (FIG. 1). In the
exemplary embodiment, and when held by the housing 28 as shown
herein, the tab 80 (and therefore the engagement surface 82) of the
PV module end 76 extends approximately parallel to the mounting
surface 40 of the housing 28. However, the tab 80 and/or the
engagement surface 82 may extend at any other angle relative to the
mounting surface 40 when the electrical contact 46 is held by the
housing 28, such as, but not limited to, an acute or obtuse angle
relative to the mounting surface 40, and/or the like.
[0033] When the junction box 14 is mounted on the dielectric
substrate 16 of the PV module 12, the tabs 80 of the PV module ends
76 of the electrical contacts 46 extend through the opening 26
(FIG. 1) within the dielectric substrate 16. The engagement
surfaces 82 of the tabs 80 engage the corresponding electrical
contact portion 22a or 22b (FIG. 1) of the foil 22 (FIG. 1) of the
PV module 12 (FIG. 1) to electrically connect each electrical
contact 46 to the corresponding electrical contact portion 22a and
22b. Each electrical contact 46 of the junction box 14 thereby
establishes an electrical connection between a corresponding one of
the electrical contact portions 22a and 22b of the foil 22 and a
corresponding one of the mating connectors. Accordingly, the
junction box 14 establishes an electrical connection between the PV
module 12 and the wires and/or cables of the power distribution
system (not shown). The engagement surfaces 82 of each of the
electrical contacts 46 may be held in engagement with the
corresponding electrical contact portion 22a or 22b of the foil 22
using any suitable method, process, structure, means, connection
type, and/or the like, such as, but not limited to, using solder
and/or the like.
[0034] The cover 30 is optionally provided for closing the opening
44 of the housing 28 at the exterior side 32 of the housing 28. In
addition or alternative to the cover 30, the opening 44 of the
housing 28 may be filled with a dielectric material (such as, but
not limited to, potting and/or the like) to environmentally seal
the opening 44. The cover 30 includes a body 86 having a mounting
side 88 that faces the exterior side 32 of the housing 28. The
cover 30 is optionally connected to the housing 28 using an
adhesive (not shown), such as, but not limited to, potting, RTV
silicone, and/or the like. In some embodiments, the adhesive seals
the cover 30 with the housing 28. In some embodiments, the mounting
side 88 of the cover 30 engages the exterior side 32 of the housing
28 when the cover 30 is mounted on the housing 28. However, it
should be understood that the adhesive may space a portion or all
of the mounting side 88 of the cover 30 from the exterior side 32
of the housing 28. Optionally, the cover 30 and/or the housing 28
each includes one or more respective openings 90 and 92 (the
openings 92 can be seen in FIG. 1) to allow air and/or excess
adhesive to escape during curing of the adhesive.
[0035] The cover 30 includes a plurality of optional latch members
94 extending outwardly on the mounting side 88 of the cover body
86. Each of the latch members 94 includes a hook 96 that engages a
latch surface 98 (FIG. 3) of the housing 28 to hold the cover 30 on
the housing 28 during curing of the adhesive. Alternatively, the
cover 30 is not connected to the housing 28 using the adhesive, but
rather is only connected to the housing 28 using the latch members
94. Although two latch members 94 are shown, the cover 30 may
include any number of the latch members 94.
[0036] FIG. 7 is a partially exploded perspective view of a portion
of an exemplary alternative embodiment of a junction box 114 having
an exemplary alternative embodiment of a cover 130. FIG. 8 is
another partially exploded perspective view of the junction box 114
viewed from a different angle than FIG. 7. The junction box 114
includes a housing 128 and the cover 130. The housing 128 has an
exterior side 132 and a mounting side 134. The mounting side 134 of
the housing 128 is configured to be mounted on the dielectric
substrate 16 (FIG. 1) of the PV module 12 (FIG. 1). The housing 128
includes an opening 144 that extends through the exterior side 132.
The cover 130 is received within the opening 144 at the exterior
side 132 for closing the opening 144 at the exterior side 132. In
addition or alternative to the cover 130, the opening 144 of the
housing 128 may be filled with a dielectric material (such as, but
not limited to, potting and/or the like) to environmentally seal
the opening 144.
[0037] The cover 130 includes a body 186 having a mounting side 188
that faces the exterior side 132 of the housing 128. The mounting
side 188 of the cover body 186 includes an optional o-ring groove
200 that receives an o-ring 202 for sealing the engagement between
the cover body 186 and the housing 128. It should be understood
that when the o-ring 202 is used to seal the engagement between the
cover body 186 and the housing 128, a portion or all of the
mounting side 188 of the cover body 186 may not engage the exterior
side 132 of the housing 128, but rather the o-ring 202 may space a
portion or all of the mounting side 188 of the cover body 186 from
the exterior side 132 of the housing 128.
[0038] The cover body 186 includes a latch member 194 extending
outwardly on the mounting side 188 of the cover body 186. The latch
member 194 is received within a latch opening 204 of the housing
128. The latch member 194 includes a hook 196 (not visible in FIG.
8) that engages a latch shoulder 198 (not visible in FIG. 8) of the
housing 128 to removably latch the cover 130 on the housing 128. In
the exemplary embodiment, the cover body 186 includes a plurality
of latch extensions 206 (not visible in FIG. 7) that are received
within openings 208 of the housing 128 to facilitate holding the
cover 130 on the housing 128. Although one latch member 194 is
shown, the cover 130 may include any number of the latch members
194 for reception within any number of latch openings 204 of the
housing 128. In the exemplary embodiment, the cover body 186
includes two latch extensions 206. However, the cover body 186 may
include any number of the latch extensions 206 for reception within
any number of openings 208 of the housing 128.
[0039] FIG. 9 is a partially exploded perspective view of a portion
of another exemplary alternative embodiment of a junction box 214
having another exemplary alternative embodiment of a cover 230. The
junction box 214 includes a housing 228 and the cover 230. The
housing 228 has an exterior side 232 and a mounting side 234. The
mounting side 234 of the housing 228 is configured to be mounted on
the dielectric substrate 16 (FIG. 1) of the PV module 12 (FIG. 1).
The housing 228 includes an opening 244 that extends through the
exterior side 232. The cover 230 is received within the opening 244
at the exterior side 232 for closing the opening 244 at the
exterior side 232. In addition or alternative to the cover 230, the
opening 244 of the housing 228 may be filled with a dielectric
material (such as, but not limited to, potting and/or the like) to
environmentally seal the opening 244.
[0040] The cover 230 includes a body 286 having a mounting side 288
that faces the exterior side 232 of the housing 228. The mounting
side 288 of the cover body 286 includes an optional o-ring groove
300 that receives an o-ring 302 for sealing the engagement between
the cover body 286 and the housing 228. The cover body 286 includes
a plurality of optional latch members 294 extending outwardly on
the mounting side 288 of the cover body 286. Each of the latch
members 294 includes a hook 296 that engages a corresponding latch
surface 298 of the housing 228 to facilitate holding the cover 230
on the housing 228. Although the cover body 286 includes four latch
members 294 in the exemplary embodiment, the cover 230 may include
any number of the latch members 294. Optionally, the cover body 286
and/or the housing 228 include one or more respective openings 304
and 306 for receiving a tool (not shown) for prying the latch
member 294 to an unlatched position to facilitate removing the
cover 230 from the housing 228.
[0041] In addition or alternative to the latch members 294, the
cover 230 is connected to the housing 228 using an adhesive (not
shown), such as, but not limited to, using potting, RTV silicone,
and/or the like. In some embodiments, the adhesive seals the cover
230 with the housing 228. The openings 304 and/or 306 may allow air
and/or excess adhesive to escape during curing of the adhesive. It
should be understood that when the o-ring 302 and/or the adhesive
is used to seal the engagement between the cover body 286 and the
housing 228, a portion or all of the mounting side 288 of the cover
body 286 may not engage the exterior side 232 of the housing 228,
but rather the o-ring 302 and/or the adhesive may space a portion
or all of the mounting side 288 of the cover body 286 from the
exterior side 232 of the housing 228.
[0042] The embodiments described and/or illustrated herein may
provide a junction box that is less difficult, less costly, and/or
less time-consuming to electrically connect to a PV module than at
least some known junction boxes. For example, the embodiments
described and/or illustrated herein may provide a junction box
having electrical contacts that are less difficult, less costly,
and/or less time-consuming to electrically connect to a PV module
than at least some known junction boxes.
[0043] Exemplary embodiments are described and/or illustrated
herein in detail. The embodiments are not limited to the specific
embodiments described herein, but rather, components and/or steps
of each embodiment may be utilized independently and separately
from other components and/or steps described herein. Each
component, and/or each step of one embodiment, can also be used in
combination with other components and/or steps of other
embodiments. When introducing elements/components/etc. described
and/or illustrated herein, the articles "a", "an", "the", "said",
and "at least one" are intended to mean that there are one or more
of the element(s)/component(s)/etc. The terms "comprising",
"including" and "having" are intended to be inclusive and mean that
there may be additional element(s)/component(s)/etc. other than the
listed element(s)/component(s)/etc. Moreover, the terms "first,"
"second," and "third," etc. in the claims are used merely as
labels, and are not intended to impose numerical requirements on
their objects. Dimensions, types of materials, orientations of the
various components, and the number and positions of the various
components described and/or illustrated herein are intended to
define parameters of certain embodiments, and are by no means
limiting and are merely exemplary embodiments. Many other
embodiments and modifications within the spirit and scope of the
claims will be apparent to those of skill in the art upon reviewing
the description and illustrations. The scope of the subject matter
described and/or illustrated herein should therefore be determined
with reference to the appended claims, along with the full scope of
equivalents to which such claims are entitled. Further, the
limitations of the following claims are not written in
means-plus-function format and are not intended to be interpreted
based on 35 U.S.C. .sctn.112, sixth paragraph, unless and until
such claim limitations expressly use the phrase "means for"
followed by a statement of function void of further structure.
[0044] While the subject matter described and/or illustrated herein
has been described in terms of various specific embodiments, those
skilled in the art will recognize that the subject matter described
and/or illustrated herein can be practiced with modification within
the spirit and scope of the claims.
* * * * *