Junction Box for Snap Together Electrical Connections to Photovoltaic Panels

Abstract

A junction box adapted to provide an electrical connection to an electrical wire attached to a photovoltaic panel. The junction box has a lower portion which has an entry slot to allow entry of the wire into the junction box and a raised protrusion over which the wire is bent and formed to be substantially in the same shape as the raised protrusion. The junction box also has a clamp adapted to be attachable to said lower portion, whereby the clamp holds the wire in place for providing the electrical connection. The wire is preferably bus ribbon. The lower portion preferably has an elastic polymeric element disposed between the raised portion and the wire. The raised protrusion may have an elastic polymeric element. The junction box also has an upper portion including a terminal. The terminal connects to an electrical load. The terminal is adapted to be applied under pressure onto the wire, thereby conforming the terminal to be of substantially the same shape as the protrusion. The upper portion typically has a fastener which closes the upper portion to the lower portion under pressure.

1 . An apparatus comprising:
 an upper portion of a junction box assembly configured to be inserted into a lower portion of the junction box assembly;   a terminal having a curved portion conformed to a shape of a protrusion at a first end and a load connection at a second end;   a bus ribbon disposed between the terminal and a protrusion, wherein the bus ribbon is electrically connected to a photovoltaic panel,   wherein when the upper portion of the junction box assembly is inserted into a lower portion of the junction box assembly, the terminal is compressively loaded onto the bus ribbon.   
     
     
         2 . The apparatus of  claim 1  wherein the terminal is compressively spring loaded onto the bus ribbon. 
     
     
         3 . The apparatus of  claim 1  wherein the terminal connects to at least one of a DC motor or a battery. 
     
     
         4 . The apparatus of  claim 1  wherein the load comprises a circuit board. 
     
     
         5 . The apparatus of  claim 4  wherein the circuit board comprises a direct current (DC) to DC converter or a DC to alternating current (AC) inverter. 
     
     
         6 . The apparatus of  claim 1  wherein the lower portion of the junction box assembly is mounted to the photovoltaic panel. 
     
     
         7 . The apparatus of  claim 6  wherein the lower portion of the junction box assembly is detachable from the upper portion of the junction box assembly without detaching the lower portion of the junction box assembly from the photovoltaic panel. 
     
     
         8 . The apparatus of  claim 1  wherein the lower portion of the junction box assembly is sealed to the upper portion of the junction box assembly. 
     
     
         9 . The apparatus of  claim 1  wherein an elastic polymeric material is inserted between the protrusion and the bus ribbon. 
     
     
         10 . The apparatus of  claim 1  wherein first gaskets seal the lower portion of the junction box assembly against ingression of water and/or dust into an aperture in the lower portion of the junction box assembly. 
     
     
         11 . The apparatus of  claim 1  wherein second gaskets seal between the lower portion of the junction box assembly and the upper portion of the junction box assembly. 
     
     
         12 . The apparatus of  claim 1  wherein the curved portion of the terminal are connected to one end of a bypass diode via the terminal. 
     
     
         13 . A method comprising:
 inserting an upper portion of a junction box assembly into a lower portion of the junction box assembly;   conforming a terminal to a shape of a protrusion, wherein the terminal has a curved portion at a first end and a load connection at a second end;   disposing a bus ribbon between the terminal and a protrusion, wherein the bus ribbon is electrically connected to a photovoltaic panel,   wherein when the upper portion of the junction box assembly is inserted into a lower portion of the junction box assembly, the terminal is compressively loaded onto the bus ribbon.   
     
     
         14 . The method of  claim 13  wherein the terminal is compressively spring loaded onto the bus ribbon. 
     
     
         15 . The method of  claim 13  wherein the terminal connects to at least one of a DC motor or a battery. 
     
     
         16 . The method of  claim 13  wherein the load comprises a circuit board. 
     
     
         17 . The method of  claim 16  wherein the circuit board comprises a direct current (DC) to DC converter or a DC to alternating current (AC) inverter. 
     
     
         18 . The method of  claim 13  wherein the lower portion of the junction box assembly is mounted to the photovoltaic panel. 
     
     
         19 . The method of  claim 18  wherein the lower portion of the junction box assembly is detachable from the upper portion of the junction box assembly without detaching the lower portion of the junction box assembly from the photovoltaic panel. 
     
     
         20 . The method of  claim 13  wherein the lower portion of the junction box assembly is sealed to the upper portion of the junction box assembly.