Electrically isolated heat dissipating junction box

• US 10,411,644 B2
• Filed: 07/17/2017
• Issued: 09/10/2019
• Est. Priority Date: 05/22/2009
• Status: Active Grant

• Current Assignee: Solaredge Technologies Incorporated
• Original Assignee: Solaredge Technologies Incorporated
• Inventors: Sella, Guy, Handelsman, Lior, Shmukler, Vadim, Adest, Meir, Gazit, Meir, Galin, Yoav
• Primary Examiner(s): Patel, Dhiru R
• Application Number:
  US15/651,134
• Publication Number:
  US 20180069505A1
• Time in Patent Office: 785 Days
• Field of Search: 174 50
• CPC Class Codes: G08B 13/1409 for removal detection of electrical appliances by detecting their physical disconnection from an electrical system, e.g. using a switch incorporated in the plug connector
• CPC Class Codes: H02G 15/10 protected by boxes, e.g. by distribution, connection or junction boxes
• CPC Class Codes: H02S 40/34 comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
• CPC Class Codes: H02S 40/345 with cooling means associated with the electrical connection means, e.g. cooling means associated with or applied to the junction box cooling means for PV cells H01L31/052, for PV modules H02S40/42
• CPC Class Codes: H05K 5/02 Details
• CPC Class Codes: H05K 5/062 sealed by a material injected between a non-removable cover and a body, e.g. hardening in situ
• CPC Class Codes: H05K 7/2039 characterised by the heat transfer by conduction from the heat generating element to a dissipating body arrangements for increasing/decreasing heat-transfer, e.g. fins details, F28F13/00
• CPC Class Codes: H05K 9/0007 Casings standardised racks H05K9/0062
• CPC Class Codes: H05K 9/0009 with provisions to reduce EMI leakage through the joining parts
• CPC Class Codes: H05K 9/0015 Gaskets or seals
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10S 248/906 Electrical outlet box support
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A junction box used for making electrical connections to a photovoltaic panel. The junction box has two chambers including a first chamber and a second chamber and a wall common to and separating both chambers. The wall may be adapted to have an electrical connection therethrough. The two lids are adapted to seal respectively the two chambers. The two lids are on opposite sides of the junction box relative to the photovoltaic panel. The two lids may be attachable using different sealing processes to a different level of hermeticity. The first chamber may be adapted to receive a circuit board for electrical power conversion. The junction box may include supports for mounting a printed circuit board in the first chamber. The second chamber is configured for electrical connection to the photovoltaic panel. A metal heat sink may be bonded inside the first chamber.

Claims

1. A junction box comprising:

a first chamber sealed against a first level of water ingress by a first lid;

a second chamber sealed against a second level of water ingress by a second lid, the first level of water ingress being different than the second level of water ingress;

a circuit board within the first chamber and designed to convert electrical power received from a photovoltaic panel; and

an electrical connection within the second chamber and designed to receive the electrical power from the photovoltaic panel.

2. The junction box of claim 1, wherein the first lid and the second lid are configured to be on opposite sides of the junction box relative to the photovoltaic panel.

3. The junction box of claim 1, further comprising a metal heat sink bonded inside the first chamber, the metal heat sink configured to dissipate heat generated by the circuit board.

4. The junction box of claim 3, wherein the metal heat sink comprises a structure adapted to prevent mutual separation of the metal heat sink from the junction box.

5. The junction box of claim 1, further comprising a wall to separate the first chamber and the second chamber, wherein the wall allows for mutual separation and reattachment of the first chamber and second chamber.

6. The junction box of claim 1, wherein a side of the second chamber is configured to attach to the photovoltaic panel, and wherein the first chamber is configured to disconnect from the photovoltaic panel without disconnecting the second chamber from the photovoltaic panel.

7. The junction box of claim 1, further comprising a re-connectable second electrical connection that connects the circuit board in the first chamber to the electrical connection in the second chamber.

8. The junction box of claim 1, further comprising a gasket configured to seal an open end of the second chamber.

9. A junction box comprising:

a first chamber comprising a circuit board designed to convert electrical power received from a photovoltaic panel;

a second chamber designed to receive the electrical power from the photovoltaic panel,

wherein the first chamber is sealed against a first level of water ingress by a first lid separately from the second chamber,

wherein the second chamber is sealed against a second level of water ingress by a second lid, and

wherein the first level of water ingress is different that the second level of water ingress.

10. The junction box of claim 9, wherein the first lid and the second lid are configured to be on opposite sides of the junction box relative to the photovoltaic panel.

11. The junction box of claim 9, further comprising a metal heat sink bonded inside the first chamber, the metal heat sink configured to dissipate heat generated by the circuit board.

12. The junction box of claim 11, wherein the metal heat sink comprises a structure adapted to prevent mutual separation of the metal heat sink from the junction box.

13. The junction box of claim 9, further comprising:

a wall to separate the first chamber and the second chamber, wherein the wall allows for mutual separation and reattachment of the first chamber and second chamber.

14. The junction box of claim 9, wherein the first chamber is configured to disconnect from the photovoltaic panel without disconnecting the second chamber from the photovoltaic panel.

15. A method comprising:

sealing, in a junction box, a first chamber against a first level of water ingress by a first lid;

sealing, in the junction box, a second chamber against a second level of water ingress by a second lid, wherein the first level of water ingress is different than the second level of water ingress;

configuring an electrical connection within the second chamber to receive electrical power from a photovoltaic panel; and

configuring a circuit board within the first chamber to receive power from the photovoltaic panel via the electrical connection of the second chamber.

16. The method of claim 15, further comprising

configuring a wall to separate the first chamber and the second chamber, wherein the wall allows for mutual separation and reattachment of the first chamber and second;

and

configuring the first chamber to disconnect from the second chamber and the photovoltaic panel without disconnecting the second chamber from the photovoltaic panel.

17. The method of claim 15, further comprising;

configuring the first lid and the second lid to be on opposite sides of the junction box relative to the photovoltaic panel.

18. The method of claim 15, further comprising;

bonding a metal sink inside the first chamber, the metal sink comprising a structure adapted to prevent mutual separation of the metal heat sink from the junction box; and

configuring the metal sink to dissipate heat generated by the circuit board.