Description:TECHNICAL FIELD
The present disclosure relates to a field of solar energy systems. Particularly, the present disclosure relates to a component used in solar energy systems, specifically a photovoltaic (PV) junction box assembly and its assembling method thereof.
BACKGROUND
The progression towards renewable energy in the global solar power sector has yielded significant advancements, yet conventional solar photovoltaic (PV) junction boxes confront persistent challenges, impeding their optimal performance. One key issue revolves around the difficulty of existing PV junction boxes in accommodating higher voltage demands as solar technology evolves. There is a pressing need for junction boxes capable of effectively handling elevated voltage levels without compromising safety and performance.
Another challenge lies in the limited ability of current PV junction boxes to withstand extreme temperatures, particularly in regions with harsh climates. These limitations impact the longevity and efficiency of solar PV systems. Furthermore, conventional PV junction boxes face durability challenges in acute weather conditions, where exposure to rain, dust, and other environmental elements can compromise system integrity, potentially leading to malfunctions over time.
Additionally, stability issues in connection points pose a concern, with soldering joints susceptible to failure under varying weather conditions and prolonged exposure to environmental stressors. The lack of robust protection against water ingress and dust infiltration further exacerbates internal damage, reducing the efficiency and lifespan of PV modules and associated components.
In conclusion, the conventional problems associated with existing solar PV junction boxes encompass challenges related to voltage tolerance, temperature resilience, weather durability, connection stability, and protection against water and dust. Addressing these issues is crucial for advancing the reliability and efficiency of solar energy technologies and ensuring their widespread adoption.
In view of the foregoing, there remains a need for technology to overcome the limitations associated with traditional solar PV junction boxes.
OBJECTIVES OF THE DISCLOSURE
A primary objective of the present disclosure is to provide a solar photovoltaic (PV) junction box assembly that can withstand high voltages, up to 1500V DC.
Another objective of the present disclosure is to enhance the temperature resilience of solar PV junction boxes, enabling them to operate effectively in both high and low ambient temperatures, thereby ensuring optimal performance across diverse climates.
Another objective of the present disclosure is to improve the weather durability of solar PV junction boxes by incorporating water-resistant seals, flame-retardant materials, and robust construction, making them resistant to harsh weather conditions and extending their lifespan.
Another objective of the present disclosure is to strengthen the connection stability within solar PV junction boxes by utilizing improved connection methods such as crimping and ultrasonic welding to create stronger and more reliable bonds between cables, connector pins, and diodes, minimizing the risk of connection failure and enhancing overall system reliability.
Another objective of the present disclosure is to accommodate the advancements in solar technology and ensure compatibility with modern solar systems.
Another objective of the present disclosure is to enhance the safety of solar PV junction boxes by preventing water and dust intrusion through the use of O-rings, tight seals, and leak-proof designs, ensuring the safety of both the system and its users.
Further objective of the present disclosure is to introduce a method of assembling solar PV junction boxes that ensures a seamless integration of various components, including housing bodies, cables, connector assemblies, diodes, and copper strips.
SUMMARY OF THE DISCLOSURE
In one aspect of the present disclosure, a solar photovoltaic (PV) junction box assembly is provided.
The solar PV junction box assembly may include:
at least one housing body with one or more housing covers;
one or more cables that may be connected to at least one housing body;
a connector assembly may be made of a plug-and-socket design with one or more male (M), female (F), and parallel or neutral (N) connectors independently molded in the housing assembly, the connector assembly further includes:
at least one connector pin housing with one or more connector pins extending therefrom may provide one or more electrical contact points;
one or more connector housings that may be adapted to accommodate and protect one or more connector pins;
at least one threaded nut that may be adapted to secure the connector housing to at least one housing body, ensuring a tight and water-resistant connection; and
at least one O-ring that may be disposed between at least one connector pin housing and one or more connector housings,
at least one diode that may be electrically connected to the connector assembly; and
at least one copper strip that may be adapted to connect the one or more connector pins to the diode,
wherein a portion of at least one housing body may be adapted to fill with silicone gel to facilitate thermal transfer and maintain joint stability,
wherein the PV junction box may be operable to withstand a maximum voltage of 1500V DC and function in high and low ambient temperatures.
In another aspect of the present disclosure, at least one housing body and connector assembly may be constructed from a flame-retardant engineered polymer for enhanced ultraviolet (UV) and voltage resistance.
In another aspect of the present disclosure, the one or more cables may be crimped to at least one copper strip for improved holding strength.
In another aspect of the present disclosure, the one or more connector housings may further include one or more connector lockings.
In another aspect of the present disclosure, at least one diode may be a surface-mounted type and further includes one or more diode soldering pins.
In another aspect of the present disclosure, at least one copper strip may be ultrasonically welded to one or more cables and diodes for stronger joints and higher heat resistance.
In another aspect of the present disclosure, the solar PV junction box may further include at least one back cover sleeve that can be ultrasonically welded to at least one housing body for leak-proofness.
In another aspect of the present disclosure, the one or more housing covers may include at least one housing locking lid that can be adapted to fit with at least one housing cover locking notch of the housing body for secure closure.
In another aspect of the present disclosure, the solar PV junction box may further include one or more lead blocks that can be disposed between at least one copper strip and at least one diode.
In a second aspect of the present disclosure, a method of assembling solar photovoltaic (PV) junction box is provided.
The method of assembling solar photovoltaic (PV) junction box, may include the steps of: forming at least one housing body and at least one connector assembly; connecting one or more cables to at least one housing body; ultrasonically welding at least one copper strip to the one or more cables and one or more connector pins; connecting at least one diode to at least one copper strip; filling at least one housing body with silicone gel; and securing the one or more connector housings to at least one housing body.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawing,
Figure 1 depicts an exploded view of a female housing assembly in a solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 2 depicts a cross-sectional view of electrical connection in female housing assembly of the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 3 depicts a front view of female housing assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 4 depicts an isometric view of female housing assembly in the solar photovoltaic (PV) junction box after filling gel, in accordance with an aspect of the present disclosure.
Figure 5 depicts a top view of a female connector assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 6 depicts an exploded view of female connector assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 7 depicts a female connector housing assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 8 depicts an exploded view of a male connector housing assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 9 depicts a cross-sectional view of electrical connection in male connector housing assembly of the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 10 depicts a front view and top view of male connector housing assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 11 depicts an isometric view of male connector housing assembly in the solar photovoltaic (PV) junction box after filling gel, in accordance with an aspect of the present disclosure.
Figure 12 depicts a male connector holder assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 13 depicts an exploded view of male connector holder assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 14 depicts a male connector housing assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 15 depicts an exploded view of a parallel housing assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
Figure 16 depicts a front view of parallel housing assembly in the solar photovoltaic (PV) junction box, in accordance with an aspect of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. Thus, the following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, known details are not described in order to avoid obscuring the description.
References to one or an embodiment in the present disclosure can be references to the same embodiment or any embodiment; and such references mean at least one of the embodiments.
Reference to "one embodiment", "an embodiment", “one aspect”, “some aspects”, “an aspect” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others.
The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Alternative language and synonyms may be used for any one or more of the terms discussed herein, and no special significance should be placed upon whether or not a term is elaborated or discussed herein. In some cases, synonyms for certain terms are provided.
A recital of one or more synonyms does not exclude the use of other synonyms.
The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only and is not intended to further limit the scope and meaning of the disclosure or of any example term. Likewise, the disclosure is not limited to various embodiments given in this specification. Without intent to limit the scope of the disclosure, examples of instruments, apparatus, methods, and their related results according to the embodiments of the present disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Unless otherwise defined, technical and scientific terms used herein have the meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions will control.
Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims or can be learned by the practice of the principles set forth herein.
As mentioned above, there is a need to overcome the limitations associated with traditional solar PV junction boxes. The present disclosure, therefore: provides a solar photovoltaic (PV) junction box assembly and its assembling method thereof.
The below reference numerals are provided for a thorough understanding of the disclosure with respect to one or more embodiments of the present disclosure.
F100: Cable (Female).
F101: Solar cable strand (Female).
F200: Terminal back cover (Female).
F201: Back cover sleeve (Female).
F300: Housing cover (Female).
F301: Housing locking lid (Female).
F400: Housing body (Female).
F401, F404: Mounting pin (Female).
F402, F403: Housing cover locking notch (Female).
F500: Lead block (Female).
F600: Diode (Female).
F601: Diode soldering pin (Female).
F700: Copper strip (Female).
F800: Connector housing (Female).
F801, F802: Connector locking (Female).
F803: Connector pin housing (Female).
F900: Water proofing ring (Female).
F1000: O-ring (Female).
F1100: Connector pin (Female).
F1200: Threaded nut (Female).
M100: Cable (Male).
M101: Solar cable strand (Male).
M200: Housing body (Male).
M201, M202: Housing cover locking notch (Male).
M203: Mounting pin (Male).
M300: Copper strip (Male).
M400: Lead block (Male).
M500: Diode (Male).
M501: Diode soldering pin (Male).
M600: Terminal back cover (Male).
M601: Back cover sleeve (Male).
M700: Housing cover (Male).
M701: Housing locking lid (Male).
M800: Threaded nut (Male).
M900: Connector housing (Male).
M901: Connector locking (Male).
M1000: Water proofing ring (Male).
M1100: O-ring (Male).
M1200: Connector pin (Male).
M1300: Flexible metal sleeve for crimping (Male).
N01, N113: Housing cover (Parallel housing).
N02: Locking notch (Parallel housing).
N110: Housing body (Parallel housing).
N111: Housing direction indicator (Parallel housing).
N112: Mounting pin (Parallel housing).
N201: Copper strip (Parallel housing).
N301: Lead block (Parallel housing).
N400: Diode (Parallel housing).
N401: Diode soldering pin (Parallel housing).
In one embodiment of the present disclosure, the solar photovoltaic (PV) junction box may include a female housing assembly, as depicted in both Figure 1 and Figure 2, embodies one or more key components contributing to its present disclosure. The female housing assembly may include at least one of a housing cover (F300), a cable (F100) which may be inserted and connected to a housing body (F400) to form a foundational structure. The female housing assembly may further include a solar cable strand (F101) that can be ultrasonically welded to a copper strip (F700), this assembly ensures a robust joint with heightened heat resistance compared to traditional soldering methods. The copper strip (F700) itself may guarantee superior conductivity, durability, and resistance to corrosion. Further, the female housing assembly may be mounted on the housing body (F400) by way of mounting pins (F401, F404). The female housing assembly may further include one or more lead blocks (F500) that may be placed on the copper strip (F700). A diode or blocking diode (F600) may be located between two copper strips (F700), and a diode soldering pin or blocking diode soldering pin (F601) may be ultrasonically welded to the copper strip (F700). The female housing assembly may further include a terminal back cover (F200) with a back cover sleeve (F201) that may be ultrasonically welded to the housing body (F400) for providing a leak proof joint. The female housing assembly may further include a housing locking lid (F301) of the housing cover (F300) that can be suitably fitted to a housing cover locking notch (F402, F403) of the housing body (F400).
In Figure 2, a detailed illustration reveals the ultrasonic welding of the solar cable strand (F101) to the copper strip (F700). Additionally, the diode soldering pin or blocking diode soldering pin (F601) is embedded on either side of the diode or blocking diode (F600), enhancing strength and heat resistance. This robust construction enables the assembly to withstand DC voltages up to 1500V, ensuring reliability and safety in various operational conditions.
Figure 3 showcases the embedding of the cable (F100) and lead block (F500) into the copper strip (F700), further fortifying the structural integrity of the assembly. This meticulous arrangement contributes to the female housing assembly's ability to withstand environmental stresses.
Figure 4 showcases the introduction of silicone gel into the female housing body (F400). This silicone gel fills a chamber containing the copper strip (F700) and part of the cable strand (F101), plays a crucial role by facilitating thermal heat transfer. The silicone gel not only secures the joint in place but also prevents potential dislocation, ensuring long-term reliability. In various embodiments, any gel may be introduced into the female housing body (F400) that facilitates good thermal heat transfer.
In Figure 5, the top view of female connector assembly in the solar PV junction box unveils additional components such as the threaded nut (F1200), connector housing (F800), connector lockings (F801, F802), and the connector pin housing (F803). The exploded view of Figure 6 further elucidates the intricate arrangement of these components. A portion of the connector pin (F1100) may be extended in the connector housing (F800), and other part of the connector pin (F1100) may be extended in the other end to crimp the solar cable strand (F101) of the cable (F100), enhancing the overall mechanical stability of the assembly.
Figure 7 provides a comprehensive view of a female connector housing assembly, where the connector housing (F800) may be seamlessly connected to the housing body (F400) through the cable (F100). The threaded nut (F1200) may be strategically placed between the cable and housing, facilitating the easy removal of the connector assembly while safeguarding against water and dust ingress. This meticulous arrangement, highlighted by the O-ring (F1000) and water-proofing rings (F900), may serve as a protective barrier, ensuring the longevity and reliability of the female connector assembly in diverse environmental conditions. In various embodiments, any fastening mechanisms may be used between the cable and housing that facilitate easy removal of the assembly.
In another embodiment of the present disclosure, the solar photovoltaic (PV) junction box may include a male connector housing assembly, as shown in both Figure 8 and Figure 9, that exhibits a meticulous design incorporating various integral components. This male connector housing assembly may include at least one of a housing cover (M700) and a cable (M100) which may be securely inserted into the housing body (M200). The male connector housing assembly may further include a solar cable strand (M101) that may undergo a sophisticated ultrasonic welding process to fuse seamlessly with a copper strip (M300). The choice of ultrasonic welding over traditional soldering may ensure a robust joint with superior heat-withstanding capabilities. The copper strip (M300) may be mounted on one or more mounting pins (M203) of the housing body (M200).
Figure 9 provides an insightful cross-sectional view, emphasizing the ultrasonic welding applied to the solar cable strand (M101) and the copper strip (M300). The male connector housing assembly may further include a diode soldering pin or blocking diode soldering pin (M501) that may be ultrasonically welded to the copper strip (M300). The male connector housing assembly may further include a diode or blocking diode (M500) that may be strategically positioned between two copper strips (M300). This arrangement may fortify the joint, offering enhanced strength and increased resistance to elevated temperatures, ultimately allowing the assembly to withstand DC voltages of up to 1500V.
Transitioning to Figure 10, the cable (M100) and lead block (M400) integration onto the copper strip (M300) is illustrated, highlighting the meticulous embedding process. This intricate structure not only reinforces the joint but also contributes to the overall stability and longevity of the assembly.
Figure 11 showcases the introduction of silicone gel into the housing body (M200). This silicone gel may occupy the chamber containing the copper strip (M300) and part of the cable strand (M101), facilitating thermal heat transfer and effectively securing the joint in place. This feature ensures the assembly's stability under varying environmental conditions, preventing dislocation.
Figure 12 showcases a top view of the male connector assembly that reveals additional components such as threaded nut (M800), connector housing (M900), connector locking mechanisms (M901, M902), and the connector pin housing (M903). In figure 13, an exploded view delves into the intricate arrangement of these components. The extended portions of the connector pin (M1200) are explicitly designed for crimping the solar cable strand (M101), contributing to the overall mechanical stability of the assembly. The male connector housing assembly may further include an flexible metal sleeve for crimping (M1300). The male connector housing assembly may further include an "O" ring (M1100) that may be positioned in close proximity to a waterproofing ring (M1000), which is embedded into the cable (M100) and housed within the threaded nut (M800). This meticulous arrangement serves as a preventive measure, effectively inhibiting water and dust ingress into the connector housing when the threaded nut (M800) of the male connector assembly is tightened.
Figure 14 showcases the male connector housing assembly that demonstrates the seamless connection between the connector housing (M900) and the housing body (M200) through the cable (M100). The threaded nut (M800) may be strategically placed between the cable and housing, facilitating easy removal of the connector assembly while acting as a barrier against water and dust ingress. The male connector housing assembly may further include a housing locking lid (M701) of the housing cover (M700) that may precisely fit into the housing cover locking notch (M201, M202) of the housing (M200), enhancing the leak-proof design of the entire assembly.
In another embodiment of the present disclosure, Figure 15 and Figure 16 depict a parallel housing assembly that may include a housing body (N110), housing cover (N01), copper strip (N201), and mounting pin (N112). The parallel housing assembly may emphasize the copper strip (N201) that may be mounted on the mounting pin (N112) of the housing body (N110). The parallel housing assembly may further include a lead block (N301) and the diode or blocking diode (N400), along with the associated diode soldering pin or blocking diode soldering pin (N401), contributes to the parallel housing assembly's capability to withstand high DC voltages (1500V) and resist corrosion over time. The housing cover (N01) may integrate seamlessly with the housing body (N110), exhibiting a well-engineered design. The parallel housing assembly may further include a housing direction indicator (N111) that may support the parallel housing assembly of bus bars, enhancing the overall functionality and versatility of the parallel housing assembly.
In further embodiment of the present disclosure, a solar photovoltaic (PV) junction box assembly may include at least one housing body (F400, M200, N110) with one or more housing covers (F300, M700, N01, N113). The solar PV junction box assembly may further include one or more cables (F100, M100) that are connected to at least one housing body (F400, M200, N110). The solar PV junction box assembly may further include a connector assembly that is made of a plug-and-socket design with one or more male (M), female (F), and parallel or neutral (N) connectors independently molded in the housing assembly. The connector assembly may further includes at least one connector pin housing (F803) with one or more connector pins (F1100, M1200) extending therefrom for providing one or more electrical contact points; one or more connector housings (F800, M900) that may be adapted to accommodate and protect one or more connector pins (F1100, M1200); at least one threaded nut (F1200, M800) that may be adapted to secure the connector housing (F800, M900) to at least one housing body (F400, M200, N110), ensuring a tight and water-resistant connection; and at least one O-ring (F1000, M1100) that may be disposed between at least one connector pin housing (F803) and one or more connector housings (F800, M900).
The solar PV junction box assembly may further include at least one diode (F600, M500, N400) that is electrically connected to the connector assembly. The solar PV junction box assembly may further include at least one copper strip (F700, M300, N201) that may be adapted to connect the one or more connector pins (F1100, M1200) to the diode (F600, M500, N400). Additionally, a portion of at least one housing body (F400, M200, N110) may be adapted to fill with silicone gel to facilitate thermal transfer and maintain joint stability. Further, the PV junction box may be operable to withstand a maximum voltage of 1500V DC and function in high and low ambient temperatures.
In accordance with the embodiments of the present disclosure, at least one housing body (F400, M200, N110) and connector assembly may be constructed from a flame-retardant engineered polymer for enhanced ultraviolet (UV) and voltage resistance.
In accordance with the embodiments of the present disclosure, one or more cables (F100, M100) may be crimped to at least one copper strip (F700, M300, N201) for improved holding strength.
In accordance with the embodiments of the present disclosure, one or more connector housings (F800, M900) may further include one or more connector lockings (F801, F802, M901).
In accordance with the embodiments of the present disclosure, at least one diode (F600, M500, N400) may be of a surface-mounted type and includes one or more diode soldering pins (F601, M501, N401).
In accordance with the embodiments of the present disclosure, at least one copper strip (F700, M300, N201) may be ultrasonically welded to one or more cables (F100, M100) and diodes (F600, M500, N400) for stronger joints and higher heat resistance.
In accordance with the embodiments of the present disclosure, the solar PV junction box may further include at least one back cover sleeve (F201, M601) that can be ultrasonically welded to at least one housing body (F400, M200, N110) for leak-proofness.
In accordance with the embodiments of the present disclosure, the one or more housing covers (F300, M700, N01, N113) may include at least one housing locking lid (F301, M701) that can be adapted to fit with at least one housing cover locking notch (F402, F403, M201, M202) of the housing body (F400, M200, N110) for secure closure.
In accordance with the embodiments of the present disclosure, the solar PV junction box may further include one or more lead blocks (F500, M400, N301) that may be disposed between at least one copper strip (F700, M300, N201) and at least one diode (F600, M500, N400).
In one embodiment of the present disclosure, a method of assembling a solar photovoltaic (PV) junction box includes the steps of: forming at least one housing body (F400, M200, N110) and at least one connector assembly; connecting one or more cables (F100, M100) to at least one housing body (F400, M200, N110); ultrasonically welding at least one copper strip (F700, M300, N201) to the one or more cables (F100, M100) and one or more connector pins (F1100, M1200); connecting at least one diode (F600, M500, N400) to at least one copper strip (F700, M300, N201); filling at least one housing body (F400, M200, N110) with silicone gel; and securing the one or more connector housings (F800, M900) to at least one housing body (F400, M200, N110).
The present disclosure provides a plurality of benefits. Some of them are listed below.
The PV junction box is designed to withstand a maximum voltage of 1500V DC, ensuring reliable performance in varying conditions.
Housing bodies and connector assemblies are constructed from flame-retardant engineered polymers, enhancing resistance to UV exposure and voltage.
The use of copper strips in the assembly guarantees better conductivity, prolonged lifespan, and corrosion resistance.
Ultrasonic welding of the solar cable strand to the copper strip ensures a robust joint with higher heat resistance compared to soldering.
Connector assemblies with threaded nuts and O-rings provide a tight and water-resistant connection, preventing water and dust ingress.
The housing bodies can be filled with silicone gel, facilitating thermal transfer to maintain joint stability and prevent disconnection due to temperature variations.
The implementation set forth in the foregoing description does not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the subject matter described. Although a few variations have been described in detail above, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementation described can be directed to various combinations and sub combinations of the disclosed features and/or combinations and sub combinations of the several further features disclosed above. In addition, the logic flows depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claims. , Claims:We Claim:
1. A solar photovoltaic (PV) junction box assembly, comprising:
at least one housing body (F400, M200, N110) with one or more housing covers (F300, M700, N01, N113);
one or more cables (F100, M100) that are connected to at least one housing body (F400, M200, N110);
a connector assembly that is made of a plug-and-socket design with one or more male (M), female (F), and parallel or neutral (N) connectors independently molded in the housing assembly, the connector assembly further comprises:
at least one connector pin housing (F803) with one or more connector pins (F1100, M1200) extending therefrom for providing one or more electrical contact points;
one or more connector housings (F800, M900) that are adapted to accommodate and protect one or more connector pins (F1100, M1200);
at least one threaded nut (F1200, M800) that is adapted to secure the connector housing (F800, M900) to at least one housing body (F400, M200, N110), ensuring a tight and water-resistant connection; and
at least one O-ring (F1000, M1100) that is disposed between at least one connector pin housing (F803) and one or more connector housings (F800, M900),
at least one diode (F600, M500, N400) that is electrically connected to the connector assembly; and
at least one copper strip (F700, M300, N201) that is adapted to connect the one or more connector pins (F1100, M1200) to the diode (F600, M500, N400),
wherein a portion of at least one housing body (F400, M200, N110) is adapted to fill with silicone gel to facilitate thermal transfer and maintain joint stability,
wherein the PV junction box is operable to withstand a maximum voltage of 1500V DC and function in high and low ambient temperatures.

2. The solar photovoltaic (PV) junction box assembly as claimed in claim 1, wherein at least one housing body (F400, M200, N110) and connector assembly are constructed from a flame-retardant engineered polymer for enhanced ultraviolet (UV) and voltage resistance.

3. The solar photovoltaic (PV) junction box assembly as claimed in claim 1, wherein the one or more cables (F100, M100) are crimped to at least one copper strip (F700, M300, N201) for improved holding strength.

4. The solar photovoltaic (PV) junction box assembly as claimed in claim 1, wherein the one or more connector housings (F800, M900) further comprises one or more connector lockings (F801, F802, M901).

5. The solar photovoltaic (PV) junction box assembly as claimed in claim 1, wherein at least one diode (F600, M500, N400) is a surface-mounted type and further comprises one or more diode soldering pins (F601, M501, N401).

6. The solar photovoltaic (PV) junction box assembly as claimed in claim 1, wherein at least one copper strip (F700, M300, N201) is ultrasonically welded to one or more cables (F100, M100) and diodes (F600, M500, N400) for stronger joints and higher heat resistance.

7. The solar photovoltaic (PV) junction box assembly as claimed in claim 1, wherein the solar PV junction box further comprises at least one back cover sleeve (F201, M601) that is ultrasonically welded to at least one housing body (F400, M200, N110) for leak-proofness.
8. The solar photovoltaic (PV) junction box assembly as claimed in claim 1, wherein the one or more housing covers (F300, M700, N01, N113) includes at least one housing locking lid (F301, M701) that is adapted to fit with at least one housing cover locking notch (F402, F403, M201, M202) of the housing body (F400, M200, N110) for secure closure.

9. The solar photovoltaic (PV) junction box assembly as claimed in claim 1, wherein the solar PV junction box further comprises one or more lead blocks (F500, M400, N301) that are disposed between at least one copper strip (F700, M300, N201) and at least one diode (F600, M500, N400).

10. A method of assembling a solar photovoltaic (PV) junction box, comprising the steps of:
forming at least one housing body (F400, M200, N110) and at least one connector assembly;
connecting one or more cables (F100, M100) to at least one housing body (F400, M200, N110);
ultrasonically welding at least one copper strip (F700, M300, N201) to the one or more cables (F100, M100) and one or more connector pins (F1100, M1200);
connecting at least one diode (F600, M500, N400) to at least one copper strip (F700, M300, N201);
filling at least one housing body (F400, M200, N110) with silicone gel; and
securing the one or more connector housings (F800, M900) to at least one housing body (F400, M200, N110).