CN102194923A - 电连接光伏面板的电极的方法 - Google Patents

电连接光伏面板的电极的方法 Download PDF

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CN102194923A
CN102194923A CN2011100696118A CN201110069611A CN102194923A CN 102194923 A CN102194923 A CN 102194923A CN 2011100696118 A CN2011100696118 A CN 2011100696118A CN 201110069611 A CN201110069611 A CN 201110069611A CN 102194923 A CN102194923 A CN 102194923A
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戴怡文
黄成沛
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Abstract

本发明提供一种电连接光伏面板的电极的方法，其包括：在所述光伏面板的所述电极上施加导电粘合剂膜，其中所述导电粘合剂膜包括绝缘粘合剂层和分布在所述绝缘粘合剂层中的导电粒子；沿着所述导电粘合剂膜提供金属条；以及经由所述导电粘合剂膜在所述金属条与所述电极之间执行电连接方法。

Description

电连接光伏面板的电极的方法
技术领域
本发明大体涉及电连接光伏面板的电极以便将太阳能转化为电能并从光伏面板导出输出的方法。
背景技术
常规上，光伏面板在两端具有导线焊接区，用于将太阳能转化为电能并从光伏面板导出输出。在导线焊接区中，若干充当正电极和负电极的焊料凸块以规则的间隔形成为一行。导线连接到焊料凸块，使得可导出光伏面板的输出。举例来说，在US 6,357,649中，提供一种可自动地将导线连接到形成于光伏面板的导线焊接区中的一行焊料凸块的方法和设备。随后，可将导线连接到附接到光伏面板的表面的接线盒。
凸块常规上可通过手动或自动焊接设备(例如，超声波焊接)而焊接并紧固。然而，不论是手动还是通过自动焊接设备来实行焊接，一些焊料凸块都可能由于设备的故障而丢失或错位，且因此导致光伏断裂。另外，当导线沿着焊料凸块行布置且对着导线从上方按压焊铁时，重量从导线的末端悬垂以向导线施加张力使得可防止导线移位或起皱(wrinkling)。焊接于焊料凸块之间的导线由于此步骤而发生应变。
US 6,402,881提供一种将太阳能电池的电极电互连的方法，其中太阳能电池的互连件采用铜条且通过银-硅树脂导电膏紧固到太阳能电池。通过此方法，可排除使用焊料凸块。然而，银-硅树脂导电膏需要固化以便形成电互连。
鉴于以上内容，需要一种可减少或排除归因于焊料凸块带来的断裂问题且较简单的电连接光伏面板的电极的方法。
发明内容
本发明的一目的是排除由光伏面板的金属线焊接区中形成的焊料凸块丢失或错位而引起的光伏断裂。
本发明的一目的是通过在光伏面板的电极上使用导电粘合剂膜而提供光伏面板的电连接。
本发明的一目的是提供一种较简单的方法，其通过在光伏面板的电极上施加导电粘合剂膜而提供光伏面板的电连接。
根据本发明，在光伏面板的电极上提供导电粘合剂膜以使得导电部件(例如，金属条)可通过导电粘合剂膜的粘合特性或通过焊接方法而附接。
根据本发明，一种电连接光伏面板的电极的方法包括：在光伏面板的电极上施加导电粘合剂膜，其中所述导电粘合剂膜包括绝缘粘合剂层和分布在绝缘粘合剂层中的导电粒子；沿着导电粘合剂膜提供金属条；且经由导电粘合剂膜在金属条与电极之间执行电连接方法。
电连接方法的步骤包括应用于光伏面板的层压步骤。所述层压步骤在连同导电粘合剂膜一起提供金属条之后应用，使得分布在导电粘合剂膜中的导电粒子经按压且彼此接触以在金属条与光伏面板的电极之间形成电连接。
本发明的方法避免了必须使用焊料凸块进行光伏面板的电连接，且因此不会由于焊料凸块丢失或错位而导致光伏面板故障问题。另外，由于用于光伏面板的常规电连接方法中使用的焊料凸块或固化方法根据本发明不再是必需的，所以所述方法可较多产且具成本效益。此外，可改进良率。
附图说明
图1是在上面形成导电粘合剂膜和金属条的本发明的光伏面板的一实施例的透视图。
图2是图1中描绘的实施例的一部分的横截面图。
相同参考数字贯穿于几幅图中表示对应的部分。尺寸未按比例绘制。
具体实施方式
来自下文描述的不同实施例的特征是权利要求书中陈述的要素的实例，且可在不脱离权利要求书的范围的情况下组合在一起成为一个实施例。
图1说明光伏面板2，其通过在电线焊接区4中的光伏面板2的电极上的导电粘合剂膜6和放置在其上的金属条8而电连接。图2是图1中描绘的光伏面板2的一部分的横截面图。
下文将针对使用含有导电粒子的导电粘合剂膜来详细描述本发明的方法。
电连接方法涉及在光伏面板2的电极上施加导电粘合剂膜6。在一个实施例中，导电粘合剂膜6可为(但不限于)各向异性导电粘合剂膜。导电粘合剂膜6包括绝缘粘合剂层6a和分布在绝缘粘合剂层6a中的导电粒子6b。导电粒子6b可为均匀分布在绝缘粘合剂层6a中的由Ni、Au、Ag、Tin或这些元素的合金制成的金属粉末，或者表面上已经镀敷金属的聚合物或塑料粉末。优选地，根据金属条的宽度，导电粒子6b的大小为约3μm到约10μm。在一个实施例中，导电粘合剂膜6通过其粘合特性而施加到光伏面板2的电极，所述粘合特性可从绝缘粘合剂层6a得到。在一个实施例中，导电粘合剂膜6是导电胶带，其通过其粘合特性而施加到光伏面板2的电极，且金属条8放置在导电粘合剂膜6上。金属条8经由导电粘合剂膜6固定在光伏面板2的电极上。接着，经由导电粘合剂膜6在金属条8与电极之间执行电连接方法。所述电连接方法包括在连同导电粘合剂膜6一起提供金属条8之后应用于光伏面板2的层压步骤。
在层压步骤期间，按压导电粘合剂膜6的导电粒子6b以便接触邻近的导电粒子6b，且在金属条8与光伏面板2的电极之间形成导电连接。
在一个实施例中，金属条8通过导电粘合剂膜6的粘合特性而附接到导电粘合剂膜6。在一个实施例中，由镀敷焊料的铜箔等制成的金属条或电线可通过常规上可用于在焊料凸块上焊接金属条的方法(如US 6,357,649中所描述)而放置在导电粘合剂膜6上。换句话说，可在本发明中应用类似于金属条焊接技术的方法以沿着导电粘合剂膜6放置金属条8。根据所述技术，可通过焊铁将金属条8按压在导电粘合剂膜6上，且可任选地从上方对金属条8进行加热。US 6,357,649中描述的相关方法的全文以引用的方式并入本文中。金属条可由(但不限于)银、铜或其它类似材料制成。
所揭示的实施例中的光伏面板2可包含由(但不限于)非晶硅、III-V、II-VI或生长于玻璃上的任何其它适宜的材料制成的结构。
在将由铜箔等制成的金属条8施加到上面放置有导电粘合剂膜的正电极和负电极之后，金属连接件的一部分可经由另一金属条10连接到附接到光伏面板的表面的接线盒，以便导出输出。金属条10可由绝缘材料围绕(除了两端处)。
在制作多个光伏面板时，可在单一衬底上形成多个光伏模块，且在划分区处切割所述单一衬底以形成多个光伏面板，且在每一光伏面板的两侧上将金属条连接到金属线焊接区。换句话说，首先在被划分的光伏面板两侧上的金属线焊接区中形成于导电粘合剂膜，且随后沿着导电粘合剂膜放置金属连接件。
所属领域的技术人员将了解，可在不脱离本发明的范围或精神的情况下对本发明的结构作出各种修改和变化。鉴于以上内容，希望本发明涵盖本发明的修改和变化，条件是其落在所附权利要求书及其等效物的范围内。

Claims (10)

1.一种电连接光伏面板的电极的方法，其包括：
在所述光伏面板的所述电极上施加导电粘合剂膜，其中所述导电粘合剂膜包括绝缘粘合剂层和分布在所述绝缘粘合剂层中的导电粒子；
沿着所述导电粘合剂膜提供金属条；以及
经由所述导电粘合剂膜在所述金属条与所述电极之间执行电连接方法。
2.根据权利要求1所述的方法，其中所述导电粘合剂膜为各向异性导电粘合剂膜。
3.根据权利要求1所述的方法，其中所述导电粒子为金属粉末。
4.根据权利要求1所述的方法，其中所述导电粒子为表面上已经镀敷金属的聚合物粉末。
5.根据权利要求1所述的方法，其中所述导电粒子为表面上已经镀敷金属的塑料粉末。
6.根据权利要求1所述的方法，其中所述导电粒子的大小为约3μm到约10μm。
7.根据权利要求1所述的方法，其中所述导电粘合剂膜为导电胶带。
8.根据权利要求1所述的方法，其中通过粘合将所述金属条附接到所述导电粘合剂膜。
9.根据权利要求1所述的方法，其中通过粘合将所述导电粘合剂膜施加在所述光伏面板的所述电极上。
10.根据权利要求1所述的方法，其中所述电连接方法的步骤包括在连同所述导电粘合剂膜一起提供所述金属条之后层压所述光伏面板的步骤，以便按压所述导电粘合剂膜且使所述导电粒子彼此接触。
CN2011100696118A 2010-03-17 2011-03-17 电连接光伏面板的电极的方法 Pending CN102194923A (zh)

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