CN104485365B - 复合型压花光伏焊带及其加工方法 - Google Patents

复合型压花光伏焊带及其加工方法 Download PDF

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CN104485365B
CN104485365B CN201410817971.5A CN201410817971A CN104485365B CN 104485365 B CN104485365 B CN 104485365B CN 201410817971 A CN201410817971 A CN 201410817971A CN 104485365 B CN104485365 B CN 104485365B
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梁哲
朱景兵
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Wuxi Suntech Power Co Ltd
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Abstract

本发明提供一种复合型压花光伏焊带，包括一根用于与太阳能电池片上的主栅线焊接的带状导电基材，在带状导电基材上表面一侧放置有数根能够反射光线的异形金属线；异形金属线的长度不超过一个太阳能电池片的最大长度。进一步地，异形金属线截面形状为顶角角度大于90°的等腰三角形。进一步地，异形金属线截面形状为半圆形。进一步地，异形金属线平行排列在带状导电基材上。进一步地，异形金属线的材料为纯铜或银，如果是纯铜，则异形金属线外表面镀有一层焊锡。本发明还提出了该复合型压花光伏焊带与太阳能电池串焊接加工结合在一起的一种加工方法。本发明能够提高光伏焊带与太阳能电池背面电极焊接强度，同时提高光伏转换效率。

Description

复合型压花光伏焊带及其加工方法
技术领域
本发明涉及太阳能电池串自动焊接领域，尤其是一种复合型压花光伏焊带及其加工方法。
背景技术
常规晶体硅太阳电池在封装成光伏组件时，需要使用光伏焊带焊接成太阳能电池串，然后进行层叠、层压和组装等加工。普通光伏焊带焊接到太阳电池后，会产生遮光区域，入射到光伏焊带2表面的光线被反射出光伏组件，无法被利用，如图1所示，导致电池片受光面积减少，转换效率降低。图1中的附图标记1为光伏组件上表面，也就是正面玻璃的上表面。
现有技术中，光伏业者在普通光伏焊带的表面压制花纹，使得照射到光伏焊带表面的光线经过多次反射，再次照射到太阳电池表面，从而提高入射光的利用效率，如图2所示。图2中附图标记1为光伏组件上表面，也就是正面玻璃的上表面；附图标记2为光伏焊带，附图标记3为光伏焊带表面压花结构。但此种压花焊带需要在焊带上精密加工V型槽压花，加工精度要求较高，生产成本高。并且由于压花都压制在焊带的上表面，当压花焊带与晶体硅太阳电池背面主栅线焊接时，接触面积较小，容易造成脱焊和虚焊，带来后续隐患。
发明内容
本发明的目的在于克服现有技术中存在的不足，提供一种复合型压花光伏焊带，以及此复合型压花光伏焊带联合太阳能电池串焊接的加工方法，能够提高光伏焊带与晶体硅太阳能电池背面电极焊接强度，同时提高光伏焊带表面入射光线利用，提高光伏转换效率。本发明所采用的技术方案是：
一种复合型压花光伏焊带，包括一根用于与太阳能电池片上的主栅线焊接的带状导电基材，在带状导电基材上表面一侧放置有数根能够反射光线的异形金属线；异形金属线的长度不超过一个太阳能电池片的最大长度。
进一步地，异形金属线截面形状为顶角角度大于90°的等腰三角形。
进一步地，异形金属线截面形状为半圆形。
进一步地，异形金属线平行排列在带状导电基材上。
进一步地，异形金属线的材料为纯铜或银，如果是纯铜，则异形金属线外表面镀有一层焊锡。
进一步地，带状导电基材采用镀锡铜带基材。
一种复合型压花光伏焊带的加工方法，包括下述步骤：
步骤一，先将第一块太阳能电池片放置在串焊台上，然后将带状导电基材、异形金属线自下而上依次放置在第一块太阳能电池片的正面主栅线上；其中，数根异形金属线放置在带状导电基材上表面一侧；
步骤二，将异形金属线、带状导电基材和第一块太阳能电池片的正面主栅线焊接在一起；
步骤三，将第二块太阳能电池片的背面主栅线与带状导电基材另一侧对准，将第二块太阳能电池片放置在带状导电基材另一侧；
步骤四，将带状导电基材与第二块太阳能电池片的背面主栅线焊接在一起。
进一步地，步骤一中，数根异形金属线平行放置在带状导电基材上表面一侧。
进一步地，步骤二和步骤四中的焊接均通过红外加热或者超声波进行焊接。
本发明的优点在于：
1）截面形状为三角形或圆弧形的异形金属线与镀锡铜带基材相结合，成为复合型焊带。
2）将复合型焊带的加工过程与电池串焊接过程相结合，尽量不增加生产成本。
3）异形金属线的加工成本低，生产效率高。
附图说明
图1为光伏焊带发射光示意图。
图2为现有的压花光伏焊带示意图。
图3为本发明的复合型压花光伏焊带示意图。
图4为本发明的复合型压花光伏焊带联合太阳能电池串焊接示意图。
具体实施方式
下面结合具体附图和实施例对本发明作进一步说明。
本发明所提出的复合型压花光伏焊带如图3所示，包括一根用于与太阳能电池片上的主栅线焊接的带状导电基材5，该带状导电基材5可采用镀锡铜带基材；在带状导电基材5上表面一侧放置有数根能够反射光线的异形金属线4；异形金属线4的材料可以为纯铜或银，如果使用纯铜，外表面应浸镀一层焊锡，异形金属线4的长度不超过一个太阳能电池片的最大长度，通常情况太阳能电池片是正方形的，则异形金属线4的长度等于太阳能电池片的长度或略小于太阳能电池片的长度也可；
异形金属线4截面形状为等腰三角形或半圆形，如截面形状为等腰三角形时，其顶角角度大于90°。
异形金属线4只是放置在带状导电基材5上，先不做焊接。不必如现有技术那般在焊带上精密加工V形槽压花。带状导电基材5上平行排列的异形金属线数量为3-10根，每根金属线尺寸相同。
复合型压花光伏焊带的加工与太阳能电池串焊接的加工结合在一起，具体加工步骤包括：
步骤一，先将第一块太阳能电池片，即图4中的电池片A放置在串焊台上，然后将带状导电基材5、异形金属线4自下而上依次放置在第一块太阳能电池片的正面主栅线上；数根异形金属线4平行放置在带状导电基材5上表面一侧；
步骤二，通过红外加热或者超声波将异形金属线4、带状导电基材5和第一块太阳能电池片的正面主栅线焊接在一起；
步骤三，将第二块太阳能电池片，即图4中的电池片B的背面主栅线与带状导电基材5另一侧对准，将第二块太阳能电池片放置在带状导电基材5另一侧；
步骤四，通过红外加热或者超声波将带状导电基材5与第二块太阳能电池片的背面主栅线焊接在一起；由于带状导电基材5另一侧上并没有异形金属线，其与第二块太阳能电池片的背面主栅线接触面积较大，焊接牢固。太阳能电池片的背面主栅线就是电池片的正电极。
上述四个步骤即可做成由两块太阳能电池片构成的电池串。实际生产中，可重复上述步骤一至步骤四，直至电池串上的电池片数量满足设计需要。
由于复合型光伏焊带的加工过程与电池串焊接过程结合在一起，因此并不影响电池串工序生产效率，生产成本增加也不明显，但由于异形金属线将入射在其表面的光线进行多次反光，被太阳能电池再次利用，可增加光伏组件最终输出功率。
异形金属线可通过轧制或模具拉丝等方式生产，与在焊带上精密加工V形槽压花相比，异形金属线的生产设备投入少，加工成本低，生产效率高。
本发明可提高照射在光伏焊带表面入射光线的利用率，从而提高光伏组件输出功率。

Claims (2)

1.一种复合型压花光伏焊带，其特征在于：包括一根用于与太阳能电池片上的主栅线焊接的带状导电基材(5)，在带状导电基材(5)上表面一侧放置有数根能够反射光线的异形金属线(4)；异形金属线(4)的长度不超过一个太阳能电池片的最大长度；
异形金属线(4)的材料为纯铜或银，如果是纯铜，则异形金属线(4)外表面镀有一层焊锡；
异形金属线(4)截面形状为顶角角度大于90°的等腰三角形或半圆形；
异形金属线(4)平行排列在带状导电基材(5)上。
2.一种复合型压花光伏焊带的加工方法，其特征在于，包括下述步骤：
步骤一，先将第一块太阳能电池片放置在串焊台上，然后将带状导电基材(5)、异形金属线(4)自下而上依次放置在第一块太阳能电池片的正面主栅线上；其中，数根异形金属线(4)放置在带状导电基材(5)上表面一侧；
步骤二，将异形金属线(4)、带状导电基材(5)和第一块太阳能电池片的正面主栅线焊接在一起；
步骤三，将第二块太阳能电池片的背面主栅线与带状导电基材(5)另一侧对准，将第二块太阳能电池片放置在带状导电基材(5)另一侧；
步骤四，将带状导电基材(5)与第二块太阳能电池片的背面主栅线焊接在一起；
步骤一中，数根异形金属线(4)平行放置在带状导电基材(5)上表面一侧；
步骤二和步骤四中的焊接均通过红外加热或者超声波进行焊接；
异形金属线(4)的材料为纯铜或银，如果是纯铜，则异形金属线(4)外表面镀有一层焊锡。
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