CN105355696A - 一种优化焊接精度的高品质太阳能组件 - Google Patents
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- H01L31/042—PV modules or arrays of single PV cells
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- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
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- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
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- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
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Abstract
本发明涉及一种优化焊接精度的高品质太阳能组件，包括基材、透明玻璃、正电极、负电极以及经优化精度的串焊电池片，所述串焊电池片设置在透明玻璃与基材之间，并由EVA进行封装，串焊电池片的正负极与正电极和负电极相连。本发明的焊接速度快、质量一致性好，表面美观，没有手工焊接的焊锡不均匀现象。设备焊接可以避免人工焊接时的各种人为因素的影响，比如操作工的情绪的影响、身体状况的影响、熟练程度的影响等。保证焊接的一致性、可靠性。降低管理难度及产品成本，减少操作人员及检验人员的数量，现在人工成本逐年增加，自动焊接机能大量减少雇佣人员，大大减少产品成本，提高产品竞争力。
Description
技术领域
本发明涉及一种太阳能组件，具体的说是一种优化焊接精度的高品质太阳能组件，属于太阳能电池技术领域。
背景技术
随着近年来国内外组件制造技术水平的快速提高，光伏发电成本不断降低，但是相对于现在的民生用电，光伏发电的成本仍然太高，仍是制约光伏发电用之于民生的重要因素。在企业利润和市场空间的不断挤压下，电池片越来越薄，从而对光伏组件各个生产环节的设备要求也越来越高，电池片单、串焊接作为组件生产中一个重要环节，它对电池片的铺设效果直接决定了组件制造成品率、可靠性等方面的优劣，也直接影响了组件的制造成本。随着组件技术不断发展，客户对组件的要求也越来越严苛，在成本和利润的矛盾中，现在很多公司已对手工焊接进行改造，都改为自动串焊机焊接，有效减少电池片隐裂及降低人工成本。因此，在现有设备的基础上，研究如何改造为自动焊接，已经成为重要的技术环节之一。
发明内容
本发明所要解决的技术问题是，克服现有技术的缺点，提供一种优化焊接精度的高品质太阳能组件，结合国外先进的焊接工艺优化产线的电池片焊接方式，实现自动焊接，提高优质率，降低不良率，从而节约生产成本，提高产品的竞争力。
为了解决以上技术问题，本发明提供一种优化焊接精度的高品质太阳能组件，包括基材、透明玻璃、正电极、负电极以及经优化精度的串焊电池片，所述串焊电池片设置在透明玻璃与基材之间，并由EVA进行封装，串焊电池片的正负极与正电极和负电极相连，所述串焊电池片的焊接包括如下步骤：
⑴采用整卷焊带进行开卷，将开卷好的焊带放入缓存器备用；
⑵切割完成的电池片由电池片盒转运至主输送带上，通过传送带传送至检测结构，剔除废料；
⑶通过检测的电池片根据设定排序送入串焊输送机；
⑷焊带由缓存器中牵引出，经助焊剂涂覆区、焊带干燥区，再由焊带拉伸、折弯和切断工序后将焊带送至串焊输送机中；
⑸串焊输送机中焊接工作台预热温度设定68-80℃，空气湿度在50±5%，焊接烙铁温度设定为320-360℃，将电池片与焊带焊接；
⑹串焊好的电池片由传送带送至检测区域，检测焊接外观和焊接牢固度；
⑺检验合格的串焊电池片送至组件工序组装太阳能组件。
本发明的进一步限定技术方案，前述的优化焊接精度的高品质太阳能组件，所述焊带与电池片主栅线错位小于0.5mm。
进一步的，前述的优化焊接精度的高品质太阳能组件，所述焊带干燥区温度为85-90℃，热风风速小于2m/s。
前述的优化焊接精度的高品质太阳能组件，所述焊带的焊接面呈波浪形结构，所述波浪形凹槽的夹角角度为45°-60°，所述焊带的波峰至波谷的垂直距离为0.40mm-1.0mm，所述焊带的成分及质量百分比为：Pb：11-13%，Fe：2-4.5%，Mg：2-3%，V：0.7-0.9%，Ti：2.5-2.7%，Ag：8-10%，Cu：5-7%，Sb：0.58-0.72%，Zn：1.2-2.5%，稀土微量元素：0.5-0.7%，余量为Sn；所述稀土微量元素按重量百分比包含以下成分：Nd：18-21%，Ce：6-10%，Tb：5-14%，余量为La；所述焊带厚度为0.25-0.45mm。
本发明的有益效果：本发明的焊接速度快、质量一致性好，表面美观，没有手工焊接的焊锡不均匀现象。设备焊接可以避免人工焊接时的各种人为因素的影响，比如操作工的情绪的影响、身体状况的影响、熟练程度的影响等。保证焊接的一致性、可靠性。降低管理难度及产品成本，减少操作人员及检验人员的数量，现在人工成本逐年增加，自动焊接机能大量减少雇佣人员，大大减少产品成本，提高产品竞争力。同时通过对焊带组分和外形结构的调整，减少焊带在热胀冷缩后的内部应力，降低了光伏焊带与电池片焊接后成“弓形”的情况，确保焊接时的焊接精度，降低了电池片碎裂的几率；并且由于设置波浪形结构，减小了光伏焊带与电池片的接触面积，增加了电池片的受光面积，还可以进一步的提高了电池组件的转换效率。
串焊机的焊接可靠性要远大于人工焊接，焊接不良是导致组件提前失效的重要原因，太阳能光伏组件的设计寿命为25年，而组件通常安装在户外，每天要承受30℃的温度变化，加上季节更替温度的变化更大。使用自动串焊机焊接，焊接效果优化明显，降低了组件的不良率。
具体实施方式
实施例1
本实施例提供的一种优化焊接精度的高品质太阳能组件，包括基材、透明玻璃、正电极、负电极以及经优化精度的串焊电池片，所述串焊电池片设置在透明玻璃与基材之间，并由EVA进行封装，串焊电池片的正负极与正电极和负电极相连，所述串焊电池片的焊接包括如下步骤：
⑴采用整卷焊带进行开卷，将开卷好的焊带放入缓存器备用；
⑵切割完成的电池片由电池片盒转运至主输送带上，通过传送带传送至检测结构，剔除废料；
⑶通过检测的电池片根据设定排序送入串焊输送机；
⑷焊带由缓存器中牵引出，经助焊剂涂覆区、焊带干燥区，焊带干燥区温度为85-90℃，热风风速小于2m/s；再由焊带拉伸、折弯和切断工序后将焊带送至串焊输送机中；
⑸串焊输送机中焊接工作台预热温度设定68-80℃，空气湿度在50±5%，焊接烙铁温度设定为320-360℃，将电池片与焊带焊接，焊带与电池片主栅线错位小于0.5mm；
⑹串焊好的电池片由传送带送至检测区域，检测焊接外观和焊接牢固度；
⑺检验合格的串焊电池片送至组件工序组装太阳能组件。
对于成品串焊电池片要求焊接表面光亮，无锡珠和毛刺，无脱焊、虚焊和过焊；电池片表面清洁，无明显助焊剂残留；互连条要均匀、平直地焊在太阳能电池片主栅线内，焊带与电池片主栅线的错位≤0.5mm；具有一定的机械强度，沿45°方向轻拉不脱落；串联时要尽量将发电电流相等或者相近的电池片串联，而且尺寸和颜色要一致，这样既保证了光电效率也使得组件更加美观。
本实施例通过对国内外先进焊接工艺及设备的研究，开发出适合自身使用的先进设备，替换原有的手工焊操作方式，增加组件优质率，降低组件的生产成本，提高组件的市场竞争力。
本实施例的焊带的焊接面呈波浪形结构，焊带厚度为0.35mm，所述波浪形凹槽的夹角角度为55°，焊带的波峰至波谷的垂直距离为0.8mm，焊带的成分及质量百分比为：Pb：13%，Fe：3.5%，Mg：3%，V：0.8%，Ti：2.6%，Ag：9%，Cu：6%，Sb：0.62%，Zn：1.8%，稀土微量元素：0.7%，余量为Sn；所述稀土微量元素按重量百分比包含以下成分：Nd：21%，Ce：6%，Tb：8%，余量为La。
除上述实施例外，本发明还可以有其他实施方式。凡采用等同替换或等效变换形成的技术方案，均落在本发明要求的保护范围。
Claims (5)
1.一种优化焊接精度的高品质太阳能组件，包括基材、透明玻璃、正电极、负电极以及经优化精度的串焊电池片，所述串焊电池片设置在透明玻璃与基材之间，并由EVA进行封装，串焊电池片的正负极与正电极和负电极相连，其特征在于：所述串焊电池片的焊接包括如下步骤：
⑴采用整卷焊带进行开卷，将开卷好的焊带放入缓存器备用；
⑵切割完成的电池片由电池片盒转运至主输送带上，通过传送带传送至检测结构，剔除废料；
⑶通过检测的电池片根据设定排序送入串焊输送机；
⑷焊带由缓存器中牵引出，经助焊剂涂覆区、焊带干燥区，再由焊带拉伸、折弯和切断工序后将焊带送至串焊输送机中；
⑸串焊输送机中焊接工作台预热温度设定68-80℃，空气湿度在50±5%，焊接烙铁温度设定为320-360℃，将电池片与焊带焊接；
⑹串焊好的电池片由传送带送至检测区域，检测焊接外观和焊接牢固度；
⑺检验合格的串焊电池片送至组件工序组装太阳能组件。
2.根据权利要求1所述的优化焊接精度的高品质太阳能组件，其特征在于：所述焊带与电池片主栅线错位小于0.5mm。
3.根据权利要求1所述的优化焊接精度的高品质太阳能组件，其特征在于：所述焊带干燥区温度为85-90℃，热风风速小于2m/s。
4.根据权利要求1所述的优化焊接精度的高品质太阳能组件，其特征在于：所述焊带的焊接面呈波浪形结构，所述波浪形凹槽的夹角角度为45°-60°，所述焊带的波峰至波谷的垂直距离为0.40mm-1.0mm，所述焊带的成分及质量百分比为：Pb：11-13%，Fe：2-4.5%，Mg：2-3%，V：0.7-0.9%，Ti：2.5-2.7%，Ag：8-10%，Cu：5-7%，Sb：0.58-0.72%，Zn：1.2-2.5%，稀土微量元素：0.5-0.7%，余量为Sn；所述稀土微量元素按重量百分比包含以下成分：Nd：18-21%，Ce：6-10%，Tb：5-14%，余量为La。
5.根据权利要求4所述的优化焊接精度的高品质太阳能组件，其特征在于：所述焊带厚度为0.25-0.45mm。
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