CN111048612A - 一种多股铜线圆型涂锡光伏焊带及其制备方法与应用 - Google Patents
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Abstract
本发明提供了一种多股铜线圆型涂锡光伏焊带及其制备方法与应用,属于光伏新能源技术领域。所述光伏焊带的制备方法为:选取原材料铜丝,将多根单股圆线铜丝进行紧密缠绕,得到多股圆型铜线基材,并在保护气体的作用下进行短路退火处理,得到退火处理后多股圆型铜线,随后将多股圆型铜线放入助焊剂中进行浸润,将浸润后的铜带送入锡炉中,进行涂锡加工,之后冷却至室温,最终得到多股铜线圆型涂锡光伏焊带。本发明制备得到的光伏焊带具有较强导电能力,可以最大化提高太阳能转换效率。
Description
技术领域
本发明属于光伏新能源技术领域,尤其是涉及一种多股铜线圆型涂锡光伏焊带及其制备方法与应用。
背景技术
太阳能电池是一种非常有前景的新型电源,它具有永久性、清洁性和灵活性三大优点。太阳能电池寿命长,只要有太阳光的存在,太阳能电池就可以一次投资而长期使用;与火力发电、核能发电相比,太阳能电池不会引起环境污染;太阳能电池可以方便地实现大中小的组合,大到百万千瓦的中型电站,小到只供一户用的太阳能电池组,这是其它电源无法比拟的。
作为光伏组件核心的电池片已是整个光伏行业关注的重点,现有电池片发电受光源限制(阴天、夜晚和透光率)、转换损耗(电力输送过程的损失)和表面积(正面导电线的遮光部分)影响其发电效率只有用20%左右,实验室的实验数据最高也只能达到25%的转换效率,如何最大化利用光源、降低转换过程电力损耗,将是后期太阳能发电发展的关键。
目前市场上光伏组件大多数采用5栅或者更高效的多主栅组件,常规的5栅组件采用的是常规扁平焊带,而多主栅采用的是圆型焊带;多主栅圆型焊带可减少遮光面积,将光有效的反射到电池上,提高组件短路电流,焊带区域光学利用率由5%以下提高到40%以上(图1)。但是,目前市场上采用的圆型焊带,均是单股铜线直接涂锡,单股铜线目前存在的问题是电阻较大,导致电池片在发电时转换损耗较大,大大的降低了发电过程中的转换效率。
发明内容
本申请针对现有技术的不足,本发明提供了一种多股铜线圆型涂锡光伏焊带及其制备方法与应用。本发明制备得到的光伏焊带具有较强导电能力,可以最大化提高太阳能转换效率。
本发明的技术方案如下:
一种多股铜线圆型涂锡光伏焊带,所述光伏焊带包括多根铜线圆型焊带与焊料涂覆层,所述铜线材质为铜丝,所述焊料涂覆层由锡与铅、铋、银中的任一种金属形成二元或三元合金。
所述的光伏焊带的制备方法包括如下步骤:
(1)多股圆型铜基材的制备:选取原材料铜丝,将多根单股圆线铜丝进行紧密缠绕,得到多股圆型铜线基材;
(2)热处理:将步骤(1)中所得多股圆型铜线基材在保护气体的作用下进行短路退火处理,得到热处理后多股圆型铜线;
(3)表面处理:将步骤(2)中所得热处理后多股圆型铜线放入助焊剂中进行浸润;
(4)涂锡:将步骤(3)中浸润之后的铜线送入锡炉中,进行涂锡加工,之后冷却至室温,得到涂锡合金的铜带;
步骤(1)中所述铜线为无氧铜,且铜含量不小于99.95%。
步骤(2)中所述保护气体为氮气。
步骤(2)中所述短路退火条件为:直流电流10-50A,电压为280-380V。
步骤(3)中所述助焊剂包括溶剂型助焊剂和水剂型助焊剂。
步骤(4)中所述锡炉温度为220-260℃,涂锡速度为100-200m/min。
一种光伏焊带在MBB多主栅电池组件中的应用。
本发明有益的技术效果在于:
本发明包括三个组成部分①基材,此部分用多股纯铜圆线制成,纯铜圆线缠绕紧密,表面光滑,尺寸可以根据不同型号定制;②绕线,打破传统单根圆线涂锡,将多根纯铜细圆线缠绕在一起,缠绕紧密,外径一致性高,并且本发明中要求单根细圆线的截面积为S1,数量为N,单根粗圆线截面积为S2,S1*N≈S2,并且缠绕完成后,多根细圆线的总截面积与单根圆线的截面积基本相等;③焊料层,多根铜线外表面涂覆一层焊料,焊料的成分与常规焊带相同,焊料层厚度可控制在10-30μm,焊料层外径尺寸均匀,一致性高。
本发明与国内市场现有的圆型焊带相比,优点在于:①相同外径尺寸情况下,多股铜线导电能力比单股铜线导电更强,电阻更低,根据电流的趋肤效应,当交变电流通过导体时,电流将集中在导体表面流过,这种现象叫趋肤效应。是电流或电压以频率较高的电子在导体中传导时,会聚集于总导体表层,而非平均分布于整个导体的截面积中。因为导电能力更强,电流通过的速度更快,可以最大化利转换过程电力损耗、可以最大化的提高太阳能转换效率。
本发明申请可以根据需要调整铜材的外径尺寸,达到φ0.15-φ0.5㎜的直径;并采用接触式短路退火,退火电流为直流或交流,适用于铜线的退火软化生产,管道退火采用电阻加热方式,退火过程中采用保护气体防止铜丝在退火过程中发生氧化;整个退火电流,通过控制两铜轮之间的电势差,得到不同电流数值,可以根据调整电压,得到不同铜带的屈服强度;本发明中助焊剂的作用是去除铜带表面氧化物,降低铜丝表面的张力,使得铜丝在涂锡过程中具有更优的浸润性;同时本发明兼顾市场主流焊接设备的性能,完美解决焊接问题,大大降低设备改造的投入,降低成本压力,更符合市场对多股铜线涂锡圆线的需求。
附图说明
图1为圆型焊带与常规焊带光反射示意图。
图2为本发明中单根铜线涂锡圆型焊带。
图3为本发明中多根铜线涂锡圆型焊带。
具体实施方式
下面结合附图和实施例,对本发明进行具体描述。
实施例1
选取含量为99.99%原材料圆线铜丝,将7根单股圆线铜棒进行紧密缠绕,得到多股圆型铜线基材;并将所得七股圆型铜线基材在氮气的作用下进行短路退火处理,此时直流电流为16A,电压为380V,结果退火之后得到热处理后多股圆型铜线;随后将所得热处理后多股圆型铜线放入溶剂型助焊剂中进行浸润,浸润结束铜线表面光滑,进行涂锡加工:将浸润之后的铜线送入锡炉中,并将温度升高至220℃,涂锡的速度设置为100m/min,进行涂锡加工,之后冷却至室温,最终得到多股铜线圆型涂锡光伏焊带。
实施例2
选取含量为99.99%原材料圆线铜丝,将15根单股圆线铜棒进行紧密缠绕,得到多股圆型铜线基材;并将所得十五股圆型铜线基材在氮气的作用下进行短路退火处理,此时直流电流为20A,电压为380V,结果退火之后得到热处理后多股圆型铜线;随后将所得热处理后多股圆型铜线放入溶剂型助焊剂中进行浸润,浸润结束铜线表面光滑,进行涂锡加工:将浸润之后的铜线送入锡炉中,并将温度升高至230℃,涂锡的速度设置为100m/min,进行涂锡加工,之后冷却至室温,最终得到多股铜线圆型涂锡光伏焊带。
实施例3
选取含量为99.99%原材料圆线铜丝,将20根单股圆线铜棒进行紧密缠绕,得到多股圆型铜线基材;并将所得二十股圆型铜线基材在氮气的作用下进行短路退火处理,此时直流电流为30A,电压为380V,结果退火之后得到热处理后多股圆型铜线;随后将所得热处理后多股圆型铜线放入溶剂型助焊剂中进行浸润,浸润结束铜线表面光滑,进行涂锡加工:将浸润之后的铜线送入锡炉中,并将温度升高至240℃,涂锡的速度设置为150m/min,进行涂锡加工,之后冷却至室温,最终得到多股铜线圆型涂锡光伏焊带。
Claims (8)
1.一种用于MBB多主栅光伏电池组件用的多股铜线圆型涂锡光伏焊带,其特征在于,所述光伏焊带包括多根铜线圆型焊带与焊料涂覆层,所述铜线材质为纯铜丝,所述焊料涂覆层由锡与铅、铋、银中的任一种金属形成二元或三元合金。
2.一种如权利要求1所述的光伏焊带的制备方法,其特征在于,所述的制备方法包括如下步骤:
(1)多股圆型铜基材的制备:选取原材料铜丝,将2-20根单股圆线铜丝进行紧密缠绕,得到多股圆型铜线基材;
(2)热处理:将步骤(1)中所得多股圆型铜线基材在保护气体的作用下进行短路退火处理,得到热处理后多股圆型铜线;
(3)表面处理:将步骤(2)中所得热处理后多股圆型铜带放入助焊剂中进行浸润;
(4)涂锡:将步骤(3)中浸润之后的铜带送入锡炉中,进行涂锡加工,之后冷却至室温,得到涂锡合金的焊带。
3.根据权利要求2所述的制备方法,其特征在于,步骤(1)中所述铜丝为无氧铜,且铜含量不小于99.95%。
4.根据权利要求2所述的制备方法,其特征在于,步骤(2)中所述保护气体为氮气。
5.根据权利要求2所述的制备方法,其特征在于,步骤(2)中所述短路退火条件为:直流电流10-50A,电压为220-380V。
6.根据权利要求2所述的制备方法,其特征在于,步骤(3)中所述助焊剂包括溶剂型助焊剂和水剂型助焊剂。
7.根据权利要求2所述的制备方法,其特征在于,步骤(4)中所述锡炉温度为220-260℃,涂锡速度为100-200m/min。
8.一种如权利要求1-2任一项所述的光伏焊带在MBB光伏电池组件中的应用。
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