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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| CN113921640A (zh) * | 2021-10-14 | 2022-01-11 | 云上新能源开发(杭州)有限公司 | 一种互联材料及电池串的串焊工艺 |
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