CN111092134A - 一种多股铜线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,之后使用压延工艺将其压制成特定规格的扁型铜带,在氩气保护作用下进行短路退火处理,得到多股铜丝组成的扁型铜带,随后将多股扁型铜带放入助焊剂中浸润,将浸润后的铜带送入锡炉中,进行涂锡加工并急速冷却至室温,最终得到多股铜线组成的涂锡光伏焊带。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,线密度较低,能减少铜材耗用,提升能耗比,更加柔软,具备更低的屈服,能有效降低电池片破片率。
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24%左右,实验室的实验数据最高也只能达到28%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,为提高组件效率,降低焊带电阻是必然趋势。目前通用的降低焊带电阻的方法是增加焊带截面积,即增加铜带尺寸,这种方案带来的问题有①增加焊带宽度,会降低电池片采光面积,提高焊带厚度,会增加EVA等封装材料的厚度,会增加成本。②提高焊带尺寸,会增大焊接后电池片内应力,增加了碎片率及隐裂风险。③增加铜金属的使用,增加焊带生产成本。而本发明的出现,正是有效解决上述问题,是焊带工艺的一次革新。
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,同时可以降低焊带屈服强度,有效减少焊接后的电池碎片率,并能有效降低铜材耗用,降低成本。
本发明的技术方案如下:
一种用于通用光伏电池组件的多股铜线光伏焊带,所述光伏焊带包括多根扁型铜带与焊料涂覆层,所述铜线材质为纯铜丝,所述焊料涂覆层由锡与铅、镍、银中的任一种金属或多种金属形成二元、三元或四元合金组成;
所述光伏焊带的制备方法包括如下步骤:
(1)将多根单股圆线铜丝进行紧密绕扎,得到多股铜线基材;
(2)将步骤(1)中所得多股铜线经过压制成型,得到多股扁型铜带;
(3)将步骤(2)中所得多股扁型铜带基材在氩气的保护作用下进行短路退火处理,得到热处理后软态多股扁铜带;
(4)将步骤(3)中所得热处理后软态多股扁型铜带放入溶剂型助焊剂中进行浸润;
(5)将步骤(4)中浸润之后的多股扁型铜带送入锡炉中,进行涂锡合金加工,之后急速冷却至室温,得到多股扁型铜线焊带。
步骤(1)中所述铜丝纯度为99.00-99.99%,所述铜丝直径为0.01mm~0.2mm,绕扎得到的多股铜线直径为0.15mm~3.0mm。
步骤(2)中所述扁型铜带厚度范围为0.1-0.5mm,宽度范围为0.7-10.0mm。
步骤(3)中所述短路退火处理条件为:电流30-60A,电压为220-380V。
步骤(5)中所述焊料涂覆层由锡与铅、镍、银中的任一种金属或多种金属形成二元、三元或四元合金,涂锡合金层厚度为10-60um。
步骤(5)锡炉温度为230-280℃,涂锡速度为150-250m/min。
一种光伏焊带在光伏电池组件中的应用。
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,采用多股纯铜圆线制成,纯铜圆线绕扎紧密,表面光滑,尺寸可以根据不同型号定制;②绕线,打破传统单根圆线镀锡,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与S2比较接近,并且缠绕完成后,在成品尺寸不变的情况下,多根细圆线的总截面积会小于单根粗圆线的截面积,但其内部表面积会远超过单根粗圆线,能够更有效的导通电流;③同理,在压制成扁形同带后,其内部仍基本保持此种状态,即可获得优于常规焊带的电阻。其中将多根绕扎而成的多根铜线组在压制成型过程中,基本只改变多股铜线的排列方式以及表面形状,而未破坏原有的截面积,使扁型铜带总体的内部依然存在较大的铜丝表面积,从而起到增大电流通过面积的功能。
本发明与国内市场现有的扁型焊带相比,优点在于:①在外径尺寸相同条件下,多股扁形铜带导电能力比单股铜带导电更强,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。因此多股铜线导电能力更强,电流通过的速度更快,可以最大化转换过程电力损耗、可以最大化的提高太阳能转换效率。②由于多股铜线组成的铜带实际截面积较小,其屈服强度会更低,表现为更加柔软,更易焊接。
本发明申请可以根据需要调整铜材的外径尺寸,可获得任意规格的多股圆形铜线,可用于任何规格的互联条和汇流条的基材生产;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焊带的需求。
附图说明
图1为本发明中使用的多股圆线示意图横截面示意图。
图2为常规单股扁型铜带涂锡光伏焊带横截面示意图。
图3为本发明中实施例1所得多股铜线扁型涂锡合金光伏焊带横截面示意图。
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15根含量为99.00%原材料圆线铜丝进行紧密缠绕,得到多股圆型铜线基材;并将所得多股圆型铜线基材压制成扁型,在氩气的保护作用下进行短路退火处理,此时直流电流为30A,电压为220V,结果退火之后得到软态多股扁型铜线;随后将所得软态多股扁型铜带放入溶剂型助焊剂中进行浸润,浸润结束铜带表面光滑,进行涂锡加工:将浸润之后的铜带送入锡炉中,并将温度升高至240℃,镀锡的速度设置为150m/min,进行涂锡加工,之后冷却至室温,最终得到多股铜线扁型涂锡合金光伏焊带,所得焊带的横截面情况见图3。
实施例2
选取含量为99.95%原材料圆线铜丝,将20根单股圆线铜丝进行紧密缠绕,得到多股圆型铜线基材;并将所得多股圆型铜线基材压制成扁形,在氩气的保护作用下进行短路退火处理,此时直流电流为45A,电压为300V,结果退火之后得到软态多股扁型铜线;随后将所得软态多股扁型铜带放入溶剂型助焊剂中进行浸润,浸润结束铜带表面光滑,进行涂锡加工,将浸润之后的铜带送入锡炉中,并将温度升高至250℃,镀锡的速度设置为180m/min,进行涂锡加工,之后急速冷却至室温,最终得到多股铜线扁型涂锡合金光伏焊带。
实施例3
选取含量为99.99%原材料圆线铜丝,将30根单股圆线铜丝进行紧密缠绕,得到多股圆型铜线基材;并将所得多股圆型铜线基材压制成型,在氩气的作用下进行短路退火处理,此时直流电流为60A,电压为380V,结果退火之后得到软态多股扁型铜线;随后将所得软态多股扁型铜带放入溶剂型助焊剂中进行浸润,浸润结束铜带表面光滑,进行涂锡加工:将浸润之后的铜带送入锡炉中,并将温度升高至280℃,镀锡的速度设置为250m/min,进行涂锡加工,之后急速冷却至室温,最终得到多股铜线扁型涂锡合金光伏焊带。
Claims (7)
1.一种用于通用光伏电池组件的多股铜线光伏焊带,其特征在于,所述光伏焊带包括多根扁型铜带与焊料涂覆层,所述铜线材质为纯铜丝,所述焊料涂覆层由锡与铅、镍、银中的任一种金属或多种金属形成二元、三元或四元合金组成;
所述光伏焊带的制备方法包括如下步骤:
(1)将多根单股圆线铜丝进行紧密绕扎,得到多股铜线基材;
(2)将步骤(1)中所得多股铜线经过压制成型,得到多股扁型铜带;
(3)将步骤(2)中所得多股扁型铜带基材在氩气的保护作用下进行短路退火处理,得到热处理后软态多股扁铜带;
(4)将步骤(3)中所得热处理后软态多股扁型铜带放入溶剂型助焊剂中进行浸润;
(5)将步骤(4)中浸润之后的多股扁型铜带送入锡炉中,进行涂锡合金加工,之后急速冷却至室温,得到多股扁型铜线焊带。
2.根据权利要求1所述的光伏焊带,其特征在于,步骤(1)中所述铜丝纯度为99.00-99.99%,所述铜丝直径为0.01mm~0.2mm,绕扎得到的多股铜线直径为0.15mm~3.0mm。
3.根据权利要求1所述的光伏焊带,其特征在于,步骤(2)中所述扁型铜带厚度范围为0.1-0.5mm,宽度范围为0.7-10.0mm。
4.根据权利要求1所述的光伏焊带,其特征在于,步骤(3)中所述短路退火处理条件为:电流30-60A,电压为220-380V。
5.根据权利要求1所述的光伏焊带,其特征在于,步骤(5)中所述焊料涂覆层由锡与铅、镍、银中的任一种金属或多种金属形成二元、三元或四元合金,涂锡合金层厚度为10-60um。
6.根据权利要求1所述的光伏焊带,其特征在于,步骤(5)锡炉温度为230-280℃,涂锡速度为150-250m/min。
7.一种如权利要求1-5任一项所述的光伏焊带在光伏电池组件中的应用。
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