CN111244215A - 一种正多边形光伏焊带及其制备方法 - Google Patents
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Abstract
本发明属于光伏焊带领域,公开了一种正多边形光伏焊带及其制备方法,解决现有圆铜丝镀锡同心度偏移的现象,保证焊接和增大铜基占比,减小焊带的电阻率,其制备方法简单,易操作实施,且正多边形光伏焊带的铜基为8/10/12边形时,铜基占比可达90.05%以上,既可满足焊接条件,又能满足减小电阻的要求。
Description
技术领域
本发明涉及光伏焊带领域,具体涉及一种正多边形光伏焊带及其制备方法。
背景技术
光伏焊带又称镀锡铜带或涂锡铜带,分汇流带和互连条,应用于光伏组件电池片之间的连接,发挥导电聚电的重要作用。光伏焊带是光伏组件焊接过程中的重要原材料,焊带质量的好坏将直接影响到光伏组件电流的收集效率,对光伏组件的功率影响很大。
目前光伏组件常用的焊带有两种,圆形焊带和扁带。对于圆形焊带来说,线材在出锡炉后气刀吹锡的时候,由于气刀内气流的波动,加之线材运行时候的抖动,容易造成同心度不良,使得焊带某个面上的锡层太薄,焊带与电池片焊接时出现虚焊或者假焊。
圆形焊带是拉丝后经过退火,进入锡炉,在通过气刀吹掉多余的锡液,然后冷却,在进行收卷包装。圆铜丝在运行过程中会有抖动,速度越高,抖动越严重,且由于线材是圆形的,气流在吹焊带的过程中也会有波动,导致圆形焊带一周受力不完全均匀,因此在镀锡后会出现同心度偏移,同心度偏移会导致焊带漏铜或组件焊接不良;且现有的圆形焊带中焊料占比较大,焊带的电阻较高。
发明内容
针对现有技术中存在的问题,本发明的目的在于提供一种正多边形光伏焊带及其制备方法,解决现有圆铜丝镀锡同心度偏移的现象,保证焊接和增大铜基占比,减小焊带的电阻率,其制备方法简单,易操作实施,且正多边形光伏焊带的铜基为8/10/12边形时,铜基占比可达90.05%以上,既可满足焊接条件,又能满足减小电阻的要求。
为了达到上述目的,本发明采用以下技术方案予以实现。
(一)一种正多边形光伏焊带,包含铜基层和锡层;所述正多边形为偶数正多边形。
优选的,所述偶数正多边形为正八边形、正十变形、正十二边形。
优选的,所述正多边形光伏焊带的铜基占比为90.05%~95.47%。
(二)一种正多边形光伏焊带的制备方法,包括以下步骤:
步骤1,将圆铜丝压沿圆铜丝长度方向延成正多边形铜丝,所述正多边形铜丝为偶数正多边形铜丝;
步骤2,将正多边形铜丝穿过玻璃管,玻璃管内充满氮气,并从玻璃管的下端浸入冷却水箱内进行退火,得退火后的铜丝;
步骤3,退火后的铜丝进入助焊剂槽,再进入锡炉进行镀锡,得正多边形光伏焊带。
优选的,步骤2中,所述退火的电压为30-40V,退火的主机速度为200-230m/min。
优选的,步骤3中,所述锡炉的温度为215-225℃。
与现有技术相比,本发明的有益效果为:
本发明的正多边形光伏焊带中包括铜基材和合金焊料,以圆铜丝为铜基材本体,轧制成正多边形,然后经过退火、涂助焊剂,并通过热浸镀的方式过锡炉,在铜基材本体的表面镀上一层锡铅合金层,制得正多边光伏焊带。
本发明所得的正多边形光伏焊带解决现有圆铜丝镀锡同心度偏移的现象,保证焊接和增大铜基占比,减小焊带的电阻率,其制备方法简单,易操作实施,且正多边形光伏焊带的铜基为8/10/12边形时,铜基占比可达90.05%以上,既可满足焊接条件,又能满足减小电阻的要求。
附图说明
下面结合附图和具体实施例对本发明做进一步详细说明。
图1为本发明提供的正八边形光伏焊带图;
图中:1铜基层;2锡层。
具体实施方式
下面将结合实施例对本发明的实施方案进行详细描述,但是本领域的技术人员将会理解,下列实施例仅用于说明本发明,而不应视为限制本发明的范围。
实施例1
一种正多边形光伏焊带的制备方法,正多边形光伏焊带由铜基和锡铅合金焊料组成,铜基是将圆铜丝轧制成正多边形,再在铜基表面镀上锡铅合金锡层,具体包括以下步骤:
步骤1,压延:铜基材本体采用圆铜丝,沿着铜丝长度方向,经过多边形齿状轧辊轧制成多边形铜丝,如压延成正六边形、正七边形、正八边形、正十边形、正十二边形等。
步骤2,退火:压延后的多边形铜丝需要进行退火处理,多边形铜丝线材穿过玻璃管,玻璃管里面充满氮气,其作用是防止多边形铜丝线材被氧化,多边形铜丝线材通过玻璃管下端浸入冷却水箱,水箱中的水是循环的,防止温度过高,退火电压30-40V,主机速度为200-230m/min。
步骤3,镀锡:多边形铜丝线材从水箱中出来以后进入助焊剂槽,所用助焊剂有合明科技881等,再进入锡炉经过压线板,开机前,压线板需没过锡炉液面,锡炉温度为220±5℃,所用锡液有Sn60Pb40、Sn63Pb37等,完成镀锡后线材过驱动轮,经过储线架进行收卷,得正多边形光伏焊带。
以上实施例中,多边形铜丝的边最好是偶数边,这样焊带与电池片焊接时,以其中的某两个面作为焊接面,一面与电池片片正面焊接,另一个面与电池片背面焊接,此焊接方式增大了焊带与电池片的焊接面积,增强了焊接效果。由于铜丝是正多边形,结合锡液的表面张力,在多边形每个面上的附着力会更强,这样做出来的焊带避免掉现有圆铜丝存在的同心度偏移的问题。
轧头对铜丝的轧制属于冷轧,在加工过程中,在铜丝内部会产生内应力,铜丝表面的硬度也比较大,直接对铜丝进行镀锡,会引起铜丝的变形或扭曲,所需要用退火的方式来消除铜丝内部的内应力。
退火后的铜丝涂上助焊剂,再进入锡炉进行镀锡,由于铜丝是多边形,焊料在平面比在曲面上的结合要更好,表面张力更大一点,确保铜丝的每个面都会被镀上锡层且不会出现焊料偏移的现象,既保证了焊带的同心度,也保证了焊接效果。
对现有的圆形焊带、三角焊带和实施例1所得的正多边形焊带的铜基占比和单面锡层厚度进行测试,试验结果如表1所示:
由表1可知,现有的焊带铜基为圆铜丝,焊带中的铜基占比是85.73%,最薄出的锡层厚度不小于8μm。当焊带的铜基为三角形或者六边形时,其铜基占比低于现有的圆形铜基焊带,不能达到减小焊带电阻的效果。当多边形为7边形时,虽然铜基占比略高于现有的圆形铜基焊带,但是正七边形焊带与电池片焊接时有一面不好焊接。当多边形大于12边形时,单层厚度太薄,同样不利于焊接。因此,铜基为8/10/12边形时,且铜基占比可达90.05%以上,既可满足焊接条件,又能满足减小电阻的要求。
表1
类型 | 铜基占比(%) | 单面锡层厚度(mm) |
圆铜丝 | 85.73 | 0.015 |
三角形 | 41.35 | 0.101 |
6边形 | 82.71 | 0.027 |
7边形 | 87.07 | 0.020 |
8边形 | 90.05 | 0.015 |
10边形 | 93.59 | 0.010 |
12边形 | 95.47 | 0.007 |
虽然,本说明书中已经用一般性说明及具体实施方案对本发明作了详尽的描述,但在本发明基础上,可以对之作一些修改或改进,这对本领域技术人员而言是显而易见的。因此,在不偏离本发明精神的基础上所做的这些修改或改进,均属于本发明要求保护的范围。
Claims (6)
1.一种正多边形光伏焊带,其特征在于,包含铜基层和锡层;所述正多边形为偶数正多边形。
2.根据权利要求1所述的正多边形光伏焊带,其特征在于,所述偶数正多边形为正八边形、正十变形、正十二边形。
3.根据权利要求1所述的正多边形光伏焊带,其特征在于,所述正多边形光伏焊带的铜基占比为90.05%~95.47%。
4.一种正多边形光伏焊带的制备方法,其特征在于,包括以下步骤:
步骤1,将圆铜丝压沿圆铜丝长度方向延成正多边形铜丝,所述正多边形铜丝为偶数正多边形铜丝;
步骤2,将正多边形铜丝穿过玻璃管,玻璃管内充满氮气,并从玻璃管的下端浸入冷却水箱内进行退火,得退火后的铜丝;
步骤3,退火后的铜丝进入助焊剂槽,再进入锡炉进行镀锡,得正多边形光伏焊带。
5.根据权利要求4所述的正多边形光伏焊带的制备方法,其特征在于,步骤2中,所述退火的电压为30-40V,退火的主机速度为200-230m/min。
6.根据权利要求4所述的正多边形光伏焊带的制备方法,其特征在于,步骤3中,所述锡炉的温度为215-225℃。
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CN207606115U (zh) * | 2017-11-28 | 2018-07-13 | 陕西光德电子材料有限公司 | 用于生产太阳能光伏焊带的拉丝机构 |
CN110311002A (zh) * | 2018-03-22 | 2019-10-08 | Lg电子株式会社 | 太阳能电池板的互连构件和包括该构件的太阳能电池板 |
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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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