CN111799345A - 一种光伏组件加工方法 - Google Patents
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Abstract
本发明公开一种光伏组件加工方法,包括步骤S1:制作半成品;步骤S2:制作表面层;步骤S3:对来料EVA卷料模切出中间EVA层;步骤S4:将半成品、中间EVA层、表面层依次叠层;步骤S5:转入层压机层压;其中步骤S2包括子步骤:步骤S21:对表面层原材料进行分切成片材;步骤S22:调配定制的印刷油墨;步骤S23:对表面层片材进行印刷;步骤S24:将印刷好的表面层片材进行烘烤,进而得到表面层。本发明采用在表面层印刷的方式遮盖栅线等,代替传统工艺中人工贴黑胶带遮盖方式,遮盖效果稳定,且减少人力以及黑胶带费用。
Description
技术领域
本发明涉及光伏组件制造领域,特别涉及一种光伏组件加工方法。
背景技术
随着近年来人们生活水平不断提高,绿色环保逐步深入人心,民用太阳能产品作为一种绿色可再生能源,一方面在大家外出旅行中带来优质的产品体验,另一方面它的时尚造型,多样外观给客户一种美的感受。
太阳能产品外观在民用产品领域要求很高,目前在半成品阶段贴黑胶带遮盖的方法来遮盖主栅线及铜带、PCB铆钉焊盘已成为行业内主流工艺,其中黑胶带的粘性,手工精准度都存在不可控风险,产生不良较高,同时黑胶带分切费用高,人工张贴效率低,黑胶带遮盖电池片导致降低产品输出参数等等因素一直是困扰行业内各企业的技术及成本的问题;
在光伏行业普通单、多晶太阳能电池片领域,现有电池片的主栅线宽度在0.3mm到2.0mm之间,为了有效减少外观不良,行业内采用的黑胶带宽度在 1.5mm-4.5mm,以156*156五线为例,张贴黑胶带导致产品效率降低10%左右,贴黑胶带人工占半成品流水线总人数比例较大,这无疑大大增加产品成本,同时让客户的产品体验大打折扣;
另外,在光伏行业Sunpower、LG太阳能电池片贴片领域,单面覆铜板正面铆钉焊盘与电池片颜色,PCB底板颜色存在差异(例如焊盘为银白色,硅片为蓝色,PCB为黑色),导致产品外观一致性不高,客户个性化需求得不到满足。
因此现有技术有待于改进。
发明内容
针对现有技术存在的问题,本发明提供一种光伏组件加工方法,具体方案如下:
包括以下步骤:
步骤S1:制作半成品;
步骤S2:制作表面层;
步骤S3:对来料EVA卷料模切出中间EVA层;
步骤S4:将半成品、中间EVA层、表面层依次叠层;
步骤S5:转入层压机层压;
其中步骤S2的具体实现方法包括以下步骤:
步骤S21:对表面层原材料进行分切成片材,其中表面层原材料为PET或玻璃或ETFE;
步骤S22:调配定制的印刷油墨;
步骤S23:对表面层片材进行印刷;
步骤S24:将印刷好的表面层片材进行烘烤,进而得到表面层。
优选地,步骤S4的具体操作为:将一个以上半成品放入层压模具中叠中间EVA层、表面层;
步骤S21中所述表面层原材料为PET,其分切片材尺寸按层压模具设计。
优选地,步骤S1的具体实现方式是:采用PCB板、硅片从下至上依次叠放制成半成品1b;具体的,PCB板上设有锡膏层以及铆钉。
优选地,步骤S3中所述中间EVA片材的尺寸要求为:中间EVA片材的长、宽均比层压模具小6-8mm。
优选地,步骤S4前还包括一个步骤S40:结合产品做半成品叠层模具;
步骤S4的具体操作为:将串焊好的半成品、中间EVA层、表面层依次放入半成品叠层模具指定位置。
优选地,步骤S1的具体操作为:采用底板、半成品EVA层、硅片从下至上依次叠放后串焊成半成品。
优选地,步骤S21中所述表面层原材料为玻璃,分切片材尺寸按产品尺寸设计。
优选地,步骤S3中对来料EVA卷料模切出中间EVA层的尺寸依据:若表采用玻璃做垫板,单个叠层层压,则中间EVA层的长、宽均比产品大 0-30mm;若采用玻璃层压板,则中间EVA层的长、宽均比产品大0-3mm。
采用本发明提供的光伏组件加工方法,具有以下有益效果:
1、采用在表面层印刷的方式遮盖栅线等,代替传统工艺中人工贴黑胶带遮盖方式,遮盖效果稳定,且减少人力以及黑胶带费用;
2、采用在表面层印刷的方式代替人工贴黑胶带,精度高,对应的,印刷尺寸小于传统加工中黑胶带的尺寸,即有效遮盖比例高,提高产品输出效率。
附图说明
图1为本发明实施例一的流程图;
图2为本发明实施例一中待加工产品的分层结构示意图;
图3为本发明实施例一步骤S5a中叠层方式的示意图;
图4为本发明实施例二的流程图;
图5为本发明实施例二中待加工产品的分层结构示意图;
图6为本发明实施例二步骤S4b中半产品放入层压模具叠层时的位置示意图。
具体实施方式
以下结合附图和具体实施例,对本发明进一步说明。
实施例一
参照图1至图3,本发明提供一种光伏组件加工方法,包括以下步骤:
步骤S1a:制作半成品;具体的,采用底板11a、半成品EVA层12a、硅片 13a从下至上依次叠放后串焊成半成品1a;
步骤S2a:制作表面层,具体的,包括步骤S21a、步骤S22a、步骤S23a、步骤S24a、步骤S25a,其中:
步骤S21a:对表面层原材料进行分切成片材,其中表面层原材料为PET 或玻璃或ETFE;当表面层原材料为玻璃,分切尺寸按产品尺寸设计;
步骤S22a:调配定制的印刷油墨;
步骤S23a:对表面层片材进行印刷;
步骤S24a:将印刷好的表面层片材进行烘烤,进而得到表面层2a;
步骤S3a:对来料EVA卷料模切出中间EVA层3a;具体的,若表采用玻璃做垫板,单个叠层层压,则中间EVA层3a的长、宽均比产品大0-30mm;若采用玻璃层压板,则中间EVA层3a的长、宽均比产品大0-3mm;
步骤S4a:结合产品做半成品叠层模具;
步骤S5a:将串焊好的半成品1a、中间EVA层3a、表面层2a依次放入半成品叠层模具指定位置;若带生产产品为压花纹产品,再进一步将其放在压花布上叠层;
步骤S6a:转入层压机层压。
本实施例提供的光伏组件加工方法,具有以下优点:
1、采用在表面层印刷的方式遮盖栅线等,代替传统工艺中人工贴黑胶带遮盖方式,遮盖效果稳定,且减少人力以及黑胶带费用;
2、采用在表面层印刷的方式代替人工贴黑胶带,精度高,对应的,印刷尺寸小于传统加工中黑胶带的尺寸,即有效遮盖比例高,提高产品输出效率。
实施例二
参照图4至图6,本发明提供一种光伏组件加工方法,其代加工产品分层结构如图5,包括半成品1b、子表面层2b、子中间EVA层3b,包括以下步骤:
步骤S1b:制作半成品1b;具体的,采用PCB板11b、硅片13b从下至上依次叠放制成半成品1b;具体的,PCB板11b上设有锡膏层12b以及铆钉111b;
步骤S2b:制作表面层,具体的,包括步骤S21b、步骤S22b、步骤S23b、步骤S24b、步骤S25b,其中:
步骤S21b:对表面层原材料进行分切成表面层片材,其中表面层原材料为PET;表面层片材尺寸按层压模具5b的尺寸设计;
步骤S22b:调配定制的印刷油墨;
步骤S23b:对表面层片材进行印刷;
步骤S24b:将印刷好的表面层片材进行烘烤,进而得到表面层;
步骤S3b:对来料EVA卷料模切出中间EVA片材;具体的,中间EVA片材的长、宽均比层压模具小6-8mm;
步骤S4b:将若干个半成品1b放入层压模具中叠中间EVA层、表面层;即多个半成品1b上只要覆盖一张中间EVA层和一张表面层,一张表面层最终应用为多张子表面层2b、一张中间EVA层最终应用为多张子中间EVA层3b。
步骤S5b:转入层压机层压。
本实施例提供的光伏组件加工方法具有和实施例一一样的优点。
以上所述仅为本发明的优选实施例,并非因此限制本发明的专利范围,凡是在本发明的发明构思下,利用本发明说明书及附图内容所作的等效结构变换,或直接/间接运用在其他相关的技术领域均包括在本发明的专利保护范围内。
Claims (8)
1.一种光伏组件加工方法,其特征在于:包括以下步骤:
步骤S1:制作半成品;
步骤S2:制作表面层;
步骤S3:对来料EVA卷料模切出中间EVA层;
步骤S4:将半成品、中间EVA层、表面层依次叠层;
步骤S5:转入层压机层压;
其中步骤S2的具体实现方法包括以下步骤:
步骤S21:对表面层原材料进行分切成片材,其中表面层原材料为PET或玻璃或ETFE;
步骤S22:调配定制的印刷油墨;
步骤S23:对表面层片材进行印刷;
步骤S25:将印刷好的表面层片材进行烘烤,进而得到表面层。
2.根据权利要求1所述的光伏组件加工方法,其特征在于:步骤S4的具体操作为:将一个以上半成品放入层压模具中叠中间EVA层、表面层;
步骤S21中所述表面层原材料为PET,其分切片材尺寸按层压模具设计。
3.根据权利要求2所述的光伏组件加工方法,其特征在于:步骤S1的具体实现方式是:采用PCB板、硅片从下至上依次叠放制成半成品1b;具体的,PCB板上设有锡膏层以及铆钉。
4.根据权利要求2所述的光伏组件加工方法,其特征在于:步骤S3中所述中间EVA片材的尺寸要求为:中间EVA片材的长、宽均比层压模具小6-8mm。
5.根据权利要求1所述的光伏组件加工方法,其特征在于:步骤S4前还包括一个步骤S40:结合产品做半成品叠层模具;
步骤S4的具体操作为:将串焊好的半成品、中间EVA层、表面层依次放入半成品叠层模具指定位置。
6.根据权利要求5所述的光伏组件加工方法,其特征在于:步骤S1的具体操作为:采用底板、半成品EVA层、硅片从下至上依次叠放后串焊成半成品。
7.根据权利要求5所述的光伏组件加工方法,其特征在于:步骤S21中所述表面层原材料为玻璃,分切片材尺寸按产品尺寸设计。
8.根据权利要求5所述的光伏组件加工方法,其特征在于:步骤S3中对来料EVA卷料模切出中间EVA层的尺寸依据:若表采用玻璃做垫板,单个叠层层压,则中间EVA层的长、宽均比产品大0-30mm;若采用玻璃层压板,则中间EVA层的长、宽均比产品大0-3mm。
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