CN113036004A - 一种无主栅太阳电池片电极复合膜制备方法 - Google Patents

一种无主栅太阳电池片电极复合膜制备方法 Download PDF

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CN113036004A
CN113036004A CN202110248460.6A CN202110248460A CN113036004A CN 113036004 A CN113036004 A CN 113036004A CN 202110248460 A CN202110248460 A CN 202110248460A CN 113036004 A CN113036004 A CN 113036004A
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CN113036004B (zh
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熊军
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Anhui Lianpeng Intelligent Equipment Co.,Ltd.
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Abstract

本发明公开了一种无主栅太阳电池片电极复合膜制备方法，包括由铜丝线放线架牵引出多根铜丝线穿过线排、正负电极滚轮组后由收卷装置收卷，多根铜丝线位于同一垂直面内且相互平行排布；由第一第二薄膜放卷装置分别放出第一第二复合薄膜，第一第二复合薄膜分别依次经张力调节、夹紧、裁切动作后得到要求尺寸大小的第一第二复合薄膜片，并分别由第一第二传送装置输送至铜丝线的两侧；第一传送装置与第二传送装置配合对铜丝线和复合薄膜片复合，第一复合薄膜片和第二复合薄膜片分别前后输送至复合处与发热的铜丝线复合形成所需的复合膜；由收卷装置对复合好的复合膜进行收卷。本发明的制备方法生产工艺简单、效率高、稳定性好。

Description

一种无主栅太阳电池片电极复合膜制备方法
技术领域
本发明涉及一种无主栅太阳电池片电极复合膜制备方法。
背景技术
随着太阳能光伏的不断发展，太阳电池片栅线数量已成为目前热门的话题，从最开始的2根栅线逐渐发展到目前主流5、7、9、12根栅线，虽然主栅数量增多增加了电池片正面电流的收集能力，然而主栅线越多，对电池片正面遮挡越严重，这部分会造成功率损失，同时主栅线越多，对焊接设备制作成本也越来越高。而无主栅则很好的兼顾了多主栅问题，因为无主栅减少遮挡和增加了电流收集能力，同时通过使用铜线代替银主栅降低成本。然而，如果采用目前的工艺生产无主栅电池焊带，制作成本非常高。
公布号CN105576046A的发明专利《一种用于太阳能电池的无主栅焊带的制备方法》中，该方法主要通过热压装置将间隔的上下热熔胶膜片熔融后与铜线压合在一起，虽然能够使铜线粘附在热熔胶膜片上，但生产过程中热熔胶膜片需全部熔融，热熔胶膜片的受热均匀性、传热效率都比较差，生产效率和工艺稳定性不高。
发明内容
本发明要解决的技术问题是提供一种无主栅太阳电池片电极复合膜制备方法，该方法以复合薄膜和铜丝线为原材料，通过将铜丝线导电受热后与复合薄膜熔融复合制作成所需的复合膜，可用于无主栅太阳能电池片互联，适用于单晶、多晶太阳能电池，旨在解决现有技术中传统制备工艺成本高、使用局限、生产效率低及稳定性差的技术问题。
本发明的技术方案是：一种无主栅太阳电池片电极复合膜制备方法，包括以下步骤：1)由铜丝线放线架牵引出多根铜丝线依次穿过线排、正电极滚轮组、负电极滚轮组后由收卷装置进行收卷，多根铜丝线位于同一垂直面内且相互平行排布；2)由第一薄膜放卷装置放出第一复合薄膜，第一复合薄膜依次经第一张力调节滚轮、第一夹紧装置、第一裁切装置得到要求尺寸大小的第一复合薄膜片，第一复合薄膜片由第一传送装置输送至铜丝线的一侧；由第二薄膜放卷装置放出第二复合薄膜，第二复合薄膜依次经第二张力调节滚轮、第二夹紧装置、第二裁切装置得到要求尺寸大小的第二复合薄膜片，第二复合薄膜片由第二传送装置输送至铜丝线的另一侧；3)第一传送装置与第二传送装置配合对铜丝线和复合薄膜片进行复合，第一复合薄膜片和第二复合薄膜片分别前后输送至复合处与发热的铜丝线复合形成所需的复合膜；4)由收卷装置对复合好的复合膜进行收卷。
进一的，本发明中所述铜丝线外表面包覆有锡层或低温合金层，铜丝线的线径为0.05～0.5mm，铜丝线的数量为5～100根，多根铜丝线呈等间距相互平行排布，相邻两根铜丝线之间的间距为2～20mm。
进一的，本发明中所述每根铜丝线的放线张力均由所述铜丝线放线架单独调节，放线张力的范围为5～50N。
进一的，本发明中所述正电极滚轮组和负电极滚轮组同时对多根铜丝线施加正负电流使铜丝线产生热量，电流范围为1～5A。
进一的，本发明中所述第一复合薄膜、第二复合薄膜分别包括基材层和胶膜层，基材层为添加有光稳定剂和抗紫外剂的PP、PC、PET、PE、PMMA、PS、PVF或PVDF薄膜，胶膜层为聚氨酯、EVA、PUR、TPO、TPU或PA胶膜，还添加有三丙烯异聚氰酸酯、过氧化二苯甲基酰、2-羟基-4-正辛氧基二苯甲酮和紫外光稳定剂。
进一的，本发明中所述第一复合薄膜、第二复合薄膜分别由第一张力调节滚轮和第二张力调节滚轮单独调节张力，张力范围为5～50N。
进一的，本发明中所述第一复合薄膜片、第二复合薄膜片均为1/N电池片大小的整片或切片，N为1～8的整数。
进一的，本发明中所述第一传送装置、第二传送装置分别包括两个滚轮和连接滚轮的传输带，第一复合薄膜片和第二复合薄膜片的胶面朝上由传输带进行输送，两个传送装置相靠近的两个滚轮相配合形成用于对铜丝线和复合薄膜片进行复合的复合滚轮，所述铜丝线通过正电极滚轮组和负电极滚轮组通电发热，第一复合薄膜片、第二复合薄膜片分别前后输送至复合滚轮处通过铜丝线热量熔融胶膜后挤压复合形成所需的复合膜。
进一的，本发明中所述第一传送装置、第二传送装置的传输带运行速度相同，运行速度范围为2～10m/min，所述复合滚轮的复合压力大小为10～30N。
进一的，本发明中复合好后的复合膜上第一复合薄膜片和第二复合薄膜片之间的间距为2～20mm。
本发明与现有技术相比具有以下优点：
1)本发明的复合膜制备方法以复合薄膜和铜丝线为原材料，通过将铜丝线导电受热后与复合薄膜熔融复合制作成所需的复合膜，可用于无主栅太阳能电池片互联，适用于单晶、多晶太阳能电池，制备得到的复合膜既能满足遮光面积少又能满足导电的要求，同时该制备方法生产工艺简单、效率高、稳定性好。
2)本发明中，通过正负电极滚轮组对铜丝线进行短路发热，铜丝线的温度均匀性、稳定性比较好，同时铜丝线的受热面积小，复合过程中热能的使用量比热压辊大幅降低，制造成本大幅降低。
3)本发明的制备方法使用范围广，复合薄膜片可以为电池片大小的整片、1/2～1/8电池片大小的切片，也可以为具有镂空结构的整片或切片，铜丝线可以为目前主流的常规光伏焊带，也可以为无主栅低温焊带。
4)本发明中，采用铜丝线受热复合，复合过程中复合薄膜的胶膜只熔融与铜丝线接触的地方，而其他地方不熔融，复合过程中胶膜不会向四周溢出造成材料浪费。
5)本发明采用双传输滚轮同步复合工艺，生产复合效率高。
附图说明
图1为本发明的复合膜制备方法的工艺流程图；
图2为本发明的复合膜制备方法的过程图示；
图3为本发明的复合膜制备方法所制得的复合膜结构示意图。
其中：1、铜丝线放线架；2、铜丝线；3、线排；4、正电极滚轮组；5、负电极滚轮组；6、收卷装置；7、第一薄膜放卷装置；8、第一复合薄膜；8a、第一复合薄膜片；9、第一张力调节滚轮；10、第一夹紧装置；11、第一裁切装置；12、第一传送装置；13、第二薄膜放卷装置；14、第二复合薄膜；14a、第二复合薄膜片；15、第二张力调节滚轮；16、第二夹紧装置；17、第二裁切装置；18、第二传送装置。
具体实施方式
以下结合附图对本发明的具体实施方式做具体说明。
实施例：
结合附图所示为本发明一种无主栅太阳电池片电极复合膜制备方法的具体实施方式，该方法主要包括以下步骤：
步骤1)，由铜丝线放线架1牵引出多根铜丝线2依次穿过线排3、正电极滚轮组4、负电极滚轮组5后由收卷装置6进行收卷。
具体的，铜丝线2外表面包覆有锡层或低温合金层，铜丝线2的线径为0.05～0.5mm，多根铜丝线2位于同一垂直面内、呈等间距相互平行排布，相邻两根铜丝线2之间的间距为2～20mm。
每根铜丝线2的放线张力均由铜丝线放线架1单独调节，确保所有铜丝线2的松紧度保持一致，放线张力的范围为5～50N。
多根铜丝线2分别穿过线排3，确保各铜丝线2之间在同一垂直面内且排列均匀。
正电极滚轮组4和负电极滚轮组5同时对多根铜丝线2施加正负电流使铜丝线2产生热量，电流范围为1～5A。
步骤2)，由第一薄膜放卷装置7放出第一复合薄膜8，第一复合薄膜8依次经第一张力调节滚轮9、第一夹紧装置10、第一裁切装置11得到要求尺寸大小的第一复合薄膜片8a，第一复合薄膜片8a由第一传送装置12输送至铜丝线2的一侧；由第二薄膜放卷装置13放出第二复合薄膜14，第二复合薄膜14依次经第二张力调节滚轮15、第二夹紧装置16、第二裁切装置17得到要求尺寸大小的第二复合薄膜片14a，第二复合薄膜片14a由第二传送装置18输送至铜丝线2的另一侧。
具体的，第一复合薄膜8、第二复合薄膜14分别包括基材层和胶膜层，基材层为添加有光稳定剂和抗紫外剂的PP、PC、PET、PE、PMMA、PS、PVF或PVDF薄膜，胶膜层为聚氨酯、EVA、PUR、TPO、TPU或PA胶膜，还添加有三丙烯异聚氰酸酯、过氧化二苯甲基酰、2-羟基-4-正辛氧基二苯甲酮和紫外光稳定剂。
第一复合薄膜8、第二复合薄膜14分别由第一张力调节滚轮9和第二张力调节滚轮15单独调节张力，张力范围为5～50N。
第一复合薄膜8、第二复合薄膜14分别由对应夹紧装置夹紧后送入对应裁切装置进行裁切，第一复合薄膜8、第二复合薄膜14裁切规格根据电池片类型/规格裁切，本实施例以158×158mm尺寸大小的电池片为例，对158mm宽的第一复合薄膜8、第二复合薄膜14分别进行裁切，得到158×158mm尺寸大小的整片的第一复合薄膜片8a、第二复合薄膜片14a。但也不限于此，也可以对158mm宽的第一复合薄膜8、第二复合薄膜14分别进行裁切，裁切成1/2～1/8电池片大小的切片，两个切片的尺寸大小保持一致。此外，第一复合薄膜8、第二复合薄膜14也可以具有镂空结构，通过裁切得到158×158mm尺寸大小的镂空薄膜整片、或者1/2～1/8电池片大小的镂空薄膜切片。
步骤3)，第一传送装置12与第二传送装置18配合对铜丝线2和复合薄膜片进行复合，第一复合薄膜片8a和第二复合薄膜片14a分别前后输送至复合处与发热的铜丝线2复合形成所需的复合膜。
具体的，第一传送装置12、第二传送装置18分别包括两个滚轮和连接滚轮的传输带，第一复合薄膜片8a和第二复合薄膜片14a的胶面朝上由传输带进行输送，两个传送装置相靠近的两个滚轮相配合形成用于对铜丝线2和复合薄膜片进行复合的复合滚轮，铜丝线2通过正电极滚轮组4和负电极滚轮组5通电发热，第一复合薄膜片8a、第二复合薄膜片14a分别前后输送至复合滚轮处通过铜丝线2热量熔融胶膜后挤压复合形成所需的复合膜，如图3所示。
具体的，第一传送装置12、第二传送装置18的传输带运行速度相同，运行速度范围为2～10m/min。复合滚轮的复合压力大小为10～30N，复合好后的复合膜上第一复合薄膜片8a和第二复合薄膜片14a之间的间距为2～20mm。
本实施例中，若复合好后的第一复合薄膜片8a和第二复合薄膜片14a之间的间距为2mm，以复合点(即复合滚轮处)为中心，假定第一复合薄膜片8a在传输带上距离复合点的距离为0mm，则第二复合薄膜片14a在传输带上距离复合点的距离为160mm。
步骤4)，由收卷装置6对复合好的复合膜进行收卷。
本发明的复合膜制备方法以复合薄膜和铜丝线为原材料，通过将铜丝线导电受热后与复合薄膜熔融复合制作成所需的复合膜，可用于无主栅太阳能电池片互联，适用于单晶、多晶太阳能电池，制备得到的复合膜既能满足遮光面积少又能满足导电的要求，同时该制备方法生产工艺简单、效率高、稳定性好。
当然上述实施例只为说明本发明的技术构思及特点，其目的在于让熟悉此项技术的人能够了解本发明的内容并据以实施，并不能以此限制本发明的保护范围。凡根据本发明主要技术方案的精神实质所做的修饰，都应涵盖在本发明的保护范围之内。

Claims (10)

1.一种无主栅太阳电池片电极复合膜制备方法，其特征在于，包括以下步骤：
1)由铜丝线放线架(1)牵引出多根铜丝线(2)依次穿过线排(3)、正电极滚轮组(4)、负电极滚轮组(5)后由收卷装置(6)进行收卷，多根铜丝线(2)位于同一垂直面内且相互平行排布；
2)由第一薄膜放卷装置(7)放出第一复合薄膜(8)，第一复合薄膜(8)依次经第一张力调节滚轮(9)、第一夹紧装置(10)、第一裁切装置(11)得到要求尺寸大小的第一复合薄膜片(8a)，第一复合薄膜片(8a)由第一传送装置(12)输送至铜丝线(2)的一侧；由第二薄膜放卷装置(13)放出第二复合薄膜(14)，第二复合薄膜(14)依次经第二张力调节滚轮(15)、第二夹紧装置(16)、第二裁切装置(17)得到要求尺寸大小的第二复合薄膜片(14a)，第二复合薄膜片(14a)由第二传送装置(18)输送至铜丝线(2)的另一侧；
3)第一传送装置(12)与第二传送装置(18)配合对铜丝线(2)和复合薄膜片进行复合，第一复合薄膜片(8a)和第二复合薄膜片(14a)分别前后输送至复合处与发热的铜丝线(2)复合形成所需的复合膜；
4)由收卷装置(6)对复合好的复合膜进行收卷。
2.根据权利要求1所述的一种无主栅太阳电池片电极复合膜制备方法，其特征在于：所述铜丝线(2)外表面包覆有锡层或低温合金层，铜丝线(2)的线径为0.05～0.5mm，铜丝线(2)的数量为5～100根，多根铜丝线(2)呈等间距相互平行排布，相邻两根铜丝线(2)之间的间距为2～20mm。
3.根据权利要求1所述的一种无主栅太阳电池片电极复合膜制备方法，其特征在于：所述每根铜丝线(2)的放线张力均由所述铜丝线放线架(1)单独调节，放线张力的范围为5～50N。
4.根据权利要求1所述的一种无主栅太阳电池片电极复合膜制备方法，其特征在于：所述正电极滚轮组(4)和负电极滚轮组(5)同时对多根铜丝线(2)施加正负电流使铜丝线(2)产生热量，电流范围为1～5A。
5.根据权利要求1所述的一种无主栅太阳电池片电极复合膜制备方法，其特征在于：所述第一复合薄膜(8)、第二复合薄膜(14)分别包括基材层和胶膜层，基材层为添加有光稳定剂和抗紫外剂的PP、PC、PET、PE、PMMA、PS、PVF或PVDF薄膜，胶膜层为聚氨酯、EVA、PUR、TPO、TPU或PA胶膜，还添加有三丙烯异聚氰酸酯、过氧化二苯甲基酰、2-羟基-4-正辛氧基二苯甲酮和紫外光稳定剂。
6.根据权利要求1所述的一种无主栅太阳电池片电极复合膜制备方法，其特征在于：所述第一复合薄膜(8)、第二复合薄膜(14)分别由第一张力调节滚轮(9)和第二张力调节滚轮(15)单独调节张力，张力范围为5～50N。
7.根据权利要求1所述的一种无主栅太阳电池片电极复合膜制备方法，其特征在于：所述第一复合薄膜片(8a)、第二复合薄膜片(14a)均为1/N电池片大小的整片或切片，N为1～8的整数。
8.根据权利要求5所述的一种无主栅太阳电池片电极复合膜制备方法，其特征在于：所述第一传送装置(12)、第二传送装置(18)分别包括两个滚轮和连接滚轮的传输带，第一复合薄膜片(8a)和第二复合薄膜片(14a)的胶面朝上由传输带进行输送，两个传送装置相靠近的两个滚轮相配合形成用于对铜丝线(2)和复合薄膜片进行复合的复合滚轮，所述铜丝线(2)通过正电极滚轮组(4)和负电极滚轮组(5)通电发热，第一复合薄膜片(8a)、第二复合薄膜片(14a)分别前后输送至复合滚轮处通过铜丝线(2)热量熔融胶膜后挤压复合形成所需的复合膜。
9.根据权利要求8所述的一种无主栅太阳电池片电极复合膜制备方法，其特征在于：所述第一传送装置(12)、第二传送装置(18)的传输带运行速度相同，运行速度范围为2～10m/min，所述复合滚轮的复合压力大小为10～30N。
10.根据权利要求1所述的一种无主栅太阳电池片电极复合膜制备方法，其特征在于：复合好后的复合膜上第一复合薄膜片(8a)和第二复合薄膜片(14a)之间的间距为2～20mm。
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