CN117293231B - Battery string repairing method, preparation method of replacement battery string and battery string - Google Patents

Battery string repairing method, preparation method of replacement battery string and battery string Download PDF

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Publication number
CN117293231B
CN117293231B CN202311577788.8A CN202311577788A CN117293231B CN 117293231 B CN117293231 B CN 117293231B CN 202311577788 A CN202311577788 A CN 202311577788A CN 117293231 B CN117293231 B CN 117293231B
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solder
battery piece
welding
battery
alloy
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CN117293231A (en
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张舒
楚海元
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Trina Solar Co Ltd
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Trina Solar Co Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H01L31/186—Particular post-treatment for the devices, e.g. annealing, impurity gettering, short-circuit elimination, recrystallisation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H01L31/0512—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module made of a particular material or composition of materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H01L31/1876—Particular processes or apparatus for batch treatment of the devices
    • H01L31/188—Apparatus specially adapted for automatic interconnection of solar cells in a module
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

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  • Engineering & Computer Science (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Manufacturing & Machinery (AREA)
  • Sustainable Energy (AREA)
  • Connection Of Batteries Or Terminals (AREA)

Abstract

The application provides a battery string repairing method, a preparation method of a replacement battery piece and a photovoltaic module. The melting point of the second solder is higher than that of the first solder, so that the melting point of the alloy is also higher than that of the first solder.

Description

Battery string repairing method, preparation method of replacement battery string and battery string
Technical Field
The invention mainly relates to the technical field of battery string repair, in particular to a battery string repair method, a preparation method of a replacement battery string and a battery string.
Background
The front side of one cell sheet is typically attached to the back side of another cell sheet adjacent to the front side by a solder strip in a string of cells, such as a string of photovoltaic cells. When one battery piece needs to be replaced due to failure, the welding strip connected between the failed battery piece and the adjacent battery piece can be cut off, then the failed battery piece is replaced by a qualified battery piece, and then the qualified battery piece and the adjacent battery piece are fixed together by heating and melting the welding material of the welding strip on the qualified battery piece and the welding material of the welding strip on the adjacent battery piece.
However, the inventor of the present application found that the solder between the qualified battery cells and the adjacent battery cells fixed in the above manner may be melted again due to the high external temperature, so that the battery cells are separated again, and the repair failure of the battery string is caused.
Disclosure of Invention
The invention aims to improve the connection reliability between the battery pieces so as to reduce the probability of repairing and invalidating the battery strings.
In order to achieve the above purpose, the invention provides a battery string repairing method, a preparation method of a replacement battery string and a battery string.
In a first aspect, the present application provides a battery string repair method, including:
cutting off a first welding strip between a fault battery piece in a battery string to be repaired and an adjacent battery piece, and taking the rest welding strip connected to the adjacent battery piece after cutting off as a welding strip to be welded, wherein the surface of the first welding strip is covered with first welding flux;
Removing the fault battery piece, and placing a replacement battery piece at a corresponding removal position, wherein a second welding strip is arranged on the replacement battery piece, the surface of the second welding strip is covered with second welding flux, and the melting point of the second welding flux is higher than that of the first welding flux;
and overlapping the welding strip to be welded with the second welding strip, and welding the overlapping part of the welding strip to be welded and the second welding strip, wherein the alloy formed by welding the overlapping part is used for fixing the replacement battery piece and the adjacent battery piece.
Alternatively, the alloy of the first solder and the second solder at the lap joint portion has a melting point higher than the temperature of the lamination process of the battery sheet.
Optionally, cutting off the first welding strip between the failed battery piece and the adjacent battery piece in the battery string to be repaired, including:
Determining a first cut-off position on a first welding strip of the fault battery piece and a first adjacent battery piece, and determining a second cut-off position on a first welding strip of the fault battery piece and a second adjacent battery piece, wherein the distance between the first cut-off position and the long side of the fault battery piece is a first length, the distance between the second cut-off position and the long side of the fault battery piece is a second length, and the second length does not exceed the first length;
and cutting off the first welding strips between the fault battery piece and the first adjacent battery piece and the second adjacent battery piece along the first cutting-off position and the second cutting-off position respectively.
Optionally, the first solder is any one of the following:
The first solder is a tin-lead-bismuth ternary alloy, and the mass percentage of bismuth in the first solder is more than or equal to 1% and less than or equal to 30%;
the first solder is a tin-lead-indium ternary alloy, and the mass percentage of indium in the first solder is more than 0% and less than or equal to 5%.
Optionally, the second solder is any one of the following:
the second solder is a tin-lead-bismuth ternary alloy, and the mass percentage of bismuth in the second solder is at least less than 30%;
The second solder is tin-lead-indium ternary alloy, and the mass percentage of indium in the second solder is at least less than 5%;
the second solder is tin-lead-silver ternary alloy, and the mass percentage of silver in the second solder is more than 0% and less than or equal to 5%;
the second solder is tin-lead binary alloy, and the mass percentage of lead in the second solder is more than 20% and less than or equal to 50%.
Optionally, welding the overlap between the weld zone to be welded and the second weld zone comprises any one or a combination of the following:
a soldering iron heating mode, an infrared heating mode, a hot air heating mode, an electromagnetic heating mode and a laser welding mode.
Alternatively, the length of the overlap is not shorter than 1mm and the length of the alloy is not shorter than 1mm.
Optionally, the end of the alloy remote from the adjacent cell does not exceed the end of the connecting wire associated with the outermost secondary grid on the adjacent cell remote from the adjacent cell in a direction perpendicular to the long side inward of the adjacent cell.
In a second aspect, the present application provides a method for manufacturing a replacement battery sheet, comprising:
Setting a battery substrate;
And arranging a replacement welding strip on the battery substrate, wherein the surface of the replacement welding strip is covered with replacement welding material, and the melting point of the replacement welding material is higher than that of the welding material covered on the surface of the welding strip on the fault battery piece to be replaced by the replacement battery piece.
In a third aspect, the present application provides a battery string comprising:
the first battery piece is provided with a first welding strip, and the surface of the first welding strip is covered with first welding flux;
the second battery piece is provided with a second welding strip, and the surface of the second welding strip is covered with second welding flux;
The first battery piece and the second battery piece are connected through the lap joint of the first welding strip and the second welding strip, and the lap joint part is provided with an alloy of the first welding material and the second welding material, wherein the melting point of the second welding material is higher than that of the first welding material.
Alternatively, the alloy of the first solder and the second solder at the lap joint portion has a melting point higher than the temperature of the lamination process of the battery sheet.
Optionally, the first solder is any one of the following:
The first solder is a tin-lead-bismuth ternary alloy, and the mass percentage of bismuth in the first solder is more than or equal to 1% and less than or equal to 30%;
the first solder is a tin-lead-indium ternary alloy, and the mass percentage of indium in the first solder is more than 0% and less than or equal to 5%.
Optionally, the second solder is any one of the following:
the second solder is a tin-lead-bismuth ternary alloy, and the mass percentage of bismuth in the second solder is at least less than 30%;
The second solder is tin-lead-indium ternary alloy, and the mass percentage of indium in the second solder is at least less than 5%;
the second solder is tin-lead-silver ternary alloy, and the mass percentage of silver in the second solder is more than 0% and less than or equal to 5%;
the second solder is tin-lead binary alloy, and the mass percentage of lead in the second solder is more than 20% and less than or equal to 50%.
Alternatively, the length of the overlap is not shorter than 1mm and the length of the alloy is not shorter than 1mm.
Optionally, an end of the alloy remote from the first cell does not exceed an end of a connecting line on the first cell associated with the outermost secondary grid remote from the first cell in a direction inward of the first cell perpendicular to the long side.
In a fourth aspect, there is provided a photovoltaic module comprising the cell string of any one of the third aspects above.
Compared with the prior art, the invention has the following advantages:
The application provides a battery string repairing method, which comprises the steps of taking the residual welding strips connected to the adjacent battery sheets after cutting as welding strips to be welded, placing a replacement battery sheet, welding the welding strips to be welded and the lap joint part of a second welding strip on the replacement battery sheet, and fixing the replacement battery sheet and the adjacent battery sheet by adopting alloy formed by welding the lap joint part. The second welding strip is provided with a second welding flux with a melting point higher than that of the first welding flux of the welding flux to be welded, so that the melting point of the alloy is also higher than that of the first welding flux.
One aspect of the application provides a method for manufacturing a replacement battery piece, which comprises the steps of arranging a battery substrate and arranging a replacement welding strip on the battery substrate. Because the melting point of the replacement solder covered on the surface of the replacement solder strip is higher than that of the solder covered on the surface of the solder strip on the fault battery piece to be replaced, when the replacement battery piece is adopted for repairing, the melting point of the formed alloy is also higher than that of the solder covered on the surface of the solder strip on the fault battery piece, and therefore, the probability of repairing and failure of the battery string can be reduced by using the replacement battery piece. And the preparation method for replacing the battery piece is simple, and has good practicability.
The application also provides a battery string, which comprises a first battery piece and a second battery piece, wherein the surface of a first welding strip of the first battery piece is covered with a first welding flux, the surface of a second welding strip of the second battery piece is covered with a second welding flux, the battery string is connected by overlapping the first welding strip and the second welding strip, and the overlapping part is provided with an alloy of the first welding flux and the second welding flux.
In one aspect, the present application further provides a photovoltaic module, including the above-mentioned battery string, in which the melting point of the second solder is higher than that of the first solder, so that the melting point of the alloy of the first solder and the second solder is also higher than that of the first solder, so that the connection between the battery pieces in the battery string is reliable, and the probability of repairing failure of the photovoltaic module can be reduced.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the principles of the application. In the accompanying drawings:
FIGS. 1 and 2 are schematic diagrams illustrating a related battery string repair technique by way of comparison;
FIG. 3 is a flowchart of a method for repairing a battery string according to an embodiment of the present application;
FIG. 4 is a schematic diagram of a battery string to be repaired according to an embodiment of the present application;
FIG. 5 is a schematic view of a solder strip cut-off according to an embodiment of the present application;
FIG. 6 is a schematic diagram of a placement of replacement battery cells according to an embodiment of the present application;
FIG. 7 is a schematic diagram of a welding strip according to an embodiment of the present application;
FIG. 8 is a schematic illustration of the length of an alloy formed after lapping according to an embodiment of the present application;
FIG. 9 is a schematic diagram of a battery string repaired according to some known repair methods;
Fig. 10 is a schematic view of a battery string that can be obtained in the present embodiment;
fig. 11 is a flowchart of a method for manufacturing a replaceable battery sheet according to an embodiment of the present application;
fig. 12 and 13 are schematic diagrams of a reworked battery string according to an embodiment of the present application;
Fig. 14 is a schematic view of a photovoltaic module according to an embodiment of the present application.
Detailed Description
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are used in the description of the embodiments will be briefly described below. It is apparent that the drawings in the following description are only some examples or embodiments of the present application, and it is apparent to those of ordinary skill in the art that the present application may be applied to other similar situations according to the drawings without inventive effort. Unless otherwise apparent from the context of the language or otherwise specified, like reference numerals in the figures refer to like structures or operations.
As used in the specification and in the claims, the terms "a," "an," "the," and/or "the" are not specific to a singular, but may include a plurality, unless the context clearly dictates otherwise. In general, the terms "comprises" and "comprising" merely indicate that the steps and elements are explicitly identified, and they do not constitute an exclusive list, as other steps or elements may be included in a method or apparatus.
The relative arrangement of the components and steps, numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present application unless it is specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective parts shown in the drawings are not drawn in actual scale for convenience of description. Techniques, methods, and apparatus known to one of ordinary skill in the relevant art may not be discussed in detail, but should be considered part of the specification where appropriate. In all examples shown and discussed herein, any specific values should be construed as merely illustrative, and not a limitation. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further discussion thereof is necessary in subsequent figures.
In the description of the present application, it should be understood that the azimuth or positional relationships indicated by the azimuth terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal", and "top, bottom", etc., are generally based on the azimuth or positional relationships shown in the drawings, merely to facilitate description of the present application and simplify the description, and these azimuth terms do not indicate and imply that the apparatus or elements referred to must have a specific azimuth or be constructed and operated in a specific azimuth, and thus should not be construed as limiting the scope of protection of the present application; the orientation word "inner and outer" refers to inner and outer relative to the contour of the respective component itself.
Spatially relative terms, such as "above … …," "above … …," "upper surface on … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial location relative to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "above" or "over" other devices or structures would then be oriented "below" or "beneath" the other devices or structures. Thus, the exemplary term "above … …" may include both orientations "above … …" and "below … …". The device may also be positioned in other different ways (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
In addition, the terms "first", "second", etc. are used to define the components, and are only for convenience of distinguishing the corresponding components, and the terms have no special meaning unless otherwise stated, and therefore should not be construed as limiting the scope of the present application. Furthermore, although terms used in the present application are selected from publicly known and commonly used terms, some terms mentioned in the present specification may be selected by the applicant at his or her discretion, the detailed meanings of which are described in relevant parts of the description herein. Furthermore, it is required that the present application is understood, not simply by the actual terms used but by the meaning of each term lying within.
At present, as shown in fig. 1, when one battery piece in a battery string needs to be replaced due to failure, a welding strip connected between the failed battery piece and an adjacent battery piece can be cut off, then the failed battery piece is replaced by a qualified battery piece, and then the qualified battery piece and the adjacent battery piece are welded together by heating and melting welding materials of the welding strip on the qualified battery piece and welding materials of the welding strip on the adjacent battery piece.
However, as shown in fig. 2, in the case where the external temperature is high (for example, when the battery string is handled in the lamination process after the above-described welding process, the lamination temperature outside the battery string may be greater than 140 ℃), and the solder between the qualified battery sheet and the adjacent battery sheet fixed in the above-described manner may be remelted. This can lead to re-separation of the cells from one another and hence to repair failure of the string.
In view of the above technical problems, an aspect of the present application provides a method for repairing a battery string, the method including taking a remaining welding strip connected to an adjacent battery piece after cutting as a welding strip to be welded, placing a replacement battery piece, welding a lap joint portion of the welding strip to be welded and a second welding strip on the replacement battery piece, and fixing the replacement battery piece and the adjacent battery piece by using an alloy formed by welding the lap joint portion. The second welding strip is provided with a second welding flux with a melting point higher than that of the first welding flux of the welding flux to be welded, so that the melting point of the alloy is also higher than that of the first welding flux, and the method can enable connection between the battery pieces to be more reliable, and further reduce the probability of repairing and failure of the battery strings.
The operations performed by the system according to the embodiment of the present application will be described using flowcharts. It should be understood that the preceding or following operations are not necessarily performed in order precisely. Rather, the various steps may be processed in reverse order or simultaneously. At the same time, other operations are added to or removed from these processes.
Referring to fig. 3, one embodiment of the present application provides a battery string repairing method, which includes:
S301, cutting off a first welding strip between a fault battery piece and an adjacent battery piece in the battery string to be repaired, and taking the rest welding strips connected to the adjacent battery pieces after cutting off as welding strips to be welded.
The first solder strip may include a first conductive substrate and a first solder. The first solder may be wrapped around the surface of the first conductive substrate.
In one embodiment, the first conductive substrate is copper; the first solder may be any of the materials shown in table 1:
TABLE 1
It will be appreciated that there may be one or more adjacent cells, and that the first solder strip connecting each adjacent cell to the faulty cell includes a first conductive substrate and the first solder may be the same or different. For ease of understanding, the two adjacent battery pieces connected to the faulty battery piece are referred to as a first adjacent battery piece and a second adjacent battery piece, respectively, where the first adjacent battery piece and the second adjacent battery piece use the same first conductive substrate and first solder.
Exemplary, as shown in fig. 4, a schematic diagram of a battery string to be repaired according to the present embodiment is provided. The repair battery string is provided with a fault battery piece to be replaced, and the fault battery piece is connected with the adjacent battery piece through a first welding strip. In particular, in fig. 4, a first adjacent cell is connected to the left side of the failed cell and a second adjacent cell is connected to the right side of the failed cell. As shown in fig. 4, a first solder strip a is connected between the first adjacent battery piece and the failed battery piece (only one is pointed in the figure, it should be understood that all the solder strips connected between the first adjacent battery piece and the failed battery piece can be used as the first solder strip a); a first solder strip b is connected between the second adjacent cell and the faulty cell (only one of which is shown, it should be understood that all of the remaining solder strips connected between the second adjacent cell and the faulty cell may be referred to as the first solder strip b).
In this embodiment, the first conductive substrates of the first solder strip a and the first solder strip b are copper; the first solders of the first welding strip a and the first welding strip b are tin-lead-bismuth ternary alloy, and comprise the following components in percentage by mass: 37% tin, 37% lead, 26% bismuth.
In one embodiment, a first cut-off position is determined on a first solder strip of a failed battery piece and a first adjacent battery piece, and a second cut-off position is determined on a first solder strip of a failed battery piece and a second adjacent battery piece, and then the first solder strip between the failed battery piece and the first and second adjacent battery pieces is cut off along the first and second cut-off positions, respectively.
The distance between the first cut-off position and the long side of the fault battery piece is a first length, the distance between the second cut-off position and the long side of the fault battery piece is a second length, and the second length does not exceed the first length.
Illustratively, as shown in fig. 5, a first cut-off position is determined on a first welding strip of the failed battery piece and a first adjacent battery piece, and a distance between the first cut-off position and a long side of the failed battery piece is a first length L1; and determining a second cut-off position on the first welding strip of the fault battery piece and the second adjacent battery piece, wherein the distance between the second cut-off position and the long side of the fault battery piece is a second length L2. As can be seen from fig. 5, L2 does not exceed L1.
For ease of illustration, the present embodiment refers to the remaining solder strips connected to the first adjacent cell as the solder strips to be soldered c, and the remaining solder strips connected to the second adjacent cell as the solder strips to be soldered d after the dicing.
S302, removing the fault battery piece, and placing a replacement battery piece at a corresponding removal position.
The replacement battery piece is provided with a second welding strip, and the second welding strip can comprise a second conductive base material and second welding flux. The second solder may cover a surface of the second conductive substrate. The second solder has a melting point higher than that of the first solder.
In one embodiment, the second conductive substrate is copper and the second solder may be any of the materials shown in table 2 below:
TABLE 2
It will be appreciated that in practical applications, one skilled in the art may use any of the materials shown in table 1 above as the first solder, and may use any of the materials shown in table 2 above as the second solder. For example, a tin-lead-bismuth ternary alloy (including the following components by mass percent: 37% tin, 37% lead, 26% bismuth) may be used as the first solder, and a tin-lead binary alloy may be used as the second solder (including the following components by mass percent: 70% tin, 30% lead).
Preferably, when the first solder and the second solder adopted by the person skilled in the art are both tin-lead-bismuth ternary alloys, the mass percentage of bismuth in the second solder is also smaller than that in the first solder.
For example, a first tin-lead-bismuth ternary alloy (comprising the following components by mass: 37% tin, 37% lead, 26% bismuth) may be used as the first solder, and a second tin-lead-bismuth alloy may be used as the second solder (comprising the following components by mass: 43% tin, 43% lead, 14% bismuth).
Preferably, when the first solder and the second solder adopted by the person skilled in the art are both tin-lead-indium ternary alloy, the mass percentage of indium in the second solder is also smaller than that in the first solder.
In the embodiment of the application, for easy understanding, a first tin-lead-bismuth ternary alloy (comprising the following components in percentage by mass: 37% of tin, 37% of lead and 26% of bismuth) is adopted as a first solder, and a second tin-lead-bismuth alloy is adopted as a second solder (comprising the following components in percentage by mass: 43% of tin, 43% of lead and 14% of bismuth). The melting point of the first solder is: 140 degrees celsius. The melting point of the second solder is: 160 degrees celsius.
Fig. 6 is a schematic diagram of the placement of the replacement battery according to the present embodiment. The replacement battery piece is placed corresponding to the removed position of the fault battery piece. And a second welding strip e is arranged on one side of the replacement battery piece, which is close to the first adjacent battery piece, and a second welding strip f is arranged on one side of the replacement battery piece, which is close to the second adjacent battery piece.
In this embodiment, the second conductive substrates of the second solder strips e and f are copper; the second solders of the second welding strip e and the second welding strip f are tin-lead-bismuth ternary alloy, and comprise the following components in percentage by mass: 43% tin, 43% lead, 14% bismuth.
S303, overlapping the welding strip to be welded with the second welding strip, and welding the overlapping part between the welding strip to be welded and the second welding strip.
In the welding process, the first solder on the surface of the welding strip to be welded and the second solder on the surface of the second welding strip are melted on the lap joint part, alloy is formed on the area covered on the lap joint part, and the alloy formed by welding the lap joint part fixes the replacement battery piece and the adjacent battery piece.
In one embodiment, the alloy formed by the first solder and the second solder has a melting point higher than the temperature of the lamination process of the battery sheet.
In one embodiment, the overlap between the weld zone to be welded and the second weld zone may be welded in any one or a combination of the following ways: a soldering iron heating mode, an infrared heating mode, a hot air heating mode, an electromagnetic heating mode and a laser welding mode.
Illustratively, as shown in fig. 7, the overlap portion C between the to-be-welded strap C and the second strap e and the overlap portion D between the to-be-welded strap D and the second strap f are welded by overlapping the to-be-welded strap C and the second strap e and overlapping the to-be-welded strap D and the second strap f. In the welding process of the welding strip D to be welded and the second welding strip f, the first solder on the surface of the welding strip D to be welded and the second solder on the surface of the second welding strip f are melted on the lap joint part D, so that an alloy can be formed on the area covered on the lap joint part D for fixing the first adjacent battery piece and the replacement battery piece. Similarly, in the welding process of the to-be-welded welding strip C and the second welding strip e, the first solder on the surface of the to-be-welded welding strip C and the second solder on the surface of the second welding strip e are melted on the lap joint part C, so that an alloy can be formed on the area covered on the lap joint part C for fixing the second adjacent battery piece and the replacement battery piece.
When the melting point of the alloy formed on the lap joint part C and the lap joint part D is higher than the temperature of the lamination process of the battery piece, even if the reworked battery string is put into the subsequent lamination process again, the alloy cannot be melted, so that the reworked battery string cannot be separated again in the lamination process, and the reworked failure of the battery string is avoided.
The present embodiment will be compared with some reworking methods known to the inventors from the viewpoint of process difficulty.
One known repair method is a colloid fixing method, that is, two welding strips are wrapped by an additional colloid at the lap joint position of the repair site, and then the welding strips at the lap joint position are fixed by solidifying the colloid. One of the disadvantages of this repair is that in the case where the glue is applied only between two solder strips, the glue is easily softened to cause the solder strips to separate; another disadvantage is that in case the glue adequately wraps the solder strip, it may affect the subsequent process of the battery string, for example, when handling the battery sheet in the lamination process, there may be a risk of puncturing the encapsulation film if the height of the glue is applied to some extent.
Another possible repair method is a high-temperature solder auxiliary fixing method, namely, auxiliary high-temperature solder is applied to the lap joint position of the repair part, and the welding strips at the lap joint position are fixed by wrapping two welding strips by the high-temperature solder. This approach is a solution because it can avoid solder re-melting. However, the inventors of the present application have found that there are some drawbacks to this repair approach. First, when high temperature solder is applied to the lap joint position at the repair site, a solder deposit and a solder burr are liable to occur, which may affect the subsequent processes of the battery string, for example, when handling the battery pieces in the lamination process, there may be a risk of piercing the packaging adhesive film if the height of the deposited solder or burr reaches a certain level. Second, the accumulated solder or burrs may deteriorate the insulating performance of the assembly, and may more easily cause stress concentration of the battery string to cause breakage thereof.
Compared with the colloid fixing mode, the battery string repairing method in the embodiment uses the alloy to fix the replacement battery piece and the adjacent battery piece, and the alloy is not softened, so that the welding strip separation caused by colloid softening in the first mode can be avoided; and the alloy does not need to completely wrap the two welding strips, so that the risk of puncturing the packaging adhesive film caused by the application height of the colloid can be avoided.
Compared with a high-temperature solder auxiliary mode, the battery string repairing method of the embodiment uses the alloy to fix and replace the battery sheet and the adjacent battery sheet, and the alloy can not generate solder accumulation and solder burrs, so that the accumulated solder or burrs can be prevented from penetrating through a packaging adhesive film, and meanwhile, the problems of deterioration of the insulating performance of the assembly and damage of the battery string are avoided. In one embodiment, the lap joint is not shorter than 1mm in length and the alloy formed is not shorter than 1mm in length.
As shown in fig. 7, between the lap joint welding strip D to be welded and the second welding strip f, the length of the lap joint part D is 1.5mm, and the length of the formed alloy is 1.5mm, so that the connection between the replacement battery piece and the second adjacent battery piece can be ensured to be more reliable.
In one embodiment, the end of the alloy remote from the adjacent cell does not exceed the end of the connecting wire associated with the outermost secondary grid on the adjacent cell remote from the adjacent cell in a direction inward of the adjacent cell perpendicular to the long side.
As shown in fig. 8, the end of the alloy (indicated by an oval shape in fig. 5, denoted by E1) remote from the second adjacent cell does not exceed the end (indicated by E2) of the connecting line on the second adjacent cell associated with the outermost sub-grid in the direction perpendicular to the inside of the long-side box.
Further, this embodiment will be compared with some of the above known rework manners from the viewpoint of process cost.
The inventor finds that, in the process of repairing the battery string by adopting the colloid fixing mode or the high-temperature solder auxiliary fixing mode, the part of the colloid (or the high Wen Fuliao) exceeding the lap joint part is likely to be contacted with the main grid connecting line of the battery piece because the area of the applied colloid (or the high Wen Fuliao) is larger than the prepared lap joint area, so that the failure risk of the battery piece in the production process is increased. Exemplary, as shown in fig. 9, a schematic diagram of a battery string repaired according to a known repair method is shown. The two welding strips of the battery string at the lap joint are fixed by the applied colloid (or height Wen Fuliao), and the area of the applied colloid (or height Wen Fuliao) is larger than the prepared lap joint area. In order to avoid short-circuit failure of the battery in the event of contact between the portion of the gel (or high Wen Fuliao) beyond the lap joint and the main gate connection line of the battery, one solution that may be adopted by the above known manner is to choose to increase the length of the main gate connection line of the battery. As shown in fig. 9, the length of the main gate connection line of the battery sheet is increased to 5 sub-gate intervals. It can be seen that even though this solution to some extent allows to protect the above-mentioned battery plates, which have been reworked according to known methods, from the risk of failure, it increases the length of the main grid connection lines of the battery plates, with the consequent significant increase in the process costs required for the repair of the battery strings.
Further, it is found that the two bonding strips at the bonding position are fixed together by the alloy formed by the first solder and the second solder, and the area of the alloy does not exceed the prepared bonding area, so that the risk of failure of the battery piece caused by contact between the alloy and the main grid connection line of the battery piece can be avoided. In addition, the embodiment realizes the complete utilization of the lap joint part, so that the length of the main grid connecting wire of the battery piece is not required to be increased, and compared with the prior art, the method remarkably reduces the process cost required by repairing the battery string. Exemplary, as shown in fig. 10, a schematic diagram of a battery string that can be obtained in this embodiment is shown. The two welding belts of the battery string at the lap joint are fixed together through the formed alloy. Since the area of the alloy does not exceed the prepared lap area, the length of the main grid connection line of the battery sheet does not need to be increased additionally. As shown in fig. 10, the length of the main gate connecting line of the battery sheet is 3 sub gate intervals. It can be seen that the process cost required for reworking a battery string of the present embodiment can be significantly reduced as compared to the battery string shown in fig. 9.
Further, referring to fig. 11, the present application provides a method for manufacturing a replaceable battery sheet, including:
S1101, a battery substrate is provided.
S1102, a replacement solder strip is provided on the battery substrate.
The surface of the replacement welding strip is covered with the replacement welding material, and the melting point of the replacement welding material is higher than that of the welding material covered on the surface of the welding strip on the fault battery piece to be replaced by the replacement battery piece.
Because the melting point of the replacement solder covered on the surface of the replacement solder strip is higher than that of the solder covered on the surface of the solder strip on the fault battery piece to be replaced, when the replacement battery piece is adopted for repairing, the melting point of the formed alloy is also higher than that of the solder covered on the surface of the solder strip on the fault battery piece, and therefore, the probability of repairing and failure of the battery string can be reduced by using the replacement battery piece. And the preparation method for replacing the battery piece is simple, and has good practicability.
For details of replacing the battery cells, reference may be made to the above-mentioned method embodiments for repairing the battery cells, which are not described herein.
The present application also provides a battery string, referring to fig. 12 and 13, comprising:
A first battery piece 121 having a first solder tape 1211, the surface of the first solder tape 1211 being covered with a first solder 12111;
a second battery piece 122 having a second solder strip 1221, the surface of which is covered with a second solder 12211;
Wherein the first and second battery pieces 121 and 122 are connected by overlapping the first and second solder strips 1211 and 1221, and the overlapping portion has an alloy 123 of the first and second solders 12111 and 12211, and the second solder 12211 has a melting point higher than that of the first solder 12111.
In one embodiment, the alloy 113 formed by the first solder 12111 and the second solder 12211 at the lap joint has a melting point higher than the temperature of the lamination process of the battery sheet.
In one embodiment, the first solder 12111 is any one of the following:
The first solder 12111 is a tin-lead-bismuth ternary alloy, and the mass percentage of bismuth in the first solder 12111 is more than or equal to 1% and less than or equal to 30%;
the first solder 12111 is a tin-lead-indium ternary alloy, and the mass percentage of indium in the first solder 12111 is more than 0% and less than or equal to 5%.
In one embodiment, the second solder 12211 is any one of the following:
the second solder 12211 is a tin-lead-bismuth ternary alloy, and the mass percentage of bismuth in the second solder 12211 is at least less than 30%;
The second solder 12211 is a tin-lead-indium ternary alloy, and the mass percentage of indium in the second solder 12211 is at least less than 5%;
The second solder 12211 is a tin-lead-silver ternary alloy, and the mass percentage of silver in the second solder 12211 is more than 0% and less than or equal to 5%;
the second solder 12211 is a tin-lead binary alloy, and the mass percentage of lead in the second solder 12211 is more than 20% and less than or equal to 50%.
In one embodiment, the length of the lap joint is not less than 1mm and the length of the alloy 113 is not less than 1mm.
In one embodiment, the end of the alloy 113 remote from the first cell is not beyond the end of the connecting line on the first cell 121 associated with the outermost secondary grid remote from the first cell 121 in a direction in which the first cell 121 is inward perpendicular to the long side.
Since the melting point of the second solder 12211 in the battery string is higher than the melting point of the first solder 12111, the melting point of the alloy 113 of the first solder 12111 and the second solder 12211 is also higher than the melting point of the first solder 12111, so that the connection between the first battery piece 121 and the second battery piece 122 in the battery string is reliable, and the probability of repairing and failure of the battery string is reduced.
For some details of the battery string embodiments, reference may be made to the above-mentioned embodiments of the battery string repair method, and details thereof are not repeated herein.
Further, referring to fig. 14, the present application further provides a photovoltaic module, which includes a cell string 14, and the cell 14 may be a cell string as shown in fig. 12 or 13.
Because the melting point of the second solder in the battery string 14 included in the photovoltaic module is higher than that of the first solder, the melting point of the alloy of the first solder and the second solder is also higher than that of the first solder, so that the connection of the battery pieces in the battery string 14 is more reliable, and the probability of repairing and invalidating the photovoltaic module is reduced.
For some details of the photovoltaic module embodiments, reference may be made to the embodiments of the above-mentioned battery string repair method, and details thereof are not repeated herein.
While the basic concepts have been described above, it will be apparent to those skilled in the art that the foregoing disclosure is by way of example only and is not intended to be limiting. Although not explicitly described herein, various modifications, improvements and adaptations of the application may occur to one skilled in the art. Such modifications, improvements, and modifications are intended to be suggested within the present disclosure, and therefore, such modifications, improvements, and adaptations are intended to be within the spirit and scope of the exemplary embodiments of the present disclosure.
Meanwhile, the present application uses specific words to describe embodiments of the present application. Reference to "one embodiment," "an embodiment," and/or "some embodiments" means that a particular feature, structure, or characteristic is associated with at least one embodiment of the application. Thus, it should be emphasized and should be appreciated that two or more references to "an embodiment" or "one embodiment" or "an alternative embodiment" in various positions in this specification are not necessarily referring to the same embodiment. Furthermore, certain features, structures, or characteristics of one or more embodiments of the application may be combined as suitable.
Similarly, it should be noted that in order to simplify the description of the present disclosure and thereby aid in understanding one or more inventive embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof. This method of disclosure does not imply that the subject application requires more features than are set forth in the claims. Indeed, less than all of the features of a single embodiment disclosed above.
In some embodiments, numbers describing the components, number of attributes are used, it being understood that such numbers being used in the description of embodiments are modified in some examples by the modifier "about," approximately, "or" substantially. Unless otherwise indicated, "about," "approximately," or "substantially" indicate that the number allows for a 20% variation. Accordingly, in some embodiments, numerical parameters set forth in the specification and claims are approximations that may vary depending upon the desired properties sought to be obtained by the individual embodiments. In some embodiments, the numerical parameters should take into account the specified significant digits and employ a method for preserving the general number of digits. Although the numerical ranges and parameters set forth herein are approximations in some embodiments for use in determining the breadth of the range, in particular embodiments, the numerical values set forth herein are as precisely as possible.
While the application has been described with reference to the specific embodiments presently, it will be appreciated by those skilled in the art that the foregoing embodiments are merely illustrative of the application, and various equivalent changes and substitutions may be made without departing from the spirit of the application, and therefore, all changes and modifications to the embodiments are intended to be within the scope of the appended claims.

Claims (14)

1. A battery string repair method, comprising:
Cutting off a first welding strip between a fault battery piece in a battery string to be repaired and an adjacent battery piece, and taking the rest welding strip connected to the adjacent battery piece after cutting off as a welding strip to be welded, wherein the surface of the first welding strip is covered with a first solder containing tin;
Removing the fault battery piece, and placing a replacement battery piece at a corresponding removal position, wherein a second welding strip is arranged on the replacement battery piece, the surface of the second welding strip is covered with a second welding material containing tin, and the melting point of the second welding material is higher than that of the first welding material;
And overlapping the welding strip to be welded with the second welding strip, and welding the overlapping part of the welding strip to be welded with the second welding strip, wherein the alloy formed by welding the overlapping part fixes the replacement battery piece and the adjacent battery piece, and the end part of the alloy, which is far away from the adjacent battery piece, is not more than the end part, which is far away from the adjacent battery piece, of the connecting wire, which is associated with the outermost auxiliary grid, on the adjacent battery piece in the direction of the adjacent battery piece, which is perpendicular to the inward long side.
2. The method of claim 1, wherein the alloy of the first solder and the second solder at the lap joint has a melting point higher than a temperature of a lamination process of the battery sheet.
3. The method of claim 1, wherein the severing the first solder strip between a failed battery cell and its neighboring battery cells in the battery string to be repaired comprises:
Determining a first cut-off position on a first welding strip of the fault battery piece and a first adjacent battery piece, and determining a second cut-off position on a first welding strip of the fault battery piece and a second adjacent battery piece, wherein the distance between the first cut-off position and the long side of the fault battery piece is a first length, the distance between the second cut-off position and the long side of the fault battery piece is a second length, and the second length does not exceed the first length;
And cutting off the first welding strips between the fault battery piece and the first adjacent battery piece and the second adjacent battery piece along the first cutting-off position and the second cutting-off position respectively.
4. The method of claim 1, wherein the first solder is any one of:
The first solder is a tin-lead-bismuth ternary alloy, and the mass percentage of bismuth in the first solder is more than or equal to 1% and less than or equal to 30%;
The first solder is a tin-lead-indium ternary alloy, and the mass percentage of indium in the first solder is more than 0% and less than or equal to 5%.
5. The method of claim 4, wherein the second solder is any one of:
the second solder is a tin-lead-bismuth ternary alloy, and the mass percentage of bismuth in the second solder is less than 30%;
The second solder is a tin-lead-indium ternary alloy, and the mass percentage of indium in the second solder is less than 5%;
The second solder is tin-lead-silver ternary alloy, and the mass percentage of silver in the second solder is more than 0% and less than or equal to 5%;
the second solder is tin-lead binary alloy, and the mass percentage of lead in the second solder is more than 20% and less than or equal to 50%.
6. The method of any of claims 1-5, wherein the welding the overlap between the weld bead to be welded and the second weld bead comprises any one or a combination of:
a soldering iron heating mode, an infrared heating mode, a hot air heating mode, an electromagnetic heating mode and a laser welding mode.
7. The method of any one of claims 1-5, wherein the lap joint is not shorter than 1mm in length and the alloy is not shorter than 1mm in length.
8. The preparation method of the replacement battery piece is characterized by comprising the following steps:
Setting a battery substrate;
And arranging a replacement welding strip on the battery substrate, wherein the surface of the replacement welding strip is covered with a tin-containing replacement welding material, the melting point of the replacement welding material is higher than that of the welding material covered on the surface of the welding strip on the fault battery piece to be replaced by the replacement battery piece, the replacement welding material and the welding material form an alloy, the end part of the alloy, which is far away from the adjacent battery piece, is vertical to the inward direction of the long edge of the adjacent battery piece, and does not exceed the end part, which is far away from the adjacent battery piece, of a connecting wire, which is associated with the outermost auxiliary grid, on the adjacent battery piece.
9. A battery string, comprising:
A first battery piece provided with a first welding strip, wherein the surface of the first welding strip is covered with a first welding flux containing tin;
the second battery piece is provided with a second welding strip, and the surface of the second welding strip is covered with a second welding material containing tin;
The first battery piece and the second battery piece are connected through the lap joint of the first welding strip and the second welding strip, the lap joint part is provided with an alloy of the first welding material and the second welding material, the melting point of the second welding material is higher than that of the first welding material, the end part of the alloy, which is far away from the first battery piece, is not more than the end part, which is far away from the first battery piece, of a connecting wire, which is associated with the outermost auxiliary grid, on the first battery piece in the direction of the first battery piece, which is perpendicular to the inward long side.
10. The battery string of claim 9, wherein the alloy of the first solder and the second solder at the lap joint has a melting point higher than a temperature of a lamination process of the battery sheet.
11. The battery string of claim 9, wherein the first solder is any one of:
The first solder is a tin-lead-bismuth ternary alloy, and the mass percentage of bismuth in the first solder is more than or equal to 1% and less than or equal to 30%;
The first solder is a tin-lead-indium ternary alloy, and the mass percentage of indium in the first solder is more than 0% and less than or equal to 5%.
12. The battery string of claim 11, wherein the second solder is any one of:
the second solder is a tin-lead-bismuth ternary alloy, and the mass percentage of bismuth in the second solder is less than 30%;
The second solder is a tin-lead-indium ternary alloy, and the mass percentage of indium in the second solder is less than 5%;
The second solder is tin-lead-silver ternary alloy, and the mass percentage of silver in the second solder is more than 0% and less than or equal to 5%;
the second solder is tin-lead binary alloy, and the mass percentage of lead in the second solder is more than 20% and less than or equal to 50%.
13. The battery string of any of claims 9-12, wherein the overlap is no shorter than 1mm in length and the alloy is no shorter than 1mm in length.
14. A photovoltaic module comprising the cell string of any one of claims 9-13.
CN202311577788.8A 2023-11-24 2023-11-24 Battery string repairing method, preparation method of replacement battery string and battery string Active CN117293231B (en)

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