JP2011073042A - Method for joining coated plate-conductor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for joining coated plate-conductors. <P>SOLUTION: In the method for joining coated plate-conductors, a first and second plate coated-conductors, which are superposed on each other without previously peeling off the coatings, are held with a bypass conductor from the outside of the conductors, and are further pinched with a pair of welding electrodes. An electric current is passed between the welding electrodes to melt and remove the coatings, so that the plate-conductors are joined. The electric current is passed while pinching and pressurizing the conductors with the pair of welding electrodes from the outside of the bypass conductor. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  TECHNICAL FIELD The present invention relates to joining of coated flat conductors used for wiring to output terminals of solar cell modules and the like, and more particularly to a method of joining coated flat conductors suitable for bonding without peeling off the coating in advance. Is.

  A solar cell device is expected as a new energy conversion device because it converts light from the sun into electricity, and in recent years, it has been actively used as a power source for general households.

Each of the solar cell elements can obtain only a small electromotive force, but it is well known that various electromotive forces can be obtained by connecting the solar cell elements in series and in parallel (for example, Patent Documents). 1).
This conventional solar cell device is configured as shown in FIG. 4, and has a solar cell group 104 in which each solar cell element 102 is connected in series, and an electromotive force is generated depending on the number of the solar cell groups. adjust.

  The solar cell group 104 connected in series is connected to covered flat conductors 106 and 107 using flat copper wires as connecting members. The covered flat conductors 106 and 107 are covered flat conductors 108 and 109, respectively. And the electromotive force is guided to the external connection terminal.

  It is necessary to change the length of the coated flat conductors 106 and 107, particularly the coated flat conductor 106 in accordance with the electromotive force. This coating prevents the connecting members from contacting each other and being electrically short-circuited. As described above, the coated flat conductors 106 and 107 are connected to the coated flat conductors 108 and 109, respectively. Therefore, it is necessary to peel off the coating in advance and then join them. It is necessary to make it the combined length. This has been a factor in raising the manufacturing cost of the solar cell device.

For this reason, the method of joining the flat conductors with a coating, without peeling a coating beforehand is calculated | required. The applicant of the present application investigated documents etc. in which such a method is described, but could not find documents etc. directly described.
However, even if the application is different but the welding current cannot be passed between the welding electrodes as it is, a method (joint flow preheating method) for joining the damping steel plates containing the insulating resin using the welding technique has been found (for example, Patent Document 2).

JP 2006-278905 A JP 62-192277 A

  However, as shown in FIG. 5, the method described in Patent Document 2 sandwiches the two damping steel plates 105 and 111 with the bypass conductor 113 from the outside of the two damping damping steel plates 105 and 111, A pair of welding electrodes 115 and 117 are brought into contact with a portion different from the portion where the bypass conductor 113 is sandwiched, and from one welding electrode 115 to the outer conductive portion of the first damping steel plate 105, the bypass conductor. 113, a current is passed to the other welding electrode 117 through the conductive portion outside the second damping steel plate 111, and the first and second damping steel plates 105, 111 are bypassed by the bypass conductor 113. There is a drawback that a sufficient current cannot flow unless the overlapping portion is held with a predetermined clamping force. On the other hand, if the holding force is to be held with a predetermined holding force, the width of the holding portion becomes narrow, and it takes time to attach and remove the bypass conductor 113, resulting in an increase in manufacturing cost.

  And above all, in this method, the welding electrodes 115, 117 and the bypass conductor 113 are not in contact with each other. Since no current flows and consequently no Joule heat is generated, the outer coating does not melt, so that there is a fatal defect that the plate conductors cannot be joined after all.

  The present invention has been made in order to solve the above-described problems, and an object of the present invention is to provide a method for joining a coated flat conductor in which a bypass conductor is sandwiched between welding electrodes and a current is supplied while being pressed.

  The method of joining the coated flat conductors according to the first aspect of the present invention is such that the first and second coated flat conductors are overlapped in advance without peeling off the covering, and sandwiched by a bypass conductor from the outside, Further, the coated flat plate conductor for joining the flat plate conductors by sandwiching the first and second coated flat plate conductors with a pair of welding electrodes and flowing a current between the weld electrodes to melt and peel the coating. It is a body joining method, wherein the pair of welding electrodes are sandwiched from the outside of the bypass conductor and a current flows while being pressed.

  The method for joining coated flat conductors according to the second aspect of the present invention is substantially U-shaped in cross section, and is located at a position where the first and second covered flat conductors are sandwiched. The bypass conductor is used in which convex portions are formed in which the hollow depth matched to the tip shape of the welding electrode from the outside toward the inside exceeds the thickness of the bypass conductor. is there.

  According to a third aspect of the present invention, there is provided a method of joining a coated flat plate conductor using the bypass conductor having a spring property between opposing holding surfaces having a U-shaped cross section. .

  According to a fourth aspect of the present invention, there is provided a method of joining a coated flat conductor, wherein the width of the narrowest portion of the sandwiching portion is determined from the thickness when the first and second coated flat conductors are stacked. The bypass conductor having a value reduced by an amount determined according to the shrinkage of the material during pressurization to 1.5 times the thickness when the material is stacked is used.

  According to a fifth aspect of the present invention, there is provided a method for joining a coated flat conductor, wherein the outer coating is melted and peeled according to the measurement result of the width between the first and second welding electrodes, and the inner coating is melted. The step of peeling and the step of welding the flat plate conductors are judged, and a current adapted to each step is passed.

  According to the first to fifth aspects of the present invention, even if the coating is not peeled off in advance, a current flows between the welding electrodes via the bypass conductor, so this current generates Joule heat, and the outer coating is first melted. Next, the inner coating is melted and peeled, and the flat conductors come into contact with each other. Since the welding current flows between the welding electrodes through the flat conductor when the flat conductor comes into contact in this way, the flat conductor can be joined and the method of joining the coated flat conductor with reduced manufacturing cost can be achieved. Can be provided.

  According to the second aspect of the present invention, since the concave conductor is formed in the bypass conductor so as to accommodate the welding electrode, the positioning of the welding electrode is easy, and since the convex portion is provided, it flows between the welding electrodes. Since the Joule heat generated by the electric current is appropriately transmitted to the coating, it is possible to appropriately perform the melt peeling of the coating and the joining of the flat conductors after the coating peeling.

  According to the invention described in claim 3, since the bypass conductor has a spring property, the open end of the bypass conductor is easy to widen, so that it can be attached to the overlapped flat plate conductor to be joined. It can be done easily. Since this spring property is provided, a welding current is passed between the welding electrodes while pressurizing between the welding electrodes to complete the joining of the plate conductors, and then applied to the bypass conductor by separating the welding electrodes from the workpiece. When the pressure is released from the applied pressure, the open end of the bypass conductor is opened, so that the bypass conductor is separated from the coated flat conductor to be joined, so that the removal can be easily performed.

  According to the invention described in claim 4, since the sandwiching width of the bypass conductor is made wider with respect to the thickness of the stacked flat conductors, the stacked flat conductors to be joined are joined. It can be easily attached to the body.

  According to the fifth aspect of the invention, in particular, the distance between the welding electrodes can be detected, and the progress stage of the work can be grasped accordingly, and an appropriate current can be passed in accordance with each stage. A method for joining flat conductors can be provided.

BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic process drawing which shows one Embodiment of the joining method of the flat conductor with a coating which becomes this invention, and is the first stage part. It is a general | schematic process drawing which shows one Embodiment of the joining method of the coated flat conductor which becomes this invention, and is the middle step part. It is a general | schematic process drawing which shows one Embodiment of the joining method of the flat conductor with a coating which becomes this invention, and is a back | latter stage part. It is a schematic block diagram of the solar cell apparatus by which the joining method of the coated flat conductor which becomes this invention is utilized. It is a figure explaining a shunt preheating method.

Next, embodiments of the present invention will be described in detail with reference to the drawings.
1 to 3 are schematic process diagrams showing an embodiment of a method for joining coated flat conductors according to the present invention. FIG. 1 shows the first stage, FIG. 2 shows the middle stage, and FIG. 3 shows the subsequent stage. is there. In these drawings, all are sectional views.

  1 to 3, 1 is a coating of a coated flat conductor 5 made of an insulating member made of PET or the like having a thickness of 0.05 mm, 3 is a coated flat plate made of a flat copper wire or the like having a width of 6 mm and a thickness of 0.3 mm. A flat conductor of the conductor 5, 7 is a bypass conductor for passing a bypass current for melting and peeling the coatings 1, 1, 1, 1 from the outside to the inside facing the U-shaped cross section A convex portion 7 a is formed in which the hollow depth matched to the tip shape of the welding electrode used in each direction exceeds the thickness of the bypass conductor 7. Although the convex portion 7a is not necessarily required for the present invention, the positioning of the welding electrode and the specific portion of the coated flat conductor are pressed, the current is passed, and the coating is melted and peeled. It is preferable for joining the two.

  Reference numerals 9 and 10 denote a pair of welding electrodes for supplying a current when the coated flat conductors 5 and 5 are joined. In addition, since the equipment necessary for flowing a current to the welding electrode such as a welding power source is not directly related to the gist of the present invention, illustration and explanation are omitted.

11 is a bypass current when melt-peeling the coatings 1, 1, 1, 1; 13 is a welding current when joining the flat conductors 3 and 3 after the melt-peeling of the coatings 1, 1, 1, 1; It is a nugget formed by flowing a welding current.
Next, the joining method of the coated flat conductor according to the present invention will be described in the order of steps with reference to FIGS.

  The step of melting and peeling the outer coatings 1 and 1 with the pressure and current applied between the welding electrodes 9 and 10 according to the coated flat conductors 5 and 5 to be bonded first, and melting and peeling the inner coatings 1 and 1 The steps are set in chronological order by dividing the step and the step of joining the flat conductors 3 and 3. The pressure and current will be referred to as the first pressure 1 and current 1, the second pressure 2 and current 2, and the third pressure 3 and current 3, respectively.

  The time required for each stage is obtained experimentally, or the values obtained by measuring the displacement between the welding electrodes 9 and 10 to detect the melt peeling of the outer coating and the melt peeling of the inner coating are obtained. Although it can be made to change to a predetermined pressure and electric current based on this, it demonstrates as using the value calculated | required experimentally here.

  After preparing to set the pressure and current for the melt peeling of the coatings 1 and 1 and the joining of the flat conductors 3 and 3 in units of time, the coatings 1 and 1 are provided without peeling in advance. The portions where the flat conductors 5 and 5 are joined are aligned and overlapped ((a) of FIG. 1).

  Next, the covered flat conductors 5 and 5 are inserted from the opening end of the bypass conductor 7, and the covered flat conductors 5 and 5 are connected with the bypass conductor 7 while aligning the bottom of the convex portion 7a with the joining portion. Holding is performed ((b) in FIG. 1). At this time, since the bypass conductor 7 has elasticity, it is convenient to sandwich the coated flat conductors 5 and 5, and the coated flat conductors 5 and 5 are sandwiched by the convex portions 7 a. Therefore, since the opening is wider than the thickness of the coated flat conductors 5 and 5, insertion is easy. Thus, the coated flat conductors 5 and 5 sandwiched by the bypass conductor 7 are sandwiched by positioning the welding electrodes 9 and 10 in the recesses of the projections 7a.

  Then, the first current 1 is allowed to flow between the welding electrodes 9 and 10 for a predetermined time while pressing the coated flat conductors 5 and 5 with the first pressure 1 between the welding electrodes 9 and 10 (FIG. c)). At this time, since the coverings 1 and 1 are not peeled off, this current becomes a bypass current 11 and flows from the welding electrode 9 toward the welding electrode 10 via the bypass conductor 7 (in the direction indicated by the arrow in FIG. 11). ).

  At this time, Joule heat is generated by the bypass current 11, and the heat generation generates a portion where the outer coating 1, 1, in particular, the projection 7 a abuts, melts and evaporates. For this reason, this part of the outer coatings 1, 1 is peeled off, and the convex portions 7a, 7a of the bypass conductor 7 come into direct contact with the flat plate conductors 3, 3 ((d) in FIG. 2). At this time, since the bypass conductor 7 has elasticity, the coated flat conductors 5 and 5 are pressed around the convex portions 7a and 7a.

  After the outer coverings 1 and 1 are melted and peeled in this way, the coated conductors 5 and 5 are pressed between the welding electrodes 9 and 10 with the second pressure 2 between the welding electrodes 9 and 10. 2 current 2 is allowed to flow for a predetermined time ((e) of FIG. 2). At this time, since the inner coatings 1 and 1 are not peeled off, this current becomes a bypass current 11 as described above, and flows from the welding electrode 9 toward the welding electrode 10 via the bypass conductor 7 ( 11 arrow direction in the figure).

  In the same manner, Joule heat is generated by this bypass current, and this heat generation melts and evaporates the inner coating 1, 1, particularly the portion where the projection 7 a abuts, thereby evaporating the inner coating 1, 1. The portions are peeled off, and the convex portions 7a and 7a of the bypass conductor 7 come into direct contact with the flat plate conductors 3 and 3 ((e) of FIG. 2). At this time, since the bypass conductor 7 has elasticity, the coated flat conductors 5 and 5 are pressed around the convex portions 7a and 7a.

  After the inner coverings 1 and 1 are melted and peeled in this way, the coated conductors 5 and 5 are pressed between the welding electrodes 9 and 10 with the third pressure 3 between the welding electrodes 9 and 10. 3 is passed for a predetermined time ((f) in FIG. 3). At this time, since the inner coatings 1 and 1 are peeled off, this current becomes a welding current 13 unlike the above, and is directed from the welding electrode 9 to the welding electrode 10 via the flat conductors 3 and 3. It flows (in the direction of arrow 13 in the figure).

  Similarly, Joule heat is generated by this bypass current, and this heat generation melts the flat conductors 3 and 3, particularly the portion where the projection 7 a abuts. The melted parts of the bodies 3 and 3 are solidified to form the nugget 15. At this time, since the bypass conductor 7 has elasticity, the coated flat conductors 5 and 5 are pressed around the convex portions 7a and 7a.

  Thereafter, the pressure 3 applied between the welding electrodes 9 and 10 is gradually released. By doing so, the bypass conductor 7 returns to its original shape due to elasticity, and can be easily separated from the coated flat conductors 5 and 5.

  In this way, the coated flat conductors 3, 3 can be bonded together without peeling off the coating in advance.

  In the above embodiment, the pressure and the current are changed according to each step with reference to the time experimentally obtained in advance, but each step is changed based on the displacement of the interval between the welding electrodes 9 and 10. It can be changed accordingly.

  That is, the interval between the welding electrodes 9 and 10 is set according to each stage, and the displacement between the welding electrodes 9 and 10 is measured from the time when the joining process of the coated flat conductors 5 and 5 is started. By comparing with the set interval, it is determined whether the outer coating 1, 1 is the melt peeling step, the inner coating 1, the melt peeling step, or the flat conductors 3, 3 is joined. According to this determination, the pressure is changed to the first to third pressures 1, 2, and 3 and the currents 1, 2, and 3. In addition, various modifications are possible without changing the gist of the present invention.

DESCRIPTION OF SYMBOLS 1 Covering 3 Flat conductor 5 Covered flat conductor 7 Bypass conductor 7a Convex part 9, 10 Welding electrode 11 Bypass current 13 Welding current 15 Nugget

Claims (5)

The first and second coated flat conductors are overlapped in advance without peeling off the coating, sandwiched by a bypass conductor from the outside, and the first and second coated flat conductors are further bonded by a pair of welding electrodes. It is a joining method of a coated flat conductor in which the flat conductor is joined by melting and peeling the coating by passing an electric current between the welding electrodes.
A method of joining a coated flat conductor, wherein the pair of welding electrodes are sandwiched from the outside of the bypass conductor and a current flows while being pressed.   The bypass conductor is substantially U-shaped in cross section, and has a tip shape of the welding electrode from the outer side to the inner side at a position where the first and second coated flat plate conductors are sandwiched. 2. The method for joining coated flat conductors according to claim 1, wherein a convex portion having a hollow depth exceeding the thickness of the bypass conductor is formed.   The said bypass conductor is provided with spring property between the opposing clamping surfaces of a U-shaped cross section, The joining method of the flat conductor with a cover of Claim 1 characterized by the above-mentioned.   The width of the narrowest part of the sandwiching portion of the bypass conductor is determined by the thickness determined when the first and second coated flat conductors are overlapped according to the contraction of the coating material during pressurization. 2. The method of joining coated flat conductors according to claim 1, wherein the thickness is from a reduced value to 1.5 times the thickness of the overlapped layers.   According to the measurement result of the width between the first and second welding electrodes, a step of melting and peeling the outer coating, a step of melting and peeling the inner coating, and a step of welding the flat conductors to each other are determined. 2. A method for joining coated flat conductors according to claim 1, wherein an electric current adapted to is applied.

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