WO2024066389A1 - 太阳能电池片焊接方法 - Google Patents
太阳能电池片焊接方法 Download PDFInfo
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- WO2024066389A1 WO2024066389A1 PCT/CN2023/094515 CN2023094515W WO2024066389A1 WO 2024066389 A1 WO2024066389 A1 WO 2024066389A1 CN 2023094515 W CN2023094515 W CN 2023094515W WO 2024066389 A1 WO2024066389 A1 WO 2024066389A1
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- WIPO (PCT)
- Prior art keywords
- strip
- welding
- shaped conductive
- conductive connector
- battery cell
- Prior art date
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- 238000000034 method Methods 0.000 title claims abstract description 54
- 238000005476 soldering Methods 0.000 title abstract description 18
- 238000010438 heat treatment Methods 0.000 claims abstract description 19
- 238000003466 welding Methods 0.000 claims description 286
- 238000001179 sorption measurement Methods 0.000 claims description 12
- 210000004027 cell Anatomy 0.000 claims 57
- 238000010030 laminating Methods 0.000 claims 2
- 230000008569 process Effects 0.000 abstract description 14
- 238000004804 winding Methods 0.000 description 24
- 238000003825 pressing Methods 0.000 description 7
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 5
- 229910021419 crystalline silicon Inorganic materials 0.000 description 5
- 238000011161 development Methods 0.000 description 5
- 229910052710 silicon Inorganic materials 0.000 description 5
- 239000010703 silicon Substances 0.000 description 5
- 235000012431 wafers Nutrition 0.000 description 5
- 230000007246 mechanism Effects 0.000 description 4
- 238000013461 design Methods 0.000 description 3
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 101000827703 Homo sapiens Polyphosphoinositide phosphatase Proteins 0.000 description 1
- 102100023591 Polyphosphoinositide phosphatase Human genes 0.000 description 1
- 101100012902 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) FIG2 gene Proteins 0.000 description 1
- 101100233916 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) KAR5 gene Proteins 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 238000013082 photovoltaic technology Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
- 239000002210 silicon-based material Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
-
- 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
- H01L31/1804—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof comprising only elements of Group IV of the Periodic Table
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
-
- 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
- H01L31/0508—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 the interconnection means having a particular shape
-
- 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
Definitions
- the invention relates to the photovoltaic field, and in particular to a solar cell sheet welding method.
- the cells In the traditional crystalline silicon photovoltaic module manufacturing process, the cells must first be welded with welding ribbons and connected in series to form a cell string.
- the method of forming a string of cells includes: placing the welding ribbons and cells alternately in sequence, with the length of the welding ribbon being approximately twice the width of the cell, so that half of the welding ribbon is on the front of a cell and the other half is on the back of the adjacent cell, and a cell string containing multiple cells and the upper and lower surfaces (i.e., positive and negative electrodes) connected in series is formed in sequence.
- the cell string is then transferred to the welding station through an adsorption track, and generally multiple pressing wires or pressing blocks are used to compact the upper and lower welding ribbons with the cells, and the welding ribbons are welded to the surface electrodes of the cells through infrared heating.
- the battery cell When welding the soldering ribbon to the battery cell, the battery cell is generally placed flat on a flat supporting surface, and the soldering ribbon is mainly pressed together with a wire mesh or a pressing block perpendicular to the direction of the soldering ribbon to bring the soldering ribbon into contact with the battery cell to complete the welding.
- the pressure is applied at several scattered points on the soldering ribbon, and effective contact cannot be guaranteed at the parts without pressure.
- the soldering ribbon is heated, the unpressed parts of the soldering ribbon are very likely to stretch and twist, making welding impossible.
- a pressing wire presses multiple soldering ribbons vertically and crosswise at the same time, and the middle soldering ribbon is subjected to little force or the pressing wire is suspended in the air and no effective pressing is formed, resulting in invalid welding at this part. Therefore, the traditional welding process for welding soldering ribbons to battery cells results in many false welds.
- triangular welding ribbons and other special-shaped welding ribbons with optical advantages are increasingly used.
- the pattern for collecting current on the surface of the battery cell is a fine grid.
- the aspect ratio of the fine grid should be as large as possible; the pattern used for connecting the battery cells in series and collecting the fine grid current is the main grid.
- the cost of crystalline silicon accounts for about half. The thicker the silicon wafer is, the more crystalline silicon material is used, and the higher the cost of crystalline silicon is, so the application of thin silicon wafers is also one of the important directions for the development of photovoltaic modules.
- the diameter of the smallest round wire welding ribbon currently used is less than 0.2mm.
- Conventional welding process equipment mainly uses grippers to grab, pull, transfer, and place, and presses blocks to reduce the offset, rolling, and twisting of the welding ribbons.
- the thinner the silicon wafer the greater the warping of the cell after welding, the higher the risk of desoldering, hidden cracks, and splits, and the cell warping is not conducive to subsequent stacking and lamination processes.
- the mainstream cell thickness is about 150um.
- the battery process can achieve mass production of thinner and thinner cells. Components urgently need to match the thin-sheet welding process to achieve the goal of reducing the cost of component crystalline silicon.
- the object of the present invention is to provide a method for welding a solar cell, including welding a strip-shaped conductive connector on one side of a cell; the method comprises the following steps:
- a bearing surface for bonding the battery cells is provided on the outer surface of a welding carrier, and the bearing surface is an outwardly convex arc surface (which may be a circular arc surface);
- the battery cell on the carrying surface so that the battery cell does not protrude from the carrying surface to which it is attached, and one side surface of the strip-shaped conductive connector on the battery cell to be welded faces outward (that is, one side surface of the strip-shaped conductive connector on the battery cell to be welded faces away from the carrying surface);
- the strip-shaped conductive connector is stretched and fitted on the outer side surface of the battery cell (i.e., the side surface of the battery cell opposite to the supporting surface) along the circumference of the supporting surface, so that the strip-shaped conductive connector presses the battery cell onto the supporting surface;
- the strip-shaped conductive connecting member is heated to weld the strip-shaped conductive connecting member onto the battery sheet.
- the extension direction of the grid lines on the outer side surface of the battery cell is made perpendicular to the axis of the supporting surface; and when the strip-shaped conductive connector is stretched and attached to the outer side surface of the battery cell, the strip-shaped conductive connector is attached correspondingly to the grid lines on the outer side surface of the battery cell.
- the strip-shaped conductive connector is cut off to achieve a small segment of the strip-shaped conductive connector remaining on the battery cell, and the small segment of the strip-shaped conductive connector is used for series connection of the battery cell on which it is located (one end of the small segment of the strip-shaped conductive connector extends beyond the battery cell on which it is located, and the other end of the small segment of the strip-shaped conductive connector does not extend beyond the battery cell on which it is located); then the battery cell is removed from the carrying surface of the welding carrier (after the battery cell is removed, it can be turned over and the strip-shaped conductive connector can be welded to one side of the battery cell again).
- the strip-shaped conductive connectors are welded on one side of the battery cell to the front and back sides of the battery cell respectively, thereby completing the double-sided welding of the strip-shaped conductive connectors on the battery cell.
- the present invention can simplify the welding process of the strip-shaped conductive connecting member (welding wire or welding ribbon) and the battery cell, can optimize the effective contact between the strip-shaped conductive connecting member (welding wire or welding ribbon) and the battery cell, can improve the welding performance, and improve the welding efficiency.
- the bearing surface of the welding carrier of the present invention is an outwardly convex arc surface
- the battery cell is attached to the bearing surface
- the strip-shaped conductive connecting member (welding wire or welding strip) is tightly attached to the battery cell along the circumferential direction of the arc surface of the bearing surface; during welding, the battery cell and the strip-shaped conductive connecting member (welding wire or welding strip) are bent on the bearing surface along the circumferential direction of the arc surface of the bearing surface, so that the strip-shaped conductive connecting member (welding wire or welding strip) and the battery cell can be continuously and fully attached together, fully stressed, and fully in contact.
- the present invention can wind multiple rows of battery sheets at one time and weld multiple rows of battery sheets at one time, thereby improving welding efficiency.
- the present invention has less false welds; since the strip-shaped conductive connecting member (welding wire or welding strip) and the battery cell can be continuously attached and evenly stressed, welding is completed under the condition of full contact under stress, so the welding is complete and sufficient, which can greatly reduce the number of false welds.
- the battery cell has less warping after welding in the present invention.
- the battery cell is generally placed flat on a flat supporting surface, and then a strip-shaped conductive connector (welding wire or welding strip) is laid on the battery cell and welded. Since the thermal expansion of the strip-shaped conductive connector (welding wire or welding strip) is generally greater than that of the battery cell (silicon wafer), after the welding is cooled, the cooling and contraction of the strip-shaped conductive connector (welding wire or welding strip) will cause the battery cell to curl toward the outer side (i.e., the welding surface), thereby causing the battery cell to warp.
- the supporting surface is an outwardly convex arc surface, and the bending direction of the supporting surface is exactly opposite to the curling direction of the battery cell after the welding is cooled, which just suppresses the warping of the battery cell, so that the warping amplitude of the battery cell after welding is greatly reduced.
- the present invention uses a small number of reels of strip-shaped conductive connectors (welding wires or welding strips) that are easy to control; the present invention can use only one strip-shaped conductive connector to wind all the battery cells on the welding carrier, and the strip-shaped conductive connectors (welding wires or welding strips) of all the battery cells on the welding carrier are from the same reel, so the number of reels is greatly reduced, which can simplify the equipment space design, and the maintenance of strip-shaped conductive connectors (welding wires or welding strips) such as breakage and deviation, as well as operations such as line replacement, are also greatly simplified.
- the strip-shaped conductive connecting member (welding wire or welding strip) has little deviation; after the strip-shaped conductive connecting member (welding wire or welding strip) comes out from the reel, it can go directly to the battery cell, and be aligned with the grid line on the battery cell and tightened and fixed, which can completely eliminate the conventional actions of cutting, clamping, stretching, and transporting the strip-shaped conductive connecting member (welding wire or welding strip), and almost completely eliminates the possibility of deviation of the strip-shaped conductive connecting member (welding wire or welding strip).
- the present invention can weld a large number of strip-shaped conductive connector segments (the strip-shaped conductive connector segments are used for the serial connection of the battery slices on which they are located) on a single battery slice at one time, and can weld and form hundreds of strip-shaped conductive connector segments on a single battery slice at one time.
- the final number of strip-shaped conductive connector segments on a single battery slice is equal to the number of rotations of the side circumference of the welding carrier when winding the strip-shaped conductive connector, which is easy to control and implement.
- the present invention can be applied to the welding of special-shaped welding strips (such as triangular welding strips) that require direction identification; when winding the triangular welding strip, the bearing surface (the convex arc surface) can automatically correct the direction of the top angle of the triangular welding strip, so that the top angle of the triangular welding strip faces upward and the bottom surface faces downward, thereby realizing the welding of special-shaped welding strips such as triangular welding strips, and the triangular welding strip is not easy to flip over and has a high yield.
- special-shaped welding strips such as triangular welding strips
- 1 to 5 are schematic diagrams of the present invention.
- the present invention provides a solar cell welding method, which completes the double-sided welding of the strip-shaped conductive connector on the solar cell by welding the strip-shaped conductive connector on the front and back sides of the solar cell on the single side.
- the single-sided welding of the strip-shaped conductive connector of the battery cell comprises the following steps:
- a supporting surface for bonding the battery cells is provided on the outer surface of a welding carrier, so that the supporting surface is an outwardly convex arc surface (which may be a circular arc surface), and the arc height of the arc surface is not greater than one quarter of the arc length;
- the battery cell on the carrying surface so that the battery cell does not protrude from the carrying surface to which it is attached, and one side surface of the strip-shaped conductive connector on the battery cell to be welded faces outward (that is, one side surface of the strip-shaped conductive connector on the battery cell to be welded faces away from the carrying surface);
- the strip-shaped conductive connector is stretched and attached to the outer side surface of the battery cell (i.e., the side surface of the battery cell opposite to the supporting surface) along the circumference of the supporting surface, and then the strip-shaped conductive connector presses the battery cell onto the supporting surface;
- the strip-shaped conductive connector is heated by direct heating, infrared heating or hot air heating, so that the strip-shaped conductive connector is welded on the battery cell;
- the strip-shaped conductive connector is cut off to achieve a small segment of the strip-shaped conductive connector remaining on the battery cell, and the small segment of the strip-shaped conductive connector is used for the series connection of the battery cell where it is located (one end of the small segment of the strip-shaped conductive connector exceeds the battery cell where it is located, and the other end of the small segment of the strip-shaped conductive connector does not exceed the battery cell where it is located);
- the battery cell is removed from the carrying surface of the welding carrier (after the battery cell is removed, it can be turned over and the strip-shaped conductive connector can be welded to the battery cell on one side again).
- the carrying surface can be endowed with a vacuum adsorption function (for example, the carrying surface can be evenly distributed with air suction ports, and vacuum adsorption can be performed through the air suction ports); and when the battery cell is attached to the carrying surface, the battery cell is vacuum adsorbed through the carrying surface, so that the battery cell is stably adsorbed and attached to the carrying surface.
- a vacuum adsorption function for example, the carrying surface can be evenly distributed with air suction ports, and vacuum adsorption can be performed through the air suction ports
- the welding carrier can be provided with a heating function, and the battery cell on the carrying surface and the strip-shaped conductive connector on the outer surface of the battery cell can be heated by the welding carrier, so that the strip-shaped conductive connector is welded to the battery cell.
- the strip-shaped conductive connector can be a welding wire or a welding strip; if the strip-shaped conductive connector has a flat bottom surface for welding with the battery cell (such as a cross-sectional shape of the strip-shaped conductive connector is a triangle or a rectangle), when the strip-shaped conductive connector is stretched and attached to the outer side of the battery cell, the flat bottom surface of the strip-shaped conductive connector is directed toward the outer side of the battery cell, so that the strip-shaped conductive connector is stably attached to the outer side of the battery cell;
- the strip-shaped conductive connector can be a triangular welding strip; when the strip-shaped conductive connector (triangular welding strip) is stretched and fitted tightly to the outer side of the battery cell, the bottom surface of the triangular welding strip is directed toward the outer side surface of the battery cell (that is, the top angle of the triangular welding strip is opposite to the outer side surface of the battery cell), so that the strip-shaped conductive connector (triangular welding strip) is stably fitted to the outer side surface of the battery cell.
- the strip-shaped conductive connector can be stretched and fitted to the outer surface of the battery cell by allowing the strip-shaped conductive connector to cross the battery cell along the circumference of the supporting surface and pulling the sections of the strip-shaped conductive connector located outside the two sides of the battery cell toward the welding carrier and/or the supporting surface.
- the welding carrier may be provided with a rotating shaft, and the outer surface of the welding carrier may include a side circumferential surface surrounding the rotating shaft; the bearing surface may be located on the side circumferential surface of the welding carrier, and the axis of the bearing surface may be parallel or colinear with the axis of the rotating shaft; and the strip-shaped conductive connector may be tightly attached to the outer surface of the battery cell by wrapping the strip-shaped conductive connector around the circumferential surface of the welding carrier and tightening the battery cell on the side circumferential surface of the welding carrier;
- the axis of the rotating shaft is located on the center line of the welding carrier, when the strip-shaped conductive connector is wound along the circumferential direction of the side surface of the welding carrier and the battery sheet on the side surface of the welding carrier is tightly wound, the side surface of the welding carrier is rotated around the axis of the rotating shaft, which can facilitate the winding of the strip-shaped conductive connector.
- only one strip-shaped conductive connection piece may be used to wrap the strip-shaped conductive connection piece around the circumference of the side surface of the welding carrier and tightly wrap the battery sheet on the side surface of the welding carrier;
- multiple rows of bearing surfaces can be arranged on the side circumferential surface of the welding carrier, and each row of bearing surfaces is arranged in sequence along the circumference of the side circumferential surface of the welding carrier, and the bearing surfaces in the same row are arranged in sequence along the axial direction of the rotating shaft, and the axis center of each bearing surface is parallel or colinear with the axis center of the rotating shaft; more specifically, multiple rows of bearing surfaces can be evenly distributed along the circumference of the side circumferential surface of the welding carrier, and even each bearing surface can be evenly distributed on the side circumferential surface of the welding carrier; battery cells are respectively bonded on multiple rows of bearing surfaces so that multiple rows of battery cells can be wound at one time and multiple rows of battery cells can be welded at one time, which can improve welding efficiency.
- this embodiment provides a method for welding a solar cell, by welding a strip-shaped conductive connector on the front and back sides of the cell, respectively, to complete the double-sided welding of the strip-shaped conductive connector on the cell; and a plurality of grid lines parallel to each other are respectively provided on the front and back sides of the cell;
- the single-sided welding of the strip-shaped conductive connector of the battery cell comprises the following steps:
- a welding carrier with a rotating shaft is provided, so that the axis of the rotating shaft is located on the center line of the welding carrier, and the welding carrier has a side circumferential surface surrounding the rotating shaft; a pair of bearing surfaces for battery cells to be attached are provided on the side circumferential surface of the welding carrier, so that the pair of bearing surfaces are both convex arc surfaces (can be circular arc surfaces), the pair of bearing surfaces are symmetrically arranged, and the axis centers of the pair of bearing surfaces are parallel or colinear with the axis center of the rotating shaft; the pair of bearing surfaces are respectively provided with a vacuum adsorption function (for example, the pair of bearing surfaces are respectively provided with exhaust ports, and vacuum adsorption can be performed through the exhaust ports); the welding carrier has a heating function that can heat the pair of bearing surfaces;
- the battery cells are respectively attached to the pair of supporting surfaces so that the battery cells do not extend beyond the supporting surfaces to which they are attached, so that one side surface of the strip-shaped conductive connector to be welded on the battery cell faces outward (that is, one side surface of the strip-shaped conductive connector to be welded on the battery cell is opposite to the corresponding supporting surface), and the extension direction of the grid lines on the outer side surface of the battery cell (that is, the side surface of the battery cell opposite to the corresponding supporting surface) is perpendicular to the axis of the corresponding supporting surface (that is, perpendicular to the axis of the rotating shaft); and the battery cells on the supporting surface are vacuum-adsorbed so that the battery cells are stably adsorbed and attached to the corresponding supporting surface;
- the strip-shaped conductive connector is wound around the circumferential direction of the side surface of the welding carrier and the battery cells on the side surface of the welding carrier are tightly wound, so that the strip-shaped conductive connector is tightly fitted on the outer side surface of each battery cell; and when winding the strip-shaped conductive connector, the strip-shaped conductive connector is made to correspond to the grid lines on the outer side surface of the battery cell; specifically, only one strip-shaped conductive connector can be used for winding; the strip-shaped conductive connector can be a flat welding strip, and when winding the flat welding strip, the bottom surface of the flat welding strip is made to face the outer side surface of the battery cell, so that the flat welding strip is stably fitted on the corresponding grid lines on the outer side surface of the battery cell; and when winding the strip-shaped conductive connector, the side surface of the welding carrier is rotated around the axis of the rotating shaft, which can facilitate the winding of the strip-shaped conductive connector; more specifically, the rotating shaft can be driven to rotate around its own axis by
- the strip-shaped conductive connector is heated, so that the strip-shaped conductive connector is synchronously welded on each battery cell; specifically: 1) the battery cells on each carrier surface and the strip-shaped conductive connector on the outer side of the battery cell can be heated by a welding carrier, so that the strip-shaped conductive connector is synchronously welded on each battery cell; 2) the outer side surface of each battery cell and the strip-shaped conductive connector on the outer side can also be heated by infrared heating (such as using linear infrared to irradiate the outer side surface of each battery cell and the strip-shaped conductive connector on the outer side surface), so that the strip-shaped conductive connector is synchronously welded on each battery cell;
- the strip-shaped conductive connector is cut off, so that a small segment of the strip-shaped conductive connector remains on each battery cell, and the small segment of the strip-shaped conductive connector is used for connecting the battery cells where it is located (one end of the small segment of the strip-shaped conductive connector exceeds the battery cell where it is located, and the other end of the small segment of the strip-shaped conductive connector does not exceed the battery cell where it is located);
- each battery cell is removed from the corresponding supporting surface of the welding carrier (after the battery cell is removed, it can be turned over and the strip-shaped conductive connector can be welded to the battery cell on one side again).
- this embodiment provides a method for welding a solar cell, by welding a strip-shaped conductive connector on the front and back sides of the cell, respectively, to complete the double-sided welding of the strip-shaped conductive connector on the cell; and a plurality of grid lines parallel to each other are respectively provided on the front and back sides of the cell;
- the single-sided welding of the strip-shaped conductive connector of the battery cell comprises the following steps:
- a welding carrier with a rotating shaft is provided, and the axis of the rotating shaft is located on the center line of the welding carrier;
- the welding carrier has a side circumferential surface surrounding the rotating shaft, and the side circumferential surface of the welding carrier is surrounded by a plurality of bearing surfaces for bonding the battery cells
- the main body of the welding carrier may be a prism coaxial with the rotating shaft
- the plurality of bearing surfaces are all convex arc surfaces (may be circular arc surfaces), and the axis centers of the plurality of bearing surfaces are parallel to or colinear with the axis center of the rotating shaft
- the plurality of bearing surfaces are respectively provided with a vacuum adsorption function (for example, the plurality of bearing surfaces are respectively provided with exhaust ports, and vacuum adsorption can be performed through the exhaust ports);
- the welding carrier has a heating function that can heat the plurality of bearing surfaces;
- the battery cells are respectively attached to the multiple carrying surfaces so that the battery cells do not extend beyond the carrying surfaces to which they are attached, so that one side surface of the strip-shaped conductive connector to be welded on the battery cell faces outward (that is, one side surface of the strip-shaped conductive connector to be welded on the battery cell is opposite to the corresponding carrying surface), and the extension direction of the grid lines on the outer side surface of the battery cell (that is, the side surface of the battery cell opposite to the corresponding carrying surface) is perpendicular to the axis of the corresponding carrying surface (that is, perpendicular to the axis of the rotating shaft); and the battery cell on the carrying surface is vacuum-adsorbed so that the battery cell is stably adsorbed and attached to the corresponding carrying surface;
- the strip-shaped conductive connector is wound around the circumferential direction of the side surface of the welding carrier and the battery cells on the side surface of the welding carrier are tightly wound, so that the strip-shaped conductive connector is tightly fitted on the outer surface of each battery cell; and when winding the strip-shaped conductive connector, the strip-shaped conductive connector is correspondingly fitted with the grid lines on the outer side surface of the battery cell; specifically, only one strip-shaped conductive connector can be used for winding; the strip-shaped conductive connector can be a round wire welding strip; and when winding the strip-shaped conductive connector, the side surface of the welding carrier is rotated around the axis of the rotating shaft, which can facilitate the winding of the strip-shaped conductive connector; more specifically, the rotating shaft can be driven to rotate around its own axis by an external mechanism (such as a motor), and the welding carrier can be driven to rotate as a whole by the rotating shaft, thereby realizing the rotation of the side surface of the welding carrier around the axis of the rotating shaft;
- an external mechanism such
- the strip-shaped conductive connector is heated, so that the strip-shaped conductive connector is synchronously welded on each battery cell; specifically: 1) the battery cells on each carrying surface and the strip-shaped conductive connector on the outer side of the battery cell can be heated by a welding carrier, so that the strip-shaped conductive connector is synchronously welded on each battery cell; 2) the outer side surface of each battery cell and the strip-shaped conductive connector on the outer side can also be heated by hot air heating (such as using hot air to blow the outer side surface of each battery cell and the strip-shaped conductive connector on the outer side surface), so that the strip-shaped conductive connector is synchronously welded on each battery cell;
- the strip-shaped conductive connector is cut off, so that a small segment of the strip-shaped conductive connector remains on each battery cell, and the small segment of the strip-shaped conductive connector is used for connecting the battery cells where it is located (one end of the small segment of the strip-shaped conductive connector exceeds the battery cell where it is located, and the other end of the small segment of the strip-shaped conductive connector does not exceed the battery cell where it is located);
- each battery cell is removed from the corresponding supporting surface of the welding carrier (after the battery cell is removed, it can be turned over and the strip-shaped conductive connector can be welded to the battery cell on one side again).
- this embodiment provides a method for welding a solar cell, by welding a strip-shaped conductive connector on the front and back sides of the cell, respectively, to complete the double-sided welding of the strip-shaped conductive connector on the cell; and a plurality of grid lines parallel to each other are respectively provided on the front and back sides of the cell;
- the single-sided welding of the strip-shaped conductive connector of the battery cell comprises the following steps:
- a welding carrier with a rotating shaft is provided, and the axis of the rotating shaft is located on the center line of the welding carrier;
- the welding carrier has a side circumferential surface surrounding the rotating shaft, and the side circumferential surface of the welding carrier is a circumferential surface coaxial with the rotating shaft (the main body of the welding carrier can be a cylinder coaxial with the rotating shaft);
- a plurality of arc surface areas are divided on the side circumferential surface of the welding carrier and are sequentially spaced along the circumferential direction of the side circumferential surface, and the plurality of arc surface areas are evenly distributed along the circumferential direction of the side circumferential surface of the welding carrier;
- each arc surface area is a bearing surface for battery cells to be attached;
- each bearing surface has a vacuum adsorption function (for example, each bearing surface is evenly distributed with an exhaust port, and vacuum adsorption can be performed through the exhaust port);
- the welding carrier has a heating function that can heat each bearing surface;
- the battery cells are respectively attached to each carrying surface so that the battery cells do not extend beyond the carrying surface to which they are attached, so that one side surface of the strip-shaped conductive connector to be welded on the battery cell faces outward (that is, one side surface of the strip-shaped conductive connector to be welded on the battery cell is opposite to the corresponding carrying surface), and the extension direction of the grid lines on the outer side surface of the battery cell (that is, the side surface of the battery cell opposite to the corresponding carrying surface) is perpendicular to the axis of the corresponding carrying surface (that is, perpendicular to the axis of the rotating shaft); and the battery cells on the carrying surface are vacuum-adsorbed so that the battery cells are stably adsorbed and attached to the corresponding carrying surface;
- the strip-shaped conductive connector is wound around the circumferential surface of the welding carrier and the battery cells on the circumferential surface of the welding carrier are tightly wound, so that the strip-shaped conductive connector is tightly fitted on the outer side of each battery cell; and when the strip-shaped conductive connector is wound, the strip-shaped conductive connector is correspondingly fitted with the grid lines on the outer side of the battery cell; specifically, only one strip-shaped conductive connector can be used for winding; the strip-shaped conductive connector can be a triangular welding strip, and when the triangular welding strip is wound, the bottom surface of the triangular welding strip is facing the outer side of the battery cell (that is, the top angle of the triangular welding strip is opposite to the outer side of the battery cell), so that the triangular welding strip is stably fitted on the outer side of the battery cell corresponding grid line; and in the process of winding the triangular welding strip, the state in which the bottom surface of the triangular welding strip is attached to the outer side surface of the battery cell is the most
- the strip-shaped conductive connector is heated, so that the strip-shaped conductive connector is synchronously welded on each battery cell; specifically: 1) the battery cells on each carrying surface and the strip-shaped conductive connector on the outer side of the battery cell can be heated by a welding carrier, so that the strip-shaped conductive connector is synchronously welded on each battery cell; 2) the outer side of each battery cell and the strip-shaped conductive connector on the outer side can also be heated by hot air heating (such as using hot air to blow the outer side of each battery cell and the strip-shaped conductive connector on the outer side), so that the strip-shaped conductive connector is synchronously welded on each battery cell;
- the strip-shaped conductive connector is cut off, so that a small segment of the strip-shaped conductive connector remains on each battery cell, and the small segment of the strip-shaped conductive connector is used for connecting the battery cells where it is located (one end of the small segment of the strip-shaped conductive connector exceeds the battery cell where it is located, and the other end of the small segment of the strip-shaped conductive connector does not exceed the battery cell where it is located);
- each battery cell is removed from the corresponding supporting surface of the welding carrier (after the battery cell is removed, it can be turned over and the strip-shaped conductive connector can be welded to the battery cell on one side again).
- this embodiment provides a method for welding a solar cell, by welding a strip-shaped conductive connector on the front and back sides of the cell, respectively, to complete the double-sided welding of the strip-shaped conductive connector on the cell; and a plurality of grid lines parallel to each other are respectively provided on the front and back sides of the cell;
- the single-sided welding of the strip-shaped conductive connector of the battery cell comprises the following steps:
- a welding carrier with a rotating shaft is provided, so that the axis of the rotating shaft is located on the center line of the welding carrier; the welding carrier has a side circumferential surface surrounding the rotating shaft, and the side circumferential surface of the welding carrier is a circumferential surface coaxial with the rotating shaft (the main body of the welding carrier can be a cylinder coaxial with the rotating shaft); a plurality of rows of arc surface areas are divided on the side circumferential surface of the welding carrier, so that each row of arc surface areas is sequentially spaced along the circumferential direction of the side circumferential surface of the welding carrier, and the arc surface areas in the same row are sequentially spaced along the axial direction of the rotating shaft; each arc surface area is a bearing surface for battery cells to be attached; each bearing surface has a vacuum adsorption function (for example, each bearing surface is evenly distributed with exhaust ports, and vacuum adsorption can be performed through the exhaust ports); the welding carrier has a heating function that can heat each bearing surface;
- the battery cells are respectively attached to each carrying surface so that the battery cells do not extend beyond the carrying surface to which they are attached, so that one side surface of the strip-shaped conductive connector to be welded on the battery cell faces outward (that is, one side surface of the strip-shaped conductive connector to be welded on the battery cell is opposite to the corresponding carrying surface), and the extension direction of the grid lines on the outer side surface of the battery cell (that is, the side surface of the battery cell opposite to the corresponding carrying surface) is perpendicular to the axis of the corresponding carrying surface (that is, perpendicular to the axis of the rotating shaft); and the battery cells on the carrying surface are vacuum-adsorbed so that the battery cells are stably adsorbed and attached to the corresponding carrying surface;
- the strip-shaped conductive connector is wound around the circumferential surface of the welding carrier and the battery cells on the circumferential surface of the welding carrier are tightly wound, so that the strip-shaped conductive connector is tightly fitted on the outer side of each battery cell; and when the strip-shaped conductive connector is wound, the strip-shaped conductive connector is correspondingly fitted with the grid lines on the outer side of the battery cell; specifically, only one strip-shaped conductive connector can be used for winding; the strip-shaped conductive connector can be a triangular welding strip, and when the triangular welding strip is wound, the bottom surface of the triangular welding strip is facing the outer side of the battery cell (that is, the top angle of the triangular welding strip is opposite to the outer side of the battery cell), so that the triangular welding strip is stably fitted on the outer side of the battery cell corresponding grid line; and in the process of winding the triangular welding strip, the state in which the bottom surface of the triangular welding strip is attached to the outer side surface of the battery cell is the most
- the strip-shaped conductive connector is heated, so that the strip-shaped conductive connector is synchronously welded on each battery cell; specifically: 1) the battery cells on each carrier surface and the strip-shaped conductive connector on the outer side of the battery cell can be heated by a welding carrier, so that the strip-shaped conductive connector is synchronously welded on each battery cell; 2) the outer side surface of each battery cell and the strip-shaped conductive connector on the outer side can also be heated by infrared heating (such as using linear infrared to irradiate the outer side surface of each battery cell and the strip-shaped conductive connector on the outer side surface), so that the strip-shaped conductive connector is synchronously welded on each battery cell;
- the strip-shaped conductive connector is cut off, so that a small segment of the strip-shaped conductive connector remains on each battery cell, and the small segment of the strip-shaped conductive connector is used for connecting the battery cells where it is located (one end of the small segment of the strip-shaped conductive connector exceeds the battery cell where it is located, and the other end of the small segment of the strip-shaped conductive connector does not exceed the battery cell where it is located);
- each battery cell is removed from the corresponding supporting surface of the welding carrier (after the battery cell is removed, it can be turned over and the strip-shaped conductive connector can be welded to the battery cell on one side again).
- Embodiment 4 can wind multiple rows of battery cells at one time and weld multiple rows of battery cells at one time, which can improve welding efficiency.
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Abstract
本发明公开了一种太阳能电池片焊接方法，包括电池片单面焊接条状导电连接件；所述电池片单面焊接条状导电连接件，包括如下步骤：在一焊接载具的外表面设置供电池片贴合的承载面，且使承载面为外凸的弧面；在承载面上贴合电池片，且使电池片上待焊接条状导电连接件的一侧表面朝外；将条状导电连接件绷紧贴合在电池片的外侧面上；对条状导电连接件加热，使条状导电连接件焊接在电池片上。本发明可简化条状导电连接件与电池片的焊接工艺，可优化条状导电连接件与电池片的有效接触，可提升焊接性能，提高焊接效率。
Description
本发明涉及光伏领域，具体涉及一种太阳能电池片焊接方法。
传统晶硅光伏组件制作工艺中，首先要对电池片焊接焊带并串联形成电池串。具体的，电池片形成串的方法包括：彼此相间的将焊带和电池片依次摆放，焊带的长度大约为电池片宽度的2倍，使得焊带的一半在一片电池片的正面、另一半在相邻片电池片的背面，依次形成包含多个电池片且上下面（即正负极）串联的电池串，电池串再通过吸附履带传送至焊接工位，一般使用多根压丝或压块将上下焊带与电池片压实，通过红外加热，将焊带焊接到电池片表面电极上。
电池片焊接焊带时，一般将电池片平置在平直承载面上，主要通过垂直于焊带方向的丝网或者压块与焊带压合，将焊带与电池片接触在一起完成焊接，施压部位为焊带上分散的几个点，没有施压的部位不能保证有效接触，特别是当焊带受热后，焊带未受压部位极易伸长扭曲，无法实现焊接；另外，一根压丝同时垂直交叉压合多根焊带，中部焊带受力小或者压丝悬空未形成有效压合，致使该部位焊接无效，所以电池片焊接焊带的传统焊接工艺虚焊多。
另外，在光伏组件中，具备光学优势的三角焊带等异形结构焊带应用越来越多，传统焊接工艺中通过夹取、转运、压合等方式很难确保三角焊带等异形焊带方向的一致性，很难确保三角焊带等异形焊带在整个电池片表面不翻转，所以异形焊带，特别是超细异形焊带的应用，需要有新的焊接方法和工艺来有效控制焊带的朝向一致性，以实现异形焊带的有效焊接。
另外，在光伏技术的发展过程中，更多主栅和薄片化仍然是电池组件技术发展的重要方向。电池片表面收集电流的图形为细栅，综合考虑遮光和电流传输损耗，细栅高宽比应尽量大；用于电池片串联及汇集细栅电流的图形为主栅，一定程度上，主栅数量越多，细栅银耗可以越少、图形可以越窄，且细栅热阻损失降低，使得电池片银耗降低同时效率提升，所以电池片主栅一直在朝着越来越多的方向发展。在光伏组件成本中，晶硅成本占比约一半，使用硅片越厚，晶硅材料越多，晶硅成本越高，所以薄硅片的应用也是光伏组件发展重要方向之一。
电池片主栅越多，需要的焊带数量越多、越细，目前使用最小圆丝焊带的直径已小于0.2mm，210mm宽度的电池片上焊带有30根之多，常规焊接工艺设备主要采用夹爪抓取、拉升、转运、摆放，并通过压块压合来降低焊带的偏移、滚动和扭曲。如此多而细的焊带，使用传统焊接工艺的控制难度急剧上升：1）一根焊带对应一个卷轴，卷轴数量多，卷轴位置设计、同时放线、布线、走线等难度大；2）自动化也需要配套缩短焊丝及电池的流转路径、焊带定位以及各动作间的前后相关匹配性设计；3）设备断线等故障影响也大大增加，故障后恢复难，设备维护也难。
另外，硅片薄片化发展路线上，硅片厚度越薄，焊接完电池片翘曲越大，脱焊、隐裂、裂片风险越高，电池翘曲也不利于后续层叠、层压等工序。目前主流电池片厚度为150um左右，随着电池技术发展，电池工艺可以实现越来越薄的电池片量产，组件急需与其匹配的薄片焊接工艺，以便共同达成降低组件晶硅成本的目的。
本发明的目的在于提供一种太阳能电池片焊接方法，包括电池片单面焊接条状导电连接件；所述电池片单面焊接条状导电连接件，包括如下步骤：
在一焊接载具的外表面设置供电池片贴合的承载面，且使承载面为外凸的弧面（可以是圆弧面）；
在承载面上贴合电池片，使电池片不超出其所贴合的承载面，且使电池片上待焊接条状导电连接件的一侧表面朝外（也即使电池片上待焊接条状导电连接件的一侧表面与承载面相背）；
沿承载面的周向将条状导电连接件绷紧贴合在电池片的外侧面（即电池片上与承载面相背的一侧表面）上，进而条状导电连接件将电池片压实在承载面上；
对条状导电连接件加热，使条状导电连接件焊接在电池片上。
优选的，若电池片的外侧面设有多个相互平行的栅线；则实现在承载面上贴合电池片时，使电池片外侧面栅线的延伸方向与承载面的轴心垂直；且实现将条状导电连接件绷紧贴合在电池片的外侧面上时，使条状导电连接件与电池片外侧面的栅线对应贴合。
优选的，实现使条状导电连接件焊接在电池片上之后，将条状导电连接件截断，实现在电池片上残留条状导电连接件小段，且条状导电连接件小段用于其所在电池片的串接（条状导电连接件小段的一端超出其所在的电池片，条状导电连接件小段的另一端不超出其所在的电池片）；然后将电池片从焊接载具的承载面上取下（电池片取下后可以翻转换一面再实施一次电池片单面焊接条状导电连接件）。
优选的，通过对电池片的正背面分别实施电池片单面焊接条状导电连接件，完成电池片双面焊接条状导电连接件。
条状导电连接件的具体选择，将条状导电连接件绷紧贴合在电池片的外侧面上的具体实现方式，对条状导电连接件加热的具体实现方式，以及其他相关的具体内容，参见实施例。
本发明的优点和有益效果在于：
本发明可简化条状导电连接件（焊丝或焊带）与电池片的焊接工艺，可优化条状导电连接件（焊丝或焊带）与电池片的有效接触，可提升焊接性能，提高焊接效率。
本发明焊接载具的承载面为外凸的弧面，电池片贴合在承载面上，且条状导电连接件（焊丝或焊带）沿承载面的弧面周向绷紧贴合在电池片上；焊接时，电池片和条状导电连接件（焊丝或焊带）在承载面上沿承载面的弧面周向弯曲，使得条状导电连接件（焊丝或焊带）与电池片能连续充分的贴合在一起、充分受力、充分接触。
本发明可以一次缠绕多排电池片和一次焊接多排电池片，可提高焊接效率。
本发明还具有如下特点：
本发明虚焊少；由于条状导电连接件（焊丝或焊带）与电池片能连续贴合、受力均匀，焊接都是在受力完全接触的情况下完成，所以焊接完整、充分，可大大降低虚焊情况。
本发明焊接后电池片翘曲小；目前一般将电池片平置在平直承载面上，然后在电池片上铺设条状导电连接件（焊丝或焊带）并进行焊接，由于条状导电连接件（焊丝或焊带）热膨胀一般比电池片（硅片）大，所以焊接冷却后，条状导电连接件（焊丝或焊带）的冷却收缩会使电池片朝外侧面（即焊接面）卷曲，进而使电池片产生翘曲；而本发明中承载面为外凸的弧面，且承载面的弯曲方向正好与焊接冷却后电池片的卷曲方向相反，这样正好抑制了电池片的翘曲，使得焊接完后电池片翘曲幅度大大减小。
本发明条状导电连接件（焊丝或焊带）的卷轴使用数量少、易控制；本发明可以仅采用一条条状导电连接件进行焊接载具上所有电池片的缠绕，焊接载具上所有电池片的条状导电连接件（焊丝或焊带）都来源于同一卷轴，所以卷轴数量大大降低，进而可使设备空间设计简化，条状导电连接件（焊丝或焊带）断线、偏移等故障维护以及换线等操作也简化很多。
本发明缠绕过程中，条状导电连接件（焊丝或焊带）偏移少；条状导电连接件（焊丝或焊带）从卷轴出线后可直接到电池片，并与电池片上的栅线对准并绷紧固定，可完全省去条状导电连接件（焊丝或焊带）裁切、夹取、拉伸、转运等常规动作，几乎完全杜绝了条状导电连接件（焊丝或焊带）的偏移可能。
本发明单个电池片上一次可焊接形成条状导电连接件小段（条状导电连接件小段用于其所在电池片的串接）的数量多，可在单个电池片一次焊接并形成上百条条状导电连接件小段。理论上，单个电池片上条状导电连接件小段的最终数量与缠绕条状导电连接件时焊接载具侧周面的旋转圈数相等，易于控制和实施。
本发明可应用于需要识别方向的异形结构焊带（如三角焊带）焊接；缠绕三角焊带时，承载面（外凸的弧面）能自动修正三角焊带顶角方向，使得三角焊带顶角朝上、底面朝下，可实现如三角焊带等异形焊带的焊接，三角焊带不易翻转、良率高。
图1至图5是本发明的示意图。
下面结合附图和实施例，对本发明的具体实施方式作进一步描述。以下实施例仅用于更加清楚地说明本发明的技术方案，而不能以此来限制本发明的保护范围。
本发明提供一种太阳能电池片焊接方法，通过对电池片的正背面分别实施电池片单面焊接条状导电连接件，完成电池片双面焊接条状导电连接件；
所述电池片单面焊接条状导电连接件，包括如下步骤：
在一焊接载具的外表面设置供电池片贴合的承载面，使承载面为外凸的弧面（可以是圆弧面），且使弧面的弧高不大于弧长的四分之一；
在承载面上贴合电池片，使电池片不超出其所贴合的承载面，且使电池片上待焊接条状导电连接件的一侧表面朝外（也即使电池片上待焊接条状导电连接件的一侧表面与承载面相背）；
然后沿承载面的周向将条状导电连接件绷紧贴合在电池片的外侧面（即电池片上与承载面相背的一侧表面）上，进而条状导电连接件将电池片压实在承载面上；
然后通过直接加热、红外加热或热风加热等方式，实现对条状导电连接件加热，使条状导电连接件焊接在电池片上；
然后将条状导电连接件截断，实现在电池片上残留条状导电连接件小段，且条状导电连接件小段用于其所在电池片的串接（条状导电连接件小段的一端超出其所在的电池片，条状导电连接件小段的另一端不超出其所在的电池片）；
然后将电池片从焊接载具的承载面上取下（电池片取下后可以翻转换一面再实施一次电池片单面焊接条状导电连接件）。
具体的：
1）可以使承载面具有真空吸附功能（如承载面可以均布抽气口，通过抽气口进行真空吸附）；且实现在承载面上贴合电池片时，通过承载面对电池片进行真空吸附，以使电池片稳定吸附贴合在承载面上。
2）可以使焊接载具具有加热功能，通过焊接载具对承载面上的电池片及电池片外侧面上的条状导电连接件进行加热，使条状导电连接件焊接在电池片上。
3）若电池片的外侧面设有栅线；则实现在承载面上贴合电池片时，使电池片外侧面栅线的延伸方向与承载面的轴心垂直；且实现将条状导电连接件绷紧贴合在电池片的外侧面上时，使条状导电连接件与电池片外侧面的栅线对应贴合。
4）条状导电连接件可以采用焊丝或焊带；若条状导电连接件具有用于与电池片焊接的平直底面（如条状导电连接件的横截面形状为三角形或矩形），则实现将条状导电连接件绷紧贴合在电池片的外侧面上时，使条状导电连接件的平直底面朝向电池片的外侧面，以使条状导电连接件稳定贴合在电池片的外侧面上；
比如，条状导电连接件可以采用三角焊带；则实现将条状导电连接件（三角焊带）绷紧贴合在电池片的外侧面上时，使三角焊带的底面朝向电池片的外侧面（也即使三角焊带的顶角与电池片的外侧面相背），以使条状导电连接件（三角焊带）稳定贴合在电池片的外侧面上。
5）如图1所示，可以通过使条状导电连接件沿承载面的周向跨过电池片，并将条状导电连接件位于电池片两侧外部的区段向焊接载具和/或承载面拉紧的方式，实现将条状导电连接件绷紧贴合在电池片的外侧面上。
6）如图2至图5所示，还可以使焊接载具设有转轴，且使焊接载具的外表面包括围绕转轴的侧周面；使承载面位于焊接载具的侧周面上，并使承载面的轴心与转轴的轴心平行或共线；且通过使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片的方式，实现将条状导电连接件绷紧贴合在电池片的外侧面上；
另外，若使转轴的轴心位于焊接载具的中心线上；则实现使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片时，使焊接载具侧周面围绕转轴的轴心转动，可以方便条状导电连接件的缠绕；
而且，可以仅采用一条条状导电连接件，实现使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片；
更优选的，可以在焊接载具的侧周面上设置多排承载面，使各排承载面沿焊接载具侧周面的周向依次设置，使同一排的承载面沿转轴的轴向依次设置，并使各承载面的轴心与转轴的轴心平行或共线；更具体的，可以使多排承载面沿焊接载具侧周面的周向均布，甚至可以使各承载面在焊接载具的侧周面上均布；在多排承载面上分别贴合电池片，以便一次缠绕多排电池片和一次焊接多排电池片，可提高焊接效率。
本发明采用缠绕条状导电连接件方式的具体实施例如下：
如图2所示，本实施例提供一种太阳能电池片焊接方法，通过对电池片的正背面分别实施电池片单面焊接条状导电连接件，完成电池片双面焊接条状导电连接件；且电池片的正背面分别设有多个相互平行的栅线；
所述电池片单面焊接条状导电连接件，包括如下步骤：
设置一具有转轴的焊接载具，使转轴的轴心位于焊接载具的中心线上，且使焊接载具具有围绕转轴的侧周面；在焊接载具的侧周面上设置一对可供电池片贴合的承载面，使该对承载面都为外凸的弧面（可以是圆弧面），使该对承载面对称设置，并使该对承载面的轴心都与转轴的轴心平行或共线；使该对承载面分别具有真空吸附功能（如该对承载面分别均布抽气口，可以通过抽气口进行真空吸附）；使焊接载具具有可以加热该对承载面的加热功能；
在该对承载面上分别贴合电池片，使电池片不超出其所贴合的承载面，使电池片上待焊接条状导电连接件的一侧表面朝外（也即使电池片上待焊接条状导电连接件的一侧表面与对应的承载面相背），并使电池片外侧面（即电池片上与对应承载面相背的一侧表面）上栅线的延伸方向与对应承载面的轴心垂直（也即与转轴的轴心垂直）；且通过承载面对其上的电池片进行真空吸附，以使电池片稳定吸附贴合在对应的承载面上；
然后通过使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片的方式，实现将条状导电连接件绷紧贴合在各电池片的外侧面上；且缠绕条状导电连接件时，使条状导电连接件与电池片外侧面的栅线对应贴合；具体的，可以仅采用一条条状导电连接件进行缠绕；条状导电连接件可以采用扁平焊带，且缠绕扁平焊带时，使扁平焊带的底面朝向电池片的外侧面，以使扁平焊带稳定贴合在电池片外侧面的对应栅线上；且缠绕条状导电连接件时，使焊接载具侧周面围绕转轴的轴心转动，可以方便条状导电连接件的缠绕；更具体的，可以通过外部机构（如电机）驱动转轴绕自身轴心转动，并通过转轴带动焊接载具整体转动，进而实现使焊接载具侧周面围绕转轴的轴心转动；
然后对条状导电连接件加热，使条状导电连接件同步焊接在各电池片上；具体的：1）可以通过焊接载具对各承载面上的电池片及电池片外侧面上的条状导电连接件进行加热，使条状导电连接件同步焊接在各电池片上；2）还可以通过红外加热方式（如使用线状红外照射各电池片的外侧面以及外侧面上的条状导电连接件），实现对各电池片的外侧面以及外侧面上的条状导电连接件进行加热，使条状导电连接件同步焊接在各电池片上；
然后将条状导电连接件截断，实现在各电池片上分别残留条状导电连接件小段，且条状导电连接件小段用于其所在电池片的串接（条状导电连接件小段的一端超出其所在的电池片，条状导电连接件小段的另一端不超出其所在的电池片）；
然后将各电池片分别从焊接载具的对应承载面上取下（电池片取下后可以翻转换一面再实施一次电池片单面焊接条状导电连接件）。
如图3所示，本实施例提供一种太阳能电池片焊接方法，通过对电池片的正背面分别实施电池片单面焊接条状导电连接件，完成电池片双面焊接条状导电连接件；且电池片的正背面分别设有多个相互平行的栅线；
所述电池片单面焊接条状导电连接件，包括如下步骤：
设置一具有转轴的焊接载具，使转轴的轴心位于焊接载具的中心线上；使焊接载具具有围绕转轴的侧周面，且使焊接载具的侧周面由多个可供电池片贴合的承载面围成（焊接载具的主体可以是与转轴共轴心的棱柱）；使该多个承载面都为外凸的弧面（可以是圆弧面），并使该多个承载面的轴心都与转轴的轴心平行或共线；使该多个承载面分别具有真空吸附功能（如该多个承载面分别均布抽气口，可以通过抽气口进行真空吸附）；使焊接载具具有可以加热该多个承载面的加热功能；
在该多个承载面上分别贴合电池片，使电池片不超出其所贴合的承载面，使电池片上待焊接条状导电连接件的一侧表面朝外（也即使电池片上待焊接条状导电连接件的一侧表面与对应的承载面相背），并使电池片外侧面（即电池片上与对应承载面相背的一侧表面）上栅线的延伸方向与对应承载面的轴心垂直（也即与转轴的轴心垂直）；且通过承载面对其上的电池片进行真空吸附，以使电池片稳定吸附贴合在对应的承载面上；
然后通过使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片的方式，实现将条状导电连接件绷紧贴合在各电池片的外侧面上；且缠绕条状导电连接件时，使条状导电连接件与电池片外侧面的栅线对应贴合；具体的，可以仅采用一条条状导电连接件进行缠绕；条状导电连接件可以采用圆丝焊带；且缠绕条状导电连接件时，使焊接载具侧周面围绕转轴的轴心转动，可以方便条状导电连接件的缠绕；更具体的，可以通过外部机构（如电机）驱动转轴绕自身轴心转动，并通过转轴带动焊接载具整体转动，进而实现使焊接载具侧周面围绕转轴的轴心转动；
然后对条状导电连接件加热，使条状导电连接件同步焊接在各电池片上；具体的：1）可以通过焊接载具对各承载面上的电池片及电池片外侧面上的条状导电连接件进行加热，使条状导电连接件同步焊接在各电池片上；2）还可以通过热风加热方式（如使用热风吹扫各电池片的外侧面以及外侧面上的条状导电连接件），实现对各电池片的外侧面以及外侧面上的条状导电连接件进行加热，使条状导电连接件同步焊接在各电池片上；
然后将条状导电连接件截断，实现在各电池片上分别残留条状导电连接件小段，且条状导电连接件小段用于其所在电池片的串接（条状导电连接件小段的一端超出其所在的电池片，条状导电连接件小段的另一端不超出其所在的电池片）；
然后将各电池片分别从焊接载具的对应承载面上取下（电池片取下后可以翻转换一面再实施一次电池片单面焊接条状导电连接件）。
如图4所示，本实施例提供一种太阳能电池片焊接方法，通过对电池片的正背面分别实施电池片单面焊接条状导电连接件，完成电池片双面焊接条状导电连接件；且电池片的正背面分别设有多个相互平行的栅线；
所述电池片单面焊接条状导电连接件，包括如下步骤：
设置一具有转轴的焊接载具，使转轴的轴心位于焊接载具的中心线上；使焊接载具具有围绕转轴的侧周面，且使焊接载具的侧周面为与转轴共轴心的圆周面（焊接载具的主体可以是与转轴共轴心的圆柱）；在焊接载具的侧周面上并沿侧周面周向依次间隔划分出多个弧面区域，且使该多个弧面区域沿焊接载具侧周面的周向均布；各弧面区域分别为可供电池片贴合的承载面；使各承载面分别具有真空吸附功能（如各承载面分别均布抽气口，可以通过抽气口进行真空吸附）；使焊接载具具有可以加热各承载面的加热功能；
在各个承载面上分别贴合电池片，使电池片不超出其所贴合的承载面，使电池片上待焊接条状导电连接件的一侧表面朝外（也即使电池片上待焊接条状导电连接件的一侧表面与对应的承载面相背），并使电池片外侧面（即电池片上与对应承载面相背的一侧表面）上栅线的延伸方向与对应承载面的轴心垂直（也即与转轴的轴心垂直）；且通过承载面对其上的电池片进行真空吸附，以使电池片稳定吸附贴合在对应的承载面上；
然后通过使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片的方式，实现将条状导电连接件绷紧贴合在各电池片的外侧面上；且缠绕条状导电连接件时，使条状导电连接件与电池片外侧面的栅线对应贴合；具体的，可以仅采用一条条状导电连接件进行缠绕；条状导电连接件可以采用三角焊带，且缠绕三角焊带时，使三角焊带的底面朝向电池片的外侧面（也即使三角焊带的顶角与电池片的外侧面相背），以使三角焊带稳定贴合在电池片外侧面的对应栅线上；且在三角焊带缠绕过程中，三角焊带的底面贴合在电池片外侧面的状态是最稳定的，所以三角焊带在缠绕过程中，可以自动修正顶角方向，使得顶角朝上、底面朝下，实现与电池片外侧面稳定贴合；且缠绕条状导电连接件时，使焊接载具侧周面围绕转轴的轴心转动，可以方便条状导电连接件的缠绕；更具体的，可以通过外部机构（如电机）驱动转轴绕自身轴心转动，并通过转轴带动焊接载具整体转动，进而实现使焊接载具侧周面围绕转轴的轴心转动；
然后对条状导电连接件加热，使条状导电连接件同步焊接在各电池片上；具体的：1）可以通过焊接载具对各承载面上的电池片及电池片外侧面上的条状导电连接件进行加热，使条状导电连接件同步焊接在各电池片上；2）还可以通过热风加热方式（如使用热风吹扫各电池片的外侧面以及外侧面上的条状导电连接件），实现对各电池片的外侧面以及外侧面上的条状导电连接件进行加热，使条状导电连接件同步焊接在各电池片上；
然后将条状导电连接件截断，实现在各电池片上分别残留条状导电连接件小段，且条状导电连接件小段用于其所在电池片的串接（条状导电连接件小段的一端超出其所在的电池片，条状导电连接件小段的另一端不超出其所在的电池片）；
然后将各电池片分别从焊接载具的对应承载面上取下（电池片取下后可以翻转换一面再实施一次电池片单面焊接条状导电连接件）。
如图5所示，本实施例提供一种太阳能电池片焊接方法，通过对电池片的正背面分别实施电池片单面焊接条状导电连接件，完成电池片双面焊接条状导电连接件；且电池片的正背面分别设有多个相互平行的栅线；
所述电池片单面焊接条状导电连接件，包括如下步骤：
设置一具有转轴的焊接载具，使转轴的轴心位于焊接载具的中心线上；使焊接载具具有围绕转轴的侧周面，且使焊接载具的侧周面为与转轴共轴心的圆周面（焊接载具的主体可以是与转轴共轴心的圆柱）；在焊接载具的侧周面上划分出多排弧面区域，使各排弧面区域沿焊接载具侧周面的周向依次间隔设置，使同一排的弧面区域沿转轴的轴向依次间隔设置；各弧面区域分别为可供电池片贴合的承载面；使各承载面分别具有真空吸附功能（如各承载面分别均布抽气口，可以通过抽气口进行真空吸附）；使焊接载具具有可以加热各承载面的加热功能；
在各个承载面上分别贴合电池片，使电池片不超出其所贴合的承载面，使电池片上待焊接条状导电连接件的一侧表面朝外（也即使电池片上待焊接条状导电连接件的一侧表面与对应的承载面相背），并使电池片外侧面（即电池片上与对应承载面相背的一侧表面）上栅线的延伸方向与对应承载面的轴心垂直（也即与转轴的轴心垂直）；且通过承载面对其上的电池片进行真空吸附，以使电池片稳定吸附贴合在对应的承载面上；
然后通过使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片的方式，实现将条状导电连接件绷紧贴合在各电池片的外侧面上；且缠绕条状导电连接件时，使条状导电连接件与电池片外侧面的栅线对应贴合；具体的，可以仅采用一条条状导电连接件进行缠绕；条状导电连接件可以采用三角焊带，且缠绕三角焊带时，使三角焊带的底面朝向电池片的外侧面（也即使三角焊带的顶角与电池片的外侧面相背），以使三角焊带稳定贴合在电池片外侧面的对应栅线上；且在三角焊带缠绕过程中，三角焊带的底面贴合在电池片外侧面的状态是最稳定的，所以三角焊带在缠绕过程中，可以自动修正顶角方向，使得顶角朝上、底面朝下，实现与电池片外侧面稳定贴合；且缠绕条状导电连接件时，使焊接载具侧周面围绕转轴的轴心转动，可以方便条状导电连接件的缠绕；更具体的，可以通过外部机构（如电机）驱动转轴绕自身轴心转动，并通过转轴带动焊接载具整体转动，进而实现使焊接载具侧周面围绕转轴的轴心转动；
然后对条状导电连接件加热，使条状导电连接件同步焊接在各电池片上；具体的：1）可以通过焊接载具对各承载面上的电池片及电池片外侧面上的条状导电连接件进行加热，使条状导电连接件同步焊接在各电池片上；2）还可以通过红外加热方式（如使用线状红外照射各电池片的外侧面以及外侧面上的条状导电连接件），实现对各电池片的外侧面以及外侧面上的条状导电连接件进行加热，使条状导电连接件同步焊接在各电池片上；
然后将条状导电连接件截断，实现在各电池片上分别残留条状导电连接件小段，且条状导电连接件小段用于其所在电池片的串接（条状导电连接件小段的一端超出其所在的电池片，条状导电连接件小段的另一端不超出其所在的电池片）；
然后将各电池片分别从焊接载具的对应承载面上取下（电池片取下后可以翻转换一面再实施一次电池片单面焊接条状导电连接件）。
实施例4可以一次缠绕多排电池片和一次焊接多排电池片，可提高焊接效率。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明技术原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。
Claims (23)
- 一种太阳能电池片焊接方法，包括电池片单面焊接条状导电连接件；其特征在于，所述电池片单面焊接条状导电连接件，包括如下步骤：在一焊接载具的外表面设置供电池片贴合的承载面，且使承载面为外凸的弧面；在承载面上贴合电池片，且使电池片上待焊接条状导电连接件的一侧表面朝外；将条状导电连接件绷紧贴合在电池片的外侧面上；对条状导电连接件加热，使条状导电连接件焊接在电池片上。
- 根据权利要求1所述的太阳能电池片焊接方法，其特征在于，所述电池片的外侧面设有多个相互平行的栅线；实现在承载面上贴合电池片时，使电池片外侧面栅线的延伸方向与承载面的轴心垂直；实现将条状导电连接件绷紧贴合在电池片的外侧面上时，使条状导电连接件与电池片外侧面的栅线对应贴合。
- 根据权利要求1或2所述的太阳能电池片焊接方法，其特征在于，通过使条状导电连接件沿承载面的周向跨过电池片，并将条状导电连接件位于电池片两侧外部的区段向焊接载具拉紧的方式，实现将条状导电连接件绷紧贴合在电池片的外侧面上。
- 根据权利要求1或2所述的太阳能电池片焊接方法，其特征在于，使焊接载具设有转轴，且使焊接载具的外表面包括围绕转轴的侧周面；使承载面位于焊接载具的侧周面上，并使承载面的轴心与转轴的轴心平行或共线；通过使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片的方式，实现将条状导电连接件绷紧贴合在电池片的外侧面上。
- 根据权利要求4所述的太阳能电池片焊接方法，其特征在于，使转轴的轴心位于焊接载具的中心线上。
- 根据权利要求4所述的太阳能电池片焊接方法，其特征在于，实现使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片时，使焊接载具侧周面围绕转轴的轴心转动。
- 根据权利要求4所述的太阳能电池片焊接方法，其特征在于，在焊接载具侧周面上设置至少两个承载面，并使各承载面的轴心与转轴的轴心平行或共线；在各承载面上分别贴合电池片，且使电池片上待焊接条状导电连接件的一侧表面朝外；通过使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片的方式，实现将条状导电连接件绷紧贴合在各电池片的外侧面上；对条状导电连接件加热，使条状导电连接件焊接在各电池片上。
- 根据权利要求7所述的太阳能电池片焊接方法，其特征在于，在焊接载具侧周面上设置多个承载面，使各承载面沿焊接载具侧周面的周向依次设置。
- 根据权利要求8所述的太阳能电池片焊接方法，其特征在于，使各承载面沿焊接载具侧周面的周向均布。
- 根据权利要求7所述的太阳能电池片焊接方法，其特征在于，在焊接载具侧周面上设置多排承载面，使各排承载面沿焊接载具侧周面的周向依次设置，使同一排的承载面沿转轴的轴向依次设置，并使各承载面的轴心与转轴的轴心平行或共线。
- 根据权利要求10所述的太阳能电池片焊接方法，其特征在于，使多排承载面沿焊接载具侧周面的周向均布。
- 根据权利要求11所述的太阳能电池片焊接方法，其特征在于，使各承载面在焊接载具的侧周面上均布。
- 根据权利要求7所述的太阳能电池片焊接方法，其特征在于，使焊接载具的侧周面由多个承载面围成。
- 根据权利要求13所述的太阳能电池片焊接方法，其特征在于，使焊接载具的侧周面与转轴共轴心。
- 根据权利要求7所述的太阳能电池片焊接方法，其特征在于，使焊接载具的侧周面为与转轴共轴心的圆周面。
- 根据权利要求4所述的太阳能电池片焊接方法，其特征在于，仅采用一条条状导电连接件，实现使条状导电连接件沿焊接载具侧周面周向缠绕并缠紧焊接载具侧周面上电池片。
- 根据权利要求1所述的太阳能电池片焊接方法，其特征在于，所述条状导电连接件采用焊丝或焊带。
- 根据权利要求1所述的太阳能电池片焊接方法，其特征在于，所述条状导电连接件具有用于与电池片焊接的平直底面；实现将条状导电连接件绷紧贴合在电池片的外侧面上时，使条状导电连接件的平直底面朝向电池片的外侧面。
- 根据权利要求1所述的太阳能电池片焊接方法，其特征在于，通过直接加热、红外加热或热风加热方式，实现对条状导电连接件加热。
- 根据权利要求19所述的太阳能电池片焊接方法，其特征在于，使焊接载具具有加热功能，通过焊接载具对承载面上的电池片及电池片外侧面上的条状导电连接件进行加热。
- 根据权利要求1所述的太阳能电池片焊接方法，其特征在于，使承载面具有真空吸附功能；实现在承载面上贴合电池片时，对电池片进行真空吸附。
- 根据权利要求1所述的太阳能电池片焊接方法，其特征在于，实现使条状导电连接件焊接在电池片上之后，将条状导电连接件截断，实现在电池片上残留条状导电连接件小段，且条状导电连接件小段用于其所在电池片的串接；然后将电池片从焊接载具的承载面上取下。
- 根据权利要求22所述的太阳能电池片焊接方法，其特征在于，通过对电池片的正背面分别实施电池片单面焊接条状导电连接件，完成电池片双面焊接条状导电连接件。
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| CN106862690A (zh) * | 2017-02-09 | 2017-06-20 | 常州天合光能有限公司 | Ibc电池单焊台、串联用焊接台及其串联焊接方法 |
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| CN106206807A (zh) * | 2014-10-31 | 2016-12-07 | 比亚迪股份有限公司 | 太阳能电池片阵列、太阳能电池组件及其制备方法 |
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