CN108110069A - 一种智能光伏晶硅组件及其制造方法 - Google Patents
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Abstract
本发明提供一种智能光伏晶硅组件及其制造方法,包括电池片和二极管,其特征在于,多个电池片正负极依次串联,多个二极管正负极依次串联,且两片电池片为一组并联一个二极管,每个二极管的负极接每组电池片的正极,每个二极管的正极接每组电池片的负极,每个二极管焊接在每组电池片的正面,每组电池片的背面放置一块铝片;本发明通过增加保护二极管的数量,以两片电池片为一组并联一个二极管,同时为了散热在每组电池片底部放一块铝片,二极管和铝片分别叠放在电池正面和背面,提高了组件安全性能,减少功率损失。
Description
技术领域
本发明涉及一种光伏晶硅组件及其制造方法,尤其是一种智能光伏晶硅组件及其制造方法,属于光伏半导体技术领域。
背景技术
光伏晶硅组件是通过晶硅半导体将光能转换为电能的一个模块,类似于光电池,且光伏晶硅组件目前广泛应用与大型地面电站、屋面、船舶、航空等领域;一般伏晶硅组件在实际应用中会遇到阴影遮挡,造成热斑等现象,长期热斑会造成组件功率损失,甚至烧毁。目前,光伏晶硅组件在设计时会在接线盒中放置6个二极管用于保护,如图1和图2所示,6个二极管两两并联,并联后的二极管两端再并联在晶硅组件串上,但这样的结构也会造成晶硅组件近1/3串上的功率损失。
如图3所示,现有晶硅组件的工艺流程为:电池串焊接-放置玻璃基板-铺下层EVA-电池串排版-铺上层EVA-铺背板-层压-装框-成品。
如图4所示,为现有常规工艺的晶硅组件进行热斑功率测试后的图像(圆圈标注处为热斑),测试条件为,在户外辐照度800W/㎡条件下,遮挡1片电池并短接线盒,测试结果如下:
由上表可知,常规工艺的晶硅组件在遇到热斑时,功率衰减在27%左右,热斑温度在93℃左右,功率损失较大,温度较高。
发明内容
本发明的目的在于针对现有晶硅组件功率损失大的问题,提出一种智能光伏晶硅组件及其制造方法,通过增加保护二极管的数量,以两片电池片为一组并联一个二极管,同时为了散热在每组电池片底部放一块铝片,二极管和铝片叠放在电池正面和背面,提高了组件安全性能,减少功率损失。
为实现以上技术目的,本发明采用的技术方案是:一种智能光伏晶硅组件,包括电池片和二极管,其特征在于,多个电池片正负极依次串联,多个二极管正负极依次串联,且两片电池片为一组并联一个二极管,每个二极管的负极接每组电池片的正极,每个二极管的正极接每组电池片的负极,每个二极管焊接在每组电池片的正面,每组电池片的背面放置一块铝片。
进一步地,所述二极管为贴片二极管。
进一步地,所述电池片的数量为二极管数量的两倍。
为了实现以上技术目的,本发明还提出一种智能光伏晶硅组件的制造方法,其特征在于,所述制造方法包括如下步骤:
步骤一.将多个电池片正负极依次焊接形成电池串;
步骤二.以两片电池片为一组,在每组电池片的背面放置一块铝片;
步骤三.在每组电池片的正面焊接一个贴片二极管;
步骤四.每个贴片二极管的正极通过导线焊接在每组电池片的负极,每个贴片二极管的负极通过导线焊接在每组电池片的正极;
步骤五.提供一玻璃基板和背板;
步骤六.在所述玻璃基板上涂覆一层聚醋酸乙烯酯形成上层聚醋酸乙烯酯层;
步骤七.将所述铝片和焊接有二极管的电池串排布在所述上层聚醋酸乙烯酯层上;
步骤八.在所述电池串上涂覆一层聚醋酸乙烯酯形成下层聚醋酸乙烯酯层;
步骤九.将所述背板覆盖在所述下层聚醋酸乙烯酯层上。
进一步地,所述制作方法还包括在步骤九后进行的:
对所述背板与所述玻璃基板之间的各层进行层压;
将层压后的所述背板与所述玻璃基板以及所述背板与所述玻璃基板之间的所述聚醋酸乙烯酯和所述电池串封装在封装框内。
进一步地,所述步骤二可在步骤六后进行,所述步骤五可在步骤一前进行。从以上描述可以看出,本发明的有益效果在于:
1)与现有晶硅组件相比,本发明晶硅组件通过每组组件并联一个二极管,使得由热斑原因引起的功率损失大幅减少,功率提升近20%;
2)本发明晶硅组件通过在每组晶硅组件背面放置一块铝片,使组件散热能力提高,热斑温度降低,提高了组件的安全性能;
3)设计贴片二极管封装工艺,封装后的组件无碎片、气泡,且工作时二极管散热快。
附图说明
图1为现有常规晶硅组件排版结构示意图。
图2为现有常规晶硅组件电路原理图。
图3为现有常规晶硅组件工艺流程图。
图4为现有常规晶硅组件热斑功率测试图。
图5为本发明晶硅组件排版结构示意图。
图6为本发明晶硅组件电路原理图。
图7为本发明晶硅组件工艺流程图。
图8为本发明晶硅组件热斑功率测试图。
附图标记说明:1-电池片、2-二极管、3-铝片和4-导线。
具体实施方式
下面结合具体附图和实施例对本发明作进一步说明。
如图1和图2所示,实施例一种智能光伏晶硅组件,包括电池片1和二极管2,其特征在于,多个电池片1正负极依次串联,多个二极管2正负极依次串联,所述二极管2为贴片二极管,所述电池片1的数量为二极管2数量的两倍,且两片电池片1为一组并联一个二极管2,每个二极管2的负极接每组电池片1的正极,每个二极管2的正极接每组电池片1的负极,每个二极管2焊接在每组电池片1的正面,每组电池片1的背面放置一块铝片3。
如图7所示,上述实施例中的一种智能光伏晶硅组件的制造方法,其特征在于,所述制造方法包括如下步骤:
步骤一.将多个电池片1正负极依次焊接形成电池串;
步骤二.以两片电池片1为一组,在每组电池片1的背面放置一块铝片3;
步骤三.在每组电池片1的正面焊接一个贴片二极管;
步骤四.每个贴片二极管的正极通过导线4焊接在每组电池片1的负极,每个贴片二极管的负极通过导线4焊接在每组电池片1的正极;
步骤五.提供一玻璃基板和背板;
步骤六.在所述玻璃基板上涂覆一层聚醋酸乙烯酯形成上层聚醋酸乙烯酯层;
步骤七.将所述铝片3和焊接有二极管2的电池串排布在所述上层聚醋酸乙烯酯层上;
步骤八.在所述电池串上涂覆一层聚醋酸乙烯酯形成下层聚醋酸乙烯酯层;
步骤九.将所述背板覆盖在所述下层聚醋酸乙烯酯层上。
本实施例中所述制作方法还包括在步骤九后进行的:
对所述背板与所述玻璃基板之间的各层进行层压;
将层压后的所述背板与所述玻璃基板以及所述背板与所述玻璃基板之间的所述聚醋酸乙烯酯和所述电池串封装在封装框内。
本实施例中所述步骤二可在步骤六后进行,所述步骤五可在步骤一前进行。
本发明提供的智能光伏晶硅组件,通过增加保护二极管的数量,以两片电池片为一组并联一个二极管,同时为了散热在每组电池片底部放一块铝片,二极管和铝片叠放在电池正面和背面;对本发明提供的智能光伏晶硅组件进行热斑功率测试,如图8所示,为本发明的晶硅组件进行热斑功率测试后的图像(圆圈标注处为热斑),热斑测试条件:在户外辐照度800W/㎡条件下,遮挡一片电池片1并短接接线盒,测试结果如下:
由上表可知,与现有的晶硅组件相比,本发明智能晶硅组件,在遇到热斑时,功率衰减在4%左右,热斑温度在70℃左右,功率损失大幅优化,温度也大幅降低。
以上对本发明及其实施方式进行了描述,该描述没有限制性,附图中所示的也只是本发明的实施方式之一,实际的结构并不局限于此。如果本领域的普通技术人员受其启示,在不脱离本发明创造宗旨的情况下,不经创造性的设计出与该技术方案相似的结构方式及实施例,均应属于本发明的保护范围。
Claims (6)
1.一种智能光伏晶硅组件,包括电池片(1)和二极管(2),其特征在于,多个电池片(1)正负极依次串联,多个二极管(2)正负极依次串联,且两片电池片(1)为一组并联一个二极管(2),每个二极管(2)的负极接每组电池片(1)的正极,每个二极管(2)的正极接每组电池片(1)的负极,每个二极管(2)焊接在每组电池片(1)的正面,每组电池片(1)的背面放置一块铝片(3)。
2.根据权利要求1所述的一种智能光伏晶硅组件,其特征在于,所述二极管(2)为贴片二极管。
3.根据权利要求所述的一种智能光伏晶硅组件,其特征在于,所述电池片(1)的数量为二极管(2)数量的两倍。
4.一种智能光伏晶硅组件的制造方法,其特征在于,所述制造方法包括如下步骤:
步骤一. 将多个电池片(1)正负极依次焊接形成电池串;
步骤二. 以两片电池片(1)为一组,在每组电池片(1)的背面放置一块铝片(3);
步骤三. 在每组电池片(1)的正面焊接一个贴片二极管;
步骤四. 每个贴片二极管的正极通过导线(4)焊接在每组电池片(1)的负极,每个贴片二极管的负极通过导线(4)焊接在每组电池片(1)的正极;
步骤五. 提供一玻璃基板和背板;
步骤六. 在所述玻璃基板上涂覆一层聚醋酸乙烯酯形成上层聚醋酸乙烯酯层;
步骤七. 将所述铝片(3)和焊接有二极管(2)的电池串排布在所述上层聚醋酸乙烯酯层上;
步骤八. 在所述电池串上涂覆一层聚醋酸乙烯酯形成下层聚醋酸乙烯酯层;
步骤九. 将所述背板覆盖在所述下层聚醋酸乙烯酯层上。
5.根据权利要求4所述的一种智能光伏晶硅组件的制造方法,其特征在于,所述制作方法还包括在步骤九后进行的:
对所述背板与所述玻璃基板之间的各层进行层压;
将层压后的所述背板与所述玻璃基板以及所述背板与所述玻璃基板之间的所述聚醋酸乙烯酯和所述电池串封装在封装框内。
6.根据权利要求4所述的一种智能光伏晶硅组件的制造方法,其特征在于, 所述步骤二可在步骤六后进行,所述步骤五可在步骤一前进行。
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