CN111564516A - 一种降低湿热衰减的阻隔型光伏焊带 - Google Patents
一种降低湿热衰减的阻隔型光伏焊带 Download PDFInfo
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Abstract
本发明公开了一种降低湿热衰减的阻隔型光伏焊带，包括光伏焊带本体，所述光伏焊带本体的不与电池栅线接触的表面具有水气阻隔层，这种水气阻隔层能够阻隔外界的水分和气体进入光伏焊带本体中，因此能够在低成本的基础上，减少组件内部的酸性物质、氧化剂和水分对光伏焊带本体造成的腐蚀，从而降低湿热环境下光伏组件的衰减。
Description
技术领域
本申请属于光伏设备技术领域，特别是涉及一种降低湿热衰减的阻隔型光伏焊带。
背景技术
光伏焊带是光伏组件焊接过程中采用的重要原材料，在组件生产过程中，通过焊接过程使用焊带将电池片的电流导出，再通过串联或并联的方式将引出的电极与接线盒形成有效的连接，根据成分来区分的话，焊带分为有铅焊带及无铅焊带，光伏组件长期在户外环境尤其是高温高湿环境下运行，组件封装材料会缓慢老化，造成内部金属部件的腐蚀，主要体现在焊带和光伏电池金属化栅线之间发生电化学腐蚀，造成电性能变差，从而组件功率衰减变大。
具体而言，温湿度作用下晶体硅光伏组件会出现腐蚀、分层和褪色等多种失效现象，这就需要对其进行测试，一般采用DH(damp heat)衰减测试，这是指在组件老化试验箱内，经过85℃、85RH相对湿度、1000小时之后，如果组件功率衰减的比例＜5％，则该组件满足质量要求。而组件经历DH3000或更长时间，则衰减明显变大，失效组件发黑区域的EVA在-1574cm-1和-3500cm-1附近出现醋酸铅的特征峰，其中铅的主要来源为含铅锡的铜焊带以及光伏电池栅线中的玻璃料含有的铅，此外电池片栅线中发现氧化银等物质，以上表明DH失效是由高温高湿环境中组件内部产生醋酸或氧化物腐蚀了金属部件造成的，具体的，晶硅光伏组件在高温高湿环境下，空气中的水分和氧气透过背板进入组件内部，材料老化水解产生醋酸或内部进入氧化气体，从而腐蚀焊带、栅线等金属部件，造成光伏组件的电性能降低，功率衰减变大。
现有的解决方式都是基于降低醋酸的产生，包括使用双玻组件降低水汽透过率，降低EVA材料的水解速率，以及采用分子聚合材料，如POE(聚烯烃弹性体)，其本身水解物不含有醋酸等物质，同时水分透过率更低；另一个方式是减少内部水解酸性物质的累计量，也就是使用透明背板组件在工作温度高于环境温度时，使得内部醋酸小分子可以逃逸出组件，避免醋酸浓度的累积；还有一种方式与本方案最接近，就是向组件内添加材料实现醋酸物质的消耗，例如公开号为CN107312473A和CN103254802A的方案中，在EVA胶膜中加入金属化合物作为醋酸捕捉剂来消耗醋酸，从而避免醋酸对组件金属部件的腐蚀，但是，该方法是有缺点的，因为增加的金属化合物需要用到稀土元素，而EVA面积较大，因此稀土用量相对较多，成本过高。
发明内容
为解决上述问题，本发明提供了一种降低湿热衰减的阻隔型光伏焊带，能够在低成本的基础上，减少组件内部的酸性物质、氧化剂和水分对光伏焊带本体造成的腐蚀，从而降低湿热环境下光伏组件的衰减。
本发明提供的一种降低湿热衰减的阻隔型光伏焊带，包括光伏焊带本体，所述光伏焊带本体的不与电池栅线接触的表面具有水气阻隔层。
优选的，在上述降低湿热衰减的阻隔型光伏焊带中，所述水气阻隔层的材质包括氟碳树脂、聚氟乙烯、聚偏氟乙烯、三氟氯乙烯-乙烯共聚物、四氟乙烯-乙烯基酯共聚物、四氟乙烯-六氟丙烯-偏氟乙烯共聚物、聚丙烯和聚苯乙烯中的至少一种。
优选的，在上述降低湿热衰减的阻隔型光伏焊带中，所述水气阻隔层的材质包括质量比为20％至55％的四氟乙烯-六氟丙烯-偏氟乙烯共聚物、质量比为10％至45％的聚偏氟乙烯、20％至35％的聚氟乙烯、质量比为10％至30％的三氟氯乙烯-乙烯共聚物。
优选的，在上述降低湿热衰减的阻隔型光伏焊带中，所述水气阻隔层的厚度为1微米至50微米。
优选的，在上述降低湿热衰减的阻隔型光伏焊带中，所述水气阻隔层的厚度为10微米至20微米。
优选的，在上述降低湿热衰减的阻隔型光伏焊带中，当所述光伏焊带本体为三角形截面时，所述水气阻隔层包裹住所述光伏焊带本体的两个面，当所述光伏焊带本体为圆形截面时，所述水气阻隔层至少包裹住所述光伏焊带本体的四分之三，当所述光伏焊带本体为矩形截面时，所述水气阻隔层包裹住所述光伏焊带本体的两个小面和一个大面。
通过上述描述可知，本发明提供的上述降低湿热衰减的阻隔型光伏焊带，由于光伏焊带本体的不与电池栅线接触的表面具有水气阻隔层，这种水气阻隔层能够阻隔外界的水分和气体进入光伏焊带本体中，因此能够在低成本的基础上，减少组件内部的酸性物质、氧化剂和水分对光伏焊带本体造成的腐蚀，从而降低湿热环境下光伏组件的衰减。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据提供的附图获得其他的附图。
图1为本申请提供的一种降低湿热衰减的阻隔型光伏焊带的实施例的示意图。
具体实施方式
本发明的核心是提供一种降低湿热衰减的阻隔型光伏焊带，能够在低成本的基础上，减少组件内部的酸性物质、氧化剂和水分对光伏焊带本体造成的腐蚀，从而降低湿热环境下光伏组件的衰减。
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
本申请提供的一种降低湿热衰减的阻隔型光伏焊带如图1所示，图1为本申请提供的一种降低湿热衰减的阻隔型光伏焊带的实施例的示意图，该光伏焊带包括光伏焊带本体101，光伏焊带本体101的不与电池栅线接触的表面具有水气阻隔层102，这种水气阻隔层102可以但不限于采用薄膜的方式来阻隔外界的水分和气体进入光伏焊带本体的内部，需要说明的是，图1中仅仅是以具有长方形截面的光伏焊带本体做的说明，但实际上并不仅限于这种形状的光伏焊带本体，在这种长方形截面的光伏焊带本体101的两个侧面和一个顶面都设置了水气阻隔层102，这里的水气阻隔层102指的是既能够阻隔水分，又能够阻隔气体，从而保证水分和气体都不能从光伏焊带本体101的两个侧面和一个顶面进入光伏焊带本体101中，而这种光伏焊带本体101的底面是与电池栅线相接触的，因为这样才能够保证能导电，因此无需在这个面设置水气阻隔层，因为这个面也不会暴露在外界中，因此能够保证水分和气体不能通过这个底面进入光伏焊带本体101中，从而这种光伏焊带本体能够全方位的防止水分和气体进入其内部造成不良影响。
通过上述描述可知，本申请提供的上述降低湿热衰减的阻隔型光伏焊带的实施例中，由于光伏焊带本体的不与电池栅线接触的表面具有水气阻隔层，这种水气阻隔层能够阻隔外界的水分和气体进入光伏焊带本体中，因此能够在低成本的基础上，减少组件内部的酸性物质、氧化剂和水分对光伏焊带本体造成的腐蚀，从而降低湿热环境下光伏组件的衰减。
在上述降低湿热衰减的阻隔型光伏焊带的一个具体实施例中，水气阻隔层102的材质包括氟碳树脂、聚氟乙烯(PVF)、聚偏氟乙烯(PVDF)、三氟氯乙烯-乙烯共聚物(ECTFE)、四氟乙烯-乙烯基酯共聚物、四氟乙烯-六氟丙烯-偏氟乙烯共聚物(THV)、聚丙烯和聚苯乙烯中的至少一种，这些材质都是现有的材质，都具有优异的耐候(耐酸、耐碱、耐高温)性能，因此更适合用在这里防止水分和气体进入光伏焊带本体内，各自还具有各自的独特优点，例如PVDF的吸水率为0.04％，三氟氯乙烯-乙烯基醚共聚物的键能更加均匀，THV材质柔软且容易粘接，可以不经过表面处理就和其他材料粘接成多层结构，ECTFE具有高耐候性和阻隔性，聚丙烯和聚苯乙烯具有较好的阻水及氧气隔绝效果，还需要说明的是，该水气阻隔层102的材质可以是上述材质中的单独一种，也可以是同时包括两种、三种或者更多，此处并不限制。
在上述降低湿热衰减的阻隔型光伏焊带的另一个具体实施例中，水气阻隔层102的材质包括质量比为20％至55％的四氟乙烯-六氟丙烯-偏氟乙烯共聚物、质量比为10％至45％的聚偏氟乙烯、20％至35％的聚氟乙烯、质量比为10％至30％的三氟氯乙烯-乙烯共聚物。
在上述降低湿热衰减的阻隔型光伏焊带的又一个具体实施例中，水气阻隔层102的厚度可以为1微米至50微米，在这种情况下，透光率可达85％至95％，这样的水气阻隔层的熔点温度可以达到240℃至270℃，这可以保证在焊接过程中水气阻隔层不会产生破损。
进一步的实施例中，水气阻隔层的厚度可以优选为10微米至20微米，这样透光率可以达到90％至92％，具体的，首先将材料称重，制备成薄膜物质或颗粒状物质，在氮气氛围中进行240-300℃下的熔化，搅拌形成均匀的混合物，然后加热状态下，可通过采用模具或部分贴合或喷涂高温不沾材料形成局部防护，使用串焊机和焊带翻面装置，将其与光伏电池的金属栅线焊接在一起，最后进行干燥和降温处理，保证焊接拉力合格即可，这样就将光伏焊带本体与这种水气阻隔层结合在一起了。
在上述降低湿热衰减的阻隔型光伏焊带的一个优选实施例中，当光伏焊带本体为三角形截面时，水气阻隔层包裹住光伏焊带本体的两个面，而第三个面直接与电池栅线相接触，因此无需设置水气阻隔层，当光伏焊带本体为圆形截面时，水气阻隔层至少包裹住光伏焊带本体的四分之三，而剩下的四分之一的部分则与电池栅线接触到一起，因此无需设置这种水气阻隔层，当光伏焊带本体为矩形截面时，水气阻隔层包裹住光伏焊带本体的两个小面和一个大面，这里说的小面即侧面，大面即顶面，而底面与电池栅线相接触因此无需设置这种水气阻隔层，这样就能够根据实际情况来形成有效的遮挡，保证外界水分和气体不能进入光伏焊带本体内部，当然还可以根据实际需要选择其他的包裹方式，此处并不限制。
下面对上述光伏焊带的制作方式的各个步骤做一个详细的说明：(1)铜基放料：在加装有减摩擦阻力装置的放料机构上加入铜料，避免铜焊带划伤；(2)助焊剂涂覆：将生产出的铜基材浸泡助焊剂；原料为有机溶剂、松香树脂及其衍生物、合成树脂表面活性剂、有机酸活化剂、防腐蚀剂，助溶剂、成膜剂；(3)锡、锡铅涂层：将浸泡完助焊剂的铜基材进行浸锡炉，涂锡焊带是在铜基材外表面涂覆一层锡铅合金，目的是形成合金，降低焊带的焊接温度；(4)润滑保护剂：有效填充锡及其合金镀层表面的焊料层，针孔、空洞、孔隙，起到更好的保护作用；(5)水气阻隔层材料的制备：采用含氟材料在高温条件下形成均匀混合物；(6)水气阻隔层，采用模具或部分贴合高温不沾材料形成局部防护，实现焊带表面增加水气阻隔层；(7)干燥处理，将制作了水气阻隔层的焊带干燥和冷却；(8)电池片与焊带间通过串焊机加热焊接，正常工艺即可满足要求。综上所述，采用上述水气阻隔层之后的光伏焊带本体，能阻挡组件中的酸性物质或者氧化介质对光伏焊带本体造成的腐蚀，进而避免焊带中的铅、锡腐蚀后形成的金属盐化物进入电池而造成电性能降低。
下面以两个实施案例对上述方案进行详细说明：
实施案例1：水气阻隔层采用六氟丙烯共聚物(FEP)、聚偏氟乙烯(PVDF)材料，采用300℃浸泡或喷涂，水气阻隔层薄膜厚度在15-20μm，透光率88-90％，材料熔点255-260℃；焊接作业温度240-245℃，使用EVA封装材料，制作组件，进行DH1000、DH3000测试功率衰减。
实施案例2：水气阻隔层采用四氟乙烯-乙烯共聚物，水气阻隔层的厚度为25-30μm；采用300℃浸泡或喷涂，透光率90-92％，材料熔点为255-260℃，焊接作业温度为235-240℃，使用EVA封装材料制作组件，进行DH1000、DH3000测试功率衰减，结果如表1所示，表1为实施案例1、实施案例2和常规焊带的测试结果对比表。
表1
| 方案 | DH 1000衰减 | DH3000衰减 |
| 常规焊带 | 3.5％ | 7.8％ |
| 实施案例1 | 2.7％ | 4.5％ |
| 实施案例2 | 1.9％ | 3.9％ |
以上数据表明，增加了水气阻隔层之后，降低了组件内部酸性物质及氧化物对光伏焊带的腐蚀，减少反应产物铅、锡金属盐等物质对电池栅线及内部的进一步腐蚀，组件的抗湿热衰减得到降低。使用带有水气阻隔层的焊带制作组件，经过湿热测试1000小时组件功率衰减低于2.5％，经过湿热测试3000小时组件功率衰减低于5％，能够更好的满足可靠性测试的要求，能实现较好的抗湿热衰减效果，而且这种水气阻隔层的厚度较小，因此，光伏焊带的整体成本增加并不大。
对所公开的实施例的上述说明，使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下，在其它实施例中实现。因此，本发明将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。
Claims (6)
1.一种降低湿热衰减的阻隔型光伏焊带，其特征在于，包括光伏焊带本体，所述光伏焊带本体的不与电池栅线接触的表面具有水气阻隔层。
2.根据权利要求1所述的降低湿热衰减的阻隔型光伏焊带，其特征在于，所述水气阻隔层的材质包括氟碳树脂、聚氟乙烯、聚偏氟乙烯、三氟氯乙烯-乙烯共聚物、四氟乙烯-乙烯基酯共聚物、四氟乙烯-六氟丙烯-偏氟乙烯共聚物、聚丙烯和聚苯乙烯中的至少一种。
3.根据权利要求2所述的降低湿热衰减的阻隔型光伏焊带，其特征在于，所述水气阻隔层的材质包括质量比为20％至55％的四氟乙烯-六氟丙烯-偏氟乙烯共聚物、质量比为10％至45％的聚偏氟乙烯、20％至35％的聚氟乙烯、质量比为10％至30％的三氟氯乙烯-乙烯共聚物。
4.根据权利要求1-3任一项所述的降低湿热衰减的阻隔型光伏焊带，其特征在于，所述水气阻隔层的厚度为1微米至50微米。
5.根据权利要求4所述的降低湿热衰减的阻隔型光伏焊带，其特征在于，所述水气阻隔层的厚度为10微米至20微米。
6.根据权利要求1-3任一项所述的降低湿热衰减的阻隔型光伏焊带，其特征在于，当所述光伏焊带本体为三角形截面时，所述水气阻隔层包裹住所述光伏焊带本体的两个面，当所述光伏焊带本体为圆形截面时，所述水气阻隔层至少包裹住所述光伏焊带本体的四分之三，当所述光伏焊带本体为矩形截面时，所述水气阻隔层包裹住所述光伏焊带本体的两个小面和一个大面。
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| CN203085560U (zh) * | 2013-02-07 | 2013-07-24 | 凡登（常州）新型金属材料技术有限公司 | 异构光伏焊带 |
| CN107393994A (zh) * | 2017-06-29 | 2017-11-24 | 中节能太阳能科技（镇江）有限公司 | 一种高性能高可靠性光伏组件 |
| KR20190028892A (ko) * | 2017-09-11 | 2019-03-20 | 엘지전자 주식회사 | 태양 전지 패널 및 이의 제조 방법 |
| CN111069918A (zh) * | 2019-12-31 | 2020-04-28 | 苏州宇邦新型材料股份有限公司 | 仅焊接区涂覆焊料的光伏焊带及光伏焊带的制造方法和设备 |
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| Publication number | Publication date |
|---|---|
| EP4156309A1 (en) | 2023-03-29 |
| US20230131984A1 (en) | 2023-04-27 |
| WO2021232511A1 (zh) | 2021-11-25 |
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