CN111020443A - 一种专用于超薄光伏电池片焊接用的低熔点光伏焊带及其制备方法与应用 - Google Patents
一种专用于超薄光伏电池片焊接用的低熔点光伏焊带及其制备方法与应用 Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 26
- 238000002360 preparation method Methods 0.000 title abstract description 7
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 90
- 229910000679 solder Inorganic materials 0.000 claims abstract description 65
- 239000010949 copper Substances 0.000 claims abstract description 55
- 229910052802 copper Inorganic materials 0.000 claims abstract description 54
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims abstract description 40
- 229910052718 tin Inorganic materials 0.000 claims abstract description 40
- 238000002844 melting Methods 0.000 claims abstract description 18
- 230000008018 melting Effects 0.000 claims abstract description 18
- 238000005476 soldering Methods 0.000 claims abstract description 16
- 238000005096 rolling process Methods 0.000 claims abstract description 15
- 239000011248 coating agent Substances 0.000 claims abstract description 14
- 238000000576 coating method Methods 0.000 claims abstract description 14
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 13
- 239000000956 alloy Substances 0.000 claims abstract description 13
- 230000004907 flux Effects 0.000 claims abstract description 13
- 238000001816 cooling Methods 0.000 claims abstract description 10
- 238000000034 method Methods 0.000 claims abstract description 10
- 229910052797 bismuth Inorganic materials 0.000 claims abstract description 8
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 claims abstract description 8
- 229910052709 silver Inorganic materials 0.000 claims abstract description 8
- 239000004332 silver Substances 0.000 claims abstract description 8
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000000203 mixture Substances 0.000 claims abstract description 6
- 238000002791 soaking Methods 0.000 claims abstract description 6
- 238000009461 vacuum packaging Methods 0.000 claims abstract description 6
- 238000000137 annealing Methods 0.000 claims abstract description 5
- 238000010438 heat treatment Methods 0.000 claims abstract description 4
- 238000001035 drying Methods 0.000 claims abstract description 3
- 238000002156 mixing Methods 0.000 claims abstract description 3
- 239000002184 metal Substances 0.000 claims description 6
- 229910052751 metal Inorganic materials 0.000 claims description 6
- 239000002904 solvent Substances 0.000 claims description 4
- 239000002994 raw material Substances 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- 239000012535 impurity Substances 0.000 claims description 2
- 238000004806 packaging method and process Methods 0.000 claims description 2
- 238000007598 dipping method Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000011247 coating layer Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000010248 power generation Methods 0.000 description 2
- 229910001174 tin-lead alloy Inorganic materials 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910002056 binary alloy Inorganic materials 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000012634 fragment Substances 0.000 description 1
- 239000010410 layer Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
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- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/26—Selection of soldering or welding materials proper with the principal constituent melting at less than 400 degrees C
- B23K35/262—Sn as the principal constituent
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
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- B23K35/24—Selection of soldering or welding materials proper
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- B23K35/268—Pb as the principal constituent
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/08—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of copper or alloys based thereon
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Abstract
本发明提供了一种专用于超薄光伏电池片焊接用的低熔点光伏焊带及其制备方法与应用。所述光伏焊带的制备步骤：将锡、铅、铋、银、铜进行混合熔解，制得合金混合物；将所得合金混合物放入锡炉内加热，得低熔点焊料；将铜丝压延成铜带后直接退火，之后冷却至室温制得铜带；将所得铜带或直接将铜丝用助焊剂浸泡，随后干燥并将所得铜带或铜丝送入锡炉内，将所得低熔点焊料涂覆在铜带或铜丝表面，得到表面涂有低熔点焊料的涂锡铜带或涂锡铜丝；将所得涂锡铜带或涂锡铜丝冷却，并将冷却后的铜带和铜丝收卷成滚轴，最后真空包装，即得低熔点光伏焊带。本发明工艺简单，成本低，制备得到的光伏焊带导电性能好，熔点低，专用于超薄光伏电池片焊接。
Description
技术领域
本发明属于光伏新能源技术领域，尤其是涉及一种专用于超薄光伏电池片焊接用的低熔点光伏焊带及其制备方法与应用。
背景技术
太阳能光伏电池是一种非常有前景的新型电源，它具有永久性、清洁性和灵活性三大优点；但目前太阳能光伏发电成本还是要远远高于常规水利及火力发电，所以降低光伏电池片组件生产成本成为各企业的重中之重。在光伏电池片组件当中，原材料光伏电池片的成本占据整个组件生产成本的80％以上，常规光伏电池片厚度通常为180±5um，使用的光伏焊带通常是以锡铅合金为主二元合金焊料，焊料熔点183℃，机焊温度通常为200-210℃。在200-210℃焊接温度下，光伏电池片基材的热膨胀系数约为2.4×10-6/K，锡铅合金热膨胀系数为 27×10-6/K，铜基材为18.5×10-6/K，焊接温度越高，电池片基材与光伏焊带间的受热伸长量差异越大。当光伏电池片厚度在180um时，因加热而产生的应力尚能支撑，但光伏电池片会有不同程度的翘曲。为了降低光伏组件的材料成本，光伏电池片的厚度将不断下降(厚度为120-170um)，如果使用常规光伏焊带，在加热200℃后，光伏电池片与焊带之间的拉伸应力会超过光伏电池片的承受能力，从而产生隐裂甚至破裂，因此，必须要设计一种符合超薄光伏电池片使用要求的光伏焊带，这种光伏焊带需要具备较低的熔点和较低的焊接温度及较低的热膨胀系数，且需要具备良好的导电性能和焊接性能。本发明就是为解决这一问题而产生的。
发明内容
本申请针对现有技术的不足，本发明提供了一种专用于超薄光伏电池片焊接用的低熔点光伏焊带及其制备方法与应用。本发明工艺简单，成本低，制备得到的光伏焊带导电性能好，熔点低。
本发明的技术方案如下：
一种低熔点光伏焊带，所述光伏焊带由铜带或铜丝与光伏焊料组成；其中所述光伏焊料包括以下金属成分：锡、铋、银、铜。
所述光伏焊料还包括铅，质量百分比为0-50％。
所述光伏焊料中原料的质量百分比为：铋10-20％、银0-5％、铜0-5％，其他组份为锡及少量不可避免的杂质。
所述的光伏焊带的制备方法具体包括：
(1)合金制备：将锡、铅、铋、银、铜进行混合熔解，制得合金混合物；
(2)光伏焊料的制备：将步骤(1)中所得合金混合物放入锡炉内加热，使得锡炉内温度保持在150-193℃范围内，得光伏焊带用低熔点焊料；
(3)铜带制备：将铜丝压延成铜带后直接退火，此时铜带的行进速度保持在100-150m/min，冷却至室温；
(4)表面涂覆焊料：将步骤(3)中所得铜带或直接将铜丝用助焊剂浸泡，随后干燥，将所得铜带或铜丝送入步骤(2)中的锡炉内，将步骤(2)中所得光伏焊带用低熔点焊料涂覆在铜带或铜丝表面，并通过风刀控制铜带或铜丝表面的光伏焊料涂层，得到表面涂有低熔点焊料的涂锡铜带或涂锡铜丝；
(5)包装：将步骤(4)中所得涂锡铜带或涂锡铜丝使用风扇或风道进行冷却，并将冷却后的铜带和铜丝收卷成滚轴，最后真空包装，即得低熔点光伏焊带。
步骤(1)中所述熔解温度为128-180℃。
步骤(4)中所述助焊剂包括溶剂型助焊剂和水剂型助焊剂。
步骤(4)中所述铜带或铜丝表面的光伏焊料涂层厚度为5-40μm。
一种光伏焊带在超薄光伏电池片焊接中的应用。
本发明有益的技术效果在于：
本发明的低熔点光伏焊带所用焊料为锡Sn、铅Pb、铋Bi、银Ag、铜Cu等金属组成的三元、四元或五元合金焊料，低熔点光伏焊带在较宽的温度范围内与常规光伏焊带有着相同的物理性能，并且很多化学特性相似，但由于加入不同的合金成分，低熔点光伏焊带可以降低熔点，减少表面张力，其熔化温度为 119℃～168℃，热膨胀系数约为20×10-6/K，与铜基材相近，由于有着较低的热膨胀系数及焊接温度，在与超薄光伏电池片焊接后，光伏电池片变形量很小，应力小于光伏电池片承受能力，可大幅降低超薄光伏电池片的隐裂和碎片率。
具体实施方式
下面结合实施例，对本发明进行具体描述。
实施例1
步骤一，按以下质量百分比将各种金属组分放在一起熔解来配制合金成分，熔融温度为128℃；
锡Sn：45-55％
铅Pb：40-50％
铋Bi：12-15％
银Ag：1-2％
铜Cu：1％
步骤二，将步骤一所得的合金放入锡炉内，锡炉内的温度保持在 183℃-193℃，制备得到光伏焊料。
步骤三，将铜丝压延成铜带直接退火，并冷却至室温，此时铜带的行进速度保持在100m/min。
步骤四，采用热浸法涂锡：将铜带浸泡溶剂型助焊剂，然后经过锡炉，将步骤二中得到光伏焊料涂覆在铜带表面，通过风刀控制铜带表面的涂锡层厚度，此时厚度达到10微米。
步骤五，使用风扇对涂有焊料的铜带的正反面进行冷却，将冷却后的低熔点的光伏焊带进行收卷成滚轴，真空包装。
本实施例所得的低熔点光伏焊带焊接温度在173-183℃。
实施例2
步骤一，按以下质量百分比将各种金属组分放在一起熔解来配制合金成分，此时熔融温度为129℃；
锡Sn：50-52％
铋Bi：15-18％
铅Pb：30-32％
银Ag：1-2％
铜Cu：1-2％
步骤二，将第一步所得的合金放入锡炉内，锡炉内的温度保持在 159℃-169℃，制备得到光伏焊料。
步骤三，采用热浸法涂锡：将铜丝浸泡在水溶型助焊剂中，然后经过锡炉，将步骤二中得到光伏焊料涂覆在铜丝表面，通过风刀控制铜丝表面的涂锡层厚度，此时厚度达到4微米。
步骤四，使用风扇对涂有焊料的铜丝进行冷却，将冷却后的低熔点的光伏焊带进行收卷成滚轴，真空包装。
本实施例所得的低熔点光伏焊带焊接温度在149℃-159℃。
实施例3
步骤一，按以下质量百分比将各种金属组分放在一起熔解来配制合金成分，此时熔融温度为130℃；
锡Sn：44-45％
铅Pb：46-47％
铋Bi：6-10％
银Ag：1-2％
铜Cu：2-3％
步骤二，将第一步所得的合金放入锡炉内，锡炉内的温度保持在 187℃-193℃，制备得到光伏焊料。
步骤三，将铜丝压延成铜带直接退火处理，此时铜带的行进速度保持在 120m/min。
步骤四，采用热浸法涂锡，铜带浸泡溶剂型助焊剂，然后经过锡炉，将步骤二中得到光伏焊料涂覆在铜带表面，通过风刀控制铜带或铜丝表面的涂锡层厚度，此时厚度达到35微米。
步骤五，使用风扇对涂有焊料的铜带的正反面进行冷却，将冷却后的低熔点的光伏焊带进行收卷成滚轴，真空包装。
本实施例所得的低熔点光伏焊带温度在177℃-187℃。
测试例
将实施例1制备得到的光伏焊带与常规焊带进行性能测试，得到如下表所述结果：
从以上表格数据可以看出：通过本发明申请制备得到的光伏焊带相比于对比例1中的常规焊带具有较底的焊料热膨胀系数，以及较底的焊接温度，表现出了优异的焊带性能，可以减少较多成本投入。
上述实施方式仅为本发明的优选实施方式，不能以此来限定本发明保护的范围，本领域的技术人员在本发明的基础上所做的任何非实质性的变化及替换均属于本发明所要保护的范围。
Claims (8)
1.一种低熔点光伏焊带，其特征在于，所述光伏焊带由铜带或铜丝与光伏焊料组成；其中所述光伏焊料包括以下金属成分：锡、铋、银、铜。
2.根据权利要求1所述的光伏焊带，其特征在于，所述光伏焊料还包括铅，质量百分比为0-50％。
3.根据权利要求1所述的光伏焊带，其特征在于，所述光伏焊料中原料的质量百分比为：铋10-20％、银0-5％、铜0-5％，其他组份为锡及少量不可避免的杂质。
4.一种如权利要求1-2中任一项所述的光伏焊带的制备方法，其特征在于，所述制备方法具体包括：
(1)合金制备：将锡、铅、铋、银、铜进行混合熔解，制得合金混合物；
(2)光伏焊料的制备：将步骤(1)中所得合金混合物放入锡炉内加热，使得锡炉内温度保持在150-193℃范围内，得光伏焊带用低熔点焊料；
(3)铜带制备：将铜丝压延成铜带后直接退火，此时铜带的行进速度保持在100-150m/min，冷却至室温；
(4)表面涂覆焊料：将步骤(3)中所得铜带或直接将铜丝用助焊剂浸泡，随后干燥，将所得铜带或铜丝送入步骤(2)中的锡炉内，将步骤(2)中所得光伏焊带用低熔点焊料涂覆在铜带或铜丝表面，并通过风刀控制铜带或铜丝表面的光伏焊料涂层，得到表面涂有低熔点焊料的涂锡铜带或涂锡铜丝；
(5)包装：将步骤(4)中所得涂锡铜带或涂锡铜丝使用风扇或风道进行冷却，并将冷却后的铜带和铜丝收卷成滚轴，最后真空包装，即得低熔点光伏焊带。
5.根据权利要求4所述的制备方法，其特征在于，步骤(1)中所述熔解温度为128-180℃。
6.根据权利要求4所述的制备方法，其特征在于，步骤(4)中所述助焊剂包括溶剂型助焊剂和水剂型助焊剂。
7.根据权利要求4所述的制备方法，其特征在于，步骤(4)中所述铜带或铜丝表面的光伏焊料涂层厚度为5-40μm。
8.一种如权利要求1-3任一项所述的光伏焊带在超薄光伏电池片焊接中的应用。
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