Bus bar for full screen assembly and manufacturing method thereof

Abstract

The invention discloses a bus bar for a full-screen assembly and a manufacturing method of the bus bar. The bus bar is characterized by comprising a conductive substrate and an insulating rubber strip, a hollow structure is arranged on the insulating rubber strip; the conductive substrate is arranged on the insulating rubber strip; and the hollow structure is covered by the conductive substrate. By improving the bus bar structure and the manufacturing and application process thereof, the improved bus bar is arranged on the back surface of the battery piece to be processed, so that the light receiving area of the module is not occupied, the full laying rate of the battery piece is improved, and the power generation power of the module is further improved; original reserved bus bar interval areas in the middle and on the periphery of the assembly are canceled, so that the whole assembly does not have a blank area any more, and the overall attractiveness is high; meanwhile, the improved bus bar is welded in the assembly lamination process, a bus bar welding process is not needed, the equipment investment can be saved, the technological process can be shortened, and the production cost can be reduced.

Description

Technical Field

[0001] The present invention belongs to the field of battery assembly preparation, and in particular relates to a bus bar for a full-screen assembly and a manufacturing method thereof. Background Art

[0002] The PN junction and metal contact of the back-contact solar cell are both on the back of the cell, and the front surface is completely shielded by the metal grid electrode, thereby increasing the area of ​​the cell absorbing sunlight, improving the conversion efficiency, and generating more electricity. At the same time, the design of the back-contact solar cell without grid lines on the surface improves the aesthetics of the module and is more in line with the needs of the high-end distributed market.

[0003] At present, the busbars of back-contact solar cells are mostly arranged in the middle or on the edges of the battery cells. This arrangement has the following common problems: 1. The busbar occupies some of the light-receiving area of ​​the component, resulting in a low component filling rate, which affects the power generation of the component; 2. A certain blank area is reserved in the middle or around the component for placing the busbar, which makes the component not aesthetically pleasing; 3. In order to achieve the welding of the busbar and the battery string, it is necessary to increase the busbar welding process and related equipment, thereby increasing the production cost.

[0004] Based on this, the traditional busbars and their arrangement will greatly reduce the technical advantages of back-contact batteries, becoming a problem that needs to be solved urgently. Summary of the invention

[0005] The present invention aims to solve the above-mentioned problems and provides a bus bar for a full-screen component and a method for manufacturing the same, which can simultaneously solve the problems of low power generation, low aesthetics and high production cost caused by the bus bar arrangement of the back contact battery.

[0006] In a first aspect, the present invention provides a bus bar for a full-screen assembly, comprising a conductive substrate and an insulating rubber strip; The insulating rubber strip is provided with a plurality of hollow structures; The conductive substrate is arranged on the insulating rubber strip; The hollow structure is covered by the conductive substrate.

[0007] Furthermore, in the busbar for the full-screen assembly of the present invention, the base material of the insulating rubber strip is POE or EVA or PUR or TPU; The thickness of the insulating tape is 1-200 μm; The width of the insulating rubber strip is greater than the width of the conductive substrate.

[0008] Furthermore, in the busbar for a full-screen assembly of the present invention, the conductive substrate is one or more of copper, aluminum, nickel, tin, and silver; when multiple materials are used, it can be an alloy of multiple metals, or a multi-layer structure combination of multiple metal materials; The thickness of the conductive substrate is 10-200 μm; The width of the conductive substrate is 1000-6000 μm.

[0009] In a second aspect, the present invention provides a method for manufacturing a bus bar for a full-screen assembly, comprising: The insulating film is cut into a specified shape and a hollow structure is formed to obtain a hollow insulating strip; during the manufacturing process, the hollow structure of the insulating strip can be formed by mechanical punching, slotting or laser punching and slotting; the shape of the hollow structure can be a regular geometric figure or a figure of any shape.

[0010] Bonding the aforementioned hollowed-out insulating rubber strip to a conductive substrate to obtain a bus bar; The hollow structure is covered by the conductive substrate.

[0011] Furthermore, in the method for manufacturing a busbar for a full-screen assembly of the present invention, the base material of the insulating rubber strip is POE or EVA or PUR or TPU; The thickness of the insulating tape is 1-200 μm; The width of the insulating rubber strip is greater than the width of the conductive substrate.

[0012] Furthermore, in the method for manufacturing a busbar for a full-screen assembly of the present invention, the conductive substrate is one or more of copper, aluminum, nickel, tin, and silver; when multiple materials are used, it can be an alloy of multiple metals, or a multi-layer structure combination of multiple metal materials; The thickness of the conductive substrate is 10-200 μm; The width of the conductive substrate is 1000-6000 μm.

[0013] In a third aspect, the present invention provides a method for applying a bus bar for a full-screen assembly, comprising: providing a conductive contact layer at a position on a backside welding strip of a cell to be processed that needs to be connected to the bus bar; The busbar prepared in the second aspect is laid at a designated position on the back of the battery cell to be processed, so that the conductive substrate corresponding to the hollow structure on the busbar only achieves ohmic contact with the conductive contact layer provided on the welding strip on the back of the battery cell; the busbar is arranged on the back of the battery cell, does not occupy the light receiving area of ​​the component, improves the filling rate of the battery cell, and effectively improves the power of the component; the interval area of ​​the busbar originally reserved in the middle and periphery of the component is cancelled, so that there is no blank area in the entire component, and the appearance is more beautiful; The conductive contact layer of the battery cell to be processed is melted and then solidified or directly solidified during the subsequent lamination, so that the circuit conduction between the welding strip on the battery cell to be processed and the bus bar is achieved; by realizing welding during the lamination process, there is no need for bus bar welding process, which saves equipment investment, shortens the process flow, and thus reduces production costs.

[0014] Furthermore, the application method of the busbar for the full-screen assembly of the present invention is characterized in that: the setting method of setting the conductive contact layer is to lay or pre-coat the conductive material; The conductive contact layer is solder paste or a tin layer or a conductive glue; The melting or solidifying temperature of the conductive contact layer is lower than the heating temperature of the lamination.

[0015] Furthermore, the application method of the busbar for the full-screen assembly of the present invention is characterized in that the heating temperature of the lamination is 130°C-160°C.

[0016] Furthermore, the application method of the busbar for the full-screen assembly of the present invention is characterized in that: the base material of the insulating rubber strip of the busbar is P0E or EVA or PUR or TPU; The thickness of the insulating tape is 1-200 μm; The width of the insulating rubber strip is greater than the width of the conductive substrate; The conductive substrate of the busbar is one or more of copper, aluminum, nickel, tin, and silver; when multiple materials are used, it can be an alloy of multiple metals, or a multi-layer structure combination of multiple metal materials; The thickness of the conductive substrate is 10-200 μm; The width of the conductive substrate is 1000-6000 μm.

[0017] The bus bar for full-screen components and the method for making the same described in the present invention improve the bus bar structure and its manufacturing and application process, and the improved bus bar is arranged on the back of the battery cell to be processed, which does not occupy the light-receiving area of ​​the component, thereby improving the filling rate of the battery cell and further improving the power generation of the component; the spacing areas of the original reserved bus bars in the middle and periphery of the component are cancelled, so that the entire component no longer has any blank areas and has a high overall aesthetics; at the same time, the improved bus bar is welded during the component lamination process, and there is no need for a bus bar welding process, which can save equipment investment, shorten the process flow, and reduce production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of the busbar structure for a full-screen assembly according to the first embodiment of the present invention; Figure 2 An exploded view of a busbar structure for a full-screen assembly according to Embodiment 1 of the present invention; Figure 3 This is a schematic diagram of the structure of a busbar with lead wires according to the second embodiment of the present invention; Figure 4 This is a schematic diagram of the arrangement of conductive materials on a battery assembly according to Embodiment 3 of the present invention; Figure 5 This is a schematic diagram of the busbar pre-fixed position structure according to the third embodiment of the present invention; Figure 6 Based Figure 5 The enlarged structural diagram of part A in the middle; Figure 7 Based Figure 5 Schematic diagram of the cross section at BB; Among them, 1-insulating rubber strip, 2-conductive substrate, 3-bus bar, 4-hollow structure, 5-lead wire, 6-conductive material, 7-solder strip, 8-battery cell. DETAILED DESCRIPTION

[0019] The bus bar 3 for a full-screen assembly and the manufacturing method thereof according to the present invention are described in detail below through the accompanying drawings and embodiments.

[0020] Embodiment 1 This embodiment discloses a bus bar 3 for a full-screen assembly, such as Figure 1 , Figure 2 As shown, it includes a conductive substrate 2 and an insulating rubber strip 1; in the embodiment of the present disclosure, the hollow structure 4 arranged on the insulating rubber strip 1 is 5 conductive holes; the conductive substrate 2 is arranged on the insulating rubber strip 1; the conductive holes are all covered by the aforementioned conductive substrate 2; the width of the insulating rubber strip 1 is greater than the width of the conductive substrate 2.

[0021] In the disclosed embodiment, the base material of the insulating rubber strip 1 is POE; the thickness of the insulating rubber strip 1 is 100 μm; the conductive substrate 2 is made of copper; the thickness of the conductive substrate 2 is 200 μm; and the width of the conductive substrate 2 is 5000 μm.

[0022] Embodiment 2 Based on the bus bar 3 for the full-screen component disclosed in the first embodiment, this embodiment discloses a method for manufacturing the bus bar 3 for the full-screen component, which specifically includes the following steps: Step 021, cutting the insulating film into a specified shape and opening a hollow structure 4 to form a through hole to obtain a hollow insulating strip 1; Step 022, bonding the aforementioned hollow insulating rubber strip 1 to the conductive substrate 2 to obtain a bus bar 3; the aforementioned conductive holes are all covered by the aforementioned conductive substrate 2.

[0023] The punching method of the insulating rubber strip 1 can be any one of mechanical punching or laser punching according to actual conditions during the manufacturing process; the specific shape of the conductive hole can be set to one of circular, diamond, rectangular, elliptical or triangular according to the actual application scenario.

[0024] In the disclosed embodiment, the insulating rubber strip 1 and the conductive substrate 2 are bonded together by infrared heating, and the surface heating of the transmission plate may also be selected according to the actual application.

[0025] In the embodiment of the present disclosure, in order to adapt to the existing junction box, such as Figure 3 As shown, the lead wire 5 of the busbar 3 is cut and folded into a thick and narrow lead wire 5 by cutting the over-wide part. In practical applications, a narrow and thick busbar 3 lead wire 5 can also be re-welded, or the over-wide part can be directly cut off to form a narrow and thin lead wire 5.

[0026] Embodiment 3 Based on the first and second embodiments, this embodiment discloses an application method of a bus bar 3 for a full-screen assembly, which specifically includes the following steps: Step S031: Figure 4 As shown, a conductive material 6 is pre-coated on the backside welding strip 7 of the to-be-processed battery cell 8 at a position where the welding strip 7 needs to be connected to the bus bar 3; Step S032: Lay the bus bar 3 described in the first embodiment or the bus bar 3 prepared in the second embodiment at a designated position on the back of the battery cell 8 to be processed, such as Figure 5 , Figure 6 As shown, the through hole of the bus bar 3 is overlapped with the conductive material 6, and the bus bar 3 is pre-fixed at this position, and the conductive substrate 2 corresponding to the through hole only achieves ohmic contact with the conductive material 6 pre-coated on the back welding strip 7 of the battery cell 8; Step S033: Figure 7 As shown, the conductive material 6 of the processed cell 8 is solidified during the subsequent lamination, so that the soldering strip 7 on the processed cell 8 and the bus bar 3 are connected to each other; while the connection is made, the lamination of the components is completed to obtain a back-contact solar component.

[0027] In the disclosed embodiment, the conductive material 6 is a tin layer; the heating temperature of the lamination is 150°C; and the curing temperature of the conductive material 6 is lower than the heating temperature of the lamination. In specific applications, technicians can also choose to lay solder paste on the back solder strip 7 of the battery cell 8 to be processed at the position where it needs to be connected to the bus bar 3 according to actual conditions. The solder paste melts and solidifies during the lamination process to achieve effective conduction.

[0028] The application method of the bus bar 3 for the full-screen component described in this embodiment arranges the bus bar 3 on the back of the battery cell 8 without occupying the light-receiving area of ​​the component, thereby improving the coverage rate of the battery cell 8 and effectively improving the power of the component; the spacing area originally reserved for the bus bar 3 in the middle and periphery of the component is cancelled, so that there is no blank area in the entire component, and the appearance is more beautiful; by realizing welding during the lamination process, there is no need for the bus bar 3 welding process, which saves equipment investment, shortens the process flow, and thus reduces production costs.

Claims

1. A bus bar for a full-screen component, characterized in that: It includes a conductive substrate and an insulating rubber strip; The insulating rubber strip is provided with a hollow structure; The conductive substrate is arranged on the insulating rubber strip; The hollow structure is covered by the conductive substrate.

2. The bus bar for a full-screen assembly according to claim 1, characterized in that: The base material of the insulating rubber strip is POE or EVA or PUR or TPU; The thickness of the insulating tape is 1-200 μm; The width of the insulating rubber strip is greater than the width of the conductive substrate.

3. The bus bar for a full-screen assembly according to claim 2, characterized in that: The conductive substrate is one or more of copper, aluminum, nickel, tin, and silver; The thickness of the conductive substrate is 10-200 μm; The width of the conductive substrate is 1000-6000 μm.

4. A method for manufacturing a busbar for a full-screen component, characterized in that include: The insulating film is cut into a specified shape and a hollow structure is formed to obtain a hollow insulating strip; Bonding the aforementioned hollowed-out insulating rubber strip to a conductive substrate to obtain a bus bar; The hollow structure is covered by the conductive substrate.

5. The method for manufacturing a bus bar for a full-screen assembly according to claim 4, characterized in that: The base material of the insulating rubber strip is POE or EVA or PUR or TPU; The thickness of the insulating tape is 1-200 μm; The width of the insulating rubber strip is greater than the width of the conductive substrate.

6. The method for manufacturing a bus bar for a full-screen assembly according to claim 5, characterized in that: The conductive substrate is one or more of copper, aluminum, nickel, tin, and silver; The thickness of the conductive substrate is 10-200 μm; The width of the conductive substrate is 1000-6000 μm.

7. A method for applying a busbar for a full-screen assembly, characterized in that include: A conductive contact layer is provided at a position on the back side welding strip of the battery cell to be processed where it needs to be connected to the bus bar; Laying the busbar prepared in claim 4 at a designated position on the back of the battery cell to be processed, so that the conductive substrate corresponding to the hollow structure on the busbar only achieves ohmic contact with the conductive contact layer provided on the welding strip on the back of the battery cell; The conductive contact layer of the battery cell to be processed is melted and then solidified or directly solidified during the subsequent lamination, so that the circuit conduction between the welding strip on the battery cell to be processed and the bus bar is achieved.

8. The method for applying the busbar for a full-screen assembly according to claim 7, characterized in that: The conductive contact layer is provided by laying or pre-coating a conductive material; The conductive contact layer is solder paste or a tin layer or a conductive glue; The melting or solidifying temperature of the conductive contact layer is lower than the heating temperature of the lamination.

9. The method for applying the busbar for a full-screen assembly according to claim 8, characterized in that: The heating temperature of the lamination is 130°C-160°C.

10. The method for applying the busbar for a full-screen assembly according to claim 9, characterized in that: The base material of the insulating rubber strip of the busbar is POE or EVA or PUR or TPU; The thickness of the insulating tape is 1-200 μm; The width of the insulating rubber strip is greater than the width of the conductive substrate; The conductive substrate of the busbar is one or more of copper, aluminum, nickel, tin, and silver; The thickness of the conductive substrate is 10-200 μm; The width of the conductive substrate is 1000-6000 μm.

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