A shaped conductive wire and a system for producing shaped conductive wires

Abstract

This invention discloses a shaped conductive wire and a system for producing the shaped conductive wire. The shaped conductive wire includes: alternating first and second conductive segments, and a third conductive segment located between the first and second conductive segments. The angle between the side surface and bottom surface of the first conductive segment is less than 90°. The cross-section of the second conductive segment is rectangular or approximately rectangular. The shaped conductive wire is applied to a battery string structure consisting of multiple back-contact solar cells. In the battery string structure, the positive and negative grids of each pair of adjacent back-contact solar cells correspond to each other. The alternating first and second conductive segments of the shaped conductive wire correspond to the alternating negative and positive grids in the same row of the battery string structure, respectively. The structure of the third conductive segment is the same as that of the first or second conductive segment, improving the light absorption of the back-contact solar cells and providing a better welding effect between the shaped conductive wire and the back-contact solar cells.

Description

Technical Field

[0001] This invention relates to a shaped conductive wire and a system for producing shaped conductive wires. Background Technology

[0002] For back-contact solar cells, the positive and negative electrodes are arranged alternately on the back side of the solar cell. Currently, a fine grid interconnection structure is used to further efficiently discharge the current generated by the back-contact solar cell. Specifically, the fine grid interconnection structure directly connects the conductive wires to the positive and negative electrodes of the back-contact solar cell.

[0003] Currently, the conductive wires used in the grid of back-contact solar cells are generally flat conductive wires with an elliptical cross-section or conductive wires with a triangular cross-section. While flat conductive wires with an elliptical cross-section can bond well with the grid, their large shading area affects the light absorption of the back-contact solar cell. Conversely, while triangular conductive wires have a smaller shading area, their bonding effect with the grid is poor. Therefore, it is essential to design a novel irregularly shaped conductive wire that can improve both the light absorption of the back-contact solar cell and the bonding effect with the grid, as well as a system for producing such a wire. Summary of the Invention

[0004] In view of this, the present invention provides a shaped conductive wire and a system for producing the shaped conductive wire. The two alternating structures of the shaped conductive wire are respectively matched with the positive and negative grids of the back contact solar cell. The first conductive segment can reduce light shading while reflecting light onto the back contact solar cell, thereby improving the light absorption of the back contact solar cell. The second conductive segment enables the shaped conductive wire to have a better welding effect with the back contact solar cell.

[0005] Specifically, the present invention provides the following technical solutions: In a first aspect, the present invention provides an irregularly shaped conductive wire, comprising: alternating first and second conductive segments, and a third conductive segment located between the first and second conductive segments. The angle between the side surface of the first conductive segment and the bottom surface of the first conductive segment is less than 90°; The cross-section of the second conductive segment is rectangular or approximately rectangular; The irregularly shaped conductive wire is applied to a battery string structure in which multiple back-contact solar cells or multiple back-contact solar cell sheets are arranged, wherein the positive grid of each pair of adjacent back-contact solar cells or back-contact solar cell sheets corresponds to the negative grid. The alternating first and second conductive segments of the irregularly shaped conductive wires correspond to the alternating negative and positive grids located in the same row in the battery string structure, respectively. The third conductive segment corresponds to the region between the two adjacent ends of the corresponding positive and negative grids of two adjacent back-contact solar cells or back-contact solar cell sheets. The structure of the third conductive segment is the same as the structure of the first conductive segment or the structure of the second conductive segment.

[0006] Secondly, embodiments of the present invention provide a system for producing conductive wires, comprising: a transmission mechanism, a limiting mechanism, a shaping mechanism, and a positioning control mechanism, wherein... Both the limiting mechanism and the shaping mechanism are disposed on the transmission mechanism, and the limiting mechanism and the shaping mechanism are arranged at intervals along the transmission direction of the transmission mechanism; The limiting mechanism is used to limit the conductive wire on the transmission mechanism; The transmission mechanism is used to transmit the conductive wire; The positioning control mechanism is used to locate the segment to be shaped of the interval of the conductive wire transmitted by the transmission mechanism in real time, and to send a squeezing command to the shaping mechanism after the segment to be shaped reaches the shaping mechanism. The shaping mechanism is used to squeeze the section of the conductive wire to be shaped located below it after receiving the squeezing command.

[0007] The technical solution of the first aspect of the above invention has the following advantages or beneficial effects: The irregularly shaped conductive wire provided in this invention can match different structures of first and second conductive segments to the corresponding positive and negative grids of a battery string structure consisting of multiple back-contact solar cells or multiple back-contact solar cells. On the one hand, it allows light reflected from the side of the first conductive segment to reach the back-contact solar cell or back-contact solar cell, improving the light absorption and light utilization rate of the back-contact solar cell or back-contact solar cell. On the other hand, the cross-section of the second conductive segment of the irregularly shaped conductive wire is rectangular or approximately rectangular, which enables a better welding effect between the second conductive segment and the grid of the back-contact solar cell or back-contact solar cell, improving the reliability and stability of the welding between the irregularly shaped conductive wire and the grid of the back-contact solar cell or back-contact solar cell. Therefore, the irregularly shaped conductive wire provided in this invention can improve the light absorption and light utilization rate of the back-contact solar cell or back-contact solar cell while ensuring a relatively reliable and stable welding connection. Attached Figure Description

[0008] Figure 1 This is a partial cross-sectional structural diagram of a back-contact solar cell using irregularly shaped conductive wires according to an embodiment of the present invention. Figure 2 This is a partial structural schematic diagram of a battery string structure provided according to an embodiment of the present invention; Figure 3 This is a partial structural schematic diagram of the application of irregularly shaped conductive wires to a battery string structure according to an embodiment of the present invention. Figure 4 This is a schematic diagram of the structure of the irregularly shaped conductive wire of the first type provided in the embodiments of the present invention; Figure 5 This is a schematic diagram of the structure of the irregularly shaped conductive wire of the second type provided in the embodiments of the present invention; Figure 6 This is a schematic cross-sectional view of the relative relationship between the irregularly shaped conductive wire and the back-contact solar cell according to an embodiment of the present invention. Figure 7 This is a schematic diagram of a system for producing irregularly shaped conductive wires according to an embodiment of the present invention; Figure 8 This is a schematic diagram of the process of producing irregularly shaped conductive wires according to an embodiment of the present invention; Figure 9 This is a schematic diagram of the structure of a conductive wire before system processing according to an embodiment of the present invention.

[0009] The attached figures are labeled as follows: 10-Transmission mechanism; 11-Second fixing member; 12-Transmission drive motor; 13-Conveyor belt; 20-Limiting mechanism; 21-Limiting part; 211-Limiting block; 22-Connecting part; 221-First connecting rod; 222-First fixing member; 223-Second connecting rod; 30-Shaping mechanism; 31-Supporting structure; 311-Supporting column; 312-Placement platform; 313-Supporting platform; 32-Driver; 33-Shaping block; 40-Positioning control mechanism; 41-Intelligent controller; 42-Light sensor; 43-Display screen; 51-Conductive wire; 52-Irregularly shaped conductive wire; 521-First conductive segment; 522-Second conductive segment; 523-Third conductive segment; 60-Back contact solar cell; 61-Positive electrode grid; 62-Negative electrode grid; K-Transmission direction. Detailed Implementation

[0010] The irregularly shaped conductive wire 52 involved in this invention is generally applied to the fine grid interconnection process of back-contact solar cells or back-contact solar cell wafers. The fine grid interconnection process mainly involves directly connecting the irregularly shaped conductive wire 52 to the fine grid (positive and negative grids) of the back-contact solar cell or back-contact solar cell wafer, omitting the main grid of the back-contact solar cell or back-contact solar cell wafer.

[0011] The back-contact solar cell 60 involved in the embodiments of the present invention is generally obtained by laser cutting of the back-contact solar cell.

[0012] Specifically, the back side of the back-contact solar cell includes alternating N-type and P-type conductive regions, and an electrical isolation region located between adjacent N-type and P-type conductive regions. The positive electrode grid 61 is disposed in the P-type conductive region, and the negative electrode grid 62 is disposed in the N-type conductive region. Generally, for a back-contact solar cell where the N-type conductive region includes an N-type polycrystalline silicon layer or an N-type diffusion layer, and the P-type conductive region includes a P-type polycrystalline silicon layer or a P-type diffusion layer, there is a certain height difference between the P-type and N-type conductive regions, i.e., as shown... Figure 1 As shown, when the back side of the back-contact solar cell faces upward, the height of the P-type conductive region is higher than the height of the N-type conductive region. The irregularly shaped conductive wire 52 provided in this embodiment of the invention can connect conductive segments with different structures to the positive and negative electrode grids respectively, so that the light reflected by the conductive segments connected to the negative electrode grid can reach the P-type conductive region and the electrically isolated region, thereby improving the light utilization rate of the back-contact solar cell or the back-contact solar cell sheet 60.

[0013] The battery string structure involved in the embodiments of the present invention is as follows: Figure 2 As shown, multiple back-contact solar cells or multiple back-contact solar cells 60 are arranged in a row, wherein the positive grid lines of each pair of adjacent back-contact solar cells or back-contact solar cells 60 correspond to the negative grid lines. This cell string structure includes multiple rows of grid lines, each row comprising alternating positive grid lines 61 and negative grid lines 62, and the alternating positive grid lines 61 and negative grid lines 62 in the same row belong to different back-contact solar cells or back-contact solar cells 60.

[0014] like Figure 3 As shown, a non-circular conductive wire 52 can simultaneously connect alternating positive grid lines 61 and negative grid lines 62 located in the same row.

[0015] The cross-section of the conductive segment involved in the embodiments of the present invention generally refers to a cross-section perpendicular to the extension direction of the conductive segment.

[0016] The bottom surface of the first conductive segment 521 in the embodiments of the present invention generally refers to the surface of the first conductive segment 521 that is in contact with the grid line (generally the negative grid line) of the back-contact solar cell or the back-contact solar cell 60.

[0017] In the embodiments of the present invention, the side surface of the first conductive segment 521 generally refers to the surface that is connected to the bottom surface of the first conductive segment 521 and forms a certain angle with the bottom surface of the first conductive segment 521.

[0018] It should be noted that the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0019] Specifically, an embodiment of the present invention provides an irregularly shaped conductive wire 52. For example... Figures 4 to 6 As shown, the irregularly shaped conductive wire 52 may include: alternating first conductive segments 521 and second conductive segments 522, and a third conductive segment 523 located between the first conductive segments 521 and the second conductive segments 522, wherein the angle between the side surface of the first conductive segment 521 and the bottom surface of the first conductive segment 521 is less than 90°; the cross-section of the second conductive segment 522 is rectangular or approximately rectangular.

[0020] The irregularly shaped conductive wire 52 provided in this embodiment of the invention is applied to a battery string structure in which multiple back-contact solar cells or multiple back-contact solar cell wafers 60 are arranged. Figure 2 and Figure 3 As shown in the figure, in the battery string structure, the positive grid 61 of each two adjacent back-contact solar cells or back-contact solar cell sheets 60 corresponds to the negative grid 62.

[0021] The alternating arrangement of the irregularly shaped conductive wires 52 in the first conductive segment 521 and the second conductive segment 522 corresponds to the alternating arrangement of the negative electrode grid 62 and the positive electrode grid 61 in the same row in the battery string structure, respectively. The third conductive segment 523 corresponds to the region between the close ends of the corresponding positive electrode grid 61 and negative electrode grid 62 of two adjacent back-contact solar cells or back-contact solar cell sheets 60; the structure of the third conductive segment 523 is the same as the structure of the first conductive segment 521 or the structure of the second conductive segment 522.

[0022] The first conductive segment 521, the second conductive segment 522, and the third conductive segment 523 of the irregularly shaped conductive wire 52 provided in this embodiment of the invention are an integral structure.

[0023] The alternating arrangement of the irregularly shaped conductive wires 52, specifically the first conductive segment 521 and the second conductive segment 522, corresponds to the specific structure of the alternating negative electrode grids 62 and positive electrode grids 61 located in the same row of the battery string structure. The taller grid in the negative electrode grids 62 and positive electrode grids 61 corresponds to the second conductive segment 522; the shorter grid in the negative electrode grids 62 and positive electrode grids 61 corresponds to the first conductive segment 521. The height of the grid is primarily determined by the upward orientation of the negative electrode grids 62 and positive electrode grids 61 included in the back-contact solar cell or back-contact solar cell sheet 60. Understandably, before the irregularly shaped conductive wires 52 are provided for the back-contact solar cell or back-contact solar cell sheet 60, the area containing the taller grid is thicker, and the area containing the shorter grid is thinner. By having the shorter grid correspond to the first conductive segment 521, it can be ensured that the light reflected from the first conductive segment 521 can reach the area containing the taller grid, thereby improving the light utilization rate of the back-contact solar cell or back-contact solar cell sheet 60.

[0024] For example, such as Figure 6 As shown, when the P-type conductive region of the back-contact solar cell or the back-contact solar cell 60 is higher than the N-type conductive region, the first conductive segment 521 corresponds to the negative electrode fine grid 62, and the second conductive segment 522 corresponds to the positive electrode fine grid 61.

[0025] The cross-section of the second conductive segment 522 being approximately rectangular means that the bottom edge of the cross-section of the second conductive segment 522 that contacts the grid line and the top edge that is away from the grid line are parallel, and the side edge located between the bottom edge and the top edge that is away from the grid line is a line segment or an arc, wherein the angle between the line segment and the bottom edge is 90°.

[0026] It is worth noting that in the battery string structure of the irregularly shaped conductive wire 52 provided in the embodiments of the present invention, there may be a certain distance between adjacent back-contact solar cells or back-contact solar cell sheets 60, and the distance between adjacent back-contact solar cells or back-contact solar cell sheets 60 may also be 0 or negative.

[0027] Furthermore, the region between the adjacent ends of the corresponding positive electrode grids 61 and negative electrode grids 62 of two adjacent back-contact solar cells or back-contact solar cells 60 generally refers to the distance between the first end of the positive electrode grid 61 of the first cell (i.e., the end near the negative electrode grid 62 of the adjacent second cell) and the second end of the negative electrode grid 62 of the second cell (i.e., the end near the positive electrode grid 61 of the first cell). For cases where the distance is 0 or negative, if the first end of the first cell is covered by the second cell, the region between the adjacent ends of the corresponding positive electrode grids 61 and negative electrode grids 62 of two adjacent back-contact solar cells or back-contact solar cells 60 is the distance from the first end of the first cell to its nearest edge; if the second end of the second cell is covered by the first cell, the region between the adjacent ends of the corresponding positive electrode grids 61 and negative electrode grids 62 of two adjacent back-contact solar cells or back-contact solar cells 60 is the distance from the second end of the second cell to its nearest edge.

[0028] in, Figure 5 The structure of the third conductive segment 523 is shown to be the same as that of the first conductive segment 521, as exemplarily illustrated. Figure 4 The structure of the third conductive segment 523 is shown to be the same as that of the second conductive segment 522. Based on this, each conductive segment can be positioned more accurately according to the spacing between the positive electrode fine gate 61, the negative electrode fine gate 62 and the adjacent ends of the positive electrode fine gate 61 and the negative electrode fine gate 62, and each conductive segment can be processed more conveniently.

[0029] by Figure 6Taking the structure of a back-contact solar cell or back-contact solar cell 60 where the P-type conductive region is higher than the N-type conductive region as an example, the side of the first conductive segment 521 connected to the negative grid line 62 is matched with a lower N-type conductive region. This allows the side of the first conductive segment 521 to reflect light to the electrical isolation region and the P-type conductive region, enabling the back-contact solar cell or back-contact solar cell 60 to further utilize light, thereby enhancing light absorption and light utilization efficiency. Therefore, the irregularly shaped conductive wire 52 provided in this embodiment of the invention can match the corresponding positive grid 61 and negative grid 62 of a battery string structure with different structures of the second conductive segment 522 and the first conductive segment 521 (for example, the positive grid 61 matches the second conductive segment 522, and the negative grid 62 matches the first conductive segment 521) to the corresponding positive grid 61 and negative grid 62 of the battery string structure. This allows the light reflected from the side of the first conductive segment 521 to reach the back-contact solar cell or back-contact solar cell 60, improving the light absorption of the back-contact solar cell or back-contact solar cell 60, thereby improving the light utilization efficiency of the back-contact solar cell or back-contact solar cell 60.

[0030] In addition, compared with the existing technology that uses a conductive wire with a triangular cross section, the first conductive segment 521 and the second conductive segment 522 have different structures, and the cross section of the second conductive segment 522 is rectangular or approximately rectangular, which has a higher contact area and can effectively reduce welding defects and welding difficulty.

[0031] In addition, compared with the existing technology that uses a rectangular cross-section conductive wire, the angle between the side surface of the first conductive segment 521 and the bottom surface of the first conductive segment 521 is less than 90°, which can reduce the light-blocking effect of the first conductive segment 521, allowing more light to reach the back contact solar cell or back contact solar cell 60, thereby improving the light utilization rate of the back contact solar cell or back contact solar cell 60.

[0032] In a preferred embodiment, such as Figure 4 and Figure 5 As shown, the cross-section of the first conductive segment 521 is triangular, with the apex angle of the triangle being 55°~65°. The triangular cross-section of the first conductive segment 521, with a apex angle of 55°~65°, is connected to the lower-height conductive area (such as...). Figure 6 The N-type conductive region shown is used in conjunction with the first conductive segment 521 to allow the light reflected from its side to better reach the P-type conductive region and the electrical isolation region, thereby further improving the light utilization and photoelectric conversion efficiency of the back-contact solar cell or back-contact solar cell 60. For example, the apex angle of the triangle can be 55°, 58°, 60°, or 65°, etc.

[0033] In one embodiment, the height of the first conductive segment 521 is 0.8mm to 1.2mm, wherein the cross-section of the first conductive segment 521 is triangular, and the height of the first conductive segment 521 is the distance from the apex of the triangle to the bottom edge. Since the height of the first conductive segment 521 affects the distribution of welding pressure applied during the welding process, the higher the height of the first conductive segment 521, the smaller the bottom area of ​​the first conductive segment 521 that can be affected by the welding pressure. By limiting the height of the first conductive segment 521, it can be ensured that the welding pressure can be evenly distributed on the bottom surface of the first conductive segment 521 during the welding process, thereby ensuring a reliable and stable electrical connection between the first conductive segment 521 and its corresponding grid lines, while also ensuring a thinner photovoltaic module. For example, the height of the first conductive segment 521 can be 0.8mm, 0.9mm, 1.0mm, 1.1mm, or 1.2mm, etc.

[0034] In one embodiment, the height of the second conductive segment 522 is 0.3mm to 0.5mm. By limiting the height of the second conductive segment 522, a reliable and stable electrical connection can be formed between the second conductive segment 522 and its corresponding gate line. For example, the height of the second conductive segment 522 can be 0.3mm, 0.4mm, or 0.5mm, etc.

[0035] More specifically, the height of the second conductive segment 522 is 30% to 50% of the height of the first conductive segment 521. For example, the height of the second conductive segment 522 can be 30%, 35%, 40%, 45%, or 50% of the height of the first conductive segment 521. By controlling the height relationship between the second conductive segment 522 and the first conductive segment 521, when the second conductive segment 522 and the first conductive segment 521 are integrated into a single structure, it can be ensured that the second conductive segment 522 and the first conductive segment 521 simultaneously match their respective gate lines, and that the second conductive segment 522 and the first conductive segment 521 can form a stable and reliable electrical connection with their respective gate lines, thereby reducing the occurrence of poor soldering and over-soldering between the second conductive segment 522 and the first conductive segment 521 and their respective gate lines.

[0036] Understandably, such as Figure 3As shown, a shaped conductive wire 52 includes alternating first conductive segments 521 and second conductive segments 522. These segments are first connected in series with alternating positive and negative electrode grids 61 and 62 of the battery string structure. Then, a portion of the shaped conductive wire 52 is truncated in a third conductive segment 523 region. The truncated third conductive segment 523 alternates with the untruncated third conductive segment 523 in the same row. For each adjacent row, the truncated third conductive segment 523 in the first row corresponds to the untruncated third conductive segment 523 in the adjacent second row, so that each adjacent pair of back-contact solar cells or back-contact solar cell sheets 60 in the battery string structure are connected in series. The specific truncation position can be determined according to the series connection relationship of the battery string structure and is not limited here.

[0037] In summary, the irregularly shaped conductive wire 52 provided in this embodiment of the invention can match the first conductive segment 521 and the second conductive segment 522 of different structures to the corresponding positive electrode grid 61 and negative electrode grid 62 of a battery string structure with multiple back-contact solar cells or multiple back-contact solar cell sheets. On the one hand, it can enable the light reflected from the side of the first conductive segment 521 to reach the back-contact solar cell or back-contact solar cell sheet, thereby improving the light absorption and light utilization rate of the back-contact solar cell or back-contact solar cell sheet. On the other hand, the cross-section of the second conductive segment 522 of the irregularly shaped conductive wire 52 is rectangular or approximately rectangular, which enables the second conductive segment 522 to have a better welding effect with the grid of the back-contact solar cell or back-contact solar cell sheet, thereby improving the reliability and stability of the welding between the irregularly shaped conductive wire 52 and the grid of the back-contact solar cell or back-contact solar cell sheet. Therefore, the irregularly shaped conductive wire 52 provided in this embodiment of the invention can improve the light absorption and light utilization rate of the back-contact solar cell or back-contact solar cell sheet while ensuring a relatively reliable and stable welding connection between it and the back-contact solar cell or back-contact solar cell sheet.

[0038] Furthermore, embodiments of the present invention provide a system for producing irregularly shaped conductive wires 52. This system can be used to produce the irregularly shaped conductive wires 52 provided in any of the above embodiments. For example... Figure 7 and Figure 8As shown, the system may include: a transmission mechanism 10, a limiting mechanism 20, a shaping mechanism 30, and a positioning control mechanism 40. The limiting mechanism 20 and the shaping mechanism 30 are both mounted on the transmission mechanism 10 and are arranged at intervals along the transmission direction K of the transmission mechanism 10. The limiting mechanism 20 is used to limit the conductive wire 51 on the transmission mechanism 10. The transmission mechanism 10 is used to transmit the conductive wire 51. The positioning control mechanism 40 is used to locate the segments of the conductive wire 51 to be shaped at intervals transmitted by the transmission mechanism 10 in real time, and sends a pressing command to the shaping mechanism 30 after the segments reach it. The shaping mechanism 30 is used to press the segments of the conductive wire 51 below it after receiving the pressing command.

[0039] The system provided in this embodiment of the invention can produce irregularly shaped conductive wires 52, including alternating first conductive segments 521 and second conductive segments 522, and a third conductive segment 523 located between the first conductive segments 521 and the second conductive segments 522, and ensures that the first conductive segments 521, the second conductive segments 522, and the third conductive segments 523 of the formed irregularly shaped conductive wires 52 are an integral structure. This system can produce irregularly shaped conductive wires 52 relatively simply and quickly.

[0040] In addition, the system, through the cooperation of the transmission mechanism 10, the limiting mechanism 20, the shaping mechanism 30 and the positioning control mechanism 40, can accurately position the segment to be shaped.

[0041] It is worth noting that the system provided in this embodiment of the invention is based on an existing conductive wire 51, and obtains an irregularly shaped conductive wire 52 by processing the segments of the conductive wire 51 to be shaped at intervals. For example, the existing conductive wire 51 can be... Figure 9 The conductive wire 51 shown has a triangular cross-section, but it can also be a conductive wire with a trapezoidal cross-section, etc.

[0042] Among them, such as Figure 7 As shown, the transmission mechanism 10 generally includes a transmission drive motor 12 and a conveyor belt 13. The transmission drive motor 12 controls the transmission rate of the conductive wire 51 and the shaped conductive wire 52 via the conveyor belt 13. The transmission rate of the conductive wire 51 and the shaped conductive wire 52 via the transmission mechanism 10 can be from 0.5 m / min to 1.2 m / min to ensure good coordination between the transmission rate of the transmission mechanism 10 and the shaping mechanism 30 and the positioning control mechanism 40. This ensures that the shaping mechanism 30 can accurately process the section to be shaped while maintaining the production efficiency of the shaped conductive wire 52. For example, the transmission rate can be 0.5 m / min, 0.6 m / min, 0.8 m / min, 0.9 m / min, 1.0 m / min, or 1.2 m / min, etc.

[0043] In one embodiment of the present invention, such as Figure 7and Figure 8 As shown, the limiting mechanism 20 may include a limiting part 21 and a connecting part 22 disposed on both sides of the limiting part 21. The connecting part 22 is detachably connected to the transmission mechanism 10, and the connecting part 22 is used to fix the limiting part 21 above the transmission mechanism 10. The shape of the side of the limiting part 21 facing the transmission mechanism 10 is consistent with the shape of the conductive wire 51.

[0044] The limiting part 21 not only restricts the conductive wire 51 to the transmission mechanism 10, but also the shape of the side facing the transmission mechanism 10 is consistent with the shape of the conductive wire 51. This allows the conductive wire 51 to maintain its shape as it passes through the limiting part 21, so that the first conductive segment 521 of the resulting irregularly shaped conductive wire 52 can maintain the original shape of the conductive wire 51 (such as a triangular or trapezoidal cross-section). Only the shaping mechanism 30 needs to process the intervals of the segments to be shaped to obtain the irregularly shaped conductive wire 52. This enables the rapid production of the irregularly shaped conductive wire 52 and ensures that the irregularly shaped conductive wire 52 has high production efficiency.

[0045] In addition, the detachable connection between the connecting part 22 and the transmission mechanism 10 allows the limiting part 21 to be replaced and maintained at any time, making the system more maintainable.

[0046] More specifically, such as Figure 7 and Figure 8 As shown, the connecting part 22 may include: a first connecting rod 221, a first fixing member 222, and a second connecting rod 223; one end of the first connecting rod 221 is fixedly connected to the side of the limiting part 21; the first fixing member 222 is used to clamp and fix the first connecting rod 221 and the second connecting rod 223, and the first connecting rod 221 and the second connecting rod 223 are perpendicular to each other; the second connecting rod 223 is fixedly connected to the transmission mechanism 10. Through the cooperation of the first connecting rod 221, the first fixing member 222, and the second connecting rod 223, the various components of the connecting part 22 can be easily replaced and disassembled. If any component of the connecting part 22 is damaged, only that component can be replaced, instead of replacing the entire connecting part 22, thereby reducing the maintenance cost of the system. In addition, by cooperating with the first connecting rod 221, the first fixing member 222 and the second connecting rod 223, the distance between the limiting part 21 and the transmission mechanism 10 can be flexibly adjusted by the connection position of the first fixing member 222 and the second connecting rod 223, so as to better match different types of conductive wires 51 and improve the practicality of the limiting part 21.

[0047] Furthermore, in one embodiment of the present invention, as... Figure 7 and Figure 8As shown, the limiting part 21 may include: two limiting blocks 211 with a wedge-shaped structure on one side; the wedge-shaped structures of the two limiting blocks 211 form a ridge-shaped wedge, which is used to limit the conductive wire 51 with a triangular cross section. By cooperating with the two limiting blocks 211, the limiting blocks 211 can be easily replaced, and by cooperating with the two limiting blocks 211, the ridge-shaped wedge can be adjusted so that the limiting part 21 can meet the cross section of the conductive wire 51 of different sizes, ensuring the adjustability of the limiting part 21.

[0048] The wedge-shaped structure of the limiting block 211 has a side width of 0.8mm to 1.2mm. For example, the side width of the wedge-shaped structure of the limiting block 211 can be 0.8mm, 0.9mm, 1.0mm, 1.1mm or 1.2mm. By limiting the side width of the wedge-shaped structure of the limiting block 211, it can be ensured that the limiting block 211 matches the side of the conductive wire 51.

[0049] The apex angle of the ridge-shaped wedge is 55°~65° to ensure a better match between the ridge-shaped wedge and the conductive wire 51, and to ensure the shape retention of the conductive wire 51. For example, the apex angle of the ridge-shaped wedge can be 55°, 58°, 60° or 65°, etc.

[0050] Furthermore, in one embodiment of the present invention, as... Figure 7 and Figure 8 As shown, the transmission mechanism 10 includes a second fixing member 11 corresponding to the connecting part 22; the second fixing member 11 is used to clamp and fix the second connecting rod 223. The second fixing member 11 allows for easy assembly and disassembly of the second connecting rod 223, thereby further improving the maintainability of the connecting part 22.

[0051] In this embodiment of the invention, the shaping mechanism 30 may include: a shaping block 33, a driver 32, and a support structure 31. The support structure 31 is used to fix the driver 32 above the transmission mechanism 10. The shaping block 33 is located below the driver 32 and is fixedly connected to the driver 32. The driver 32 is used to drive the shaping block 33 to move downwards, so as to compress the segment to be shaped located below the shaping block 33 into a rectangular or approximately rectangular cross-section. For example, the shaping block 33 compresses the segment to be shaped located below it, which has a triangular cross-section, into a rectangular or approximately rectangular cross-section. By cooperating with the driver 32, after the segment to be shaped is located below the shaping block 33, the driver 32 drives the shaping block 33 to flatten the segment to be shaped, so that the segment to be shaped forms a rectangular or approximately rectangular structure.

[0052] In a preferred embodiment, the length of the shaping block 33 along the transmission direction is equal to the length of the segment to be shaped, so that a segment to be shaped can be flattened by pressing down the shaping block 33 once, thus ensuring the operability of shaping the conductive wire 51 into alternating first conductive segments 521 and second conductive segments 522.

[0053] In one embodiment of the present invention, such as Figure 7 and Figure 8 As shown, the support structure 31 may include: a plurality of support columns 311, a placement platform 312 fixed on the plurality of support columns 311, and a support platform 313, wherein, The placement platform 312 and the support platform 313 are both located above the transmission mechanism 10, with the placement platform 312 located above the support platform 313, and the support platform 313 located above the shaping block 33. The placement platform 312 is used to place and fix the driver 32. The movable end below the driver 32 passes through the mounting hole of the support platform 313, and the movable end below the driver 32 is movably connected to the mounting hole and fixedly connected to the shaping block 33 located below the support platform 313.

[0054] for example, Figure 7 and Figure 8 As shown, the support structure 31 includes four support columns 311, which can stably support the placement platform 312 and the support platform 313. In addition, the support columns 311 can also be fixed to the side of the transmission mechanism 10 to further ensure the support stability of the support structure 31.

[0055] In addition, by placing and fixing the driver 32 on the placement platform 312, the stable operation of the driver 32 can be ensured. Furthermore, by cooperating with the shaping block 33 on the support platform 313, the shaking of the shaping block 33 can be prevented, so that the shaping block 33 can accurately position the segment to be shaped.

[0056] Specifically, for conductive wires that are currently used in most photovoltaic modules, especially for conductive wires with a triangular cross-section, the pressure of the shaping block 33 pressing the section to be shaped can be set to 8MPa~12MPa to effectively control the height of the extruded second conductive section 522 and reduce the risk of breakage of the second conductive section 522.

[0057] Furthermore, the lower surface hardness of the shaping block 33 is ≥ HRC60. HRC is generally a hardness scale for steel; the higher the HRC value, the greater the hardness of the steel. In the system provided by this embodiment, the lower surface hardness of the shaping block 33 is not less than HRC60, which ensures that the section to be shaped is flattened and avoids damage to the lower surface of the shaping block 33 during the flattening process.

[0058] Furthermore, in this embodiment of the invention, the system may further include: a heating component (not shown in the figure) disposed on the shaping block 33, the heating component being used to heat the shaping block 33 when it presses the section to be shaped, so as to quickly and easily flatten the section to be shaped. Understandably, the heating temperature must prevent the irregularly shaped conductive wire 52 from melting. More specifically, the heating temperature can generally be controlled between 75°C and 85°C, for example, the heating temperature can be 75°C, 78°C, 80°C, 83°C, or 85°C, etc. It is worth noting that this heating temperature is applicable to most materials and types of conductive wires used in photovoltaic modules, and in particular, this heating temperature is applicable to most materials and types of conductive wires with a triangular cross-section. For conductive wires that are not suitable for this temperature range, the heating temperature can be re-determined experimentally based on the material and type of the conductive wire.

[0059] In embodiments of the present invention, such as Figure 7 and Figure 8 As shown, in the transmission direction K of the transmission mechanism 10, the shaping mechanism 30 is located downstream of the limiting mechanism 20 to facilitate the implementation of the entire system. More specifically, when the shaping mechanism 30 is located downstream of the limiting mechanism 20, the positioning control mechanism 40 may include: an intelligent controller 41 and a light sensor 42. In the transmission direction K of the transmission mechanism 10, the light sensor 42 is located between the limiting mechanism 20 and the shaping mechanism 30. After the light sensor 42 detects the conductive wire 51 transmitted by the transmission mechanism 10, it sends a trigger signal to the intelligent controller 41. The intelligent controller 41 is used to start timing for the conductive wire 51 according to the received trigger signal. Based on the timing start time, the transmission rate of the transmission mechanism 10, the length of the section to be shaped, the length of the non-shaped section between two adjacent sections to be shaped, the length of the non-shaped section at the end of the conductive wire 51, and the distance between the light sensor 42 and the shaping mechanism 30, it determines the time point for sending the compression command and sends the compression command to the shaping mechanism 30 according to the time point for sending the compression command.

[0060] The intelligent controller 41 determines the timing of sending the extrusion command and sends the extrusion command to the shaping mechanism 30 according to the timing of sending the extrusion command, which can be controlled by program logic.

[0061] In addition, such as Figure 7 and Figure 8 As shown, the positioning control mechanism 40 may also include a display screen 43, which can visually display the time point of sending the squeezing command and user control buttons or interface, so that the user can operate and control the program running by the intelligent controller 41 through the display screen 43, and control the shaping mechanism 30, etc. through the program running by the intelligent controller 41.

[0062] The system, through the positioning control mechanism 40 in conjunction with the shaping mechanism 30 and the transmission mechanism 10, can precisely control the pressing time and pressure of the shaping mechanism 30, thereby accurately controlling the thickness and length of the second conductive segment 522 of the produced irregular conductive wire 52, ensuring the consistency of the irregular conductive wire 52 produced in batches.

[0063] Specifically, the intelligent controller 41 starts timing for the conductive wire 51 based on the received trigger signal. Essentially, the intelligent controller 41 uses the time of the received trigger signal as the starting point for timing the conductive wire 51. It is worth noting that the shaping block 33 can compress the section to be shaped instantaneously. Therefore, during the compression of the section by the shaping block 33, the transmission mechanism 10 can continue transmitting the conductive wire 51 without pausing the transmission mechanism 10.

[0064] If a second conductive segment 522 is provided at one end of the irregular conductive wire 52, and the structure of the third conductive segment 523 is the same as that of the second conductive segment 522, then the timing of sending the squeezing command is determined according to the program logic corresponding to the following calculation formula (1).

[0065] (1)

[0066] in, This indicates the time point at which the extrusion command is sent, where a second conductive segment 522 is provided at one end of the irregularly shaped conductive wire 52 and the structure of the third conductive segment 523 is the same as the structure of the second conductive segment 522. This indicates the time point at which the conductive wire 51 starts timing; Represented as the first extrusion of conductive wire 51 Second conductive segment 522; This indicates the length of the first conductive segment 521; This indicates the length of the second conductive segment 522; This indicates the length of the third conductive segment 523; This indicates the transmission rate of the conductive wire 51 transmitted by the transmission mechanism 10; This indicates the distance between the light sensor 42 and the shaping mechanism 30. Specifically, the distance between the light sensor 42 and the shaping mechanism 30 refers to the distance between the light sensor 42 and the side of the shaping mechanism 30 to which the light sensor 42 is located.

[0067] If the irregular conductive wire 52 has two ends that are both first conductive segments 521 and the structure of the third conductive segment 523 is the same as that of the second conductive segment 522, then the timing of sending the squeezing command is determined according to the program logic corresponding to the following calculation formula (2).

[0068] (2)

[0069] in, This indicates the time point at which the squeezing command is sent for a structure in which both ends of the irregularly shaped conductive wire 52 are first conductive segments 521 and the structure of the third conductive segment 523 is the same as the structure of the second conductive segment 522. This indicates the time point at which the conductive wire 51 starts timing; Represented as the first extrusion of conductive wire 51 Second conductive segment 522; This indicates the length of the first conductive segment 521; This indicates the length of the second conductive segment 522; This indicates the length of the third conductive segment 523; This indicates the transmission rate of the conductive wire 51 transmitted by the transmission mechanism 10; This indicates the distance between the light sensor 42 and the shaping mechanism 30.

[0070] If the irregular conductive wire 52 has a second conductive segment 522 at both ends and the structure of the third conductive segment 523 is the same as that of the second conductive segment 522, then the timing of sending the squeezing command is determined according to the program logic corresponding to the following calculation formula group (3).

[0071] (3)

[0072] in, This indicates the time point at which the extrusion command is sent, where the second conductive segment 522 is provided at both ends of the irregularly shaped conductive wire 52 and the structure of the third conductive segment 523 is the same as that of the second conductive segment 522. This indicates the time point at which the conductive wire 51 starts timing; Represented as the first extrusion of conductive wire 51 Second conductive segment 522; This indicates the length of the first conductive segment 521; This indicates the length of the second conductive segment 522; This indicates the length of the third conductive segment 523; This indicates the transmission rate of the conductive wire 51 transmitted by the transmission mechanism 10; S represents the distance between the light sensor 42 and the shaping mechanism 30; S represents the total number of the second conductive segments 522 included in the irregular conductive wire 52.

[0073] If a second conductive segment 522 is provided at one or both ends of the irregular conductive wire 52, and the structure of the third conductive segment 523 is the same as that of the first conductive segment 521, then the timing of sending the squeezing command is determined according to the program logic corresponding to the following calculation formula (4).

[0074] (4)

[0075] in, This indicates the time point at which the extrusion command is sent, where a second conductive segment 522 is provided at one or both ends of the irregularly shaped conductive wire 52 and the structure of the third conductive segment 523 is the same as the structure of the first conductive segment 521. This indicates the time point at which the conductive wire 51 starts timing; Represented as the first extrusion of conductive wire 51 Second conductive segment 522; This indicates the length of the first conductive segment 521; This indicates the length of the second conductive segment 522 (i.e., the length of the segment to be shaped); This indicates the length of the third conductive segment 523; This indicates the transmission rate of the conductive wire 51 transmitted by the transmission mechanism 10; This indicates the distance between the light sensor 42 and the shaping mechanism 30.

[0076] If the irregularly shaped conductive wire 52 has two ends that are both first conductive segments 521, and the structure of the third conductive segment 523 is the same as that of the first conductive segment 521, then the timing of sending the squeezing command is determined according to the program logic corresponding to the following calculation formula (5).

[0077] (5)

[0078] in, This indicates the time point at which the squeezing command is sent for a structure in which both ends of the irregularly shaped conductive wire 52 are first conductive segments 521 and the structure of the third conductive segment 523 is the same as the structure of the first conductive segment 521. This indicates the time point at which the conductive wire 51 starts timing; Represented as the first extrusion of conductive wire 51 Second conductive segment 522; This indicates the length of the first conductive segment 521; This indicates the length of the second conductive segment 522; This indicates the length of the third conductive segment 523; This indicates the transmission rate of the conductive wire 51 transmitted by the transmission mechanism 10; This indicates the distance between the light sensor 42 and the shaping mechanism 30.

[0079] The conductive wire 51 processed by the system is used as Figure 9 Taking a conductive wire with a triangular cross-section as an example, after processing by the system provided in this embodiment of the invention, different irregularly shaped conductive wires 52 with different structures can be obtained by selecting different program control logics deployed by the intelligent controller 41. For example, after system processing, the following can be obtained: Figure 4 and Figure 5The irregularly shaped conductive wire 51 shown includes alternating first conductive segments 521 and second conductive segments 522. The second conductive segments 522 are structures obtained after being compressed by the shaping block 33, while the first conductive segments 521 retain their original conductive wire structure. Additionally, the irregularly shaped conductive wire 51 also includes a third conductive segment 523 located between adjacent first and second conductive segments 521 and 522. The structure of this third conductive segment 523 can be as follows... Figure 4 The third conductive segment 523 shown has the same structure as the first conductive segment 521, and can also be arranged as follows: Figure 5 The third conductive segment 523 shown has the same structure as the second conductive segment 522. Understandably, since the structure of the third conductive segment 523 is the same as that of the first conductive segment 521, the length of the segment to be shaped that the shaping block 33 of the system needs to press is equal to the length of the second conductive segment 522. Since the structure of the third conductive segment 523 is the same as that of the second conductive segment 522, the shaping block 33 of the system can press both the third conductive segment 523 and the second conductive segment 522 simultaneously.

[0080] The above steps are provided only to help understand the method, structure, and core ideas of this invention. Those skilled in the art can make various improvements and modifications to this invention without departing from its principles, and these improvements and modifications also fall within the scope of protection of the claims.

Claims

1. A shaped conductive wire, characterized in that, include: The alternating arrangement of a first conductive segment (521) and a second conductive segment (522), and a third conductive segment (523) located between the first conductive segment (521) and the second conductive segment (522). The angle between the side surface of the first conductive segment (521) and the bottom surface of the first conductive segment (521) is less than 90°; The cross-section of the second conductive segment (522) is rectangular or approximately rectangular; The irregularly shaped conductive wire (52) is applied to a battery string structure in which multiple back-contact solar cells or multiple back-contact solar cell sheets (60) are arranged, wherein the positive grid (61) of each two adjacent back-contact solar cells or back-contact solar cell sheets (60) corresponds to the negative grid (62). The alternating first conductive segment (521) and second conductive segment (522) of the irregularly shaped conductive wire (52) correspond to the alternating negative electrode grid (62) and positive electrode grid (61) located in the same row in the battery string structure, respectively. The third conductive segment (523) corresponds to the region between the close ends of the corresponding positive grid (61) and negative grid (62) of two adjacent back-contact solar cells or back-contact solar cell sheets (60). The structure of the third conductive segment (523) is the same as that of the first conductive segment (521) or the second conductive segment (522).

2. The irregularly shaped conductive wire according to claim 1, characterized in that, The cross-section of the first conductive segment (521) is triangular, wherein the vertex angle of the triangle is 55°~65°; And / or, The height of the first conductive segment (521) is 0.8mm~1.2mm; And / or, The height of the second conductive segment (522) is 0.3mm~0.5mm; And / or, The height of the second conductive segment (522) is 30% to 50% of the height of the first conductive segment (521).

3. A system for producing irregularly shaped conductive wires, characterized in that, include: The transmission mechanism (10), the limiting mechanism (20), the shaping mechanism (30), and the positioning control mechanism (40) are included, among which, The limiting mechanism (20) and the shaping mechanism (30) are both disposed on the transmission mechanism (10), and the limiting mechanism (20) and the shaping mechanism (30) are arranged at intervals along the transmission direction (K) of the transmission mechanism (10); The limiting mechanism (20) is used to limit the conductive wire (51) on the transmission mechanism (10); The transmission mechanism (10) is used to transmit the conductive wire (51). The positioning control mechanism (40) is used to locate the interval of the conductive wire (51) transmitted by the transmission mechanism (10) in real time and send a squeezing command to the shaping mechanism (30) after the segment to be shaped reaches the shaping mechanism (30). The shaping mechanism (30) is used to squeeze the section of the conductive wire (51) below it to be shaped after receiving the squeezing command.

4. The system according to claim 3, characterized in that, The limiting mechanism (20) includes: a limiting part (21) and connecting parts (22) respectively disposed on both sides of the limiting part (21), wherein, The connecting part (22) is detachably connected to the transmission mechanism (10), and the connecting part (22) is used to fix the limiting part (21) above the transmission mechanism (10); The shape of the limiting part (21) facing the transmission mechanism (10) is consistent with the shape of the conductive wire (51).

5. The system according to claim 4, characterized in that, The connecting part (22) includes: a first connecting rod (221), a first fixing member (222), and a second connecting rod (223); One end of the first connecting rod (221) is fixedly connected to the side of the limiting part (21); The first fixing member (222) is used to clamp and fix the first connecting rod (221) and the second connecting rod (223), and the first connecting rod (221) and the second connecting rod (223) are perpendicular to each other; The second connecting rod (223) is fixedly connected to the transmission mechanism (10).

6. The system according to claim 4, characterized in that, The limiting part (21) includes: two limiting blocks (211) with a wedge-shaped structure on one side; The two limiting blocks (211) form a ridge-shaped wedge with their wedge-shaped structures facing each other, which is used to limit the conductive wire (51) with a triangular cross section.

7. The system according to claim 5, characterized in that, The transmission mechanism (10) includes a second fixing member (11) corresponding to the second connecting rod (223); The second fastener (11) is used to clamp and fix the second connecting rod (223).

8. The system according to any one of claims 4 to 7, characterized in that, The shaping mechanism (30) includes: a support structure (31), a driver (32), and a shaping block (33). The support structure (31) is used to fix the driver (32) above the transmission mechanism (10); The shaping block (33) is located below the driver (32) and is fixedly connected to the driver (32); The driver (32) is used to drive the shaping block (33) to move downwards, so as to squeeze the section to be shaped located below the shaping block (33) into a rectangular or approximately rectangular cross section.

9. The system according to claim 8, characterized in that, The support structure includes: a plurality of support columns (311), a placement platform (312) fixed on the plurality of support columns (311), and a support platform (313), wherein, The placement platform (312) and the support platform (313) are both located above the transmission mechanism (10), and the placement platform (312) is located above the support platform (313), and the support platform (313) is located above the shaping block (33); The placement platform (312) is used to place and fix the driver (32); The movable end below the driver (32) passes through the mounting hole of the support platform (313), and the movable end below the driver (32) is movably connected to the mounting hole and fixedly connected to the shaping block (33) located below the support platform (313). And / or, The system further includes a heating component disposed on the shaping block (33). The heating component is used to heat the shaping block (33) when the shaping block (33) presses the section to be shaped. And / or, The lower surface hardness of the shaping block (33) is ≥HRC60.

10. The system according to claim 3, characterized in that, The shaping mechanism (30) is located downstream of the limiting mechanism (20); The positioning control mechanism (40) includes: an intelligent controller (41) and a light sensor (42). In the transmission direction of the transmission mechanism (10), the optical sensor (42) is located between the limiting mechanism (20) and the shaping mechanism (30); After the optical sensor (42) detects the conductive wire (51) transmitted by the transmission mechanism (10), it sends a trigger signal to the intelligent controller (41). The intelligent controller (41) is used to start timing for the conductive wire (51) according to the received trigger signal, and to determine the time point for sending the squeezing command according to the time point when the timing starts, the transmission rate of the transmission mechanism (10), the length of the section to be shaped, the length of the non-shaped section between two adjacent sections to be shaped, the length of the non-shaped section at the end of the conductive wire (51) and the distance between the photosensitive sensor (42) and the shaping mechanism (30), and to send the squeezing command to the shaping mechanism (30) according to the time point when the squeezing command is sent.

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