Photovoltaic Module Junction Box Plate Joining with Dual Laser Seams
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Solution Overview
Problem
Existing photovoltaic module connection methods, such as soldering and laser welding, face challenges in efficiency and reliability due to thermal shock and poor soldering efficiency, requiring complex operations and materials that are prone to desoldering.
Innovation Solution
A photovoltaic module design utilizing laser soldering with multiple soldering seams extending through and into a plate, reducing the need for precise positioning and improving production efficiency by using a laser head to form connections between a solder strip and a junction box plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If soldering with solder material is used to connect the solder strip and the plate, then the connection can be formed, but the process requires complicated machining operations and solder material preparation
Solution Approach 1:
The invention extracts and eliminates the solder material from the connection process. Instead of using traditional soldering with external solder material, the patent uses laser welding to directly fuse the solder strip and plate together, removing the need for separate solder material preparation and application steps
Solution Approach 2:
The invention replaces the thermal-mechanical soldering process with a laser-based welding process. The laser energy directly melts and fuses the metal surfaces without requiring solder material, simplifying the overall manufacturing process and reducing operational complexity
2Reliability
If traditional soldering is used to connect the solder strip and the plate, then the connection can be formed, but the different melting points of materials make it prone to desoldering due to thermal shock
Solution Approach 1:
The invention replaces traditional soldering with laser welding, creating a direct metal-to-metal fusion bond between the solder strip and plate. This weld bond has higher strength and better thermal stability compared to solder joints, making it resistant to desoldering under thermal shock conditions
Solution Approach 2:
The invention creates a composite structure through laser welding where the solder strip and plate are fused into a unified joint. This welded joint combines the properties of both materials with enhanced mechanical and thermal performance, superior to traditional soldered connections
3Reliability
If laser soldering is used to directly melt the plate and solder strip to form a soldering seam, then no solder material is needed and connection reliability improves, but soldering efficiency is poor
Solution Approach 1:
The invention segments the laser soldering process into two distinct regions: a first region where the laser melts both the solder strip and plate to form a strong fusion bond, and a second region where the laser only melts the plate surface. This segmentation allows the process to achieve reliable connections while improving overall soldering efficiency by reducing unnecessary melting in areas where the solder strip is not present
Solution Approach 2:
The invention applies different laser processing conditions to different regions of the plate. In the first region (under the solder strip), the laser parameters are optimized for melting both materials to create strong bonds. In the second region (without solder strip), the laser parameters are adjusted to only melt the plate surface, reducing energy consumption and improving efficiency while maintaining connection quality
4Manufacturing precision
If the solder strip is precisely positioned on the plate before soldering, then the soldering quality can be ensured, but the positioning difficulty increases production time
Solution Approach 1:
The invention performs preliminary action by pre-processing the plate surface in the second region before the solder strip is positioned. The laser creates a prepared surface structure in advance, which facilitates subsequent soldering and reduces the need for precise positioning adjustments, thereby saving production time while maintaining soldering quality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances connection reliability and manufacturing efficiency by simplifying the soldering process, ensuring stable connections without the need for additional solder materials and reducing the complexity of positioning, thereby improving production line speed.
Implementation Method 1
a soldering seam formed by laser soldering includes a first soldering seam and a second soldering seam
Implementation Method 2
The plate and the solder strip can be directly molten to form a soldering seam by the laser soldering
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A photovoltaic module, including a laminate including a solder strip; and a junction box arranged on a surface of the laminate and including a plate connected to the solder strip by laser soldering. The plate has a first region and a second region, in which a region covered by 5the solder strip on the plate is the first region, and a region not covered by the solder strip on the plate is the second region. A soldering seam formed by laser soldering includes a first soldering seam and a second soldering seam. The first soldering seam is located in the first region, and the first soldering seam extends through the solder strip into the plate along a thickness direction of the laminate. The second soldering seam is located in the second region, 10and the second soldering seam extends directly into the plate along the thickness direction of the laminate.