光伏组件接线盒引线激光焊接的可靠性研究  

Research on the Reliability of Laser Welding for Photovoltaic Module Junction Box Leads

作　　者：陈宏月 沈正鸿 薛文娟 李会玲 符永高 张臻[3] CHEN Hong-yue;SHEN Zheng-hong;XUE Wen-juan;LI Hui-ling;FU Yong-gao;ZHANG Zhen(JA Solar Co.,Ltd.,Xingtai 055550;China National Electrical Apparatus Research Institute Co.,LTD.,Guangzhou 510663;Shanghai Jiao Tong University,Shanghai 200240;JA(Yangzhou)Solar Technology Co.,Ltd.,Yangzhou 225009)

机构地区：[1]晶澳太阳能有限公司,邢台055550 [2]中国电器科学研究院股份有限公司,广州510663 [3]上海交通大学,上海200240 [4]晶澳(扬州)太阳能科技有限公司,扬州225009

出　　处：《环境技术》2025年第3期30-36,共7页Environmental Technology

摘　　要：光伏组件接线盒的焊接工艺主要采用热压焊接,但其焊接良率一直是光伏组件生产中的痛点。热压焊接容易出现虚焊、脱焊等缺陷导致接线端子接触电阻增大、电弧产生等问题,进而影响组件功率输出。在严重情况下,还可能引发组件着火,存在重大安全隐患。随着光伏组件技术向高效率、高功率方向发展,组件的额定电流不断增加,对接线盒与汇流带焊接的可靠性提出了更高要求。目前,电阻焊接和激光焊接等新型焊接工艺的研究进展较快。其中,激光焊接的设备及工艺流程已基本成熟,但其可靠性仍需进一步验证。本文对激光焊接的焊点形貌进行了观察,并测试了焊接拉力和接触电阻和冷热冲击测试,结果表明,激光焊接工艺具有高良率、高焊接拉力、低接触电阻和高可靠性的特点。同时对激光焊接的光伏组件进行了TC200和反向电流过载测试,激光焊接组件能够通过测试,且功率损失均小于0.5%远小于标准要求5%,具有很高的可靠性。本研究为未来大电流光伏组件引线焊接工艺的选择提供了重要的参考依据。The welding process for photovoltaic(PV)module junction boxes primarily employs thermo-compression welding.However,the welding yield has long been a pain point in the PV module manufacturing process.Common defects such as poor soldering and de-soldering can lead to increased contact resistance at the terminals,arcing,and other issues that affect the module’s power output.In severe cases,these defects can even cause module fires,posing a significant safety hazard.Currently,PV module technology is evolving towards higher efficiency and higher rated power,with the rated current of modules continuously increasing.This trend demands higher safety protection standards and greater reliability for the welding of junction boxes and busbars.To address these challenges,alternative welding methods for PV junction boxes,such as resistance welding and laser welding,have been extensively studied and tested in production lines.Among them,laser welding technology has seen relatively rapid progress.The equipment and welding process for laser welding have been developed,although its reliability still requires further validation.This paper investigates the morphology of laser welding,tests the welding tensile strength and contact resistance,and conducts comprehensive reliability tests on laser-welded junction boxes and PV modules.The results show that laser welding has a high process yield,high tensile strength,low contact resistance,and high reliability.Additionally,photovoltaic modules assembled using laser welding were subjected to TC200 and reverse current overload tests.The laser-welded modules passed these tests with power losses of less than 0.5%,which is significantly lower than the standard requirement of 5%,demonstrating excellent reliability.This study provides important reference for the selection of interconnection welding processes in future high-current photovoltaic modules.

关 键 词：光伏组件 激光焊接 可靠性 

分 类 号：TM61[电气工程—电力系统及自动化]