Research on the Reliability of Resistance Welding Photovoltaic Module Junction Boxes
Due to the increasing rated current of photovoltaic modules and the matching junction boxes,the requirements for the firmness of the welding between the junction boxes and busbars are becoming higher.However,most existing junction boxes adopt the Habba welding mode,which is prone to a series of welding defects such as under soldering,virtual soldering,and desoldering,resulting in an increase in contact resistance and power loss of the junction boxes.In severe cases,it may lead to module ignition and burning,posing serious safety hazards to the operation and maintenance of the power station.This article proposes a resistance welding mode for junction box welding by studying the reliability of resistance welding junction boxes,which effectively solves the problem of poor welding between junction boxes and component busbars;Through temperature rise testing,it was found that the junction temperature of the diode in resistance welding is significantly lower than that in Habba welding.Upon dissection of the welding end face,it was found that resistance welding can completely melt the busbar and the copper substrate of the solder pad into a unified entity,solving the problem of obvious boundary between the busbar and the solder pad in Habba welding;After undergoing strict TC200 testing on the resistance welding junction box,the contact resistance between the junction box and the busbar increased from 0.270 mΩ to 0.264 mΩ,with little change.This indicates that the reliability of resistance welding is extremely high,providing a certain reference value for the safe application of high current components in the future.
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