In the fields of manufacturing solar panels, it refers to a kind of semiconductor manufacture, including the coating, forming and cutting of PN semiconductor membranes. In order to induce the current generated by solar panels effectively, at the last stage of completing the solar modules it relies mainly on the ultrasonic welding of the electrodes.

Ultrasonic metal welding is based esstinally on high-frequency mechanical to friction overlap the same or different metl materials and to press the welding horn with proper pressure down to the parts making friction on the metal surfaces for welding. No welding additive is required.

This is a special welder designed for welding the electrode of Amorphous PV, base on the ultrasonic metal welding principles, to generate high frequency vibration energy so as to weld the solar energy collection plates (glasses) coated with aluminum together with the aluminum foil. Because the welding method does not use any solder flux, therefore, the resistance of the welding area (joint) is very low, thus it will not generate heat during power loading and/or discharge, so that the service life of the end products can be extended remarkably.

According to our analysis on the traditional welding technologies, we find out some issues, including:

the welding width is not enough

The width of joint processed by former equipments is about 1-2mm. Not only the width of joint, there are also great possibilities to improve the quality of joints, including straightness and stability. For this issue, we develop a new mechanism to realize a wider welding. The width of joints can be 6~8mm.

it is impossible to use several welders at the same time to make series connections of the solar panels:

According to our past experiences, the main reason for being impossible to use several welders at the same time to make series connections of the solar panels is that the ultrasonic oscillation system is larger than the welding horn (sonotrode), as a result, there will be interference to the welding operation. Therefore, we are endeavoring to develop a welding machine with its welding horn larger than its vibration system.

the problem of uneven welding surface

In the past, a traditional ultrasonic welding equipment uses usually a smooth (non-knurling) welding horn (sonotrode) which might cause deflection phenomenon during the welding process. For this reason, we will use a knurled welding horn to increase the welding reliability.

ultrasonic output is not stable

It has been found that the performance and stability of ultrasonic equipment will affect the efficiency and yield of the welding process. We have introduced ultrasonic equipment capable of digital adjustment, automatic tracking compensation and instant feedback information to improve this problem. We introduced the ultrasonic equipment capable of digital adjustment, in-time monitoring and auto tuning to improve this problem.