When CCA busbar is used for photovoltaic welding tapes, the difference in copper content has a significant impact on its electrical conductivity, mechanical properties, durability and the overall stability of the photovoltaic system. Increases or decreases in copper content can directly affect the electrical properties, weld quality and oxidation resistance of CCA busbar. Below are a few of the possible effects of varying copper content in CCA busbar:
- Electrical Conductivity
CCA busbar with high copper content: Copper is more conductive than aluminum, so CCA busbar with high copper content has better electrical conductivity. For photovoltaic systems, high electrical conductivity ensures more efficient current transfer, reduces energy loss, and improves the overall efficiency of the PV module.
CCA busbar with high copper content: generally above 20%, the conductivity is close to that of pure copper materials, but due to the presence of an aluminum core, it may still be slightly lower than that of pure copper welding tapes.
CCA busbar with low copper content: A low copper content (e.g. below 10%) results in a higher resistance, which affects the efficiency of the current transfer. More energy loss may occur when current passes through, reducing the energy conversion efficiency of the PV system.
- Welding performance
CCA busbar with high copper content: The copper layer is thicker and has better welding performance. When soldering, the copper layer combines better with the solder material, resulting in a stronger solder joint and ensuring a lower resistance at the joint.
CCA busbars with a high copper content are suitable for PV systems that require higher soldering reliability and longer service life, especially under high loads and high temperatures, to ensure the stability of the soldered joints.
CCA busbars with a low copper content: The copper layer is thin, which can lead to uneven welding and weak joints, resulting in increased resistance and even poor contact. Poor welding quality will lead to unstable system operation and affect the long-term performance of PV modules.
- Oxidation resistance
CCA busbar with high copper content: the copper layer is thicker and has a stronger antioxidant capacity. Copper itself has superior antioxidant performance, CCA busbar can effectively prevent the oxidation of the aluminum core in humid or high temperature environment, to maintain a longer period of stable performance. Especially in photovoltaic systems that are exposed to the outdoors for long periods of time, stronger antioxidant properties can help extend the service life of photovoltaic modules.
CCA busbar with low copper content: The copper layer is thin and easily affected by the external environment, especially in harsh environments such as high humidity and high temperatures, oxidation is prone to occur. Oxidation of aluminum will lead to increased resistance, affecting current transmission, and in serious cases, it may also lead to poor electrical contact and even cause fire and other safety hazards.
PV welding tape production equipment for different specification materials
- Mechanical properties
CCA busbar with high copper content: the mechanical properties of copper are stronger than aluminum, and the overall mechanical strength of CCA busbar is better. CCA busbar with high copper content can withstand higher tensile and mechanical stresses and is suitable for application scenarios that require higher loads and vibrations. For photovoltaic modules, this helps to maintain the stability of the soldered joints and reduces the risk of solder breakage or poor contact due to mechanical stress.
CCA busbar with low copper content: A thinner copper layer and lower overall mechanical strength may lead to fracture or damage under bending, stretching or external forces, affecting the long-term stability of the PV system. Especially during long-term use, the CCA busbar may shed the copper layer due to external pressure, thus exposing the aluminum core and increasing the risk of oxidation.
- Cost and cost-effectiveness
CCA busbar with high copper content: CCA busbar with high copper content has a higher material cost, so for mass production and high cost control requirements, the copper content of CCA busbar may need to balance between cost and performance. CCA busbar with higher copper content provides better conductivity and stability, but its cost also increases.
CCA busbars with low copper content: CCA busbars with low copper content are less costly and therefore may be widely used in cost-sensitive markets. For some low-load, short-term use PV systems, CCA busbar with low copper content may be an economical choice, but its electrical performance and stability are relatively poor.
- Long-term stability
CCA busbar with high copper content: Due to its better electrical conductivity and oxidation resistance, CCA busbar with high copper content can maintain stability for a longer period of time in high-temperature, humid and other environments, which reduces the frequency of maintenance and the risk of failure.For PV systems that require long term stability, CCA busbar with high copper content is a more ideal choice.
CCA busbar with low copper content: CCA busbar with low copper content may be more susceptible to environmental factors, which may lead to degradation of electrical performance after long-term use, thus affecting the stability and efficiency of the PV system.
- Thermal stability
CCA busbar with high copper content: High copper content helps to improve the thermal stability of CCA busbar, especially in high temperature working environment, it can better withstand the thermal expansion pressure brought about by temperature changes.CCA busbar with low copper content: Low copper content may lead to poor thermal stability, and prolonged exposure to high temperatures may cause the copper layer to peel off or oxidize, further affecting the performance and service life of the PV module.Summary:
High copper content CCA busbar (usually 20% copper content or higher) has better electrical conductivity, oxidation resistance, soldering performance and stability, and is suitable for high performance, high reliability requirements of PV systems, especially in the need for long-term stable operation of the application scenarios.Low copper content CCA busbar (less than 10% copper content) usually has lower cost, but its electrical properties, oxidation resistance and mechanical strength are poorer, which may be suitable for low load or short-term applications, but not for high-efficiency and long-life PV systems.
Therefore, the selection of CCA busbar requires a trade-off between cost and performance, with the appropriate level of copper content determined by specific application requirements (e.g., electrical conductivity, solder quality, environmental tolerance, etc.).