{"id":33589,"date":"2025-04-28T17:00:46","date_gmt":"2025-04-28T09:00:46","guid":{"rendered":"https:\/\/www.ray-tron.com\/?p=33589"},"modified":"2025-04-28T17:01:19","modified_gmt":"2025-04-28T09:01:19","slug":"2025042802-2","status":"publish","type":"post","link":"https:\/\/www.ray-tron.com\/en\/2025042802-2\/","title":{"rendered":"Feasibility of copper clad aluminum wire (CCA wire) in the photovoltaic industry"},"content":{"rendered":"<p>Finding a balance between &quot;reducing costs and increasing efficiency&quot; and &quot;ensuring power generation&quot; is the core issue for photovoltaic companies. The following is an analysis of the selection process from five dimensions: materials, processes, performance, economy and risks.<a href=\"https:\/\/www.ray-tron.com\/en\/tongbaolvdai\/\" data-internallinksmanager029f6b8e52c=\"178\" title=\"Copper clad aluminum strip manufacturer_Copper clad aluminum wire supplier_Copper clad aluminum strip wholesaler manufacturer\">Copper clad aluminum wire<\/a>(CCA line) feasibility in the photovoltaic industry.<\/p><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h4 class=\"wp-block-heading\">1. Material availability and cost<\/h4><ul class=\"wp-block-list\"><li><strong>Aluminum resources are abundant and cost is low<\/strong><ul class=\"wp-block-list\"><li>The price of aluminum is about \u00bc to 1\/3 of the price of copper.<\/li>\n\n<li>At the same weight, CCA line can save about 30% to 40% of raw material cost.<\/li><\/ul><\/li>\n\n<li><strong>Copper layer thickness adjustable<\/strong><ul class=\"wp-block-list\"><li>Good conductivity can be achieved with a copper layer \u2265 0.03 mm;<a href=\"https:\/\/www.ray-tron.com\/en\/pvribbon\/\" data-internallinksmanager029f6b8e52c=\"43\" title=\"Photovoltaic welding ribbon\">Photovoltaic welding ribbon<\/a>Recommended \u2265 0.05 mm to ensure reliable welding.<\/li><\/ul><\/li><\/ul><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p><strong>in conclusion<\/strong>\uff1aSufficient material supply and stable prices, with significant cost advantages.<\/p><\/blockquote><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h4 class=\"wp-block-heading\">2. Process maturity<\/h4><ul class=\"wp-block-list\"><li><strong>Composite rolling and diffusion bonding<\/strong><ul class=\"wp-block-list\"><li>Modern multi-pass cold rolling + high temperature diffusion annealing can achieve a strong metallurgical bond between copper and aluminum (peel strength \u2265 10 N\/cm).<\/li><\/ul><\/li>\n\n<li><strong>Online quality control<\/strong><ul class=\"wp-block-list\"><li>Laser thickness measurement, constant tension control, and online peeling test can ensure uniform copper layer thickness and reliable bonding.<\/li><\/ul><\/li>\n\n<li><strong>Tin plating and surface treatment<\/strong><ul class=\"wp-block-list\"><li>The hot-dip tinning process is mature, and the tin layer of 5\u201310 \u03bcm prevents oxidation and improves solderability.<\/li><\/ul><\/li><\/ul><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p><strong>in conclusion<\/strong>: The key technology is mature, and leading manufacturers (such as<a href=\"https:\/\/www.ray-tron.com\/en\/\" data-internallinksmanager029f6b8e52c=\"19\" title=\"Ruichuang 2\">Raytron<\/a>) can be stably mass-produced.<\/p><\/blockquote><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h4 class=\"wp-block-heading\">3. Electrical and mechanical properties<\/h4><figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><thead><tr><th>project<\/th><th>CCA Line<\/th><th>Pure copper wire<\/th><\/tr><\/thead><tbody><tr><td>Electrical conductivity<\/td><td>60%\u201365% IACS; close to copper at high frequencies (skin effect)<\/td><td>100% IACS<\/td><\/tr><tr><td>Resistivity<\/td><td>0.028\u20130.030 \u03a9 mm\u00b2\/m<\/td><td>0.017 \u03a9\u00b7mm\u00b2\/m<\/td><\/tr><tr><td>tensile strength<\/td><td>120\u2013180 MPa<\/td><td>180\u2013250 MPa<\/td><\/tr><tr><td>Elongation<\/td><td>\u2265 10%<\/td><td>\u2265 20%<\/td><\/tr><tr><td>Bending life<\/td><td>\u2265 5,000 times<\/td><td>\u2265 10,000 times<\/td><\/tr><\/tbody><\/table><\/figure><ul class=\"wp-block-list\"><li>For high frequency (&gt;5 MHz) signal transmission, there is almost no difference between CCA and copper.<\/li>\n\n<li>In high DC current scenarios, the cross-sectional area needs to be increased (approximately 1.5\u00d7) to compensate for the conductivity difference.<\/li><\/ul><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p><strong>in conclusion<\/strong>\uff1aThe performance meets the requirements of photovoltaic welding ribbons, and can be compensated by cross-sectional area design when necessary.<\/p><\/blockquote><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h4 class=\"wp-block-heading\">4. Economic and system-level benefits<\/h4><ul class=\"wp-block-list\"><li><strong>Component Cost<\/strong>\uff1aUsing CCA solder ribbon can reduce the cost of component solder ribbon by 20%\u201330%.<\/li>\n\n<li><strong>Transportation and installation<\/strong>: The density is only 40% of copper, the weight reduction is \u2248 50%, and the installation cost is reduced by 30%+.<\/li>\n\n<li><strong>System efficiency<\/strong>: The measured power loss is &lt; 2 W, and the component efficiency only decreases by \u2248 1%\u20132%.<\/li>\n\n<li><strong>return on investment<\/strong>\uff1aCost savings benefits \uff1eefficiency losses, improving overall LCOE (LCOE) competitiveness.<\/li><\/ul><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p><strong>in conclusion<\/strong>: From the perspective of system economics, the CCA line has significant cost reduction benefits and the power generation loss is controllable.<\/p><\/blockquote><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h4 class=\"wp-block-heading\">5. Risk and reliability management<\/h4><figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><thead><tr><th>Risk Points<\/th><th>Risk Performance<\/th><th>Risk Mitigation Measures<\/th><\/tr><\/thead><tbody><tr><td>Copper stripping<\/td><td>Copper layer falls off after welding or bending<\/td><td>Adopt high peel strength process; online peel test<\/td><\/tr><tr><td>Electrochemical corrosion<\/td><td>Copper exposure at the edge causes corrosion of the aluminum core<\/td><td>Strictly tin-plated surface; component packaging moisture-proof<\/td><\/tr><tr><td>Thermal expansion stress<\/td><td>Microcracks caused by interface stress under temperature cycling<\/td><td>Optimize annealing + composite parameters; design reasonable weld width and thickness ratio<\/td><\/tr><tr><td>Long term efficiency decay<\/td><td>The increase in contact resistance causes the power generation efficiency to gradually decrease<\/td><td>Regular operation and maintenance monitoring; use pure copper or mixed welding strip solutions at key nodes<\/td><\/tr><\/tbody><\/table><\/figure><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p><strong>in conclusion<\/strong>: Through process and packaging optimization, as well as operation and maintenance monitoring, the risk can be reduced to an acceptable range.<\/p><\/blockquote><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\">Summary<\/h3><ul class=\"wp-block-list\"><li><strong>Cost Advantage<\/strong> \u00d7 <strong>Mature technology<\/strong> \u00d7 <strong>Controllable risks<\/strong> = <strong>High feasibility<\/strong><\/li>\n\n<li>In mainstream components such as PERC, TOPCon, and HJT, CCA solder ribbons have been verified and applied by many leading manufacturers.<\/li>\n\n<li>For the pursuit<strong>Cost Optimization<\/strong>,right<strong>Slight compromise in efficiency is acceptable<\/strong> In the market, CCA line is an extremely attractive solution.<\/li>\n\n<li>for<strong>High reliability<\/strong>,<strong>Ultimate power density<\/strong>For different scenarios, a &quot;CCA + pure copper&quot; hybrid or pure copper key area strategy can be adopted.<\/li><\/ul><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p><strong>Recommended strategies<\/strong>:<a href=\"https:\/\/www.ray-tron.com\/en\/\" data-internallinksmanager029f6b8e52c=\"14\" title=\"Photovoltaic modules\">Photovoltaic modules<\/a>Enterprises can give priority to using CCA wires in conventional welding strips, and retain pure copper welding strips for high-stress or high-power channels, thereby achieving the optimal balance of &quot;cost reduction - efficiency assurance&quot;.<\/p><\/blockquote>","protected":false},"excerpt":{"rendered":"<p>Finding a balance between \u201creducing costs and increasing efficiency\u201d and \u201censuring power generation\u201d is the core issue for photovoltaic companies. The following is an analysis of the five dimensions of materials, processes, performance, economy and risks.<\/p>","protected":false},"author":1,"featured_media":9053,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[19],"tags":[],"class_list":["post-33589","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog"],"_links":{"self":[{"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/posts\/33589","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/comments?post=33589"}],"version-history":[{"count":0,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/posts\/33589\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/media\/9053"}],"wp:attachment":[{"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/media?parent=33589"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/categories?post=33589"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.ray-tron.com\/en\/wp-json\/wp\/v2\/tags?post=33589"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}