Photovoltaic module frame dismounting method and portable frame dismounting device

Abstract

The application discloses a photovoltaic module frame dismounting method and a portable frame dismounting device, and relates to the technical field of photovoltaic module recycling and repair, which comprises the following steps: determining the number and position of the frame of the photovoltaic module that needs to be replaced; performing a heating treatment on the photovoltaic module to soften the encapsulating material thereof; cutting along the front and back surfaces of the module laminated piece and the frame by using a cutting tool; injecting bubble sealant into the frame cavity until the frame cavity is filled with the bubble sealant, and then allowing the bubble sealant to solidify for 15 minutes; and using the frame dismounting device to apply force from the inside to the outside of the frame filled with the bubble sealant, and sequentially applying force at multiple positions from one end to the other end along the length direction of the frame to complete the dismounting of the frame. The device comprises a cross beam, a jacking device, a short edge fixing clamp and a long edge fixing frame fixing pin. By adopting the method and the device, the tearing of the frame sidewall can be avoided, the loss or explosion of the laminated piece caused by the tearing of the frame sidewall can be avoided, and the frame dismounting efficiency and the laminated piece integrity can be effectively improved.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic module recycling and repair technology, specifically relating to a method for disassembling photovoltaic modules and a portable disassembly device. Background Technology

[0002] With technological advancements and the application of new materials in the photovoltaic industry, the trend towards lightweight photovoltaic module frames has become an inevitable direction for industry development. The research and application of new materials will continue to drive cost reduction and performance improvement. However, lightweighting of photovoltaic module frames also leads to a reduction in their strength and thickness, frequently resulting in frame repairs or replacements at production or installation sites, necessitating frame removal. Currently, photovoltaic module manufacturers often remove frame frames manually using rubber hammers at production or installation sites. During disassembly, the uncontrolled force and speed of the hammering frequently cause photovoltaic modules to explode or develop large-area microcracks.

[0003] Therefore, it is necessary to provide a method for disassembling photovoltaic modules and a portable disassembly device to solve the problem of explosions or large-area microcracks in the modules caused by human impact during the disassembly process of existing photovoltaic modules. Summary of the Invention

[0004] The purpose of this invention is to provide a method for removing the frame of a photovoltaic module and a portable frame removal device to solve the above-mentioned technical problems existing in the prior art.

[0005] To achieve the above objectives, the present invention provides a method for disassembling photovoltaic modules, comprising the following steps:

[0006] Step S1: Determine the number and location of the frames in the photovoltaic modules that need to be replaced;

[0007] Step S2: Heat the photovoltaic module to soften its encapsulation material;

[0008] Step S3: Use a cutting tool to cut along the front and back sides of the component laminate and the frame;

[0009] Step S4: Inject bubble sealant into the frame cavity until the frame cavity is full of bubble sealant, and let it stand for 15 minutes to cure the bubble sealant.

[0010] Step S5: Using a frame removal device, apply force from the inside of the frame with the cured bubble sealant outwards, and apply force sequentially at multiple positions along the length of the frame from one end to the other to complete the removal of the frame.

[0011] Preferably, in step S2, heating the photovoltaic module to soften its encapsulation material includes: connecting the photovoltaic module to a constant current source as a load, passing a current of 1 Isc through the constant current source to the photovoltaic module for 30 minutes to heat the photovoltaic module and soften the encapsulation material.

[0012] Preferably, injecting bubble sealant into the frame cavity includes: making a hole in the frame or using an existing drain outlet on the frame to inject bubble sealant into the frame cavity, injecting from one side of the frame through the hole or drain outlet until the bubble sealant overflows from the other side through the hole or drain outlet.

[0013] Preferably, when the removed frame is a long frame, before injecting the bubble sealant, a steel wire with an outer diameter of 0.3 cm is introduced between the two openings or drain outlets, and one end of the steel wire is locked, while the other end is tightened after applying a tension of 50 N.

[0014] Preferably, in step S5, the pressure between the frame disassembly device and the frame is monitored in real time by a pressure sensor. When the pressure decreases to 90% of the peak pressure, the force application is stopped, and the force application position is moved to complete the disassembly of the entire frame.

[0015] On the other hand, the present invention provides a portable frame removal device for performing the photovoltaic module frame removal method described in any of the above claims. The device includes a crossbeam, and two opposing short-side fixing clips are detachably connected to the outer surface of the crossbeam near both ends. A lifting device is threadedly connected to the outer surface of the crossbeam at an adjustable position. The lifting direction of the lifting device is perpendicular to the crossbeam. A groove for accommodating the frame is opened on the inner side of the crossbeam, and a frame fixing hole is opened on the crossbeam that corresponds to the position of the mounting hole on the frame and penetrates the top and bottom of the crossbeam. A frame fixing pin is connected in the fixing hole.

[0016] Preferably, the lifting device includes a fixed base, a cylinder fixedly connected to the fixed base, a first push rod fixedly connected to the cylinder, a second push rod whose position is adjustable and inserted into the end of the first push rod away from the cylinder, and a top block fixedly connected to the end of the second push rod away from the first push rod.

[0017] Preferably, a pressure sensor is provided between the top block and the second top rod.

[0018] Preferably, at least one of the short-side fixing clips is elastically connected to a clamping plate facing the other short-side fixing clip.

[0019] Preferably, the frame fixing pin includes a threaded pin and a wing nut.

[0020] Preferably, the crossbeam is a U-shaped channel steel.

[0021] Preferably, the outer surface of the beam has a plurality of elongated holes spaced apart along its length.

[0022] Compared with the prior art, the present invention discloses at least the following beneficial effects:

[0023] This invention increases the strength of the frame by filling the frame cavity with bubble sealant, preventing damage or bursting of the laminated components due to tearing of the frame sidewalls. Using a pressure sensor to control the lifting pressure avoids damage to the frame from excessive force, effectively protecting the edges of the laminated components from impacts in the event of frame breakage. Using steel wire clamps to hold the bubble sealant further enhances the strength of the long side of the frame. The method and apparatus of this invention for removing the module frame can replace manual frame disassembly, reducing the difficulty of disassembly, saving labor, and solving the problem of photovoltaic module explosions or large-area microcracks in the cells caused by uncontrolled force and speed during manual frame disassembly. It also avoids damage or bursting of the laminated components due to tearing of the frame sidewalls, effectively improving disassembly efficiency and the integrity of the laminated components. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a flowchart of the photovoltaic module frame removal method of the present invention;

[0026] Figure 2 This is a front view of the portable frame removal device of the present invention;

[0027] Figure 3 This is a top view of the portable frame removal device of the present invention;

[0028] Figure 4 This is a right view of the portable frame removal device of the present invention;

[0029] Figure 5 This is an isometric view of the portable frame removal device of the present invention;

[0030] Figure 6 This is a front view of the second short-side fixing clip in the portable frame removal device of the present invention;

[0031] Figure 7 This is a top view of the second short-side fixing clip in the portable frame removal device of the present invention;

[0032] Figure 8 This is an isometric view of the second short-side fixing clamp in the portable frame removal device of the present invention;

[0033] Figure 9This is an exploded view of the second short-side fixing clip in the portable frame removal device of the present invention;

[0034] Figure 10 This is a schematic diagram of the frame fixing pin in the portable frame removal device of the present invention;

[0035] In the diagram: 1. Crossbeam; 2. Fixing seat; 3. Cylinder; 4. First push rod; 5. Second push rod; 6. Push rod fixing pin; 7. Pressure sensor; 8. Top block; 9. Bolt; 10. Long hole; 11. Frame fixing pin one; 12. Frame fixing pin two; 13. First short side fixing clamp; 14. Second short side fixing clamp; 15. Frame fixing hole; 16. Push rod fixing hole; 111. Threaded pin; 112. Wing nut; 141. Base plate; 142. Connecting plate; 143. Lateral positioning plate one; 144. Lateral positioning plate two; 145. Clamping plate; 146. Spring; 147. Connecting hole. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0038] Reference Figure 1 As shown, the present invention provides a method for disassembling photovoltaic modules, comprising the following steps:

[0039] Step S1: Determine the number and location of the frames in the photovoltaic modules that need to be replaced.

[0040] Step S2: Heat the photovoltaic module to soften its encapsulation material.

[0041] In some embodiments, heating the photovoltaic module to soften its encapsulation material specifically includes: connecting the photovoltaic module to a constant current source as a load, applying a current of 1 Isc to the photovoltaic module through the constant current source for 30 minutes, and heating the photovoltaic module to soften the encapsulation material.

[0042] In some embodiments, the positive terminal of the photovoltaic module is connected to the positive terminal of the constant current source, and the negative terminal of the photovoltaic module is connected to the negative terminal of the constant current source, thereby forming a load.

[0043] Step S3: Use a cutting tool to cut along the front and back sides of the component laminate and the frame.

[0044] Step S4: Inject bubble sealant into the frame cavity until the frame cavity is full of bubble sealant, and let it stand for 15 minutes to cure the bubble sealant.

[0045] In the actual disassembly process, when it is necessary to remove the short side frame, since there are two drainage holes on the short side frame, bubble sealant can be injected directly from one drainage hole until the bubble sealant overflows from the other drainage hole. At this time, the bubble sealant fills the entire frame cavity.

[0046] When it is necessary to remove the long side frame, use a drilling tool to drill two 0.5cm diameter round holes 5cm from the end on the outside of the long side frame. Insert a steel wire with an outer diameter of 0.3cm between the two round holes, lock one end of the steel wire, apply a tension of 50N to the other end and lock it, and then inject bubble sealant into the cavity of the long side frame through the round holes to complete the anchoring.

[0047] Step S5: Using a frame removal device, apply force from the inside of the photovoltaic module to the outside of the frame with the cured bubble sealant. Apply force sequentially at multiple positions along the length of the frame from one end to the other to complete the removal of the frame.

[0048] In some embodiments, a pressure sensor monitors the pressure between the frame removal device and the frame in real time when the force is applied. When the pressure decreases to 90% of the peak pressure, the force is stopped, and the force application position is moved to complete the removal of the entire frame.

[0049] It should be understood that bubble sealant is used to enhance the strength of the frame, improve the uniformity of stress, and prevent local deformation of the frame during disassembly, thereby avoiding problems such as photovoltaic module explosion or large-area microcracks in the cells of the module during the disassembly process.

[0050] It should also be understood that certain curable fillers with a certain structural strength can also serve as alternatives to bubble sealants. In this embodiment, bubble sealants typically contain specific foaming agents, reinforcing agents, fillers, and curing agents. For example, the core components of some bubble sealants are silicone resins, polyurethanes, or acrylics, which provide the adhesive with basic bonding properties and strong filling strength after foaming, while also exhibiting rapid foaming characteristics. Reinforcing agents and fillers can improve the tensile strength, shear strength, and abrasion resistance of the sealant, thereby maintaining stable performance in various environments, such as polyurethane foam.

[0051] Reference Figures 2 to 10 As shown, the present invention provides a portable frame removal device, including a crossbeam 1, a pair of short-side fixing clips detachably connected to the outer facade of the crossbeam 1 near both ends, a lifting device detachably connected to the outer facade of the crossbeam 1, and two frame fixing pins inserted through and near the crossbeam 1.

[0052] The crossbeam 1 is made of U-shaped metal material, such as U-shaped channel steel, with a length of 260cm and a width of 5cm. One side has a groove to accommodate the frame. Multiple elliptical slots 10, approximately 10cm long and 1cm wide, are distributed at equal or unequal intervals along the length of the crossbeam 1 for installing lifting devices and short-side fixing clips, etc. Multiple corresponding frame fixing holes 15 are opened on the top and bottom surfaces of the crossbeam 1, the positions of which correspond to the existing mounting holes on the photovoltaic module frame. In use, the frame can be fixed to the crossbeam 1 by using frame fixing pins 11 and 12 in conjunction with the two mounting holes on the frame.

[0053] The design was further optimized, and the structure of the frame fixing pins (including frame fixing pin 11 and frame fixing pin 212) is as follows: Figure 10 As shown, it includes a threaded pin 111 and a wing nut 112 threaded onto the threaded pin 111. The threaded pin 111 passes through the frame fixing hole 15 on the crossbeam 1, and the wing nut 112 is threaded onto one end of the pin for fastening. The wing nut 112 can be easily and quickly disassembled manually.

[0054] like Figures 2 to 5 As shown, the outer facade of the beam 1 is detachably connected to the first short side fixing clip 13 and the second short side fixing clip 14 facing each other by bolts 9 near both ends. The first short side fixing clip 13 and the second short side fixing clip 14 are used to clamp and fix the photovoltaic module from both sides.

[0055] In a further optimized design, during use, the first short-side fixing clip 13 (or the second short-side fixing clip 14, described here using the first short-side fixing clip 13 as an example) can be fixed to the crossbeam 1 as a fixing block, while the second short-side fixing clip 14 can be adjusted to be connected to the crossbeam 1 as an adjustable clip. By changing the connection position between the second short-side fixing clip 14 and the crossbeam 1 according to the size of the photovoltaic module, the distance between the first short-side fixing clip 13 and the second short-side fixing clip 14 can be changed, thereby adapting to the fixing requirements of different sized frames.

[0056] The design is further optimized so that the first short-side fixing clip 13 and the second short-side fixing clip 14 have basically the same structure. Taking the second short-side fixing clip 14 as an example, for instance... Figures 6 to 9As shown, the second short-side fixing clamp 14 is a plate structure with an E-shaped cross-section, including a base plate 141, a connecting plate 142, a first transverse positioning plate 143, and a second transverse positioning plate 144. The connecting plate 142, the first transverse positioning plate 143, and the second transverse positioning plate 144 are all vertically fixed to one side of the base plate 141, and the connecting plate 142, the first transverse positioning plate 143, and the second transverse positioning plate 144 are respectively spaced apart. The space between the first transverse positioning plate 143 and the second transverse positioning plate 144 forms a clamping position to accommodate the frame. The connecting plate 142 has at least one connecting hole 147 in the center for connecting with the crossbeam 1. The first transverse positioning plate 143 and the second transverse positioning plate 144 have notches corresponding to the connecting holes 147 to facilitate the insertion and removal of bolts 9 without affecting the clamping of the frame.

[0057] In a further optimized design, the first short-side fixing clip 13 and / or the second short-side fixing clip 14 are elastically connected to opposing clamping plates 145, such as... Figure 9 As shown, two springs 146 are fixedly connected to the back of the clamping plate 145. One end of the two springs 146 is fixedly connected to the clamping plate 145, and the other end is fixedly connected to the base plate 141. The front of the clamping plate 145 is used to press against the frame to form a clamp.

[0058] like Figure 4 and Figure 5 As shown, the lifting device includes a fixed base 2, a cylinder 3 fixed to the fixed base 2, a first push rod 4 fixed to the cylinder 3, a second push rod 5 adjustablely inserted into the end of the first push rod 4 away from the cylinder 3, and a top block 8 fixed to the end of the second push rod 5 away from the first push rod 4. The fixed base 2 is fixed to the side of the cylinder 3 and is fixed to the outer surface of the crossbeam 1 by bolts 9. It can be fixed by moving its position on the crossbeam 1. The first push rod 4 is connected to the cylinder 3. The first push rod 4 is a metal tube with an inner diameter of 3cm and a length of 20cm. A pair of radially penetrating push rod fixing holes 16 are opened 5cm from the top of the first push rod 4 (the end away from the cylinder 3). The diameter of the push rod fixing holes 16 is 1cm, which are used for the push rod fixing pin 6 to pass through. A second top rod 5 is inserted into the first top rod 4. The second top rod 5 has multiple sets of top rod fixing holes 16 spaced along its length for the top rod fixing pins 6 to pass through. The second top rod 5 is adjustablely connected to the first top rod 4 via the top rod fixing pins 6. The second top rod 5 has an outer diameter of 2.7 cm and is a cylindrical solid or hollow metal rod, approximately 20 cm long. A 1 cm diameter top rod fixing hole 16 is drilled every 5 cm on the rod. By changing the connection position between the second top rod 5 and the first top rod 4, the length of the entire lifting device can be changed, thus accommodating the removal of frames of different sizes.

[0059] In a further optimized design, a pressure sensor 7 is connected to the end of the second push rod 5. One end of the pressure sensor 7 is connected to the second push rod 5, and the other end is connected to the top block 8. When the top block 8 abuts against the frame, the pressure value can be measured in real time.

[0060] All aspects not detailed in this invention are conventional technical means well known to those skilled in the art.

[0061] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0062] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A method for disassembling photovoltaic modules, characterized in that, Includes the following steps: Step S1: Determine the number and location of the frames in the photovoltaic modules that need to be replaced; Step S2: Heat the photovoltaic module to soften its encapsulation material: Connect the photovoltaic module to a constant current source as a load, and apply a current of 1 Isc to the photovoltaic module for 30 minutes to heat the photovoltaic module and soften its encapsulation material. Step S3: Use a cutting tool to cut along the front and back sides of the component laminate and the frame; Step S4: Inject bubble sealant into the frame cavity until the frame cavity is full of bubble sealant, and let it stand for 15 minutes to cure the bubble sealant; wherein, injecting bubble sealant into the frame cavity includes: injecting bubble sealant into the frame cavity using the existing drainage outlets on the frame, injecting from one side of the frame drainage outlet until the bubble sealant overflows from the other side drainage outlet; by filling the frame cavity with bubble sealant, the strength of the frame is increased, and the sidewalls of the frame are prevented from tearing, which could cause damage or bursting of the laminate; Step S5: Use the frame removal device to apply force from the inside of the frame with the cured bubble sealant outwards, and apply force sequentially at multiple positions along the length of the frame from one end to the other to complete the removal of the frame; wherein, the pressure between the frame removal device and the frame is monitored in real time by a pressure sensor, and the force is stopped when the pressure decreases to 90% of the peak pressure, and the force application position is moved to complete the removal of the entire frame.

2. The photovoltaic module frame removal method according to claim 1, characterized in that, When the frame to be removed is the long side frame, before injecting the bubble sealant, introduce a steel wire with an outer diameter of 0.3cm between the two drain outlets, lock one end of the steel wire, and apply a tension of 50N to the other end and lock it.

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