How to disassemble a photovoltaic conversion module

Abstract

To provide a method for disassembling a photoelectric conversion module which can remove a frame with smaller force.SOLUTION: A photoelectric conversion module 10 has a panel 100, a plurality of frames 200 which is provided along the side part of the panel and has hollow parts 200h, and a connection tool 300 which is inserted into the hollow parts of the frames and connects the mutually adjacent frames. A method for disassembling a photoelectric conversion module includes a breaking step of breaking wall parts surrounding the hollow parts of the frames, and thereby taking out the connection tool.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to a method for disassembling a photovoltaic conversion module. [Background technology]

[0002] As measures to reduce carbon dioxide emissions are implemented, it is expected that photovoltaic conversion modules such as solar cell modules, which are a type of renewable energy, will become more widespread. Currently, solar cell modules are being considered for dismantling and recycling when they are discarded.

[0003] A solar cell module generally includes a flat solar cell panel (photoelectric conversion panel) that converts light energy into electrical energy, and a frame provided on the outer periphery of the solar cell panel (see Patent Documents 1 and 2 below). The frame has a fitting portion into which the outer periphery of the solar cell panel is fitted. An adhesive (sealing material) is filled in the fitting portion of the frame into which the outer periphery of the solar cell panel is fitted, thereby firmly adhering the solar cell panel to the frame.

[0004] In Patent Document 2, the frames have hollow structures. Adjacent frames are adjacent to each other so that their hollow structures communicate with each other. Connectors (corner pieces) are press-fitted into the hollow structures of the adjacent frames, spanning between them. In this way, the connectors connect the adjacent frames to each other. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2014-116363 A [Patent Document 2] JP 2010-199147 A Summary of the Invention [Problem to be solved by the invention]

[0006] In Patent Document 2, the connector is press-fitted into the hollow structure between adjacent frames, straddling the hollow structures. This firmly connects the frames together, so that when dismantling the photovoltaic conversion module, it is necessary to forcibly separate the frames by applying a strong pressing force to the frames. In this case, a strong force is also applied to the ends of the panels fixed to the frames, and the ends of the panels may crack during dismantling. If the ends of the panels crack during dismantling, the ends of the panels may remain attached to the frames.

[0007] Therefore, a method for disassembling a photovoltaic conversion module that enables removal of the frame with less force is desired. [Means for solving the problem]

[0008] A method for dismantling a photoelectric conversion module according to one embodiment relates to a method for dismantling a photoelectric conversion module including a panel, a plurality of frames provided along sides of the panel, the plurality of frames having hollow portions, and connectors inserted into the hollow portions of the frames to connect adjacent ones of the frames, the method including a breaking step of removing the connectors by breaking walls surrounding the hollow portions of the frames. Effect of the Invention

[0009] According to the above aspect, it is possible to provide a method for disassembling a photovoltaic conversion module that enables the frame to be removed with less force. [Brief description of the drawings]

[0010] [Figure 1] 1 is a perspective view of a photovoltaic conversion module according to one embodiment. [Diagram 2] 2A is a cross-sectional view of the photovoltaic conversion module taken along line 2A-2A in FIG. [Diagram 3] 2 is a plan view of the photoelectric conversion module as viewed from the rear surface side. FIG. [Figure 4]1 is an enlarged perspective view of the vicinity of a corner of the photoelectric conversion module as viewed from the back side. [Diagram 5] FIG. 5A is a cross-sectional view taken along line 5A-5A in FIGS. 3 and 4. [Figure 6] FIG. 1 is a perspective view of a connector according to one embodiment. [Figure 7] FIG. 4 is a schematic diagram for explaining a breaking step according to the first embodiment. [Figure 8] FIG. 4 is a schematic diagram for explaining a frame separation step according to the first embodiment. [Figure 9] FIG. 9 is a schematic diagram for explaining a state following FIG. 8. [Figure 10] 10A to 10C are schematic diagrams for explaining examples of positions at which an external force is applied to the frame in the frame separation step. [Figure 11] FIG. 11 is a schematic diagram for explaining a breaking step according to the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, the embodiments will be described with reference to the drawings. In the following drawings, the same or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic and the ratios of dimensions may differ from the actual ones.

[0012] [Photoelectric conversion module] FIG. 1 is a perspective view of a photovoltaic conversion module according to one embodiment. FIG. 2 is a cross-sectional view of the photovoltaic conversion module taken along line 2A-2A in FIG. 1. FIG. 3 is a plan view of the photovoltaic conversion module as viewed from the rear side. In FIG. 3, a connector provided inside a frame cannot be seen from the photovoltaic conversion module, but is shown by a dotted line for the purpose of explanation. FIG. 4 is an enlarged perspective view of the vicinity of a corner of the photovoltaic conversion module as viewed from the rear side. FIG. 5 is a cross-sectional view taken along line 5A-5A in FIGS. 3 and 4. FIG. 6 is a perspective view of a connector according to one embodiment.

[0013] The photovoltaic conversion module 10 may be, for example, a solar cell module that converts light energy into electrical energy. Such a solar cell module may be installed outdoors, for example, on the roof or wall of a building.

[0014] The photovoltaic conversion module 10 includes a flat panel 100 and a frame structure 200. The panel 100 may include a photovoltaic conversion element that converts light energy into electrical energy and vice versa. In this embodiment, the panel 100 has a substantially rectangular shape when viewed from a direction perpendicular to the surface of the panel 100 (height direction). The height direction corresponds to the Z direction in the figure.

[0015] The frame structure 200 is attached to the periphery of the panel 100 and is provided along the sides of the panel 100. The frame structure 200 may include at least a plurality of frames 220 connected to each other. The frames 220 are provided along the edges of the panel 100.

[0016] In the example shown in Fig. 1, two frames 220 extend in a first direction (hereinafter sometimes referred to as "horizontal direction") along a first edge of the panel 100, and the remaining two frames 200 extend in a second direction (hereinafter sometimes referred to as "vertical direction") along a second edge adjacent to the first edge of the panel 100. Here, the horizontal direction corresponds to the X direction in the figure, and the vertical direction corresponds to the Y direction in the figure. The first direction (horizontal direction) and the second direction (vertical direction) may be directions that intersect with each other, and are preferably directions that are perpendicular to each other.

[0017] Adjacent frames 220 are connected to each other at the ends of the frames 220. In the example shown in Fig. 1, four frames 220 are connected to each other to form a substantially rectangular frame.

[0018] Each frame 220 may have a holding portion 221, legs 222, sidewalls 223, flanges 224, and a panel receiving portion 225 (see FIG. 2 in particular). The holding portion 221, legs 222, sidewalls 223, and flanges 224 extend along the direction in which the frame 220 extends (extension direction). The holding portion 221, legs 222, sidewalls 223, and flanges 224 may be molded integrally and inseparably with one another.

[0019] The panel receiving portion 225 may be composed of a holding portion 221, a side wall portion 223, and a flange 224. Specifically, the panel receiving portion 225 has a substantially "C" shape in a cross section perpendicular to the extension direction of the frame 220 (see FIG. 2). As a result, the panel receiving portion 225 is configured to be able to receive an end portion of the panel 100.

[0020] The flange 224 protrudes from an upper portion of the side wall portion 223 toward the inside of the panel 100, and covers the surface of the end portion of the panel 100. The holding portion 221 protrudes from the side wall portion 223 toward the inside of the panel 100, and faces the flange 224. The holding portion 221 is configured to support the end portion of the panel 100 from below.

[0021] The inside of the panel receiving portion 225 may be filled with an adhesive 229. This allows the panel receiving portion 225 to hold the panel 100 in a state in which the end portion of the panel 100 is received therein.

[0022] The adhesive 229 may be provided over the entire panel receiving portion 225 in the extension direction of the frame 220, or may be provided over only a partial area of ​​the panel receiving portion 225 in the extension direction of the frame 220. The adhesive 229 may be an adhesive containing a thermoplastic resin. Examples of such adhesives include a silicone-based adhesive and a butyl rubber-based adhesive.

[0023] The legs 222 may extend from the holding portion 221 in a direction away from the panel 100. That is, the legs 222 may extend from the panel receiving portion 225 toward the back side of the photovoltaic conversion module.

[0024] The frame 220 has a hollow portion 222h and walls 222a and 222b surrounding the hollow portion 222h (see FIGS. 2 and 5). The hollow portion 222h extends along the extension direction of the frame 220. In this embodiment, the walls 222a and 222b surrounding the hollow portion 222h are provided on the leg portion 222.

[0025] Specifically, the wall surrounding the hollow portion 222h, i.e., the wall constituting the leg portion 222, may have an outer wall portion 222a exposed to the outside of the photoelectric conversion module 10 and an inner wall portion 222b facing the inside of the photoelectric conversion module. The outer wall portion 222a and the inner wall portion 222b may extend from the holding portion 221 toward the back side of the photoelectric conversion module. The hollow portion 222h is defined by the space between the outer wall portion 222a and the inner wall portion 222b.

[0026] The leg 222 may include an end 222c bent toward the surface of the panel furthest from the panel 100. The end 222c may extend beyond the inner wall 222b from the outer wall 222a toward the inside of the photovoltaic conversion module.

[0027] The outer walls 222a of the legs 222 abut against the outer walls 222a of the adjacent frames 220 at both ends of the frames 220 (see FIGS. 1 and 4). When the adjacent frames 220 are connected to each other, the hollow portions 222h of the frames 220 are aligned and communicate with each other.

[0028] The photovoltaic conversion module 10 has a connector 300 that connects adjacent frames 220 together (see FIGS. 3, 5, and 6). The connector 300 has a shape that allows it to be inserted into the hollow portion 222h of the frame 220. Specifically, the connector 300 is inserted across both of the hollow portions 222h of the adjacent frames 200. The connector 300 may be bent into an L-shape when viewed from a direction perpendicular to the surface of the panel 100.

[0029] The connector 300 may be press-fitted into both hollow portions 222h of adjacent frames 200. In this way, the adjacent frames 200 are connected to each other by the connector 300. As shown in Fig. 6, the connector 300 may have a wall portion surrounding the hollow portion 222h, and a plurality of protrusions 310 that are in pressure contact with the inner wall portion 222b in the illustrated embodiment.

[0030] When the connector 300 has a protrusion 310, the inner wall 222b may have a recess (not shown) that engages with the protrusion 310, although this is not essential.

[0031] The configuration of the photoelectric conversion module has been described with reference to the drawings. It should be noted that the configuration of the photoelectric conversion module is not limited to the above-described configuration, and can be modified in various ways as long as the following disassembly method can be applied.

[0032] [How to disassemble a photovoltaic conversion module] [First embodiment] Next, a method for dismantling a photovoltaic conversion module will be described with reference to Fig. 7 to Fig. 10. Fig. 7 is a schematic diagram for explaining a breaking step according to the first embodiment. Fig. 8 is a schematic diagram for explaining a frame separation step according to the first embodiment. Fig. 9 is a schematic diagram for explaining a state following Fig. 8. Fig. 10 is a schematic diagram for explaining an example of a position where an external force is applied to the frame in the frame separation step.

[0033] The method for disassembling the photovoltaic conversion module may include a pre-processing step, a breaking step, and a frame separation step, which are performed as necessary. The configuration of the photovoltaic conversion module is as described above.

[0034] (Pre-processing step) First, prepare a photovoltaic conversion module to be disassembled. Accessories such as a terminal box provided on the photovoltaic conversion module may be removed in advance as necessary. Alternatively, the steps described below may be performed without removing the accessories.

[0035] (Break Step) In the breaking step, the coupler 300 is removed by breaking the wall surrounding the hollow portion 222h of the frame 220 (see FIG. 7). In the first embodiment, the breaking step includes breaking the outer wall 222a around the coupler 300 inserted into the hollow portion 222h. This exposes the hollow portion 222h to the outside, allowing the coupler 300 in the hollow portion 222h to be removed.

[0036] More specifically, as shown in Fig. 7, the inner wall portion 222b of the frame 220 is not broken, and only the outer wall portion 222a is broken. It is preferable that all the connectors 300 are removed by breaking the outer wall portion 222a of the frame 220 for each corner of the frame structure 200. Breaking of the frame 220 can be performed by a tool such as a screwdriver, pliers, a punching tool, or a cutter.

[0037] In the breaking step, it is preferable that the region where the connector 300 is inserted and the surrounding region of the wall surrounding the hollow portion 222h of the frame 220 are broken. More specifically, the region to be broken may be within the range of the region where the connector 300 is inserted (reference symbol A1 in FIG. 3) and a region at a predetermined distance from the region A1 (reference symbol A2 in FIG. 3). That is, it is preferable that the outer wall portion 222a surrounding the hollow portion 222h is broken within the range of the regions A1 and A2 shown in FIG. 3. Here, the predetermined distance A2 may be, for example, 5 cm or less, preferably 3 cm or less.

[0038] When only the region where the connector 300 is inserted and the region around it are broken, the work required to break the wall surrounding the hollow portion 222h is advantageously simplified. Also, by making the break region of the frame 220 as small as possible, the overall strength of the frame 220 is not significantly reduced, and the frame 220 can be easily removed from the panel 100 in the frame separation step described below.

[0039] (Frame separation step) In the frame separation step, after the breaking step is performed, an external force is applied to the frame 220 to remove the frame 220 from the panel 100. Specifically, an external force F is applied to the frame 220 in a direction away from the panel 100 so that the holding portion 221 of the frame 220 receives a force in a direction away from the panel 100. Because the connector 300 has been removed in the breaking step described above, the frame 200 can be removed from the panel 100 with a smaller external force F compared to a state in which the connector 300 is not removed.

[0040] 8 and 9 show how an external force F is applied to the frame 220 using the disassembly device 400. The disassembly device may have, for example, a pressing unit 410 that presses the frame 220 outward.

[0041] 8 and 9, the pressing unit 410 moves from the center of the photoelectric conversion module 10 toward the outside and comes into contact with the inner wall 222b of the frame 220. The pressing unit 410 further moves from the center of the photoelectric conversion module 10 toward the outside and presses the inner wall 222b of the frame 220 toward the outside. This external force F causes the frame 220 to come off the panel 100 (see FIG. 9). The pressing unit 410 may be operated manually or automatically.

[0042] In the frame separation step, it is preferable that the external force F is applied to the leg 222 at a position closer to the panel receiving portion 225 than midway between the end 222c of the leg 222 that is farthest from the panel 100 in a direction perpendicular to the panel 100 and the panel receiving portion 225 of the leg 222.

[0043] If an external force is applied near the end 222c of the leg 222 farthest from the panel 100, the frame 220 receives a force that rotates around the vicinity of the panel receiving portion 225. As a result, the panel 100 near the panel receiving portion 225 receives a force in a direction that causes the panel 100 to bend from the flange 224 of the frame 220. As a result, the panel 100 may crack, and a part of the panel 100 may remain in the panel receiving portion 225. In the above embodiment, the external force F is applied near the panel receiving portion 225 of the leg 222, so that cracking of the panel 100 is suppressed, and the material of the panel 100 is easily separated cleanly from the frame 220. This is effective for recycling the materials that constitute the photovoltaic conversion module 10.

[0044] Alternatively to the above-described embodiment, if the panel 100 is not easily broken, the external force F may be applied near the end 222c of the leg 222 that is farthest from the panel 100, or near the center of the leg 222 in the height direction.

[0045] In the frame separation step, the external force F may be applied to the inner wall portion 222b of the leg portion 222 with the outer wall portion 222a of the leg portion 222 being held by the back plate 480. As shown in Figures 8 and 9, the back plate 480 may be in contact with at least the outer wall portion 222a of the leg portion 222. The back plate 480 may be substantially U-shaped so as to fit along the end portion 222c and the flange 224 of the leg portion 222 (see Figures 8 and 9).

[0046] The back plate 480 is preferably provided at least at a position where the external force F is applied. The back plate 480 may be provided across the region where a portion of the frame 220 is broken from the position where the external force F is applied. Since the strength of the region where the portion of the frame 220 is broken is reduced, when the external force F is applied, the frame 220 may bend without coming off the panel 100. Since the frame 220 becomes less likely to bend by using the back plate 480, the external force F is more likely to be firmly applied to the frame 220 so that the frame 220 comes off the panel 100.

[0047] The back plate 480 is used to suppress rotation of the frame 220 due to an external force F by supporting the frame 220 from the outside. In other words, the back plate 480 suppresses the panel 100 near the panel receiving portion 225 from receiving a force in a direction in which the panel 100 is bent from the flange 224 of the frame 220. Therefore, cracking of the panel 100 is suppressed, and the material of the panel 100 can be easily and neatly separated from the frame 220.

[0048] Alternatively, if the panel 100 is not crack resistant, the back plate 480 is not required during the frame separation step.

[0049] Next, an example of the position at which an external force is applied to frame 220 in the frame separation step will be described with reference to Fig. 10. In the frame separation step, external force F is preferably applied to a position closer to the end of frame 220 than to the middle between the center of frame 220 and the end of the frame in the extension direction of frame 220. In other words, external force F is preferably applied within a range of ¼ of the length of frame 220 from the end of frame 220 (region indicated by symbol L1 in Fig. 10). In this case, external force F acts near the end of frame 220.

[0050] More preferably, in the frame separation step, the external force F is applied in the extension direction of the frame 220 to an area outside the area where the frame 220 is broken in the breaking step. That is, the external force F is preferably applied to a position where the frame 220 is not broken in the extension direction of the frame 220. Even in this case, the external force F is preferably applied to a range L1 having a length of 1 / 4 of the length of the frame 220 from the end of the frame 220. The strength of the frame 220 is not significantly reduced in the position where the frame 220 is not broken when the external force F is applied. Therefore, the frame 220 is not easily bent when the external force F is applied, and the frame 220 is easily removed from the panel 100.

[0051] The external force F may be applied near one end of the frame 220, and then near the other end of the frame 220. In this case, the vicinity of one end of the frame 220 comes off from the panel 100, and then the vicinity of the other end of the frame 220 comes off from the panel 100. Alternatively, the external force F may be applied near both ends of the frame 220 simultaneously.

[0052] All of the frames 220 may be removed from the panel 100 by the method described above. In the embodiment described above, the frames 220 are removed from the panel 100 by the pressing portion 410 of the dismantling device 400. Instead, the frames 220 may be removed from the panel 100 by hand, if possible.

[0053] [Second embodiment] Next, a method for disassembling a photovoltaic conversion module according to a second embodiment will be described with reference to Fig. 11. Fig. 11 is a schematic diagram for explaining a breaking step according to the second embodiment. Note that the same reference numerals are used for configurations similar to those in the first embodiment. Please note that the description of the same configurations as those in the first embodiment may be omitted.

[0054] In the second embodiment, in the breaking step, the connecting device 300 is removed by cutting out the entire region of the frame 220 into which the connecting device 300 is inserted. Specifically, the outer wall portion 222a and the inner wall portion 222b near the corner of the frame 220 are cut, so that the connecting device 300 is removed together with the corner of the frame 220 (see FIG. 11). Breaking the frame 220 in this manner can be performed by, for example, a cutting device such as a cutter.

[0055] Preferably, the holding portion 221 and the flange 224 of the frame 220 are not cut. This prevents the panel 100 received in the panel receiving portion 225 from cracking in the breaking step.

[0056] In the second embodiment, similarly to the first embodiment, the region of the frame 220 to be broken is preferably a region near the end of the frame 220. In this case, the external force F is applied to a position in the extension direction of the frame 220 where the frame 220 is not broken.

[0057] Next, a frame separation step is performed. The frame separation step is the same as that in the first embodiment, and therefore a description thereof will be omitted. In the second embodiment, the connector 300 is also removed in the breaking step, so that the frame 200 can be removed from the panel 100 with a smaller external force F than in a state in which the connector 300 is not removed.

[0058] As described above, the contents of the present invention have been disclosed through the embodiments, but the descriptions and drawings forming part of this disclosure should not be understood as limiting the present invention. From this disclosure, various alternative embodiments, examples and operating techniques will be apparent to those skilled in the art. Therefore, the technical scope of the present invention is defined only by the invention-specific matters related to the appropriate claims from the above description.

[0059] For example, between the breaking step and the frame separation step, a step of heating the adhesive 229 may be performed. By heating the adhesive 229, the frame 220 can be detached from the panel 100 with a smaller external force F in the frame separation step.

[0060] Furthermore, between the breaking step and the frame separation step, a cut may be made in the adhesive 229. By making a cut in the adhesive 229, the frame 220 can be removed from the panel 100 with a smaller external force F in the frame separation step. [Explanation of symbols]

[0061] 10 Photoelectric conversion module 100 Panels 220 frames 222 Legs 222a Exterior wall 222b Inner wall 222h Hollow part 300 Connector

Claims

1. A method for dismantling a photovoltaic conversion module including a panel, a plurality of frames provided along sides of the panel, the plurality of frames having hollow portions, and connectors that are inserted into the hollow portions of the frames to connect adjacent ones of the frames, the method comprising the steps of: A method for dismantling a photovoltaic conversion module, comprising a breaking step of removing the connector by breaking a wall portion surrounding the hollow portion of the frame.

2. The method for dismantling a photovoltaic conversion module according to claim 1 , wherein the breaking step includes breaking the wall portion surrounding the hollow portion within a range of an area where the connector is inserted and a distance of no more than 5 cm from the area.

3. the wall portion surrounding the hollow portion has an outer wall portion exposed to an outside of the photoelectric conversion module and an inner wall portion facing an inside of the photoelectric conversion module, The method for dismantling a photovoltaic conversion module according to claim 1 or 2, wherein the breaking step includes breaking the outer wall portion around the connector inserted into the hollow portion.

4. The method for disassembling a photovoltaic conversion module according to claim 1 or 2, wherein in the breaking step, the connector is removed by cutting away an entire area of ​​the frame into which the connector is inserted.

5. The method for disassembling a photovoltaic conversion module according to claim 1 , further comprising a frame separating step of removing the frame from the panel by applying an external force to the frame after the breaking step is performed.

6. The method for dismantling a photovoltaic conversion module according to claim 5, wherein in the frame separation step, the external force is applied at a position closer to the end of the frame than midway between the center of the frame and the end of the frame in the extension direction of the frame.

7. 7. The method for disassembling a photovoltaic conversion module according to claim 5, wherein in the frame separating step, the external force is applied to an area outside an area in which the frame is broken in the breaking step in an extension direction of the frame.

8. The frame has a panel receiving portion configured to be able to receive an end portion of the panel, and a leg portion extending in a direction away from the panel, The method for dismantling a photovoltaic conversion module according to claim 5 , wherein in the frame separation step, the external force is applied to an inner wall portion of the leg portion while an outer wall portion of the leg portion is held by a back plate.

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