System, method and container for mobile recycling processing of photovoltaic modules

Abstract

The present invention relates to a system, method and vehicle for efficiently recycling silicon photovoltaic modules, using entirely mechanical approaches. The method includes manual separation, crushing and screening, ensuring the complete recycling of the constituent materials. It uses an adjustable press for separating the sandwich panel from the photovoltaic module frame, a sandwich panel processing assembly, a receiving conveyor belt for transporting the sandwich panels, sorting screens, and elevators to receive the crushed and separated sandwich panels to optimise the recycling method. The aim is to reduce environmental impact by integrating recycled materials into the production chain in a sustainable manner.

Description

SYSTEM, METHOD, AND CONTAINER FOR MOBILE RECYCLING PROCESSING OF PHOTOVOLTAIC MODULES TECHNICAL FIELD

[0001] This patent application relates to an on-site recycling system and method for entities with photovoltaic modules. This mobile solution seeks to address the growing challenge of properly disposing of these devices, especially given the increase in photovoltaic installations. The system, centralized in a container, offers practicality and sustainability to the mobile recycling process of photovoltaic modules. BACKGROUND

[0002] With the popularization of solar energy, it is important to ensure that solar panels are disposed of correctly, which has generated a need to develop equipment and techniques for separating and utilizing materials safely and effectively.

[0003] Photovoltaic module technology, since it has the capacity to generate energy from the incidence of sunlight on solar panels, provides the generation of electrical energy in a clean manner, becoming an alternative with practically no environmental impact.

[0004] Monocrystalline silicon panels, although they represent a small portion of the recycling market, currently rely on manual processes or processes that use equipment adapted for this purpose. However, as the use of this technology becomes more popular worldwide, the need to develop new, safer, and more effective techniques for correctly separating the constituent materials present in photovoltaic modules also increases.

[0005] However, as this is a technology whose useful life is estimated at at least 25 years, studies on recycling photovoltaic modules are still in their infancy.

[0006] In this sense, documents such as US20220184939A1 and WO2021017236A1 shows systems and methods that directly or indirectly improve the recycling of photovoltaic modules.

[0007] By way of example, document US20220184939A1 discloses a method for rapidly detaching the casing of solar modules and disassembling the modules for reuse or recycling of components, wherein electromagnetic radiation is applied to a solar module in a temperature and humidity-controlled environment to detach the casing layers. In Figure 3, US20220184939A1 describes an embodiment of a system for mobile recycling of solar module assemblies, where the system may contain an assembly demounting unit or a module disassembly unit.

[0008] However, it is noted that the systems and methods known in the state of the art are generally for applications that employ electromagnetic radiation (US20220184939A1) and, in some cases, in sets with equipment that use a thermal process (WO2021017236A1).

[0009] It is therefore clear that there is a need to present a functionality that makes it possible to solve the difficulties related to the correct recycling of photovoltaic modules. OBJECTIVES

[0010] The main objective of the present invention is to provide a solution to the problem of properly disposing of photovoltaic modules resulting from the growth of their respective installations. Additionally, such a solution can be implemented in a container, enabling on-site recycling of photovoltaic modules.

[0011] An objective of the present invention is to provide a system and method for the efficient recycling of silicon photovoltaic modules. In line with contemporary challenges, the system seeks, first and foremost, to provide a fully mechanical approach, comprising manual separation, crushing, and sieving steps.

[0012] The central purpose is to ensure the complete recycling of the materials constituting photovoltaic modules, aiming to significantly reduce the environmental impact associated with the improper disposal of these components. The innovation extends to the use of an adjustable press for efficient separation of the sandwich from the frame, and the use of classification screens to optimize recycling, allowing for the specific disposal of materials of different particle sizes. SUMMARY OF THE INVENTION

[0013] The present invention relates to a system, a method, and a vehicle for mobile recycling of photovoltaic modules. The system comprises: a receiving conveyor for receiving and transporting photovoltaic module sandwiches, a sandwich processing module configured to shred the sandwiches received from the receiving conveyor, a slit conveyor for transporting the shredded sandwiches from the sandwich processing module, and a classifying sieve configured to separate the shredded sandwiches received from the slit conveyor. The classifying sieve comprises: sieve meshes for separating the shredded sandwiches according to the spacing dimensions of the first, second, and third sieve meshes, and elevators for receiving the shredded sandwiches and separating them according to the spacing dimensions of the sieve meshes, and for transporting the received sandwiches to different storage locations.

[0014] The method comprises: transporting the photovoltaic module sandwiches by means of a receiving conveyor, crushing the sandwiches received by the receiving conveyor using a sandwich processing module, transporting the crushed sandwiches by the sandwich processing module by means of a slit conveyor, separating the crushed sandwiches received by the slit conveyor using a classifying sieve, receiving the sandwiches separated by the classifying sieve using elevators, and transport the received sandwiches to different storage locations. The vehicle houses the mobile photovoltaic module recycling processing system.

[0015] The main objective of the present invention is to reduce the environmental impact associated with the improper disposal of these modules, thus minimizing the impact on the use of natural resources. The proposed method includes essential steps such as manual separation, shredding, and the separation of glass, metals, and other materials present in the photovoltaic modules.

[0016] The main innovation of this invention lies in its approach, which uses fully mechanical separation, crushing, and screening steps, performed in a simplified manner. These steps are designed to ensure mobile processing for the complete recycling of modules, avoiding environmental liabilities resulting from improper disposal in landfills or dumps. The proposal stands out for the ecological introduction of these materials into the production chain, aligning with the principles of environmental sustainability. REFERENCE SIGNS

[0017] 1 - Receiving belt 2 - Receiving belt tension roller 3 - Receiving belt chassis 4 - Crusher motor 5 - Crusher pulley 6 - Tallised mat 7 - Crusher structure 8 - Removable shredder cover 9 - Receiving belt roller scraper 10 - Talisman track frame 11 - Receiving belt compression rollers 12 - Receiving belt roller stretcher - Belt reducer receiving pulley - Crusher shaft issuing pulley - Receiving belt belt - Receiving belt reducer - Crusher shaft - Crusher processed material collector - Split belt collector - Crusher hammer - Crusher flange - Receiving belt drive roller - Crusher motor belts - Crusher screen - First stage sieve elevator - Second stage sieve elevator - Third stage sieve elevator - Unscreened material output belt - Support pulleys on the front of the screen - Sieve tubular frame - First sieve mesh - Second sieve mesh - Third sieve mesh - Elevator motor - Sieve inlet chute - Unscreened residue output chute - Sieve gear motor - Control panel - Split belt gear motor - Support frame for fixing the sieve meshes - Screw conveyors 42 - Screw conveyor drive gear motor 43 - Collector of sieved materials BRIEF DESCRIPTION OF THE FIGURES

[0018] Figure IA illustrates a perspective view of the crusher assembly, where the receiving belt, the crusher and the crushed material outlet belt can be seen.

[0019] Figure 1B illustrates a left side cross-sectional view of the crusher assembly as well as the drive of the receiving belt.

[0020] Figure 2A illustrates a cross-sectional view of the crushing assembly, showing the screen and hammer assembly.

[0021] Figure 2B illustrates a left side view of the crusher assembly.

[0022] Figure 3A illustrates a rear view of the crushing assembly, where the conveyor belt for the crushed materials can be seen.

[0023] Figure 3B illustrates a front view of the crusher assembly.

[0024] Figure 4A illustrates a left-hand perspective of the classification sieve.

[0025] Figure 4B illustrates a view of the right side of the classification sieve, where one can see the sieve meshes and the funnels where the materials are conducted to the container outlet.

[0026] Figure 4C illustrates a perspective of the left side of the classification sieve, where the screw conveyors can be seen.

[0027] Figure 5 represents a perspective view of the classification meshes that make up the classification sieve.

[0028] Figure 6A represents a perspective view of the recycling plant with a section that allows observation of the equipment inside the container.

[0029] Figure 6B represents a perspective view of the recycling plant with a section that allows observation of the equipment in the inside the container.

[0030] Figure 7 A represents a perspective view of the material outlets and the bags that will receive the materials separated for disposal. DETAILED DESCRIPTION OF THE INVENTION

[0031] The present invention relates to a system, a method, and a vehicle for on-site recycling. The present invention begins with the classification of modules, where they are separated according to their size, constituent materials, and weight. This ensures that, in subsequent steps, the separation equipment is pre-adjusted to maximize material utilization and optimize processing time, thus achieving maximum productivity without compromising material separation quality.

[0032] Figure IA shows a detailed view of the shredding assembly used in the mobile processing system for recycling photovoltaic modules. Shredding assembly 7 consists of two main tracks: receiving track 1 and grooved track 6.

[0033] In an optional embodiment of the invention, the receiving belt 1 is composed of the stretcher roller 2, roller scraper 9, whose function is to remove the accumulation of dust and residues on the roller, which in turn could cause problems and change the diameter of the roller, causing a lateral displacement of the belt, and compression roller 11. These components operate together to control the speed of entry of the material into the crusher.

[0034] In the embodiment illustrated in Figure 1A, the grooved belt 6 is driven by a geared motor 39 mounted on a chassis 10. The geared motor 39 is responsible for driving the grooved belt 6 to transport the crushed materials through the crushing assembly to the classification screen. Preferably, the crusher is equipped with a motor three-phase motor 4, a removable cover 8, a shaft 17, belts 23, and a pulley 5. The three-phase motor 4 transmits a force to the shaft 17 of the shredder through a set of pulleys 5, whose diameters are adjusted to obtain the most suitable rotation for the best separation of the shredded materials. The shredder receives the sandwiches through the receiving belt 1 and shreds the parts of the constituent materials of the photovoltaic modules.

[0035] Figure 1B shows a left side cross-sectional view of the shredder assembly, providing a detailed view of the components that make up the shredder drive system. In this optional embodiment, the three-phase motor drive system 4 consists of a receiving pulley 13, an output pulley 14, a belt 15, a reducer 16, and a roller tensioner 12 for the receiving belt 1. The function of the roller tensioner 12, which consists of a tensioner screw, is to keep the receiving belt 1 tensioned. The function of the receiving pulley of the belt reducer 13 is to receive the rotary motion of the drive pulley of the shredder shaft 14, through the receiving belt belt 15, and relay it to the shaft of the receiving belt reducer 16, which in turn will reduce the rotation and drive the drive roller of the receiving belt 22.

[0036] Figure 2 A represents a cross-sectional view of the crushing assembly, where it is possible to observe an internal sieve 24, a flange 21, a drive roller 22 of the receiving belt 1, a collector 18 of the crushed materials in the crushing assembly, a collector 19 of the grooved belt 6 and a set of hammers 20.

[0037] Hammer assembly 20, through its rotary motion, crushes the constituent parts of the photovoltaic modules. The parts crushed by hammer assembly 20 are conveyed to internal sieve 24, which directs the crushed materials through collector 18 to collector 19 of the grooved conveyor belt. The latter is responsible for transporting the crushed materials to the classification sieve.

[0038] Figure 2B shows a left side view of the crushing assembly, where the connection between collector 18 of internal sieve 24 and collector 19 of grooved belt 6 can be seen.

[0039] Figure 3A shows a rear view of the crushing assembly 7, where the arrangement of the grooved belt 6 that transports the material to the classification sieve can be observed.

[0040] Figure 3B shows a front view of the crushing assembly, where the arrangement of the motor 4 driving the crushing assembly 7 can be seen, where the motor 4 is coupled to the end of the shaft 17.

[0041] Figure 4A shows a left-hand perspective view of the grading screen. Preferably, the assembly includes a support pulley 29, a tubular frame 30, a first screening mesh 31, a second screening mesh 32, a third screening mesh 33, elevators 25, 26, 27 corresponding to the screening meshes, an inlet chute 35, and an outlet conveyor 28.

[0042] The crushed materials coming from the grooved conveyor belt 6 are directed to the input chute 35. At this point, the crushed materials are separated through different sieving meshes: the first mesh 31 separates the glass powder, the second mesh 32 separates the glass with medium particle size and the third mesh 33 separates the glass with larger particle size.

[0043] After the separation step by the sieving meshes, the crushed and separated materials are transported by specific elevators. The first elevator 25 carries the material separated by the first mesh 31, the second elevator 26 carries the material separated by the second mesh 32, and the third elevator 27 carries the material separated by the third mesh 33. These elevators direct the materials to different storage locations, which may be boxes or disposal bags.

[0044] Any materials not crushed or separated by the grading screen are conveyed by the exit conveyor 28 to a different storage location than the separated materials.

[0045] Figure 4B shows a perspective of the classification meshes, where the arrangement of the elevator motor 34, the sieve gear motor 37, the collector 43 for the sieved materials and the outlet chute 36 for the uncrushed waste can be observed.

[0046] Motor 34 is connected to the outlet chutes of the first, second, and third screening meshes, driving elevators 25, 26, and 27 to transport the crushed and separated materials to their respective disposal boxes or bags. Simultaneously, gear motor 37 controls the rotation speed of the screening screen, ensuring efficient operation.

[0047] Figure 4C shows a perspective of the classification sieve, where the arrangement of the screw conveyors 41 and the drive gear motors 42 of the screw conveyors 41 can be observed.

[0048] The screw conveyors 41 are driven by the drive gear motors 42 and receive the materials sieved by the three classification meshes through the collectors 43, where after receiving the sieved materials, the screw conveyors 41 carry them to a storage location.

[0049] Figure 5 shows a perspective view of the sieve meshes 31, 32, and 33 that make up the classifying sieve, highlighting the presence of the support frame 40 and the sieve meshes. The support frame 40 serves to secure the sieve meshes, preventing undulations at the attachment points and ensuring process stability.

[0050] Figure 6 A shows a front view of the recycling plant, where the arrangement of the elements can be observed. make up the photovoltaic module recycling system. As can be seen, the entire plant is configured to be contained within a container.

[0051] Figure 6B shows a perspective view of the recycling plant, with a cutaway, showing the arrangement of the components that make up the photovoltaic module recycling system, along with control panel 38, which is supplied with a three-phase power supply, which can be 220V or 380V. Control panel 38 houses the drive switches, inverters, and electronic resources necessary for starting and monitoring all motors that will drive the equipment installed inside the container. Additionally, control panel 38 is responsible for comprehensively controlling the operation of the system as a whole.

[0052] Figure 7 A shows a perspective view of the recycling plant, where it is possible to observe the elevators 25, 26, 27 to transport the received sandwiches to different storage locations, highlighting the exits of the shredded and separated materials directed to the destination boxes or bags.

[0053] The present invention also relates to a method for mobile recycling of photovoltaic modules. Specifically, the method comprises the steps of: transporting the photovoltaic module sandwiches via a receiving conveyor 1; shredding the sandwiches received via the receiving conveyor 1 using a sandwich processing module 7; transporting the shredded sandwiches via the sandwich processing module 7 via a grooved conveyor 6; separating the separated sandwiches using a sorting sieve comprising screening meshes; and transporting the received sandwiches using elevators 25, 26, 27 to different storage locations.

[0054] To begin the photovoltaic module recycling process, the junction box and connected power cables are first removed using an extraction device, such as a power tool. After removing the junction box and power cables, the sandwich is separated from the photovoltaic module frame.

[0055] The separation is performed by a press with adjustable arms that apply an inside-out force to detach the aluminum profile from the encapsulant, which in turn holds the frame, silicon wafer, and sandwich together. This device can be transported together with or separately from the system for mobile recycling of photovoltaic modules proposed by the present invention.

[0056] The sandwich containing the encapsulant, the glass plate, and the other materials comprising the photovoltaic modules are then conveyed by a receiving conveyor (1), whose function is to transport the sandwiches separated from the photovoltaic module frames to the shredding assembly (7). The receiving conveyor operates via opposing rollers (2), pressed by springs whose working pressure can be adjusted via threads. These rollers are arranged in two sets, driven by synchronizing gears. The drive force is obtained from the shredder shaft (17), which is reduced to the appropriate speed by a reducer connected to the first shaft of the first set of rollers. Transmission to the second set of rollers occurs via chain gears and a chain installed opposite the roller synchronizing gears.This prevents the crusher rotor from locking, which in turn improves the crushing of the materials making up the sandwich, due to the controlled entry of said sandwich into contact with the crushing hammers 20.

[0057] During the crushing stage, the crusher receives the sandwich from the receiving belt 1 and separates the sandwich's constituent parts through the rotary motion of the hammers 20. After reaching a particle size of less than 10 mm, they pass through a sieve 24 located inside the crusher. This sieve has a semicircular shape, with a radius larger than the circular motion of the hammers 20. The crusher operates using a set of pulleys, the diameters of which can be adjusted to achieve the most appropriate rotation for the best separation of the glass without excessively reducing the plastic part of the sandwich. Its main feature is its 1200 mm width, allowing it to receive the sandwich without excessively tearing the plastic film. After the crushing stage, the resulting materials pass through sieve 24 to the lower part of the crusher and continue through a grooved belt 6 to the set of classification sieves.

[0058] The classifying sieve is a piece of equipment comprising a tubular arrangement 30 mounted on a metal frame, where collecting funnels for each screening stage, connected by a standardized flange to the extraction systems, are attached to the classification meshes 31, 32, and 33, which can be manufactured from steel wire, stainless steel, or perforated steel plates. Regarding the aforementioned tubular arrangement 30, it has a wire screen 40 with an opening larger than desired for the screening process. This larger opening serves as a support for the finer screening meshes, thus preventing undulations at the attachment points, which could cause premature wear due to the abrasive action of the glass on the protrusions during the rotary movement of the screening.

[0059] The sieving process consists of three separation stages: in the first separation stage, the first classification mesh 31 with a finer opening allows the passage of the finest particles, These are composed primarily of glass powder. In the second separation stage, the second classification mesh 32 allows the passage of mainly medium-sized glass, which will be specifically destined for production sectors that require glass of this size. In the third separation stage, the third classification mesh 33 allows the passage of larger-sized glass, which is then sent to specific destinations for this material. After the screening process, the resulting materials, such as plastics, copper filaments, and solar cells, are conveyed through a rear opening of the assembly and transported via an output conveyor 28 to a box or bag for disposal.

[0060] Finally, the present invention also relates to a Container for mobile recycling processing of photovoltaic modules, which stores the system for mobile recycling processing of photovoltaic modules previously described.

[0061] In short, this invention not only addresses the growing problem of photovoltaic modules but also stands out for its operational efficiency, sustainability, and versatility in waste management. This solution represents a significant advance in the field of solar technology recycling, promoting responsible environmental practices and contributing to the circular economy.

Claims

CLAIMS 1. A system for mobile recycling processing of photovoltaic modules, the system comprising: a receiving belt (1) for receiving and transporting sandwiches of the photovoltaic modules; a sandwich processing module (7) configured to crush the sandwiches received from the receiving belt (1); a slit belt (6) for transporting the crushed sandwiches by the sandwich processing module (7); a classifying sieve configured to separate the crushed sandwiches received by the slit belt (6), the sieve comprising: sieving meshes (31, 32, 33) for separating the crushed sandwiches according to the spacing dimensions of the screens of the first, second and third sieving meshes;and elevators (25, 26, 27) to receive the crushed and separated sandwiches according to the spacing dimensions of the sieving mesh screens, and to transport the received sandwiches to different storage locations.; 2. System according to claim 1, characterized in that it additionally comprises screw conveyors (41), configured to receive the crushed and separated sandwiches according to the spacing dimensions of the screens of the sieving meshes, and transport the sandwiches to different deposit locations; in which the screw conveyors (41) are driven by the drive gear motors (42).

3. System according to claim 1 or 2, characterized in that it additionally comprises a separate extraction device attachable to the system, configured to separate the sandwiches from the photovoltaic module frames; wherein the extraction device comprises a press with adjustable arms.

4. System according to any one of claims 1 to 3, characterized in that the sandwich processing module (7) comprises a crusher equipped with an internal sieve (24) and at least one hammer (20); in which the crusher crushes the constituent parts of the sandwiches by means of the rotary movement of the at least one hammer (20); and in which the internal sieve 24 has a semicircular shape with a radius greater than the circular movement of the hammers and operates through a set of pulleys with diameters adjusted to obtain the most suitable rotation for the best way of separating the glass.

5. System according to any one of claims 1 to 4, characterized in that the classifying sieve additionally comprises: a tubular arrangement (30) with a support frame (40) with an opening larger than that desired in the sieving process, in which this larger opening serves as support for the finest classification meshes; an output conveyor (28); an input chute (35); and support pulleys (29); in which the support pulleys (29) are configured to support the front part of the classifying sieve.

6. System according to any one of claims 1 to 5, characterized by the fact that the different storage locations comprise destination boxes or bags.

7. System according to any one of claims 1 to 6, characterized by the fact that recycled photovoltaic modules comprise silicon photovoltaic modules.

8. System according to any one of claims 1 to 7, characterized by the fact that the steps of the separation, crushing and sieving process are carried out in a completely mechanical manner.

9. System according to any one of claims 1 to 8, characterized by the fact that after carrying out the screening process, the resulting materials such as plastics, copper filaments and cells are conducted through a rear opening of the classification screen and are transported through an exit conveyor (28) to a deposit location.

10. System according to any one of claims 1 to 9, characterized in that it additionally comprises a control panel (38) that has drive switches, inverters and electro-electronic resources for starting and monitoring the motors.

11. System according to any one of claims 1 to 10, characterized in that it additionally comprises a three-phase motor drive system (4) equipped with: a roller tensioner (12) for keeping the receiving belt (1) tensioned; a receiving pulley (13) and an emitting pulley (14), in which the receiving pulley (13) is configured to receive the rotary movement of the emitting pulley (14) and retransmit the rotary movement to a reduction shaft (16); in which the emitting pulley (14) transmits the rotary movement by means of a belt (15); and in which the reducer (16) reduces the rotation and drives the tensioner roller of the receiving belt (22).

12. System according to any one of claims 1 to 1, characterized in that the receiving belt (1) is equipped with: a stretch roller (2), a scraper roller (9) and a compression roller (11); that the rollers (2, 9, 11) operate together to hold and control the speed of material entering the crusher.

13. Method for mobile recycling processing of photovoltaic modules using the system for mobile recycling processing of photovoltaic modules as defined in claim 1, the method characterized by the fact that it comprises the steps of: transporting sandwiches of the photovoltaic modules by means of a receiving belt (1); crushing the sandwiches received by the receiving belt (1) using a sandwich processing module (7); transporting the crushed sandwiches by the sandwich processing module (7) by means of a slitted belt (6); separating the separated sandwiches by the classifying sieve comprising sieving meshes (31, 32, 33); and transporting the received sandwiches using elevators (25, 26, 27) to different deposit locations.

14. Method according to claim 13, characterized in that the step of separating the sandwiches is composed of three separation steps: in the first separation step, the first classification mesh (31) with a finer opening allows the passage of the finest particles; in the second separation step, the second classification mesh (32) allows the passage mainly of glass with medium particle size; and in the third separation step, the third classification mesh (33) allows the passage of glass with larger particle size.

15. Method according to claim 13 or 14, characterized in that it additionally comprises separating the sandwiches of the photovoltaic module frames, by means of an extraction device; in which the extraction device comprises a press with adjustable arms that act by applying a force from the inside out, in order to detach the aluminum profile from the encapsulant, which in turn holds the frame with the silicon plate and the sandwich together.

16. Method according to any one of claims 13 to 15, characterized in that the step of crushing the sandwiches comprises the use of a crusher equipped with an internal sieve (24) and at least one hammer (20); in which the crusher crushes the constituent parts of the sandwiches by means of the rotary movement of the at least one hammer (20) until they reach a certain particle size.

17. Method according to any one of claims 13 to 16, characterized in that the steps of the separation, crushing and sieving process are carried out in a fully mechanical manner.

18. Container for mobile recycling processing of photovoltaic modules, characterized in that it stores the system as defined in any one of claims 1 to 12.

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