Heated-Wire Solar Module Delamination and Testing for Recycling
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Solution Overview
Problem
The increasing environmental stress from waste accumulation and the need for sustainable management of solar modules at the end of their lifecycle, coupled with the desire to maximize energy efficiency by refurbishing or recycling these modules.
Innovation Solution
A method involving the use of a heated wire to delaminate solar modules, combined with cleaning and testing processes to assess and separate reusable components, including polarized light for fracture detection and conveyor systems for thorough cleaning, followed by shredding and material separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If solar modules are disposed of in landfills, then waste accumulation is reduced, but environmental stress and resource loss increase
Solution Approach 1:
The patent implements a recycling system that recovers materials from end-of-life solar modules through automated processing. The system separates valuable materials such as silicon, silver, and aluminum from the module structure, converting waste into recoverable resources that can be reused in new solar panel manufacturing, thereby reducing both material loss and environmental stress.
Solution Approach 2:
The recycling process segments the solar module into its constituent materials through automated disassembly and separation techniques. The system divides the integrated module structure into separable components including glass, encapsulant, metal frames, and photovoltaic cells, enabling targeted recovery of each material type for reuse.
2Productivity
If solar modules are refurbished, then resource utilization is improved, but processing complexity and time increase
Solution Approach 1:
The refurbishment system incorporates automated testing and sorting mechanisms that enable the process to self-regulate based on module condition. Testing equipment automatically assesses module functionality, and sorting systems direct modules to appropriate refurbishment pathways without manual intervention, reducing operational complexity while maintaining high throughput.
Solution Approach 2:
The system performs preliminary testing and classification of solar modules before entering the refurbishment process. By pre-assessing module condition and categorizing them by refurbishment needs, the system prepares modules in advance for specific processing streams, streamlining the overall refurbishment workflow and reducing processing time.
3Manufacturing precision
If heating is applied to delaminate encapsulant, then separation efficiency is improved, but energy consumption increases
Solution Approach 1:
The system optimizes the heating parameters of the wire by controlling temperature, heating duration, and wire movement speed to achieve effective delamination with minimum energy input. By precisely adjusting these parameters, the system maintains high delamination precision while minimizing the total energy required for the heating process.
Solution Approach 2:
The heated wire rapidly passes through the encapsulant layer in a quick, continuous motion, applying heat only for the brief duration necessary to achieve separation. This rushing-through approach minimizes the total heating time and energy consumption while maintaining effective delamination of the encapsulant from the solar cells.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates efficient recycling and refurbishment of solar modules by ensuring accurate separation of materials, reducing waste and extending the lifespan of solar panels through precise delamination and cleaning techniques.
Implementation Method 1
a (heated) wire may be used to cut through one or more layers (e.g., front encapsulant, back encapsulant, both front and back encapsulant, backsheet) of a solar module
Implementation Method 2
applying light to the transparent top sheet; and detecting a fracture in the transparent top sheet based upon polarized light from the transparent top sheet
Data Source
AI summary
Embodiments relate to one or more techniques that may be employed alone or in combination, in the refurbishment or recycling of used solar modules. In certain approaches, a (heated) wire may be used to cut through one or more layers (e.g., front encapsulant, back encapsulant, both front and back encapsulant, backsheet) of a solar module that is being recycled or refurbished. Some approaches may employ testing of a used solar module, alone or in combination with information (e.g., as part of a received package) regarding parameters of a used solar module such as panel size, width, length, height, thickness of glass, or others. According to specific embodiments, used solar modules may be subjected to various cleaning processes at one or more points during refurbishment/recycling.