Microwave Delamination of Photovoltaic Modules

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Solution Overview

Problem

The lamination and delamination processes of photovoltaic modules are inefficient, with lamination being slow and energy-intensive, and delamination processes being slow, complex, and energy-inefficient.

Innovation Solution

A method using microwave radiation to heat solar cells in photovoltaic modules to a temperature above the melting point of the encapsulant material, allowing for efficient delamination by melting or softening the encapsulant, and optionally using differences in thermal expansion coefficients to facilitate separation of protective sheets.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional thermal heating apparatus is used for lamination, then the encapsulant material can be melted to bond protective sheets, but the process is slow and energy intensive

Engineering Contradiction:

Improvebonding qualityVSAvoidprocessing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces conventional thermal heating apparatus with a microwave heating system. The microwave generator emits microwave energy that directly heats the encapsulant material through dielectric heating, eliminating the need for external thermal conduction. This substitution achieves rapid heating and melting of the encapsulant while maintaining reliable bonding, thereby resolving the contradiction between bonding quality and processing speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The microwave heating system operates by emitting periodic microwave pulses to the encapsulant material. This periodic energy input enables controlled heating cycles that melt the encapsulant material efficiently without requiring prolonged exposure, thus improving processing speed while ensuring adequate bonding quality through repeated heating cycles if necessary.

Inventive Principle:

Principle #19Periodic action

2Reliability

If conventional thermal heating apparatus is used for lamination, then the encapsulant material can be melted to bond protective sheets, but the process consumes excessive energy

Engineering Contradiction:

Improvebonding qualityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by stationary object

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The microwave heating system enables the encapsulant material to heat itself through dielectric heating. The microwave energy penetrates the material and causes molecular vibration and rotation, generating heat internally within the encapsulant. This self-heating mechanism eliminates energy losses associated with external heating, significantly reducing overall energy consumption while maintaining effective bonding.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If traditional delamination methods (mechanical, thermal, or chemical) are used, then protective sheets can be removed from solar cells, but the processes are slow, complex, and energy inefficient

Engineering Contradiction:

Improvedelamination simplicityVSAvoidprocessing speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces mechanical, thermal, or chemical delamination methods with a microwave-based delamination system. The microwave generator emits microwave energy that selectively heats the encapsulant material, causing it to soften and lose adhesion to the protective sheets. This allows for rapid and simple separation of the protective sheets from the solar cells without complex mechanical tools, thermal furnaces, or chemical solvents, thereby resolving the contradiction between operational simplicity and processing speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The microwave delamination process changes the physical state of the encapsulant material by selectively heating it to a temperature where it softens and loses adhesion. This parameter change (temperature increase through microwave heating) transforms the encapsulant from a bonded state to a separable state, enabling fast and simple delamination without requiring complex mechanical or chemical processes.

Inventive Principle:

Principle #35Parameter changes

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

This method significantly improves the efficiency of both lamination and delamination processes by providing a direct, volumetric, and selective heating technique, reducing energy consumption, and enabling faster processing times.

Implementation Method 1

applying microwave radiation to the at least one solar cell to heat the at least one solar cell

Methodology Applied

Scientific EffectMicrowave radiation: Microwave Radiation

Implementation Method 2

applying microwave radiation to the at least one solar cell to heat the at least one solar cell

Methodology Applied

Scientific EffectElectromagnetic energy absorption: Absorption (EM radiation)

Implementation Method 3

heat is transferred from the at least one solar cell to the first encapsulant material

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

heat is transferred from the at least one solar cell to the first encapsulant material, causing the first encapsulant material to melt or soften

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 5

differences in thermal expansion coefficients between the components of the photovoltaic module, may cause a structural modification in the first encapsulant material

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20250115042A1Delaminating and laminating of photovoltaic modules and solar cells using microwaves

Publication Date: 2025.04.10 MACQUARIE UNIV

AI summary

A method of delaminating a photovoltaic module is disclosed wherein the photovoltaic module comprises at least one solar cell having a first surface and a second surface opposite to the first surface, a first protective sheet, and a first encapsulant material positioned between the first surface of the at least one solar cell and the first protective sheet and fixing the first protective sheet to the at least one solar cell, the method comprising applying microwave radiation to the at least one solar cell to heat the at least one solar cell to a temperature above a melting or softening temperature of the first encapsulant material, wherein heat is transferred from the at least one solar cell to the first encapsulant material. A method of manufacturing a photovoltaic module is also disclosed that comprises applying microwave radiation to at least one solar cell.