Multilayer System Delamination Using Supercritical Fluids
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Solution Overview
Problem
Current recycling methods for multilayer systems, particularly photovoltaic panels, face challenges in safely and efficiently separating layers due to the presence of fluorinated polymers, leading to toxic compound formation and energy-intensive processes, which result in incomplete recovery of valuable materials and environmental concerns.
Innovation Solution
A method using a fluid composed of a gas and a mixture of non-reactive liquids, such as CO2, water, and acetone, is applied at controlled temperature and pressure conditions to swell and separate layers without degrading the constituents, allowing for the recovery of undegraded layers in a supercritical environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal processes are used to remove fluoropolymer layers, then the layers can be separated, but toxic fluorinated compounds are generated and energy is consumed
Solution Approach 1:
The invention changes the physical-chemical parameters of the separation process by using supercritical fluids (CO2, water, acetone) instead of thermal processes. The multilayer system is treated at controlled temperature (30-150°C) and pressure (5-50 MPa) conditions, transforming the fluoropolymer layer into a swelled state that allows clean separation without decomposition and toxic compound generation
Solution Approach 2:
The invention introduces a supercritical fluid mixture (CO2, water, acetone) as an intermediary substance that penetrates and swells the fluoropolymer layer, enabling separation through a benign chemical mechanism rather than direct thermal decomposition. This intermediary fluid acts as a mediator that facilitates layer separation without causing harmful side reactions
2Reliability
If thermal processes are used to remove fluoropolymer layers, then the layers can be separated, but significant energy is required to reach high temperatures
Solution Approach 1:
The invention fundamentally changes the energy parameters of the separation process by operating at moderate temperatures (30-150°C) using supercritical fluids, compared to the high temperatures (450-600°C) required by conventional thermal processes. This parameter change reduces energy consumption while achieving complete layer separation
Solution Approach 2:
The invention replaces the thermal field (heat-based separation) with a supercritical fluid-based separation mechanism. Instead of using high-temperature thermal energy to decompose and separate layers, the system uses the unique solvating and swelling properties of supercritical fluids at lower temperatures, substituting a mechanical/chemical process for a thermal process
3Loss of substance
If grinding is used to separate layers, then some glass can be recovered, but the glass quality is degraded and additional treatment is required
Solution Approach 1:
The invention replaces the mechanical grinding process with a chemical/supercritical fluid-based separation process. Instead of mechanically abrasive grinding that degrades glass surfaces and requires subsequent purification, the supercritical fluid penetrates interfaces and enables clean separation, preserving glass integrity and eliminating the need for additional purification steps
Solution Approach 2:
The supercritical fluid acts as an intermediary that selectively penetrates the interfaces between layers without mechanically damaging the glass. This chemical mediation enables separation based on interfacial properties rather than mechanical force, preserving the structural integrity and quality of recovered glass materials
4Reliability
If incineration at high temperature is used, then organic layers can be eliminated, but the process is energy-intensive and glass may break due to heat stress
Solution Approach 1:
The invention changes the temperature parameter from high-temperature incineration (450-600°C) to moderate-temperature supercritical fluid treatment (30-150°C). This parameter change enables organic layer removal through supercritical fluid penetration and swelling mechanisms rather than combustion, dramatically reducing energy consumption while preventing thermal stress damage to glass
Solution Approach 2:
The invention converts the previously harmful effect of heat (which causes glass breakage) into a beneficial low-temperature process. By using supercritical fluids at moderate temperatures, the process achieves organic layer removal without the harmful thermal stress that causes glass fragmentation, turning a harmful thermal process into a benign chemical process
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 approach enables the clean separation and recovery of high-purity materials with reduced energy and environmental impact, minimizing the formation of toxic compounds and preserving the integrity of materials like glass and solar cells.
Implementation Method 1
a gas having the particularity of causing the swelling of at least one of the layers
Implementation Method 2
the gas/liquid fluid being raised in temperature and pressure, in particular in a supercritical environment
Data Source
AI summary
Method and device for delamination/dismantling of multi-layer systems SM comprising several layers including at least one organic layer, wherein the layers are separated by interfaces, characterized in that it comprises at least the following steps:Mixing the multilayer system with a fluid composed of at least one gas having the particularity of causing the swelling of at least one of the layers and one or more non-reactive liquids having the particularity of allowing the separation of each layer unitarily or of subsets of layers composing the multilayer system without degradation of the constituents of the layers, the gas/liquid fluid being raised in temperature and pressure,Recovering separately at least one or more layers or a subset of undegraded layers.