Photovoltaic Module Encapsulant Ionizing Treatment for Recycling
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Solution Overview
Problem
Current recycling methods for photovoltaic modules are energy-intensive and environmentally costly due to the ductility of encapsulating polymer materials like EVA, making it difficult to efficiently separate and recover materials.
Innovation Solution
An ionizing treatment is applied to modify the mechanical properties of the polymer encapsulant, making it more brittle and easier to machine into smaller chips, followed by mechanical processing to facilitate recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical machining is applied directly to the encapsulant without prior treatment, then the encapsulant can be processed, but the ductility of the polymer material causes slow machining speed and difficult separation
Solution Approach 1:
The patent applies an ionizing treatment (such as electron beam irradiation or gamma radiation) to the encapsulant before mechanical machining to modify its mechanical properties. This preliminary action transforms the ductile polymer material into a more brittle state, enabling faster and easier machining operations. The ionizing treatment creates free radicals that initiate crosslinking or chain scission, fundamentally changing the material's response to mechanical stress.
Solution Approach 2:
The patent changes the physical and mechanical parameters of the encapsulant by applying ionizing radiation. This treatment modifies the polymer chain structure through crosslinking or degradation, transforming the material from a ductile state to a brittle state. The parameter change enables the encapsulant to be easily machined into chips or granules, facilitating subsequent separation and recycling of photovoltaic cells.
2Loss of energy
If traditional recycling methods are used, then materials can be separated, but the process is energy-intensive and environmentally costly
Solution Approach 1:
The patent replaces traditional high-energy mechanical separation methods with an ionizing treatment approach. Instead of using forceful mechanical means to separate the encapsulant from photovoltaic cells, the method uses ionizing radiation to modify the encapsulant's properties, allowing for easier and less energy-intensive separation. This substitution significantly reduces energy consumption while improving recycling efficiency.
Solution Approach 2:
The ionizing treatment acts as an intermediary that facilitates the separation process. By applying radiation energy, the encapsulant's mechanical properties are modified in between the initial state (ductile, difficult to separate) and the final state (brittle, easy to machine). This intermediary treatment enables efficient separation without requiring excessive energy input or complex mechanical systems.
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
The method reduces energy consumption and environmental impact by enabling faster and more efficient machining, increasing chip production by up to 70% in mass and 60% in volume, allowing for easier recovery and reuse of materials.
Implementation Method 1
irradiation of the functional device by an ionizing treatment modifying the mechanical properties of the encapsulant
Data Source
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Figure 3(a)~4
AI summary
Processing method for recycling a functional device, in particular a photovoltaic module (M), the functional device comprising at least one of a photovoltaic cell (20) or a light-emitting diode (LED) embedded in an encapsulant (21) comprising a polymer material, the process comprising the following steps: (a) irradiation of the functional device by an ionizing treatment modifying the mechanical properties of the encapsulant, and (b) machining of the encapsulant (21), in order to reduce it to chips.