Photovoltaic Module Debonding for Portable On-Site Recycling

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Solution Overview

Problem

Current solar module recycling methods, such as pyrolysis, are inefficient and cause damage to materials, requiring specialized equipment and resulting in emissions and residue that hinder material reuse, necessitating centralized processing and additional processing steps.

Innovation Solution

A system using X-ray radiation and controlled temperature and humidity to debond encapsulant layers from solar modules, allowing for disassembly and separation of components within portable shipping containers, eliminating the need for pyrolysis and enabling on-site recycling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If pyrolysis is used to remove encapsulant, then encapsulant is removed, but combustion gases are emitted and burnt debris is left on solar cells

Engineering Contradiction:

Improveencapsulant removalVSAvoidcombustion gases and burnt debris

Core Design Contradiction:

Loss of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the thermal/chemical pyrolysis system with an electromagnetic radiation system (X-ray emitter) to remove encapsulant. The X-ray emitter debonds the encapsulant from solar cells through electromagnetic radiation rather than combustion, eliminating harmful emissions and burnt debris while achieving clean separation of materials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of substance

If pyrolysis is used to remove encapsulant, then encapsulant is removed, but glass is damaged and cannot be reused without remelting

Engineering Contradiction:

Improveencapsulant removalVSAvoidglass integrity

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The patent substitutes the high-temperature pyrolysis process with X-ray electromagnetic radiation that selectively debonds encapsulant without transferring sufficient thermal energy to damage the glass. This allows glass to be recovered in usable condition without requiring energy-intensive remelting processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of substance

If pyrolysis equipment is used, then encapsulant can be removed, but specialized equipment is required that is not easily transportable

Engineering Contradiction:

Improveencapsulant removalVSAvoidequipment portability

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent divides the recycling system into modular components including a portable X-ray emitter, controlled environment chamber, and separation mechanisms that can be transported in standard shipping containers. This segmentation enables the equipment to be deployed to remote decommissioning sites rather than requiring centralized fixed facilities.

Inventive Principle:

Principle #1Segmentation

4Loss of substance

If modules are shipped to dedicated recycling centers, then recycling can be performed, but additional shipping and processing time is required

Engineering Contradiction:

Improvematerial recoveryVSAvoidshipping and processing time

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The patent performs the encapsulant removal action at the decommissioning site before shipping, rather than shipping entire modules to recycling centers. By conducting preliminary separation of valuable components (solar cells, glass, metals) from the encapsulant in-situ, the patent reduces subsequent shipping volume and processing time at centralized facilities.

Inventive Principle:

Principle #10Preliminary action

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 accelerates the debonding process, reduces material damage, and allows for efficient recycling of solar module components, including metals and glass, with minimal logistical and energy costs, as the system can be transported and operated directly at decommissioning sites.

Implementation Method 1

an emitter positioned within the vessel and configured to emit electromagnetic radiation toward the solar module to debond at least one of the first encapsulant layer or the second encapsulant layer

Methodology Applied

Scientific EffectElectromagnetic radiation: Electromagnetic Induction

Implementation Method 2

a vessel configured to control a temperature and a humidity therewithin

Methodology Applied

Scientific EffectTemperature control: Heating

Implementation Method 3

a vessel configured to control a temperature and a humidity therewithin

Methodology Applied

Scientific EffectHumidity control: Evaporation

Data Source

PatentUS11987037B2Methods and systems for recycling end-of-life photovoltaic modules

Publication Date: 2024.05.21 KIM TAESUNG

AI summary

A system for preparing a solar module assembly for recycling includes a vessel configured to control a temperature and a humidity therewithin and to receive a solar module of the solar module assembly, the solar module including a plurality of solar cells, a front layer coupled to the plurality of solar cells by a first encapsulant layer, and a back sheet coupled to the plurality of solar cells by a second encapsulant layer. The system further includes an emitter positioned within the vessel and configured to emit electromagnetic radiation toward the solar module to debond at least one of the first encapsulant layer or the second encapsulant layer and a peel block configured to separate at least one of the front layer or the back sheet from the plurality of solar cells. The system is configured to be transported in one or more standard shipping containers.