Photovoltaic Module Ribbon Removal for Localized Layer Machining

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Solution Overview

Problem

Existing methods for recycling photovoltaic modules are energy-intensive and inefficient, particularly due to the interference of interconnecting ribbons during the machining of the intermediate layer, leading to equipment damage and increased maintenance costs.

Innovation Solution

A method and system for localized machining of the intermediate layer in a photovoltaic module by identifying and removing interconnecting ribbons before other processing steps, using optical capture and sanding tools to define and execute a work area that excludes photovoltaic cells, ensuring precise removal of the ribbons.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If sanding belt is applied to remove intermediate layer, then material removal is achieved, but interconnecting ribbons are torn off and accumulate near the sanding belt causing equipment damage

Engineering Contradiction:

Improveintermediate layer removal efficiencyVSAvoidsanding belt durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary action by removing interconnecting ribbons from the intermediate layer before the sanding process. The system identifies ribbon locations using optical sensors and uses cutting tools to remove ribbons in advance, preventing them from being torn during subsequent sanding operations. This preliminary removal protects the sanding belt from damage while maintaining efficient material removal.

Inventive Principle:

Principle #10Preliminary action

2Loss of substance

If entire module is crushed and subjected to mechanical/thermal/chemical treatments, then material separation is achieved, but energy consumption increases and environmental impact worsens

Engineering Contradiction:

Improvematerial separation efficiencyVSAvoidrecycling energy consumption

Core Design Contradiction:

Loss of substanceVSUse of energy by moving object

Solution Approach 1:

The patent applies segmentation by dividing the recycling process into separate, targeted operations for different materials. Instead of crushing the entire module, the system uses optical identification to locate specific materials (interconnecting ribbons, photovoltaic cells, encapsulation material) and applies appropriate processing methods to each region. This selective approach separates materials more efficiently with lower energy consumption compared to bulk mechanical/thermal/chemical treatment.

Inventive Principle:

Principle #1Segmentation

3Loss of substance

If multiple separate processing stations are used for cutting and grinding each layer, then material separation is achieved, but device complexity and processing time increase

Engineering Contradiction:

Improvelayer separation capabilityVSAvoidnumber of processing stations

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent applies merging by combining multiple processing functions into a single integrated system. The apparatus incorporates optical sensors for identification, cutting tools for ribbon removal, and sanding capabilities for intermediate layer removal, all controlled by a centralized processing unit. This integration eliminates the need for multiple separate processing stations while maintaining the ability to perform distinct operations on different materials within the same equipment.

Inventive Principle:

Principle #5Merging (Combining)

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

Prevents damage to machining equipment and reduces maintenance costs by effectively isolating and removing interconnecting ribbons, facilitating efficient recycling of photovoltaic modules.

Implementation Method 1

the interconnect ribbon localization step is implemented by optical capture of the intermediate layer

Methodology Applied

Scientific EffectOptical capture: Reflection

Implementation Method 2

The machining step is implemented by sanding

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 3

The sanding belt is applied to the surface of the layer to be treated

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP4683463A1Method of processing a photovoltaic module for removal of interconnect ribbons

Publication Date: 2026.01.21 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

Figure 1A~1C
Figure 2A
Figure 2B

AI summary

The invention relates to a method for processing a photovoltaic module (M), said photovoltaic module comprising in particular an intermediate layer (2), this intermediate layer having an encapsulation envelope (21) in which photovoltaic cells (20) and at least one interconnecting ribbon (23) are placed, said photovoltaic cells being arranged in several strings, the strings being connected to each other by means of said interconnecting ribbon (23), said method comprising: - A step of locating the interconnecting ribbon (23) inside the intermediate layer (2), - A step of determining a work area (Z1) to be machined, said work area (Z1) being delimited to include the interconnecting ribbon (23) and exclude any photovoltaic cell (20), - A machining step localized on said work area (Z1) only.