Photovoltaic Module Disassembly Using Abrasive Wire Cutting

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Solution Overview

Problem

Existing methods for disassembling photovoltaic modules at the end of their life or as production rejects are not environmentally friendly, are energy-intensive, and do not allow for the recovery of constituents in an intact or largely intact state, especially due to the risk of toxic gas emissions from fluorinated polymers.

Innovation Solution

A method involving the use of an abrasive wire to cut the envelope of a photovoltaic module, allowing for the separation of photovoltaic cells from the protective elements without the need for heating, thus reducing energy consumption and minimizing the risk of toxic gas emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If thermal or chemical treatments are used to separate materials from photovoltaic modules, then material separation is achieved, but toxic gas emissions increase and environmental friendliness decreases

Engineering Contradiction:

Improvematerial separationVSAvoidtoxic gas emissions

Core Design Contradiction:

Loss of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent replaces thermal and chemical treatment systems with a mechanical cutting system. An abrasive wire cutter physically separates the encapsulant material from photovoltaic cells through mechanical abrasion, eliminating the need for heating or chemical reactions that would generate toxic emissions from fluorinated polymers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the harmful thermal process into a beneficial cold cutting process. By using abrasive wire cutting instead of thermal treatment, the method eliminates toxic gas emissions while maintaining effective material separation, turning a potentially harmful thermal process into an environmentally friendly mechanical process.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Productivity

If heating is applied to photovoltaic modules for material separation, then separation efficiency improves, but energy consumption increases

Engineering Contradiction:

Improveseparation efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent substitutes thermal energy input with mechanical cutting action. The abrasive wire cutter uses mechanical abrasion to separate materials at ambient temperature, replacing the energy-intensive heating process while maintaining separation efficiency through the cutting action of the abrasive wire.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If heating is applied to photovoltaic modules for separation, then material separation is facilitated, but photovoltaic module integrity deteriorates

Engineering Contradiction:

Improveseparation facilitationVSAvoidmodule integrity

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent replaces thermal processing with mechanical cutting to separate materials. The abrasive wire cutter cleanly cuts through the encapsulant and separates components without applying heat that would cause warping, melting, or degradation of the photovoltaic cells and other sensitive materials, thereby preserving module integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Loss of substance

If grinding is used to recycle photovoltaic modules, then material recovery is achieved, but component integrity is lost

Engineering Contradiction:

Improvematerial recoveryVSAvoidcomponent integrity

Core Design Contradiction:

Loss of substanceVSStrength

Solution Approach 1:

The patent uses an abrasive wire cutter to segment and separate the photovoltaic module into distinct components along clean cutting lines. This segmentation approach allows each component (glass, cells, encapsulant, backsheet) to be recovered in intact form, unlike grinding which reduces everything to particles and loses component integrity.

Inventive Principle:

Principle #1Segmentation

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 effectively disassembles photovoltaic modules while being more environmentally friendly and energy-efficient, allowing for the recovery of components such as glass, metals, and fluorinated polymers for recycling.

Implementation Method 1

the step of separating the photovoltaic cells with respect to the first protective element comprises a step of cutting the first portion of the envelope by means of an abrasive wire

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS12275221B2Method for disassembling a photovoltaic module and associated installation

Publication Date: 2025.04.15 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

AI summary

A photovoltaic module includes a first protective element, a second protective element, photovoltaic cells that are located between the first protective element and the second protective element, an envelope in which the photovoltaic cells are encapsulated. The envelope links the first protective element to the second protective element and includes a first portion that is located between the photovoltaic cells and the first protective element, and a second portion that is located between the photovoltaic cells and the second protective element. The disassembly method includes separating the photovoltaic cells with respect to the first protective element and cutting the first portion of the envelope by an abrasive wire.