Photovoltaic Module Recycling Using X-Ray Encapsulant Debonding
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Solution Overview
Problem
Current recycling methods for end-of-life photovoltaic solar modules involve pyrolysis, which is lengthy, emits harmful gases, leaves debris on the cells, and requires specialized equipment, making it difficult to recycle materials efficiently and transportably.
Innovation Solution
A system using electromagnetic radiation (EMR) with wavelengths less than 100 nm under controlled temperature and humidity conditions to debond encapsulant layers, followed by a peel block to separate the front and back sheets from the solar cells, all contained in portable shipping containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If pyrolysis is used to remove encapsulant, then encapsulant can be removed, but the process is lengthy and causes emission of harmful gases
Solution Approach 1:
The patent replaces the thermal/chemical pyrolysis system with an electromagnetic radiation system. The emitter generates EMR with wavelengths less than 100 nm that directly debonds the encapsulant from solar cells through electromagnetic interaction, eliminating combustion and harmful gas emissions while achieving encapsulant removal.
Solution Approach 2:
The patent changes the physical parameters of the processing method by using electromagnetic radiation with specific wavelength characteristics (less than 100 nm) instead of high-temperature thermal processing. This parameter change enables encapsulant debonding without the harmful side effects of pyrolysis.
2Loss of substance
If pyrolysis is used to remove encapsulant, then encapsulant can be removed, but specialized equipment is required that is not easily transportable
Solution Approach 1:
The patent creates a multi-functional system that can be contained within a standard shipping container. The emitter, vessel, and control systems are integrated into a portable unit that combines encapsulant removal, temperature control, and humidity control functions, making the equipment transportable and deployable at various locations.
Solution Approach 2:
The patent segments the recycling system into portable modular components that fit within standard shipping containers. This segmentation allows the complex equipment to be transported and deployed in a flexible manner, bringing the recycling capability to different locations rather than requiring fixed specialized facilities.
3Loss of substance
If modules are shipped to dedicated recycling centers for processing, then recycling can be performed, but transportation costs and processing time increase
Solution Approach 1:
The patent enables preliminary action by allowing solar modules to be processed at or near their installation sites before decommissioning or recycling. The portable system can be deployed to perform encapsulant removal and initial separation on-site, eliminating the need to transport entire modules to centralized recycling facilities and reducing overall processing time.
Solution Approach 2:
The patent inverts the traditional recycling logistics by bringing the recycling equipment to the modules rather than shipping modules to fixed recycling centers. This inversion of the process location eliminates transportation time and costs while maintaining effective recycling capability.
4Loss of substance
If pyrolysis is used to remove encapsulant, then encapsulant can be removed, but burn marks on glass prevent reuse without additional remelting
Solution Approach 1:
The patent replaces thermal pyrolysis with electromagnetic radiation processing. The EMR debonds the encapsulant through electromagnetic interaction without the high-temperature burning that causes burn marks on glass, preserving glass quality and enabling direct reuse without remelting.
Solution Approach 2:
The patent converts the potential harm of high-energy electromagnetic radiation into a beneficial process by using controlled EMR with wavelengths less than 100 nm to selectively debond the encapsulant. This controlled application achieves encapsulant removal while avoiding the harmful thermal effects of pyrolysis that damage the glass.
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
Facilitates rapid and efficient recycling of solar module components with minimal damage, allowing for higher recovery rates and reduced processing time without the need for pyrolysis, and enables on-site recycling with reduced logistical and energy costs.
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
Implementation Method 2
a vessel configured to control a temperature and a humidity therewithin
Implementation Method 3
a vessel configured to control a temperature and a humidity therewithin
Data Source
AI summary
A method of decommissioning a solar module installation including a plurality of solar modules includes selecting a first solar module of the plurality of solar modules, the first solar module including a plurality of solar cells, a front layer, a back sheet, a first layer of encapsulant between the front layer and the plurality of solar cells, and a second layer of encapsulant between the back sheet and the plurality of solar cells. The method further includes applying X-ray radiation to the first solar module to debond at least one of the first layer of encapsulant or the second layer of encapsulant; and separating at least one of the front layer or the back sheet from the plurality of solar cells.