Solar Cell Module Thermoplastic Resin Layer Disassembly
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Solution Overview
Problem
Conventional silicon solar cell modules are difficult to disassemble for recycling due to the use of thermosetting polymers, which require time-consuming and labor-intensive methods that cause secondary pollution, making it challenging to separate and reuse the glass and cells without damage.
Innovation Solution
A solar cell module design incorporating a thermoplastic resin layer between the cell unit and thermosetting resin layers, allowing for easy disassembly through thermal or chemical dissociation methods, maintaining high light transmittance, low water absorption, and resistance to environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If thermosetting polymers (EVA or PO) are used as packaging materials to encapsulate and fix solar cells, then the service life and structural stability of the solar module are extended, but the glass and solar cell panel cannot be separated by heating and melting, making disassembly and recycling difficult
Solution Approach 1:
The patent divides the packaging structure into multiple layers: an inner thermoplastic resin layer (first packaging layer) that can be easily separated, and an outer thermosetting resin layer (second packaging layer) that provides structural stability. This segmentation allows the thermoplastic layer to be removed during disassembly while the thermosetting layer remains to maintain module integrity during operation.
Solution Approach 2:
The thermoplastic resin layer acts as an intermediary between the solar cells and the thermosetting resin layer. It provides initial encapsulation and protection, and crucially, serves as a removable interface that facilitates easy disassembly by melting and separation, while the thermosetting layer provides long-term structural support.
2Stability of the object's composition
If conventional thermosetting plastic material is used for encapsulation, then structural stability is maintained, but time-consuming and labor-intensive methods are required for removal, causing secondary pollution
Solution Approach 1:
The packaging is segmented into two functional layers: the thermoplastic resin layer that can be quickly removed by heating to melt and separate, and the thermosetting resin layer that maintains structural stability. This allows rapid disassembly of the thermoplastic layer without requiring time-consuming chemical treatments or high-temperature incineration.
Solution Approach 2:
The patent utilizes the temperature-dependent properties of thermoplastic resin, which transitions from solid to liquid state at relatively low temperatures (compared to thermosetting resins). This parameter change enables easy removal through controlled heating, significantly reducing disassembly time and avoiding the need for extreme temperature treatments that cause pollution.
3Ease of manufacture
If high temperature heating (300-550°C) is applied to separate glass from solar cell module, then the packaging film is degraded, but the process is time-consuming and causes secondary pollution
Solution Approach 1:
The patent extracts the easy-to-remove thermoplastic resin layer as a separate functional component from the traditional single-layer thermosetting structure. This extracted layer can be removed at lower temperatures through melting, avoiding the need for high-temperature incineration and the associated secondary pollution, while the thermosetting layer remains to maintain structural integrity.
Solution Approach 2:
The thermoplastic resin layer functions as a disposable or temporarily retained component that can be easily removed and replaced. Its design prioritizes ease of removal over long-term permanence, allowing it to be discarded or recycled through simple melting processes rather than requiring energy-intensive high-temperature degradation methods.
4Ease of manufacture
If acid solution or organic solvent is used to decompose EVA, then the packaging material is removed, but the process is time-consuming and labor-intensive
Solution Approach 1:
The patent replaces chemical decomposition methods (acid solutions or organic solvents) with a thermal-mechanical approach. The thermoplastic resin layer is removed by controlled heating that causes melting and physical separation, eliminating the need for complex chemical treatment systems, acid handling equipment, and extensive labor-intensive processes.
Solution Approach 2:
The patent exploits the thermal parameters of thermoplastic resin, which undergoes phase transition from solid to liquid at accessible temperatures. This parameter change enables removal through simple heating and mechanical separation, avoiding the need for complex chemical decomposition processes and reducing both time and labor requirements.
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
Enables efficient and environmentally friendly disassembly and recycling of solar cell modules without damaging the glass or cells, while maintaining performance and durability, meeting industry standards for high-value recycling.
Implementation Method 1
allowing for easy disassembly through thermal or chemical dissociation methods
Implementation Method 2
allowing for easy disassembly through thermal or chemical dissociation methods
Data Source
AI summary
A solar cell module is provided. The solar cell module includes a first substrate, a second substrate opposite the first substrate, a cell unit disposed between the first and second substrates, a first thermosetting resin layer disposed between the cell unit and the first substrate, a first thermoplastic resin layer disposed between the cell unit and the first thermosetting resin layer, a second thermosetting resin layer disposed between the cell unit and the second substrate, and a second thermoplastic resin layer disposed between the cell unit and the second thermosetting resin layer.