Solar Module Cooling Layout to Prevent Glass Cracking
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Solution Overview
Problem
The thermal decomposition of solar cell modules for recycling is inefficient due to energy consumption and apparatus size, as well as the risk of glass plate cracking from uneven cooling, which reduces the recycling value of intact glass plates.
Innovation Solution
A thermal decomposition apparatus with a heating zone, cooling zone, and conveying mechanisms that ensure uniform cooling by maintaining a consistent temperature gradient across the glass plate surface, using inclined surfaces and temperature adjustment devices to control temperature differences and prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple solar cell modules are placed into a single heating apparatus for batch processing, then the integrity of glass plates is preserved through gradual cooling, but the processing time is extended and energy consumption increases due to reheating requirements
Solution Approach 1:
The heating apparatus is divided into multiple independent heating zones (first heating zone, second heating zone, etc.), each capable of processing solar cell modules independently. This segmentation allows continuous processing of different batches without waiting for complete cooling of previous batches, thereby reducing overall processing time while maintaining glass plate integrity through controlled gradual cooling in each zone.
Solution Approach 2:
The multiple heating zones enable continuous processing operations where the first heating zone can be reheating for the next batch while the second heating zone is still cooling down. This continuous operation eliminates idle waiting time and maintains constant productivity, resolving the contradiction between preserving glass integrity and improving processing efficiency.
2Reliability
If multiple solar cell modules are placed into a single heating apparatus for batch processing, then the integrity of glass plates is preserved through gradual cooling, but energy consumption increases due to reheating requirements
Solution Approach 1:
Dividing the heating apparatus into multiple independent heating zones allows different thermal states to coexist simultaneously. While one zone cools down, another zone can be reheating, optimizing energy utilization and reducing total energy consumption compared to a single large batch process that requires complete cooling before reheating.
Solution Approach 2:
The system recovers thermal energy by allowing cooling zones to naturally dissipate heat while other zones are being heated. This staggered operation pattern reduces peak energy demands and improves overall energy efficiency by avoiding the need to reheat entire batches from cold state.
3Productivity
If solar cell modules are conveyed one by one through heating and cooling apparatuses via a conveyor belt, then the apparatus size is reduced, but the cooling apparatus must be lengthy to prevent excessive temperature difference, occupying significant volume
Solution Approach 1:
The cooling process is transitioned from a horizontal conveyor belt arrangement to a vertical inclined surface configuration. Modules slide down inclined surfaces under gravity, providing adequate cooling time and space in the vertical dimension rather than requiring extensive horizontal length. This dimensional change reduces the footprint of the cooling apparatus while maintaining effective temperature control.
Solution Approach 2:
The inclined surfaces are designed to utilize gravitational potential energy, allowing modules to move through the cooling zone without requiring additional mechanical driving force. This passive gravity-driven movement reduces the complexity and volume of the cooling apparatus while ensuring sufficient cooling time to prevent thermal stress cracking.
4Reliability
If solar cell modules are conveyed one by one through heating and cooling apparatuses via a conveyor belt, then processing is continuous, but the cooling apparatus must be lengthy to prevent excessive temperature difference along the conveying direction
Solution Approach 1:
The cooling path is reconfigured from horizontal to vertical using inclined surfaces. Modules slide down under gravity, experiencing controlled cooling along the inclined path. This vertical arrangement achieves uniform temperature distribution without requiring long horizontal distances, as the modules spend sufficient time in the cooling zone during their descent.
Solution Approach 2:
The inclined surfaces are pre-configured with appropriate angles and lengths to ensure modules experience the necessary cooling duration before reaching the bottom. This preliminary design of the cooling path geometry ensures uniform temperature distribution without requiring excessive apparatus length.
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 approach reduces energy consumption and processing time while maintaining the integrity of glass plates, allowing for efficient and rapid recycling with minimal risk of cracking, thus enhancing the recycling value of solar cell components.
Implementation Method 1
The carrier has an inclined surface. A position of the inclined surface located close to the second inlet is higher than a position of the inclined surface located close to the second outlet along a gravity direction.
Implementation Method 2
thermal decomposition apparatus and a thermal decomposition method applying the same for decomposing a solar cell module by high temperature
Implementation Method 3
The separated glass plates necessitate a cooling process.
Data Source
AI summary
A thermal decomposition apparatus includes a heating zone, a cooling zone, a first conveying mechanism and a second conveying mechanism. The heating zone has a first space, a first inlet and a first outlet. The first inlet and the first outlet are located at two opposite sides of the first space. The cooling zone has a second space, a second inlet and a second outlet. The second inlet is selectively in space communication connection with the first outlet of the heating zone. The first conveying mechanism is at least partially disposed in the first space. The second conveying mechanism includes a carrier disposed in the second space. The carrier has an inclined surface. A position of the inclined surface located close to the second inlet is higher than a position of the inclined surface located close to the second outlet along a gravity direction.