Solar Module Fragmenting for Low-Contamination Material Recovery
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Solution Overview
Problem
Existing methods for dismantling solar cell modules involve thermal decomposition, which contaminates the cover plate and solar cell, produces harmful VOCs and HFCs, and requires high energy consumption, leading to environmental pollution and low economic benefits for recycling.
Innovation Solution
A system for physically dismantling solar cell modules using two fragmenting apparatuses with a platform, fragmenting unit, and material-collecting and sorting device, which employs purely physical methods to fragment the back plate and cell encapsulation laminate without chemical processes, thereby separating and sorting recycled materials effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermal decomposition is used to separate solar cell module components, then the adhesive layers can be chemically broken down for separation, but the cover plate and solar cell become contaminated and harmful substances are produced
Solution Approach 1:
The patent replaces the chemical thermal decomposition system with a mechanical fragmenting system. The fragmenting unit uses mechanical forces to physically separate the solar cell module into components without chemical reactions, thereby avoiding contamination and harmful emissions while achieving effective separation of adhesive layers and other materials
Solution Approach 2:
The patent changes the fundamental parameter of the separation process from chemical (thermal decomposition temperature, chemical reactions) to physical (mechanical force, vibration frequency, particle size). This parameter transformation allows separation to occur without chemical changes to the materials, preventing contamination and harmful substance generation
2Ease of manufacture
If thermal decomposition is used to dismantle solar cell modules, then components can be separated, but high energy consumption is required making the process uneconomical
Solution Approach 1:
The patent substitutes the energy-intensive thermal decomposition process with a mechanical fragmenting process. The fragmenting unit utilizes mechanical energy through vibration and impact forces to achieve separation, which consumes significantly less energy compared to heating the entire solar cell module to decomposition temperatures, thereby improving economic viability
3Productivity
If the whole solar cell module is directly fragmented, then the structure can be broken down for material recovery, but the adhesive layers remain bonded and require additional chemical processing
Solution Approach 1:
The patent applies segmentation by first fragmenting the solar cell module into smaller particles, then using air classification and vibration screening to further segment and separate different materials based on their physical properties. This multi-stage segmentation process effectively separates adhesive layers from other components through physical differences in density, size, and shape without requiring additional chemical processing
Data Source
AI summary
A system for physically dismantling a solar cell module includes two fragmenting apparatuses. The solar cell module includes a cell encapsulation laminate, and a back plate and a cover plate respectively disposed on two opposite sides of the cell encapsulation laminate. Each fragmenting apparatus includes a platform, a fragmenting unit disposed on and movable relative to the platform in three axial directions for fragmenting one of the cell encapsulation laminate and the back plate of the solar cell module, and a material-collecting and sorting device connected to the platform and the fragmenting unit for collecting and sorting recycled materials produced by the fragmenting unit.