Solar Panel Cover Glass Separation via Impact Media

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current recycling methods for solar panels are inefficient due to lengthy processing times and damage to the power generating layer during the separation of cover glass, which hinders effective resource recovery.

Innovation Solution

A method and device that assess the feature amounts of solar panels, such as cover glass thickness and hardness, to set appropriate processing conditions for applying an impact force using processing media to separate the cover glass without damaging the power generating layer, utilizing particles with controlled energy and hardness to crack and remove the cover glass in a controlled manner.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If heating and softening process is used to separate cover glass from solar panel, then the adhesion between cover glass and encapsulant is decreased, but the processing time becomes excessively long (60 to 90 minutes)

Engineering Contradiction:

Improveseparation of cover glassVSAvoidprocessing time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent replaces the thermal field (heating) with a mechanical field (impact force). Instead of using heat to soften the encapsulant over 60-90 minutes, the invention applies impact force from processing media to mechanically separate the cover glass, dramatically reducing processing time while achieving the same separation effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the processing parameter from temperature (heating) to mechanical impact force. By controlling the impact force parameters of the processing media, the encapsulant can be broken and cover glass separated without requiring prolonged thermal treatment, thus resolving the time-efficiency problem.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If crushing method is used to process solar panels, then processing is simplified, but the cover glass cannot be separated for recycling and valuable resources are lost

Engineering Contradiction:

Improveprocessing simplicityVSAvoidcover glass and valuable resources

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent applies local quality by using processing media with specific properties (hardness, size, shape) that are tailored to affect only the encapsulant layer. The processing media are designed to break the soft encapsulant while leaving the harder cover glass and solar cells intact, enabling selective separation rather than universal crushing.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent segments the solar panel structure by selectively breaking only the encapsulant layer, separating it from the cover glass and solar cells. This segmentation allows the cover glass to be recovered and recycled separately, preventing loss of valuable resources while maintaining processing efficiency.

Inventive Principle:

Principle #1Segmentation

3Loss of time

If impact force is applied to separate cover glass, then processing time is reduced, but the power generating layer may be damaged

Engineering Contradiction:

Improveprocessing timeVSAvoidintegrity of power generating layer

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

The patent controls the impact force parameters (hardness, size, shape, material) of the processing media to match the properties of the encapsulant. By carefully selecting these parameters, the impact force is sufficient to break the encapsulant but insufficient to damage the harder cover glass and solar cells, thus protecting the power generating layer while achieving rapid separation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses processing media that replicate the ideal impact characteristics needed for separation. The processing media are designed with specific properties that copy the desired interaction pattern: hard enough to break encapsulant but soft enough to protect solar cells, achieving reliable separation without damage.

Inventive Principle:

Principle #26Copying

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 enables efficient separation of cover glass from solar panels with minimal damage to the power generating layer, allowing for effective recycling and recovery of valuable resources like silver and aluminum, while reducing processing time and preventing impurities from mixing with the recycled materials.

Implementation Method 1

applying an impact force to the solar panel by means of processing media to separate the cover glass

Methodology Applied

Scientific EffectImpact force: Impact Force

Data Source

PatentUS20230339001A1Method for recycling solar panel, and device for recycling solar panel

Publication Date: 2023.10.26 SINTOKOGIO LTD

AI summary

A method and device for recycling a solar panel with which a cover glass is separated efficiently from the solar panel, the method including: [1] ascertaining feature quantities of the solar panel, including the thickness of a cover glass and the hardness of the cover glass; [2] setting a process condition on the basis of the feature quantities of the solar panel; and [3] separating the cover glass from the solar panel by imparting an impact force to the solar panel by means of a processing medium, on the basis of the process condition.