Solar Panel Cutting Unit for Layer Separation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing methods for disposing of discarded solar panels are inefficient, particularly in separating the glass plate and backsheet layer, and often result in environmental pollution due to chemical treatments, and there is a lack of effective apparatus for separating layers when the panels are damaged or deformed.

Innovation Solution

A solar panel cutting unit comprising a frame with a transport roller, heating unit, pressurization rollers, trimmer, peeling unit, and collection roller that sequentially heats, trims, peels, and collects the layers, allowing for easy separation and winding of thin layers into a roll shape, even for deformed panels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If chemical treatment is used to extract metal from solar panels, then metal recovery is achieved, but environmental pollution occurs

Engineering Contradiction:

Improvemetal recoveryVSAvoidenvironmental pollution

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent replaces chemical treatment methods with a mechanical separation system consisting of cutting units, peeling units, and conveying mechanisms that physically separate layers and extract metals without chemical reactions, thereby eliminating environmental pollution while achieving metal recovery

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The solar panel is divided into multiple layers (glass front plate, adhesive layer, solar cell layer, backsheet layer) and each layer is separately processed and removed through dedicated cutting and peeling units, enabling mechanical separation and metal extraction without chemical treatment

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If existing separation processes are used for deformed solar panels, then processing is simple, but layer separation becomes difficult

Engineering Contradiction:

Improveprocessing simplicityVSAvoidlayer separation capability

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The cutting units and peeling units are designed with movable and adjustable components that can adapt to different panel shapes and deformation states, allowing the system to maintain processing simplicity while effectively separating layers from both intact and deformed solar panels

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system can adjust cutting depth, peeling force, and conveying speed parameters to accommodate different panel conditions, enabling effective layer separation from deformed panels while maintaining operational simplicity through automated parameter adjustment

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If manual separation of solar panel layers is performed, then processing flexibility is maintained, but productivity is low

Engineering Contradiction:

Improveprocessing flexibilityVSAvoidseparation efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Multiple functions (cutting, peeling, conveying, collecting) are merged into an integrated automated system where units work in sequence, maintaining processing flexibility through coordinated operation while dramatically increasing productivity compared to manual separation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The solar panel is continuously conveyed through the system while cutting and peeling operations are performed in continuous sequence without interruption, eliminating the stops and starts inherent in manual processing and thereby significantly increasing separation efficiency

Inventive Principle:

Principle #20Continuity of useful action

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 separation of solar panel layers with reduced force, allowing for easy recycling and storage of individual components, while minimizing environmental impact by avoiding chemical treatments.

Implementation Method 1

a heating unit that heats the solar panel transported by the transport roller unit

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a pair of pressurization roller units that pressurizes and transports the solar panel transported by the transport roller unit

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12129144B2Solar panel cutting unit

Publication Date: 2024.10.29 WON KWANG S&T

AI summary

A solar panel cutting unit may include a frame, a transport roller unit provided at the frame to transport, in a first direction, a solar panel having a glass plate, an adhesive layer, a solar cell layer, and a backsheet layer stacked sequentially, a heating unit to heat the solar panel, a pair of pressurization roller units to pressurize and transport the solar panel, a trimmer unit that moves in a second direction perpendicular to the first direction and removes the backsheet layer, the solar cell layer, and the adhesive layer, a peeling unit that inserts a blade into the adhesive layer of the solar panel passing by the trimmer unit and removes a flexible film to which the solar cell layer and the backsheet layer is adhered, and a collection roller that collects the flexible film peeled by the peeling unit.