Solar Panel Layer Separation Using Heated EVA Adhesive Removal
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Solution Overview
Problem
Existing solar panel disassembly processes result in pollution due to the inability to efficiently recycle stacked materials beyond the aluminum frame and junction box, primarily because of adhesive layers that require thermal cracking or combustion, lacking an environmentally friendly method.
Innovation Solution
An automated dismantling and separation system comprising a frame disassembly system with clamps, a handling device, and a stack material disassembly system with a heating and temperature control module and scraper module to melt and remove adhesive layers, allowing for sequential recycling of solar panel components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermal cracking or combustion process is used to treat stacked materials, then the adhesive layers can be broken down, but pollution problems occur
Solution Approach 1:
The patent replaces the chemical/combustion process (thermal cracking) with a mechanical separation system. The disassembly platform with heating units and scrapers mechanically separates the adhesive layers from the stacked materials without combustion, eliminating pollution while maintaining processing capability
Solution Approach 2:
The patent changes the processing parameters from high-temperature combustion to controlled heating at specific temperature ranges. The heating units heat the stacked materials to a temperature sufficient to soften the adhesive layers for mechanical removal, but below combustion temperatures, thus avoiding pollution while achieving separation
2Ease of operation
If manual disassembly is used for aluminum frames and junction boxes, then these components can be separated, but the stacked materials cannot be recycled in layers due to adhesive layers
Solution Approach 1:
The patent segments the disassembly process into distinct stages: frame removal by linear transmission devices, followed by layer-by-layer separation of stacked materials on the disassembly platform. The heating units and scrapers work together to separate each layer individually, enabling complete recycling of all components including previously non-recyclable adhesive-bound materials
Solution Approach 2:
The patent replaces manual disassembly operations with an automated mechanical system. The linear transmission devices automatically remove frames, and the disassembly platform with heated scrapers automatically separates stacked material layers, significantly improving productivity while maintaining ease of operation through automation
3Productivity
If crushing and third-party treatment is used for stacked materials, then processing can be completed, but environmental friendliness is compromised
Solution Approach 1:
The patent replaces the crushing and external treatment process with an in-situ thermal-mechanical separation system. The heating units soften the adhesive layers and the scrapers mechanically remove them, allowing all stacked materials to be separated and recycled on-site without crushing or external combustion processing, maintaining productivity while achieving environmental friendliness
Solution Approach 2:
The patent introduces heating units as an intermediary between the stacked materials and the scrapers. The heat softens the adhesive layers, creating a state that allows easy mechanical removal by scrapers, enabling complete separation and recycling without harmful combustion or crushing processes
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 dismantling of solar panels by melting adhesive layers and sequentially removing components for recycling, reducing pollution and enhancing recycling efficiency.
Implementation Method 1
the stack material is heated through the heating unit to melt the EVA adhesive between the glass upper cover, wafer layer and backplane layer
Implementation Method 2
the residual adhesive is scraped off by the scraper
Data Source
AI summary
An automated dismantling and separation system for solar panels is provided, which mainly disassembles the aluminum frame of the solar panel to form the stack material through the frame disassembly system, and the stack material is transported by the handling device to the stack material disassembly system, and the stack material is heated through the heating unit to melt the EVA adhesive between the glass upper cover, wafer layer and backplane layer. Then the topmost material is removed through the suckers of the handling device to expose the residual adhesive, and the residual adhesive is scraped off by the scraper, so that each layer of material is repeatedly removed in sequence and collected and recycled respectively to achieve the purpose of high efficiency and environmental protection.