Solar Panel Glass Separation via Thermal Softening
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Solution Overview
Problem
Current recycling methods for waste silicon solar panels are inefficient, with high energy demands, material losses, environmental emissions, and lengthy processes, particularly in separating and utilizing the cover glass effectively.
Innovation Solution
A method involving heating the solar panel to 40-110°C to loosen the cover glass adhesion, followed by bending and mechanical action with a cleaning roller or air stream to separate the glass shards, which are then sorted granulometrically and by translucency for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical force is applied to crush, grind, cut or mill the solar panel, then the cover glass can be removed from the plastic layers, but high energy is consumed and glass is lost in the form of small-grained shards that cannot be used as glass raw material
Solution Approach 1:
The patent changes the physical state and adhesion properties of the plastic encapsulant by heating it to its melting point or above, transforming it from a solid adhesive state to a molten state. This parameter change (temperature) allows the glass to be separated without mechanical crushing, thereby reducing energy consumption and preventing glass fragmentation into unusable shards
2Ease of manufacture
If mechanical force is applied to crush, grind, cut or mill the solar panel, then the cover glass can be removed from the plastic layers, but glass is lost in the form of small-grained shards which cannot be used as glass raw material
Solution Approach 1:
By changing the temperature parameter of the plastic encapsulant to its melting point or above, the patent transforms the separation process from mechanical (crushing) to thermal (melting). This allows the glass to be released as intact pieces rather than fragmented shards, thereby reducing glass loss and maintaining its usability as raw material
Solution Approach 2:
The patent replaces the mechanical separation system (crushers, grinders, cutters) with a thermal separation system (heating device). Instead of using mechanical force to break apart the panel, heat is applied to melt the plastic encapsulant, allowing the glass to be separated intact and reducing glass fragmentation into unusable small-grained shards
3Ease of manufacture
If heat is applied to the plastic layers to cause pyrolysis or combustion, then the cover glass is isolated in the form of glass shards, but emissions of sulfur dioxide, hydrochloric acid and hydrogen fluoride are produced which are technically and economically difficult to capture
Solution Approach 1:
The patent changes the temperature parameter to a specific range (melting point or above, but below decomposition point) that melts the plastic encapsulant without causing pyrolysis or combustion. This controlled parameter change separates the glass while avoiding the formation of harmful emissions such as sulfur dioxide, hydrochloric acid, and hydrogen fluoride
4Ease of manufacture
If polar and non-polar solvents are used to remove the plastic layers, then the cover glass is released in the form of glass shards, but the process takes several days and requires solvent regeneration
Solution Approach 1:
The patent replaces the chemical separation system (solvents) with a thermal separation system (heating). By applying heat to melt the plastic encapsulant, the process achieves glass separation in a matter of minutes or hours rather than several days, dramatically reducing process duration and eliminating the need for solvent regeneration
Solution Approach 2:
The patent changes the separation mechanism from chemical (solvent dissolution) to thermal (heat melting). By controlling the temperature parameter to melt the plastic encapsulant, the process achieves rapid glass release as intact pieces rather than shards, reducing both time and complexity compared to multi-day solvent-based processes
5Ease of manufacture
If thermal procedures are used to isolate the cover glass, then glass shards are produced, but carbon dioxide emissions are generated
Solution Approach 1:
The patent changes the temperature parameter to a controlled range that melts the plastic encapsulant without causing complete combustion or pyrolysis. This controlled thermal process separates the glass while minimizing carbon dioxide emissions by avoiding the burning of organic materials
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 method efficiently separates and recovers usable glass from waste silicon solar panels with reduced energy consumption and environmental impact, enabling the glass to be reused as raw material.
Implementation Method 1
a stream of hot air is directed onto the upper cover glass, which is heated by the stream of hot air to a temperature of 100 to 700°C
Implementation Method 2
the plastic film is heated to a temperature at which the plastic film softens and releases its adhesion to the glass
Implementation Method 3
the remainder of the solar panel is transferred to a bending roller, by which the remainder of the solar panel is bent by 180 degrees
Implementation Method 4
a cleaning roller whose blades rotate against the direction of movement of the solar panel shards
Implementation Method 5
a stream of hot air is directed onto the upper cover glass, which is heated by the stream of hot air
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a method of separating usable materials from waste silicon solar panels, in which the solar panel, stripped of its aluminum frame and connection box, is freed from the cover glass under the influence of a temperature in the range of 40 to 110 degrees Celsius, and subsequently the solar panel is bent through a bending device with a diameter 10 to 50 millimeters by 45 to 220 degrees while acting on the glass shards of the solar panel with a counter-rotating cleaning roller, the blades of which rotate against the direction of movement of the solar panel shards, or a brush or a scraper bar that moves against the direction of movement of the solar panel shards, or a stream of air that blows against the movement of the solar panel shards. A device for separating usable materials from waste silicon solar panels for carrying out this method, where a heat source (11) is arranged in front of the cleaning roller (15) and includes a bending means with a diameter of 10 to 50 millimeters, to which is assigned a counter-rotating mechanical cleaning means directed against the movement of the solar panel shards or a source of air flow that is directed against the movement of the solar panel shards. The present invention enables environmentally friendly separation of usable materials, especially aluminum and glass from waste silicon solar panels.