JP7609743B2 - How to disassemble a photovoltaic conversion module - Google Patents

Description

The present invention relates to a method for dismantling a photoelectric conversion module.

As measures to reduce carbon dioxide emissions are implemented, it is expected that the use of photovoltaic conversion modules such as solar cell modules, which are a form of renewable energy, will become more widespread. Currently, there are plans to dismantle solar cell modules and recycle them when they are discarded.

A solar cell module generally includes a flat solar cell panel (photoelectric conversion panel) that converts light energy into electrical energy, and a frame attached to the outer periphery of the solar cell panel (see Patent Documents 1 and 2 below). The frame has a fitting portion into which the outer periphery of the solar cell panel is fitted. An adhesive (sealing material) is filled into the fitting portion of the frame into which the outer periphery of the solar cell panel is fitted, thereby firmly adhering the solar cell panel to the frame.

In Patent Document 2, the frames have a hollow structure. Adjacent frames are adjacent to each other so that their hollow structures are in communication with each other. Connectors (corner pieces) are press-fitted into the hollow structures of the adjacent frames, spanning between them. In this way, the connectors connect the adjacent frames to each other.

JP 2014-116363 A JP 2010-199147 A

In Patent Document 2, the connector is press-fitted into the hollow structures of adjacent frames, spanning the hollow structures. This firmly connects the frames, so when dismantling the photovoltaic conversion module, it is necessary to apply a strong pressing force to the frames to forcibly separate them. In this case, a strong force is also applied to the ends of the panels fixed to the frames, which may crack during dismantling. If the ends of the panels crack during dismantling, they may remain attached to the frame.

Therefore, a method for dismantling a photovoltaic conversion module that allows the frame to be removed with less force is desirable.

A method for dismantling a photoelectric conversion module according to one embodiment relates to a method for dismantling a photoelectric conversion module having a panel, a plurality of frames provided along the sides of the panel, the plurality of frames having hollow portions, and connectors that are inserted into the hollow portions of the frames and connect adjacent ones of the frames to each other. The method includes a breaking step of removing the connectors by breaking walls surrounding the hollow portions of the frames.

The above aspect provides a method for dismantling a photoelectric conversion module that allows the frame to be removed with less force.

1 is a perspective view of a photovoltaic conversion module according to one embodiment. 2A is a cross-sectional view of the photovoltaic conversion module taken along line 2A-2A in FIG. 1. 2 is a plan view of the photoelectric conversion module as viewed from the rear surface side. FIG. 1 is an enlarged perspective view of the vicinity of a corner of the photoelectric conversion module as viewed from the back side. 5A is a cross-sectional view taken along line 5A-5A in FIG. 3 and FIG. 4. FIG. 1 is a perspective view of a connector according to one embodiment. FIG. 4 is a schematic diagram for explaining a breaking step according to the first embodiment. FIG. 4 is a schematic diagram for explaining a frame separation step according to the first embodiment. FIG. 9 is a schematic diagram for explaining a state following FIG. 8 . 10A to 10C are schematic diagrams for explaining examples of positions at which an external force is applied to the frame in the frame separation step. FIG. 11 is a schematic diagram for explaining a breaking step according to the second embodiment.

The following describes the embodiments with reference to the drawings. In the following drawings, identical or similar parts are denoted by identical or similar reference symbols. However, it should be noted that the drawings are schematic and the ratios of dimensions may differ from the actual ones.

[Photoelectric conversion module]
FIG. 1 is a perspective view of a photovoltaic conversion module according to one embodiment. FIG. 2 is a cross-sectional view of the photovoltaic conversion module taken along line 2A-2A in FIG. 1. FIG. 3 is a plan view of the photovoltaic conversion module as viewed from the rear side. In FIG. 3, a connector provided inside the frame cannot be seen from the photovoltaic conversion module, but is shown by a dotted line for the purpose of explanation. FIG. 4 is an enlarged perspective view of the vicinity of a corner of the photovoltaic conversion module as viewed from the rear side. FIG. 5 is a cross-sectional view taken along line 5A-5A in FIGS. 3 and 4. FIG. 6 is a perspective view of a connector according to one embodiment.

The photovoltaic conversion module 10 may be, for example, a solar cell module that converts light energy into electrical energy. Such a solar cell module may be installed outdoors, for example, on the roof or wall of a building.

The photoelectric conversion module 10 has a flat panel 100 and a frame structure 200. The panel 100 may include a photoelectric conversion element that converts light energy into electrical energy and vice versa. In this embodiment, the panel 100 has a substantially rectangular shape when viewed from a direction perpendicular to the surface of the panel 100 (height direction). The height direction corresponds to the Z direction in the figure.

The frame structure 200 is attached to the periphery of the panel 100 and is provided along the side of the panel 100. The frame structure 200 may have at least a plurality of frames 220 connected to each other. The frames 220 are provided along the edges of the panel 100.

In the example shown in FIG. 1, two frames 220 extend in a first direction (hereinafter sometimes referred to as the "horizontal direction") along a first edge of the panel 100, and the remaining two frames 200 extend in a second direction (hereinafter sometimes referred to as the "vertical direction") along a second edge adjacent to the first edge of the panel 100. Here, the horizontal direction corresponds to the X direction in the figure, and the vertical direction corresponds to the Y direction in the figure. The first direction (horizontal direction) and the second direction (vertical direction) may be directions that intersect with each other, and are preferably directions that are perpendicular to each other.

Adjacent frames 220 are connected to each other at the ends of the frames 220. In the example shown in FIG. 1, four frames 220 are connected to each other to form a substantially rectangular frame.

Each frame 220 may have a retaining portion 221, a leg portion 222, a side wall portion 223, a flange 224, and a panel receiving portion 225 (see FIG. 2 in particular). The retaining portion 221, the leg portion 222, the side wall portion 223, and the flange 224 extend along the direction in which the frame 220 extends (extension direction). The retaining portion 221, the leg portion 222, the side wall portion 223, and the flange 224 may be molded integrally and inseparably with one another.

The panel receiving portion 225 may be composed of a holding portion 221, a side wall portion 223, and a flange 224. Specifically, the panel receiving portion 225 has a substantially "C" shape in a cross section perpendicular to the extension direction of the frame 220 (see FIG. 2). This allows the panel receiving portion 225 to be configured to receive the end portion of the panel 100.

The flange 224 protrudes from the upper part of the side wall portion 223 toward the inside of the panel 100 and covers the surface of the end of the panel 100. The retaining portion 221 protrudes from the side wall portion 223 toward the inside of the panel 100 and faces the flange 224. The retaining portion 221 is configured to support the end of the panel 100 from below.

The inside of the panel receiving portion 225 may be filled with adhesive 229. This allows the panel receiving portion 225 to hold the panel 100 while receiving the end of the panel 100.

The adhesive 229 may be provided over the entire panel receiving portion 225 in the extension direction of the frame 220, or may be provided only in a partial area of the panel receiving portion 225 in the extension direction of the frame 220. The adhesive 229 may be an adhesive containing a thermoplastic resin. Examples of such adhesives include silicone-based adhesives and butyl rubber-based adhesives.

The legs 222 may extend from the holding portion 221 away from the panel 100. That is, the legs 222 may extend from the panel receiving portion 225 toward the back side of the photoelectric conversion module.

The frame 220 has a hollow portion 222h and walls 222a, 222b surrounding the hollow portion 222h (see Figures 2 and 5). The hollow portion 222h extends along the extension direction of the frame 220. In this embodiment, the walls 222a, 222b surrounding the hollow portion 222h are provided on the leg portion 222.

Specifically, the wall portion surrounding the hollow portion 222h, i.e., the wall portion constituting the leg portion 222, may have an outer wall portion 222a exposed to the outside of the photoelectric conversion module 10, and an inner wall portion 222b facing the inside of the photoelectric conversion module. The outer wall portion 222a and the inner wall portion 222b may extend from the holding portion 221 toward the back side of the photoelectric conversion module. The hollow portion 222h is defined by the space between the outer wall portion 222a and the inner wall portion 222b.

The leg 222 may include an end 222c that is bent toward the surface of the panel 100 at the point farthest from the panel. The end 222c may extend beyond the inner wall 222b from the outer wall 222a toward the inside of the photovoltaic conversion module.

The outer wall portions 222a of the legs 222 abut against the outer wall portions 222a of the adjacent frames 220 at both ends of the frames 220 (see Figures 1 and 4). When adjacent frames 220 are connected to each other, the hollow portions 222h of the frames 220 are aligned and communicate with each other.

The photovoltaic conversion module 10 has a connector 300 that connects adjacent frames 220 together (see Figures 3, 5, and 6). The connector 300 has a shape that allows it to be inserted into the hollow portion 222h of the frame 220. Specifically, the connector 300 is inserted across both hollow portions 222h of the adjacent frames 200. The connector 300 may be bent into an L-shape when viewed from a direction perpendicular to the surface of the panel 100.

The connector 300 may be press-fitted into both hollow portions 222h of adjacent frames 200. In this way, the adjacent frames 200 are connected to each other by the connector 300. As shown in FIG. 6, the connector 300 may have a wall portion surrounding the hollow portion 222h, and in the illustrated embodiment, a plurality of protrusions 310 that are in pressure contact with the inner wall portion 222b.

When the connector 300 has a protrusion 310, the inner wall 222b may have a recess (not shown) that engages with the protrusion 310, although this is not required.

The configuration of the photoelectric conversion module has been described with reference to the drawings. Please note that the configuration of the photoelectric conversion module is not limited to the above-mentioned configuration, and can be modified in various ways as long as the following disassembly method can be applied.

[Method of disassembling a photoelectric conversion module]
[First embodiment]
Next, a method for dismantling a photovoltaic conversion module will be described with reference to Fig. 7 to Fig. 10. Fig. 7 is a schematic diagram for explaining a breaking step according to the first embodiment. Fig. 8 is a schematic diagram for explaining a frame separation step according to the first embodiment. Fig. 9 is a schematic diagram for explaining a state following Fig. 8. Fig. 10 is a schematic diagram for explaining an example of a position where an external force is applied to the frame in the frame separation step.

The method for dismantling a photoelectric conversion module may include a pre-processing step, a breaking step, and a frame separation step, which are performed as necessary. The configuration of the photoelectric conversion module is as described above.

(Pre-processing step)
First, prepare a photovoltaic conversion module to be disassembled. Accessories such as a terminal box provided on the photovoltaic conversion module may be removed in advance as necessary. Alternatively, the steps described below may be performed without removing the accessories.

(Breaking Step)
In the breaking step, the coupler 300 is removed by breaking the wall surrounding the hollow portion 222h of the frame 220 (see FIG. 7). In the first embodiment, the breaking step includes breaking the outer wall 222a around the coupler 300 inserted into the hollow portion 222h. This exposes the hollow portion 222h to the outside, so that the coupler 300 in the hollow portion 222h can be removed.

More specifically, as shown in FIG. 7, the inner wall portion 222b of the frame 220 is not broken, and only the outer wall portion 222a is broken. For each corner of the frame structure 200, it is preferable to remove all of the connectors 300 by breaking the outer wall portion 222a of the frame 220. Breaking the frame 220 can be performed, for example, with a tool such as a screwdriver, pliers, a punching tool, or a cutter.

In the breaking step, it is preferable that the wall surrounding the hollow portion 222h of the frame 220 is broken in the area where the connector 300 is inserted and the surrounding area. More specifically, the area to be broken may be within the range of the area where the connector 300 is inserted (reference symbol A1 in FIG. 3) and an area at a predetermined distance from the area A1 (reference symbol A2 in FIG. 3). In other words, it is preferable that the outer wall 222a surrounding the hollow portion 222h is broken within the range of areas A1 and A2 shown in FIG. 3. Here, the predetermined distance A2 may be, for example, an area of 5 cm or less, preferably 3 cm or less.

When only the area where the connector 300 is inserted and the area around it are broken, the advantage is that the work required to break the wall surrounding the hollow portion 222h is as simple as possible. In addition, by making the break area of the frame 220 as small as possible, the overall strength of the frame 220 is not significantly reduced, making it easier to remove the frame 220 from the panel 100 in the frame separation step described below.

(Frame Separation Step)
In the frame separation step, after the breaking step is performed, an external force is applied to the frame 220 to remove the frame 220 from the panel 100. Specifically, an external force F is applied to the frame 220 in a direction away from the panel 100 so that the holding portion 221 of the frame 220 receives a force in a direction away from the panel 100. Since the connector 300 has been removed in the breaking step described above, the frame 200 can be removed from the panel 100 with a smaller external force F compared to a state in which the connector 300 is not removed.

8 and 9 show how an external force F is applied to the frame 220 using a dismantling device 400. The dismantling device may have, for example, a pressing unit 410 that presses the frame 220 outward.

As shown in Figures 8 and 9, the pressing portion 410 moves from the center of the photoelectric conversion module 10 toward the outside and abuts against the inner wall portion 222b of the frame 220. The pressing portion 410 further moves from the center of the photoelectric conversion module 10 toward the outside and presses the inner wall portion 222b of the frame 220 toward the outside. This external force F causes the frame 220 to detach from the panel 100 (see Figure 9). Note that the pressing portion 410 may be operated manually or automatically.

In the frame separation step, it is preferable that the external force F is applied to the leg 222 at a position closer to the panel receiving portion 225 than the midpoint between the end 222c of the leg 222 that is farthest from the panel 100 in the direction perpendicular to the panel 100 and the panel receiving portion 225 of the leg 222.

If an external force is applied near the end 222c of the leg 222, which is the furthest from the panel 100, the frame 220 receives a force that rotates around the vicinity of the panel receiving portion 225. As a result, the panel 100 near the panel receiving portion 225 receives a force in a direction that causes it to bend from the flange 224 of the frame 220. This may cause the panel 100 to crack, and a part of the panel 100 may remain in the panel receiving portion 225. In the above embodiment, the external force F is applied near the panel receiving portion 225 of the leg 222, so cracking of the panel 100 is suppressed, and the material of the panel 100 is easily separated cleanly from the frame 220. This is effective for recycling the materials that make up the photovoltaic conversion module 10.

In place of the above-mentioned embodiment, if the panel 100 is not easily broken, the external force F may be applied near the end 222c of the leg 222 that is farthest from the panel 100, or near the center of the leg 222 in the height direction.

In the frame separation step, the external force F may be applied to the inner wall portion 222b of the leg portion 222 while the outer wall portion 222a of the leg portion 222 is held by the back plate 480. The back plate 480 may be in contact with at least the outer wall portion 222a of the leg portion 222 as shown in Figs. 8 and 9. The back plate 480 may be substantially U-shaped so as to fit along the end portion 222c and the flange 224 of the leg portion 222 (see Figs. 8 and 9).

It is preferable that the back plate 480 is provided at least at a position where the external force F is applied. The back plate 480 may be provided from the position where the external force F is applied to the area where a portion of the frame 220 is broken. Since the strength of the area where a portion of the frame 220 is broken is reduced, when the external force F is applied, the frame 220 may bend without coming off the panel 100. Since the frame 220 becomes less likely to bend by using the back plate 480, the external force F is more likely to be applied firmly to the frame 220 so that the frame 220 comes off the panel 100.

The back plate 480 is used to support the frame 220 from the outside, thereby preventing the frame 220 from rotating due to an external force F. In other words, the back plate 480 prevents the panel 100 near the panel receiving portion 225 from receiving a force in a direction that would cause the panel 100 to bend from the flange 224 of the frame 220. This prevents the panel 100 from cracking, and makes it easier for the material of the panel 100 to be neatly separated from the frame 220.

Alternatively, if the panel 100 is not easily broken, the back plate 480 is not required in the frame separation step.

Next, an example of the position at which an external force is applied to the frame 220 in the frame separation step will be described with reference to FIG. 10. In the frame separation step, the external force F is preferably applied to a position closer to the end of the frame 220 in the extension direction of the frame 220 than to the midpoint between the center of the frame 220 and the end of the frame. In other words, the external force F is preferably applied within a range of 1/4 of the length of the frame 220 from the end of the frame 220 (the region indicated by the symbol L1 in FIG. 10). In this case, the external force F acts near the end of the frame 220.

More preferably, in the frame separation step, the external force F is applied in the extension direction of the frame 220 to an area outside the area where the frame 220 was broken in the breaking step. That is, the external force F is preferably applied to a position where the frame 220 is not broken in the extension direction of the frame 220. Even in this case, the external force F is preferably applied to a range L1 that is 1/4 the length of the frame 220 from the end of the frame 220. The strength of the frame 220 is not significantly reduced in the position where the frame 220 is not broken when the external force F is applied. Therefore, the frame 220 is less likely to bend when the external force F is applied, and the frame 220 is easily detached from the panel 100.

The external force F may be applied near one end of the frame 220 and then near the other end of the frame 220. In this case, the one end of the frame 220 comes off the panel 100, and then the other end of the frame 220 comes off the panel 100. Alternatively, the external force F may be applied near both ends of the frame 220 simultaneously.

All of the frames 220 can be removed from the panel 100 using the method described above. In the embodiment described above, the frames 220 are removed from the panel 100 by the pressing portion 410 of the dismantling device 400. Alternatively, the frames 220 may be removed from the panel 100 by hand, if possible.

[Second embodiment]
Next, a method for disassembling a photovoltaic conversion module according to a second embodiment will be described with reference to Fig. 11. Fig. 11 is a schematic diagram for explaining a breaking step according to the second embodiment. Note that the same reference numerals are used for configurations similar to those in the first embodiment. Please note that the description of the same configurations as those in the first embodiment may be omitted.

In the second embodiment, in the breaking step, the connecting device 300 is removed by cutting out the entire area of the frame 220 into which the connecting device 300 is inserted. Specifically, the outer wall portion 222a and the inner wall portion 222b near the corner of the frame 220 are cut, and the connecting device 300 is removed together with the corner of the frame 220 (see FIG. 11). Breaking the frame 220 in this manner can be performed, for example, by a cutting device such as a cutter.

Preferably, the retaining portion 221 and the flange 224 of the frame 220 are not cut. This prevents the panel 100 received in the panel receiving portion 225 from cracking during the breaking step.

In the second embodiment, the region of the frame 220 that is broken is preferably a region near the end of the frame 220, as in the first embodiment. In this case, the external force F is applied to a position in the extension direction of the frame 220 where the frame 220 is not broken.

Next, the frame separation step is performed. The frame separation step is the same as in the first embodiment, and therefore its description is omitted. In the second embodiment, the connector 300 is also removed in the breaking step, so that the frame 200 can be removed from the panel 100 with a smaller external force F than when the connector 300 is not removed.

As described above, the contents of the present invention have been disclosed through the embodiments, but the descriptions and drawings forming part of this disclosure should not be understood as limiting the present invention. From this disclosure, various alternative embodiments, examples and operating techniques will become apparent to those skilled in the art. Therefore, the technical scope of the present invention is determined only by the invention-specific matters relating to the scope of the claims that are appropriate from the above explanation.

For example, a step of heating the adhesive 229 may be performed between the breaking step and the frame separation step. By heating the adhesive 229, the frame 220 can be removed from the panel 100 with a smaller external force F in the frame separation step.

Also, a cut may be made in the adhesive 229 between the breaking step and the frame separation step. By making a cut in the adhesive 229, the frame 220 can be removed from the panel 100 with a smaller external force F in the frame separation step.

10 Photoelectric conversion module 100 Panel 220 Frame 222 Leg 222a Outer wall 222b Inner wall 222h Hollow portion 300 Connector

Claims (8)

A method for dismantling a photovoltaic conversion module including a panel, a plurality of frames provided along sides of the panel, the plurality of frames having hollow portions, and connectors that are inserted into the hollow portions of the frames to connect adjacent ones of the frames, the method comprising the steps of:
A method for dismantling a photovoltaic conversion module, comprising a breaking step of removing the connector by breaking a wall portion surrounding the hollow portion of the frame. The method for dismantling a photoelectric conversion module according to claim 1, wherein the breaking step includes breaking the wall surrounding the hollow portion within a region where the connector is inserted and a distance of 5 cm or less from the region. the wall portion surrounding the hollow portion has an outer wall portion exposed to an outside of the photoelectric conversion module and an inner wall portion facing an inside of the photoelectric conversion module,
The method for dismantling a photovoltaic conversion module according to claim 1 or 2, wherein the breaking step includes breaking the outer wall portion around the connector inserted into the hollow portion. The method for dismantling a photoelectric conversion module according to claim 1 or 2, wherein in the breaking step, the connector is removed by cutting out the entire area of the frame into which the connector is inserted. The method for dismantling a photovoltaic conversion module according to any one of claims 1 to 4, further comprising a frame separation step of removing the frame from the panel by applying an external force to the frame after the breaking step is performed. The method for dismantling a photovoltaic conversion module according to claim 5 , wherein in the frame separation step, the external force is applied at a position closer to the end of the frame than midway between the center of the frame and the end of the frame in the extension direction of the frame. 7. The method for disassembling a photovoltaic conversion module according to claim 5 , wherein in the frame separating step, the external force is applied to an area outside an area in which the frame is broken in the breaking step in an extension direction of the frame. The frame has a panel receiving portion configured to be able to receive an end portion of the panel, and a leg portion extending in a direction away from the panel,
The method for dismantling a photovoltaic conversion module according to claim 5 , wherein in the frame separation step, the external force is applied to an inner wall portion of the leg portion while an outer wall portion of the leg portion is held by a back plate.

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