Open-source distributed production of polycarbonate solar photovoltaic modules designed for disassembly

▼Western University's Free Appropriate Sustainability Technology (FAST) Research Group

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Despite their environmentally sustainable performance, the majority of solar photovoltaic (PV) modules are eventually landfilled as this is less costly than recycling standard EVA encapsulated PV. The purpose of this study is to overcome that environmental shortcoming. For the first time, this study investigates a novel laminate-free polycarbonate (PC)-encapsulated PV design. This is accomplished by subjecting single-cell test mini-modules to reliability testing. Spectral transmissivity analysis is performed on the PC sheets and current-voltage (IV) curves are prepared before and after module encapsulation to observe any performance drops due to the PC optical losses. IEC 61215-1:2021-02 certification's core mechanical Module Quality Tests including 01, 06.1, 16, 17, and 20 are replicated to demonstrate the design's mechanical integrity. The results of this study revealed an 80% light transmissivity for the PC sheets, and while substantially below solar grade glass, the loss is offset by the module's improved recyclability and potential for extended material reuse. This study demonstrated that the proposed encapsulation processes maintain cell performance within ±5% of initial measurements for VOC and ISC. The module design successfully passed several IEC 61215-1:2021-02 sequences, including static and dynamic mechanical load assessments, but it failed hail tests, which demand future work. The module design, however, also achieved an IP68 equivalent rating for underwater testing. By eliminating conventional lamination, the novel design simplifies end-of-life processing, enabling intact recovery of solar cells for reuse or refurbishment. This study thus successfully developed a novel laminate-free PC-encapsulated PV module design that enables a circular economy framework.

▼Pearce publications

FAST · MOST · QAS

Agrivoltaics · Energy Conservation · Energy Policy · Floatovoltaivs · Industrial Symbiosis · Life Cycle Analysis · Materials Science · Medical · Open Source · Photovoltaic Systems · Resilient Food · Solar Cells · Sustainable Development · Sustainability Education · Water

Energy, Materials, photovoltaics, renewable, solar, sustainability, Open-source, Photovoltaic, mechanical design, renewable energy, recycling, environmental impact, Module, Manufacturing, Plastic, solar panel, Design for disassembly

• First attempt to build solar modules using polycarbonate encapsulant PV Magazine
• Primer intento de construir módulos solares utilizando encapsulante de policarbonato PV Magazine - Mexico

• Technical, Economic and Environmental Potential of Recycled Polycarbonate Solar Photovoltaic Frames
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  Technical, Economic and Environmental Potential of Recycled Polycarbonate Solar Photovoltaic Frames

• Roof-mounted
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• FPV
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  The Greenest Solar Power? Life Cycle Assessment of Foam-Based Flexible Floatovoltaics
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  Design and Performance Analysis of Foam-Based Floating Photovoltaic Systems in Winter Climates: Case Study of an Experimental 7kW Floatovoltaics in Canada

• Circular PV
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  Open-source distributed production of polycarbonate solar photovoltaic modules designed for disassembly

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