Cradle-to-Cradle Design of Photovoltaic Modules

Introduction

The project cradle-to-cradle design of photovoltaic modules (C2C-PV) will design and build the first photovoltaic module with full cradle-to-cradle (C2C) recyclability. Achieving this goal requires a radically new design framework. Today’s photovoltaic modules were not designed for recycling, resulting in a recycling process that is slow and delivers materials of inferior quality.

Project Goals

In contrast, C2C-PV will apply the principles of green engineering and techno-economics to create a photovoltaic module with minimal environmental impact over multiple generations and economic viability. Unique to this project is the design of a complex opto-electronic device from scratch according to these principles.

Scientific Challenge

The scientific challenge of this proposal is to reconcile durability and separability. Current photovoltaic modules follow a “design for immortality” approach, monolithically integrating solar cells in a module to minimize exposure to the environment.

Durability vs. Separability

This approach pits durability against separability and is the root cause of all challenges in current photovoltaic module recycling. Highly adhesive interfaces make a clean separation of components slow and challenging at best, and often infeasible. Yet, high throughput and retention of material quality are essential for the economic viability of recycling.

Key Solutions

The key to resolving this challenge lies in the choice of materials and the design of interfaces. Following the design principles of C2C, the project C2C-PV will:

1. Only use materials that can be produced and processed in a close-loop manner.
2. Avoid toxicity and scarcity.
3. Ensure material, energy, and capital efficiency.

Interface Design

Interface design will focus on eliminating unnecessary adhesion and equip all necessary sealing with a mechanism for separation. Perovskite solar cells and photovoltaic modules will serve as a vehicle for demonstrating multigenerational close-loop recyclability.

Tracking and Evaluation

Tracking material, energy, and capital flow over multiple generations will allow quantifying and optimizing the overall system performance.