Recycling of Thin Film Solar Cells

A recycling process for solar panels that enables the recovery of valuable materials through multiple separation stages. The process involves a series of chemical, physical, and thermal treatments that separate the panel's components into distinct fractions. These fractions are enriched in precious metals, photovoltaic material, and other valuable materials. The fractions are then processed through selective precipitation, selective leaching, and electrolysis to produce high-purity materials. The process achieves a 100% recovery rate of valuable materials, enabling the reuse of solar panels for lower-cost recycling.

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A method for recycling photovoltaic (PV) panels using a thermoplastic matrix material, which enables the reuse of valuable materials like aluminum, copper, and high-purity silicon while producing a visually appealing end product. The recycling process involves crushing and screening the PV panel particles, followed by addition of glass spheres to enhance surface quality. The composite material is then formed through pressing, injection molding, or similar techniques, resulting in a durable and visually appealing product. This approach addresses the environmental concerns associated with traditional PV panel disposal while maintaining the performance characteristics of the original material.

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Thermolysis-based recycling of solar panels and cells to produce clean fuel gas and char while eliminating hazardous materials. The process involves a continuous, oxygen-free pyrolysis of solar panel waste in a reactor system. The waste is shredded and then processed in multiple stages of thermolysis using heat energy, resulting in the production of a clean fuel gas and char containing valuable photovoltaic materials and metals. The char can be further processed to extract metals, silicon, and other valuable components. The process achieves complete destruction of fluorinated compounds, including fluorine and chlorine, while generating clean fuel gas and char.

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A novel method for efficient and environmentally friendly silicon and silver recycling from waste solar panels. The process utilizes a molten alkali leaching method to selectively extract and recover silicon and silver from the solar panel's metallurgical-grade silicon (MG-Si) and metallurgical-grade silicon (MG-Si) wafers, respectively. The recovery process involves a controlled temperature and salt composition in the molten salt, enabling rapid separation of the target materials from the remaining photovoltaic material. The method achieves higher purity silicon and silver recoveries compared to conventional recycling methods, with a simplified preparation process and lower environmental impact.

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A method for extracting valuable components from photovoltaic panels through controlled thermal disassembly, enabling the recovery of reusable materials. The process involves cooling the photovoltaic panel's glass structure with liquid nitrogen while maintaining structural integrity, followed by mechanical separation of the glass and aluminum frame. The cooled glass is then processed to remove contaminants and prepare it for further processing into raw materials. The aluminum frame is then extracted and processed into individual profiles, which can be used in new photovoltaic panels or other products.

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Comprehensive recycling method for waste photovoltaic modules to maximize resource recovery and minimize environmental impact. The method involves: 1) Separating the modules into components like glass, frames, junction boxes, and cells. 2) Recycling the separated components using established processes for materials like glass, aluminum, and silicon. 3) Extracting valuable metals like silver, aluminum, copper, and tin from the cells and frames using a process like pyrometallurgy. This allows recovery of these high-value metals from the waste modules instead of landfilling them. The resulting powdered cells can be further processed to extract other valuable materials like cadmium and telluride.

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A solar cell recycling method that enables efficient and cost-effective recovery of photovoltaic materials from end-of-life modules. The process involves disassembling the solar cell module, specifically the metal frame, tempered glass, and backsheet, to separate the individual components. The backsheet is removed through a controlled mechanical separation process. The solar cell is then cleaned in a selective solvent, followed by pulverization to separate the silicon and other materials. The pulverized material is then classified and sorted by particle size using a combination of sieves and a classifier. This enables the recovery of silicon, glass, and other valuable materials in their pure form for reuse in the manufacturing process.

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A method for recycling photovoltaic modules through a single-step process that efficiently recovers all components, including glass, plastic, aluminum, copper, silver, and silicon. The method involves thermal cutting to separate components, followed by crushing and sorting of cells to obtain tinned copper strips and cell powders. The copper strips are then processed using acid leaching to extract silver, while the silicon powder is purified through a combination of acid leaching and chemical treatment. The purified components are then combined to form a new product with high value-added properties.

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A pretreatment method for photovoltaic modules to enhance recycling efficiency by selectively degrading the photovoltaic cell and glass layers. The method involves irradiating the photovoltaic module with ultraviolet light to accelerate photodegradation of the EVA layer, followed by crushing the module to separate glass fragments and solar cells. The EVA layer's photodegradation enables the separation of glass and solar cells, while maintaining the aluminum frame intact for subsequent recycling. This approach enables the efficient separation of valuable components from photovoltaic modules, making recycling more viable for photovoltaic waste.

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A comprehensive recycling system for photovoltaic modules that maximizes material recovery while ensuring high-quality recyclable products. The system comprises sequential processing steps: pretreatment, cutting, heat treatment, and chemical etching. The pretreatment step removes contaminants and prepares the module for processing. The cutting step enables precise separation of photovoltaic cells from the assembly. The heat treatment step ensures the silicon wafers are fully deformed and prepared for chemical etching. The chemical etching step removes the EVA layer, glass, and metal components. The system integrates a vacuum adsorption device for back panel disassembly and a resistance-type hot wire cutter for precise cell separation.

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A comprehensive recycling method for photovoltaic modules that enables complete recycling of glass and silicon wafers without compromising the integrity of the photovoltaic components. The method employs a multi-step approach involving thermal treatment of the module assembly, selective etching of the silicon wafer, and controlled diamond wire cutting of the glass. The thermal treatment process enhances the separation of glass and silicon components, while the diamond wire cutting process enables precise separation of the glass and silicon wafers without damaging the photovoltaic cells. The thermal treatment and diamond wire cutting processes are optimized to ensure complete separation of the components, allowing for the recovery of valuable materials like aluminum, silicon, and rare earth metals.

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A method and system for efficient photovoltaic module recycling that eliminates the need for organic solvents in the traditional mechanical crushing and sorting process. The method involves a single-step pretreatment unit that removes the module assembly components, followed by a specialized cutting unit that peels off the battery sheets and removes the EVA backplate. The cutting unit incorporates a precision cutting mechanism with a flat or oblique blade that enables effective separation of the module components. This integrated pretreatment and cutting process eliminates the environmental and operational issues associated with traditional mechanical crushing and sorting methods.

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A full-cycle recycling system for solar photovoltaic modules that enables efficient extraction of valuable materials from decommissioned panels. The system employs a thermal cracking reactor to convert the module's aluminum frame and backplane into valuable metals, followed by precise sorting and purification processes for copper, glass, and solar cells. The system integrates waste heat recovery, scrubbing, and refining technologies to produce high-quality materials, including copper alloys, glass aggregate, and silicon wafers. This comprehensive approach addresses the environmental and economic challenges of solar panel disposal while enabling closed-loop recycling.

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A low-cost and environmentally friendly cadmium telluride solar cell recycling system that enables the recovery of tellurium and cadmium from photovoltaic waste without generating hazardous waste. The system employs a closed-loop process with integrated waste heat recovery, where primary dust is collected and processed through a shredder, followed by a secondary dust collector and tertiary dust collector. The system includes a flue gas purification unit to remove sulfur dioxide emissions. The system's design combines the primary and secondary dust collectors into a single unit, with the tertiary dust collector providing additional purification capacity. This integrated approach enables the recovery of valuable materials while minimizing environmental impact.

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A photovoltaic module recycling system that enables efficient separation of photovoltaic components through a novel Taylor reactor-based process. The system employs a Taylor reactor to separate photovoltaic components by density differences, with the EVA film, glass, and aluminum being separated from the metal components. The separated components are then processed through a multi-stage cyclone for further separation of metals. This approach eliminates the need for complex chemical treatments and conventional mechanical separation methods, reducing energy consumption and environmental impact.

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A novel method for the efficient recycling of photovoltaic cells through the recovery of valuable materials. The process involves a multi-step approach that leverages the unique properties of photovoltaic cells to achieve the recycling of silicon, aluminum, and silver. The method begins by disassembling the cell and removing the protective aluminum frame, junction box, and EVA film. The resulting polycrystalline silicon is then broken down and processed into a powder. The powder is then mixed with concentrated sulfuric acid at specific concentrations to form a solution containing aluminum sulfate and silver sulfate. Electrolysis of this solution precipitates aluminum and silver while the remaining silicon is converted into a solution containing aluminum sulfate and silicon. The aluminum sulfate solution is then reduced to produce elemental aluminum, while the silver sulfate solution is reduced to produce elemental silver. The waste gas generated during the reduction is recovered to produce elemental aluminum and silver.

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A novel method for recovering valuable materials from CIGS solar cells through selective extraction of metals from the cell structure. The method employs an inorganic acid aqueous solution as a solvent to selectively dissolve copper, indium, and gallium ions, which are then extracted and purified through different extraction times. This selective extraction enables the recovery of the valuable metals while minimizing the generation of hazardous waste and ensuring the purity of the recovered materials.

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A solar cell waste recycling and reprocessing process that enables efficient separation of solar cell components through a novel mechanical cleaning system. The process involves a specially designed liquid storage tank with integrated chip removal ports, a bottom storage groove for glass debris, and a metal filter frame. When the solar panel is crushed during disassembly, the glass and other components are separated cleanly from the metal frame, while the chip removal ports facilitate efficient collection of the glass debris. This innovative approach enables the automated separation of solar cell components, including glass, copper tape, and other materials, for recycling and remanufacturing.

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A process for recovering valuable metals from cadmium telluride thin-film solar cells through controlled thermal treatment. The method involves mechanically peeling the solar cell's back glass, followed by oxidation and roasting of the broken glass and encapsulated film in a controlled furnace environment. The generated tellurium and cadmium oxides are then collected and processed to recover the metals. This approach addresses the environmental concerns associated with traditional cadmium recovery methods while maintaining high recovery efficiency and minimizing environmental impact.

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A method for recycling waste film from solar battery backplanes and their scraps, achieving high-efficiency compatibilization of the resulting material. The method involves blending waste film with an ester copolymer and a high-efficiency compatibilizer, which forms a stable, non-fragmenting melt that can be processed into various shapes for use in electrical appliances, building materials, agriculture, photovoltaics, and other applications. The compatibilizer enhances the material's compatibility between the fluorine-containing solar cell backplane waste film and polyester components, while the ester copolymer contributes to the material's soft and tough properties.

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Integrated solar panel recycling system that efficiently separates aluminum frame and tempered glass components from photovoltaic panels through a single-step process. The system employs a frame removal unit, tempered glass crushing unit, and heating unit to process the photovoltaic panel while maintaining temperature uniformity on both surfaces. The frame removal unit secures the panel, while the tempered glass crushing unit shreds the glass from the panel's side. The heated panel is then processed in a tempered glass separation unit, where the shreds are separated from the aluminum frame through a peeling blade. The separated glass is then recovered and reused in new solar panels.

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A waste photovoltaic module recycling system that maximizes resource recovery while minimizing waste generation through precise separation of valuable components. The system employs a novel glass separation unit that enables rapid and precise separation of glass panels from photovoltaic modules through controlled wire cutting. This innovative approach eliminates the need for conventional crushing and chemical treatment methods, significantly reducing processing time and environmental impact. The system also integrates a comprehensive recycling pathway that includes frame separation, defect diagnosis, and component recovery, enabling the efficient recycling of photovoltaic modules while minimizing waste.

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A recycling process for solar panels that leverages silicon extraction and chemical processing to create valuable materials. The process involves extracting silicon from the panel through a wafer extraction step, followed by heat treatment to remove glass and backsheet components. Silicon powder is then processed to produce micro- and nano-sized particles through ball milling, which are then chemically etched to remove metal impurities. The resulting silicon powder is then converted into a high-quality silicon nitride through nitridation. The process enables the recovery of valuable silicon components while producing a valuable silicon nitride product.

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Method for manufacturing light-transmitting flexible thin-film solar cells that improves efficiency through enhanced hole processing control. The method employs a novel post-processing step after hole formation in the solar cell's light transmission path, specifically targeting areas where holes create shunts. This targeted cleaning process ensures that only the critical regions of the solar cell's interface layers are cleaned, while maintaining the integrity of the rest of the cell structure. This approach enables the creation of high-efficiency solar cells with reduced shunt generation, thereby improving overall performance.

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Method for recycling solar cells through a multi-step process that separates the active material layer from the stainless steel substrate without damaging the substrate. The method involves immersing the solar cell in a treatment solution containing a passivation agent, followed by a reduction step using a peroxide solution. The treatment solution is then subjected to a leaching process that selectively precipitates the active elements, including selenium, gallium, indium, cadmium, and zinc, while leaving the stainless steel substrate intact. The separated active material is then recovered through wet separation, allowing for the efficient recycling of multiple solar cell components.

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Recycling method and device for waste photovoltaic modules that increases the efficiency and completeness of recycling crystalline silicon solar cells. The method involves immersing the module in a peeling solution that dissolves the packaging film. A peeling brush rolls against the module to physically peel off the film as it dissolves. This combined chemical and mechanical peeling improves recycling efficiency by dissolving the film faster and protecting the cells from damage.

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A method and system for recycling photovoltaic modules through a multi-step process that separates the module components while preserving their original integrity. The system employs a crushing device followed by a stripping device, where the crushing action peels off the EVA film and silicon layers from the solar cells. The silicon and EVA are then separated from the remaining module components through a metal separation device, while the backplane and EVA film are separated immediately. The separated components are then processed in a cyclone separation device, which separates the metal components from the non-metal components. The resulting separated components can be further processed for reuse in the manufacturing process.

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A method for recovering glass substrates from solar cells through selective material removal, eliminating the need for corrosive etching processes. The method involves removing defective layers while preserving the glass substrate, by selectively blasting away specific layers based on their failure characteristics. The approach enables efficient and environmentally friendly recycling of solar cell substrates, particularly for solar cells with complex multi-layer structures.

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A solar cell module that enables efficient recycling of solar cell waste during production, while maintaining performance and cost-effectiveness. The module comprises a solar cell array with integrated recycling capabilities for broken or damaged cells. The array includes a frame, tempered glass, EVA interlayer, and a transparent TPT backsheet. The solar cells are arranged in a standard five-layer configuration, with each cell containing multiple square cells. The module's design enables the collection and processing of broken solar cells during manufacturing, while maintaining the structural integrity of the array. The recycling process can be performed through a series of mechanical and chemical treatments, allowing for the recovery of valuable materials from waste solar cells.

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A method for recycling solar cells that eliminates harmful gases and waste while achieving energy efficiency. The process involves immersing unqualified solar cells in a hydrochloric acid solution to remove aluminum, followed by a treatment in hydrofluoric acid to remove silicon nitride. The resulting silicon-rich acid solution is then neutralized with alkaline solution to produce a non-toxic liquid. This liquid is used as a raw material for producing silicon, silver, and alumina, which can be recovered through the same process. The method eliminates the need for mixed acid treatments, resulting in a cleaner and more environmentally friendly recycling process.

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A solar module recycling system that enables precise and rapid separation of photovoltaic cells and tempered glass through a single cutting blade. The system employs a heated blade with heat-generating elements spaced at regular intervals to achieve uniform heating across the cutting edge. This configuration enables efficient separation of cells and tempered glass while minimizing thermal stress on the cells. The system's precision cutting mechanism ensures accurate separation of the photovoltaic components, while the heat-generating elements maintain optimal operating conditions for both cell and glass separation. The system's design allows for rapid processing of various solar module sizes, reduces cutting blade load, and minimizes residual material in the cells.

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Mechanical abrasion recovery treatment method for cadmium telluride thin film solar cells that enables efficient recovery of valuable metals from the photovoltaic film layer. The method involves mechanically crushing the solar cell to separate the film from the substrate glass and cover glass, followed by a controlled abrasion process that selectively removes the valuable metal components from the film. The resulting metal-rich glass and film fragments can be processed further for recycling of rare earth metals, cadmium, and other valuable materials. This approach addresses the traditional limitations of wet crushing and leaching methods by preserving the structural integrity of the solar cell components.

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Cryogenic refrigeration recovery treatment method for cadmium telluride thin film solar cells that enables efficient recovery of valuable metals while maintaining the structural integrity of the photovoltaic module. The method involves cryogenically treating the solar cell to remove the metal-containing photovoltaic material, followed by mechanical separation of the metal-containing substrate glass and cover glass. The cryogenic treatment selectively preserves the structural integrity of the backsheet and substrate glass while selectively leaching the metal-containing photovoltaic material.

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A method for recovering copper indium gallium selenide (CIGS) photovoltaic modules from stainless steel substrates while maintaining high-grade recovery of indium, gallium, and selenium. The method employs a novel thermal treatment process that selectively extracts these rare metals from the CIGS layer while preserving the photovoltaic performance of the module. This approach enables the efficient recovery of valuable materials from CIGS substrates, significantly reducing waste generation compared to conventional wet chemical processing methods.

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Method for recycling solar cell modules by selectively removing the enclosing layer while preserving the light-receiving surface layer and back sheet. The method involves mechanically removing the back sheet, then selectively removing the solar cell and enclosing layer to a predetermined depth while preserving the light-receiving surface layer. The remaining enclosing layer is then immersed in a swelling solution, allowing it to disintegrate without damaging the solar cell. This approach enables efficient recycling while maintaining the structural integrity of the solar cell and its supporting components.

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A thin film solar cell film removal process and thin film solar cells that enable precise edge removal of the solar cell module's glass substrate while maintaining high efficiency and performance. The process employs a novel laser-based edge removal system that uses focused laser energy to selectively remove the edge regions of the solar cell module's glass substrate, eliminating the need for traditional grinding or sandblasting methods. This approach enables precise control over the edge removal process, ensuring complete removal of the edge regions while minimizing contamination and ensuring reliable electrical insulation and sealing of the solar cell module.

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A method for recycling photoanode materials from sensitized solar cells, enabling the reuse of both the semiconductor and conductive substrate components. The method involves selective acid dissolution of the photoanode, followed by separation of the semiconductor material from the conductive substrate. The semiconductor material is then purified and re-deposited onto a new substrate, while the conductive substrate is recycled for use in further solar cell production. This approach enables the recovery of valuable materials from end-of-life solar cells, reducing waste and the environmental impact of traditional disposal.

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Flexible solar cell scrap recycling method that enables the reuse of defective solar cells by integrating them into functional products. The method involves selective application of non-performing solar cells into battery packs, where they can be used to enhance performance and reduce waste. This approach addresses the conventional problem of defective solar cells being discarded, rather than being directly scrapped, by converting them into valuable components.

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Solar cell processing technology for improved efficiency and environmental sustainability. The technology utilizes plasma-enhanced chemical vapor deposition (PECVD) to create a thin silicon nitride layer on solar cell surfaces, enhancing anti-reflective properties and reducing surface reflection. This layer prevents short-circuit currents and improves cell efficiency. The process enables the creation of high-quality solar cells with reduced material waste compared to traditional wet etching methods. The silicon nitride layer is deposited using low-temperature plasma technology, allowing precise control over film thickness and composition. This approach enables the production of high-performance solar cells while minimizing environmental impact.

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A method for recovering copper-indium-gallium (Cu-In-Ga) photovoltaic modules from substrates using a novel alkaline leaching process. The method employs a specially designed leaching tank with an integrated leaching basket to separate the photovoltaic components from the substrate and resin layer. The basket contains the photovoltaic elements while the substrate and resin layer remain in the leaching tank. This approach enables the recovery of Cu-In-Ga elements without the conventional acid-leaching method, which can be problematic for stainless steel substrates. The leaching process is optimized to maximize the recovery of these critical materials, enabling efficient recycling of Cu-In-Ga components.

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A solar cell production process that eliminates waste generation by recycling and reusing materials. The process involves removing silicon nitride reflective layers from de-silvered solar cells using acid solution, then processing the resulting silicon wafers into reusable raw materials. The acid solution is combined with copper powder to produce silver-coated paste for screen printing, while the silicon wafers are used as raw material for future solar cell production. The acid solution is also used to recover and process waste materials like quartz soil and mortar, while the silicon wafers are recycled into new cutting mortar. This closed-loop recycling approach eliminates the need for acid-base waste treatment, centralized destruction, and environmental pollution associated with traditional solar cell production.

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A method for recovering high-value materials from flexible solar panels through a novel, integrated approach. The method employs cryogenic cold source devices to selectively extract metal-containing components from the panel's substrate and coating layers. The extracted metals are then processed using electrolysis, sandblasting, and acid leaching to recover valuable materials. The recovered metals can be further refined and reused in the production of solar cells, eliminating the need for expensive raw materials and hazardous waste management.

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A novel method for recycling multi-element compound thin-film solar cells, such as cadmium sulfide and copper-incorporated selenium (CIGS) cells, that enables efficient and effective recovery of valuable metals while minimizing processing time. The method employs a single-step chemical extraction process that selectively separates the metals from the solar cell structure through controlled oxidation and precipitation reactions. This approach addresses the conventional multi-step chemical extraction methods while achieving comparable or better metal recovery rates.

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Thin-film solar cell with a back electrode that enhances power conversion efficiency through a novel barrier layer approach. The cell employs a multi-layered barrier structure comprising alternating inorganic and organic barrier layers, where the organic barrier layer is formed through a polymeric binder material. This multi-layered barrier system provides superior moisture and humidity resistance while maintaining excellent electrical properties. The multi-layered barrier structure enables the formation of a compact, water-resistant, and weather-resistant solar cell with improved performance compared to traditional barrier layer configurations.

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A method for recycling thin-film solar cells that eliminates the complex liquid-phase recovery process typically associated with traditional methods. The recycling process involves a single-step crushing and pulverizing of the solar panels, followed by a controlled dissolution of the photovoltaic material in a solution containing cadmium sulfide (CdS) and telluride (Te) ions. The solution is then filtered to remove glass and other debris, and a solution of alkaline and chloride is added to precipitate the photovoltaic material. Activated carbon is added to the solution to remove residual impurities. The resulting precipitate is then filtered through a membrane filter to remove any remaining photovoltaic material. This single-step process eliminates the need for complex chemical treatments and membrane separations, making it a more efficient and environmentally friendly method for solar cell recycling.

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Chemical-mechanical etching method for recycling solar cells by combining chemical etching with mechanical polishing to remove damaged surfaces while preserving the wafer's structural integrity. The method involves etching the damaged solar cell surface with nitric acid to remove the damaged anti-reflection coating, emitter layer, and PN junction, followed by mechanical polishing to remove mechanical damage. The resulting polished surface is then treated with potassium hydroxide solution to remove any remaining mechanical damage. This approach enables efficient recycling of solar cell wafers while preserving their structural integrity.

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A method for recycling solar cells through a novel approach that enables cost-effective recovery of valuable materials. The method involves dissolving solar cells in a silver-containing acid solution while adding copper powder to the solution. The resulting solid-liquid mixture is then processed to produce a copper-silver alloy with high purity and conductivity. This approach eliminates the need for traditional destruction methods, reduces material waste, and enables the recovery of valuable metals while minimizing environmental impact.

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Thin-film solar cell with enhanced short-circuit current density and open-circuit voltage through a novel antimony-based photoelectric conversion layer. The cell incorporates a layer comprising antimony sulfide and selenium, where the antimony sulfide site enables higher light absorption beyond the conventional silicon-based conversion mechanism. The antimony selenium site, meanwhile, provides improved stability and durability. The cell architecture combines these sites with organic semiconductor layers, enabling both high current density and open-circuit voltage while maintaining excellent performance characteristics.

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Flexible copper indium gallium (CIGS) thin-film solar cell recycling method for environmentally responsible recycling of CIGS solar cells. The method enables the recovery and recycling of CIGS solar cells through a simple, economical, and low-technology process that preserves the solar cell's structural integrity. The recycling process involves a controlled thermal treatment of the solar cells in a controlled atmosphere, eliminating the need for complex acid extraction and distillation steps.

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Method for recycling solar cells by selectively extracting transition metal ions from the solar cell structure. The method involves a heat treatment process that selectively forms the transition metal layer on the solar cell substrate, followed by a selective removal process that targets the formed metal ions. The selective removal process can be achieved through mechanical scraping or ultrasonic cleaning, allowing for the recovery of the transition metal without generating waste. This approach enables the efficient separation of the transition metal layer from the solar cell structure, enabling its recycling while minimizing environmental impact.

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