WO2024020626A1

WO2024020626A1 - Layer removal device

Info

Publication number: WO2024020626A1
Application number: PCT/AU2023/050673
Authority: WO
Inventors: Rick Brown
Original assignee: PV Industries Pty Ltd
Priority date: 2022-07-25
Filing date: 2023-07-24
Publication date: 2024-02-01

Abstract

The invention relates to a layer removal device for a multilayer panel, comprising: a conveying unit comprising: a first pair of rollers; and a second pair of rollers; wherein each pair of rollers are configured to convey the multilayer panel along a conveying path; a driving shaft located substantially midway along and below the conveying path; and a plurality of impact members coupled to the driving shaft; wherein rotation of the driving shaft causes the plurality of impact members to impact against an external layer of the multilayer panel, as it is conveyed along the conveying path, causing the external layer to fracture and form a plurality of particulates that are dislodged from the multilayer panel. The invention further relates to methods of removing an external layer from a multilayer panel thereof.

Description

Layer Removal Device

Technical Field

[0001] This disclosure relates to a layer removal device for multilayer panels. In particular for the removal of an external layer from a solar module/panel.

Background

[0002] Photovoltaic (PV) modules/panels are a key component of solar power systems, such as grid-connected power systems, stand-alone solar power systems, and concentrated solar power systems. PV modules/panels that are installed in these solar power systems may be retired for various reasons, such as being damaged or reaching an end of operational life. Retired PV modules/panels may be recycled to minimise waste and reclaim core materials, such as aluminium, copper, glass, and silver. However, the majority of recycling process are costly, due to the relatively high costs of processing to reduce the weight/bulk of the retired PV modules/panels, and the low monetary return of selling the reclaimed materials.

[0003] There exist several methods for recycling PV modules/panels, including thermal processing methods, chemical processing methods, and mechanical processing methods.

[0004] Thermal processing of PV modules/panels involves subjecting the PV modules/panels to high temperatures to break down the organic materials, such as polymers and encapsulants. However, thermal processing techniques have several disadvantages. For example, thermal processing involves high temperature treatments which can lead to significant energy consumption. Further, the high-temperature treatments can result in the release of harmful emissions (for both the environment and humans). In effect, this may off-set the intended benefits of recycling the PV modules/panels. Further, thermal processing can result in the loss or damage of certain materials and components within the PV modules, particularly volatile materials and materials with low melting points.

[0005] Chemical processing of PV modules/panels involves dissolving and separating semiconductor materials, such as silicon, from the PV modules/panels. Chemical processing techniques are typically more complex than other PV modules/panels recycling methods and require the use of specific chemical solutions to recover valuable materials, from the PV modules/panels. As with thermal processing techniques, chemical processing techniques have several disadvantages. For example, chemical processing of PV modules/panels often involves the use of complex and hazardous chemical solutions to dissolve and extract valuable materials from the PV modules/panels. Appropriate handling of such materials can pose several environmental and health challenges. Further, improper handling or disposal of such chemical reagents and solutions can lead to environmental pollution and potential harm to ecosystems and human health. In addition, chemical processing techniques can be costly because of the high costs associated with acquiring and managing the chemicals involved.

[0006] Mechanical processing techniques typically involve the disassembly of PV modules/panels and subsequent mechanical processing of the PV modules/panels into individual constituents. For example, mechanical processing may involve shredding, crushing, and sieving of the PV modules/panels to recover the glass, metals (aluminium and silver), and semiconductor materials (silicon wafers).

[0007] There are two primary methods for removing the bulky and heavy external glass layer from the retired PV modules/panels. The first method involves the use of labour and/or mechanical means to remove the metallic frame and external glass layer from the retired PV modules/panels. The second method involves the use of industrial machinery to crush/shred the entire retired PV module/panel into small pieces for subsequent component separation. Both methods can result in the loss or damage of certain materials, and can create or result in fine dust and airborne particles. Such particles may pose health and safety risks to workers and potentially require additional air quality control. Further, both methods create inefficiencies and additional costs from the high costs of manual labour, and the additional processes required for successful component separation after crushing/shredding.

[0008] Thus, there remains a need to provide an economical, cost-effective method or means for recycling PV modules/panels. Particularly, cost-effective methods or means with minimal or lessened repercussions for the environment and for human health.

[0009] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.

Summary

[0010] It is an aim and objective of the present invention to provide a layer removal device for removing an external layer from a multilayer panel. In particular, the multilayer panel is a solar module/panel and the external layer is the outer glass layer. This ensures that the solar module/panel is stripped of the heavy and bulky glass layer, enabling easier recycling of the other components of solar module/panel.

[0011] It is an object of the present invention to overcome or ameliorate at least one of the aforementioned disadvantages of the prior art, or at least to provide a useful alternative.

[0012] According to a first aspect of the present invention, there is provided a layer removal device for a multilayer panel, comprising: a conveying unit comprising: a first pair of rollers; and a second pair of rollers; wherein each pair of rollers are configured to convey the multilayer panel along a conveying path; a driving shaft located substantially midway along and below the conveying path; and a plurality of impact members coupled to the driving shaft; wherein rotation of the driving shaft causes the plurality of impact members to impact against an external layer of the multilayer panel, as it is conveyed along the conveying path, causing the external layer to fracture and form a plurality of particulates that are dislodged from the multilayer panel.

[0013] In an embodiment, the first pair of rollers rotates at a faster speed than the second pair of rollers.

[0014] In an embodiment, the layer removal device further comprises a backing plate, located above the conveying path, wherein the backing plate is configured to support the multilayer panel while undergoing impact by the plurality of impact members.

[0015] In an embodiment, the backing plate is configured with a removable wear plate.

[0016] In an embodiment, the driving shaft is configured to move vertically towards or away from the conveying path.

[0017] In an embodiment, the driving shaft is configured to laterally reciprocate during rotation.

[0018] In an embodiment, the plurality of impact members are configured as bars or blades.

[0019] In an embodiment, the plurality of impact members are formed from tungsten carbide. [0020] In an embodiment, the layer removal device further comprises: a housing with a first opening located in a first wall, and a second opening located directly opposite the first opening in an opposing wall; wherein the first opening is configured to receive and direct the multilayer panel to the first pair of rollers, and the second opening is configured to receive the multilayer panel from the second pair of rollers and discharge it from the housing.

[0021] In an embodiment, the housing is configured to be substantially sealed from the external environment.

[0022] In an embodiment, the layer removal device further comprises a receptacle located in the housing for collecting the plurality of particulates.

[0023] In an embodiment, the receptacle has a conveyor for dispensing the plurality of particulates to an external receptacle.

[0024] In an embodiment, the conveyor is an auger.

[0025] In an embodiment, the layer removal device further comprises an extraction system, located in the housing, configured to extract a plurality of fine particles from the housing.

[0026] In an embodiment, the extraction system further comprises a fines receptacle for storing the extracted fine particles.

[0027] In an embodiment, the multilayer panel is a solar panel and the external layer is glass.

[0028] According to a second aspect of the present invention, there is provided a method of removing an external layer from a multilayer panel, comprising: conveying, using a first pair of rollers and a second pair of rollers, the multilayer panel along a conveying path; rotating, using a driving shaft, a plurality of impact members located substantially midway along and below the conveying path; wherein the rotation of the driving shaft causes the plurality of impact members to impact against the external layer of the multilayer panel, as it is being conveyed along the conveying path, causing the external layer to fracture and form a plurality of particulates that are dislodged from the multilayer panel.

[0029] In an embodiment, the conveying path is located within a housing.

[0030] In an embodiment, the method further comprises collecting the plurality of particulates in a receptacle located below the conveying path.

[0031] In an embodiment, the method further comprises collecting a plurality of fine particulates using an exhaust system.

[0032] The invention is to be interpreted with reference to at least one of the technical problems described or affiliated with the background art. The present invention aims to solve or ameliorate at least one of the technical problems and this may result in one or more advantageous effects as defined in this specification and described in detail with reference to the preferred embodiments of the present invention.

Brief Description of Drawings

[0033] Preferred embodiments of the invention will now be described, by way of nonlimiting example only, with reference to the following drawings:

[0034] Fig. 1 is a side cross sectional view of a layer removal device.

[0035] Fig. 2 is a side cross sectional view of the layer removal device processing a multilayer panel.

Description of Embodiments [0036] Preferred embodiments of the invention will now be described with reference to the accompanying drawings and non-limiting examples.

[0037] Although the invention has been described with reference to specific embodiments and examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms, in keeping with the broad principles and the spirit of the invention described herein.

General terms

[0038] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

Layer Removal Device

[0039] The present disclosure comprises a layer removal device 10 as shown generally in FIG. 1 and FIG. 2. The layer removal device of the present disclosure is configured for removing a glass layer from a PV module/panel. However, a person skilled in the art would appreciate that the layer removal device may be used to remove an external layer, being made of a brittle material, from any multilayer panels.

[0040] FIG. 1 illustrates an exemplary embodiment of the layer removal device 10 having a conveying unit 12, a driving shaft 14 having a plurality of impact membersl6a, 16b, and a housing 18. The conveying unit 12 is configured to receive a multilayer panel 20, from outside of the housing 18, and convey it along a conveying path until it is discharged from inside of the housing 18. The driving shaft 14 is located substantially midway along and below the conveying path, such that the plurality of impact members 16a, 16b are aligned to impact against an external layer of the multilayer panel 20 as it is being conveyed along the conveying path. The impact of the plurality of impact members 16a, 16b, caused by the rotation of the driving shaft 14, imparts sufficient energy to fracture the material of the external layer causing it to form a plurality of particulates that are dislodged from the multilayer panel and fall free. It is to be appreciated that the impact members may be configured to impact the external layer of the multilayer panel in a variety of different ways so as to fracture the material of the external layer of the multilayer panel thereby causing the external layer to form a plurality of particulates that are dislodged from the multilayer panel, and that the embodiments shown and described herein are by way of non-limiting example only.

[0041] The housing 18 has a first wall 26 with a first opening 28 and a second opposing wall 22 with a second opening 24. The first opening 28 is an inlet for receiving the multilayer panel 20, having an opening that is dimensioned substantially the same as the cross sectional area of the multilayer panel 20. This ensures that as the multilayer panel 20 is fed through the first opening 28, it will be correctly aligned for feeding to the conveying unit 12, providing the advantage of reduced damage to the multilayer panel 20 during the feeding process and reduced chances of misfeeding causing disruptions to the operation of the layer removal device 10. It is to be appreciated that the housing may be constructed in a variety of suitable ways such that the first wall of the housing has a variety of different sized first openings, to suit a variety of different sized multilayer panels, and that the examples shown and described herein are by way of non-limiting example only. The second opening 24 is located substantially or directly opposite the first opening 28, ensuring that the conveying path is substantially straight, to reduce the chances of premature cracking in the multilayer panel 20 or the misalignment of the multilayer panel 20 as it is being processed by the layer removal device 10. The second opening 24 function as an outlet for discharging a post-processed multilayer panel for further downstream processing. The second opening 24 typically has an opening that is dimensioned substantially the same as the cross sectional area of the multilayer panel 20, however it would be appreciated by persons skilled in the art that it may be of a different dimension based upon the cross sectional area of the processed multilayer panel 20.

[0042] The conveying unit 12 is comprised of a first pair of rollers 34 and a second pair of rollers 32, wherein the distance between them defines the conveying path. The distance between the first pair of rollers and the second pair of rollers may be configured to be any suitable distance and may be selected depending on the size and dimensions of the multilayer panel. For example and without limitation, the distance between the first pair of rollers and the second pair of rollers may be between about 25 mm to about 500 mm, between about 50 mm to about 450 mm, between about 75 mm to about 400 mm, between about 100 mm to about 350 mm, between about 150 mm to about 300 mm, between about 150 mm to about 250 mm, or about 200 mm.

Alternately, and without limitation, the distance between the first pair of rollers and the second pair of rollers may be between about 100mm to about 700mm, between about 150mm to about 650mm, between about 200mm to about 600mm, between about 250mm to about 550mm, between about 300mm to about 500mm, between about 350mm to about 500mm, between about 400mm to about 500mm, or between about 425mm to about 475mm. It is to be appreciated that the distance between the first pair of rollers and the second pair of rollers may be configured to be any suitable distance, and that the examples shown and described herein are by way of non-limiting example. The first pair of rollers 34 and the second pair of rollers 32 each have a driving roller 38, 36 configured to rotate towards the second opening 24, so as to direct the multilayer panel 20 along the conveying path. Additionally, the first pair of rollers 34 and the second pair of rollers 32 each have a driven roller 42, 40 configured to be adjacent to or abutting the corresponding driving roller 38, 36. When the multilayer panel 20 is fed into the first and second pairs of rollers 34, 32, the multilayer panel 20 is nipped between the driving rollers 38, 36 and driven rollers 42, 40. As the driving rollers 38, 36 rotate, the nipped multilayer panel 20 is conveyed from the first pair of rollers 34, towards the second pair of rollers 32 and subsequently towards the second opening 24 for discharge from the housing 18. In another preferred embodiment, the driven rollers 42, 40 have one or more compressions springs (not shown) to bias the driven rollers 42, 40 towards the corresponding driving rollers 38, 36. The compression springs are compressed when the multilayer panel 20 is fed into the first and second pairs of rollers 34, 32. This causes the driven rollers 42, 40 to be displaced in accordance to the height of the multilayer panel 20 but retains sufficient force upon the top of the multilayer panel 20 to reduce the chances of misalignment during conveyance. In another preferred embodiment, the first pair of rollers 34 rotates at a faster rate than the second pair of rollers 32, to assist in maintaining the tautness of the multilayer panel 20 as it is being processed. In an alternate embodiment, the second pair of rollers rotate at a faster rate than the first pair of rollers. It may be advantageous to configure the device such that the second pair of rollers rotate at a faster rate than the first pair of rollers because this configuration may allow the second pair of rollers to assist with the processing of the multilayer panel through the device, when in use. It is to be appreciated that the rate of rotation of each pair of rollers may be adjusted and selected as desired, so as to control the respective rate of processing of the multilayer panel. Preferably, the rate of rotation of each respective pair of rollers is selected to be between about 5 rpm to about 50 rpm, preferably between about 10 rpm to about 45 rpm, more preferably between about 15 rpm to about 40 rpm, more preferably between about 20 rpm to about 35 rpm, when in use. Preferably, the rate of rotation of the first pair of rollers is configured to be between about 5 rpm to about 35 rpm, between about 10 rpm to about 30 rpm, between about 15 rpm to about 30 rpm, or between about 20 rpm to about 25 rpm. Preferably the rate of rotation of the second pair of rollers is configured to be between about 10 rpm to about 50 rpm, between about 15 rpm to about 45 rpm, between about 20 rpm to about 40 rpm, between about 25 rpm to about 40 rpm, between about 30 rpm to about 40 rpm, or between about 30 rpm to about 35 rpm.

[0043] It would be appreciated by persons skilled in the art that the conveying unit 12 may comprise several pairs of rollers. Additionally, each pair of rollers may have two driving rollers rather than one driving roller and one driven rollers. Furthermore, in this exemplary example, the driving rollers are driven by an external electric motor, however it may be configured with an internal motor for rotation. It is to be appreciated that each roller or each pair of rollers may be constructed of any suitable material. Non-limiting examples of suitable materials may include:

[0044] Steel: steel is an alloy of iron and carbon known for its strength and durability. Steel can handle heavy loads and thus make it a suitable material for various applications, including for providing rollers as described in the present disclosure. [0045] Stainless steel: Stainless steel is a variant of steel that contains chromium, thereby providing excellent corrosion resistance.

[0046] Aluminium: Aluminium rollers are sufficiently lightweight, which may be advantageous in applications where minimising the overall weight of the device of the present disclosure is desirable.

[0047] Rubber: Rubber rollers are known for their excellent friction properties.

[0048] Polyurethane: Polyurethane rollers may be desirable because such rollers offer good wear resistance, flexibility and chemical resistance.

[0049] Nylon: Nylon rollers are lightweight, have low friction characteristics, and offer good resistance to wear and abrasion.

[0050] Ultra-High Molecular Weight (UHMW) Polyethylene: UHMW polyethylene rollers are known for their high impact strength, low friction, and excellent resistance to wear. Thus, UHMW polyethylene may be desirable because of their suitability for heavy-duty industrial applications.

[0051] Ceramic: Ceramic rollers offer high-temperature resistance and excellent chemical inertness.

[0052] Carbon Fiber: Carbon fiber rollers are lightweight and have high strength-to- weight ratios.

[0053] Composites: Rollers of the present disclosure may be made from composite materials, which combine any two or more suitable materials so as to achieve specific properties.

[0054] In one embodiment, the first pair of rollers may be constructed of a different material to that of the second pair of rollers. In one embodiment, the first pair of rollers may be constructed of any one or more of rubber, polyurethane, or nylon, preferably rubber. In one embodiment, the second pair of rollers may be constructed of any one or more of steel, stainless steel, or aluminium, preferably steel or stainless steel.

[0055] FIG. 2 illustrates the driving shaft 14 being configured to be coupled to a plurality of plates 44, each plate has a pair of impact members 16a, 16b in the form that produces high impact energy, such as bars or blades, made from material with high hardness, such as tungsten carbide, diamond, and cubic boron nitride. It is to be appreciated that the impact members may be constructed of any suitable material. Nonlimiting examples of suitable materials that the impact members may be constructed of include:

[0056] High-Speed Steel (HSS): HSS is a type of tool steel known for its excellent heat resistance and hardness. It is commonly used for cutting tools due to its ability to maintain sharpness and withstand high temperatures.

[0057] Carbide: Carbide impact members are often made from tungsten carbide or a combination of tungsten carbide and cobalt. Carbide is known for its exceptional hardness and wear resistance, making it suitable for impacting hard materials such as metals, alloys, and composites.

[0058] Diamond: Diamond is one of the hardest materials known and offers exceptional impact performance. Diamond impact members are typically used for applications involving extremely hard or abrasive materials like ceramics, glass, or certain composites.

[0059] Ceramic: Ceramic impact members are made from advanced ceramic materials such as alumina or zirconia. Ceramics offer high hardness, excellent wear resistance, and can be effective for impacting abrasive materials. [0060] Stainless Steel: For certain applications where the impact requirements are less demanding, stainless steel impact members can be used. Stainless steel offers good durability and corrosion resistance.

[0061] The number of plates 44 may depend upon the width of the multilayer panel 20 being processed, with more plates 44 being coupled to the driving shaft 14 for larger panel sizes. For example, it may be desirable to include a greater number of plates (such as and without limitation, two or more, five or more, 10 or more, 15 or more, 20 or more, 25 or more, 30 or more, 35 or more, 40 or more) for use with multilayer panels having a greater width because including a greater number of plates may decrease the processing time of the multilayer panel through the device. Thus, it is to be appreciated that the device of the present invention may include any suitable number of plates, and that the examples shown and described herein are by way of non-limiting example only. Preferably, the number of plates may selected to be between about 10 to about 35, between about 15 to about 30, or between about 20 to about 25. The plates are configured with mounting points 46, 48 for the replaceable impact elements 16a, 16b such that these impact elements 16a, 16b may be replaced when they are sufficiently worn or damaged. Additionally, the mounting points 46, 48 allow for the use of different replaceable impact elements 16a, 16b that may be of different composition, size, and/or shape. This advantageously allows for the processing of different types of multilayer panels 20 based upon the hardness/toughness characteristics of the external layer that is required for removal. It would be appreciated by persons skilled in the art that the plates 44 may be configured to have additional mounting points for retaining more impact blades.

[0062] Preferably, the plates may be coupled to the driving shaft from a first end of the driving shaft to a second end of the driving shaft such that the plates form a corkscrew configuration around the longitudinal axis of the driving shaft. It is to be appreciated that the plates may be coupled to the driving shaft in a variety of suitable ways, such as and without limitation, to form a wound configuration, a coil configuration, a helical configuration, or a corkscrew configuration around the longitudinal axis of the driving shaft. It may be advantageous to configure the plates around the longitudinal axis of the driving shaft in such a way because it allows the respective impact members coupled to the plates to apply a consistent level of pressure to the multilayer panel, as the driving shaft is being rotated.

[0063] The driving shaft 14 may be configured to be perpendicularly moveable from the conveying path, to allow for height adjustment so as to remove more or less of the external layer of the multilayer panel 20. Alternatively, the height may be adjusted to remove more than just the external layer of the multilayer panel 20. Additionally, the drive shaft 14 may be configured to move laterally while rotating, allowing for the plurality of impact elements to traverse and process more of the surface area than being limited to a single row and to reduce the chances of having residual rows and/or formations of unprocessed external layer due to gaps between the blades caused by misalignment of the blades and/or damage to the blades. It is to be appreciated that the rate of rotation of the drive shaft may be adjusted and selected as desired, so as to control the respective rate of impact movement of the plurality of impact members, and that the examples described herein are by way of non-limiting example only.

Preferably, the rate of rotation of the of the drive shaft is selected to be between about 100 rpm to about 3500 rpm, between about 200 rpm to about 3000 rpm, between about 300 rpm to about 3000 rpm, between about 500 rpm to about 2750 rpm, between about 750 rpm to about 2750 rpm, between about 1000 rpm to about 2500 rpm, between about 1500 rpm to about 2500 rpm, or about 2000 rpm.

[0064] The driving shaft 14 may be powered by an external motor, however it may also be powered by an internal motor or any other means of rotating the driving shaft 14.

[0065] FIG. 2 illustrates a backing plate 50 located above the conveying path and the driving shaft 14. The backing plate 50 may be positioned so that is it adjacent to the multilayer panel 20, as it is being conveyed along the conveying path, and acts to support the multilayer panel 20 as it is undergoing impact by the impact members 16a, 16b. This advantageously reduces the amount of impact force lost by the impact members 16a, 16b as they strike the external layer of the multilayer panel 20. In one embodiment, the backing plate is configured to have a length that substantially corresponds to the distance between the first pair of rollers and the second pair of rollers. In an alternate embodiment, the backing plate is configured to have a length that is substantially less than the distance between the first pair of rollers and the second pair of rollers. Preferably, the backing plate may be configured to have a length of between about 50 mm to about 500 mm, between about 100 mm to about 400 mm, between about 150 mm to about 250 mm, or about 200 mm. Preferably, the backing plate may have a thickness that extends substantially less than the height of any one of the rollers. In one embodiment, the backing plate may have a thickness of between about 5 mm to about 50 mm, between about 10 mm to about 40 mm, between about 10 mm to about 30 mm, between 15 mm to about 25 mm, or about 20 mm. It may be advantageous to configure the backing plate in a manner as described above, because such configuration may reduce interference of the backing plate with the processing of the multilayer panel through the conveying path and concurrently minimise the amount of impact force lost by the impact members as they strike the multilayer panel, when in use. It is to be appreciated that the backing plate may be configured in a variety of ways (such as by way of shape and size), and that the embodiments shown and described herein are by way of non-limiting example only. For example, the backing plate may have a quadrilateral configuration, substantially rectangular configuration, substantially square configuration, or substantially triangular configuration.

[0066] It is to be appreciated that the backing plate may be constructed of any suitable material. Non-limiting examples of suitable materials include:

[0067] Steel: steel is an alloy of iron and carbon known for its strength and durability. Steel can handle heavy loads and thus make it a suitable material for various applications, including for providing backing plates as described in the present disclosure.

[0068] Stainless steel: Stainless steel is a variant of steel that contains chromium, thereby providing excellent corrosion resistance. [0069] Aluminium: Aluminium backing plates are sufficiently lightweight, which may be advantageous in applications where minimising the overall weight of the device of the present disclosure is desirable.

[0070] In a preferred embodiment, the backplate 50 is configured with a removable wear plate. In one embodiment, the removeable wear plate is positioned beneath the backing plate and extends substantially the length of the backing plate. The removeable wear plate may be configured to have a length of between about 50 mm to about 500 mm, between about 100 mm to about 400 mm, between about 150 mm to about 250 mm, or about 200 mm. The removeable wear plate may be configured to have a thickness substantially less than the thickness of the backing plate. For example, and without limitation, the wearing plate may be configured to have a thickness of between about 1 mm to about 30 mm, between about 2 mm to about 25 mm, between about 2 mm to about 20 mm, between about 5 mm to about 15 mm, between about 7 mm to about 12 mm, or about 10 mm.

[0071] In an alternate embodiment, the removeable wear plate may be configured in shape, size and positioned to substantially overlay or encapsulate the backing plate. It is to be appreciated that the removeable wear plate may be configured in a variety of suitable ways (such as by way of shape, size and position) so as to protect the backing plate from damage, and that the embodiments shown and described herein are by way of non-limiting example only. The removeable wear plate may be constructed of a variety of different suitable materials. Non-limiting examples of suitable materials may include any one or more of:

[0072] Polyester: Polyester is a synthetic material known for its strength, durability, and resistance to stretching and shrinking. Polyester is known for its excellent strength - to-weight ratio and resistance to abrasion.

[0073] Polypropylene: Polypropylene is a synthetic thermoplastic polymer. It is lightweight, durable, and has good chemical resistance. [0074] Polyethylene: Polyethylene is a plastic and is known for its flexibility, toughness, and chemical resistance. Preferred forms of polyethylene may include high- density polyethylene (HDPE) and low-density polyethylene (LDPE).

[0075] Acrylic: Acrylic is a synthetic polymer known for its transparency, UV resistance, and weatherability.

[0076] Polyurethane: Polyurethane is a versatile material known for its excellent abrasion resistance and flexibility. Polyurethane has excellent durability and impact resistance.

[0077] Ethylene-vinyl acetate (EVA): EVA is a type of copolymer known for its flexibility, shock absorption, and low -temperature toughness. EVA is known for its flexibility and impact resistance properties.

[0078] Polycarbonate: Polycarbonate is a strong and impact-resistant thermoplastic often used in applications where high strength and transparency are required.

[0079] Polyethylene Terephthalate (PET): PET is a durable and lightweight plastic. PET has excellent durability and chemical resistance properties.

[0080] Melamine: Melamine is a type of hard plastic. It may be preferrable because it is lightweight and shatter-resistant.

[0081] Silicone: Silicone removeable wear plates are flexible and heat-resistant.

[0082] Polycarbonate: Polycarbonate removeable wear plates are durable, impactresistant, and can withstand high temperatures.

[0083] In one embodiment (not shown), the housing includes a first access port configured and positioned to optionally provide access to the inside of the housing. In one embodiment, the first access port is provided at the second opposing wall of the housing. In an alternate embodiment, the first access port is provided at the first wall of the housing. It is to be appreciated that the first access port may be provided at any suitable position with respect to the housing so as to facilitate controlled access to the inside of the housing, and that the embodiments shown and described herein are by way of non-limiting example only.

[0084] In one embodiment (not shown), a top side of the housing provides a second access port, the second access port being positioned and configured so as to optionally provide access to the first pair of rollers housed within the housing. In one embodiment (not shown), the top side of the housing provides a third access port, the third access port being configured and positioned so as to optionally provide access to the second pair of rollers housed within the housing. It is to be appreciated that the second access port and the third access port may be positioned with respect to the housing in a variety of suitable ways so as to optionally provide access to the first pair of rollers and the second pair of rollers, respectively, and that the embodiments shown and described herein are by way of non-limiting example only. For example, the second access port and/or the third access port may each be provided at a position adjacent the top side of the housing. The second access port and/or the third access port may advantageously provide means for inspecting each respective pair of rollers and/or to clear blockages from within the device.

[0085] In a preferred embodiment, the housing 18 may be configured to be substantially sealed from the external environment, such that particles and particulates of any size fraction created from the processing of the multilayer panel 20 is contained within the housing 18. This advantageously allows for the safe encapsulation of these particles and particulates, so that risk of inhalation of fine particles and risk of injury from contact with sharp particulates by workers is substantially reduced.

[0086] The housing 18 may be further configured with a receptacle, located at the base of the housing 18, for collecting the plurality of particles that are dislodged from the processing of the multilayer panel 20. The receptacle 56 is typically in the form of a tapered container or chamber to encourage the funnelling of the particles to a base of the receptacle 56 . In a preferred embodiment, the base of the receptacle 56 has a first conveyor, in the form of an auger, for conveying the plurality of particles to an external receptacle, such as a bulker bag or stillage. It is to be appreciated that the external receptacle may be connected to the base of the receptacle in a variety of suitable ways, so as to receive the plurality of particles, when in use. In one embodiment, the external receptacle may be positioned adjacent a bottom end of the first conveyor. In an alternate embodiment, a top of the external receptacle may be positioned adjacent the base of the housing such that the first conveyor is housed substantially within the housing or the external receptacle. It is to be appreciated that the external receptacle may be positioned relative to the base of the receptacle and the first conveyor in a variety of suitable ways so as to receive the plurality of particles that are produced from the processing of the multilayer panel, when in use, and that the embodiments shown and described herein are by way of non-limiting example only. In another embodiment, the base of the receptacle 56 may have a hatch or port for discharging the plurality of particles.

[0087] In one embodiment, a sieve including a mesh portion arranged in a sieve frame, may be positioned between the bottom of the first conveyor and the top of the external receptacle so as to receive and filter the plurality of particles into the external receptacle, when in use. It is to be appreciated that the sieve frame may be configured to be any suitable shape and size, and that the embodiments shown and described herein are by way of non-limiting example only. In one embodiment, the sieve is configured in shape and size such that the sieve frame substantially complements the shape and size of the bottom of the housing. In an alternate embodiment, the sieve is configured in shape and size such that the sieve frame is substantially larger than the bottom of the first conveyor such that, in use, the sieve captures or receives all of the plurality of particles that are produced from the processing of the multilayer panel, or a substantial amount thereof, when in use. For example, and without limitation, the sieve frame may have a quadrilateral shape, a substantially rectangular shape, a substantially square shape, a substantially triangular shape, or a substantially circular or rounded shape. [0088] In a preferred embodiment, the sieve includes a plurality mesh portions, wherein the plurality of mesh portions are, together, arranged in the sieve frame. In one embodiment, the plurality of mesh portions may be arranged in a stacked arrangement substantially within the sieve frame. In one embodiment, each mesh portion provides a plurality of different sized apertures. In an alternate embodiment, each mesh portion provides a plurality of apertures, wherein the size of each aperture within each mesh portion differs between each mesh portion.

[0089] In one embodiment, the sieve includes a first mesh portion and a second mesh portion, wherein each mesh portion provides a plurality of apertures. In one embodiment, the plurality of apertures provided by the first mesh portion are configured to be a different size with respect to the plurality of apertures provided by the second mesh portion. In one example, the first mesh portion and the second mesh portion are configured in a stacked arrangement within the sieve frame.

[0090] It is to be appreciated that the sieve may include any suitable number of mesh portions that may, together, be arranged within the sieve frame in any suitable way, such as three or more mesh portions, four or more mesh portions, five or more mesh portions, six or more mesh portions, or seven or more mesh portions, and that the embodiments shown and described herein are by way of non-limiting example only.

[0091] In use, the plurality of particles are conveyed from the first conveyor and into the sieve positioned adjacent the bottom of the bottom of the first conveyor. In a preferred embodiment, the sieve is a powered vibrating sieve. By way of example only, an electric or battery powered vibrating sieve may be used to separate the particles that are produced from the processing of the multilayer panel by size. This may be done in order to collect powders or fractions of specific particle sizes that may be resold or recycled into further processing, for example. Vibration sieve equipment can perform this task effectively because it maximises flow, including through screens and mesh.

[0092] In a preferred embodiment, the housing 18 may be configured with an extraction system (not shown) for extracting a plurality of fine particles from the internal atmosphere of the housing 18. The extraction system may be in the form of a suction system with a fines receptacle for collecting any extract fine particles. In a preferred embodiment, the extraction system is configured to provide a vacuum suction extraction system. This advantageously allows for the safe removal of fine particulates that are difficult to retrieve and may cause respiratory health issues to workers that do not have adequate respiratory protection. Further, the collected fine particulates may be advantageously recycled or reused for manufacturing purposes. It is to be appreciated that the extraction system may be configured and positioned with respect to the housing in a variety of suitable ways, and that the embodiments shown and described herein are by way of non-limiting example only. In one embodiment, the extraction system may be in fluid communication with the housing so as to receive or extract the plurality of fine particles from the internal atmosphere of the housing, when in use. In one embodiment, a first end of a connector connects to the housing and a second end of the connector connects to the extraction system, such that the connector facilitates the fluid communication between the housing and the extraction system. In a preferred embodiment, the connector is a hose. In one embodiment, the extraction system is in fluid communication with the housing at a position adjacent the base of the housing. It is to be appreciated that the extraction system may be connected to the housing in a variety of suitable ways so as to facilitate the extraction of the plurality of fine particles from the internal atmosphere of the housing, and that the embodiments shown and described herein are by way of non-limiting example only.

[0093] The device, or any part of the device thereof, may be made of plastic, reinforced plastic, metal inserts (reinforced) plastic, carbon fibre or reinforced nylon. It may be advantageous to make the device from a material such as carbon steel, mild steel, or tool steel which is heat treatable and can go through the hardening process. This may be advantageous in providing a device which is durable and fit for use in a work environment where devices, such as the device of the present disclosure, are used extensively and may not be stored or handled with delicacy or care.

[0094] In a preferred embodiment, a table may be provided, wherein the table is configured and adapted to assist feeding of the multilayer panel into the first opening of the housing, when in use. The table may have a height that substantially corresponds to the height of the first opening of the housing and/or the height of the second opening of the housing. The table may be configured and positioned such that the table top is adjacent the first opening of the housing so as to support the bottom side of multilayer panel as the first opening of the housing receives the multilayer panel, when in use. The table may be configured and positioned such that the table top is adjacent the second opening of the housing so as to support the bottom side of the multilayer panel as the multilayer panel is processed and passes through the second opening of the housing, when in use. In an alternate embodiment, a second conveyor may be provided, wherein the second conveyor is configured and adapted to assist feeding of the multilayer panel into the first opening of the housing, when in use.

Method of Removing an External Layer from a Multilayer Panel

[0095] A method of removing the external layer 54 from the multilayer panel 20 initially comprises feeding through the first opening 28 in the housing 18 the multilayer panel 20 with the external layer 54 facing downwards for processing by the plurality of impact members 16a, 16b. As the multilayer panel 20 is fed through the first opening 28, the first set of rollers 34 conveys the panel 20 along a conveying path towards the second set of rollers 32 and the second opening 24 . As the multilayer panel 20 is conveyed, the rotating driving shaft 14, coupled to the plurality of impact members 16a, 16b and is located substantially midway along and below the conveying path, causes the plurality of impact members 16a, 16b to impact against the external layer 54 of the panel 20. This causes the external layer 54 to fracture and form a plurality of particulates that are dislodged from the multilayer panel 20 and fall.

[0096] In an embodiment, the plurality of particulates are collected in the receptacle 56 located below the conveying path prior to conveying the plurality of particulates from the receptacle 56 to an external receptacle.

[0097] In another embodiment, the plurality of fine particulates that are suspended in the atmosphere of the housing 18 is collecting using an exhaust system. [0098] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

1. A layer removal device for a multilayer panel, comprising: a conveying unit comprising: a first pair of rollers; and a second pair of rollers; wherein each pair of rollers are configured to convey the multilayer panel along a conveying path; a driving shaft located substantially midway along and below the conveying path; and a plurality of impact members coupled to the driving shaft; wherein rotation of the driving shaft causes the plurality of impact members to impact against an external layer of the multilayer panel, as it is conveyed along the conveying path, causing the external layer to fracture and form a plurality of particulates that are dislodged from the multilayer panel.

2. A layer removal device according to claim 1, wherein the first pair of rollers rotates at a faster speed than the second pair of rollers.

3. A layer removal device according to any one of the preceding claims, further comprising a backing plate, located above the conveying path, wherein the backing plate is configured to support the multilayer panel while undergoing impact by the plurality of impact members.

4. A layer removal device according to claim 3, wherein the backing plate is configured with a removable wear plate.

5. A layer removal device according to any one of the preceding claims, wherein the driving shaft is configured to move perpendicularly towards or away from the conveying path.

6. A layer removal device according to any one of the preceding claims, wherein the driving shaft is configured to laterally reciprocate during rotation.

7. A layer removal device according to any one of the preceding claims, wherein the plurality of impact members are configured as bars or blades.

8. A layer removal device according to any one of the preceding claims, wherein the plurality of impact members are formed from tungsten carbide.

9. A layer removal device according to any one of the preceding claims, further comprising: a housing with a first opening located in a first wall, and a second opening located directly opposite the first opening in an opposing wall; wherein the first opening is configured to receive and direct the multilayer panel to the first pair of rollers, and the second opening is configured to receive the multilayer panel from the second pair of rollers and discharge it from the housing.

10. A layer removal device according to claim 9, wherein the housing is configured to be substantially sealed from the external environment.

11. A layer removal device according to either claim 9 or 10, further comprising a receptacle located in the housing for collecting the plurality of particulates.

12. A layer removal device according to claim 11, wherein the receptacle has a conveyor for dispensing the plurality of particulates to an external receptacle.

13. A layer removal device according to claim 12, wherein the conveyor is an auger.

14. A layer removal device according to any one of claims 9 to 13, further comprising an extraction system, located in the housing, configured to extract a plurality of fine particles from the housing.

15. A layer removal device according to claim 14, where in the extraction system further comprises a fines receptacle for storing the extracted fine particles.

16. A layer removal device according to any one of the preceding claims, wherein the multilayer panel is a solar panel and the external layer is glass.

17. A method of removing an external layer from a multilayer panel, comprising: conveying, using a first pair of rollers and a second pair of rollers, the multilayer panel along a conveying path; rotating, using a driving shaft, a plurality of impact members located substantially midway along and below the conveying path; wherein the rotation of the driving shaft causes the plurality of impact members to impact against the external layer of the multilayer panel, as it is being conveyed along the conveying path, causing the external layer to fracture and form a plurality of particulates that are dislodged from the multilayer panel.

18. A method according to claim 17, wherein the conveying path is located within a housing.

19. A method according to claim 18, further comprising collecting the plurality of particulates in a receptacle located below the conveying path.

20. A method according to either claim 18 or 19, further comprising collecting a plurality of fine particulates using an exhaust system.