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

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 V OC and I SC . 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.