WO2011103683A1 - Crucible and method for furnace capacity utilization - Google Patents
Crucible and method for furnace capacity utilization Download PDFInfo
- Publication number
- WO2011103683A1 WO2011103683A1 PCT/CA2011/050111 CA2011050111W WO2011103683A1 WO 2011103683 A1 WO2011103683 A1 WO 2011103683A1 CA 2011050111 W CA2011050111 W CA 2011050111W WO 2011103683 A1 WO2011103683 A1 WO 2011103683A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- crucible
- sides
- blocks
- ingot
- furnace
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims description 43
- 238000004519 manufacturing process Methods 0.000 claims abstract description 19
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 13
- 229910052710 silicon Inorganic materials 0.000 claims description 13
- 239000010703 silicon Substances 0.000 claims description 13
- 238000005520 cutting process Methods 0.000 claims description 12
- 229910002804 graphite Inorganic materials 0.000 claims description 12
- 239000010439 graphite Substances 0.000 claims description 12
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 239000010453 quartz Substances 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 239000000463 material Substances 0.000 description 38
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 12
- 238000005259 measurement Methods 0.000 description 10
- 238000010438 heat treatment Methods 0.000 description 7
- 239000012768 molten material Substances 0.000 description 7
- 238000000576 coating method Methods 0.000 description 6
- 238000012986 modification Methods 0.000 description 6
- 230000004048 modification Effects 0.000 description 6
- 238000005266 casting Methods 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000000470 constituent Substances 0.000 description 3
- 238000011109 contamination Methods 0.000 description 3
- 238000002425 crystallisation Methods 0.000 description 3
- 230000008025 crystallization Effects 0.000 description 3
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 3
- 229910010271 silicon carbide Inorganic materials 0.000 description 3
- 239000011343 solid material Substances 0.000 description 3
- 238000007711 solidification Methods 0.000 description 3
- 230000008023 solidification Effects 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 235000012431 wafers Nutrition 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 239000000356 contaminant Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 239000012809 cooling fluid Substances 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 229910003460 diamond Inorganic materials 0.000 description 2
- 239000010432 diamond Substances 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 239000003082 abrasive agent Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 239000002178 crystalline material Substances 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 238000009658 destructive testing Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000013507 mapping Methods 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 238000009659 non-destructive testing Methods 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 230000006798 recombination Effects 0.000 description 1
- 238000005215 recombination Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 230000002123 temporal effect Effects 0.000 description 1
- 230000036346 tooth eruption Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B14/00—Crucible or pot furnaces
- F27B14/08—Details peculiar to crucible or pot furnaces
- F27B14/10—Crucibles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D7/00—Casting ingots, e.g. from ferrous metals
- B22D7/06—Ingot moulds or their manufacture
- B22D7/066—Manufacturing, repairing or reinforcing ingot moulds
- B22D7/068—Manufacturing, repairing or reinforcing ingot moulds characterised by the materials used therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D7/00—Casting ingots, e.g. from ferrous metals
- B22D7/06—Ingot moulds or their manufacture
- B22D7/08—Divided ingot moulds
-
- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B11/00—Single-crystal growth by normal freezing or freezing under temperature gradient, e.g. Bridgman-Stockbarger method
- C30B11/002—Crucibles or containers for supporting the melt
-
- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B29/00—Single crystals or homogeneous polycrystalline material with defined structure characterised by the material or by their shape
- C30B29/02—Elements
- C30B29/06—Silicon
-
- C—CHEMISTRY; METALLURGY
- C30—CRYSTAL GROWTH
- C30B—SINGLE-CRYSTAL GROWTH; UNIDIRECTIONAL SOLIDIFICATION OF EUTECTIC MATERIAL OR UNIDIRECTIONAL DEMIXING OF EUTECTOID MATERIAL; REFINING BY ZONE-MELTING OF MATERIAL; PRODUCTION OF A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; SINGLE CRYSTALS OR HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; AFTER-TREATMENT OF SINGLE CRYSTALS OR A HOMOGENEOUS POLYCRYSTALLINE MATERIAL WITH DEFINED STRUCTURE; APPARATUS THEREFOR
- C30B30/00—Production of single crystals or homogeneous polycrystalline material with defined structure characterised by the action of electric or magnetic fields, wave energy or other specific physical conditions
Definitions
- the solidification or crystallization of some materials from their liquid states can sometimes produce a solid with more consistent structural qualities when performed in the absence of certain gasses or other foreign materials that can contaminate or react with the material.
- the material in contact with or nearest a crucible can be contaminated from the crucible or from the coatings of the crucible as it solidifies; this impure material may be trimmed off the solid material after solidification is complete.
- the surface area of the material that is exposed to air or the crucible or other contaminants during the process can be minimized, therefore material wasted by trimming off material made impure by contamination can be minimized.
- the last-to-freeze material often has the highest contaminant concentration can be located at the surfaces of a solidified material, and often these surfaces are also trimmed off a solidified material before use.
- this wasted material is minimized by using larger shapes.
- Advantages of larger scale have encouraged the use of larger furnaces and larger crucibles for formation of ingots from molten materials, especially where the intended use for the resulting ingots requires high-quality ingots.
- a current standard is 6" x 6" ( 156 mm x 156 mm) blocks or wafers, which are cut from an ingot after casting.
- 16 blocks are made in a 4 x 4 grid (see Table 1 ).
- the corner blocks and side blocks tend to result in lower quality solar cells.
- the 4 x 4 grid produces 4 corner blocks, 8 side blocks, and 4 center blocks.
- a 5 x 5 grid is used and 25 blocks are produced (see Table 1 ). This produces 4 corner blocks, 12 side blocks, and 9 center blocks.
- a larger crucible produces more center blocks and less corner and side blocks of a given size as a ratio of the number of blocks per crucible, see for example Table 1.
- the height to width ratio of the crucible can be maintained by also increasing the length and width, but not by just increasing the height alone.
- Making a taller crucible without increasing the length and width to increase weight of silicon per batch can make a lower quality ingot since it gets harder and harder as the height grows to maintain the temperature gradient from the bottom to the top of the ingot.
- FIG. 1 shows a top- view of a 32 block 156 mm x 156 mm crucible according to an embodiment of the present invention.
- FIG. 2 shows top- view of a 32 block 156 mm x 156 mm ingot in a crucible according to a specific embodiment of the present invention.
- FIG. 3 shows a side-view of the crucible 100 according to a specific embodiment of the present invention.
- the present invention provides a crucible and method of using the same for efficient furnace capacity utilization in the production of an ingot.
- the crucible includes an interior for the production of an ingot.
- the crucible also includes an exterior shape that approximately matches the interior shape of the furnace in which the ingot is produced.
- Embodiments of the invention can provide an ingot that gives a batch of blocks of overall higher quality.
- the crucible and method can also produce more blocks in a single batch of blocks in a given furnace than similar crucibles and methods.
- the ingot can be a silicon ingot, and if used to make solar cells, the blocks derived from the ingot can produce more efficient solar cells.
- the present invention provides a crucible that includes an interior for the production of an ingot.
- the crucible includes an exterior shape approximately matching the interior shape of a furnace in which the ingot is produced.
- the ingot also includes a multiplicity of blocks. Additionally, the multiplicity of blocks are arranged in a grid.
- the exterior shape of the crucible matching the interior shape of the furnace can allow for the generation of a larger number of blocks than the number of blocks that could be generated from the furnace using a crucible with a square shape.
- the interior shape of the furnace has an approximately round shape.
- the crucible also has an exterior perimeter that includes approximately eight sides. Additionally, the eight sides of the crucible include two sets of approximately opposing longer sides of approximately equal length. In addition, the eight sides of the crucible can also include two sets of approximately opposing shorter sides of approximately equal length. Additionally the eight sides of the crucible are such that the longer sides of the crucible alternate with the shorter sides of the crucible.
- the present invention provides a method for furnace capacity utilization.
- the method includes creating an ingot using a crucible.
- the crucible includes an interior.
- the interior of the crucible is for the production of an ingot.
- the crucible also includes an exterior shape.
- the exterior shape of the crucible approximately matches the interior shape of a furnace in which the ingot is produced.
- step A is carried out first
- step E is carried out last
- steps B, C, and D can be carried out in any sequence between steps A and E, and that the sequence still falls within the literal scope of the claimed process.
- a given step or sub-set of steps can also be repeated.
- specified steps can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed step of doing X and a claimed step of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.
- Embodiments of the invention relate to a crucible and method for efficient furnace capacity utilization in the production of an ingot.
- the crucible can include an interior for the production of an ingot.
- the crucible can include an exterior shape that approximately matches the interior shape of the furnace in which the ingot is produced.
- the method provides the use of the crucible for the production of an ingot.
- the method also provides the use of a crucible with an exterior shape that approximately matches the interior shape of a furnace in which an ingot is produced.
- the method provides the production of blocks from the ingot using a cutting device.
- the ingot can be cut into blocks using a wire saw, band saw, circular saw or other cutting methods.
- the ingot can be silicon.
- the apparatus and method of the present invention can make more efficient use of furnace capacity than other apparatus and methods.
- the crucible and method of the present invention can produce more blocks in a single batch of blocks.
- the purchasing of a larger furnace can be avoided.
- Crucibles and methods according to the present invention can also produce a batch of blocks with a smaller proportion of corner blocks. Since corner blocks, cut from the corner of an ingot, can be of lower quality, the invention can provide a batch of ingots of overall higher quality.
- Crucibles and methods according to the present invention can achieve improved throughput of high-quality material.
- the solar cells can overall have improved cell efficiency.
- block refers to a piece of an ingot that can be any shape. Generally, a block is square shaped.
- side block refers to a block that shares one side with the perimeter of an ingot.
- center block refers to a block that does not share a side with the perimeter of an ingot.
- corner block refers to a block that shares two sides with the perimeter of an ingot.
- coating refers to a layer of material that covers at least part of another material, wherein the layer can be as thick, thicker, or thinner than the material that it covers.
- counter-sunk refers to a manner of installing a screw, bolt, or similar hardware wherein a secondary conical or semi-conical hole of wider circumference is made closer to the surface of a material approximately above a primary cylindrical hole of a particular circumference in that material, such that the hardware does not protrude above the surface in which it is installed, or such that the hardware protrudes less above the surface in which it is installed than if there was not a secondary hole.
- counter-bored refers to a manner of installing a screw, bolt, or similar hardware wherein a secondary cylindrical hole of wider circumference is made closer to the surface of a material approximately above a primary cylindrical hole of a particular circumference in that material, such that the hardware does not protrude above the surface in which it is installed, or such that the hardware protrudes less above the surface in which it is installed than if there was not a secondary hole.
- crucible refers to a container that can hold molten material, that can hold material as it is melted to become molten, and that can hold molten material as it solidifies or crystallizes or a combination thereof.
- curve refers to a surface that is approximately curved, or following an approximate arc shape, and need not be completely curved. In approximating whether a surface is curved, the average is considered, such that a surface that in some parts (including one part), several parts, or in all parts follows a straight line or lines can be a curved surface if overall the surface follows an approximate arc.
- grid refers to at least two blocks, the pattern of the edges of the blocks forming generally a pattern of regularly spaced horizontal and vertical lines.
- ingot refers to a block of solid or crystalline material or materials, or a combination thereof.
- internal angle refers to the angle formed between two surfaces that is the smaller angle of the two angles.
- flat side refers to a side that is approximately straight, is minimally curved overall, and need not be completely flat. In approximating straightness, the average is considered, such that a side that curves slightly back and forth several times can be a flat side if overall the side follows an approximately straight line.
- furnace refers to a machine, device, apparatus, or other structure that has a compartment for heating a material.
- Furnace capacity refers to the volume of a compartment of a furnace.
- octagonal refers to a shape or object having eight sides.
- peripheral refers to the outer edge of an object or shape.
- round refers to a shape that does not have sharp corners, for example a shape that does not have 90 degree corners.
- a round shape can be circular or oblong.
- a round shape can include a square shape with the edges rounded-off.
- FIG. 1 a top- view of crucible 100 is shown, according to some embodiments.
- the crucible 100 includes an interior 102 for the production of an ingot.
- FIG. 2 a top- view of an ingot 200 in crucible 100 is shown.
- the ingot 200 can include portions of the perimeter 201 that are trimmed off after the molten material goes through solidification, crystallization, or a combination thereof.
- the ingot 200 includes a multiplicity of blocks 202.
- the blocks 202 can be formed from ingot 200 using a cutting device.
- the ingot can include silicon.
- the molten material can include molten silicon.
- the blocks 202 are arranged within the ingot 200 in a grid.
- the exterior shape of crucible 100 approximately matches the interior shape of a furnace in which ingots are produced, which can be a furnace with an interior compartment with an approximately round shape.
- crucible 100 can fit a larger quantity of molten material in the furnace, thus can more efficiently utilize the capacity of the furnace.
- the crucible 100 can generate an ingot 200 that give a larger number of blocks 202 than the number of blocks that can be generated from the furnace using a crucible with a square shape.
- ingot 200 When compared to a grid in an ingot from a square-shaped crucible, in ingot 200 the percentage of side or center blocks relative to the percentage of corner blocks can be greater, and the percentage of side blocks relative the to percentage of center blocks can be increased. See table 2. When compared to a square-shaped crucible, the percentage of corner blocks in ingot 200 from crucible 100 has been reduced.
- the crucible of the present invention includes blocks.
- the blocks are joined together in the ingot that results from the crucible; therefore, the ingot includes blocks. They become separate blocks by being cut apart from one another after the casting process is complete.
- the blocks can be cut in a grid pattern.
- the cutting can be done by any suitable cutting device known to those in the art.
- An example of a suitable cutting device is a saw that uses abrasive material, such as diamond, or cutting teeth, attached to a band that turns in a continuous loop.
- the cutting may include cooling with water to prevent overheating of the blade.
- Another example of a suitable cutting device is a wire saw which uses steel wire with cooling fluid and SiC grit or steel wire coated with diamond grit and a cooling fluid.
- the causes of the inferior quality of an ingot can include the proximity of the solidified or crystallized material to the walls of the crucible.
- the crucible can be coated with or include a material that prevents the material from sticking to the crucible, allowing for easy removal of the solid. While helpful to prevent sticking, the coating or constituent of the crucible can diffuse into the molten material, affecting the purity of the solid material closest to the walls of the crucible. Therefore, when less of an ingot contacts the walls of the crucible, less material is contaminated by diffusion from a constituent or coating of the crucible.
- the top surface of the silicon in the crucible in the corners can solidify last, and last-to-freeze material in a crystallization can contain the highest levels of impurities.
- the last-to-freeze portions of an ingot can be removed prior to use, e.g. with a cutting device, prior to use of the ingot.
- the present invention includes ingots that have less corners, such that they include less blocks that share two edges with the perimeter of the crucible. The present invention can thus produce a smaller percentage of lower quality product and can result in less waste or in less recycled silicon.
- the crucible 100 includes a perimeter which includes eight sides, 104 and 106.
- the eight sides include two sets of approximately opposing first sides 104 which are of approximately equal length.
- the eight sides also include two sets of approximately opposing second sides 106 which are of approximately equal length.
- the eight sides of crucible 100 correspond to eight sides of the ingot 200 that is formed from the crucible 100, including first sides 204 and second sides 206.
- the first sides 104 and the second sides 106 are approximately flat.
- the first sides 104 are longer than the second sides 106.
- the first sides 104 alternate with the second sides 106.
- the height of crucible 100 can be 2-20 cm taller than other crucibles, which can allow, for example, the same amount of silicon as a 36- block 750 kg square crucible could hold .
- the height of the crucible can be made taller so that, e.g., lower density material such as lower density silicon can be used economically, such that that more material can be loaded into the crucible.
- the first sides 204 can be
- the second sides 206 can be approximately 1 1.14 inches.
- the dimensions of the blocks 202 can be 6.00 inches x 6.00 inches.
- the thickness of the sides of the crucible can be 0.67 inches.
- the thickness of the material removed from the sides of the ingot 200 can be 1 .88 inches.
- FIG. 3 a side view of the crucible 100 in a specific embodiment is shown.
- the width of the crucible 308 can be 41.00 inches.
- the height of the crucible 306 can be 18.00 inches.
- the sides 302 can be 0.67 inches thick.
- the crucible can have a bottom 304.
- the crucible can include first sides and second sides that are approximately the same length.
- the crucible can include first sides that are curved, or that include curves, and the crucible can independently include second sides that are curved, or that include curves. Therefore, the crucible can include first sides that are curved, and second sides that are approximately straight; the crucible can also include second sides that are curved, and first sides that are approximately straight.
- the curve of a side can include multiple approximately flat surfaces that taken together form an arc shape, or that form more than one arc.
- the curve of a side can include one single curve.
- the curve of a side can include multiple curved surfaces that taken together form an arc shape, or that form more than one arc.
- the design can include a furnace that has four crucibles in it and only one corner in each crucible is reduced in area.
- the crucible of the present invention can be made from or include silica, SiC, quartz, graphite, S1 3 N4, or a combination thereof.
- the choice of constituents or coatings can include, for example, non-sticking properties, as well as heating resistant properties.
- the crucible can include a coating that contains S1 3 N4, graphite, or S1O2 which can coat the crucible partially, completely, or to any degree in-between.
- the crucible can include internal angles between sides included in the perimeter of approximately 1 10- 160 degrees.
- the crucible can include internal angles between sides included in the perimeter of approximately 125- 145 degrees.
- the crucible can also include outer or inner corners and edges that are curved.
- the present invention provides a method of using a crucible with an interior shape for the production of ingots, including the crucible as described above, wherein the exterior shape of the crucible approximately matches the interior shape of a furnace in which ingots are produced.
- the interior shape of the furnace can be approximately round.
- the interior shape of the furnace can be modified to fit the crucible.
- the dimensions of the crucible are such that the method can generate 32 156 mm x 156 mm blocks from a 25 block 156 mm x 156 mm 450 kg furnace. In another embodiment, the dimensions are such that that the method can generate 21 180 mm x 180 mm blocks from a 25 block 450 kg ingot furnace.
- the present invention can provide a method for improving the throughput of high-quality material.
- the present invention can provide a method for efficient and cost-effective quality control of the resulting ingots.
- the extra 4 half-blocks 203 can be used for destructive and nondestructive testing to improve quality and speed up throughput time of wafer manufacturing. Measuring only 4 corner blocks 203, rather than all the blocks 202, can save time and related costs, including: saving measurement time, saving time needed for block cleaning after conducting measurements, and saving time needed for block cleaning before conducting block cutting post measurements. This can help to achieve higher throughput while maintaining necessary material quality.
- Measurement a) can give reliable information about the growth front of the total ingot if specific growth characteristics of individual casting tools are known (this can be determined for every casting tool).
- Subsequent wafering can be based on information about the growth front.
- Measurement b) can allow measurement of the lifetime as a function of the distance from the crucible walls which, in turn, can give some guidance on potential measures to be initiated for material quality improvement in the wafer level.
- Measurement c) can give orientation information about the ingot.
- the modification of the furnace to fit the crucible can be any suitable modification known to those skilled in the art.
- the modification can include making the bolts, washers, or plates of a box that holds or surrounds the ceramic crucible thinner.
- the box holding the crucible can be made from graphite plates.
- the modification can also include counter-sinking or counter- boring into the graphite plate a nut that is part of the box, or otherwise reducing the profile of hardware that holds the box together. Joints between the graphite plates can be dadoed, mortised, or dovetailed. A bottom graphite plate that holds the crucible can be enlarged.
- a stainless steel cage for holding the movable elements can be made octagonal with diagonals added to the corners or the size of the diagonals can be enlarged.
- the insulation of a cage can be made thinner.
- the heating elements can be moved closer to a wall of the furnace or the heater cage.
- the graphite nuts holding heating elements together can be counter-sunk or counter-bored.
- Angled graphite washers can be used on the diagonal support plates to maintain a flat surface or custom shapes can be used to maintain flat section to fasten the graphite plates together. Corner extensions can be added to a corner piece of the heating element to move the heating elements out on all sides, including moving the heating elements out 3" on all sides.
- a lip for sealing the bottom of the cage can be made smaller.
- the modification could also include lowering the stand that holds the crucible to allow for a taller crucible.
- the legs that support the crucible stand can be upgraded to support the extra weight by adding another leg, moving the legs further apart or threaded into a thicker cooling plate.
- Other insulating materials can be used for the insulating steel cage other than rigidized graphite felt so that the section can be made thinner. Two insulation materials can be used with one material used away from the hot face in a two layer design. The second insulating material would have better insulating properties so that a thinner cross section can be used for the cage.
- Embodiment 1 provides a crucible including: an interior for the production of an ingot; and, an exterior shape approximately matching the interior shape of a furnace in which the ingot is produced.
- Embodiment 2 provides the crucible of embodiment 1 , wherein the ingot includes a multiplicity of blocks.
- Embodiment 3 provides the crucible of embodiment 2, wherein the blocks include a grid.
- Embodiment 4 provides the crucible of any one of embodiments
- Embodiment 5 provides the crucible of any one of embodiments
- Embodiment 6 provides the crucible of any one of embodiments
- the perimeter of the crucible includes approximately eight major sides, wherein the eight sides include two sets of approximately opposing first sides of approximately equal length, and two sets of approximately opposing second sides of approximately equal length, wherein the first sides alternate with the second sides.
- Embodiment 7 provides the crucible of embodiment 6, wherein the first sides are longer than the second sides.
- Embodiment 8 provides the crucible of any one of embodiments
- Embodiment 9 provides the crucible of any one of embodiments
- first sides include approximately flat sides.
- Embodiment 10 provides the crucible of any one of embodiments
- Embodiment 1 1 provides the crucible of any one of embodiments 6- 10, wherein the first sides include curved sides.
- Embodiment 12 provides the crucible of any one of embodiments
- Embodiment 13 provides the crucible of any one of embodiments
- the blocks include a grid, wherein compared to a grid in a square- shaped crucible, the percentage of side or center blocks relative to the percentage of corner blocks is increased.
- Embodiment 14 provides the crucible of any one of embodiments
- Embodiment 15 provides a method for furnace capacity utilization, including, use of the crucible of any one of embodiments 1 - 14 to create an ingot.
- Embodiment 16 provides the method of embodiment 15, further including the use of a cutting device to cut the ingot into the blocks.
- Embodiment 17 provides the method of embodiment 16, wherein
- 32 156 mm x 156 mm blocks are generated from a 25 block 450 kg ingot furnace.
- Embodiment 18 provides the method of embodiment 16, wherein
- 21 180 mm x 180 mm blocks are generated from a 25 block 250 kg ingot furnace.
- Embodiment 1 provides the method of any one of embodiments
- the furnace includes a furnace modified to fit the crucible.
- Embodiment 20 provides the method of any one of embodiments
- Embodiment 21 provides the method of any one of embodiments
- Embodiment 22 provides a crucible including: an interior for the production of an ingot; an exterior shape approximately matching the interior shape of a furnace in which the ingot is produced; wherein the ingot includes a multiplicity of blocks; wherein the multiplicity of blocks include a grid; wherein the exterior shape matching the interior shape of the furnace allows the generation of a larger number of blocks than the number of blocks that can be generated from the furnace using a crucible with a square shape; wherein the interior shape of the furnace includes an approximately round shape; and, wherein the perimeter of the crucible includes approximately eight major sides, wherein the eight sides include two sets of approximately opposing longer sides of approximately equal length, and two sets of approximately opposing shorter sides of approximately equal length, wherein the longer sides alternate with the shorter sides.
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Crystallography & Structural Chemistry (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- General Engineering & Computer Science (AREA)
- Crystals, And After-Treatments Of Crystals (AREA)
- Silicon Compounds (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Crucibles And Fluidized-Bed Furnaces (AREA)
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP11746802.5A EP2539659A4 (en) | 2010-02-26 | 2011-02-25 | Crucible and method for furnace capacity utilization |
BR112012021539A BR112012021539A8 (en) | 2010-02-26 | 2011-02-25 | crucible and method for using oven capacity |
JP2012554180A JP5678103B2 (en) | 2010-02-26 | 2011-02-25 | Crucible and method of using furnace capacity |
CN2011800103144A CN102869940A (en) | 2010-02-26 | 2011-02-25 | Crucible and method for furnace capacity utilization |
KR1020127024902A KR101416081B1 (en) | 2010-02-26 | 2011-02-25 | Crucible and method for furnace capacity utilization |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US30881710P | 2010-02-26 | 2010-02-26 | |
US61/308,817 | 2010-02-26 | ||
US12/716,889 US20110210470A1 (en) | 2010-02-26 | 2010-03-03 | Crucible and method for furnace capacity utilization |
US12/716,889 | 2010-03-03 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2011103683A1 true WO2011103683A1 (en) | 2011-09-01 |
Family
ID=44504867
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/CA2011/050111 WO2011103683A1 (en) | 2010-02-26 | 2011-02-25 | Crucible and method for furnace capacity utilization |
Country Status (8)
Country | Link |
---|---|
US (1) | US20110210470A1 (en) |
EP (1) | EP2539659A4 (en) |
JP (1) | JP5678103B2 (en) |
KR (1) | KR101416081B1 (en) |
CN (1) | CN102869940A (en) |
BR (1) | BR112012021539A8 (en) |
TW (1) | TWI444581B (en) |
WO (1) | WO2011103683A1 (en) |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102010048602A1 (en) * | 2010-10-15 | 2012-04-19 | Centrotherm Sitec Gmbh | Crucible for silicon, crucible arrangement and separation unit for a crucible |
US20130192516A1 (en) * | 2012-01-27 | 2013-08-01 | Memc Singapore Pte. Ltd. (Uen200614794D) | Method of preparing cast silicon by directional solidification |
KR101461163B1 (en) * | 2013-03-19 | 2014-11-13 | 소스트 주식회사 | Rectangular block type ingot growth device |
CN106702485A (en) * | 2017-03-14 | 2017-05-24 | 晶科能源有限公司 | Polycrystal ingot furnace |
DE102020102483A1 (en) * | 2020-01-31 | 2021-08-05 | Kennametal Inc. | Evaporation boat |
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US5980629A (en) * | 1995-06-14 | 1999-11-09 | Memc Electronic Materials, Inc. | Methods for improving zero dislocation yield of single crystals |
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JP3206540B2 (en) * | 1998-02-26 | 2001-09-10 | 三菱マテリアル株式会社 | Laminated crucible for producing silicon ingot and method for producing the same |
WO2002040732A1 (en) * | 2000-11-15 | 2002-05-23 | G.T. Equipment Technologies Inc. | A protective layer for quartz crucibles used for silicon crystallization |
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-
2010
- 2010-03-03 US US12/716,889 patent/US20110210470A1/en not_active Abandoned
-
2011
- 2011-02-24 TW TW100106219A patent/TWI444581B/en not_active IP Right Cessation
- 2011-02-25 BR BR112012021539A patent/BR112012021539A8/en not_active IP Right Cessation
- 2011-02-25 WO PCT/CA2011/050111 patent/WO2011103683A1/en active Application Filing
- 2011-02-25 CN CN2011800103144A patent/CN102869940A/en active Pending
- 2011-02-25 KR KR1020127024902A patent/KR101416081B1/en not_active IP Right Cessation
- 2011-02-25 JP JP2012554180A patent/JP5678103B2/en not_active Expired - Fee Related
- 2011-02-25 EP EP11746802.5A patent/EP2539659A4/en not_active Withdrawn
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US3351334A (en) * | 1965-03-01 | 1967-11-07 | Gen Electric | Container for molten fused silica |
Also Published As
Publication number | Publication date |
---|---|
TWI444581B (en) | 2014-07-11 |
CN102869940A (en) | 2013-01-09 |
EP2539659A1 (en) | 2013-01-02 |
EP2539659A4 (en) | 2015-04-15 |
US20110210470A1 (en) | 2011-09-01 |
TW201144732A (en) | 2011-12-16 |
BR112012021539A8 (en) | 2018-08-28 |
KR20120134130A (en) | 2012-12-11 |
BR112012021539A2 (en) | 2017-02-07 |
JP5678103B2 (en) | 2015-02-25 |
JP2013520384A (en) | 2013-06-06 |
KR101416081B1 (en) | 2014-07-07 |
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