Manufacturing method of ceramic insertion frame
By using alumina powder as the main material, and through molding, dry pressing, and multiple sintering to manufacture ceramic inserts, the problem of easy corrosion of quartz carriers has been solved, resulting in ceramic inserts with good acid corrosion resistance and reducing the production cost of solar cells.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-30
- Publication Date
- 2026-03-31
AI Technical Summary
The quartz carriers used in existing solar cell production are easily corroded in hydrofluoric acid environment, resulting in a short service life and increased production costs. In addition, the various shapes of ceramic socket parts make manufacturing difficult.
Using alumina powder as the main material, ceramic inserts are manufactured through steps such as molding, dry pressing, isostatic pressing, and multiple sintering. The inserts include dry-pressed upper and lower support plates, isostatically pressed support rods and ears, which are connected using ceramic slurry and then sintered twice to improve corrosion resistance and connection strength.
The resulting ceramic socket has good acid corrosion resistance and a service life extended to 8-10 months, reducing the production cost of solar cells, and the manufacturing process is relatively simple.
Smart Images
Figure CN121758153A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of solar cell manufacturing, and particularly to a method for manufacturing a ceramic socket and the ceramic socket itself. Background Technology
[0002] Currently, existing solar cell production processes use quartz carriers. However, during the process, the solar cells need to pass through hydrofluoric acid, and the quartz carriers will gradually corrode in the hydrofluoric acid environment, resulting in a very short lifespan of only 2-4 months, leading to high production costs for the solar cells. Ceramic sockets, on the other hand, have a structure... Figure 1 As shown, its components include an upper support plate 1 and a lower support plate 2. At least one pair of support rods 3 are provided between the upper support plate 1 and the lower support plate 2. Multiple teeth are longitudinally distributed on the support rods 3. Ears 4 are provided at the upper part between the two pairs of support rods 3, and lower support rods 5 are provided at the lower part between the two pairs of support rods. The different shapes of each component make it impossible to mold the ceramic holder in one piece, which is difficult to manufacture. Summary of the Invention
[0003] The technical problem to be solved by the present invention is to provide a method for manufacturing a ceramic insert, which is simple in steps and produces a ceramic insert that can replace the existing quartz carrier, has corrosion resistance, and can reduce the production cost of solar cells.
[0004] The technical solution adopted by this invention to solve its technical problem includes a method for manufacturing a ceramic insert. The ceramic insert comprises an upper support plate, a lower support plate, a support rod, ears, and a lower support rod, specifically including the following steps: Ceramic powder is placed in a mold and pressed to obtain a ceramic blank of the part; The ceramic blank is degreased and sintered; The sintered ceramic blank is ground, processed, and cleaned to obtain the part. Apply ceramic slurry to the joints of the parts and assemble the parts according to the drawings; The assembled ceramic insert is then subjected to secondary sintering.
[0005] Furthermore, this embodiment of the invention also discloses that the upper support plate and the lower support plate are formed by dry pressing, using a special tungsten steel mold, and formed under the action of a press with a pressure condition of 490-610 tons.
[0006] Furthermore, embodiments of the present invention also disclose that the support rod, ear, and lower support rod are pressed using isostatic pressing.
[0007] Furthermore, the embodiments of the present invention also disclose that the ceramic powder is alumina powder, wherein the alumina content is 98-99.5 wt%.
[0008] Furthermore, embodiments of the present invention also disclose that the particle diameter of the alumina powder is 0.1-60 μm.
[0009] Furthermore, the embodiments of the present invention also disclose that when degreasing and sintering ceramic blanks, the ceramic blanks are placed in a high-temperature electric furnace, first heated to 150-500°C for degreasing, and then heated to 1630-1650°C for sintering; after the ceramics are formed, the temperature is slowly lowered, and the total time for heating, holding and cooling is 125-135 hours.
[0010] Furthermore, this embodiment of the invention also discloses that when the assembled ceramic insert is sintered for the second time, the sintering temperature is 1380-1410℃, and the total duration of the sintering process from heating, holding, and cooling is 35-40 hours.
[0011] Furthermore, the technical solution adopted by the present invention to solve its technical problem also includes a ceramic insert holder, which is manufactured using the above-described method for manufacturing ceramic insert holders.
[0012] Furthermore, embodiments of the present invention also disclose that the average density of the ceramic holder is 3.9-4.0 g / cm³. 3 .
[0013] The beneficial effects of this invention are that the ceramic holder produced by this invention has better dimensional stability, better rigidity, and is more resistant to acid corrosion compared with existing quartz carriers. It will not react with hydrofluoric acid, can replace existing quartz carriers, has corrosion resistance, and extends the service life to 8-10 months, thereby reducing the production cost of solar cells. Attached Figure Description
[0014] The present invention will be further described below with reference to the accompanying drawings and embodiments.
[0015] Figure 1 This is a schematic diagram of a ceramic connector structure in this invention.
[0016] Figure 2 This is a schematic diagram of the ceramic insert placed in the sintering mold in this invention. Detailed Implementation
[0017] To make the objectives, technical solutions, and advantages of the present invention clear and complete, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only some, not all, embodiments of the present invention, and are merely illustrative of the embodiments of the present invention. They are not intended to limit the embodiments of the present invention. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0018] In the description of this invention, it should be noted that the terms "center," "middle," "upper," "lower," "left," "right," "inner," "outer," "top," "bottom," "side," "vertical," and "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "a," "first," "second," "third," "fourth," "fifth," and "sixth" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0019] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0020] For purposes of simplicity and illustration, the principles of the embodiments are described primarily by way of example. In the following description, numerous specific details are set forth to provide a thorough understanding of the embodiments. However, it will be apparent to those skilled in the art that these embodiments may not be limited to these specific details in practice. In some instances, well-known methods and structures have not been described in detail to avoid unnecessarily obscuring these embodiments. Furthermore, all embodiments can be used in combination with each other.
[0021] Explain the relationship between the graphs.
[0022] This invention discloses a method for manufacturing a ceramic insert holder, wherein the structure of the ceramic insert holder is as follows: Figure 1 As shown, the components include an upper support plate 1 and a lower support plate 2. At least one pair of support rods 3 are disposed between the upper support plate 1 and the lower support plate 2. Specifically, this invention uses two pairs. Multiple teeth are longitudinally distributed on each support rod 3, with the teeth in each pair of support rods 3 arranged opposite each other to support the solar cell. Ears 4 are provided at the upper part between the two pairs of support rods 3 to facilitate the removal of the ceramic insert. A lower support rod 5 is provided at the lower part between the two pairs of support rods to enhance the support strength.
[0023] The manufacturing method of the above-mentioned ceramic insert includes the following steps: S1: Ceramic powder is placed in a mold and pressed to obtain the ceramic blank of the above-mentioned part. Because different parts have different shapes and sizes, different molding methods are used, specifically including: S11: The upper support plate and the lower support plate are formed by dry pressing using a special tungsten steel mold under the action of a press with a pressure of 490-610 tons. S12: The support rod, ear, and lower support rod are pressed using isostatic pressing.
[0024] Furthermore, the ceramic powder used is alumina powder, with an alumina content of 98-99.5 wt%, and the remainder being resin. The resin can specifically be one or more of polyvinyl alcohol, phenolic resin, and epoxy resin. The resin is mainly used to improve powder flowability and ensure green body strength.
[0025] Furthermore, the particle diameter of alumina powder is 0.1-60 μm.
[0026] S2: Degreasing and sintering the ceramic blank. Specifically, the ceramic blank is placed in a high-temperature electric furnace, first heated to 150-500℃ for degreasing, then heated to 1630-1650℃ for sintering; it is held at this temperature for a period of time, and after the ceramic is formed, it is slowly cooled down. The total time for heating, holding and cooling is 125-135 hours.
[0027] S3: Grind, process and clean the sintered parts to obtain the parts required for the ceramic insert.
[0028] S4: Apply ceramic paste to the joints of the parts, assemble the parts according to the drawings, and place them as shown in the image. Figure 2 The sintering fixture shown is used to control the relative position of the parts on the carrier during the sintering process, preventing excessive changes and deformation of the parts.
[0029] Specifically, such as Figure 2 As shown, the sintering fixture includes a sintering support plate 6, with support grooves 7 on both sides of the sintering support plate 6 for placing the upper support plate 1 and the lower support plate 2. Ear support blocks 8 are also provided on the sintering support plate 6 for placing the ears 4.
[0030] S5: The assembled ceramic insert is sintered a second time at a temperature of 1380-1410℃. The total sintering time, from heating to holding and cooling, is 35-40 hours.
[0031] The ceramic holders produced in this way have an average density of 3.9-4.0 g / cm³. 3 .
[0032] Furthermore, to ensure the connection strength at the ceramic insert joint, the ceramic slurry used includes solid powder and a binder. The solid powder includes alumina, titanium dioxide, and silicon dioxide. Specifically, alumina accounts for 95-97 wt% of the total solid powder, titanium dioxide accounts for 1-3 wt%, and silicon dioxide accounts for 1-3 wt%.
[0033] In the above technical solution, alumina serves as the main material, providing strength, high-temperature resistance, and corrosion resistance to the joints of the ceramic insert. Titanium oxide, as a sintering aid, forms a limited solid solution with alumina, lowering the sintering temperature, refining the grains, and increasing density. Silica reacts with alumina at high temperatures to form an aluminosilicate glass phase, filling grain boundary pores and improving fracture toughness. The binder specifically uses one or more of polyvinyl alcohol, phenolic resin, and epoxy resin, with the binder content accounting for 1-5 wt% of the total ceramic slurry. The particle size of the solid powder is 0.1-20 μm.
[0034] The technical solution of the present invention will be further described below by way of examples. However, the present invention is not limited to these examples.
[0035]
Example 1
[0036] S2: Place the above ceramic blank in a high-temperature electric furnace, first heat it to 200℃ for degreasing, then heat it to 1650℃ for sintering; hold it at that temperature for a period of time, and after the ceramic is formed, start to slowly cool it down. The total time for heating, holding and cooling is 130 hours.
[0037] S3: Grind, process and clean the sintered parts to obtain the parts required for the ceramic holder. Observe the surface of the parts to ensure there are no cracks.
[0038] S4: Apply ceramic slurry to the joints of the parts, assemble the parts according to the drawings, and place them on the sintering fixture. The binder in the ceramic slurry is polyvinyl alcohol, accounting for 1 wt%. The solid powder consists of 96 wt% alumina, 2.5 wt% titanium dioxide, and 1.5 wt% silica. The particle size of the solid powder is 1 μm.
[0039] S5: The assembled ceramic insert is sintered a second time at a temperature of 1380℃. The total sintering time, from heating to cooling, is 35 hours.
[0040] The ceramic holder prepared in this embodiment was inspected using a handheld microscope. The joints were found to be tightly connected, and no cracks were found. The density of the main body of the ceramic holder was measured to be 3.93 g / cm³, and the density of the joints was 3.95 g / cm³, with very little difference between the two.
[0041]
Example 2
[0042] S2: Place the above ceramic blank in a high-temperature electric furnace, first heat it to 350℃ for degreasing, then heat it to 1630℃ for sintering; hold it at this temperature for a period of time, and after the ceramic is formed, start to slowly cool it down. The total time for heating, holding and cooling is 135 hours.
[0043] S3: Grind, process and clean the sintered parts to obtain the parts required for the ceramic holder. Observe the surface of the parts to ensure there are no cracks.
[0044] S4: Apply ceramic slurry to the joints of the parts, assemble the parts according to the drawings, and place them on the sintering fixture. The binder in the ceramic slurry is phenolic resin, accounting for 5 wt%. The solid powder consists of 97 wt% alumina, 2 wt% titanium dioxide, and 1 wt% silica. The particle size of the solid powder is 20 μm.
[0045] S5: The assembled ceramic insert is sintered a second time at a temperature of 1395℃. The total sintering time, from heating to holding and cooling, is 40 hours.
[0046] The ceramic holder prepared in this embodiment was inspected using a handheld microscope. The joints were found to be tightly connected, and no cracks were found. The density of the main body of the ceramic holder was measured to be 3.90 g / cm³, and the density of the joints was 3.92 g / cm³, with very little difference between the two.
[0047]
Example 3
[0048] S2: Place the above ceramic blank in a high-temperature electric furnace, first heat it to 500℃ for degreasing, then heat it to 1640℃ for sintering; hold it at this temperature for a period of time, and after the ceramic is formed, start to slowly cool it down. The total time for heating, holding and cooling is 126 hours.
[0049] S3: Grind, process and clean the sintered parts to obtain the parts required for the ceramic holder. Observe the surface of the parts to ensure there are no cracks.
[0050] S4: Apply ceramic slurry to the joints of the parts, assemble the parts according to the drawings, and place them on the sintering fixture. The binder in the ceramic slurry is epoxy resin, accounting for 3 wt%. The solid powder consists of 95.5 wt% alumina, 1.5 wt% titanium dioxide, and 3 wt% silica. The particle size of the solid powder is 10 μm.
[0051] S5: The assembled ceramic insert is sintered a second time at a temperature of 1405℃. The total sintering time, from heating to holding and cooling, is 38 hours.
[0052] The ceramic holder prepared in this embodiment was inspected using a handheld microscope. The joints were found to be tightly connected, and no cracks were found. The density of the main body of the ceramic holder was measured to be 3.95 g / cm³, and the density of the joints was 3.98 g / cm³, with very little difference between the two.
[0053] Furthermore, in order to verify the corrosion resistance of the ceramic insert prepared in this application, the ceramic insert prepared in Example 1 and an existing quartz carrier were immersed in hydrofluoric acid solutions with concentrations of 10% and 15%, respectively, and their dimensional changes were measured. The comparison results are shown in the table below.
[0054]
[0055] As shown in the table above, the ceramic insert obtained by this invention has better dimensional stability, better rigidity, and is more resistant to acid corrosion than existing quartz carriers. It does not react with hydrofluoric acid and can replace existing quartz carriers. It has corrosion resistance and its service life is extended to 8-10 months, which can reduce the production cost of solar cells.
[0056] Although the illustrative specific embodiments of the present invention have been described above to enable those skilled in the art to understand the invention, the invention is not limited to the scope of the specific embodiments. For those skilled in the art, all inventions utilizing the concept of the present invention are protected as long as various variations are within the spirit and scope of the invention as defined and determined by the appended claims.
Claims
1. A method of manufacturing a ceramic socket comprising a plurality of parts, characterized in that, The method comprises the following steps: Placing ceramic powder in a mold to mold a ceramic blank of the part; Defatting and sintering the ceramic blank; Processing and cleaning the sintered ceramic blank to obtain the part; Applying ceramic slurry to the connecting part of the part to assemble the parts together; Secondary sintering the assembled ceramic holder.
2. The method of claim 1, wherein The parts of the ceramic holder include an upper support plate, a lower support plate, a support rod, an ear, and a lower support rod.
3. The method of claim 2, wherein The upper support plate and the lower support plate are formed by dry pressing using a tungsten steel special mold under the action of a press machine, and the pressure condition is 490-610 tons.
4. The method of claim 2, wherein The support rod, the ear, and the lower support rod are formed by isostatic pressing.
5. The method of claim 1, wherein The ceramic powder is alumina powder, and the content of alumina is 98-99.5wt%.
6. The method of claim 5, wherein The particle diameter of the alumina powder is 0.1-60μm.
7. The method of claim 1, wherein When defatting and sintering the ceramic blank, the ceramic blank is placed in a high-temperature electric furnace, first heated to 150-500℃ for defatting, and then heated to 1630-1650℃ for sintering; after the ceramic is formed, slow cooling is started, and the total time of heating and holding and cooling is 125-135 hours.
8. The method of claim 1, wherein When secondary sintering the assembled ceramic holder, the sintering temperature is 1380-1410℃, and the total time of the sintering process from heating, holding, and cooling is 35-40 hours.
9. A ceramic socket, characterized by The ceramic holder is obtained by the method of any one of claims 1-8.
10. A ceramic socket according to claim 9, wherein The average density of the ceramic insert is 3.9-4.0 g / cm 3 .