Ceramic Support Plate for Noble Metal Crucible Oxidation Control
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Solution Overview
Problem
Oxidation of crucibles made from noble metals during the manufacturing of single crystal boules leads to loss of noble metal and increased manufacturing costs due to diffusion and evaporation, necessitating a solution to minimize such losses.
Innovation Solution
A ceramic-ceramic composite base plate with porosity of 1 to 80% and alternating ridges and channels is used to support the crucible, minimizing contact and facilitating inert gas circulation to prevent oxidation, while supporting the crucible during the growth of high-temperature materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If refractory materials are used to support the crucible, then the crucible can be supported during high temperature processing, but noble metal diffuses into the refractory materials causing loss of expensive metal
Solution Approach 1:
A ceramic support plate is introduced as an intermediary component between the crucible and the refractory materials. The support plate serves as a barrier that prevents direct contact between the noble metal crucible and the refractory materials, thereby stopping the diffusion of noble metal into the refractory materials while still providing the necessary mechanical support during high temperature processing
Solution Approach 2:
The support plate is made from a ceramic-ceramic composite material that combines the properties of ceramic strength and chemical inertness. This composite material provides both the mechanical support needed during high temperature processing and the chemical resistance to prevent noble metal diffusion, resolving the contradiction between support capability and metal loss prevention
2Productivity
If the crucible is exposed to the processing atmosphere, then melting and crystal growth can occur, but oxidation of the crucible causes local evaporation and noble metal loss
Solution Approach 1:
The ceramic support plate acts as a protective intermediary that creates a physical barrier between the crucible and the oxidizing processing atmosphere. This barrier prevents direct exposure of the noble metal crucible to oxygen and other oxidizing agents, thereby preventing oxidation and subsequent evaporation of noble metal while allowing the crystal growth process to proceed efficiently
3Strength
If refractory materials are placed in contact with the crucible, then structural support is provided, but points of contact cause noble metal diffusion into refractory materials
Solution Approach 1:
The ceramic support plate is positioned between the crucible and the refractory materials to serve as a non-contact support interface. This intermediary structure provides the necessary structural support while eliminating direct contact points between the noble metal crucible and refractory materials, thereby preventing noble metal diffusion into the refractory materials
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces noble metal loss and manufacturing costs by preventing oxidation of the crucible, ensuring efficient production of single crystal boules with enhanced mechanical and physical properties.
Implementation Method 1
the crucible is heated by inductive heating using inductive coils that are located outside the outer tube
Implementation Method 2
the first base plate has a porosity of 1 to 80 volume percent, based on a total volume of the first base plate
Data Source
AI summary
Disclosed herein is a device for manufacturing a single crystal comprising: a furnace that includes a furnace wall; a crucible disposed on a first base plate within the furnace; where the first base plate has a porosity of 1 to 80 volume percent, based on a total volume of the first base plate; and where the first base plate does not comprise free flowing particles; an induction coil disposed inside the furnace wall and outside the crucible; and a refractory lining being disposed in an annulus between the furnace wall and the crucible.