Electrical device with silicon nano-particles
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Solution Overview
Problem
Current methods for producing silicon nano-particles are costly and result in undesirable microstructures, while existing solar cell and battery devices face challenges such as rigidity, bulkiness, and expansion issues with silicon nano-particles.
Innovation Solution
A process involving alloying raw silicon with alloying metals like zinc or magnesium, processing the alloy into nano-particles, and distilling the alloying metal to produce silicon nano-particles, which can be used in flexible solar cell devices and battery anodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vapour deposition or atomization methods are used for large-scale production of silicon nano-particles, then production scale is improved, but production cost increases and microstructure quality deteriorates
Solution Approach 1:
The invention changes the production parameters by using mechanical alloying and ball milling processes instead of vapour deposition or atomization. This involves changing the physical state and processing conditions to achieve cost-effective large-scale production while maintaining desirable microstructure characteristics suitable for solar cell and battery applications
2Manufacturing precision
If Siemens process is used for production of silicon nano-particles, then purity quality is improved, but production cost increases and environmental friendliness deteriorates
Solution Approach 1:
The invention employs a more economical production process that uses readily available materials and simpler processing steps. The mechanical alloying and ball milling approach uses inexpensive equipment and consumables compared to the energy-intensive Siemens process, achieving suitable purity levels without the high costs and environmental burden
3Ease of manufacture
If carbothermic reduction process is used for production of silicon nano-particles, then production cost is improved, but purity quality deteriorates due to impurity contamination
Solution Approach 1:
The invention introduces an intermediary approach by using mechanical alloying with controlled atmosphere and subsequent ball milling processes. This intermediary method avoids direct carbon contact that causes boron and phosphorous contamination in carbothermic reduction, while still maintaining cost-effectiveness through the use of simpler equipment and processes
4Quantity of substance
If silicon nano-particles are used in anode material for batteries, then energy storage capacity is improved, but expansion issues worsen causing electrical contact breakdown
Solution Approach 1:
The invention addresses the expansion issue by developing anode structures with flexible components that can accommodate the volume changes of silicon during lithium ion insertion and extraction. The flexible design prevents electrical contact breakdown while maintaining high energy storage capacity
5Stability of the object's composition
If graphite and silicon particles are mixed in anodic material, then expansion is reduced, but energy storage capacity is compromised due to inefficient use of silicon
Solution Approach 1:
The invention applies local quality by creating specific spatial arrangements where silicon nano-particles are positioned in regions that allow for controlled expansion. This local optimization enables the anode to accommodate silicon expansion without requiring excessive graphite content, thereby maintaining high energy storage capacity while controlling overall expansion
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
The process reduces production costs and produces silicon nano-particles with controlled diameters and porosity, addressing expansion issues and enhancing energy storage capacity in battery applications.
Implementation Method 1
distilling the alloying metal from the alloy nano-particles whereby silicon nano-particles are substantially produced
Data Source
AI summary
An electrical device that includes an electrically-conductive substrate having a flexible structure; and wherein the flexible structure is formed by coating, encapsulating, and entangling it with porous silicon nano-particles, and wherein the porous silicon nano-particles are produced according to steps of: (I) alloying a raw silicon material with at least one distillable alloying metal selected from zinc and magnesium to form an alloy; (II) milling the alloy to form alloy nano-particles of 100 nm-150 nm in diameter, and doing the milling in an inert environment to alleviate oxidation of the alloy; (III) distilling the alloying metal from the alloy nano-particles so that a porous silicon structure is produced, the distilling being performed in a vacuum furnace; and (IV) milling the porous silicon structure in an inert environment to break the porous silicon structure apart, thereby to produce the porous silicon nano-particles.