Continuous Evaporator Refilling via Vacuum Lock and Siphon

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Solution Overview

Problem

The existing methods for evaporating selenium and other chalcogens in thin-film solar cell production require frequent interruptions for refilling, ventilation, and cooling, making the process time-consuming and costly, and preventing continuous selenium vaporization.

Innovation Solution

A method and device for continuously refilling an evaporator chamber by transferring solid material through a vacuum lock into a heated vacuum chamber, where it liquefies and is transferred via a connecting channel into an evaporator chamber, allowing for continuous operation by maintaining different pressure levels and using a siphon system to separate the chambers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the evaporator chamber is refilled by interrupting the evaporation process for ventilation and cooling, then the selenium can be replenished, but the production time increases and costs rise

Engineering Contradiction:

Improveselenium supplyVSAvoidproduction efficiency

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The system is divided into two separate chambers: a first chamber for storing solid selenium material and a second chamber for evaporation. This segmentation allows independent operation of each chamber, enabling continuous evaporation while material is replenished in the first chamber without interrupting the process in the second chamber.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A bridging element connects the first chamber and second chamber, allowing liquid selenium to flow from the first to the second chamber. This intermediary connection enables continuous material supply while maintaining separate pressure zones, eliminating the need to interrupt evaporation for refilling.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the evaporation process is interrupted for refilling and ventilation, then the selenium chamber can be maintained, but the process duration increases

Engineering Contradiction:

Improveprocess stabilityVSAvoidprocess interruption time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The evaporation process continues uninterrupted in the second chamber while the first chamber is refilled. The liquid selenium flow through the bridging element ensures continuous material supply to the evaporation zone, eliminating downtime and maintaining continuous productive action.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of manufacture

If solid material is transferred into the evaporator chamber directly, then refilling is simplified, but pressure equilibrium cannot be maintained

Engineering Contradiction:

Improverefilling simplicityVSAvoidpressure difference

Core Design Contradiction:

Ease of manufactureVSStress or pressure

Solution Approach 1:

Different pressure conditions are maintained in different locations: the first chamber operates at a higher pressure suitable for material storage and transfer, while the second chamber maintains a vacuum for evaporation. The bridging element is specifically designed to handle liquid flow between these different pressure zones, allowing local optimization of each chamber's conditions.

Inventive Principle:

Principle #3Local quality

4Object-affected harmful factors

If the chamber is cooled for ventilation, then safety is improved, but the evaporation process must stop

Engineering Contradiction:

Improveselenium vapor concentrationVSAvoidevaporation continuity

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The system separates the ventilation function from the evaporation function by dividing it into two chambers. The first chamber can be ventilated and cooled independently without affecting the second chamber where evaporation continues, allowing safety maintenance without productivity loss.

Inventive Principle:

Principle #1Segmentation

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

Enables continuous operation of the evaporation process without interruptions, improving efficiency and reducing costs by allowing seamless refilling and maintaining optimal pressure and temperature conditions for selenium vaporization.

Implementation Method 1

the material (1) in the vacuum chamber (3) is heated by a heating jacket (29) of the vacuum chamber (3) until it liquefies

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a partition (28) which is only permeable to liquid material (1)

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 3

Solid material (1) is transferred via a vacuum lock (19) into a vacuum chamber (3)

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Implementation Method 4

allowing for continuous operation by maintaining different pressure levels and using a siphon system to separate the chambers

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentEP2553136B1Method for refilling an evaporation chamber

Publication Date: 2016.11.09 SAINT GOBAIN VITRAGE SA

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AI summary

The invention relates to a method for continuously refilling an evaporator chamber, wherein a. solid material (1) is transferred into a vacuum chamber (3) via a vacuum lock (19), wherein the vacuum chamber (3) has a partition (28) permeable only to liquid material (1), b. the material (1) is heated in the vacuum chamber (3) by a heating jacket (29) of the vacuum chamber until liquefaction, and c. the material (1) is transferred into a basin (9) within an evaporator chamber (8) via a drain (21) and a connecting channel (20).