Mechanical Silicon Seed Coupling for High-Purity Rod Joining

Solution Overview

Problem

The existing methods for manufacturing silicon seed rods, such as the Siemens method, result in shorter seed rods due to carbon contamination, necessitating frequent replacement or extension, and previous welding techniques are inefficient and prone to defects.

Innovation Solution

A mechanical coupling method where the peripheral portions of silicon seed rods are removed to create a protruding central portion, allowing for the insertion of a corresponding coupling member to join two seed rods end-to-end, ensuring stable and high-purity connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If welding method is used to join silicon seed rods, then the rods can be connected end-to-end, but the process is time-consuming and energy-intensive

Engineering Contradiction:

Improvejoining efficiencyVSAvoidwelding time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces the thermal welding process with a mechanical coupling system. A coupling member with a coupling hole is inserted between two silicon seed rods, and clamping members are pressed against the rods through the coupling hole to mechanically secure them together. This mechanical fastening method eliminates the need for time-consuming heating and melting processes, significantly reducing joining time and energy consumption while maintaining strong connections between rods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If welding method is used to join silicon seed rods, then the rods can be connected, but welding defects occur and metal contamination increases

Engineering Contradiction:

Improveconnection qualityVSAvoidmetal contamination

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the thermal welding process with a mechanical coupling system. A coupling member with a coupling hole is inserted between two silicon seed rods, and clamping members are pressed against the rods through the coupling hole to mechanically secure them together. This mechanical fastening method eliminates the need for time-consuming heating and melting processes, significantly reducing joining time and energy consumption while maintaining strong connections between rods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a coupling member as an intermediary component between the two silicon seed rods. This coupling member serves as a mediator that mechanically connects the rods without requiring direct thermal contact or melting of the rod ends. The coupling member isolates the rods from each other during the joining process, preventing direct contact that could lead to contamination or defect formation, while still achieving a reliable end-to-end connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If high-frequency heating coil is moved to weld silicon seed rods, then the abutted portion is melted, but the process is complicated to control

Engineering Contradiction:

Improvewelding precisionVSAvoidheating coil control complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the thermal welding process with a mechanical coupling system. A coupling member with a coupling hole is inserted between two silicon seed rods, and clamping members are pressed against the rods through the coupling hole to mechanically secure them together. This mechanical fastening method eliminates the need for time-consuming heating and melting processes, significantly reducing joining time and energy consumption while maintaining strong connections between rods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a coupling member as an intermediary component between the two silicon seed rods. This coupling member serves as a mediator that mechanically connects the rods without requiring direct thermal contact or melting of the rod ends. The coupling member isolates the rods from each other during the joining process, preventing direct contact that could lead to contamination or defect formation, while still achieving a reliable end-to-end connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10968934B2Mechanical seed coupling

Publication Date: 2021.04.06 HIGH-PURITY SILICON CORP

AI summary

An apparatus and method of manufacturing silicon seed rod in which two silicon seeds are joined into one long silicon seed rod by mechanical coupling. A mechanical seed coupler is a body in having an outer wall, an upper surface with an upper aperture, a lower surface with a lower aperture, and an inner wall surrounding an inner space. The mechanical seed couple can be of a shape including a cylinder shape, an elliptical tube shape, a rectangular tube shape and a square tube shape. Furthermore the mechanical seed coupler can be of unitary construction, made from one solid piece of material, or it can be composed of subparts.