Solar Cell Paste Cavitation for High-Viscosity Particle Dispersion

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Solution Overview

Problem

Existing cavitation systems are limited to processing low viscosity materials and cannot handle medium or high viscosity materials, leading to poor dispersity and agglomeration of particles.

Innovation Solution

A method and apparatus system that exposes raw materials to a first pressure and temperature to reduce viscosity, allowing them to be processed through a hydrodynamic cavitation chamber, followed by a thermal control system to maintain stable product temperature and achieve finely dispersed, non-agglomerated particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If pre-existing cavitation systems are used to process materials, then low viscosity materials can be processed, but medium or high viscosity materials cannot be processed because they cannot flow into the cavitation machine

Engineering Contradiction:

Improveviscosity range processabilityVSAvoidmaterial flow capability

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent applies parameter changes by controlling temperature and pressure conditions to modify the viscosity of medium or high viscosity materials, enabling them to flow into the cavitation system. By adjusting these parameters, the material properties are changed to match the flow requirements of the cavitation machine, thus resolving the contradiction between handling high viscosity materials and maintaining ease of operation.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If milling techniques (three-roll milling, attritor milling, bead milling) are used to fabricate dispersed particles, then particle dispersion can be achieved, but poor dispersity and particle agglomeration occur in the product

Engineering Contradiction:

Improveparticle dispersityVSAvoidparticle agglomeration

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent replaces traditional mechanical milling techniques with a cavitation-based process. Instead of using mechanical forces from mills and graters, the invention uses cavitation bubbles and their collapse to disperse particles. This substitution eliminates the harmful mechanical stresses that cause particle agglomeration while achieving superior dispersity, thus resolving the contradiction between manufacturing precision and harmful factors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes phase transitions of cavitation bubbles (formation and collapse) to achieve particle dispersion. The cyclic formation and implosion of cavitation bubbles create localized high-energy zones that effectively separate and disperse particles without causing agglomeration, providing a non-mechanical approach to achieving fine particle distribution.

Inventive Principle:

Principle #36Phase transitions

3Productivity

If emulsifying equipment capable of cavitating very low viscosity materials is used, then low viscosity liquid processing is improved, but the system cannot process medium or high viscosity materials

Engineering Contradiction:

Improvelow viscosity liquid processing capabilityVSAvoidviscosity range handling

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent applies universality by designing a cavitation system that can handle multiple viscosity ranges (low, medium, and high viscosity materials) through a single apparatus. By incorporating temperature and pressure control mechanisms, the system becomes multi-functional, capable of adapting to different material viscosities while maintaining effective cavitation processing, thus resolving the contradiction between productivity for low viscosity liquids and adaptability for broader viscosity ranges.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system effectively processes medium to high viscosity materials, achieving stable temperature control and producing de-agglomerated particles with consistent properties, suitable for applications in devices such as solar cells and electronic components.

Implementation Method 1

exposing a raw material having a first viscosity to a first pressure and a first temperature such that the raw material after the exposure has a second viscosity

Methodology Applied

Scientific EffectPressure and temperature effect on viscosity:

Implementation Method 2

subjecting the raw material having the second viscosity to the hydrodynamic cavitation process to make a product material having a third viscosity

Methodology Applied

Scientific EffectHydrodynamic cavitation: Hydrodynamic Cavitation

Data Source

PatentUS12457821B2Systems and method for manufacturing solar cell paste

Publication Date: 2025.10.28 APPLIED CAVITATION INC

AI summary

Provided in one embodiment is a method of making, comprising: exposing a raw material having a first viscosity to a first pressure and a first temperature such that the raw material after the exposure has a second viscosity, wherein the raw material comprises particles comprising at least one electrically conductive material, and wherein the second viscosity is sufficiently low for the raw material to be adapted for a hydrodynamic cavitation process; and subjecting the raw material having the second viscosity to the hydrodynamic cavitation process to make a product material having a third viscosity. Apparatus employed to apply the method and the exemplary compositions made in accordance with the method are also provided.