Solar Cell Paste Processing with Hydrodynamic Cavitation
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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 hydrodynamic cavitation processing of medium to high viscosity materials, using an air-driven piston and thermal control system to manage temperature and viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pre-existing cavitation systems are used to process low viscosity materials, then the materials can be processed through the cavitation machine, but medium or high viscosity materials cannot flow into the system and cannot be processed
Solution Approach 1:
The patent applies parameter changes by heating the medium or high viscosity material to reduce its viscosity, enabling it to flow into the cavitation system. The system includes a heating device that raises the material temperature to a level where the viscosity is sufficiently low for the material to be pumped and processed through the cavitation machine, thereby expanding the adaptability of the system to handle various viscosity ranges.
2Manufacturing precision
If milling techniques (three-roll milling, attritor milling, bead milling) are used to fabricate dispersed particles, then particles can be produced, but poor dispersity and agglomeration of particles occur in the product
Solution Approach 1:
The patent replaces traditional mechanical milling techniques with a hydrodynamic cavitation system. This substitution uses cavitation bubbles generated by rapid pressure changes to disperse and de-agglomerate particles, eliminating the poor dispersity and agglomeration problems associated with conventional mechanical milling methods.
Solution Approach 2:
The patent utilizes phase transitions of cavitation bubbles (formation and collapse) to achieve particle dispersion. The rapid formation and collapse of cavitation bubbles in the liquid medium generate intense local shear forces and micro-jets that effectively break up particle agglomerates and disperse particles uniformly, overcoming the limitations of mechanical milling.
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
Achieves finely dispersed and non-agglomerated particles, with improved particle size distribution and stability over time, 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
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
Data Source
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.