Transportable Process Box for Thin-Film Solar Substrates
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Solution Overview
Problem
Current process boxes for heat treatment of substrates in thin-film solar cell production are costly and energy-intensive, with limited system throughput and potential for substrate bending during processing, which can lead to quality issues and increased production costs.
Innovation Solution
A transportable process box design that allows for full-surface support of substrates, enabling simultaneous processing of two substrates without bending, with a modular structure that includes a base, frame, and intermediate element for uniform heat treatment and gas control, facilitating automated handling and reducing operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If substrates are processed in conventional process boxes without full-surface support, then device complexity is reduced, but substrate bending occurs leading to quality issues
Solution Approach 1:
The process box is divided into a base unit and a lid unit that can be separated. The base unit includes support structures for full-surface substrate support, while the lid unit contains the heating elements. This segmentation allows the support structure to be optimized for substrate flatness without complicating the entire process box design.
Solution Approach 2:
A susceptor is introduced as an intermediary element between the substrate and the base support. The susceptor provides uniform support across the entire substrate surface, preventing bending during processing while maintaining a relatively simple process box structure.
2Productivity
If process boxes are designed for single substrate processing, then manufacturing precision is maintained, but system throughput is limited
Solution Approach 1:
Multiple substrates are processed simultaneously in a single process box. The base unit is designed to accommodate multiple substrates arranged in parallel, each with its own susceptor for full-surface support. This merging approach increases throughput while maintaining processing quality through uniform heating and support for each substrate.
Solution Approach 2:
The process box base unit is designed as a universal platform that can accommodate different numbers and arrangements of substrates. The support structures and susceptors are configured to provide full-surface support for any substrate size or quantity, enabling both high throughput and consistent manufacturing precision.
3Ease of operation
If process boxes are made transportable and modular, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The process box is segmented into distinct modular units: a base unit with support structures, a lid unit with heating elements, and removable susceptors. This segmentation enables easy assembly, disassembly, and transport of individual components, improving operational ease while keeping each module relatively simple in design.
4Use of energy by moving object
If conventional heating methods are used without radiant energy, then device complexity is reduced, but energy efficiency deteriorates
Solution Approach 1:
Conventional contact-based or convection heating mechanisms are replaced with radiant energy heating elements in the lid unit. The heating elements emit radiant energy that directly heats the substrates through the transparent or translucent lid, eliminating the need for complex mechanical heating systems while significantly improving energy efficiency.
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 solution enhances system throughput, reduces operational costs, and ensures high-quality substrate processing by preventing substrate bending and allowing for precise control of the processing environment, thereby improving the efficiency and quality of thin-film solar module production.
Implementation Method 1
the base being designed in such a way that coatings of the substrates, essentially or predominantly a coating of the first substrate, by which radiant energy of radiation applied to the underside of the floor can be heat-treated
Data Source
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AI summary
The present invention relates to a transportable process box for processing substrates coated on one side, comprising: a base for the placement of a first substrate in a manner such that the latter is supported over the full area, wherein the base is designed in such a manner that coatings of the substrates can be subjected to a heat treatment by radiation energy supplied on the underside of the base, a frame, a cover which is placed onto the frame, an intermediate element which is arranged between the base and the cover and is intended for the placement of a second substrate in a manner such that the latter is supported over the full area, wherein the cover is designed in such a manner that the coatings of the substrates can be subjected to a heat treatment by radiation supplied on the top side of the cover. The invention also extends to arrangements and methods for processing substrates, in which a process box or a process carrier is mounted and loaded with substrates, is transported into a process chamber, and radiation energy is irradiated from above the cover and/or below the base. In the case of a premounted process carrier, the cover or a cover connected to the frame is delivered to the process carrier in order to form the process box.