Intro to Glass-to-Metal Seals

A true glass-to-metal seal is defined as one in which inorganic glass is heated to the point where intimate contact (“wetting”) is attained upon a hot metal surface and is retained when the glass and metal are cooled to room temperature. The glass and metal components usually have similar Expansion coefficients and rates of expansion.

The glass layer is electrically insulated. Its resistance depends on the types of the glass, the temperature, and the condition of the surface. On the other hand, glass can be given a metallic oxide coating that conducts electricity. The glass can perform under high pressure, vacuum, high temperature, thermal cycling, radiation, shock and vibration, totally inorganic. They will not degrade with time.

Stay tuned for the Glass-to-Metal Seals series of blogs

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From Solarfeeds.com: Making Microchips at 1,300 Degrees C

This is an article from solarfeeds.com...

"Today's microchips are marvels of nanoscale engineering. A modern microprocessor contains hundreds of millions of transistors packed onto a thumbnail-size piece of silicon. However, our customers are hard at work on designs that will make today’s chips seem crude by comparison.

The semiconducting channel at the heart of each transistor is created, or activated, by quickly heating up the wafer to a set high temperature and cooling it down again, selectively turning the top few atomic layers from an insulator to a semiconductor.

This critical process is called rapid thermal processing, or RTP. Differences of just a few degrees Celsius will change the channel depth enough to affect the whole chip. The effect is small, but at the leading edge, small effects make a major difference.

 Applied Materials' Shankar Muthukrishnan discusses the role of RTP in manufacturing microchips and the progression of the technology from the simple furnaces of the 1970s all the way to the state of the art - the Applied Vantage Vulcan RTP system - that was unveiled today."

To read the entire article:

http://www.solarfeeds.com/index.php?option=com_content&view=article&id=17375&catid=321&Itemid=524

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From Solarfeeds.com: Plastic Photovoltaic Film

Solar Cells have always been very rigid silicon cells, however, now they are being made into flexible plastic films for the purpose of being able to form them into a multitude of shapes.  Oh how far we are coming along in the world of photovoltaics.  Check out the entire article right here..

http://www.solarfeeds.com/ecofriend/17331-in-focus-plastic-photovoltaics

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What is CIGS?

This is great information on CIGS!  This is an excerpt from an article written by ISET


What is CIGS?


CIGS is a compound semiconductor made up of the elements Copper, Indium, Gallium and Selenium. This material is a very powerful absorber of the Sun’s rays, with demonstrated conversion efficiencies approaching 20% for small-scale CIGS solar cells produced at the National Renewable Energy Laboratory (NREL). A CIGS absorber film requires only 1-2µm of material to convert sunlight into electricity, offering potential for significantly reduced material costs over conventional silicon solar cells.

CIGS films are coated onto substrates that have been metallized with Molybdenum as a back contact to collect electric current. A thin buffer layer of Cadmium Sulfide (CdS) is deposited onto the absorber film, forming a junction between a p-type semiconductor (CIGS) and an n-type CdS layer. A transparent conductive window layer, typically doped zinc oxide (ZnO), forms the top contact of the device, resulting in a complete CIGS solar cell.

As light passes through the ZnO layer, it is absorbed by the CIGS, creating electron-hole pairs. An electric field created at the CIGS/CdS junction draws negatively charged electrons to the ZnO layer, which generates a flow of positive charges in the opposite direction, producing an electric current.

CIGS solar cells can be fabricated on both rigid and flexible substrates, adding to their desirability as the next generation photovoltaic material of choice. When properly sealed and laminated, CIGS modules can deliver stable performance while withstanding exposure to the elements as well as direct solar radiation for over 20 years in the field. For the entire article go to http://www.isetinc.com/technology-overview.php Like us on facebook: http://www.facebook.com/torreyhillstechnologies

Furnace Brazing Atmosphere

The furnace atmosphere can be divided into two major parts; Gaseous and Vacuum.  The gaseous atmospheres include both active and neutral gases.  The neutral gas is generally nitrogen and the active gas will consist of one or several of the carbon monoxide, hydrogen, and hydrocarbon.  The gases can be categorized as Reducing, Oxidizing, Carburizing, and Decarburizing atmospheres.

Each active gas can effect the brazing materials.  The reducing effect can be balanced by the oxidizing effect.  Similarly, the carburizing effect can be balanced by the decarburizing effect.  It's important to keep the balance between those active gases in order to achieve atmosphere control.

The brazing atmospheres can also influence the heat transfer and post-braze cooling.  The type of gas, the pressure, and the gas flow rate will also influence the heat transfer rate.

Although oxidation should be avoided, an atmosphere with low oxygen and low moisture levels will allow the filler metal to melt and flow into very tightly jointed clearances.  The oxygen or moisture present in the joining environment will negatively interfere with wetting.  Therefore, the quality of the joint will degrade if the oxygen and moisture levels rise.

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Brazing Thermal Cycle

Brazing liquifies the alloy at temperatures higher than 450 degrees C and below the melting point of the substrate material. The typical processing temperature is 540-1620 degrees C. The typical brazing process includes preheating (optional), holding, ramp to temperature, brazing, cool down and, finally, exit.


Preheating and Holding- Preheating is done to the temperature below the melting point of the filler metal. It helps stabilize the temperature before heating. The time required for this stage is determined by the parts' thickness and volume.


Ramp to Temperature- The parts should heat quickly and uniformly. The heating time is limited due to the risk of creating distortion from thermal stress build up.


Brazing- Brazing time is the minimum time in which the braze alloy is allowed to flow through the joint. It should be controlled within suitable range depending upon the brazing situation. Theoretically, the joint between the filler and the base form quickly. Extending the processing time can lead to excessive interactions between the filler metal and the base metal, grain growth, and recrystallization.

Cooling and Exit- A controlled cool down within a protective atmosphere allows the joint to solidify. Usually, a temperature of about 150 degrees C will avoid discoloration of parts exiting the furnace.

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Types of Furnaces used for Brazing

Various types of furnaces are used for brazing which mostly employ either a gaseous atmosphere or a vacuum. The overall furnace construction is based on either batch type or continuous operation. Batch operation includes retort type furnaces used for hydrogen brazing and vacuum chambers for vacuum brazing.

Retort-type Furnaces- Different from other batch-type furnaces in that they make use of a sealed lining called a retort. The retort is made of heat resistant alloys that resist oxidation. It is filled with the desired atmosphere (hydrogen, sometimes mixed with inert gas for safety reasons) and then heated externally by conventional heating elements. Due to the high temperatures, the retort is usually made of heat resistant alloys that resist oxidation. Retort furnaces are often used in batch or semi-continuous versions.

Vacuum-type Furnaces- These are a high capital investment but are extremely versatile and safe, as well as, produce high quality. It offers excellent oxide prevention and is usually used to braze materials with very stable oxides; Such as aluminum, titanium, and zirconium. The three types of Vacuum Furnaces are "single-wall hot retort", "double-walled hot retort", and "cold-wall retort". Furnaces used today are usually based on a cold-wall construction.

Continuous-type Furnaces- These are the best suited for a steady flow of similar sized parts. Often conveyor fed, these furnaces allow parts to move through the hot zone at a controlled speed. IT is common to use either a controlled atmosphere or a pre-applied flux in continuous furnaces. With very low manual labor requirements, these types of furnaces are best suited for large-scale production operations.

For more information visit us at http:www.beltfurnaces.com or contact Torrey Hills Technologies at 858.558.6666

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An Introduction to Furnace Brazing

Brazing is the oldest method for joining metals, other than mechanical means. It has many advantages over other metal-joining techniques. First, it does not melt the base metal of the joint. It allows tighter control over tolerances and produces a clean joint without the need for secondary finishing. Additionally, dissimilar metals and non-metals (i.e. metalized ceramics) can be brazed. Also, brazing can be easily adapted to mass production which is favored by industries.

Furnaces brazing is a semi-automatic brazing process which has the advantages of mass production. In addition, the process offers the benefits of controlled heat cycle and does not need post braze cleaning.

For more information please contact Torrey Hills Technologies, LLC 858.558.6666

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Videos of Belt Furnaces in Action

If you want to see belt furnaces in action check out these videos! They will give you a close-up look into how they function and what they're used for!

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THT HSG Series Thick Film Drying Belt Furnace

Features

Infrared Heating
SUS Belt Conveyor and Tunnel
Long Entrance and Exit Table
Perfect Exhaust Design

Applications

Drying and curing, such as thick film circuit, paste on SMD terminal, etc.

Advantages

Highly efficient; Super light insulation materials; Energy efficient; Multi-zone control; Convenient adjustment.

HSG Series Drying Furnace Models

Model Control Zone Belt Width Overall Length
HSG2705D-0304 3 270mm 8150mm
HSG3004-0304 3 300mm 3260mm
HSG5502-0404 4 550mm 4890mm
HSG6002-0304 3 600mm 3700mm
HSG6006-0303 3 600mm 4075mm
HSG6310-0503 5 630mm 7335mm
HSG6005-0304 Drying Furnace Specifications

Specification HSG6005-0304
Rate Temperature 350 deg.c
Operation Temperature RT+20-300 deg.c
Belt Width 600mm/24"
Heating Length 1500mm/59"
Control Zones 3
Speed Range 100-500mm(4"-20")/min (other speed range as required)
Outside Dimension L3700mm/146" x W1040mm/41" x H1390mm/55"
Net Weight 500kg
Power 240V, 3 phase, 60HZ, 5 wire, 15KVA
Spare Part 2 heating tubes
Options and Customizations

Available Options
Belt Speed Range
Other Power Utility
UPS

Our dedicated engineers will always take the extra step to work with clients for customized designs.

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Advantages of THT's RSA1310-6NH11 Atmosphere Conveyor Series Furnace

Rated to 1,050° C, the RSA Series has a high-temperature muffle for clean application and features an ultra-clean low-mass refractory heating chamber. The RSA1310-6NH11 heats from ambient to 1,050° C in approximately 60 minutes, and is designed to sustain continuous on/off heating and cooling cycles resulting from alternating periods of production and nonuse. HengLi RSA Series is an energy efficient precision thermal processing system that provides unequaled performance through features such as:

1. 6 channel temperature profiler unit for independent temperature profiling. Includes 3 T.C.,
sampling unit and analyses software, LCD data display and check, RS232 interface to computer.
2. Atmosphere distribution and management system eliminate thermal shock and process
contamination.
3. High-temperature muffle for a clean application.
4. Ultrasonic belt cleaning system including drying system.
5. Windows XP DSC based profiling and monitoring system for monitoring, recording the firing
process, including temperature and speed.
6. UPS for the computer system and conveyor drive for power failure.
7. Extraction of burn-off effluents across entire chamber width improves yields.
8. Stable, special temperature uniformity control ensures consistent "firing" results.

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DSSC Processing Furnaces

TiO2 nanoparticles have been used extensively to increase the interfacial surface area in Dye Sensitized Solar Cells. Nanoparticle films are general made by screen printing a paste of titania nanocrystals and then sintering the particles together at 450-500°C.

Torrey Hills HENGLI furnaces have secured a dominating position in the supply of DSSC application furnaces. The furnaces' uniform and high-precision heating is indispensible for the improvement of DSSC performances.

For specs and more info on THT/Hengli Furnaces for DSSC go here..

http://www.beltfurnaces.com/dsscfurnace.html

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THT and KIC Working Together

Torrey Hills Technologies, LLC (THT) and KIC announced in March an agreement to form a strategic business alliance to speed up the optimal thermal process setup of THT belt furnaces through the use of KIC thermal profilers. Under the terms of the agreement, THT will introduce KIC thermal profilers to its current and prospective furnace customers, while KIC will perform all sales and service support associated with the profilers.

"KIC is recognized as the market leader for thermal profilers," said Joyce Zhang, THT’s Marketing Manager. "We welcome their technical expertise, state-of-the-art products and the industry’s best customer support. KIC thermal process tools will help deliver faster furnace setup and higher efficiencies in both high volume production lines and development labs.”

Based in San Diego, KIC is the leader in thermal process development and control products. For nearly three decades it has advanced industries worldwide with their innovative technology firsts. KIC thermal profilers, including KIC Explorer, KIC Vision, and SlimKIC 2000, are great accessories for THT’s belt furnaces. These profilers remove the complexities typically associated with thermal process setup, allowing furnace operators to easily acquire an accurate product thermal profile and quickly achieve the optimal process.

THT will also endorse KIC’s recently developed profiling and thermal process optimization tools for the solar cell manufacturing industry. These tools take advantage of KIC’s extensive technology platform developed in the semiconductor and SMT industries. They are designed for quick and accurate profiling and process optimization for higher efficiency cell manufacturing. The product range includes the SunKIC profiler, the e-Clipse TC attachment fixture, and the Spectrum process optimization software.

"We are pleased to be in partnership with THT and have great confidence that our profilers will enable THT furnace customers to easily reach a whole new level of process improvement and control." said Bjorn Dahle, President of KIC.

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Technological Description of DSSC's

A schematic depiction of the components and operating mechanism of a typical PV dye cell can be seen at http://www.beltfurnaces.com/dssc.html. The photoanode (facing the light source) is a glass plate whose inner surface has been coated with a thin layer (0.5 micron) of transparent conducting tin oxide (TCO). Onto this layer is coated (e.g. by sintering, other low temperature methods are available such as Electrophoresis) a several micron thick porous layer of nanocrystalline titanium dioxide (particle size about 20 nanometers) on which a monolayer of sensitizer dye is absorbed (ruthenium complex). The cell also comprises electrolyte containing a redox species based on iodide/tri-iodide, and a counter electrode (cathode) consisting of a glass plate also with a conducting tin oxide layer, coated with a few mono-layers of catalyst (platinum was originally used and can be replaced with carbon-based alternatives). In our approach the carbon layer can be applied directly on the Titania. This eliminates the need for a second sheet of FTO glass in the cell.

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Market Advantages for DSSC

The production of DSSCs incur relatively low cost: new patented technologies will result in less than $1.5 ppw for module manufacturing cost at initial production, dropping to about half this figure ($0.7 ppw) on the basis of economy of scale from multiple plants as opposed to more than $3 ppw today.

DSSCs have an additional advantage in that they are particularly suited to warmer climates. When hot, crystalline silicon modules lose efficiency far more than do dye cells.

DSSCs also work well in a wide range of lighting conditions and orientation, and they are less sensitive to partial shadowing and low-level illumination compared to silicon.

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