US4224355A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method for quality film formation
Assignee: TOTAL ENERGIE DEVELOPPEMENT
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Filing: 1978-03-15
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Granted: 1980-09-23
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Expires: 1998-03-15
Abstract
Abstract Methods and apparatus are provided for forming films of materials which are component layers of solar energy conversion devices, e.g. photovoltaic cells and heat collector panels. A selected substrate, generally glass, is heated while being sprayed with solutions which react on the heated surface to form a particular film. Films of SnOx and CdS are particularly produced. According to the present invention, a thermal energy input gradient is provided to approximate the energy loss gradient during the spray process. Radiative heaters provide a rapid resupply of energy to the substrate and, in some instances, directly to the film forming surface. Temperature detectors, such as thermocouples, monitor substrate temperature to provide the radiative energy input needed for substantial temperature uniformity.
Inventors
- 👤 Curtis M. Lampkin
- 👤 Guy A. Roderick
- 👤 Peter Locke
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 05:10
CPC Classifications
H; H10; H10F; H10F71/00; H10F71/128; F; F24; F24S; F24S80/00; F24S80/50; F24S80/58; F24S80/52; Y; Y02; Y02E; Y02E10/00; Y02E10/40
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
129 words
A method of forming films of material suitable for solar energy conversion devices and the like, comprising the steps of: moving a glass substrate through a plurality of heat zones; establishing at least one surface of said substrate within said heat zones at preselected temperatures; spraying a portion of said at least one surface with a composition while said portion of said at least one surface is within at least one of said heat zones; and selectively energizing heaters within each of said heat zones to obtain a thermal energy input distribution within each of said heat zones adjacent said substrate approximating thermal energy losses from said substrate to maintain said at least one surface within a range of temperatures effective to produce said film from said sprayed composition.
Claim 2
Independent Claim
129 words
A method of forming films of material suitable for solar energy conversion devices and the like, comprising the steps of: moving a glass substrate through a plurality of heat zones; establishing at least one surface of said substrate within said heat zones at preselected temperatures; spraying a portion of said at least one surface with a composition while said portion of said at least one surface is within at least one of said heat zones; and selectively energizing heaters within each of said heat zones to obtain a thermal energy input distribution within each of said heat zones adjacent said substrate approximating thermal energy losses from said substrate to maintain said at least one surface within a range of temperatures effective to produce said film from said sprayed composition.
Claim 3
Dependent Claim
74 words
The method of claim 1, wherein moving said substrate through said plurality of heat zones comprises the steps of: moving said substrate to a first pre-spray heat zone for heating said at least one surface to a first selected uniform temperature; and thereafter moving said substrate to a second spray heat zone for maintaining said portion of said at least one surface being sprayed within said range of temperatures effective to produce said film.
Claim 4
Dependent Claim
36 words
The method of claim 2, including: moving said substrate to a third post-spray heat zone for heating said at least one surface to a second selected uniform temperature effective to promote forming said film of material.
Claim 5
Dependent Claim
47 words
The method described in claim 1 or claim 3, wherein spraying said surface includes spraying only a portion of said surface at any instant of time and at a rate of spray functionally related to the thermal energy input to said substrate from said spray heat zones.
Claim 6
Dependent Claim
74 words
The method described in claim 1 or claim 2, wherein selectively energizing said heat zones includes the steps of: detecting a temperature functionally related to the temperature of said substrate within each of said heat zones; and controlling a plurality of radiative heaters in each of said heat zones as a function of said detected temperature to obtain said thermal energy input distribution adjacent said substrate approximating said thermal energy losses from said substrate.
Claim 7
Dependent Claim
26 words
The method described in claim 5, further including supporting said substrate to provide substantially uniform illumination of the surface of said substrate facing said radiative heaters.
Claim 8
Independent Claim
130 words
A method of forming films of materials suitable for solar energy conversion devices and the like, comprising the steps of: moving a glass substrate through a plurality of heat zones; establishing at least one surface of said substrate within said heat zones at preselected temperatures; spraying a portion of said at least one surface with a composition while said portion of said at least one surface is within at least one of said heat zones; and radiatively heating said substrate within each of said heat zones to obtain a thermal energy input distribution within each of said heat zones adjacent said substrate approximating thermal energy losses from said substrate to maintain said at least one surface within a range of temperature effective to produce said film from said sprayed composition.
Claim 9
Independent Claim
130 words
A method of forming films of materials suitable for solar energy conversion devices and the like, comprising the steps of: moving a glass substrate through a plurality of heat zones; establishing at least one surface of said substrate within said heat zones at preselected temperatures; spraying a portion of said at least one surface with a composition while said portion of said at least one surface is within at least one of said heat zones; and radiatively heating said substrate within each of said heat zones to obtain a thermal energy input distribution within each of said heat zones adjacent said substrate approximating thermal energy losses from said substrate to maintain said at least one surface within a range of temperature effective to produce said film from said sprayed composition.
Claim 10
Dependent Claim
65 words
The method described in claim 7, wherein radiatively heating said substrate includes the steps of: detecting the temperature of said substrate within each of said heat zones; and controlling a plurality of radiative heaters in each of said heat zones as a function of said detected temperature to obtain said thermal energy input distribution adjacent said substrate approximating said thermal energy losses from said substrate.
Claim 11
Dependent Claim
77 words
The method of claim 7 or claim 8, wherein moving said substrate through said plurality of heat zones comprises the steps of: moving said substrate to a first pre-spray heat zone for heating said at least one surface to a first selected uniform temperature; and thereafter moving said substrate to a second spray heat zone for maintaining said portion of said at least one surface being sprayed within said range of temperatures effective to produce said film.
Claim 12
Dependent Claim
37 words
The method described in claim 9, including: moving said substrate to a third post-spray heat zone for heating said at least one surface to a second selected uniform temperature effective to promote forming said film of material.
Claim 13
Dependent Claim
47 words
The method described in claim 7 or claim 8, wherein spraying said surface includes spraying only a portion of said surface at any instant of time and at a rate of spray functionally related to the thermal energy input to said substrate from said spray heat zones.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-09-23 | 1984-03-24 | 1984-09-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-09-23 | 1988-03-24 | 1988-09-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-09-23 | 1992-03-24 | 1992-09-23 | $7700.00 | Window Closed / Lapsed |