Multizone crucible apparatus

Patent metadata

Field	Value
Publication number	US-2022267890-A1
Application number	US-202017638785-A
Country	US
Kind code	A1
Filing date	Aug 21, 2020
Priority date	Aug 30, 2019
Publication date	Aug 25, 2022
Grant date	—

Abstract

A crucible apparatus includes a crucible and one or more induction coils arranged around the crucible. Upon application of electric power to the one or more induction coils, a first thermal zone is generated in at least a first portion of the crucible and a second thermal zone is generated in at least a second portion of the crucible, wherein a first thermal characteristic of the first thermal zone is different from a second thermal characteristic of the second thermal zone.

First claim

1 . A crucible apparatus, comprising:
a crucible; one or more induction coils arranged around the crucible such that, upon application of electric power to the one or more induction coils, a first thermal zone is generated in at least a first portion of the crucible and a second thermal zone is generated in at least a second portion of the crucible; and refractory material arranged, at least in part, around the one or more induction coils, wherein a first thermal characteristic of the first thermal zone is different from a second thermal characteristic of the second thermal zone, and wherein in use, applying the electric power causes motion of a liquid in the crucible.

2 . The crucible apparatus of claim 1 , wherein:
the first thermal zone is located between a base of the crucible and the second portion of the crucible; the first thermal characteristic is a first temperature of the first thermal zone; the second thermal characteristic is a second temperature of the second thermal zone; and the second temperature is higher than the first temperature.

3 . The crucible apparatus of claim 1 , wherein the one or more induction coils comprise:
a first induction coil arranged around the first portion of the crucible; and a second induction coil arranged around the second portion of the crucible, such that a first electric power is applicable to the first induction coil and a second electric power, different from the first electric power, is applicable to the second induction coil.

4 . The crucible apparatus of claim 3 , comprising:
a first cooling system arranged to cool the first induction coil; and a second cooling system arranged to cool the second induction coil.

5 . The crucible apparatus of claim 4 , wherein at least one of the first cooling system or the second cooling system is a water-cooling system.

6 . The crucible apparatus of claim 1 , comprising insulation arranged between the one or more induction coils and the crucible.

7 . (canceled)

8 . The crucible apparatus of claim 1 , wherein the crucible apparatus is arranged such that, upon the application of the electric power to the one or more induction coils, heating of the crucible is induced, for heating of a material at least partly within the crucible.

9 . The crucible apparatus of claim 1 , comprising a control system arranged to, in use:
receive measurement data representative of a measurement of at least one of the first thermal characteristic or the second thermal characteristic; and control the electric power applied to the one or more induction coils based on the measurement data.

10 . The crucible apparatus of claim 9 , comprising a temperature sensor arranged to obtain the measurement data, wherein the first thermal characteristic is a first temperature of the first thermal zone and the second thermal characteristic is a second temperature of the second thermal zone.

11 . The crucible apparatus of claim 9 , wherein the first thermal characteristic is a first temperature of the first thermal zone, and the control system is arranged to, in use, control the electric power applied to the one or more induction coils such that the first temperature meets or exceeds a first temperature threshold for melting of a material to be heated by the crucible apparatus, in use.

12 . The crucible apparatus of claim 9 , wherein the second thermal characteristic is a second temperature of the second thermal zone, and the control system is arranged to, in use, control the electric power applied to the one or more induction coils such that the second temperature meets or exceeds a second temperature threshold for evaporation of a material to be heated by the crucible apparatus, in use.

13 . The crucible apparatus of claim 1 , comprising a chamber arranged between the crucible and a base of the crucible apparatus.

14 . The crucible apparatus of claim 13 , comprising a third cooling system arranged to cool the chamber.

15 . The crucible apparatus of claim 1 , wherein the crucible apparatus is arranged for use in an evaporative deposition process.

16 . The crucible apparatus of claim 1 , wherein the crucible apparatus is arranged for use in manufacture of an energy storage device.

17 . A method for controlling thermal characteristics of a crucible via induction heating, the method comprising:
providing refractory material arranged, at least in part, around one or more induction coils; and applying electric power to the one or more induction coils arranged around the crucible to generate a first thermal zone in a first portion of the crucible and a second thermal zone in a second portion of the crucible, wherein a first thermal characteristic of the first thermal zone is different from a second thermal characteristic of the second thermal zone, and wherein applying the electric power causes motion of a liquid in the crucible.

18 . The method of claim 17 , wherein:
the first thermal zone is located between a base of the crucible and the second portion of the crucible; the first thermal characteristic is a first temperature of a first thermal zone; the second thermal characteristic is a second temperature of a second thermal zone; and the second temperature is higher than the first temperature.

19 . The method of claim 17 , wherein applying the electric power to the one or more induction coils comprises:
applying a first electric power to a first induction coil of the one or more induction coils; and applying a second electric power, different from the first electric power, to a second induction coil of the one or more induction coils.

20 . The method of claim 17 , comprising controlling at least one of a current, a voltage or a frequency applied to the one or more induction coils.

21 . The method of claim 17 , wherein applying the electric power causes:
melting of a first portion of a material in the first portion of the crucible; and evaporation of a second portion of the material in the second portion of the crucible.

22 . The method of claim 17 , wherein applying the electric power causes induction heating of a material in the crucible to generate a vapour of the material, and the method comprises depositing the vapour on a substrate.

23 . The method of claim 22 , comprising controlling the electric power applied to the one or more induction coils to control at least one of: a density of the vapour deposited on the substrate or a rate of depositing the vapour on the substrate.

24 . The method of claim 17 , comprising:
receiving measurement data representative of a measurement of at least one of the first thermal characteristic or the second thermal characteristic; and controlling the electric power applied to the one or more induction coils based on the measurement data.

Assignees

• Dyson Technology Ltd

Inventors

• Rendall Michael Edward

Classifications

• H05B6/30

  Arrangements for remelting or zone melting · CPC title

• H05B6/24 Primary

  Crucible furnaces (H05B6/30 takes precedence) · CPC title

• H05B6/067

  for melting furnaces · CPC title

• C23C14/26 Primary

  by resistance or inductive heating of the source · CPC title

• C23C14/243 Primary

  Crucibles for source material (C23C14/28, C23C14/30 take precedence) · CPC title