Abstract: Embodiments of a system and method for melting feedstock and casting ingots are disclosed. The system comprises a feedstock source, a stationary melting furnace, and one or more solidification modules capable of receiving molten feedstock from the melting furnace. In some embodiments, the system further includes a feed system for transferring feedstock from the feedstock source to the melting furnace. Feedstock is fed into the melting furnace and heated to produce molten feedstock. Molten feedstock flows into a solidification crucible within the solidification module. The solidification crucible is cooled to provide directional solidification and production of an ingot. The melting furnace may include a thermal valve system to prevent molten feedstock from flowing into the solidification crucible until substantially all of the feedstock within the melting furnace is molten. In some embodiments, the feedstock consists essentially of silicon and a multi-crystalline silicon ingot is produced.

Abstract: Fluidized bed reactor systems for producing high purity silicon-coated particles are disclosed. A vessel has an outer wall, an insulation layer inwardly of the outer wall, at least one heater positioned inwardly of the insulation layer, a removable concentric liner inwardly of the heater, a central inlet nozzle, a plurality of fluidization nozzles, at least one cooling gas nozzle, and at least one product outlet. The system may include a removable concentric sleeve inwardly of the liner. In particular systems the central inlet nozzle is configured to produce a primary gas vertical plume centrally in the reactor chamber to minimize silicon deposition on reactor surfaces.

Abstract: Fluidized bed reactor systems for producing high purity silicon-coated particles are disclosed. A vessel has an outer wall, an insulation layer inwardly of the outer wall, at least one heater positioned inwardly of the insulation layer, a removable concentric liner inwardly of the heater, a central inlet nozzle, a plurality of fluidization nozzles, at least one cooling gas nozzle, and at least one product outlet. The system may include a removable concentric sleeve inwardly of the liner. In particular systems the central inlet nozzle is configured to produce a primary gas vertical plume centrally in the reactor chamber to minimize silicon deposition on reactor surfaces.

Abstract: Systems and methods for converting a powder to a solid mass are disclosed. A furnace is provided to melt the powder and deliver a stream of resulting molten material to a bed of beads on a vibratory conveyor. Cooling gas flows through nozzles positioned above and along the conveyor to cool the beads and liquid. The liquid solidifies and forms a solid mass, incorporating beads from the bed. The conveyor can be periodically stopped to produce a plurality of discrete solid masses. Masses and unincorporated beads fall into a collection container. Unincorporated beads pass through a screening device and are returned to the bed of beads. A make-up bead system adds beads to the bed as needed to maintain a suitable bed depth. In some embodiments, the powder and beads consist essentially of silicon, and the solid masses formed are suitable for preparing silicon ingots.

Abstract: Embodiment of a disclosed seam tool comprise a rigid backing configured to be positioned about a seam region defined by at least two adjacent pattern segments. The rigid backing further includes an injection port and, typically, a gas outlet port, fluidly coupled to the seam region. The disclosed device may further include a resilient liner which contacts and forms a seal with surfaces of the pattern segments. Compensating grooves may be formed in the resilient material to allow complete filling of the seam region by weld-forming material. An injection fitting may be operably coupled to an injection port to provide an improved ability to receive weld-forming material to form welds. A method for forming a weld between plural, adjacently positioned pattern segments also is disclosed. The method comprises positioning the disclosed embodiments of the seam tool about a seam region defined between adjacent pattern segments.

Abstract: Embodiment of a disclosed seam tool comprise a rigid backing configured to be positioned about a seam region defined by at least two adjacent pattern segments. The rigid backing further includes an injection port and, typically, a gas outlet port, fluidly coupled to the seam region. The disclosed device may further include a resilient liner which contacts and forms a seal with surfaces of the pattern segments. Compensating grooves may be formed in the resilient material to allow complete filling of the seam region by weld-forming material. An injection fitting may be operably coupled to an injection port to provide an improved ability to receive weld-forming material to form welds. A method for forming a weld between plural, adjacently positioned pattern segments also is disclosed. The method comprises positioning the disclosed embodiments of the seam tool about a seam region defined between adjacent pattern segments.