azonenberg changed the topic of #homecmos to: Homebrew CMOS and MEMS foundry design | Wiki: http://homecmos.drawersteak.com/wiki/Main_Page | Repository: http://code.google.com/p/homecmos/ | Logs: http://en.qi-hardware.com/homecmos-logs/
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<hozer> so I had a stupid idea a few seconds ago... how hard would it be to make a silicon wafer from corn cobs.. http://www.academia.edu/3429841/Extraction_and_characterization_of_Amorphous_Silica_from_Corn_Cob_Ash_by_Sol-Gel_Method
* mrdata checks
<mrdata> hozer, whats the purity of the silica?
<mrdata> they only show extraction yield and moisture content
<mrdata> so, if 53% yield then 53% of the silican in the ash was extracted
<mrdata> but what else came with it?
<mrdata> any aluminum or vanadium would be picked up, and some other stuff; idk what levels those are, in corn cob ash, though
<hozer> well I can get plenty of corn cob ash
<mrdata> thats good
<mrdata> and NaOH is plentiful
<mrdata> so,
<hozer> I spread several tons of corn cobs around a field today
<mrdata> can you find a way to figure purity?
<mrdata> ok, maybe start with a tonne of cobs, reduce that to ashes, do the extraction
<mrdata> will there be under about 4L of ashes from a tonne of cobs?
<mrdata> or more
<hozer> well
<hozer> collecting a ton is actually a bit of a problem, they come flying out the back of the combine
<mrdata> pick up a bushel then
<mrdata> you might get a couple cups of ashes
<mrdata> and can probably test those
<hozer> well I wonder how much contact with the ground would change it
<mrdata> do you have a kiln?
<hozer> but I don't have one of those ;)
<mrdata> you can rinse them off before firing if you want
<mrdata> even float them
<hozer> some sort of rinse/wash is probably a good idea
<mrdata> heck, you can probably compare these to starting with a pile of earth
<mrdata> what sort of soil do you have?
<hozer> hrrm
<hozer> black, clay loam
<hozer> you think aluminum and vanadium are the most likely contaminants?
<hozer> The farm equipment is generally steel/iron (maybe some aluminum parts)
<mrdata> aluminum is defrinitely a major component of clay
<mrdata> the black is organic matter
<mrdata> vanadium is only going to be around in traces, as is gallium i think
<mrdata> other elements end up in this too usually
<hozer> lots of dolomite limestone around too (Ca/Mg
<mrdata> yes, but those will not be amphoteric
<mrdata> oh, zinc will end up in the product as well i believe
<hozer> hrrm
<hozer> so galvanized sheet metal might be an issue
<mrdata> yeah, anything amphoteric is going to get in
<mrdata> so, at least for chip making, you want to purify your silica
<mrdata> 99.999% is okay for silicon solar cells
<mrdata> there is a method for removing phosphorus and boron with molten calcium iirc
<mrdata> fairly recent us patent
<mrdata> aluminum is the number 1 contaminant probably
<mrdata> biologically, it gets taken up by plants to some extent
<diginet> it does not make sense to try and make your own wafers
<diginet> I cannot see how it would ever be feasible to do so for an individual
<SpeedEvil> Well - it depends.
<SpeedEvil> i could see it being fun to make a working semiconductor from scratch
<SpeedEvil> and that's not quite impossible.
<SpeedEvil> Is it sensible or making economic sense - in almost no case
<SpeedEvil> Sometimes stupid stuff is fun thouh.
* SpeedEvil is seriously considering making an energy storage battery, for example.
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<hozer> well, I can make a convoluted argument about how the only thing in my supply chain as a farmer that I can't replace myself are the computer chips for precision farming
<hozer> thus it would be wise to invest in being able to make silicon wafers from corncobs
<hozer> the reality is it makes no economic sense, except for one thing:
<hozer> * leverage so farm equipment and silicon manufacturers know I won't buy their products unless I have the freedom and ability to replace the silicon chips
<hozer> I can buy a used combine for say $5000 and fix it up, and it picks the same quality corn as a $250,000 new one that includes GPS auto-steer
<hozer> so if I buy 2 or 3 used ones, and spend $100,000 developing/modifying some open-source autonomous robot software , I can pick corn faster for half the price
<SpeedEvil> err - no - that's retarded
<SpeedEvil> The starting point there isn't 'build a silicon chip'
<SpeedEvil> It's 'buy a beaglebone black' or whatever
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<mrdata> feasibility of making your own wafer has improved, though, since the patent i mentioned above
* mrdata digs up the reference..
<SpeedEvil> mrdata: sure
<mrdata> ugh. cant find the recent one, yet; similar though, is http://www.google.de/patents/US4828814
<mrdata> the process made use of calcium
<mrdata> the newer process cut costs dramatically, but still yielded 99.999% purity
<mrdata> good enough for PV
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<mrdata> still havent found it, but here's a review article on various methods
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<mrdata> "The target cost in the race to produce 6-nines pure s-Si is $15 per kg."
<nmz787_i> have you seen the spherical silicon substrates?
<nmz787_i> they made circuits on them, and used some dropping droplet method to create each spherical crystal
* SpeedEvil ponders making solar cells as balls, then cleaving them.
<mrdata> how would that work
<SpeedEvil> You create Si balls - say 10um in diameter.
<SpeedEvil> Then you dope them as they fall through a hot compressed gas to form solar cells.
<SpeedEvil> Cleave themthrough some mechanism I'm omitting, and then connect up the base and the edge through some means I'm also omitting
<nmz787_i> i didn't even search solar
<nmz787_i> 'Crystal evaluation of spherical silicon produced by dropping method and their solar cell performance'
<nmz787_i> i only searched spherical silicon crystal
* SpeedEvil stabs being unable to read papers.
<nmz787_i> this is where i first read about the spherical Si and circuits on them http://www.natureinterface.com/e/ni07/P058-059/
<nmz787_i> '(a) Gas phase process (single tube)'
<mrdata> dont you need two dopants, on opposing sides?
<SpeedEvil> no
<SpeedEvil> inside and outside
<SpeedEvil> And you don't actually as I found out need to cleave them - just polish off one edge
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<_Sync_> SpeedEvil: how will you connect them?
<SpeedEvil> Duct tape!
<SpeedEvil> 0th suggestion - take some glass, with x/y tracks on it, covering say 10% of the surface in a collector mesh pattern, and slight dimples.
<SpeedEvil> spread balls on evenly so one goes in each dimple.
<SpeedEvil> reflow
<SpeedEvil> now, polish off the back 1/8th of the balls or so, and then etch another 1/8th with a dip or something.
<SpeedEvil> Now, place on another conductive substrate and reheat