Morning (06–14)
Physics Lab
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FIRST-PRINCIPLES PROCESS MODEL · PERC

Physics Lab

Live single-diode I-V solver coupled to diffusion, PECVD, firing, and lamination kinetics.

Cell I-V (single diode)

η = 22.84%
Voc
0.721V
Jsc
0.04A/cm²
FF
0.775
Pmax
6.26W
η
22.84%

Derived cell parameters

Iph
11.194A
I0
1.10e-10A
Rs
4.02mΩ
Rsh
360Ω
n (ideality)
1.10
Tc
25°C
Cell electrical → diffusion (Rsheet) → PECVD optics (n, d) → firing (Ag-paste Rc) → I-V solver. Every arrow is computed from the recipe knobs, not assumed.

Diffusion (POCl₃)

in
Rsheet 100 Ω/□
Tpeak855°C
Dwell1500s
POCl₃ flow1.00×nom

PECVD SiNₓ

in
n=2.08 · d=75 nm · R̄=10.0%
RF power3500W
Pressure1500mTorr
SiH₄/NH₃0.45
Dep time320s

Firing furnace

in
Tcell 770 °C · Rc×1.00 · t>600°C 18.6 s
Peak setpoint770°C
Belt speed5.8m/min
Cooling flow1.00×nom

EVA lamination

in
DoC 99% · bubble risk 0% · pass 100%
Plate T150°C
Cycle time900s
Vacuum dwell300s
Press dwell480s

Vibration-driven RUL · Diffusion exhaust blower

BPFI 160.7 Hz · BPFO 106.3 Hz · BSF 69.8 Hz
RUL 457 h
Hours observed800
Degradation rate0.00
Trend fit: v(t) = 1.68 · exp(1.15e-3·t). Cross-time with ISO alarm (7.1 mm/s) = remaining useful life.

Yield from physics · 200-cell Monte Carlo

η̄ = 22.85%
Cells sampled around the coupled (Iph, I0, Rs, Rsh) state — no hard-coded yieldRate.
A 100% · within 0.3 pp
B 0% · 0.3–1.0 pp
C 0% · >1.0 pp loss

Equipment-level load · physics-driven

Σ 341 kW
Diffusion furnace47 kW
PECVD chamber23 kW
Firing furnace24 kW
Lamination press40 kW
Compressed air69 kW
Cleanroom HVAC96 kW
Lighting + IT42 kW

Causal chain

  1. STEP 1
    Process inputs
    Tpeak, dwell, RF power, belt speed, vacuum dwell
  2. STEP 2
    Physics intermediates
    Rsheet 100 Ω/□ · n 2.08 · Tcell 770 °C
  3. STEP 3
    Cell parameters
    Iph 11.19 A · Rs 4.0 mΩ · I0 1.1e-10 A
  4. STEP 4
    I-V solution
    Voc 0.721 · FF 0.775 · η 22.84%
  5. STEP 5
    Yield outcome
    Lam pass 100% · grade band derived from η-band