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Cu- or Ag-containing Bi-Sb-Te for in-line roll-to-roll patterned thin-film thermoelectrics
Xudong Tao1, Qianfang Zheng2, Chongyang Zeng3
1Department of Materials, University of Oxford, Parks Road, Oxford, UK. xt240@cam.ac.uk.
Nature Communications
|January 3, 2025
Summary
This study demonstrates a new method for creating flexible thermoelectric devices using roll-to-roll processing. The technique enhances material performance and enables wearable electronics manufacturing.
Area of Science:
- Materials Science
- Nanotechnology
- Electronics Engineering
Background:
- Selective Metallization Technique (SMT) is promising for flexible electronics but faces challenges with sputtering functional materials.
- Roll-to-roll (R2R) processing offers high-throughput manufacturing potential for large-scale flexible electronics.
- Thermoelectric materials convert heat energy into electrical energy, crucial for waste heat recovery and wearable power generation.
Purpose of the Study:
- To adapt the Selective Metallization Technique for simultaneous sputtering and evaporation of thermoelectric materials.
- To demonstrate large-scale, high-throughput manufacturing of functional thin-film thermoelectric patterns using R2R processing.
- To investigate the impact of metal evaporation on material properties and device performance in flexible electronics.
Main Methods:
- Simultaneous sputtering of Bismuth-Antimony-Telluride (Bi-Sb-Te) and evaporation of Silver (Ag) or Copper (Cu) using SMT.
- Roll-to-roll processing of a 0.8 m wide polymer web at a speed of 25 m/min.
- Plasma cleaning to remove residual oil contamination affecting Bi-Sb-Te deposition.
Main Results:
- Achieved high-throughput production of nanometer-thick functional thin-film thermoelectric patterns.
- Demonstrated significantly enhanced thermoelectric performance in room-temperature-deposited materials.
- Observed an n-type-to-p-type transition in Bi-Sb-Te composite films containing Ag or Cu.
- Validated thermoelectric devices in wearable applications, including a wristband design.
Conclusions:
- The adapted SMT effectively integrates sputtering and evaporation for advanced thermoelectric thin-film fabrication.
- Roll-to-roll processing enables scalable and efficient manufacturing of high-performance flexible thermoelectric devices.
- The developed material system and fabrication process are suitable for next-generation wearable electronics and energy harvesting applications.
