Open Access Article
Phil M. Smith‡
a,
Laisuo Su‡
ab,
Yanfei Xu
c,
B. Reeja-Jayana and
Sheng Shen
*a
aDepartment of Mechanical Engineering, Carnegie Mellon University, Pittsburgh PA 15213, USA. E-mail: sshen1@cmu.edu
bDepartment of Materials Science and Engineering, University of Texas at Dallas, Richardson, TX 75080, USA
cDepartment of Mechanical and Industrial Engineering, University of Massachusetts-Amherst, Amherst, MA 01003, USA
First published on 7th October 2024
Oxidative chemical vapor deposition (oCVD) has emerged as one of the most promising techniques for conjugated polymer deposition, especially for unsubstituted polythiophene thin films. oCVD overcomes the insolubility challenge that unsubstituted polythiophene (PT) presents and adds the ability to control morphological and molecular structure. This control is important for enhancing the performance of devices which incorporate organic conductors. In this work, Raman spectroscopy, UV-vis spectroscopy, and AFM reveal that the relative amount of distortion in the polymer chains, the conjugation length and the film roughness are all affected by the CVD deposition conditions, in particular the reactor pressure. PT films deposited at 150 mT and 300 mT are found to have lower chain distortion, longer conjugation lengths and lower surface roughness compared to other deposition pressures. The oCVD PT film is also directly grafted to the trichloro(phenylethyl)silane (PTS) treated substrates, where the effect of PTS grafting is observed to significantly affect film roughness. In addition, we report the first study of the effect of oCVD PT films on the performance of lithium-ion battery electrodes. These oCVD PT films are used to engineer a LiCoO2 cathode in lithium-ion batteries. The observed improvements are a 52% increase in the discharge capacity (67 mA h g−1 to 102 mA h g−1) at 10C and a 500% improvement in cycling stability tested at 5C within the voltage range of 3.0–4.5 V (capacity fading rate is reduced from 1.92%/cycle to 0.32%/cycle).
Oxidative chemical vapor deposition (oCVD) is a vapor phase polymerization technique where all the reactants are in the vapor phase allowing for the deposition of insoluble polymers.5 Various polymers have been successfully deposited via the oCVD technique, such as PT,6,7 polypyrrole,8 polyaniline,9 PEDOT.10,11 The vapor deposition feature helps generate uniform thin films with controllable thickness for these polymers, which are crucial for applications such as surface engineering and sensor development.12,13 While there are several studies reporting the deposition of conductive polymers by oCVD, critical gaps exist in understanding the impact of deposition parameters on the morphology and electrical properties of the resulting films.10 Many conductive polymers can be derived from PT to achieve certain properties. Unsubstituted PT itself also exhibits excellent thermal and environmental stability, high conductivity, tunable electrical and optical properties, and easy processability.14 Moreover, unsubstituted PT has been successfully deposited with oCVD, using both liquid oxidants like vanadium oxytrichloride15 and solid-state iron(III) chloride (FeCl3) as the oxidant.6,7 Therefore, PT is a good candidate to investigate the impact of deposition parameters in oCVD on its morphology and electrical properties.
Here, we study the effect of the deposition pressure on the morphology and molecular structure of unsubstituted PT films deposited using oCVD. Different from the existing study that requires high flow rate (31 sccm) of monomers,6,7 we explored and optimized the chamber pressure in the low-rate region with FeCl3 oxidant. The low flow rate can help control the thin film uniformity and thickness, and thus is crucial for certain applications. The molecular structure is studied using spectroscopic characterization techniques like Raman and UV-vis, and the morphology is studied using atomic force microscopy (AFM) and scanning electron microscopy (SEM). Furthermore, we investigate the PT film deposition on trichloro(phenylethyl)silane (PTS) treated substrates as compared to untreated substrates. PTS is a silane coupling agent which can be used to bond organic and inorganic materials. Thereby, the PT films graft directly to the PTS treated substrates, which is quite unique to oCVD conjugated polymers.16–19 To demonstrate the applicability of the oCVD PT, we applied it as a coating on the surface of battery cathode electrode. The coating acts as a physical barrier between reactive electrolytes and the cathode electrolyte, which can eliminate the side reactions between them. In addition, the high conductivity of the PT coating helps the charge rate of the electrode. It is worth noting that applying oCVD polymers for battery application is a novel research direction with little reports.5 To the best of our knowledge, this is the first report on applying oCVD PT films on the performances of lithium-ion battery electrodes.
The general procedure and oCVD reactor used in this work has been reported by the authors previously.10,11 The deposition parameters for all the films studied here are identical except for the deposition pressure. This results in different film thicknesses because the deposition process was not optimized for identical film thickness but for monitoring the effect of deposition pressure on the film's morphology and structure. Due to the volatility of the monomer thiophene, heating the monomer jar is not necessary to create vapors, however, the jar temperature was maintained at 30 °C to avoid temperature fluctuations from the room which could alter the monomer flow rate. Previous reports used a total gas flow as high as 31 sccm to promote adsorption of the monomer on the substrate surface.6,7 Such a high total gas flow would necessitate a high monomer flow rate which is not conducive to smooth films. From our process development for oCVD PT films, using a monomer flow rate of ∼1.5 sccm required the stage temperature to be lower than room temperature. A temperature of 10 °C was chosen because it is the lower limit of the system used for all depositions. Typically, when optimizing CVD processes, the ratio of the partial pressure and the saturation pressure of the monomer needs to be determined. However, since the flow rate of the solid oxidant is difficult to determine, this approach could not be used. Instead, post deposition characterizations were done, the deposition parameters were adjusted, and the cycle repeated until the films met the desired requirements. Two types of Si substrates were used for the depositions. In this report the plain untreated Si substrate is referred to as “Plain” and the PTS treated substrate is referred to as “PTS”.
:
1 in volume) as the electrolyte. The PT-coated LiCoO2 was rinsed in methanol for 5 min to remove residual monomer and oxidant. The electrochemical performances of coin cells were tested using a VMP3 (Biologic Company) and LAND battery cyclers (LAND Electronics Co., Ltd). All cells were cycled using a C/10 (1C = 145 mA h g−1) rate three times within the 3.0–4.2 V voltage range before conducting other tests. All tests were conducted at room temperature (around 20 °C). The rate capability was measured using the constant–current (CC) constant–voltage (CV) charging protocol followed by CC protocol at different C-rates within 3.0–4.2 V. The current during CC charging is C/3, and the cut-off current during CV charging is C/100. EIS measurement was conducted at 4.0 V (open circuit voltage) for all cells by applying an AC voltage of 10 mV amplitude over the frequency range of 100 kHz to 10 mHz. A high voltage cycling test was carried out within the voltage range of 3.0 V to 4.5 V at 5C using CC protocol for both charging and discharging.
C stretching while the peak at ∼1460 cm−1 corresponding to the symmetric C
C stretching mode. A shift in the asymmetric C
C peak to lower wavenumbers corresponds to an increase in the conjugation length. On the other hand, the symmetric C
C peak has been shown to be independent of conjugation length.7,15,20 Table 1 provides the position of the asymmetric C
C peak for samples deposited on plain substrates and PTS substrates at different deposition pressure. For the most part, the asymmetric C
C peak shifts to lower wavenumber as the deposition pressure increases, indicating that the film deposited at 300 mT has the highest conjugation length. This holds true for both substrates used. Additionally, at each pressure, the position of the asymmetric C
C peak is very similar for both substrates indicating that the conjugation length is not affected by the different substrates. Region 2 in Fig. 1 contains four distinguishable peaks. The strongest peak located at ∼1403 cm−1 corresponds to the C–H bending mode while the peak at ∼1215 cm−1 is assigned to Cα–Cα′ linkage vibration between thiophene rings. The remaining two peaks are associated with the distorted parts of the polymer chain often called defect bands.21 The peaks in the third region show the weakest intensity of all three but is one of the most interesting regions. The peak near ∼700 cm−1 is assigned to the C–S–C thiophene ring vibration while the peaks at ∼652 cm−1 and ∼680 cm−1 are defect bands. The intensity ratio between the defect bands and the C–S–C band (I680/I700) gives a good indicator of the relative amounts of defects or distortion in the polymer chains.20,22 As seen in Table 1, films deposited at 150 mT and 300 mT demonstrate the lowest amount of chain distortion while films deposited at 100 mT and 200 mT has the highest. Except for the 300 mT film, the relative amount of chain distortion between films deposited on the two different substrates are very similar. These results suggest that films deposited at 300 mT possess the best transport properties due to the relatively larger conjugation length and lower amount of chain distortion.
![]() | ||
| Fig. 1 Raman spectra of oCVD PT films deposited on a plain substrate at different pressures. The three main region for PT films are highlighted by transparent blue boxes. | ||
| Pressure (mT) | C C antisymmetric (cm−1) |
Distortion ratio | ||
|---|---|---|---|---|
| Plain | PTS | Plain | PTS | |
| 100 | 1499.48 | 1499.48 | 0.8791 | 0.8613 |
| 150 | 1499.48 | 1498.51 | 0.8096 | 0.8165 |
| 200 | 1494.92 | 1495.88 | 0.8799 | 0.8739 |
| 300 | 1494.66 | 1494.66 | 0.7971 | 0.8314 |
The Raman spectra of pristine and rinsed films are shown in Fig. 2. The differences seen are indicative of a de-doped film. The rinsed film has narrower and more well-defined peaks compared to the broader peaks seen in the pristine films.23 The peaks between 900 cm−1 and 1000 cm−1 correspond to ferric resonances. The disappearance of the peaks after rinsing confirms the removal of unreacted FeCl3 oxidant in the deposited films. The pristine films contain both unreacted monomers and residual oxidants, which causes instabilities in the transport properties.24,25 Post deposition rinsing improves the transport and physical properties of the film. Like the data discussed from Table 1, the relative distortion ratio as a function of pressure follows a similar trend. However, the actual amount of distortion is greater in the pristine film for reasons previously discussed.
![]() | ||
| Fig. 2 Raman spectra of pristine and rinsed oCVD PT films. This spectrum represents a film deposited at 150 mT. | ||
The UV-vis absorption spectra of oCVD PT films deposited on plain and PTS substrates at different pressures are shown in Fig. 3. After rinsing the films, a single pronounced peak is seen. In addition, an absorption shoulder at ∼585 nm is observed from all samples. This shoulder has been seen previously in PT films7,15 and in poly(3-hexylthiophene) (P3HT)26 films. In P3HT films, this shoulder is a signature of closely packed polymer chains indicating that there is a small degree of ordering in the chains.27,28 From Table 2, the absorption maxima (λmax) for films deposited at 150 mT and 300 mT are redshifted compared to films deposited at 100 mT and 200 mT. This redshift of λmax is related to an increase in conjugation in the polymer films, which is a well-established relationship from previous work.29,30 This suggests that the film deposited at 150 mT has the largest conjugation length while the film deposited at 100 mT has the shortest. This result directly contradicts the Raman results where the 300 mT film was predicted to have the largest conjugation length. While Raman spectroscopy can provide information about conjugation length, UV-vis is more sensitive to the conjugation in polymers, as a result, the UV-vis result is more reliable when determining relative conjugation length.31 Furthermore, Borrelli et al. reported higher field effect mobility and channel conductivity for films deposited at 150 mT compared to 300 mT which supports the UV-vis result obtained in this manuscript.7 Comparing λmax for PT films deposited on plain and PTS substrates, the PT films on the plain substrates have larger conjugation lengths than the PT films on the PTS substrates. This suggests that the transport properties of PT films on the plain substrates will be better.
![]() | ||
| Fig. 3 UV-vis absorption spectra of oCVD PT films deposited on plain and PTS substrates at different pressures. | ||
| Pressure (mT) | λmax (nm) | Optical band gap (eV) | ||
|---|---|---|---|---|
| Plain | PTS | Plain | PTS | |
| 100 | 511 | 504 | 1.92 | 1.92 |
| 150 | 527 | 521 | 1.94 | 1.92 |
| 200 | 513 | 506 | 1.93 | 1.92 |
| 300 | 521 | 519 | 1.90 | 1.90 |
The optical band gap was determined from the tangent to the band edge or the absorption edge wavelength. The spectrum for the oCVD PT film deposited on a plain silicon substrate at 150 mT, along with the tangent line, is shown in Fig. S1.† The optical band gaps shown in Table 2, are from 1.90–1.94 eV and are in good agreement with those of other oCVD PT films.6,15,32 The two substrates give identical optical band gaps while the 300 mT sample appear to have the lowest optical band gap. Smaller band gaps are typically correlated to an enhanced conductivity which in conjugated polymers mean longer conjugation length,33,34 however, the band gap is also sensitive to defects.35,36 The defects or distortion results from Raman spectroscopy and the conjugation length from UV-vis only paints part of the picture when it comes to understanding carrier mobility in these films. Thermal and electronic characterization of these films will provide a more complete story, this will be explored in a subsequent manuscript.
We employ atomic force microscopy (AFM) to study the morphology of the prepared oCVD PT thin films. 10 μm × 10 μm AFM scans of the oCVD PT films deposited on plain and PTS substrates at different deposition pressures are shown in Fig. 4. The corresponding 2 μm × 2 μm scans and SEM images are shown in Fig. S2 and S3,† respectively. The morphological features of the resulting PT films in this work are smaller and more well defined compared to the porous morphology previously reported for oCVD PT films deposited using the oxidant FeCl3.7,37 This is further confirmed by the root mean square (RMS) roughness listed in Table 3. At the same deposition pressure, the morphology and roughness of PT films are visually smoother and smaller than previously reported.7 This is mainly due to the low substrate temperature during deposition which promotes monomer adsorption and the significantly lower monomer flow rate which promotes the growth of smoother films.38,39 As a function of deposition pressure, the film roughness decreases with increasing deposition pressure (Table 3) except for the film deposited at 150 mT which has a lower roughness than the film deposited at 200 mT. Comparing the different substrates, for the most part, the films deposited on the plain substrates have lower roughness values and have lower film thickness. This could be due to non-uniform distribution of binding sites during PTS attachment causing small dense polymer regions as seen in the AFM and SEM images. This, however, does not significantly affect the roughness of the films deposited on the PTS substrates since the roughness is still within an order of magnitude to the films on the plain substrate. As mentioned earlier, only the deposition pressure was adjusted during film growth while all other deposition parameters were held constant. This explains the disparity among the measured film thicknesses. Since the oxidant is kept in the chamber, the deposition pressure would affect the temperature at which the oxidant vaporizes as a result to optimize the deposition for comparable film thickness, the oxidant temperature would also need to be adjusted.
![]() | ||
| Fig. 4 10 μm × 10 μm AFM scans of oCVD PT films deposited on plain and PTS substrates at different deposition pressures, including (A) 100 mT, (B) 150 mT, (C) 200 mT, and (D) 300 mT. | ||
| Pressure (mT) | Roughness (nm) | Film thickness (nm) | ||
|---|---|---|---|---|
| Plain | PTS | Plain | PTS | |
| 100 | 7.1 | 6.8 | 214 ± 11.2 | 218 ± 4.6 |
| 150 | 2.5 | 6.6 | 107 ± 2.2 | 155 ± 3.7 |
| 200 | 4.8 | 10.7 | 162 ± 5.0 | 258.5 ± 11.5 |
| 300 | 1.6 | 7.3 | 63 ± 3.6 | 89 ± 2.3 |
Surface engineering is an effective method to improve the performance of battery electrodes,40 and oCVD polymers have been proven to be effective at reducing interfacial resistances and promoting charge transport across electrode particles.11,13 Particularly, the oCVD technique can deposit an uniform coating layer on a complex surface and control the coating thickness on the scale of nanometers. As a proof of concept, we present the effect of a 50 nm oCVD PT film coating on the overall electrochemical performance of LiCoO2 electrodes. The thickness of the films is measured using a Rudolph Ellipsometer AutoEL III. From our previous study, a ∼50 nm thick polymer coating provides the best protection to the LiCoO2 battery electrodes.13 Fig. 5A compares the discharge curves of the two types of coin cells made from LiCoO2 with and without the PT coating. The PT coating not only increased the discharge capacities, but also promoted the discharge voltages at high rates. For example, the discharge capacity was increased from 67 mA h g−1 to 102 mA h g−1 at 10C by the PT coating. Fig. 5B further compares the rate capability of LiCoO2 electrodes. The statistical results from four coin cells show that the PT coating significantly improved the rate capability. Compared to the C/3 capacity, the 10C capacity remains 77% in the PT coated LiCoO2 electrodes, while it only remains 37% in the pristine LiCoO2. Fig. 5C compares the electrochemical impedance spectroscopy (EIS) of coin cells with the two different types of the LiCoO2 electrodes. As the same lithium metal was used as the anode for all tested coin cells, the different impedance was contributed from the cathode side. The reduced overall impedance suggests that the PT coating promoted the Li+ and electron transport at the electrode–electrolyte interface. The increased Li+ transport kinetics explains the improved rate capability of the LiCoO2 electrode, as shown in Fig. 5A and B. Moreover, Fig. 5D shows that the PT coating largely improved the cycling stability of LiCoO2 electrodes under high current (5C) and high voltage (4.5 V). For example, the capacity fading rate is reduced from 1.92%/cycle to 0.32%/cycle, a 500% improvement, when the specific discharge capacity of the LiCoO2 cathode degraded to 50 mA h g−1. The transport of Li+ in the PT film can be correlated to the Li+–polymer binding energy and the number of Li+ binding sites in the polymer. Small binding energy and sufficient binding sites in the PT film facilitate Li+ transport in the polymer film.
Footnotes |
| † Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d4ra06472k |
| ‡ These authors contributed equally to this work. |
| This journal is © The Royal Society of Chemistry 2024 |