TWI441937B - 形成用於電解質薄膜之濺鍍靶材的方法 - Google Patents

形成用於電解質薄膜之濺鍍靶材的方法 Download PDF

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TWI441937B
TWI441937B TW097149784A TW97149784A TWI441937B TW I441937 B TWI441937 B TW I441937B TW 097149784 A TW097149784 A TW 097149784A TW 97149784 A TW97149784 A TW 97149784A TW I441937 B TWI441937 B TW I441937B
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sputtering
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lithium
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Bernd J Neudecker
Jay F Whitacre
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Infinite Power Solutions Inc
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    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
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Description

形成用於電解質薄膜之濺鍍靶材的方法
本發明與用於薄膜電化學能量儲存及轉換裝置的鋰離子薄膜電解質的製造有關。
目前，鋰離子電解質膜層是由陶瓷、絕緣濺鍍靶材沉積而成，其利用射頻(RF)激發(1MHz-1GHz)於濺鍍靶材上、以RF微調器與RF匹配網路而行。此方式的主要理由在於，陶瓷靶材組成或計量可製為與欲沉積之鋰離子膜層的計量相同、或至少大部分相似；然而，使用陶瓷絕緣濺鍍靶材與RF濺鍍方法之相關成本高、沉積區域與速率受限、且有硬體精密度之挑戰。
電絕緣類型靶材在濺鍍時一般需使用RF激發；否則，如未使用RF激發(例如：以直流電流(DC)、脈衝式DC(如250kHz)、或較低頻率之交流電流(AC；如100kHz)激發)，靶材表面實質上會充電，並以電弧的形式對基板、腔室壁及/或深空間屏蔽釋放建立之電荷。電弧的程度可能嚴重到使連接至濺鍍靶材的電源中之電子裝置都無法避免此事件的發生，其對基板上薄膜成長有不利的影響；或是濺鍍程序會因為電源的預防性電子裝置而過度頻繁地被中斷，導致無法發生濺鍍沉積。不幸的是，在濺鍍靶材周圍的全部RF電子裝置都相當昂貴，且需要真空沉積腔室以與RF相容。在半導體製程中所使用的大部分大型濺鍍沉積工具並不與RF相容，而僅與直流電流(DC)或脈衝式DC相容；設計或建造新的、大型的真空沉積腔室耗費相當的時間與金錢，這是因為這種腔室並不被大量建造與販售。
RF濺鍍的另一個問題是，對於氧化物介電質薄膜沉積而言，由於在製造大面積陶瓷濺鍍靶材時適用於濺鍍程序的厚度限制(例如：1/4英吋)，陶瓷靶材一般是由多個較小瓦材(tile)形成。此外，RF濺鍍所需之反應器也較為複雜；特別是在RF系統中，對濺鍍陰極的低電容有效RF電力分佈之工程是困難的，向前饋送低電容以及將電力返送至反應腔室的真空管通常會暴露電力路徑，使得在某些相配網路之阻抗調整的條件下產生擴散電漿放電。
一般而言，大面積、絕緣的陶瓷濺鍍靶材是難以製造的，這是因為在高速濺鍍沉積之熱應力下進行濺鍍時，就陶瓷濺鍍靶材之瓦材性能需求而言，其組成瓦材尺寸(單一瓦材或多重瓦材)係受限於今日的可用陶瓷處理方法(冷壓加上後續的燒結、或是對適當的起始粉末進行熱壓)。然而，在使用於磁控濺鍍靶材時，由於陶瓷瓦材固有的脆性及其受限之實際厚度(就實際使用需求而言，一般厚度約1/2至1/4英吋)，其中磁電管(magnetron)的磁場必須均勻穿透濺鍍靶材的瓦材厚度，因而瓦材製造者面臨一種具挑戰性的任務：在受限於其厚度下，使靶材瓦材盡可能為大。故，靶材製造者已遭遇較寬鬆定義的每一靶材瓦材材料之面積/厚度比限制的困難，在該限制上靶材瓦材產率係變低至不具經濟效益。為求實際可用以及妥善實行Li3 PO4 濺鍍靶材瓦材，今日對1/4英吋厚之靶材的瓦材尺寸限制係直徑為10”之等級、或非碟形之7”×7”大小。
除了難以(或甚至不可能)製造出在高速濺鍍沉積下仍機械上足以回復之大面積、絕緣的陶瓷濺鍍靶材外，仍有其他問題會使得已發展良好之陶瓷濺鍍靶材(例如Al2 O3 )與較未發展之陶瓷材料(例如Li3 PO4 )的理論可行之濺鍍靶材面積分別受到限制而低於約1000cm2 與500cm2 ，例如局部充電/起弧、與其他區域之串音、以及電源與沉積環境之間嚴重且變化之阻抗不匹配。
鑑於陶瓷瓦材製造以及RF靶材激發之相關使用的上述問題，如果金屬瓦材所需之反應濺鍍沉積可行的話，便樂於從陶瓷轉換為金屬靶材瓦材，因為厚度約為4英吋之金屬板可更輕易地製造為具有大面積。另一項使用金屬靶材優於陶瓷靶材的固有好處係源於金屬靶材之絕佳延展性使其可於高出相當程度之沉積功率與沉積速率下進行濺鍍，其於濺鍍靶材瓦材內部產生一具應力之溫度梯度，相較於脆性的陶瓷瓦材而言，金屬靶材瓦材可藉此而更直接地進行處理。
鋰離子薄膜電化學儲存與轉換裝置的大量生產之經濟效益係與既定生產量之主要花費高度相關，而生產量係受到沉積速率、沉積面積、沉積產量與設備暖機時間影響。因此，在將鋰離子薄膜電化學儲存與轉換裝置的生產製程放大為工業等級時，必須結合RF濺鍍靶材使用相對較小的脆性陶瓷濺鍍靶材或靶材瓦材的問題會是一個明顯的經濟障礙。
為避免RF濺鍍中所涉及的成本與工具問題，可使用DC或脈衝式DC靶材激發功率而從電傳導濺鍍靶材濺鍍沉積出電解質或介電質膜層。在這種情況下，充電與電弧的問題會變得較少且其一般係可受控制。這些DC濺鍍方法皆比RF便宜，且在真空沉積系統中皆較易於施行。然而，為了從電傳導濺鍍靶材得到電絕緣、但為離子(此處為鋰離子)傳導的電解質或介電質膜層，必須在反應性氣氛中濺鍍沉積靶材材料，以得正確計量比之電絕緣薄膜組成。在某些例子中，可選擇經由從適當的第二濺鍍靶材進行共濺鍍而得到正確的薄膜計量比；若為電絕緣，其需RF功率激發；而若為電傳導，則可藉由DC或脈衝式DC進行濺鍍。
在產生濺鍍沉積靶材的領域中並沒有關於在沉積時可以DC或脈衝式DC沉積來製造絕緣/介電、含具電解質特性之鋰薄膜的實質記錄，也沒有對特別使用替代濺鍍靶材組成或配置以進行濺鍍材料之DC沉積、使其在沉積時同時藉由變成電絕緣與離子傳導而轉化為電解質的公開工作文獻，這種公開資訊或專利的不足不只是關於鋰離子，也關於所有的電解質。在此領域中的大部分公開工作文獻都是針對如何增加靶材面積、或是如何增進硬體設備。然而，本發明之動機在於製造一種傳導性靶材組成，其允許了使用DC或脈衝式DC濺鍍功率來更便宜且更快速地完成鋰離子電解質薄膜。
美國專利申請第2006/0054496號揭露了藉由DC濺鍍方法自一金屬靶材材料沉積出氧化物與氮氧化物薄膜。然而，此份文獻係針對濺鍍硬體而行，其並未解決如調整靶材的組成/結構以增進濺鍍材料(其物理氣相沉積薄膜可轉化為薄膜電解質)的DC功率沉積之問題。
美國專利號第5,753,385號(「’385專利」)使用了鋯與釔之金屬濺鍍靶材來形成氧化物，其用於固體氧化物燃料電池中作為高溫、氧離子傳導薄膜。雖然這些薄膜具有電解質特性，然其僅為高溫電解質特性且僅特定為氧離子相關。相對的，本發明係針對如周圍環境溫度之鋰離子電解質。形成氧離子電解質與鋰離子電解質的基本化學與物理參數是非常不同的。舉例而言，高溫氧離子電解質需要是結晶態，而本發明之鋰離子電解質僅需為玻璃態或非晶態。事實上，當本發明之鋰離子電解質在其製造期間或在其生命週期的任一時間點之後是結晶態、或變成結晶態時，其將使相關之鋰薄膜電化學儲存與轉換裝置嚴重限制為只可使用非金屬鋰離子陽極，這是因為金屬鋰陽極會經由結晶態電解質內部的晶界擴散而產生從陽極到陰極的一條電化學短路路徑，而使鋰薄膜電化學儲存與轉換裝置短路。如果無晶界存在(玻璃態或非晶態鋰離子電解質)、或幾乎無晶界存在(奈米晶態鋰離子電解質)，便不會發生無意及不想要的電化學短路形成。’385專利可以避免使用(高溫氧離子)結晶態電解質的原因主要在於燃料電池裝置不具潛變、輕易擴散、會產生短路的金屬鋰陽極。由於本發明與’385專利的動機與效益非常不同，熟習該領域技術之人士並不會以’385專利為基礎而藉由非RF濺鍍沉積技術來製造如鋰離子薄膜電解質。
美國專利第7,179,350B2號揭露了一種適用於反應性濺鍍的最佳複合方式，藉此，磁控頭係由DC控制器與RF控制器兩者同時驅動。然其目的是在於濺鍍硬體的調整而並非針對用於產生鋰電解質薄膜的靶材組成。
然由於以射頻(RF)濺鍍來沉積電池與燃料電池薄膜電解質已經超過十年，用於這些成長的儀器已變為相對的小：僅止於研究與發展或引導線路系統。由於此技術已調整至需要的(有用的)完整工業等級的規模，因而需要更具經濟效益的設備以及更低成本的消耗。因此，非常需要可以在非常大面積上藉由使用較大的金屬靶材及較不昂貴的DC型濺鍍靶材激發而更快速、更少花費地在非常大面積上濺鍍沉積出電解質與介電質膜層，且適當的解決方式應會明顯節省在高生產量期間的時間與金錢。
解決背景技術之特定缺失以及相關產業之迫切需求的本發明各種構想與實施例係詳細舉例說明於下；據此，本發明係與濺鍍靶材及形成濺鍍靶材的方法有關，其實質上處理了因習知相關技術的限制與缺失而產生的一或多種缺陷及問題。
在本文中，使用用語「電傳導」與「電絕緣」來描述材料時，係可分別與「電子性傳導」與「電子性絕緣」替換；使用這些用語所描述之材料並非排他地或內含地指該材料是否同時為傳導離子。
薄膜電化學儲存與轉換裝置包括電絕緣、但具離子傳導性之膜層，即所謂的電解質或介電質膜層°在濺鍍沉積這些膜層時，可使用電絕緣或電傳導之濺鍍靶材。本發明之薄膜電化學儲存與轉換裝置應用鋰離子電解質膜層(離子傳導膜層的一種)，其主要是傳導鋰離子。
本發明之實施例的構想之一包括了使用較不昂貴的DC或脈衝式DC方法來進行電絕緣但為鋰離子傳導薄膜(傳導性陶瓷薄膜)之濺鍍沉積；相較於較為精密複雜且較為昂貴的RF方法而言，DC或脈衝式DC兩者於任何真空沉積工具/腔室中皆可施行地更為簡單且更為可靠。這種DC或脈衝式DC的方式使用電傳導濺鍍靶材並藉由反應性濺鍍沉積而將其組成轉換為正確的薄膜計量比。
本發明之實施例的另一構想係為克服濺鍍靶材尺寸的實際限制，包括表面積與厚度、及/或多瓦材之濺鍍靶材內的濺鍍瓦材尺寸，以沉積出所需之電絕緣、鋰離子傳導電解質或介電質膜層。
本發明之實施例的又一構想包括金屬靶材具有比對應的陶瓷材更高的熱傳導性，而可使用較厚的金屬濺鍍靶材，這是因為對於給定的濺鍍靶材厚度而言，金屬靶材於靶材自冷卻之靶材背板透過濺鍍靶材整體塊材而冷卻時更有效率，然其熱梯度一般卻小得多。使用較厚的金屬靶材之相關優點為維修排程的頻率較低、生產設備的冷機時間減少，且因而具有較低的薄膜電化學儲存與轉換裝置製造成本，這是因為較厚的濺鍍靶材可運作較長時間才需要被替換。需要在靶材厚度與濺鍍靶材表面之磁電管作用之間尋求一種折衷方式以使生產濺鍍設備的性能得以最佳化。
以下將結合伴隨圖式中所示之示範實施例來進一步詳細說明本發明之上述與其他構想。
應知本發明並不限於此處所說明之特定方法、組成物、材料、製造技術、用途以及應用方式，其可視情況而加以變化；同時應知此處所使用之用語係僅為說明特定實施例之用，而非用於限制本發明之範疇。必須注意的是，在此處與如附申請專利範圍中，若非於文中特別清楚指明，單數形式「一」、「一個」以及「該」也包括複數態樣；因此，舉例而言，「一元件」是代表一或多個元件，且包括該領域技術人士所知的等效形式。同樣的，「一步驟」或「一裝置」是代表一或多個步驟或裝置，且包括其子步驟與次要裝置。所使用之所有結合是為以可能包含的形式而被瞭解，因此，如非特別於文中指明，用語「或」應被理解為具有邏輯上「或」的定義、而非邏輯上「排除其他方式的或」的定義。此處所說明的結構是為被理解為也可代表這些結構的功能性等效例。如非於文中清楚指明，用於表達趨近之語言應可被如此理解。
如非經定義，此處所使用的所有技術性與科學性用語具有與發明所屬領域技術人士所共同熟知者相同的意義；本文說明的是較佳的方法、技術、裝置與材料，然與此處所述者具有相同效果的任何方法、技術、裝置與材料也可實際使用或用於測試本發明。本文所述之結構僅為被理解為代表這些結構的功能性等效例；除非在說明書內文或申請專利範圍中特別指明，否則如「靶材」與「靶材瓦材」等用語是可以互相交替使用的。
所說明之所有專利與其他發表文獻係藉由引用形式而併入本文，以作為說明與揭示之用；舉例而言，在這些文獻中所說明的方法可與本發明連結使用。這些文獻係單獨作為發明申請前之揭露用，而並非代表發明人認同可由先前發明或基於任何其他理由而推知這些揭露內容。
圖1說明了根據本發明某些實施例之用於製造鋰離子薄膜電解質的示範程序100，該鋰離子薄膜電解質係用於薄膜電化學能量儲存與轉換裝置。舉例而言，程序100包括了製造一機械上強健且實質上具傳導性的濺鍍靶材(步驟101)、提供一真空沉積腔室(步驟103)、濺鍍該機械上強健且實質上具傳導性的濺鍍靶材(步驟105)、以及於一反應性濺鍍氣體氣氛中沉積該鋰離子薄膜電解質(步驟107)。
根據本發明之實施例，在步驟101中，濺鍍靶材係由電傳導性(或至少半導性)靶材材料所製成，其於室溫下具有高於約10-4 S/cm之傳導度。就本發明而言，室溫下傳導度較佳是至少10-8 S/cm，且最佳是在室溫下為1S/cm。藉由使用適當材料作為濺鍍靶材並使其運作於反應性氣體環境中，即可沉積出電絕緣但具鋰離子傳導性之薄膜。此效應仰賴於使用反應性濺鍍氣體環境，藉此讓產出之靶材材料彼此反應，並與濺鍍電漿中中性及/或離子化成分的部分子集合反應，以於基板上形成一種新的化學化合物。在步驟107中，於一反應性濺鍍氣體氣氛中進行之沉積可以將自一鋰離子傳導濺鍍靶材所濺鍍之材料轉化為電絕緣且具鋰離子傳導性之電解質薄膜。在步驟107中，可用的氣體成分包括了以氣態形式(化學元素或化學化合物)導入濺鍍反應室之氧、氮、氟、氯、溴、碘、硫、硒、碲、磷、砷、銻、鉍、鉛、碳、氫、矽、鋰、鈉、鎂與鋯。可能的靶材組成包括鋰、磷、氧、氮、氟、氯、溴、碘、硫、硒、碲、銻、鉍、鉛、碳、氫、矽、鈉、鎂與鋯，以及選自磷酸鋰(Li3 PO4 )、氮化磷酸鋰、鋰磷化物與次磷化物(Lix P，1≦x≦100)、鋰氮化物與次氮化物(Lix N，3≦x≦100)、磷氧化物與次氧化物(POx ，x≦2.5)、磷氮化物與次氮化物(PNx ，x≦1.7)、以及鋰氧化物與次氧化物(Lix O，1≦x≦100)所組成之群組的材料。也可以選擇材料系統，使得因與濺鍍氣體反應而形成於靶材表面上的任何絕緣薄膜不實質妨礙後續的沉積步驟。在沉積時，薄膜的表面上會發生反應，使得濺鍍成分與氣體成分得以轉化為電解質薄膜。
藉由使靶材具電傳導性，靶材激發的類型便不再受限於RF功率。因此，在步驟103中，所提供之真空沉積腔室不一定要與RF相容，否則則因大量製造工具而具有難度。同樣的，步驟105中的濺鍍程序也可以用比RF便宜的DC或脈衝式DC功率電子元件以較高速率進行。此外，步驟107中的沉積程序可比先前之RF方法更快且更便宜地完成。
根據本發明之實施例，係可以RF(從1MHz至1GHz)、AC、脈衝式DC與DC功率之任意組合(單獨或一起組合為不同形式)而進行步驟103、105與107，以產生所需之薄膜。也可行的是，在步驟107中，可使用非濺鍍技術(例如：熱蒸鍍、化學氣相沉積、或陰極電弧沉積)來依序沉積出一種以上的薄膜成分。此一非濺鍍之成分係由一電絕緣或傳導來源沉積而成，後者之來源材料最佳是包括在反應性氣氛中關於來源材料的化學反應性所進行之沉積。
根據本發明之實施例，步驟101中的濺鍍靶材可由單一化合物、多成分化合物或具有明顯不同組成之靶材範圍內的靶材瓦材集合所製成。在所有的情形中，個別瓦材區段較佳為大於300cm2 。如果需要一種以上的不同種類之靶材來產生所需的薄膜，則可使用基板轉移結合選擇性靶材轉換及/或自多種濺鍍陰極之沉積，其濺鍍之物種係同時被引導向基板上正在成長的薄膜。本發明之另一附加效益為電傳導靶材比一般的電絕緣靶材熱傳導性更佳，這種熱傳導性的增加允許了比先前那些薄靶材(0.6cm)厚之較厚靶材(達5cm)之使用，藉以降低靶材替換的頻率(因而降低了製造的整體成本)。
以下實例係用於提供對本發明之進一步瞭解，並納入說明書做為說明書的一部分，以描述本發明之示範實施例。
實例1(圖2)提供了程序100之一示範實施例，其中，具有組成為Li2.9 PO3.3 N0.46 之LIPON電解質薄膜205係藉由DC、脈衝式DC、AC或RF反應性濺鍍而自組成為Li3 P之半導體靶材沉積在基板207上，其係浸沒於含有濺鍍材料及氧與氮反應氣體混合物(且具有、或不具如氬氣之惰性氣體)之濺鍍電漿煙塵203中。由於沉積之Li與P物種與氧結合的親和力比氮高，故O2 /N2 比率係低於1/100。對於真空沉積反應器內部的既定氧/氮比率(例如1/1000)而言，動能與熱動力因子兩者皆決定所成長之Lix POy Nz 薄膜中的計量參數x、y與z。這些動能參數包括了靶材濺鍍功率(例如：對於直徑為10英吋之Li3 P靶材而言是2000W)、脈衝週期(例如：週期為電力開啟2μs及電力關閉2μs)、靶材與基板間距離(例如：7.5cm)、沉積速率(例如：3μm/h)、基板溫度(例如：150℃)、基板偏壓(例如：-70V)、氮氣流率(例如：300sccm)、以及氧氣流率(例如：0.3sccm，其係透過含氧量為0.1vol%之N2 氣體來源而間接形成)。相對於這些動能參數，基板溫度(在其他因子中，其皆為濺鍍靶材功率之函數)以及成長薄膜表面之氧/氮比率等熱動力因子同樣會影響成長之LIPON薄膜的計量比。
實例2(圖3)提供了程序100之一示範實施例，其中，具有組成為Li2.9 PO3.3 N0.46 之LIPON電解質薄膜205係藉由DC、脈衝式DC、AC或RF反應性濺鍍而自由富鋰之Lix P(x>>3)305與Li2 O 307所組成之複合靶材301沉積而成，該複合靶材301係由實質上彼此靠近、交替配置之Lix P瓦材與Li2 O瓦材以微米等級或以釐米等級複合而成，因此在反應性氣體(至少是含有氮氣之濺鍍電漿煙塵303、另含有或不含氬氣等惰性氣體)中濺鍍時，Li/P的濃度比率達約2.9，O/P比率達約3.3，而N/P比率約為0.46。Lix P(x>>3)305與Li2 O 307的微觀組成較佳為高於釐米尺度之複合物，這是因為其提供了濺鍍靶材301之一半導性表面，其有助於在DC或脈衝式濺鍍條件下操作靶材。
實例3(圖4)提供了程序100之一示範實施例，其中，濺鍍靶材401係包括Li3 N 407、而非實例2中所述之Li2 O 307，且所製造之濺鍍靶材401係於至少含有氮與氧之電漿煙塵403中進行DC、脈衝式DC、AC或RF濺鍍。
實例4提供了程序100之一示範實施例，其中濺鍍靶材包括P2 O5 、而非實例3(圖4)中所述之Lix P(x>>3)，且所製造之濺鍍靶材係於至少含有氮之氣氛中進行DC、脈衝式DC、AC或RF濺鍍。
實例5提供了程序100之一示範實施例，其中濺鍍靶材包括PN、而非實例4中所述之P2 O5 ，且所製造之濺鍍靶材係於至少含有氮與氧之氣氛中進行DC、脈衝式DC、AC或RF濺鍍。
實例6提供了程序100之一示範實施例，其中濺鍍靶材係由金屬鋰與PN之微觀複合物製得，且所製造之濺鍍靶材係於至少含有氮與氧之氣氛中進行DC、脈衝式DC、AC或RF濺鍍。
實例7(圖5)提供了程序100之一示範實施例，其中，具有組成為Li2.9 PO3.3 N0.46 之LIPON電解質薄膜205係藉由DC、脈衝式DC、AC或RF反應性濺鍍而自至少兩種個別的濺鍍靶材201與501沉積而成，其濺鍍電漿煙塵503與503A兩者皆被導向欲成長Li2.9 PO3.3 N0.46 電解質薄膜205之基板207上。第一濺鍍靶材201係製為如實例1(圖2)所提供者，而第二濺鍍靶材501係製為如實例5所提供者。為增進薄膜的組成均勻性與其他所需之均勻性特徵(如厚度)，可使基板207於組成稍微不同的濺鍍煙塵503與503A中沿其垂直軸505旋轉。可在真空沉積腔室中增加一第三濺鍍靶材，其可具有與第一或第二靶材相同的組成，或是具有不同的組成，如實例6中所述之靶材。
實例8(圖6)提供了程序100之一示範實施例，其中，由實例3(圖4)所提供之LIPON薄膜205之沉積係由非濺鍍式沉積程序600所支持，例如從一適當的坩堝601(如Ta)中進行金屬鋰之阻抗性蒸鍍。被引導至成長LIPON薄膜205之鋰蒸氣603不僅調整了薄膜205中的鋰濃度，其亦透過在含氮氣與氧氣氣氛403與605中進行鋰沉積而改變了共同沉積至薄膜的氧與氮濃度。為增進薄膜的組成均勻性與其他所需之均勻性特徵(如厚度)，可使基板207沿其垂直軸505旋轉。
實例9提供了程序100之一示範實施例，其中由實例8所提供之沉積係包含一隔板機制，其可暫時中斷濺鍍沉積或非濺鍍沉積數秒至數分鐘，以產生出不同電解質作用層的層狀堆疊，其可藉由沉積期間或沉積後之LIPON薄膜熱處理而擴散或不擴散至彼此中。
實例10(圖7)提供了程序100之一示範實施例，其中，濺鍍靶材701是由Li50 Al50 合金製造而成，且在含有濺鍍材料以及F2 -Ar之反應性氣體混合物的濺鍍電漿煙塵703中進行DC、脈衝式DC、AC或RF濺鍍沉積而產生了玻璃態的鋰離子電解質LiAlF4 705。Li50 Al50 合金具金屬傳導性，且可於惰性氣體(如氬氣)氣氛中利用標準冶金方法而製造為達5cm厚。由於此靶材具有高熱傳導性，可透過靶材背板709而進行靶材背側707之冷卻711，故仍可濺鍍此一厚靶材701。這種厚靶材的替換頻率比較薄靶材低，因而可減少(i)真空沉積反應器的維修時程以及(ii)運作成本。
上述實施例與實例僅作為示例之用，該領域技術人士可由此處說明之實施例而得知各種變化例，其皆涵蓋於本發明之揭示範圍內。因此，本發明係由如附申請專利範圍加以限定，因而本發明涵蓋了所提供之修飾例，其皆不脫如附申請專利範圍與其等效例之範疇。
100．．．程序
101、103、105、107．．．步驟
201．．．靶材
203．．．電漿煙塵
205．．．薄膜
207．．．基板
301．．．複合靶材
303．．．電漿煙塵
305．．．Lix P
307．．．Li2 O
401．．．靶材
403．．．電漿煙塵
407．．．Li3 N
501．．．靶材
503、503A．．．電漿煙塵
505．．．垂直軸
600．．．沉積程序
601．．．坩堝
603．．．鋰蒸氣
605．．．氣氛
701．．．靶材
703．．．電漿煙塵
705．．．LiAlF4
707．．．靶材背側
709．．．靶材背板
711．．．冷卻
本發明之部分特徵與優勢係參照特定較佳實施例而加以說明，其係用於說明、但非限制本發明。
伴隨之圖式用於提供對本發明之進一步理解並構成本發明說明書的一部分，且說明了本發明的示範實施例與說明，其用於闡明本發明之原理，在圖式中：
圖1係根據本發明之一實施例而說明處理步驟的順序，其可用於製造用於薄膜電化學能量儲存與轉換裝置之鋰離子薄膜電解質；
圖2說明了在O2 /N2 反應性電漿濺鍍煙塵中自一Li3 P濺鍍靶材濺鍍沉積一電解質薄膜的實施例，其中基板係浸沒於該O2 /N2 反應性電漿濺鍍煙塵中，使電解質薄膜沉積於基板上；
圖3說明了自含有Lix P相與Li2 O相之化合濺鍍靶材濺鍍沉積一電解質薄膜之實施例；
圖4說明了在以Li3 N取代Li2 O時自圖3進行濺鍍沉積之實施例；
圖5說明了在一基板上濺鍍沉積一電解質薄膜之實施例，該基板係浸沒於由兩種不同濺鍍靶材所形成的兩種電漿內；
圖6說明了在一基板上濺鍍沉積一電解質薄膜之實施例，其係由將濺鍍沉積的電漿濺鍍煙塵與反應性蒸鍍的蒸發煙塵引導至基板上而產生；
圖7說明了一種以厚金屬濺鍍靶材進行電解質薄膜濺鍍沉積的方法的實施例。
100．．．程序
101、103、105、107．．．步驟

Claims (25)

  1. 一種製造一鋰離子薄膜電解質的方法，包括：提供在室溫下的電子傳導率不低於10-8 S/cm之一電氣上傳導性濺鍍靶材；提供一真空沉積腔室；濺鍍該傳導性濺鍍靶材；以及於一反應性濺鍍氣體氣氛中沉積一鋰離子薄膜電解質。
  2. 如申請專利範圍第1項之方法，其中該薄膜電解質包括鋰磷氮氧化物(lithium phosphorus oxynitride)。
  3. 如申請專利範圍第1項之方法，其中該鋰離子薄膜電解質包括至少一選自下列所組成之群組的元素：氧、氮、氟、氯、溴、碘、硫、硒、碲、磷、砷、銻、鉍、鉛、碳、氫、矽、鈉、鎂、鋯。
  4. 如申請專利範圍第1項之方法，其中該真空沉積腔室不與RF相容。
  5. 如申請專利範圍第1項之方法，其中該反應性濺鍍氣體氣氛包括至少一選自下列所組成之群組的元素：氧、氮、氟、氯、溴、碘、硫、硒、碲、磷、砷、銻、鉍、鉛、碳、氫、矽、鋰、鈉、鎂、鋯。
  6. 如申請專利範圍第5項之方法，更包括於濺鍍沉積製程條件下以一氣體化學元素的形式提供具有該至少一元素之該反應性濺鍍氣體氣氛。
  7. 如申請專利範圍第5項之方法，更包括於濺鍍沉積製 程條件下以氣體化學化合物的形式提供具有該至少一元素之該反應性濺鍍氣體氣氛。
  8. 如申請專利範圍第1項之方法，其中該傳導性濺鍍靶材包括至少一選自下列所組成之群組的元素：氧、氮、氟、氯、溴、碘、硫、硒、碲、磷、砷、銻、鉍、鉛、碳、氫、矽、鋰、鈉、鎂、鋯。
  9. 如申請專利範圍第1項之方法，其中該傳導性濺鍍靶材包括至少一選自下列所組成之群組的材料：磷化鋰與次磷化鋰(Lix P，1≦x≦100)、氮化鋰與次氮化鋰(Lix N，3≦x≦100)、磷氧化物與次氧化物(POx ，x≦2.5)、磷氮化物與次氮化物(PNx ，x≦1.7)、氧化鋰與次氧化鋰(Lix O，1≦x≦100)以及磷元素。
  10. 如申請專利範圍第1項之方法，更包括以頻率範圍介於1MHz與1GHz之間的射頻(RF)電力來激能該傳導性濺鍍靶材。
  11. 如申請專利範圍第1項之方法，更包括以頻率範圍介於1Hz與1MHz之間的交流(AC)電力來激能該傳導性濺鍍靶材。
  12. 如申請專利範圍第1項之方法，更包括以直流(DC)電力來激能該傳導性濺鍍靶材。
  13. 如申請專利範圍第1項之方法，更包括以脈衝式直流(脈衝式DC)電力來激能該傳導性濺鍍靶材。
  14. 如申請專利範圍第1項之方法，更包括以一RF、AC、脈衝式DC與DC之組合所構成的一混合電力來激能 該傳導性濺鍍靶材。
  15. 如申請專利範圍第1項之方法，其中該傳導性濺鍍靶材在室溫下的電子傳導率高於10-4 S/cm。
  16. 如申請專利範圍第1項之方法，其中該傳導性濺鍍靶材在室溫下的電子傳導率高於1S/cm。
  17. 如申請專利範圍第1項之方法，更包括於基板表面將該傳導性濺鍍靶材材料轉化為薄膜電解質材料。
  18. 如申請專利範圍第1項之方法，更包括使用超過一種傳導性濺鍍靶材來沉積該薄膜電解質。
  19. 如申請專利範圍第1項之方法，更包括提供一或多種非濺鍍沉積層至一成長薄膜區上。
  20. 如申請專利範圍第1項之方法，更包括以一交替週期形式提供一或多種非濺鍍沉積層至一成長薄膜區上。
  21. 如申請專利範圍第19項之方法，更包括自一材料源提供該非濺鍍沉積，該材料源係電傳導或電絕緣。
  22. 如申請專利範圍第1項之方法，其中該傳導性濺鍍靶材包括一介於0.6cm與5cm間之厚度。
  23. 如申請專利範圍第1項之方法，其中該傳導性濺鍍靶材包括靶材瓦材(tile)區段。
  24. 如申請專利範圍第23項之方法，其中該靶材瓦材區段包括至少一選自下列所組成之群組的元素：一單相材料、一多相材料、一材料複合物。
  25. 如申請專利範圍第23項之方法，其中該靶材瓦材區段中至少其一係大於300cm2 。
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