Synthesis of nanoporous Ca3Co4O9 thin films for flexible thermoelectrics

Abstract: During energy generation, transportation and usage, large amounts of energy are lost as waste heat. With increasing energy consumption and environmental issues, exploiting this waste heat has drawn extensive attention. Thermoelectric energy conversion is an approach to take advantage of the ability of thermoelectric materials to convert waste heat into electricity.The thermoelectric effect was initially studied in the early 19th century with the discovery of the Seebeck effect. Thermoelectric materials and devices can directly convert thermal energy (temperature gradients) into electric energy (voltage) and vice versa. Thermoelectric devices have been used in space as energy generators and as coolers in small-scale instruments and devices. However, thermoelectrics remain limited in terms of applications. The traditional state-of-the-art thermoelectric materials, such as Bi2Te3, PbTe, and SnTe, exhibit high thermoelectric properties, but their disadvantages of toxicity, extreme rarity of tellurium, and oxidation when exposed to high temperature air restrict them from widespread use in applications. Compared to traditional thermoelectric materials, misfit-layered Ca3Co4O9 not only has the typical advantages of oxides including low cost, being environmentally friendly, and good chemical stability at high temperatures, but also has relatively high thermoelectric properties due to the complex structure which composed of CoO2 conductive layers and rock-salt type Ca2CoO3 insulating layers. Many strategies have been used to enhance the thermoelectric performance of Ca3Co4O9. Compared with bulk materials, thermoelectric thin films can exhibit improved thermoelectric properties and new application in flexible devices and miniaturization. Flexibility can be induced in Ca3Co4O9 by nanostructural tailoring to act as fully inorganic flexible thermoelectrics.In order to explore how to produce Ca3Co4O9 nanoporous thin film and control the porosity in the films, I have investigated the nanoporous Ca3Co4O9 system. Nanoporous Ca3Co4O9 thin films were synthesized using sequential reactive magnetron sputtering and post annealing to determine the key factors of nanoporous Ca3Co4O9 formation and tailoring of the porosity.