Alexander Bouman | SparkNano: What if you could perform Atomic Layer Deposition at atmospheric pressure, 100x faster than traditional methods, and with almost no wasted material?
00:06:23.105 - 00:08:02.245
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Summary of the clip:
What if you could perform Atomic Layer Deposition at atmospheric pressure, 100x faster than traditional methods, and with almost no wasted material?
This clip provides a clear, fundamental explanation of Spatial Atomic Layer Deposition (SALD), a technique that revolutionizes the ALD process. Unlike conventional (temporal) ALD, which separates precursor and reactant gases in time within a vacuum chamber, SALD separates them in space. The animation shows a substrate moving continuously beneath a stationary injector head, which has distinct zones for the metal precursor, an inert gas purge, and the co-reactant, enabling a continuous deposition process.
The key innovation is the use of inert gas shields, or "virtual walls," which confine the reactive gases to their respective zones and prevent them from mixing prematurely. This elegant solution allows the entire process to operate at or near atmospheric pressure, eliminating the need for slow and costly vacuum systems. This is the primary enabler for the technology's high speed and its suitability for integration into in-line, roll-to-roll manufacturing systems.
Operating at atmospheric pressure and confining the reaction to the substrate surface yields significant efficiency benefits. Because the precursors are only active in the small volume between the injector and the substrate, there is no deposition on reactor walls, which plagues temporal ALD systems. This eliminates the need for frequent cleaning cycles and dramatically increases precursor utilization efficiency, directly lowering the cost of ownership and making ALD economically viable for large-area applications like solar cells and displays.
In this short video, you can learn:
* The fundamental principle of Spatial ALD: separating precursors in space instead of time.
* How atmospheric pressure operation enables ultra-high deposition speeds and roll-to-roll integration.
* The concept of "virtual gas walls" and how they lead to higher precursor efficiency and eliminate reactor cleaning.
📋 **Clip Abstract** This clip provides a concise technical breakdown of how Spatial Atomic Layer Deposition (SALD) works. It explains the use of an injector head and inert gas shields to enable a continuous, atmospheric-pressure process, highlighting key advantages like high speed and superior material efficiency over traditional ALD.
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#SpatialALD, #AtmosphericPressureDeposition, #RollToRollManufacturing, #VirtualGasWalls, #PrintedElectronics, #PerovskiteTechnology
This is a highlight of the presentation:
Roll-to-Roll spatial ALD advances scalable perovskite solar cell manufacturing
More Highlights from the same talk.
03:16 - 05:09
Can a few nanometers of atomic layer deposition solve the notorious degradation challenge of perovskite solar cells?
Can a few nanometers of atomic layer deposition solve the notorious degradation challenge of perovskite solar cells?
Perovskite solar cells offer exceptional light-to-electricity conversion efficiency and low potential manufacturing costs. However, their industrial viability is severely bottlenecked by poor long-term stability and rapid degradation when exposed to ambient moisture, heat, and oxygen.
By replacing standard bathocuproine (BCP) buffer layers with spatial atomic layer deposition (ALD) of thin tin oxide (SnOx), researchers can dramatically improve current densities and device lifetimes. Adding even a minute sub-nanometer capping layer of aluminum oxide (Al2O3) creates a highly robust barrier that practically halts performance decay, opening a clear path to commercial durability.
To make this commercially viable, manufacturers must transition from slow vacuum batch systems to high-speed, atmospheric-pressure roll-to-roll configurations. SparkNano's spatial ALD technology enables this transition, delivering conformal, pinhole-free barrier and charge-transport layers at high throughput.
In this short video, you can learn:
* How thin-film metal oxides like tin oxide and aluminum oxide stabilize perovskite active layers.
* The performance trade-offs of BCP buffer layers versus ALD-grown inorganic thin films.
* Why high-speed roll-to-roll ALD is crucial for lowering the levelized cost of energy (LCOE) for perovskites.
📋 **Clip Abstract** This clip explains how integrating spatial ALD-grown tin oxide and aluminum oxide layers resolves the long-term degradation issues of perovskite solar cells. By replacing unstable organic materials with ultra-thin inorganic barriers, the technology vastly improves current density and device lifetime.
#SpatialALD, #PerovskitePhotovoltaics, #RollToRollALD, #MetalOxideBarriers, #FlexibleElectronics, #ThinFilmSolar
17:06 - 18:21
Is the prohibitive cost of TDMA-Tin precursors holding back the industrial scale-up of perovskite photovoltaics?
Is the prohibitive cost of TDMA-Tin precursors holding back the industrial scale-up of perovskite photovoltaics?
The industrial integration of tin oxide buffer layers in perovskite solar cells is heavily constrained by the high cost of metal-organic precursors like Tetrakis(dimethylamino)tin (TDMA-Sn). In conventional atomic layer deposition systems, low precursor utilization rates lead to significant chemical waste, directly impacting the capital and operational expenses of the production line.
To mitigate these costs, manufacturers must optimize both film thickness and precursor chemistry. Depositing thinner, more precise layers minimizes material consumption while preventing parasitic optical absorption, while co-developing novel, low-cost precursors specifically tailored for atmospheric spatial ALD significantly reduces raw material costs.
Working in tandem with precursor manufacturers allows for the engineering of high-reactivity chemistry optimized for spatial delivery. This collaborative approach, combined with spatial ALD's inherent high precursor utilization efficiency, provides a viable roadmap to drastically lower the dollar-per-watt cost of next-generation perovskite devices.
In this short video, you can learn:
* The commercial and optical benefits of optimizing thin-film barrier thicknesses in solar stacks.
* Why TDMA-Sn is a major cost driver and how novel alternative precursors address this bottleneck.
* The role of hardware-precursor co-design in driving down chemical consumption during high-throughput ALD.
📋 **Clip Abstract** This Q&A session addresses the cost barriers of using expensive precursors like TDMA-Sn in perovskite solar cell manufacturing. The speaker explains how minimizing film thickness and collaborating on custom, high-utilization precursor chemistry can dramatically lower production costs.
#SpatialALD, #TDMASn, #TinOxideBuffer, #PerovskiteSolarCells, #PerovskitePhotovoltaics, #ThinFilmPV
07:38 - 09:47
How do you deposit atomic-scale coatings at roll-to-roll speeds without a vacuum chamber turning your precursors into uncontrolled CVD?
How do you deposit atomic-scale coatings at roll-to-roll speeds without a vacuum chamber turning your precursors into uncontrolled CVD?
Traditional temporal atomic layer deposition (ALD) relies on static batch reactors where precursors are introduced sequentially, separated by time-consuming purge steps under high vacuum. While this produces highly conformal and precise thin films, the process is far too slow for high-volume manufacturing of batteries, solar cells, and flexible electronics.
Spatial ALD solves this bottleneck by physically separating the precursor and co-reactant gases into distinct zones. A moving flexible substrate passes underneath an injector head, experiencing a continuous flow of precursors separated by an engineered nitrogen "gas shield" or nitrogen curtain. This inert gas curtain prevents gas-phase mixing, ensuring self-limiting surface reactions occur sequentially in space rather than time.
Crucially, this entire deposition sequence operates at atmospheric pressure without requiring expensive and slow vacuum equipment. By shifting the temporal separation to spatial separation, processing times for high-quality nano-coatings are compressed from hours to mere minutes, maintaining high precursor efficiency with zero deposition on reactor walls.
In this short video, you can learn:
* The mechanics of spatial ALD and how gas-phase mixing is prevented using nitrogen curtains.
* Why atmospheric pressure operation eliminates vacuum bottlenecks and enables rapid scaling.
* How spatial ALD achieves high precursor utilization while preventing deposition on reactor walls.
📋 **Clip Abstract** The speaker details the operational physics of spatial atomic layer deposition (s-ALD) utilizing an injector head and an inert nitrogen gas shield. This design enables high-speed, atmospheric-pressure deposition of pinhole-free coatings on moving substrates without the need for high-vacuum chambers.
#SpatialALD, #AtmosphericALD, #RollToRollALD, #NitrogenGasShield, #ThinFilmEncapsulation, #FlexibleElectronics