Piezoelectric Material Pulsed Laser Deposition Rate Control

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Solution Overview

Problem

High deposition rates in pulsed laser deposition of piezoelectric materials result in erratic crystal orientation and porous microstructure, leading to reduced performance when a voltage is applied, while low deposition rates increase manufacturing time and restrict expansion.

Innovation Solution

A two-layer deposition method where the first layer is deposited at a low rate (less than 40 nm/min) followed by a second layer at a higher rate (up to 85 nm/min) to enhance crystal orientation and microstructure uniformity, with the first layer acting as a template for the second layer, and increasing pulse frequency for the second layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a low deposition rate is used in pulsed laser deposition, then the crystal structure becomes uniformly oriented and the microstructure becomes dense, but the manufacturing time increases

Engineering Contradiction:
Improvecrystal structure orientation uniformityVSAvoidmanufacturing time
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The deposition process is divided into multiple sequential steps with different deposition rates. The first step uses a low deposition rate to establish a template layer with uniform crystal orientation, while subsequent steps use higher deposition rates to complete the film formation. This segmentation allows each step to optimize for its specific function, resolving the contradiction between manufacturing precision and time loss.

Inventive Principle:
Principle #1Segmentation

2Productivity

If a high deposition rate is used, then the manufacturing time decreases, but the crystal structure becomes erratic and the microstructure becomes porous

Engineering Contradiction:
Improvedeposition speedVSAvoidcrystal structure orientation
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

A preliminary low-rate deposition step is performed first to create a template layer with properly oriented crystal structure. This preliminary action establishes the foundation that guides subsequent high-rate deposition, ensuring that even when depositing at higher speeds, the crystal structure maintains uniform orientation. This resolves the contradiction by preparing the system in advance to handle faster deposition without sacrificing precision.

Inventive Principle:
Principle #10Preliminary action

3Manufacturing precision

If a low deposition rate is used, then the piezoelectric material exhibits restricted expansion due to clamping effect, but the crystal structure remains uniform

Engineering Contradiction:
Improvemicrostructure densityVSAvoidexpansion freedom
Core Design Contradiction:
Manufacturing precisionVSEase of operation

Solution Approach 1:

The deposition is segmented into a first layer at low rate and subsequent layers at higher rates. The first layer maintains the dense, uniform microstructure that provides good piezoelectric coupling, while the higher-rate subsequent layers create a less constrained structure that allows freer expansion. This segmentation resolves the contradiction by assigning different functional roles to different parts of the film.

Inventive Principle:
Principle #1Segmentation

4Ease of operation

If a high deposition rate is used, then the piezoelectric material allows free shrinkage movement, but the crystal structure becomes erratic

Engineering Contradiction:
Improveshrinkage freedomVSAvoidcrystal structure orientation
Core Design Contradiction:
Ease of operationVSManufacturing precision

Solution Approach 1:

The preliminary low-rate deposition creates a template layer with uniform crystal orientation that serves as a foundation. This preliminary structure provides the necessary piezoelectric performance, while the subsequent high-rate deposition layers provide the free shrinkage movement capability. The preliminary action ensures that even with erratic high-rate deposition, the overall structure maintains good orientation from the foundation layer.

Inventive Principle:
Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach results in improved expansion and unhindered shrinkage when a voltage is applied, achieving a d33 value of over 300 pm/V, surpassing that of bulk ceramics and single-layer deposited materials.

Implementation Method 1

a first layer of piezoelectric material is deposited on a substrate by pulsing a laser at a target

Methodology Applied
Scientific EffectPulsed laser deposition: Pulsed Laser Deposition

Implementation Method 2

pulsing a laser at a target to provide a plasma plume

Methodology Applied
Scientific EffectLaser ablation: Laser Ablation

Implementation Method 3

the material will exhibit an expansion when a voltage is applied over the material

Methodology Applied
Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentEP3340327B1Method for manufacturing an improved piezoelectric material
Publication Date: 2022.04.20 LAM RES CORP
  • EP3340327B1 patent drawingFigure 1
  • EP3340327B1 patent drawingFigure 2
  • EP3340327B1 patent drawingFigure 3

AI summary

The invention relates to a method for manufacturing an improved piezo electric material comprising the steps of: - providing a pulsed laser deposition device with a target and a substrate, wherein the target material is a piezo electric material; - depositing a first layer of target material on the substrate by operating the pulsed laser deposition device, wherein the deposition rate is set to a first value; - depositing a second layer of target material on top of the first layer by operating the pulsed laser deposition device, wherein the deposition rate is set to a second value, wherein the second value is at least one and a half of the first value.