Cu- or Ag-containing Bi-Sb-Te for in-line roll-to-roll patterned thin-film thermoelectrics

Xudong Tao (), Qianfang Zheng, Chongyang Zeng, Harry Potter, Zheng Zhang, Joshua Ellingford, Ruy S. Bonilla, Emiliano Bilotti, Patrick S. Grant and Hazel E. Assender
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Xudong Tao: Parks Road
Qianfang Zheng: Parks Road
Chongyang Zeng: Exhibition Road
Harry Potter: Parks Road
Zheng Zhang: Parks Road
Joshua Ellingford: Hook
Ruy S. Bonilla: Parks Road
Emiliano Bilotti: Exhibition Road
Patrick S. Grant: Parks Road
Hazel E. Assender: Parks Road

Nature Communications, 2025, vol. 16, issue 1, 1-12

Abstract: Abstract The Selective Metallization Technique shows promise for roll-to-roll in-line patterning of flexible electronics using evaporated metals, but challenges arise when applied to sputtering functional materials. This study overcomes these challenges with simultaneous sputtering of Bi-Sb-Te and evaporation of metal (Ag or Cu) for thermoelectric layers when using Selective Metallization Technique. Large-scale manufacturing is demonstrated through roll-to-roll processing of a 0.8 m wide polymer web at 25 m/min, achieving high-throughput production of functional thin-film patterns with nanometer thickness. The room-temperature-deposited material system exhibits significantly enhanced thermoelectric performance and facilitates an n-type-to-p-type transition in the Cu- or Ag-containing Bi-Sb-Te-based composite film. Here, we show that while applying Selective Metallization Technique, the evaporation of metal modifies the impact of residual oil on Bi-Sb-Te, which can be effectively removed with a few seconds of plasma exposure, and the fabricated thermoelectric devices are validated in wearable applications utilizing a coiled-up wristband design.

Date: 2025
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DOI: 10.1038/s41467-024-55279-7

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