STTR Phase I: Novel Electrode Materials for Multi-Layer Capacitors

This Small Business Technology Transfer Phase I project will develop technology for the manufacture of low cost miniaturized multi-layer capacitors (MLCs). A titania (TiO2) thin film will be deposited on 60 to 150 nanometer nickel (Ni) particles to protect the ultrafine Ni particles from slow oxidation degradation while simultaneously providing a chemically compatible surface with the dielectric barium titanate (BaTiO3) layer during processing. The TiO2 film will allow the sintering temperature of the ultrafine Ni particles to be increased so the intercleaved Ni/BaTiO3 electrode/dielectric multilayers can be easily fabricated upon firing. The manufacture of composite TiO2/Ni particles via novel Atomic Layer Deposition (ALD) thin film technology allows for the synthesis of composite ultrafine Ni substrate particles with dual effectiveness (resisting oxidation, increasing sintering temperature). In the first aspect of this work, TiO2 will be deposited on 60 to 150 nm Ni particles by ALD. In the second aspect of this work, the composite powders will be characterized for film quality, oxidation resistance, and thermal expansion upon heating (i.e. sinterability). In the third aspect of this work, a 1 kg sample of the composite powder will be synthesized and supplied to a partner/customer for feasibility evaluation. Commercially, the potential impact of successful large scale processing extends far beyond this proposed MLC application. Nanoscience will only achieve true "disruptive" technology status if the individual surfaces of ultrafine particles can be functionalized. ALD nanocoating of ultrafine particles provides such an opportunity. It is now possible to produce ultrafine particles with designed electrical, magnetic, optical, mechanical, rheological, or other properties. Markets for such functionalized ultra-fine powders include microelectronics, defense, hard metals, cosmetics, drug delivery, energetic materials, and polymer/ceramic nanocomposites, among others. A better understanding of the nanocoating of ultra-fine particles and its cost/performance value will be developed.