Kitchen Gadget Inspires Scientist to Make More Effective Plastic Electronics

Fabricating single crystal organic field-effect transistors using ultra-thin polymer membrane for a gate insulator. In the upper row, the membrane is stretched over the transistor before vacuum is applied. In the lower row, the vacuum has been applied and the membrant is adhering to the organic crystal. Photos on the right are close-up views of the transistor, with the organic semiconductor crystal in red. (Credit: Credit: H. T. Yi, et. al.)

One day in 2010, Rutgers physicist Vitaly Podzorov watched a store employee showcase a kitchen gadget that vacuum-seals food in plastic. The demo stuck with him. The simple concept -- an airtight seal around pieces of food -- just might apply to his research: developing flexible electronics using lightweight organic semiconductors for products such as video displays or solar cells.

"Organic transistors, which switch or amplify electronic signals, hold promise for making video displays that bend like book pages or roll and unroll like posters," said Podzorov. But traditional methods of fabricating a part of the transistor known as the gate insulator often end up damaging the transistor's delicate semiconductor crystals.

Drawing inspiration from the food-storage gadget, Podzorov and his colleagues tried an experiment. They suspended a thin polymer membrane above the organic crystal and created a vacuum underneath, causing the membrane to collapse gently and evenly onto the crystal's surface. The result: a smooth, defect-free interface between the organic semiconductor and the gate insulator.

The researchers reported their success in the journal Advanced Materials. In the article,Podzorov and three colleagues describe how a single-crystal organic field effect transistor (OFET) made with this thin polymer gate insulator boosted electrical performance. The researchers further reported that they could remove and reapply membranes to the same crystal several times without degrading its surface.

Organic transistors electrically resemble silicon transistors in computer chips, but they are made of flexible carbon-based molecules that can be printed on sheets of plastic. Silicon transistors are made in rigid, brittle wafers of silicon.

The methods that scientists previously applied to organic transistor fabrication were based on silicon semiconductor processing, explained Podzorov, assistant professor in the Department of Physics and Astronomy, School of Arts and Sciences. These involved high temperatures, high-energy plasmas or chemical reactions, all of which could damage the delicate organic crystal surface and hinder the transistor's performance.

"People have tendencies to go with something they've known for a long time," he said. "In this case, it doesn't work right."

Podzorov's innovation builds upon a decade of Rutgers research in this field, including his invention of the first single crystal organic transistor in 2003. While his latest innovation is still a ways from commercial reality, he sees an immediate application in the classroom.

"Our technique takes 10 minutes," he said. "It should be exciting for students to actually build these devices and immediately see them work, all within one lab session."

Podzorov was actually trying to solve another problem when he first recalled the food packaging demo. He was thinking about how to protect organic crystals from airborne impurities when his lab shipped samples to collaborating scientists in California and overseas.

"We could place our samples between plastic sheets and pull a vacuum," he said. "Then I thought, 'why don't we try doing this for our gate insulator?'"

Funding for the research was provided by the U. S. Department of Energy and the Rutgers Institute for Advanced Materials and Devices for Nanotechnology. Collaborators in Podzorov's lab were postdoctoral researchers Hee Taek Yi and Yuanzhen Chen, and undergraduate student Krzysztof Czelen. The department's machine shop made a custom-designed vacuum chamber for the project

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The above story is reprinted from materials provided byRutgers University.

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Journal Reference:

1. H. T. Yi, Y. Chen, K. Czelen, V. Podzorov. Vacuum Lamination Approach to Fabrication of High-Performance Single-Crystal Organic Field-Effect Transistors. Advanced Materials, 2011; 23 (48): 5807 DOI:10.1002/adma.201103305

Fuel and plastics production could be made more energy efficient and cost effective

ScienceDaily (Oct. 12, 2011) — A University of Minnesota team of researchers has overcome a major hurdle in the quest to design a specialized type of molecular sieve that could make the production of gasoline, plastics and various chemicals more cost effective and energy efficient. The breakthrough research, led by chemical engineering and materials science professor Michael Tsapatsis in the university's College of Science and Engineering, is published in the most recent issue of the journal Science.

After more than a decade of research, the team devised a means for developing free-standing, ultra-thin zeolite nanosheets that as thin films can speed up the filtration process and require less energy. The team has a provisional patent and hopes to commercialize the technology.

"In addition to research on new renewable fuels, chemicals and natural plastics, we also need to look at the production processes of these and other products we use now and try to find ways to save energy," Tsapatsis said.

Separating mixed substances can demand considerable amounts of energy -- currently estimated to be approximately 15 percent of the total energy consumption -- part of which is wasted due to process inefficiencies. In days of abundant and inexpensive fuel, this was not a major consideration when designing industrial separation processes such as distillation for purifying gasoline and polymer precursors. But as energy prices rise and policies promote efficiency, the need for more energy-efficient alternatives has grown.

One promising option for more energy-efficient separations is high-resolution molecular separation with membranes. They are based on preferential adsorption and/or sieving of molecules with minute size and shape differences. Among the candidates for selective separation membranes, zeolite materials (crystals with molecular-sized pores) show particular promise.

While zeolites have been used as adsorbents and catalysts for several decades, there have been substantial challenges in processing zeolitic materials into extended sheets that remain intact. To enable energy-savings technology, scientists needed to develop cost-effective, reliable and scalable deposition methods for thin film zeolite formation.

The University of Minnesota team used sound waves in a specialized centrifuge process to develop "carpets" of flaky crystal-type nanosheets that are not only flat, but have just the right amount of thickness. The resulting product can be used to separate molecules as a sieve or as a membrane barrier in both research and industrial applications.

"We think this discovery holds great promise in commercial applications," said Kumar Varoon, a University of Minnesota chemical engineering and materials science Ph.D. candidate and one of the primary authors of the paper published in Science. "This material has good coverage and is very thin. It could significantly reduce production costs in refineries and save energy."

Members of the research team include Ph.D. candidates Kumar Varoon and Xueyi Zhang; postdoctoral fellows Bahman Elyassi and Cgun-Yi Sung; former students and Ph.D. graduates Damien Brewer, Sandeep Kumar, J. Alex Lee and Sudeep Maheshwari, graduate student Anudha Mittal; former undergraduate student Melissa Gettel; and faculty members Matteo Cococcioni, Lorraine Francis, Alon McCormick, K. Andre Mkhoyan and Michael Tsapatsis.

This research is being funded by the United States Department of Energy (including the Carbon Sequestration Program and the Catalysis Center for Energy Innovation -- An Energy Frontier Center), the National Science Foundation and a variety of University of Minnesota partners.

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Story Source:

The above story is reprinted (with editorial adaptations by ScienceDaily staff) from materials provided by University of Minnesota.

Journal Reference:

K. Varoon, X. Zhang, B. Elyassi, D. D. Brewer, M. Gettel, S. Kumar, J. A. Lee, S. Maheshwari, A. Mittal, C.-Y. Sung, M. Cococcioni, L. F. Francis, A. V. McCormick, K. A. Mkhoyan, M. Tsapatsis. Dispersible Exfoliated Zeolite Nanosheets and Their Application as a Selective Membrane. Science, 2011; 334 (6052): 72 DOI: 10.1126/science.1208891

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