IMPROVED PASSIVATING ETCHANTS FOR METALLIC PARTICLES

Abstract: The present invention provides a process for etching the corrosion layer from and passivating the surface of metallic particles, comprising forming a reaction mixture by dispersing particles, having a passivating surface layer, in a solution comprising a hexafluoracetylacetonate metal chelate, and reacting the mixture for a time sufficient to etch and passivate the surface.

Description: Improved Passivating Etchants for Metallic Particles Contractual Origin of the Invention: The United States Government has rights to this invention pursuant to Contract No. DE- AC36-99GO-10337 between the United States Department of Energy and the Midwest Research Institute. Pursuant to 35 U.S.C 120, 365(c) and 119(e) this application is a continuation-in-part of PC T/US00/01742, an international application designating the United States, filed 21 January 2000 claiming the benefit of U.S. Ser. No. 60/116,561, a 35 USC 111(b) application, filed 21 January 1999. Tchnical Field: This invention relates to etchants for metallic particles, and in particular to methods for etching oxide and hydroxide corrosion layers, or both, from the surface of metallic particles and passivating the surfaces for use in the formation of thin film conductors, and the like. Background Art: There is a push in the microelectronics and photovoltaics industries to replace traditional metallization processes, such as high vacuum sputtering or evaporation, and screen printing, with simple and less costly processes. For example, as applied in the field of photovoltaics, traditional metallization processes require a mask-based step prior to the deposition of metal films or lines, to extract current, on the junction part of the device. Improved direct write processes for printing conducting metal layers and grids using a non- vacuum spray or ink-jet deposition apparatus is one viable alternative to the traditional methods. Ink-jet printing has the further advantage of depositing very narrow grid lines resulting in a decrease in shading losses and an increase in efficiency. However, in order to realize a commercially viable direct write metallization process, new metal-particle based inks must be developed, because current methods for application of these particles have been hampered by a lack of good interparticle connectivity when the particles are directly deposited as films to substrates. This connectivity, both structural and electrical, is in many cases limited by the formation of a corrosion layer (i.e., oxide or hydroxide) contaminating the surface of the particles. These passivated surfaces generally give rise to an insulating effect electrically and an impedance in particle sintering structurally. In order to form a thin-film, for use in photoconversion and microelectronic device applications, the regions coated with particles have traditionally been sintered to ensure electrical continuity across the feature. High temperature sintering often eliminates some of the problems associated with surface contamination. However, when used in the formation of nanoparticle contacts to photovoltaic semiconductors, standard high-temperature sintering often cannot be performed due to the thermal limitations associated with the underlying layers of the device. Chemical etches have also been used to remove the oxide coating on nano-phase metals, such as aluminum, Petzow, G., Metallographic Etching, American Society of Metals, 39-42 (1978), but these etches have been found to completely dissolve the nanoparticles. Moreover, treatment with a variety of organic chelating agents has also proved unsuccessful. Therefore, what is needed is an improved method for etching metal particles, to be used as inks in the metallization of microelectronics. Disclosure of Invention: Accordingly, it is a primary object of the present invention to provide a method for etching the oxide and hydroxide corrosion layers, or both, from the surface of metallic particles and passivating the surfaces for use in the formation of thin film conductors, and the like. It is another object of the invention to improve the electrical conductivity for particle derived metal contacts. Another object of the present invention is to provide an improved method for forming ohmic contacts from copper or aluminum metallic particles with ap-type silicon layer in a silicon solar cell. These and other objects of the present invention will become apparent throughout the description of the invention which now follows. In order to overcome the problems associated with the background art, the invention provides a process for etching the corrosion layer from and passivating the surface of metallic particles, comprising forming a reaction mixture by dispersing particles, having a passivating surface layer, in a solution comprising a hexafluoroacetylacetonate metal chelate, and reacting the mixture for a time sufficient to etch and passivate the surface. Brief Description of Drawings: Figure 1 shows the current- voltage characteristics of a solar cell where particulate aluminum is slurried onto -type silicon and annealed at 645°C in argon for one hour. This is a control sample. Figure 2 shows the current- voltage characteristics of a solar cell where particulate aluminum is etched/passivated with Na(hfa), slurried onto -type Si, and annealed at 649°C in argon for one hour. Figure 3 shows the I-N curve for contact to -type silicon derived from oxide-coated nano-aluminum. Figure 4(A) shows the TEM-EDS characterization of nano-aluminum before and 4(B) after treatment with Hhfa. Figure 5 shows the FT-IR spectrum obtained from aΝujol mull of treated nano- aluminum powder. The Νujol peaks are marked with an "*". Figure 6 is the linear I-N curve for contact to -type silicon derived from Hhfa-treated nano-aluminum. Figure 7(A) shows the XRD characterization of the oxide coated copper nanoparticles, as received. Figure 7(B) shows that, pursuant to XRD characterization, after etching the particles in Hhfa, the oxide coating was removed. Best Mode for Carrying Out the Invention: Unless specifically defined otherwise, all technical or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the presently preferred methods and materials are now described. The etchants, in accordance with the present invention, are metal chelate organometallic complexes which remove the oxide and hydroxide corrosion layers, or both, from the surface of metallic particles and passivate the surfaces for use in the formation of thin film conductors, and the like. The metal chelates are pure synthetic compounds which etch cleanly at low temperature. The metal-chelates comprise hexafluoroacetylacetone and preferably include the organometallic complexes Νa(hfa), Cu(hfa)*VTMS, and neat hexafluoroacetylacetone (Hhfa), where hfac = 1,1,1,5,5,5-hexafluoroacetylacetonate, and NTMS is vinyltrimethylsilane. NTMS has the additional advantage of acting as a stabilizer. The metal nanoparticles, to be etched, preferably have a mean particle diameter in the range of 1 to 500 nanometers, and more particularly in the range of 1 and 100 nanometers. The nanoparticles may be produced according to any method well known in the art, such as the Argonide Corporation's, Sanford, FL, nano aluminum or copper particles, which are formed by electroexplosion of wire. When applied in the field of polycrystalline photovoltaic cell technology these particles may include all metals having properties as conductors, such as Νi, Au, Al, Ag, Mo, Cu, Pt and Pd. After etching, the particles may be used in the formation of ohmic contacts on any suitable surface or substrate, for example on carbon, silicon, germanium, III-N semiconductors, II-NI semiconductors, and I-III-NI semiconductors. These compounds, and their application in solid state electronic devices, are well known. All references herein to a Class of Compounds herein refers to the Class of Elements as set forth in the Periodic Table of the Elements, published by the American Chemical Society. EXAMPLE I A particle aluminum reaction mixture was prepared by dispersing 0.12g Al particulate powder into a mixture comprising 1 l.Og hexafluoroacetylacetonate in approximately 150ml hexane. An aliquot of ΝaH was added to the reaction mixture and the mixture was allowed to react approximately twelve hours with stirring under nitrogen gas aeration. These mixing conditions provided a sufficient time for etching of the oxide and/or hydroxide groups from the Al particles and concomitant formation of a passivation layer. Hexane supernatant was then decanted from the reaction mixture and the remaining suspension was separated by centrifugation at 2,600 rpm for 10 minutes. Supernatant fluid was then decanted from the centrifuge tube and the remaining solvent removed in vacuo. The remaining solid was transferred to a Dailey Sublimer in a He-filled globe box. The sublimer was placed onto a Schlenk line and evacuated to 10 "3 torr. An oil bath was employed and the mixture was heated to 200° C. At this temperature, the unreacted Νa(hfa) sublimed up to the cold finger leaving Na(hfa)-treated Al particles in the bottom. FTIR spectroscopy of a sample of Na(hfa)-treated Al showed peaks due to the hfa ligand. TEM-EDS showed a marked reduction in oxygen content as well as the appearance of fluorine. Na(hfa)-treated Al powder was then applied to p-type Si to check for ohmic contact. A control sample was prepared using untreated Al powder on p-type Si. In both instances, an aliquot of Al was slurried with hexane in a He-filled glovebox and dropped onto the Si wafer. These samples were transferred to a tube furnace, the tube was purged with argon, and the samples were heated for one hour at 645-649°C. After the contact anneal, the residue that remained where the Al slurry was dropped, was removed using an isopropanol-wetted Q-tip. Silver paint was added to these regions and I-N characterization was performed. Figure 1 shows the current- voltage characteristics of the solar cell where the particulate aluminum was slurried onto p-type silicon and annealed at 645°C in argon for one hour. This is a control sample. Figure 2 shows the current- voltage characteristics of the solar cell where the particulate aluminum was etched/passivated withΝa(hfa), slurried onto p-type Si, and annealed at 649°C in argon for one hour. EXAMPLE II The following example relates to the formation of a nano-aluminum contact to silicon. Nano-aluminum, produced by the electroexplosion process, was obtained from Argonide, Corporation, Sanford, FL. TEM characterization of this material shows the majority to be spherical particles with diameters ranging from 50-300 nm with small irregular chunks as small as 10 nm interspersed. TEM-EDS shows aluminum with a significant amount of oxygen present. This is due to surface oxidation of the particles resulting in an aluminum oxide surface layer. These particles were slurried in toluene, applied to silicon substrates, and annealed at 650°C for 1 hour under argon. The I-N curve of the resulting contact is shown in Figure 3. The curvature observed at higher current densities indicates that the contact formed is not ohmic. Chemical etching to remove the oxide coating on the nano-aluminum particles was attempted but it was found that these etchants (ΝaOH 1.0 - 0.03 molar) completely dissolved the nanoparticles. However, treatment of oxide-coated nano-aluminum with neat hexafluoroacetyacetone (Hhfa) for 16 hours followed by decanting the liquid phase, washing with toluene, and drying was found to remove the oxide coat. Referring now to Figures 4A and 4B, TEM-EDS characterization of nano-aluminum particles before [(Figure 4(A)] and after [(Figure 4(B)] this Hhfa treatment is shown. After the etch, the surface of the cleaned nano- aluminum particles is coordinated with hexafluoroacetylacetonate (hfa) legands. In Figure 5, one can observe the results of the FT-IR spectrum which was obtained from a nujol mull of treated nano-aluminum powder. The peaks at 1675, 1600 and 1536 cm "1 are C-O stretches and the peaks at 1636, 1261 and 1212 cm "1 are C=C and C-F stretches of the coordinated hfa ligand. When Hhfa-treated nano-aluminum was used to form a contact top-silicon in the manner described above, the linear I-N curve shown in Figure 6 was obtained. EXAMPLE III The following example illustrates the use of hfa, and in particular Cu(hfa)NTMS, for etching the native oxide (Cu 2 O) from the surface of copper nano-particles. The copper nanoparticles were also formed from the electroexplosion of copper wire and, as shown in Figure 7(A) after XRD characterization, are oxide coated, as received. The native oxide coating on the nano-sized Cu particles was removed at room temperature using a wet hexafluoracetylacetone chemical chelating etch. As shown in Figure 7(B), after etching the particles with hfa, the oxide layer was removed. It also can be seen that the Hhfa is coordinated to the Cu metal after the etch. While the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.

Claims: Claims 1. A process for etching the corrosion layer from and passivating the surface of metallic particles, comprising: (a) forming a reaction mixture by dispersing particles, having a passivating surface layer in a solution comprising a hexafluoroacetylacetonate metal chelate; and (b) reacting the mixture for a time sufficient to etch and passivate the surface. 2. The process of claim 1 wherein the passivating surface layer is selected from the species consisting of oxide and hydroxide. 3. The process of claim 2 wherein the metal chelate is selected from the group consisting of Cu(hfa)-NTMS, Hhfa, and Νa(hfa). 4. The process of claim 3 wherein the metallic particles are aluminum or copper. 5. The process of claim 3 further comprising, after reacting, washing the mixture in an organic solvent and then drying. 6. The process of claim 4 wherein the particles comprise nanoparticles in the range of 1 - 10 nm. 7. The process of claim 5 wherein the time is in a range of 1-24 hours. 8. The process of claim 5 wherein the organic solvent is selected from the group consisting of hexane or toluene.

Inventors: CURTIS CALVIN J, GINLEY DAVID S, SCHULZ DOUGLAS L, CURTIS, CALVIN, J., GINLEY, DAVID, S., SCHULZ, DOUGLAS, L.
Applicants: CURTIS CALVIN J, GINLEY DAVID S, MIDWEST RESEARCH INST, SCHULZ DOUGLAS L, CURTIS, CALVIN, J., GINLEY, DAVID, S., MIDWEST RESEARCH INSTITUTE, SCHULZ, DOUGLAS, L.
Application year: 2001
Main classification: B22F1
IPC codes: B22F1, C23C8, C23C22, C23G5, H01L21, H01L31