A new plasma-enhanced
atomic layer deposition process was developed
to deposit iron phosphate by using a sequence of trimethyl phosphate
(TMP, Me3PO4) plasma, O2 plasma,
and tert-butylferrocene (TBF, Fe(C5H5)(C5H4C(CH3)3))
exposures. Using in situ spectroscopic ellipsometry and ex situ X-ray
reflectometry, the growth linearity, growth per cycle (GPC), and density
of the resulting thin films was investigated as a function of the
pulse times and the substrate temperature. At a substrate temperature
of 300 °C and using saturated pulse times, an exceptionally high
GPC of 1.1 nm/cycle without nucleation delay was achieved, resulting
in amorphous films with an empirical stoichiometry of FeP1.5O4.7 with 0.9% hydrogen and no detectable carbon residue.
Trigonal FePO4 (Berlinite) was formed upon annealing in
air. Remarkably, annealing in helium resulted in the formation of
elemental phosphorus. The as-deposited, amorphous material became
active as a Li-ion cathode after an initial irreversible electrochemical
lithiation, showing insertion and extraction of Li+ around
a potential of 3.1 V vs Li/Li+. By conformally depositing
the same material on a 3D-microstructured substrate consisting of
Pt-coated Si micropillars, the capacity could be drastically increased
without sacrificing rate performance.