High rate vacuum deposition of polymer electrolytes

Two new, high rate, vacuum processes have been developed for the deposition of polymer electrolyte layers on wide web substrates. One method involves the vacuum extrusion of monomer salt solutions followed by e-beam or ultraviolet (UV) curing. The second method involves the vacuum flash evaporation of the monomer salt solution followed by e-beam or UV curing. Each method is compatible with simultaneous, in-line, deposition by conventional processes like sputtering or evaporation in a wide web system. Optically clear polymer electrolyte layers may be deposited at line speeds in excess of 100 meters per minute with these new techniques. Ionic conductivity measurements will be presented for vacuum deposited, evaporated and extruded, polymer electrolyte layers. Films were deposited with thicknesses ranging from 2 to 50 μm. Application of these methods to ongoing electrochromic and battery work at the Pacific Northwest Laboratory will be discussed.