the Creative Commons Attribution 4.0 License.
the Creative Commons Attribution 4.0 License.
A comprehensive design schedule for electrosprayed thin films with different surface morphologies
Abstract. Electrospraying is a technique where a liquid jet breaks up into droplets under the influence of electrical forces. The technique is outstanding because of its high deposition efficiency and ability to achieve thin films with different surface morphologies. Nowadays, it is applied in the deposition of thin films for nanoelectronics in Li-ion batteries, fuel cells and solar cells, where performance of the deposited layers is determined by their morphologies. Though important in the design of thin films, a systematic way of depositing thin films with desired surface morphologies for optimal operation is not available. In this study, a literature survey has been conducted from which key electrospray parameters have been identified and a comprehensive design schedule for thin films with different surface morphologies has been developed. To verify the developed schedule, different thin films have been deposited on aluminium foil substrates using lithium salt precursor solutions by altering key electrospray parameters. Surface morphologies of the thin films have been characterized using scanning electron microscopy. Results show three distinct surface morphologies which include porous with agglomerates, porous reticular and dense particulate and they agree with the predictions of the developed design schedule.
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Status: open (until 01 May 2024)
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RC1: 'Comment on ar-2024-10', Ivo B. Rietveld, 11 Apr 2024
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The paper provides an overview of the electrospray film deposition parameters that are important for the control of film quality. This is absolutely important and useful for the application of electrospray to generate films with desired properties.ÂThe paper is well written and clear to follow and merits publication.ÂI would only suggest to link Table 3 more clearly to the figures that have been produced by the settings listed in Table 3. It also makes cross-referencing between the Tables 1 and 3 easier in my opinion.I also suggest to add in the abstract and the conclusions that the parameters and the film quality mapping are applicable to inorganic salts, as the results in film quality with organic molecules and in particular polymers are expected to differ more or less extensively depending on their interaction with the electrospray solvent and depending on their crystallisation behaviour, because in particular the amorphous/crystalline behaviour is rather different between polymers and inorganic salts.ÂThis has been demonstrated for polymers in the following papers:ÂÂIvo B. Rietveld, Kei Kobayashi, Takuya Honjo, Kenji Ishida, Hirofumi Yamada, Kazumi MatsushigeElectrospray induced ferroelectricity in poly(vinylidene fluoride) thin films.Journal of Materials Chemistry 2010, 20, 8272–8278http://dx.doi.org/10.1039/C0JM01265CÂRietveld I.B., Kobayashi K., Yamada H., Matsushige K.Process parameters for fast production of ultra-thin polymer film with electrospray deposition under ambient conditionsJournal of Colloid and  Interface Science 2009, 339, 481-488ÂRietveld I.B., Kobayashi K., Yamada H., Matsushige K.Electrospray deposition producing ultra-thin polymer films with a regular surface structureSoft Matter 2009, 5, 593-598ÂRietveld I.B., Suganuma N., Kobayashi K., Yamada H., Matsushige K.Electrospray Deposition of Photoresist; A Low Impact Method for the Fabrication of Multilayered FilmsMacromolecular Materials Engineering 2008, 293, 325-440ÂRietveld I.B., Kobayashi K., Yamada H., Matsushige K.Electrospray deposition, model and experiment; towards general control of film morphologyJournal of Physical Chemistry B 2006, 110, 23351-23364ÂRietveld I.B., Kobayashi K., Yamada H., Matsushige K.Morphology control of poly(vinylidene fluoride) thin film made with electrosprayJournal of Colloid and  Interface Science 2006, 298(2), 639-651
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Citation: https://doi.org/10.5194/ar-2024-10-RC1 -
AC1: 'Reply on RC1', Susan Karuga, 18 Apr 2024
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Thank you very much for your insightful and encouraging feedback on our paper. We are pleased to hear that you found the overview of electrospray film deposition parameters to be important and useful for practical applications. Your suggestion regarding the clearer linkage between Table 3 and the corresponding figures, as well as facilitating cross-referencing between Tables 1 and 3, is well-taken. We will certainly work on enhancing these aspects to improve the clarity and accessibility of the paper.
Moreover, your recommendation to explicitly mention in the abstract and conclusions that the parameters and film quality mapping are applicable to inorganic salts is valuable. We acknowledge the inherent differences in behaviour between inorganic salts and organic molecules, especially polymers, in response to electrospray conditions and subsequent film formation. Highlighting this distinction will undoubtedly provide greater context and clarity for readers interested in applying our findings across different materials systems.
We sincerely appreciate your thoughtful and constructive suggestions, which will undoubtedly strengthen the manuscript. We will incorporate these revisions accordingly and ensure that they are reflected in the final version of the paper. Once again, thank you for your time and valuable input.
Citation: https://doi.org/10.5194/ar-2024-10-AC1
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AC1: 'Reply on RC1', Susan Karuga, 18 Apr 2024
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RC2: 'Comment on ar-2024-10', Alfonso Ganan-Calvo, 19 Apr 2024
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Please see attached document.
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