Patent Application
20120192791
The present invention relates to a manufacturing apparatus. More specifically, the present invention relates to an electrode utilized within the manufacturing apparatus.
Manufacturing apparatuses for the deposition of a material on a carrier body are known in the art. Such manufacturing apparatuses comprise a housing that defines a chamber. Generally, the carrier body is substantially U-shaped, having a first end and a second end spaced from each other. Typically, a socket is disposed at each end of the carrier body. Generally, two or more electrodes are disposed within the chamber for receiving the respective socket disposed at the first end and the second end of the carrier body. The electrode also includes a contact region, which supports the socket and, ultimately, the carrier body to prevent the carrier body from moving relative to the housing. The contact region is the portion of the electrode adapted to be in direct contact with the socket and provides a primary current path from the electrode to the socket and into the carrier body.
A power supply device is coupled to the electrode for supplying an electrical current to the carrier body. The electrical current heats both the electrode and the carrier body to a deposition temperature. A processed carrier body is formed by depositing the material on the carrier body at the deposition temperature.
As known in the art, variations exist in the shape of the electrode and the socket to account for thermal expansion of the material deposited on the carrier body as the carrier body is heated to the deposition temperature. One such method utilizes a flat head electrode and a socket in the form of a graphite sliding block. The graphite sliding block acts as a bridge between the carrier body and the flat head electrode. The weight of the carrier body and the graphite sliding block acting on the contact region reduces the contact resistance between the graphite sliding block and the flat head electrode. Another such method involves the use of a two-part electrode. The two-part electrode includes a first half and a second half for compressing the socket. A spring element is coupled to the first half and the second half of the two-part electrode for providing a force to compress the socket. Another such method involves the use of an electrode defining a cup with the contact region located within the cup of the electrode. The socket is adapted to fit into the cup of the electrode and to contact the contact region located within the cup of the electrode. Alternatively, the socket may be structured as a cap that fits over the top of the electrode.
In some manufacturing apparatuses, a fouling of the electrode occurs on the contact region due to the buildup of deposits, especially when the material deposited on the carrier body is polycrystalline silicon that forms as a result of decomposition of chlorosilanes. The deposits result in an improper fit between the socket and the electrode over time. The improper fit causes small electrical arcs between the contact region and the socket that result in metal contamination of the material deposited on the carrier body. The metal contamination reduces the value of the carrier body, as the material deposited is less pure. Additionally, the fouling reduces the heat transfer between the electrode and the socket, resulting in the electrode reaching higher temperatures to effectively heat the socket and ultimately the carrier body. The higher temperatures of the electrode result in accelerated deposition of the material on the electrode. This is especially the case for electrodes that comprise silver or copper as the sole or main metal present therein.
The electrode must be replaced when one or more of the following conditions occur: first, when the metal contamination of the material being deposited upon the carrier body exceeds a threshold level; second, when fouling of the contact region of the electrode causes the connection between the electrode and the socket to become poor; third, when excessive operating temperatures for the electrode are required due to fouling of the contact region of the electrode. The electrode has a life determined by the number of carrier bodies the electrode can process before one of the above occurs.
It is known in the art to provide silver plating over a stainless steel electrode. As known in the art, silver has higher thermal conductivity and lower electrical resistivity as compared to stainless steel and will provide immediate benefits relative to enhancing heat transfer and electrical conductivity properties of the electrode. Based upon the teachings of the prior art, providing silver plating over the stainless steel electrode is sufficient to satisfy the goals of enhancing heat transfer and electrical conductivity properties of the electrode. However, the prior art fails to address considerations relative to extending the useful life of electrodes.
In view of the foregoing problems related to fouling of the electrodes, there remains a need to further develop the structure of the electrodes to improve the productivity and increase the life of the electrode.
The present invention relates to a manufacturing apparatus for deposition of a material on a carrier body and an electrode for use with the manufacturing apparatus. The carrier body has a first end and a second end spaced from each other. A socket is disposed at each of the ends of the carrier body.
The manufacturing apparatus includes a housing that defines a chamber. The housing also defines an inlet for introducing a gas into the chamber and an outlet for exhausting the gas from the chamber. At least one electrode is disposed through the housing with the electrode at least partially disposed within the chamber for coupling to the socket. The electrode has an exterior surface. A first exterior coating is disposed on the exterior surface of the electrode. The first exterior coating has an electrical conductivity of at least 7×106 Siemens/meter at room temperature. A second exterior coating is disposed on the first exterior coating. The second exterior coating is different from the first exterior coating. A power supply device is coupled to the electrode for providing an electrical current to the electrode.
There are many advantages to providing the first and second exterior coatings on the exterior surface of the electrode. One advantage is that it is possible to delay fouling of the electrode by tailoring the first and second exterior coatings on the exterior surface of the electrode with different materials based on the source of fouling, and based upon the location of the first and second exterior coatings on the exterior surface of the electrode. By delaying fouling, the life of the electrode is extended, resulting in a lower production cost and reducing the production time of the processed carrier bodies. Further, by including the first exterior coating and the second exterior coating, multiple disparate considerations may be taken into account that may all contribute to maximizing the life of the electrode. In particular, the first exterior coating, having the specified electrical conductivity, may be provided to particularly address one consideration or group of considerations that contributes to maximizing the life of the electrode, while the second exterior coating may be provided to address another consideration or group of considerations that contributes to maximizing the life of the electrode.
Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a manufacturing apparatus 20 for deposition of a material 22 on a carrier body 24 is shown in
Typically, with methods of chemical vapor deposition known in the art such as the Siemens method, the carrier body 24 is substantially U-shaped and has a first end 54 and a second end 56 spaced and parallel to each other. A socket 57 is disposed at each of the first end 54 and the second end 56 of the carrier body 24.
The manufacturing apparatus 20 includes a housing 28 that defines a chamber 30. Typically, the housing 28 comprises an interior cylinder 32, an outer cylinder 34 and a base plate 36. The interior cylinder 32 includes an open end 38 and a closed end 40 spaced from each other. The outer cylinder 34 is disposed about the interior cylinder 32 to define a void 42 between the interior cylinder 32 and the outer cylinder 34, typically serving as a jacket to house a circulated cooling fluid (not shown). It is to be appreciated by those skilled in the art that the void 42 can be, but is not limited to, a conventional vessel jacket, a baffled jacket, or a half-pipe jacket.
The base plate 36 is disposed on the open end 38 of the interior cylinder 32 to define the chamber 30. The base plate 36 includes a seal (not shown) disposed in alignment with the interior cylinder 32 for sealing the chamber 30 once the interior cylinder 32 is disposed on the base plate 36. In one embodiment, the manufacturing apparatus 20 is a Siemens type chemical vapor deposition reactor.
The housing 28 defines an inlet 44 for introducing a gas 45 into the chamber 30 and an outlet 46 for exhausting the gas 45 from the chamber 30. Typically, an inlet pipe 48 is connected to the inlet 44 for delivering the gas 45 to the housing 28 and an exhaust pipe 50 is connected to the outlet 46 for removing the gas 45 from the housing 28. The exhaust pipe 50 can be jacketed with a cooling fluid such as water or a commercial heat transfer fluid.
At least one electrode 52 is disposed through the housing 28 for coupling with the socket 57. In one embodiment, as shown in
The electrode 52 comprises an electrically conductive material having a minimum electrical conductivity at room temperature of from about 14×106 to 42×106 Siemens/meter or S/m. For example, the electrode 52 can comprise at least one of copper, silver, nickel, Inconel and gold, each of which meets the conductivity parameters set forth above. Additionally, the electrode 52 can comprise an alloy that meets the conductivity parameters set forth above. In one embodiment, the electrode 52 comprises electrically conductive material having a minimum electrical conductivity at room temperature of about 58×106 S/m. Typically, the electrode 52 comprises copper, which has an electrical conductivity at room temperature of about 58×106 S/m, and the copper is typically present in an amount of about 100% by weight based on the weight of the electrode 52. The copper can be oxygen-free electrolytic copper grade UNS 10100.
Referring also to
In one embodiment the electrode 52 includes a shaft 58 having a first end 61 and a second end 62. When present, the shaft 58 further defines the exterior surface 60 of the electrode 52. Generally, the first end 61 is an open end of the electrode 52. In one embodiment, the shaft 58 is generally cylindrically shaped and defines a diameter D1 as shown in
The electrode 52 can also include a head 64 disposed on one of the ends 61, 62 of the shaft 58. It is to be appreciated that the head 64 can be integral to the shaft 58. Typically, when the head 64 is present, the contact region 66 is located on the head 64. It is to be appreciated by those skilled in the art that the method of connecting the socket 57 to the electrode 52 can vary between applications without deviating from the subject invention. For example, in one embodiment, such as for flat head electrodes (not shown), the contact region 66 can merely be a top, flat surface of the electrode 52 and the socket 57 can define a socket cup (not shown) that fits over the second end 62 of the electrode 52. In another embodiment, as shown in
A first set of threads 70 can be disposed on the exterior surface 60 of the electrode 52. Referring back to
Typically, at least one of the shaft 58 and the head 64 include an interior surface 76 defining the channel 78. The interior surface 76 includes a terminal end 80 spaced from the first end 61 of the shaft 58. The terminal end 80 is generally flat and parallel to the first end 61 of the electrode 52. It is to be appreciated that other configurations of the terminal end 80 can be utilized such as a cone-shaped configuration, an ellipse-shaped configuration, or an inverted cone-shaped configuration (none of which are shown). The channel 78 has a length L that extends from the first end 61 of the electrode 52 to the terminal end 80. It is to be appreciated that the terminal end 80 can be disposed within the shaft 58 of the electrode 52 or the terminal end 80 can be disposed within the head 64 of the electrode 52, when present, without deviating from the subject invention.
The manufacturing apparatus 20 further includes a power supply device 82 coupled to the electrode 52 for providing an electrical current. Typically, an electric wire or cable 84 couples the power supply device 82 to the electrode 52. In one embodiment, the electric wire 84 is connected to the electrode 52 by disposing the electric wire 84 between the first set of threads 70 and the nut 74. It is to be appreciated that the connection of the electric wire 84 to the electrode 52 can be accomplished by different methods.
The electrode 52 has a temperature, which is modified by passage of the electrical current there through resulting in a heating of the electrode 52 and thereby establishing an operating temperature of the electrode 52. Such heating is known to those skilled in the art as Joule heating. In particular, the electrical current passes through the electrode 52, through the socket 57 at the contact region 66 of the electrode 52, and into the carrier body 24 resulting in the Joule heating of the carrier body 24. Additionally, the Joule heating of the carrier body 24 results in a radiant/convective heating of the chamber 30. The passage of electrical current through the carrier body 24 establishes an operating temperature of the carrier body 24.
Referring to
The circulating system 86 includes a coolant in fluid communication with the channel 78 of the electrode 52 for reducing the temperature of the electrode 52. In one embodiment, the coolant is water; however, it is to be appreciated that the coolant can be any fluid designed to reduce heat through circulation without deviating from the subject invention. Moreover, the circulating system 86 also includes a hose 90 coupled between the electrode 52 and a reservoir (not shown). Referring only to
The coolant within the circulating system 86 is under pressure to force the coolant through the inner tube 92 and the outer tubes 94. Typically, the coolant exits the inner tube 92 and is forced against the terminal end 80 of the interior surface 76 of the electrode 52 and subsequently exits the channel 78 via the outer tube 94 of the hose 90. It is to be appreciated that reversing the flow configuration such that the coolant enters the channel 78 via the outer tube 94 and exits the channel 78 via the inner tube 92 is also possible. It is also to be appreciated by those skilled in the art of heat transfer that the configuration of the terminal end 80 influences the rate of heat transfer due to the surface area and proximity to the head 64 of the electrode 52. As set forth above, the different geometric contours of the terminal end 80 result in different convective heat transfer coefficients for the same circulation flow rate.
Referring to
The type of material used for the first and second exterior coatings 96, 106 may vary depending upon the location of the first and second exterior coatings 96, 106 on the exterior surface 60 of the electrode 52. In particular, depending upon the location of the first and second exterior coatings 96, 106 on the exterior surface 60 of the electrode 52, different physical properties of the first and second coatings 96, 106 have more or less of an effect on the life of the electrode 52. Physical properties that may have an effect on the life of the electrode 52, at various locations thereon, include electrical conductivity (or resistance), wear resistance, thermal reflectivity, thermal conductivity, corrosion resistance to gases present in the chamber 78 during operation of the manufacturing apparatus 20, thermal resistance, purity of the first or second exterior coatings 96, 106, and release of deposits from the first or second exterior coatings 96, 106. Furthermore, the manner in which the first and second exterior coatings 96, 106 are formed may also affect the life of the electrode 52. As described in further detail below, selection of material and manner of formation for the first and second exterior coatings 96, 106 may be varied to exploit one or more of the above physical properties, depending upon the location of the first and second exterior coatings 96, 106 on the exterior surface 60 of the electrode 52. Accordingly, the benefits associated with providing the first and second exterior coatings in accordance with the instant invention go far beyond merely enhancing heat transfer and electrical conductivity properties of the electrode.
In the embodiment of the electrode 52 shown in
Generally, the electrode 52 must be replaced once the metal contamination exceeds the threshold level in polycrystalline silicon or once the material 22 is deposited on the electrode 52 and prevents the removal of the socket 57 from the cup 68 of the electrode 52 after processing. To illustrate this situation, copper contamination of polycrystalline silicon due to copper-based electrodes is typically below a threshold of 0.01 ppba. However, it is recognized to those skilled in the art of producing semiconductor materials of high purity that specifications for transition metal contamination differ based upon the particular application. For example, it is known that silicon used in the manufacture of ingots and wafers for photovoltaic cells can tolerate appreciably higher levels of copper contamination relative to semiconductor-grade silicon, e.g. 100-10,000 fold, without significant loss in lifetime and cell performance. As such, each purity specification for polycrystalline silicon may be evaluated individually when viewed against the electrode replacement need.
The first exterior coating 96 is typically provided to effectively seal the material of the electrode 52, which is typically copper. By effectively sealing the material of the electrode 52, purity and contamination concerns may be alleviated depending upon the material used for the first exterior coating 102. In this regard, the first exterior coating is typically disposed directly on the exterior surface 60 of the electrode 52. Referring to
The first exterior coating 96 has an electrical conductivity of at least 7×106 Siemens/meter, alternatively at least 20×106 S/m, alternatively at least 40×106 S/m, each as measured at room temperature, with the upper limit of electrical conductivity not limited. The electrical conductivity of the first exterior coating 96 is sufficiently high to effectively transfer heat from the electrode 52 to the socket 57 through Joule heating. The first exterior coating 96 also typically less contaminating to the material 22 deposited on the carrier body 24 than copper. Suitable materials that can be used for the first exterior coating 96 include nickel, gold, platinum, palladium, silver, chromium, titanium, and combinations thereof. In one specific embodiment, the first exterior coating 96 comprises nickel, which is sufficiently electrically conductive and which is relatively non-contaminating as compared to copper. Typically, the first exterior coating 96 includes at least one of the above-listed metals in an amount of at least 50% by weight based on the total weight of the first exterior coating 96. More typically, the first exterior coating 96 includes substantially only the above-listed metals.
Electrical conductivity of the first exterior coating 96 that is disposed on the contact region 66 is of greater concern than for other portions of the electrode 52 that are not in the primary current path between the electrode 52 and the carrier body 24. Without being bound by any particular theory, it is believed that the first exterior coating 96 that is disposed on the contact region 66 maintains the electrical conductivity between the electrode 52 and the socket 57, which allows a reduction of the operating temperature of the electrode 52 and prevents the deposition of the material 22 on the electrode 52. Contamination from the electrically conductive material of the electrode 52 is of greater concern on the exterior surface 60 outside of the contact region 66 such that it is still preferable to include the first exterior coating 96 thereon, even though electrical conductivity is immaterial outside of the contact region 66 of the electrode 52.
In one embodiment, the first exterior coating 96 may be further defined as an electroplated coating, which exhibits minimal porosity as compared to coatings that are formed through other techniques. The electroplated first exterior coating 96 effectively seals the material of the electrode 52, thereby minimizing metal contamination of the material 22 deposited on the carrier body 24 that is associated with some electrically conductive materials of the electrode 52 such as copper.
The first exterior coating 96 typically has a thickness of from 0.00254 to 0.254 mm, more typically from 0.00508 mm to 0.127 mm and most typically from 0.00508 mm to 0.0254 mm.
As set forth above, the second exterior coating 106 is disposed on the first exterior coating 96. While the first exterior coating 96 is effective for many purposes as mentioned above, including effectively sealing the electrically conductive material of the electrode 52 to prevent metal contamination of the material 22 deposited on the carrier body 24 and to inhibit deposition of the material 22 on the electrode, other physical properties of the electrode 52 can be further enhanced by the second exterior coating. For example, wear resistance, thermal reflectivity, purity, and deposit release properties can be enhanced by including the second exterior coating 106. Furthermore, while metals such as nickel are less contaminating than copper, nickel in particular is moderately reactive with chlorosilanes and, thus, it may be possible to further inhibit formation of deposits on the electrode by covering the first exterior coating 96 with the second exterior coating 106, especially when the first exterior coating 96 comprises nickel.
One particular physical property of the second exterior coating 106 that is effective for purposes of maximizing the life of the electrode 52 is wear resistance, regardless of the location of the exterior coating 106 on the exterior surface 60 of the electrode 52. The electrode 52 is continually subject to a mechanical cleaning operation to remove deposits that may have formed thereon during deposition of the material 22 on the carrier body 24. The mechanical cleaning operation is typically performed on all portions of the electrode 52 that are disposed in the chamber 30, including the contact region 66 and the exterior surface 60 of the electrode 52 that is outside of the contact region 66. Whereas corrosion and deposit formation shorten the life of the electrode 52 as indicated above, wear attributable to the mechanical cleaning operation may also shorten the life of the electrode. While the first exterior coating 96 provides many advantages as set forth above, the second exterior coating typically has a greater wear resistance than said first exterior coating as measured in mm3/N*m wear, which enhances the overall wear resistance of the electrode 52. Wear resistance can be measured by ASTM G99-5 “Standard Test Method for Wear Testing with Pin-on-Disk Apparatus”. The second exterior coating typically has a wear resistance of at least 6*106 mm3/N*m, alternatively at least 1*108 mm3/N*m, which is many orders of magnitude higher than wear resistance of the metals that are suitable for the first exterior coating 96 such as nickel. In particular, a nickel coating on a copper substrate has low wear resistance of about 1.5×10−5 mm3/N*m, and silver and gold have similarly low wear resistance, which can accelerate the demise of the electrode 52
In one embodiment, the second exterior coating 106 may be further defined as one of a physical vapor deposition (PVD) coating or a plasma-assisted chemical vapor deposition (PCVD) coating. In another embodiment, the second exterior coating 106 is further defined as a dynamic compound deposition coating. Dynamic Compound Deposition (DCD) is a proprietary low temperature coating process practiced by Richter Precision, Inc. of East Petersburg, Pa. The PVD, PCVD, and DCD coatings are typically formed from materials that are difficult to electroplate, but that provide enhanced properties to the electrode 52 as indicated above. The dynamic compound deposition coating 106 possesses a considerably decreased friction coefficient and increased durability as compared to coatings formed through other techniques.
As set forth above, the type of material used for the second exterior coating 106 may vary depending upon the location of the second exterior coating 106 on the exterior surface 60 of the electrode 52. In particular, the type of material used for the second exterior coating may be varied depending upon the physical property to be enhanced, albeit taking into consideration physical properties such as electrical conductivity. For example, as indicated above, electrical conductivity of the contact region 66 is of greater concern than for other portions of the electrode 52 that are not in the primary current path between the electrode 52 and the carrier body 24. As such, when the second exterior coating 106 is disposed on the first exterior coating 96 on the contact region 66, materials are typically selected for the second exterior coating 106 that possess electrical conductivity of at least 7×106 Siemens/meter at room temperature. In one embodiment, the second exterior coating 106 comprises a titanium-containing compound having electrical conductivity of at least 7×106 Siemens/meter at room temperature. Suitable such titanium-containing compounds may be selected from the group of titanium nitride, titanium carbide, and combinations thereof. The second exterior coating 106 may include other metals and/or compounds so long as sufficient electrical conductivity of the overall second exterior coating 106 of at least 7×106 Siemens/meter at room temperature is achieved for the second exterior coating 106 disposed on the first exterior coating 96 on the contact region 66. For example, in one embodiment, the second exterior coating 106 may further include at least one of silver, nickel, chromium, gold, platinum, palladium; alloys thereof, such as a nickel/silver alloy; and titanium oxide, which does not possess sufficient electrical conductivity itself but which can be combined with electrically-conductive titanium-containing compounds (such as those set forth above) to result in the second exterior coating 106 having sufficient electrical conductivity. Typically, the second exterior coating 106 disposed on the contact region 66 includes substantially only the titanium-containing compounds having the electrical conductivity of at least 7×106 Siemens/meter at room temperature. However, when one or more of the other metals or compounds are present, the total amount of the titanium-containing compounds having the electrical conductivity of at least 7×106 Siemens/meter at room temperature is typically at least 50% by weight based on the total weight of the second exterior coating 106.
The titanium-containing compounds having the electrical conductivity of at least 7×106 Siemens/meter at room temperature have sufficient electrical conductivity and wear resistance such that the titanium-containing compounds are ideal when the second exterior coating 106 is disposed on the first exterior coating 96 on the contact region 66 of the electrode 52. Furthermore, the titanium-containing compounds have excellent corrosion resistance, especially against chlorosilanes at high reactor temperatures such that the titanium-containing compounds are also suitable outside of the contact region 66. More specifically, it is to be appreciated that the titanium-containing compounds are suitable for the second exterior coating 106 that is disposed on the first exterior coating 96 outside of the contact region 66 due to the excellent wear resistance properties thereof, even though electrical conductivity is immaterial outside of the contact region 66 of the electrode 52.
Because electrical conductivity is immaterial outside of the contact region 66 of the electrode 52, materials other than the titanium-containing compounds having the electrical conductivity of at least 7×106 Siemens/meter at room temperature can be used for the second exterior coating 106 that is disposed on the first exterior coating 96 outside of the contact region 66. As such, when the second exterior coating 106 is disposed on the first exterior coating 96 outside of the contact region 66, materials may be selected based upon their ability to enhance thermal reflectivity, purity, and deposit release properties with less focus on electrical conductivity. For example, when the second exterior coating 106 is disposed on the first exterior coating outside of said contact region (as shown in
When the second exterior coating 106 has an electrical conductivity of less than 7×106 Siemens/meter at room temperature, the second exterior coating 106 may comprise, but is not limited to, a diamond-like carbon compound. Diamond-like carbon compounds are known in the art and are identifiable by those of skill in the art. As known in the art, naturally occurring diamond has a purely cubic orientation of sp3 bonded carbon atoms. Diamond growth rates from molten material in both natural and bulk synthetic diamond production methods are slow enough that the lattice structure has time to grow in the cubic form that is possible for sp3 bonding of carbon atoms. In contrast, the exterior coating 106 comprising the diamond-like carbon compound can be produced by several methods which result in unique final desired coating properties to match the application requirements. As such, both cubic and hexagonal lattices can be randomly intermixed, layer by atomic layer, because there is no time available for one of the crystalline geometries to grow at the expense of the other before the atoms are “frozen” in place in the material. As a result, amorphous diamond-like carbon coatings can result that have no long range crystalline order. Such lack of long range crystalline order provides advantages in that there are no brittle fracture planes, so such coatings are flexible and conformal to the underlying shape being coated, while still being as hard as diamond.
Coatings comprising diamond-like carbon compounds are commercially available from Richter Precision, Inc. under the tradename Tribo-kote™. The second external coating 106 comprising the diamond-like carbon compound, in particular, possesses excellent thermal reflectivity, purity, and deposit release properties, which are ideal for the exterior surface 60 of the electrode outside of the contact region 66 and in the chamber 30 because the exterior surface 60 of the electrode 52 outside of the contact region 66 is exposed to the chamber 30 and to the material 22 during deposition on the carrier body 24. In particular, the diamond-like carbon compound typically has a specular reflectance of from 10 to 20% in the far IR wavelengths of from 15 to 30 microns, 25 to 33% in the near IR wavelengths of from 1000 to 2500 nm, and from 10 to 26% in the UV-visible wavelengths of less than 500 nm, as measured with a Lambda 19 spectrophotometer from Perkin Elmer. When used, the diamond-like carbon compound is typically present in the second exterior coating 106 in an amount of greater than 95% by weight based on the total weight of the second exterior coating 106. More typically, the second exterior coating 106 comprises only the diamond-like carbon compound when used. The diamond-like carbon compounds are typically deposited through dynamic coating deposition techniques (as described above), although it is to be appreciated that the instant invention is not limited to deposition of the diamond-like carbon coating through any particular technique.
As an alternative to the diamond-like carbon, titanium oxide is also suitable for the second exterior coating 106 outside of the contact region 66. Titanium oxide, although possessing insufficient electrical conductivity to be used alone for the second exterior coating 106 that is disposed on the first exterior coating 96 on the contact region 66, has excellent specular reflectivity such that the titanium oxide may be particularly suitable for the second exterior coating 106 outside of the contact region 66. In particular, the titanium oxide typically has a specular reflectance of from 58 to 80% in the far IR wavelengths of from 1 to 30 microns, from 5 to 66% in the near IR wavelengths of from 1000 to 1500 nm, from 30 to 66% in the near IR wavelengths of from 1500 to 2500 nm, and from 40 to 65% in the UV-visible wavelengths of less than 500 nm. As such, titanium oxide can provide significant advantages relative to higher spectral reflectance.
The second exterior coating 106 typically has a thickness of from about 0.1 μm to about 5 μm. While not shown in the Figures, it is to be appreciated that the second exterior coating 106 may comprise multiple individual layers having a common compositional makeup, such as for purposes of achieving higher effective thicknesses of the second exterior coating 106. Further, it is to be appreciated that additional coatings may be disposed over the second exterior coating 106 without deviating from the scope of the instant invention.
Based upon the above, it is clear that the content of the second exterior coating 106 may vary depending upon the location of the second exterior coating 106 on the electrode. For example, when the electrode 52 defines the cup 68 with the contact region 66 located within a portion of the cup 68, the second exterior coating 106 may be different on a bottom 102 of the cup 68 than on the side walls 104 of the cup 68 due to the fact that electrical conductivity may not be a concern with the bottom 102 of the cup 68. As such, the second exterior coating 106 that is disposed on the bottom 102 of the cup 68 may have an electrical conductivity of less than 7×106 Siemens/meter at room temperature and may comprise the diamond-like carbon compound.
As alluded to above, the electrode 52 having the first exterior coating 96 and the second exterior coating 106 (and, optionally, one or more additional interlayer coatings) may exhibit corrosion resistance to gases present in the chamber 78 during operation of the manufacturing apparatus 20. In particular, the electrodes 52 may exhibit excellent resistance to hydrogen and trichlorosilane at elevated temperatures of up to 450° C. For example, the electrode 52 having the first exterior coating 96 and the second exterior coating 106 (and, optionally, one or more additional interlayer coatings) may exhibit either no change or a positive change in weight after exposure to an atmosphere of hydrogen and trichlorosilane gas at a temperature of 450° C. for a period of 5 hours, along with low or no surface bubbling or degradation (as determined through visual observation), thereby indicating low or no corrosion of the electrode 52 or various coatings 96, 106 by the gases. Although some weight loss is acceptable (indicating surface degradation), such weight loss is typically less than or equal to 20% by weight, alternatively less than or equal to 15% by weight, alternatively less than or equal to 10% by weight of the total weight of the second exterior coating 106, with no weight loss preferred. However, it is to be appreciated that the electrodes of the instant invention are not limited to any particular physical properties with regard to corrosion resistance.
Selective coating of the electrode 52 may also be desirable under some circumstances, depending upon factors such as the particular electrically conductive material of the electrode 52, the material 22 that is deposited on the carrier body 56, the metal included in the first exterior coating 96, and the conditions under which the manufacturing apparatus is intended to be used. In one embodiment, as shown in
In addition, a channel coating 100 can be disposed on the interior surface 76 of the electrode 52 for maintaining the thermal conductivity between the electrode 52 and the coolant. Generally, the channel coating 100 has a higher resistance to corrosion that is caused by the interaction of the coolant with the interior surface 76 as compared to the resistance to corrosion of the electrode 52. The channel coating 100 typically includes a metal that resists corrosion and that inhibits buildup of deposits. For example, the channel coating 100 can comprise at least one of silver, gold, nickel, chromium, and alloys thereof, such as a nickel/silver alloy. Typically, the channel coating 100 is nickel. The channel coating 100 has a thermal conductivity of from 70.3 to 427 W/m K, more typically from 70.3 to 405 W/m K and most typically from 70.3 to 90.5 W/m K. The channel coating 100 also has a thickness of from 0.0025 mm to 0.026 mm, more typically from 0.0025 mm to 0.0127 mm and most typically from 0.0051 mm to 0.0127 mm.
It is to be appreciated that the electrode 52 can include an anti-tarnishing layer (not shown) disposed on the channel coating 100. The anti-tarnishing layer is a protective thin film organic layer that is applied on top of the channel coating 100. Protective systems such as Technic Inc.'s Tarniban™ can be used following the formation of the channel coating 100 of the electrode 52 to reduce oxidation of the metal in the electrode 52 and in the channel coating 100 without inducing excessive thermal resistance. For example, in one embodiment, the electrode 52 can comprise silver and the channel coating 100 can comprise silver with the anti-tarnishing layer present for providing enhanced resistance to the formation of deposits compared to pure silver. Typically, the electrode 52 comprises copper and the channel coating 100 comprises nickel for maximizing thermal conductivity and resistance to the formation of deposits, with the anti-tarnishing layer disposed on the channel coating 100.
A typical method of deposition of the material 22 on the carrier body 24 is discussed below and refers to
Once the carrier body 24 is processed, the electrical current is interrupted so that the electrode 52 and the carrier body 24 stop receiving the electrical current. The gas 45 is exhausted through the outlet 46 of the housing 28 and the carrier body 24 is allowed to cool. Once the operating temperature of the processed carrier body 24 has cooled, the processed carrier body 24 can be removed from the chamber 30. The processed carrier body 24 is then removed and a new carrier body 24 is placed in the manufacturing apparatus 20.
Various examples were prepared to illustrate corrosion resistance of sample coupons that are formed from nickel or copper, with various coatings disposed thereon as described in Table 1 below.
The coupons were placed in an environment of hydrogen and trichlorosilane gas (at a 2:1 molar ratio) at 350° C. and left for 5 hours. The weights of the coupons were recorded before and after each run. The initial and final physical condition of the coupons (e.g., surface bubbling and degradation) was also observed. The results of the testing are provided in Table 2 below.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described within the scope of the appended claims. It is to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments which fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, it is to be appreciated that different, special, and/or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.
It is also to be understood that any ranges and subranges relied upon in describing various embodiments of the present invention independently and collectively fall within the scope of the appended claims, and are understood to describe and contemplate all ranges including whole and/or fractional values therein, even if such values are not expressly written herein. One of skill in the art readily recognizes that the enumerated ranges and subranges sufficiently describe and enable various embodiments of the present invention, and such ranges and subranges may be further delineated into relevant halves, thirds, quarters, fifths, and so on. As just one example, a range “of from 0.1 to 0.9” may be further delineated into a lower third, i.e., from 0.1 to 0.3, a middle third, i.e., from 0.4 to 0.6, and an upper third, i.e., from 0.7 to 0.9, which individually and collectively are within the scope of the appended claims, and may be relied upon individually and/or collectively and provide adequate support for specific embodiments within the scope of the appended claims. In addition, with respect to the language which defines or modifies a range, such as “at least,” “greater than,” “less than,” “no more than,” and the like, it is to be understood that such language includes subranges and/or an upper or lower limit. As another example, a range of “at least 10” inherently includes a subrange of from at least 10 to 35, a subrange of from at least 10 to 25, a subrange of from 25 to 35, and so on, and each subrange may be relied upon individually and/or collectively and provides adequate support for specific embodiments within the scope of the appended claims. Finally, an individual number within a disclosed range may be relied upon and provides adequate support for specific embodiments within the scope of the appended claims. For example, a range “of from 1 to 9” includes various individual integers, such as 3, as well as individual numbers including a decimal point (or fraction), such as 4.1, which may be relied upon and provide adequate support for specific embodiments within the scope of the appended claims.
The subject patent application claims priority to, and all the benefits of, U.S. Provisional Patent Application Ser. No. 61/250,317 filed on Oct. 9, 2009. The entirety of this provisional patent application is expressly incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US10/51945 | 10/8/2010 | WO | 00 | 4/5/2012 |
| Number | Date | Country | |
|---|---|---|---|
| 61250317 | Oct 2009 | US |
