High velocity metallic mass increment vacuum deposit gun

Claim 2

A vacuum deposit apparatus comprising: (a) a gun having first and second rail electrodes, and operable within a vacuum chamber (b) means for supporting a metallic mass in an initial position adjacent said electrodes, (c) an electrical discharge circuit including: (1) capacitor means for storing a charge, (2) circuit elements in circuit with said capacitor means, said rail electrodes and said mass for providing a bipolar discharge current, at least a portion of said discharge current passing through said mass for accelerating said mass adjacent said electrodes, and (3) switch means operative in a predetermined state for preventing said discharge current from passing through said mass, (d) a time delay circuit, coupled to said switch means, for operating said switch means in said predetermined state prior to a change in polarity of said bipolar discharge current, and (e) said circuit elements and time delay circuit cooperate to control the magnitude and time duration of said discharge current to accelerate said mass along said rails without vaporization of said mass.

Claim 3

A vacuum deposit apparatus as recited in claim 1 wherein said bipolar discharge current is an underdamped discharge current.

Claim 4

A vacuum deposit apparatus as recited in claim 1 or 2 wherein said time delay circuit operates said switch means after a predetermined time interval sufficient to permit travel of said mass proximate the end of said rail electrodes.

Claim 5

A vacuum deposit apparatus as recited in claim 3 wherein said discharge current produces a magnetic pinch pressure on said mass larger than the thermal expansion pressure of said mass for maintaining said mass in a solid, non-vapor state during acceleration.

Claim 6

A vacuum deposit apparatus as recited in claim 4 wherein said rail electrodes are positioned parallel to one another and said mass is accelerated in a region between said electrodes.

Claim 7

A vacuum deposit apparatus as recited in claim 3, wherein said rails have a length determined by said predetermined time interval for providing a desired terminal exit velocity of said mass.

Claim 8

A vacuum deposit apparatus as recited in claim 6, wherein said bipolar discharge current is a sinusoidal current and said time delay circuit is operative for terminating said discharge current through said rails and mass at approximately the end of one-half cycle of said sinusoidal current.

Claim 9

A vacuum deposit apparatus as recited in claim 2, wherein one of said circuit elements comprises an inductor having an inductive reactance larger than the internal inductive reactance of said rail electrodes and mass.

Claim 10

A vacuum deposit apparatus as recited in claim 8, wherein said inductor has an inductive reactance of about two orders of magnitude larger than said rail and mass internal inductive reactance.

Claim 11

A vacuum deposit apparatus as recited in claim 1, further comprising a switch, separate from said switch means, for discharging said capacitor and initiating said discharge current and wherein the length of said rail electrodes is a function of the mass of said metallic mass, the inductance per unit length of said rail electrodes, the capacitance of said capacitor, and the initial voltage established by the initial charge on said capacitor immediately prior to operation of said separate switch.

Claim 12

A vacuum deposit apparatus as recited in claim 1, further comprising: (a) a backstrap electrode, (b) means for supporting said backstrap electrode spaced from and parallel to the initial position of said mass, and (c) means for connecting said backstrap electrode in series with one of said rail electrodes, said mass and another of said rail electrodes whereby discharge current in said backstrap electrode runs opposite to said discharge current in said mass to produce mutual repulsion for augmenting acceleration of said mass.

Claim 13

A vacuum deposit apparatus as recited in claim 11, wherein said backstrap electrode comprises a first and second strip spaced from and parallel to one another and symmetricaly positioned adjacent the initial position of said mass whereby said mass is focused during initial acceleration of said mass between said electrodes.

Claim 14

A vacuum deposit apparatus as recited in claim 1, 11 or 12, wherein said mass comprises a metallic foil and said means for supporting said mass in said initial position comprises: (a) a flexible support belt, (b) means for securing said foil to said support belt, (c) means for automatically feeding a portion of said support belt and foil to the initial position adjacent said rail electrodes, and (d) means for automatically feeding said portion of said belt away from said initial position after firing of said gun and for simultaneously feeding another portion of said support belt and foil to said initial position whereby said gun may be automatically loaded and reloaded with metallic foil mass.

Claim 15

A vacuum deposit apparatus as recited in claim 13, wherein said means for securing comprises projections extending from a surface of said support belt for registration through apertures in said foil.

Claim 16

A vacuum deposit apparatus as recited in claim 14, further comprising a supply reel onto which said foil is wrapped, said means for automatically feeding comprising means for rotating said supply reel.

Claim 17

A high velocity metallic spray vacuum deposit device comprising: (a) a vacuum chamber, (b) an electromagnetically driven linear mass accelerator gun for heating a metallic mass and accelerating the mass to a desired terminal velocity, said gun being positioned within said vacuum chamber, (c) a discharge circuit connected to said gun for supplying a cyclic discharge current having a predetermined time variation and magnitude, said discharge current passing through said mass for accelerating said mass, said discharge circuit including means for preventing said discharge current from passing through said mass at a time prior or equal to the zero crossing of said current, said discharge current producing a magnetic pinch pressure on said mass larger than the thermal expansion pressure of said mass for maintaining said mass in a solid, non-vapor state during acceleration within said gun, (d) means for triggering said discharge circuit for accelerating said mass, (e) a movable support positioned within the vacuum chamber for supporting a substrate having a desired deposition area, and (f) means for coordinating the motion of said support with the triggering of said gun to precisely locate the metallic mass on the desired deposition area of the substrate.

Claim 18

A high velocity metallic spray vacuum deposit device comprising: (a) a vacuum chamber, (b) an electromagnetically driven linear mass accelerator gun for heating a metallic mass and accelerating the mass to a desired terminal velocity, said gun being positioned within said vacuum chamber, (c) a discharge circuit connected to said gun for supplying a cyclic discharge current having a predetermined time variation and magnitude, said discharge current passing through said mass for accelerating said mass, said discharge circuit including means for preventing said discharge current from passing through said mass at a time prior or equal to the zero crossing of said current, said discharge current producing a magnetic pinch pressure on said mass larger than the thermal expansion pressure of said mass for maintaining said mass in a solid, non-vapor state during acceleration within said gun, (d) means for triggering said discharge circuit for accelerating said mass, (e) a movable support positioned within the vacuum chamber for supporting a substrate having a desired deposition area, and (f) means for coordinating the motion of said support with the triggering of said gun to precisely locate the metallic mass on the desired deposition area of the substrate.

Claim 19

A device as recited in claim 16, wherein said gun comprises: a pair of parallel rail electrodes having a given length, width, spacing distance and inductance per unit length, input power means for connecting said electrodes to said discharge circuit, and means for clamping the metallic mass at an initial loading position between said rail electrodes to pass the discharge current through the mass during the triggering of said gun.

Claim 20

A device as recited in claim 17, wherein said gun further includes a backstrap electrode positioned behind and substantially parallel to the initial loading position of the metallic mass for passing a current anti-parallel to the discharge current passing through the mass during the triggering of said gun.

Claim 21

A device as recited in claim 18, wherein said backstrap electrode is symmetrically split about the initial mass loading position to provide an axial magnetic field component for focusing said mass inwardly during the initial acceleration of said mass.

Claim 22

A device as recited in claim 19, wherein said metallic mass is a thin metallic foil strip having a given thickness, and a width corresponding to the width of said rail electrodes.

Claim 23

A device as recited in claim 20, wherein said electrodes are dimensioned to cut out a foil area from the foil strip corresponding to a desired mass of known magnitude for a given initial foil thickness and composition.

Claim 24

A device as recited in claim 21, wherein said input power means comprises input power electrodes and the foil strip is clamped between faces of said rail electrodes and said input power electrodes.

Claim 25

A device as recited in claim 22, wherein said rail electrodes are movably mounted to said input electrodes to create a gun breach into which the foil strip can be fed.

Claim 26

A device as recited in claim 16 or 23, wherein said discharge circuit comprises: a capacitor, means for charging said capacitor to a given voltage, a circuit inductance substantially greater than the gun inductance, a circuit resistance predominantly that of the foil mass, means for discharging said capacitor through said circuit inductance and said circuit resistance to provide an underdamped oscillating discharge current having a predetermined magnitude and time variation, and said discharge current preventing means includes: an arc diverter switch for terminating current through said mass, and a time delay generator, activated concurrently with said discharging means for operating said diverter switch prior to or at the end of the first half cycle of discharge current oscillation.

Claim 27

A device as recited in claim 24, wherein the mass acceleration given along said rail electrodes is matched to the magnitude of said mass, the discharge circuit capacitance, the discharge circuit inductance, the initial charge on said capacitor and the gun inductance so that the discharge current reaches the end of the first half cycle of oscillation as the mass reaches the end of said rail electrodes with a desired, reproducible mass exit velocity.

Claim 28

A device as recited in claim 16, wherein said mass comprises a metallic foil and said device further comprises: a pair of rail electrodes for accelerating said mass therebetween, means for securing said foil to an initial position adjacent said rail electrodes, a flexible support belt, means for securing said foil to said support belt, means for automatically feeding a portion of said support belt and foil to the initial position adjacent said rail electrodes, and means for automatically feeding said portions of said belt away from said initial position after firing of said gun and for simultaneously feeding another portion of said support belt and foil to said initial position whereby said device may be automatically loaded and reloaded with said metallic foil mass.

Claim 29

A device as recited in claim 26, wherein said means for securing comprises projections extending from a surface of said support belt for registration through apertures in said foil.

Claim 30

A device as recited in claim 27, further comprising a supply reel onto which said foil is wrapped, said means for automatically feeding comprising means for rotating said supply reel.