Method and apparatus for evaporating material in vacuum

Claim 1

A method of coating comprising exposing a substrate to be coated in a vacuum chamber to vapors produced with an electric arc discharge, the steps of said method including; (1) arranging in a single vacuum chamber the substrate to be coated, a cold cathode and an anode spaced from said substrate; (2) employing as the anode, a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) with space maintained between said cathode and anode, and in the absence of a discharge-sustaining gas in the path between said cathode and anode, maintaining a stable DC arc discharge between said cathode and anode for an extended duration, by: (5a) continuously applying an arc-producing DC voltage between said cathode and anode for an extended duration, (5b) maintaining the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, and (5c) maintaining cathode spots on said cold cathode that have a current density in the range of 10 5 to 10 7 A/cm 2 , whereby ionized vapors of anode material from the resulting fixed anode region are continuously provided over a prolonged period; and (6) exposing said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 2

A method of coating comprising exposing a substrate to be coated in a vacuum chamber to vapors produced with an electric arc discharge, the steps of said method including; (1) arranging in a single vacuum chamber the substrate to be coated, a cold cathode and an anode spaced from said substrate; (2) employing as the anode, a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) with space maintained between said cathode and anode, and in the absence of a discharge-sustaining gas in the path between said cathode and anode, maintaining a stable DC arc discharge between said cathode and anode for an extended duration, by: (5a) continuously applying an arc-producing DC voltage between said cathode and anode for an extended duration, (5b) maintaining the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, and (5c) maintaining cathode spots on said cold cathode that have a current density in the range of 10 5 to 10 7 A/cm 2 , whereby ionized vapors of anode material from the resulting fixed anode region are continuously provided over a prolonged period; and (6) exposing said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 5

A method of coating comprising exposing a substrate to be coated in a vacuum chamber to vapors produced with an electric arc discharge, the steps of said method including: (1) arranging in a single vacuum chamber the substrate to be coated, a cold cathode including means for cooling with a cooling medium and an anode spaced from said substrate; (2) employing as the anode, a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) with space maintained between said cathode and anode, and in the absence of a discharge-sustaining gas in the path between said cathode and anode, maintaining a stable DC arc discharge between said cathode and anode for an extended duration, by: (5a) continuously applying an arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintaining the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region are continuously provided over a prolonged period; and (6) exposing said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 6

A method of coating comprising exposing a substrate to be coated in a vacuum chamber to vapors produced with an electric arc discharge, the steps of said method including: (1) arranging in a single vacuum chamber the substrate to be coated, a cold cathode including means for cooling with a cooling medium and an anode spaced from said substrate; (2) employing as the anode, a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) with space maintained between said cathode and anode, and in the absence of a discharge-sustaining gas in the path between said cathode and anode, maintaining a stable DC arc discharge between said cathode and anode for an extended duration, by: (5a) continuously applying an arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintaining the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region are continuously provided over a prolonged period; and (6) exposing said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 7

A method of coating comprising exposing a substrate to be coated in a vacuum chamber to vapors produced with an electric arc discharge, the steps of said method including: (1) arranging in a single vacuum chamber the substrate to be coated, a cold cathode and an anode spaced from said substrate, said cold cathode being compact, spaced from and opposed to the end of said anode in a relationship that enables production of electrons from concentrated cathode spots on said cold cathode; (2) employing as the anode, a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) with space maintained between said cathode and anode, and in the absence of a discharge-sustaining gas in the path between said cathode and anode, maintaining a stable DC arc discharge between said cathode and anode for an extended duration by: (5a) continuously applying an arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintaining the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region are continuously provided over a prolonged period; and (6) exposing said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 8

A method of coating comprising exposing a substrate to be coated in a vacuum chamber to vapors produced with an electric arc discharge, the steps of said method including: (1) arranging in a single vacuum chamber the substrate to be coated, a cold cathode and an anode spaced from said substrate, said cold cathode being compact, spaced from and opposed to the end of said anode in a relationship that enables production of electrons from concentrated cathode spots on said cold cathode; (2) employing as the anode, a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) with space maintained between said cathode and anode, and in the absence of a discharge-sustaining gas in the path between said cathode and anode, maintaining a stable DC arc discharge between said cathode and anode for an extended duration by: (5a) continuously applying an arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintaining the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region are continuously provided over a prolonged period; and (6) exposing said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 9

A method of coating comprising exposing a substrate to be coated in a vacuum chamber to vapors produced with an electric arc discharge, the steps of said method including: (1) arranging in a single vacuum chamber the substrate to be coated, a cold cathode and an anode spaced from said substrate; (2) employing as the anode, a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) in the absence of a discharge-sustaining gas, while maintaining said vacuum, initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) with space maintained between said cathode and anode, and in the absence of a discharge-sustaining gas in the path between said cathode and anode, maintaining a stable DC arc discharge between said cathode and anode for an extended duration by: (5a) continuously applying an arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintaining the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region are continuously provided over a prolonged period; and (6) exposing said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 10

A method of coating comprising exposing a substrate to be coated in a vacuum chamber to vapors produced with an electric arc discharge, the steps of said method including: (1) arranging in a single vacuum chamber the substrate to be coated, a cold cathode and an anode spaced from said substrate; (2) employing as the anode, a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) in the absence of a discharge-sustaining gas, while maintaining said vacuum, initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) with space maintained between said cathode and anode, and in the absence of a discharge-sustaining gas in the path between said cathode and anode, maintaining a stable DC arc discharge between said cathode and anode for an extended duration by: (5a) continuously applying an arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintaining the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region are continuously provided over a prolonged period; and (6) exposing said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 11

An apparatus for coating a substrate in a vacuum chamber by exposure to vapors produced with an electric arc discharge, comprising: (1)a single vacuum chamber having therein a support for a substrate to be coated, a cold cathode and an anode spaced from said substrate and said cathode; (2) said anode comprising a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) means for maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) means for initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) means including a DC voltage source for maintaining a stable DC arc discharge between said spaced cathode and anode in the absence of a discharge-sustaining gas in the path between said cathode and anode, said means constructed and arranged to: (5a) continuously apply said arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintain the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, (5c) maintain cathode spots on said cold cathode that have a current density in the range of 10 5 to 10 7 A/cm 2 , whereby ionized vapors of anode material from the resulting fixed anode region can be continuously provided over a prolonged period; and said apparatus arranged to expose said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 12

An apparatus for coating a substrate in a vacuum chamber by exposure to vapors produced with an electric arc discharge, comprising: (1)a single vacuum chamber having therein a support for a substrate to be coated, a cold cathode and an anode spaced from said substrate and said cathode; (2) said anode comprising a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) means for maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) means for initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) means including a DC voltage source for maintaining a stable DC arc discharge between said spaced cathode and anode in the absence of a discharge-sustaining gas in the path between said cathode and anode, said means constructed and arranged to: (5a) continuously apply said arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintain the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, (5c) maintain cathode spots on said cold cathode that have a current density in the range of 10 5 to 10 7 A/cm 2 , whereby ionized vapors of anode material from the resulting fixed anode region can be continuously provided over a prolonged period; and said apparatus arranged to expose said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 13

An apparatus for coating a substrate in a vacuum chamber by exposure to vapors produced with an electric arc discharge, comprising: (1)a single vacuum chamber having therein a support for a substrate to be coated, a cold cathode including means for cooling with a cooling medium and an anode spaced from said substrate and said cathode; (2) said anode comprising a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) means for maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) means for initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) means including a DC voltage source for maintaining a stable DC arc discharge between said spaced cathode and anode in the absence of a discharge-sustaining gas in the path between said cathode and anode, said means constructed and arranged to: (5a) continuously apply said arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintain the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region can be continuously provided over a prolonged period; and said apparatus arranged to expose said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 14

An apparatus for coating a substrate in a vacuum chamber by exposure to vapors produced with an electric arc discharge, comprising: (1)a single vacuum chamber having therein a support for a substrate to be coated, a cold cathode including means for cooling with a cooling medium and an anode spaced from said substrate and said cathode; (2) said anode comprising a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) means for maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) means for initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) means including a DC voltage source for maintaining a stable DC arc discharge between said spaced cathode and anode in the absence of a discharge-sustaining gas in the path between said cathode and anode, said means constructed and arranged to: (5a) continuously apply said arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintain the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region can be continuously provided over a prolonged period; and said apparatus arranged to expose said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 15

An apparatus for coating a substrate in a vacuum chamber by exposure to vapors produced with an electric arc discharge, comprising: (1) a single vacuum chamber having therein a support for a substrate to be coated, a cold cathode and an anode spaced from said substrate and said cold cathode being compact, spaced from and opposed to the end of said anode in a relationship that enables production of electrons from concentrated cathode spots on said cold cathode; (2) said anode comprising a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) means for maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) means for initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) means including a DC voltage source for maintaining a stable DC arc discharge between said spaced cathode and anode in the absence of a discharge-sustaining gas in the path between said cathode and anode, said means constructed and arranged to: (5a) continuously apply said arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintain the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region can be continuously provided over a prolonged period; and said apparatus arranged to expose said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 16

An apparatus for coating a substrate in a vacuum chamber by exposure to vapors produced with an electric arc discharge, comprising: (1) a single vacuum chamber having therein a support for a substrate to be coated, a cold cathode and an anode spaced from said substrate and said cold cathode being compact, spaced from and opposed to the end of said anode in a relationship that enables production of electrons from concentrated cathode spots on said cold cathode; (2) said anode comprising a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) means for maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) means for initiating an arc discharge between said cathode and said vaporizable anode material to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) means including a DC voltage source for maintaining a stable DC arc discharge between said spaced cathode and anode in the absence of a discharge-sustaining gas in the path between said cathode and anode, said means constructed and arranged to: (5a) continuously apply said arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintain the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region can be continuously provided over a prolonged period; and said apparatus arranged to expose said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 17

An apparatus for coating a substrate in a vacuum chamber by exposure to vapors produced with an electric arc discharge, comprising: (1)a single vacuum chamber having therein a support for a substrate to be coated, a cold cathode and an anode spaced from said substrate and said cathode; (2) said anode comprising a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) means for maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) means for initiating an arc discharge between said cathode and said vaporizable anode material in the absence of a discharge containing gas, in said vacuum to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) means including a DC voltage source for maintaining a stable DC arc discharge between said spaced cathode and anode in the absence of a discharge-sustaining gas in the path between said cathode and anode, said means constructed and arranged to: (5a) continuously apply said arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintain the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region can be continuously provided over a prolonged period; and said apparatus arranged to expose said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.

Claim 18

An apparatus for coating a substrate in a vacuum chamber by exposure to vapors produced with an electric arc discharge, comprising: (1)a single vacuum chamber having therein a support for a substrate to be coated, a cold cathode and an anode spaced from said substrate and said cathode; (2) said anode comprising a main anode body of refractory material and a vaporizable anode material supported at the end of the main anode body facing said cathode; (3) means for maintaining a vacuum in said chamber to the degree that only a vacuum arc discharge from the cathode to the anode can be maintained; (4) means for initiating an arc discharge between said cathode and said vaporizable anode material in the absence of a discharge containing gas, in said vacuum to produce cathode spots from which electrons travel to the anode to produce an arc current; (5) means including a DC voltage source for maintaining a stable DC arc discharge between said spaced cathode and anode in the absence of a discharge-sustaining gas in the path between said cathode and anode, said means constructed and arranged to: (5a) continuously apply said arc-producing DC voltage between said cathode and anode for an extended duration, and (5b) maintain the arc current low, but at a level sufficient to maintain a fixed region of anode material in a continuous evaporating state such that vapors of anode material from said fixed region continuously sustain said arc discharge, whereby ionized vapors of anode material from the resulting fixed anode region can be continuously provided over a prolonged period; and said apparatus arranged to expose said substrate to be coated to said ionized vapors during said prolonged period to produce a homogeneous, adherent coating on said substrate.