WO2021247379A1 - Temperature-controlled shield for an evaporation source, material deposition apparatus and method for depositing a material onto a substrate - Google Patents
Temperature-controlled shield for an evaporation source, material deposition apparatus and method for depositing a material onto a substrate Download PDFInfo
- Publication number
- WO2021247379A1 WO2021247379A1 PCT/US2021/034598 US2021034598W WO2021247379A1 WO 2021247379 A1 WO2021247379 A1 WO 2021247379A1 US 2021034598 W US2021034598 W US 2021034598W WO 2021247379 A1 WO2021247379 A1 WO 2021247379A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- substrate
- temperature
- evaporation source
- controlled
- shield
- Prior art date
Links
- 238000001704 evaporation Methods 0.000 title claims abstract description 202
- 230000008020 evaporation Effects 0.000 title claims abstract description 198
- 239000000758 substrate Substances 0.000 title claims description 265
- 239000000463 material Substances 0.000 title claims description 208
- 238000000151 deposition Methods 0.000 title claims description 174
- 230000008021 deposition Effects 0.000 title claims description 133
- 238000000034 method Methods 0.000 title claims description 34
- 238000001816 cooling Methods 0.000 claims abstract description 17
- 238000010438 heat treatment Methods 0.000 claims abstract description 17
- 239000011248 coating agent Substances 0.000 description 26
- 238000000576 coating method Methods 0.000 description 26
- 238000013461 design Methods 0.000 description 14
- 239000011888 foil Substances 0.000 description 13
- 239000007789 gas Substances 0.000 description 12
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 10
- 238000009833 condensation Methods 0.000 description 10
- 230000005494 condensation Effects 0.000 description 10
- 229910052744 lithium Inorganic materials 0.000 description 10
- 238000004519 manufacturing process Methods 0.000 description 10
- 230000009286 beneficial effect Effects 0.000 description 8
- 238000012545 processing Methods 0.000 description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000007740 vapor deposition Methods 0.000 description 5
- 239000000112 cooling gas Substances 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 230000037303 wrinkles Effects 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- 229910052814 silicon oxide Inorganic materials 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 238000002207 thermal evaporation Methods 0.000 description 3
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 238000009501 film coating Methods 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000005240 physical vapour deposition Methods 0.000 description 2
- 239000010409 thin film Substances 0.000 description 2
- 238000001771 vacuum deposition Methods 0.000 description 2
- 241000518994 Conta Species 0.000 description 1
- 229910001374 Invar Inorganic materials 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910052769 Ytterbium Inorganic materials 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000011889 copper foil Substances 0.000 description 1
- 230000002596 correlated effect Effects 0.000 description 1
- 230000000875 corresponding effect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000003792 electrolyte Substances 0.000 description 1
- RFHAOTPXVQNOHP-UHFFFAOYSA-N fluconazole Chemical compound C1=NC=NN1CC(C=1C(=CC(F)=CC=1)F)(O)CN1C=NC=N1 RFHAOTPXVQNOHP-UHFFFAOYSA-N 0.000 description 1
- 239000007792 gaseous phase Substances 0.000 description 1
- PQXKHYXIUOZZFA-UHFFFAOYSA-M lithium fluoride Chemical compound [Li+].[F-] PQXKHYXIUOZZFA-UHFFFAOYSA-M 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 230000037373 wrinkle formation Effects 0.000 description 1
- NAWDYIZEMPQZHO-UHFFFAOYSA-N ytterbium Chemical compound [Yb] NAWDYIZEMPQZHO-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/54—Controlling or regulating the coating process
- C23C14/542—Controlling the film thickness or evaporation rate
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/14—Metallic material, boron or silicon
- C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/24—Vacuum evaporation
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/24—Vacuum evaporation
- C23C14/243—Crucibles for source material
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/54—Controlling or regulating the coating process
- C23C14/541—Heating or cooling of the substrates
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/56—Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks
- C23C14/562—Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks for coating elongated substrates
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/56—Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks
- C23C14/564—Means for minimising impurities in the coating chamber such as dust, moisture, residual gases
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J37/00—Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
- H01J37/32—Gas-filled discharge tubes
- H01J37/32431—Constructional details of the reactor
- H01J37/32623—Mechanical discharge control means
- H01J37/32651—Shields, e.g. dark space shields, Faraday shields
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Definitions
- Embodiments of the present disclosure relate to substrate coating by thermal evaporation in a vacuum chamber. Embodiments of the present disclosure further relate to material deposition of evaporated material onto a substrate. Embodiments also relate to temperature-controlled deposition of material onto a substrate.
- Various techniques for deposition on a substrate for example, chemical vapor deposition (CVD) and physical vapor deposition (PVD) are known.
- CVD chemical vapor deposition
- PVD physical vapor deposition
- thermal evaporation may be used as a PVT) process.
- a source material is heated up to produce a vapor that may be deposited, for example, on a substrate.
- Increasing the temperature of the heated source material increases the vapor concentration and can facilitate high deposition rates.
- the temperature for achieving high deposition rates depends on the source material physical properties, e.g. vapor pressure as a function of temperature, and substrate physical limits, e.g. melting point.
- the material to be deposited on the substrate can be heated in a crucible to produce vapor at an elevated vapor pressure.
- the vapor can he transported from the crucible to a heated vapor distributor with a plurality' of nozzles.
- the vapor can be directed by the one or more nozzles onto a substrate in a coating volume, for example, in a vacuum chamber.
- a metal e.g. lithium
- a flexible substrate e.g. on a copper substrate
- evaporation may be used for the manufacture of batteries, such as Li-batteries.
- a lithium layer may be deposited on a thin flexible substrate for producing the anode of a baten, ' .
- the manufactured layer arrangement may be rolled or otherwise stacked to produce the Li-batery.
- the material to be deposited is heated up to high temperatures, thereby providing a high heat load to the substrate to be coated. High temperatures, however, may negatively influence the substrate. It is thus beneficial, to provide an improved material deposition apparatus to at least partially overcome the problems in the art.
- a temperature-controlled shield for an evaporation source is provided.
- the temperature-controlled shield is configured to provide a pre-heating zone or a post-cooling zone.
- a material deposition apparatus for depositing an evaporated material onto a substrate.
- the material deposition apparatus includes one or more temperature-controlled shields according to embodiments of the present disclosure.
- a material deposition apparatus for depositing an evaporated material onto a substrate is provided.
- the material deposition apparatus includes an evaporation source for providing the evaporated material to the substrate, the evaporation source having a first end and a second end opposite the first end and a surface having a length in between the first end and the second end; and one or more temperature-controlled shields being arranged at at least one of the first end or the second end of the evaporation source, the one or more temperature-controlled shields extending outward from the evaporation source, wherein the one or more temperature-controlled shields provide a width of at least 20% of the length of the surface in between the first end and the second end of the evaporation source.
- a material deposition apparatus for depositing an evaporated material onto a substrate.
- the material deposition apparatus includes an evaporation source for providing the evaporated material to the substrate, the evaporation source having a first end and a second end opposite the first end; and one or more temperature-controlled shields being arranged at at least one of the first end or the second end of the evaporation source, the one or more temperature-controlled shields extending outward from the evaporation source by a wide-angle.
- a material deposition apparatus for depositing an evaporated material onto a substrate.
- the material deposition apparatus includes a substrate transportation device for transporting the substrate along a substrate transportation direction; and at least two evaporation sources along the substrate transportation direction for providing the evaporated material to the substrate, the at least two evaporation sources each include one or more asymmetric temperature-controlled shields.
- an evaporation source for providing an evaporated material to a substrate in a vacuum chamber.
- the evaporation source includes a nozzle assembly shield having a plurality of nozzles arranged in at least one row, the row including two outermost nozzles, wherein the two outermost nozzles are tilted in different directions.
- an evaporation source for providing an evaporated material to a substrate m a vacuum chamber.
- the evaporation source includes a nozzle assembly shield having a first end and a second end and a surface between the first and the second end facing the substrate, the nozzle assembly shield having a plurality of openings being arranged in at least one row at the surface between the first end and the second end, the at least one row having a first outermost opening provided adjacent to the first end and a second outermost opening provided adjacent to the second end; and a plurality of nozzles extending through the plurality' of openings, wherein the plurality' of nozzles comprises a first outermost nozzle extending through the first outermost opening and a second outermost nozzle extending through the second outermost opening, the first and second outermost nozzle being tilted by an angle with respect to the surface between the first end and the second end.
- a method for depositing a material onto a substrate in a vacuum chamber includes evaporating the material in an evaporation source having a vapor emission area; and guiding the evaporated material by a temperature-controlled shield towards a substrate area, the substrate area being larger than the vapor emission area,
- a method of manufacturing an anode of a batery includes a method for depositing a material onto a substrate in a vacuum chamber according to any of the embodiments described herein.
- a method of manufacturing an anode of a batery includes guiding a web comprising or consisting of an anode layer in a material deposition apparatus according to embodiments of the present disclosure; and depositing a lithium containing material or lithium on the web with the vapor deposition apparatus.
- Embodiments are also directed at apparatuses for carrying out the disclosed methods and include apparatus parts for performing each described method aspect These method aspects may be performed by way of hardware components, a computer programmed by appropriate software, by any combination of the two or in any other manner. Furthermore, embodiments according to the present disclosure are also directed at methods for operating the described apparatus. It includes method aspects for carrying out every function of the apparatus.
- Fig. 1 shows a schematic view' of a material deposition apparatus according to embodiments described herein;
- Fig. 2A shows a schematic view of a material deposition apparatus according to embodiments described herein;
- Fig. 2B shows a temperature profile at a substrate according to embodiments described herein;
- Fig. 3 shows a schematic view of a material deposition apparatus according to embodiments described herein
- Fig. 4A shows a schematic view of a material deposition apparatus according to embodiments described herein;
- Fig, 4B shows a heat load profile at a substrate according to embodiments described herein; and Fig. 5 shows a flow diagram of a method according to embodiments described herein.
- the embodiments provided herein relate to thin film coating by evaporation, particularly to thin film coating in a vacuum chamber.
- the material to be coated is heated up to a material-specific temperature to be evaporated.
- higher evaporation rates can be provided at higher temperatures.
- the respective temperature for a specific coating rate depends amongst others e.g. on the material vapor pressure.
- the condensation heat load of the material may dominate the heat load on the substrate.
- the evaporated material will condensate on surfaces of the system components having a lower temperature than the evaporated material
- the substrate includes a lower temperature such that the evaporated material may be coated onto the substrate to form a thin layer on the substrate.
- Fig. 1 exemplarily shows a material deposition apparatus according to embodiments described herein that can be combined with any other embodiment described herein.
- the material deposition apparatus 100 may include a vacuum chamber 105.
- a vacuum may be provided in the vacuum chamber.
- the material deposition apparatus may include a vacuum pump for providing the vacuum in the vacuum chamber,
- the term “vacuum” as used herein can be understood in the sense of a technical vacuum having a vacuum pressure of less than, for example, 10 mbar.
- the pressure in a vacuum chamber as described herein may be between 10 4 mbar and about 10 “8 mbar, more typically between IQ 4 mbar and IQ '7 mbar, and even more typically between about i0 "5 mbar and about lO 4 mbar.
- the total pressure in the one or more vacuum chambers may range from about 10 4 mbar to about 10' 7 mbar.
- the vacuum chamber can be a “vacuum deposition chamber”, i.e, a vacuum chamber configured for vacuum deposition.
- the material deposition apparatus may include an evaporation source 110.
- the evaporation source rs configured to provide evaporated material towards a substrate 122.
- the evaporation source 110 can be provided in the vacuum chamber 105 or can at least partially be provided in the vacuum chamber 105
- the material deposition apparatus may include a substrate transportation device 120.
- the substrate transportation device may be configured to transport the substrate 122.
- the substrate 122 may be arranged around the substrate transportation device 120.
- the substrate transportation device 120 may be a coating drum as exemp!ari!y shown in Fig. 1.
- the coating drum may include a curved drum surface, and the vapor deposition apparatus may be configured to move the substrate 122 on the curved drum surface past the evaporation source 110 in a circumferential direction or substrate transport direction D.
- the substrate may be a flexible web or foil, and the material deposition apparatus may be a roll-to-roll deposition apparatus.
- the coating drum may be a cylinder extending in a length direction perpendicular to the paper plane of Fig. 1.
- the substrate transportation device may be movable, i.e. the coating drum may be rotated around axis A.
- the substrate transportation device may be moved or rotated clockwise or counterclockwise.
- the substrate transportation device may change direction during deposition, e.g. when the substrate transportation device is rotated clockwise during deposition, the rotational direction may he changed to counterclockwise and vice versa.
- the substrate may be moved in the circumferential direction or the substrate transportation direction indicated by arrow D in Fig. 1.
- the coating drum may be a gas cushion coating drum.
- the gas cushion coating drum provides a cooling gas between the surface of the drum and the substrate.
- the drum and the cooling gas can be cooled to temperatures below room temperature. Heat can be removed from the substrate to allow for higher deposition rates without damaging the thin foil or web on which the material is deposited.
- a first subgroup of gas outlets ie., the open gas outlets
- a second subgroup of gas outlets i.e., closed gas outlets
- gas is only emitted in the web guiding region where it is needed to form the hover cushion, no or little gas is directly emitted into a region not overlapped by the web, waste of gas may be reduced arrf/or a better vacuum may be maintained at lesser strain on the pump system.
- the outer surface of the processing drum may be coated with a microporous surface.
- the microporous surface may allow' for a small amount of cooling gas to flow' from inside the processing drum to the surface of the processing drum.
- the cooling gas may form a gas cushion between the processing drum and the web or foil guided over the processing drum for material deposition thereon.
- the substrate can be a thin substrate, e.g. a foil or web.
- the substrate to be coated may have a thickness of 50 mhi or less, particularly 20 pm or less, or even 10 mih or less.
- a metal foil or a flexible metal-coated foil may be coated in the vapor deposition apparatus.
- the substrate 10 is a thin copper foil or a thin aluminum foil having a thickness below 30 pm, e.g. 10 pm or less.
- the material deposition apparatus may include a substrate provision or unwinding roll (not shown in Fig. 1) for providing an unprocessed substrate.
- the substrate provision or unwinding roll may be moved i.e. rotated such that the substrate may be unrolled from the substrate provision or unwinding roll.
- the material deposition apparatus may include a substrate receiving roll for taking up the processed substrate after deposition of material onto the substrate has taken place.
- the substrate receiving roll may be moved, re. the substrate receiving roll may be rotated for taking up the processed substrate.
- the substrate receiving roll and the substrate provision or unwinding roll may be rotated in the same direction, i.e. both rolls may be rotated clockwise or the substrate provision or unwinding roll may be rotated in opposing directions, i.e. one roll may be rotated clockwise and the other roll may be rotated counterclockwise or vice versa.
- the substrate transportation device can also be a roll-to-roll transportation device although not shown in Fig. 1.
- the roll-to- roll transportation device may include an unwinding or substrate provision roll from which the unprocessed substrate may be provided.
- the roll-to-roll transportation device may further include a receiving roll for rolling up the processed substrate.
- the unwinding or substrate provision roll and the receiving roil may be each provided in different vacuum chambers compared to the evaporation source or may be provided in the same vacuum chamber as the evaporation source.
- the substrate may be provided in vicinity to the evaporation source for depositing material onto the substrate.
- the substrate may be “spanned” between the unwinding roll and the receiving roll and may be guided above the evaporation source for receiving the evaporated material.
- the substrate may be provided with defined and/or controlled forces.
- a substrate tensioner may be provided
- the evaporation soiree 110 may have a first end and a second end opposite the first end.
- the first end and the second end may define a space in between.
- the term “a second end opposite the first end” as used through out the present disclosure may be understood as two sides of the evaporation source being arranged next to each other.
- the evaporation source may include a first wall and a second wall extending in the same direction and being arranged next to each other.
- the first end and the second end may be understood as the side wall limitations of the evaporation source.
- the first end and the second end may define a surface 119 in between, ie, a surface that may be substantially perpendicular to the first wall and the second wall of the evaporation source.
- the surface of the evaporation source may be aligned with the substrate transportation device, ie. the surface 119 of the evaporation source may be oriented such that a provision of material to be deposited may be enhanced.
- the evaporation source may provide material to be deposited to the substrate.
- the evaporation source may include a crucible where the material to be deposited may be evaporated by providing a temperature to the material suitable to evaporate the material.
- the material to be deposited can include, for example, metal, in particular lithium, metal alloys, and other vaporizable materials or the like which have a gaseous phase under given conditions.
- the material may include magnesium (Mg), ytterbium (Yb) and lithium fluoride (LiF).
- the evaporation source may include a distributor.
- the distributor may distribute the evaporated material.
- the material may be provided in the distributor, for example, by the crucible being connected to the distributor via an inlet opening.
- the distributor may have one or more openings. Evaporated material to be deposited can exit the distributor through the openings.
- the source material can be deposited on the substrate 122 by a plurality of nozzles extending through the openings.
- the evaporation source may include one or more nozzles for providing evaporated material to the substrate.
- the material to be deposited may e.g. be sprayed to the substrate by the plurality of nozzles.
- the temperature-controlled shield 112 may be heatable, such that vapor condensation on the temperature-controlled shield 112 can be reduced or prevented when the temperature-controlled shield 112 is heated to an operation temperature, e.g, an operation temperature of 500°C or more in some embodiments.
- the temperature- controlled shield has a width along the transport direction which is at least 10% larger, particularly at least 20% larger than the corresponding width of the evaporation source.
- material deposition is not limited to an area of the evaporation source in the transport direction. Limiting the plume of material to an area of the evaporation source may result in a sudden increase in temperature of the substrate, which may result in wrinkles and warping of the substrate, e.g, a thin foil or web. Accordingly, the plume of material from the evaporation source is allowed to spread towards the sides of the evaporation zone for having a pre-heating zone and/or a post-cooling zone.
- the extended shape of the heated shield results in low deposition rate at the entrance.
- the deposition rate increases, for example, continuously increases up to a maximum deposition rate at the main body of the evaporation source.
- the heat load is mainly provided by the condensation energy. Accordingly, the temperature profile of the web or foil is proportional to the deposition rate. Accordingly, the temperature profile increases similar to the above described profile of the deposition rate.
- a first temperature-controlled shield may be provided at the first end of the evaporation source and a second temperature-controlled shield may be provided at the second end of the evaporation source.
- a first portion of the temperature-controlled shield may be provided at the first end of the evaporation source and a second portion of the temperature-controlled shield may be provided at the second end of the evaporation source.
- the temperature-controlled shield 112 does not contact the substrate transportation device 120, such that the substrate supported on the substrate transportation device 120 can move past the evaporation source 110 and past the temperature-controlled shield 112 during material deposition.
- the temperature-controlled shield 112 may only leave a small gap between the temperature-controlled shield 112 and the substrate transportation device 120, e.g a gap of 5 mm or less, 3 mrn or less, 2 mm or less, or even about 1 mm, such that hardly any vapor can propagate past the temperature-controlled shield, e.g. in a lateral direction.
- the temperature-controlled shield may extend along the circumferential direction or substrate transportation direction D.
- the temperature-controlled shield may include a width dimension along the axis of the substrate transportation device 120 and a length dimension in a direction different from the axis of the substrate transportation device 120 i.e, in the circumferential direction or substrate transportation direction D.
- the temperature-controlled shield may extend radially or laterally away from the evaporation source, in the following, such a temperature-controlled shield may also be referred to as an “elongated shield”.
- the temperature-controlled shield may include a straight portion 113 extending radially away or outward from the evaporation source.
- the temperature-controlled shield or the straight portion may be directed from the evaporation source towards the substrate 122.
- the temperature-controlled shield or the straight portion 113 may delimit a deposition area towards the substrate.
- the temperature-controlled shield or the straight portion may be angled with respect to the evaporation source.
- the temperature-controlled shield may be arranged in a wide-angle a with respect to the evaporation source 110 i.e. with respect to the surface 119 of the evaporation source between the first end and the second end of the evaporation source.
- the wide-angle may be between 95° and 180°, particularly between 110° and 140°, more particularly between 110° and 130°.
- the material deposition apparatus may include a deposition area between the evaporation source 110 and the substrate transportation device 120.
- the deposition area may be understood as an area where the material to be deposited is provided to the substrate.
- the deposition area can be filled with the material to be deposited from the evaporation source and may be limited sidewise by the one or more temperature-controlled shields, for example, to provide for a uniform material deposition.
- the one or more temperature-controlled shields may be arranged at at least one of the first end or the second end of the evaporation source and may extend outwardly towards the substrate transportation device and may be configured to enlarge the deposition area, particularly as compared to a straight shield extending at an angle of 90° towards the substrate.
- the one or more temperature shields each may have a length of at least 20% of the length of the surface 119 in between the first end and the second end of the evaporation source 110.
- the one or more temperature-controlled shields may be heated The temperature of the shield may be controlled such that condensation of the material to be deposited is prevented or avoided. If material to be deposited condensates at the shield, heating of the one or more temperature-controlled shields may lead to re-evaporation of the condensed material.
- high deposition yields can be achieved.
- Both curves show a temperature profile for the same deposition thickness, i,e. the overall deposition rate.
- Each of the plateaus may be regarded as the substrate being arranged directly above one of the evaporation sources.
- the x-axis representing the time indicates the time of a substrate section being moved over the four evaporation sources. Accordingly, before reaching the first plateau, the substrate may be regarded as being spatially in front of the first evaporation source ie. on the left side of the left evaporation source shown in Fig. 2A.
- Embodiment 14 The material deposition apparatus for depositing an evaporated material onto a substrate of embodiment 13, wherein the two asymmetric temperature-controlled shields are arranged at opposing sides of each of the at least two evaporation sources, and wherein the two asymmetric temperature-controlled shields extend towards the substrate transportation device in different directions.
- Embodiment 15 The material deposition apparatus for depositing an evaporated material onto a substrate of embodiments 13 or 14, wherein the second temperature- controlled shields of the at least two evaporation sources are arranged adjacent to each other and wherein the second temperature-controlled shields are bent away from the substrate and/or towards each other.
- Embodiment 16 The material deposition apparatus for depositing an evaporated material onto a substrate of embodiments 13 to 15, wherein the first asymmetric temperature-controlled shield is a temperature-controlled shield of embodiments 1 to 6.
- Embodiment 17 The material deposition apparatus for depositing an evaporated material onto a substrate of embodiments 7 to 16, the material deposition apparatus further comprising: a vacuum chamber housing at least the temperature-controlled shield.
- Embodiment 20 An evaporation source for providing an evaporated material to a substrate in a vacuum chamber, the evaporation source comprising: a nozzle assembly shield having a first end and a second end and a surface between the first and the second end facing the substrate, the nozzle assembly shield having a plurality of openings being arranged in at least one row at the surface between the first end and the second end, the at least one row having a first outermost opening provided adjacent to the first end and a second outermost opening provided adjacent to the second end; and a plurality' of nozzles extending through the plurality of openings, wherein the plurality ' of nozzles comprises a first outermost nozzle extending through the first outermost opening and a second outermost nozzle extending through the second outermost opening, the first and second outermost nozzle being tilted by an angle with respect to the surface between the first end and the second end.
- Embodiment 25 The method of embodiments 23 to 24, wherein the substrate area outside the emission area has a deposition rate that is smaller than the deposition rate in the emission area, particularly at least 10% of the substrate area outside the emission area has a deposition rate that is at least 50% smaller than the deposition rate in the emission area.
- Embodiment 26 A method of manufacturing an anode of a battery, comprising: a method for depositing a material onto a substrate in a vacuum chamber of embodiments 23 to 25.
- Embodiment 29 The method of embodiment 27, wherein the web comprises graphite and silicon and/or silicon oxide.
- Embodiment 30 The method of embodiment 29, wherein the anode layer is pre- lithiated.
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Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
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KR1020237000102A KR20230018517A (en) | 2020-06-04 | 2021-05-27 | Temperature Controlled Shield for Evaporation Source, Material Deposition Apparatus, and Method for Depositing Material on a Substrate |
JP2022574431A JP2023528467A (en) | 2020-06-04 | 2021-05-27 | Temperature controlled shield for evaporation source, material deposition apparatus, and method for depositing material on substrate |
EP21818824.1A EP4162093A4 (en) | 2020-06-04 | 2021-05-27 | Temperature-controlled shield for an evaporation source, material deposition apparatus and method for depositing a material onto a substrate |
CN202180039228.XA CN115698370A (en) | 2020-06-04 | 2021-05-27 | Temperature-controlled shield for an evaporation source, material deposition apparatus and method for depositing material on a substrate |
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US202063034529P | 2020-06-04 | 2020-06-04 | |
US63/034,529 | 2020-06-04 |
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US (1) | US12049691B2 (en) |
EP (1) | EP4162093A4 (en) |
JP (1) | JP2023528467A (en) |
KR (1) | KR20230018517A (en) |
CN (1) | CN115698370A (en) |
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WO (1) | WO2021247379A1 (en) |
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EP4273292A1 (en) * | 2022-05-06 | 2023-11-08 | Bühler Alzenau GmbH | Device for vacuum deposition system and system for vacuum deposition |
WO2024022579A1 (en) * | 2022-07-26 | 2024-02-01 | Applied Materials, Inc. | Evaporation source, material deposition apparatus, and method of depositing material on a substrate |
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Also Published As
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US20210381102A1 (en) | 2021-12-09 |
EP4162093A1 (en) | 2023-04-12 |
EP4162093A4 (en) | 2024-07-17 |
US12049691B2 (en) | 2024-07-30 |
TWI839613B (en) | 2024-04-21 |
TW202200811A (en) | 2022-01-01 |
CN115698370A (en) | 2023-02-03 |
JP2023528467A (en) | 2023-07-04 |
KR20230018517A (en) | 2023-02-07 |
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