Apparatus and method for plasma treating an article
First Claim
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1. An apparatus for generating a substantially controllable plasma, the apparatus comprising:
- a) at least one plasma source, said at least one plasma source comprising a plasma chamber in which said substantially controllable plasma is generated, at least one cathode and an anode disposed in said plasma chamber, said at least one cathode and said anode being separated by a gap, said gap being adjustable, a power source coupled to said anode and said at least one cathode for providing a voltage across said anode and said at least one cathode, a plasma gas inlet for introducing a plasma gas from a plasma gas source into said plasma chamber at a plasma gas flow rate, and a sensor for monitoring conditions within said plasma chamber; and
b) a second chamber in fluid communication with said plasma chamber through an exit port, wherein said second chamber is maintained at a second pressure that is less than a first pressure in said plasma chamber, and wherein said substantially controllable plasma flows from said plasma chamber into said second chamber through said exit port.
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Abstract
An apparatus that generates at least one plasma that is stable and adjustable in real time. In one embodiment, the apparatus includes multiple plasma sources that can either be “tuned” in real time to generate plasmas that are similar to each other or, conversely, “detuned” to generate dissimilar plasmas. The apparatus may be sued to provide plasma treatment—such as, but not limited to, coating, etching and activation for an article. The invention also provides a plasma source in which operating parameters are adjustable in real time. Methods of providing such plasmas and treating an article using such plasmas are also disclosed.
27 Citations
75 Claims
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1. An apparatus for generating a substantially controllable plasma, the apparatus comprising:
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a) at least one plasma source, said at least one plasma source comprising a plasma chamber in which said substantially controllable plasma is generated, at least one cathode and an anode disposed in said plasma chamber, said at least one cathode and said anode being separated by a gap, said gap being adjustable, a power source coupled to said anode and said at least one cathode for providing a voltage across said anode and said at least one cathode, a plasma gas inlet for introducing a plasma gas from a plasma gas source into said plasma chamber at a plasma gas flow rate, and a sensor for monitoring conditions within said plasma chamber; and
b) a second chamber in fluid communication with said plasma chamber through an exit port, wherein said second chamber is maintained at a second pressure that is less than a first pressure in said plasma chamber, and wherein said substantially controllable plasma flows from said plasma chamber into said second chamber through said exit port. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A plasma source for generating a substantially controllable plasma, said plasma source comprising:
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a) a plasma chamber in which said substantially controllable plasma is generated;
b) an anode disposed at a first end of said plasma chamber, said first end having an exit port through which said substantially controllable plasma exits said plasma chamber;
c) at least one adjustable cathode disposed in said plasma chamber, wherein said at least one adjustable cathode is movable to establish a gap between said anode and said at least one adjustable cathode;
d) a power source coupled to said anode and said at least one adjustable cathode for providing a voltage across said anode and said at least one adjustable cathode;
e) a plasma gas inlet for introducing a plasma gas from a plasma gas source into said plasma chamber at a plasma gas flow rate; and
f) at least one sensor for detecting and monitoring conditions within said plasma chamber. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. An apparatus for generating a substantially controllable expanding thermal plasma, said apparatus comprising:
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a) at least one expanding thermal plasma source, said at least one expanding thermal plasma source comprising;
a plasma chamber in which said substantially controllable plasma is generated;
an anode;
at least one adjustable cathode disposed in said plasma chamber, wherein said at least one adjustable cathode is movable to establish a gap between said anode and said at least one adjustable cathode;
a power source coupled to said anode and said at least one adjustable cathode for providing a voltage across said anode and said at least one adjustable cathode;
a plasma gas inlet for introducing a plasma gas from a plasma gas source into said plasma chamber at a plasma gas flow rate; and
at least one sensor for detecting and monitoring conditions within said plasma chamber; and
b) a second chamber in fluid communication with said plasma chamber through an exit port, wherein said second chamber is maintained at a second pressure that is less than a first pressure in said plasma chamber, and wherein said substantially controllable plasma flows from said plasma chamber into said second chamber through said exit port. - View Dependent Claims (34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58)
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59. A method for generating a substantially controllable plasma, the method comprising the steps of:
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a) providing at least one plasma source, the at least one plasma source comprising;
a plasma chamber;
an anode;
at least one adjustable cathode disposed in the plasma chamber;
a power source coupled to the anode and the at least one adjustable cathode;
a plasma gas inlet; and
at least one sensor;
b) providing a plasma gas through the plasma gas inlet to the plasma chamber in each of the at least one plasma source;
c) generating a plasma in the plasma chamber;
d) monitoring at least one parameter within the plasma chamber; and
e) controlling the plasma, wherein the plasma is controlled by adjusting conditions within the plasma chamber, based upon the monitoring of the at least one parameter. - View Dependent Claims (60, 61, 62, 63, 64, 65)
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66. A method for treating an article using a substantially controllable expanding thermal plasma, the method comprising the steps of:
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a) providing at least one expanding thermal plasma source, wherein the at least one expanding thermal plasma source comprises;
a plasma chamber;
an anode;
at least one adjustable cathode disposed in the plasma chamber;
a power source coupled to the anode and the at least one adjustable cathode;
a plasma gas inlet; and
at least one sensor;
b) providing a plasma gas through the plasma gas inlet to the plasma chamber in each of the at least one expanding plasma source;
c) generating a plasma in the plasma chamber;
d) monitoring at least one parameter within the plasma chamber; and
e) controlling the plasma, wherein the plasma is controlled by adjusting conditions within the plasma chamber, based upon the monitoring of the at least one parameter;
f) forming an expanding thermal plasma by expanding the plasma through an exit port into a second chamber in fluid communication with the plasma chamber, wherein the second chamber contains the article and is maintained at a second pressure that is less than a first pressure in said plasma chamber; and
g) impinging the expanding thermal plasma on a surface of the article, thereby treating the article. - View Dependent Claims (67, 68, 69, 70, 71, 72)
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73. An article having at least one coating disposed on a surface of the article, wherein the at least one coating is substantially uniform and has a selected property that exhibits a variation of less than about 10% across the surface of said article, the coating being deposited on the surface by:
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a) providing at least one expanding thermal plasma source, wherein the at least one expanding thermal plasma source comprises;
a plasma chamber;
an anode;
at least one adjustable cathode disposed in the plasma chamber;
a power source coupled to the anode and the at least one adjustable cathode;
a plasma gas inlet; and
at least one sensor;
b) providing a plasma gas through the plasma gas inlet to the plasma chamber in each of the at least one expanding plasma source;
c) generating a plasma in the plasma chamber;
d) monitoring at least one parameter within the plasma chamber; and
e) controlling the plasma, wherein the plasma is controlled by adjusting conditions within the plasma chamber, based upon the monitoring of the at least one parameter;
f) forming an expanding thermal plasma by expanding the plasma through an exit port into a second chamber in fluid communication with the plasma chamber, wherein the second chamber contains the article and is maintained at a second pressure that is less than a first pressure in said plasma chamber;
g) injecting at least one reactant gas into the expanding thermal plasma; and
h) depositing a coating on the surface of the article. - View Dependent Claims (74, 75)
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Specification