The disadvantages of thermal evaporation methods, particularly resistive thermal evaporation, include limitations in handling high radiant-heat loads, the need for advanced vacuum materials and techniques, and challenges in depositing refractory materials. Additionally, thermal evaporation can lead to thermal decomposition, polymerization, or metamorphic changes in sensitive materials, especially under prolonged thermal stress.
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Handling High Radiant-Heat Loads: Thermal evaporation historically faced challenges due to high radiant-heat loads, which required materials and techniques capable of withstanding such heat. This limitation was particularly pronounced in early systems that were not designed to handle these conditions efficiently.
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Need for Advanced Vacuum Materials and Techniques: The development of thermal evaporation was significantly influenced by the availability of vacuum materials and techniques that could withstand high temperatures. The lack of suitable materials and techniques inhibited the early development of this method, highlighting a critical disadvantage in terms of technological readiness and compatibility with high-temperature processes.
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Depositing Refractory Materials: While thermal evaporation is suitable for materials with low melting points, it faces challenges with refractory materials. The introduction of e-beam evaporation helped address this by allowing the deposition of refractory materials, but this also underscores the inherent limitation of traditional thermal evaporation methods in handling such materials.
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Thermal Decomposition and Quality Degradation: Thermal evaporation can cause thermal decomposition, polymerization, or metamorphic changes in the materials being processed, especially in organic substances like vitamins, flavoring agents, or pharmaceutical intermediates. This can lead to a loss of quality in the final product, particularly under conditions of high temperature and prolonged thermal stress. The method's efficiency in maintaining product quality is thus compromised, necessitating more controlled and specialized equipment to mitigate these effects.
In summary, while thermal evaporation offers advantages such as high deposition rates and simplicity, it is constrained by technical challenges related to heat management, material compatibility, and product quality preservation. These disadvantages highlight the need for continuous technological advancements and careful process design to optimize the use of thermal evaporation methods.
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