Thermal evaporation is a method used to deposit thin films, but it comes with several drawbacks that can affect the quality and efficiency of the process.
What are the 6 drawbacks of thermal evaporation?
1. Quality Degradation of Sensitive Materials
Thermal evaporation can degrade sensitive materials. This includes organic substances, vitamins, flavoring agents, and pharmaceutical intermediates. These materials can break down or react at relatively low temperatures, negatively impacting the final product.
2. Impurities in Thin Films
Thermal evaporation, especially resistive thermal evaporation, can result in thin films with higher impurity levels. This is because the crucible, which holds the material, is heated and can contaminate the film.
3. Less Dense Thin Film Coatings
Thermal evaporation often produces less dense thin film coatings compared to e-beam evaporation. This is due to the lower energy of evaporated particles, which leads to less efficient packing and bonding in the deposited films.
4. Limited to Lower Melting Point Materials
Thermal evaporation works best with materials that have lower melting points. It struggles with higher temperature materials like oxides, which are better handled by e-beam evaporation.
5. Lower Deposition Rates
Thermal evaporation generally has lower deposition rates compared to e-beam evaporation. This can slow down the process, especially in industrial applications where high-volume production is needed.
6. Thermal Stress
The process involves significant thermal stress on the materials being evaporated. This can cause structural changes or damage, particularly in sensitive materials. While this stress can be reduced by adjusting pressure and using special designs, these solutions add complexity and cost.
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