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All atmospheric pressure
plasmas either result from electric arc discharges that are
intentionally created, producing thermal plasmas, or have a means to
suppress or inhibit arcing in order to form a non-thermal plasma. The
most common forms of atmospheric pressure plasmas are illustrated
below.
Dielectric Barrier Discharge (also called "silent discharge")
Invented in the late 1800s, this broad class of plasma source has an
insulating (dielectric) cover over one or both of the electrodes and
operates with high voltage power ranging from low frequency AC to 100
KHz. A multitude of random, numerous arcs forms between the two
electrodes. The purpose of the dielectric is to extinguish the arcs
after they form by charging the surface. These discharges may use
helium for a more uniform appearance, but they can also produce ozone.
Ozone is useful in some applications, such as water treatment, but it
would need to be properly contained and exhausted to avoid hazardous
exposures for employees. The principal disadvantage is that they
produce a relatively low average density of atomic species because most
of the active atoms are produced inside the narrow confines of an arc
and are rapidly lost to recombination. Regardless of what common or
trade name is applied, if a dielectric film is needed for operation,
the plasma source is considered a dielectric barrier discharge. This
form of discharge is often confused with corona discharges.
Corona Discharge
Used extensively over the past 100 years, corona discharges result from
the high electric field that surrounds a sharply pointed electrode
powered with high continuous or pulsed DC voltages. The high electric
field causes ionization of air or other gases, and a weak plasma is
created. These discharges are about 10X lower in density of active
species than the dielectric barrier discharge but have the advantage of
an arc-free process. They are inherently non-uniform and are often used
for treating polymeric films to avoid the tendency of the dielectric
barrier discharge to punch holes in the films.
Microwave Plasmas
Microwave devices provide a means to ionize at lower power than with
radio frequency (RF) or DC/AC power, but the much smaller wavelength
also means that the plasma will be less uniform than an RF plasma and these plasmas are hampered with scale-up problems.
Microwaves are also prone to substrate heating problems and are prone
to non-uniform processing. Microwave plasmas are either smaller, highly
localized discharges, or are thermal plasmas which are unsuitable for
material processing applications. Microwave plasmas are frequently used
in vacuum-based technology as a downstream method because they provide
higher dissociation rates than RF-based vacuum plasmas. Users of microwave plasmas should be vigiliant about health issues caused by exposure to microwave radiation.
Atmospheric Pressure Plasma Jet (APPJ)
First patented in 1999 by the founders of APJeT, this unique source has no dielectric cover and
is capable of producing a chemical flux 100x greater than a dielectric
barrier discharge and 1000x greater than a corona discharge. The use of
helium, to inhibit arcing, the absence of the dielectric cover, the gap
spacing between the electrodes and the RF frequencies used for powering
the discharge are all patented aspects of this technology. Many
different source designs have been demonstrated, and power densities of
up to 500 W/cm3
have been demonstrated with gas temperatures below 150°C. Substrates
may be treated using a downstream approach or they may be placed
directly inside the discharge.
Factors/
Systems |
Apjet |
Diffuse
Dielectric Barrier |
Corona |
Microwave |
| Method |
Helium Process Gas with added reactive gas |
Dielectric Cover on Electrode with He process gas |
Sharply Pointed Electrode at HV |
Wave Guides
Resonant Cavity. Complex |
| Frequency |
2-60 MHz RF |
1-100 KHz AC |
DC/Pulsed Pwr |
2.45 GHz |
Plasma Density
Electrons/cm3
(volume average) |
1011-1012 |
109 |
108 |
1011 |
Reactive Species:
O/cm3 |
1016 |
1013 |
1013 |
? (Limited due to ozone generation) |
Undesirable byproducts:
Ozone/cm3 |
1016 |
1018 |
1013 |
High |
| Temperature |
Low |
Low |
High at edge |
RF Substrate Heating |
| Uniform Glow |
Yes |
Yes? |
No |
Point Source |
| Process Methods |
Downstream or In-situ |
In-situ |
In-situ |
Downstream |
| Flexible Shapes |
Yes |
Yes |
No |
No |
| Hazards |
Low |
High Ozone
Substrate Damage
High Voltage |
High Ozone |
Signficant Health & Safety (microwave) + High Ozone |
| Scalable to large area? |
Yes |
Yes |
No |
No |
Please contact us at 1-505-471-6399
or info@apjet.com for more information.
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