Methods for measuring the degree of ionization and the rate of evaporation in a vapor deposition coating system

A method for melting and evaporating a solid material comprising the steps of:

• melting the solid material in a melting crucible to form molten material;
• flowing the molten material from the melting crucible into an evaporating crucible connected to the melting crucible;
• evaporating the molten material in the evaporating crucible to form a vapor;
• and
• releasing the vapor from the evaporating crucible.

A system for continuously melting and evaporating a solid material comprising:

• a pivotable melting crucible for receiving and melting the solid material to form molten material;
• and
• an evaporating crucible, positioned below the melting crucible, for evaporating the molten material,
• wherein the melting crucible is selectively pivotable between an upright position in which the melting crucible receives and melts the solid material, and alternatively, a tilted position in which the melting crucible pours the molten material in the evaporating crucible.

A method for continuously melting and evaporating a solid material comprising:

• (a) melting the solid material in a melting crucible in an upright position to form molten material;
• and
• (b) pivoting the melting crucible from the upright position to a tilted position and pouring the molten material in an evaporating crucible positioned below the melting crucible;
• (c) evaporating the molten material from the evaporating crucible;
• (d) pivoting the melting crucible from the tilted position to the upright position;
• and
• (e) repeating steps a-d.

A system for continuously melting and evaporating a solid material comprising:

• a melting crucible for receiving and melting the solid material to form molten material;
• an electrically conductive evaporating member disposed in the melting crucible for evaporating the molten material;
• and
• an electric power supply for supplying electric power to the evaporating member such that the power supply, the evaporating member, the molten material and the melting crucible form an electric circuit, the power supply supplying sufficient power to heat the evaporating member and evaporate at least a portion of the molten material which contacts the evaporating member.

A method for continuously melting and evaporating a solid material comprising:

• filling a melting crucible with the solid material;
• placing an electrically conductive evaporating member in the melting crucible;
• melting at least a portion of the solid material to form molten material;
• and
• supplying electric power supply to the evaporating member such that the power supply, the evaporating member, the molten material and the melting crucible form an electric circuit, the power supply supplying sufficient power to heat the evaporating member and evaporate at least a portion of the molten material which contacts the evaporating member.

A vapor deposition coating system comprising:

• a vacuum cell capable of maintaining a vacuum within the vacuum cell;
• a source of coating vapor disposed in the vacuum cell;
• a first electrode disposed in the vacuum cell;
• a second electrode disposed in the vacuum cell so that there is a gap between the first and second electrodes and coating vapor passes through the gap when the source of coating vapor produces coating vapor;
• an electric power supply for supplying electric power to the first and second electrodes so that the first and second electrodes become oppositely charged and create an electric arc discharge between the first and second electrodes;
• and
• a switch connecting the power supply to the first and second electrodes for selectively switching polarity between the first and second electrodes.

A method for ionizing a coating vapor in a vapor deposition coating system comprising the steps of:

• forming a vacuum within a vacuum cell;
• supplying a coating vapor in the vacuum cell;
• passing the coating vapor through a gap between a first electrode disposed in the vacuum cell and a second electrode disposed in the vacuum cell;
• supplying electric power to the first and second electrodes so that the first and second electrodes become oppositely charged and create an electric arc discharge between the first and second electrodes;
• and
• switching polarity between the first and second electrodes while the electric power is supplied to the first and second electrodes.

A vapor deposition coating system comprising:

• a vacuum cell capable of maintaining a vacuum within the vacuum cell;
• a source of coating vapor disposed in the vacuum cell;
• an electric arc discharge apparatus disposed in the vacuum cell, the electric arc discharge apparatus comprising a cathode, an anodic hood at least partially covering the cathode, and an electrical insulating material connecting the cathode to the anodic hood, the cathode and the anodic hood arranged to form an ionization chamber and the anodic hood having a plasma discharge opening for discharging plasma from the electric arc discharge apparatus;
• and
• an electric power supply for supplying electric power to the electric arc discharge apparatus so that when the electric power supply supplies electric power to the electric arc discharge apparatus, the cathode becomes negatively charged and the anodic hood becomes positively charged so that (a) an electric arc discharge is created between the cathode and the anodic hood in the ionization chamber, (b) the cathode emits electrons and ionizes the coating vapor in the vacuum cell by the source of coating vapor, (c) the cathode vaporizes and forms an ionized cathode vapor within the ionization chamber, and (d) the ionized cathode vapor is emitted from the discharge opening of the anodic hood and mixes with the coating vapor.

A method for ionizing a coating vapor in a vapor deposition coating system comprising the steps of:

• forming a vacuum within a vacuum cell;
• supplying a coating vapor in the vacuum cell;
• passing the coating vapor adjacent an electric arc discharge apparatus disposed in the vacuum cell, the electric arc discharge apparatus comprising a cathode, an anodic hood at least partially covering the cathode, and an electrical insulating material connecting the cathode to the anodic hood, the cathode and the anodic hood arranged to form an ionization chamber and the anodic hood having a plasma discharge opening;
• and
• supplying electric power to the electric arc discharge apparatus so that the cathode becomes negatively charged and the anodic hood becomes positively charged so that (a) an electric arc discharge is created between the cathode and the anodic hood in the ionization chamber, (b) the cathode emits electrons and ionizes the coating vapor in the vacuum cell by the source of coating vapor, (c) the cathode vaporizes and forms an ionized cathode vapor within the ionization chamber, and (d) the ionized cathode vapor is emitted from the discharge opening of the anodic hood and mixes with the coating vapor.

A continuously fed electrode comprising:

• a plurality of electrode members which vaporize when discharged in an electric arc discharge;
• a housing defining a loading chamber for receiving the electrode members in series;
• and
• an electrode member feeder for continuously feeding the plurality of electrode members, in series, through the housing to an electric arc discharge position so that one of the plurality of electrode members is in the electric arc discharge position at a time.

A vapor deposition coating system comprising:

• an ionized vapor enclosure;
• an evaporator for producing coating vapor in the ionized vapor enclosure at a rate of evaporation;
• an ionizing source for ionizing the coating vapor to a degree of ionization;
• and
• an apparatus for measuring the rate of evaporation from the evaporator and the degree of ionization of the coating vapor comprising:
• an electrically conductive element;
• an ammeter connected to the electrically conductive element for measuring electric current through the electrically conductive element;
• an electric power supply for supplying electric current to the electrically conductive element through the ammeter;
• and
• a switch for selectively connecting the electric power supply to the electrically conductive element, closing the electric circuit, and causing the power supply to heat the electrically conductive element, and, alternatively, disconnecting the electric power supply from the electrically conductive element, opening the electric circuit, and allowing the electrically conductive element to cool,
• wherein, when the switch is open and electric power is supplied to the electrically conductive element, a first circuit is formed and electric current flows from the electric power source, through the electrically conductive element, ammeter, and the ionizing vapor to a ground, and when the switch is closed and electric power is supplied to the electrically conductive element, a second circuit is formed and electric current flows from the power supply, through the electrically conductive element, the ammeter, and the switch.

A method for measuring the degree of ionization in a vapor deposition coating system which comprises an ionized vapor enclosure, an evaporator for producing coating vapor in the ionized vapor enclosure, and an ionizing source for ionizing the coating vapor to a degree of ionization, the method comprising the steps of:

• exposing an electrically conductive element to the ionized coating vapor in the ionized vapor enclosure;
• supplying electric current to the electrically conductive element so that the electric current flows through the electrically conductive element and the ionized vapor to ground;
• and
• measuring electric current through the electrically conductive element with an ammeter.

A method for measuring the rate of evaporation from an evaporator in a vapor deposition coating system which comprises an ionized vapor enclosure, the evaporator for producing coating vapor in the ionized vapor enclosure at a rate of evaporation, and an ionizing source for ionizing the coating vapor, the method comprising the steps of:

• exposing an electrically conductive element to the ionized coating vapor;
• supplying electric current to the electrically conductive element and closing a first circuit including the electrically conductive element to heat the electrically conductive element;
• opening the first circuit;
• and thereafter
• while still supplying electric current to the electrically conductive element, measuring the rate of change of the electric current through the electrically conductive element and the ionized coating vapor to ground with an ammeter.

A vapor deposition coating system comprising:

• a vacuum cell having an interior and capable of maintaining a vacuum within the vacuum cell;
• a source of ionized coating vapor disposed in the vacuum cell;
• an electrode disposed in the vacuum cell;
• and
• an ionizing power supply connected to the electrode for supplying sufficient power to the electrode to ionize gas in the vacuum cell so that the ionized gas removes deposited volatile material from the interior of the vacuum cell.