Abstract-Soft-vacuum-generated electron beams employed to create a large area plasma for assisting chemical vapor deposition (CVD) of thin films are reviewed. The electron beam plasma is used both directly, where electron impact dissociation of feedstock gases plays a dominant role, and indirectly in a downstream afterglow, where electron impact dissociation of feedstock reactants plays no role. Rather, photodissociation and metastable atom-molecule reactions dominate in the downstream afterglow. To better understand electron-beam-created plasmas using a slotted ring cathode, the transmitted beam spatial intensity profiles have been quantified from initial generation at a slotted line-shaped cold cathode through acceleration in the cathode sheath and propagation in the ambient gas. To better understand the role of photodissociation in downstream plasma-assisted CVD, the VUV output spectrum and VUV generation efficiency from electron-beam-excited plasmas have been measured. The properties of films deposited via both direct electron-beam-generated plasma-assisted CVD and downstream afterglow CVD are reviewed and compared to conventional plasma assisted CVD films.
I. SOFT-VACUUM ELECTRON BEAM GENERAnONA. Thermionic Sources T HE conventional means of producing electron beams uses thermionic cathode sources to emit electrons, which are accelerated in an ambient pressure typically below 10-4 torr. Thermionic emitters have limited application because of the low required operating pressure and the likelihood of poisoning from ambients other than inert gases. Wide area ( > 10 em") electron beams are usually not generated from thermionic cathodes, further precluding the use of this type of source in many practical applications.
B. Glow Discharge SourcesA glow discharge environment provides a simple means to produce wide-area electron beams without the need of Manuscript received April 3, 1989; revised May 30, 1990 either thermionic sources or acceleration in high vacuum. In general, there are two groups of electrons that emerge from the cathode sheath created in a gas discharge plasma. One group contains the electrons that have undergone many inelastic collisions with gas atoms and are less energetic and isotropic in direction. Another group is comprised of energetic and highly directed electrons that have been produced at the cold cathode and accelerated perpendicular to the cathode surface. These electrons are often called beam electrons. Five established methods to create soft-vacuum electron beams from a plasma are outlined next.
1) Cold Cathodes:Electrons are emitted from a cold cathode following bombardment of the cathode by energetic species (ions, metastables, and photons) whose energy exceeds the threshold for cold electron emission, which is roughly equal to the work function of the surface for pure metal cathodes. Ion-induced secondary emission usually dominates in a discharge, and the secondary emission coefficient varies with ion species, the work function, and the Fermi energy of the cathode [I]. Cold-cathod...