In this case, the reactions are essentially surface
reactions involving heat activation.
Physical vapour deposition (PVD), one of the
most commonly used ‘dry’ processes for inor-
ganic coatings, includes two methods. The first
is sputtering, involving bombardment of a solid
to obtain a vapor phase, which is then condensed
on a cold substrate to form another compound.
The other method is vapor deposition (VD),
sometimes called thermal evaporation, which
produces inorganic or organic thin films through
evaporation of the source. In the case of polymer
sources, the source is heated or irradiated. How-
ever, the deposition process (PVD) may decrease
the molar mass of the resulting film.
Chemical vapor deposition (CVD), a process in
which a thin film is synthesized from a g as phase
precursor that undergoes a chemical reaction
(decomposition, grafting reaction) at the sub-
strate’s surfa ce. These reactions distinguish
CVD from physical deposition processes, such
as evaporation, bombardment or sublimation.
CVD is a well-known process used to produce
high purity inorganic and organic thin films.
This chapter examines chemical deposition,
which is very relevant today. Thin film polymer
coatings made from precursors using PECVD
(plasma-enhanced chemical vapor deposition)
are now common and can be found in a grow-
ing number of applications [25] (optics, mechan-
ics, chemical protection, nano-systems, micro-
electronics, etc.). The success of these coatings in
surface functionality is related to their high poten-
tial for innovation and their ‘ clean’ technology,
which is environment-friendly with low material
consumption.
In PECVD, ‘cold’ plasmas are used because
they are very thermodyn amically unbalanced
(T
e
>> T
i
and T
n
, where T
e
, T
i
and T
n
are electron,
ion and neutral temperatures, respectively).
Plasma is an electrically neutral environment
composed of ions, neutrals, radicals, electrons
and photons [26]. The gas precursors are dissoci-
ated in a controlled-pressure reactor (from a few
millitorr to atmospheric pressure) in which an
electrical discharge is applied. This partially
ionizes the gas. In these plasmas, the electrons
have high kinetic energy (1–10 eV or more); the
ions, radicals and neutrals have lower kinetic
energies (around 0.5 and 0.1 eV, respectively).
This is the advantage of plasma; the active species
are produced in the plasma phase before contact
with the surface, allowing the energy of the ions
to be controlled when they reach the surface.
The numerous collisions between neutrals and
electrons generate active species at ambient
temperature. This enables treatments on all types
of substrate, with numerous reaction paths due
to the large quantity of active species created.
There are several ways to obtain these plasmas.
However, thin film deposition techniques mainly
use a capacitive discharge obtained by applying
an alt ernating electrical field between two elec-
trodes. There are three categories of excitation
frequency: low frequency discharges (where
20 kHz < f < 200 kHz) resulting in very low den-
sity plasma (low electron density), capacitive
radiofrequency (RF) discharges (where f =
13.56 MHz) resulting in electron density of
around 10
10
cm
3
, inductive RF discharges
(where f = 13.56 MHz) and microwave dis-
charges (where f = 2.45 GHz) for which the elec-
tron density is much larger, i.e. greater than
10
10
cm
3
.
For polymerization to occur, the precursors
must contain atoms capable of forming chains,
such as carbon, silicon or sulfur. Plasma polymer-
ization is very different from conventional poly-
merization. Chemically speaking, polymerization
is the reaction of activated monomers, producing
a long repeating chain. During plasma polymeri-
zation, the notion of monomers does not really
apply beyond the precursor stage. In fact, all the
species created in the plasma participate in the
reaction. In other words, activated radicals inter-
act at the surface of the substrate and in the
plasma, mainly through termination reactions.
The terms ‘plasma polymerization’ and ‘plasma-
induced polymerization’ are used because plasma
produces free radicals and molecules with unsat-
urated bonds. The structure of the monomer (pre-
cursor) is not preserved and the product obtained
is more or less disorganized, with variable cross-
linking.
254 CHAPTER 15 Polymer Thin Films – Processes, Parameters and Property Control