We have developed an improved vapor-phase deposition method and apparatus
for the application of films/coatings on substrates. The method provides
for the addition of a precise amount of each of the reactants to be
consumed in a single reaction step of the coating formation process. In
addition to the control over the amount of reactants added to the process
chamber, the present invention requires precise control over the total
pressure (which is less than atmospheric pressure) in the process
chamber, the partial vapor pressure of each vaporous component present in
the process chamber, the substrate temperature, and typically the
temperature of a major processing surface within said process chamber.
Control over this combination of variables determines a number of the
characteristics of a film/coating or multi-layered film/coating formed
using the method. By varying these process parameters, the roughness and
the thickness of the films/coatings produced can be controlled.