Patent Description:
In high power devices for space, secondary electron emission governs a multipactor effect which is a resonant vacuum electron avalanche detected in microwave (MW) and radio frequency (RF) space instrumentation, large accelerator structures and thermonuclear toroidal plasma devices; which are manufactured in a wide array of geometries and which are working in a frequency range from MHz range up to tens of GHz. The fundamental mechanism behind this serious problem of multipactor discharge is the electron discharge caused by secondary electron emission (SEE); therefore, multipactor discharge imposes a limit on the total power that may be transmitted by a high powered system in vacuum.

Multipactor is a serious issue in fields of great technological importance such as high power RF hardware in space, high-energy particle accelerators, and klystrons and other high-power RF vacuum tubes. The resonance conditions of multipactor can often be inhibited by an adequated design of parameters pertaining the RF electromagnetic field; but, there remain always critical regions where that resonance conditions can only be avoided by using low-secondary emission surfaces.

It has been suggested that a key issue for the manufacture of future advanced devices for space is the development of anti-multipactor coatings which should have good surface electrical conductivity for avoiding RF losses, large resistance to air exposure and low SEE. Surface roughness can be an issue in power loss in metallic materials because of the high surface electrical resistance or high insertion loss, or even small skin depth at high frequencies. In the limit of high frequencies, the induced current in the material is strictly localized into the surface and the resistance increases in the ratio of the area of the roughened surface to the projected area (for transversal 2D roughness). For lower frequencies, the induced current distributes exponentially in depth according to the skin depth and the surface resistance decreases with the dc resistance as a limit. In a waveguide of conductive metallic surfaces, the power attenuation measured in dB (the insertion loss IL) is proportional to the RF surface resistance.

Well-known techniques for reducing the secondary electron emission yield (SEY) are surface roughness cleaning/conditioning or surface roughness increase [<NPL>)]. For many years silver has been used in different electric devices due to its high electrical conductivity, for instance, in high quality RF connectors and RF devices working under vacuum conditions. Silver presents a secondary electron emission coefficient (SEY) higher than <NUM> after exposure to air. However, to prevent multipactor discharge it is mandatory to use surfaces with low SEY, lower than <NUM>. Many researchers have attempted to overcome these problems.

Rough coatings applied to the silver surface can substantially reduce SEY [<NPL>).

"<NPL> describes a complicated and very expensive preparation method for suppressing multipactor effect in space instrumentation comprising micro-structured gold/silver coatings. In that work the measured SEY is high (SEY= <NUM>) and multipactor discharge was detected.

Etching of the flat silver coatings for increasing the surface roughness and thus achieving low-SEE and low insertion loss is a method that has been described previously. Nevertheless etching of flat surfaces only produced a moderate decrease of SEY (up to SEY > <NUM>) and a strong increase of the insertion loss. In addition the mechanical properties of the silver deteriorated after that particular etching process. [Rf component and the method thereof for surface finishing <CIT> and <NPL>].

Air exposure produces a so important increase of SEY that coatings can become unusable for anti-multipactor applications, for instance, an increase from <NUM> to <NUM>. Multilayer coatings with a low SEY that prevents interference resulting from secondary electron emission can be found in the state of art (for example <CIT>). Nevertheless, no reference to the effect of the exposure to the air is disclosed.

Furthermore, graphene flakes coatings were also studied for this application but its theoretical high insertion loss values (<NUM> dB) are not suitable for these applications [<NPL>]. <CIT> discloses a method of reducing multipactor effect occurrence on surfaces RF devices. The method includes forming porous layer of Anomag disposed over the wall material surface and a conductive layer disposed over the porous layer upper surface. Anomag is an oxide layer and for this reason its resistivity is higher than a metallic layer. The consequent expected high insertion loss values are not adequate for a normal operation of these RF high power devices.

<CIT> discloses an aluminum alloy microwave component designed for low secondary electron emission: An aluminum alloy substrate is covered by a layer of copper, and a silver layer is sputtered on top of the copper layer (abstract), silver having a electrical conductivity.

For the reasons stated above, it is needed to develop anti-multipactor coatings with low SEY, low insertion loss and high resistance to air exposure.

The invention relates to a low secondary electron emission material. It is a rough anti-multipactor coating deposited onto a substrate consisting of a metal or a mixture of metals that can be exposed to the air and still maintains a low SEY and a low insertion loss.

Furthermore the invention relates to the procedure of obtainment of the anti-multipactor coating by simple chemical methods. This process enhanced height-to-width grooves aspect ratios to inhibit multipactor effect. The main potential advantages of this nano-microtechnology technique are the following:.

Additionally, the present invention relates to its use for the fabrication of high power devices working at high frequencies.

A first aspect of the present invention relates to an anti-multipactor coating deposited onto a substrate characterized in that.

In the present invention the term "anti-multipactor coating" describes a coating deposited onto a substrate that prevents or decreases the secondary electron emission detected in high power devices working at high powers of the orders of <NUM><NUM> W in RF space instrumentation. This means, the anti-multipactor coating deposited onto a substrate prevents or decreases the resonant vacuum electron avalanche detected in the mentioned devices.

The anti-multipactor coating deposited onto a substrate of the present invention has a secondary electron emission yield between <NUM> and <NUM>, for an incident or primary electron energy range between <NUM> and <NUM> eV.

The anti-multipactor coating deposited onto a substrate of the present invention can be exposed to air, it maintains its low SEY even after long air exposure.

The term "grooves aspect ratio" as used herein defines the final surface roughness of the anti-multipactor coating of the present invention and refers to the geometric shape of the grooves, this means, the ratio of the depth to dwell width.

The grooves aspect ratio of the anti-multipactor coating of the present invention is greater than <NUM> with a surface grooves density ><NUM>%.

The term "insertion loss" as used herein refers to the loss of signal power of the anti-multipactor coating deposited onto a substrate of the present invention. For instance, insertion loss is a figure of merit for an electronic filter and this data is generally specified with a filter; it is defined as a ratio of the signal level in a test configuration without the filter installed to the signal level with the filter installed. This ratio is described in dB.

The anti-multipactor coating deposited onto a substrate of the present invention is characterized by an insertion loss of between <NUM> and <NUM> dB.

Thus, a preferred embodiment of the present invention provides an anti-multipactor coating deposited onto a substrate wherein the substrate consist of a metal or a mixture of metals selected from Ni doped with P, Al, Cu and Ag.

In a preferred embodiment, the high conductive metal of each layer forming the anti-multipactor coating described above is selected independently from Au, Ag and Cu; more preferably is selected independently from Ag and Cu.

In another preferred embodiment, the secondary electron emission yield of the anti-multipactor coating described above ranges values between <NUM> and <NUM> for an incident or primary electron energy range between <NUM> and <NUM> eV.

A second aspect of the present invention relates to a process of obtainment of the anti-multipactor coating deposited onto a substrate described previously wherein the process comprises at least the following steps:.

and d) electroless plating of a high conductive metal, of an electrical conductivity greater than <NUM>×<NUM><NUM> S·m-<NUM>, onto the activated etched layer obtained in step c) using a solution of high conductive metal ions and a reducing agent.

Preferably, step a) relates to the deposition of a high conductive metal layer, made of Ag or Cu.

In a preferred embodiment, the deposition is performed by conventional deposition techniques such as chemical deposition techniques such as plating, chemical solution deposition, spin coating, chemical vapor deposition and atom layer deposition, and/or physical deposition techniques such as electron beam evaporator, molecular beam epitaxy, pulsed laser deposition, sputtering, cathodic arc deposition and electrospray deposition.

Step b) describes the etching of the deposited high conductive metal layer of step a) by an acid dissolution, so that the final surface roughness is characterised with a grooves aspect ratio above <NUM> with a surface grooves density greater than <NUM>%.

Etching of the flat metallic surface is a mandatory step to grow a an adequate strong metallic rough layer on it.

In a preferred embodiment, the acid dissolution of step b) comprises hydrofluoric acid, nitric acid, acetic acid, deionized water or a mixture thereof.

Preferably, the acid dissolution consists of hydrofluoric acid, nitric acid, acetic acid and deionized water in a stoichiometric ratio of <NUM>:<NUM>:<NUM>:<NUM>.

Preferably, the acid dissolution consists of hydrofluoric acid, nitric acid and deionized water in a stoichiometric ratio of <NUM>:<NUM>:<NUM>.

Step c) relates to the activation of the etched layer obtained in step b).

In a preferred embodiment, this activation is performed by adding an aqueous solution of SnCl<NUM> or PdCl<NUM>.

More preferably, the aqueous solution of SnCl<NUM> is in a concentration range between <NUM> - <NUM> % in weight to the etched layer obtained in step b). A rinse in deionized water is performed subsequently. Even more preferably the concentration range of the aqueous solution of SnCl<NUM> is <NUM> - <NUM>% in weight. Sn ions will reduce the silver species to metallic Ag and the silver deposition process continues because silver is autocatalytic for the deposition of itself.

Step d) relates to the electroless plating of a high conductive metal onto the activated etched layer obtained in step c) using a solution of high conductive metal ions and a reducing agent.

Electroless plating process is based on chemical reduction reactions and does not need to apply any external electrical potential. Therefore, electroless does not require an electrical contact to the substrate; this fact increases the processing flexibility. In electroless plating, the substrate is just immersed into the plating dissolution containing reducing agents and silver ions. Conformal coverage can be provided by this electroless plating.

In a preferred embodiment, the high conductive metal used during step d) of electroless plating is selected from Au, Ag and Cu, more preferably is selected from Ag and Cu.

In another preferred embodiment, step d) of electroless plating is performed under continuous agitation and using a bath temperature between <NUM> and <NUM>ºC; preferably between <NUM> and 70ºC.

Preferably, the solution of high conductive metal ions of step d) is an aqueous solution of AgNO<NUM>. More preferably, this aqueous solution is in a concentration of <NUM>.

In another preferred embodiment, the reducing agent of step d) is selected from triethanolamine, diethanolamine or monoethanolamine. More preferably, a reducing agent such as triethanolamine is slowly added drop by drop. In case of using Ag triethanolamine is slowly added until the initially formed silver oxide or silver hydroxide precipitate (solution with a brown color) is redissolved with constant stirring (colorless solution) obtaining metallic silver.

The last aspect of the invention refers to the use of the anti-multipactor coating deposited onto a substrate described previously for the fabrication of high power devices, operating at powers higher than <NUM> kW, working at high frequencies, from MHz range up to tens of GHz.

Preferably, the device is a microwave, a radio frequency device for space, thermonuclear or large accelerator instrumentation working at high power, higher than <NUM> kW, between <NUM> kW and 100kW, more preferably between <NUM> kW and and 50kW.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. Throughout the description and claims the word "comprise" and its variations are not intended to exclude other technical features, additives, components, or steps. Additional objects, advantages and features of the invention will become apparent to those skilled in the art upon examination of the description or may be learned by practice of the invention. The following examples and drawings are provided by way of illustration and are not intended to be limiting of the present invention.

A chemical deposition treatment was developed for creating an appropriate submicron surface roughness on a Ag plating of the waffle-iron type filters.

<FIG> shows a photo of a Ku band filter, <FIG> shows a photo of a Ku band filter, <NUM> indicates the inner part.

A silver coated aluminum sample of <NUM><NUM> was etched in a Teflon baker of <NUM> with dissolution of HNO<NUM>, HF and deionized water <NUM>:<NUM>:<NUM> during <NUM>. The sample was cleaned in water and treated in a dissolution of SnCl<NUM> (<NUM>) and deionized water (<NUM>) during <NUM>.

An electroless plating process was required for the preparation of the top microstructured silver coating of the filters. The procedure was performed in a round glassware or baker of <NUM> containing AgNO<NUM> (<NUM>) and deionized water (<NUM>) of <NUM> Mohms. cm; drops of triethanolamine were subsequently added and the solution take on light brown in color and subject to energetic agitation until to achieve a transparent dissolution, then more deionized water is added up to obtain <NUM>. The pretreated samples (prismatic shape or plates of <NUM> × <NUM> × <NUM>) were placed in the center of the baker with its small side parallel to the base of the baker during <NUM>.

<FIG> shows a scanning electron microscopy (SEM) image of the transversal section of the silver flat coating deposited on Ni/Al substrate.

A homogeneous silver thickness is observed along the sample surface. It is remarkable the good interlayer adhesion.

a) and b) show SEM images of the silver coating and c) shows a scheme of the monolayer silver structure deposited on Ni(P)/Al substrate.

The surface roughness of high aspect ratio is produced by the continuous silver growing on the previously etched surface of the standard silver plating of the aluminum alloy device. The dark black regions represent a sinkhole area of ~<NUM> %. The 3D surface shown in this figure is a realistic simulation obtained by the AFM software. In the inset of the upper right is remarked the monolayer structure of this antimultipactor coating.

SEY tests were performed in an ultra-high vacuum chamber (<<NUM>-<NUM> hPa) equipped with two Kimball Physics electron guns in the range <NUM>-<NUM> eV, ion-gun, a concentric hemispherical analyzer. The energy of the electrons leaving the sample are determined using this analyzer and the excitation sources energetic electrons or x-ray, MgKα radiation (hv= <NUM> eV). The sample can be rotated in front of the electron spectrometer for the surface composition or cleanliness examination, and in front of the programmable electron guns for the SEY measurements by using two micrometric XYZθ manipulators, and liquid helium cryostat for sample cooling, and also can be heated (<<NUM>).

The SEY measurements were made via computer-controlled data acquisition; the sample is connected to a precision electrometer (conductive samples). The electron beam is pulsed by counter-bias of the wehnelt. The primary beam current can be measure by a Faraday cup attached to the system.

The current I<NUM> is always negative, while Is can be positive or negative depending on the primary energy and SEY values of the sample. Low primary electron current (I<NUM> <5nA) was used to avoid surface contamination or modification.

No witness samples were required because filters can be directly measured in this SEY set-up.

<FIG> shows SEY curves of the filter sample with the optimum roughness as measured in the corrugated part of the filter before and after anti-multipactor treatment.

It is remarkable SEY of the coated filter is lower than <NUM> in all primary energy range SEY of pillars.

<FIG> discloses the primary energy and angular dependences of the SE yield of electrons colliding with filters surface with primary energies of E = <NUM>-<NUM> eV, at incoming angles in interval -<NUM>° ≤θ≤ <NUM>°, before and after anti-multipactor treatment.

A relevant decrease of the SEY after anti-multipactor treatment compared with as-received filter is obtained. SEY rises as the incidence angle of primary electrons is increased. The variation is lower for the anti-multipactor coating and higher for the silver flat reference sample. It is remarkable that microstructured coating (coated filter) achieves a constant SEY as a function of the incident angle, and SEY<<NUM> in all primary energy range.

The incident-angle dependence of the total SEY data is well fitted by Furman and Pivi equation <MAT>.

A good fit of SEY (θ) (secondary and backscattered electrons) is achieved with a constant value of α = <NUM> and β ranges from <NUM>·<NUM>-<NUM> to <NUM>·<NUM>-<NUM> for the primary energy range <NUM>-<NUM> eV.

The return loss of these coated Ku band samples, as well as the insertion loss, was measured at Tesat Spacecom by using a network analyzer equipment. S-parameter measurements were performed on each DUT (Device under test) before and after treatment.

A low value of insertion loss was measured, <NUM>,14dB.

Multipactor test were performed at the European High Power Laboratory in Valencia (Spain). Reference document: ECSS Space Engineering - T\TuHipact. ioll design and test RCSS-E-<NUM>-01A.

The filter sample was installed inside a vacuum chamber and one <NUM>Sr radioactive β-source and one UV lamp were employed simultaneously during the tests. A total of two electron probes were used during the test. It is worth mentioning that the detection systems as well as the radioactive source and the optical fiber (UV light) were positioned nearby the critical area of the filter sample.

Claim 1:
Anti-multipactor coating deposited onto a substrate characterized in that
• said coating comprises at least two contacting high conductive metal layers with an electrical conductivity greater than <NUM>×<NUM><NUM> S·m-<NUM>, wherein the high conductive metal of each layer is selected from the group consisting of Ag and Cu,
• said coating has a secondary electron emission yield between <NUM> and <NUM> for an incident electron energy range between <NUM> and <NUM> eV,
• said coating has a final surface roughness defined by a geometric shape of grooves,
• said coating has an aspect ratio greater than <NUM> and a surface grooves density greater than <NUM>%, wherein the aspect ratio is defined by the ratio of the depth to dwell width of the grooves,
• and it has an insertion loss of between <NUM> and <NUM> dB, wherein the substrate consists of a metal or a mixture of metals.