Patent ID: 7179500

Claim:
A method for fabricating a continuous film on a porous substrate, said method comprising: a. selecting a deposition material having a oxidation expansion ratio, wherein an in-plane portion of the oxidation expansion ratio is equal to the second power of the third root of the oxidation expansion ratio; b. depositing said deposition material with a deposition height and deposition density on top of said porous substrate, said deposition material being in an unoxidized condition; c. oxidizing said deposition material on top of said substrate whereby said deposition material is converted into an oxidized material being spatially expanded with respect to said deposition material; wherein said deposition density is greater than or equal to the inverse of said in-plane portion of the oxidation expansion ratio; wherein said deposition height and said deposition density are selected in conjunction with said spatial oxidation expansion such that during said oxidizing a substantially void-free film is formed on top of said substrate; and d. heat treating said void-free film to recombine said oxidized material into said continuous film.