Patents by Inventor Thomas H. Metcalf

Thomas H. Metcalf has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11384421
    Abstract: A method for producing a sputtered stoichiometric a-Al2O3 thin film. A substrate is placed into a chamber containing an Al target to be sputtered. The chamber is evacuated to a base pressure of about 7×10?8 Torr or lower and the temperature of the substrate is maintained. With a sputtering shutter in the chamber closed, Ar gas is flowed into the chamber to backsputter the Al target and Ar and O2 gases are flowed into the chamber to presputter the target. The shutter is opened and Al is sputtered onto the substrate in the presence of the Ar and O2 gases to obtain a sputtered a-Al2O3 film on the substrate.
    Type: Grant
    Filed: February 14, 2019
    Date of Patent: July 12, 2022
    Assignee: The Government of the United States of America, as represented by the Secretary of the Navy
    Inventors: Xiao Liu, Battogtokh Jugdersuren, Matthew R. Abernathy, Thomas H. Metcalf
  • Publication number: 20190284677
    Abstract: A method for producing a sputtered stoichiometric a-Al2O3 thin film. A substrate is placed into a chamber containing an Al target to be sputtered. The chamber is evacuated to a base pressure of about 7×10?8 Torr or lower and the temperature of the substrate is maintained. With a sputtering shutter in the chamber closed, Ar gas is flowed into the chamber to backsputter the Al target and Ar and O2 gases are flowed into the chamber to presputter the target. The shutter is opened and Al is sputtered onto the substrate in the presence of the Ar and O2 gases to obtain a sputtered a-Al2O3 film on the substrate.
    Type: Application
    Filed: February 14, 2019
    Publication date: September 19, 2019
    Applicant: The Government of the United States of America, as represented by the Secretary of the Navy
    Inventors: Xiao Liu, Battogtokh Jugdersuren, Matthew R. Abernathy, Thomas H. Metcalf
  • Patent number: 9741921
    Abstract: A hydrogen-free amorphous dielectric insulating film having a high material density and a low density of tunneling states. The film is prepared by deposition of a dielectric material on a substrate having a high substrate temperature Tsub under high vacuum and at a controlled low deposition rate. In one embodiment, the film is amorphous silicon while in another embodiment the film is amorphous germanium.
    Type: Grant
    Filed: November 16, 2016
    Date of Patent: August 22, 2017
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Xiao Liu, Daniel R. Queen, Frances Hellman, Thomas H. Metcalf, Matthew R. Abernathy, Glenn G. Jernigan
  • Publication number: 20170069819
    Abstract: A hydrogen-free amorphous dielectric insulating film having a high material density and a low density of tunneling states. The film is prepared by deposition of a dielectric material on a substrate having a high substrate temperature Tsub under high vacuum and at a controlled low deposition rate. In one embodiment, the film is amorphous silicon while in another embodiment the film is amorphous germanium.
    Type: Application
    Filed: November 16, 2016
    Publication date: March 9, 2017
    Applicant: The Government of the United States of America, as represented by the Secretary of the Navy
    Inventors: Xiao Liu, Daniel R. Queen, Frances Hellman, Thomas H. Metcalf, Matthew R. Abernathy, Glenn G. Jernigan
  • Patent number: 9577174
    Abstract: A process for forming a doped nc-Si thin film thermoelectric material. A nc-Si thin film is slowly deposited on a substrate, either by hot-wire CVD (HWCVD) with a controlled H2:SiH4 ratio R=6-10 or by plasma-enhanced (PECVD) with a controlled R=80-100, followed by ion implantation of an n- or p-type dopant and a final annealing step to activate the implanted dopants and to remove amorphous regions. A doped nc-Si thin film thermoelectric material so formed has both a controllable grain size of from a few tens of nm to 3 nm and a controllable dopant distribution and thus can be configured to provide a thermoelectric material having predetermined desired thermal and/or electrical properties. A final annealing step is used to activate the dopants and remove any residual amorphous regions.
    Type: Grant
    Filed: September 6, 2016
    Date of Patent: February 21, 2017
    Assignee: The United States of America, as represented by the Secretary of the Navy
    Inventors: Xiao Liu, Thomas H. Metcalf, Daniel R. Queen, Battogtokh Jugdersuren, Qi Wang, William Nemeth
  • Publication number: 20160372651
    Abstract: A process for forming a doped nc-Si thin film thermoelectric material. A nc-Si thin film is slowly deposited on a substrate, either by hot-wire CVD (HWCVD) with a controlled H2:SiH4 ratio R=6-10 or by plasma-enhanced (PECVD) with a controlled R=80-100, followed by ion implantation of an n- or p-type dopant and a final annealing step to activate the implanted dopants and to remove amorphous regions. A doped nc-Si thin film thermoelectric material so formed has both a controllable grain size of from a few tens of nm to 3 nm and a controllable dopant distribution and thus can be configured to provide a thermoelectric material having predetermined desired thermal and/or electrical properties. A final annealing step is used to activate the dopants and remove any residual amorphous regions.
    Type: Application
    Filed: September 6, 2016
    Publication date: December 22, 2016
    Applicant: The Government of the United States of America, as represented by the Secretary of the Navy
    Inventors: Xiao Liu, Thomas H. Metcalf, Daniel R. Queen, Battogtokh Jugdersuren, Qi Wang, William Nemeth
  • Patent number: 9472745
    Abstract: A process for forming a doped nc-Si thin film thermoelectric material. A nc-Si thin film is slowly deposited on a substrate, either by hot-wire CVD (HWCVD) with a controlled H2:SiH4 ratio R=6-10 or by plasma-enhanced (PECVD) with a controlled R=80-100, followed by ion implantation of an n- or p-type dopant and a final annealing step to activate the implanted dopants and to remove amorphous regions. A doped nc-Si thin film thermoelectric material so formed has both a controllable grain size of from a few tens of nm to 3 nm and a controllable dopant distribution and thus can be configured to provide a thermoelectric material having predetermined desired thermal and/or electrical properties. A final annealing step is used to activate the dopants and remove any residual amorphous regions.
    Type: Grant
    Filed: February 19, 2016
    Date of Patent: October 18, 2016
    Assignee: The United States of America, as represented by the Secretary of the Navy
    Inventors: Xiao Liu, Thomas H. Metcalf, Daniel R. Queen, Battogtokh Jugdersuren, Qi Wang, William Nemeth
  • Publication number: 20160247997
    Abstract: A process for forming a doped nc-Si thin film thermoelectric material. A nc-Si thin film is slowly deposited on a substrate, either by hot-wire CVD (HWCVD) with a controlled H2:SiH4 ratio R=6-10 or by plasma-enhanced (PECVD) with a controlled R=80-100, followed by ion implantation of an n- or p-type dopant and a final annealing step to activate the implanted dopants and to remove amorphous regions. A doped nc-Si thin film thermoelectric material so formed has both a controllable grain size of from a few tens of nm to 3 nm and a controllable dopant distribution and thus can be configured to provide a thermoelectric material having predetermined desired thermal and/or electrical properties. A final annealing step is used to activate the dopants and remove any residual amorphous regions.
    Type: Application
    Filed: February 19, 2016
    Publication date: August 25, 2016
    Applicant: The Government of the United States of America, as represented by the Secretary of the Navy
    Inventors: Xiao Liu, Thomas H. Metcalf, Daniel R. Queen, Battogtokh Jugdersuren, Qi Wang, William Nemeth
  • Patent number: 9054640
    Abstract: This invention provides an extremely accurate way to characterize the Young's modulus of thin film materials with thicknesses in the nanometer range. It takes advantage of a recently developed high Q silicon Young's modulus resonator (YMR), which has a record high quality factor of about fifty million in operation at temperatures below 10 degrees Kelvin (10K). Because of the high Q of the YMR, the temperature stability of the YMR's resonance frequency below 1K, and the extremely high degree of vibration isolation inherent in the inventive design, the relative resolution of the resonant frequency is typically in 2×10?7. This is enough to resolve a resonant frequency shift after a deposition of a thin film onto the sensitive part of the resonator, and to compute the Young's modulus of thin film materials of even a few monolayers thickness.
    Type: Grant
    Filed: June 27, 2013
    Date of Patent: June 9, 2015
    Assignee: The United States of America, as represented by the Secretary of the Navy
    Inventors: Xiao Liu, Thomas H. Metcalf
  • Publication number: 20140002203
    Abstract: This invention provides an extremely accurate way to characterize the Young's modulus of thin film materials with thicknesses in the nanometer range. It takes advantage of a recently developed high Q silicon Young's modulus resonator (YMR), which has a record high quality factor of about fifty million in operation at temperatures below 10 degrees Kelvin (10K). Because of the high Q of the YMR, the temperature stability of the YMR's resonance frequency below 1K, and the extremely high degree of vibration isolation inherent in the inventive design, the relative resolution of the resonant frequency is typically in 2×10?7. This is enough to resolve a resonant frequency shift after a deposition of a thin film onto the sensitive part of the resonator, and to compute the Young's modulus of thin film materials of even a few monolayers thickness.
    Type: Application
    Filed: June 27, 2013
    Publication date: January 2, 2014
    Applicant: US Gov't Represented by Secretary of the Navy Chief of Naval Research Office of Counsel ONR/NRL
    Inventors: Xiao Liu, Thomas H. Metcalf