U.S. patent application number 11/492628 was filed with the patent office on 2007-05-03 for coated substrate created by systems and methods for modulation of power and power related functions of pecvd discharge sources to achieve new film properties.
Invention is credited to Michael W. Stowell.
Application Number | 20070098893 11/492628 |
Document ID | / |
Family ID | 37685856 |
Filed Date | 2007-05-03 |
United States Patent
Application |
20070098893 |
Kind Code |
A1 |
Stowell; Michael W. |
May 3, 2007 |
Coated substrate created by systems and methods for modulation of
power and power related functions of PECVD discharge sources to
achieve new film properties
Abstract
A method of generating a film during a chemical vapor deposition
process is disclosed. One embodiment includes creating a substrate
by generating a first electrical pulse having a first pulse
amplitude; using the first electrical pulse to generate a first
density of radicalized species; disassociating a feedstock gas
using the radicalized species in the first density of radicalized
species, thereby creating a first deposition material; depositing
the first deposition material on a substrate; generating a second
electrical pulse having a second pulse amplitude, wherein the
second pulse amplitude is different from the first pulse width;
using the second electrical pulse to generate a second density of
radicalized species; disassociating a feedstock gas using the
radicalized species in the second density of radicalized species,
thereby creating a second deposition material; and depositing the
second plurality of deposition materials on the first deposition
material.
Inventors: |
Stowell; Michael W.;
(Loveland, CO) |
Correspondence
Address: |
COOLEY GODWARD KRONISH LLP;ATTN: Patent Group
Suite 500
1200 - 19th Street, NW
WASHINGTON
DC
20036-2402
US
|
Family ID: |
37685856 |
Appl. No.: |
11/492628 |
Filed: |
July 25, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11264596 |
Nov 1, 2005 |
|
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11492628 |
Jul 25, 2006 |
|
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Current U.S.
Class: |
427/248.1 ;
427/561; 427/569 |
Current CPC
Class: |
C23C 16/515 20130101;
C23C 16/308 20130101; C23C 16/029 20130101; C23C 16/52 20130101;
C23C 16/401 20130101; H01J 37/32201 20130101 |
Class at
Publication: |
427/248.1 ;
427/569; 427/561 |
International
Class: |
C23C 16/00 20060101
C23C016/00; B05D 3/00 20060101 B05D003/00; H05H 1/24 20060101
H05H001/24 |
Claims
1. A substrate coated with a thin film, the substrate formed by:
generating a first electrical pulse having a first pulse width;
using the first electrical pulse, generating a first density of
radicalized species; disassociating a first portion of a feedstock
gas using the first density of radicalized species, thereby
creating a first plurality of deposition materials; depositing the
first plurality of deposition materials on the substrate as a first
layer; generating a second electrical pulse having a second pulse
width, wherein the second pulse width is different from the first
pulse width; using the second electrical pulse, generating a second
density of radicalized species; disassociating a second portion of
a feedstock gas using the radicalized species in the second density
of radicalized species, thereby creating a second plurality of
deposition materials; and depositing the second plurality of
deposition materials on the first layer.
2. A substrate coated with a thin film, the substrate formed by:
generating a plasma having a density of radicalized species,
wherein the plasma is generated using a power signal;
disassociating a first portion of a feedstock gas using the
radicalized species in the first density of radicalized species,
thereby creating a first deposition material; depositing the first
deposition material on the substrate, thereby forming a first
layer; modifying the density of radicalized species by modulating
the power signal used to generate the plasma; disassociating a
second portion of the feedstock gas using the radicalized species
in the modified density of radicalized species, thereby creating a
second deposition material; and depositing the second deposition
material on the first layer, thereby forming a second layer.
3. The substrate of claim 2, further formed by: modifying the
density of radicalized species by modulating the power signal used
to generate the plasma, thereby creating a third density of
radicalized species; disassociating a third portion of the
feedstock gas using the third density of radicalized species,
thereby creating a third deposition material; and depositing the
third deposition material on the second layer, thereby forming a
third layer.
4. The substrate of claim 2, wherein the first layer and the second
layer comprise separate layers of deposition material within a film
deposited on the substrate.
5. The substrate of claim 2, wherein the first layer and the formed
second layer comprises a single gradient stack deposited on the
substrate.
6. The substrate of claim 2, wherein modifying the density of
radicalized species by modulating the power signal used to generate
the plasma comprises: modulating an amplitude characteristic of the
power signal used to generate the plasma.
7. The substrate of claim 2, wherein modifying the density of
radicalized species by modulating the power signal used to generate
the plasma comprises: modulating a frequency characteristic of the
power signal used to generate the plasma.
8. The substrate of claim 2, wherein modifying the density of
radicalized species by modulating the power signal used to generate
the plasma comprises: modulating a pulse width characteristic of
the power signal used to generate the plasma.
9. The substrate of claim 2, wherein modifying the density of
radicalized species by modulating the power signal used to generate
the plasma comprises: modulating a pulse position characteristic of
the power signal used to generate the plasma.
10. The substrate of claim 2, wherein the power signal comprises a
high-frequency signal for generating the plasma.
11. The substrate of claim 2, wherein the power signal is usable by
a high-frequency generator so that the high-frequency generator can
generate a high-frequency signal for generating the plasma.
12. The substrate of claim 11, wherein the high-frequency signal
comprises microwaves.
13. A substrate coated with a film, the substrate formed by:
generating a first electrical pulse having a first pulse amplitude;
using the first electrical pulse to generate a first density of
radicalized species; disassociating a first portion of a feedstock
gas using the radicalized species in the first density of
radicalized species, thereby creating a first deposition material;
depositing the first deposition material on the substrate;
generating a second electrical pulse having a second pulse
amplitude, wherein the second pulse amplitude is different from the
first pulse amplitude; using the second electrical pulse to
generate a second density of radicalized species; disassociating a
second portion of the feedstock gas using the radicalized species
in the second density of radicalized species, thereby creating a
second deposition material; and depositing the second plurality of
deposition materials on the first deposition material.
Description
PRIORITY
[0001] The present invention claims priority to commonly owned and
assigned patent application Ser. No. 11/264,596 entitled SYSTEM AND
METHOD FOR MODULATION OF POWER AND POWER RELATED FUNCTIONS OF PECVD
DISCHARGE SOURCES TO ACHIEVE NEW FILM PROPERTIES, which is
incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to power supplies, systems,
and methods for chemical vapor deposition.
BACKGROUND OF THE INVENTION
[0003] Chemical vapor deposition (CVD) is a process whereby a film
is deposited on a substrate by reacting chemicals together in the
gaseous or vapor phase to form a film. The gases or vapors utilized
for CVD are gases or compounds that contain the element to be
deposited and that may be induced to react with a substrate or
other gas(es) to deposit a film. The CVD reaction may be thermally
activated, plasma induced, plasma enhanced or activated by light in
photon induced systems.
[0004] CVD is used extensively in the semiconductor industry to
build up wafers. CVD can also be used for coating larger substrates
such as glass and polycarbonate sheets. Plasma enhanced CVD
(PECVD), for example, is one of the more promising technologies for
creating large photovoltaic sheets, LCD screens, and polycarbonate
windows for automobiles.
[0005] FIG. 1 illustrates a cut away of a typical PECVD system 100
for large-scale deposition processes--currently up to 2.5 meters
wide. This system includes a vacuum chamber 105 of which only two
walls are illustrated. The vacuum chamber 105 houses a linear
discharge tube 110. The linear discharge tube 110 is formed of an
inner conductor 115 that is configured to carry a microwave signal,
or other signals, into the vacuum chamber 105. This microwave power
radiates outward from the linear discharge antenna 115 and ignites
the surrounding support gas 120 that is introduced through the
support gas tube 120. This ignited gas is a plasma and is generally
adjacent to the linear discharge tube 110. Radicals generated by
the plasma and electromagnetic radiation disassociate the feedstock
gas(es) 130 introduced through the feedstock gas tube 125 thereby
breaking up the feedstock gas to form new molecules. Certain
molecules formed during the dissociation process are deposited on
the substrate 135. The other molecules formed by the dissociation
process are waste and are removed through an exhaust port (not
shown)--although these molecules tend to occasionally deposit
themselves on the substrate. This dissociation process is extremely
sensitive to the amount of power used to generate the plasma.
[0006] To coat large substrate surface areas rapidly, a substrate
carrier (not shown) moves the substrate 135 through the vacuum
chamber 105 at a steady rate, although the substrate 135 could be
statically coated in some embodiments. As the substrate 135 moves
through the vacuum chamber 105, the dissociation should continue at
a steady rate and target molecules from the disassociated feed gas
theoretically deposit on the substrate, thereby forming a uniform
film on the substrate. But due to a variety of real-world factors,
the films formed by this process are not always uniform.
[0007] Nonconductive and conductive films deposited utilizing
plasma enhanced chemical vapor sources have been achieved with many
types of power sources and system configurations. Most of these
sources utilize microwaves, radio frequency (RF), high frequency
(HF), or very high frequency (VHF) energy to generate the excited
plasma species.
[0008] Those of skill in the art know that for a given process
condition and system configuration of PECVD, it is the average
power introduced into the plasma discharge that is a major
contributing factor to the density of radicalized plasma species
produced. These radicalized plasma species are responsible for
disassociating the feedstock gas. For typical PECVD processes, the
necessary density of produced radicalized species from the plasma
must be greater than that required to fully convert all organic
materials. Factors such as consumption in the film deposition
processes, plasma decomposition processes of the precursor
materials, recombination losses, and pumping losses should be taken
into consideration.
[0009] Depending upon the power type, configuration and materials
utilized, the required power level for producing the necessary
density of radicalized plasma species can unduly heat the substrate
beyond its physical limits, and possibly render the films and
substrate unusable. This primarily occurs in polymer material
substrates due to the low melting point of the material.
[0010] To reduce the amount of heat loading of the substrate, a
method of high power pulsing into the plasma, with off times in
between the pulsing, can be used. This method allows the plasma
during the short high energy pulses to reach saturation of the
SUMMARY OF THE INVENTION
[0011] Exemplary embodiments of the present invention that are
shown in the drawings are summarized below. These and other
embodiments are more fully described in the Detailed Description
section. It is to be understood, however, that there is no
intention to limit the invention to the forms described in this
Summary of the Invention or in the Detailed Description. One
skilled in the art can recognize that there are numerous
modifications, equivalents and alternative constructions that fall
within the spirit and scope of the invention as expressed in the
claims.
[0012] One embodiment includes creating a coated substrate by
generating a first electrical pulse having a first pulse amplitude;
using the first electrical pulse to generate a first density of
radicalized species; disassociating a feedstock gas using the
radicalized species in the first density of radicalized species,
thereby creating a first deposition material; depositing the first
deposition material on a substrate; generating a second electrical
pulse having a second pulse amplitude, wherein the second pulse
amplitude is different from the first pulse width; using the second
electrical pulse to generate a second density of radicalized
species; disassociating a feedstock gas using the radicalized
species in the second density of radicalized species, thereby
creating a second deposition material; and depositing the second
plurality of deposition materials on the first deposition
material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Various objects and advantages and a more complete
understanding of the present invention are apparent and more
readily appreciated by reference to the following radicalized
species required for the film deposition process and loss to occur,
while reducing the instantaneous and continuous heating of the
substrate through the reduction of other forms of electromagnetic
radiation.
[0014] Film property requirements are achieved by setting the
process conditions for deposition, including the power levels,
pulsing frequency and duty cycle of the source. To achieve required
film properties the structure and structural content of the
deposited film must be controlled. The film properties can be
controlled by varying the radical species content, (among other
important process parameters), and as stated in the above, the
radical density is controlled primarily by the average and peak
power levels into the plasma discharge.
[0015] To achieve several important film properties, and promote
adhesion to some types of substrates, the films organic content
must be finely controlled, or possibly the contents must be in the
form of a gradient across the entire film thickness. Current
technology, which enables control of only certain process
parameters, cannot achieve this fine control. For example, current
technology consists of changing the deposition conditions, usually
manually or by multiple sources and chambers with differing process
conditions, creating steps in the film stack up to achieve a
gradient type stack. Primarily the precursor vapor content, system
pressure, and or power level at one or more times is used to
develop a stack of layers. These methods are crude at best and do
not enable fine control. Accordingly, a new system and method are
needed to address this and other problems with the existing
technology.
Detailed Description and to the appended claims when taken in
conjunction with the accompanying Drawing wherein:
[0016] FIG. 1 illustrates one type of PECVD system;
[0017] FIG. 2a illustrates a power supply for a PECVD system in
accordance with one embodiment of the present invention;
[0018] FIG. 2b is an alternative depiction of a power supply for a
PECVD system in accordance with one embodiment of the present
invention;
[0019] FIG. 3 illustrates one example of a pulse-width modulated
power signal;
[0020] FIG. 4 illustrates one example of a pulse-amplitude
modulated power signal;
[0021] FIG. 5 illustrates one example of a frequency-modulated
power signal;
[0022] FIG. 6a illustrates one example of a gradient film formed
using pulse-width modulation;
[0023] FIG. 6b illustrates one example of a multi-layer gradient
film formed using pulse-width modulation;
[0024] FIG. 7a illustrates one example of a gradient film formed
using amplitude-width modulation;
[0025] FIG. 7b illustrates one example of a multi-layer gradient
film formed using amplitude-width modulation; and
[0026] FIGS. 8a-8d illustrate the development of a multi-layer
gradient film over time using a pulse-width modulated power
signal.
DETAILED DESCRIPTION
[0027] In some PECVD processes the typical radical lifetime (time
for the loss of and consumption of the radical species) is long
enough so that there can be an off time of the plasma during which
the radical density remaining is gradually consumed by the
deposition of the film and loss mechanisms. Therefore, by
controlling the total radical density during these on and off times
of the plasma the chemical makeup of the film can be altered, as
well as the over all layer properties of the film.
[0028] By modulating the power level into the plasma, the on time
of the plasma and the timing between the power pulses, the user can
make films that were not achievable before in PECVD. The layers
could be a single gradient layer or a multiple stack of hundreds to
thousands of micro layers with varying properties between each
layer. Both processes can create a unique film.
[0029] FIG. 2a illustrates a system constructed in accordance with
one embodiment of the present invention. This system includes a DC
source 140 that is controllable by the pulse control 145. The terms
"DC source" and "DC power supply" refer to any type of power
supply, including those that use a linear amplifier, a non-linear
amplifier, or no amplifier. The DC source 145 powers the magnetron
150, which generates the microwaves, or other energy waves, that
drive the inner conductor within the linear discharge tube (not
shown). The pulse control 145 can contour the shape of the DC
pulses and adjust the set points for pulse properties such as duty
cycle, frequency, and amplitude. The process of contouring the
shape of the DC pulses is described in the commonly owned and
assigned attorney docket number APPL-008/00US, entitled "SYSTEM AND
METHOD FOR POWER FUNCTION RAMPING OF MICROWAVE LINEAR DISCHARGE
SOURCES," which is incorporated herein by reference.
[0030] The pulse control 145 is also configured to modulate the DC
pulses, or other energy signal, driving the magnetron 150 during
the operation of the PECVD device. In some embodiments, the pulse
control 145 can be configured to only modulate the signal driving
the magnetron 150. In either embodiment, however, by modulating the
DC pulses, the power level into the plasma can also be modulated,
thereby enabling the user to control radical density and make films
that were not achievable before in PECVD. This system can be used
to form variable, single gradient layers or a multiple stack of
hundreds to thousands of micro layers with varying properties
between each other.
[0031] FIG. 2b illustrates an alternate embodiment of a power
supply. This embodiment includes an arbitrary waveform generator
141, an amplifier 142, a pulse control 145, a magnetron 150, and a
plasma source antenna 152. In operation, the arbitrary waveform
generator 141 generates a waveform and corresponding voltage that
can be in virtually any form. Next, the amplifier 142 amplifies the
voltage from the arbitrary waveform generator to a usable amount.
In the case of a microwave generator (e.g., the magnetron 150) the
signal could be amplified from +/.sub.--5VDC to 5,000 VDC. Next,
the high voltage signature is applied to the magnetron 150, which
is a high frequency generator. The magnetron 150 generates a power
output carrier (at 2.45 GHZ in this case) that has its amplitude
and or frequency varied based upon the originally generated voltage
signature. Finally, the output from the magnetron is applied to the
source 152 to generate a power modulated plasma.
[0032] Signal modulation can be applied by the pulse control 145 to
the arbitrary waveform generator 141. Signal modulation is a
well-known process in many fields--the most well known being FM
(frequency modulated) and AM (amplitude modulated) radio. But
modulation has not been used before to control film properties and
create layers during PECVD. Many forms of modulation exist that
could be applied to a waveform power level, duty cycle or
frequency, but only a few are described below. Those of skill in
the art will recognize other methods. Note that modulation is
different from simply increasing or decreasing the power or duty
cycle of a power signal into a source.
[0033] FIG. 3 illustrates pulse-width modulation, which varies the
width of pulse widths over time. With pulse-width modulation, the
value of a sample of data is represented by the length of a
pulse.
[0034] FIG. 4 illustrates pulse-amplitude modulation, which is a
form of signal modulation in which the message information is
encoded in the amplitude of a series of signal pulses. In the case
of plasma sources the voltage, current or power level can be
amplitude modulated by whatever percentage desired.
[0035] FIG. 5 illustrates frequency modulation (FM), which is the
encoding of information in either analog or digital form into a
carrier wave by variation of its instantaneous frequency in
accordance with an input signal.
[0036] Referring now to FIGS. 6 and 7, they show two examples of
multi-layer films that could be produced with two differing forms
of modulation, pulse-width and pulse-amplitude modulation. Both of
these figures illustrate the film layers deposited on the substrate
and the corresponding modulated power signal that is used to
generate the plasma. Notice that the power signal is modulated
during the deposition process, which differs from establishing and
leaving initial set points that are static during the deposition
process.
[0037] Referring first to FIG. 6a, it illustrates a variable film
157 produced by pulse-width modulation. In this embodiment, the
cycle between short pulse widths and long pulse widths is
relatively long. This long cycle produces a variable-gradient
coating on the substrate that varies through its thickness from a
flexible, organo-silicon film located next to the substrate to a
rigid, dense SiO2 or SiOxNy film. The film produced by this process
becomes harder and more rigid as it extends out from the
substrate.
[0038] A benefit is realized with this single, variable gradient
layer because the flexible, softer portion of the film bonds better
to the substrate than would the dense, rigid portion. Thus, the
pulse width modulation allows a film to be created that bonds well
with the substrate but also has a hardened outer portion that
resists scratches and that has good barrier properties. This type
of film could not be efficiently created without a modulated power
signal.
[0039] By changing the modulation of the power signal, a multilayer
gradient coating can be deposited on the substrate. FIG. 6b
illustrates this type of substrate and film 160. In this
embodiment, the cycle between short pulse widths and long pulse
widths is relatively short, thereby creating multiple layers. These
individual layers can also vary from less dense to more dense
within a single layer--much as the single gradient layer in FIG. 6a
does.
[0040] In this embodiment, a less-dense, organo-silicon layer is
initially deposited on the substrate. This type of layer bonds best
with the substrate. The next layer is slightly more dense, and the
third layer is an almost pure SiO2 or SiOxNy layer, which is
extremely dense and hard. As the pulse width modulates to shorter
pulse widths, the next layer is again a less-dense, organo-silicon
layer that bonds easily to the dense layer just below. This cycle
can repeat hundreds or even thousands of times to create a
multilayer, gradient film that is extremely hard, resilient, and
with good barrier properties. Further, this film can be produced
with a minimal amount of heat and damage to the substrate.
[0041] FIGS. 7a and 7b illustrate another series of films similar
to those shown in FIGS. 6a and 6b. These films, however, are
created using pulse-amplitude modulation. Again, both a single
gradient film 165 or a multilayer gradient film 170 can be created
using modulation techniques. Note that this process works for
almost any precursor and is not limited to silicon-based
compounds.
[0042] Variable films can be created with other modulation
techniques. In fact, there are many modulation technologies that
could be implemented to effectively control the radical species
density and electromagnetic radiation in relation to time,
including, PWM--Pulse Width Modulation, PAM--Pulse Amplitude
Modulation, PPM--Pulse Position Modulation, AM--Amplitude
modulation, FM--Frequency Modulation, etc. Again, these techniques
involve modulating a power signal during film deposition rather
than setting an initial power point or duty cycle.
[0043] Referring now to FIGS. 8a through 8d, they show an example
of pulse-width modulation and its possible affects on the films
properties for SiO2 and or SiOxNy. A sign wave signal is used to
drive the pulsing frequency at a fixed peak power level to increase
or decrease the short term average power into the plasma. The sign
wave shown is the drive signal, and it also indicates power.
[0044] At the beginning portion (left side) of the FIG. 8a, the
modulation increases the power level per given time interval by
increasing the on-time and decreasing the off-time of the plasma,
thus increasing the instantaneous radical density and
electromagnetic components of the plasma. This process increases
the radical density to the point at which all material was
converted and deposited and a new material is the dominate
contributor to the growing film stack, SiO2 or SiOxNy. FIG. 8b
shows the dense layer formed next to the substrate during this
phase.
[0045] In the center of the drive signal, the on-time is at its
lowest and off-time at its highest value. This effect decreases the
instantaneous radical density to the point at which all material
was consumed and the precursor material again becomes the dominate
contributor to the growing film stack. FIG. 8c shows the
less-dense, more-organic layer formed during the second phase. This
layer is deposited on the first layer.
[0046] Finally in the last portion of the waveform, the process
returns to saturation of the radical density like in the first
portion of the waveform. This phase deposits a hardened, dense
layer. FIG. 8d shows the dense, third layer deposited on the second
layer. Accordingly, the three phases together leaving an inter
layer of organic material between two hard, dense layers--thereby
introducing flexibility into the entire film stack.
[0047] These modulation techniques can be used during inline or
dynamic deposition processes. By utilizing these modulation
techniques with the dynamic deposition process, it is possible to
produce alignment layers for applications such as LCD displays,
thereby replacing the polymide layers presently being used.
[0048] In summary, this discovery allows the user to achieve PECVD
films not possible in the past, possibly with extended film
properties and qualities not possible to date. The higher quality
thin films are achieved from the ability to actively control the
plasmas radical/electromagnetic radiation densities in continuous
way per unit time by contouring the average and or peak power level
per time interval. The drive waveform can be any waveform or even
an arbitrary function. This technique can also be used to control
the localized etching rate when the source and system is configured
to do so.
[0049] In conclusion, the present invention provides, among other
things, a system and method for controlling deposition onto
substrates. Those skilled in the art can readily recognize that
numerous variations and substitutions may be made in the invention,
its use and its configuration to achieve substantially the same
results as achieved by the embodiments described herein.
Accordingly, there is no intention to limit the invention to the
disclosed exemplary forms. Many variations, modifications and
alternative constructions fall within the scope and spirit of the
disclosed invention as expressed in the claims.
* * * * *