U.S. patent application number 11/608833 was filed with the patent office on 2007-05-31 for high-power pulsed magnetron sputtering.
This patent application is currently assigned to ZOND, INC.. Invention is credited to Roman Chistyakov.
Application Number | 20070119701 11/608833 |
Document ID | / |
Family ID | 32028517 |
Filed Date | 2007-05-31 |
United States Patent
Application |
20070119701 |
Kind Code |
A1 |
Chistyakov; Roman |
May 31, 2007 |
High-Power Pulsed Magnetron Sputtering
Abstract
Magnetically enhanced sputtering methods and apparatus are
described. A magnetically enhanced sputtering source according to
the present invention includes an anode and a cathode assembly
having a target that is positioned adjacent to the anode. An
ionization source generates a weakly-ionized plasma proximate to
the anode and the cathode assembly. A magnet is positioned to
generate a magnetic field proximate to the weakly-ionized plasma.
The magnetic field substantially traps electrons in the
weakly-ionized plasma proximate to the sputtering target. A power
supply produces an electric field in a gap between the anode and
the cathode assembly. The electric field generates excited atoms in
the weakly ionized plasma and generates secondary electrons from
the sputtering target. The secondary electrons ionize the excited
atoms, thereby creating a strongly-ionized plasma having ions that
impact a surface of the sputtering target to generate sputtering
flux.
Inventors: |
Chistyakov; Roman; (Andover,
MA) |
Correspondence
Address: |
RAUSCHENBACH PATENT LAW GROUP, LLC
P.O. BOX 387
BEDFORD
MA
01730
US
|
Assignee: |
ZOND, INC.
137A High Street
Mansfield
MA
02048
|
Family ID: |
32028517 |
Appl. No.: |
11/608833 |
Filed: |
December 10, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10065277 |
Sep 30, 2002 |
7147759 |
|
|
11608833 |
Dec 10, 2006 |
|
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Current U.S.
Class: |
204/192.1 ;
204/298.16 |
Current CPC
Class: |
C23C 14/35 20130101;
H01J 37/3408 20130101; H01J 37/32082 20130101 |
Class at
Publication: |
204/192.1 ;
204/298.16 |
International
Class: |
C23C 14/32 20060101
C23C014/32; C23C 14/00 20060101 C23C014/00 |
Claims
1-40. (canceled)
41. A magnetically enhanced sputtering source comprising: a) an
anode; b) a cathode assembly that is positioned adjacent to the
anode, the cathode assembly including a sputtering target; c) an
ionization source that generates a weakly-ionized plasma proximate
to the anode and the cathode assembly; d) a magnet that is
positioned to generate a magnetic field proximate to the
weakly-ionized plasma, the magnetic field substantially trapping
electrons in the weakly-ionized plasma proximate to the sputtering
target; and e) a power supply generating a voltage pulse that
produces an electric field between the cathode assembly and the
anode, the voltage pulse having at least one of an amplitude and a
rise time that increases an excitation rate of ground state atoms
that are present in the weakly-ionized plasma to create a
multi-step ionization process that generates a strongly-ionized
plasma without forming an arc discharge.
42. The sputtering source of claim 41 wherein the power supply
generates a constant power.
43. The sputtering source of claim 41 wherein the power supply
generates a constant voltage.
44. The sputtering source of claim 41 wherein the electric field
comprises a quasi-static electric field.
45. The sputtering source of claim 41 wherein the electric field
comprises a pulsed electric field.
46. The sputtering source of claim 41 wherein the at least one of
the amplitude and the rise time of the voltage pulse is chosen to
causes substantially uniform erosion of the sputtering target.
47. The sputtering source of claim 41 further comprising a
substrate support that is positioned in a path of the sputtering
flux.
48. The sputtering source of claim 47 further comprising a
temperature controller that controls the temperature of the
substrate support.
49. The sputtering source of claim 47 further comprising a bias
voltage power supply that applies a bias voltage to a substrate
that is positioned on the substrate support.
50. The sputtering source of claim 41 wherein the ionization source
is chosen from the group comprising a UV source, an X-ray source,
an electron beam source, and an ion beam source.
51. The sputtering source of claim 41 wherein the sputtering target
is formed of a material chosen from the group comprising a metallic
material, a polymer material, a superconductive material, a
magnetic material, a non-magnetic material, a conductive material,
a non-conductive material, a composite material, a reactive
material, and a refractory material.
52. A method of generating sputtering flux, the method comprising:
a) ionizing a feed gas to generate a weakly-ionized plasma
proximate to a sputtering target; b) generating a magnetic field
proximate to the weakly-ionized plasma, the magnetic field
substantially trapping electrons in the weakly-ionized plasma
proximate to the sputtering target; c) generating a voltage pulse
having at least one of an amplitude and a rise time that increases
an excitation rate of ground state atoms present in the
weakly-ionized plasma to create a multi-step ionization process;
and d) applying the voltage pulse to the weakly-ionized plasma to
generate a strongly-ionized plasma without forming an arc
discharge.
53. The method of claim 52 wherein the voltage pulse generates a
quasi-static electric field.
54. The method of claim 52 further comprising selecting at least
one of the amplitude and the rise time of the voltage pulse to
increase an ionization rate of the strongly-ionized plasma.
55. The method of claim 52 further comprising selecting at least
one of the amplitude and a pulse width of the voltage pulse to
increase an ionization rate of the strongly-ionized plasma.
56. The method of claim 52 further comprising selecting at least
one of the amplitude and a pulse width of the voltage pulse to
cause the strongly-ionized plasma to be substantially uniform in an
area adjacent to a surface of the sputtering target.
57. The method of claim 52 further comprising controlling a
temperature of the film.
58. The method of claim 52 further comprising applying a bias
voltage to the film.
59. The method of claim 52 wherein the ionizing the feed gas
comprises exposing the feed gas to at least one of a UV source, an
X-ray source, an electron beam source, and an ion beam source.
60. A magnetically enhanced sputtering source comprising: a) means
for ionizing a feed gas to generate a weakly-ionized plasma
proximate to a sputtering target; b) means for generating a
magnetic field proximate to the weakly-ionized plasma, the magnetic
field substantially trapping electrons in the weakly-ionized plasma
proximate to the sputtering target; and c) means for generating a
voltage pulse with at least one of an amplitude and a rise time
chosen for generating a multi-step ionization process; and d)
applying the voltage pulse to the weakly-ionized plasma to generate
a strongly ionized plasma.
Description
BACKGROUND OF THE INVENTION
[0001] Sputtering is a well-known technique for depositing films on
substrates. Sputtering is the physical ejection of atoms from a
target surface and is sometimes referred to as physical vapor
deposition (PVD). Ions, such as argon ions, are generated and then
directed to a target surface where the ions physically sputter
target material atoms. The target material atoms ballistically flow
to a substrate where they deposit as a film of target material.
[0002] Diode sputtering systems include a target and an anode.
Sputtering is achieved in a diode sputtering system by establishing
an electrical discharge in a gas between two parallel-plate
electrodes inside a chamber. A potential of several kilovolts is
typically applied between planar electrodes in an inert gas
atmosphere (e.g., argon) at pressures that are between about
10.sup.-1 and 10.sup.-2 Torr. A plasma discharge is then formed.
The plasma discharge is separated from each electrode by what is
referred to as the dark space.
[0003] The plasma discharge has a relatively constant positive
potential with respect to the target. Ions are drawn out of the
plasma, and are accelerated across the cathode dark space. The
target has a lower potential than the region in which the plasma is
formed. Therefore, the target attracts positive ions. Positive ions
move towards the target with a high velocity. Positive ions impact
the target and cause atoms to physically dislodge or sputter from
the target. The sputtered atoms then propagate to a substrate where
they deposit a film of sputtered target material. The plasma is
replenished by electron-ion pairs formed by the collision of
neutral molecules with secondary electrons generated at the target
surface.
[0004] Magnetron sputtering systems use magnetic fields that are
shaped to trap and to concentrate secondary electrons, which are
produced by ion bombardment of the target surface. The plasma
discharge generated by a magnetron sputtering system is located
proximate to the surface of the target and has a high density of
electrons. The high density of electrons causes ionization of the
sputtering gas in a region that is close to the target surface.
[0005] One type of magnetron sputtering system is a planar
magnetron sputtering system. Planar magnetron sputtering systems
are similar in configuration to diode sputtering systems. However,
the magnets (permanent or electromagnets) in planar magnetron
sputtering systems are placed behind the cathode. The magnetic
field lines generated by the magnets enter and leave the target
cathode substantially normal to the cathode surface. Electrons are
trapped in the electric and magnetic fields. The trapped electrons
enhance the efficiency of the discharge and reduce the energy
dissipated by electrons arriving at the substrate.
[0006] Conventional magnetron sputtering systems deposit films that
have relatively low uniformity. However, the film uniformity can be
increased by mechanically moving the substrate and/or the
magnetron, but such systems are relatively complex and expensive to
implement. Conventional magnetron sputtering systems also have
relatively poor target utilization. By poor target utilization, we
mean that the target material erodes in a non-uniform manner.
BRIEF DESCRIPTION OF DRAWINGS
[0007] This invention is described with particularity in the
detailed description. The above and further advantages of this
invention may be better understood by referring to the following
description in conjunction with the accompanying drawings, in which
like numerals indicate like structural elements and features in
various figures. The drawings are not necessarily to scale,
emphasis instead being placed upon illustrating the principles of
the invention.
[0008] FIG. 1 illustrates a cross-sectional view of a known
magnetron sputtering apparatus having a pulsed power source.
[0009] FIG. 2 illustrates a cross-sectional view of an embodiment
of a magnetron sputtering apparatus according to the present
invention.
[0010] FIG. 3 illustrates a cross-sectional view of the anode and
the cathode assembly of the magnetron sputtering apparatus of FIG.
2.
[0011] FIG. 4 illustrates a graphical representation of the applied
power of a pulse as a function of time for periodic pulses applied
to the plasma in the magnetron sputtering system of FIG. 2.
[0012] FIG. 5 illustrates graphical representations of the absolute
value of applied voltage, current, and power as a function of time
for periodic pulses applied to the plasma in the magnetron
sputtering system of FIG. 2.
[0013] FIG. 6A through FIG. 6D illustrate various simulated
magnetic field distributions proximate to the cathode assembly for
various electron ExB drift currents according to the present
invention.
[0014] FIG. 7 illustrates a cross-sectional view of another
embodiment of a magnetron sputtering apparatus according to the
present invention.
[0015] FIG. 8 illustrates a graphical representation of pulse power
as a function of time for periodic pulses applied to the plasma in
the magnetron sputtering system of FIG. 7.
[0016] FIG. 9A through FIG. 9C are cross-sectional views of various
embodiments of cathode assemblies according to the present
invention.
[0017] FIG. 10 illustrates a cross-sectional view of another
illustrative embodiment of a magnetron sputtering apparatus
according to the present invention.
[0018] FIG. 11 is a cross-sectional view of another illustrative
embodiment of a magnetron sputtering apparatus according to the
present invention.
[0019] FIG. 12 is a flowchart of an illustrative process of sputter
deposition according to the present invention.
[0020] FIG. 13 is a flowchart of an illustrative process of
controlling sputtering rate according to the present invention.
DETAILED DESCRIPTION
[0021] The magnetic and electric fields in magnetron sputtering
systems are concentrated in narrow regions close to the surface of
the target. These narrow regions are located between the poles of
the magnets used for producing the magnetic field. Most of the
ionization of the sputtering gas occurs in these localized regions.
The location of the ionization regions causes a non-uniform erosion
or wear of the target that results in poor target utilization.
[0022] Increasing the power applied between the target and the
anode can increase the amount of ionized gas and, therefore,
increase the target utilization. However, undesirable target
heating and target damage can occur. Furthermore, increasing the
voltage applied between the target and the anode increases the
probability of establishing an undesirable electrical discharge (an
electrical arc) in the process chamber.
[0023] Pulsing the power applied to the plasma can be advantageous
since the average discharge power can remain low while relatively
large power pulses can be periodically applied. Additionally, the
duration of these large voltage pulses can be preset so as to
reduce the probability of establishing an electrical breakdown
condition leading to an undesirable electrical discharge. However,
very large power pulses can still result in undesirable electrical
discharges and undesirable target heating regardless of their
duration.
[0024] FIG. 1 illustrates a cross-sectional view of a known
magnetron sputtering apparatus 100 having a pulsed power source
102. The known magnetron sputtering apparatus 100 includes a vacuum
chamber 104 where the sputtering process is performed. The vacuum
chamber 104 is positioned in fluid communication with a vacuum pump
106 via a conduit 108. The vacuum pump 106 is adapted to evacuate
the vacuum chamber 104 to high vacuum. The pressure inside the
vacuum chamber 104 is generally less than 100 Pa during operation.
A feed gas source 109, such as an argon gas source, is introduced
into the vacuum chamber 104 through a gas inlet 110. The gas flow
is controlled by a valve 112.
[0025] The magnetron sputtering apparatus 100 also includes a
cathode assembly 114 having a target material 116. The cathode
assembly 114 is generally in the shape of a circular disk. The
cathode assembly 114 is electrically connected to a first output
118 of the pulsed power supply 102 with an electrical transmission
line 120. The cathode assembly 114 is typically coupled to the
negative potential of the pulsed power supply 102. In order to
isolate the cathode assembly 114 from the vacuum chamber 104, an
insulator 122 can be used to pass the electrical transmission line
120 through a wall of the vacuum chamber 104. A grounded shield 124
can be positioned behind the cathode assembly 114 to protect a
magnet 126 from bombarding ions. The magnet 126 shown in FIG. 1 is
generally ring-shaped having its south pole 127 on the inside of
the ring and its north pole 128 on the outside of the ring. Many
other magnet configurations can also be used.
[0026] An anode 130 is positioned in the vacuum chamber 104
proximate to the cathode assembly 114. The anode 130 is typically
coupled to ground. A second output 132 of the pulsed power supply
102 is also typically coupled to ground. A substrate 134 is
positioned in the vacuum chamber 104 on a substrate support 135 to
receive the sputtered target material 116. The substrate 134 can be
electrically connected to a bias voltage power supply 136 with a
transmission line 138. In order to isolate the bias voltage power
supply 136 from the vacuum chamber 104, an insulator 140 can be
used to pass the electrical transmission line 138 through a wall of
the vacuum chamber 104.
[0027] In operation, the pulsed power supply 102 applies a voltage
pulse between the cathode assembly 114 and the anode 130 that has a
sufficient amplitude to ionize the argon feed gas in the vacuum
chamber 104. This typical ionization process is referred to as
direct ionization or atomic ionization by electron impact and can
be described as follows:
Ar+e.sup.-.fwdarw..fwdarw.Ar.sup.++2e.sup.-
[0028] where Ar represents a neutral argon atom in the feed gas and
e.sup.- represents an ionizing electron generated in response to
the voltage pulse applied between the cathode assembly 114 and the
anode 130. The collision between the neutral argon atom and the
ionizing electron results in an argon ion (Ar.sup.+) and two
electrons.
[0029] The negatively biased cathode assembly 114 attracts
positively charged ions with sufficient acceleration so that the
ions sputter the target material 116. A portion of the sputtered
target material 116 is deposited on the substrate 134.
[0030] The electrons, which cause the ionization, are generally
confined by the magnetic fields produced by the magnet 126. The
magnetic confinement is strongest in a confinement region 142 where
there is relatively low magnetic field intensity. The confinement
region 142 is substantially in the shape of a ring that is located
proximate to the target material. Generally, a higher concentration
of positively charged ions in the plasma is present in the
confinement region 142 than elsewhere in the chamber 104.
Consequently, the target material 116 is eroded rapidly in areas
directly adjacent to the higher concentration of positively charged
ions. The rapid erosion in these areas results in undesirable
non-uniform erosion of the target material 116 and, thus relatively
poor target utilization.
[0031] Dramatically increasing the power applied to the plasma can
result in more uniform erosion of the target material 116. However,
the amount of applied power necessary to achieve this increased
uniformity can increase the probability of generating an electrical
breakdown condition that leads to an undesirable electrical
discharge between the cathode assembly 114 and the anode 130
regardless of the duration of the pulses. An undesirable electrical
discharge will corrupt the sputtering process and cause
contamination in the vacuum chamber 104. Additionally, the
increased power can overheat the target and cause target
damage.
[0032] FIG. 2 illustrates a cross-sectional view of an embodiment
of a magnetron sputtering apparatus 200 according to the present
invention. The magnetron sputtering apparatus 200 includes a
chamber 202, such as a vacuum chamber. The chamber 202 is coupled
in fluid communication to a vacuum system 204 through a vacuum
control system 206. In one embodiment, the chamber 202 is
electrically coupled to ground potential. The chamber 202 is
coupled by one or more gas lines 207 to a feed gas source 208. In
one embodiment, the gas lines 207 are isolated from the chamber and
other components by insulators 209. Additionally, the gas lines 207
can be isolated from the feed gas source using in-line insulating
couplers (not shown). A gas flow control system 210 controls the
gas flow to the chamber 202. The gas source 208 can contain any
feed gas, such as argon. In some embodiments, the feed gas includes
a mixture of gases. In some embodiments, the feed gas includes a
reactive gas.
[0033] A substrate 211 to be sputter coated is supported in the
chamber 202 by a substrate support 212. The substrate 211 can be
any type of work piece such as a semiconductor wafer. In one
embodiment, the substrate support 212 is electrically coupled to an
output 213 of a bias voltage source 214. An insulator 215 isolates
the bias voltage source 214 from a wall of the chamber 202. In one
embodiment, the bias voltage source 214 is an alternating current
(AC) power source, such as a radio frequency (RF) power source. In
other embodiments (not shown), the substrate support 212 is coupled
to ground potential or is electrically floating.
[0034] The magnetron sputtering apparatus 200 also includes a
cathode assembly 216. In one embodiment, the cathode assembly 216
includes a cathode 218 and a sputtering target 220 composed of
target material. The sputtering target 220 is in contact with the
cathode 218. In one embodiment, the sputtering target 220 is
positioned inside the cathode 218. The distance from the sputtering
target 220 to the substrate 211 can vary from a few centimeters to
about one hundred centimeters.
[0035] The target material can be any material suitable for
sputtering. For example, the target material can be a metallic
material, polymer material, superconductive material, magnetic
material including ferromagnetic material, non-magnetic material,
conductive material, non-conductive material, composite material,
reactive material, or a refractory material.
[0036] The cathode assembly 216 is coupled to an output 222 of a
matching unit 224. An insulator 226 isolates the cathode assembly
216 from a grounded wall of the chamber 202. An input 230 of the
matching unit 224 is coupled to a first output 232 of a pulsed
power supply 234. A second output 236 of the pulsed power supply
234 is coupled to an anode 238. An insulator 240 isolates the anode
238 from a grounded wall of the chamber 202. Another insulator 242
isolates the anode 238 from the cathode assembly 216.
[0037] In one embodiment, the first output 232 of the pulsed power
supply 234 is directly coupled to the cathode assembly 216 (not
shown). In one embodiment, the second output 236 of the pulsed
power supply 234 is coupled to ground (not shown). In this
embodiment, the anode 238 is also coupled to ground (not
shown).
[0038] In one embodiment (not shown), the first output 232 of the
pulsed power supply 234 couples a negative voltage impulse to the
cathode assembly 216. In another embodiment (not shown), the first
output 232 of the pulsed power supply 234 couples a positive
voltage impulse to the anode 238.
[0039] In one embodiment, the pulsed power supply 234 generates
peak voltage levels of up to about 30,000V. Typical operating
voltages are generally between about 100V and 30 kV. In one
embodiment, the pulsed power supply 234 generates peak current
levels of less than one ampere to about 5,000 A or more depending
on the size of the magnetron sputtering system. Typical operating
currents varying from less than a few amperes to more than a few
thousand amperes depending on the size of the magnetron sputtering
system. In one embodiment, the power pulses have a repetition rate
that is below 1 kHz. In one embodiment, the pulse width of the
pulses generated by the pulsed power supply 234 is substantially
between about one microsecond and several seconds.
[0040] The anode 238 is positioned so as to form a gap 244 between
the anode 238 and the cathode assembly 216 that is sufficient to
allow current to flow through a region 245 between the anode 238
and the cathode assembly 216. In one embodiment, the gap 244 is
between approximately 0.3 centimeters (0.3 cm) and ten centimeters
(10 cm). The volume of region 245 is determined by the area of the
sputtering target 220. The gap 244 and the total volume of region
245 are parameters in the ionization process as will be discussed
with reference to FIG. 3.
[0041] An anode shield 248 is positioned adjacent to the anode 238
so as to protect the interior wall of the chamber 202 from being
exposed to sputtered target material. Additionally, the anode
shield 248 can function as an electric shield to electrically
isolate the anode 238 from the plasma. In one embodiment, the anode
shield 248 is coupled to ground potential. An insulator 250 is
positioned to isolate the anode shield 248 from the anode 238.
[0042] The magnetron sputtering apparatus 200 also includes a
magnet assembly 252. In one embodiment, the magnet assembly 252 is
adapted to create a magnetic field 254 proximate to the cathode
assembly 216. The magnet assembly 252 can include permanent magnets
256, or alternatively, electro-magnets (not shown). The
configuration of the magnet assembly 252 can be varied depending on
the desired shape and strength of the magnetic field 254. In
alternate embodiments, the magnet assembly can have either a
balanced or unbalanced configuration.
[0043] In one embodiment, the magnet assembly 252 includes
switching electro-magnets, which generate a pulsed magnetic field
proximate to the cathode assembly 216. In some embodiments,
additional magnet assemblies (not shown) can be placed at various
locations throughout the chamber 202 to direct different types of
sputtered target materials to the substrate 212.
[0044] In one embodiment, the magnetron sputtering apparatus 200 is
operated by generating the magnetic field 254 proximate to the
cathode assembly 216. In the embodiment shown in FIG. 2, the
permanent magnets 256 continuously generate the magnetic field 254.
In other embodiments, the magnetic field 254 is generated by
energizing a current source (not shown) that is coupled to
electro-magnets. In one embodiment, the strength of the magnetic
field 254 is between about one hundred and two thousand gauss.
After the magnetic field 254 is generated, the feed gas from the
gas source 208 is supplied to the chamber 202 by the gas flow
control system 210. In one embodiment, the feed gas is supplied to
the chamber 202 directly between the cathode assembly 216 and the
anode 238.
[0045] In one embodiment, the pulsed power supply 234 is a
component in an ionization source that generates the weakly-ionized
plasma. The pulsed power supply applies a voltage pulse between the
cathode assembly 216 and the anode 238. In one embodiment, the
pulsed power supply 234 applies a negative voltage pulse to the
cathode assembly 216. The amplitude and shape of the voltage pulse
are such that a weakly-ionized plasma is generated in the region
246 between the anode 238 and the cathode assembly 216. The
weakly-ionized plasma is also referred to as a pre-ionized plasma.
In one embodiment, the peak plasma density of the pre-ionized
plasma is between about 10.sup.6 and 10.sup.12 cm.sup.-3 for argon
feed gas. The pressure in the chamber can vary from about 10.sup.-3
to 10 Torr. The peak plasma density of the pre-ionized plasma
depends on the properties of the specific magnetron sputtering
system and is a function of the location of the measurement in the
pre-ionized plasma.
[0046] In one embodiment, the pulsed power supply 234 generates a
low power pulse having an initial voltage of between about one
hundred volts and five kilovolts with a discharge current of
between about 0.1 amperes and one hundred amperes in order to
generate the weakly-ionized plasma. In some embodiments the width
of the pulse can be in on the order of 0.1 microseconds up to one
hundred seconds. Specific parameters of the pulse are discussed
herein in more detail in connection with FIG. 4 and FIG. 5.
[0047] In one embodiment, prior to the generating of the
weakly-ionized plasma, the pulsed power supply 234 generates a
potential difference between the cathode assembly 216 and the anode
238 before the feed gas is supplied between the cathode assembly
216 and the anode 238.
[0048] In another embodiment, a direct current (DC) power supply
(not shown) is used to generate and maintain the weakly-ionized or
pre-ionized plasma. In this embodiment, the DC power supply is
adapted to generate a voltage that is large enough to ignite the
pre-ionized plasma. In one embodiment, the DC power supply
generates an initial voltage of several kilovolts with a discharge
current of several hundred milliamps between the cathode assembly
216 and the anode 238 in order to generate and maintain the
pre-ionized plasma. The value of the current depends on the power
level generated by the power supply and is a function of the size
of the magnetron. Additionally, the presence of a magnetic field in
the region 245 can have a dramatic effect on the value of the
applied voltage and current required to generate the weakly-ionized
plasma.
[0049] In some embodiments, the DC power supply generates a current
that is between about 1 mA and 100 A depending on the size of the
magnetron and the strength of a magnetic field in the region 245.
In one embodiment, before generating the weakly-ionized plasma, the
DC power supply is adapted to generate and maintain an initial
voltage between the cathode assembly 216 and the anode 238 before
the introduction of the feed gas.
[0050] The pre-ionized or weakly-ionized plasma can be generated by
numerous other techniques including UV radiation techniques, X-ray
techniques, electron beam techniques, ion beam techniques, or
ionizing filament techniques, for example. In one embodiment, an
alternating current (AC) power supply can be used. Generally, an AC
power supply can require less power to generate a weakly-ionized
plasma than a DC power supply.
[0051] Forming a weakly-ionized or pre-ionized plasma substantially
eliminates the probability of establishing a breakdown condition in
the chamber 202 when high-power pulses are applied between the
cathode assembly 216 and the anode 238. The probability of
establishing a breakdown condition is substantially eliminated
because the weakly-ionized plasma has a low-level of ionization
that provides electrical conductivity through the plasma. This
conductivity substantially prevents the formation of a breakdown
condition, even when high power is applied to the plasma.
[0052] Once the weakly-ionized plasma is formed, high-power pulses
are then generated between the cathode assembly 216 and the anode
238. In one embodiment, the pulsed power supply 234 generates the
high-power pulses. The desired power level of the high-power pulse
depends on several factors including the desired deposition rate,
the density of the pre-ionized plasma, and the size of the
magnetron, for example. In one embodiment, the power level of the
high-power pulse is in the range of about one kilowatt to about ten
megawatts or more. This power level range corresponds to target
densities that are on the order of 0.01 kilowatt per square
centimeter to more than ten kilowatts per square centimeter.
[0053] Each of the high-power pulses are maintained for a
predetermined time that, in alternate embodiments, is approximately
one microsecond to ten seconds. The repetition frequency or
repetition rate of the high-power pulses, in one embodiment, is in
the range of between about 0.1 Hz to 1 kHz. In order to minimize
undesirable target heating, the average power generated by the
pulsed power supply 234 can be less than one megawatt depending on
the size of the magnetron. In one embodiment, the thermal energy in
the sputtering target 220 is conducted away or dissipated by liquid
or gas cooling such as helium cooling (not shown).
[0054] The high-power pulses generate a strong electric field
between the cathode assembly 216 and the anode 238. This strong
electric field is substantially located in the region 245 that is
in the gap 244 between the cathode assembly 216 and the anode 238.
In one embodiment, the electric field is a pulsed electric field.
In another embodiment, the electric field is a quasi-static
electric field. By quasi-static electric field, we mean an electric
field that has a characteristic time of electric field variation
that is much greater than the collision time for electrons with
neutral gas particles. Such a time of electric field variation can
be on the order of ten seconds. The strength and the position of
the strong electric field will be discussed in more detail with
reference to FIG. 3.
[0055] The high-power pulses generate a highly-ionized or a
strongly-ionized plasma from the weakly-ionized plasma. The
discharge current density that is formed from this strongly-ionized
plasma can be as high as about five-hundred amperes per squared
centimeter or more for a pressure that is as high as about ten
Torr. Since the sputtering target 220 is typically negatively
biased, the positively charged ions in the strongly-ionized plasma
accelerate at high velocity towards the sputtering target 220. The
accelerated ions impact the surface of the sputtering target 220,
causing the target material to be sputtered. The strongly-ionized
plasma of the present invention results in a very high sputtering
rate of the target material.
[0056] In addition, the strongly-ionized plasma tends to diffuse
homogenously in the region 246. The homogenous diffusion results in
accelerated ions impacting the surface of the sputtering target 220
in a more uniform manner than with conventional magnetron
sputtering. Consequently, the surface of the sputtering target 220
is eroded more evenly and, thus higher target utilization is
achieved. Furthermore, since the target material is sputtered more
uniformly across the surface of the sputtering target 220, the
uniformity and homogeneity of the material deposited on the
substrate 211 is also increased without the necessity of rotating
the substrate 211 and/or the magnet assembly 252. The physical
mechanism responsible for this homogenous diffusion is described
with reference to FIG. 6A through FIG. 6D.
[0057] In one embodiment, the high-power pulsed magnetron
sputtering system 200 of the present invention generates a
relatively high electron temperature plasma and a relatively high
density plasma. One application for the high-power pulsed magnetron
sputtering system 200 of the present invention is ionized physical
vapor deposition (IPVD), which is a technique that converts neutral
sputtered atoms into positive ions to enhance the sputtering
process.
[0058] FIG. 3 illustrates a cross-sectional view of the cathode
assembly 216 and the anode 238 of FIG. 2. In one embodiment, the
strong electric field 260 is located in the region 245 between the
cathode assembly 216 and the anode 238. The strong electric field
260 facilitates a multi-step ionization process that substantially
increases the rate at which the strongly-ionized plasma is
formed.
[0059] The feed gas 264 flows between the cathode assembly 216 and
the anode 238. A pre-ionizing voltage is applied between the
cathode assembly 216 and the anode 238 across the feed gas 264
which forms the weakly-ionized plasma. The weakly-ionized plasma is
generally formed in the region 245 and diffuses to a region 266 as
the feed gas 264 continues to flow. The electrons in the
weakly-ionized plasma are substantially trapped in the region 266
by the magnetic field 254. In one embodiment (not shown), the
magnetic field 254 is generated in the region 245 to substantially
trap electrons where the weakly-ionized plasma is ignited.
[0060] After the formation of the weakly-ionized plasma, a
high-power pulse is then applied between the cathode assembly 216
and the anode 238. This high-power pulse generates the strong
electric field 260 in the region 245 between the cathode assembly
216 and the anode 238. The strong electric field 260 results in
collisions occurring between neutral atoms and ions in the weakly
ionized plasma. These collisions generate numerous excited atoms in
the weakly-ionized plasma. The accumulation of excited atoms in the
weakly-ionized plasma alters the ionization process. Instead of
direct ionization, the strongly-ionized plasma is generated by a
multi-step ionization process having an efficiency that increases
as the density of excited atoms in the weakly-ionized plasma
increases.
[0061] The distance or gap 244 between the cathode assembly 216 and
the anode 238 is chosen so as to maximize the rate of excitation of
the atoms. The value of the electric field 260 in the region 245
depends on the voltage level applied by the pulsed power supply 234
(FIG. 2) and the size of the gap 244 between the anode 238 and the
cathode assembly 216. In alternative embodiments, the strength of
the electric field 260 can vary between about 10 V/cm and 10.sup.5
V/cm depending on various parameters and operating conditions of
the magnetron system. In some embodiments, the gap 244 can be
between about 0.30 cm and about 10 cm depending on various
parameters of the process. In one embodiment, the electric field
260 in the region 245 is rapidly applied to the pre-ionized or
weakly-ionized plasma. In some embodiments, the rapidly applied
electric field 260 is generated by a voltage pulse having a rise
time that is between about 0.1 microsecond and ten seconds.
[0062] In one embodiment, the dimensions of the gap 244 and the
parameters of the applied electric field 260 are varied in order to
determine the optimum condition for a relatively high rate of
excitation of the atoms in the region 245. For example, an argon
atom requires an energy of about 11.55 eV to become excited. Thus,
as the feed gas 264 flows through the region 245, the
weakly-ionized plasma is formed and the atoms in the weakly-ionized
plasma undergo a stepwise ionization process. The excited atoms in
the weakly-ionized plasma then encounter the electrons that are
trapped in the region 266 by the magnetic field 254. Since excited
atoms only require about 4 eV of energy to ionize while neutral
atoms require about 15.76 eV of energy to ionize, the excited atoms
will ionize at a much higher rate than neutral atoms. In one
embodiment, ions in the strongly-ionized plasma bombard the
sputtering target 220 causing secondary electron emission from the
sputtering target 220. These secondary electrons are substantially
trapped by the magnetic field 254 and interact with any neutral or
excited atoms in the strongly-ionized plasma. This process further
increases the density of ions in the strongly-ionized plasma as the
feed gas 264 is replenished.
[0063] The multi-step ionization process corresponding to the rapid
application of the electric field 260 can be described as follows:
Ar+e.sup.-.fwdarw.Ar* +e.sup.- Ar*+e.sup.-.fwdarw.Ar.sup.++2e where
Ar represents a neutral argon atom in the feed gas and e.sup.-
represents an ionizing electron generated in response to a
pre-ionized plasma, when sufficient voltage is applied between the
cathode assembly 216 and the anode 238. Additionally, Ar*
represents an excited argon atom in the weakly-ionized plasma. The
collision between the excited argon atom and the ionizing electron
results in an argon ion (Ar.sup.+30) and two electrons.
[0064] As previously discussed, the excited argon atoms generally
require less energy to become ionized than neutral argon atoms.
Thus, the excited atoms tend to more rapidly ionize near the
surface of the sputtering target 220 than the neutral argon atoms.
As the density of the excited atoms in the plasma increases, the
efficiency of the ionization process rapidly increases. The
increased efficiency eventually results in an avalanche-like
increase in the density of the strongly-ionized plasma. Under
appropriate excitation conditions, the proportion of the energy
applied to the weakly-ionized plasma which is transformed to the
excited atoms is very high for a pulsed discharge in the feed
gas.
[0065] Thus, in one embodiment of the invention, high power pulses
are applied to a weakly-ionized plasma across the gap 244 to
generate a strong electric field between the anode 238 and the
cathode assembly 216. This strong electric field generates excited
atoms in the weakly-ionized plasma. The excited atoms are rapidly
ionized by secondary electrons emitted by the sputtering target
220. This rapid ionization results in a strongly-ionized plasma
having a large ion density being formed in an area proximate to the
cathode assembly 216.
[0066] FIG. 4 illustrates a graphical representation 300 of the
applied power of a pulse as a function of time for periodic pulses
applied to the plasma in the magnetron sputtering system of FIG. 2.
At time t.sub.0, the feed gas from the gas source 208 flows into
the chamber 202 before the pulsed power supply 234 is activated.
The time required for a sufficient quantity of gas to flow from the
gas source 208 into the chamber 202 depends on several factors
including the flow rate of the gas and the desired pressure in the
chamber 202.
[0067] In one embodiment (not shown), the pulsed power supply 234
is activated before the feed gas flows into the chamber 202. In
this embodiment, the feed gas is injected between the anode 238 and
the cathode assembly 216 where it is ignited by the pulsed power
supply 234 to generate the weakly-ionized plasma.
[0068] In one embodiment, the feed gas flows between the anode 238
and the cathode assembly 216 between time t.sub.0 and time t.sub.1.
At time t.sub.1, the pulsed power supply 234 generates a pulse 302
between the cathode assembly 216 and the anode 238 that has a power
level between about 0.01 kW and 100 kW depending on the size of the
magnetron. The pulse 302 is sufficient to ignite the feed gas to
generate the weakly-ionized plasma.
[0069] In another embodiment (not shown), the pulsed power supply
234 applies a potential in the gap 244 between the cathode assembly
216 and the anode 238 before the feed gas from the gas source 208
is delivered into the chamber 202. In this embodiment, the feed gas
is ignited as it flows between the cathode assembly 216 and the
anode 238. In another embodiment, the pulsed power supply 234
generates the pulse 302 between the cathode assembly 216 and the
anode 238 when the feed gas from the gas source 208 is delivered
into the chamber 202.
[0070] The power generated by the pulsed power supply 234 partially
ionizes the gas that is located in the region 245 between the
cathode assembly 216 and the anode 238. The partially ionized gas
is also referred to as a weakly-ionized plasma or a pre-ionized
plasma. As described herein, the formation of weakly-ionized plasma
substantially eliminates the possibility of creating a breakdown
condition when high-power pulses are applied to the weakly-ionized
plasma.
[0071] In one embodiment, the power is continuously applied for
between about one microsecond and one hundred seconds to allow the
pre-ionized plasma to form and be maintained at a sufficient plasma
density. In one embodiment, the power from the pulsed power supply
234 is continuously applied after the weakly-ionized plasma is
ignited to maintain the weakly-ionized plasma. The pulsed power
supply 234 can be designed so as to generate a continuous nominal
power in order to generate and sustain the weakly-ionized plasma
until a high-power pulse is delivered by the pulsed power supply
234.
[0072] At time t.sub.2, the pulsed power supply 234 delivers a
high-power pulse 304 across the weakly-ionized plasma. In some
embodiments, the high-power pulse 304 has a power that is in the
range of between about one kilowatt to ten megawatts depending on
the size of the magnetron. The high-power pulse has a leading edge
306 with a rise time that is between about 0.1 microseconds and ten
seconds
[0073] The high-power pulse 304 has a power and a pulse width that
is sufficient to transform the weakly-ionized plasma to a
strongly-ionized plasma. In one embodiment, the high-power pulse
304 is applied for a time that is in the range of between about ten
microseconds and ten seconds. At time t.sub.4, the high-power pulse
304 is terminated.
[0074] The power supply 224 maintains the weakly-ionized plasma
after the delivery of the high-power pulse 304 by applying
background power that, in one embodiment, is between about 0.01 kW
and 100 kW. The background power can be a pulsed or continuously
applied power that maintains the pre-ionization condition in the
plasma, while the pulsed power supply 234 prepares to deliver
another high-power pulse 308.
[0075] At time t.sub.5, the pulsed power supply 234 delivers
another high-power pulse 308. The repetition rate between the
high-power pulses 304, 308 is, in one embodiment, between about 0.1
Hz and 1 kHz. The particular size, shape, width, and frequency of
the high-power pulses 304, 308 depend on various factors including
process parameters, the design of the pulsed power supply 234, the
size of the magnetron, and the design of the sputter system. The
shape and duration of the leading edge 308 and the trailing edge
310 of the high-power pulse 304 is chosen to sustain the
weakly-ionized plasma while controlling the rate of ionization of
the strongly-ionized plasma. In one embodiment, the particular
size, shape, width, and frequency of the high-power pulse 304 is
chosen to control the rate of sputtering of the target
material.
[0076] FIG. 5 illustrates graphical representations 320, 322, and
324 of the absolute value of applied voltage, current, and power,
respectively, as a function of time for periodic pulses applied to
the plasma in the magnetron sputtering system of FIG. 2. In one
embodiment, at time t.sub.0 (not shown), the feed gas from the gas
source 208 flows into the chamber 202 before the pulsed power
supply 234 is activated. The time required for a sufficient
quantity of gas to flow from the gas source 208 into the chamber
202 depends on several factors including the flow rate of the gas
and the desired pressure in the chamber 202.
[0077] In the embodiment shown in FIG. 5, the power supply 238
generates a constant power. At time t.sub.1, the pulsed power
supply 234 generates a voltage 326 across the anode 238 and the
cathode assembly 216. In one embodiment, the voltage 326 is
approximately between one hundred and two thousand volts. The
period between time t.sub.0 and time t.sub.1 (not shown) can be on
the order of several microseconds up to several milliseconds. At
time t.sub.1, the current 328 and the power 330 have constant
value.
[0078] Between time t.sub.1 and time t.sub.2, the voltage 326, the
current 328, and the power 326 remain constant as the
weakly-ionized plasma is generated. The voltage 332 at time t.sub.2
is between about 100V and 2,000V. The current 334 at time t.sub.2
is between about 0.1 A and 100 A. The power 336 delivered at time
t.sub.2 is between about 0.01 kW and 100 kW.
[0079] The power 336 generated by the pulsed power supply 234
partially ionizes the gas that is located between the cathode
assembly 216 and the anode 238. The partially ionized gas is also
referred to as a weakly-ionized plasma or a pre-ionized plasma. As
described herein, the formation of weakly-ionized plasma
substantially eliminates the possibility of creating a breakdown
condition when high-power pulses are applied to the weakly-ionized
plasma. The suppression of this breakdown condition substantially
eliminates the occurrence of undesirable arcing in the chamber
202.
[0080] In one embodiment, the period between time t.sub.1 and time
t.sub.2 is between about one microsecond and one hundred seconds to
allow the pre-ionized plasma to form and be maintained at a
sufficient plasma density. In one embodiment, the power 336 from
the pulsed power supply 234 is continuously applied to maintain the
weakly-ionized plasma. The pulsed power supply 234 can be designed
so as to output a continuous nominal power into order to sustain
the weakly-ionized plasma.
[0081] Between time t.sub.2 and time t.sub.3, the pulsed power
supply 234 delivers a large voltage pulse 338 across the
weakly-ionized plasma. In some embodiments, the large voltage pulse
338 has a voltage that is in the range of two hundred to thirty
thousand volts. In some embodiment, the period between time t.sub.2
and time t.sub.3 is between about 0.1 microseconds and ten seconds.
The large voltage pulse 338 is applied between time t.sub.3 and
time t.sub.4, before the current across the plasma begins to
increase. In one embodiment, the time period between time t.sub.3
and time t.sub.4 can be between about one microsecond and ten
seconds.
[0082] Between time t.sub.4 and time t.sub.5, the voltage 340 drops
as the current 342 increases. The power 344 also increases between
time t.sub.4 and time t.sub.5, until a quasi-stationary state
exists between the voltage 346 and the current 348. The period
between time t.sub.4 and time t.sub.5 can be on the order of one to
one hundred microseconds.
[0083] In one embodiment, at time t.sub.5, the voltage 346 is
between about one hundred and thirty thousand volts, the current
348 is between about one hundred and five thousand amperes and the
power 350 is between about one kilowatt and ten megawatts. The
power 350 is continuously applied to the plasma until time t.sub.6.
In one embodiment, the period between time t.sub.5, and time
t.sub.6 is approximately between one microsecond and ten
seconds.
[0084] The pulsed power supply 234 delivers a high-power pulse
having a maximum power 350 and a pulse width that is sufficient to
transform the weakly-ionized plasma to a strongly-ionized plasma.
At time t.sub.6, the maximum power 350 is terminated. In one
embodiment, the pulsed power supply 234 continues to supply a
background power that is sufficient to maintain the plasma after
time t.sub.6.
[0085] In one embodiment, the power supply 234 maintains the plasma
after the delivery of the high-power pulse by continuing to apply a
power 352 that can be between about 0.01 kW and 100 kW to the
plasma. The continuously generated power maintains the
pre-ionization condition in the plasma, while the pulsed power
supply 234 prepares to deliver the next high-power pulse.
[0086] At time t.sub.7, the pulsed power supply 234 delivers the
next high-power pulse (not shown). In one embodiment, the
repetition rate between the high-power pulses is between about 0.1
Hz and 1 kHz. The particular size, shape, width, and frequency of
the high-power pulses depend on various factors including process
parameters, the design of the pulsed power supply 234, the size of
the magnetron, and the design of the sputter system.
[0087] In another embodiment (not shown), the power supply 234
generates a constant voltage. In this embodiment, the applied
voltage 320 is continuously applied from time t.sub.2 until time
t.sub.6. The current 322 and the power 324 change to keep the
applied voltage 320 constant. The current 322 and the power 224
rise until time t.sub.6, where the voltage 320 is terminated.
[0088] FIG. 6A through FIG. 6D illustrate various simulated
magnetic field distributions 400, 402, 404, and 406 that are
proximate to the cathode assembly 116 for various electron ExB
drift currents in the magnetron sputtering apparatus 200 of FIG. 2.
The simulated magnetic fields distributions 400, 402, 404, and 406
indicate that high-power plasmas having high current density tend
to diffuse homogeneously in the area 246 of the magnetron
sputtering apparatus 200 of FIG. 2.
[0089] The high-power pulses between the cathode assembly 216 and
the anode 238 generate secondary electrons from the cathode
assembly 216 that move in a substantially circular motion proximate
to the cathode assembly 216 according to crossed electric and
magnetic fields. The substantially circular motion of the electrons
generate an electron ExB drift current. The magnitude of the
electron ExB drift current is proportional to the magnitude of the
discharge current in the plasma and, in one embodiment, is
approximately in the range of between about three and ten times the
magnitude of the discharge current.
[0090] In one embodiment, the substantially circular electron ExB
drift current generates a magnetic field that interacts with the
magnetic field generated by the magnet assembly 252. In one
embodiment, the magnetic field generated by the electron ExB drift
current has a direction that is substantially opposite to the
direction of the magnetic field generated by the magnet assembly
252. The magnitude of the magnetic field generated by the electron
ExB drift current increases with increased electron ExB drift
current. The homogeneous diffusion of the strongly-ionized plasma
in the region 246 is caused, at least in part, by the interaction
of the magnetic field generated by the magnet assembly 252 and the
magnetic field generated by the electron ExB drift current.
[0091] In one embodiment, the electron ExB drift current defines a
substantially circular shape for low current density plasma.
However, as the current density of the plasma increases, the
substantially circular electron ExB drift current tends to describe
a more complex shape as the interaction of the magnetic field
generated by the magnet assembly 252, the electric field generated
by the high-power pulse, and the magnetic field generated by the
electron ExB drift current becomes more acute. For example, in one
embodiment, the electron ExB drift current has a substantially
cycloidal shape. Thus, the exact shape of the electron ExB drift
current can be quite elaborate and depends on various factors.
[0092] For example, FIG. 6A illustrates the magnetic field lines
408 produced from the interaction of the magnetic field generated
by the magnet assembly 252 and the magnetic field generated by an
electron ExB drift current 410 illustrated by a substantially
circularly shaped ring. The electron ExB drift current 410 is
generated proximate to the cathode assembly 216.
[0093] In the example shown in FIG. 6A, the electron ExB drift
current 410 is approximately one hundred amperes (100 A). In one
embodiment of the invention, the electron ExB drift current 410 is
between approximately three and ten times as great as the discharge
current. Thus, in the example shown in FIG. 6A, the discharge
current is approximately between 10 A and 30 A.
[0094] The magnetic field lines 408 shown in FIG. 6A indicate that
the magnetic field generated by the magnet assembly 252 is
substantially undisturbed by the relatively small magnetic field
that is generated by the relatively small electron ExB drift
current 410.
[0095] FIG. 6B illustrates the magnetic field lines 412 produced
from the interaction of the magnetic field generated by the magnet
assembly 252 and the magnetic field generated by an electron ExB
drift current 414. The electron ExB drift current 414 is generated
proximate to the cathode assembly 216.
[0096] In the example shown in FIG. 6B, the electron ExB drift
current 414 is approximately 300 A. Since the electron ExB drift
current 414 is typically between about three and ten times as great
as the discharge current, the discharge current in this example is
approximately between 30 A and 100 A.
[0097] The magnetic field lines 412 that are generated by the
magnet assembly 252 are substantially undisturbed by the relatively
small magnetic field generated by the relatively small electron ExB
drift current 414. However, the magnetic field lines 416 that are
closest to the electron ExB drift current 414 are somewhat
distorted by the magnetic field generated by the electron ExB drift
current 414. The distortion suggests that a larger electron ExB
drift current should generate a stronger magnetic field that will
interact more strongly with the magnetic field generated by the
magnet assembly 252.
[0098] FIG. 6C illustrates the magnetic field lines 418 that are
produced from the interaction of the magnetic field generated by
the magnet assembly 252 and the magnetic field generated by an
electron ExB drift current 420. The electron ExB drift current 420
is generated proximate to the cathode assembly 216.
[0099] In the example shown in FIG. 6C, the electron ExB drift
current 420 is approximately 1,000 A. Since the electron ExB drift
current 420 is typically between about three and ten times as great
as the discharge current, the discharge current in this example is
approximately between 100 A and 300 A.
[0100] The magnetic field lines 418 that are generated by the
magnet assembly 252 exhibit substantial distortion that is caused
by the relatively strong magnetic field generated by the relatively
large electron ExB drift current 420. Thus, the larger electron ExB
drift current 420 generates a stronger magnetic field that strongly
interacts with and can begin to dominate the magnetic field
generated by the magnet assembly 252.
[0101] The interaction of the magnetic field generated by the
magnet assembly 252 and the magnetic field generated by the
electron ExB drift current 420 substantially generates magnetic
field lines 422 that are somewhat more parallel to the surface of
the sputtering target 220 than the magnetic field lines 408, 412,
and 416 in FIG. 6A and FIG. 6B. The magnetic field lines 422 allow
the strongly-ionized plasma to more uniformly distribute itself in
the area 246. Thus, the strongly-ionized plasma is substantially
uniformly diffused in the area 246, and consequently, the
sputtering target 220 is eroded more uniformly thereby resulting in
higher target utilization than can be achieved than in conventional
magnetron sputtering systems.
[0102] FIG. 6D illustrates the magnetic field lines 424 produced
from the interaction of the magnetic field generated by the magnet
assembly 252 and the magnetic field generated by an electron ExB
drift current 426. The electron ExB drift current 426 is generated
proximate to the cathode assembly 216.
[0103] In the example shown in FIG. 6D, the electron ExB drift
current 426 is approximately 5,000 A. The discharge current in this
example is approximately between 500 A and 1,700 A.
[0104] The magnetic field lines 424 generated by the magnet
assembly 252 are relatively distorted due to their interaction with
the relatively strong magnetic field generated by the relatively
large electron ExB drift current 426. Thus, in this embodiment, the
relatively large electron ExB drift current 426 generates a very
strong magnetic field that is substantially stronger than the
magnetic field generated by the magnet assembly 252.
[0105] FIG. 7 illustrates a cross-sectional view of another
embodiment of a magnetron sputtering apparatus 450 according to the
present invention. The magnetron sputtering apparatus 450 includes
an electrode 452 that generates a weakly-ionized or pre-ionized
plasma. The electrode 452 is also referred to as a pre-ionizing
filament electrode and is a component in an ionization source that
generates the weakly ionized plasma.
[0106] In one embodiment, the electrode 452 is coupled to an output
454 of a power supply 456. The power supply 456 can be a DC power
supply or an AC power supply. An insulator 458 isolates the
electrode 452 from the grounded wall of the chamber 202. In one
embodiment, the electrode 452 is substantially shaped in the form
of a ring electrode. In other embodiments, the electrode 452 is
substantially shaped in a linear form or any other shape that is
suitable for pre-ionizing the plasma.
[0107] In one embodiment, a second output 460 of the power supply
456 is coupled to the cathode 218. The insulator 226 isolates the
cathode 218 from the grounded wall of the chamber 202. In one
embodiment, the power supply 456 generates an average output power
that is in the range of between about 0.01 kW and 100 kW. Such an
output power is sufficient to generate a suitable current between
the electrode 452 and the cathode assembly 216 to pre-ionize feed
gas that is located proximate to the electrode 452.
[0108] In operation, the magnetron sputtering apparatus 450
functions in a similar manner to the magnetron sputtering apparatus
200 of FIG. 2, but with some operational differences. The magnetic
field 254 is generated proximate to the cathode assembly 216. In
one embodiment, the strength of the magnetic field 254 is between
about one hundred and two thousand gauss. The feed gas is supplied
from the gas source 208 to the chamber 202 by the gas flow control
system 210.
[0109] The power supply 456 applies a suitable current between the
cathode assembly 216 and the electrode 452. The parameters of the
current are chosen to establish a weakly-ionized plasma in the area
246 proximate to the electrode 452. In one embodiment, the power
supply 456 generates a voltage of between about one hundred volts
and five thousand volts with a discharge current that is between
about 0.1 A and 100 A depending on the size of the magnetron. An
example with specific parameters will be discussed herein in more
detail in connection with FIG. 8.
[0110] In one embodiment, the resulting pre-ionized plasma density
is in the range between approximately 10.sup.6 and 10.sup.12
cm.sup.-3 for argon sputtering gas. In one embodiment, the pressure
in the chamber 202 is in the range of approximately 10.sup.-3 to 10
Torr. As previously discussed, the weakly-ionized or pre-ionized
plasma reduces or substantially eliminates the possibility of
establishing a breakdown condition in the chamber 202 when
high-power pulses are applied to the plasma.
[0111] The pulsed power supply 234 then generates a high-power
pulse between the cathode assembly 216 and the anode 238. The
high-power pulse generates a strongly-ionized plasma from the
weakly-ionized plasma. The parameters of the high-power pulse
depend on various parameters including the size of the magnetron,
the desired deposition rate, and the concentration of the
pre-ionized plasma necessary for depositing the target
material.
[0112] In one embodiment, the high-power pulse between the cathode
assembly 216 and the anode 238 is in the range of about one
kilowatt to about ten megawatts. This corresponds to target
densities on the order of several kilowatts per square centimeter.
In one embodiment, the ion current density that can be generated
from the strongly-ionized plasma is greater than about one ampere
per squared centimeter for a pressure of approximately ten
mTorr.
[0113] In one embodiment, the high-power pulse has a pulse width
that is in the range of approximately one microsecond to several
seconds. In one embodiment, the repetition rate of the high-power
discharge is in the range of between about 0.1 Hz to 1 kHz. In one
embodiment, in order to minimize undesirable target heating, the
average power generated by the pulsed power supply is less than one
megawatt depending on the size of the magnetron. In one embodiment,
the thermal energy in the sputtering target 220 is conducted away
or dissipated by liquid or gas cooling (not shown).
[0114] The gas flow control system 210 provides a feed gas flow
rate that is high enough to maintain the strongly-ionized plasma.
Additionally, the vacuum control system 206 controls the pressure
so as to maintain the pressure inside the chamber 202 in a range
that supports the strongly-ionized plasma.
[0115] The ions in the strongly-ionized plasma accelerate towards
the sputtering target 220 at high velocity and impact the surface
of the sputtering target 220. The strongly ionized plasma causes a
very high sputtering rate of the target material. Furthermore, as
described herein in connection with FIG. 6A though FIG. 6D, the
strongly-ionized plasma generated by the sputtering systems
according to the present invention tends to diffuse homogenously in
the area 246 due to the interaction of generated magnetic fields.
This homogenous diffusion results in a more uniform distribution of
ions impacting the surface of the target material 220 compared with
conventional magnetron sputtering systems, thereby resulting in
relatively high target utilization and relatively uniform
deposition of target material on the substrate 211.
[0116] FIG. 8 illustrates a graphical representation of pulse power
as a function of time for periodic pulses applied to the plasma in
the magnetron sputtering system of FIG. 7. In one embodiment, the
feed gas from the gas source 208 flows into the chamber 202 at time
t.sub.0, before either the power supply 456 or the pulsed power
supply 234 are activated.
[0117] In another embodiment, prior to the formation of the
weakly-ionized plasma, the power supply 456 and/or the pulsed power
supply 234 are activated at time t.sub.0 before the gas enters the
chamber 202. In this embodiment, the feed gas is injected between
the electrode 452 and the cathode assembly 216 where it is ignited
by the power supply 456 to generate the weakly-ionized plasma.
[0118] The time required for a sufficient quantity of gas to flow
into the chamber 202 depends on several factors including the flow
rate of the gas and the desired operating pressure in the chamber
202. At time t.sub.1, the power supply 456 generates a power 502
that is in the range of between about 0.01 kW to about 100 kW
between the electrode 452 and the cathode assembly 216. The power
502 causes the gas proximate to the electrode 452 to become
partially ionized, thereby generating a weakly-ionized plasma or a
pre-ionized plasma.
[0119] At time t.sub.2, the pulsed power supply 234 delivers a
high-power pulse 504 to the weakly-ionized plasma that is on the
order of less than one kilowatt to about ten megawatts depending on
the size of the magnetron. The high-power pulse 504 is sufficient
to transform the weakly-ionized plasma to a strongly-ionized
plasma. The high-power pulse has a leading edge 506 having a rise
time that is between about 0.1 microseconds and ten seconds.
[0120] In one embodiment, the pulse width of the high-power pulse
504 is in the range of between about one microsecond and ten
seconds. The high-power pulse 504 is terminated at time t.sub.4.
Even after the delivery of the high-power pulse 504, the power 502
from the power supply 456 is continuously applied to sustain the
pre-ionized plasma, while the pulsed power supply 234 prepares to
deliver another high-power pulse 508. In another embodiment (not
shown), the power supply 456 is an AC power supply and delivers
suitable power pulses to ignite and sustain the weakly-ionized
plasma.
[0121] At time t.sub.5, the pulsed power supply 234 delivers
another high-power pulse 508. In one embodiment, the repetition
rate of the high-power pulses can be between about 0.1 Hz and 1
kHz. The particular size, shape, width, and frequency of the
high-power pulse depend on the process parameters and on the design
of the pulsed power supply 234 and the sputter system. The shape
and duration of the leading edge 506 and the trailing edge 510 of
the high-power pulse 504 is chosen to control the rate of
ionization of the strongly-ionized plasma. In one embodiment, the
particular size, shape, width, and frequency of the high power
pulse 504 is chosen to control the rate of sputtering of the target
material.
[0122] FIG. 9A through FIG. 9C are cross-sectional views of various
embodiments of cathode assemblies 216', 216'', and 216''' according
to the present invention. FIG. 9A through FIG. 9C illustrate one
side (the right side with reference to FIG. 7) of each cathode
assembly. The left side of each cathode assembly is generally
symmetrical to the illustrated right side. FIG. 9A through FIG. 9C
illustrate various configurations of the electrode 452 and the
cathode assemblies 216', 216'', and 216'''. These various
configurations can affect the parameters of the electric field
generated between the electrode 452 and each of the cathode
assemblies 216', 216'', and 216'''. The parameters of the electric
field can influence the ignition of the pre-ionized plasma as well
as the pre-ionization process generally. In one embodiment, these
various embodiments create the necessary conditions for breakdown
of the feed gas and ignition of the weakly-ionized plasma in the
region between the anode 238 and each respective cathode assembly
216', 216'', and 216'''.
[0123] FIG. 9A illustrates one side of the cathode assembly 216'.
In this embodiment, a sputtering target 220' is substantially
positioned in contact with a cathode 218'. The sputtering target
220' extends past the bend 520 of the ring-shaped electrode 452. In
this embodiment, the electric field lines (not shown) from the
electric field generated between the cathode assembly 216' and the
ring-shaped electrode 452 are substantially perpendicular to the
cathode assembly 216' along the circumference of the ring-shaped
electrode 452. This embodiment can increase the efficiency of the
pre-ionization process. Furthermore, since the cathode 218' is
never directly exposed to the plasma, ions from the plasma do not
bombard the cathode 218' and therefore, any contamination that
could otherwise be generated by the cathode material is
substantially reduced.
[0124] FIG. 9B illustrates one side of the cathode assembly 216''.
In this embodiment, a sputtering target 220'' is substantially
positioned in contact with a cathode 218''. The sputtering target
220'' extends to the point 524 on the cathode assembly 216''. In
this embodiment, the electric field lines (not shown) generated
between the cathode assembly 216'' and the electrode 452 are
substantially perpendicular to the cathode assembly 216'' at the
point 528 on the cathode 218''. The electric field in the gap 530
between the electrode 452 and the cathode 218'' is adapted to
ignite the plasma from the feed gas flowing through the gap 530.
Depending on various parameters such as where the magnetic field is
generated relative to the sputtering target 220'' and the pressure
in the area proximate to the cathode assembly 216'', this
embodiment can increase the efficiency of the pre-ionization
process.
[0125] FIG. 9C illustrates one side of the cathode assembly 216'''.
In this embodiment, a sputtering target 220''' is substantially
positioned in contact with a cathode 218'''. The sputtering target
220''' extends to position 532 on the cathode assembly 216'''. In
this embodiment, the electric field lines (not shown) generated
between the cathode assembly 216''' and the electrode 452 are
substantially perpendicular to the cathode assembly 216''' at the
position 538. The electric field in the gap 540 between the
electrode 452 and the cathode 218'''is adapted to ignite the plasma
from the feed gas flowing through the gap 540. Depending on various
parameters such as where the magnetic field is generated relative
to the sputtering target 220''' and the pressure in the area
proximate to the cathode assembly 216''', this embodiment can
increase the efficiency of the pre-ionization process.
[0126] FIG. 10 is a cross-sectional view of another embodiment of a
magnetron sputtering apparatus 450' according to the present
invention. This embodiment is similar to the magnetron sputtering
apparatus 450 of FIG. 7. However, in this embodiment, the electrode
452', which is a component of the ionization source, substantially
surrounds the cathode assembly 216. The position of the electrode
452' relative to the cathode assembly 216 is chosen to achieve
particular electrical conditions in the gap 244 between the anode
238 and the cathode assembly 216. For example, in this embodiment,
since the pre-ionizing electrode 452' is not physically located in
the region 245' between the anode 238 and the cathode assembly 216,
it does not interfere with the strong electric field that results
when a high-power pulse is applied between the anode 238 and the
cathode assembly 216. Additionally, the location of the
pre-ionizing electrode 452' results in a more uniformly distributed
weakly-ionized plasma in the region 246'.
[0127] The power supply 456 applies a substantially constant
voltage between the cathode assembly 216 and the electrode 452'.
The substantially constant voltage generates a weakly-ionized or
pre-ionized plasma proximate to the electrode 452' and the cathode
assembly 216. The pre-ionized plasma substantially eliminates the
possibility of establishing a breakdown condition in the chamber
202 when high-power pulses are applied to the plasma. In one
embodiment, the power supply 456 is a DC power supply that
generates a DC voltage that is in the range of between about one
hundred volts and several kilovolts with a discharge current that
is in the range of between about 0.1 A and 10 A. In another
embodiment, the power supply 456 is an AC power supply that
generates voltage pulses between the cathode assembly 216 and the
electrode 452'.
[0128] Since the electrode 452' substantially surrounds the cathode
assembly 216, a distance 462 between the electrode 452' and the
cathode 218 can be varied by changing the diameter of the electrode
452'. For example, the distance 462 can be varied from about 0.1 cm
to about 10 cm. The distance 462 is optimized to generate
sustainable weakly-ionized plasma in the region 246'. The vertical
position of the electrode 452' relative to the cathode assembly 216
can also be varied.
[0129] FIG. 11 illustrates a cross-sectional view of another
illustrative embodiment of a magnetron sputtering apparatus 450''
according to the present invention. The magnetron sputtering
apparatus 450'' is similar to the magnetron sputtering apparatus
450 of FIG. 7. The electrode 452'' is a component of an ionization
source. However, the electrode 452'' is coupled to a first power
supply 464 and also to an additional second power supply 466. The
position of the electrode 452'' relative to the cathode assembly
216 is chosen to achieve particular sputtering characteristics.
[0130] A first output 468 of the first power supply 464 is coupled
through the insulator 458 to a first side 470 of the electrode
452''. A second output 472 of the first power supply 464 is coupled
to a second side 474 of the electrode 452'' through an insulator
476. The first power supply 464 is adapted to generate a current
through the electrode 452''. The current essentially generates heat
in the electrode 452''. The heated electrode 452'' emits electrons
in the area 245''.
[0131] In one embodiment, the first power supply 464 is a DC power
supply and applies a substantially constant current through the
electrode 452''. In another embodiment, the first power supply 464
is an AC power supply.
[0132] A first output 478 of the second power supply 466 is coupled
to the anode 238 through an insulator 480. A second output 482 of
the second power supply 466 is coupled to the second side 474 of
the electrode. The second power supply 466 is adapted to apply a
voltage between the electrode 452'' and the anode 238. The second
power supply 466 can be an AC power supply or a DC power supply. In
one embodiment, the second power supply 466 generates a voltage in
the range of about one hundred volts and several kilovolts with a
discharge current that is in the range of between about 0.1 A and
10 A.
[0133] In one embodiment, the second power supply 466 applies a
substantially constant voltage that generates a weakly-ionized or
pre-ionized plasma proximate to the electrode 452'' and the cathode
assembly 216. The pre-ionized plasma substantially eliminates the
possibility of establishing a breakdown condition in the chamber
202 when high-power pulses are applied to the plasma.
[0134] The pulsed power supply 234 then generates a high-power
pulse between the cathode assembly 216 and the anode 238. The
high-power pulse generates a strongly-ionized plasma from the
weakly-ionized plasma. The parameters of the high-power pulse
depend on various parameters including the size of the magnetron,
the desired deposition rate, and the concentration of the
pre-ionized plasma necessary for depositing the target material,
for example.
[0135] FIG. 12 is a flowchart 600 of an illustrative process of
sputter deposition according to the present invention. The process
is initiated (step 602) by activating various systems in the
magnetron sputtering apparatus 200 of FIG. 2. For example, the
chamber 202 is initially pumped down to a specific pressure (step
604). Next, the pressure in the chamber 202 is checked (step 606).
In one embodiment, feed gas is then pumped into the chamber (step
608). The gas pressure is then checked (step 610). If the gas
pressure is correct, the chamber pressure is then re-checked (step
612). If the chamber pressure is correct, an appropriate magnetic
field is generated proximate to the feed gas (step 614). In one
embodiment, the magnet assembly 252 of FIG. 2 includes at least one
permanent magnet, where magnetic field is generated constantly,
even before the process is initiated. In another embodiment, a
magnetic assembly (not shown) includes at least one electromagnet,
where the magnetic field is generated only when the electromagnet
is operating.
[0136] When the magnetic field is appropriate (step 616), the feed
gas is ionized to generate a weakly-ionized plasma (step 618). In
one embodiment, the weakly-ionized plasma can be generated by
creating a relatively low current discharge in the gap 244 between
the cathode assembly 216 and the anode 238 of FIG. 2. In another
embodiment, the weakly-ionized plasma can be generated by creating
a relatively low current discharge between the electrode 452 and
the cathode assembly 216 of FIG. 7. In yet another embodiment, the
electrode 452'' is heated to emit electrons proximate to the
cathode assembly 216 of FIG. 11. In the embodiment of FIG. 11, a
relatively low current discharge is created between the anode 238
and the electrode 452''.
[0137] In the embodiment shown in FIG. 2, the weakly-ionized plasma
is generated by applying a potential across the gap 244 between the
cathode assembly 216 and the anode 238 before the introduction of
the feed gas. In the embodiment shown in FIG. 7, the weakly-ionized
plasma is generated by applying a potential difference between the
electrode 452 and the cathode assembly 216 before the introduction
of the feed gas to generate the weakly-ionized plasma.
[0138] When the gas is weakly ionized (step 620), a
strongly-ionized plasma is generated from the weakly-ionized plasma
(step 622). In one embodiment, the strongly-ionized plasma is
generated by applying a high-power pulse in the gap 244 between the
cathode assembly 216 and the anode 238. As previously discussed,
the high-power pulse results in a strong electric field being
generated in the gap 244 between the anode 238 and the cathode
assembly 216. The strong electric field results in a stepwise
ionization process. In one embodiment, the strongly-ionized plasma
is substantially homogeneous in the area 246 of FIG. 2. This
homogeneity results in substantially uniform erosion of the
sputtering target 220 and, therefore, relatively high sputtering
target utilization.
[0139] The cathode assembly 216 attracts ions from the
strongly-ionized substantially uniform plasma because the cathode
assembly 216 is negatively biased relative to the anode 238. This
causes the ions to bombard the cathode assembly 216 causing
sputtering of the target material.
[0140] In one embodiment, the sputter deposition is monitored (step
628) by known monitoring techniques. Once the sputter deposition is
completed (step 630), the sputter process is ended (step 632).
[0141] FIG. 13 is a flowchart 650 of an illustrative process of
controlling the sputter rate according to the present invention.
The process is initiated (step 602) by activating various systems
in the magnetron sputtering apparatus 200 of FIG. 2. For example,
the chamber 202 is initially pumped down to a specific pressure
(step 604). Next, the pressure in the chamber 202 is evaluated
(step 606). In one embodiment, feed gas is then pumped into the
chamber (step 608). The gas pressure is evaluated (step 610). If
the gas pressure is correct, the pressure in the chamber 202 is
again evaluated (step 612). If the pressure in the chamber 202 is
correct, an appropriate magnetic field is generated proximate to
the feed gas (step 614).
[0142] Assuming that the magnetic field is appropriate (step 616),
the feed gas is ionized to generate a weakly-ionized plasma (step
618). In one embodiment, the weakly-ionized plasma can be generated
by creating a relatively low current discharge between the cathode
assembly 216 and the anode 238 of FIG. 2.
[0143] After the weakly-ionized plasma is generated (step 620), a
strongly-ionized plasma is generated from the weakly-ionized plasma
(step 622). In one embodiment, the strongly-ionized plasma is
generated by applying a high-power pulse in the gap 244 between the
cathode assembly 216 and the anode 238. In one embodiment, the
strongly-ionized plasma is substantially homogeneous in the area
246 of FIG. 2. This homogeneity results in more uniform erosion of
the sputtering target 220.
[0144] The cathode assembly 216 attracts ions from the
strongly-ionized substantially uniform plasma because the the
cathode assembly 216 is negatively biased relative to the anode
238. This causes the ions to bombard the cathode assembly 216
causing sputtering of the target material.
[0145] In one embodiment, the sputter rate is monitored (step 652)
by known monitoring techniques. If the sputter rate is not
sufficient (step 654), the power delivered to the plasma is
increased (step 656). Increasing the magnitude of the high-power
pulse applied in the gap 244 between the cathode assembly 216 and
the anode 238 increases the power delivered to the plasma. The
sputter rate is again evaluated (step 652). This process continues
(step 658) until the sputter rate is sufficient (step 654). Once
the sputter deposition is completed (step 660), the sputter process
is ended (step 662).
Equivalents
[0146] While the invention has been particularly shown and
described with reference to specific preferred embodiments, it
should be understood by those skilled in the art that various
changes in form and detail may be made therein without departing
from the spirit and scope of the invention as defined herein.
* * * * *