U.S. patent application number 13/840469 was filed with the patent office on 2014-09-18 for physical vapor deposition methods and systems to form semiconductor films using counterbalance magnetic field generators.
The applicant listed for this patent is Samsung Electronics Co., Ltd., SEMICAT, INC.. Invention is credited to Jae Yeol PARK, JEONGHEE PARK.
Application Number | 20140262754 13/840469 |
Document ID | / |
Family ID | 51522592 |
Filed Date | 2014-09-18 |
United States Patent
Application |
20140262754 |
Kind Code |
A1 |
PARK; JEONGHEE ; et
al. |
September 18, 2014 |
PHYSICAL VAPOR DEPOSITION METHODS AND SYSTEMS TO FORM SEMICONDUCTOR
FILMS USING COUNTERBALANCE MAGNETIC FIELD GENERATORS
Abstract
Embodiments relate generally to semiconductor device fabrication
and processes, and more particularly, to systems and methods that
implement magnetic field generators configured to generate rotating
magnetic fields to facilitate physical vapor deposition ("PVD"). In
one embodiment, a system generates a first portion of a magnetic
field adjacent a first circumferential portion of a substrate, and
can generate a second portion of the magnetic field adjacent to a
second circumferential portion of the substrate. The second
circumferential portion is disposed at an endpoint of a diameter
that passes through an axis of rotation to another endpoint of the
diameter at which the first circumferential portion resides. The
second peak magnitude can be less than the first peak magnitude.
The system rotates the first and second portions of the magnetic
fields to decompose a target material to form a plasma adjacent the
substrate. The system forms a film upon the substrate
Inventors: |
PARK; JEONGHEE;
(Hwasung-City, KR) ; PARK; Jae Yeol; (San Ramon,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SEMICAT, INC.
Samsung Electronics Co., Ltd. |
Milpitas
Suwon-si |
CA |
US
KR |
|
|
Family ID: |
51522592 |
Appl. No.: |
13/840469 |
Filed: |
March 15, 2013 |
Current U.S.
Class: |
204/192.25 |
Current CPC
Class: |
H01J 37/3405 20130101;
H01L 45/144 20130101; C23C 14/35 20130101; H01J 37/32669 20130101;
H01J 37/3455 20130101; C23C 14/3407 20130101; H01J 37/345 20130101;
H01L 45/1233 20130101; H01L 45/06 20130101; C23C 14/0623 20130101;
H01L 45/1625 20130101; H01J 2237/332 20130101; H01L 21/02266
20130101; H01J 37/3452 20130101 |
Class at
Publication: |
204/192.25 |
International
Class: |
H01L 21/02 20060101
H01L021/02; C23C 14/35 20060101 C23C014/35 |
Claims
1. A method for processing a semiconductor substrate comprising:
generating a first portion of a magnetic field having a first peak
magnitude of magnetic field strength adjacent a first
circumferential portion of a semiconductor substrate; generating a
second portion of the magnetic field having a second peak magnitude
of magnetic field strength adjacent to a second circumferential
portion of the semiconductor substrate, the second circumferential
portion being at an endpoint of a diameter passing through an axis
of rotation to another endpoint of the diameter at which the first
circumferential portion resides, the second peak magnitude being
less than the first peak magnitude; rotating the first portion of
the magnetic field and the second portion of the magnetic field
about the axis of rotation; decomposing a target material to form a
plasma at a plasma processing region adjacent the semiconductor
substrate within a chamber; and forming a film upon the
semiconductor substrate.
2. The method of claim 1 wherein generating the second portion of
the magnetic field comprises: generating a minimum magnitude of
magnetic field strength disposed between the second peak magnitude
and the axis of rotation.
3. The method of claim 1 wherein rotating the first portion of the
magnetic field and the second portion of the magnetic field about
the axis of rotation comprises: rotating a first magnetic field
generator to rotate the first portion of the magnetic field about
the axis of rotation; rotating a second magnetic field generator to
rotate the second portion of the magnetic field about the axis of
rotation to counterbalance the first magnetic field generator,
wherein the first magnetic field generator and the second magnetic
field generator generate the first portion of magnetic field and
the second portion of the magnetic field, respectively.
4. The method of claim 1 wherein the first magnetic field generator
comprises a different cross-sectional area in a plane of rotation
than the second magnetic field generator.
5. The method of claim 1 wherein rotating the first portion of the
magnetic field and the second portion of the magnetic field about
the axis of rotation comprises: rotating a first magnetic field
generator having a periphery coextensive with a first sector in a
plane of rotation about the axis of rotation, the first magnetic
field generator including permanent magnet material of different
magnetic characteristics to produce a magnetic strength profile
from the first peak magnitude of magnetic field strength to an
intermediate magnitude of magnetic field strength adjacent the axis
of rotation; and rotating a second magnetic field generator having
a periphery coextensive with a second sector in the plane of
rotation, the second magnetic field generator including other
permanent magnet material of different magnetic characteristics
disposed near the second circumferential portion to produce another
magnetic strength profile from the intermediate magnitude of
magnetic field strength adjacent to the axis of rotation to the
second peak magnitude of magnetic field strength adjacent the
second circumferential portion.
6. The method of claim 5 wherein the first sector comprises two
radial peripheral portions offset by an angle that is less than
another angle that offsets two radial peripheral portions of the
second sector.
7. The method of claim 1 further comprising: including supplemental
magnetic elements; and modifying the first peak magnitude of
magnetic field strength as a function of the magnetic
characteristics of the supplemental magnetic elements.
8. The method of claim 1 further comprising: igniting the
plasma.
9. The method of claim 8 wherein igniting the plasma further
comprises: rotating a magnetic structure configured to receive the
first portion of the magnetic field and the second portion of the
magnetic field, the magnetic structure including triangular-shaped
surface areas oriented parallel to a plane of rotation, wherein a
group of vertices of the triangular-shaped surface areas each lies
on a line perpendicular to a radial line extending from the axis of
rotation.
10. The method of claim 1 wherein generating the first portion of
the magnetic field comprises: generating magnetic flux in a
direction substantially circumferential relative to the axis of
rotation, the magnetic flux extending between a first group of
magnetic elements disposed on two principal radial lines and a
second group of magnetic elements disposed between the two
principal radial lines; and generating magnetic flux in a direction
substantially radial relative to the axis of rotation, the magnetic
flux extending between a third group of magnetic elements disposed
at a principal distal line coupled to the two principal radial
lines and the second group of magnetic elements disposed between
the two principal radial lines, wherein the two principal radial
lines and the principal distal line constitute portions of a
periphery of a first magnetic field generator.
11. The method of claim 10 wherein generating the second portion of
the magnetic field comprises: generating magnetic flux in another
direction substantially circumferential relative to the axis of
rotation, the magnetic flux extending between a fourth group of
magnetic elements disposed on two secondary radial lines and a
fifth group of magnetic elements disposed between the two secondary
radial lines; and generating magnetic flux in another direction
substantially radial relative to the axis of rotation, the magnetic
flux extending between a sixth group of magnetic elements disposed
at a secondary distal line coupled to the two secondary radial
lines and the fifth group of magnetic elements disposed between the
two secondary radial lines, wherein the secondary two radial lines
and the secondary distal line constitute portions of a periphery of
a second magnetic field generator.
12. The method of claim 1 wherein decomposing the target materials
comprises: sputtering a chalcogenide material.
13. The method of claim 1 wherein modifying the non-metal film
comprises: depositing one or more layers including germanium,
antimony and tellurium ("GST").
14. The method of claim 1 wherein decomposing the one or more
non-metal target materials comprises: sputtering a material
including germanium, antimony and tellurium ("GST") in the form:
Ge.sub.2Sb.sub.2Te.sub.5.
15. The method of claim 1 furthering comprising: biasing a wafer
chuck configured to support the semiconductor substrate.
16. The method of claim 15 wherein biasing the wafer chuck
comprising: generating a radio-frequency ("RF") voltage signal to
supply RF power; matching impedance between the plasma including
germanium, antimony and tellurium ("GST") and a source generating
the RF voltage; and controlling the generation of the RF voltage to
facilitate generation of the plasma to modify the non-metal film to
deposit one or more layers of GST.
17-28. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to U.S. Nonprovisional
application Ser. No. 12/551,356 filed on Aug. 31, 2009 with
Attorney Docket No. SEM-002, U.S. Nonprovisional application Ser.
No. ______ and Ser. No. 12/551,379 filed on Aug. 31, 2009 with
Attorney Docket No. SEM-003, all of which are hereby incorporated
by reference for all purposes.
BRIEF DESCRIPTION OF THE INVENTION
[0002] Embodiments of the invention relate generally to
semiconductor device fabrication and processes, and more
particularly, to systems and methods that implement magnetic field
generators configured to generate rotating magnetic fields to
facilitate physical vapor deposition ("PVD").
BACKGROUND OF THE INVENTION
[0003] Traditional techniques for fabricating semiconductors
include vapor deposition processes, which are used typically to
deposit relatively thin films onto semiconductor substrates to form
electronic devices. Semiconductor manufacturers expect that vapor
deposition processes and equipment are to provide a certain level
of, for example, step coverage over topologies and features over
which a film is deposited. FIG. 1 illustrates conventional
deposition equipment, such as a DC magnetron, that is used in some
traditional deposition processes. Diagram 100 includes a magnetron
assembly 101 including a magnet assembly 122 connected to a
counterweight 120, whereby magnetron assembly 101 is designed to
rotate about an axis of rotation 108 in a chamber depicted as
having chamber walls 110. Magnet assembly 122 extends a distance
("d") 102, with magnet assembly 112 extending along radius ("r2")
106 from axis of rotation 108 and counterweight 120 extending along
radius ("r1") 104 from axis of rotation 108. Typically, magnetron
assembly 101 is designed for semiconductor processing for a
specific size of wafer, and the configuration is not well-suited to
scale up for larger sizes of wafers.
[0004] FIG. 2 depicts a magnetic field typically generated by
magnetron assembly 101 along the cross-section A-A' shown in FIG.
1. Diagram 200 depicts a magnetic field 216 generated by magnet
assembly 122 of FIG. 1. As shown, magnetic field 216 normally has a
relatively constant magnitude ("Ms") 214 along radial distance 206,
which coincides with radius 106 of FIG. 1. As shown, counterweight
120 does not contribute to generation of a magnetic field along
radial distance 204, which coincides with radius 104 of FIG. 1. In
operation, magnetic field 216 rotates about an axis of rotation
relative to a surface of a substrate 210 for fabricating a
semiconductor structure, such as a film.
[0005] While functional, there are a variety of drawbacks
associated with magnetron assembly 101 and the fabrication
processes using the same. One drawback is that magnetron assembly
101 and the PVD processes using the magnetron assembly 101 tend to
form suboptimal film structures, including instances when the size
of substrate 210 increases beyond 200 mm (e.g., up to 300 mm, or
greater) for certain materials to be deposited.
[0006] In view of the foregoing, it is be desirable to provide an
apparatus, a system, and a method for overcoming the drawbacks of
the conventional deposition processes to deposit semiconductor
layers, including, but not limited to, non-metal layers (e.g., a
chalcogenide-based film.)
SUMMARY OF THE INVENTION
[0007] Embodiments of the invention relate generally to
semiconductor device fabrication and processes, and more
particularly, to systems and methods that implement magnetic field
generators configured to generate rotating magnetic fields to
facilitate physical vapor deposition ("PVD"). In one embodiment, a
system generates a first portion of a magnetic field having a first
peak magnitude of magnetic field strength adjacent a first
circumferential portion of a semiconductor substrate. The system
also can generate a second portion of the magnetic field having a
second peak magnitude of magnetic field strength adjacent to a
second circumferential portion of the semiconductor substrate. The
second circumferential portion is disposed at an endpoint of a
diameter that passes through an axis of rotation to another
endpoint of the diameter at which the first circumferential portion
resides. The second peak magnitude can be less than the first peak
magnitude. The system rotates the first portion of the magnetic
field and the second portion of the magnetic field about the axis
of rotation to decompose a target material to form a plasma at a
plasma processing region adjacent the semiconductor substrate
within a chamber. Also, the system operates to form a film upon the
semiconductor substrate.
BRIEF DESCRIPTION OF THE FIGURES
[0008] The invention is more fully appreciated in connection with
the following detailed description taken in conjunction with the
accompanying drawings, in which:
[0009] FIG. 1 illustrates conventional deposition equipment that is
used in some traditional deposition processes;
[0010] FIG. 2 depicts a magnetic field typically generated by a
conventional magnetron assembly along the cross-section A-A' shown
in FIG. 1;
[0011] FIG. 3 depicts an example of an apparatus for depositing a
film structure in relation to a semiconductor substrate in
accordance with at least one embodiment;
[0012] FIG. 4 depicts an example of a magnetic field profile in
accordance with at least one embodiment;
[0013] FIG. 5 is a view of a surface of a magnetic field generator
apparatus configured to confront a surface of a substrate,
according to various embodiments;
[0014] FIG. 6 depicts distributions of magnetic strength, according
to some embodiments;
[0015] FIG. 7 depicts an example of an arrangement of magnetic
elements for a magnetic field generator apparatus, according to
some embodiments;
[0016] FIG. 8 is an example of a flow chart depicting a process by
which to manufacture a magnetic field generator apparatus,
according to an embodiment;
[0017] FIG. 9 depicts an example of a magnetic field generator
apparatus implementing supplemental magnetic structures, according
to some embodiments;
[0018] FIG. 10 depicts a magnetic profile having a configurable
profile portion, according to some embodiments;
[0019] FIG. 11 depicts a specific example of one or more
arrangements of magnetic elements used to form a magnetic field
generator apparatus, according to some embodiments;
[0020] FIG. 12 is an example of a flow chart depicting a process by
which to manufacture a bowtie-shaped magnetic field generator
apparatus, according to an embodiment;
[0021] FIG. 13 depicts an example of a system for modifying a
non-metal film on a semiconductor substrate in accordance with at
least one embodiment;
[0022] FIG. 14 is an example of a flow chart depicting a process by
which to form semiconductor film using an example of a magnetic
field generator, according to various embodiments; and
[0023] FIG. 15 depicts an example of a memory cell including a
layer of chalcogenide-based material as formed by deposition
processes and systems in accordance with at least one
embodiment.
[0024] Like reference numerals refer to corresponding parts
throughout the several views of the drawings. Note that most of the
reference numerals include one or two left-most digits that
generally identify the figure that first introduces that reference
number.
DETAILED DESCRIPTION
[0025] FIG. 3 depicts an example of an apparatus for depositing a
film structure in relation to a semiconductor substrate in
accordance with at least one embodiment. Diagram 300 depicts a
perspective view of an arrangement of magnetic field generators 320
and 322, each of which is configured to rotate about an axis of
rotation 332 to facilitate generation of an electromagnetic field
having a magnetic profile (or a portion thereof) that contributes
to plasma processing in a plasma processing region. A
electromagnetic field and/or a magnetic field can induce ionization
of the molecules or atoms of a target material to establish, for
example, the formation of plasma to perform vapor deposition
processes (e.g., PVD, CVD, and the like). In particular, a magnetic
field generator 320 is configured to rotate--either clockwise or
counter-clockwise--about axis of rotation 332 in a region 310, such
as a circular region in a plane of rotation 330. Magnetic field
generator 320 is further configured to generate a first magnetic
field profile portion having a first magnitude, the first magnetic
field profile describing the magnetic field adjacent to a
circumferential portion 311b of a circular region 310. Magnetic
field generator 322 is configured to rotate about axis of rotation
322 in opposition to magnetic field generator 320, and can be
further configured to generate a second magnetic field profile
portion having a second magnitude, the second magnetic field
profile describing the magnetic field adjacent to a circumferential
portion 311a of circular region 310. One or more of the first and
second magnetic field profiles can either be of constant or
variable magnitude. Further, the first and second magnetic field
profiles can either be similar or different. According to some
embodiments, the second magnitude can be less than the first
magnitude. At least in some embodiments, magnetic field generator
320 and magnetic field generator 322 can be referred to as a
rotatable magnetic field generator and a counterbalance magnetic
field generator, respectively.
[0026] Further to FIG. 3, magnetic field generator 320 and magnetic
field generator 322 are configured to generate a magnetic field
between plane of rotation 330 and a plane 334, which is parallel to
plane of rotation 330. The magnetic field extends along a diameter
from circumferential portion 311b to circumferential portion 311a.
Plane 334 and plane of rotation 330 are separated by a distance
336. Rotation of magnetic field generators 320 and 322 facilitate
plasma formation to form a film upon substrate 340. Magnetic field
generator 322 can include a mass equivalent or approximate to that
of magnetic field generator 320 to counter act a force (e.g.,
centripetal force) generated magnetic field generator 320 on a
shaft or another structure coincident with axis of rotation 332
(not shown) about which magnetic field generator 320 rotates.
Further, magnetic field generator 322 provides a portion of the
magnetic field that can extend over some or all of a diameter of
circular region 310. As used herein, at least in some cases, the
term "circumferential portion" can describe areas, regions, lines,
surfaces, structures, etc. disposed at or adjacent an edge or
constituting an outer boundary relative to an axis of rotation. For
example, circumferential portions 311a and 311b includes areas or
regions at or near a boundary of circular region 310. Note, too,
that "circumferential" can refer to a direction, such as along a
portion of a circle centered at an axis, or in tangential direction
that is perpendicular to a radial line extending from the axis of
rotation.
[0027] FIG. 4 depicts an example of a magnetic field profile in
accordance with at least one embodiment. Magnetic field profiles
can be generated by magnetic field generators in accordance with
various embodiments. One example of a magnetic field profile is
depicted as magnetic field profile 400, which is generated by
magnetic field generators 320 and 322 of FIG. 3. Magnetic field
profile 400 extends along a distance ("D") 402, which is
representative of a distance (e.g., a diameter) between a distal
end 303a of magnetic field generator 320 and distal end 303b of
magnetic field generator 322. According to some embodiments,
magnetic field profile 400 can depict a magnetic characteristic
such as, but not limited to, magnetic strength expressed in
relative units of Gauss ("G") relative to a radial distance from a
reference point ("0") through which axis of rotation 332 of FIG. 3
passes. Magnetic field generator 320 of FIG. 3 (or a portion
thereof) is configured to generate a magnetic field profile portion
406, whereas magnetic field generator 322 of FIG. 3 (or a portion
thereof) is configured to generate a magnetic field profile portion
404. In some embodiments, magnetic field generators form magnetic
field portions having field strengths configured to generate plasma
for semiconductor wafer processing in accordance with magnetic
field profile portions 404 and 406, whereby the field strengths
associated with magnetic field profile portions 404 and 406 can be
configured to constant or can vary, for example, as a function of
distance 402.
[0028] In the example shown, a profile of magnetic strength for the
magnetic field, such as magnetic field profile 400, has one or more
peak or maximum magnitudes, such as peak magnitude ("Ms(p1)") 413,
relative to a minimum magnitude ("Ms(m)") 412. Either or both of
peak magnitude 413 and minimum magnitude 412 can represent the
maximum and the minimum magnitudes, respectively, for either
magnetic field profile portion 406 or magnetic field profile 400.
Further, profile 400 of magnetic strength also can have one or more
other peak or maximum magnitudes, such as peak magnitude ("Ms(p2)")
411, relative to a minimum magnitude 412. According to some
embodiments, peak magnitudes 411 and 413 are local peak magnitudes
(i.e., each is a maximum in respective magnetic field profile
portions 404 and 406). Either or both of peak magnitude 411 and
minimum magnitude 412 can represent maximum and minimum magnitudes,
respectively, for either magnetic field profile portion 404 or
magnetic field profile 400. A magnetic field generator, such as
magnetic field generator 320 of FIG. 3, or a portion thereof, can
be configured to generate a magnetic strength profile portion 406
such that peak magnitude 413 is generated to influence the
formation of a semiconductor layer or film on substrate 410 at or
adjacent to a region 408b, according to the fabrication processes
of the various embodiments. Further to the example shown, the
magnetic field strength decreases from peak magnitude 413 to a
magnitude 414 as a function of distance from the reference point.
In some cases, magnitude 414 can represent a magnitude of magnetic
field strength generated by, for example, both magnetic field
generators 320 and 322 of FIG. 3. While region 408b is depicted as
being at or adjacent to distance R2, which can coincide with an
edge of substrate 410, region 408b and/or peak magnitude 413 can be
located anywhere along distance 402 of profile 400. In this
example, peak magnitude 413 is located at distance 430 from the
reference point. Further, minimum magnitude 412 can represent a
magnitude field magnetic that is negligible or equivalent to zero,
or can represent an intermediate magnitude of magnetic field
strength that is non-zero.
[0029] Similarly, another magnetic field generator serving as a
counterbalance, such as magnetic field generator 322 of FIG. 3, or
a portion thereof, can be configured to generate a magnetic
strength profile portion 404 such that peak magnitude 411 is
generated to influence the formation of a semiconductor layer or
film on substrate 410 at or adjacent to a region 408a, according to
the fabrication processes of the various embodiments. Further, peak
magnitude 411 of the magnetic field strength decreases to a minimum
magnitude 412 as a function of distance from the reference point.
While region 408a is depicted as being at or adjacent to distance
R1, which can coincide with another edge of substrate 410, region
408a and/or peak magnitude 411, as well as minimum magnitude 412,
can be located anywhere along distance 402 of profile 400. In this
example, peak magnitude 411 and minimum magnitude 412 are located
at distances 432 and 434, respectively, from the reference point.
Specifically, minimum magnitude 412 of the magnetic strength is
disposed between axis of rotation 332 of FIG. 3 and peak magnitude
411 of the magnetic field.
[0030] In view of the foregoing, magnetic field generator 322 of
FIG. 3 can serve a multi-function purpose to serve as a
counterweight and to generate a portion of the magnetic field that
can extend on either side of or through axis of rotation 332. Thus,
a magnetic field extending from one end (e.g., distal end 303b) of
circular region 310 to another end (e.g., distal end 303a) can be
applied to a processing region in which plasma is generated for
processing, for example, semiconductor wafers during vapor
deposition (e.g., "PVD") to form semiconductor structures. Either
magnetic field generator 320 or 322, or both, can be configured to
generate varying magnetic field strength values at various units of
surface area defined by plane 330 of rotation. In some embodiments,
magnetic field generators 320 and 322 are configurable to generate
different magnitudes of magnetic strength to form any number of
magnetic strength profiles other than profile 400 depicted in FIG.
4. Further, the surface areas (e.g., the sizes of cross-sectional
areas in plane 330) of magnetic field generator 320 or 322 are
configurable to vary the magnetic strength and/or the flux density
(e.g., concentration of a magnetic flux per unit area). For
instance, angles coextensive with lateral portions of the magnetic
field generators 320 and 322 can be configured to modify the
magnetic strength to, for example, enhance localized magnetic field
strength (e.g., increase the concentration of magnetic field
strength, or the flux density) relative to other regions in which
semiconductor films are formed. In some cases, supplemental
magnetic generators (not shown) can be disposed adjacent to the
lateral portions to enhance or modify the localized magnetic field
strength. Alternatively, lateral portions of the magnetic field
generators 320 and 322 can be shaped to include protruding edge
surfaces (not shown) in, for example, in a zigzag shape to, for
example, facilitate ignition of plasma, among other things.
Magnetic field generator 320 and 322 can enhance the symmetry of
semiconductor structures formed at the edge portions and the center
portion of a semiconductor substrate. Therefore, the structures
and/or functionalities of magnetic field generator 320 and 322 can
enhance side wall and/or step coverage over topologies and features
over which a film is deposited. For example, the structures and/or
functionalities of the various apparatuses and/or processes can
enhance uniformity of thickness of layers deposited on a substrate,
such as a layer including germanium, antimony and tellurium ("GST")
in the form of, for example, Ge.sub.2Sb.sub.2Te.sub.5, or any
variants thereof, as well as any other type of semiconductor film.
The structures and/or functionalities of magnetic field generator
320 and 322 can facilitate deposition over substrates sized at 200
mm and greater, including substrates having a size of 300 mm. In
some embodiments, the magnetic field generators can generate
sufficient magnetic field magnitudes over a sufficient amount of
area over substrate 340 to provide uniform coverage of a layer of
material being deposited (e.g., a metal or non-metal material,
compound, molecule or element), thereby reducing deposition
non-uniformity across the substrate at exemplary amounts of, for
example, less than 3% deviations.
[0031] Referring back to FIG. 3, magnetic field generators 320 and
322 can configured to have any shape, for example, to obtain a
certain localization of magnetic field strength, according to
various embodiments. According to some embodiments, the term
"localization" can refer to, for example, a concentration of
magnetic field(s) that may or may not enhance the magnetic flux
density. In some embodiments, either one of magnetic field
generators 320 and 322, or both, can be configured to have a
triangular-shaped periphery. In instances that magnetic field
generators 320 and 322 both have triangular-shaped peripheries, one
of the vertices of the triangular-shaped peripheries is coupled at
or adjacent to the other of the vertices of the other
triangular-shaped periphery at or near axis of rotation 332. The
vertices of the triangular-shaped peripheries and/or areas (e.g.,
surface or cross-sectional areas) each lie on a line, such as an
axis of rotation, that is perpendicular to a radial line. In these
cases, the triangular-shaped peripheries can form a bowtie-shaped
periphery. For example, a triangular-shaped periphery can extend
from axis of rotation 332 to one of points 307 to the other of
points 307, and back to axis of rotation 332. In some embodiments,
cross-sectional areas of magnetic field generators 320 and 322 can
be triangular-shaped in plane 330. In some embodiments, either one
of magnetic field generators 320 and 322, or both, can be
configured to have a sector-shaped periphery, whereby a sector
includes portion of a circle or a disk bounded by two radii
disposed at an angle between the two radii, and the sector includes
an arc. For example, magnetic field generator 320 can include an
arc coextensive with circumferential portion 311a of circular
region 310, and magnetic field generator 322 can include a similar
arc coextensive with circumferential portion 311b. According to
some embodiments, magnetic field generators 320 and 322 include
permanent magnet material of different magnetic characteristics
(e.g. per unit area) to produce a magnetic strength profile, an
example of which is depicted in FIG. 4. Note that the term
"triangular-shaped" can refer, at least in some implementations, to
shapes having lateral portions spaced at an angle (e.g., an acute
angle), such that magnetic field generators can have triangular
shapes, sector shapes, or any other shape that can form a magnetic
field generator for applying a magnetic field and/or
counter-balancing a magnetic field generator.
[0032] Lateral portions can be disposed at or adjacent the portions
of the periphery that lie along or substantially along radial
lines, examples of which are depicted as lateral portions 301a and
301b of magnetic field generator 320. Magnetic field generator 322
can have similar lateral portions, too. As such, the sizes of
cross-sectional areas in plane 330 of magnetic field generators 320
and 322 are configurable to vary the magnetic strength (and/or
concentrations thereof) by selecting, among other things, an angle
between the lateral portions. For example, angle 309b between
lateral portions 301a and 301b can establish a cross-sectional area
in plane 330 for magnetic field generator 320, and that angle is
configurable to establish a magnetic field profile in association
with magnetic field generator 322. Similarly, angle 309a between
the lateral portions of magnetic field generator 322 can establish
another cross-sectional area in plane 330 for magnetic field
generator 322. In some embodiments, angles 309a and 309b can be the
same or can be different. Accordingly, magnetic field generator 320
can include an equivalent or a different cross-sectional area in
plane of rotation 330 than magnetic field generator 322.
[0033] In some embodiments, magnetic field generators 320 and 322
can be configured to generate a magnetic profile over or
substantially over a diameter 350 of substrate 340. In some
examples, diameter 350 of substrate 340 can be representative of
distance 402 for substrate 410 of FIG. 4. Referring back to FIG. 3,
portions of magnetic field generators 320 and 322 can conceptually
exclude magnetic field generating structures at approximately
center region 305. Or, portions of magnetic field generators 320
and 322 can include magnetic field generating structures, such as
magnetic elements, in center region 305 (not shown). Regardless,
center region includes a structure for affixing magnetic field
generators 320 and 322 relative to axis of rotational 332 so that
magnetic field generators 320 and 322 can rotate about that
axis.
[0034] Regions of magnetic field generation 308a and 308b can be
configured to generate magnetic fields with peak magnitudes (e.g.,
local peak magnitudes or otherwise), according to at least some
embodiments. In some examples, regions of magnetic field generation
308a and 308b can be disposed respectively at or adjacent
circumferential portions 311a and 311b of a circular region 310. In
operation, as magnetic field generators 320 and 322 rotate about
axis of rotational 332 to rotate a magnetic field profile about the
axis, with regions of magnetic field generation 308a and 308b
generating magnetic fields (e.g., in the z-axis direction) with
peak magnitudes adjacent to or above regions 321a and 321b,
respectively, of substrate 340. In some examples, regions 321a and
321b can coincide with or can be representative of regions 408a and
408b, respectively, of FIG. 4. Note that FIGS. 3 and 4 depict an
example of some implementations, and various embodiments of
magnetic field generators and magnetic field strength profiles are
not limited to those shown or described. For example,
counter-balancing magnetic field generator 320 can be replaced with
a counterweight (e.g. that does not generate magnetic fields) for
use with magnetic field generator 320, which is configured to
generate a variable magnetic field strength profile as a function
of distance. In another example, there can be more than two
magnetic field generators (e.g., there can be three, four, or more
magnetic field generators coupled at the axis of rotation).
[0035] FIG. 5 is a view of a surface of a magnetic field generator
apparatus configured to confront a surface of a substrate,
according to various embodiments. Magnetic field generator
apparatus 500 includes an opening 532 through which a rotatable
shaft is disposed and affixed to magnetic field generator apparatus
500. Magnetic field generator apparatus 500 includes a rotatable
magnetic field generator 520 and a counterbalance magnetic field
generator 522. Magnetic field generator apparatus 500 also includes
interior portions 559a and 559b within an interior region of
rotatable magnetic field generator 520 and an interior region of a
counterbalance magnetic field generator 522, respectively. In
various examples, rotatable magnetic field generator 520 and
counterbalance magnetic field generator 522 each can be composed of
one or more individual structures combined to form magnetic field
generator apparatus 500. Further, rotatable magnetic field
generator 520 and counterbalance magnetic field generator 522 can
be integrated, or otherwise formed to produce magnetic field
generator apparatus 500 as a monolithic structure. In some
embodiments, interior portions 559a and 559b, and one or more
periphery structures can include one or more magnetic structures
configured to generate magnetic flux to magnetically couple with
other magnetic structures.
[0036] Rotatable magnetic field generator 520 and a counterbalance
magnetic field generator 522 can include lateral portions and at
least one distal portion. Examples of lateral portions (or
subportions thereof) of rotatable magnetic field generator 520 are
depicted as lateral portions 592a and 592b, and examples of lateral
portions (or subportions thereof) of counterbalance magnetic field
generator 522 are depicted as lateral portions 591a and 591b.
Examples of distal portions for rotatable magnetic field generator
520 and counterbalance magnetic field generator 522 are depicted as
distal portion 593b and distal portion 593a, respectively. As
depicted, lateral portions 592a and 592b are oriented at an angle
with respect to a reference point 516, which can lie either off the
axis of rotation (as shown) or coincident with the axis of rotation
(e.g., within opening 532). Lateral portions 592a and 592b each are
oriented along or substantially along one of radial lines 513.
According to some embodiments, the lateral portions need not align
coincide with radial lines 513. That is, a subportion of lateral
portions 592a and 592b need not be in alignment with radial lines
513. Further, the lateral portions can have curved or substantially
curved portions (e.g., either convex or concave). Or, the lateral
portions can have any other shape. The one or more lateral portions
592a, 592b, 591a, and 591b can vary in circumferentially direction
along radial lines 513. For instance, one or more of lateral
portions 592a, 592b, 591a, and 591b can vary circumferentially in
alternating clockwise and counter-clockwise directions along radial
lines 513 to form equidistant line segments that cross back and
forth along radial lines 513 to form, for example, zigzag shapes.
Optionally, distal portions 593a and 593b can coincide or
substantially coincide with arc segments between radial lines 513,
such as arc 515. Any of the distal portions can have an arc-like
shape, such as distal portion 593a, which can be coextensive with
arc 515. Or, distal portions 593a and 593b can be formed to have
any other shape, including straight (e.g., one or more straight
line segments between radial lines 513). As used herein, at least
in some cases, the term "distal portion" can describe areas,
regions, lines, surfaces, structures, etc. disposed at or adjacent
an edge or constituting a boundary opposite to a proximal portion
coupled at an axis of rotation. For example, distal portions 593a
and 593b includes areas or regions at or near a boundary (e.g., an
arc-like or tangential boundary between radial lines). Distal
portions 593a and 593b can be described, in some cases, as
peripheral portions as they are portions of the periphery of a
magnetic field generator apparatus. In other cases, distal portions
593a and 593b can be described, in some cases, as circumferential
portions that are coextensive with an arc or circle centered at the
axis of rotation. As used herein, at least in some cases, the term
"lateral portion" can describe areas, regions, lines, surfaces,
structures, etc. disposed at or adjacent an edge or constituting a
boundary relative coextensive with a radial line, or with at least
one line segment extending from an axis of rotation to a distal
portion.
[0037] Peripheral portion 556 can be formed on a base 550 as a
contiguous structure configured to generate one or more magnetic
fields, or as a structure composed of any number of constituent
substructures configured to generate one or more magnetic fields,
the substructures being similar or different in structure and/or
functionality relative to each other. Further, interior portions
559a and 559b each can be formed as a contiguous structure
configured to generate one or more magnetic fields, or a structure
composed of any number of constituent substructures configured to
generate one or more magnetic fields, the substructures being
similar or different in structure and/or functionality relative to
each other. In some embodiments, periphery structure 556 is a
magnetically permeable material (e.g., a magnetic metal) disposed
on a number of magnetic elements (not shown) configured to generate
magnetic fields, the magnetic elements disposed between periphery
structure 556 and base 550. Also, a subset of magnetic elements are
disposed between interior region structure 552, which can be a
magnetically permeable material, and base 550, whereas another
subset of magnetic elements are disposed between interior region
structure 554, which can be a magnetically permeable material, and
base 550. Note that interior region structure 554 can include an
opening 555 to base 550 in which magnetic elements are absent. Note
that any of interior portions 559a and 559b, distal portions 593a
and 593b, and lateral portions 592a, 592b, 591a, and 591b can be
representative of any structure configured to generate magnetic
fields and are not limited to the structures described in the
various examples. Examples of structures configured to generate
magnetic fields include magnetic elements, such as "magnets." The
term "magnet" can refer to a body that produces a magnetic field
externally unto itself, including permanent magnets (e.g.,
including permanent magnet materials), electromagnets, and the
like. As used herein, the term "magnetic field generator" can
refer, at least in some embodiments, to one or more permanent
magnets, electromagnets, or any other structure known to produce
magnetic fields.
[0038] In some embodiments, interior portion 559a, distal portion
593a, lateral portion 592a, and lateral portion 592b of rotatable
magnetic field generator 520 are configured to include magnetic
structures for generating a first magnetic field profile. Interior
portion 559b, distal portion 593b, lateral portion 591a, and
lateral portion 591b of rotatable magnetic field generator 522 are
configured to include magnetic structures for generating a second
magnetic field profile. In one example, interior portion 559a is a
magnetic structure having a first direction of polarization and
distal portion 593a, lateral portion 592a, and lateral portion 592b
are magnetic structures having a second direction of polarization.
In some instances, interior portion 559a is configured to form a
first magnet pole (e.g., a south pole), whereas distal portion
593a, lateral portion 592a and lateral portion 592b collectively
form a second magnet pole (e.g., a north pole). Distal portion 593a
is magnetically coupled via gap 567 to interior portion 559a.
Lateral portions 592a and 592b are magnetically coupled via gaps,
such as gap 566, to interior portion 559a. Similarly, interior
portion 559b is a magnetic structure having a first direction of
polarization and distal portion 593b, lateral portion 591a, and
lateral portion 591b are magnetic structures having a second
direction of polarization. As such, interior portion 559b is
configured to form a first magnet pole (e.g., a south pole), and
distal portion 593a, lateral portion 592a and lateral portion 592b
collectively form a second magnet pole (e.g., a north pole). Distal
portion 593b is magnetically coupled via a gap to interior portion
559b, and lateral portions 592a and 592b are magnetically coupled
via other gaps to interior portion 559b. According to some
examples, gaps 567 and 566, as well as the gaps in counterbalance
magnetic field generator 522 are configurable to influence the
magnitudes of magnetic strength and/or flux density in the magnetic
field profiles for rotatable magnetic field generator 520 and
counterbalance magnetic field generator 522. According to some
embodiments, one or more groups of magnetic elements (not shown)
are disposed at or adjacent a distal end 503b in rotatable magnetic
field generator 520 to generate a first peak magnitude. Also, one
or more groups of magnetic elements (not shown) are disposed at or
adjacent a distal end 503a of counterbalance magnetic field
generator 522 to generate a second peak magnitude.
[0039] FIG. 6 depicts distributions of magnetic strength, according
to some embodiments. Magnetic field generator apparatus 600
includes rotatable magnetic field generator 620 and counterbalance
magnetic field generator 622 and the relative magnitudes of
magnetic strength, for example, per unit area 651 relative to base
650, as well as the directions of polarization indicated by arrow
heads. Rotatable magnetic field generator 620 and counterbalance
magnetic field generator 622 are configured to rotate about axis of
rotation 532 in center region 595. As shown, rotatable magnetic
field generator 620 is configured to generate magnetic fields
and/or flux at a distal portion 692 at a distal end having a first
magnitude 684 in a first direction of polarization (e.g., as north
poles). Lateral portions 694 of rotatable magnetic field generator
620 are configured to: (1) generate magnetic fields and/or flux at
or adjacent to distal portion 692 with the first magnitude 684 for
a longer range of radial distances from axis of rotation 532, (2)
generate magnetic fields and/or flux with a second magnitude 682
for an intermediate range of radial distances from axis of rotation
532, and (3) generate magnetic fields and/or flux with a third
magnitude 680 for an shorter range of radial distances from axis of
rotation 532 (and into center region 595). First magnitude 684 of
the magnetic field is greater than second magnitude 682, which, in
turn, is greater than third magnitude 680, all of which share the
same direction of polarization.
[0040] An interior portion of rotatable magnetic field generator
620 is shown to generate magnetic fields and/or flux at a first
magnitude 685, the magnetic fields and/or flux having a second
direction of polarization (e.g., as south poles). Further, the
interior portion also generates magnetic fields and/or flux at a
second magnitude 683, with the magnetic fields and/or flux being in
the second direction of polarization. The magnitudes and directions
of polarization of rotatable magnetic field generator 620 can be
generated by magnetic elements, such as permanent magnets. Further,
more or fewer magnitudes that the three magnitudes can be
implemented. Further, the magnitudes and directions of polarization
of rotatable magnetic field generator 620 are configured to shape
and generate a magnetic field profile portion having a first
magnitude adjacent to the distal end (e.g., based on magnetic
coupling between north and south poles).
[0041] Counterbalance magnetic field generator 622 is configured to
generate magnetic fields and/or flux at a distal portion 698 at a
distal end having a third magnitude 680 in a first direction of
polarization (e.g., as north poles). Lateral portions 694 of
rotatable magnetic field generator 620 also are configured to
generate magnetic fields and/or flux with a third magnitude 680
along radial distances from the distal end to the axis of rotation
532 (and into center region 595). The magnetic fields having third
magnitude 680 share the same direction of polarization. An interior
portion of counterbalance magnetic field generator 622 is shown to
generate magnetic fields and/or flux at third magnitude 681 and at
a second direction of polarization (e.g., as south poles). The
magnitudes and directions of polarization of counterbalance
magnetic field generator 622 can be generated by magnetic elements,
such as permanent magnets. Further, more or fewer magnitudes that
the magnitudes shown can be implemented. Further, the magnitudes
and directions of polarization of counterbalance magnetic field
generator 622 are configured to shape and generate a magnetic field
profile portion having a second magnitude adjacent to the distal
end (e.g., based on magnetic coupling between north and south
poles). Note that the individual arrows of FIG. 6 can represent
flux per unit area, such as magnitude 684a of unit area 651. Or,
the individual arrows of FIG. 6 can represent the magnetic flux
generated by a discrete magnetic element, such as a permanent
magnet.
[0042] FIG. 7 depicts an example of an arrangement of magnetic
elements for a magnetic field generator apparatus, according to
some embodiments. Magnetic field generator apparatus 700 includes
rotatable magnetic field generator 720 and counterbalance magnetic
field generator 722, both including various magnetic elements
disposed on base 750. Also, magnetic field generator apparatus 700
includes interior portions including magnetic elements. Rotatable
magnetic field generator 720 and counterbalance magnetic field
generator 722 are configured to rotate about axis of rotation 732
in center region 795.
[0043] Lateral portions 711a and 711b of counterbalance magnetic
field generator 722, such as lateral portion 796, and distal
portion 798 include magnetic elements 780, each having an
equivalent capacity for generating similar amounts of magnetic flux
in a first direction of polarization. Interior portion 759b
includes magnetic elements each having a capacity for generating
similar amounts of magnetic flux in a second direction of
polarization. Lateral portions 711a and 711b are shown to be
coextensive with radial lines 713 at an angle ("A") 715. Lateral
portions 701a and 701b of rotatable magnetic field generator 720,
such as lateral portion 792, include different or the same magnetic
elements. In this example, lateral portions 701a and 701b include
magnetic elements 780, 782, and 784, each of which share a common
direction of polarization (e.g., as north poles). Interior portion
759a includes magnetic elements each having a capacity for
generating similar or different amounts of magnetic flux in a
second direction of polarization (e.g., as south poles). In
particular, magnetic elements 785 generate similar magnitudes of
flux as magnetic elements 784, but in a second direction of
polarization. Similarly, magnetic elements 783 generate similar
magnitudes of flux as magnetic elements 782, but in a second
direction of polarization.
[0044] In operation, magnetic elements in lateral portions 711a and
711b and distal portion 798 magnetically couple to magnetic
elements 781 in interior region 759b to form magnetic fields having
a profile that can vary along a radial line from the axis of
rotation. Further, magnetic elements in lateral portions 701a and
701b and the distal portion (e.g., magnetic elements 784)
magnetically couple to magnetic elements 783 and 785 in interior
region 759a to form magnetic fields having a profile that can vary
along a radial line from the axis of rotation. Specifically,
magnetic elements 784 in the distal portion of rotatable magnetic
field generator 720 generate magnetic flux 793 passing in radial
direction through to at least magnetic elements 785 and others in
interior portion 759a. Similarly, at least magnetic elements 782
and 784 in lateral portions 701a and 701b of rotatable magnetic
field generator 720 generate magnetic flux 791 passing in a
circumferential or tangential direction (e.g., perpendicular to a
radial line extending from the axis of rotation) through to at
least magnetic elements 783 and 785 in interior portion 759a.
Magnetic elements can be composed of similar or different magnetic
materials, such as one or more rare-earth magnet materials that are
known in the art, such as Neodymium Iron Boron ("NdFeB"), Samarium
Cobalt ("SmCo") and variants of both, as well as ceramic magnets
and iron-based magnets. In some embodiments, lateral portions 701a
and 701b of rotatable magnetic field generator 720 can be
coextensive with radial line 713, wherein in other embodiments,
lateral portions 701a and 701b of rotatable magnetic field
generator 720 can be coextensive with radial lines 713a at an angle
("B") 717, which, in turn, reduces the cross-sectional area of
rotatable magnetic field generator 720 by an amount 758. In some
cases, magnetic elements, such as magnetic element 780b, includes a
projection 787 for attaching or securing within magnetic field
generator apparatus 700. In some examples, magnetic elements 780,
782, and 784 can be differently-sized relative to each other, and
can include different amounts of permanent magnet material. For
example, magnetic element 784a (similar to element 784) is depicted
as being relatively larger in diameter and generates a magnetic
field strength 731c, which is depicted as being capable of
generating the greatest amount of flux. Magnetic element 782a
(similar to element 782) is depicted as being relatively moderate
in diameter and generates a magnetic field strength 731b, which is
depicted as being capable of an intermediate amount of flux.
Magnetic element 780a (similar to element 780) is depicted as being
relatively small in diameter and generates a magnetic field
strength 731a, which is depicted as being capable of generating the
least amount of flux (as depicted by the relative sizes of the
arrows). Magnetic elements 780a, 783a, and 784a are shown disposed
on a portion of base 750a, which is a portion of base 750.
[0045] FIG. 8 is an example of a flow chart depicting a process by
which to manufacture a magnetic field generator apparatus,
according to an embodiment. In flow 800, a profile of magnetic
strength is determined at 802. For example, a desired profile of
magnetic strength can be based on the types of materials being
deposited, the size of the substrate, the step and sidewall
coverage, and/or other like factors. At 804, a first array of
magnetic elements is formed. For example, lateral, distal and
interior portions of a rotatable magnetic field generator can be
formed. At 806, the magnetic field strength can be modified or
configured to form a certain shape of a portion of the profile of
magnetic field strength. For example, a supplemental array of
magnetic elements can be used. Or, the magnetic elements can
include different magnetic materials to vary the magnetic field
strength at certain positions along a diameter of a substrate. At
808, the first array of magnetic elements is counterbalanced with a
second array of magnetic elements. For example, a counterbalance
magnetic field generator can be formed. At 810, the magnetic field
strength of the counterbalance magnetic field generator can be
modified or configured to form a certain shape of the profile for a
portion of the magnetic field strength. A determination is made
whether a minimum magnitude ought to be included in a magnetic
profile at 812. If so, the second portion of the magnetic profile,
which corresponds to the counterbalance magnetic field generator,
is modified. The flow terminates at 816.
[0046] FIG. 9 depicts an example of a magnetic field generator
apparatus implementing supplemental magnetic structures, according
to some embodiments. Magnetic field generator apparatus 900
includes rotatable magnetic field generator 920 and counterbalance
magnetic field generator 922, both including magnetic structures to
generate magnetic fields, including, but not limited to, magnetic
elements disposed in periphery 956 (or peripheral portions thereof)
and within interior portions 952 and 954. Magnetic field generator
apparatus 900 includes interior portions 952 and 954, which can be
composed of magnetic elements. Further, magnetic field generator
apparatus 900 includes one or more supplemental magnetic structures
998 disposed adjacent to (and can be coupled to) lateral portions
901a and/or 901b. Supplemental magnetic structures 998 can be
configured to generate variable amounts of supplemental magnetic
flux, and can include a variable number of magnetic elements (not
shown). Supplemental magnetic structures 998 are configured to
rotate in synchronicity with rotatable magnetic field generator
920.
[0047] FIG. 10 depicts a magnetic profile having a configurable
profile portion, according to some embodiments. In one
implementation, a certain amount of magnetic elements and/or
magnetic material can produce a profile portion 1026, in which a
range of magnetic field strength including a peak magnitude is
generated in region 1027b along a radial distance ("R2") 1006. The
profile portion 1026 decreases in region 1027a from region 1027b to
a reference point ("0"). Supplemental magnetic structures can
include additional amounts of magnetic elements and/or magnetic
material to form profile portions 1026a and 1026b, both of which
have increased magnitudes. Or, supplemental magnetic structures can
include fewer amounts of magnetic elements and/or magnetic material
to form profile portions 1026c and 1026d, both of which have
decreased magnitudes. Profile portion 1024 can be shaped and
generated along radial distance ("R1") by a counterbalance magnetic
field generator (not shown).
[0048] Referring back to FIG. 9, periphery 956 (or portions
thereof) can be formed with zigzag-shaped lateral portions in which
protruding edge surfaces are formed to facilitate ignition of
plasma, among other things. For example, a portion 901c of
periphery 956 is formed to include a zigzag portion 957 of metal
(e.g., formed from a sheet of magnetically permeable metal) that
includes protruding edge surfaces 961 between gaps 962. In some
embodiments, protruding edge surfaces 961 are leading edges when
rotating in a plane about an axis of rotation. In some cases,
magnetic flux generated by underlying magnetic elements (not shown)
can be concentrated or localized at or adjacent to protruding edge
surfaces 961 or the surface 960 of zigzag portion 957. The surface
area of surface 960 is less than if material resided at gaps 962,
and, thus, facilities an increased amount of flux to pass through
per unit area (e.g., facilitates increased magnetic flux).
[0049] FIG. 11 depicts a specific example of one or more
arrangements of magnetic elements used to form a magnetic field
generator apparatus, according to some embodiments. Magnetic field
generator apparatus 1100 includes a rotatable magnetic field
generator 1120 and a counterbalance magnetic field generator 1122
formed on or integrated with a base 1150, which can be composed of
magnetically permeable material, magnetic metals and the like. Base
1150 can be formed from a planar piece of magnetically permeable
material. Rotatable magnetic field generator 1120 and
counterbalance magnetic field generator 1122 are configured to
generate a magnetic profile along medial line 1162 similar to
magnetic profile 400 of FIG. 4. Optionally, rotatable magnetic
field generator 1120 can include supplemental magnetic structures
1198 disposed adjacent to (and/or coupled to) lateral portions
1101a and 1101b. In some embodiments, magnetic field generator
apparatus 1100 can be described as a bowtie-shaped magnetic
generator.
[0050] In the examples shown, magnetic elements 1183, 1184, and
1180 are implemented as magnets having south poles disposed at base
1150 and north poles being adjacent zigzag-shaped surface 1151,
which can be formed from a sheet of magnetically permeable
material. The magnetic elements in supplemental magnetic structures
1198 are oriented similarly to form north poles at surfaces 1199,
which can be formed from a sheet of magnetically permeable
material. By contrast, magnetic elements 1181, 1182 and 1185 are
implemented as magnets having north poles disposed at base 1150 and
south poles being adjacent interior portions 1154 and 1152, either
or both of which can be formed from a sheet of magnetically
permeable material,
[0051] Magnetic elements disposed between periphery surface 1151
and base 1150 at distal end 1103 are configured to generate flux in
a direction that is radial (includes substantially radial) along
radial segment 1167. Magnetic elements disposed between periphery
surface 1151 and base 1150 at either lateral portion 1101a or 1101b
are configured to generate flux in a direction that is tangential
(includes substantially tangential) to radial lines or
circumferential (includes substantially circumferential) about an
axis of rotation. Flux generated tangentially and/or
circumferentially can flow in a direction along flux path segment
1166. Further to the example shown in FIG. 11, the magnetic
elements are arranged to generate, for example, a magnetic return
flux path 1140 in or adjacent to the surface of base 1150, as well
as another magnetic return flux path 1142 that passes through the
environment, vacuum, or any other gaseous materials in a chamber to
form a plasma. Filled hole 1161 represents an opportunity to remove
a magnetic element to decrease the magnetic strength of a part of
the magnetic profile, whereas an empty hole 1160 represents an
opportunity to add a magnetic element to increase the magnetic
strength.
[0052] FIG. 12 is an example of a flow chart depicting a process by
which to manufacture a bowtie-shaped magnetic field generator
apparatus, according to an embodiment. In flow 1200, a profile of
magnetic strength is determined at 1202. For example, a desired
profile of magnetic strength can be based on the types of materials
being deposited, the size of the substrate, the step and sidewall
coverage, and/or other like factors. At 1204, a bowtie-shaped array
of magnetic elements is formed. For example, magnetic elements can
be disposed between a base, peripheral portions and interior
portions for a rotatable magnetic field generator and a
counterbalance magnetic field generator. At 1206, forming the
bowtie-shaped array of magnetic elements includes disposing magnets
along radial lines at 1206 of one or more lateral portions of
either or both magnetic field generators. At 1208, forming the
bowtie-shaped array of magnetic elements includes disposing magnets
along the periphery at distal portions of either or both magnetic
field generators. Angles between one or more sets of radial lines
can be modified at 1210, according to various embodiments.
Optionally, supplemental magnets can be implemented at 1212 to
modify a portion of a magnetic strength profile. For example, more
or fewer amounts of magnetic material can be implemented in, for
example, supplemental magnetic structures 1198 of FIG. 11.
Returning back to FIG. 12, an optional zigzag-shape can be
implemented on the periphery of the magnetic field generator
apparatus at 1214. The flow then terminates.
[0053] The magnetic field strength can be modified or configured to
form a certain shape of a portion of the profile of magnetic field
strength. For example, a supplemental array of magnetic elements
can be used. Or, the magnetic elements can include different
magnetic materials to vary the magnetic field strength at certain
positions along a diameter of a substrate. At 1208, the first array
of magnetic elements is counterbalanced with a second array of
magnetic elements. For example, a counterbalance magnetic field
generator can be formed. At 1210, the magnetic field strength of
the counterbalance magnetic field generator can be modified or
configured to form a certain shape of the profile for a portion of
the magnetic field strength. A determination is made whether a
minimum magnitude ought to be included in a magnetic profile at
1212. If so, the second portion of the magnetic profile, which
corresponds to the counterbalance magnetic field generator, is
modified. The flow terminates at 1216.
[0054] FIG. 13 depicts an example of a system for modifying a
non-metal film on a semiconductor substrate in accordance with at
least one embodiment. Diagram 1300 depicts a top view 1302 and a
side view 1320 of a plasma implementation system. In the example
shown, chamber 1390 is configured to facilitate plasma processing
in a plasma processing region 1305 to modify and/or form a
semiconductor layer of a non-metal material (or other semiconductor
materials) located, for example, on a substrate 1350. In some
embodiments, the system shown in FIG. 13 is configured to perform
physical vapor deposition ("PVD") to deposit a non-metal material,
such as a chalcogenide material, onto a substrate to fabricate
semiconductor device structures. As an example, the non-metal
material that can be deposited on a substrate may form the memory
material for a memory cell, such as a phase change memory cell. In
some embodiments, the plasma implementation system can be
configured to deposit a layer including germanium, antimony and
tellurium ("GST"). In at least one embodiment, the GST can be
deposited in the form: Ge.sub.2Sb.sub.2Te.sub.5.
[0055] According to various embodiments, the plasma implementation
system of FIG. 13 can include one or more magnetic field generators
1322 configured to rotate about centerline 1308 to generate
magnetic fields and magnetic field profile portions for use in
plasma processing in chamber 1390. Chamber 1390 includes an outer
chamber wall 1306 and an inner chamber wall 1307, and can be
configured to house a shield 1391. Shield 1391 includes an inner
shield wall 1309b that is configured to enclose plasma processing
region 1305. In some alternative embodiments, one or more magnetic
field generators can be disposed within any regions between shield
1311 and inner chamber wall 1307, examples of which are disclosed
in U.S. Nonprovisional application Ser. Nos. 12/551,356 and
12/551,379. Note that centerline 1308 need not be straight and can
be curved or can include a turn. Note, too, that centerline 1308
can be oriented at 90 degrees (or any amount of degrees) from the
position shown in FIG. 13.
[0056] To perform plasma processing within plasma processing
region, chamber 1390 includes one or more ports. For example,
inlet/outlet port 1321a can be configured as an inlet port to
introduce a gas (e.g., an inert gas) into chamber 1390 for
ionization purposes. An example of an inert gas is argon.
Inlet/outlet port 1321b can be configured as an outlet port to
evacuate gaseous byproducts. The plasma implementation system also
includes a magnet field generator ("Magnetic Field Generator") 1322
positioned internal to chamber 1390, as shown, or external to
chamber 1390 (e.g., above chamber top surface 1371) to confront a
semiconductor layer on substrate 1350. Magnet field generator 1322
can include a rotatable magnetic field generator and a
counterbalance magnetic field generator, as described herein. In
accordance with the various embodiments, a rotatable magnetic field
generator of magnet field generator 1322 can generate a portion of
a magnetic field profile in plasma 1330 that includes a first
magnitude ("M1") 1327. Further, a counterbalance magnetic field
generator of magnet field generator 1322 can generate another
portion of the magnetic field profile in plasma 1330 that includes
a second magnitude ("M2") 1325. In some cases, a minimum magnitude
of magnetic strength can be generated between magnitudes 1327 and
1325.
[0057] In some embodiments, magnet field generator 1322 can include
a bowtie-shaped arrangement of magnetic elements positioned to
implement a target material, the bowtie-shaped arrangement of
magnetic elements being configured to rotate about centerline 1308.
In some cases, the bowtie-shaped arrangement of magnetic elements
includes a first magnetic field generator having a first
triangular-shaped periphery (e.g., including sector shapes, diamond
shapes, rectangular shapes, square shapes, or any other shape). The
bowtie-shaped arrangement of magnetic elements also includes a
second magnetic field generator having a second triangular-shaped
periphery. At least one of the vertices of the second
triangular-shaped periphery is coupled adjacent to centerline 1308
to one of the vertices of the first triangular-shaped periphery.
The second magnetic field generator can have a mass equivalent to
that of the first magnetic field generator to counteract a force
generated by rotation about centerline 1308. The bowtie-shaped
arrangement of magnetic elements can be configured to apply to
plasma processing region 1305 magnetic flux having peak magnitudes
of magnetic strength adjacent to the periphery of the semiconductor
layer formed on substrate 1350 and a minimum magnitude of magnetic
strength therebetween. Note that magnitudes 1327 and 1325, and the
minimum magnitude of magnetic strength are disposed substantially
along a diameter that rotates in synchronization with a medial
line, such as medial line 1162 of FIG. 11, passing through the
bowtie-shaped arrangement of magnetic elements.
[0058] The bowtie-shaped arrangement of magnetic elements can
include a first group of magnets disposed along the periphery
(e.g., magnetic elements disposed along peripheral structure or
region 556 of FIG. 5) of the bowtie-shaped arrangement, and a
second group of magnets disposed within the periphery of the
bowtie-shaped arrangement (e.g., as interior portions within
interior regions of either a rotatable magnetic field generator or
a counterbalance magnetic field generator, or both). The first and
the second groups of magnets are polarized so that magnet flux
passes from the first group of magnets along the periphery to the
second group of magnets within the interior. Note that the first
and the second groups of magnets include subsets of magnets having
different magnetic characteristics to generate different amounts of
flux (e.g., magnets in each subset can generate a magnetic strength
with different magnitudes, such as first magnitude, a second
magnitude, a third magnitude, etc., as described FIG. 7). The first
and the second groups of magnets respectively can constitute a
first magnet pole and a second magnet pole. The first magnet pole
can include a peripheral structure to establish the first magnetic
pole, including a sawtooth-shaped edge in a plane of rotation.
[0059] The plasma implementation system can include an orifice
configured to accept a wafer chuck 1352 that, among other things,
supports substrate 1350 during plasma processing. Wafer chuck 1352
can be configured to receive a biasing signal, such as a
radio-frequency ("RF") voltage signal, to facilitate generation of
plasma in plasma processing region 1305 to perform RF sputtering
deposition. In some implementations, wafer chuck 1352 can be
described as an electrostatic chuck ("ESC") or "e-chuck."
[0060] A target 1324 can be disposed between magnetic field
generator 1322 and substrate 1350. Or, target 1324 can be located
at other regions within chamber 1390. Target 1324 can include one
or more metal, metalloid, or non-metal elements. An example of a
suitable non-metal as a constituent of target 1324 is Germanium
("Ge"), and examples of suitable metalloids include Antimony ("Sb")
and Tellurium ("Te"). As used herein, the term "non-metal" can
refer, at least in some embodiments, to both non-metals and
metalloids. In some embodiments, target 1324 can include one or
more chalcogenide elements. In one embodiment, target 1324 can
include a material of germanium, antimony and tellurium ("GST") in
the form of, for example, Ge.sub.2Sb.sub.2Te.sub.5, or any variants
thereof. This material can be used to form a layer of GST or other
equivalent structures. Note that the plasma implementation system
of FIG. 13 can be configured to perform other processing operations
other than deposition, such as etching, according to some
embodiments. In some embodiment, target 1324 can include metals,
such as copper, aluminum, tin, and the like, as well as metal
alloys and metal and non-metals.
[0061] FIG. 14 is an example of a flow chart depicting a process by
which to form semiconductor film using an example of a magnetic
field generator, according to various embodiments. In flow 1400, a
first portion of a magnetic field is generated at 1402. For
example, a desired profile of magnetic strength can be generated by
a rotatable magnetic field generator, the profile having one or
more ranges of magnitude of magnetic field strength adjacent a
first circumferential portion of a semiconductor substrate. At
1404, a first portion of a magnetic field is generated at 1404. For
example, another desired profile of magnetic strength can be
generated by a counterbalance magnetic field generator, the profile
having one or more ranges of peak magnitude of magnetic field
strength adjacent to a second circumferential portion of the
semiconductor substrate. The second circumferential portion can be
at an endpoint of a diameter passing through an axis of rotation to
another endpoint of the diameter at which the first circumferential
portion resides. In some examples, the second peak magnitude is
less than the first peak magnitude.
[0062] At 1406, first portion of the magnetic field and the second
portion of the magnetic field are rotated about an axis of
rotation. At 1408, a determination is made whether to generate a
minimum magnitude. If not, flow 1400 moves to 1418. Otherwise, flow
1400 moves to 1410 at which a minimum magnitude of a magnetic field
strength is disposed between a first and a second peak magnitude.
At 1418, a determination is made whether to rotate a magnetic
structure. If so, flow 1400 moves to 1420, at which a magnetic
structure (e.g., one or more magnetic field generators) with
triangular-shaped cross-sections is rotated in relation to a plasma
processing region. At 1430, plasma is ignited. Optionally, plasma
ignition is facilitated by rotating triangular-shaped
cross-sections with zigzag peripheral portions in which edge
protrusions are oriented in the direction of rotation. In some
cases, the edge protrusions of zigzag edges facilitate localization
of magnetic flux, which can facilitate ignition of the plasma. A
target material is decomposed at 1432 to form a plasma at a plasma
processing region adjacent the semiconductor substrate within a
chamber. If GST or any chalcogenide material (or any other
material) is included in the target material, it will be sputtered
at 1440. GST can be deposted in the form of, for example,
Ge2Sb2Te5, or any variants thereof. But if at 1438 GST is not
included, than flow 1400 moves to 1450 at which a film is formed
upon a semiconductor substrate. At 1450 (or at other portions of
flow 1400), a wafer chuck configured to support the semiconductor
substrate is biased, whereby a radio-frequency ("RF") voltage
signal is used to supply RF power. The source generating the RF
voltage has its impedance matched with the plasma including
germanium, antimony and tellurium ("GST"). The generation of the RF
voltage is then controlled to facilitate generation of the plasma
to modify the non-metal film to deposit one or more layers of GST.
The flow terminates at 1452.
[0063] FIG. 15 depicts an example of a memory cell including a
layer of chalcogenide-based material as formed by deposition
processes and systems in accordance with at least one embodiment of
the invention. Diagram 1500 includes a semiconductor substrate
1540, such as a silicon-based substrate, over which an insulator
structure 1530 is formed. An example of such a structure is a SiO2
structure. On top of insulator structure 1530, a bottom electrode
structure 1520 is formed as a titanium nitride ("TiN")-based or
metal-based structure. Upon the bottom electrode structure 1520,
insulator structures 1510a and 1510b are formed as, for example,
SiO2 structures. A non-metal layer 1504, such as a chalcogenide
layer, is formed over insulator structures 1510a and 1510b. In some
instances, arrangements of magnetic field generators can reduce or
eliminate, for example, voids in area 1508, and/or form crystal
structure having relatively fewer defects than otherwise might be
the case. In some embodiments, non-metal layer 1504 includes a
material of germanium, antimony and tellurium ("GST") in the form
of, for example, Ge.sub.2Sb.sub.2Te.sub.5. A top electrode
structure 1502 can be formed upon non-metal layer 1504. In various
other embodiments, the systems, apparatuses, and methods can be
used to perform deposition of metals, including copper ("Cu") and
any other metal or metal-based material, as well as any non-metal
or non-metal based material.
[0064] In at least some of the embodiments of the invention, one or
more of the structures and/or functions of any of the
above-described features can be implemented in software, hardware,
firmware, circuitry, or a combination thereof. Note that the
structures and constituent elements above, as well as their
functionality, can be aggregated with one or more other structures
or elements. Alternatively, the elements and their functionality
can be subdivided into constituent sub-elements, if any.
[0065] The foregoing description, for purposes of explanation, used
specific nomenclature to provide a thorough understanding of the
invention. However, it will be apparent to one skilled in the art
that specific details are not required in order to practice the
invention. In fact, this description should not be read to limit
any feature or aspect of the present invention to any embodiment;
rather features and aspects of one embodiment can readily be
interchanged with other embodiments.
[0066] Thus, the foregoing descriptions of specific embodiments of
the invention are presented for purposes of illustration and
description. They are not intended to be exhaustive or to limit the
invention to the precise forms disclosed; many alternatives,
modifications, equivalents, and variations are possible in view of
the above teachings. For the purpose of clarity, technical material
that is known in the technical fields related to the embodiments
has not been described in detail to avoid unnecessarily obscuring
the description. Thus, the various embodiments can be modified
within the scope and equivalents of the appended claims. Further,
the embodiments were chosen and described in order to best explain
the principles of the invention and its practical applications;
they thereby enable others skilled in the art to best utilize the
invention and various embodiments with various modifications as are
suited to the particular use contemplated. Notably, not every
benefit described herein need be realized by each embodiment of the
present invention; rather any specific embodiment can provide one
or more of the advantages discussed above. In the claims, elements
and/or operations do not imply any particular order of operation,
unless explicitly stated in the claims. It is intended that the
following claims and their equivalents define the scope of the
invention.
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