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| United States Patent | 5464518 |
| Link to this page | http://www.wikipatents.com/5464518.html |
| Inventor(s) | Sieck; Peter A. (Santa Rosa, CA);
Porter; John R. (Napa, CA) |
| Abstract | A rotating cylindrical sputtering target surface as part of a magnetron has
cylindrical shields adjacent each end of the target that are shaped at
their respective inner edges to maximize etching and to prevent
condensation and subsequent arcing that undesirably occurs when certain
materials, particularly dielectrics, are being sputtered. If two or more
rotating targets are employed in a single magnetron system, each is
similarly shielded. In an alternative form, the target is provided with a
single cylindrical shield that is cut away for a significant portion of
the distance around the cylinder to provide an opening through which a
sputtering region of the target is accessible, while maintaining shielding
of the target end regions. This alternative single shield is similarly
shaped at portions of its inner edges adjacent to the opening to maximize
etching and to prevent undesired condensation and subsequent arcing. The
preferred shield structure is rotatable in order to allow the position of
the sputtering activity to be selected. |
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Title Information  |
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Drawing from US Patent 5464518 |
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Cylindrical magnetron shield structure |
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| Publication Date |
November 7, 1995 |
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| Filing Date |
September 19, 1994 |
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| Parent Case |
This is a continuation of application Ser. No. 08/004,964, filed Jan. 15,
1993, abandoned. |
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Title Information  |
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References  |
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| *references marked with an asterisk below are user-added references |
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U.S. References |
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| | Reference | Relevancy | Comments | Reference | Relevancy | Comments | 5213672 Hartig 204/298.22 May,1993 |      Your vote accepted [0 after 0 votes] | | 5108574 Kirs 204/298.22 Apr,1992 |      Your vote accepted [0 after 0 votes] | | 4525264 Hoffman 204/298.22 Jun,1985 |      Your vote accepted [0 after 0 votes] | | 4466877 McKelvey 204/298.23 Aug,1984 |      Your vote accepted [0 after 0 votes] | | 4443318 McKelvey 204/298.23 Apr,1984 |      Your vote accepted [0 after 0 votes] | | 4417968 McKelvey 204/192.12 Nov,1983 |      Your vote accepted [0 after 0 votes] | | 4410407 Macaulay 204/192.25 Oct,1983 |      Your vote accepted [0 after 0 votes] | | 4407708 Landau 204/192.13 Oct,1983 |      Your vote accepted [0 after 0 votes] | | 4356073 McKelvey 204/192.12 Oct,1982 |      Your vote accepted [0 after 0 votes] | | 4422916 McKelvey 204/192.12 Dec,1969 |      Your vote accepted [0 after 0 votes] | | |
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Market Review  |
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Technical Review  |
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Claims  |
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It is claimed:
1. A sputtering apparatus for depositing film on a substrate in a vacuum
chamber, comprising:
a magnetron including therein at least one target structure with an outer
cylindrically-shaped surface of sputtering material;
first and second support structures holding said target structure at
opposite ends thereof such that said target structure is rotatable about
its longitudinal axis;
a magnet assembly within said target structure that provides a magnetic
field zone extending along a length of said sputtering material surface
and extending a circumferential distance therearound;
first and second cylindrical shields, said shields carried at opposite ends
of said target structure by said first and second support structures and
extended axially along said sputtering material surface to substantially
cover the ends of said sputtering material surface, said first shield
having an inner edge closest to said second shield and said second shield
having an inner edge closest to said first shield;
said inner edges being non-rectangularly shaped to conform substantially to
a shape of a pattern of condensation of vaporized material on said target
structure which forms when said target structure is held stationary; and
said inner edges being positioned to shield regions where condensation of
vaporized material on said target structure would otherwise occur at a
rate which exceeds a rate at which deposited condensate is removed from
said target structure by sputtering.
2. A sputtering apparatus for depositing film on a substrate in a vacuum
chamber, comprising:
a magnetron including therein at least one target structure with an outer
cylindrically-shaped surface of sputtering material;
first and second support structures holding said target structure at
opposite ends thereof such that said target structure is rotatable about
its longitudinal axis;
a magnet assembly within said target structure that provides a magnetic
field zone extending along a length of said sputtering material surface
and extending a circumferential distance therearound;
first and second cylindrical shields, said shields carried at opposite ends
of said target structure by said first and second support structures and
extended axially along said sputtering material surface to substantially
cover the ends of said sputtering material surface, said first shield
having an inner edge closest to said second shield and said second shield
having an inner edge closest to said first shield;
said inner edges being non-rectangularly shaped to conform substantially to
a shape of a pattern of etching of sputtering material on said target
structure which occurs when said target structure is held stationary; and
said inner edges being positioned to shield regions where condensation of
vaporized material on said target structure would otherwise occur at a
rate which exceeds a rate at which deposited condensate is removed from
said target structure by sputtering.
3. The apparatus according to any one of claims 1 and 2, wherein each of
said first and second cylindrical shields is additionally shaped with
continuous portions around its circumference at each of said opposite ends
that are positioned to cover said sputtering surface for a distance
adjacent each of its said opposite ends and extend over adjacent portions
of said first and second support structures.
4. The apparatus according to any one of claims 1 and 2, wherein said inner
edges of said shields are positioned a distance from said magnetic field
zone sufficient to stabilize arcing adjacent to said magnetic field zone.
5. The apparatus according to any one of claims 1 and 2, wherein said
shields are connected at corresponding portions of their inner edges which
are not adjacent to said magnetic field zone by a cylindrically-shaped
structure extending around a portion of the circumference of said
sputtering material surface that is substantially outside said magnetic
field zone to form a unified shield, said unified shield having an opening
at least as large as said magnetic field zone and extending around a
portion of the circumference of said sputtering material surface that is
substantially inside said magnetic field zone and having a length less
than a distance between opposite ends of the sputtering surface of said
target structure.
6. A sputtering apparatus for depositing film on a substrate in a vacuum
chamber, comprising:
at least one elongated target having a sputtering surface with an outside
cylindrical shape of a given diameter and a given length between first and
second ends thereof;
first and second support structures respectively supporting said first and
second sputtering surface ends in a manner that allows said target to
rotate about a central longitudinal axis thereof;
means positioned within said target for providing a magnetic field zone
extending along a length of said sputtering surface and a circumferential
distance therearound;
electrically controlled driving means coupled to said target structure for
rotating said sputtering surface through said magnetic field zone;
first and second cylindrical shields separated by a distance of less than
substantially one-quarter inch from said sputtering surface for minimizing
condensation of vaporized material at said first and second sputtering
surface ends, said shields carried at opposite ends of said target by said
first and second support structures and extended axially along said
sputtering surface to substantially cover the ends of said sputtering
surface, said shields having continuous portions extending around the
circumference of said first and second ends positioned to cover said
sputtering surface for a distance adjacent each of its said first and
second ends and extend over adjacent portions of said first and second
support structures, said first shield having an inner edge closest to said
second shield and said second shield having an inner edge closest to said
first shield;
said inner edges being non-rectangularly shaped to conform substantially to
a shape of a pattern of condensation of vaporized material on said target
structure which forms when said target structure is held stationary; and
said inner edges being positioned to shield regions where condensation of
vaporized material on said target structure would otherwise occur at a
rate which exceeds a rate at which deposited condensate is removed from
said target structure by sputtering.
7. A sputtering apparatus for depositing film on a substrate in a vacuum
chamber, comprising:
at least one elongated target having a sputtering surface with an outside
cylindrical shape of a given diameter and a given length between first and
second ends thereof;
first and second support structures respectively supporting said first and
second sputtering surface ends in a manner that allows said target to
rotate about a central longitudinal axis thereof;
means positioned within said target for providing a magnetic field zone
extending along a length of said sputtering surface and a circumferential
distance therearound;
electrically controlled driving means coupled to said target structure for
rotating said sputtering surface through said magnetic field zone;
first and second cylindrical shields separated by a distance of less than
substantially one-quarter inch from said sputtering surface for minimizing
condensation of vaporized material at said first and second sputtering
surface ends, said shields carried at opposite ends of said target by said
first and second support structures and extended axially along said
sputtering surface to substantially cover the ends of said sputtering
surface, said shields having continuous portions extending around the
circumference of said first and second ends positioned to cover said
sputtering surface for a distance adjacent each of its said first and
second ends and to extend over adjacent portions of said first and second
support structures, said first shield having an inner edge closest to said
second shield and said second shield having an inner edge closest to said
first shield;
said inner edges being non-rectangularly shaped to conform substantially to
a shape of a pattern of etching of sputtering material on said target
structure which occurs when said target structure is held stationary; and
said inner edges being positioned to shield regions where condensation of
vaporized material on said target structure would otherwise occur at a
rate which exceeds a rate at with deposited condensate is removed from
said target structure by sputtering.
8. The apparatus according to any one of claims 6 and 7, wherein said inner
edges of said shields are positioned a distance from said magnetic field
zone sufficient to stabilize arcing adjacent to said magnetic field zone.
9. The apparatus according to any one of claims 6 and 7, wherein said
shields are connected at corresponding portions of said inner edges which
are not adjacent to the magnetic field zone by a cylindrically-shaped
structure extending around a portion of the circumference of said
sputtering surface that is substantially outside said magnetic field zone
to form a unified shield, said unified shield having an opening at least
as large as said magnetic field zone and extending around the portion of
the circumference of said sputtering surface that is substantially inside
said magnetic field zone and having a length less than a distance between
said first and second ends of said sputtering surface.
10. The apparatus according to any one of claims 1, 6, 9, 2 and 7, in which
said inner edges adjacent to said magnetic field zone have a curved shape.
11. The apparatus according to any one of claims 1, 6, 2 and 7, in which
said inner edges adjacent to said magnetic field zone have a notched
shape.
12. A method of forming cylindrical end shields for use in a sputtering
apparatus for depositing film on a substrate in a vacuum chamber comprised
of a rotating cylindrical magnetron including therein at least one
rotatable target structure, having an outer cylindrically-shaped surface
of sputtering material and held at opposite ends thereof by first and
second support structures, a magnet assembly within said target structure
that provides a magnetic field zone, and first and second cylindrical end
shields carried at opposite ends of said target structure by said support
structures, said first shield having an inner edge closest to said second
shield and said second shield having an inner edge closest to said first
shield, comprising the steps of:
(a) operating said rotating cylindrical magnetron such that said magnetic
field zone is provided and said target structure is immobile;
(b) determining positions on said immobilized target structure where
condensation of material vaporized during said operation has occurred; and
(c) shaping said shields at said inner edges, non-rectangularly, to conform
substantially to a pattern of said positions determined in step (b).
13. The method of claim 12, additionally comprising the step of optimizing
the distance between said shields and said magnetic field zone by placing
said shields on said opposite ends of a cylindrical sputtering structure,
operating said rotating cylindrical magnetron, recording arcing activity
using recording means, and adjusting said distance to minimize said arcing
activity.
14. The method of claim 12, additionally comprising the step of optimizing
the distance between said shields and said magnetic field zone by placing
said shields on said opposite ends of a cylindrical sputtering structure,
operating said rotating cylindrical magnetron, recording voltage within
the vacuum chamber of the sputtering apparatus using recording means, and
adjusting said distance to minimize variations in voltage adjacent to said
magnetic field zone.
15. The method of claim 12, additionally comprising the step of connecting
said end shields at portions of said inner edges which are not adjacent to
said magnetic field zone by a cylindrically-shaped structure extending
around the portion of the circumference of a cylindrical sputtering
structure that is substantially outside said magnetic field zone to form a
unified shield, said unified shield having an opening at least as large as
said magnetic field zone and extending around the portion of the
circumference of said cylindrical sputtering structure that is
substantially inside said magnetic field zone and having a length less
than a distance between opposite ends of said cylindrical sputtering
structure.
16. The method of claim 12, additionally comprising the steps of:
(a) optimizing the distance between said shields and said magnetic field
zone by placing said shaped shields on said opposite ends of a cylindrical
sputtering structure, operating said rotating cylindrical magnetron such
that said magnetic field zone is provided, recording arcing activity using
recording means, and adjusting said distance to minimize said arcing
activity; and
(b) connecting said end shields at portions of said inner edges which are
not adjacent to said magnetic field zone by a cylindrically-shaped
structure extending around the portion of the circumference of said
cylindrical sputtering structure that is substantially outside said
magnetic field zone to form a unified shield, said unified shield having
an opening at least as large as said magnetic field zone and extending
around the portion of the circumference of said cylindrical sputtering
structure that is substantially inside said magnetic field zone and having
a length less than a distance between opposite ends of said cylindrical
sputtering structure.
17. The method of claim 12, additionally comprising the steps of:
(a) optimizing the distance between said shields and said magnetic field
zone by placing said shaped shields on said opposite ends of a cylindrical
sputtering structure, operating said rotating cylindrical magnetron such
that said magnetic field zone is provided, recording voltage within the
vacuum chamber of the sputtering apparatus using recording means, and
adjusting said distance to minimize variations in voltage adjacent to said
magnetic field zone; and
(b) connecting said end shields at portions of said inner edges which are
not adjacent to said magnetic field zone by a cylindrically-shaped
structure extending around the portion of the circumference of said
cylindrical sputtering structure that is substantially outside said
magnetic field zone to form a unified shield, said unified shield having
an opening at least as large as said magnetic field zone and extending
around the portion of the circumference of said cylindrical sputtering
structure that is substantially inside said magnetic field zone and having
a length less than a distance between opposite ends of said cylindrical
sputtering structure.
18. The method according to claim 12, in which the shaping step includes
shaping said shields at said inner edges such that said inner edges have a
curved shape.
19. The method according to claim 12, in which the shaping step includes
shaping said shields at said inner edges such that said inner edges have a
notched shape.
20. A method of sputter etching a cylindrical sputtering structure using a
sputtering apparatus for depositing film on a substrate in a vacuum
chamber comprised of a rotating cylindrical magnetron including therein at
least one rotatable target structure, having an outer cylindrically-shaped
surface of sputtering material and held at opposite ends thereof by first
and second support structures, and a magnet assembly within said target
structure that provides a magnetic field zone, comprising the steps of:
(a) operating said rotating cylindrical magnetron such that said magnetic
field is provided and said target structure is held stationary;
(b) determining a shape of a pattern of condensation of vaporized material
on said target structure which forms when said rotating cylindrical
magnetron is operated according to step (a); and
(c) blocking regions at opposite ends of said target structure where
condensation of vaporized material on said target structure would
otherwise occur at a rate which exceeds a rate at which deposited
condensate is removed from said target structure by sputtering using
blocking means, said blocking means being non-rectangularly shaped to
conform substantially to the shape of the pattern of condensation
determined according to step (b) and positioned to shield said regions.
21. The method of claim 20, wherein said blocking means extends around the
portion of the circumference of said cylindrical sputtering structure that
is substantially outside said magnetic field zone.
22. A sputtering apparatus for depositing film on a substrate in a vacuum
chamber, comprising:
a magnetron including therein at least one target structure with an outer
cylindrically-shaped surface of sputtering material;
first and second support structures holding said target structure at
opposite ends thereof such that said target structure is rotatable about
its longitudinal axis;
a magnet assembly within said target structure that provides a magnetic
field zone extending along a length of said sputtering material surface
and extending a circumferential distance therearound;
first and second cylindrical shields, said shields carried at opposite ends
of said target structure by said first and second support structures and
extended axially along said sputtering material surface to substantially
cover the ends of said sputtering material surface, said first shield
having an inner edge closest to said second shield and said second shield
having an inner edge closest to said first shield; and
said inner edges being non-rectangularly shaped to conform substantially to
a pattern of deposition of vaporized material on said target structure
adjacent to the ends thereof which is determinable when said magnetron is
operated without rotating said target structure.
23. The apparatus according to claim 22, wherein the pattern is curved.
24. The apparatus according to claim 22, wherein the inner edges of the
shields are positioned along a longitudinal axis of said target structure
to cover regions where vaporized material would otherwise be deposited at
a rate that exceeds a rate at which such deposited material is removed by
sputtering.
25. In a magnetron including a vacuum chamber and therein, at least one
elongated cylindrical sputtering surface rotatable about an axis thereof
and a magnetic structure carried non-rotatably therewithin and extending
along a length thereof, a method of depositing a material on a substrate
positioned within the chamber by sputtering from the sputtering surface,
comprising:
(a) defining a pattern of deposition of vaporized material on the
sputtering surface adjacent to ends thereof which is determinable when the
magnetron is operated without rotating the sputtering surface;
(b) shielding regions of the sputtering surface where vaporized material
would otherwise be deposited, with shields having non-rectangular inner
edges substantially conforming to the defined pattern; and
(c) operating the magnetron with the sputtering surface rotating and the
shields held non-rotatably.
26. The method according to claim 25, wherein the defined pattern is
curved.
27. The method according to claim 25, wherein step (b) includes positioning
the edges of the shields along a longitudinal axis of the sputtering
surface to cover regions where vaporized material would otherwise be
deposited at a rate that exceeds a rate at which deposited material is
removed by sputtering.
28. A method of forming cylindrical end shields for use in a sputtering
apparatus for depositing film on a substrate in a vacuum chamber comprised
of a rotating cylindrical magnetron including therein at least one
rotatable target structure, having an outer cylindrically-shaped surface
of sputtering material and held at opposite ends thereof by first and
second support structures, a magnet assembly within said target structure
that provides a magnetic field zone, and first and second cylindrical end
shields carried at opposite ends of said target structure by said support
structures, said first shield having an inner edge closest to said second
shield and said second shield having an inner edge closest to said first
shield, comprising the steps of:
(a) defining a pattern of deposition of vaporized material on the target
structure adjacent to the ends thereof which would occur if the magnetron
were operated without rotating the target structure;
(b) shaping the inner edges of the shields, non-rectangularly, to conform
substantially to the defined pattern.
29. The method of claim 28, wherein the defined pattern is curved.
30. The method of claim 28, further comprising the step of optimizing the
distance between the inner edges of the shields along a longitudinal axis
of the sputtering surface, thereby shielding regions where vaporized
material would otherwise be deposited at a rate that exceeds a rate at
which deposited material is removed by sputtering. |
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Claims  |
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Description  |
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BACKGROUND OF THE INVENTION
This invention relates generally to magnetrons of a type using rotating
cylindrical sputtering targets, and, more specifically, to structures and
techniques for minimizing arcing in such magnetrons.
Cylindrical magnetrons are becoming widely used for depositing films on
substrates. An example is the deposition of a stack of dielectric and
metal layers on a surface of a glass substrate for the purpose of
filtering out a portion of solar energy from passing through the glass.
Such a substrate is positioned within a vacuum chamber containing at least
one, and usually two, rotating cylindrical targets containing sputtering
material on an outer surface thereof. Both inert and reactive gases are
generally introduced into the chamber. A voltage applied to the sputtering
target, with respect to either the vacuum chamber enclosure or a separate
anode, creates a plasma that is localized along a sputtering zone of the
target by stationary magnets positioned within the target. Material is
sputtered off the target surface and onto the substrate by bombarding the
target with electrons and ions of the plasma as it passes through the
stationary sputtering zone.
The magnets are usually of a permanent magnet type, arranged along a line
within the rotating cylindrical target and held against rotation with the
target. The sputtering zone is created by the magnets along substantially
the entire length of the cylindrical sputtering target and extends only a
small circumferential (radial) distance around it. Traditionally, the
magnets are arranged so that the sputtering zone exists at the bottom of
the cylindrical target, facing a substrate being coated directly beneath.
Although deposition of the film is desired to take place only on the
substrate, it is also deposited on other surfaces within the reactive
chamber. This can create a problem in many situations, especially when
certain dielectrics are being deposited as the film. For example, if the
target surface is silicon or aluminum and the reactive gas is oxygen,
silicon dioxide is deposited on the target surface, surfaces of target
supporting structures, and the like, as well as on the substrate that is
intended to be coated. After a certain build-up of dielectric material on
internal vacuum chamber surfaces has occurred over time, arcing to those
surfaces can begin. Arcing is undesirable since it generates particles
that contaminate the film being deposited on the substrate, and overloads
the power supply that creates the plasma through an electrical connection
with the sputtering target surface and the vacuum chamber walls or some
other anode.
An advantage of a rotating cylindrical sputtering target is that such a
film deposited on the target is subjected to being sputtered away as the
target surface passes through the sputtering zone, thus counteracting the
undesirable film build-up. Despite this self-cleaning characteristic,
however, undesirable arcing still occurs in rotary magnetrons under
certain circumstances.
Recently, a cylindrical magnetron shield structure has been developed to
minimize this undesirable arcing that occurs in rotary cylindrical
magnetrons. See Kirs, Milan R., et al., "Cylindrical Magnetron Shield
Structure,"U.S. Pat. No. 5,108,574. As shown in Kirs et al., the
deposition of dielectric film can be minimized by dark space shielding,
which prevents plasma formation in the dark space and thereby reduces film
deposition and subsequent arcing.
Although the shield structure of Kirs et al. greatly enhances the
self-cleaning characteristic of rotary cylindrical magnetrons, some
deposition of condensate has been found to occur at the far ends of the
target cylinder. Unlike the deposition of dielectric films that concerned
Kirs et al., this deposition of condensate from the vapor present in the
system occurs regardless of the existence of plasma. Thus, the problem of
condensate deposition is not fully resolved by the use of dark space
shielding.
Because even slight deposition of dielectric or insulating materials can
lead to undesirable arcing, it is a principal object of the present
invention to provide a mechanism and technique for further minimizing such
deposition and related arcing.
SUMMARY OF THE INVENTION
This and additional objects are accomplished by the present invention,
wherein, briefly and generally, a shaped cylindrical shield structure is
provided around and spaced apart from at least a portion of the sputtering
target outside of said sputtering zone. By careful examination of the
shape of the magnetic field zone and the distribution of the condensate at
the ends of the tube, the shape of the cylindrical shield structure is
designed to conform to the contours of the magnetic field zone, thereby
maximizing sputter etching of the tube ends while minimizing deposition of
condensate. In a preferred form, the shield structure consists of separate
cylindrical end shields positioned at opposite ends of the target
structure and shaped at their respective inner edges adjacent to the
magnetic field zone to conform to the outer contours of the "race-track"
pattern of the magnetic field zone. The shield structure may also consist
of a unified shield wherein these shaped cylindrical end shields are
connected at the portions their respective inner edges lying outside the
magnetic field zone by a cylindrically shaped structure, leaving a window
opening in the shield structure adjacent to the magnetic field zone so
that the target surface is bombarded by electrons and ions of the plasma
as it is rotated through the sputtering zone. The cylindrical shield
structure does not rotate with the cylindrical target. In systems that
provide for the sputtering zone to be circumferentially positionable
around the target by rotation of its magnets, the cylindrical shield
structure is also made rotatable so that its window may follow the
sputtering zone to its new position.
Such a shield structure has been found to be beneficial in three primary
respects. First, it has been found that the self-cleaning attribute of a
rotating sputtering target generally does not extend to the far ends of
the target cylinder since the sputtering zone controlled by the magnets
within the cylinder does not extend completely to its ends. An abrupt
termination of the permanent magnets within the target cylinder creates
some discontinuities in the sputtering zone at the ends of the cylinder,
and thus in the character of the plasma itself. Since the self-cleaning
attribute of a rotating target does not fully extend to the ends of the
target cylinder, the shield structure of the present invention extends
completely around the sputtering cylinder at its ends and, further, may be
extended to cover portions of rotating target support structures adjacent
to its ends which are particularly susceptible to undesirable film
build-up because of their proximity to the sputtering surface and plasma.
Additionally, it has been found that much like planar magnetrons, rotary
cylindrical magnetrons etch the sputtering surface in a "race-track"
pattern, while causing a buildup of arc-causing condensate film at the
ends of the target cylinder in a pattern that conforms to the shape of the
"race-track." Since this undesirable condensate film conforms to the
"race-track" shape of the magnetic field zone, the shield structure of the
present invention is similarly shaped to conform to the contours of the
magnetic field zone, thereby shielding those areas at the ends of the
target cylinder that would otherwise be exposed to condensate film
build-up and subsequent arcing.
A third beneficial aspect of the shield structure comes from covering a
central portion of the length of the sputtering target cylinder, despite
the self-cleaning attribute of a rotating magnetron mentioned above. It
has been found that there are circumstances where an undesired dielectric
or other film deposited on portions of the target outside of the
sputtering zone are not completely removed when those surface portions
again pass through the sputtering zone. Further, there are circumstances
where it has been found desirable to be able to cover a portion of the
cylindrical target surface during co-sputtering; that is, in a situation
where two rotating cylindrical target structures are adjacent one another
and material from at least one of them is being sputtered onto the surface
of another before being resputtered onto a substrate. Such co-sputtering
techniques are described in U.S. patent application Ser. No. 07/549,392,
filed Jul. 6, 1990, now abandoned, which is incorporated herein by this
reference. It is the ability to cover a portion of the target during such
co-sputtering that is provided by the present invention.
Additional objects, features and advantages of the present invention will
become apparent from the following description of a preferred embodiment
thereof, which description should be taken in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a dual cylindrical sputtering target
magnetron that utilizes the improvement of the present invention;
FIG. 2 shows in isometric view a portion of one of the target assemblies of
FIG. 1, including the improvement of the present invention;
FIG. 3 shows in isometric view a portion of one of the target assemblies of
FIG. 1, including the improvement of the present invention;
FIG. 4 is a cross-section of a target assembly taken at Section 4--4 of
FIG. 2;
FIG. 5 is a partial section view of a preferred support assembly for a
rotating target assembly of the types illustrated in FIGS. 1-5; and
FIG. 6 shows in isometric view a "racetrack" pattern of etching and a
conforming pattern of condensation at the end portions of a cylindrical
sputtering target assembly of FIG. 1 that are used in designing the
improvement of the present invention.
DESCRIPTION OF A PREFERRED EMBODIMENT
Referring initially to FIG. 1, an entire magnetron system utilizing the
present invention is generally described before the details of the
invention's preferred implementation are explained. A box 11, shown in
dotted outline, indicates metallic walls of a vacuum chamber in which the
sputtering occurs. Within that chamber are two rotatable cylindrical
target structures 13 and 15 which are held by the frame 11 in a manner to
be rotatable about their longitudinal axes. The target structures 13 and
15 are generally held with their axes parallel to one another, but that is
not a requirement. Further, although two target structures are illustrated
in FIG. 1, many applications need only employ one such target, and other
applications can benefit by having more than two. However, the use of two
target structures 13 and 15 is common.
The magnetron of FIG. 1 is shown to have a substrate 17 held by a support
structure 19. The support structure 19 may be rollers to allow the
substrate 17 to be passed through the vacuum chamber in a continuous
process. A vacuum is drawn within the vacuum chamber by an appropriate
pumping system 21. One or more gases are provided by a supply 23 to the
vacuum chamber by some convenient delivery system, such as a perforated
tube 25 positioned across the vacuum chamber. The particular gases
utilized depend primarily upon the film desired to be deposited on the
substrate 17.
Cylindrical pieces 27 and 29 of sputtering material provided as part of the
target structures 13 and 15, respectively, are generally made of the same
material but can be of different materials, depending upon the nature of
the film to be deposited on the substrate 17. An electric motor source 31,
positioned outside the vacuum chamber, rotates the target assemblies by
rotating, through a toothed belt 33, pulleys 35 and 37 which are attached
to respective spindles 39 and 41. The sputtering materials 27 and 29 are
attached to the respective spindles 39 and 41 in order to rotate with
them.
A plasma is created within the vacuum chamber by applying a negative
voltage from a power supply 40 to the sputtering surfaces with respect to
the vacuum chamber metal frame 11 or some other anode, which is usually
connected to ground potential. The plasma is positioned adjacent a
sputtering zone of the cylindrical sputtering targets 27 and 29,
controlled by the positioning of their respective magnets (not shown in
FIG. 1). These magnets are positioned along the length of their respective
cylindrical sputtering targets 27 and 29, while extending a small
circumferential, or radial, distance therearound. These magnets are most
conveniently held within the sputtering targets 27 and 29 by attachment to
respective coolant conduits 43 and 45. These cooling conduits are provided
as part of their respective target assemblies in a manner to be rotatable
independently of rotation of their respective cylindrical sputtering
targets 27 and 29.
Thus, the position of the magnets in each target assembly, and thus the
position of the sputtering zone of each, is controlled by rotation of
these cooling conduits. Specifically, a pulley 47 is attached to the
conduit 43 and driven from an electrical motor source 49 outside the
vacuum chamber by a toothed belt 51. Similarly, a pulley 53 is attached to
the coolant conduit 45 and is controlled as to rotatable position by an
electrical motor source 55 positioned outside the vacuum chamber and
connected with it by a toothed belt 57. The motor sources 49 and 55 are
preferably stepper motors which thereby hold their respective conduits 43
and 45 in selected positions and keep them from rotating with their
respective sputtering targets 27 and 29.
A cooling liquid supply and exhaust system (not shown) outside the vacuum
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