Patent ID: 7645483
Filing Date: 2010-01-12
Classification: C23C

Abstract:
1. A method for forming a layer on a substrate surface in making a device, comprising, (a) providing a distribution member for receiving vaporized material, the distribution member having one or more walls defining a chamber wherein a polygonal two-dimensional pattern of apertures is formed in a wall, which deliver vaporized material in a plume of molecular flow onto the surface; (b) positioning the substrate to be held in a fixed position relative to the distribution member by a substrate holder so that the substrate surface is spaced apart from the distribution member by a throw distance d; (c) providing the polygonal two-dimensional pattern of apertures to have at least four vertices, with a first set of apertures disposed at the vertices, a second set of edge apertures disposed between the apertures of the first set and defining the edges of the polygonal two-dimensional pattern, and a third set of interior apertures disposed within the periphery of the polygonal two-dimensional pattern defined by the first and second sets of apertures; and (d) dimensioning the first, second, and third set of apertures to obtain a greater flow rate per unit wall area from the first set of apertures than from the second and third set of apertures, and to obtain a greater flow rate per unit wall area from the second set of apertures than from the third set of apertures, by applying the following relationship to the first and second sets of apertures: wherein C/C o is the vapor conductance enhancement factor relative to the third set of apertures, P a is the pitch or number of apertures per unit length in a given dimension, and a, b, and c are respective quadratic, linear, and constant coefficients, such that the values of a, b, and c depend upon the plume shape, different values of a, b, and c are obtained for the first and second sets of apertures, the first set of apertures have quadratic coefficients a in the range of 0.1 to 0.7, b in the range of 0.5 to 1.2, and c in the range of −0.4 to +0.4, and the second set of apertures have quadratic coefficients a in the range of 0.1 to 0.5, b in the range of 0.1 to 0.7, and c in the range of −0.2 to +0.2.