Abstract:
A rotary sputter magnetron assembly for use in sputtering target material onto a substrate is provided. The assembly comprises a longitudinally extending target tube having a longitudinal central axis, said target tube extending about a magnet array that is configured to generate a plasma confining magnetic field adjacent the target tube, said target tube supported for rotation about its longitudinal central axis and a pair of side shunts positioned parallel to the longitudinal central axis, and on opposing lengthwise sides of said target tube.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention generally relates to magnetron cathode sputter apparatus. More specifically to the sputtering of indium tin oxide (ITO) on large substrates or over large areas. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0002]      FIG. 1  is a cross section view of a rotary magnetron cathode with a magnetic anode; 
           [0003]      FIG. 2  shows the  FIG. 1  section view with magnetic field streamlines; 
           [0004]      FIGS. 3  is a side view of the rotary magnetron cathode with magnetic anode shown in  FIGS. 1 and 2 ; 
           [0005]      FIGS. 4A and 4B  show cross section views of magnetic shunts without and with the use of magnetic material. 
           [0006]      FIG. 5  is a cross section view of a planar magnetron cathode with a magnetic anode; 
           [0007]      FIG. 6  is a cross section view of a rotary magnetron with magnetic anode where the magnetic anodes have magnets rather than only ferromagnetic material; 
           [0008]      FIG. 7  is a cross section view of rotary magnetrons configured for dual magnetron sputtering with an AC power supply. Magnetic shunts extend along the sides of the target tubes. 
           [0009]      FIGS. 8A and 8B  show cross sections of RM&#39;s with standard strength magnetic field and high strength magnetic field magnet packs inside the RM target tubes respectively and compares the plasma lobe locations on the outside of the target tubes. 
       
    
    
     DESCRIPTION OF THE INVENTION 
       [0010]    Indium tin oxide (ITO) is used in many applications because it is both optically clear and electrically conductive. Typically, ITO is deposited by magnetron sputtering. Recently, rotary magnetron ITO targets have become commercially available. Rotary magnetrons have several advantages over planar magnetrons including: Improved target cooling, stable operation, longer production runs and higher power operation. While these advantages are attractive, the desired ITO optical and electrical film properties, achieved with planar magnetron sputtering, have not been matched with existing rotary magnetron magnetic plasma confinement designs. 
         [0011]    In magnetron sputtering of ITO, the strength of the plasma confinement magnetic field significantly effects film properties. This sensitivity is less pronounced for other materials. In sputtering ITO, a strong magnetic field improves the conductivity of ITO. This is well documented in ITO sputtering with planar magnetrons. A typical planar magnetron magnetic field strength at the target surface might be 250-500 G, improved ITO properties are seen with target surface magnetic fields of 700-1200 G. Therefore, a challenge for rotary magnetron ITO sputtering is to configure the RM to have a strong magnetic field. One solution is to use bigger magnets inside the RM. This works to strengthen the magnetic field, however, because the target tube diameter is set by industry standards and bigger magnets take up more room inside the RM, the racetrack straight-aways are spaced further apart on the target tube OD (Please see  FIGS. 8A and 8B ). When sputter plasma straight-aways move apart, the sputter flux from the target is directed less at the substrate and more toward the process chamber side walls. Additionally, the flux that does hit the substrate has an angled, longer travel path. This results in a lower particle arrival energy and a loss of film quality. Therefore, an improved RM for sputtering ITO is needed that maintains or improves upon the ITO properties achieved with planar magnetron sputtering. 
         [0012]      FIG. 1  shows a cross section view of an inventive embodiment a rotary magnetron  16  with magnetic anodes  8 . Rotary magnetron  16  has a stationary magnet pack  15  positioned inside target back tube  2 . Target tube  1  is made of the material to be sputtered onto substrate  9 , for instance, ITO. The deposited sputter material  14  grows in thickness on substrate  9  as substrate  9  is moved past rotary magnetron  16 . Magnets  5  and  6  and shunt  7  form electron confining racetrack magnetic field lines  12  on the outside of target tube  1  and, when the magnetron is operating, a plasma racetrack  11  is visible. Magnets  5  and  6  and shunt  7  are enclosed in a hermetically sealed pouch  4 . Pouch  4  seals out the cooling water filling tube  2  (not shown). As is known in the art, tube  2  with target material  1  rotates continuously during operation. External to target tube  1 , magnetic anodes  8  are positioned as shown on both sides of tube  1 . The anodes  8  extend along the target tube  1  parallel to the electron confining racetrack  12 . In this embodiment of the invention, magnetic anodes  8  are made of mild steel. Other high permeability materials can also be used. Magnetic anodes  8  draw magnetic field lines  13  that otherwise would spread out in the vacuum chamber. Sputtered flux cosine distribution  18  from target tube  1  is depicted on one plasma racetrack  11 . 
         [0013]      FIG. 2  shows the same cross section view of a rotary magnetron  16  with magnetic anodes  8  as  FIG. 1 . In  FIG. 2 , Additional magnetic field lines  16  are shown to further explain the benefit of magnetic anodes  8 . Additionally, the path  17  of an electron as it moves along magnetic field lines is shown. 
         [0014]      FIGS. 3  is a side view of the rotary magnetron with magnetic anodes shown in  FIGS. 1 and 2 . The rotating target tube  1  is attached by target clamps  24  to end blocks  25  and  26 . The end blocks are attached to the chamber lid  20 . Support members  21 ,  22  and  23  attach to the chamber lid and support the magnetic anodes  8  such that anodes  8  remain stationary. These members also electrically isolate anode  8  from target tube  1  and from ground. Substrate  9  is supported by O-rings  28  on rollers  27 . As shown in  FIG. 3 , anodes  8  extend along target tube  1  for nearly the length of tube  1 . 
         [0015]    The RM with magnetic anodes as shown in  FIGS. 1-3  delivers the sought-after properties of sputtered ITO, equaling the performance of planar magnetron sputtered films, while maintaining the advantages of RM sputtering. As shown in  FIGS. 1-3 , the magnets  5  and  6  inside the magnet pouch  4  are large, producing a magnetic field at the sputter surface of the target tube 1 of &gt;1000 G. In order to keep angle theta small, outer racetrack magnets  5  are the same size as inner magnet  6 . Because there are two outer magnets  5  for every inner magnet  6 , the magnetic field is unbalanced toward the center. This is termed a Type II unbalanced magnetron configuration according to Windows and Saavides. The stronger outside field pushes the sputter lobes  12  in toward the center and effectively maintains a small theta. In the embodiment shown, theta is 13°. This unbalanced configuration can normally cause a second racetrack to light on the outside of the target tube (see  FIGS. 4A and 4B ). One purpose of the magnetic anodes is to pull field lines away from the target tube to eliminate the second racetrack from lighting. 
         [0016]    The magnetic anodes  8  also enhance deposition uniformity. By locating the anodes close to the plasma racetrack  11 , electron flow away from the cathode to the anode can be controlled. If the anodes are further from the plasma lobes  11 , magnetic field lines can exist from the magnet pouch  15  to the substrate or to process chamber walls or shields. These ‘stray’ field lines impede electron flow to the anode and significantly affect deposition uniformity. Locating anodes  8  as shown in  FIGS. 1-3 , eliminates stray field lines and leaves only field lines that confine the magnetron sputter plasma  11  (including field lines  12  and  16 ) and field lines  13  that terminate in magnetic anode  8 . This is shown in  FIG. 2 . 
         [0017]    In specific inventive embodiments, the primary racetrack plasma magnetic field is approximately 500 to 1200 G, as compared to existing rotary magnetron designs that have magnetic fields of between 250-500 G. The aforementioned magnetic field values are measured at the surface of a 10 mm thick cylindrical target of embodiment of the inventive rotary magnetron. A strong magnetic field lowers the voltage of the plasma discharge making for a more electrically efficient process. In addition, sputtering of certain substances such as indium tin oxide (ITO) is benefitted by a stronger racetrack magnetic field. 
         [0018]    Embodiments of the inventive magnetron increase the strength of the magnetic field without spreading the plasma lobes apart, which as described above is a problem with previous magnetron designs, by increasing the size of the outside magnets relative to the center magnet. The additional outside magnetic field tends to push the racetrack inward toward the center, and is an effective method to keep the primary racetrack separation angle small and between 5 and 20 degrees. By way of example, and angle of 13 degrees is shown in  FIG. 4B  that promotes on-angle sputter while still allowing large magnets to be used. The difficulty encountered is that all the field lines exiting the larger outer magnets  42  do not pass into the center magnet  44 . A significant number of the field lines wrap the opposite direction, and cause the formation of a secondary racetrack plasma  74  as shown in  FIG. 4A . The present invention invokes side anodes or shunts  56  to stop this secondary plasma from forming and enable the use of larger outer magnets  42 . The end result is a high magnetic field strength primary plasma  60  with a small separation angle between plasma lobes that solves this long standing problem in the field of rotary magnetrons. 
         [0019]    Note that the magnetic anodes can be connected as anodes to the plasma power supply or alternately not connected and be electrically floating or grounded. In the case where the anodes are not electrically connected to the power supply, they function as magnetic shunts and as such serve to benefit overall operation as described herein. 
         [0020]    A small plasma lobe separation, represented by angle theta and provided present invention, has several benefits. With a small plasma lobe separation, the path length of the sputter flux is reduced for a given target to substrate distance so the number of particle collisions encounter is reduced and the energy of the particles arriving at the substrate is increased. The more direct impact with a smaller separation distance improves the density of the sputtered film on the substrate, compared to more oblique impact angles, while the deposition rate is improved as more sputtered flux hits the substrate rather than the side shields. As a result, less deposition buildup on the side shields occurs and flaking and particle contamination on the substrate is reduced. A reduction of flaking and contamination reduces the frequency of shield cleaning to increase overall efficiency of machine operation. Furthermore, with a more direct sputter flux path, target tubes are used more efficiently as more of the target material is deposited on the substrate, so as to achieve savings on target materials and less frequent changing of the target tubes. 
         [0021]    Minimizing the plasma lobe separation angle theta according to the present invention helps to reduce side sputtering and consequently facilitating compact placement of adjacent rotary magnetron target tubes. The side shunts themselves that are employed in embodiments of the inventive rotary magnetron have some functionality to shield one target tube from sputtered flux from an adjacent tube. 
         [0022]    In embodiments of the inventive rotary magnetron, the magnetic anodes or side shunts can be electrically floating, grounded or connected to the sputter power supply as the anodes. With or without electrical connection, the anodes/shunts allow an unbalanced (type II) configuration to be implemented with a rotary magnetron cathode. The anodes/shunts should be installed on both sides of a rotary magnetron target tube, since if one side of the target is left open, a secondary plasma can ignite along the length of the target tube on that unshielded side. It has been found that even with the side shunts, a weak closed magnetic field can form close to the target. However, if the weak closed path magnetic field is less than 25% the strength of the primary closed field, a secondary plasma will not ignite. For purposes of measuring the weak closed path magnetic field, this field is measured tangential to the target tube at the target tube surface. 
         [0023]    Furthermore at the ends of the rotary target tube, at the turnarounds of the primary plasma, anodes/shunts are not required. Without intending to be bound to a particular theory, because the turnaround region is relatively short in a racetrack configuration, even if a secondary confinement region is created by the magnetic design, the secondary plasma cannot ignite or will be insignificant due to the comparatively small area of this region relative to the racetrack straight sections. With typical sputtering operational parameters, a length of about 300 mm is required before a secondary plasma can build sufficient intensity to be problematic. At a target tube end, as the primary plasma turnaround wraps over the target tube from one side to the other, the plasma length is typically only about 100 mm. 
         [0024]      FIG. 4A  is a cross-sectional view of an RM with magnetic anodes/shunts except the ferromagnetic shunt  56 A material is non-magnetic. This view is intended to illustrate what happens when magnetic material is not used for anode/shunt  56 A. As shown, the result is a second plasma  74  lights on the target tube  1 . 
         [0025]      FIG. 4B  is a cross-sectional view of an RM with magnetic anodes/shunts  56 . In this view, the anodes are ferromagnetic (mild steel) and as can be seen, the magnetic field lines  58  are pulled to this shunt  56  and secondary plasmas are eliminated. With the side shunts  56 , magnetic field lines enter and exit the side shunt rather than close over the target tube. The side shunts are electrically floating, grounded or connected to the anode of the power supply. As such, the side shunts are not at cathode potential and a secondary plasma cannot light. 
         [0026]      FIG. 5  is a cross section view of a planar magnetron fitted with magnetic anodes  106 . Though primarily intended to improve RM&#39;s, magnetic anodes  106  can also be applied to planar magnetrons. 
         [0027]      FIG. 6  is a cross section view of another embodiment of the invention. In this embodiment. ferromagnetic anodes  8  (from  FIGS. 1-3 ) are replaced by non-magnetic anodes  203  with magnets  202  inside the anodes  203 . Due to heating effects, these anodes must be water cooled  204  by known techniques. The use of magnets makes drawing stray magnetic field lines  206  away from the RM magnet pouch  201 . This advantage is weighed against the complexity of the anode with magnets vs a simple, one piece ferromagnetic anode. 
         [0028]      FIG. 7  is a cross-sectional view of a configuration  300  for dual rotary magnetrons  306  with an AC power supply  308 . In this case, the magnetic anodes/shunts  304  are not connected to the power supply but are simply electrically floating or grounded. In this case, the anodes/shunts are used as magnetic shunts to collect stray magnetic field  307  and prevent second plasma racetracks from lighting on the target tubes  306 . 
         [0029]    It is appreciated that the dimensions of the side anodes/shunts are determined by the magnetic design of the magnet bar inside the target tube as well as the target material thickness and target tube diameter. The side shunts must effectively pull the magnetic field away from the target tube surface so that the secondary plasma doesn&#39;t light and stray magnetic field lines are eliminated. For example in  FIGS. 1 through 3 , 5 millimeter (5 mm) thick side shunts are shown. These side shunts are sufficiently thick to pull the required magnetic field without becoming saturated. If the shunts are too thin, they are magnetically saturated and become less effective. It is further appreciated that the minimum thickness is also dependent upon the side shunt material. For low cost and sufficient performance, mild steel side shunts may be used in the  FIGS. 1-3 . In  FIGS. 1-3 , the base tube  2  is 133 mm OD by 125 mm ID (the most common standard tube size). The target tube  1  material thickness may be from 2 to 30 mm. Due to the expense, indium tin oxide (ITO) target tubes  1  are typically thinner, 10 mm thick. 
         [0030]    While the present invention has particular advantages in the sputter deposition of ITO coatings, this should not limit the target materials that can be used nor the scope of the invention. 
         [0031]    The foregoing description is illustrative of particular embodiments of the invention, but is not meant to be a limitation upon the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the invention.