Sputtering apparatus with a rotating magnet array

Abstract: A sputtering apparatus includes a rotatable array plate (112) and a magnetic array including a group of permanent magnets (200; 300; 306; 310; 314; 400) arranged around the plate periphery in one or more quadrants. Each magnet (200; 300; 306; 310; 314; 400) is perpendicular to the plate (112), having a pole of a first polarity (N or S) facing toward the target (108). A bar permanent magnet (202; 302; 308; 312; 404; 406; 408; 410; 412; 414) is affixed to the plate (112) within the same quadrant of a group of magnets and is located between a centre axis of rotation (204; 304; 418) and the magnet group. The bar permanent magnet (202; 302; 308; 312; 404; 406; 408; 410; 412; 414) is perpendicular to the plate (112), having a pole of a second polarity (S or N) facing toward the target (108). In one arrangement the magnets (200; 300; 306; 310; 314) create a closed-loop static magnetic field that is substantially triangular in shape, concentrated in the quadrant, and offset from the centre axis of rotation (204; 304). The magnets in one quadrant may be replicated to fill up to four quadrants. In another arrangement the magnets (400) fill up four quadrants and additional bar magnets (402, 416) are arranged to create a rotating magnetic field at the target (108) that patterns the plasma to a maximum plasma density in the shape of a kidney. Each arrangement creates an axisymmetric target erosion profile for optimizing deposition uniformity at the substrate (106), when rotated behind the sputtering target (108).

Description: BACKGROUND OF THE INVENTION Field of the Invention The invention relates to sputtering apparatus and in particular to an r.f. (radio frequency) diode sputtering apparatus using a rotatable magnet array. Background Art In semiconductor device fabrication, a large number of integrated circuit devices are formed on a thin, circular semiconductor substrate called a wafer. A process of physical vapour deposition by sputtering is used to provide metallization layers and interconnects between device layers fabricated on the wafer. Deposition of layers on the wafer may be performed by direct current (d.c.) magnetron sputtering or radio frequency (r.f.) diode sputtering. A wafer is set in a vacuum chamber anode opposite a target (cathode). A sputtering gas is introduced into the vacuum chamber. When a negative electrical bias or an r.f. (radio frequency) potential is supplied to the target a glow discharge occurs and a high-density plasma, i.e. an electrically neutral, highly-ionized gas, for sputtering is confined near the target. Atoms of the target are sputtered when ions in the plasma collide with the target. The sputtered atoms are transferred from the target to the wafer and adhere to the surface of the wafer, forming a thin film by sputter deposition. A magnetic force having field lines which loop through the sputter target surface may be used to restrict the paths of the electrons in the plasma, thereby intensifying and confining the plasma and making possible d.c. (direct current) operation. Wafer sizes have continually increased, and now the use of 8 inch (20.32 cm) diameter wafers is common. Larger wafer sizes permit a larger number of integrated circuit devices to be grown on a single wafer thus increasing device throughput. However, larger wafer sizes make it more difficult for the sputtering apparatus to deposit layers of uniform thickness over an entire wafer surface. The prior art describes a sputtering device to which is added a mechanically rotated circular permanent magnet assembly. The rotation of the permanent magnet assembly causes a more uniform erosion of the target surface. The rotating magnet is mounted behind the target and sweeps the plasma over the face of the target. Rotation of the plasma is for improving uniformity of film coverage, as well as for improving the target utilization. While a significant improvement over sources employing stationary magnets can be obtained, a very uniform sputtered film is not generally realized. Good film thickness uniformity is achieved by making the target large with respect to the wafer size. Furthermore the target to wafer distance is generally made as small as possible. For magnetic film deposition, a magnetic orienting field is required to obtain the desired magnetic properties of the deposited thin film. Such a magnetic field causes distortion of the plasma, leading to a non-uniform film thickness distribution across the wafer, and causing operational problems. Figure 1 of United States Patent Specification No. 4,746,417 discloses a magnetron sputtering cathode for a vacuum coating apparatus which has a circular target plate and a first one magnet system disposed in back of it which forms a first endless tunnel of magnetic lines of force over the target plate. This first magnet system is mounted on a rotatable yoke plate and comprises two endless rows of permanent magnets lying concentrically one within the other, all of the magnets of the outer row having the same polarity (e.g. N) but a polarity opposite that of the inner magnet row. An endless tunnel of magnetic lines of force is formed, issuing from one magnet row and returning to the other magnet row over the target plate. Between the inner row and the axis of rotation there is a second, off-centre magnet system which likewise consists of two rows of permanent magnets disposed one inside the other, the magnets of the outer row of this second magnet system having all the same polarity, but opposite to that of the inner row of the first magnet system, while the magnets of the inner row of the second magnet system all have a polarity opposite to that of the outer row of the second magnet system. A second endless tunnel of magnetic lines of force is built up over the target plate, the lines of force issuing from the one row of magnets of the second magnet system and returning to the other row of magnets. This second magnet system and the magnetic tunnel that it forms extends over only one sector of the target plate, namely over about one quadrant of the target plate. In Figures 6 and 7 of United States Patent Specification No. 9,872,964 there is disclosed a planar magnetron sputtering apparatus with two rings of magnets mounted eccentrically on a base plate, the magnets of one ring having an opposite polarity from those of the other ring. European Patent Specification No. 0 365 249 A2 discloses in Figure 6 a similar arrangement of magnets fixed on a rotatable yoke for use in a magnetron discharge type sputtering apparatus. Yet another arrangement of magnets in a planar magnetron sputtering source is taught in European Patent Specification No. 0 451 642 A2. A magnetron sputtering device with triangular shaped magnetic fields is known from Japanese Published Patent Application No. 62-89864. United States Patent Specification No. 5,374,343 teaches a magnetron sputtering apparatus with a magnetic field applying means provided near the back side of the target and a rotary driving means for rotating the position of a magnetic field on the surface of the target. United States Patent Specification No. 5,194,131 discloses a source for use in a magnetron sputtering apparatus which comprises a rotatable closed-loop magnet having a plurality of curved sections of different average radius interconnected by an equal number of radial sections. It is therefore desirable to provide a method and apparatus for obtaining good deposited film uniformity in r.f. diode sputtering systems. It is also desirable to provide an apparatus that is capable of achieving high deposited film uniformity with relatively small targets and in the presence of a deposition magnetic field such as is required for deposition of magnetic materials. SUMMARY OF THE INVENTION According to this invention, an r.f. diode sputtering apparatus comprises: a vacuum chamber; a target within said chamber from which target material is sputtered; and a rotatable circular plate having an axis of rotation and positioned behind said target; said plate having in at least one quadrant thereof a number of permanent magnets located around a periphery of said plate in said quadrant and a bar permanent magnet positioned between said axis of rotation and said number of permanent magnets in said quadrant for providing a magnetic field which is sufficiently weak and discontinuous for preventing induction of a magnetron effect on said target; said permanent magnets and said bar permanent magnet being perpendicular to said plate and of opposing polarity. Preferably in such an r.f. diode sputtering apparatus a thin film of material is sputtered onto a wafer at an anode from a sputtering target cathode comprising: a rotatable array plate; a magnetic array comprising a group of permanent magnets uniformly arranged around a periphery of said array plate in one quadrant thereof; each magnet in said group of permanent magnets being perpendicular to said plate and having a pole of a first polarity (N or S) facing toward said target; a bar permanent magnet affixed to said plate within the same quadrant as said group of permanent magnets and located between a centre axis of rotation and said group of permanent magnets; said bar permanent magnet being perpendicular to said plate and having a pole of a second polarity (S or N) facing toward said target; said group of permanent magnets and said bar permanent magnet creating a closed-loop static magnetic field that is substantially triangular in shape, concentrated in said one quadrant, and offset from said centre axis of rotation. In a further preferred r.f. diode sputtering apparatus wherein a thin film of material is sputtered onto a wafer at an anode from a sputtering target cathode comprising: a rotatable array plate; a magnetic array comprising groups of permanent magnets, said permanent magnets being uniformly arranged within each group at a periphery of said array plate in each of four quadrants thereof; each magnet in a group being perpendicular to said array plate and having a pole of a first polarity (N or S) facing toward said target cathode; and bar permanent magnets affixed to said array plate within respective quadrants, each located between a centre axis of rotation and each of said permanent magnet groups; said bar permanent magnets being perpendicular to said plate surface and having poles of a second polarity (S or N) facing toward said target; and said groups of permanent magnets and said bar permanent magnets creating magnetic fields that are substantially triangular in shape, concentrated in each quadrant, and offset from said centre axis. The invention thus provides an r.f. diode sputtering apparatus which includes a rotatable array plate wherein a thin film of material is sputtered onto a substrate at small negative potential relative to an anode from a sputtering target cathode. A magnetic array is provided that includes a group of permanent magnets uniformly arranged around a periphery of the array plate in one or more quadrants thereof. Each magnetic axis in the group of permanent magnets is perpendicular to the plate, having a pole of a first polarity facing toward the target. A bar permanent magnet is affixed to the plate within the same quadrant as the group of permanent magnets and located between a centre axis of rotation and the group of permanent magnets. The bar permanent magnetic axis is perpendicular to the plate, having a pole of a second polarity facing toward the target. The magnets create a closed-loop dipole magnetic field that is somewhat triangular in shape, concentrated in the one quadrant, and offset from the centre axis of rotation. In accordance with another aspect of the invention, the magnets in one quadrant are replicated to fill up to four quadrants and additional bar magnets are arranged to create a rotating magnetic field at the target that patterns the plasma to a maximum plasma density in the shape of a kidney. The plasma wraps around the centre of rotation of the magnetic array such that at the centre of rotation plasma density is at a minimum. In accordance with an aspect of the invention, the magnetic force field is of a magnitude sufficiently weak and discontinuous to prevent inducing a magnetron effect on the target. The invention has the advantage of excellent thickness uniformity of a film deposited by r.f. diode sputtering and in the presence or absence of an orienting magnetic field using a target size that is much smaller than is commonly practised. BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a cross-sectional diagram of a sputtering apparatus in which the invention is embodied; FIGURE 2 is a diagram of a single magnet set of a rotating magnetic array in an r.f. diode sputtering system in accordance with the invention; FIGURE 3 is a diagram of a four magnet set of a rotating magnetic array in an r.f. diode sputtering system in accordance with the invention; and FIGURE 4 is a diagram of a high intensity plasma pattern achieved by a prior art rotating magnetic array. DESCRIPTION OF THE PREFERRED EMBODIMENTS Refer to FIGURE 1 which is a cross-sectional diagram of a sputtering apparatus in which the invention is embodied. An r.f. diode sputtering device has a low pressure inert gas chamber or vacuum chamber (100). Within the chamber is a support (102) with a table (104) for holding an object such as a semiconductor wafer (106) having a surface to be coated. A target (108) within the chamber provides a source of coating material. The target (108) is held to a rear plate (110) and together they form the cathode of the system. A circular magnetic array plate (112) is positioned behind the target surface and comprises a plurality of permanent magnets. The magnetic array plate (112) is connected to a drive shaft (114) driven by a motor (116) to cause movement of the plate with respect to the target such that the lines of magnetic flux created by the magnets on the plate sweep the surface of the target. The coating material of the target is transferred from the target (108) to the wafer (106) such that the motion of the magnetic source depletes the target in a manner to coat the wafer uniformly. A sputtering gas is introduced into the vacuum chamber (100) by means which are not shown but are well known. Electrical power is supplied to the target (108) by power supply (118) which is connected to the cathode rear plate (110). A glow discharge occurs and a high-density plasma for sputtering is enclosed and confined near the target by a magnetic field created by the rotating magnetic source (112). Atoms of the target (108) are sputtered when ions in the plasma collide with the target. The sputtered atoms adhere to the surface of the wafer (106), which is an anode electrode of the system, forming a thin film by deposition. A magnetic force generated by the magnetic source (112) having field lines which loop through the sputter target surface (108) confines the electrons in the plasma, thereby intensifying and confining the plasma. In sputtering systems good film thickness uniformity is achieved by making the target (108) large with respect to the wafer (106). The target to wafer distance is made as small as possible. For magnetic film deposition on the wafer (106), a static magnetic orienting field is introduced to obtain desired magnetic properties in the thin film that is deposited. RF Diode Sputtering System Refer to FIGURE 2 which is a diagram of a single magnet set of a rotating magnetic array plate (112) in an r.f. diode sputtering system in accordance with the invention. The magnetic array is comprised of a number of small round permanent magnets (200) uniformly arranged around the periphery of the array plate in one quadrant thereof. A bar permanent magnet (202) is affixed to the plate (112) within the same quadrant as the round permanent magnets (200) and located between the centre axis of rotation (204) and the round magnets (200). Each round magnet is perpendicular to the plate surface and has its north pole facing upward toward the target (108) of FIGURE 1. The bar permanent magnet (202) is perpendicular to the plate surface and has its south pole facing upward toward the target (108) of FIGURE 1. This arrangement of magnets creates a closed-loop static magnetic force field that is somewhat triangular in shape, concentrated in one quadrant, and offset from the axis (204). As magnetic array plate (112) rotates about the centre axis of rotation (204) the magnetic field patterns the plasma density in the RF diode sputtering system. The rotating magnetic field is created behind the target and creates a uniform deposition profile across the anode as the magnetic field sweeps over the target (108). The strengths of the magnets on the plate (112) are chosen such that the magnetic field created by the magnets is of a magnitude sufficiently weak and discontinuous such that the field does not induce a magnetron effect. Refer to FIGURE 3 which is a diagram of a four magnet set of a rotating magnetic array in an RF diode sputtering system in accordance with the invention. In FIGURE 3 magnet sets of one quadrant as shown in FIGURE 2 are replicated in four quadrants. It will be understood that the magnet sets of one quadrant as shown in FIGURE 2 can be replicated in two, three or four quadrants. The magnetic array is comprised of a number of groups of small round permanent magnets (300, 306, 310, 314) uniformly arranged around the periphery of the array plate in each of four quadrants thereof. Bar permanent magnets (302, 308, 312, 316) are affixed to the plate (112) within the respective quadrants, each located between the centre axis of rotation (304) and each of the round permanent magnet groups. Each round magnet is perpendicular to the plate surface and has its north pole facing upward toward the target (108) of FIGURE 1. The bar permanent magnets are perpendicular to the plate surface and have their south poles facing upward toward the target (108) of FIGURE 1. This arrangement of magnets creates four magnetic force fields that are somewhat triangular in shape, concentrated in each quadrant, and offset from the axis (304). As magnetic array plate (112) rotates about the centre axis of rotation (204) the magnetic field patterns the plasma density in the RF diode sputtering system. The rotating magnetic field is created behind the target and creates a uniform deposition profile across the anode as the magnetic field sweeps over the target (108). The strengths of the magnets on the plate (112) are chosen such that the magnetic field created by the magnets is sufficiently weak and discontinuous so that the field does not induce a magnetron effect. In practice, in an r.f. sputtering system, film thickness uniformity of less than 4% at 3 sigma over a 6 inch x 6 inch (15.2 cm x 15.24 cm) square wafer or 8.5 inch (21.59 cm) diameter wafer has been achieved using 13 inch (33.02 cm) diameter targets. This result has been achieved both with and without a magnetic deposition field being applied during r.f. diode sputtering deposition. FIGURE 4 is a diagram of a high intensity plasma pattern achieved by a prior art rotating magnetic array. The plasma density is concentrated in a ring (600) around the periphery of the array and an oval (602) that is concentrated at the centre of rotation (604) and offset therefrom. While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and detail may be made therein without departing from the scope of the invention as defined in the appended claims.

Claims: An r.f. diode sputtering apparatus comprising: a vacuum chamber (100); a target (108) within said chamber (100) from which target material is sputtered; and a rotatable circular plate (112) having an axis of rotation (204; 304) and positioned behind said target (108); said plate (112) having in at least one quadrant thereof a number of permanent magnets (200; 300; 306; 310; 314) located around a periphery of said plate (112) in said quadrant and a bar permanent magnet (202; 302; 308; 312; 316) positioned between said axis of rotation (204; 304) and said number of permanent magnets (200; 300; 306; 310; 314) in said quadrant for providing a magnetic field which is sufficiently weak and discontinuous for preventing induction of a magnetron effect on said target (108); said permanent magnets (200; 300; 306; 310; 314) and said bar permanent magnet (202; 302; 308; 312; 316) being perpendicular to said plate (112) and of opposing polarity. An r.f. diode sputtering apparatus according to claim 1, wherein a thin film of material is sputtered onto a wafer (106) at an anode from a sputtering target cathode (108) comprising: a rotatable array plate (112); a magnetic array comprising a group of permanent magnets (200) uniformly arranged around a periphery of said array plate (112) in one quadrant thereof; each magnet (200) in said group of permanent magnets (200) being perpendicular to said plate (112) and having a pole of a first polarity (N or S) facing toward said target (108); a bar permanent magnet (202) affixed to said plate (112) within the same quadrant as said group of permanent magnets (200) and located between a centre axis of rotation (204) and said group of permanent magnets (200); said bar permanent magnet (202) being perpendicular to said plate (112) and having a pole of a second polarity (S or N) facing toward said target (108); said group of permanent magnets (200) and said bar permanent magnet (202) creating a closed-loop static magnetic field that is substantially triangular in shape, concentrated in said one quadrant, and offset from said centre axis of rotation (204). An r.f. diode sputtering apparatus according to claim 1, wherein a thin film of material is sputtered onto a wafer (106) at an anode from a sputtering target cathode (108) comprising: a rotatable array plate (112); a magnetic array comprising groups of permanent magnets (300; 306; 310; 314), said permanent magnets (300; 306; 310; 314) being uniformly arranged within each group at a periphery of said array plate (112) in each of four quadrants thereof; each magnet (300; 306; 310; 314) in a group being perpendicular to said array plate (112) and having a pole of a first polarity (N or S) facing toward said target cathode (108); and bar permanent magnets (302; 308; 312; 316) affixed to said array plate (112) within respective quadrants, each located between a centre axis (304) of rotation and each of said permanent magnet groups (300; 306; 310; 314); said bar permanent magnets (302; 308; 312; 316) being perpendicular to said plate surface and having poles of a second polarity (S or N) facing toward said target (108); and said groups of permanent magnets (300; 306; 310; 314) and said bar permanent magnets (302; 308; 312; 316) creating magnetic fields that are substantially triangular in shape, concentrated in each quadrant, and offset from said centre axis (304).

Inventors: PEARSON DAVID IAN CHARLES, TAN SWIE-IN, PEARSON, DAVID IAN CHARLES, TAN, SWIE-IN
Applicants: NORDIKO TECHNICAL SERVICES LTD, NORDIKO TECHNICAL SERVICES LIMITED
Application year: 1998
Main classification: H01J37
IPC codes: H01L21, C23C14, H01J37