NANO-MATERIAL

Abstract: A method of making a thin film nano-material, the method comprising simultaneously depositing atoms of a ferro-magnetic substance together with clusters of a non-magnetic substance onto a surface, thereby providing a thin film nano-material comprising a matrix of the ferro-magnetic substance formed around the clusters of non-magnetic substance.

Description: NANO-MATERIAL The present invention relates to a nano-material, and in particular to a nano-material provided as a thin film. Nano-materials have been fabricated in many laboratories around the world. A polycrystalline nano-material is generally considered to be one in which the grain size of the polycrystalline material is 100 nanometers or less. A nano-material may be provided as a thin film, which typically comprises a layer of material less than 100 nanometers thick. A thin film nano-material may be constructed using for example chemical vapour deposition or atomic deposition. Nano-materials are the subject of a considerable amount of research. It is known that the properties of a material will be modified considerably when it is structured on a nanometer scale. For example, dramatic increases in hardness occur when the grain size of a polycrystalline material is reduced to a nanometer scale. Furthermore, it is known that the band gap of a polycrystalline semiconductor will increase as the diameter of semiconductor crystals is reduced below about 4 nanometers. It is an object of the present invention to provide a novel method of producing a thin film nano-material. According to a first aspect of the invention there is provided a method of making a nano-material, the method comprising simultaneously depositing atoms of a ferromagnetic substance together with clusters of atoms of a non-magnetic substance onto a surface, thereby providing a nano-material comprising a polycrystaline matrix of grains of the ferro-magnetic substance surrounded by clusters of atoms of the nonmagnetic substance. The simultaneous atomic and cluster deposition of the magnetic and non-magnetic materials allows the morphology of the resultant material to be carefully controlled. I he iidno material may be piov idcd as a thin film typically having a thickness of 100 nanometers or less Nano-matenals made according to the inv ention ai e advantageous because the c hii-iu o l non magnetic substance pn-Λ cnt the ioi mation ol laigc ci ystal l mc gi ains of the feπo-magnetic substance The non magnetic clusters sui iound the magnetic giams limiting the grain size of the feiro magnetic substance, as co pai ed to the gi ain size w hich would occui if the substance had been pioduced using dn ect atomic deposition With the present inv ention the magnetic material giain size can be reduced to close to the superpaiamagnetic limit The i eduction in gram size has sev eral beneficial effects, paiticularlv when the matenal is used as a magnetic media used, for instance, to stoie data The i educed grain size provides fastei switching ot the magnetism of each gra of the feπ o-magnetic substance, since the magnetic moments required to switch the magnetism are reduced This allows faster reading/writing when the material is used as a magnetic data storage medium The increased density of ferro-magnetic grains w hich results from the reduced gram size also allows an increased density of data to be stored In addition, the sepai ation of magnetic grams by the non-magnetic clustei s to some extent magnetically de couples adjacent grains The reduced gram size also substantially inci eases the haidness of the nano-material This can be of benefit in increasing ear resistance, paiticularly wheie the matenal is piov ided as a thin film, for instance ll used as the data storage medium of a computei haid disc additional protecti e coatings mav not be requned Preiei ably, the non-magnetic clustei s ai e embedded at a density of less than 20% olume into the matrix of fei ro magnetic substance, and most preferably at a density less than 10% by volume Preferably, a majority oi the non magnetic clusters hav e diametei s of less than 1 0 nano mctu s foi instance betw Ui 1 πid 7 nanomclei s Preferably, a majority of grains of the ferro-magnetic substance are less than 20 nanometers in diameter. For instance the grain size may be of the order of 10 nanometers in diameter the minum size being determined by the superparamagnctic limit of the pai ticulai magnetic substance used Preferably, the ferro-magnetic substance is cobalt Any othei suitable ferro-magnetic substance mav howe ei be used, for example iron Preferably, the non-magnetic substance is a substance that w ill not dissolve in the ferro-magnetic substance. Any elemental non-magnetic substance which is immiscible in the ferro-magnetic substance may be used. Preferably, the non-magnetic substance is copper Copper is preferred because it does not dissolve in cobalt but it will be appreciated that there are other substances that could be used. The surface may be provided by any suitable substrate such as a silicon or a metal, although any suitable substrate may be used The thin film nano-material may be deposited directly onto a conventional computer hard disk surface for instance The thin film nano-material may comprise one single layer of a multi-layer material Preferably, the atoms of the ferro-magnetic substance and the clusters of the nonmagnetic substance are generated at separate sources Preferably, the atoms of the ferro-magnetic substance ai e genei atcd in a fu st magnetron ' 1 he atoms are preferably dii ectcd to the surface in a jet of argon atoms This is atomic deposition. Preferably, atoms of the non-magnetic substance arc generated in a second magnetron, and group together to form clusters in a cooled chamber The clusters are preferably directed to the surface in a jet of argon atoms. According to a second aspect of the invention there is provided a thin film nano- material comprising a polycrystaline matrix of ferro-magnetic grains surrounded b \ clusters of atoms of a non-magnetic substance A specific embodiment of the invention w ill now be described with reference to the accompanying figure, which shows schematically an apparatus capable of producing the thin film nano-material according to the invention. In one example of the invention, copper clusters having diameters between 1 5 nanometers and 7 nanometers are embedded into a matrix of ferro-magnetic cobalt These clusters prevent the formation of large crystalline grains of cobalt, the grains being typically less than approximately 20 nanometers in diameter, rather than 50 to 60 nanometers that would form in the absence of the copper clusters. A further advantage of such small cobalt grains in addition to those mentioned above is that they are stable, as compared to cobalt grains of 50 to 60 nanometers diameter which are liable to grow when subjected to a magnetic field Magnetic nano-materials according to the present invention are particularly suitable for use as magnetic storage media As mentioned above the increased density of cobalt grains allows an increased density of data to be stored, and perhaps more significantly the reduced grain size provides faster switching ol the magnetism ol each cobalt gram, since the magnetic moments required to switch the magnetism ai e reduced This allows faster reading/writing to the data storage medium. Other advantages of the cobalt and copper of the present invention film include impi ov cϋ stabi lity and haidncss A magnetron sputtering apparatus which may be used to produce the cobalt and copper film is illustrated in Figure 1. A first magnetron 1 provides a jet of atomic cobalt 2, and a second magnetron 3 provides a jet of copper clusters 4. Inside the first magnetron 1 is a plate bearing cobalt (not shown). A magnet (not shown) situated behind the plate produces a magnetic field in front of the plate. The plate forms a cathode, and suitably located anodes (not shown) are placed around the plate. Low pressure argon gas is introduced into the magnetron in a continuous stream 8. The argon gas is ionised by the electric field inside the magnetron 1, and electrons which are separated from the argon atoms strike the cathode plate, thereby knocking cobalt atoms from the plate. These cobalt atoms are sputtered atoms. The cobalt atoms are carried from the magnetron 1 by a jet of argon atoms, such that the jet of atomic cobalt 2 in fact comprises atomic cobalt and atomic argon. The presence of the argon in the jet 2 may be ignored since it is inert. The second magnetron 3 is similarly constructed to the first magnetron 3, a constant stream of low pressure argon gas 8 again being introduced into the magnetron 3. However, in this case the plate (not shown) bears copper rather than cobalt. The beam of atomic cobalt 2 is produced in a vacuum of 10 "3 Torr. In contrast to this, the second magnetron 3 is located inside a chamber 5 containing a mixture of helium and argon at a pressure between 0.1 and 1.5 mbar (typically 1 Torr). The chamber 5 is cooled by liquid nitrogen. Copper atoms are emitted from the second magnetron 3 into the chamber 5, and have a restricted mobility due to the presence of the helium and argon atoms. The copper atoms tend to drift together and stick together, thereby forming clusters; a process known as gas aggregation. The copper clusters leave the chamber 5 with the helium atoms and argon atoms in a supersonic jet. A skimmer 6 is provided to skim off the helium, which rapidly expands as it leaves the cooled chamber 5, thereby leaving a jet 4 of copper clusters and argon atoms. Again, the presence of the argon atoms in the jet 4 may be ignored, since they are inert. Focusing lenses are not i cquired to pioduce the jet of copper clusteis 4 Instead, an appiopnately funnelled hole 9 is used Both the jet of cobalt atoms 2 and the jet of copper clusters 4 may be stopped using shutters 1 1 C oppci clusteis ai e deposikd togethei w ith cobalt atoms onto a suitable substi te 7 a process known as vacuum deposition The substrate is held at a vacuum of 10 s Ton to prevent impurities being deposited onto the substi ate 7 The atomic cobalt deposition and copper cluster deposition oecui at the same time so that a cobalt matrix grows up aiound the coppei clustei sites The cobalt atomic beam is approximately ten to twenty times moi e intense than the coppei clustei beam The deposition l ates are monitored using a stabilised oscillat g-crystal thickness monitoi (not shown) The size of the copper clusters provided by the appai atus of Figuie 1 may be selected from me iange 1 5 nanometei s to 7 nanometeis, by appiopnate adjustment of the apparatus The full width half maximum of the cluster size distribution is appioximately 30%o of the av ei age size The deposition late for the clusters is up to 5 A/s The deposition l ate piov ided by the apparatus is ultimately limited only by the source of the atomic cobalt jet 2 It is known that the nature of a substrate ma> affect the nature of a thin film of feno- magnetic material piovided on that substiate In this instance, bv choosing a particulai substiate which will act as a former to du ect the growth ol cobalt gi ains one pai ticular direction, the magnetism of the cobalt can be consti amed to be into oi out of the plane of the layer Propeities of the cobalt and coppei film can be manipulated easily and in a systematically i epeatable mannei by carefully conti oiling the size and density of the copper clusters I he cobalt and copper film is hard because the giain size of the cobalt is limited to less than approximately 20 nanometeis Existing cobalt films, w hich do not include copper clusters, have a giain size of 50 to 60 nanometers, and consequently aie significantly less hai d Conventional magnetic haid disks compi ise a cobalt allov fi lm hav ing a gi ain size smallci than 50 to 00 nanometei s, and include a piotectiv e layer on top of the cobalt film in order to piev ent damage by the i ccordmg head of the cobalt film A magnetic hard disk constt ucted using the cobalt and copper film according to the invention would not requn e a piotective layei and w ould therefoi e be simpler and cheaper to produce than existing magnetic hard disks A low density of copper clusteis, of the oi der of 10% or less (by v olume), is l equn cd to avoid adversely affecting the magnetic pi operties of the film A coppei clustei density of 5%> to 10% is piefen ed A clustei density of moi e than 20% mav significantly inhibit the ability of the film to lecoid magnetic information Fl.e substiate 7 can be any suitable substance, for example glass, silicon (or some other semi-conductor wafer or a metal) It is envisaged that in the manufacture of magnetic haid disks, the copper clusters and cobalt atoms will be deposited directly Multi-layei materials, with one layer containing clusteis, may be made using the apparatus shown in Figure 1 A thermal atomic source, for example a K-cell 10, mav be used to pi oduce atoms for vacuum deposition of a layer not containing clustei s Copper cluster sizes can be changed by adjusting parameters within the second magnetron 3, such as the pressure of the helium and argon gases, and the positioning ol the second magneti on 3 w ithin the cooled chambeι The rate of deposition is dependent upon the source of atoms and the soui ce of clusters The deposition rates quoted above are for an experimental apparatus If the apparatus were scaled up to provide coating of hard disks, then the deposition rates ill be mci eased, foi example to the i ange 50 100 A/s Although the invention has been described with reference to cobalt other magnetic materials could be used Cobalt however cunently predominates on the pioduction of magnetic data storage media Similai ly othei non-magnetic matenals such as gold and chi omium cold be used instead ol coppei I hese ai e non limiting examples

Claims: Claims 1 A method of making a thin film nano-material, the method comprising simultaneously depositing atoms of a fe o-magnetic substance together with clustei s of a non magnetic substanc-. onto a surface, thei eby pi ov iding a thin film nano material compi ising a polycrystaline matrix of grains of the feno-magnetic substance sun ounded by clustei s of atoms of the non-magnetic substance 2 A method according to claim 1 , vvheiem the non-magnetic clusters are embedded at a density of less than 20% by volume into the ati ix of ferro-magnetic substance 3 A method according to claim 2, vvheiem the non magnetic clusteis are embedded at a density of less than 10% by volume into the mati ix of fen o magnetic substance 4 According to any preceding claim, wherein a majority of the non-magnetic clusteis have diameteis of less than 10 nanometers 5 A method according to claim 4, wherein a majonty of the non-magnetic clusters ha e diameteis of less than 7 nanometeis 6 A method according to any preceding claim, wherein a majority of gi ams of the feπo-magnetic substance are less than 20 nanometei s in diametei 7 A method according to any claim 6, wherein a majority of giains of the feπo- magnelic substance are of the oider of 10 nanometei s in diametei 8 A method according to any preceding claim, wherein the feno-magnetic substance is cobalt 9. A method according to any preceding claim, wherein the non-magnetic substance is a substance that will not dissolve in the fenO-magnetic substance. 10. A method according to any preceding claim, wherein the non-magnetic clustei s ai e copper 1 1 . A method according to any preceding claim, wherein the surface is a si licon substrate, glass or a metal. 12. A method according to any preceding claim, wherein the thin film nano- material comprises a single layer of a multi-layer material. 13. A method according to any preceding claim, wherein the atoms of the ferromagnetic substance and the clusters of the non-magnetic substance are generated at separate sources. 14. A method according to claim 13, wherein the atoms of the ferro-magnetic substance are generated in a first magnetron 15. A method according to claim 13 or 14, wherein atoms of the non-magnetic substance are generated in a second magnetron, and group together to form clusters in a cooled chamber. 16. A thin film nano-material comprising a polycrystaline matrix of fcπ o- magnetic surrounded by clusters of a non-magnetic substance. 1 7. A method substantially as hereinbefore dcsci ibcd with l efei cnce to the accompanying figure. 18 A thin film nano-material substantially as hereinbefore described with reference to the accompanying figure.

Inventors: EASTHAM DEREK, EASTHAM, DEREK
Applicants: COUNCIL CENT LAB RES COUNCILS, EASTHAM DEREK, COUNCIL FOR THE CENTRAL LABORATORY OF THE RESEARCH COUNCILS, EASTHAM, DEREK
Application year: 2001
Main classification: C23C14
IPC codes: C23C14, H01F10, H01F41