Abstract:
The embodiments disclose a method of creating a mask by depositing a protection layer that mechanically strengthens patterned features that are imprinted into a resist layer that is deposited onto a magnetic layer, implanting mechanically strengthened patterned resist layer features into the magnetic layer using ion implantation and removing the resist layer and the mask to expose at least a portion of the magnetic layer.

Description:
BACKGROUND 
       [0001]    Patterning of recording stacks may have side-effects including size deformation and feature position shifting in stacks including bit-patterned media (BPM) as feature densities have increased for example a density of 0.5 Tera dots per square inch (Td/in 2 ) and above. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0002]      FIG. 1  shows a block diagram of an overview of a method of magnetic media manufacturing of one embodiment. 
           [0003]      FIG. 2A  shows a block diagram of an overview flow chart of a method of magnetic media manufacturing of one embodiment. 
           [0004]      FIG. 2B  shows a block diagram of an overview flow chart of fabricating a conformal protection layer stop of one embodiment. 
           [0005]      FIG. 2C  shows a block diagram of an overview flow chart of the fabrication of a high selectivity mask of one embodiment. 
           [0006]      FIG. 3  shows a block diagram of an overview flow chart of patterning the magnetic layer of one embodiment. 
           [0007]      FIG. 4A  shows for illustrative purposes only an example of a first thickness of conformal protection layer of one embodiment. 
           [0008]      FIG. 4B  shows for illustrative purposes only an example of a partial etch-back and planarization of conformal protection layer of one embodiment. 
           [0009]      FIG. 4C  shows for illustrative purposes only an example of lifting off mask residue of one embodiment. 
           [0010]      FIG. 5A  shows for illustrative purposes only an example of a conformal protection layer stop of one embodiment. 
           [0011]      FIG. 5B  shows for illustrative purposes only an example of a deposition of third thickness of conformal protection layer of one embodiment. 
           [0012]      FIG. 5C  shows for illustrative purposes only an example of ion beam exposure of one embodiment. 
           [0013]      FIG. 5D  shows for illustrative purposes only an example of conformal protection layer patterned magnetic layer recording features of one embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0014]    In a following description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration a specific example in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present embodiments. 
       General Overview: 
       [0015]    It should be noted that the descriptions that follow, for example, in terms of a method of magnetic media manufacturing is described for illustrative purposes and the underlying system can apply to any number and multiple types of stacks. In one embodiment, the conformal protection layer can be configured using a first thickness of conformal protection layer materials. The conformal protection layer can be configured to include a sacrificial layer of a second thickness of conformal protection layer materials and can be configured to include a third thickness of conformal protection layer materials of one embodiment. 
         [0016]      FIG. 1  shows a block diagram of an overview of a method of magnetic media manufacturing of one embodiment.  FIG. 1  shows a conformal deposition of a protection layer on imprinted resist layer on a magnetic layer on top of a substrate  100 . The conformal deposition of a protection layer on imprinted resist layer on a magnetic layer on top of a substrate  100  is processed using a partial etch-back and planarization to create a mask  110 . The mask is used for patterning the magnetic layer by ion beam exposure for ion implantation  120 . Cleaning mask residue above the magnetic layer by lifting it off  130  prepares the patterned magnetic layer for a deposition of a carbon over coat (COC) layer  140  of one embodiment. 
         [0017]    The conformal deposition of a protection layer on imprinted resist layer on a magnetic layer on top of a substrate  100  is used for bonding imprint resist features  150  and protecting imprint resist features from damage caused by other processing  154  and eliminates a de-scum process  170 . The partial etch-back and planarization to create a mask  110  eliminates a reverse tone mask formation process  180  releasing stress formed during processes including reverse tone mask formation  158 . Lessening the number of steps used in stack fabrication processing  190  and using the conformal protection layer created mask is used for reducing pattern feature size deformation and dislocations  160  thereby increasing pattern feature uniformity  165  in patterned stacks including bit patterned media (BPM) including BPM with pattern densities greater than 0.5 Tera dots per square inch (Td/in 2 ) of one embodiment. 
       Detailed Description: 
       [0018]      FIG. 2A  shows a block diagram of an overview flow chart of a method of magnetic media manufacturing of one embodiment.  FIG. 2A  shows an imprinted resist layer deposited on a magnetic layer on top of a substrate  200 . A conformal deposition of protection layer on the imprinted resist layer  205  eliminates a de-scum process  170 . The conformal deposition of protection layer on the imprinted resist layer  205  and is used for protecting imprint resist features from damage caused by other processing  154  by bonding imprint resist features  150  of  FIG. 1 . In one embodiment a first thickness of conformal protection layer materials  210  is deposited on the imprinted resist layer including using chemical vapor deposition (CVD)  212  and atomic-layer deposition (ALD)  214 . Conformal protection layer materials  220  include for example carbon (C)  222 , cyanide (CN)  224 , silicon carbide (SiC)  226 , titanium oxides (Ti x O y )  228 , tantalum oxides (Ta x O y )  230 , tantalum (Ta)  232 , tungsten (W)  234  and other materials  236  of one embodiment. 
         [0019]    The first thickness of conformal protection layer materials  210  is processed using a partial etch-back and planarization  110  including an isotropic plasma etch  240  and slanted beam milling  242  to a level above the tops of the imprinted resist layer  244  creating a mask  246 . Creating a mask  246  eliminates a reverse tone mask formation process  180 . Processing description continue as shown in  FIG. 3  of one embodiment. 
       Conformal Protection Layer Stop: 
       [0020]      FIG. 2B  shows a block diagram of an overview flow chart of fabricating a conformal protection layer stop of one embodiment.  FIG. 2B  shows another embodiment continuing from  FIG. 2A  including a conformal deposition of a second thickness of conformal protection layer stop  250 . The conformal deposition of a second thickness of conformal protection layer stop  250  includes using chemical vapor deposition (CVD)  212  and atomic-layer deposition (ALD)  214 . The conformal protection layer materials  220  include for example carbon (C)  222 , cyanide (CN)  224 , silicon carbide (SiC)  226 , titanium oxides (Ti x O y )  228 , tantalum oxides (Ta x O y )  230 , tantalum (Ta)  232 , tungsten (W)  234  and other materials  236 . The conformal deposition of a second thickness of conformal protection layer stop  250  is used to deposit a sacrificial layer of thin film on the surfaces of the imprinted resist features  252  to create a conformal protection layer stop  254 . A conformal deposition of a third thickness of conformal protection layer materials  260  using chemical vapor deposition (CVD)  212  and atomic-layer deposition (ALD)  214 . Continuing processes are further described in  FIG. 2C  of one embodiment. 
       High Selectivity Mask: 
       [0021]      FIG. 2C  shows a block diagram of an overview flow chart of the fabrication of a high selectivity mask of one embodiment.  FIG. 2C  shows a continuation from  FIG. 2B  wherein the conformal protection layer materials  220  include for example carbon (C)  222 , cyanide (CN)  224 , silicon carbide (SiC)  226 , titanium oxides (Ti x O y )  228 , tantalum oxides (Ta x O y )  230 , tantalum (Ta)  232 , tungsten (W)  234  and other materials  236 . The conformal deposition of a third thickness of conformal protection layer materials  260  of  FIG. 2B  is filling the thin film coated imprinted resist features on top of conformal protection layer stop  262  to a level above the tops of the imprinted resist layer  264 . 
         [0022]    A partial etch-back and planarization of the third thickness of conformal deposited materials  270  using processes including an isotropic plasma etch  240  and slanted beam milling  242  to the conformal protection layer stops on the tops of the imprinted resist features  272  creating a high selectivity mask  280 . Creating a high selectivity mask  280  eliminates a reverse tone mask formation process  180  releasing stress formed during reverse tone mask formation  274 . Further processing is described in  FIG. 3  of one embodiment. 
       Patterning the Magnetic Layer: 
       [0023]      FIG. 3  shows a block diagram of an overview flow chart of patterning the magnetic layer of one embodiment.  FIG. 3  shows processes continuing from  FIG. 2A  and  FIG. 2C  including patterning the magnetic layer using ion beam exposure  300  to create ion implantation  310 . Patterning the magnetic layer using ion beam exposure  300  that passes through the conformal protection layer mask and imprinted resist layer and using ion implantation  310  creates ion implanted magnetic layer materials  312  and magnetic layer magnetic patterned recording features  314 . The magnetic layer magnetic patterned recording features  314  include for example patterned stack features including bit patterned media (BPM) including BPM with pattern densities greater than 0.5 Tera dots per square inch (Td/in 2 ) of one embodiment. 
         [0024]    Following ion implantation  310  cleaning mask and resist residue above the magnetic layer by lifting it off  130  includes using lift off cleaning processes  320  including solvent  322 , baking  324  and plasma strip  326 . The lift off cleaning processes  320  includes using solvent, baking and plasma strip processes separately or in combinations prior to a deposition of a carbon over coat (COC) layer  140 . The deposition of carbon over coat (COC) layer protects the patterned magnetic layer during back-end processing including lube, buff, etc.  340 . 
         [0025]    Lessening the number of steps used in stack fabrication processing  190  produces reduced cost of stack manufacturing  330 . The conformal protection layer protecting imprint resist features from damage caused by other processing  154  by bonding imprint resist features  150  of  FIG. 1  is used for reducing pattern feature size deformation and dislocations  160  thereby increasing pattern feature uniformity  165  in patterned stacks of one embodiment. 
       First Thickness of Conformal Protection Layer: 
       [0026]      FIG. 4A  shows for illustrative purposes only an example of a first thickness of conformal protection layer of one embodiment.  FIG. 4A  shows an imprinted resist layer  404  on top of a magnetic layer  402  deposited on a substrate  400 . The magnetic layer  402  includes materials for example cobalt, chromium and platinum (CoCrPt). The substrate  400  includes materials for example quartz and silicon (Si). The imprinted resist layer  404  includes imprinted resist features  406 . A deposition of a first thickness of conformal protection layer  410  is processed using atomic-layer deposition (ALD)  214 . The deposition of a first thickness of conformal protection layer  410  is used to create the first thickness of conformal protection layer materials  210  on top of the imprinted resist features  406 . Descriptions of continuing processes follow in  FIG. 4B  of one embodiment. 
       Partial Etch-Back and Planarization: 
       [0027]      FIG. 4B  shows for illustrative purposes only an example of a partial etch-back and planarization of conformal protection layer of one embodiment.  FIG. 4B  shows processes continuing from  FIG. 4A  including a partial etch-back and planarization of the first thickness of conformal protection layer  430 . The partial etch-back and planarization of the first thickness of conformal protection layer  430  is performed using slanted beam milling  242  down to a level above the tops of the imprinted resist features  406 . An etch-backed first thickness of conformal protection layer  440  is used for creating a mask  246  to transfer the patterns of the imprinted resist features  406  into the magnetic layer  402  deposited on the substrate  400  of one embodiment. 
         [0028]    An ion implantation in magnetic layer  450  using ion beam exposure  455  is used to pattern the magnetic layer  402  using the imprinted resist features  406  and mask. The ion beam exposure  455  passes through the etch-backed first thickness of conformal protection layer  440  and imprinted resist features  406  into the magnetic layer  402  to the substrate  400 . The ion beam exposure  455  is used for creating ion implanted magnetic layer materials  312  and magnetic layer magnetic patterned recording features  314  including for example dots in a bit patterned media (BPM) of one embodiment. The processing is further described in  FIG. 4C . 
       Lifting Off Mask Residue: 
       [0029]      FIG. 4C  shows for illustrative purposes only an example of LIFTING OFF mask residue of one embodiment.  FIG. 4C  shows descriptions of processes that continue from  FIG. 4B  including cleaning mask and resist residue above the magnetic layer  470 . Cleaning mask and resist residue above the magnetic layer  470  includes using a lift off using solvent and baking  475 . The cleaning mask and resist residue above the magnetic layer  470  is exposing the ion implanted magnetic layer materials  312  and magnetic layer magnetic patterned recording features  314  in the magnetic layer  402  above the substrate  400 . 
         [0030]    The deposition of a carbon over coat (COC) layer  140  uses chemical vapor deposition (CVD)  212  in creating a COC protection layer  490 . Creating a COC protection layer  490  is used for protecting the ion implanted magnetic layer materials  312  and magnetic layer magnetic patterned recording features  314  in the magnetic layer  402  above the substrate  400  prior to fabrication processes that follow of one embodiment. 
       Conformal Protection Layer Stop: 
       [0031]      FIG. 5A  shows for illustrative purposes only an example of a conformal protection layer stop of one embodiment.  FIG. 5A  shows the imprinted resist features  406  in the imprinted resist layer  404  on top of the magnetic layer  402  deposited on top of the substrate  400 . A deposition of a second thickness of conformal protection layer stop  500  using atomic-layer deposition (ALD)  214  is creating a conformal protection layer stop  515 . The deposition of a second thickness of conformal protection layer stop  500  is a thin film on the surfaces of the imprinted resist features  406 . The conformal protection layer stop  510  is bonding imprint resist features  150  of  FIG. 1  of one embodiment. A continuation of the processing is described in  FIG. 5B . 
       Deposition of Third Thickness of Conformal Protection Layer: 
       [0032]      FIG. 5B  shows for illustrative purposes only an example of a deposition of third thickness of conformal protection layer of one embodiment.  FIG. 5B  shows a continuation from  FIG. 5A  that includes a deposition of third thickness of conformal protection layer  520  using the chemical vapor deposition (CVD)  212  on top of the conformal protection layer stop  510 . The deposition of third thickness of conformal protection layer  520  is filling the thin film coated imprinted resist features  406  with a third thickness of materials to a level above the tops of the conformal protection layer stop  510  of one embodiment. 
         [0033]    A process is used for etching back the third thickness of conformal protection layer to the stop  530  using an isotropic plasma etch back  534 . The etching back to conformal protection layer stop  510  creates an etched back third thickness of conformal protection layer  540  used for creating a high selectivity mask  538 . Creating a high selectivity mask  538  is used for transferring the imprinted resist features  406  of the imprinted resist layer  404  to the magnetic layer  402  deposited on the substrate  400  of one embodiment. The processing is further described in  FIG. 5C . 
       Ion Beam Exposure: 
       [0034]      FIG. 5C  shows for illustrative purposes only an example of ion beam exposure of one embodiment.  FIG. 5C  shows continued processing from  FIG. 5B  including the ion implantation in the magnetic layer  450  using the ion beam exposure  455  of the magnetic layer  402 . The ion beam exposure  455  through the etched back third thickness of conformal protection layer  540 , conformal protection layer stop  510  and imprinted resist layer  404  is used for patterning the magnetic layer  402  with the imprinted resist features  406  down to the substrate  400 . The ion implantation in the magnetic layer  450  is creating ion implanted magnetic layer materials  312  and magnetic layer magnetic patterned recording features  314  for example dots in a bit patterned media (BPM) of one embodiment. 
         [0035]    The cleaning mask and resist residue above the magnetic layer  470  using a lift off using baking and plasma strip  550  is removing the etched back third thickness of conformal protection layer  540 , conformal protection layer stop  510  and imprinted resist layer  404 . The cleaning mask and resist residue above the magnetic layer  470  is exposing the ion implanted magnetic layer materials  312  and magnetic layer magnetic patterned recording features  314  in the magnetic layer  402  of one embodiment. Descriptions of continuing processes are shown in  FIG. 5D . 
       Patterned Magnetic Layer Recording Features: 
       [0036]      FIG. 5D  shows for illustrative purposes only an example of conformal protection layer patterned magnetic layer recording features of one embodiment.  FIG. 5D  shows processing continuing from  FIG. 5C  that includes the deposition of a carbon over coat (COC) layer  140 . The deposition of a carbon over coat (COC) layer  140  includes using a sputtering process  560  on top of the magnetic layer  402  to protect the ion implanted magnetic layer materials  312  and magnetic layer magnetic patterned recording features  314  in the magnetic layer  402  on the substrate  400 . The method of magnetic media manufacturing using the conformal protection layer high selectivity mask  538  is reducing pattern feature size deformation and dislocations  160  and increasing pattern feature uniformity  165  in patterned stacks including bit patterned media (BPM) including BPM with pattern densities greater than 0.5 Tera dots per square inch (Td/in 2 ) of one embodiment. 
         [0037]    The foregoing has described the principles, embodiments and modes of operation of the present embodiments. However, the invention should not be construed as being limited to the particular embodiments discussed. The above described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope of the present embodiments as defined by the following claims.