Abstract:
In deposition devices, a precursor is directed at a substrate within a deposition chamber, and a block plate comprising a set of block plate apertures adjusts the direction and volume of the outflowing precursor. However, arrangements of block plate apertures that are suitable for some deposition scenarios (such as one type of precursor) are unsuitable for other deposition scenarios, resulting in precursor deposition that is undesirably thick, thin, or inconsistent. A set of block plate masks positioned over respective zones of the block plate are adjustable to align a set of masking apertures with respect to the block plate apertures, such as by operating a block plate motor to rotate a ring-shaped block plate mask over a cylindrical zone of the block plate. This configuration enables adjustable exposure of the block plate apertures to control the adjusted outflow of precursor through the block plate.

Description:
BACKGROUND 
       [0001]    The present disclosure is related to deposition devices and techniques, wherein a substrate is positioned within a deposition chamber and exposed to a series of precursors to form microscopically thin layers of deposited material. 
       SUMMARY 
       [0002]    This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to be an extensive overview of the claimed subject matter, identify key factors or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. 
         [0003]    In many scenarios, deposition is typically performed by injecting a gaseous or vaporous precursor toward a substrate positioned within a deposition chamber. In order to control the distribution of the precursor over the surface of the substrate, a block plate is positioned between the substrate source and the substrate, where the block plate comprises an array of block plate apertures that permit passage of the precursor to specific locations of the surface of the substrate. While the use of a block plate improves such distribution, the block plate is typically disposed within the deposition device in a fixed location and orientation, and with a symmetry or uniformity of the distribution of the block plate apertures over the block plate. This fixed position and uniform of the block plate apertures results in only one option for controlling the injection of the precursor at the substrate. In some cases, a pattern of block plate apertures, used with some precursors, injection patterns, and substrates, results in an uneven distribution of precursors. However, altering the distribution pattern often involves manually replacing the block plate with an alternative block plate having a different distribution of block plate apertures. 
         [0004]    The present disclosure involves placing a set of block masks between the precursor source and the block plate, where the block mask comprises an array of masking apertures that, for a particular zone of the block plate, are alignable in various ways with the block plate apertures within the zone of the block plate. For example, a ring-shaped block mask, when positioned over a ring-shaped zone of the block plate, enables the selection of the alignment of the masking apertures and the block plate apertures by rotating the block mask ring. Options achievable by different alignments include exposing a variable arrangement of block plate apertures, and selecting block plate apertures with different block plate aperture profiles. The selecting and exposing a subset of the block plate apertures of the block plate through the positioning of the block mask over the block plate enable greater process control and, in some circumstances, greater distribution consistency of the deposited precursor across the surface of the substrate. 
         [0005]    To the accomplishment of the foregoing and related ends, the following description and annexed drawings set forth certain illustrative aspects and implementations. These are indicative of but a few of the various ways of embodying one or more aspects of the presented techniques. Other aspects, advantages, and novel features of the disclosure will become apparent from the following detailed description when considered in conjunction with the annexed drawings. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0006]    Aspects of the disclosure are understood from the following detailed description when read with the accompanying drawings. It will be appreciated that elements and structures of the drawings are not necessarily be drawn to scale. Accordingly, the dimensions of the various features is arbitrarily increased and reduced for clarity of discussion. 
           [0007]      FIG. 1  is an illustration of an exemplary deposition device. 
           [0008]      FIG. 2  is an illustration of an exemplary deposition device including an adjustable block mask in accordance with the techniques presented herein. 
           [0009]      FIG. 3  is a chart illustrating the distribution of a precursor over the surface of a substrate in a first deposition device not having a block plate and a second deposition device having a block plate. 
           [0010]      FIG. 4  is a flow chart illustrating an exemplary method of directing a precursor at a substrate positioned within a deposition chamber in accordance with the techniques presented herein. 
           [0011]      FIG. 5  is an illustration of an exemplary computer-readable storage medium storing instructions configured to cause a computing device to perform the techniques presented herein. 
           [0012]      FIG. 6  is an illustration of an exemplary configuration of three exemplary variations in the distribution of block plate apertures of a block plate. 
           [0013]      FIG. 7  is an illustration of various profiles of block plate apertures, and various alignments of masking apertures and block plate apertures. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    Embodiments or examples, illustrated in the drawings, are disclosed below using specific language. It will nevertheless be understood that the embodiments or examples are not intended to be limiting. Any alterations and modifications in the disclosed embodiments, and any further applications of the principles disclosed in this document are contemplated as would normally occur to one of ordinary skill in the pertinent art. 
         [0015]      FIG. 1  presents an illustration of an exemplary deposition technique for forming a layer on a substrate. In this exemplary scenario, a deposition chamber  102  includes a substrate stage  106  on which is positioned a substrate  104 . The precursor  110  is stored by a precursor source  108  that is controllably connected with the deposition chamber  102 , such as through a controllable inlet that, when opened, enables an outflow  112  of the precursor  110  into the deposition chamber  102 . In order to direct the outflow  112  toward the substrate  104  and to provide consistent distribution of the outflow  112  of the precursor  110  toward the substrate  104 , a block plate  104  is positioned therebetween, comprising a set of block plate apertures  116  through which of the precursor  110  of the outflow  112  is toward the substrate  104 . The adjusted outflow  118  emitting from the block plate  114  is more controllably directed toward the substrate  104 . 
         [0016]    While the inclusion of a block plate  114  improves the guidance of the outflow  112  toward the substrate  104 , the deposition device depicted in the exemplary scenario  100  of  FIG. 1  presents some limitations due to the fixed configuration of block plate apertures  116  in the block plate  114 . For some selected precursors  110 , a single configuration of block plate apertures  116  results in uneven distribution of the selected precursor  110  toward the substrate  104 , and a fixed flow rate of the adjusted outflow  118 . Additionally, changing the configuration of block plate apertures  116  often involves a manual substitution of the block plate  114  with a second block plate  114  having a different configuration of block plate apertures  116 , which is time-consuming, not amenable to automation, and not feasible for the exposure of a single substrate  104  to different precursors  110  utilizing different block plates  114  having different configurations of block plate apertures  116 . 
         [0017]    Presented herein are techniques for varying the adjusted outflow  118  provided by the block plate  114  through the inclusion of a block mask set, positioned in the deposition device between the precursor source  108  and the block plate  114 , and comprising a series of block masks that controllably vary the adjusted outflow  118  generated by the block plate  114 . Respective block masks overlap a portion of the block plate  114 , herein termed a “zone,” such that an adjustment of the position of the block mask results in variable exposure of the block plate apertures  116  within the zone of the block plate  114  covered by the block mask. For example, in a first selected alignment, the masking apertures and the block plate apertures  116  of the corresponding zone are completely aligned, such that the adjusted outflow  118  emitting from the block plate  114  is not affected by the presence of the block mask. However, in a second selected alignment, the masking apertures partially masking the block plate apertures  116  in the zone of the block plate  114  (either by partially occluding each bock plate aperture  116 , or by exposing some of the block plate apertures  116  and completely occluding other block plate apertures  116 ), thus reducing the adjusted outflow  118  from the block plate  114  as compared with the first selected alignment. Some such alignments also alter the angle, shape, or profile of the adjusted outflow  118  emitting through the block plate apertures  116 . In a third selected alignment, the masking apertures are aligned such that no block plate apertures  116  are exposed, thus fully blocking the adjusted outflow  118  through this zone  208  of the block plate  114 . In this manner, the selectable alignment of the block masks  204  provides tighter control of the adjusted outflow  118  emitting from the block plate  114  by permitting, reducing, shaping, or blocking the adjusted outflow  118 . Moreover, the inclusion of a block mask motor to adjust the position of the block mask over the zone enables an automated adjustment of the components of the deposition device. 
         [0018]      FIG. 2  presents an illustration of an exemplary scenario  200  depicting a deposition device having an adjustable adjusted outflow  118  of the precursor  110  directed at the substrate  104  through the inclusion of a block mask set  202  comprising a series of block masks  204  respectively having a set of masking apertures  206 . In this exemplary scenario  200 , the block masks  204  are provided as a set of rings, each positioned to cover a zone  208  of the block plate  114  (which, in this exemplary scenario  200  are not necessarily physically demarcated on the block plate  114 , but are simply the portion of the block plate  114  covered by the block mask  204 ). For respective block plates  204 , a position  210  is selectable (in this exemplary scenario  200 , by rotating the ring-shaped block mask  204 ) to select an alignment  212  of the masking apertures  206  and the block plate apertures  116 , such as fully exposing all of the masking apertures  206 ; partially occluding the masking apertures  206  in order to reduce the adjusted outflow  118  or to alter its shape; and fully occluding the masking apertures  206 . In this manner, the selection of a position  210  of each block mask  204  achieves a selected alignment  212  of the masking apertures  206  and the block plate apertures  116  affecting the adjusted outflow  118  directed through the zone  208  of the block plate  114  toward the substrate  104 , without having to access or swap the block plate  114 . 
         [0019]      FIG. 3  presents a chart  300  depicting some experimental results demonstrating the deposition profile of a substrate  104  with precursor  110  when directed through a block plate  114  with and without the use of a block mask set  202 . In this chart  300 , a target deposition profile of 1.00 is desirable, but a first data set  302  illustrating the achieved deposition profile using only a fixed block plate  114  illustrates various peaks and troughs, reflecting the distribution of block plate apertures  116  over the block plate  114 . However, a second data set  304  illustrating the achieved deposition profile using a block mask set  202  of blocking masks  204  illustrates a first reduction  308  of the peaks and a second reduction  310  of the troughs depicted in the first data set  302 . This chart  300  thus reveals an achievable advantage of including the blocking mask set  202  to render increased consistency in the adjusted outflow  118  of precursor  110  directed at the substrate  104  positioned within the deposition chamber  102 . 
         [0020]      FIG. 4  presents an illustration of an exemplary method  400  of depositing a layer on a surface of a substrate  104  in accordance with the techniques presented herein. The exemplary method  400  involves a deposition device comprising a precursor source  108  storing a precursor  110 ; a block plate  114  comprising block plate apertures  116  directing injection of the precursor  110  at the substrate  104 ; and at least one block mask  204  comprising masking apertures  206  and positioned to cover a zone  208  of the block plate  114 . The exemplary method  400  involves positioning  402  the respective block masks  204  over the zone  208  of the block plate  114  to achieve a selected alignment  212  of the masking apertures  116  and the block plate apertures  206 . The exemplary method  400  also involves directing  404  the precursor  110  from the precursor source  108  through the masking apertures  206  and exposed block plate apertures  116  toward the substrate  104 . In this manner, the exemplary method  400  achieves the adjustable direction of the precursor  110  toward the aperture  104  in the deposition device. 
         [0021]    Still another embodiment involves a computer-readable medium comprising processor-executable instructions configured to implement one or more of the techniques presented herein. An example embodiment of a computer-readable medium or a computer-readable device that is devised in these ways is illustrated in  FIG. 5 , wherein an implementation  500  comprises a computer-readable medium  502 , such as a CD-R, DVD-R, flash drive, a platter of a hard disk drive, etc., on which is encoded computer-readable data  504 . This computer-readable data  506 , such as binary data comprising a plurality of zeroes and ones, in turn comprises a set of computer instructions  506  configured to operate according to one or more of the principles set forth herein. In an embodiment  500 , the processor-executable computer instructions  506  are configured to perform a method, such as at least some of the exemplary method  400  of  FIG. 4 . Many such computer-readable media are devised by those of ordinary skill in the art that are configured to operate in accordance with the techniques presented herein. 
         [0022]    Some variations of respective aspects of the techniques presented herein enable additional advantages and/or reduce disadvantages as compared with other such variations of the techniques presented herein and/or other techniques. 
         [0023]    A first aspect having respective variations among embodiments involves the positioning of the block plate  114  and the block mask set  202  within a deposition device. As one variation, the deposition device further comprises a deposition chamber lid, and the precursor source  108  controllably injects the precursor  110  downward through the deposition chamber lid. In such embodiments, the block plate  114  is positioned in the deposition chamber lid, and the block masks  204  are positioned above the block plate  114  in the deposition chamber lid, such that the precursor source  108  injects the precursor  110  downward through the block masks  202  and the block plate  114  within the deposition chamber lid in order to inject the adjusted outflow  118  into the deposition chamber  102 . In other variations, the block mask set  202  and the block plate  114  are positioned (together or separately) in other portions of the deposition device. 
         [0024]    A second aspect having respective variations among embodiments involves the shape and selectable positions  210  of the block masks  204  of the block mask set  202 . As a first variation, the block plate  114  comprises a first disc, and at least one block mask  204  comprises a second disc positioned to cover a circular zone  208  of the block plate  114  and rotatable to select an alignment  212  of the masking apertures  206  with the block plate apertures  116  in the circular zone  208  of the block plate  114 . In the particular example depicted in the exemplary scenario  200  of  FIG. 2 , the zones  208  of the block plate  114  comprise a number of concentric rings, and the block masks  204  also comprise concentric rings respectively positioned over a selected concentric ring of the block plate  114 , and independently rotatable to select an alignment  212  of the masking apertures  206  of the block mask  204  and the block plate apertures  116  in the selected concentric ring of the block plate  114 . A second variation involves a block mask set  202  comprising a grid of independent, substantially square block masks  204  arrayed as a grid and overlapping an array of grid regions comprising the zones  208  of the block plate  114 , and where the selection  210  comprises laterally shifting respective substantially square block masks  204  to alter the alignment  212  of the masking apertures  206  with the block plate apertures  116  in the overlapped grid region of the block plate  208 . Many such configurations of block masks  204  and zones  208  of the block plate  114  are compatible with the techniques presented herein. 
         [0025]    A third aspect having respective variations among embodiments involves the distribution of the masking apertures  206  over the block mask  204 .  FIG. 2  depicts that the distribution of the masking apertures  206  having approximately the number and position of masking apertures  206  as the block plate apertures  106 .  FIG. 6  depicts three such variations, including a first variation  602  in which the masking apertures  206  are distributed in a spiral pattern; a second variation  604  in which the masking apertures  206  are distributed in a radial pattern; and a third variation  606  in which the masking apertures are distributed in a polar pattern. 
         [0026]    A fourth aspect having respective variations among embodiments involves the manner of selecting the position  210  of the block masks  204  with the zone  208  of the block plate  114 . In a first such example, a block mask motor is included and operable to rotate the block mask  204  to achieve a selected alignment of the masking apertures  206  of the block mask  204  and the block plate apertures  116  of the block plate  114 . In a second such example, the positions  210  of the block masks  204  are manually selectable, such as through levers or dials providing manual adjustment of the position of a block mask  204  with respect to the zone  208  of the block plate  114 . 
         [0027]    A fifth aspect having respective variations among embodiments involves the design of the masking apertures  206  and the block plate apertures  604 . As a first variation of this fifth aspect, both sets of apertures have various lateral diameters. A lateral diameter of approximately 0.7 millimeters for the masking aperture  206  and the block plate apertures  116  is well-suited for the flow of some precursors  110 . 
         [0028]    As a second variation of this fifth aspect, the number, positioning, and spacing of the masking apertures  206  and block plate apertures  116  enables various alignments  212  selectable through various positions  210  of the block masks  204 .  FIG. 6  further presents an exemplary scenario  600  featuring one such example, wherein the alignments  212  comprise a variable arrangement of block plate apertures  116  exposed by the masking apertures  206 . A first alignment  212  is achieved by rotating the block mask  204  over a first position  604  within the zone  208  of the block plate  114 , such that the masking apertures  206  are fully exposed. Other alignments  212 , achieved by rotating the block mask  204  over other positions  604  within the zone  208  of the block plate  114 , partially expose or fully obstruct the block plate apertures  116 , thus providing other adjusted outflows  118  of the precursor  110  through the block plate  114 . Other arrangements of block plate apertures  116  and masking apertures  206  (such as a spiral arrangement of block plate apertures  116 ) enable other selectable alignments  212  having various properties, such as a variable arrangement of exposed block plate apertures  116  at various selectable alignments  212 . 
         [0029]    As a third variation of this fifth aspect, the masking apertures  206  are formed through the block mask  204  with various masking aperture profiles; and similarly, the block plate apertures  116  are formed through the block plate  114  with various block plate aperture profiles.  FIG. 7  depicts various block plate aperture profiles, such as a cone block plate aperture profile; a horn block plate aperture profile; and a cylindrical block plate aperture profile. The masking apertures  206  also present a cone masking aperture profile; a horn masking aperture profile; and a cylindrical masking aperture profile. Respective aperture profiles affect the alteration of the adjusted outflow  118  of the precursor  110 , such as the shape and volume of the adjusted outflow  118 . Additionally, the adjusted outflow  118  is affected by the combined shape formed by the alignment  212  of the masking aperture  206  and the block plate aperture  116 . As a first example, as further illustrated in the exemplary scenario  700  of  FIG. 7 , the flow of precursor  110  through a first masking aperture  206  and an aligned block plate aperture  116  having a conical block plate aperture profile provides a first conical adjusted outflow  110  provides different dispersal (broader or narrower) than a second masking aperture  206  and an aligned block plate aperture  116  having a horn block plate aperture profile. However, it is desirable to select the profiles of the masking apertures  206  and the alignment  212  to match the profiles of the block plate apertures  116 . For example, with respect to a surface lateral diameter of the block plate aperture profile on the surface of the block plate  114  facing the block mask  204 , and it is desirable to form the masking apertures  206  and to align the masking apertures  206  to present a lateral diameter on the surface of the block mask  204  facing the block plate  114  that matches the surface lateral diameter of the block plate aperture profile. As further illustrated in the exemplary scenario  700  of  FIG. 7 , in the first two alignments  212 , the position and width of the profile of the masking aperture  206  are aligned  702  with the position and width of the profile of the block plate aperture  116 . However, in a third alignment  212 , the profile of the masking aperture  206  is misaligned  706  with the position of the block plate aperture  116 , creating a dead space in the block plate aperture  116  that creates eddies  704  in the flow of the precursor  110  through the block plate  114  that disrupts the consistency of the adjusted outflow  118  of the precursor  110 . Such eddies  704  are avoidable by forming and aligning the profiles of the masking apertures  206  to match the profiles of the block plate apertures  116 . 
         [0030]    A first embodiment of the techniques provided herein comprises a deposition device, comprising a deposition chamber, a substrate stage positioning a substrate within the deposition chamber, a precursor source controllably injecting a precursor into the deposition chamber, and a block plate comprising block plate apertures directing injection of the precursor at the substrate. In accordance with the techniques provided herein, the first embodiment further comprises at least one block mask comprising masking apertures and positioned to cover a zone of the block plate with an alignment of the masking apertures and the block plate apertures to alter directing the injection of the precursor at the substrate. 
         [0031]    A second embodiment of the techniques provided herein comprises a block mask set usable with a deposition device comprising a deposition chamber, a substrate stage positioning a substrate within the deposition chamber, a precursor source controllably injecting a precursor into the deposition chamber, and a block plate comprising block plate apertures directing injection of the precursor at the substrate. In accordance with the techniques provided herein, the block mask set comprises at least one block mask comprising masking apertures and positioned to cover a zone of the block plate with an alignment of the masking apertures and the block plate apertures to alter directing the injection of the precursor at the substrate. 
         [0032]    A third embodiment of the techniques provided herein comprises a method of exposing a substrate to a precursor in a deposition device comprising a precursor source storing a precursor, a block plate comprising block plate apertures directing injection of the precursor at the substrate, and at least one block mask comprising masking apertures and positioned to cover a zone of the block plate. In accordance with the techniques provided herein, the method comprises positioning respective block masks over the zone of the block plate to achieve a selected alignment of the masking apertures and the block plate apertures, and injecting the precursor from the precursor source through the masking apertures and exposed block plate apertures toward the substrate. 
         [0033]    Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter of the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. 
         [0034]    Various operations of embodiments are provided herein. The order in which some or all of the operations are described should not be construed as to imply that these operations are necessarily order dependent. Alternative ordering will be appreciated by one skilled in the art having the benefit of this description. Further, it will be understood that not all operations are necessarily present in each embodiment provided herein. 
         [0035]    It will be appreciated that layers, features, elements, etc. depicted herein are illustrated with particular dimensions relative to one another, such as structural dimensions and/or orientations, for example, for purposes of simplicity and ease of understanding and that actual dimensions of the same differ substantially from that illustrated herein, in some embodiments. Additionally, a variety of techniques exist for forming the layers, features, elements, etc. mentioned herein, such as implanting techniques, doping techniques, spin-on techniques, sputtering techniques such as magnetron or ion beam sputtering, growth techniques, such as thermal growth and/or deposition techniques such as chemical vapor deposition (CVD), for example. 
         [0036]    Moreover, “exemplary” is used herein to mean serving as an example, instance, illustration, etc., and not necessarily as advantageous. As used in this application, “or” is intended to mean an inclusive “or” rather than an exclusive “or”. In addition, “a” and “an” as used in this application are generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form. Also, at least one of A and B and/or the like generally means A or B or both A and B. Furthermore, to the extent that “includes”, “having”, “has”, “with”, or variants thereof are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising”. 
         [0037]    Also, although the disclosure has been shown and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art based upon a reading and understanding of this specification and the annexed drawings. The disclosure includes all such modifications and alterations and is limited only by the scope of the following claims.