The present invention relates to a dual magnetron sputtering power supply and to a magnetron sputtering apparatus in combination with or having such a dual magnetron sputtering power supply.
When using magnetron sputtering apparatus problems can arise with so-called target poisoning. For example, with an aluminum cathode and using O2 as the reactive gas, the cathode is initially clean aluminum. In the presence of reactive O2 a layer of aluminum oxide forms on the target thus poisoning it. A layer of aluminum oxide also forms on the anode, and this insulating layer means the anode starts to “disappear” so far as the cathode is concerned. By changing the polarity of the power supply to the cathode, which inherently occurs in a dual magnetron sputtering apparatus because an alternating power source is connected between the two cathodes, the oxide film on the one cathode, which was previously an anode, is initially more negative because of the electrons which accumulated on the insulating layer and is more strongly bombarded with ions thus cleaning it, i.e. the partial insulating coating on the cathodes, broken down again by the inert gas ions present in the chamber. The coating of articles placed in the vacuum chamber effectively takes place alternately from the first and second cathodes which are operated anti-phase. When one cathode is operating as a cathode, the other cathode is operating as an anode. The voltage at the cathodes varies with the degree of poisoning of the target, i.e. of the cathode surface.
Dual magnetron sputtering systems are, for example, used in glass coating applications and have two cathodes arranged alongside one another, with a supply of oxygen generally being located between them. The state of the art for a dual magnetron sputtering configuration (as it seems to be done in glass coaters) appears to use a voltage feedback signal to control the reactive gas flow to one of the cathodes in order to keep that cathode at a stable working point. However, it seems to be problematic to achieve such a control over a range of working conditions because of hysteresis in the relationship between the voltage feedback signal and the degree of poiconing of the cathode which is dependent on the reactive gas flow, on the amount of reactive gas which can react with the cathode and the cleaning of the cathode which takes place in alternate half cycles.
The object underlying the present invention is to provide a dual magnetron sputtering power supply and magnetic sputtering apparatus in combination with or having such a dual magnetron sputtering power supply which is able to operate in a stable manner over any desired length of a sputter coating phase, which ensures that the desired balanced operation of sputtering from each of the two cathodes is achieved and leads to a high quality sputtered coating with relatively inexpensive means. Furthermore, it is an object of the present invention to provide a dual magnetron sputtering power supply, and a magnetron sputtering apparatus in combination with or having such a dual magnetron sputtering power supply, which is able to cope with voltage variations at the cathodes arising from the movement of individual articles to be coated and elements of the workpiece support for the articles (the workpiece table) through the space in front of the cathodes. It should also be able to take account of the fact that the vacuum pump used to maintain the vacuum chamber at the required low pressure level inevitably tends to remove more reactive gas from one cathode than the other cathode for symmetry reasons.
In order to satisfy this object there is provided, in accordance with the present invention, a dual magnetron sputtering power supply for use with a magnetron sputtering apparatus having at least first and second sputtering cathodes for operation in the dual magnetron sputtering mode, there being an AC power supply connected to the first and second sputtering cathodes, a means for supplying a flow of reactive gas to each of said first and second cathodes via first and second flow control valves each associated with a respective one of said first and second cathodes and each adapted to control a flow of reactive gas to the respectively associated cathode, the power supply having, for each of said first and second cathodes, a means for deriving a feedback signal relating to the voltage prevailing at that cathode, a control circuit for controlling the flow of reactive gas to the respectively associated cathode by controlling the respective flow control valve and adapted to adjust the respective flow control valve to obtain a voltage feedback signal from the respective cathode corresponding to a set point value set for that cathode.
By providing a dual magnetron sputtering power supply of this kind it is possible to control the flow of the reactive gas to each of the cathodes, by controlling the respective flow control valves for the supply of reactive gas to each said cathode in such a way that balanced operation of a magnetron sputtering apparatus is achieved and thus a stable working point. Because each cathode becomes slightly poisoned during one half cycle of the AC power supply and is then partially cleaned again during the next half cycle, it is desirable to achieve an average degree of poisoning of each cathode which remains constant over many cycles of an AC power supply and indeed preferably for the degree of poisoning of each cathode to be the same, and indeed taking automatic account of the possible asymmetry of the removal of reactive gases from the vicinity of each of the cathodes by the vacuum pump associated with the apparatus. The above recited system makes it possible to achieve this end.
Preferred embodiments of the invention are set forth in the subordinate claims. It is particularly expeditious to measure the voltage prevailing at each of the cathodes with reference to earth or ground because this provides voltage feedback signals related to a common reference point (ground).
In a particularly preferred embodiment the control circuit comprises a respective regulator or controller for each cathode having as inputs the feedback signals from the cathodes and respective set point signals and producing as outputs a respective partial pressure set point signal, wherein a respective probe respectively associated with each cathode generates an actual pressure signal of the reactive gas, wherein the partial pressure set point signals and the respective actual pressure signals are applied to respective inputs of further regulators or controllers, the respective output signals of which serve to generate actuation signals for actuating the flow control valves supplying reactive gas to the respectively associated cathodes. That is to say there are nested voltage and partial pressure control loops which result in a high quality control of the dual magnetron sputtering apparatus so that very stable operation can be maintained at each of the two cathodes with the desired composition of the sputtered coating being obtained.
The present invention will now be explained in more detail with reference to the embodiments and to the accompanying drawings in which are shown:
Turning now to
The cathodes may be, but do not necessarily need to be opposed to each other. State of the art for a DMS configuration (as it seems to be done in glass coaters) is that a voltage feedback signal controls the reactive gas flow (here: O2 flow) to cathode 1, in order to keep the cathode at a stable working point (see literature of Bill Sproul on IRESS). The O2 flow to the second cathode 4 is controlled in the prior art by an Optical Emission Controller.
In contrast, in accordance with the present invention, a feedback signal (“V1-signal”) from first cathode 1 voltage (or from the DMS power supply) is used for control of a first O2 inlet valve 12 at the first cathode 1, whereas control of a second O2 inlet valve at the second cathode 4 is governed by the feedback signal (“V4-signal”) of the second cathode 4 voltage. These are separate transmitters of voltage, measuring AC apparent voltage, AC rectified voltage or DC voltage. The elements shown in the drawing by symbols have their usual meaning. Thus, the triangle in a circle 16 represents the vacuum pump for producing the required operating vacuum in the chamber and the triangle in a square symbol signifies a feedback controlled regulator 18, 20 respectively.
In both cases the O2-flow is increased until the respective cathode voltage reaches the set point value V1 SET POINT and V4 SET POINT respectively corresponding to the requirement of the control system. This set point value is generally chosen to be a DC voltage but it could also be a profiled, time dependent voltage. For O2 this value is lower than the voltage in metallic (non-reactive) mode, at least when the cathodes are made of Al for forming, e.g., an Al2O3 coating. For other gas/metal combinations this might be a higher value.
The argon (Ar) flow for sputtering (non-reactive sputter gas) is supplied at a different place 22 than the O2 inlet (in general this is the state of the art), but it could also be supplied near the cathode, e.g. at 22′, or combined near the cathode. It can also be supplied at one of the other cathodes or centrally or at any other appropriate place in or adjacent to the vacuum chamber or system.
The control system is preferably realized with fast response MFC's (mass flow controllers), i.e. 18, 20, for reactive sputtering of oxygen or other difficult to sputter materials with a fairly big voltage difference between the metallic mode and the fully poisoned reactive mode. The problem of target poisoning is one of the prime reasons for using a dual mode magnetron sputtering system. For example, with an Al cathode and using O2 as the reactive gas the cathode is initially clean aluminum. In the presence of reactive O2 a layer of aluminum oxide forms on the target thus poisoning it. By changing the polarity of the power supplied to the cathode, inherent in DMS, the oxide film is broken down again by the inert gas ions in the chamber. Thus the coating of articles placed in the vacuum chamber effectively takes place alternately from the first and second cathodes which are operated antiphase. The voltage at the cathodes varies with the degree of poisoning of the target (cathode surface).
Turning now to
Because the two cathodes 1 and 4 are connected to respective output terminals of the AC source and because the conditions inside the vacuum chamber means that this acts as a rectifier diode, the voltage at the cathodes 1 and 4 in each case corresponds to a negative half wave of the sinusoidal supply, with the two half waves being shifted relative to one another by 180° as shown in
It should be noted that the peak negative amplitude of the voltage present at the cathodes 1 and 4 as shown in
Turning now to
The pivotally mounted doors 34, 36 can be pivoted into the position shown in broken lines to close the chamber in use. The chamber typically has a generally octagonal base and octagonal cover which seal the chamber so that a vacuum can be generated therein by the vacuum pump 16. Within the chamber there is usually a rotary table 28 which carries workpieces either directly or on further smaller rotary tables 40 which rotate about their own axes as well as rotating with the table 38 about the central vertical axis of the chamber.
It can be seen from
Turning now to
Again, the magnet systems associated with the cathodes 1 and 4 are not shown and also relative to
In the embodiment of
In a dual mode magnetron sputtering system having workpieces on a movable workpiece table 38 there is a significant tendency for electrons in the vicinity of the cathodes 1 and 4 to be affected by gaps which appear on rotation of the workpiece table in such a way that they may tend to move to the other respective cathode when acting as an anode and thus result in fluctuation of the voltage signals V1 and V4. The regulators or controllers 18, 20 are selected to be relatively slow regulators so that they tend to smooth out voltage fluctuations and maintain the voltages V1 and V4 measured at the respective cathodes 1 and 4 within preselected bandwidths. Thus, fluctuations of the voltages V1 and V4 do not lead to instabilities in operation.
As stated earlier, the output signals of the regulators or controller 18, 20 are used as desired partial pressure signals for the partial pressures of the reactive gas present in the vicinity of the cathodes 1 and 4. The action of the output signals P1OUT and P4OUT of the further regulators 30 and 32 on the mass flow controllers 12 or 14 thus tries to correct the supply of reactive gas to the respective cathodes 1 and 4 so that the actual pressure values P1ACT and P4ACT correspond as closely as possible to the partial pressure desired signals P1DES.O2 and P4DES.O2. The respective partial pressures set in this way in turn vary the voltage feedback signals V1 and V4 and thus permit correction of the conditions prevailing at the cathodes 1 and 4 so that these are operated at or close to the desired set point values V1SETPOINT and V4SETPOINT respectively.
Although the further regulators 30 and 32 are described as hard regulators in the sense that they react quickly to changes of the desired partial pressures P1DES and P4DES, it is believed that these could also be realized as soft regulators without significant disadvantage.
It should be noted that when using lambda sensors the character of the feedback signal means that a decrease of the set point value physically relates to an increase of the partial pressure (for example in mbar).
So the actual pressures are sensed as samples and after each sampling interval a change of a set point can occur. The precise layout of the controls can include multiplication of signals with predefined values to improve the control response and to ensure that the system operates within the preset bandwidths.
It should also be noted that it is possible to build in alarms into the system such that if operating parameters move outside of the preset bandwidths an alarm signal is generated and optionally some other step is automatically taken to overcome the difficulty, for example shutdown of the apparatus until the reason for the alarm has been diagnosed and remedied.
Number | Date | Country | Kind |
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06022396.3 | Oct 2006 | EP | regional |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2007/009326 | 10/26/2007 | WO | 00 | 2/12/2010 |