The invention relates to methods, devices, and systems of monitoring a discharge in a plasma process.
Coating of substrates, for example glass substrates, by means of cathode sputtering in plasma processes is a well-known process. Cathode sputtering can be performed conventionally or by use of a reactive gas. In the latter case, it is called reactive sputtering. A plasma is generated by means of a current or voltage source, which removes material from a target. The removed material is then deposited on the substrate. Before deposition, the atoms of the target material can combine with gas atoms or molecules in a reactive process.
In reactive processes, medium frequency (MF) generators may be used. Such generators typically operate at frequencies in the range from 10 to 500 kHz. Furthermore, pulsed generators may be used, in particular bipolar pulsed generators. Those generators have in common that they produce a periodic output signal. The periodic output signal is supplied to the plasma process. Typically, the output voltage of such generators is supplied to the plasma chamber by means of two electrodes, which are in turn used as cathode and anode. Both electrodes are connected to a target respectively. The generators may be freely oscillating generators or generators having a controlled frequency.
In particular, if reactive processes are being used, arcs can occur. If arcs occur, they may damage the substrate or the targets. Therefore, arcs should be avoided or, if an arc is detected, it should be quickly extinguished. To be able to extinguish an arc, it is necessary to detect arcs quickly and reliably. To detect arcs, the output signal of the power supply, i.e., a power supply signal, may be observed. In particular, if the output signal changes its value periodically, like in bipolar pulsed or MF plasma processes, the output signal at a specific time in a later period can be compared with a corresponding value at the same time in a previous period. Problems arise, when the output signal rises or falls very quickly. Especially, in bipolar pulse powered plasmas this is very relevant. If this happens, false arcs may be detected, i.e., an apparent arc may be detected even though there is no arc present. This can lead to an interruption of the plasma process, which is undesirable. On the other hand, if the threshold for arc detection is made too large to avoid these false arc detections, real arcs may be detected too late or not at all.
One aspect of the present invention features methods of monitoring a discharge in a plasma process. The methods include the steps of:
a) supplying a plasma process with a periodic power supply signal;
b) determining a first power supply signal waveform within a first time interval within a first period of the power supply signal;
c) determining a second power supply signal waveform within a second time interval within a second period of the power supply signal, wherein the second time interval is at a position in the second period that corresponds to the position of the first time interval within the first period;
d) comparing the second power supply signal waveform of the second time interval with a reference signal waveform associated with the first power supply signal waveform of the first time interval, and determining a first comparison result, wherein the reference signal waveform can be the first power supply signal waveform itself or be generated from the first power supply signal waveform;
e) if the first comparison result corresponds to a given first comparison result, time-shifting one of the second power supply signal waveform in the second time interval and the reference signal waveform associated with the first power supply signal waveform in the first time interval to produce a time-shifted signal; and comparing the time-shifted signal with one of the signal waveforms that was not time-shifted, thereby obtaining a second comparison result.
Because the power supply signal is periodic, e.g., a sine waveform, the second time interval can have the same time interval for the second period as the first time interval for the first period. That is, a value within the second time interval in the second period has the same phase as a corresponding value at the same time within the first time interval in the first period. The values having the same phases in the first period of the first power supply signal waveform and in the second period of the second power supply signal waveform can be compared to determine the first comparison result.
One of the first and second comparison results may be obtained by determining a difference between the first and second power supply waveforms and determining if the difference is above or below a given reference value. Depending on whether an output current, an output voltage, or an output power is observed as the power supply signal, an arc is detected if the difference between the first and second power supply signal waveforms rises above or falls below a given reference value. Typically, the output voltage drops if an arc occurs and the output current increases if an arc occurs. Thus, by comparing the first and second power supply signal waveforms, in particular by detecting the difference between the first and second power supply signal waveforms, an arc may be detected.
The reference signal waveform may be the first power supply signal waveform in the first interval itself. Alternatively, the reference signal waveform may be determined by multiplying the first power supply signal waveform in the first interval with a given value or by adding or subtracting a constant value from the first power supply signal waveform in the first interval. If such a reference signal waveform is compared with the currently measured output signal waveform (that is, the second power supply signal waveform) and the currently measured output signal waveform intersects the reference signal waveform, this may be indicative of an arc having occurred.
Hence, one of the first or second comparison results may be obtained by monitoring if the second power supply signal waveform intersects the reference signal waveform.
A signal waveform can be time-shifted by moving the signal waveform along the time axis by a certain distance or an amount of time. The distance can be in a range between 1% and 20% of a length of a period of the signal waveform. The time-shifted version of the signal waveform and the non-time-shifted signal waveform can be sampled, digitized, and stored. The starting point for the sampling can be for example the beginning of a period.
In some cases, to compare two waveforms, corresponding samples of two waveforms are compared, for example, the first sample of the first waveform is compared with the first sample of the second waveform. If the first waveform is time-shifted and to be compared to the second waveform that is not time-shifted, the first sample of the time-shifted first waveform can be compared with for example the 20th sample of the non-time-shifted second waveform, second with 21st, and so on.
The signal waveform that has been time-shifted in step e) above may be time-shifted in the opposite direction and the time-shifted signal may be compared to one of the signal waveforms that were not time-shifted, thereby obtaining a third comparison result. In this way it is possible to detect arcs reliably when the output voltage is rising.
An arc detection signal may be generated if the first comparison result corresponds to the first given comparison result and at least one of the second or third comparison results corresponds to the second or third given comparison result respectively. Hence, an arc detection signal is generated only if the first comparison result has been confirmed by either the second or the third comparison result.
These methods allow safe and reliable arc detection. These methods lead to a more reliable arc detection because not only one comparison is performed but two comparisons are performed. False arc detection, for example due to a frequency jitter, can thus be avoided. The second comparison is used to confirm that the first comparison has detected a real arc.
Another aspect of the invention features monitoring devices that can be used for monitoring a discharge in a plasma process, which is supplied by a power supply signal. The monitoring devices include:
a) a first determining device arranged to determine a first power supply signal waveform within a first time interval within a first period of the power supply signal;
b) a second determining device arranged to determine a second power supply signal waveform within a second time interval within a second period of a power supply signal, wherein the second time interval is at a position in the second period that corresponds to the position of the first time interval within the first period;
c) a first comparator arranged to compare the second power supply signal waveform of the second time interval with the first power supply signal waveform of the first time interval or a reference signal waveform and to determine a first comparison result;
d) a first time-shifter arranged to time-shift one of the second power supply signal waveform in the second interval, the first power supply signal waveform in the first time interval, or the reference signal waveform; and
e) a second comparator arranged to compare the time-shifted signal with one of the signal waveforms that were not time-shifted to determine a second comparison result.
Such monitoring devices allow fast and reliable detection of arcs in a plasma process.
At least one of the first and second comparators can include a subtracting device for subtracting one signal waveform from another signal waveform. The obtained difference indicates the presence of an arc, if it corresponds to a given comparison result, for example, if the difference is above or below a given reference value.
The monitoring device, e.g., the first comparator, can be configured to determine that no arc is present in the plasma process if the first comparison result does not correspond to a first given comparison result. The monitoring device, e.g., the second comparator and/or the first comparator, can be configured to determine that no arc is present in the plasma process if the first comparison result corresponds to the first given comparison result and the second comparison result does not correspond to a second given comparison result.
The monitoring device can include a reference signal waveform generator. In particular, the reference signal waveform generator can include a multiplier arranged to multiply a measured output signal waveform with a given value or, the reference signal waveform generator can include an adder or subtracter, which adds or subtracts a constant given value from a measured signal waveform.
A second time-shifter may be provided for time-shifting a signal waveform in the opposite direction compared to the time-shift performed by the first time-shifter. Thus, the comparison result achieved by the first comparator can be further confirmed.
A third comparator may be provided for comparing the output signal of the second time-shifter with a signal waveform that has not been time-shifted. This also serves for confirming the first comparison result.
An arc signal generator may be provided, which is connected to the first comparator and at least one of the second or third comparator. Thus, it can be ensured that an arc signal is generated only if the first comparison result obtained from the first comparator and a further comparison result obtained from the second or third comparator both indicate the presence of an arc.
A third aspect of the invention features plasma process systems including a power supply configured to supply power to a plasma process with a periodic power supply signal and a plasma discharge monitor for monitoring a discharge in the plasma process. The plasma discharge monitor includes the monitoring device as discussed above.
Note that the terms “arc,” “arc discharge,” and “discharge” are used interchangeably herein.
Further advantages and advantageous embodiments of the subject matter of the invention are more fully understood from the following description, the claims, and the drawings. Furthermore, the features described herein can be applied as such or severally in any desired combinations. The illustrated and described embodiments are not to be taken as a definitive list but, instead, are exemplary in nature for the depiction of the invention. The drawings show the subject matter of the invention in a very diagrammatic manner and are not to be regarded as being to scale.
In the situation shown in
The part 31.1 of the waveform 31 corresponds to a second power supply signal waveform that has been determined within a second time interval Δt within a second period of a power supply signal, wherein the second time interval is at a position in the second period that corresponds to the position of the first time interval within the first period. Also, the time intervals chosen for the first and second period are of equal length in this example, which provides a preferred way of comparing the signal waveform 30.1 and 31.1 within the interval Δt. However, a person skilled in the art would understand that it is not essential that the first and the second intervals must be of equal length to compare both signal waveforms.
As can be seen in
The situation shown in
Note that the reference signal waveform 30 or 40 is associated with the first power supply signal waveform, e.g., generated based on the first power supply signal waveform. In some cases, the reference signal waveform is the first power supply signal waveform itself, and a first time interval of the first power supply signal waveform is directly compared to a corresponding second time interval of the second power supply signal waveform to determine a comparison result. In some cases, the reference signal waveform may be not associated with the first power supply signal waveform. For example, the reference signal waveform can be a standard waveform of the power supply signal.
In
In the present example the time interval Δt has been selected around point 52. Therefore, signal waveform 51, in particular the part 51.1 that is within time interval Δt, had to be time-shifted. It would have been possible, to only determine the signals 50 and 51 in the time interval Δt and only compare the signal waveforms 51.1 and 50.1. On the other hand, the time interval Δt could have been chosen to be the entire period of the power supply signal or half a period of the power supply signal. In particular, the signals 50 and 51 could be determined only in corresponding time intervals Δt for two different periods of the power supply signal.
The power supply signal may be measured via measuring means 78, 79, e.g., a directional coupler, a voltage sensor, or a current sensor. A first determining device 80, e.g., a logic unit or a field-programmable gate array (FPGA), is provided for determining a first power supply signal waveform within a first time interval within a first period of the power supply signal. Furthermore, a second determining device 81, e.g., a logic unit or an FPGA, is provided for determining a second power supply signal waveform within a second time interval within a second period of the power supply signal, wherein the second time interval is at a position in the second period with corresponds to the position of the first time interval within the first period. In one embodiment, the first power supply signal waveform and the second power supply signal waveform are both measured with one measuring means.
The first determining device 80 is connected to a reference signal generator 82, which produces a reference signal waveform. The reference signal waveform is supplied to a first comparator 83 as well as the power supply waveform determined by the second determining device 81. If a predefined comparison result is obtained, a signal is supplied to an arc signal generator 84. For example, a signal is supplied to the arc signal generator 84, if the power supply signal waveform determined by the second determining device 81 intersects the reference signal waveform produced in the reference signal generator 82.
The reference signal waveform produced by reference signal generator 82 is also supplied to a second comparator 85, as well as the signal produced by a first time-shifter 86. The first time-shifter 86 shifts the power supply signal waveform which has been determined by the second determining device 81. It is possible to time-shift the entire determined power supply signal waveform or only that part of the power supply signal waveform that lies in the second interval. In particular, the interval may be chosen dependent on the point where one signal waveform interests the other. If a given second comparison result is reached by a second comparator 85, a signal is supplied to the arc signal generator 84. The arc signal generator 84 has now received a signal from the first comparator 83 and the second comparator 85. Therefore, the arc signal generator 84 produces an arc detection signal, which is fed to the power supply 71 as well as an arc extinction device 87, e.g., a switch, a capacitor, or a diode. In that way, the power supply 71 and the substrate processed in the plasma process can be protected from damage.
As can be seen from
As an alternative to time-shifting the power supply signal waveform determined by the second determining device 81 according to this invention it is also possible to time-shift the reference signal waveform produced in the reference signal generator 82 with first and second time-shifter 86, 90. The second determining device 81 is then connected to first, second and third comparators 83, 85, 89. In that case the power supply signal waveform determined by the second determining device 81 is compared with the reference signal waveform and the time-shifted reference signal waveforms generated by first and second time-shifter 86, 90 respectively. This alternative is outlined in
The monitoring device 72 may also be part of the power supply 71. Also the extinction device 87 may be part of the power supply 71. Also measuring means 78, 79 may be part of the power supply 71. The monitoring device 72 as a whole or at least partly may be incorporated in a microcontroller, or digital signal processor or in particular in a programmable digital logic device (PLD). This PLD may be a field programmable gate array (FPGA). With such devices an arc may be detected extremely quickly and reliably.
In step 103 a reference signal waveform is generated. For example, the reference signal waveform can be produced from the power supply signal waveform determined in step 101. In step 104 the power supply signal waveform determined in step 102 is compared with the reference signal waveform to obtain a first comparison result. In step 105 it is checked if a given first comparison result is reached. If that is the case, in step 106 the power supply signal waveform determined in step 102 is time-shifted. If that is not the case, no arc signal is generated in step 110. In step 107, which follows step 106, the time-shifted signal is compared to the reference signal waveform to obtain a second comparison result. In step 108 it is checked if a second given comparison result is reached. If that is the case, an arc signal is generated in step 109. If that is not the case, in step 116 the power supply signal waveform determined in step 102 may be time-shifted in the other direction, e.g., an opposite direction. In step 117 the time-shifted signal may be compared to the reference signal waveform to obtain a third comparison result. In step 118 it may be checked if a third given comparison result is reached. If that is the case, an arc signal is generated in step 109. If that is not the case, no arc signal is generated in step 110.
As disclosed earlier it is as an alternative also possible to time-shift the reference signal waveform in steps 106, 116. The power supply signal waveform is then compared with the time-shifted reference signal waveforms in steps 107, 117.
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
Number | Date | Country | Kind |
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14461506 | Feb 2014 | EP | regional |
This application is a continuation of and claims priority under 35 U.S.C. § 120 to PCT Application No. PCT/EP2015/052490 filed on Feb. 6, 2015, which claims priority to European Application No. EP 14 461 506.9, filed on Feb. 7, 2014. The contents of both of these priority applications are hereby incorporated by reference in their entireties.
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Number | Date | Country | |
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Parent | PCT/EP2015/052490 | Feb 2015 | US |
Child | 15230017 | US |