Sputter chamber pressure gauge with vibration absorber

Abstract

A pressure gauge for measuring pressure in a vacuum chamber includes a flange couplable with the vacuum chamber, a pressure sensor configured to measure pressure, an air valve between the flange and the pressure sensor, and a vibration dampening assembly configured to dampen vibration in the pressure gauge. A sputtering system for sputter deposition includes a sputter chamber and the pressure gauge. The flange of the pressure gauge is coupled with the sputter chamber. A method of measuring pressure in a vacuum chamber with the pressure gauge includes coupling the flange with the vacuum chamber, dampening vibration in the pressure gauge with the vibration dampening assembly, and obtaining a pressure measurement from the pressure sensor.

Description

BACKGROUND

Machines that utilize pressure may include a pressure gauge to monitor pressure. One such machine is a sputter machine for production of magnetic media for hard disk drives. Sputter machines include multiple sputter chambers, which are under pressure during operation (sputter deposition). A conventional pressure gauge may be coupled to a sputter chamber to measure the pressure of the sputter chamber. The pressure sensor may be connected to a manufacturing computer to provide real time pressure measurements. However, during magnetic media production, the sputter chamber can experience vibration. One source of the vibration can be due to a carrier holder traveling from one sputter chamber to the next. Another source of the vibration can be a gate valve assembly opening and closing. This vibration may result in the pressure gauge proving a false reading, which can even lead to stopping the sputter chamber operation.

Thus, there is a need in the art for a pressure gauge for use with a sputter chamber that prevents false readings due to vibration originating from the sputter chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the present invention will now be presented in the detailed description by way of example, and not by way of limitation, with reference to the accompanying drawings, wherein:

FIG. 1 is a perspective view of an exemplary embodiment of a pressure gauge.

FIG. 2 is a side view of the exemplary embodiment pressure gauge of FIG. 1.

FIG. 3 is an exploded view of the exemplary embodiment pressure gauge of FIG. 1.

FIG. 4 is a perspective view of an exemplary embodiment of a sputtering system having a sputtering chamber coupled with the exemplary embodiment pressure gauge of FIG. 1.

FIG. 5 is a side view of the exemplary embodiment sputtering system of FIG. 4 coupled with the exemplary embodiment pressure gauge of FIG. 1.

FIG. 6 is a flowchart of a method of measuring pressure in a vacuum chamber with a pressure gauge.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appended drawings is intended as a description of various exemplary embodiments of the present invention and is not intended to represent the only embodiments in which the present invention may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details. In some instances, well-known structures and components are shown in block diagram form in order to avoid obscuring the concepts of the present invention. Acronyms and other descriptive terminology may be used merely for convenience and clarity and are not intended to limit the scope of the invention.

The various aspects of the present invention illustrated in the drawings may not be drawn to scale. Rather, the dimensions of the various features may be expanded or reduced for clarity. In addition, some of the drawings may be simplified for clarity. Thus, the drawings may not depict all of the components of a given apparatus or method.

The word “exemplary” is used herein to mean serving as an example, instance, or illustration. Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Likewise, the term “embodiment” of an apparatus, method or article of manufacture does not require that all embodiments of the invention include the described components, structure, features, functionality, processes, advantages, benefits, or modes of operation.

Any reference to an element herein using a designation such as “first,” “second,” and so forth does not generally limit the quantity or order of those elements. Rather, these designations are used herein as a convenient method of distinguishing between two or more elements or instances of an element. Thus, a reference to first and second elements does not mean that only two elements can be employed, or that the first element must precede the second element.

As used herein, the terms “comprises,” “comprising,” “includes,” and/or “including,” when used herein, specify the presence of the stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof

In the following detailed description, various aspects of the present invention will be presented in the context of apparatuses and methods for measuring pressure in a sputtering system (e.g., a sputter chamber of the sputtering system) used to produce magnetic media for hard disk drives (HDD). However, those skilled in the art will realize that these aspects may be extended to any suitable application where it is desirable to accurately measure pressure of a chamber with a pressure gauge when vibration originates from the chamber (e.g., to avoid a false reading in a pressure gauge due to pressure originating from the chamber). Accordingly, any reference to a measuring pressure of a sputter chamber of a sputtering system used to produce magnetic media for an HDD is intended only to illustrate the various aspects of the present invention, with the understanding that such aspects may have a wide range of applications.

FIGS. 1-3 are various views of an exemplary embodiment of a pressure gauge 10. The pressure gauge 10 may generally include a flange 11, an air valve 12, and a pressure sensor 13, where all three are mechanically and fluidly connected. Pressure sensor 13 may be a capacitance manometer. For example, the pressure sensor may be a Baratron® capacitance manometer manufactured by MKS Instruments Inc. The pressure gauge 10 may further include a vibration dampening assembly 24 configured to dampen vibration in the pressure gauge 10. In one exemplary embodiment, the vibration may originate from a sputter chamber 30 of a sputtering system (FIGS. 4 and 5). The dampening assembly 24 may be configured to dampen the vibration originating from the sputter chamber 30 thereby minimizing the propagation of the vibration through the pressure gauge 10. Without the vibration dampening assembly 24, the vibration originating from the sputter chamber 30 may propagate through a pressure gauge and cause the pressure sensor to measure an incorrect pressure. The incorrect pressure measurement may trigger an alarm that requires inspection and possible interruption of the sputtering process. By dampening the vibration with the vibration dampening assembly 24, the pressure sensor 13 of the pressure gauge 10 will accurately measure the pressure in the sputter chamber 30, thereby avoiding and/or reducing the occurrence of a false alarm.

The vibration dampening assembly 24 may include an air conduit 17, a ring member 16, a clamp member 15a, 15b, and a base member 14. The air valve 12 and pressure sensor 13 may be connected to each other through the air conduit 17. As shown in FIGS. 1-3, one end of the air conduit 17 may be coupled with the pressure sensor 13 and the opposite end may be coupled with the air valve 12. The air conduit 17 may be coupled to the pressure sensor 13 and the air vale 12 through any suitable fastening mechanism, such as through a threaded portion. The air conduit 17 may be configured to reduce vibration originating from the sputter chamber 30 of the sputtering system. The air conduit 17 may include a tube 22 and a flexible bellows 26. The flexible bellows 26 may circumferentially surround a portion of the tube 22. As shown in FIGS. 1-3, the flexible bellows 26 may extend along a longitudinal axis of the tube 22 and may be approximately centered relative to the ends of the tube 22. Due to the flexible nature, the flexible bellows 26 assists in dampening vibration propagating through the tube 22.

The ring member 16 may be coupled with pressure sensor 13 and may be configured to further reduce vibration at the pressure sensor 13. The ring member 16 may be made from any suitable material that is capable of dampening vibration at the pressure sensor. For example the ring member 16 may comprise a sponge material. As shown in FIGS. 1-2, the ring member 16 may circumferentially surround the pressure sensor 13. The ring member 16 may be disposed around the pressure sensor 13 at any location suitable for optimally dampening vibration at the pressures sensor 13. For example, as shown in FIGS. 1-2, the ring member 16 may be disposed around the pressure sensor 13 such that the ring member 16 is closer to the end of the pressure sensor 13 coupled with the air conduit 17.

The ring member 16 may be secured around the pressure sensor 13 by the clamp member 15a, 15b. The clamp member may include a first portion 15a, and a second portion 15b. Each of the first portion 15a and the second portion 15b may be curved to correspond to the curvature of the ring member 16. As shown in FIGS. 1-3, the first portion 15a may surround an upper portion of the ring member 16 while the second portion 15b may surround a lower portion of the ring member 16. The first portion 15a may be coupled with the base member 14. As shown in FIG. 3, the first portion 15a may be integrally formed with the base member 14 to provide optimal stability. The second portion 15b may be a separate piece that is mechanically coupled to the first portion 15a. For example, as shown in FIG. 3, each of the first portion 15a and the second portion 15b may include tabs 27 with through holes. The tabs 27 may extend radially away from the ring member 16. The vibration dampening assembly 23 may include a plurality of securing member 28 that may pass through the through holes of the tabs 27 to secure the first portion 15a to the second portion 15b. For example, as shown in FIGS. 1-3, two sets of nuts and bolts may be used to secure the first portion 15a to the second portion 15b.

The base member 14 may further include a seat 18 for receiving the underside surface of the air valve 12. The air valve 12 may include a body 29 that houses the flow path. As shown in FIGS. 1-2, one end of the body 29 may be coupled with the air conduit 17 and the opposing end may be coupled with the flange 11. The seat 18 may be shaped to match the shape of the underside surface of the body 29 to provide optimal support. For example, as shown in FIG. 3, when the body 29 has a generally square shaped underside surface, the seat 18 may similarly have a square shaped surface. The body 29 may be mounted onto the seat 18 of the base member 14. The seat 18 may include one or more through holes (e.g., four) to securely mount the body 29 onto the seat 18. Any suitable fastening member (not shown) may be used to secure the body 29 to the seat 18. The securing of the valve 12 to the base member 14 provides a point of stability in addition to the clamp member 15a, 15b.

As shown in FIG. 3, the base member 14 may further include a free end portion 19 that extends substantially perpendicular relative to the longitudinal axis of the base member (e.g. upwardly). The free end portion 19 may include holes 20 having an open upper edge (e.g., the material of the base portion does not surround all sides of the holes). The holes 20 may also be referred to as cutouts. While two holes are shown in the exemplary embodiment, it should be understood that one hole or more than two holes may also be used. Furthermore, while shown having a rectangular shape, the holes may have any shape that is capable of receiving a securing member (e.g., a screw, a bolt, and the like). Additionally, instead of having an open upper edge the holes may be enclosed (e.g., such that the entire perimeter of the hole is surrounded by the material of the base portion).

The length of the free end portion 19 and location of the cutouts 20 may be configured such that the cutouts 20 are aligned with the flange 11 to provide stable engagement of the base member 14 with the flange 11. As shown in FIGS. 1 and 3, the flange 11 may include a plurality of through holes 21 along the circumferential edge of the flange face. The through holes 21 may pass entirely through flange. The through holes 21 may be threaded. As best shown in FIGS. 1 and 2, when the air valve 12, pressure sensor 13, and flange 11 are mounted onto the base member 14, each of the cutouts 20 may align with one of the holes 21 of the flange 11. Thus, a securing member (not shown), such as a screw, may pass through the flange via the holes 21 and then pass through the cutouts 20. In another exemplary embodiment the cutouts may be threaded such that a securing member may be securely fixed within a cutout.

FIGS. 4 and 5 show a perspective view and a side view, respectively, of the pressure gauge 10 coupled with a sputtering system having a sputter chamber 30. As best shown in FIG. 4, the sputter chamber 30 may include a plurality of mounting rings 32. Each of the mounting rings may include a plurality of holes 34. The number and positioning of the holes 34 of each of the mounting rings 32 of the sputter chamber 30 may correspond to the number and positioning of the holes 21 of the flange 11. Thus, when the flange 11 is aligned with one of the rings 32, each of the holes 21 of the flange 11 will be aligned with one of the holes 34 of the ring 32. Once aligned, the user can then secure the pressure gauge 10 to the sputter chamber 30 by passing securing member (not shown) through the aligned holes 21, 34. As noted above, two of the holes 21 of the flange 11 may be aligned with the cutouts 20 of the base member 14 after the flange 11 has been mounted to the base member 14. Thus, once the flange 11 is aligned with the mounting ring 32, each of the cutouts 20 will be aligned with one of the holes 21 of the flange 11 and one of the holes 34 of the mounting ring 32. A securing member such as screw can be inserted through each of the sets of holes. The securing member that passes through holes 11, 21 that are aligned with a cutout 20, may also pass into the cutout 20. This arrangement provides for an additional point of stability for the pressure gauge relative to the sputter chamber 30.

While only one pressure gauge 10 is shown as being coupled with the sputter chamber 30, it should be understood that more than one pressure gauge 10 may be coupled with the sputter chamber 30 via another ring 32. For example, a second pressure gauge (or more) may provide a backup measurement if another pressure gauge fails, or may ensure that the other pressure gauge (or gauges) is running properly. For example, if two pressure gauges are providing different pressure measurements then this may indicate that one of the gauges is not working properly.

FIG. 6 is a flowchart illustrating a method of measuring pressure in a vacuum chamber with the pressure gauge 10. The method may begin with step 40, coupling the flange with a vacuum chamber/sputter chamber 30 of a sputtering system. The coupling the flange 11 with the vacuum chamber 30 may include first aligning the flange 11 of the pressure gauge 10 with the mounting ring 32. The aligning the flange 11 with mounting ring 32 may further include aligning the holes 21 of the flange 11 and the holes 20 of the base member 14 with the holes 34 of the mounting ring 32. Once aligned, the user may then secure the flange 11 to the mounting ring 34 by inserting a securing member (e.g., a screw) through holes 21, 34. The securing member may pass through each of the sets of holes 21, 34. With respect to holes 21, 34 that are aligned with the holes 20 of the base member 14, the securing member may also be inserted into the holes 20.

After the pressure gauge 10 is secured to the vacuum chamber 30, the method may proceed to step 42, dampening vibration in the pressure gauge 10 with the vibration dampening assembly 24. As noted above, during operation of the sputter chamber, vibrations may be produced that may propagate into the pressure gauge. Thus, the dampening assembly 24 dampens these vibrations to prevent the vibrations from interfering with reading of the pressure sensor 3. The vibration may be dampened at least in part by the bellows 26 surrounding the tube 22. The vibration may further be dampened by the ring member being secured around the circumferences of the pressure sensor 13.

The method may then proceed to step 44 of obtaining a pressure measurement from the pressure sensor. Because the vibration has been dampened by the dampening assembly, the pressure sensor is more likely to provide an accurate pressure reading.

The method may further include repeating the steps of dampening the vibration and obtaining the pressure reading periodically. The obtained pressure measurement may be monitored by a computer controller. The computer controller may be configured to report an alert if an obtained pressure measurement is higher or lower than a predetermined acceptable range. The pressure measurement may be obtained on a constant basis by the computer controller so that a “real time” measurement is always available and so that an alert can be generated immediately if the measured pressure falls outside of the predetermined range.

The various aspects of this disclosure are provided to enable one of ordinary skill in the art to practice the present invention. Various modifications to exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be extended to other devices. Thus, the claims are not intended to be limited to the various aspects of this disclosure, but are to be accorded the full scope consistent with the language of the claims. All structural and functional equivalents to the various components of the exemplary embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. §112(f) unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”

Claims

1. A pressure gauge for measuring pressure in a vacuum chamber, the pressure gauge comprising: a flange couplable with the vacuum chamber;a pressure sensor configured to measure pressure;an air valve between the flange and the pressure sensor; anda vibration dampening assembly disposed between the air valve and the pressure sensor configured to dampen vibration in the pressure gauge.

2. The pressure gauge of claim 1, wherein the vibration dampening assembly further comprises an air conduit between the air valve and the pressure sensor, and wherein the air conduit is configured to dampen vibration from the vacuum chamber.

3. The pressure gauge of claim 2, wherein a portion of the air conduit is flexible along a longitudinal axis of the air conduit.

4. The pressure gauge of claim 3, wherein the flexible portion comprises a bellows.

5. The pressure gauge of claim 1, wherein the vibration dampening assembly further comprises a ring member circumferentially coupled to the pressure sensor, and wherein the ring member is configured to dampen vibration at the pressure sensor.

6. The pressure gauge of claim 5, wherein the vibration dampening assembly further comprises a clamp member configured to secure the ring member to the pressure sensor.

7. The pressure gauge of claim 6, wherein the clamp member comprises a first portion and a second portion coupled with the first portion, wherein the vibration dampening assembly further comprises a base member, and wherein the base member comprises the first portion of the of the clamp member.

8. The pressure gauge of claim 1, wherein the pressure sensor comprises a capacitance manometer.

9. The pressure gauge of claim 1, wherein the vibration dampening assembly further comprises a base member having a valve seat, and wherein the air valve is coupled to the valve seat.

10. The pressure gauge of claim 1, wherein the flange comprises a least one through hole, wherein the vibration dampening assembly further comprises a base member having at least one through hole, and wherein the at least one through hole of the flange is aligned with the at least one through hole of the base member.

11. A sputtering system for sputter deposition, comprising: a sputter chamber; anda pressure gauge comprising: a flange coupled with the sputter chamber;a pressure sensor configured to measure pressure;an air valve between the flange and the pressure sensor; anda vibration dampening assembly disposed between the air valve and the pressure sensor configured to dampen vibration in the pressure gauge.

12. The sputtering system of claim 11, wherein the vibration dampening assembly further comprises an air conduit between the air valve and the pressure sensor, and wherein the air conduit is configured to dampen vibration from the sputter chamber.

13. The sputtering system of claim 12, wherein a portion of the air conduit is flexible along a longitudinal axis of the air conduit.

14. The sputtering system of claim 13, wherein the flexible portion comprises a bellows.

15. The sputtering system of claim 11, wherein the vibration dampening assembly further comprises a ring member circumferentially coupled to the pressure sensor, and wherein the ring member is configured to dampen vibration from the pressure sensor.

16. The sputtering system of claim 15, wherein the vibration dampening assembly further comprises a clamp member configured to secure the ring member to the pressure sensor.

17. The sputtering system of claim 16, wherein the clamp member comprises a first portion and a second portion coupled with the first portion, wherein the vibration dampening assembly further comprises a base member, and wherein the base member comprises the first portion of the of the clamp member.

18. The sputtering system of claim 11, wherein the pressure sensor comprises a capacitance manometer.

19. The sputtering system of claim 11, wherein the vibration dampening assembly further comprises a base member having a valve seat, and wherein the air valve is coupled to the valve seat.

20. The sputtering system of claim 11, wherein the flange comprises a least one through hole, wherein the vibration dampening assembly further comprises a base member having at least one through hole, and wherein the at least one through hole of the flange is aligned with the at least one through hole of the base member.

21. A method of measuring pressure in a vacuum chamber with a pressure gauge, the pressure gauge having a flange, a pressure sensor, an air valve between the flange and the pressure sensor, and a vibration dampening assembly, the method comprising: coupling the flange with the vacuum chamber;dampening vibration in the pressure gauge with the vibration dampening assembly disposed between the air valve and the pressure sensor; andobtaining a pressure measurement from the pressure sensor.

22. The method of claim 21, wherein the vibration dampening assembly further comprises an air conduit between the air valve and the pressure sensor, and wherein the dampening the vibration in the pressure gauge further comprises dampening vibration from the vacuum chamber with the air conduit.

23. The method of claim 22, wherein a portion of the air conduit is flexible along a longitudinal axis of the air conduit.

24. The method of claim 23, wherein the flexible portion comprises a bellows.

25. The method of claim 21, wherein the vibration dampening assembly further comprises a ring member circumferentially coupled to the pressure sensor, and wherein the dampening the vibration in the pressure gauge further comprises dampening vibration from the pressure sensor with the ring member.

26. The method of claim 25, wherein the vibration dampening assembly further comprises a clamp member, the method further comprising securing the ring member to the pressure sensor.

27. The method of claim 26, wherein the clamp member comprises a first portion and a second portion coupled with the first portion, wherein the vibration dampening assembly further comprises a base member, and wherein the base member comprises the first portion of the of the clamp member.

28. The method of claim 21, wherein the pressure sensor comprises a capacitance manometer.

29. The method of claim 21, wherein the vibration dampening assembly further comprises a base member having a valve seat, and wherein the air valve is coupled to the valve seat.

30. The method of claim 21, wherein the flange comprises a least one through hole, wherein the vibration dampening assembly further comprises a base member having at least one through hole, and wherein the at least one through hole of the flange is aligned with the at least one through hole of the base member.