阅读说明：本技术 离子束溅射设备和方法 (Ion beam sputtering apparatus and method ) 是由 R·J·富特 R·J·戴维森 J·莱韦纳尔 约翰·V·肯尼迪 于 2018-12-21 设计创作，主要内容包括：本发明的一个方面提供了一种离子束溅射设备,该离子束溅射设备包括：离子源,该离子源被构造为沿着束轴线生成中空离子束,该束轴线位于束的中空部分中；和溅射靶,该溅射靶具有限定至少一个靶表面的靶体,靶体包括可溅射粒子,靶体相对于离子源定位,使得离子束撞击至少一个靶表面,以从靶体朝向要改性的物体的表面溅射粒子。靶体被成形为使得朝向待改性表面溅射的粒子通常相对于束轴线在径向延伸的溅射方向上从溅射靶溅射,溅射方向是(i)朝向束轴线延伸的方向和(ii)远离束轴线延伸的方向中的一个。(An aspect of the present invention provides an ion beam sputtering apparatus including: an ion source configured to generate a hollow ion beam along a beam axis, the beam axis being located in a hollow portion of the beam; and a sputtering target having a target body defining at least one target surface, the target body including sputterable particles, the target body being positioned relative to the ion source such that the ion beam impinges on the at least one target surface to sputter particles from the target body toward the surface of the object to be modified. The target body is shaped such that particles sputtered toward the surface to be modified are sputtered from the sputtering target generally in a sputtering direction extending radially with respect to the beam axis, the sputtering direction being one of (i) a direction extending toward the beam axis and (ii) a direction extending away from the beam axis.)

1. An ion beam sputtering apparatus, comprising:

an ion source configured to generate a hollow ion beam along a beam axis, the beam axis being located in a hollow portion of the beam; and

a sputter target having a target body defining at least one target surface, said target body comprising sputterable particles, said target body being positioned relative to said ion source such that said ion beam impinges said at least one target surface to sputter particles from said target body towards the surface of the object to be modified;

wherein the target body is shaped such that the particles sputtered towards the surface to be modified are sputtered from the sputtering target generally in a radially extending sputtering direction relative to the beam axis, the sputtering direction being one of: (i) a direction extending toward the beam axis and (ii) a direction extending away from the beam axis.

2. The apparatus of claim 1, wherein the target body has a target passageway extending therethrough, the target passageway having an ion beam inlet for the ion beam and a particle outlet for sputtered particles exiting the target passageway toward a surface to be modified, and the at least one target surface is in the form of at least a surface of the target body that at least partially defines the passageway.

3. The apparatus of claim 2, wherein a cross-sectional area of the ion beam inlet in a plane perpendicular to the beam axis is substantially larger than a cross-sectional area bounded by a periphery of the ion beam such that the beam can pass through the inlet.

4. The apparatus of claim 2 or 3, wherein the sputtering direction is a direction extending towards the beam axis.

5. The apparatus of claim 4, wherein a cross-sectional area of the particle outlet in a plane perpendicular to the beam axis is substantially smaller than a cross-sectional area of a hollow portion of the ion beam.

6. The apparatus of claim 4 or 5, wherein at least part of the target passageway intermediate the ion beam entrance and the particle exit tapers towards the particle exit.

7. The apparatus of claim 6, wherein the target passageway tapers from at or near the ion beam entrance to at or near the particle exit.

8. The apparatus of claim 7, wherein the channel tapers at a substantially constant rate.

9. The apparatus of claim 2 or 3, wherein the sputtering direction is a direction extending away from the beam axis.

10. The apparatus of claim 9, wherein a cross-sectional area of at least a portion of the target body increases in a direction away from the ion source such that the hollow ion beam impinges the at least one target surface.

11. The apparatus of claim 10, wherein a cross-sectional area of at least a portion of the target body increases in a direction away from the ion source from a first cross-sectional area substantially smaller than a cross-sectional area of the hollow portion of the hollow ion beam to a second cross-sectional area substantially larger than a cross-sectional area of the periphery of the hollow ion beam.

12. The apparatus of claim 10 or 11, wherein the cross-sectional area of the periphery of the target body increases at a substantially constant rate in the direction of the hollow ion beam.

13. The apparatus of any preceding claim, wherein the target passageway is shaped to prevent the ion beam from exiting the target passageway through the particle outlet towards a surface to be modified outside the passageway without impacting the target surface.

14. The apparatus of any one of claims 2 to 13, wherein the beam axis intersects the ion beam inlet, the target passageway, and the particle outlet.

15. The apparatus of claim 14, wherein the beam axis is a central beam axis and the target passageway has a central passageway axis that is substantially coaxial with the beam axis.

16. The apparatus of claim 15, wherein the target channel is generally symmetrical about the central channel axis and/or the beam axis.

17. The apparatus of claim 16, wherein the target body is also generally symmetric about the central channel axis and/or the beam axis.

18. The apparatus of any one of claims 2 to 17, wherein the ion beam inlet and the particle outlet are substantially centred on the channel axis and/or the beam axis.

19. The apparatus of any preceding claim, wherein a cross-sectional shape of the ion beam inlet in a plane perpendicular to the beam axis is selected from the group consisting of substantially circular, oval, and rectangular with rounded corners.

20. The apparatus of any one of the preceding claims, wherein the cross-sectional shape of the particle outlet in a plane perpendicular to the beam axis is selected from the group consisting of substantially circular, oval, and rectangular with rounded corners.

21. The apparatus of any preceding claim, further comprising a template at or near the particle outlet, the template defining a pattern for depositing the sputtered particles onto a surface to be modified according to the pattern.

22. The apparatus of claim 21, wherein the template is positioned adjacent to the particle outlet and extends at least partially across the particle outlet.

23. The apparatus of any preceding claim, wherein the sputter target comprises one or more vacuum vents or openings extending through the target body.

24. The apparatus of claim 23 wherein the or each vent extends through the target body from a first end or portion of the target body at or near the ion beam entrance to a second end or portion of the target body at or near the particle exit.

25. The apparatus of any preceding claim, comprising or being associated with a support for at least partially supporting an object having a surface to be modified outside the channel adjacent the particle outlet of the sputter target.

26. The apparatus of any one of the preceding claims, wherein the ion source and the sputter target are movable in a direction substantially perpendicular to the beam axis relative to an object having a surface to be modified positioned outside the channel adjacent to the particle outlet.

27. The apparatus of any preceding claim, wherein the hollow ion beam has a width W and an inner radius R at the ion source, and the increase in beam width as the hollow ion beam travels towards the sputter target exhibits an increase in beam width comprising:

an increase in beam width away from the beam axis A; and

an increase in beam width B towards the beam axis.

28. The apparatus of claim 27, wherein the sputter target has a height d, defined by d ═ a + W + B) tan, where represents the slope of the sputter target relative to the hollow ion beam.

29. The apparatus of claim 28, wherein said sputter target has a maximum inner radius R equal to the inner radius R-B of said hollow ion beam as said hollow ion beam impacts said sputter target, said maximum inner radius defined by a ≦ R-B.

30. The apparatus of claim 28 or 29, wherein the sputter target has a minimum height defined by h ≧ d.

31. The apparatus of any one of claims 27 to 30, wherein the sputter target has a minimum width defined by W ≧ A + W + B.

32. The apparatus of any one of the preceding claims, wherein the sputter target comprises a single material such that the at least one target surface provides the sputterable particles.

33. The apparatus of any of claims 1 to 31, wherein the sputter target comprises at least a first material and a second material, the first material being different from the second material.

34. The apparatus of claim 33, wherein the first material and the second material are positioned at substantially the same incident angle relative to the hollow ion beam.

35. The apparatus of claim 33, wherein the first material is positioned at a first incident angle with respect to the hollow ion beam and the second material is positioned at a second incident angle with respect to the hollow ion beam, the first incident angle being different than the second incident angle.

36. A method of sputtering particles onto a surface, the method comprising the steps of:

positioning the surface adjacent to the particle outlet of the sputtering apparatus of claim 1 or 2 outside the target channel;

creating at least a partial vacuum within a vacuum chamber defined at least in part by a housing associated with and/or part of the sputtering apparatus;

generating a hollow ion beam with the ion source of the sputtering apparatus; and

directing the hollow ion beam into the target passageway via the ion beam entrance to sputter particles onto the surface.

37. A method of sputtering particles onto an outer surface of an arcuate surface, the method comprising the steps of:

positioning the surface within the sputtering chamber of a sputtering apparatus according to any one of claims 4 to 8 such that the surface extends at least partially across the sputtering chamber;

creating at least a partial vacuum within a vacuum chamber defined at least in part by a housing associated with and/or part of the sputtering apparatus;

generating a hollow ion beam with the ion source; and

directing the hollow ion beam into the sputtering chamber via the ion beam inlet to sputter particles onto the surface.

38. A method of sputtering particles onto an inner surface of an arcuate surface, the method comprising the steps of:

positioning the sputtering apparatus according to any one of claims 10 to 12, such that a sputter target is at least partially located within said tube;

creating at least a partial vacuum within a vacuum chamber defined at least in part by a housing associated with and/or part of the sputtering apparatus;

generating a hollow ion beam with the ion source; and

directing the hollow ion beam onto the target surface of the sputtering target to sputter particles onto the inner surface.

39. A method of sputtering particles onto a surface to be modified, the method comprising the steps of:

positioning a sputter target adjacent to the particle exit of a sputtering apparatus, the sputter target having a target body defining at least one target surface;

creating at least a partial vacuum within a vacuum chamber defined at least in part by a housing associated with and/or part of the sputtering apparatus;

generating a hollow ion beam with the ion source of the sputtering apparatus; and

directing the hollow ion beam into the target passageway via the ion beam entrance such that the hollow ion beam impinges the at least one target surface to sputter particles onto the surface to be modified;

wherein the target body is shaped such that the particles sputtered toward the surface to be modified are sputtered from the sputtering target in a sputtering direction extending generally radially with respect to the beam axis, the sputtering direction being one of (i) a direction extending toward the beam axis and (ii) a direction extending away from the beam axis.

40. The method of claim 39, wherein the ion beam is prevented from exiting the target passageway through the particle outlet toward the surface to be modified.

41. The method of any of claims 36 to 40, wherein the sputter target comprises a single material such that the at least one target surface provides the sputterable particles.

42. The method of any of claims 36 to 40, wherein the sputter target comprises at least a first material and a second material, the first material being different from the second material.

43. The method of any one of claims 36 to 42, further comprising the step of: a template is positioned at or near the particle outlet, the template defining a pattern for depositing the sputtered particles onto a surface to be modified according to the pattern.

Technical Field

The present disclosure relates to ion beam sputtering apparatus and methods for sputtering particles onto a surface.

More particularly, but not exclusively, the present disclosure relates to ion beam sputtering apparatus and methods for sputtering particles onto a flat surface.

The present disclosure also relates to ion beam sputtering apparatus and methods for sputtering particles onto the inner and/or outer surfaces of a duct.

Background

Ion Beam Surface Modification (IBSM) techniques, such as ion beam sputtering, are used to deposit thin films of materials onto surfaces. The IBSM technique has several practical advantages over other existing surface modification techniques.

For example, IBSM metallization in particular does not require prior surface preparation, since the energy of the deposited atoms is high enough to break chemical bonds on the surface. Like other physical deposition techniques, the IBSM technique facilitates patterning with resolution that is currently improved only by post-processing with laser techniques and complex multi-step lithographic techniques. However, since this is a process that minimizes the temperature rise on the coated substrate and is a line-of-sight technique, it allows the use of thin organic material templates.

A typical conventional sputtering system includes an ion or deposition source, a sputtering target (or source), and a support arranged to support a substrate or other object having a surface to be modified or coated relative to the ion source and sputtering target. The ion source, sputtering target, and support are arranged in a vacuum chamber containing an inert gas such as argon. The ion source is configured to generate a plasma and strip high energy, positively charged ions from the plasma. The ions bombard the sputter target, which "sputters" or ejects atomic-sized particles from the sputter target. The sputtered particles are directed and deposited on the surface to be modified.

In conventional systems, the ion source typically provides a spot ion beam directed at a generally planar surface of the sputtering target. The angle of incidence of the ion beam (the angle between the ion beam and a line normal to the surface of the sputtering target at the point of incidence between the ion beam and the surface) is typically greater than or equal to 45 degrees. That is, the glancing angle of the ion beam (the angle between the ion beam and the sputter target surface at the point of incidence) is typically less than or equal to 45 degrees. The sputtered particles (or atoms or molecules) are ejected from the surface at a range of angles. However, most sputtered particles are typically ejected from the surface of the sputtering target in a direction close to perpendicular to the ion beam. Further, due to the low pressure in the vacuum chamber, most of the sputtered particles follow a substantially linear trajectory. Thus, in conventional systems, the ion source, sputter target, and surface to be modified typically need to be aligned in a non-linear arrangement within the chamber, the ion source, sputter target, and source typically being aligned perpendicular to each other. In practice, a relatively large vacuum chamber is often required to house the ion source, the sputtering target, and the surface to be modified.

Heretofore, IBSM have not been suitable for treating relatively large area surfaces, such as relatively large area flat surfaces. IBSM are typically limited to batch processing in high vacuum environments, where a carousel can be used to move (e.g., rotate) the surface to be modified in front of the sputter source within the vacuum environment. Further, in addition to the microelectronics industry, IBSM is limited to laboratory applications because IBSM currently requires relatively large, complex vacuum equipment and is incompatible with industry requirements (low cost and high throughput). For example, industrial polymer surface processes typically need to be operated over relatively large areas and with large throughputs.

Many existing IBSM techniques are not suitable and/or practical for coating the inside or outside of a pipe, such as a pipe, tube or barrel. To coat such cylinders, physical deposition techniques, particularly IBSM, require either a rotating source or sample, or multiple sources around or in the circumference of the sample.

For example, some configurations of ion beam sputtering may allow for the simultaneous coating of a first side of an annular object, but still require flipping the sample to coat a second side. Furthermore, since these configurations use a full beam, they have the potential for very low power efficiency-the portion of the ion beam that strikes the protective cap above the ring does not contribute to the sputtering yield.

One of the problems with existing IBSM techniques arises from the geometry of sputtering. A large amount of sputtered material is typically deposited on the walls and other parts of the vacuum chamber rather than on the sample. This may result in waste of sputtered material and lower yield.

It is an aim of at least the preferred embodiments of the present invention to address at least some of the above disadvantages. It is a further or alternative object to at least provide the public with a useful choice.

Disclosure of Invention

According to an aspect of the present invention, an ion beam sputtering apparatus includes: an ion source configured to generate a hollow ion beam along a beam axis, the beam axis being located in a hollow portion of the beam; and a sputtering target having a target body defining at least one target surface, the target body including sputterable particles, the target body being positioned relative to the ion source such that the ion beam impinges on the at least one target surface to sputter particles from the target body toward the surface of the object to be modified. The target body is shaped such that particles sputtered toward the surface to be modified are sputtered from the sputtering target in a sputtering direction extending generally radially with respect to the beam axis, the sputtering direction being one of (i) a direction extending toward the beam axis and (ii) a direction extending away from the beam axis.

The term "comprising" as used in this specification means "consisting at least in part of … …". When interpreting statements in this specification which include the term "comprising", features other than the one or those prefaced by the term may also be present. Related terms such as "include" and "including" are to be interpreted in the same manner.

In an embodiment, the target body has a target passage extending through the target body, the target passage has an ion beam inlet for an ion beam and a particle outlet for sputtered particles exiting the target passage towards the surface to be modified, and the at least one target surface is in the form of at least a surface of the target body at least partially defining the passage.

In an embodiment, a cross-sectional area of the ion beam inlet in a plane perpendicular to the beam axis is substantially larger than a cross-sectional area bounded by a periphery of the ion beam such that the beam can pass through the inlet.

In an embodiment, the sputtering direction is a direction extending towards the beam axis.

In an embodiment, the target channel is shaped to prevent the ion beam from exiting the target channel (or reaching the surface to be modified outside the channel) through the particle outlet towards the surface to be modified outside the channel without impinging on the target surface.

In an embodiment, a cross-sectional area of the particle outlet in a plane perpendicular to the beam axis is substantially smaller than a cross-sectional area of the hollow portion of the ion beam.

In an embodiment, the beam axis intersects the ion beam entrance, the target passageway, and the particle exit. In an embodiment, the beam axis is a central beam axis and the target passageway has a central passageway axis substantially coaxial with the beam axis. In an embodiment, the target passage is substantially symmetrical about the central passage axis and/or the beam axis. In embodiments, the target body is also generally symmetric about the central channel axis and/or the beam axis.

In an embodiment, at least a portion of the target passageway intermediate the ion beam entrance and the particle exit is tapered towards the particle exit.

In an embodiment, the target passageway tapers from at or near the ion beam entrance to at or near the particle exit. In an embodiment, the channel tapers at a substantially constant rate. In an embodiment, the target passage has a substantially frustoconical (or truncated cone) shape.

In an embodiment, the cross-sectional shape of the ion beam entrance (in a plane perpendicular to the beam axis) is substantially circular. Alternatively, the cross-sectional shape of the ion beam entrance may be other shapes, for example, substantially oval or rectangular with rounded corners. In an embodiment, the cross-sectional shape of the particle outlet (in a plane perpendicular to the beam axis) is substantially circular. Alternatively, the cross-sectional shape of the particle outlet may be other shapes, for example, substantially oval or rectangular with rounded corners.

In an embodiment, the ion beam entrance is a circle substantially centered on the channel axis and/or the beam axis. In an embodiment, the particle outlet is a circle substantially centered on the channel axis and/or the beam axis. In an embodiment, the ion beam inlet and the particle outlet are substantially centered on the channel axis and/or the beam axis.

In an embodiment, an ion beam sputtering apparatus includes a template at or near a particle exit, the template defining a pattern for depositing sputtered particles onto a surface to be modified according to the pattern. In an embodiment, the template is positioned adjacent to the particle outlet and extends at least partially across the particle outlet.

In an embodiment, the sputtering target includes one or more vacuum vents or openings, each vent or opening extending through the target body. In an embodiment, the or each vent extends through the target body from a first end or portion of the target body at or near the ion beam entrance to a second end or portion of the target body at or near the particle exit.

In an embodiment, the sputtering apparatus comprises or is associated with a support for at least partially supporting an object having a surface to be modified outside the channel adjacent to the particle outlet of the sputtering target.

In an embodiment, the ion source and the sputter target are movable in a direction substantially perpendicular to the beam axis relative to an object having a surface to be modified positioned outside the channel adjacent to the particle outlet.

According to a further aspect of the invention, a method of sputtering particles onto a surface comprises the steps of: positioning the surface adjacent to a particle outlet of a sputtering apparatus outside of the target passageway; creating at least a partial vacuum within a vacuum chamber defined at least in part by a housing associated with and/or part of a sputtering apparatus; generating (or providing) a hollow ion beam with an ion source; and directing an ion beam into the target passageway via the ion beam inlet to sputter particles onto the surface.

In an embodiment, the surface is a planar surface, e.g., a planar surface of a substrate.

In an embodiment, the method comprises the steps of: the surface to be modified is moved (or advanced) relative to the particle outlet.

In an embodiment, the method comprises the steps of: the surface to be modified is moved relative to the particle outlet in a direction substantially perpendicular to the beam axis.

Disclosed herein is a target body defining a sputtering chamber for modifying a surface of an object to be modified located within the sputtering chamber with sputtered particles, the target body having an ion beam inlet (or opening or mouth) for an ion beam, the ion beam inlet opening into the sputtering chamber, and at least one target surface being in the form of (or provided by) at least one chamber (or interior) surface of the target body at least partially defining the chamber.

In an embodiment, the cross-sectional area of the ion beam entrance (in a plane perpendicular to the beam axis) is substantially larger than the cross-sectional area bounded by the periphery of the ion beam, such that the beam can pass through the entrance.

In an embodiment, the sputtering chamber is shaped such that particles sputtered towards the object having the surface to be modified are generally sputtered towards a central region within the sputtering chamber.

In an embodiment, the sputter target comprises one or more shields (or shields), the or each shield being arranged to prevent the ion beam from striking (or reaching) an object having a surface to be modified within the sputter chamber. In an embodiment, the one or more shields include one or more radially and circumferentially extending (relative to the bundle axis) shields. In use, the or each shield will be located upstream (with respect to the ion beam) of an object located at least partially within the sputtering chamber.

In an embodiment, the beam axis intersects the ion beam entrance and the sputtering chamber. In an embodiment, the beam axis is a central beam axis and the sputtering chamber has a central chamber axis substantially coaxial with the beam axis. In an embodiment, the sputtering chamber is generally symmetrical about a central chamber axis and/or a beam axis. In an embodiment, the target body is substantially symmetrical about the central chamber axis and/or the beam axis.

In an embodiment, at least a portion of the sputtering chamber between the ion beam entrance and an end (or base) of the sputtering chamber downstream (relative to the ion beam) of the ion beam entrance is tapered in a direction toward the end. In an embodiment, the sputtering chamber is tapered from at or near the ion beam entrance to at or near the end. In an embodiment, the channel tapers at a substantially constant rate. In an embodiment, the sputtering chamber has a substantially conical shape and/or a substantially frustoconical shape intermediate the ion beam entrance and the end.

In an embodiment, the cross-sectional shape of the ion beam entrance (in a plane perpendicular to the beam axis) is substantially circular (or ring). Alternatively, the cross-sectional shape of the ion beam entrance may be other shapes, for example, substantially oval or rectangular with rounded corners.

In an embodiment, the sputtering apparatus comprises or is associated with a support feature for at least partially supporting (or holding or suspending) an object having a surface to be modified within the sputtering chamber. For example, the object can extend through an aperture (or opening) in the target body such that the object extends at least partially across and within the sputtering chamber.

In an embodiment, the ion source and the sputtering chamber are movable relative to an object having a surface to be modified in a direction substantially perpendicular to the beam axis. For example, the object may be fed through the sputtering chamber in a direction perpendicular to the beam axis.

In an embodiment, the ion source and the sputter target can be rotated about an axis perpendicular to the beam axis relative to the surface to be modified within the sputter chamber. For example, an object comprising the surface may be rotated.

According to a further aspect of the invention, a method of sputtering particles onto a surface comprises the steps of: positioning the surface within a sputtering chamber of a sputtering apparatus such that the surface extends at least partially across the sputtering chamber; creating at least a partial vacuum within a vacuum chamber defined at least in part by a housing associated with and/or part of a sputtering apparatus; generating (or providing) a hollow ion beam with an ion source; and directing a hollow ion beam into the sputtering chamber via the ion beam inlet to sputter particles onto the surface.

In an embodiment, the surface is an arcuate surface. In an embodiment, the surface is an outer surface of a pipe (such as a tube or pipe). Alternatively, the surface may be a flat surface.

In an embodiment, the method comprises the steps of: the surface to be modified is moved (or advanced) relative to the ion beam and/or sputtering chamber.

In an embodiment, the method comprises the steps of: the surface to be modified is moved relative to the ion beam and/or the sputtering chamber in a direction substantially perpendicular to the beam axis.

In an embodiment, the method comprises the steps of: the surface to be modified is rotated relative to the sputtering chamber.

In an embodiment, the sputtering direction is a direction extending away from the beam axis.

In an embodiment, the target body has at least one peripheral surface defining at least one target surface.

In an embodiment, at least a portion of the target body increases in cross-sectional area in a direction away from the ion source such that the hollow ion beam impinges at least one target surface.

In an embodiment, the cross-sectional area (in a plane perpendicular to the beam axis) bounded by at least part of the periphery of the target body increases in a direction away from the ion source in a direction of the beam axis.

In an embodiment, a cross-sectional area of at least a portion of the target body increases in a direction away from the ion source from a first cross-sectional area substantially smaller than a cross-sectional area of the hollow portion of the hollow ion beam to a second cross-sectional area substantially larger than a cross-sectional area of a periphery of the hollow ion beam.

In an embodiment, the cross-sectional area bounded by the periphery of the target increases from at or near a first end of the target proximate to the ion source to a second end of the target distal from the ion source and downstream of the first end relative to the ion beam.

In an embodiment, the cross-sectional area of the periphery of the target body increases at a substantially constant rate in the direction of the hollow ion beam.

In an embodiment, at least a portion of the periphery of the target body intermediate the first end and the second end has a substantially conical shape or a substantially frustoconical shape.

In an embodiment, the sputtering apparatus is configured to extend at least partially within a hollow object, such as a pipe, or tube, such that the beam axis is aligned (parallel or coaxial) with the central (or longitudinal) axis of the pipe.

In an embodiment, the sputter target is movable in a direction substantially parallel to the beam axis relative to the object having the surface to be modified.

In an embodiment, at least the sputter target is movable within the hollow object having the inner surface to be modified in a direction substantially parallel to the beam axis.

According to a further aspect of the invention, a method of sputtering particles onto an inner surface of a pipe comprises the steps of: positioning the sputtering apparatus such that the sputtering target is at least partially within the tube; creating at least a partial vacuum within a vacuum chamber defined at least in part by a housing associated with and/or part of a sputtering apparatus; generating (or providing) a hollow ion beam with an ion source; and directing a hollow ion beam onto a target surface of the sputtering target to sputter particles onto the interior surface.

In an embodiment, the surface is an arcuate surface. In an embodiment, the conduit is a pipe or tube.

In an embodiment, the method comprises the steps of: the surface to be modified is moved (or advanced) relative to the sputter target. In an embodiment, the method comprises the steps of: the surface to be modified is moved relative to the sputter target in a direction substantially parallel to the beam axis.

In an embodiment, the cross-sectional shape of the ion beam in a plane perpendicular to the beam axis is substantially a hollow circle (or ring). The cross-section bounded by the periphery of the ion beam is a circle. Alternatively, the cross-sectional shape of the ion beam may be other shapes, for example, a substantially hollow oval shape or a hollow rectangle with rounded corners.

In an embodiment, the ion beam has a potential or acceleration energy greater than or equal to 500V. In an embodiment, the ion beam has a potential or acceleration energy in a range of about 1kV to about 30 kV. In an embodiment, the ion beam has a potential or acceleration energy in a range of about 15kV to about 25 kV.

In an embodiment, the incident angle of the ion beam is greater than or equal to about 45 degrees. That is, the glancing angle of the ion beam (the angle between the ion beam and the sputter target surface at the point of incidence) is less than or equal to about 45 degrees. In an embodiment, the incident angle is in a range of about 50 degrees to about 80 degrees (the grazing angle of the ion beam is in a range of about 10 degrees to about 40 degrees). In an embodiment, the angle of incidence is in a range from about 60 degrees to about 75 degrees. In an embodiment, the angle of incidence is in a range from about 65 degrees to about 75 degrees. In an embodiment, the angle of incidence is about 70 degrees.

In an embodiment, a sputtering apparatus includes or is associated with a housing that at least partially defines a vacuum chamber for an ion source and a sputtering target.

In an embodiment, the sputtering target is a monolithic part. Alternatively, the sputtering target may be formed of two or more pieces that are joined and/or arranged together.

In an embodiment, the ion source is coupled to a heat sink to cool the ion source. In an embodiment, the heat sink comprises or is one or more copper parts or bodies.

In an embodiment, the target passage is shaped to prevent the ion beam from exiting the target passage through the particle outlet towards the surface to be modified outside the passage without impinging on the target surface.

In an embodiment, the beam axis intersects the ion beam entrance, the target passageway, and the particle exit.

In an embodiment, the beam axis is a central beam axis and the target passageway has a central passageway axis substantially coaxial with the beam axis.

In an embodiment, the target passage is substantially symmetrical about the central passage axis and/or the beam axis.

In embodiments, the target body is also generally symmetric about the central channel axis and/or the beam axis.

In an embodiment, the ion beam inlet and the particle outlet are substantially centered on the channel axis and/or the beam axis.

In an embodiment, the cross-sectional shape of the ion beam inlet in a plane perpendicular to the beam axis is selected from the group consisting of substantially circular, oval, and rectangular with rounded corners.

In an embodiment, the cross-sectional shape of the particle outlet in a plane perpendicular to the beam axis is selected from the group consisting of substantially circular, oval, and rectangular with rounded corners.

In an embodiment, the apparatus further comprises a template at or near the particle outlet, the template defining a pattern for depositing sputtered particles onto the surface to be modified according to the pattern.

In an embodiment, the template is positioned adjacent to the particle outlet and extends at least partially across the particle outlet.

In an embodiment, the sputtering target includes one or more vacuum vents or openings, each vent or opening extending through the target body.

In an embodiment, the or each vent extends through the target body from a first end or portion of the target body at or near the ion beam entrance to a second end or portion of the target body at or near the particle exit.

In an embodiment, the apparatus comprises or is associated with a support for at least partially supporting the object having the surface to be modified outside the channel adjacent to the particle exit of the sputter target.

In an embodiment, the ion source and the sputter target are movable in a direction substantially perpendicular to the beam axis relative to an object having a surface to be modified positioned outside the channel adjacent to the particle outlet.

In an embodiment, the hollow ion beam has a width W and an inner radius R at the ion source, and the increase in beam width as the hollow ion beam travels toward the sputtering target exhibits an increase in beam width comprising:

an increase in beam width away from the beam axis A; and

increase in beam width B towards the beam axis.

In an embodiment, the sputter target has a height d, which is defined by d ═ a + W + B) tan, where the slope of the sputter target relative to the hollow ion beam is expressed.

In an embodiment, as the hollow ion beam strikes the sputter target, the sputter target has a maximum inner radius R equal to the inner radius R-B of the hollow ion beam, the maximum inner radius defined by a ≦ R ≦ R-B.

In an embodiment, the sputter target has a minimum height h defined by h ≧ d.

In an embodiment, the sputter target has a minimum width W defined by W ≧ A + W + B.

In an embodiment, the sputter target comprises a single material such that at least one target surface provides sputterable particles.

In an embodiment, the sputter target comprises at least a first material and a second material, the first material being different from the second material.

In an embodiment, the first material and the second material are positioned at substantially the same incident angle with respect to the hollow ion beam.

In an embodiment, the first material is positioned at a first incident angle with respect to the hollow ion beam and the second material is positioned at a second incident angle with respect to the hollow ion beam, the first incident angle being different from the second incident angle.

According to a further aspect of the invention, a method of sputtering particles onto a surface to be modified comprises the steps of: positioning a sputter target adjacent to a particle exit of a sputtering apparatus, the sputter target having a target body defining at least one target surface; creating at least a partial vacuum within a vacuum chamber defined at least in part by a housing associated with and/or part of a sputtering apparatus; generating a hollow ion beam using an ion source of a sputtering apparatus; and directing a hollow ion beam into the target passageway via the ion beam entrance such that the hollow ion beam impinges at least one target surface to sputter particles onto the surface to be modified. The target body is shaped such that particles sputtered toward the surface to be modified are sputtered from the sputtering target in a sputtering direction extending generally radially with respect to the beam axis, the sputtering direction being one of (i) a direction extending toward the beam axis and (ii) a direction extending away from the beam axis.

In an embodiment, the ion beam is prevented from exiting the target passage through the particle outlet towards the surface to be modified.

In an embodiment, the sputter target comprises a single material such that at least one target surface provides sputterable particles.

In an embodiment, the sputter target comprises at least a first material and a second material, the first material being different from the second material.

In an embodiment, the method further comprises the steps of: a template is positioned at or near the particle exit, the template defining a pattern for depositing sputtered particles onto a surface to be modified according to the pattern.

The present invention in one aspect includes several steps. In the following detailed disclosure, the relationship of one or more of such steps to each of the other steps, the apparatus embodying features of construction, and the combination of elements and arrangement of parts adapted to effect such steps, are all exemplified.

Many changes in construction and widely differing embodiments and applications of the invention will suggest themselves to those skilled in the art to which the invention pertains without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting. Where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

In addition, where features or aspects of the invention are described in the context of Markush groups, those skilled in the art will appreciate that the invention is also thereby described in the context of any individual member or subgroup of members of the Markush group.

As used herein, the term "(s)" following a noun means the plural and/or singular form of the noun.

As used herein, the term "and/or" means "and" or ", or the context allows both.

It is intended that reference to a range of numbers disclosed herein (e.g., 1 to 10) also encompass reference to all rational numbers within that range (e.g., 1, 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9, and 10) and any range of rational numbers within that range (e.g., 2 to 8, 1.5 to 5.5, and 3.1 to 4.7), and thus, all subranges of all ranges expressly disclosed herein are hereby expressly disclosed. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated, are to be considered to be expressly stated in this application in a similar manner.

The qualifiers "upper", "lower", "top", "base", "underside", "top", "above" and "below", and the like, as well as "horizontal" and "vertical" and the like, are for convenience and clarity in use herein with reference to the features shown in the drawings, and should not be construed as limiting the operation or use of the sputtering apparatus or sputtering apparatus and/or components thereof to any particular orientation, including but not limited to any orientation described herein and/or depicted in the drawings.

In this specification where reference is made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents or such sources of information is not to be construed as an admission that such documents or such sources of information are prior art, or form part of the common general knowledge in the art, in any jurisdiction.

In the description of this specification, reference may be made to subject matter that is not within the scope of the appended claims. The subject matter should be readily identifiable by a person skilled in the art and may assist in the practice of the invention as defined in the claims appended hereto.

While the invention is broadly defined above, those skilled in the art will appreciate that the invention is not so limited and that the invention also includes embodiments of which the following description gives examples.

Drawings

Embodiments of the present disclosure will now be described, by way of non-limiting example only, and with reference to the accompanying drawings, in which:

fig. 1 shows a schematic cross-sectional view of an ion beam deposition system having an ion beam sputtering apparatus according to a first embodiment of the present disclosure;

FIG. 2A shows a schematic side view of a portion of an ion source housing of the sputtering apparatus of FIG. 1;

figure 2B shows a cross-sectional view of the ion source housing taken at plane a-a in figure 2A;

fig. 2C shows a top side view of the ion source housing of fig. 2A in the direction labeled B in fig. 2A;

FIG. 3A shows a schematic perspective view of an ion source of the sputtering apparatus of FIG. 1;

FIG. 3B shows an exploded perspective view of the ion source of FIG. 3A;

FIG. 3C shows a side view of the ion source of FIG. 3A;

FIG. 3D shows a top side view of the ion source of FIG. 3A in the direction labeled C in FIG. 3C;

FIG. 3E shows a bottom side view of the ion source of FIG. 3A in the direction labeled D in FIG. 3C;

FIG. 3F shows a cross-sectional view of the ion source of FIG. 3A taken in plane A-A in FIG. 3E;

FIG. 4 shows a bottom side view of an ion source having a generally rectangular opening with a straight square end;

FIG. 5 shows a bottom side view of an ion source having a generally rectangular opening with rounded corners;

FIG. 6 shows a bottom side view of an ion source having a generally oval or elliptical opening;

FIG. 7 shows a schematic cross-sectional side view of an ion source and sputtering target of the sputtering apparatus of FIG. 1;

FIG. 8 shows a schematic cross-sectional side view of a sputtering target of the sputtering apparatus of FIG. 1 for sputtering particles onto a flat surface;

FIG. 9 shows a partial schematic cross-sectional side view of a portion of the ion beam and sputtering target of the sputtering apparatus of FIG. 1;

FIG. 10A shows a schematic top view of a sputtering target of a sputtering apparatus for sputtering particles onto a surface of an object at least partially suspended in a sputtering chamber within the sputtering target according to a second embodiment of the present disclosure;

FIG. 10B shows a cross-sectional side view of the sputtering target of FIG. 10A taken in plane A-B in FIG. 10A;

FIG. 10C shows a cross-sectional side view of the sputtering target of FIG. 10A taken in plane C-D in FIG. 10A;

FIG. 11 shows a schematic cross-sectional side view of a sputter target of a sputtering apparatus for sputtering particles onto an inner surface of a tube according to a second embodiment of the present disclosure;

FIG. 12 shows an example of a hollow beam of an ion beam deposition system;

FIG. 13 shows a graph of the resulting variation in average deposited copper thickness for different displacement speeds of the sputtering system on the glass;

FIG. 14 shows a graph of the variation in average deposited copper thickness for different acceleration voltages of the sputtering system on the glass;

FIG. 15 shows a graph of the variation in average deposited titanium thickness for different acceleration voltages of the sputtering system on the glass; and

figure 16 shows a graph of the variation in average deposited copper thickness obtained for different displacement speeds of the sputtering system on the glass.

Detailed Description

Sputtering equipment (fig. 1 to 9)

Fig. 1-9 schematically illustrate an ion beam deposition system 10 suitable for depositing at least one material on a substantially planar surface (or region) 12 a. The deposition system 10 includes an ion beam sputtering apparatus (or sputtering device) 14 according to a first embodiment of the present disclosure.

The sputtering apparatus 14 includes or is associated with: a housing 16, an energetic ion or deposition source 18 for generating or providing an energetic ion beam 20 along a beam axis 22, and a sputter target 24 comprising sputterable particles. Housing 16 at least partially defines a vacuum chamber 26 for ion source 18 and sputter target 24, both of which are located and retained in housing 16. Source 18 operates under vacuum. As will be described below, source 18 is positioned relative to sputter target 24 such that ion beam 20 impinges upon, or strikes or bombards, sputter target 24 to sputter or eject atomic-sized particles, or atoms or molecules, from sputter target 24 toward surface 12a to be modified.

An example ion source 18 is shown in fig. 3A-3F. The various major components of the ion source 18 are generally circular or annular about the beam axis 22 and share a common axial centerline that is coaxial with the beam axis 22. The main components of ion source 18 are a cathode 28, an anode 30, and a magnet 32. The cathode 28 is provided or formed by a front piece 28a, a body piece 28b and a rear piece 28 c. The ion source 18 further comprises: an insulator 34 for the anode voltage, which extends through the generally circular cathode rear block 28c to the anode 30; an insulator 36 for gas supply; and an insulator or barrier 38 between the cathode rear block 28c and the anode 30. A generally circular cathode front block 28a is mounted to one end of the magnet 32. The magnet 32 may comprise or consist of one or more magnets, such as one or more permanent magnets. In another embodiment, the magnet comprises one or more electromagnets.

In an embodiment, ion source 18 has an annular opening 40 for generating a thin hollow ion beam. Examples of hollow ion beams are indicated at 20 in fig. 8, 9, 10B, 10C, and 11.

In an embodiment, the ion beam is a stream of ions of similar charge that propagates along an electric field gradient. A hollow ion beam is an ion beam that is generally cylindrical in shape. It exhibits a circular cross-section so that there is little to no ion flow through the center of the cylinder and a maximum number of ions flow through the walls of the cylinder. The hollow ion beam is further described below with reference to fig. 12.

The opening 40 has a cross-sectional shape (in a plane perpendicular to the beam axis 22) that is substantially in the shape of a hollow circle (or ring), such that the cross-section of the resulting ion beam 20 is a hollow circle. The outer diameter of the cathode body piece 28b may be about 23mm and the inner diameter of the cathode front piece 28a may be about 17mm, such that the width of the opening 40 (and the corresponding thickness or width 220 of the ion beam 20) is about 3 mm. The beam axis 22 is located in the hollow portion of the ion beam. The beam axis is a central beam axis 30 that intersects the center of the hollow portion of the ion beam. The circumferentially extending ends 42, 44 of the cathode front block 28a and the cathode body block 28b at least partially define the opening 40 and are each inclined, for example, to define an angle 46 of about 45 degrees with the beam axis 22 at the opening 40.

Alternatively, the ion source 18 may have other shaped openings for generating or providing other shaped ion beams.

For example, fig. 4 shows a generally rectangular opening 40A having a straight square end such that the cross-section of the resulting bundle is a hollow rectangular shape having a straight square end. Fig. 5 shows a generally rectangular opening 40B having rounded corners such that the cross-section of the resulting bundle is a hollow rectangular shape with rounded corners.

Advantageously, the rectangular configuration facilitates deposition on the elongated surface area. For example, US8134287(Price) describes and illustrates an ion source having an elongated rectangular opening with rounded corners or ends.

Fig. 6 shows an opening 40C in the form of an oval or elliptical opening such that the cross-section of the resulting ion beam is a hollow oval or ellipse.

Sputtering target 24 has a target body 46 defining at least one target surface 48 for ion beam 20. Sputtering target 46 comprises sputterable particles. In an embodiment, the sputterable particles include, but are not limited to, metals, metal oxides, and/or semiconductors. Examples of metals of interest include copper, gold, platinum, titanium, tungsten, tin, indium, rhodium, samarium, iron, cobalt, nickel, chromium, zinc, and alloys of these metals. Examples of metal oxides of interest include zinc oxide, magnetite, titanium oxide, and tungsten oxide. Examples of the semiconductor include oxides such as zinc oxide, tungsten oxide, and indium tin oxide. Examples of non-oxide semiconductors include silicon and germanium and compounds such as gallium arsenide.

In an embodiment, the sputtering target is made of a single material such that the face exposed to the beam provides sputterable particles.

For example, the sputtering target body 46 can be a body that includes copper (for heat dissipation) and other non-copper sputterable particles. In an embodiment, heat dissipation from sputter target 24 is ensured by conducting heat directly to the external environment.

The sputtering target can also be made of more than one material. For example, the body of the sputtering target can be made of a first material comprising a thermally conductive material such as aluminum or copper.

For elongated shapes, such as rectangular with rounded portions, slots can be made from the body of the sputtering target to allow for the insertion of a plate or insert of the second or additional material where the beam is expected to strike the sputtering target.

In an embodiment, the insert is made of the same material on both sides of the sputter target, or of different materials. For example, one side may be made of iron and the other side of nickel. As the beam strikes both inserts simultaneously, different sputtered particles deposit on the sample being processed. One example includes forming an alloy layer, such as an iron-nickel alloy layer, on the surface.

In an embodiment, the insert is mechanically pressed against the sputtering target body to maximize heat exchange to the body of the sputtering target, which allows for heat dissipation.

In embodiments using an insert, the sputtering target comprises a low sputtering yield material to avoid contamination. Examples of such low sputter yield materials include, but are not limited to, aluminum and graphite.

In an embodiment, the first material and the second material are positioned at substantially the same incident angle with respect to the hollow ion beam.

In another embodiment, the sputtering body does not exhibit a symmetrical cross-section such that the insert may exist at different incident angles with respect to the ion beam. The first material is positioned at a first incident angle with respect to the hollow ion beam, and the second material is positioned at a second incident angle with respect to the hollow ion beam. The first angle of incidence is different from the second angle of incidence.

This allows control of the sputtering yield of the different materials making up the insert. For example, one side of component A may have a smaller angle than the other side of component B to produce a composite having component A_xB_1-xWherein x is a function of the incident energy, the angle of each insert a, the height at which the beam strikes the insert, and the composition of inserts a and B.

A first estimate of x can be obtained by calculating the sputtering yield Y of materials a and B, respectively_AAnd Y_BAnd calculating the ratio of sputtering yield (such as x-Y)_B/Y_A) To obtain the final product.

In an embodiment, when different angles are used, the sputter target is shaped such that the distance between the ion source and the portion of the insert struck by the beam is the same for inserts a and B. This requires a distance r between the central axis of the beam and the insert a_ADifferent from the distance r between the central axis of the beam and the insert B_B。

In an embodiment, the target body 46 has or defines a target passage or opening 50 extending through the target body 46. The target passageway 50 has an ion beam inlet 52 for the ion beam 20 from the ion source to enter the passageway 50, and a particle outlet or exit 54 for sputtered particles to exit the target passageway 50 toward the surface 12a to be modified.

The target passageway 50 has a central passageway axis 56 that intersects the inlet 52 and the outlet 54. The target passageway 50 is substantially symmetrical about a central passageway axis 56. The target 46 may also be substantially symmetrical about the central passage axis 56.

Ion source 18 and sputter target 24 are held within or by housing 16 such that inlet 52 is located upstream (relative to ion beam 20) of particle outlet 54. Inlet 52 is located proximal to ion source 18 or at least located closer to ion source 18 than is particle outlet 54 located distal to ion source 18 or at least located further from ion source 18. The beam axis 22 intersects the inlet 52, the passage 50, and the outlet 54. Sputter target 24 and ion source 18 are linearly aligned such that axis 56 of channel 50 is substantially parallel, preferably parallel, more preferably substantially coaxial, more preferably coaxial, with beam axis 22.

The cross-sectional shape of the ion beam entrance 52 (in a plane perpendicular to the beam axis 22) is substantially circular. The cross-sectional shape of the particle outlet 54 (in a plane perpendicular to the beam axis 22) is substantially circular. The ion entrance 52 is substantially centered on the beam axis 22. The outlet 54 is substantially centered on the beam axis 22. Alternatively, the cross-sectional shape of each of the ion beam inlet 52 and the particle outlet 54 may be another shape, for example, substantially oval, or rectangular with rounded corners. The cross-sectional shape of the inlet 52 may be different than the cross-sectional shape of the outlet 54.

The cross-sectional area of the ion beam entrance 52 (in a plane perpendicular to the beam axis 22) is substantially larger than the cross-sectional area bounded by the periphery of the ion beam 20 such that the ion beam enters the passageway 50. In an embodiment, the diameter of the ion beam entrance 52 (in a plane perpendicular to the beam axis 22) is substantially larger than the diameter of the periphery of the ion beam 20.

The target passageway 50 is shaped to prevent the ion beam 20 from exiting the target passageway 50 through the particle outlet 54 toward the surface to be modified 12a outside the passageway 50 or to the surface to be modified 12a outside the passageway 50 without impacting the target surface 48, as will be described below. The cross-sectional area of the particle exit 54 (in a plane perpendicular to the beam axis 22) is substantially smaller than the cross-sectional area of the hollow portion of the ion beam 20. In an embodiment, the diameter of the exit 54 (in a plane perpendicular to the beam axis 22) is substantially smaller than the diameter of the circular hollow portion of the ion beam 20.

The target surface 48 is in the form of or provided by at least one channel or inner surface of the target body 46 that at least partially defines a channel 50. Target surface 48 is a substantially continuous channel surface. Alternatively, target surface 48 may include two or more adjacently positioned surfaces. At least a portion of the target passageway 50 between the inlet 52 and the outlet 54 tapers (decreases in size) toward the particle outlet 54 such that the target surface 48 is inclined relative to the beam axis 22. The target passageway 50 tapers from at or near the inlet 52 to at or near the outlet 54. The channel 50 tapers at a substantially constant rate. Alternatively, the channel 50 may taper at a non-constant rate, for example, the channel 50 may taper at a greater or lesser rate as the channel 50 is closer to the outlet 54.

In an embodiment, the target passageway 50 has a generally funnel shape, such as a substantially frustoconical (or truncated cone) shape. An angle 58 defined between the angled target surface 48 and the channel axis 56 and/or the beam axis 22 is between 0 degrees and 90 degrees. The angle 58 is preferably greater than or equal to 30 degrees, more preferably greater than or equal to 35 degrees. Alternatively, the target passage 50 may have another shape.

Sputter target 24 includes one or more vacuum vents 60. The or each vent 60 extends through the target 46. The vent or vents 60 extend through the target body 46 from a first end or portion 62 of the target body 46 at or near the inlet 52 to a second end or portion 64 of the target body 46 at or near the outlet 54. Sputter target 24 has three vents 60. The vents 60 are circumferentially spaced about the channel axis 58/bundle axis 22, preferably substantially equally spaced. The vent 60 may be pressed through the target 46.

The sputtering apparatus 14 includes a heat sink 66 coupled to the ion source 18 to dissipate heat from the ion source 18. The heat sink 66 cools the ion source 18 to maintain the operating temperature below the curie temperature at which the strength of the magnet 32 is reduced and/or irreversibly weakened. In an embodiment, heat sink 66 includes: a first member in the form of a circular plate 66a coupled to the cathode back mass 28 c; a second member in the form of a second circular plate 66b spaced from the first plate 66a and coupled to the housing 16; and a third component in the form of an elongate member or rod 66c extending between the first and second plates 66a, 66 b. The surface of the first plate 66A is adjacent to the surface of the rear cathode block 28 c. The rod 66c extends into the cathode back block 28c through an opening 68 in the back cathode block 28 c. The rods 66c are arranged to extract heat from the first plate 66a and/or the rear cathode block 28c to the second plate 66b and the casing 16. The heat sink 66 may, for example, comprise or may be copper. By implementing a direct thermal connection between the ion source 18 and the environment outside the vacuum chamber 26, the temperature inside the source 18 is reduced. Alternatively or additionally, heat sink 66 may include one or more other materials having a relatively high thermal conductivity. One or more air-to-heat or liquid-to-heat exchangers can be used to provide additional cooling from outside the sputtering apparatus 14, if necessary.

Shown in fig. 2A-2C is a portion 16a of the housing 16 which, in use, is located above (as shown in) the surface 12A. The embodiment housing 16 includes a first generally cylindrical or annular portion 70 housing a vacuum pump 72, a second generally cylindrical or annular portion 74 including a gas inlet or communication 76 and a connector 78 for an anode voltage, and a third at least partially generally cylindrical or annular portion 80 configured to facilitate sealing at the interface of the housing 16 and the surface to be modified 12 a. In an embodiment, vacuum pump 72 is, for example, a turbomolecular pump arranged to establish and maintain a vacuum within housing 16, and preferably substantially seal housing 16 to surface 12a at a housing-surface interface. The pump 72 may draw a vacuum through the vent 60 to maintain a good vacuum level. The connector 78 for the anode voltage may be, for example, a Neissiman Bayland Neil Concelman (BNC) connector. The third portion 80 has a flange 82 for a vacuum gauge for measuring pressure within at least a portion of the vacuum chamber 26 defined by the housing 16. The first and second portions and the second and third portions are each separated by a respective insulator 84, 86.

In an embodiment, ion source 18 and sputter target 24 are movable relative to surface to be modified 12 a. In one embodiment, ion source 18 and sputter target 24 can be actuated and slid over the stationary surface 12a being processed, such as in a direction 88 substantially perpendicular to beam axis 22. In another embodiment, surface to be modified 12a slides under or in front of static ion source 18 and static sputter target 24.

By limiting the area of contact with the housing 16 at the housing-surface interface and placing additional suction mechanisms on both sides 12a, 12b of the surface to be modified, a small vacuum can be established on a substrate that is difficult to seal, such as a rough substrate like wood or leather. The surface of the soft substrate can also be treated by clamping the substrate inside the vacuum chamber 26 with one or more clamps 90 to reduce leakage. It has also been found that locally heating the area around the interface between the housing 16 and the substrate 12 having surfaces 12a, 12b helps to achieve a vacuum more quickly.

Sputtering method (FIGS. 8 and 9)

A method of sputtering particles onto the surface 12a of the object to be modified using the sputtering apparatus 14 will be described below with reference to fig. 8 and 9. In the embodiment shown in fig. 1-9, the object is a substrate 12 and the surface 12a is a substantially planar surface of the substrate. In alternative embodiments, the surface 12a may be substantially non-planar. In an alternative embodiment, the object may be a pipe, for example, a tube or pipe having an arcuate outer surface that may rotate below the outlet 54.

The surface 12a is positioned adjacent to a particle outlet 54 of the sputtering apparatus 14 outside of the target passageway 50. Housing 16, which is part of and/or associated with sputtering apparatus 14, at least partially defines a vacuum chamber 26 for ion source 18 and sputtering target 24. A partial vacuum, typically less than 10, is created in the vacuum chamber 26^-4Millibar. In one embodiment, the partial vacuum generated in the vacuum chamber 26 is at about 5X 10^-6Mbar to about 3X 10^-5In the millibar range, preferably below about 5X 10^-5Millibar. The housing 16 is arranged to substantially seal the opposing surfaces 12a, 12b of the substrate. Voltages are applied to the cathode 28 and the anode 30, and the voltage difference between the anode 30 and the cathode blocks 28a, 28b, 28c is sufficient to cause plasma formation at a given partial pressure. The voltage difference is typically in the range of about 500V to about 3kV, typically in the range of about 1kV to about 2 kV. The voltage source is from a power source external to the housing 16. The voltage has with respect to sputtering target 24Positive polarity, the sputtering target is preferably at ground or earth potential. A small input of gas, for example a gas comprising an inert gas such as argon, is introduced via inlet 76. At these pressures, and with the applied voltage and gas introduced between cathode 28 and anode 30, ion source 18 generates a plasma. Source 18 generates or provides a high energy ion beam 20 by stripping positively charged ions from the plasma, which are directed or accelerated by a high potential difference along beam axis 22 outwardly toward sputter target 24 through opening 40. In an embodiment, the ion beam 20 has a potential or acceleration energy of greater than or equal to about 500V, preferably in the range of about 1kV to about 30kV, and more preferably in the range of about 15kV to about 25 kV.

The thin hollow beam 20 passes through an ion beam entrance 52 and into a channel 50 of a sputter target 24 located directly below the ion source 18. Ion beam 20 impacts, or strikes or bombards, target surface 48 to sputter or eject particles (schematically indicated by red shading) from body 46 of sputter target 24 toward surface 12 a. Body 46 of sputter target 24 is gradually eroded. Particles sputtered toward surface 12a pass through exit 54 of sputter target 24 and are deposited on the substrate directly below.

In an embodiment, the circular opening 40 and the circular outlet 54 of the high energy source produce a disc-shaped deposit on the surface 12 a. In another embodiment, the ion source 18, the opening 40, and the generated beam 20 may have a rounded rectangular shape. This configuration allows uniform deposition over the elongated area. Advantageously, the sputtering apparatus 14 can be scaled for large linear shapes and to increase the area of simultaneous deposition.

While it will be appreciated that some of the particles (generally indicated by reference numeral 92) are sputtered back from the sputter target toward the ion source, the particles sputtered toward the surface (generally indicated by reference numeral 94) are sputtered from the sputter target generally in a radially extending sputtering direction relative to the beam axis 22, generally indicated by arrow 96, which is one of (i) a direction extending toward the beam axis 22 and (ii) a direction extending away from the beam axis 22. In the embodiment shown in fig. 1-9, the radially extending sputtering direction is the radially extending direction towards the beam axis 22, and the sputtering apparatus 14 is arranged to sputter particles from the sputtering target 24 over the entire circumference of the ion beam 20.

Ions sputtered back from the sputter target toward the ion source may coat insulators 34, 36 inside the ion source 18. To avoid such backward deposition causing shorting, in an embodiment, the insulators 34, 36 are shaped to increase the exposed surface area so as to limit the rate of thickness increase of any backward deposition. Some regions of the insulators 34, 36 may also be masked from direct exposure to the back-deposited ions to limit the rate of thickness increase.

The shape of the target passageway 50 and/or the size of the exit 54 prevents and/or prevents the ion beam 20 from reaching the surface to be modified. The smaller diameters of the passageway 50 and the outlet 54 downstream of the inlet 52 prevent the ion beam 20 from reaching the surface 12 a. Ion beam 20 instead strikes angled surface 48 of gradually eroded sputtering target 24. In an embodiment, the angle of incidence (or angles of incidence) of the ion beam, which is the angle between the ion beam 20 and a line normal to the target surface 48 at the point of incidence between the ion beam 20 and the target surface 48, is greater than or equal to about 45 degrees. That is, the grazing angle 98 of the ion beam (the angle between ion beam 20 and surface 48 of sputter target 24 at the point of incidence) is less than or equal to about 45 degrees. In an embodiment, the incident angle is in a range of about 60 degrees to about 80 degrees (the grazing angle of the ion beam is in a range of about 10 degrees to about 30 degrees).

Referring to fig. 9 (which shows a portion of ion beam 20 and sputter target 24), most or a larger portion of the sputtered particles will be projected in a main direction (generally corresponding to the direction of sputtered particle beam 202) that is angled 204 relative to a normal axis 206 that is perpendicular to surface 48 of sputter target 24. The angle 204 is generally near or about the same as the angle of incidence 208 of the ion beam 20.

In an embodiment, the particle exit 54 needs to be large enough such that the main sputtering direction from the point of incidence 210 (indicated at the center of the width 220 of the ion beam 20) at one side 46a of the sputtering body 46 is not blocked by the opposite side 46b of the sputtering body 46. In one embodiment, for example, a distance 212 between center points 212 of particle outlets 54 (or channel axis 58/beam axis 22) in a direction perpendicular to channel axis 58/beam axis 22 is equal to or greater than a sum of (i) a distance 214 in the direction perpendicular to channel axis 58/beam axis 22 between incident point 210 and an edge of particle outlets 48 and (ii) a distance 216 in the direction perpendicular to channel axis 58/beam axis 22 between the edge of particle outlets 48 and center points 212.

The sputtering yield varies and can be controlled by the energy and angle of incidence of the bombarding ions. In an embodiment, the potential or acceleration energy and/or angle of incidence of ion beam 20 (or alternatively the angle 98 of ion beam 20 at the point of incidence with surface 48 of sputter target 24) is selected to optimize the sputtering yield retrieved from the ion beam sputtering conditions.

For each combination of incident ion species, sputter target material, and incident angle, there is an energy that results in maximum sputter yield. For example, in one embodiment, a majority of the positively charged argon (Ar) is between about 55 degrees and about 75 degrees for incident angles with ion energies between 15 and 20keV⁺) Ion beam to achieve the best sputtering yield.

Similarly, for each combination of incident ion species, sputter target material, and beam energy, there is an angle of incidence that results in maximum sputter yield. For example, in one embodiment, at an incident angle between about 55 degrees and about 75 degrees, for most Ar at energies between about 15 and about 20keV⁺Ion beam to achieve the best sputtering yield.

An additional high voltage bias may be applied between sputter target 24 and ground to provide an accelerating voltage to any ionized sputter atoms. The bias voltage is advantageous when sputtering apparatus 14 is used to implant atoms and molecules from sputter target 24 onto and/or into surface 12 a. In one embodiment, the bias voltage applied between sputter target 24 and ground is in the range of, for example, about 1kV to about 50 kV. A bias voltage in this range (about 1kV to about 50kV) is understood to be beneficial in providing an accelerating voltage without requiring large additional electrical insulation and radiation shielding. In another embodiment, the bias voltage applied between sputter target 24 and ground is in a range of, for example, about 15kV to about 20 kV. A bias voltage within this range (about 15kV to about 20kV) is understood to favor the generation of surface and near-surface nanoparticles of the majority of metallic elements on and within organic and inorganic substrates.

In an embodiment, the sputtering apparatus 14 optionally includes a template 100 at or near the outlet 54 that defines a pattern for depositing sputtered particles onto the surface 12a according to the pattern. In an embodiment, the method comprises the steps of: the template 100 is positioned adjacent the particle outlet 54 such that the template 100 extends at least partially across the particle outlet 54.

In one embodiment, an electron gun (not shown) is directed at or near the exit of the sputtered atoms to promote positive ionization of the sputtered atoms.

In an embodiment, the sputtering apparatus 14 is or forms part of a dynamic vacuum system that facilitates deposition of materials on the planar surface 12a, particularly on large area planar surfaces.

Housing 16, ion beam source 18, and sputter target 24 are movable relative to surface to be modified 12 a. In an embodiment, the method comprises the steps of: surface 12a is moved or fed from, for example, atmospheric pressure (outside of housing 16) into a vacuum chamber 26 at least partially defined by the housing, in front of a deposition beam having sputtered particles from sputter target 24. The dynamic sealing of the vacuum chamber 26 allows an active pressure gradient to be set between the ion source 18 and the surface 12A to be processed.

In an embodiment, the sputtering apparatus 14 has one or more dynamic seals 102a, 102b, 102c for forming a seal at the interface between the enclosure and the surface 12a, 12b of the substrate. In an embodiment, the sputtering apparatus has three concentrically arranged seals 102a, 102b, 102c for each of the upper surface (as seen in the figure) 12a and the lower surface 2 b.

In an embodiment, each seal 102a, 102b, 102c is formed of two distinct components, each component having low gas permeability. One component is a low friction incompressible member 104 formed of a rigid material such as teflon. The second part is formed by a compressible resilient member 106, such as an O-ring. Each seal 102a, 102b, 102c surrounds a region between the two surfaces 110, 12a that is subject to a pressure gradient. The first rigid member 104 is located within a recess 108 formed in a first surface 110 of the housing 16. The second elastic member 106 is in contact with both the first rigid member 104 and the upper surface 12a (or the lower surface 12b) of the base material 12. The seals 102a, 102b, 102c work particularly well where the surfaces 12a and/or 12b contain discontinuities and imperfections.

The area between adjacent concentric rings may be partially evacuated, thus creating a pressure gradient. For example, as indicated by arrow 112, a vacuum pump 72 may be used to induce a first or primary pressure inside the innermost seal. A second pressure, higher than the first pressure, may be induced by one or more additional pumps between the outer concentric rings, as indicated by arrow 114. An overpressure (high pressure) area outside the concentric ring can be used to further isolate the vacuum chamber 26 from the outside environment.

Advantageously, the embodiment sputtering apparatus 14 does not require the object 12 having the surface 12a to be modified to be arranged perpendicular to the ion beam 20. Object 12 may instead be aligned in a straight line (or linearly), for example, directly below ion source 18 and beam 20. Thus, advantageously, vacuum chamber 26 for ion source 18 and sputter target 24 can be made smaller. Thus, advantageously, the embodiment sputtering apparatus 14 can be made simpler and cheaper.