Magnetron sputter apparatus

Claim 2

In a magnetron sputter gun for establishing a glow discharge at subatmospheric pressure to produce sputtering of material from a cathode target onto a workpiece to be coated; anode and cathode electrode means for operating at different electrical potentials to establish in use an electrical field intercepted by said cathode electrode means; said cathode electrode means including a target portion means made of a material to be sputtered and for sputtering from said target portion means of said cathode electrode means onto the workpiece; magnet means for providing a magnetic circuit for producing a magnetic field in the glow discharge region of space between said anode and said cathode electrode means, said magnetic field having a substantial component thereof orthogonally directed to the direction of the electric field component in the glow discharge region overlying said target portion means of said cathode electrode means; and said cathode sputter target portion means comprising a main target loop portion means for sputtering therefrom a preponderance of the target material to be sputtered and a separate auxiliary target loop portion means of target material, said separate loop portion means being axially displaced and partially axially coextensive with respect to each other, and said auxiliary target loop portion means having a mean radius of curvature greater than that of said main target loop portion means.

Claim 3

The apparatus of claim 1 wherein said magnetic circuit means includes a magnetic permeable pole piece means for shaping the magnetic field overlying said target portions of said cathode electrode means, said pole piece means being disposed surrounding said main and auxiliary target portion means, and said pole piece means being axially coextensive with portion means of both said main and auxiliary target loop portions.

Claim 4

The apparatus of claim 2 wherein said pole piece means includes a portion radially coextensive with at least a portion of said auxiliary target portion means.

Claim 5

The apparatus of claim 3 wherein said radially coextensive portion of said pole piece means is of reduced axial extent relative to other portions of said pole piece means disposed surrounding said radially coextensive region.

Claim 6

The apparatus of claim 2 wherein said auxiliary cathode target portion means is disposed within a counterbored inner lip portion of said magnetic pole piece.

Claim 7

The apparatus of claim 1 wherein said main and auxiliary cathode target portion means are closed loops of target material, said loops being axially and radially displaced relative to each other so that the centers of the annuli defined by said loops fall on an outwardly flared generally conical surface.

Claim 8

In a magnetron sputter gun for establishing a glow discharge at subatmospheric pressure to produce sputtering of material from a cathode target onto a workpiece to be coated: anode and cathode electrode means for operation at different electrical potentials to establish in use an electrical field intercepted by said cathode means; said cathode electrode means including a target portion means made of a material to be sputtered and for sputtering from said target portion means of said cathode electrode means onto the workpiece; magnet means for providing a magnetic circuit for producing a magnetic field in the glow discharge region between said anode and cathode electrode means, said magnetic field having a substantial component thereof orthogonally directed to the electric field component in the glow discharge region overlying said target portion means of said cathode electrode means; and said cathode sputter target portion means comprising a main target portion means and an auxiliary target portion means wherein said main and auxiliary target portion means are closed loops of target material, said loops being axially displaced and partially axially coextensive with respect to each other, said auxiliary target portion means having a mean radius of curvature greater than that of said main target portion means, and said target portion means being formed and arranged relative to said magnetic circuit for providing a nearly constant sputtering rate therefrom with constant applied anode to cathode potential and constant current drawn by the glow discharge during the time to produce erosion of a preponderance of the volume of said main target portion means of said cathode sputter target portion means.

Claim 9

In a magnetron sputter gun for establishing a glow discharge at subatmospheric pressure to produce sputtering of material from a cathode target onto a workpiece to be coated: anode and cathode electrode means for operation at different electrical potentials to establish in use an electrical field intercepted by said cathode means; said cathode electrode means including a target portion means made of a material to be sputtered and for sputtering from said target portion means of said cathode electrode means onto the workpiece; magnet means for providing a magnetic circuit for producing a magnetic field in the glow discharge region between said anode and cathode electrode means, said magnetic field having a substantial component thereof orthogonally directed to the electric field component in the glow discharge region overlying said target portion means of said cathode electrode means; and said cathode sputter target portion means comprising a main target portion means and an auxiliary target portion means wherein said main and auxiliary target portion means are closed loops of target material, said loops being axially displaced and partially axially coextensive with respect to each other, said auxiliary target portion means having a mean radius of curvature greater than that of said main target portion means, and said target portion means being formed and arranged relative to said magnetic circuit for providing a nearly constant sputtering rate therefrom with constant applied anode to cathode potential and constant current drawn by the glow discharge during the time to produce erosion of a preponderance of the volume of said main target portion means of said cathode sputter target portion means.

Claim 10

The apparatus of claim 1 wherein said magnetic means includes a magnetically permeable pole piece means for shaping the magnetic field overlying said target portion of said cathode electrode means, said pole piece means being disposed surrounding said main and auxiliary target portion means, and said pole piece means being axially coextensive with portions of both said main and auxiliary target loops.

Claim 11

The apparatus of claim 8 wherein said pole piece means includes a portion radially coextensive with at least a portion of said auxiliary target portion.

Claim 12

The apparatus of claim 9 wherein said radially coextensive portion of said pole piece means is reduced in axial extent relative to other portions of said pole piece means disposed surrounding said radially coextensive portion.

Claim 13

The apparatus of claim 8 wherein said auxiliary cathode target portion means is disposed within a counterbored inner lip portion of said magnetic pole piece.

Claim 14

The apparatus of claim 7 wherein said main and auxiliary cathode target portions means are closed loops of target material, said loops being axially and radially displaced relative to each other so that the centers of the annuli defined by said loops fall on an outwardly flared conical surface.

Claim 15

In a method of operating a magnetron sputter gun for establishing a glow discharge at subatmospheric pressure to produce sputtering of material from a cathode target onto a workpiece to be coated: providing anode and cathode electrodes for operation at different electrical potentials to establish an electrical field intercepted by said cathode; said cathode electrode including a target portion made of a material to be sputtered from said target portion of said cathode electrode onto the workpiece; energizing said anode and cathode electrodes to establish said electric field; producing a magnetic field in the glow discharge region between said anode and cathode electrodes, said magnetic field having a substantial component thereof orthogonally directed to the electric field component in the glow discharge region overlying said target portion of said cathode electrode; said cathode sputter target portion comprising a main target portion and an auxiliary target portion, said main target portion having two intersecting faces and being formed and arranged relative to the electric and magnetic fields in the glow discharge region for producing an erosion pattern of said main cathode target portion along said two intersecting faces; and sputtering material from said main target portion in such a manner that said two intersecting faces are maintained as receding intersecting faces during the time required to produce erosion of a preponderance of the volume of said main target portion of said cathode sputter target.

Claim 16

In a method of operating a magnetron sputter gun for establishing a glow discharge at subatmospheric pressure to produce sputtering of material from a cathode target onto a workpiece to be coated: providing anode and cathode electrodes for operation at different electrical potentials to establish an electrical field intercepted by said cathode; said cathode electrode including a target portion made of a material to be sputtered from said target portion of said cathode electrode onto the workpiece; energizing said anode and cathode electrodes to establish said electric field; producing a magnetic field in the glow discharge region between said anode and cathode electrodes, said magnetic field having a substantial component thereof orthogonally directed to the electric field component in the glow discharge region overlying said target portion of said cathode electrode; said cathode sputter target portion comprising a main target portion and an auxiliary target portion, said main target portion having two intersecting faces and being formed and arranged relative to the electric and magnetic fields in the glow discharge region for producing an erosion pattern of said main cathode target portion along said two intersecting faces; and sputtering material from said main target portion in such a manner that said two intersecting faces are maintained as receding intersecting faces during the time required to produce erosion of a preponderance of the volume of said main target portion of said cathode sputter target.

Claim 17

The method of claim 13 wherein said main cathode sputter target portion comprises a right circular cylinder having when new an end flat surface face and an inside cylindrical surface face and wherein during use said end surface face recedes leaving an outer marginal lip which is subject to less erosion, and wherein said inner face recedes leaving a bottom marginal lip which is subject to less erosion.

Claim 18

The method of claim 13 wherein said main cathode portion is a ring and including a non magnetic cathode electrode disposed adjacent and axially spaced from said main cathode ring, said cathode electrode having an upturned inner lip portion axially coextensive with a portion of said main cathode ring.