Rapid rate reactive sputtering of a group IVb metal

Claim 2

A process for the effective, rapid rate reactive deposition of a metallic compound in a chamber, using a metal from group IVb of the periodic table, including the steps of: evacuating the chamber and then filling the chamber with an inert gas, providing a target of the metal to be deposited in the chamber, positioning a substrate to be coated in the chamber below the target, admitting into the chamber a second gas adapted to react with the metal of the target, applying electrical power to the target to ionize the inert gas and bombard the target with the gas ions to initiate sputtering, controlling the level of electrical power supplied to the target to be substantially constant, sensing the composition of the gases in the chamber and providing a control signal related to the amount of said second gas in the chamber, and regulating the admission of said second gas to the chamber in accordance with said control signal.

Claim 3

A control system for regulating the reactive deposition of a metallic compound, comprising: a sealed chamber, having an access port; a substrate positioned within the chamber; a target of the metal to be deposited, positioned within the chamber and spaced from the substrate; a first control system connected to regulate the admission of an inert gas into the chamber; a second control system, connected to regulate the admission of a reactive gas into the chamber, for reaction with the target metal; means for supplying electrical power at a constant level to the target metal, to ionize the inert gas and bombard the target with the gas ions thus produced to initiate sputtering; and means, coupled between the chamber and the second control system, for sensing the composition of the gases in the chamber to provide a control signal which varies as a function of the amount of the reactive gas in the chamber, and for regulating operation of the second control system in accordance with said control signal.

Claim 4

A control system for regulating the reactive deposition of a metallic compound, comprising: a sealed chamber, having an access port; a substrate positioned within the chamber; a target of the metal to be deposited, positioned within the chamber and spaced from the substrate; a first control system connected to regulate the admission of an inert gas into the chamber; a second control system, connected to regulate the admission of a reactive gas into the chamber, for reaction with the target metal; means for supplying electrical power at a constant level to the target metal, to ionize the inert gas and bombard the target with the gas ions thus produced to initiate sputtering; and means, coupled between the chamber and the second control system, for sensing the composition of the gases in the chamber to provide a control signal which varies as a function of the amount of the reactive gas in the chamber, and for regulating operation of the second control system in accordance with said control signal.

Claim 5

A control system as claimed in claim 2, and in which means is provided for applying a potential to the substrate with respect to the potential of the target metal.

Claim 6

A control system as claimed in claim 2, and furthr comprising a shutter defining an opening therein, which shutter is positioned between the target and the substrate to assist in directing the movement of sputtered metal from the target toward the substrate.

Claim 7

A control system as claimed in claim 4, in which said shutter and said substrate are relatively movable during the deposition process.

Claim 8

A control system as claimed in claim 2, in which the means for supplying electrical power includes means for sensing both the current level and the voltage level of the power supplied to the target, and for providing an indication of actual power supplied to the target.

Claim 9

A control system as claimed in claim 6, in which the means for supplying electrical power further comprises means for comparing the actual power supplied to the target with a desired power delivery level, and for regulating the actual power supplied to the target as a function of an error signal derived from the comparison of the actual and desired power levels.

Claim 10

A control system as claimed in claim 2, in which the means for sensing the composition of the gases in the chamber is a mass spectrometer which provides said control signal, and further comprising an adjustable circuit coupled to the mass spectrometer for providing a specific peak signal from the various signals initially provided by the mass spectrometer.

Claim 11

A control system as claimed in claim 8, and in which the specific signal selected is that denoting the amount of reactive gas in the chamber, and a flow controller is provided and regulated as a function of said specific signal to continually control the admission of the reactive gas, to maintain sputtering of the metal onto the substrate at a rate approaching that of the metal itself.

Claim 12

A processing system for regulating the reactive deposition of a metallic compound, comprising: a sealed chamber, having an access port; a substrate positioned within the chamber; a target, formed of the metal to be deposited, positioned within the chamber and spaced from the substrate; a first control system, including a first control valve, connected to regulate the passage of an inert gas from a supply location through the control valve into the chamber; a second control system, including a second control valve, connected to regulate passage of a reactive gas from a source through the second control valve into the chamber; a power supply, connected to transfer electrical power at a constant level to the target metal, to ionize the inert gas and bombard the target with the gas ions thus produced and thereby initiate sputtering of the target metal; a mass spectrometer, coupled to the chamber, for sensing the composition of the gases in the chamber and providing a plurality of signals which vary in relation to the amounts of said gases; and circuit means, coupled between the mass spectrometer and said second control valve, for providing a window straddling the signal denoting the amount of reactive gas in the chamber, and utilizing the signal centered in the window to regulate continuous admission of the reactive gas into the chamber during the sputtering process in such a way that the metal deposition rate is not lowered.

Claim 13

A processing system for regulating the reactive deposition of a metallic compound, comprising: a sealed chamber, having an access port; a substrate positioned within the chamber; a target, formed of the metal to be deposited, positioned within the chamber and spaced from the substrate; a first control system, including a first control valve, connected to regulate the passage of an inert gas from a supply location through the control valve into the chamber; a second control system, including a second control valve, connected to regulate passage of a reactive gas from a source through the second control valve into the chamber; a power supply, connected to transfer electrical power at a constant level to the target metal, to ionize the inert gas and bombard the target with the gas ions thus produced and thereby initiate sputtering of the target metal; a mass spectrometer, coupled to the chamber, for sensing the composition of the gases in the chamber and providing a plurality of signals which vary in relation to the amounts of said gases; and circuit means, coupled between the mass spectrometer and said second control valve, for providing a window straddling the signal denoting the amount of reactive gas in the chamber, and utilizing the signal centered in the window to regulate continuous admission of the reactive gas into the chamber during the sputtering process in such a way that the metal deposition rate is not lowered.

Claim 14

A processing system as claimed in claim 10, in which said circuit means includes a first means adjustable to regulate the position of the window, to ensure capture of the signal denoting the amount of reactive gas in the chamber.

Claim 15

A processing system as claimed in claim 11, in which said circuit means includes a second means adjustable to regulate the width of the window.

Claim 18

A method of controlling deposition as set forth in claim 13, in which a graph of excess reactive gas in the chamber versus the reactive gas flow results in a hysteresis curve.

Claim 19

A method of controlling deposition as set forth in claim 14; in which a point on the curve for a low excess reactive gas level provides deposition of a substantially stoichiometric metallic compound on the substrate.

Claim 20

A method of controlling deposition as set forth in claim 15, in which a low excess reactive gas level will provide little coating of the target with the metallic compound.