Constricted glow discharge plasma source

Claim 2

A source of plasma comprising: a hollow enclosure having a gas inlet opening and a gas discharge constriction passage; a cathode surface being exposed to an interior space of said enclosure, wherein said cathode is connected to a DC power supply providing a negative voltage to said cathode; an anode surface exposed to said discharge constriction passage, wherein said anode is connected to an electrical ground, where the positive voltage of said DC power supply is connected to said electrical ground, said anode being remote from said discharge constriction passage; and a gas source connected to feed gas to said gas inlet opening; wherein said gas discharge constriction passage is sized to provide a localized voltage drop between the cathode and anode in the gas flowing through said gas discharge constriction passage at said gas discharge constriction passage so that the flow of current between the cathode and anode is concentrated at the gas discharge constriction passage such that the localized voltage drop exceeds the ionization potential of the flowing gas creating additional plasma which is blown out of said gas discharge constriction passage by a pressure gradient between the inside of the hollow enclosure and a space into which gas flowing from said gas discharge constriction passage discharges.

Claim 3

A source of plasma as in claim 1, further comprising; a substrate being processed by plasma emitted from said source; wherein an electrical potential of said substrate is substantially at the same level as the potential of said anode.

Claim 4

The source of plasma as in claim 1, further comprising: a cooling member in thermal contact with a portion of said hollow enclosure, wherein said cooling member is configured with a passage for thermal transfer fluid.

Claim 5

The source of plasma as in claim 1, further comprising: a support member at ground potential separated from the cathode by an insulating member and preventing and acting as part of an insulating enclosure preventing said cathode from being exposed to the environment around it.

Claim 6

The source of plasma as in claim 4, further comprising: a movable support member to move a substrate being processed by the source of plasma within a vacuum chamber during processing of said substrate.

Claim 7

The source of plasma as in claim 4, wherein said support member is linked to a bellows support which moves said hollow enclosure along an axis substantially perpendicular to a surface of a substrate to be processed.

Claim 8

The source of plasma as in claim 4, wherein said insulating member includes a gas feed hole through the member, the gas inlet opening is routed to the gas feed hole and the gas feed hole acts as a restricting orifice to prevent gas from said gas source from freely passing into said hollow enclosure through said gas inlet opening.

Claim 9

The source of plasma as in claim 1, further comprising: a movable support member to move a substrate being processed by the source of plasma in a direction lateral to an axis of said discharge constriction passage within a vacuum chamber during processing of said substrate.

Claim 10

The source of plasma as in claim 1, further comprising: a movable support for the hollow enclosure in a direction along an axis of said discharge constriction passage.

Claim 11

The source of plasma as in claim 1, further comprising: an inlet orifice in a hollow chamber inlet passage which is a portion of an inlet piping system that conducts gas from said gas source to said gas inlet opening, the inlet orifice creates a pressure differential across the orifice at a process gas flowrate and pressure to prevent plasma formation in said inlet piping system during processing.

Claim 12

The source of plasma as in claim 1, wherein said localized voltage drop substantially exceeds the gas ionization potential.

Claim 13

A source of plasma comprising: a hollow enclosure having a gas inlet opening and a gas discharge constriction passage; a cathode surface being exposed to an interior space of said enclosure; an anode surface exposed to said gas discharge constriction passage a gas source connected to feed gas to said gas inlet opening; wherein the material of the cathode is such that when it is sputtered with a gas supplied by said gas source, and the cathode material and gas constituents combine to form a film on said cathode surface, said film material is substantially electrically conductive.

Claim 14

A source of plasma comprising: a hollow enclosure having a gas inlet opening and a gas discharge constriction passage; a cathode surface being exposed to an interior space of said enclosure; an anode surface exposed to said gas discharge constriction passage a gas source connected to feed gas to said gas inlet opening; wherein the material of the cathode is such that when it is sputtered with a gas supplied by said gas source, and the cathode material and gas constituents combine to form a film on said cathode surface, said film material is substantially electrically conductive.

Claim 15

The source of plasma as in claim 12, wherein said gas is oxygen and said material of said cathode is stainless steel.

Claim 16

The source of plasma as in claim 12, wherein said gas is nitrogen, said material of said cathode is titanium.

Claim 17

A source of plasma comprising: a vacuum processing chamber having an anode at a ground potential; a hollow enclosure within said chamber having a gas inlet opening and a gas discharge constriction passage; a surface of a cathode exposed to an interior space of said hollow enclosure energized with a DC bias with respect to said ground potential at said anode; and a gas source connected said gas inlet opening, to supply gas to be excited into a plasma; wherein said gas discharge constriction passage is an outlet orifice whose outlet opening faces a substrate processing location in said chamber, wherein said anode located outside of said hollow enclosure and said substrate are at approximately the same electrical potential, and said anode is positioned remote from said gas discharge constriction passage so as to cause the plasma emitted from said discharge constriction passage to be directed toward the substrate processing location; wherein said gas discharge constriction passage is sized to provide a voltage drop between the cathode and anode in the gas flowing through said gas discharge constriction passage at said gas discharge constriction passage so that the flow of current between the cathode and anode is concentrated at the gas discharge constriction passage to produce a plasma which is blown out of said gas discharge constriction passage by a pressure gradient between the inside of the hollow enclosure and a space into which gas flowing from said gas discharge constriction passage discharges.

Claim 18

A source of plasma comprising: a vacuum processing chamber having an anode at a ground potential; a hollow enclosure within said chamber having a gas inlet opening and a gas discharge constriction passage; a surface of a cathode exposed to an interior space of said hollow enclosure energized with a DC bias with respect to said ground potential at said anode; and a gas source connected said gas inlet opening, to supply gas to be excited into a plasma; wherein said gas discharge constriction passage is an outlet orifice whose outlet opening faces a substrate processing location in said chamber, wherein said anode located outside of said hollow enclosure and said substrate are at approximately the same electrical potential, and said anode is positioned remote from said gas discharge constriction passage so as to cause the plasma emitted from said discharge constriction passage to be directed toward the substrate processing location; wherein said gas discharge constriction passage is sized to provide a voltage drop between the cathode and anode in the gas flowing through said gas discharge constriction passage at said gas discharge constriction passage so that the flow of current between the cathode and anode is concentrated at the gas discharge constriction passage to produce a plasma which is blown out of said gas discharge constriction passage by a pressure gradient between the inside of the hollow enclosure and a space into which gas flowing from said gas discharge constriction passage discharges.

Claim 19

The source of plasma as in claim 15, wherein said cathode is substantially surrounded by insulating members, except on the surface where the cathode is exposed to the interior of said hollow enclosure.

Claim 20

The source of plasma as in claim 15, wherein said gas inlet opening includes an inlet orifice to create a substantial pressure differential across said inlet orifice as gas is fed into said hollow enclosure.

Claim 21

The source of plasma as in claim 15, wherein said localized voltage drop substantially exceeds the gas ionization potential.

Claim 22

A source of plasma comprising: a hollow enclosure having a gas inlet opening and a gas discharge constriction passage; a cathode surface being exposed to an interior space of said enclosure; an anode surface exposed to said gas discharge constriction passage; and a gas source connected to feed gas to said gas inlet opening; wherein the material of the cathode is such that when it is sputtered with a gas supplied by said gas source, and the cathode material and gas constituents combine to form a film on said cathode surface, said film material is substantially electrically conductive; wherein said gas discharge constriction passage is sized to provide a localized voltage drop between the cathode and anode in the gas flowing through said gas discharge constriction passage at said gas discharge constriction passage so that the flow of current between the cathode and anode is concentrated at the gas discharge constriction passage such that the localized voltage drop exceeds the ionization potential of the flowing gas creating additional plasma which is blown out of said gas discharge constriction passage by a pressure gradient between the inside of the hollow enclosure and a space into which gas flowing from said gas discharge constriction passage discharges.

Claim 23

A source of plasma comprising: a hollow enclosure having a gas inlet opening and a gas discharge constriction passage; a cathode surface being exposed to an interior space of said enclosure; an anode surface exposed to said gas discharge constriction passage; and a gas source connected to feed gas to said gas inlet opening; wherein the material of the cathode is such that when it is sputtered with a gas supplied by said gas source, and the cathode material and gas constituents combine to form a film on said cathode surface, said film material is substantially electrically conductive; wherein said gas discharge constriction passage is sized to provide a localized voltage drop between the cathode and anode in the gas flowing through said gas discharge constriction passage at said gas discharge constriction passage so that the flow of current between the cathode and anode is concentrated at the gas discharge constriction passage such that the localized voltage drop exceeds the ionization potential of the flowing gas creating additional plasma which is blown out of said gas discharge constriction passage by a pressure gradient between the inside of the hollow enclosure and a space into which gas flowing from said gas discharge constriction passage discharges.

Claim 24

The source of plasma as in claim 19, wherein said anode is remote from said discharge constriction passage.