SOFT MAGNETIC MULTILAYER DESPOSITION APPARATUS, METHODS OF MANUFACTURING AND MAGNETIC MULTILAYER
20240186064 ยท 2024-06-06
Inventors
Cpc classification
B32B15/04
PERFORMING OPERATIONS; TRANSPORTING
C22C38/002
CHEMISTRY; METALLURGY
International classification
B32B15/04
PERFORMING OPERATIONS; TRANSPORTING
C23C14/56
CHEMISTRY; METALLURGY
Abstract
The soft magnetic material multilayer deposition apparatus includes a circular arrangement of a multitude of substrate carriers in a circular inner space of a vacuum transport chamber. In operation the substrate carriers pass treatment stations. One of the treatment stations has a sputtering target made of a first soft magnetic material. A second treatment station includes a target made of a second soft magnetic material which is different from the first soft magnetic material of the first addressed target. A control unit controlling relative movement of the substrate carriers with respect to the treatment stations provides for more than one 360? revolution of the multitude of substrate carriers around the axis AX of the circular inner space of the vacuum transport chamber, while the first and second treatment stations are continuously operative.
Claims
1. A method of manufacturing a substrate with a core for an induction device, comprising: providing a vacuum transport chamber with a circular inner space about an axis; providing along a plane perpendicular to said axis, a circular arrangement comprising a multitude of substrate carriers in said circular continuous inner space and coaxially to said axis; providing along a plane perpendicular to said axis, a circular arrangement of substrate treatment stations being positioned to be treatment-operative into said circular continuous inner space; providing a rotational drive operationally coupled between said circular arrangement of said multitude of substrate carriers and said circular arrangement of substrate treatment stations; providing said circular arrangement of said multitude of substrate carriers and said circular arrangement of substrate treatment stations mutually aligned; wherein at least one of said treatment stations is a first sputter deposition station with a single target; wherein at least one of said treatment stations is a second sputter deposition station with a single target; providing said single target of said first sputter deposition station of a first soft magnetic material; providing said target of said second sputter deposition station of a second soft magnetic material different from said first soft magnetic material; providing a control unit operationally coupled to said treating stations and to said rotational drive; loading substrates to said substrate carriers; establishing a relative rotation between said circular arrangement of said multitude of substrate carriers and said circular arrangement of said substrate treatment stations by said rotational drive; depositing on said substrates a first layer of said first soft magnetic material and a second layer of said second soft magnetic material; controlling by said control unit said at least one first sputter deposition station and said at least one second sputter deposition station to continuously sputter-deposit towards and onto said circular arrangement comprising said multitude of said substrate carriers, at least during more than one 360? revolution of said circular arrangement comprising said multitude of said substrate carriers relative to said circular arrangement of said substrate treatment stations and about said axis, said more than one 360? revolutions directly succeeding one another; and depositing during at least some of said more than one revolution, layers of said first soft magnetic material and layers of said second soft magnetic material directly one upon the other on said substrates.
2. The method of claim 1, wherein said circular continuous inner space comprises an annular or cylindrical continuous inner space, and wherein said arrangement of said multitude of said substrate carriers or said circular arrangement of said substrate treatment stations is mounted to the radially outer circular surface of said continuous annular inner space or to the surrounding surface of said continuous cylindrical inner space or to the top or bottom surface of said continuous annular inner space or of said continuous cylindrical inner space or to the radially inner circular surface of said continuous annular inner space.
3. The method of claim 1, wherein said first soft magnetic material comprises or consists of one or more than one element out of the group Fe, Ni, Co and said second soft magnetic material comprises or consists of one or more than one element of the group Fe, Ni, Co.
4. The method of claim 1, wherein at least one of said first soft magnetic material and said second soft magnetic material comprises one or more than one element out of the group Fe, Ni, Co and at least one non-ferromagnetic element.
5. The method of claim 4, wherein said at least one non-ferromagnetic element comprises at least one element out of the groups IIIA, IVB and VB of the periodic system (according to groups 13,4,5 of IUAPC) or at least one of the group B,Ta,Zr.
6. The method of claim 1, comprising establishing said relative rotation between said circular arrangement of said multitude of substrate carriers and said circular arrangement of said substrate treatment stations by said rotational drive to be continuous for at least some of said more than one 360? revolutions directly succeeding one another.
7. The method of claim 1, comprising controlling by said control unit sputtering powers of at least said first and of said second sputter deposition stations and exposure time each of said substrates is exposed to said first and to said second sputter deposition stations, respectively, and depositing by each of said first and second sputter deposition stations a layer of said first and of said second soft magnetic materials, respectively, of a respectively desired thickness d.sub.1,d.sub.2, being 0.5 nm?(d.sub.1,d.sub.2,)?0.1 nm or 0.5 nm?(d.sub.1,d.sub.2,)?0.2 nm.
8. The method of claim 7, comprising depositing said first layer of FeCoB and said second layer of CoTaZr.
9. The method of claim 1, comprising at least one further layer deposition station, wherein said control unit controls the material deposition rate of said further layer deposition station in dependency of an exposure time each of said substrate carriers is exposed to said further layer deposition station, so as to deposit by said further layer deposition station a layer of a desired thickness d.sub.3 for which there is valid: 10 nm?(d.sub.3)?0.1 nm.
10. The method of claim 1, wherein said first and said second sputter deposition stations are two layer deposition stations of a group of more than two layer deposition stations, positioned along said continuous inner space one neighboring the other.
11. The method of claim 10, comprising providing more than one of said groups and/or different of said groups.
12. The method of claim 1, wherein said arrangement of substrate treatment stations comprises at least one further sputter deposition station for sputter depositing a further material towards said substrate carriers.
13. The method of claim 12, wherein said further material comprises a non-magnetic metal or metal alloy or a dielectric material.
14. The method of claim 1, comprising selecting one of said first and of said second targets of Fe.sub.x1Co.sub.y1, wherein there is valid x1+y1=100 and 20<y1<50 and providing a further sputter deposition station neighboring succeeding said one sputter deposition station and depositing by said further sputter deposition station Boron, and enabling said further sputter deposition station directly after enabling said one sputter deposition station.
15. The method of claim 1, comprising selecting at one of said first and of said second sputter deposition station respectively one of said first and of said second targets of Co, providing at said arrangement of treatment stations at least two further sputter deposition stations, neighboring said selected one sputter deposition station and having targets of Ta and of Zr.
16. The method of claim 1, wherein at least one of said first and of said second targets comprises Fe.sub.x2Co.sub.y2B.sub.z2, wherein x2+y2+z2=100.
17. The method of claim 1, wherein at least one of said first and second targets comprises Ni.sub.x3Fe.sub.y3, wherein x3+y3=100 and there is valid 50<y3<60 or 17.5<y3<22.5.
18. The method of claim 1, wherein said first target comprises Fe.sub.x4Co.sub.y4, said second target comprises Ni.sub.x5Fe.sub.y5 whereby there is valid x4+y4=100 and x5+y5=100 and 5<y4<20 and 17.5<y5<22.5 or 50<y5<60.
19. The method of claim 1, wherein said first target comprises Fe.sub.x6Co.sub.y6B.sub.z6 and said second target comprises Co.sub.x7Ta.sub.y7Zr.sub.z7, wherein x6+y6+z6=100 and x7+y7+z7=100 and wherein there is valid at least one of: x6>y6, y6?z6, x7>y7, y7?z7.
20. The method of claim 1, wherein said first target comprises Fe.sub.x6Co.sub.y6B.sub.z6 and said second target comprises Co.sub.x7Ta.sub.y7Zr.sub.z7, wherein x6+y6+z6=100 and x7+y7+z7=100 wherein there is valid at least one of: 45?x6?60, 50?x6?55, x6=52, 20?y6?40, 25?y6?30, y6=28, 10?z6?30, 15?z6?25, z6=20, 85?x7?95, 90?x7?93, x7=91.5, 3?y7?6, 4?y7?5, y7=4.5, 2?z7?6, 3?z7?5, z7=4.
Description
[0161]
[0162] Along the cylindrical surface 7.sub.c of the inner space 7, still according to the embodiment of
[0163] A rotational drive 19 is operationally coupled to the transport carrousel 9 so as to rotate carrousel 9 about the axis AX. Thereby the arrangement 16 of the multitude of substrate carriers 11, loaded with the substrates 13, passes through the treatment areas of the respective treatment stations of the arrangement 15. Thus, there is established a relative rotation of the arrangement 16 of the multitude of substrate carriers 11 with respect to the arrangement 15 of treatment stations.
[0164] The arrangement 15 of treatment stations comprises or even, in a minimum configuration, consists of a first sputter deposition station 17A and of a second sputter deposition station 17B. The first sputter deposition station 17A has a first sputtering target T.sub.A which consists of a first soft magnetic material to be deposited as a layer material on the substrates 13. This first target material is addressed in
[0165] The second sputter deposition station 17B comprises a second target T.sub.B which consists of a second soft magnetic material M.sub.B which is to be deposited as a layer material on the substrates 13 and which is different from the soft magnetic material M.sub.A of target T.sub.A of the first sputtering station 17A. The material M.sub.B may consist of one or more than one of the ferromagnetic elements Fe,Co,Ni or may comprise, beside of one or more than one of these elements, one or more than one of non-ferromagnetic elements. Such at least one non-ferromagnetic element may be one or more than one element out of the groups IIIA, IVB and VB of the periodic system (according to groups 13,4,5 of IUAPC), thereby especially out of the group B,Ta,Zr.
[0166] Thus, at these two sputtering stations 17A and 17B non-reactive sputter deposition is performed and the material to be deposited on the substrates 13 is the solid material of the respective target T.sub.A, T.sub.B. Thereby, and if M.sub.A and/or M.sub.B are materials of more than one element, the stoichiometry and constancy of the stoichiometry over time of the material deposited on the extended surfaces 13.sub.o of the substrate 13 is accurately determined.
[0167] The sputtering stations 17A and 17B are electrically supplied by respective supply units 21A and 21B. Depending on the target material M.sub.A and M.sub.B the supply units 21A and 21B are DC-, pulsed DC-, including HIPIMS-supply units or are Rf supply units for single or for multiple frequency electric supply. It is also possible (not shown) to electrically bias the substrate carriers 11 of the arrangement 16 of the multitude of substrate carriers 11, either equally for depositing both materials M.sub.A and M.sub.B or selectively. In the embodiment of
[0168] The apparatus 1 further comprises a control unit 23. The control unit 23 on one hand controls the rotational drive 19 and thus relative rotational movement of the transport carrousel 9 and, on the other hand, treatment enablement and disablement of the sputter deposition stations 17A and 17B. Thereby, the control unit 23 maintains the sputter deposition stations 17A and 17B deposition-enabled, with respect to sputter depositing target material towards the substrate carriers 11 and thus upon the substrates 13 during more than one directly succeeding 360? relative revolutions of the arrangement 16 of the multitude of substrate carriers 11 with respect to the arrangement 15 of treatment stations, about axis AX. The number of revolutions during which the sputter deposition stations 17A and 17B are deposition-enabled, depends on the number of thin layers of the materials M.sub.A and M.sub.B to be deposited as a stack upon the extended surfaces 13.sub.o of the substrates 13. The addressed more than one 360? relative revolutions during which the sputter deposition stations 17A and 17B are deposition-enabled, are directly succeeding one another.
[0169] E.g., to load and unload substrates 13 to the apparatus, according to the embodiment of
[0170] Whereas it is absolutely possible to perform the relative rotational movement of the arrangement 16 of the multitude of substrate carriers 11, according to
[0171] In the case, according to a good embodiment, in which the transport carrousel 9 is controlled via the rotational drive 19 and control unit 23 to relatively rotate at a constant angular relative speed about axis AX at least during some of the more than one 360? uninterrupted relative revolutions, the thickness of each very thin layer deposited especially by the sputter deposition stations 17A and 17B on the surfaces 13.sub.o of the substrate 13 becomes governed by the power with which the respective sputtering stations 17A and 17B are supplied by the supply units 21A and 21B, in fact by the respective deposition rate i.e. amount of material deposited per time unit. Thus, the control unit 23 controls the power delivered by the supply units 21A and respectively 21B to the respective sputter deposition stations 17A and 17B, on one hand in dependency from the constant relative rotational speed of the arrangement 16 of the multitude of substrate carriers 11 with respect to the arrangement 15 of treatment stations and, on the other hand, in dependency from the desired very small layer thickness d.sub.1 for material M.sub.A and d.sub.2 for material M.sub.B.
[0172] If the arrangement 15 of treatment stations comprises further layer deposition stations which are deposition enabled during the same time as the first and second sputter deposition stations 17A,17B the same prevails: Deposition rate of such further stations is also controlled by the control unit 23 in dependency from the constant relative rotational speed as addressed and, on the other hand, in dependency from the desired very small layer thickness to be deposited by such further layer deposition station.
[0173] The thicknesses d including d.sub.1,d.sub.2 of the respective materials M.sub.A and M.sub.B and possibly of further materials, which are realized by the apparatus according to the invention and as exemplified in
[0174] If the arrangement 16 of the multitude of substrate carriers 11, as on the transport carousel 9 of
[0175] If the addressed relative rotation is driven by rotational drive 19 and controlled by control unit 23 for constant relative angular speed rotation, then the angular spacing of treatment stations of the arrangement 15 needs not be adapted to the mutual angular spacing of the substrate carriers 11 e.g. along the transport carrousel 9.
[0176] Especially in that case, in which the relative rotation is controlled by the control unit 23 and via rotational drive 19 to be continuous for two or more than two 360? succeeding relative revolutions, homogeneity of the resulting overall stack of very thin layers is improved by inverting the direction of relative revolution e.g. of the transport carrousel 9, as shown in
[0177] According to
[0178] As further shown in
[0179] Whereas in the embodiments of
[0180]
[0181] A neighboring succeeding further sputter deposition station 18a has a target of at least one of the element B,Ta,Zr.
[0182] The second sputter deposition station 17B has a target of Co. Neighboring succeed, further sputter deposition stations 18b and 18c are installed and have, respectively, targets of Ta and Zr.
[0183] All the stations 18a to 18c are, as an example, deposition enabled same time as the stations 17A and 17B.
[0184] To further improve magnetic characteristics of the very thin layers, collimators (not shown) may be provided between the respective targets T.sub.A and T.sub.B and the revolving substrate carriers 11. Such collimators may also be provided at further layer deposition stations of the arrangement 15 of treatment stations.
[0185]
[0186] In cycle according to
[0187] Specifically, and in one example, the material M.sub.A was Fe.sub.52Co.sub.28B.sub.20 and the material MB was Co.sub.91.5Ta.sub.4.5Zr.sub.4. The sum of thicknesses d.sub.1 and d.sub.2 was about 2 nm.
[0188] There resulted a layer stack of the addressed M.sub.A- and M.sub.B-very thin layers with a total thickness of about 80 nm. After having deposited this layer stack of about 80 nm thickness, the deposition chamber 25, for aluminum oxide deposition, was deposition-enabled and a thin layer of about 4 nm thickness of aluminum oxide was deposited on the 80 nm layer stack according to cycle of
[0189] By subsequent 40 360? anticlockwise continuous revolutions of transport carrousel 9 there was again deposited a 80 nm stack of very thin layers of the material M.sub.A and M.sub.B.
[0190] Thereby it was found, that by reducing d.sub.1 as well as d.sub.2 of the layers deposited from the addressed M.sub.A and M.sub.B material targets, e.g. from 1 nm down to 0.2 nm, the magnetic property H.sub.k of the stack was improved from 35 Oe to nearly 50 Oe maintaining coercivity extremely low, i.e. smaller than about 0.1 to 0.2 Oe, which is mandatory for soft magnetic multilayers as required by ultra-low loss RF passive devices.
[0191] According to cycle (e) and the possibly following further cycles, the cycles (a) to (c) may be repeated as often as desired.
[0192] It has to be noted that the stoichiometry parameters and x.sub.n,y.sub.n,z.sub.n may be varied within the ranges as were addressed above to further optimize the soft magnetic behavior of the resulting stack of very thin, soft magnetic material layers for very high frequency applications as of one or several GHZ.
[0193] The substrates which were coated in the example according to
[0194] Whereas, according to the embodiments of
[0195]
[0196] In the embodiment of
[0197] In the embodiment of
[0198] In the embodiment of
[0199] In the embodiment of
[0200] Please note that the stationary mount in the
[0201] In the embodiment of
[0202] In the embodiment of
[0203] In the embodiment of
[0204] As now becomes apparent to the skilled artisan further mechanical combinations of realizing the arrangement 16 of the multitude of substrate carriers 11 for the substrates 13 and of the arrangement 15 of treatment stations are possible, without leaving the scope of the present invention.
[0205] All explanations which were given with respect to the embodiment of the