GB2069008A - Coating in a glow discharge - Google Patents

Coating in a glow discharge Download PDF

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Publication number
GB2069008A
GB2069008A GB8100335A GB8100335A GB2069008A GB 2069008 A GB2069008 A GB 2069008A GB 8100335 A GB8100335 A GB 8100335A GB 8100335 A GB8100335 A GB 8100335A GB 2069008 A GB2069008 A GB 2069008A
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substrate
chamber
cathode
plasma
coating
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GB8100335A
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GB2069008B (en
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UK Secretary of State for Defence
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/34—Sputtering
    • C23C14/3435—Applying energy to the substrate during sputtering
    • C23C14/345—Applying energy to the substrate during sputtering using substrate bias
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/34—Sputtering
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
    • C23C16/458—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for supporting substrates in the reaction chamber
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
    • C23C16/50—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H01L31/20—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof such devices or parts thereof comprising amorphous semiconductor materials
    • H01L31/202—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof such devices or parts thereof comprising amorphous semiconductor materials including only elements of Group IV of the Periodic System
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Description

1
SPECIFICATION Method and apparatus for depositing coatings in a glow discharge
This invention concerns a method and apparatus for depositing coatings in a glow 70 discharge plasma. Coating may be of hard carbon, silicon, germanium or other suitable materials capable of being ionised to form plasma.
Carbon coatings are useful on for example germanium lenses used in infra red thermal imagers since the carbon coatings are very hard, wear-resistant and substantially transparent to infra red radiation. Both silicon and germaneium are transparent to infra red and are useful in various infra-red equipments.
There are a number of techniques for coatings substrates. For example a substrate may be suspended above a cathode target of the coating material in a vacuum. Argon ions are caused to strike the target thereby knocking off small particles of the target material which adhere to the substrate. Such a technique is known as sputtering. Carbon can be sputtered but the coating formed is graphitic not diamond-like.
Coatings may be grown in a plasma. For example a substrate may be used as a cathode in a DC or RF excited hydrocarbon plasma. Carbon ions are attracted to strike the substrate and form a carbon layer which for appropriate temperature and pressure conditions, is diamond-like. Likewise silicon and germanium may be respectively grown from a silane and germane plasma.
Amorphous layers of silicon have been grown for use as solar cells by controlling doping impurities in the plasma. This control of doping allows p-n junctions and p-i-n junctions to be formed by deposition in a glow discharge.
Techniques for growing carbon films are described in the following articles and their associated references: Thin Film Solids 58 (1979) 105 10 1 -105, 106, 107- 116, 117-120.
Techniques for growing amorphous layers of silicon and germanium by glow discharge are described in the following article and its associated references: Spear W. E., Doped Amorphous Semiconductor, Advances in Physics 1977 Vol 26, No. 6,811-845.
A disadvantage with the prior art glow discharge deposition is that in order to achieve reasonable deposition rates high potentials have to be applied or developed at the cathode, so that the substrate is subjected to high energy incident particles. This tends to affect the stress in the coating and increases the back sputtering rate. In some cases this prevents deposition of a layer at all.
In the present invention the generation of ions and the deposition of a coating are controlled independently.
According to this invention a method of 125 depositing carbon coatings comprises the steps of providing a plasma containing material to be deposited as a coating in a chamber having a cathode structure, arranging a substrate to be GB 2 069 008 A 1 coated in the plasma at a pre-determined distance from the cathode structure, controlling the substrate temperature independently of the plasma temperature, the arrangement being such that ions in the plasma are attached to and strike the cathode structure and a significant number leave the cathode structure and strike the substrate to form the required layer.
According to this invention apparatus for depositing a coating on a substrate comprises a vacuum tight chamber, a pump for providing a vacuum within the chamber, means for introducing a gas within the chamber, means including a cathode structure within the chamber and means for establishing a plasma within the chamber, means for supporting a substrate a spaced distance from the cathode, means for controlling the temperature of the substrate independently of the plasma temperature, the arrangement being such that a plasma may be formed in the chamber so that ions will strike the cathode and a significant number of atoms leave the cathode to strike the substrate and form the required coating.
Additionally the method and apparatus may include a bias voltage supply to the substrate for preliminary cleaning and for use during deposition of carbon to affect an ion plating enhancement of the deposition.
The gas admitted to the chamber may be a hydro carbon (e.g. propane, butane, etc.) to form a hard carbon coating; or silane to form a silicon coating; or germane to form a germanium coating. Additionally a dopant in the form of phosphine or borane may be admitted together with the silane or germane.
The method and apparatus of this invention separates the generation of ions of carbon, silicon, germanium, etc. and the deposition onto the substrate. Also the substrate temperature and potential is independent of the temperature and potential involved in the generation of the ions.
The invention will now be described, by way of example only, with reference to the accompanying drawings, of which Figure 1 is a diagrammatic view in section of apparatus for growing coatings of hard carbon, silicon, and germanium; Figure 2 is a cross section of a carbon coating on a substrate, and Figure 3 is a cross section of a solar cell.
As shown in Figure 1 a vacuum tight chamber 1 has an annular wall section 2 and top and bottom end plates 3, 4 respectively. A gas inlet pipe 5 allows gas to enter the chamber 1 through a valve 6. A gas supply (not shown) is connected to the valve 6 and may be pressurised cylinders of argon, butane, silane, germane, phosphine, or borane. A gas outlet pipe 7, valve 8 and vacuum pump 9 enable the required pressure to be maintained in the chamber 1. Inside the chamber 1 is a water cooled cathode structure 10 comprising an aluminium plate 11 spaced from the chamber bottom plate 4 by an insulator 12 which also carries an RF supply conductor 13 and cooling 2 GB 2 069 008 A 2 water to the cathode plate 11. An RF supply 14 typically 200 watts, 1,000 volts at 13 mHz feeds the cathode 10 through a 200pF capacitor 15.
The top and bottom plates 3, 4 are electrically connected together and to earth.
A substrate 16 to be coated is held in a substrate mounting 17 which is insulated from the top plate 3. The distance between the cathode plate 11 and substrate 16 is typically 7 cm. Inside the substrate mounting 17 is a heater/cooler 18 connected to a heater/cooler supply 19 outside the chamber 1. The substrate 16 may have a bias voltage applied thereto from a bias voltage supply 20. A sheathed thermo couple 21 passes inside a tube 22 in the mounting 17 to measure substrate 16 temperature.
In a modification the RF supply 14 is replaced by a DC supply and the capacitor 15 removed.
Operation to carbon coat a substrate of electrically conducting (e.g. resistivity 5-20 ohm cm) doped germanium is as follows.
The substrate 16 is mounted on the mounting 17 and cleaned in the usual manner e.g. by wiping with a solvent such as alcohol. The apparatus of Figure 2 is assembled and the chamber 1 evacuated by the pump 9 to less than 10-5 Torr.
to remove contaminants.
Argon gas ia admitted through the valve 6 and pipe 5 to a pressure of about 10-1 Torr. on an air calibrated gauge and the substrate 17 heated to 9 about 2000C.
The pasma is generated in argon by energising the cathode 10 whilst a bias voltage of about -200 volts DC is applied to the substrate 17 from the supply 20. This provides bombardment of the substrate with argon ions thereby cleaning the substrate surface to be coated. About 2 minutes of cleaning is adequate. The cleaning bias voltage is then removed.
The argon is then removed from the chamber 1 by the pump 9 and a hydro-carbon gas, e.g.
butane, is admitted to the chamber 1 through the inlet pipe 5 to a pressure of 0.7-1 x 10' Torr.
on the air calibrated gauge.
A bias voltage of about -200 volts DC is applied to the heated substrate 16 and the RF supply 14 to the cathode 11 is switched on.
Typically the RF is 1 Kvolt at 13 MHz, and at 200 watts power. In consequence the butane gas becomes ionised; positively charged carbon ions strike the cathode 11 where some stick but most leave as neutral carbon ions and strike the substrate 16. The result of the bias voltage on the substrate is to increase bonding between substrate and carbon by the process of ion plating. 120 After an initial amount of carbon has been deposited the bias voltage is gradually reduced to around 0 to -200 volts DC.
After about two hours the substrate is coated to a thickness of about 1 am with a hard carbon 125 coating 21 (Figure 2). The apparatus is then switched off and allowed to cool.
If a new cathode plate 11 is to be used it is given an initial carbon coating following the above process without use of a substrate. This reduces 130 the possibility of sputtering aluminium.
The above process of depositing hard carbon using an RF supply can also be carried out using a DC (direct current) supply. In this case the cathode supply is at about -1 Kvolt.
The independent control of carbon ion generation. i.e. gas ionisation and impact of the cathode, and the control of deposition onto the substrate by substrate temperature and bias voltage allows deposition of the desired carbon form with reduced induced stress. This permits growth of thick low strain carbon coatings.
Electrically insulating substrates may also be coated with hard carbon coatings. For example calcium aluminate, zinc sulphide, and zinc selenide may be coated.
To coat insulating or other substrates the process is similar except that if the film bond proves to be weak depending upon the material a thin bonding layer of silicon or germanium may be deposited on e.g. aluminium or stainless steel, or glass, substrates prior to carbon coating.
Such bonding layers may be deposited by sputtering off a silicon or germanium target in a well known manner. Alternatively the bonding layers may be deposited by glow discharge using a gas of silane or germane instead of butane in the illustrated apparatus. Deposition of the carbon -layer follows deposition of the bonding layer. For some substrate materials an initial bonding layer of oxide may be necessary under the silicon or germanium layer.
In all the above processes carbon coatings may be deposited without a bias voltage on the substrate.
The apparatus of Figure 1 may be used to produce photovoltaic solar cells shown in cross section in Figure 3. The cell 25 comprises a glass front cover 26 carrying an indium tin oxide electrode structure 27 form e.g. by vapour deposition or sputtering. A thin p-type silicon layer 28 is grown from a silane or diborane glow discharge plasma. This is followed by glow discharge deposition of an undoped layer 29 of silicon (no diborane in the silane) of about 1 am thickness, and an n- type silicon layer 30 using phosphine in the silane. A thin aluminium electrode layer 31 is evaporated onto the n-type silicon and the whole assembly fixed on a support 32.
Irradiation of sunlight through the glass cover 26 produces a voltage between the electrodes 27 and 31.
An alternative construction of solar cell employs a Schottky barrier and comprises a stainless steel substrate, a highly doped n+ silicon layer, a 1 pm thick undoped silicon layer, a thin (e.g. about 50 A thick) layer of platinum or gold, and an anti-reflection layer of zirconium oxide.
Other devices using p-n junction (e.g. diodes) may be constructed by deposition in the glow discharge chamber of Figure 1.
The plasma in the chamber 1 may be excited externally e.g. by inductive coils. This is useful when the chamber 1 is constructed of an 3 GB 2 069 008 A 3 insulating material such as glass. Alternatively two electrodes may be inserted into the chamber and used to ionise the gas.

Claims (29)

1. A method of depositing carbon coatings comprising the steps of providing a plasma containing material to be deposited as a coating in 55 a chamber having a cathode structure, arranging a substrate to be coated in the plasma at a pre- determined distance from the cathode structure, controlling the substrate temperature independently of the plasma temperature, the arrangement being such that ions in the plasma are attached to and strike the cathode structure and a significant number leave the cathode structure and strike the substrate to form the required layer.
2. Apparatus for depositing a coating on a substrate comprising a vacuum tight chamber, a pump for providing a vacuum within the chamber, means for introducing a gas within the chamber, means including a cathode structure within the chamber and means for establishing a plasma within the chamber, means for supporting a substrate a spaced distance from the cathode, means for controlling the temperature of the substrate independently of the plasma temperature, the arrangement being such that a plasma may be formed in the chamber so that ions will strike the cathode and a significant number of atoms leave the cathode to strike the substrate and form the required coating.
3. Apparatus according to claim 2 and further comprising means for applying a bias voltage to the substrate.
4. Apparatus according to claim 2 wherein the substrate is held by a substrate mounting 85 incorporating a substrate heater.
5. Apparatus according to claim 2 wherein the substrate is held by a substrate mounting incorporating a substrate cooler.
6. Apparatus according to claim 2 wherein the plasma is established between the cathode and an anode structure inside the chamber. 45
7. Apparatus according to claim 6 wherein the anode structure is a part of the chamber.
8. Apparatus according to claim 2 wherein the plasma is established by inductive coils external to the chamber.
9. Apparatus according to claim 2 wherein an R.F. voltage is applied to the cathode.
10. Apparatus according to claim 2 wherein a D.C. voltage is applied to the cathode.
11. Apparatus according to claim 2 wherein the gas is a hydrocarbon gas.
12. Apparatus according to claim 2 wherein the gas is silane.
13. Apparatus according to claim 2 wherein the gas is germane.
14. A substrate coated with a layer of material by the method and apparatus of claims 1 and 2.
15. A substrate according to claim 14 wherein the coating is a layer of hard carbon.
16. A substrate according to claim 14 wherein the coating is a layer of silicon.
17. A substrate according to claim 14 wherein the coating is a layer of germanium.
18. A substrate according to claim 15 wherein the substrate is coated first with a bonding layer and then with a layer of hard carbon.
19. A substrate according to claim 18 wherein the bonding layer is silicon.
20. A substrate according to claim 18 wherein the bonding layer is germanium.
2 1. A substrate according to claim 18 wherein the bonding layer is an oxide.
22. A substrate according to claim 16 having a plurality of differently doped layers of silicon.
23. A substrate according to claim 17 having a plurality of differently doped layers of germanium.
24. A substrate according to claim 14 wherein the substrate is an electrically conducting material.
25. A substrate according to claim 14 wherein the substrate is an electrically insulating material.
26. A substrate according to claim 14 wherein the substrate is germanium.
27. A substrate according to claim 14 wherein the substrate is zinc sulphide.
go
28. A substrate according to claim 14 wherein the substrate is zinc selenide.
29. Apparatus according to claim 2 constructed, arranged and adapted to operate substantially as hereinbefore described with reference to the accompanying drawings.
Printed for Her Majesty's Stationery Office by the Courier Press, Leamington Spa, 1981. Published by the Patent Office, 25 Southampton Buildings, London, WC2A lAY, from which copies may be obtained.
GB8100335A 1980-01-16 1981-01-07 Coating in a glow discharge Expired GB2069008B (en)

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GB8001383 1980-01-16

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GB2069008A true GB2069008A (en) 1981-08-19
GB2069008B GB2069008B (en) 1984-09-12

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US (1) US4394400A (en)
EP (1) EP0032788B2 (en)
JP (1) JPS56146876A (en)
DE (1) DE3167761D1 (en)
GB (1) GB2069008B (en)

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GB2119278A (en) * 1982-04-13 1983-11-16 Michael Paul Neary Improvements in or relating to a chemical method
GB2122224A (en) * 1982-06-23 1984-01-11 Atomic Energy Authority Uk Ion beam carbon layers
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US4504519A (en) * 1981-10-21 1985-03-12 Rca Corporation Diamond-like film and process for producing same
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GB2069008B (en) 1984-09-12
EP0032788B2 (en) 1989-12-06
EP0032788A1 (en) 1981-07-29
JPS56146876A (en) 1981-11-14
JPH036223B2 (en) 1991-01-29
EP0032788B1 (en) 1984-12-19
DE3167761D1 (en) 1985-01-31
US4394400A (en) 1983-07-19

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