JP2009062579A - Film deposition system - Google Patents

Film deposition system Download PDF

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JP2009062579A
JP2009062579A JP2007231285A JP2007231285A JP2009062579A JP 2009062579 A JP2009062579 A JP 2009062579A JP 2007231285 A JP2007231285 A JP 2007231285A JP 2007231285 A JP2007231285 A JP 2007231285A JP 2009062579 A JP2009062579 A JP 2009062579A
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electrode
film
film forming
plate
forming apparatus
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JP5077748B2 (en
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Shin Shimozawa
慎 下沢
Yuji Tsukahara
祐二 塚原
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Fuji Electric Co Ltd
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Fuji Electric Systems Co Ltd
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<P>PROBLEM TO BE SOLVED: To provide a film deposition system capable of suppressing generation of abnormal discharge, normally depositing a thin film, and enhancing the yield. <P>SOLUTION: The film deposition system comprises a film deposition chamber 2 which is a space for performing the film deposition, a first electrode 4 and a second electrode 5 arranged in the film deposition chamber, a mechanism constituted of a high frequency power source and a matching circuit to supply the power to one of the first electrode 4 and the second electrode 5 from the outside of the film deposition chamber 2, a mechanism to supply the power to the other of the first electrode 4 and the second electrode 5 from the outside of the film deposition chamber 2 or to be connected to the ground potential, a mechanism which allows gas to flow into between the first electrode 4 and the second electrode 5 and supplies the power to form plasma, and heats the film deposition chamber 2 so as to perform the film deposition by using the plasma, and a plurality of deposition-preventive plates 6 arranged corresponding to a plurality of side face parts in the film deposition chamber 2 so as to surround the film deposition chamber 2. The deposition-preventive plate 6 is divided into a plurality of portions, and spaces 6a, 6b are formed between the deposition-preventive plates 6 close to each other. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

本発明は、プラズマを利用して成膜を行う成膜室を備えている成膜装置に関する。   The present invention relates to a film forming apparatus provided with a film forming chamber for forming a film using plasma.

製品の表面に薄膜を形成させる成膜装置は、太陽電池モジュールの製造等多くの製品に用いられている。特に太陽電池モジュールでは、フィルム基板上等に光電変換層等を成膜する際、プラズマCVD(Chemical Vapor Deposition)技術が用いられており、成膜装置内に設けられた成膜室で前記フィルム基板上にSi系薄膜を形成し、光電変換層を成膜することが行われている。具体的には、真空状態の成膜室内にSi系(例えばSiH4)等の成膜ガスを充填させ、プラズマ放電を行うことによってフィルム基板上にSi系薄膜等を形成している。このとき、成膜室の内壁に薄膜が付着するおそれがあるため、内壁を覆うように防着板が配置されている。 A film forming apparatus for forming a thin film on the surface of a product is used in many products such as manufacturing a solar cell module. Particularly in a solar cell module, when a photoelectric conversion layer or the like is formed on a film substrate or the like, a plasma CVD (Chemical Vapor Deposition) technique is used, and the film substrate is formed in a film forming chamber provided in a film forming apparatus. A Si-based thin film is formed thereon to form a photoelectric conversion layer. Specifically, a Si-based thin film or the like is formed on a film substrate by filling a vacuum deposition chamber with a film-forming gas such as Si (eg, SiH 4 ) and performing plasma discharge. At this time, since a thin film may adhere to the inner wall of the film forming chamber, an adhesion preventing plate is disposed so as to cover the inner wall.

また、フィルム状の太陽電池モジュールの成膜装置には、ロールツーロール方式およびステッピングロール方式が採用されている。ここで具体的に成膜装置の構造について説明すると、成膜装置は巻出し用コアおよび巻取り用コアを備えており、巻出し用コアおよび巻取り用コアはフィルム基板の搬送方向に間隔を空けて配置されている。フィルム基板は、巻出し用コアから巻出され、かつ巻取り用コアで巻取られて、成膜装置内で搬送されることとなる。また、成膜装置内では、成膜室が巻出し用コアと巻取り用コアとの間の区間に配置されており、フィルム基板は、成膜室を通過し、成膜室内で成膜されることとなる。そのため、成膜室は、成膜室を通過する前記フィルム基板の形状に対応させて、真空状態を保つために密閉性を高めて、補強し易く、かつ簡単な構造とすることが求められており、略直方体に形成されている。また、防着板は、略直方体に形成された成膜室の内壁に対応させて配置されている。このような成膜装置の構造は特許文献1に開示されている。   Moreover, the roll-to-roll system and the stepping roll system are adopted for the film-formation apparatus for the film-like solar cell module. Here, the structure of the film forming apparatus will be described in detail. The film forming apparatus includes an unwinding core and a winding core, and the unwinding core and the winding core are spaced apart in the transport direction of the film substrate. It is arranged in the space. The film substrate is unwound from the unwinding core, wound up by the winding core, and conveyed in the film forming apparatus. In the film forming apparatus, a film forming chamber is arranged in a section between the unwinding core and the winding core, and the film substrate passes through the film forming chamber and is formed in the film forming chamber. The Rukoto. Therefore, the film formation chamber is required to have a simple structure that is easy to reinforce, enhances hermeticity in order to maintain a vacuum state, corresponding to the shape of the film substrate that passes through the film formation chamber. It is formed in a substantially rectangular parallelepiped. Further, the deposition preventing plate is disposed so as to correspond to the inner wall of the film forming chamber formed in a substantially rectangular parallelepiped. The structure of such a film forming apparatus is disclosed in Patent Document 1.

このような装置を用いて薄膜を形成する工程では、まず成膜室内をある程度の真空状態にするため、成膜装置に設けられたガス排気系の機構によって真空引きを行い、その後、必要に応じて成膜装置に設けられたヒーターにより基板を加熱して、脱ガスを行っている。この脱ガスの後、場合によっては数種類の成膜ガスを適当な流量比で混合した混合ガスを、成膜装置に設けられたガス導入ラインから成膜室内に流入させ、成膜装置に設けられた圧力制御器により成膜室内を適切な圧力に維持し、高周波電極に電力を印加して、電極間にプラズマを発生させて、基板上に薄膜を形成している。このような工程によって、例えば、種々の成膜条件で基板上に多層膜を形成し、薄膜太陽電池等を作製することが可能となる。   In the process of forming a thin film using such an apparatus, first, in order to make the inside of the film forming chamber into a certain vacuum state, evacuation is performed by a mechanism of a gas exhaust system provided in the film forming apparatus. The substrate is heated by a heater provided in the film forming apparatus to perform degassing. After this degassing, in some cases, a mixed gas in which several kinds of film forming gases are mixed at an appropriate flow ratio is allowed to flow into the film forming chamber from the gas introduction line provided in the film forming apparatus, and is provided in the film forming apparatus. A thin film is formed on the substrate by maintaining an appropriate pressure in the film forming chamber with the pressure controller and applying power to the high frequency electrodes to generate plasma between the electrodes. Through such a process, for example, it is possible to form a multilayer film on a substrate under various film forming conditions to manufacture a thin film solar cell or the like.

この工程のうち真空引きを行った直後では、成膜室内や基板の表面等に水分等が吸着することが多くなっている。これらの不純物が十分に脱ガスされない状態で薄膜形成を行った場合、薄膜中に大量の不純物が含まれることとなり、膜質の低下につながるおそれがある。そのため、成膜室内の脱ガスを促進する目的で、薄膜形成前にガス導入ラインから成膜室内にガスを導入し、圧力制御器およびガス排気ラインによって成膜室内を一定の圧力に維持した状態で、成膜室内の加熱(ベーキング)を数時間行っている。この加熱中、成膜室内に流入させるガスには、H2等の熱伝導性の良いガス、He、Ar等の不活性ガス、あるいは成膜を行う際に成膜室内に流入させる成膜ガス等が採用されている。
特開2006−144091号公報
Immediately after evacuation in this process, moisture or the like is often adsorbed on the film formation chamber or the surface of the substrate. When a thin film is formed in a state where these impurities are not sufficiently degassed, a large amount of impurities are contained in the thin film, which may lead to deterioration in film quality. Therefore, for the purpose of promoting degassing in the deposition chamber, gas is introduced from the gas introduction line into the deposition chamber before the thin film is formed, and the deposition chamber is maintained at a constant pressure by the pressure controller and the gas exhaust line. Then, heating (baking) in the film formation chamber is performed for several hours. During this heating, the gas that flows into the film formation chamber includes a gas having good thermal conductivity such as H 2 , an inert gas such as He and Ar, or a film formation gas that flows into the film formation chamber during film formation. Etc. are adopted.
JP 2006-144091 A

特許文献1に開示されている成膜装置の成膜室は、略直方体の形状であり、近接した内壁に囲まれ、急激に形状の変化する角部を有することとなる。前記プラズマ放電は、高周波電力により生成されるプラズマを用いており、突起部分や窪み部分等急激に形状が変化している箇所で異常放電を引き起こし易い。異常放電が発生した場合、前記薄膜が正常に形成されず、歩留まりが低下する問題がある。   The film forming chamber of the film forming apparatus disclosed in Patent Document 1 has a substantially rectangular parallelepiped shape, is surrounded by adjacent inner walls, and has corners whose shape changes abruptly. The plasma discharge uses plasma generated by high-frequency power, and is likely to cause abnormal discharge at locations where the shape changes rapidly, such as protrusions and depressions. When abnormal discharge occurs, there is a problem that the thin film is not formed normally and the yield is lowered.

また、特に基板上にSi系薄膜をプラズマにより成膜する成膜装置では、ヒーターにより加熱する温度を100℃〜350℃程度とすることが多く、成膜室を形成する内壁および防着板はヒーターからの輻射およびガスからの伝熱により加熱されることとなる。そのため、成膜室の構成部品は、熱に対して形状等の安定性を確保することが求められる。この安定性が確保されない場合、成膜中に防着板等の変形が発生し、急激に形状の変化する突起部分および窪み部分等が形成される結果となり、異常放電の発生要因となり、薄膜が正常に形成されず、歩留まりが低下する問題がある。   Particularly, in a film forming apparatus for forming a Si-based thin film on a substrate by plasma, the temperature heated by the heater is often set to about 100 ° C. to 350 ° C., and the inner wall and the deposition plate forming the film forming chamber are It is heated by radiation from the heater and heat transfer from the gas. Therefore, the components of the film formation chamber are required to ensure the stability of the shape and the like against heat. If this stability is not ensured, deformation of the deposition plate, etc. will occur during film formation, resulting in the formation of protrusions and depressions whose shape changes rapidly, causing abnormal discharge, and the thin film There is a problem that it is not formed normally and the yield decreases.

さらに、熱安定性を確保する目的で成膜室の内壁および防着板等、ヒーター以外の成膜室の構成部材を冷却水等により冷却する構成を有する場合、基板上にSi系薄膜がプラズマにより形成されると共に、冷却された部分で粉末状の副生成物が大量に形成されることとなる。この副生成物が基板上に形成される薄膜に混入すると、薄膜が正常に形成されずに、良品率が大幅に低下してしまう問題がある。   In addition, in order to ensure thermal stability, the Si-based thin film is plasma on the substrate when the components of the deposition chamber other than the heater, such as the inner wall of the deposition chamber and the deposition plate, are cooled by cooling water or the like. And a large amount of powdery by-products are formed in the cooled portion. When this by-product is mixed in the thin film formed on the substrate, the thin film is not formed normally, and the yield rate is significantly reduced.

そのために本発明の課題は、異常放電の発生を抑制し、薄膜を正常に形成し、歩留まりを向上させる成膜装置を提供することにある。   Therefore, an object of the present invention is to provide a film forming apparatus that suppresses the occurrence of abnormal discharge, forms a thin film normally, and improves the yield.

課題を解決するために本発明の成膜装置は、成膜を行う空間である成膜室と、前記成膜室の内部に配置された第1の電極および第2の電極と、高周波電源および整合回路から構成され、かつ前記第1の電極および前記第2の電極のうち一方の電極に成膜室の外部から電力を供給する機構と、前記第1の電極および前記第2の電極のうち他方の電極に前記成膜室の外部から電力を供給し、または接地電極に接続する機構と、前記第1の電極と前記第2の電極との間にガスを流入させて、電極を供給することによりプラズマを形成し、前記プラズマを利用して成膜を行うように成膜室を加熱する機構と、前記成膜室内を囲むように前記成膜室内の複数の側面部に対応させて配置している複数の防着板と、を備えている成膜装置において、前記防着板を複数に分割し、近接する前記防着板同士の間に隙間を設けていることを特徴としている。   In order to solve the problem, a film forming apparatus according to the present invention includes a film forming chamber which is a space for film forming, a first electrode and a second electrode disposed in the film forming chamber, a high-frequency power source, A mechanism configured of a matching circuit and supplying power from one outside of the film formation chamber to one of the first electrode and the second electrode; and of the first electrode and the second electrode Electricity is supplied to the other electrode from the outside of the film formation chamber or connected to the ground electrode, and gas is supplied between the first electrode and the second electrode to supply the electrode. And a mechanism for heating the film formation chamber so as to form a film using the plasma, and a plurality of side surfaces disposed in the film formation chamber so as to surround the film formation chamber. A plurality of deposition preventing plates, and the deposition preventing apparatus. Was divided into a plurality, it is characterized in that a gap is provided between the deposition preventing plate between adjacent.

本発明の成膜装置は、前記成膜室内の角部に対応する部分で前記防着板の端部が湾曲していても良い。   In the film forming apparatus of the present invention, an end portion of the deposition preventing plate may be curved at a portion corresponding to a corner portion in the film forming chamber.

本発明の成膜装置では、前記第1の電極板の周縁部または前記第1の電極板および前記第2の電極板の周縁部と、前記防着板の端部同士の間に形成された直線部と、の距離がXとなっている成膜装置において、湾曲した前記防着板の前記端部と、前記第1の電極板または前記第1の電極板および前記第2の電極板と、の距離が0.95X〜1.05Xとなるように前記端部が形成されていても良い。   In the film forming apparatus according to the present invention, the first electrode plate or the first electrode plate and the second electrode plate are formed between a peripheral portion of the first electrode plate and the end portions of the deposition preventing plate. In the film forming apparatus in which the distance to the straight line portion is X, the end portion of the curved deposition preventing plate, the first electrode plate or the first electrode plate, and the second electrode plate The end portion may be formed such that the distance between and is 0.95X to 1.05X.

本発明の成膜装置では、前記防着板が絶縁体により作製されていても良い。   In the film forming apparatus of the present invention, the deposition preventing plate may be made of an insulator.

本発明の成膜装置では、前記防着板のプラズマに暴露される側の端部が面取り形状またはR形状となっていても良い。   In the film forming apparatus of the present invention, the end of the deposition preventing plate exposed to the plasma may be chamfered or rounded.

本発明の成膜装置では、前記成膜室内の角部に対応する部分に配置された前記防着板の前記端部に近接する前記電極板の角部が面取り形状またはR形状となっていても良い。   In the film forming apparatus of the present invention, a corner portion of the electrode plate adjacent to the end portion of the deposition preventing plate disposed at a portion corresponding to the corner portion in the film forming chamber has a chamfered shape or an R shape. Also good.

本発明の成膜装置では、前記防着板のプラズマに暴露される側面部のみが凹凸形状を有するように加工されていても良い。   In the film forming apparatus of the present invention, only the side surface exposed to the plasma of the deposition preventing plate may be processed so as to have an uneven shape.

本発明の成膜装置では、前記防着板の両側の側面部が凹凸形状を有するように加工されていても良い。   In the film forming apparatus of the present invention, the side portions on both sides of the deposition preventing plate may be processed so as to have an uneven shape.

本発明の成膜装置では、前記凹凸形状が、前記防着板の前記側面部から見て直径5μm〜200μmの略円形状に形成されていても良い。   In the film forming apparatus of the present invention, the uneven shape may be formed in a substantially circular shape having a diameter of 5 μm to 200 μm when viewed from the side surface portion of the deposition preventing plate.

本発明の成膜装置によれば、以下の効果を得ることができる。すなわち、本発明の成膜装置は、防着板を複数に分割し、近接する前記防着板同士の間に隙間を設けていることにより、成膜室の内壁および前記防着板が加熱された状態で、前記防着板の熱膨張に対する逃げを確保することが可能となり、熱変形に伴う突起および窪みの形成を抑制することが可能となる。また、前記防着板1枚当たりの面積を小さくすることにより、加熱された場合の熱膨張による変形量を小さく抑えることが可能となる。さらに熱変形を抑制するためのネジなどの固定具の数を減らすことにより、取付け・取外しなどのメンテナンス時間を短縮することが可能となる。   According to the film forming apparatus of the present invention, the following effects can be obtained. That is, in the film forming apparatus of the present invention, the inner plate of the film forming chamber and the deposition preventing plate are heated by dividing the deposition preventing plate into a plurality of portions and providing a gap between the neighboring deposition preventing plates. In this state, it is possible to ensure escape from thermal expansion of the deposition preventing plate, and it is possible to suppress formation of protrusions and depressions due to thermal deformation. Further, by reducing the area per one of the deposition preventing plates, it is possible to suppress the deformation amount due to thermal expansion when heated. Further, by reducing the number of fixtures such as screws for suppressing thermal deformation, it is possible to shorten the maintenance time such as attachment / removal.

前記成膜室内の角部に対応する部分で前記防着板の端部が湾曲していても良く、角部など形状の急激に変化する部分に放電集中する傾向のある高周波放電において、前記成膜室内の急激に変化する部分の減少により、異常放電の発生を減少させることが可能となる。   In the high frequency discharge in which the end of the deposition preventing plate may be curved at a portion corresponding to the corner in the film forming chamber, and the discharge tends to concentrate on a portion where the shape changes rapidly, such as the corner. The occurrence of abnormal discharge can be reduced by reducing the rapidly changing portion in the membrane chamber.

前記第1の電極板の周縁部または前記第1の電極板および前記第2の電極板の周縁部と前記防着板の端部同士の間に形成された直線部との距離がXとなっている成膜装置において、湾曲した前記防着板の前記端部と、前記第1の電極板または前記第1の電極板および前記第2の電極板との距離が0.95X〜1.05Xとなるように前記端部が形成されていても良く、前記電極板と前記防着板との距離を前記成膜室内全体で均一に保つことが容易となる。高周波電極と接地電位を有する部分との距離は、放電し易さに影響し、この距離が他の部位と異なると、この部分で放電集中または放電が立たなくなるなどの現象が発生し、プラズマの均一性が悪化することとなる。プラズマの均一性の悪化は基板上に形成される薄膜の膜圧の均一性を悪化させる要因となるからである。   The distance between the peripheral portion of the first electrode plate or the peripheral portion of the first electrode plate and the second electrode plate and the straight portion formed between the end portions of the deposition preventing plate is X. In the film forming apparatus, the distance between the end portion of the curved deposition preventing plate and the first electrode plate or the first electrode plate and the second electrode plate is 0.95X to 1.05X. The end portion may be formed so that the distance between the electrode plate and the deposition preventing plate can be easily maintained uniformly throughout the film forming chamber. The distance between the high-frequency electrode and the part having the ground potential affects the ease of discharge, and if this distance is different from other parts, a phenomenon such as the concentration of discharge or the inability to discharge can occur in this part, and the plasma Uniformity will deteriorate. This is because the deterioration of the plasma uniformity becomes a factor that deteriorates the uniformity of the film pressure of the thin film formed on the substrate.

前記防着板が絶縁体により作製されていても良く、前記防着板自体に高周波放電が印加されなくなり、前記防着板の端部の形状などに起因した異常放電を抑制することが可能となる。   The deposition plate may be made of an insulator, and high frequency discharge is not applied to the deposition plate itself, and abnormal discharge due to the shape of the end of the deposition plate can be suppressed. Become.

前記防着板のプラズマに暴露される側の端部が面取り形状またはR形状となっていても良く、前記防着板の全体で角形状部分が減少し、異常放電の発生要因となる形状の急激に変化する部分が減少させることが可能となる。   The end of the adhesion-preventing plate exposed to plasma may be chamfered or rounded, and the square-shaped portion of the entire adhesion-preventing plate is reduced, resulting in abnormal discharge. It is possible to reduce the rapidly changing portion.

前記成膜室内の角部に対応する部分に配置された前記防着板の前記端部に近接する前記電極板の角部が面取り形状またはR形状となっていても良く、前記成膜室の角部における前記第1の電極板および前記第2の電極板と前記防着板との距離を、前記防着板の直線部と電極板の直線部との距離に対して0.95倍〜1.05倍に保ち易くなり、成膜室の角部での放電環境の変化を抑制することが可能となる。   A corner portion of the electrode plate adjacent to the end portion of the deposition plate disposed at a portion corresponding to the corner portion in the film forming chamber may be chamfered or R-shaped. The distance between the first electrode plate and the second electrode plate at the corner portion and the deposition preventing plate is 0.95 times the distance between the rectilinear portion of the deposition preventing plate and the rectilinear portion of the electrode plate. It becomes easy to keep 1.05 times, and it becomes possible to suppress the change of the discharge environment at the corner of the film forming chamber.

前記防着板のプラズマに暴露される側面部のみが凹凸形状を有するように加工されていても良く、前記防着板上に形成された薄膜の剥離を抑制することが可能となる。このような片面のみ凹凸形状を施した防着板の場合、前記防着板自体が凹凸形状を形成する時に反り等の変形が生じ易い。これは、特に前記防着板の厚さが薄くなると、その傾向が顕著になる。   Only the side surface exposed to the plasma of the deposition preventive plate may be processed so as to have a concavo-convex shape, and peeling of the thin film formed on the deposition preventive plate can be suppressed. In the case of such an adhesion-preventing plate having a concavo-convex shape on only one surface, deformation such as warpage is likely to occur when the proofing plate itself forms an uneven shape. This tendency becomes prominent particularly when the thickness of the deposition preventing plate is reduced.

前記防着板の両側の側面部が凹凸形状を有するように加工されていても良く、プラズマに暴露されない側に凹凸形状を設けることにより、凹凸形状形成時に発生する前記防着板内の内部応力を緩和することが可能となり、ブラスト処理等の防着板への付着膜の除去工程を数回繰り返しても、前記防着板の形状を直線状または面状形状に保つことが可能となる。   Side surfaces on both sides of the deposition preventive plate may be processed so as to have a concavo-convex shape, and by providing the concavo-convex shape on the side not exposed to plasma, internal stress in the deposition preventive plate is generated when the concavo-convex shape is formed. Therefore, even if the process of removing the adhesion film on the adhesion-preventing plate such as blasting is repeated several times, the shape of the adhesion-preventing plate can be kept linear or planar.

前記凹凸形状が、前記防着板の前記側面部から見て直径5μm〜200μmの略円形状に形成されていても良く、防着板へ付着した膜の剥離強度を高めることが可能となる。   The concavo-convex shape may be formed in a substantially circular shape having a diameter of 5 μm to 200 μm when viewed from the side surface portion of the deposition preventing plate, and the peel strength of the film attached to the deposition preventing plate can be increased.

本発明の第一実施形態について以下に説明する。図1は、成膜装置1の内部の概略を示している。成膜装置1の内部には、略直方体の成膜室2が配置され、加工対象であるフィルム基板3が搬送方向Aに沿って搬送されるように配置されている。成膜室2の略中央の高さに入口開口2aおよび出口開口2bが設けられており、フィルム基板3は、入口開口2aから挿入され、成膜室2内を通過し、出口開口2bから搬出されている。成膜室2の内部には、高周波電源および整合回路から構成された高周波電極(第1の電極に相当)4および接地電極(第2の電極に相当)5が設けられている。高周波電極4は、成膜室2の外部から電力を供給する機構を備えており、フィルム基板3の一方の面側に配置されている。接地電極5はフィルム基板3の他方の面側に配置されている。また、接地電極5内には基板を加熱するヒーター(図示せず)が備えられており、フィルム基板3の他方の面側に配置されている。成膜室2の接地電極5側の内壁は、フィルム基板3に接近する方向に稼動する機構を備えており、フィルム基板3に光電変換素子などを成膜する際は、成膜室2の内壁で基板3を挟み込み、成膜室2が外部と隔離された状態で成膜ガスを充填され、高周波電極4に高周波電力を印加することにより高周波電極4から接地電極5に向かうプラズマを発生させる。   A first embodiment of the present invention will be described below. FIG. 1 schematically shows the inside of the film forming apparatus 1. Inside the film forming apparatus 1, a substantially rectangular parallelepiped film forming chamber 2 is arranged, and the film substrate 3 to be processed is arranged so as to be conveyed along the conveying direction A. An inlet opening 2a and an outlet opening 2b are provided at a substantially central height of the film forming chamber 2, and the film substrate 3 is inserted from the inlet opening 2a, passes through the film forming chamber 2, and is discharged from the outlet opening 2b. Has been. A high-frequency electrode (corresponding to a first electrode) 4 and a ground electrode (corresponding to a second electrode) 5 each including a high-frequency power source and a matching circuit are provided inside the film forming chamber 2. The high frequency electrode 4 includes a mechanism for supplying electric power from the outside of the film forming chamber 2 and is disposed on one surface side of the film substrate 3. The ground electrode 5 is disposed on the other surface side of the film substrate 3. Further, a heater (not shown) for heating the substrate is provided in the ground electrode 5 and is disposed on the other surface side of the film substrate 3. The inner wall on the ground electrode 5 side of the film forming chamber 2 is provided with a mechanism that operates in a direction approaching the film substrate 3, and when forming a photoelectric conversion element or the like on the film substrate 3, the inner wall of the film forming chamber 2 is provided. Then, the substrate 3 is sandwiched between them, and a film forming gas is filled in a state where the film forming chamber 2 is isolated from the outside, and high frequency power is applied to the high frequency electrode 4 to generate plasma from the high frequency electrode 4 to the ground electrode 5.

図2は、図1で示した成膜装置1のB−B断面図を示している。成膜装置1の略中央部に略長方形の高周波電極4は配置され、成膜室2の四方の内壁に対応させて防着板6がそれぞれ配置されている。成膜室2の各側面部に配置された防着板6は図2のB−B断面で見て2分割されており、室温時では防着板6,6同士の間に、成膜室2の直線部の隙間6aおよび成膜室2の角部の隙間6bが存在している。成膜室2内を加熱する時には、防着板6は、成膜室2を構成する部材との差、または熱容量の差から防着板6,6同士の間の隙間6a,6bを狭める方向に伸びることとなる。薄膜太陽電池を形成する際、基板上に複数の薄膜から成る積層膜を形成する必要がある。成膜装置1は各種の薄膜を形成するための成膜室2、防着板6などをそれぞれ有し、ヒーター温度およびガス圧力等がそれぞれ異なり、各々の成膜室2、防着板6などの温度が異なっている。加熱後の成膜開始時の熱平衡状態で、防着板6,6同士の間の隙間6a,6bが無くなるように設定することが好ましい。   FIG. 2 shows a cross-sectional view of the film forming apparatus 1 shown in FIG. A substantially rectangular high-frequency electrode 4 is disposed at a substantially central portion of the film forming apparatus 1, and an adhesion preventing plate 6 is disposed corresponding to the four inner walls of the film forming chamber 2. The adhesion preventing plates 6 arranged on the respective side portions of the film forming chamber 2 are divided into two as seen from the BB cross section of FIG. 2, and the film forming chambers are formed between the adhesion preventing plates 6 and 6 at room temperature. There are a gap 6a in the straight line portion 2 and a gap 6b in the corner portion of the film forming chamber 2. When heating the inside of the film forming chamber 2, the adhesion preventing plate 6 narrows the gaps 6 a and 6 b between the adhesion preventing plates 6 and 6 due to a difference from a member constituting the film forming chamber 2 or a difference in heat capacity. Will grow. When forming a thin film solar cell, it is necessary to form a laminated film composed of a plurality of thin films on a substrate. The film forming apparatus 1 includes a film forming chamber 2 for forming various thin films, a deposition plate 6, and the like, each having a different heater temperature, gas pressure, and the like. The temperature is different. It is preferable to set so that the gaps 6a and 6b between the deposition preventing plates 6 and 6 are eliminated in a thermal equilibrium state at the start of film formation after heating.

さらに、成膜室2における到達温度以上の耐熱性を有し、かつ絶縁性の材質で形成された防着板6を適用することにより、高周波電極4と防着板6との間で放電が発生しない構成となり、異常放電を抑制することが可能となる。   Further, by applying a deposition plate 6 having a heat resistance equal to or higher than the temperature reached in the film formation chamber 2 and formed of an insulating material, a discharge is generated between the high-frequency electrode 4 and the deposition plate 6. It becomes the structure which does not generate | occur | produce and it becomes possible to suppress abnormal discharge.

第一実施形態の第一変形例として、防着板6,6同士の間の隙間6a,6bを高周波電極4と接地電極5間との距離(電極間距離)の1/10以下にしても良い。そのため、室温時における防着板6,6同士の間の隙間6a,6bは、各々の成膜室2などの使用環境に合わせて異なる値にすることが好ましい。   As a first modification of the first embodiment, the gaps 6a and 6b between the adhesion preventing plates 6 and 6 are set to 1/10 or less of the distance between the high-frequency electrode 4 and the ground electrode 5 (interelectrode distance). good. Therefore, it is preferable that the gaps 6a and 6b between the deposition preventing plates 6 and 6 at room temperature have different values according to the use environment of each film forming chamber 2 or the like.

また、第一実施形態の第二変形例として、成膜室2の側面部における防着板6の分割数は2である必要はなく、3以上であってもよい。また、分割数は全ての成膜室2の側面部で同じにする必要はなく、例えば取付け易さを考慮して、取付け困難な側面部の分割数を低く、取付け容易な側面部の分割数を高くしても良い。   Further, as a second modification of the first embodiment, the number of divisions of the deposition preventing plate 6 in the side surface portion of the film forming chamber 2 does not have to be 2, and may be 3 or more. Further, the number of divisions does not need to be the same for the side surfaces of all the film forming chambers 2. For example, considering the ease of attachment, the number of divisions of the side portions that are difficult to attach is low, and the number of divisions of the side portions that are easy to attach May be high.

このような防着板6を成膜室2に設けることにより、成膜室2の加熱時に防着板6の熱膨張に伴う突起発生要素を減少させることが可能であり、成膜中に異常放電の発生回数を減少させることが可能となる。   By providing such a deposition preventing plate 6 in the film forming chamber 2, it is possible to reduce the projection generating elements accompanying the thermal expansion of the deposition preventing plate 6 when the deposition chamber 2 is heated. It is possible to reduce the number of occurrences of discharge.

図3は、本発明の第二実施形態における防着板6および成膜室2を示した図である。第二実施形態は、基本的な構造を第一実施形態、第一実施形態の第一変形例または第二変形例のいずれかと同様としており、これらと異なる部分を以下に説明する。具体的には、成膜室2内の角部に対応する部分で防着板6の端部6dを湾曲させると共に、防着板6の端部6dを近接させて配置している。隣り合っている2枚の防着板6,6は、隙間6bを空けながら端部6dの湾曲形状に合わせて一体となり、1つの湾曲形状を形成している。また、この隙間6bは防着板6が高温下で線膨張した場合でも、隣り合っている2枚の防着板6,6が互いに当接しないような間隔に設定している。   FIG. 3 is a view showing the deposition preventing plate 6 and the film forming chamber 2 in the second embodiment of the present invention. In the second embodiment, the basic structure is the same as that of the first embodiment, the first modified example or the second modified example of the first embodiment, and different parts will be described below. Specifically, the end 6d of the deposition preventing plate 6 is curved at the portion corresponding to the corner in the film forming chamber 2, and the end 6d of the deposition preventing plate 6 is disposed close to the end 6d. The two adhesion preventing plates 6 and 6 adjacent to each other are integrated with each other in accordance with the curved shape of the end 6d while leaving a gap 6b to form one curved shape. Further, the gap 6b is set at such an interval that the two adjacent anti-adhesion plates 6 and 6 do not contact each other even when the anti-adhesion plate 6 undergoes linear expansion at a high temperature.

このような構成を取ることにより、成膜室2内で急激に形状の変化する箇所を減少させることが可能となり、異常放電の発生回数を減少させることが可能となる。第一実施形態と同様に、防着板6,6同士の間の隙間6bは、加熱後の成膜開始時の熱平衡状態で隙間が無くなくなる距離にするように設定することが好ましい。   By adopting such a configuration, it is possible to reduce the number of places where the shape suddenly changes in the film forming chamber 2, and it is possible to reduce the number of occurrences of abnormal discharge. As in the first embodiment, the gap 6b between the deposition preventing plates 6 and 6 is preferably set to a distance that eliminates the gap in the thermal equilibrium state at the start of film formation after heating.

また、成膜室2の一対の角部の間に配置された高周波電極4の直線部4aと防着板6の直線部6cとの距離をX(図3および図4中のX)としている成膜装置1で、防着板6に設けた湾曲部の曲率を変えることにより、成膜室2の角部における高周波電極4と防着板6との距離D(図3および図4中のD)を0.95X〜1.05Xにした場合が、同0.9Xおよび同1.1Xとした場合と比較して±5%程度膜圧の均一性が改善することとなる。   Further, the distance between the straight portion 4a of the high-frequency electrode 4 disposed between the pair of corners of the film forming chamber 2 and the straight portion 6c of the deposition preventing plate 6 is X (X in FIGS. 3 and 4). By changing the curvature of the curved portion provided in the deposition plate 6 in the deposition apparatus 1, the distance D between the high-frequency electrode 4 and the deposition plate 6 at the corner of the deposition chamber 2 (in FIGS. 3 and 4). When D) is set to 0.95X to 1.05X, the uniformity of the film pressure is improved by about ± 5% as compared with the case where 0.9X and 1.1X are set.

第二実施形態の変形例として、防着板6,6同士の湾曲部の突合せ部を熱平衡状態で、隙間6bが無くなるようにすることが難しい場合、防着板6の湾曲部を有する端部6dの近傍を成膜室2の内壁に他の部位と比較して強く固定し、他方の湾曲部を有しない端部6dが優先的に熱膨張で伸張するような構成にすると良い。   As a modification of the second embodiment, when it is difficult to eliminate the gap 6b in the thermal equilibrium state between the butted portions of the adhesion preventing plates 6 and 6, the end portion having the bending portion of the adhesion preventing plate 6 The vicinity of 6d may be strongly fixed to the inner wall of the film formation chamber 2 as compared with other portions, and the other end 6d having no curved portion may be preferentially expanded by thermal expansion.

図4は、本発明の第三実施形態における高周波電極4と防着板6とを示している。第三実施形態は、基本的な構造を第二実施形態または第二実施形態の変形例と同様としており、第二実施形態と異なる部分を以下に説明する。具体的には、高周波電極4の角部4bと成膜室2の角部に配置された防着板6の端部6dとが湾曲している。このような構成とすることにより、高周波電極4の角部4bと防着板6の湾曲部を有する端部6dとの距離Dを0.95X〜1.05Xに保ち易くなり、膜圧の均一性を確保することが容易となっている。加えて、高周波電極4の突起部も減少するので、異常放電の発生回数も抑制することが可能となる。   FIG. 4 shows the high-frequency electrode 4 and the deposition preventing plate 6 in the third embodiment of the present invention. In the third embodiment, the basic structure is the same as that of the second embodiment or the modified example of the second embodiment, and parts different from the second embodiment will be described below. Specifically, the corner 4 b of the high-frequency electrode 4 and the end 6 d of the deposition preventing plate 6 disposed at the corner of the film formation chamber 2 are curved. With this configuration, the distance D between the corner 4b of the high-frequency electrode 4 and the end 6d having the curved portion of the deposition preventing plate 6 can be easily maintained at 0.95X to 1.05X, and the film pressure is uniform. It is easy to ensure the property. In addition, since the protrusions of the high-frequency electrode 4 are reduced, the number of occurrences of abnormal discharge can be suppressed.

さらに、本発明の第四実施形態について説明する。図5(a)は、図2〜4に示した第一実施形態〜第三実施形態の防着板6のうち第一実施形態の防着板6を代表例として示している。具体的には、図5(a)に示した防着板6の端部6dは、鋭角な角部分を有する形状となっている。第四実施形態では、基本的な構造は、第一実施形態〜第三実施形態(各変形例を含む)のいずれかと同様であり、これらと異なる点について説明する。図5(b)に示すように、図2のB−B断面に示した防着板6の端部6dを面取り形状としている。この面取り箇所はプラズマに暴露される側の端部6dの全てで行われることが好ましく、異常放電の発生を防止することが可能となる。または、この面取り形状をR形状としても良く、同様の効果が得られる。   Furthermore, a fourth embodiment of the present invention will be described. Fig.5 (a) has shown the adhesion prevention board 6 of 1st embodiment among the adhesion prevention boards 6 of 1st embodiment-3rd embodiment shown to FIGS. 2-4 as a representative example. Specifically, the end 6d of the deposition preventing plate 6 shown in FIG. 5A has a shape having an acute corner. In the fourth embodiment, the basic structure is the same as that of any one of the first to third embodiments (including the respective modifications), and differences from these will be described. As shown in FIG.5 (b), the edge part 6d of the adhesion prevention board 6 shown to the BB cross section of FIG. 2 is made into the chamfering shape. This chamfered portion is preferably performed at all of the end portion 6d on the side exposed to the plasma, and abnormal discharge can be prevented. Alternatively, this chamfered shape may be an R shape, and the same effect can be obtained.

第四実施形態の変形例として、プラズマに暴露されない側も、防着板6の端部6dを面取り形状とすることで、防着板6の表裏どちらをプラズマに暴露しても成膜室2の全体の構成が変わらなくなり、防着板6の表裏両側を使用することが可能となり、防着板6の有効利用を図ることが可能となる。   As a modification of the fourth embodiment, the film forming chamber 2 is exposed to either the front or back side of the deposition preventing plate 6 by exposing the side not exposed to the plasma to a chamfered end 6d of the deposition preventing plate 6. Therefore, it becomes possible to use both the front and back sides of the deposition preventive plate 6 and to make effective use of the deposition preventive plate 6.

加えて、本発明の第五実施形態について説明する。図6(a)は、第二実施形態〜第三実施形態の防着板6を示している。具体的には、図6(a)に示した防着板6の端部6dは、鋭角な角部分を有する形状となっている。第五実施形態では、基本的な構造は、第二実施形態または第三実施形態(各変形例を含む)のいずれかと同様であり、これらと異なる点について説明する。図6(b)に示すように、図3のC部における防着板6の端部6dを面取り形状としている。図6(b)のような構成の防着板6を使用することによって、異常放電の発生を防止することが可能となる。また、この面取り形状をR形状としても良く、同様の効果が得られる。   In addition, a fifth embodiment of the present invention will be described. Fig.6 (a) has shown the adhesion prevention board 6 of 2nd embodiment-3rd embodiment. Specifically, the end 6d of the deposition preventing plate 6 shown in FIG. 6A has a shape having an acute corner. In the fifth embodiment, the basic structure is the same as that of either the second embodiment or the third embodiment (including the respective modifications), and differences from these will be described. As shown in FIG.6 (b), the edge part 6d of the adhesion prevention board 6 in the C section of FIG. 3 is made into the chamfering shape. By using the deposition preventing plate 6 having the configuration as shown in FIG. 6B, it is possible to prevent the occurrence of abnormal discharge. Further, this chamfered shape may be an R shape, and the same effect can be obtained.

本発明の第六実施形態について説明する。第六実施形態は基本的な構成は第一実施形態〜第五実施形態(各変形例を含む)のいずれかと同様になっており、これらと異なる点について以下に説明する。上述したような熱膨張対策および異常放電対策を施した防着板6の側面部で、プラズマに暴露される側にのみブラスト処理により凹凸形状を設けている。その結果、防着板6に付着した膜の剥離が発生し難くなり、薄膜太陽電池の良品率を向上することが可能となる。   A sixth embodiment of the present invention will be described. The basic configuration of the sixth embodiment is the same as that of any one of the first to fifth embodiments (including the respective modifications), and differences from these will be described below. In the side surface portion of the deposition preventive plate 6 that has been subjected to measures against thermal expansion and abnormal discharge as described above, a concavo-convex shape is provided by blasting only on the side exposed to the plasma. As a result, it is difficult for the film attached to the deposition preventing plate 6 to peel off, and the yield rate of thin film solar cells can be improved.

さらに、防着板6の側面部から見た凹凸形状は略円形状となっており、この略円形状の直径を5μm以上とすることにより、成膜中、防着板6へ付着した薄膜の防着板6からの剥離を少なくすることが可能となる。具体的には5μm〜200μmとすると良く、防着板6へ付着した薄膜の防着板6からの剥離をより少なくすることが可能となる。また、防着板6の凹凸の度合いは、5μm〜100μm程度であるとさらに好適である。   Furthermore, the concave-convex shape seen from the side surface portion of the deposition preventing plate 6 is a substantially circular shape. By setting the diameter of this substantially circular shape to 5 μm or more, the thin film adhered to the deposition preventing plate 6 during the film formation. It becomes possible to reduce peeling from the deposition preventing plate 6. Specifically, the thickness is preferably 5 μm to 200 μm, and the peeling of the thin film attached to the deposition preventing plate 6 from the deposition preventing plate 6 can be further reduced. The degree of unevenness of the deposition preventing plate 6 is more preferably about 5 μm to 100 μm.

また、第六実施形態の変形例として、凹凸形状を防着板6のプラズマに露出する側だけでなく、防着板6のプラズマに露出されない側にも同様に設けても良く、防着板6自体の反りや変形等を抑制することが可能となる。また、両側の側面部に凹凸形状を形成することにより、防着板6の両側の側面部を使用することが可能となり、防着板6の有効利用が可能となる。   Further, as a modification of the sixth embodiment, the uneven shape may be provided not only on the side of the deposition preventing plate 6 exposed to the plasma but also on the side of the deposition preventing plate 6 not exposed to the plasma. It is possible to suppress the warpage or deformation of the 6 itself. Further, by forming the concave and convex shapes on the side surface portions on both sides, the side surface portions on both sides of the deposition preventing plate 6 can be used, and the deposition preventing plate 6 can be effectively used.

上述した実施形態では高周波電極4の詳細な形状に関してのみ記載したが、接地電極5を高周波電極4と同様の形状としても良く、また接地電極5のみを上述した高周波電極4の形状としても良い。   Although only the detailed shape of the high-frequency electrode 4 has been described in the above-described embodiment, the ground electrode 5 may be the same shape as the high-frequency electrode 4, or only the ground electrode 5 may be the shape of the high-frequency electrode 4 described above.

本発明の実施形態における成膜装置の内部構造をフィルム基板の搬送方向の側面から見た概略である。It is the outline which looked at the internal structure of the film-forming apparatus in embodiment of this invention from the side surface of the conveyance direction of a film substrate. 本発明の第一実施形態における成膜装置を図1のB-B断面で見た図である。It is the figure which looked at the film-forming apparatus in 1st embodiment of this invention in the BB cross section of FIG. 本発明の第二実施形態における成膜装置を図1のB-B断面で見た図である。It is the figure which looked at the film-forming apparatus in 2nd embodiment of this invention in the BB cross section of FIG. 本発明の第三実施形態における成膜装置を図1のB-B断面で見た図である。It is the figure which looked at the film-forming apparatus in 3rd embodiment of this invention in the BB cross section of FIG. (a)図2の防着板を拡大して表した図である。(b)本発明の第四実施形態における防着板を図5(a)と同様に表した図である。(A) It is the figure which expanded and represented the adhesion prevention board of FIG. (B) It is the figure which represented the adhesion prevention board in 4th embodiment of this invention similarly to Fig.5 (a). (a)図3および図4のC部を表した図である。(b)本発明の第五実施形態における防着板を図6(a)と同様に表した図である。(A) It is the figure showing the C section of FIG. 3 and FIG. (B) It is the figure showing the adhesion prevention board in 5th embodiment of this invention similarly to Fig.6 (a).

符号の説明Explanation of symbols

1 成膜装置
2 成膜室
2a 入口開口
2b 出口開口
3 フィルム基板
4 高周波電極(第1の電極)
4a 直線部
4b 角部
5 接地電極(第2の電極)
6 防着板
6a,6b 隙間
6c 直線部
6d 端部
A 搬送方向
X 距離
D 距離
DESCRIPTION OF SYMBOLS 1 Film-forming apparatus 2 Film-forming chamber 2a Inlet opening 2b Outlet opening 3 Film substrate 4 High frequency electrode (1st electrode)
4a Straight portion 4b Corner portion 5 Ground electrode (second electrode)
6 Protection plate 6a, 6b Gap 6c Straight line 6d End A Transport direction X Distance D Distance

Claims (9)

成膜を行う空間である成膜室と、前記成膜室の内部に配置された第1の電極および第2の電極と、高周波電源および整合回路から構成され、かつ前記第1の電極および前記第2の電極のうち一方の電極に成膜室の外部から電力を供給する機構と、前記第1の電極および前記第2の電極のうち他方の電極に成膜室の外部から電力を供給し、または接地電位に接続する機構と、前記第1の電極と前記第2の電極との間にガスを流入させて、電極を供給することによりプラズマを形成し、前記プラズマを利用して成膜を行うように前記成膜室を加熱する機構と、前記成膜室内を囲むように前記成膜室内の複数の側面部に対応させて配置している複数の防着板と、を備えている成膜装置において、
前記防着板を複数に分割し、近接する前記防着板同士の間に隙間を設けていることを特徴とする成膜装置。
A film formation chamber which is a space for film formation, a first electrode and a second electrode arranged in the film formation chamber, a high frequency power source and a matching circuit, and the first electrode and the A mechanism for supplying electric power to one of the second electrodes from the outside of the film formation chamber, and electric power to the other electrode of the first electrode and the second electrode are supplied from the outside of the film formation chamber. Alternatively, a plasma is formed by supplying a gas by flowing a gas between the first electrode and the second electrode and a mechanism connected to the ground potential, and using the plasma to form a film A mechanism for heating the film formation chamber so as to perform a plurality of deposition plates, and a plurality of deposition plates arranged corresponding to a plurality of side surface portions in the film formation chamber so as to surround the film formation chamber. In the film forming apparatus,
The deposition apparatus according to claim 1, wherein the deposition preventing plate is divided into a plurality of portions, and a gap is provided between the deposition preventing plates adjacent to each other.
前記成膜室内の角部に対応する部分で前記防着板の端部が湾曲していることを特徴とする請求項1に記載の成膜装置。   The film forming apparatus according to claim 1, wherein an end portion of the deposition preventing plate is curved at a portion corresponding to a corner portion in the film forming chamber. 前記第1の電極板の周縁部または前記第1の電極板および前記第2の電極板の周縁部と、前記防着板の端部同士の間に形成された直線部と、の距離がXとなっている成膜装置において、
湾曲した前記防着板の前記端部と、前記第1の電極板または前記第1の電極板および前記第2の電極板と、の距離が0.95X〜1.05Xとなるように前記端部が形成されていることを特徴とする請求項1に記載の成膜装置。
The distance between the peripheral edge portion of the first electrode plate or the peripheral edge portions of the first electrode plate and the second electrode plate and the linear portion formed between the end portions of the deposition preventing plate is X In the film forming apparatus
The end so that a distance between the bent end portion of the deposition preventing plate and the first electrode plate or the first electrode plate and the second electrode plate is 0.95X to 1.05X. The film forming apparatus according to claim 1, wherein a portion is formed.
前記防着板が絶縁体により作製されていることを特徴とする請求項1に記載の成膜装置。   The film forming apparatus according to claim 1, wherein the deposition preventing plate is made of an insulator. 前記防着板のプラズマに暴露される側の端部が面取り形状またはR形状となっていることを特徴とする請求項1〜4のいずれか一項に記載の成膜装置。   5. The film forming apparatus according to claim 1, wherein an end of the deposition preventing plate exposed to plasma has a chamfered shape or an R shape. 前記成膜室内の角部に対応する部分に配置された前記防着板の前記端部に近接する前記電極板の角部が面取り形状またはR形状となっていることを特徴とする請求項1〜4のいずれか一項に記載の成膜装置。   2. The corner portion of the electrode plate adjacent to the end portion of the deposition preventing plate disposed at a portion corresponding to the corner portion in the film forming chamber is chamfered or R-shaped. The film-forming apparatus as described in any one of -4. 前記防着板のプラズマに暴露される側面部のみが凹凸形状を有するように加工されていることを特徴とする請求項1〜6のいずれか一項に記載の成膜装置。   The film forming apparatus according to claim 1, wherein only the side surface exposed to the plasma of the deposition preventing plate is processed so as to have an uneven shape. 前記防着板の両側の側面部が凹凸形状を有するように加工されていることを特徴とする請求項1〜6のいずれか一項に記載の成膜装置。   The film forming apparatus according to claim 1, wherein side surfaces on both sides of the deposition preventing plate are processed so as to have an uneven shape. 前記凹凸形状が、前記防着板の前記側面部から見て直径5μm〜200μmの略円形状に形成されていることを特徴とする請求項7または8に記載の成膜装置。   The film forming apparatus according to claim 7, wherein the uneven shape is formed in a substantially circular shape having a diameter of 5 μm to 200 μm when viewed from the side surface portion of the deposition preventing plate.
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