WO2011030004A1 - Multilayer coating, method for fabricating a multilayer coating, and uses for the same - Google Patents

Multilayer coating, method for fabricating a multilayer coating, and uses for the same Download PDF

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Publication number
WO2011030004A1
WO2011030004A1 PCT/FI2010/050700 FI2010050700W WO2011030004A1 WO 2011030004 A1 WO2011030004 A1 WO 2011030004A1 FI 2010050700 W FI2010050700 W FI 2010050700W WO 2011030004 A1 WO2011030004 A1 WO 2011030004A1
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WO
WIPO (PCT)
Prior art keywords
precursor
layer
coating
substrate
reaction space
Prior art date
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PCT/FI2010/050700
Other languages
French (fr)
Inventor
Sami Sneck
Nora ISOMÄKI
Jarmo Maula
Olli JYLHÄ
Matti Putkonen
Runar Törnqvist
Mikko SÖDERLUND
Original Assignee
Beneq Oy
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Publication date
Application filed by Beneq Oy filed Critical Beneq Oy
Priority to EA201290148A priority Critical patent/EA022723B1/en
Priority to EP10815048.3A priority patent/EP2478127A4/en
Priority to JP2012528401A priority patent/JP2013504866A/en
Priority to CN201080040851.9A priority patent/CN102575345B/en
Priority to US13/395,942 priority patent/US20120177903A1/en
Publication of WO2011030004A1 publication Critical patent/WO2011030004A1/en

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Classifications

    • 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
    • C23C16/455—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 introducing gases into reaction chamber or for modifying gas flows in reaction chamber
    • C23C16/45523—Pulsed gas flow or change of composition over time
    • C23C16/45525—Atomic layer deposition [ALD]
    • C23C16/45527—Atomic layer deposition [ALD] characterized by the ALD cycle, e.g. different flows or temperatures during half-reactions, unusual pulsing sequence, use of precursor mixtures or auxiliary reactants or activations
    • C23C16/45529—Atomic layer deposition [ALD] characterized by the ALD cycle, e.g. different flows or temperatures during half-reactions, unusual pulsing sequence, use of precursor mixtures or auxiliary reactants or activations specially adapted for making a layer stack of alternating different compositions or gradient compositions
    • 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
    • C23C16/22—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 deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/40—Oxides
    • C23C16/403—Oxides of aluminium, magnesium or beryllium
    • 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
    • C23C16/22—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 deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/40—Oxides
    • C23C16/405—Oxides of refractory metals or yttrium
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/04—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material
    • C23C28/042—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings of inorganic non-metallic material including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/40—Coatings including alternating layers following a pattern, a periodic or defined repetition
    • C23C28/42—Coatings including alternating layers following a pattern, a periodic or defined repetition characterized by the composition of the alternating layers
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495—Thickness [relative or absolute]
    • Y10T428/24967—Absolute thicknesses specified
    • Y10T428/24975—No layer or component greater than 5 mils thick

Definitions

  • the present invention relates to film deposi ⁇ tion technology. Especially the present invention re ⁇ lates to multilayer coatings, methods for their fabrication, and uses for the same. BACKGROUND OF THE INVENTION
  • Barrier coatings are commonly used to protect an underlying substrate from the surrounding environment. Many barrier coating are especially used as chemical barriers which protect the substrate by pre- venting or minimizing diffusion of a chemically active species from the environment through the barrier coat ⁇ ing and onto the surface of the substrate. These chemical barrier coatings, often referred to as diffu ⁇ sion barriers, have been developed against many dif- ferent potentially reactive species. Diffusion barri ⁇ ers exist against, for example, water, oxygen, various acids and toxic chemicals.
  • the performance of the diffusion barrier against a specific material depends on e.g. the mate- rial of the coating, the thickness of the coating and the quality of the coating which is significantly af ⁇ fected by the fabrication method used to deposit or to otherwise form the coating on the substrate.
  • Diffusion barrier coatings known from the prior art fall short in their performance, i.e. in their ability to minimize diffusion of a specific spe ⁇ cies through the coating, for several reasons.
  • An important reason is that many known barrier coatings are fabricated using methods which result in films includ- ing different types of defects such as pinholes, pores or cracks, or even dislocations in crystallized mate- rial. These defects generate routes through which dif ⁇ fusion can efficiently occur. Methods resulting in such defective coatings include e.g. chemical vapour deposition (CVD) , physical vapour deposition (PVD) , various aerosol based methods and sputtering.
  • CVD chemical vapour deposition
  • PVD physical vapour deposition
  • a purpose of the present invention is to re ⁇ smile the aforementioned technical problems of the prior-art by providing a new type of multilayer coat ⁇ ing a new type of method for fabricating the multi- layer coating and uses for the same.
  • the method according to the present invention is characterized by what is presented in independent claim 1.
  • the product according to the present inven ⁇ tion is characterized by what is presented in inde ⁇ pendent claim 13.
  • the method according to the present invention is a method for fabricating a multilayer coating on a substrate, the coating being arranged to minimize dif- fusion of atoms through the coating.
  • the method comprises the steps of introducing a substrate to a reac ⁇ tion space, depositing a layer of first material on the substrate, and depositing a layer of second mate ⁇ rial on the layer of first material.
  • Depositing the layer of first material comprises the steps of, intro ⁇ ducing a first precursor into the reaction space such that at least a portion of the first precursor adsorbs onto the surface of the substrate and subsequently purging the reaction space, and introducing a second precursor into the reaction space such that at least a portion of the second precursor reacts with the first precursor adsorbed onto the surface of the substrate and subsequently purging the reaction space.
  • Deposit ⁇ ing the layer of second material comprises the steps of, introducing a third precursor into the reaction space such that at least a portion of the third pre ⁇ cursor adsorbs onto the surface of the layer of first material and subsequently purging the reaction space, and introducing a fourth precursor into the reaction space such that at least a portion of the fourth pre ⁇ cursor reacts with the third precursor adsorbed onto the surface of the layer of first material and subse ⁇ quently purging the reaction space.
  • the first material is selected from the group of titanium oxide and alu- minum oxide
  • the second material is the other from the group of titanium oxide and aluminum oxide.
  • An in- terfacial region is formed in between titanium oxide and aluminum oxide.
  • a multilayer coating on a substrate is arranged to minimize diffusion of atoms through the coating.
  • the coating comprises a layer of first material on the substrate, and a layer of second material on the layer of first material.
  • the first material is selected from the group of titanium oxide and aluminum oxide, the second material being the other from the group of titanium oxide and aluminum oxide.
  • the multilayer coating comprises an interfacial region in between titanium oxide and aluminum oxide.
  • the method of the present invention is used to fabricate a multi ⁇ layer coating on a substrate, to minimize diffusion of water from the environment through the coating onto the surface of the substrate.
  • the multi- layer coating of the present invention is used on a substrate, to minimize diffusion of water from the en ⁇ vironment through the coating onto the surface of the substrate .
  • the present invention provides a multilayer coating which efficiently minimizes diffusion of mate ⁇ rial, i.e. atomic or molecular diffusion, onto a sub ⁇ strate from the environment through the multilayer coating.
  • environment should be understood as the region on the oppo- site side of the coating as viewed from the side of the substrate.
  • the present invention also provides a multi ⁇ layer coating, which efficiently minimizes diffusion of such material that has traversed the substrate, through the multilayer coating (e.g. barrier-on-foil embodiment) .
  • the multilayer coating according to the invention minimizes diffusion of material through the coating regardless of the direction from which the material is heading towards the coating.
  • the coating is fabricated by depositing the layer of first material by introducing a first precursor into a reaction space such that at least a portion of the first precursor adsorbs onto the surface of the sub ⁇ strate and subsequently purging the reaction space, and introducing a second precursor into the reaction space such that at least a portion of the second pre ⁇ cursor reacts with the first precursor adsorbed onto the surface of the substrate and subsequently purging the reaction space; depositing the layer of second ma ⁇ terial by introducing a third precursor into the reac- tion space such that at least a portion of the third precursor adsorbs onto the surface of the layer of first material and subsequently purging the reaction space, and introducing a fourth precursor into the reaction space such that at least a portion of the fourth precursor reacts with the third precursor adsorbed onto the surface of the layer of first material and subsequently purging the reaction space.
  • a multi ⁇ layer structure comprising a layer of titanium oxide and a layer of aluminum oxide in contact with each other efficiently reduces material diffusion through the structure.
  • the titanium oxide and the aluminum oxide layers are deposited by alter ⁇ nately introducing at least two different precursors into the reaction space such that at least a portion of the introduced precursor adsorbs onto the deposi ⁇ tion surface, the barrier performance of the multi ⁇ layer coating is further enhanced, i.e. material dif ⁇ fusion through the coating is reduced.
  • the observed advantages are achieved since aluminum oxide and titanium oxide form an interfacial region in between the two materials.
  • This interfacial region possesses a structure which efficiently pre ⁇ vents material diffusion through the aluminum oxide and titanium oxide interface.
  • the chemical composition changes in the interfacial region in between titanium oxide and aluminum oxide.
  • the interfacial region comprises an alumi- nate phase of titanium oxide and aluminum oxide. The aluminate phase is thermodynamically more stable than the single layers of titanium oxide and aluminum ox ⁇ ide.
  • a densification occurs at the interfacial region of ti ⁇ tanium oxide and aluminum oxide providing a reduction in the diffusion of atoms through the multilayer coat- ing. Furthermore, the surface governed growth mecha ⁇ nism resulting from the alternating adsorption of precursors leads to dense films with only a negligible amount of pores or pinholes, which increases the den ⁇ sity of the titanium oxide and aluminum oxide layers. This leads to an additional reduction in the diffusion of atoms through the multilayer coating.
  • the method comprises the step of depositing another layer of first material onto a layer of second mate- rial, to form a second interfacial region between ti ⁇ tanium oxide and aluminum oxide.
  • the coating comprises an ⁇ other layer of first material on a layer of second ma ⁇ terial, to form a second interfacial region between titanium oxide and aluminum oxide.
  • the method comprises forming two or more interfacial regions in the multilayer coating.
  • the multilayer coating comprises two or more interfacial regions.
  • An advan ⁇ tage of the two or more interfacial regions is the further reduction of diffusion of atoms through the multilayer coating.
  • the second material is titanium oxide.
  • Long term dura ⁇ bility of the multilayer barrier coating against weather or against other potentially harsh and/or chemically aggressive environmental conditions can be improved by ensuring that the coating comprises a sec ⁇ tion where a layer of titanium oxide resides on a layer of aluminum oxide, i.e. a layer of titanium ox- ide resides closer to the above environment than a layer of aluminum oxide.
  • a titanium oxide layer pro ⁇ tects chemically an underlying aluminum oxide layer which then imparts the good diffusion barrier properties on the multilayer coating.
  • the titanium oxide layer acts as a resilient material against chemi ⁇ cals from the environment. This enables an aluminum oxide layer having good barrier properties under the titanium oxide layer to better maintain its structure, which prolongs the lifetime of the multilayer coating.
  • a layer of titanium oxide is deposited by selecting the first precursor or the third precursor from the group of water and titanium tetrachloride, while the second precursor or the fourth precursor are the other from the group of water and titanium tetrachloride, respectively.
  • a layer of aluminum oxide is deposited by selecting the first precursor or the third precursor from the group of water and trimethylaluminum, while the second precursor or the fourth precursor are the other from the group of water and trimethylaluminum, respectively.
  • Titanium tetrachloride and water are precursors which can be used to deposit titanium oxide such that the growth of the titanium oxide layer oc- curs essentially through chemical surface reactions on the deposition surface.
  • trimethylaluminum and water are precursors which can be used to deposit aluminum oxide such that the growth of the ti ⁇ tanium oxide layer occurs essentially through chemical surface reactions on the deposition surface. Under suitable process condition, discussed later, these surface reactions can be made essentially self- limiting, which results in very conformal, uniform and dense films.
  • the process chemistry in these embodi- ments of the invention enables deposition of the mul ⁇ tilayer coating with excellent diffusion barrier properties even over non-planar three-dimensional sub ⁇ strates having a surface with a complex geometry.
  • the method comprises depositing a layer of first mate ⁇ rial having suitably a thickness of below 25 nano ⁇ metres and preferably a thickness of below 10 nano ⁇ metres, and a layer of second material having suitably a thickness of below 25 nanometres and preferably a thickness of below 10 nanometres.
  • a layer of first material has suitably a thickness of below 25 nanometres and preferably a thickness of below 10 nanometres
  • a layer of second material has suitably a thickness of below 25 nanometres and preferably a thickness of be ⁇ low 10 nanometres.
  • the multilayer coating and the method for its formation can be realized cost effi ⁇ ciently in a simple and rapid process with only mini- mal consumption of precursor materials.
  • suitable inexpensive precursor materials for fabricat ⁇ ing the multilayer coating of the present invention such as the aforementioned trimethylaluminum, water (or de-ionized water) and titanium tetrachloride, are readily available.
  • the method comprises depositing at a temperature not more than 150 °C .
  • the method com- prises depositing at a temperature not more than 100 °C.
  • the multilayer coating is fabricated at a depositing temperature not more than 150 °C . According to another embodiment of the invention the multilayer coating is fabricated at a depositing temperature not more than 100 °C.
  • the multilayer coating is fabricated on a moisture- permeable substrate.
  • the method comprises fabricating a mul ⁇ tilayer coating on a substrate comprising a moisture sensitive device.
  • the method comprises fabricating a multi- layer coating on a substrate comprising polymer.
  • the sub ⁇ strate comprises a moisture sensitive device.
  • the substrate comprises polymer. LED and OLED are mentioned as exam- pies of a moisture sensitive device.
  • the polymer is selected from a group consisting of polyethylene naphthalate (PEN) , polyethylene terephthalate (PET) , polypropylene (PP) , and nylon.
  • PEN polyethylene naphthalate
  • PET polyethylene terephthalate
  • PP polypropylene
  • the in ⁇ vention is used for a substrate comprising polymer.
  • the invention is used for a substrate comprising a moisture sensitive device.
  • titanium oxide and aluminum oxide are in amorphous form.
  • the present invention provides, according to one embodiment, glasslike moisture-barrier properties for a polymer coating (i.e. barrier-on-foil ) .
  • Fig. 1 is a flow-chart illustration of a method according to one embodiment of the present in ⁇ vention
  • Fig. 2 is a schematic illustration of a mul ⁇ tilayer coating according to one embodiment of the present invention.
  • Fig. 3 is a schematic illustration of a mul ⁇ tilayer coating according to one embodiment of the present invention.
  • Atomic Layer Deposition is a method which can be used for depositing uniform and conformal thin-films over substrates of various shapes, even over complex 3D (three dimensional) structures.
  • ALD the coating is grown by alternately repeating, essen- tially self-limiting, surface reactions between a pre ⁇ cursor and a surface to be coated. Therefore the growth mechanism in an ALD process enables coating without directional effects like in coating methods relying on rapid gas-phase reactions, such as metal- organic chemical vapour deposition (MOCVD) , or without line of sight effects observed in physical vapour deposition (PVD) .
  • MOCVD metal- organic chemical vapour deposition
  • PVD physical vapour deposition
  • ALD ALD
  • two or more different chemicals are introduced to a reaction space in a sequential, alternating, manner and the precursors adsorb on surfaces, e.g. on a substrate, inside the reaction space.
  • the sequential, alternat ⁇ ing, introduction of precursors is commonly called pulsing (of precursors) .
  • pulsing of precursors
  • a film can be grown by an ALD process by repeating several times a pulsing sequence comprising the aforementioned precur ⁇ sor pulses and purging periods. The number of how many times this sequence called the "ALD cycle" is repeated depends on the targeted thickness of the film, or coating .
  • a processing tool suitable for carrying out the methods in the fol ⁇ lowing embodiments will be obvious for the skilled person.
  • the tool can be e.g. a conventional ALD tool suitable for handling the chemicals discussed below.
  • ALD tools i.e. reactors
  • US patent 4389973 and US patent 4413022 which are in ⁇ cluded herein as references.
  • Many of the steps related for handling such tools, such as delivering a substrate into the reaction space, pumping the reaction space down to a low pressure, heating the substrates and the reaction space etc. will be obvious for the skilled person.
  • many other known operations or features are not described in detail nor mentioned, in order to emphasize relevant aspects of the various em ⁇ bodiments of the invention.
  • An embodiment of the present invention pre ⁇ sented by the flow-chart of Fig. 1 begins by bringing the substrate 3 into the reaction space (step P) ) of a typical reactor tool, e.g. a tool suitable for carry ⁇ ing out an ALD process.
  • the reaction space is subse ⁇ quently pumped down to a pressure suitable for forming the film using e.g. a mechanical vacuum pump.
  • the sub- strate 3 is also heated to a temperature suitable for forming the film by the used method.
  • the substrate 3 can be introduced to the reaction space through e.g. an airtight load-lock system or simply through a loading hatch.
  • the substrate 3 can be heated by e.g. re- sistive heating elements which also heat the entire reaction space.
  • Step P) may also include other prepa ⁇ ration procedures which depend on the reactor tool, on the overall process, or on the environment in which the tool is operated.
  • the substrate 3 may me coated with a film of other material 4 or the sur ⁇ face of the substrate 3 may be otherwise treated with or exposed to chemicals. These procedures will be ob ⁇ vious for the skilled person in light of this specifi ⁇ cation .
  • the alternate introduc- tion of precursors into the reaction space and onto the surface of the substrate 3 is started.
  • the surface of the substrate 3 is preferably exposed to precursors in their gaseous form. This can be realized by first evaporating the precursors in their respective source containers which may or may not be heated depending on the properties of the precursor itself.
  • the evaporated precursor can be delivered into the reaction space by e.g. dosing it through the pipework of the reactor tool comprising flow channels for delivering the vaporized precursors into the reaction space. Controlled dosing of vapour into the reaction space can be realized by valves installed in the flow channels.
  • valves are commonly called pulsing valves in an ALD system.
  • other mechanisms of bringing the sub ⁇ strate 3 into contact with a precursor inside the re ⁇ action space may be conceived.
  • One alternative is to make the surface of the substrate 3 (instead of the vaporized precursor) move inside the reaction space such that the substrate 3 moves through a region occu ⁇ file by gaseous precursor.
  • a typical ALD reactor also comprises a system for introducing inert gas, such as nitrogen or argon into the reaction space such that the reaction space can be purged from surplus precursor and reaction byproducts before introducing the next precursor into the reaction space.
  • inert gas such as nitrogen or argon
  • This feature together with the controlled dosing of vaporized precursors enables al ⁇ ternately exposing the surface to precursors without significant intermixing of different precursors in the reaction space or in other parts of the ALD reactor.
  • the flow of inert gas is commonly continu ⁇ ous through the reaction space throughout the deposi ⁇ tion process and only the various precursors are al- ternately introduced to the reaction space with the inert gas.
  • purging of the reaction space does not necessarily result in complete elimination of surplus chemicals or reaction by-products from the re ⁇ action space but residues of these or other materials may always be present.
  • step al is carried out in order to start the growth of the layer of first material 1 onto the substrate.
  • the first material is alumi- num oxide and the second material is titanium oxide.
  • the exact composition and phase of the aluminum oxide and titanium oxide can vary. These materials may obvi ⁇ ously also include impurities although their concen ⁇ tration remains relatively low as a result of the growth method.
  • step al gaseous trimethylaluminum is introduced to the reaction space and thereby the surface of the substrate 3 is exposed to trimethylaluminum. Exposure of the surface to trimethylaluminum results, in suitable process conditions discussed below, in the adsorption of a portion of the introduced trimethylaluminum onto the surface. After purging of the reac ⁇ tion space from trimethylaluminum water vapor is introduced to the reaction space and thereby the surface of the substrate, which in this case has the adsorbed portion of the trimethylaluminum precursor adsorbed onto it, is exposed to water (step bl)), some of which in turn gets adsorbed onto the surface. The reaction space is subsequently purged from the water.
  • Thickness of the resulting aluminum oxide film on the substrate 3 can be increased by repeating the steps al) and bl), in this order, as presented by the flow-chart of Fig. 1.
  • the number of how many times the steps al) and bl) are repeated depends on the targeted film thickness and on the growth rate of the aluminum oxide film under the specific process conditions.
  • the tar- geted thickness for the layer of first material 1 in this embodiment of the invention is below 25 nano ⁇ metres (nm) .
  • step a2) the deposition of the layer of second material 2 is started onto the layer of first material 1.
  • step a2 titanium tetrachloride is introduced to the reaction space.
  • Ex- posure of the surface to titanium tetrachloride re ⁇ sults, in suitable process conditions discussed below, in the adsorption of a portion of the introduced va ⁇ porized titanium tetrachloride onto the deposition surface.
  • step b2 After purging of the reaction space from ti- tanium tetrachloride vaporized water is introduced to the reaction space and thereby the surface of the sub ⁇ strate, which in this case has the adsorbed portion of the titanium tetrachloride precursor adsorbed onto it, is exposed to water (step b2)), some of which in turn gets adsorbed onto the deposition surface.
  • the reac ⁇ tion space is subsequently purged from the water.
  • Thickness of the resulting titanium oxide film on the aluminum oxide film can be increased by repeating the steps a2) and b2), in this order, as presented by the flow-chart of Fig. 1.
  • the number of how many times the steps a2) and b2) are repeated depends on the targeted film thickness and on the growth rate of the titanium oxide film under the specific process conditions.
  • the targeted thickness for the layer of second material 2 in this embodiment of the invention is below 25 nano ⁇ metres (nm) .
  • Fig. 1 results in a multilayer coating on a substrate 3.
  • This coating is presented in Fig. 2, which also presents an optional layer of other material 4 which may be grown in between the substrate 3 and the multi- layer coating during the preparation step P) .
  • a layer of titanium oxide second material 2 resides on a layer of aluminum oxide first material 1.
  • Fig. 3 is presented a multilayer coating on a substrate 3 according to one embodiment of the present invention.
  • the interfacial region 5 formed in between titanium oxide 2 and aluminum oxide 1 is presented.
  • the following example describes in detail how the multilayer coating can be grown on the substrate 3.
  • multilayer coatings were formed on Ca-substrates (Calcium substrates) .
  • the substrates were first inserted inside the reaction space of a P400A ALD tool (available from Beneq OY, Finland) .
  • the Ca-substrates were planar to enable reliable permea ⁇ tions rate measurements.
  • the inert gas discussed above and responsible for purging the reac ⁇ tion space was nitrogen (N 2 ) .
  • the reaction space of the ALD tool was pumped down to the processing pressure of about 1 mbar and the substrates were subsequently heated to the processing temperature of about 100 °C .
  • the temperature was stabilized to the processing tem ⁇ perature inside the reaction space by a computer con- trolled heating period of two to four hours.
  • step P) the surface of the substrate 3 was ex ⁇ posed to an ozone treatment and a thin conditioning layer 4 of aluminum oxide was subsequently grown from trimethylaluminum and water, on the substrate 3.
  • step P the processing temperature
  • step al the surface of the substrate 3 was ex ⁇ posed to an ozone treatment and a thin conditioning layer 4 of aluminum oxide was subsequently grown from trimethylaluminum and water, on the substrate 3.
  • the pulsing sequence of al) then bl) was carried out once and then repeated 53 times to form a first layer of aluminum oxide with a thickness of approximately 5 nm on the substrate. After this layer was formed the process moved to step a2) and subsequently to step b2) .
  • the pulsing sequence of a2) then b2) was carried out once and then repeated 110 times to form a layer of titanium oxide with a thick- ness of approximately 5 nm on the layer of first mate ⁇ rial 1 (aluminum oxide) .
  • this structure comprised 19 inter ⁇ faces between aluminum oxide and titanium oxide in a multilayer coating having a total thickness of only about 100 nm, which resulted in surprisingly efficient diffusion barrier properties in view of the total thickness of the layer, as will be discussed subse ⁇ quently.
  • the growth process was ended, after which heating of the reaction space was turned off and the substrates were ejected from the reaction space and from the ALD- tool .
  • Exposure of the surface of the substrate 3 to a specific precursor was carried out by switching on the pulsing valve of the P400 ALD-tool controlling the flow of the precursor into the reaction space.
  • Purging of the reaction space was carried out by closing the valves controlling the flow of precursors into the re ⁇ action space, and thereby letting only the continuous flow of inert gas flow through the reaction space.
  • the pulsing sequence in this example for the aluminum oxide layer was in detail as follows; 0.6 s exposure to trimethylaluminum, 1.0 s purge, 0.6 s ex ⁇ posure to 3 ⁇ 40, 5 s purge.
  • the pulsing sequence in this example for the titanium oxide layer was in detail as follows; 0.6 s exposure to titanium tetrachloride, 1.0 s purge, 0.6 s exposure to H 2 0, 3 s purge.
  • An exposure time and a purge time in this sequence signify a time a specific pulsing valve for a specific precursor was kept open and a time all the pulsing valves for pre ⁇ cursors were kept closed, respectively.
  • the aluminum oxide and the titanium oxide layers were formed at a processing temperature of about 100 °C at which temperature the aluminum oxide layers and the titanium oxide layers grew essentially amorphous. This further helped reducing grain boundaries, dislo- cations and other defects mostly associated with crys ⁇ talline materials.
  • the permeations rate for the grown multilayer coatings were measured in an environment having a relative humidity of 80% and a temperature of 80 ° C.
  • the testing procedure followed the widely used "80/80"-test in which the Ca-substrate immediately re ⁇ acted with water that diffused from the humid environ ⁇ ment into contact with the Ca-substrate through the multilayer coating.
  • the details of the "80/80"-test will be obvious for a skilled person.
  • the measured value of per- meation of water through the coating i.e.
  • the permeations rate for water was about 0.8 g/ (m 2 day) (grams of water through one square meter of coating in one day) .
  • the pulsing sequence and the process parameters used in the example additionally contributed to the resulting very conformal and uniform films over large areas of the substrate 3 surface and even over complex non-planar surfaces.

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Abstract

A multilayer coating and a method for fabricating a multilayer coating on a substrate (3). The coating is arranged to minimize diffusion of atoms through the coating, the method comprising the steps of introducing a substrate (3) to a reaction space, depositing a layer of first material (1) on the substrate (3), and depositing a layer of second material (2) on the layer of first material (1). Depositing the layer of first material (1) and the layer of second material (2) comprises alternately introducing precursors into the reaction space and subsequently purging the reaction space after each introduction of a precursor. The first material being selected from the group of titanium oxide and aluminum oxide, the second material being the other from the group of titanium oxide and aluminum oxide. An interfacial region is formed in between titanium oxide and aluminum oxide.a.

Description

MULTILAYER COATING, METHOD FOR FABRICATING A MULTILAYER COATING, AND USES FOR THE SAME
FIELD OF THE INVENTION
The present invention relates to film deposi¬ tion technology. Especially the present invention re¬ lates to multilayer coatings, methods for their fabrication, and uses for the same. BACKGROUND OF THE INVENTION
Barrier coatings are commonly used to protect an underlying substrate from the surrounding environment. Many barrier coating are especially used as chemical barriers which protect the substrate by pre- venting or minimizing diffusion of a chemically active species from the environment through the barrier coat¬ ing and onto the surface of the substrate. These chemical barrier coatings, often referred to as diffu¬ sion barriers, have been developed against many dif- ferent potentially reactive species. Diffusion barri¬ ers exist against, for example, water, oxygen, various acids and toxic chemicals.
The performance of the diffusion barrier against a specific material depends on e.g. the mate- rial of the coating, the thickness of the coating and the quality of the coating which is significantly af¬ fected by the fabrication method used to deposit or to otherwise form the coating on the substrate.
Diffusion barrier coatings known from the prior art fall short in their performance, i.e. in their ability to minimize diffusion of a specific spe¬ cies through the coating, for several reasons. An important reason is that many known barrier coatings are fabricated using methods which result in films includ- ing different types of defects such as pinholes, pores or cracks, or even dislocations in crystallized mate- rial. These defects generate routes through which dif¬ fusion can efficiently occur. Methods resulting in such defective coatings include e.g. chemical vapour deposition (CVD) , physical vapour deposition (PVD) , various aerosol based methods and sputtering. For ex¬ ample US patent application publication 2008/0006819A1 teaches the fabrication of moisture barriers using PECVD. Although process parameters can naturally be optimized in the aforementioned methods to reduce the density of the defects the growth mechanism of the coating in the methods makes is difficult to obtain coatings with a quality suitable for efficient diffu¬ sion barriers.
Many of the known diffusion barrier coatings comprise layers of different materials on top of each other to form a multilayer structure. In these multi¬ layer diffusion barriers the layers of different mate¬ rials commonly impart different functions to the coat¬ ing. When fabricated with the aforementioned methods, the problem of defective films still remains. Examples of multilayer coatings used as a diffusion barrier can be found in US patent # 5607789 and US patent applica¬ tion publication 2008/0006819A1. PURPOSE OF THE INVENTION
A purpose of the present invention is to re¬ duce the aforementioned technical problems of the prior-art by providing a new type of multilayer coat¬ ing a new type of method for fabricating the multi- layer coating and uses for the same.
SUMMARY OF THE INVENTION
The method according to the present invention is characterized by what is presented in independent claim 1. The product according to the present inven¬ tion is characterized by what is presented in inde¬ pendent claim 13.
The use according to the present invention is characterized by what is presented in independent claim 26 or 27.
The method according to the present invention is a method for fabricating a multilayer coating on a substrate, the coating being arranged to minimize dif- fusion of atoms through the coating. The method comprises the steps of introducing a substrate to a reac¬ tion space, depositing a layer of first material on the substrate, and depositing a layer of second mate¬ rial on the layer of first material. Depositing the layer of first material comprises the steps of, intro¬ ducing a first precursor into the reaction space such that at least a portion of the first precursor adsorbs onto the surface of the substrate and subsequently purging the reaction space, and introducing a second precursor into the reaction space such that at least a portion of the second precursor reacts with the first precursor adsorbed onto the surface of the substrate and subsequently purging the reaction space. Deposit¬ ing the layer of second material comprises the steps of, introducing a third precursor into the reaction space such that at least a portion of the third pre¬ cursor adsorbs onto the surface of the layer of first material and subsequently purging the reaction space, and introducing a fourth precursor into the reaction space such that at least a portion of the fourth pre¬ cursor reacts with the third precursor adsorbed onto the surface of the layer of first material and subse¬ quently purging the reaction space. The first material is selected from the group of titanium oxide and alu- minum oxide, and the second material is the other from the group of titanium oxide and aluminum oxide. An in- terfacial region is formed in between titanium oxide and aluminum oxide.
A multilayer coating on a substrate, according to the present invention, is arranged to minimize diffusion of atoms through the coating. The coating comprises a layer of first material on the substrate, and a layer of second material on the layer of first material. The first material is selected from the group of titanium oxide and aluminum oxide, the second material being the other from the group of titanium oxide and aluminum oxide. The multilayer coating comprises an interfacial region in between titanium oxide and aluminum oxide.
According to the present invention the method of the present invention is used to fabricate a multi¬ layer coating on a substrate, to minimize diffusion of water from the environment through the coating onto the surface of the substrate.
According to the present invention the multi- layer coating of the present invention is used on a substrate, to minimize diffusion of water from the en¬ vironment through the coating onto the surface of the substrate .
The present invention provides a multilayer coating which efficiently minimizes diffusion of mate¬ rial, i.e. atomic or molecular diffusion, onto a sub¬ strate from the environment through the multilayer coating. In this particular context the word "environment" should be understood as the region on the oppo- site side of the coating as viewed from the side of the substrate.
The present invention also provides a multi¬ layer coating, which efficiently minimizes diffusion of such material that has traversed the substrate, through the multilayer coating (e.g. barrier-on-foil embodiment) . I.e. the multilayer coating according to the invention minimizes diffusion of material through the coating regardless of the direction from which the material is heading towards the coating.
According to one embodiment of the invention the coating is fabricated by depositing the layer of first material by introducing a first precursor into a reaction space such that at least a portion of the first precursor adsorbs onto the surface of the sub¬ strate and subsequently purging the reaction space, and introducing a second precursor into the reaction space such that at least a portion of the second pre¬ cursor reacts with the first precursor adsorbed onto the surface of the substrate and subsequently purging the reaction space; depositing the layer of second ma¬ terial by introducing a third precursor into the reac- tion space such that at least a portion of the third precursor adsorbs onto the surface of the layer of first material and subsequently purging the reaction space, and introducing a fourth precursor into the reaction space such that at least a portion of the fourth precursor reacts with the third precursor adsorbed onto the surface of the layer of first material and subsequently purging the reaction space.
It has surprisingly been found that a multi¬ layer structure comprising a layer of titanium oxide and a layer of aluminum oxide in contact with each other efficiently reduces material diffusion through the structure. When additionally the titanium oxide and the aluminum oxide layers are deposited by alter¬ nately introducing at least two different precursors into the reaction space such that at least a portion of the introduced precursor adsorbs onto the deposi¬ tion surface, the barrier performance of the multi¬ layer coating is further enhanced, i.e. material dif¬ fusion through the coating is reduced.
The observed advantages are achieved since aluminum oxide and titanium oxide form an interfacial region in between the two materials. This interfacial region possesses a structure which efficiently pre¬ vents material diffusion through the aluminum oxide and titanium oxide interface. According to one embodi¬ ment of the invention the chemical composition changes in the interfacial region in between titanium oxide and aluminum oxide. According to one embodiment of the invention the interfacial region comprises an alumi- nate phase of titanium oxide and aluminum oxide. The aluminate phase is thermodynamically more stable than the single layers of titanium oxide and aluminum ox¬ ide. According to one embodiment of the invention a densification occurs at the interfacial region of ti¬ tanium oxide and aluminum oxide providing a reduction in the diffusion of atoms through the multilayer coat- ing. Furthermore, the surface governed growth mecha¬ nism resulting from the alternating adsorption of precursors leads to dense films with only a negligible amount of pores or pinholes, which increases the den¬ sity of the titanium oxide and aluminum oxide layers. This leads to an additional reduction in the diffusion of atoms through the multilayer coating.
According to one embodiment of the invention the method comprises the step of depositing another layer of first material onto a layer of second mate- rial, to form a second interfacial region between ti¬ tanium oxide and aluminum oxide. According to another embodiment of the invention the coating comprises an¬ other layer of first material on a layer of second ma¬ terial, to form a second interfacial region between titanium oxide and aluminum oxide. As is compatible with the aforementioned it has been observed that forming a multilayer coating having a second interfacial region between a layer of aluminum oxide and a layer of titanium oxide further reduces the diffusion of atoms through the multilayer coating.
According to one embodiment of the invention the method comprises forming two or more interfacial regions in the multilayer coating. According to one embodiment of the invention the multilayer coating comprises two or more interfacial regions. An advan¬ tage of the two or more interfacial regions is the further reduction of diffusion of atoms through the multilayer coating.
According to one embodiment of the invention the second material is titanium oxide. Long term dura¬ bility of the multilayer barrier coating against weather or against other potentially harsh and/or chemically aggressive environmental conditions can be improved by ensuring that the coating comprises a sec¬ tion where a layer of titanium oxide resides on a layer of aluminum oxide, i.e. a layer of titanium ox- ide resides closer to the above environment than a layer of aluminum oxide. Again, without limiting the invention to any theoretical speculation, in this embodiment of the invention a titanium oxide layer pro¬ tects chemically an underlying aluminum oxide layer which then imparts the good diffusion barrier properties on the multilayer coating. I.e. the titanium oxide layer acts as a resilient material against chemi¬ cals from the environment. This enables an aluminum oxide layer having good barrier properties under the titanium oxide layer to better maintain its structure, which prolongs the lifetime of the multilayer coating.
According to one embodiment of the invention a layer of titanium oxide is deposited by selecting the first precursor or the third precursor from the group of water and titanium tetrachloride, while the second precursor or the fourth precursor are the other from the group of water and titanium tetrachloride, respectively. According to another embodiment of the invention a layer of aluminum oxide is deposited by selecting the first precursor or the third precursor from the group of water and trimethylaluminum, while the second precursor or the fourth precursor are the other from the group of water and trimethylaluminum, respectively. Titanium tetrachloride and water are precursors which can be used to deposit titanium oxide such that the growth of the titanium oxide layer oc- curs essentially through chemical surface reactions on the deposition surface. Correspondingly trimethylaluminum and water are precursors which can be used to deposit aluminum oxide such that the growth of the ti¬ tanium oxide layer occurs essentially through chemical surface reactions on the deposition surface. Under suitable process condition, discussed later, these surface reactions can be made essentially self- limiting, which results in very conformal, uniform and dense films. The process chemistry in these embodi- ments of the invention enables deposition of the mul¬ tilayer coating with excellent diffusion barrier properties even over non-planar three-dimensional sub¬ strates having a surface with a complex geometry.
According to one embodiment of the invention the method comprises depositing a layer of first mate¬ rial having suitably a thickness of below 25 nano¬ metres and preferably a thickness of below 10 nano¬ metres, and a layer of second material having suitably a thickness of below 25 nanometres and preferably a thickness of below 10 nanometres. According to one em¬ bodiment of the invention a layer of first material has suitably a thickness of below 25 nanometres and preferably a thickness of below 10 nanometres, and a layer of second material has suitably a thickness of below 25 nanometres and preferably a thickness of be¬ low 10 nanometres. The method according to the present invention enables using surprisingly thin aluminum and titanium oxide layers without compromising the barrier properties of the multilayer coating. Therefore, as the thin layers in the multilayer structure according to the present invention results in significantly bet¬ ter diffusion barrier properties than a single layer of aluminum oxide or titanium oxide with an equivalent physical thickness, the multilayer coating and the method for its formation can be realized cost effi¬ ciently in a simple and rapid process with only mini- mal consumption of precursor materials. Additionally, suitable inexpensive precursor materials for fabricat¬ ing the multilayer coating of the present invention, such as the aforementioned trimethylaluminum, water (or de-ionized water) and titanium tetrachloride, are readily available.
According to one embodiment of the present invention the method comprises depositing at a temperature not more than 150 °C . According to another embodiment of the present invention the method com- prises depositing at a temperature not more than 100 °C.
According to one embodiment of the invention the multilayer coating is fabricated at a depositing temperature not more than 150 °C . According to another embodiment of the invention the multilayer coating is fabricated at a depositing temperature not more than 100 °C.
According to one embodiment of the invention the multilayer coating is fabricated on a moisture- permeable substrate. According to one embodiment of the invention the method comprises fabricating a mul¬ tilayer coating on a substrate comprising a moisture sensitive device. According to one embodiment of the invention the method comprises fabricating a multi- layer coating on a substrate comprising polymer. According to one embodiment of the invention the sub¬ strate comprises a moisture sensitive device. Accord¬ ing to one embodiment of the invention the substrate comprises polymer. LED and OLED are mentioned as exam- pies of a moisture sensitive device. According to one embodiment of the invention the polymer is selected from a group consisting of polyethylene naphthalate (PEN) , polyethylene terephthalate (PET) , polypropylene (PP) , and nylon. According to one embodiment the in¬ vention is used for a substrate comprising polymer. According to one embodiment the invention is used for a substrate comprising a moisture sensitive device.
According to one embodiment of the invention titanium oxide and aluminum oxide are in amorphous form.
The present invention provides, according to one embodiment, glasslike moisture-barrier properties for a polymer coating (i.e. barrier-on-foil ) .
The embodiments of the invention described hereinbefore may be used in any combination with each other. Several of the embodiments may be combined to- gether to form a further embodiment of the invention. A method, a product, or a use, to which the invention is related, may comprise at least one of the embodi¬ ments of the invention described hereinbefore. DETAILED DESCRIPTION OF THE INVENTION
In the following, the present invention will be described in more detail with exemplary embodiments by referring to the accompanying figures, in which
Fig. 1 is a flow-chart illustration of a method according to one embodiment of the present in¬ vention,
Fig. 2 is a schematic illustration of a mul¬ tilayer coating according to one embodiment of the present invention, and
Fig. 3 is a schematic illustration of a mul¬ tilayer coating according to one embodiment of the present invention.
Atomic Layer Deposition (ALD) is a method which can be used for depositing uniform and conformal thin-films over substrates of various shapes, even over complex 3D (three dimensional) structures. In ALD the coating is grown by alternately repeating, essen- tially self-limiting, surface reactions between a pre¬ cursor and a surface to be coated. Therefore the growth mechanism in an ALD process enables coating without directional effects like in coating methods relying on rapid gas-phase reactions, such as metal- organic chemical vapour deposition (MOCVD) , or without line of sight effects observed in physical vapour deposition (PVD) .
In an ALD process two or more different chemicals (precursors) are introduced to a reaction space in a sequential, alternating, manner and the precursors adsorb on surfaces, e.g. on a substrate, inside the reaction space. The sequential, alternat¬ ing, introduction of precursors is commonly called pulsing (of precursors) . In between each precursor pulse there is commonly a purging period during which a flow of inert gas, often called the carrier gas, purges the reaction space from e.g. surplus precursor and by-products resulting from reactions between the deposition surface and the precursor. A film can be grown by an ALD process by repeating several times a pulsing sequence comprising the aforementioned precur¬ sor pulses and purging periods. The number of how many times this sequence called the "ALD cycle" is repeated depends on the targeted thickness of the film, or coating .
The description below discloses some embodi¬ ments of the invention in such a detail that a person skilled in the art is able to utilize the invention based on the disclosure. Not all steps of the embodi¬ ments are discussed in detail, as many of the steps will be obvious for the person skilled in the art based on this specification.
For example, the construction of a processing tool suitable for carrying out the methods in the fol¬ lowing embodiments will be obvious for the skilled person. The tool can be e.g. a conventional ALD tool suitable for handling the chemicals discussed below. ALD tools (i.e. reactors) are disclosed in e.g. US patent 4389973 and US patent 4413022 which are in¬ cluded herein as references. Many of the steps related for handling such tools, such as delivering a substrate into the reaction space, pumping the reaction space down to a low pressure, heating the substrates and the reaction space etc., will be obvious for the skilled person. Also, many other known operations or features are not described in detail nor mentioned, in order to emphasize relevant aspects of the various em¬ bodiments of the invention.
An embodiment of the present invention pre¬ sented by the flow-chart of Fig. 1 begins by bringing the substrate 3 into the reaction space (step P) ) of a typical reactor tool, e.g. a tool suitable for carry¬ ing out an ALD process. The reaction space is subse¬ quently pumped down to a pressure suitable for forming the film using e.g. a mechanical vacuum pump. The sub- strate 3 is also heated to a temperature suitable for forming the film by the used method. The substrate 3 can be introduced to the reaction space through e.g. an airtight load-lock system or simply through a loading hatch. The substrate 3 can be heated by e.g. re- sistive heating elements which also heat the entire reaction space. Step P) may also include other prepa¬ ration procedures which depend on the reactor tool, on the overall process, or on the environment in which the tool is operated. For example the substrate 3 may me coated with a film of other material 4 or the sur¬ face of the substrate 3 may be otherwise treated with or exposed to chemicals. These procedures will be ob¬ vious for the skilled person in light of this specifi¬ cation .
After the substrate 3 and the reaction space have reached the targeted temperature and other condi¬ tions suitable for deposition the alternate introduc- tion of precursors into the reaction space and onto the surface of the substrate 3 is started. The surface of the substrate 3 is preferably exposed to precursors in their gaseous form. This can be realized by first evaporating the precursors in their respective source containers which may or may not be heated depending on the properties of the precursor itself. The evaporated precursor can be delivered into the reaction space by e.g. dosing it through the pipework of the reactor tool comprising flow channels for delivering the vaporized precursors into the reaction space. Controlled dosing of vapour into the reaction space can be realized by valves installed in the flow channels. These valves are commonly called pulsing valves in an ALD system. Also other mechanisms of bringing the sub¬ strate 3 into contact with a precursor inside the re¬ action space may be conceived. One alternative is to make the surface of the substrate 3 (instead of the vaporized precursor) move inside the reaction space such that the substrate 3 moves through a region occu¬ pied by gaseous precursor.
A typical ALD reactor also comprises a system for introducing inert gas, such as nitrogen or argon into the reaction space such that the reaction space can be purged from surplus precursor and reaction byproducts before introducing the next precursor into the reaction space. This feature together with the controlled dosing of vaporized precursors enables al¬ ternately exposing the surface to precursors without significant intermixing of different precursors in the reaction space or in other parts of the ALD reactor. In practice the flow of inert gas is commonly continu¬ ous through the reaction space throughout the deposi¬ tion process and only the various precursors are al- ternately introduced to the reaction space with the inert gas. Obviously, purging of the reaction space does not necessarily result in complete elimination of surplus chemicals or reaction by-products from the re¬ action space but residues of these or other materials may always be present.
Following the step of various preparations (step P) discussed above) , in the embodiment of the present invention illustrated in Fig. 1, step al) is carried out in order to start the growth of the layer of first material 1 onto the substrate. In this em¬ bodiment of the invention the first material is alumi- num oxide and the second material is titanium oxide. The exact composition and phase of the aluminum oxide and titanium oxide can vary. These materials may obvi¬ ously also include impurities although their concen¬ tration remains relatively low as a result of the growth method.
In step al) gaseous trimethylaluminum is introduced to the reaction space and thereby the surface of the substrate 3 is exposed to trimethylaluminum. Exposure of the surface to trimethylaluminum results, in suitable process conditions discussed below, in the adsorption of a portion of the introduced trimethylaluminum onto the surface. After purging of the reac¬ tion space from trimethylaluminum water vapor is introduced to the reaction space and thereby the surface of the substrate, which in this case has the adsorbed portion of the trimethylaluminum precursor adsorbed onto it, is exposed to water (step bl)), some of which in turn gets adsorbed onto the surface. The reaction space is subsequently purged from the water.
Thickness of the resulting aluminum oxide film on the substrate 3 can be increased by repeating the steps al) and bl), in this order, as presented by the flow-chart of Fig. 1. In this embodiment of the invention the number of how many times the steps al) and bl) are repeated depends on the targeted film thickness and on the growth rate of the aluminum oxide film under the specific process conditions. The tar- geted thickness for the layer of first material 1 in this embodiment of the invention is below 25 nano¬ metres (nm) .
After the layer of first material 1 has been grown to the desired film thickness the deposition of the layer of second material 2 is started onto the layer of first material 1. The growth of the layer of second material 2 starts with step a2), where titanium tetrachloride is introduced to the reaction space. Ex- posure of the surface to titanium tetrachloride re¬ sults, in suitable process conditions discussed below, in the adsorption of a portion of the introduced va¬ porized titanium tetrachloride onto the deposition surface. After purging of the reaction space from ti- tanium tetrachloride vaporized water is introduced to the reaction space and thereby the surface of the sub¬ strate, which in this case has the adsorbed portion of the titanium tetrachloride precursor adsorbed onto it, is exposed to water (step b2)), some of which in turn gets adsorbed onto the deposition surface. The reac¬ tion space is subsequently purged from the water.
Thickness of the resulting titanium oxide film on the aluminum oxide film can be increased by repeating the steps a2) and b2), in this order, as presented by the flow-chart of Fig. 1. In this embodi¬ ment of the invention the number of how many times the steps a2) and b2) are repeated depends on the targeted film thickness and on the growth rate of the titanium oxide film under the specific process conditions. The targeted thickness for the layer of second material 2 in this embodiment of the invention is below 25 nano¬ metres (nm) .
The embodiment of the invention presented in Fig. 1 results in a multilayer coating on a substrate 3. This coating is presented in Fig. 2, which also presents an optional layer of other material 4 which may be grown in between the substrate 3 and the multi- layer coating during the preparation step P) . In the multilayer coating, a layer of titanium oxide second material 2 resides on a layer of aluminum oxide first material 1. By suitably choosing the chemicals and the process parameters utilized to deposit the layer of first material 1 and the layer of second material 2 the adsorption reactions responsible for film-growth exhibit self-limiting characteristics, and the confor- mality, the homogeneity and the barrier properties of the individual layers and of the whole multilayer coating can be further improved.
In Fig. 3 is presented a multilayer coating on a substrate 3 according to one embodiment of the present invention. In fig. 3 the interfacial region 5 formed in between titanium oxide 2 and aluminum oxide 1 is presented.
The following example describes in detail how the multilayer coating can be grown on the substrate 3.
EXAMPLE
According to the embodiment of the invention presented in Fig. 1 multilayer coatings were formed on Ca-substrates (Calcium substrates) . The substrates were first inserted inside the reaction space of a P400A ALD tool (available from Beneq OY, Finland) . The Ca-substrates were planar to enable reliable permea¬ tions rate measurements. In this example the inert gas discussed above and responsible for purging the reac¬ tion space was nitrogen (N2) .
In this example Ca-substrates were used. How¬ ever, in an equal manner any other suitable substrate material could be used.
After preparations for loading the sub¬ strates into the ALD tool, the reaction space of the ALD tool was pumped down to the processing pressure of about 1 mbar and the substrates were subsequently heated to the processing temperature of about 100 °C . The temperature was stabilized to the processing tem¬ perature inside the reaction space by a computer con- trolled heating period of two to four hours.
After the processing temperature was reached and stabilized, the surface of the substrate 3 was ex¬ posed to an ozone treatment and a thin conditioning layer 4 of aluminum oxide was subsequently grown from trimethylaluminum and water, on the substrate 3. After this the method moved from step P) to the step al), according to Fig. 1. The pulsing sequence of al) then bl) was carried out once and then repeated 53 times to form a first layer of aluminum oxide with a thickness of approximately 5 nm on the substrate. After this layer was formed the process moved to step a2) and subsequently to step b2) . The pulsing sequence of a2) then b2) was carried out once and then repeated 110 times to form a layer of titanium oxide with a thick- ness of approximately 5 nm on the layer of first mate¬ rial 1 (aluminum oxide) .
In this example the aforementioned structure of a 5 nm thick titanium oxide layer on a 5 nm thick aluminum oxide layer was grown ten times altogether, to form a multilayer coating consisting of the 10 layers of first material 1 and the 10 layers of second material 2. Hence, this structure comprised 19 inter¬ faces between aluminum oxide and titanium oxide in a multilayer coating having a total thickness of only about 100 nm, which resulted in surprisingly efficient diffusion barrier properties in view of the total thickness of the layer, as will be discussed subse¬ quently. After the growth of this multilayer coating the growth process was ended, after which heating of the reaction space was turned off and the substrates were ejected from the reaction space and from the ALD- tool . Exposure of the surface of the substrate 3 to a specific precursor was carried out by switching on the pulsing valve of the P400 ALD-tool controlling the flow of the precursor into the reaction space. Purging of the reaction space was carried out by closing the valves controlling the flow of precursors into the re¬ action space, and thereby letting only the continuous flow of inert gas flow through the reaction space.
The pulsing sequence in this example for the aluminum oxide layer was in detail as follows; 0.6 s exposure to trimethylaluminum, 1.0 s purge, 0.6 s ex¬ posure to ¾0, 5 s purge. The pulsing sequence in this example for the titanium oxide layer was in detail as follows; 0.6 s exposure to titanium tetrachloride, 1.0 s purge, 0.6 s exposure to H20, 3 s purge. An exposure time and a purge time in this sequence signify a time a specific pulsing valve for a specific precursor was kept open and a time all the pulsing valves for pre¬ cursors were kept closed, respectively. In this exam- pie the aluminum oxide and the titanium oxide layers were formed at a processing temperature of about 100 °C at which temperature the aluminum oxide layers and the titanium oxide layers grew essentially amorphous. This further helped reducing grain boundaries, dislo- cations and other defects mostly associated with crys¬ talline materials.
The permeations rate for the grown multilayer coatings were measured in an environment having a relative humidity of 80% and a temperature of 80 °C. The testing procedure followed the widely used "80/80"-test in which the Ca-substrate immediately re¬ acted with water that diffused from the humid environ¬ ment into contact with the Ca-substrate through the multilayer coating. The details of the "80/80"-test will be obvious for a skilled person. Results indi¬ cated a surprisingly low permeations rate for the ex¬ emplary multilayer coating. The measured value of per- meation of water through the coating, i.e. the permeations rate for water, was about 0.8 g/ (m2day) (grams of water through one square meter of coating in one day) . The pulsing sequence and the process parameters used in the example additionally contributed to the resulting very conformal and uniform films over large areas of the substrate 3 surface and even over complex non-planar surfaces.
Although the permeations rate for the exem¬ plary structure was measured for water, low permea¬ tions rates were observed also for other species, for e.g. oxygen, and the multilayer coatings were generally observed to minimize diffusion of atoms through the coating.
As is clear for a person skilled in the art, the invention is not limited to the examples described above but the embodiments can freely vary within the scope of the claims.

Claims

1. A method for fabricating a multilayer coating on a substrate (3) , the coating being arranged to minimize diffusion of atoms through the coating, the method comprising the steps of introducing a sub¬ strate (3) to a reaction space, depositing a layer of first material (1) on the substrate (3), and deposit¬ ing a layer of second material (2) on the layer of first material (1) , characteri zed in that de- positing the layer of first material (1) comprises the steps of,
- introducing a first precursor into the reaction space such that at least a portion of the first precursor adsorbs onto the surface of the substrate (3) and subse¬ quently purging the reaction space, and
- introducing a second precursor into the reaction space such that at least a portion of the second precursor reacts with the first precursor adsorbed onto the surface of the substrate (3) and subsequently purg¬ ing the reaction space;
depositing the layer of second material (2) comprises the steps of,
- introducing a third precursor into the reaction space such that at least a portion of the third precursor adsorbs onto the surface of the layer of first material (1) and subsequently purging the reaction space, and
- introducing a fourth precursor into the reaction space such that at least a portion of the fourth precursor reacts with the third precursor adsorbed onto the surface of the layer of first material (1) and sub¬ sequently purging the reaction space; the first material being selected from the group of titanium oxide and aluminum oxide, the second material being the other from the group of titanium oxide and aluminum oxide, and in that an interfacial region is formed in between titanium oxide and aluminum oxide.
2. The method of claim 1, characteri zed in that the method comprises the step of de¬ positing another layer of first material (1) onto a layer of second material (2), to form a second inter- facial region between titanium oxide and aluminum oxide .
3. The method of any one of claims 1 - 2, characteri zed in that the method comprises forming two or more interfacial regions in the multi- layer coating.
4. The method of any one of claims 1 - 3, characteri zed in that the second material is titanium oxide.
5. The method of any one of claims 1 - 4, characteri zed in that a layer of titanium ox¬ ide is deposited by selecting the first precursor or the third precursor from the group of water and tita¬ nium tetrachloride, while the second precursor or the fourth precursor are the other from the group of water and titanium tetrachloride, respectively.
6. The method of any one of claims 1 - 5, characteri zed in that a layer of aluminum ox¬ ide is deposited by selecting the first precursor or the third precursor from the group of water and trimethylaluminum, while the second precursor or the fourth precursor are the other from the group of water and trimethylaluminum, respectively.
7. The method of any one of claims 1 - 6, characteri zed in that the method comprises de- positing a layer of first material (1) having suitably a thickness of below 25 nanometres and preferably a thickness of below 10 nanometres, and a layer of sec- ond material (2) having suitably a thickness of below 25 nanometres and preferably a thickness of below 10 nanometres .
8. The method of any one of claims 1 - 7, characteri zed in that the method comprises de¬ positing at a temperature not more than 150 °C .
9. The method of any one of claims 1 - 7, characteri zed in that the method comprises de¬ positing at a temperature not more than 100 °C .
10. The method of any one of claims 1 - 9, characteri zed in that the method comprises fabricating a multilayer coating on a substrate (3) comprising a moisture sensitive device.
11. The method of any one of claims 1 - 9, characteri zed in that the method comprises fabricating a multilayer coating on a substrate (3) comprising polymer.
12. The method of any one of claims 1 - 11, characteri zed in that titanium oxide and alu- minum oxide are in amorphous form.
13. A multilayer coating on a substrate (3), the coating being arranged to minimize diffusion of atoms through the coating, the coating comprising a layer of first material (1) on the substrate (3), and a layer of second material (2) on the layer of first material (1) , characteri zed in that the first material is selected from the group of titanium oxide and aluminum oxide, the second material being the other from the group of titanium oxide and aluminum oxide, and in that the multilayer coating comprises an interfacial region in between titanium oxide and alu¬ minum oxide.
14. The multilayer coating of claim 13, characteri zed in that the coating is fabri- cated by depositing the layer of first material (1) by
- introducing a first precursor into a reaction space such that at least a portion of the first precursor adsorbs onto the sur¬ face of the substrate (3) and subsequently purging the reaction space, and
- introducing a second precursor into the re- action space such that at least a portion of the second precursor reacts with the first precursor adsorbed onto the surface of the substrate (3) and subsequently purg¬ ing the reaction space;
depositing the layer of second material (2) by
- introducing a third precursor into the reaction space such that at least a portion of the third precursor adsorbs onto the surface of the layer of first material (1) and subsequently purging the reaction space, and
- introducing a fourth precursor into the reaction space such that at least a portion of the fourth precursor reacts with the third precursor adsorbed onto the surface of the layer of first material (1) and sub¬ sequently purging the reaction space.
15. The multilayer coating of any one of claims 13 - 14, characteri zed in that the coating comprises another layer of first material (1) on a layer of second material (2), to form a second interfacial region between titanium oxide and aluminum oxide .
16. The multilayer coating of any one of claims 13 - 15, characteri zed in that the mul¬ tilayer coating comprises two or more interfacial re¬ gions .
17. The multilayer coating of any one of claims 13 - 16, characteri zed in that the sec- ond material is titanium oxide.
18. The multilayer coating of any one of claims 13 - 17, characteri zed in that a layer of titanium oxide is deposited by selecting the first precursor or the third precursor from the group of water and titanium tetrachloride, while the second pre¬ cursor or the fourth precursor are the other from the group of water and titanium tetrachloride, respec¬ tively.
19. The multilayer coating of any one of claims 13 - 18, characteri zed in that a layer of aluminum oxide is deposited by selecting the first precursor or the third precursor from the group of water and trimethylaluminum, while the second precursor or the fourth precursor are the other from the group of water and trimethylaluminum, respectively.
20. The multilayer coating of any one of claims 13 - 19, characteri zed in that a layer of first material (1) has suitably a thickness of be¬ low 25 nanometres and preferably a thickness of below 10 nanometres, and a layer of second material (2) has suitably a thickness of below 25 nanometres and pref- erably a thickness of below 10 nanometres.
21. The multilayer coating of any one of claims 13 - 20, characteri zed in that the coating is fabricated at a depositing temperature not more than 150 °C .
22. The multilayer coating of any one of claims 13 - 20, characteri zed in that the coating is fabricated at a depositing temperature not more than 100 °C .
23. The multilayer coating of any one of claims 13 - 22, characteri zed in that the sub¬ strate (3) comprises a moisture sensitive device.
24. The multilayer coating of any one of claims 13 - 22, characteri zed in that the sub¬ strate (3) comprises polymer.
25. The multilayer coating of any one of claims 13 - 24, characteri zed in that titanium oxide and aluminum oxide are in amorphous form.
26. Use of the method of claim 1 to fabricate a multilayer coating on a substrate (3) , to minimize diffusion of water from the environment through the coating onto the surface of the substrate (3) .
27. Use of the multilayer coating of claim 13 on a substrate (3) , to minimize diffusion of water from the environment through the coating onto the sur¬ face of the substrate (3) .
28. The use of claim 26 or claim 27, characteri zed in that the substrate comprises poly¬ mer .
29. The use of claim 26 or claim 27, characteri zed in that the substrate comprises a mois¬ ture sensitive device.
PCT/FI2010/050700 2009-09-14 2010-09-13 Multilayer coating, method for fabricating a multilayer coating, and uses for the same WO2011030004A1 (en)

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CN201080040851.9A CN102575345B (en) 2009-09-14 2010-09-13 Multilayer coating, method for fabricating a multilayer coating, and uses for the same
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