WO2015068535A1 - スパッタリングターゲットおよびその製造方法 - Google Patents
スパッタリングターゲットおよびその製造方法 Download PDFInfo
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- WO2015068535A1 WO2015068535A1 PCT/JP2014/077288 JP2014077288W WO2015068535A1 WO 2015068535 A1 WO2015068535 A1 WO 2015068535A1 JP 2014077288 W JP2014077288 W JP 2014077288W WO 2015068535 A1 WO2015068535 A1 WO 2015068535A1
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- WIPO (PCT)
- Prior art keywords
- powder
- sputtering target
- content
- raw material
- zinc oxide
- Prior art date
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- 238000005477 sputtering target Methods 0.000 title claims abstract description 69
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 24
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims abstract description 195
- 239000011787 zinc oxide Substances 0.000 claims abstract description 95
- 239000011701 zinc Substances 0.000 claims abstract description 65
- 239000002994 raw material Substances 0.000 claims abstract description 63
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 62
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 60
- 238000004544 sputter deposition Methods 0.000 abstract description 24
- 230000015572 biosynthetic process Effects 0.000 abstract 2
- 239000000843 powder Substances 0.000 description 99
- 239000000919 ceramic Substances 0.000 description 34
- 238000000034 method Methods 0.000 description 33
- 238000004438 BET method Methods 0.000 description 15
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 11
- 238000010304 firing Methods 0.000 description 11
- 238000010438 heat treatment Methods 0.000 description 11
- 229910005191 Ga 2 O 3 Inorganic materials 0.000 description 10
- 239000002002 slurry Substances 0.000 description 10
- 230000000052 comparative effect Effects 0.000 description 9
- 239000011230 binding agent Substances 0.000 description 7
- 238000000465 moulding Methods 0.000 description 7
- 239000006259 organic additive Substances 0.000 description 7
- 239000010409 thin film Substances 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 6
- 239000000470 constituent Substances 0.000 description 6
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 5
- 238000001035 drying Methods 0.000 description 5
- 238000002156 mixing Methods 0.000 description 5
- 239000001301 oxygen Substances 0.000 description 5
- 229910052760 oxygen Inorganic materials 0.000 description 5
- 238000012545 processing Methods 0.000 description 5
- 238000006467 substitution reaction Methods 0.000 description 5
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 4
- 239000002270 dispersing agent Substances 0.000 description 4
- 239000002612 dispersion medium Substances 0.000 description 4
- 239000010408 film Substances 0.000 description 4
- 229910052738 indium Inorganic materials 0.000 description 4
- 239000011812 mixed powder Substances 0.000 description 4
- 230000003746 surface roughness Effects 0.000 description 4
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 3
- 238000001354 calcination Methods 0.000 description 3
- 239000000839 emulsion Substances 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 229910052733 gallium Inorganic materials 0.000 description 3
- 229910052602 gypsum Inorganic materials 0.000 description 3
- 239000010440 gypsum Substances 0.000 description 3
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 description 3
- 229920005646 polycarboxylate Polymers 0.000 description 3
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- QGZKDVFQNNGYKY-UHFFFAOYSA-N ammonia Natural products N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- 235000019270 ammonium chloride Nutrition 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 238000009694 cold isostatic pressing Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000004973 liquid crystal related substance Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 229910000679 solder Inorganic materials 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 238000007088 Archimedes method Methods 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 description 1
- JODIJOMWCAXJJX-UHFFFAOYSA-N [O-2].[Al+3].[O-2].[Zn+2] Chemical compound [O-2].[Al+3].[O-2].[Zn+2] JODIJOMWCAXJJX-UHFFFAOYSA-N 0.000 description 1
- 239000006061 abrasive grain Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000000498 ball milling Methods 0.000 description 1
- FFBHFFJDDLITSX-UHFFFAOYSA-N benzyl N-[2-hydroxy-4-(3-oxomorpholin-4-yl)phenyl]carbamate Chemical compound OC1=C(NC(=O)OCC2=CC=CC=C2)C=CC(=C1)N1CCOCC1=O FFBHFFJDDLITSX-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- AJNVQOSZGJRYEI-UHFFFAOYSA-N digallium;oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Ga+3].[Ga+3] AJNVQOSZGJRYEI-UHFFFAOYSA-N 0.000 description 1
- 238000005401 electroluminescence Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 229910001195 gallium oxide Inorganic materials 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 238000010191 image analysis Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910003437 indium oxide Inorganic materials 0.000 description 1
- PJXISJQVUVHSOJ-UHFFFAOYSA-N indium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[In+3].[In+3] PJXISJQVUVHSOJ-UHFFFAOYSA-N 0.000 description 1
- 238000002354 inductively-coupled plasma atomic emission spectroscopy Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000001755 magnetron sputter deposition Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 239000011164 primary particle Substances 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000013077 target material Substances 0.000 description 1
- 238000003826 uniaxial pressing Methods 0.000 description 1
- 238000001771 vacuum deposition Methods 0.000 description 1
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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/34—Sputtering
- C23C14/3407—Cathode assembly for sputtering apparatus, e.g. Target
- C23C14/3414—Metallurgical or chemical aspects of target preparation, e.g. casting, powder metallurgy
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/08—Oxides
- C23C14/086—Oxides of zinc, germanium, cadmium, indium, tin, thallium or bismuth
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/02104—Forming layers
- H01L21/02107—Forming insulating materials on a substrate
- H01L21/02225—Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer
- H01L21/0226—Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process
- H01L21/02263—Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process deposition from the gas or vapour phase
- H01L21/02266—Forming insulating materials on a substrate characterised by the process for the formation of the insulating layer formation by a deposition process deposition from the gas or vapour phase deposition by physical ablation of a target, e.g. sputtering, reactive sputtering, physical vapour deposition or pulsed laser deposition
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L29/00—Semiconductor devices specially adapted for rectifying, amplifying, oscillating or switching and having potential barriers; Capacitors or resistors having potential barriers, e.g. a PN-junction depletion layer or carrier concentration layer; Details of semiconductor bodies or of electrodes thereof ; Multistep manufacturing processes therefor
- H01L29/66—Types of semiconductor device ; Multistep manufacturing processes therefor
- H01L29/68—Types of semiconductor device ; Multistep manufacturing processes therefor controllable by only the electric current supplied, or only the electric potential applied, to an electrode which does not carry the current to be rectified, amplified or switched
- H01L29/76—Unipolar devices, e.g. field effect transistors
- H01L29/772—Field effect transistors
- H01L29/78—Field effect transistors with field effect produced by an insulated gate
- H01L29/786—Thin film transistors, i.e. transistors with a channel being at least partly a thin film
Definitions
- the present invention relates to a sputtering target and a manufacturing method thereof, and more particularly, to a sputtering target containing zinc oxide having improved sputtering characteristics and a manufacturing method thereof.
- a transparent conductive film typified by an AZO (ZnO—Al 2 O 3 ) thin film has high conductivity and excellent translucency, and is used as a thin film for liquid crystal displays and solar cells.
- Semiconductor films typified by IGZO (In 2 O 3 —Ga 2 O 3 —ZnO) thin films are various displays such as liquid crystal display devices (LCD), electroluminescence display devices (EL), and field emission displays (FED).
- a thin film transistor (TFT) is used as a switching element for driving a display device by applying a driving voltage to the display element.
- TFT thin film transistor
- a method for producing these thin films there are a spray method, a dip method, a vacuum deposition method, a sputtering method, etc., but manufacturing cost, productivity, large area uniformity, film quality, film characteristics (conductivity, translucency, etc.)
- the sputtering method has become the mainstream of the current production technology because the sputtering method is relatively superior in terms of
- the target has a high density and the number of target divisions is small, that is, the number of divided target materials constituting the target is small.
- the metal element which is a constituent element of the target it is not well understood about the influence of the metal element which is a constituent element of the target on the sputtering characteristics.
- Patent Document 1 describes a method of adding metallic zinc to increase the strength of an IZO (In 2 O 3 —ZnO) target.
- Patent Document 2 describes a method in which zinc metal is added to lower the resistance of a zinc oxide based sputtering target.
- An object of the present invention is to provide a sputtering target containing zinc oxide that generates less arcing and nodules during sputtering.
- the present inventors have found that in a sputtering target containing zinc oxide, by making the metallic zinc contained in zinc oxide used as a raw material a certain amount or less, an excellent target with less arcing and nodules can be obtained.
- the present invention has been completed.
- the present invention is a sputtering target containing zinc oxide, produced using a zinc oxide raw material having a metallic zinc content of 100 ppm or less, preferably an oxidation having a metallic zinc content of 10 ppm or less.
- Examples of the sputtering target include AZO made of an oxide of zinc and aluminum and IGZO made of an oxide of zinc, indium and gallium.
- this invention manufactures a sputtering target using the process which reduces content of metallic zinc of a zinc oxide raw material, and the zinc oxide raw material whose content of metallic zinc obtained at the said process is 100 ppm or less. It is a manufacturing method of a sputtering target including a process.
- the step of reducing the content of metallic zinc in the zinc oxide raw material is a step of heat-treating the zinc oxide raw material.
- the sputtering target of the present invention is a sputtering target containing zinc oxide and generates less arcing and nodules during sputtering.
- the sputtering target production method of the present invention can efficiently produce a sputtering target containing zinc oxide and generating less arcing and nodules during sputtering.
- the sputtering target of this invention is a sputtering target containing zinc oxide manufactured using the zinc oxide raw material whose content of metallic zinc is 100 ppm or less.
- the zinc oxide raw material is usually zinc oxide powder.
- the sputtering target of the present invention is usually produced using zinc oxide powder. A specific method for producing the sputtering target of the present invention will be described later.
- the zinc oxide raw material has a metallic zinc content of 100 ppm or less, preferably 10 ppm or less, and more preferably 2 ppm or less.
- ppm means mass ppm (ppmw).
- Zinc oxide powder that can be used as a target raw material is produced by volatilizing high-purity metallic zinc at a high temperature and reacting the zinc vapor with oxygen in the air. At this time, unreacted metallic zinc remains in the zinc oxide powder depending on the reaction conditions.
- a target produced using a zinc oxide raw material containing a large amount of metallic zinc is dotted with portions having a high content of metallic zinc. In addition, these parts are considered to have less oxygen content than other parts. If there is a part with a low oxygen content in the target, the electrical resistance value is locally different from that part only, and uniform sputtering cannot be performed. As a result, arcing and nodules are likely to occur.
- the content of metallic zinc in the zinc oxide raw material is 100 ppm or less, the generation of arcing and nodules can be sufficiently reduced practically.
- the sputtering target of the present invention is preferably a ceramic sputtering target.
- the type and composition ratio of the ceramic are not particularly limited, and examples include aluminum oxide-zinc oxide (AZO), indium oxide-gallium oxide-zinc oxide (IGZO), and the like.
- the ceramic sputtering target is manufactured from a zinc oxide raw material and other metal oxide raw materials necessary for producing the ceramic.
- the target is usually manufactured from zinc oxide powder and aluminum oxide powder.
- the target is usually manufactured from zinc oxide powder, indium oxide powder, and gallium oxide powder.
- zinc oxide raw materials may contain metallic zinc, and other raw materials are substantially free of metallic zinc.
- the sputtering target of the present invention is an AZO sputtering target
- the Al content is 0.1 to 10% by mass in terms of Al 2 O 3
- the Zn content is 90 to 99.9% by mass in terms of ZnO.
- the ones are common.
- a target becomes low resistance in content of Al and Zn in the said range.
- the sputtering target of the present invention is an IGZO sputtering target
- the In content is 43.7 to 44.7% by mass in terms of In 2 O 3
- the Ga content is in terms of Ga 2 O 3 . 29.2 to 30.6% by mass, the balance being ZnO and inevitable impurities.
- TFT Thin Film Transistor
- the shape of the sputtering target of the present invention includes a plate shape and a cylindrical shape.
- the sputtering target of the present invention can be used for sputtering by bonding to a substrate using a low melting point solder by a conventional method.
- the sputtering target of the present invention generates less arcing and nodules during sputtering. It should be noted that the occurrence of arcing during sputtering and the generation of nodules are in a parallel relationship, and it can be evaluated that the occurrence of arcing is small if the generation of nodules is small.
- the sputtering target can be manufactured according to a conventionally known manufacturing method. That is, it can be produced by molding raw material powder and firing the obtained molded body. As the molding method, for example, the following casting method can be used.
- a molding method a method of obtaining a molded body by uniaxial pressing of a dried and granulated raw material, a method of molding by CIP molding (Cold Isostatic Pressing), or the like is also used. Can do.
- a method of manufacturing a flat ceramic sputtering target using a casting method will be described. This manufacturing method can also be applied to a cylindrical target.
- a slurry containing a ceramic raw material powder and an organic additive is poured into a mold, and then drained and molded to produce a molded body, Step 1 for drying the molded body, Step 2 for drying the molded body, and the dried It is a manufacturing method including the step 3 for obtaining a fired body by firing the molded body and the step 4 for obtaining a target by processing the fired body.
- Process 1 a slurry containing ceramic raw material powder and an organic additive is poured into a mold, and then drained and molded to produce a molded body.
- Ceramic raw material powder contains zinc oxide powder.
- the metallic zinc content of this zinc oxide powder is 100 ppm or less.
- step 1 Before step 1, a step of reducing the content of metallic zinc of the zinc oxide raw material can be performed. As described above, the smaller the content of metallic zinc in the zinc oxide raw material, the lower the generation of arcing and nodules. Therefore, before step 1, the metallic zinc content in the zinc oxide raw material is reduced. It is effective to carry out the process. By performing this step, step 1 can be performed after further reducing the metallic zinc content of the zinc oxide raw material having a metallic zinc content of 100 ppm or less. Further, when the content of metallic zinc in the zinc oxide raw material is more than 100 ppm, Step 1 can be performed after the content of metallic zinc in the zinc oxide raw material is reduced to 100 ppm or less.
- the method for reducing the content of metallic zinc in the zinc oxide raw material is not particularly limited, but the method of heat treating the zinc oxide raw material, that is, the so-called calcination method is the most effective.
- the heat treatment is usually performed in the atmosphere, and the heat treatment temperature is usually 800 to 1200 ° C., preferably 800 to 1000 ° C. When the heat treatment temperature is lower than 800 ° C., the reduction of metallic zinc does not proceed efficiently. On the other hand, when the heat treatment temperature is higher than 1200 ° C., primary particles grow and the specific surface area decreases, resulting in insufficient sintering after molding. Thus, the density of the sintered body may decrease.
- the heat treatment time is usually 3 to 12 hours, preferably 5 to 8 hours. The degree to which the content of metallic zinc is reduced can be appropriately adjusted by the heat treatment temperature, the heat treatment time, and the like.
- the ceramic is AZO
- a mixed powder of Al 2 O 3 powder and ZnO powder can be used as the ceramic raw material powder, and an AZO powder may be used in combination.
- the Al 2 O 3 powder, ZnO powder and AZO powder each have a specific surface area of usually 1 to 20 m 2 / g measured by the BET method.
- the mixing ratio of the Al 2 O 3 powder, the ZnO powder, and the AZO powder is appropriately determined so that the content of the constituent elements in the target is within the above range.
- the content (mass%) of the Al 2 O 3 powder and ZnO powder in the ceramic raw material powder is finally It has been confirmed that the obtained target can be equated with the Al content (mass%) in the Al 2 O 3 substitution and the Zn content (mass%) in the ZnO substitution.
- the specific surface area is measured by using, for example, a fully automatic specific surface area measuring device (Macsorb (registered trademark) HM HM model-1210, manufactured by Mountec Co., Ltd.), using a mixed gas containing 30% nitrogen and 70% helium as an adsorbed gas, and BET It can be measured by the single point method.
- Macsorb registered trademark
- HM HM model-1210 manufactured by Mountec Co., Ltd.
- BET BET It can be measured by the single point method.
- a mixed powder of In 2 O 3 powder, Ga 2 O 3 powder and ZnO powder can be used as the ceramic raw material powder, and IGZO powder may be used in combination.
- In 2 O 3 powder, Ga 2 O 3 powder, ZnO powder and IGZO powder each have a specific surface area of usually 1 to 20 m 2 / g measured by the BET method.
- the mixing ratio of the In 2 O 3 powder, the Ga 2 O 3 powder, the ZnO powder, and the IGZO powder is appropriately determined so that the content of the constituent elements in the target is within the above-described range.
- each powder and zirconia balls can be placed in a pot and mixed in a ball mill.
- the organic additive is a substance added to suitably adjust the properties of the slurry and the molded body.
- examples of the organic additive include a binder and a dispersant.
- the binder an emulsion-based binder is generally used, and as the dispersant, ammonium polycarboxylate or the like is generally used.
- the dispersion medium used when preparing the slurry containing the ceramic raw material powder and the organic additive is not particularly limited, and can be appropriately selected from water, alcohol and the like according to the purpose.
- the method for preparing the slurry containing the ceramic raw material powder and the organic additive is not particularly limited, and for example, a method in which the ceramic raw material powder, the organic additive and the dispersion medium are put in a pot and ball mill mixed can be used.
- step 2 the molded body formed in step 1 is dried.
- step 3 the dried molded body obtained in step 2 is fired.
- the baking furnace conventionally used for manufacture of the ceramic targets can be used.
- the firing temperature is usually 1250 to 1500 ° C., preferably 1300 ° C. to 1450 ° C., more preferably 1350 ° C. to 1450 ° C.
- the temperature is usually 1300 to 1500 ° C, preferably 1400 ° C to 1450 ° C.
- the firing temperature is too high, the sintered structure of the target is enlarged and easily cracked.
- the fired body obtained in step 3 is cut. Processing is performed using a surface grinder or the like.
- the surface roughness Ra after processing can be controlled by selecting the size of the abrasive grains of the grindstone.
- the value of the surface roughness Ra is preferably 1.5 ⁇ m or less, more preferably 1.0 ⁇ m or less, and most preferably 0.8 ⁇ m or less from the viewpoint of further suppressing the generation of arcing and nodules.
- the evaluation methods for the relative density and the presence or absence of nodules of the sputtering targets obtained in the examples and comparative examples are as follows.
- the evaluation results for the AZO sputtering target (Examples 1 to 6, Comparative Examples 1 and 2) are shown in Table 1, and the evaluation results for the IGZO sputtering target (Examples 7 to 9 and Comparative Examples 3 and 4) are shown in Table 2.
- Tables 1 and 2 show the content of the metal oxide powder contained in the ceramic raw material powders prepared in the examples and comparative examples, and the metallic zinc content of the ZnO powder used in the examples and comparative examples. .
- the measuring method of metallic zinc content of ZnO powder is as mentioned later. 1.
- Relative density The relative density of the sputtering target was measured based on the Archimedes method. Specifically, the air weight of the sputtering target is divided by the volume (the weight of the sputtering target in water / the specific gravity of water at the measurement temperature), and the percentage value with respect to the theoretical density ⁇ (g / cm 3 ) based on the following formula (X) is obtained. Relative density (unit:%) was used.
- Metallic zinc content of ZnO powder 10 g of ZnO powder was weighed into a beaker, 100 ml of 10% ammonium chloride solution and 20 ml of aqueous ammonia were added and dissolved by heating. After allowing to stand, the liquid was discarded, and 100 ml of 10% ammonium chloride solution and 20 ml of aqueous ammonia were added to the residue and dissolved by heating. The above process was repeated 5 times or more until ZnO was completely dissolved. The final residue was washed with pure water, filtered, dissolved in hydrochloric acid, made up to a volume of 10 ml, and quantitatively analyzed by ICP-AES. This quantitative value corresponds to the metallic zinc content in the ZnO powder.
- Example 1 The content of metallic zinc is less than 2ppm, Al 2 O 3 powder is a ZnO powder specific surface area measured by the BET method is 4m 2 / g, the measured specific surface area by the BET method 5 m 2 / g Were mixed by ball milling with zirconia balls in a pot to prepare a ceramic raw material powder.
- the content of Al 2 O 3 powder in the ceramic raw material powder was 5% by mass, and the content of ZnO powder was 95% by mass.
- the obtained molded body was dried at 25 ° C. for 48 hours and then fired to produce a fired body. Firing was performed at a firing temperature of 1400 ° C., a firing time of 10 hours, a heating rate of 300 ° C./h, and a cooling rate of 50 ° C./h.
- Example 2 to 4 were all the same as Example 1 except that the content of Al 2 O 3 powder in the ceramic raw material powder was changed as shown in Table 1 and the remainder was changed to ZnO powder.
- An AZO sputtering target having the same dimensions as 1 was produced.
- Example 5 instead of the ZnO powder in Example 1, the same procedure as in Example 1 was used except that a ZnO powder having a metallic zinc content of 97 ppm and a specific surface area measured by the BET method of 3 m 2 / g was used. An AZO sputtering target having the same dimensions as in Example 1 was manufactured. [Example 6] A ZnO powder having a metallic zinc content of 200 ppm and a specific surface area measured by the BET method of 3 m 2 / g was calcined at 800 ° C. for 5 hours in the air. The content of metallic zinc in the ZnO powder after calcination was 32 ppm.
- Example 1 An AZO sputtering target having the same dimensions as in Example 1 was produced in the same manner as in Example 1 except that the calcined ZnO powder was used instead of the ZnO powder in Example 1.
- the same procedure as in Example 1 was used except that a ZnO powder having a metallic zinc content of 200 ppm and a specific surface area measured by the BET method of 4 m 2 / g was used.
- An AZO sputtering target having the same dimensions as in Example 1 was manufactured.
- Example 2 instead of the ZnO powder in Example 1, the same procedure as in Example 1 was used except that a ZnO powder having a metallic zinc content of 1200 ppm and a specific surface area measured by the BET method of 4 m 2 / g was used. An AZO sputtering target having the same dimensions as in Example 1 was manufactured.
- Example 7 The content of metallic zinc is less than 2ppm, In 2 O 3 powder is a ZnO powder specific surface area measured by the BET method is 4m 2 / g, the measured specific surface area by the BET method 7m 2 / g Then, Ga 2 O 3 powder having a specific surface area measured by the BET method of 10 m 2 / g was ball mill mixed with zirconia balls in a pot to prepare a ceramic raw material powder. The content of In 2 O 3 powder in the ceramic raw material powder was 44.2% by mass, the content of ZnO powder was 25.9% by mass, and the content of Ga 2 O 3 powder was 29.9% by mass.
- the obtained molded body was dried at 25 ° C. for 48 hours and then fired to produce a fired body. Firing was performed at a firing temperature of 1400 ° C., a firing time of 10 hours, a heating rate of 300 ° C./h, and a cooling rate of 50 ° C./h.
- Example 8 instead of the ZnO powder in Example 7, the same procedure as in Example 7 was used except that a ZnO powder having a metallic zinc content of 97 ppm and a specific surface area measured by the BET method of 3 m 2 / g was used. An IGZO sputtering target having the same dimensions as in Example 7 was produced.
- Example 9 A ZnO powder having a metallic zinc content of 200 ppm and a specific surface area measured by the BET method of 4 m 2 / g was calcined at 800 ° C. for 5 hours in the air. The content of metallic zinc in the ZnO powder after calcination was 32 ppm.
- An IGZO sputtering target having the same dimensions as in Example 7 was produced in the same manner as in Example 7 except that the calcined ZnO powder was used instead of the ZnO powder in Example 7.
- Example 3 instead of the ZnO powder in Example 7, the same procedure as in Example 7 was used except that a ZnO powder having a metallic zinc content of 200 ppm and a specific surface area measured by the BET method of 4 m 2 / g was used. An IGZO sputtering target having the same dimensions as in Example 7 was produced.
- Example 4 instead of the ZnO powder in Example 7, the same procedure as in Example 7 was used except that a ZnO powder having a metallic zinc content of 1200 ppm and a specific surface area measured by the BET method of 3 m 2 / g was used. An IGZO sputtering target having the same dimensions as in Example 7 was produced.
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Abstract
Description
本発明のスパッタリングターゲットは、金属性亜鉛の含有量が100ppm以下である酸化亜鉛原料を用いて製造された、酸化亜鉛を含有するスパッタリングターゲットである。
<スパッタリングターゲットの製造方法>
前記スパッタリングターゲットは、従来知られている製造方法に従って製造することができる。すなわち原料粉末を成形し、得られた成形体を焼成して製造できる。成形法として例えば次に紹介するキャスト法を用いることができる。ただし、成形法としては、原料を乾燥・造粒したものを一軸プレスして成形体を得る方法や、CIP成形(Cold Isostatic Pressing(冷間等方圧成形))により成形する方法等も用いることができる。ここでは一例として、キャスト法を用いて平板状のセラミックス製スパッタリングターゲットを製造する方法を説明する。この製造方法は円筒形状ターゲットに対しても適用可能である。
(工程1)
工程1では、セラミックス原料粉末および有機添加物を含有するスラリーを型に流し込んで、次いで排水して成形し、成形体を作製する。
(工程2)
工程2では、工程1で成形した成形体を乾燥する。
(工程3)
工程3では、工程2で得られた乾燥された成形体を焼成する。焼成炉には特に制限はなく、セラミックス製ターゲットの製造に従来使用されている焼成炉を使用することができる。
(工程4)
工程4では、工程3で得られた焼成体を切削加工する。加工は、平面研削盤等を用いて行う。加工後の表面粗度Raは、砥石の砥粒の大きさを選定することにより制御することができる。この表面粗度Raの値としては、アーキングやノジュールの発生をさらに抑制する観点から1.5μm以下が好ましく、さらに1.0μm以下が好ましく、0.8μm以下が最も好ましい。
1.相対密度
スパッタリングターゲットの相対密度はアルキメデス法に基づき測定した。具体的には、スパッタリングターゲットの空中重量を体積(スパッタリングターゲットの水中重量/計測温度における水比重)で除し、下記式(X)に基づく理論密度ρ(g/cm3)に対する百分率の値を相対密度(単位:%)とした。
ρ=((C1/100)/ρ1+(C2/100)/ρ2+・・・+(Ci/100)/ρi)-1 ・・・(X)
(式中C1~Ciはそれぞれスパッタリングターゲットの構成物質の含有量(重量%)を示し、ρ1~ρiはC1~Ciに対応する各構成物質の密度(g/cm3)を示す。)
2.ノジュールの有無
スパッタリングターゲットをCu製の基材に、低融点半田としてインジウムを使用して接合し、下記条件でスパッタを行った。
装置:DCマグネトロンスパッタ装置、排気系クライオポンプ、ロータリーポンプ
到達真空度:3×10-4Pa
スパッタ圧力:0.4Pa
酸素分圧:4×10-2Pa
スパッタ後のターゲットの表面を写真撮影し、画像解析により、ターゲット表面の面積に対するターゲット表面におけるノジュールの面積の比率(%)をノジュールの量として評価した。AZOではノジュール量が10.0%以下、IGZOではノジュール量が6.0%以下であると、実用上好適なスパッタリングが実施できていると評価される。
3.ZnO粉末の金属性亜鉛含有量
ビーカーにZnO粉末を10g量り採り、塩化アンモニウム10%液100mlとアンモニア水20mlを加えて加熱溶解した。静置した後、液を捨て、残渣に再び塩化アンモニウム10%液100mlとアンモニア水20mlを加えて加熱溶解した。ZnOが完全に溶解するまで5回以上前記工程を繰り返した。最終残渣を純水にて洗浄し、濾過した後、塩酸にて溶解し10mlに定容してICP-AESにて定量分析を行った。この定量値がZnO粉末中の金属性亜鉛含有量に相当する。
<AZOスパッタリングターゲット>
[実施例1]
金属性亜鉛の含有量が2ppm未満で、BET法により測定された比表面積が4m2/gであるZnO粉末と、BET法により測定された比表面積が5m2/gであるAl2O3粉末とをポット中でジルコニアボールによりボールミル混合して、セラミックス原料粉末を調製した。セラミックス原料粉末におけるAl2O3粉末の含有量は5質量%、ZnO粉末の含有量は95質量%であった。
[実施例2~4]
実施例2~4については、セラミックス原料粉末におけるAl2O3粉末の含有量を表1に示したように変更し、残部をZnO粉末にしたこと以外は全て実施例1と同様して実施例1と同寸法のAZOスパッタリングターゲットを製造した。
[実施例5]
実施例1におけるZnO粉末の替わりに、金属性亜鉛の含有量が97ppmで、BET法により測定された比表面積が3m2/gであるZnO粉末を使用したこと以外は全て実施例1と同様にして実施例1と同寸法のAZOスパッタリングターゲットを製造した。
[実施例6]
金属性亜鉛の含有量が200ppmで、BET法により測定された比表面積が3m2/gであるZnO粉末を、大気中で、800℃で5時間仮焼した。仮焼後のZnO粉末の金属性亜鉛の含有量は32ppmであった。実施例1におけるZnO粉末の替わりに前記仮焼後のZnO粉末を使用したこと以外は全て実施例1と同様にして実施例1と同寸法のAZOスパッタリングターゲットを製造した。
[比較例1]
実施例1におけるZnO粉末の替わりに、金属性亜鉛の含有量が200ppmで、BET法により測定された比表面積が4m2/gであるZnO粉末を使用したこと以外は全て実施例1と同様にして実施例1と同寸法のAZOスパッタリングターゲットを製造した。
[比較例2]
実施例1におけるZnO粉末の替わりに、金属性亜鉛の含有量が1200ppmで、BET法により測定された比表面積が4m2/gであるZnO粉末を使用したこと以外は全て実施例1と同様にして実施例1と同寸法のAZOスパッタリングターゲットを製造した。
<IGZOスパッタリングターゲット>
[実施例7]
金属性亜鉛の含有量が2ppm未満で、BET法により測定された比表面積が4m2/gであるZnO粉末と、BET法により測定された比表面積が7m2/gであるIn2O3粉末と、BET法により測定された比表面積が10m2/gであるGa2O3粉末をポット中でジルコニアボールによりボールミル混合して、セラミックス原料粉末を調製した。セラミックス原料粉末におけるIn2O3粉末の含有量は44.2質量%、ZnO粉末の含有量は25.9質量%、Ga2O3粉末の含有量は29.9質量%であった。
[実施例8]
実施例7におけるZnO粉末の替わりに、金属性亜鉛の含有量が97ppmで、BET法により測定された比表面積が3m2/gであるZnO粉末を使用したこと以外は全て実施例7と同様にして実施例7と同寸法のIGZOスパッタリングターゲットを製造した。
[実施例9]
金属性亜鉛の含有量が200ppmで、BET法により測定された比表面積が4m2/gであるZnO粉末を、大気中で、800℃で5時間仮焼した。仮焼後のZnO粉末の金属性亜鉛の含有量は32ppmであった。実施例7におけるZnO粉末の替わりに前記仮焼後のZnO粉末を使用したこと以外は全て実施例7と同様にして実施例7と同寸法のIGZOスパッタリングターゲットを製造した。
[比較例3]
実施例7におけるZnO粉末の替わりに、金属性亜鉛の含有量が200ppmで、BET法により測定された比表面積が4m2/gであるZnO粉末を使用したこと以外は全て実施例7と同様にして実施例7と同寸法のIGZOスパッタリングターゲットを製造した。
[比較例4]
実施例7におけるZnO粉末の替わりに、金属性亜鉛の含有量が1200ppmで、BET法により測定された比表面積が3m2/gであるZnO粉末を使用したこと以外は全て実施例7と同様にして実施例7と同寸法のIGZOスパッタリングターゲットを製造した。
Claims (6)
- 金属性亜鉛の含有量が100ppm以下である酸化亜鉛原料を用いて製造された、酸化亜鉛を含有するスパッタリングターゲット。
- 金属性亜鉛の含有量が10ppm以下である酸化亜鉛原料を用いて製造された、酸化亜鉛を含有するスパッタリングターゲット。
- AZO製である請求項1または2に記載のスパッタリングターゲット。
- IGZO製である請求項1または2に記載のスパッタリングターゲット。
- 酸化亜鉛原料の金属性亜鉛の含有量を減少させる工程、および前記工程で得られた金属性亜鉛の含有量が100ppm以下である酸化亜鉛原料を用いてスパッタリングターゲットを製造する工程を含むスパッタリングターゲットの製造方法。
- 前記酸化亜鉛原料の金属性亜鉛の含有量を減少させる工程が、酸化亜鉛原料を熱処理する工程である請求項5に記載のスパッタリングターゲットの製造方法。
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