WO2015068564A1 - スパッタリングターゲット - Google Patents
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- WO2015068564A1 WO2015068564A1 PCT/JP2014/077948 JP2014077948W WO2015068564A1 WO 2015068564 A1 WO2015068564 A1 WO 2015068564A1 JP 2014077948 W JP2014077948 W JP 2014077948W WO 2015068564 A1 WO2015068564 A1 WO 2015068564A1
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- 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
- wet mixing means a mixing method in which raw material powder is mixed using a liquid such as water or alcohol as a dispersion medium. When wet mixing is performed, mixing of the raw material powder becomes good, and a target having a uniform composition is obtained. In dry mixing in which the raw material powder is mixed without using a dispersion medium, the aggregation of the raw material powder is difficult to loosen, and it is difficult to obtain a uniform mixed state of the raw material powder. The compound having a high bulk resistance is likely to be generated.
- a molded body is produced by a slip casting method, a method of spray-drying the slurry to produce granules, filling the granules into a mold, and press-molding. These methods will be described later.
- the median diameter (D50) of each raw material powder is 5 ⁇ m or less.
- the median diameter (D50) of indium oxide powder, gallium oxide powder, and zinc oxide powder is preferably 5 ⁇ m or less.
- the median diameter (D50) is more preferably 2 ⁇ m or less, and further preferably 1 ⁇ m or less.
- the lower limit of the median diameter (D50) is not particularly limited, but is usually 0.3 ⁇ m.
- the difference in median diameter (D50) between the raw material powders is preferably 2 ⁇ m or less.
- the difference in median diameter (D50) between indium oxide powder and gallium oxide powder, the difference in median diameter (D50) between indium oxide powder and zinc oxide powder, and the median diameter (D50) between gallium oxide powder and zinc oxide powder It is preferable that all the differences are 2 ⁇ m or less.
- the difference in the median diameter (D50) is more preferably 1 ⁇ m or less, and further preferably 0.5 ⁇ m or less. Most preferably, there is no difference in the median diameter (D50), that is, the median diameters (D50) of the raw material powders are all the same.
- slip Casting Method In the slip casting method, a slurry containing the mixed powder and the organic additive is prepared, the slurry is poured into a mold, and then drained and molded.
- organic additive examples include a binder and a dispersant.
- a 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 mixed 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 obtained slurry is spray-dried to produce a dry powder having a moisture content of 1% or less, filled in a mold, and pressed by a uniaxial press or an isostatic press to form a molded body.
- step 2 the molded body obtained in step 1 is fired to produce a fired body.
- a baking furnace The baking furnace conventionally used for manufacture of a ceramic target material can be used.
- ⁇ Sputtering conditions Equipment: DC magnetron sputtering equipment, exhaust system cryopump, rotary pump Ultimate vacuum: 3 ⁇ 10 ⁇ 4 Pa Sputtering pressure: 0.4 Pa Oxygen partial pressure: 4 ⁇ 10 -2 Pa
- the surface of the target after sputtering was photographed, and by image analysis, the ratio (%) of the area of the nodule on the target surface to the area of the target surface was defined as the nodule amount. Further, this nodule amount was evaluated according to the following criteria A to D from the smaller area ratio.
- the obtained fired body was cut to obtain a sputtering target having a surface roughness Ra of 0.7 ⁇ m, a diameter of 152.4 mm, and a thickness of 6 mm.
- a # 170 grindstone was used for processing.
- Example 3 A dry powder was obtained in the same manner as in Example 2.
- Example 4 A zinc oxide powder having a median diameter (D50) of 3.2 ⁇ m, an indium oxide powder having a median diameter (D50) of 2.5 ⁇ m, and a gallium oxide powder having a median diameter (D50) of 4.5 ⁇ m in the pot Then, a ball mill was dry-mixed with zirconia balls to prepare a mixed powder.
- Example 1 The obtained molded body was fired and processed in the same manner as in Example 1 to obtain a sputtering target having the same dimensions as in Example 1.
- a 0.2 wt% PVA binder was mixed with the mixed powder, filled in a mold without wet mixing, and pressed with a uniaxial press of 800 kgf / cm 2 to obtain a molded body.
- the obtained compact was fired and processed in the same manner as in Example 1 to obtain a sputtering target having the same dimensions as in Example 1.
- Example 1 The obtained molded body was fired and processed in the same manner as in Example 1 to obtain a sputtering target having the same dimensions as in Example 1.
- the relative density of the sputtering target, the mass ratio of the dissolved residue, and the amount of nodules were determined by the above method. The results are shown in Table 1. The result of X-ray diffraction was the same as in FIG.
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Abstract
Description
<スパッタリングターゲットの製造方法>
本発明のスパッタリングターゲットは、たとえば、該ターゲットの製造に必要な複数の原料粉末である酸化インジウム(In2O3)粉末、酸化ガリウム(Ga2O3)粉末、酸化亜鉛(ZnO)粉末、IGZO粉末を混合し、得られた混合原料を成形して成形体を作製し、該成形体を焼成して製造することができる。
工程1では、原料粉末から成形体を作製する。
スリップキャスト方法では、前記混合粉末および有機添加物を含有するスラリーを調製し、このスラリーを型に流し込み、次いで排水して成形する。
スラリーを噴霧乾燥する方法では、前記混合粉末および有機添加物を含有するスラリーを調製し、このスラリーを噴霧乾燥して得られた乾燥粉末を型に充填して加圧成形する。
工程2では、工程1で得られた成形体を焼成し、焼成体を作製する。焼成炉には特に制限はなく、セラミックスターゲット材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3では、工程2で得られた焼成体を切削加工し、スパッタリングターゲットを作製する。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。
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文字(g/cm3)に対する百分率の値を相対密度(単位:%)とした。
2.溶解残渣
スパッタリングターゲットを3cm角以下に破砕した試料4kgを、80℃の28質量%塩酸10kgに、温度を80℃に保持し、撹拌しながら24時間浸漬した。24時間浸漬した時点で試料の溶解は進行していないことを確認した。得られた残渣含有液をろ過して、溶解残渣を回収し、100℃で24時間乾燥して、その質量を測定した。浸漬した試料の質量に対する溶解残渣の質量の比率(溶解残渣の質量比(%))を求めた。
3.原料粉末のメジアン径(D50)
原料粉末のメジアン径(D50)は日機装株式会社製レーザー回折・散乱式粒度分布測定装置(HRA9320-X100)を用いて測定した。溶媒は水を使用し、測定物質の屈折率2.20で測定した。
4.ノジュール量
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(%)をノジュール量とした。また、このノジュール量を面積比率の少ない方から下記のA~Dの判定基準で評価した。
B:3%以上6%未満
C:6%以上9%未満
D:9%以上
ノジュール量が少ないほど好適なスパッタリング膜が形成出来ていると評価できる。AまたはB判定となったターゲットはノジュール量が少なく、生成された膜の大面積での均一性、膜質、導電率、透光性等の膜特性が良好となる。従って、AまたはB判定となったターゲットであれば従来よりも歩留り良く、効率的に酸化物半導体膜を得ることができるといえる。
[実施例1]
メジアン径(D50)が0.8μmである酸化亜鉛粉末と、メジアン径(D50)が0.6μmである酸化インジウム粉末と、メジアン径(D50)が2μmである酸化ガリウム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乾式混合して、混合粉末を調製した。混合粉末における酸化インジウム粉末の含有量は44.2質量%、酸化亜鉛粉末の含有量は25.9質量%、酸化ガリウム粉末の含有量は29.9質量%であった。この配合比により、実質的に溶解残渣以外の部分の組成がInGaZnO4である単相構造のスパッタリングターゲットが得られる。
[実施例2]
実施例1と同様に乾式混合して混合粉末を調製した。
[実施例3]
実施例2と同様にして乾燥粉末を得た。
[実施例4]
メジアン径(D50)が3.2μmである酸化亜鉛粉末と、メジアン径(D50)が2.5μmである酸化インジウム粉末と、メジアン径(D50)が4.5μmである酸化ガリウム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乾式混合して、混合粉末を調製した。混合粉末における酸化インジウム粉末の含有量は44.2質量%、酸化亜鉛粉末の含有量は25.9質量%、酸化ガリウム粉末の含有量は29.9質量%であった。この配合比により、実質的に溶解残渣以外の部分の組成がInGaZnO4である単相構造のスパッタリングターゲットが得られる。
[比較例1]
実施例1と同様に乾式混合して混合粉末を調製した。
[比較例2]
メジアン径(D50)が7.2μmである酸化亜鉛粉末と、メジアン径(D50)が8.5μmである酸化インジウム粉末と、メジアン径(D50)が7.5μmである酸化ガリウム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乾式混合して、混合粉末を調製した。混合粉末における酸化インジウム粉末の含有量は44.2質量%、酸化亜鉛粉末の含有量は25.9質量%、酸化ガリウム粉末の含有量は29.9質量%であった。
[比較例3]
メジアン径(D50)が0.8μmである酸化亜鉛粉末と、メジアン径(D50)が0.6μmである酸化インジウム粉末と、メジアン径(D50)が4.5μmである酸化ガリウム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乾式混合して、混合粉末を調製した。混合粉末における酸化インジウム粉末の含有量は44.2質量%、酸化亜鉛粉末の含有量は25.9質量%、酸化ガリウム粉末の含有量は29.9質量%であった。
Claims (5)
- In、GaおよびZnの酸化物からなるスパッタリングターゲットであって、80℃の28質量%塩酸に、該塩酸に対し40質量%の量の前記スパッタリングターゲットを24時間浸漬したときに得られる溶解残渣の、前記浸漬したスパッタリングターゲットに対する質量比が0.5質量%以下であるスパッタリングターゲット。
- スパッタリングターゲットの製造原料である複数の原料粉末の混合を湿式で行い、得られた混合原料を成形して成形体を作製し、該成形体を焼成して製造された請求項1に記載のスパッタリングターゲット。
- 前記複数の原料粉末のメジアン径(D50)が5μm以下であり、さらに前記各原料粉末相互のメジアン径(D50)の差が2μm以下である請求項2に記載のスパッタリングターゲット。
- 前記溶解残渣以外の部分が単相構造である請求項1~3のいずれかに記載のスパッタリングターゲット。
- 前記溶解残渣以外の部分の組成がInGaZnO4である請求項4に記載のスパッタリングターゲット。
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WO2019244509A1 (ja) * | 2018-06-19 | 2019-12-26 | 三井金属鉱業株式会社 | 酸化物焼結体およびスパッタリングターゲット |
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