WO2016007214A1

WO2016007214A1 - Magnetic chucking of mask with halbach array

Info

Publication number: WO2016007214A1
Application number: PCT/US2015/029263
Authority: WO
Inventors: Tommaso Vercesi; Zuoqian WANG; John M. White
Original assignee: Applied Materials, Inc.
Priority date: 2014-07-08
Filing date: 2015-05-05
Publication date: 2016-01-14
Also published as: KR20170031175A; JP2017520122A; CN106575633B; CN106575633A; JP6502396B2; KR102279086B1; TW201622055A

Abstract

A processing system for chucking a mask to a substrate is provided. The processing system includes a process chamber and a magnetic chuck disposed in the process chamber. The magnetic chuck includes a chucking surface, one or more rotation mechanisms, and a plurality of magnets oriented in one or more Halbach arrays relative to the chucking surface. Each magnet has a north pole oriented in one of four directions. The one or more rotation mechanisms are coupled to change the direction of the north pole of at least one of the magnets.

Description

MAGNETIC CHUCKING OF MASK WITH HALBACH ARRAY

FIELD

[0001] The embodiments of the present disclosure relate generally to chucking of a mask over a substrate. More particularly, embodiments relate to magnetic chucking of a mask over a substrate using a Halbach array.

BACKGROUND

[0002] Masks are often placed over semiconductor substrates to control which areas of a substrate are processed. The substrates as well as the masks are often held on a substrate support using mechanical force. Conventional mechanical contacts used to hold the substrate and the mask during processing may often result in substrate damage due to the high mechanical force applied. The mechanical force is further applied to hold the mask in place during processing. The conventional mechanical carriers generally hold the substrate at the edges, thus resulting in a highly concentrated physical contact with the edges of the substrate so as to ensure sufficient clamping force applied to securely pick up the substrate. This mechanical contact concentrated at the edges of the substrate inevitably creates contact contamination or physical damage to the substrate.

[0003] Newer processing systems have incorporated alternative mechanisms for chucking the substrate to avoid the above described damage, such as holding the substrate in place using electrostatic force. Electrostatic force can effectively hold the substrate in position during processing while minimizing contact between metal components of the system and the substrate. However, the electrostatic force used for chucking the substrate cannot effectively chuck the mask in position as well.

[0004] Therefore, there is a need for a method and apparatus for positioning and chucking a mask independently of the positioning and chucking of the substrates in a processing system.

SUMMARY

[0005] In one embodiment, a processing system for chucking a mask to a substrate is provided. The processing system includes a process chamber and a magnetic chuck disposed in the process chamber. The magnetic chuck includes a chucking surface, one or more rotation mechanisms, and a plurality of magnets oriented in one or more Halbach arrays relative to the chucking surface. Each magnet has a north pole oriented in one of four directions. The one or more rotation mechanisms are coupled to change the direction of the north pole of at least one of the magnets.

[0006] In another embodiment, a substrate carrier for use in a process chamber is provided. The substrate carrier includes a support base, an electrode assembly, a substrate supporting surface, and a magnetic chuck. The support base is operable to move the substrate carrier into and out of a process chamber. The electrode assembly is disposed on the support base to electrostatically chuck a substrate to the substrate supporting surface. The substrate supporting surface is disposed on the electrode assembly. The magnetic chuck is integrated with the support base. The magnetic chuck includes one or more rotation mechanisms and a plurality of magnets oriented in one or more Halbach arrays relative to the substrate supporting surface. Each magnet has a north pole oriented in one of four directions. The one or more rotation mechanisms are coupled to change the direction of the north pole of at least one of the magnets.

[0007] In another embodiment, a method for chucking a mask to a substrate in a process chamber is provided. The method includes transferring a substrate disposed on a substrate supporting surface of a substrate carrier into a process chamber; chucking a mask to the substrate; depositing a layer through the mask onto the substrate; and moving at least some of a plurality of magnets arranged in one or more Halbach arrays in a magnetic chuck proximate the substrate supporting surface to dechuck the mask from the substrate disposed on the substrate carrier.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] So that the manner in which the above recited features of the embodiments disclosed above can be understood in detail, a more particular description, briefly summarized above, may be had by reference to the following embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments and are therefore not to be considered limiting of its scope to exclude other equally effective embodiments.

[0009] Figures 1A to 1 D show schematic top views illustrating an evaporation source for organic material in use with a magnetic chucking assembly, according to embodiments described herein.

[0010] Figure 2 shows a schematic top view of a deposition apparatus with a magnetic chucking assembly according to embodiments described herein.

[0011] Figure 3 depicts an exploded view of one embodiment of a substrate carrier with integrated electrostatic chuck according to one embodiment.

[0012] Figure 4 depicts a chucking assembly with a magnetic chuck including multiple Halbach arrays, according to one embodiment.

[0013] Figures 5A to 5C depict front schematic views of a magnetic chuck including a Halbach array, according to one embodiment.

[0014] Figures 6A and 6B depict front schematic views of a magnetic chuck including multiple Halbach arrays, according to one embodiment.

[0015] Figure 7 depicts a schematic top view of a magnetic chuck including a Halbach array, according to one embodiment.

[0016] Figure 8 is a process flow diagram, according to one embodiment.

[0017] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.

DETAILED DESCRIPTION

[0018] The present disclosure generally relates to apparatuses for chucking of a mask over a substrate and methods for using the same. A magnetic chuck having one or more Halbach arrays can be integrated into a process chamber or a substrate carrier for use in a process chamber. By incorporating a series of magnets arranged in a Halbach array, the mask can be chucked in position over the substrate in a controlled fashion by moving at least some of the magnets in the Halbach array.

[0019] Figures 1 A to 1 D show top views of an evaporation source 100 in various positions 1 1 -14 in a process chamber 1 10 with respect to a first mask 132a and a second mask 132b, according to embodiments described herein. Process chamber 1 10 could be a vacuum process chamber. According to typical embodiments, the masks 132a, 132b are each provided in a mask frame 131 a, 131 b respectively to hold the masks 132a, 132b in a predetermined position. The movement of the evaporation source 100 between the different positions is indicated by arrows 101 B, 101 C, and 101 D. Figures 1A to 1 D show the evaporation source 100 having an evaporation crucible 104 and a distribution pipe 106. The distribution pipe 106 is supported by a support 102. Further, according to some embodiments, the evaporation crucible 104 can also be supported by the support 102.

[0020] A first substrate 121 a and a second substrate 121 b are provided in the process chamber 1 10. The first substrate 121 a and the second substrate 121 b are supported and chucked by a first substrate carrier 150a and a second substrate carrier 150b respectively. Carriers 150a, 150b are described in further detail with reference to Figure 3 below. The first mask 132a and second mask 132b are provided between each respective substrate 121 a, 121 b and the evaporation source 100. The first mask 132a and second mask 132b are chucked by a first magnetic chuck 151 a and a second magnetic chuck 151 b respectively. The mask chucking assemblies 151 a, 151 b can minimize and reduce the force of contact between each respective substrate 121 a, 121 b and mask 132a, 132b during display manufacturing when compared to traditional mechanical clamping of masks. In some embodiments, each magnetic chuck 151 a, 151 b can be a component of a respective substrate carrier 150a, 150b. In other embodiments, each magnetic chuck 151 a, 151 b can be a separate device relative to the respective substrate carrier 150a, 150b. Mask chucking assemblies 151 a, 151 b are described in further detail with reference to Figures 4 to 7 below.

[0021 ] As illustrated in Figures 1 A to 1 D, organic material is evaporated from the distribution pipe 106 to deposit a layer on the substrates 121 a, 121 b. A spray path 10 indicates the direction the evaporation source 100 is spraying the deposition material as the evaporation source deposits the material on the substrate 121 a (see Figures 1 B and 1 C) and the substrate 121 b (see Figure 1 D). The first mask 132a and the second mask 132b can mask areas of the respective substrates 121 a, 121 b during the deposition.

[0022] In Figure 1A, the evaporation source 100 is shown in the first position 1 1 with the first substrate carriers 150a, 150b holding the respective substrates 121 a, 121 b in position to begin the deposition process. Because the deposition process has not yet begun, the masks 132a, 132b are not chucked and are thus shown spaced apart from the respective substrates 121 a, 121 b.

[0023] In Figure 1 B, the first magnetic chuck 151 a has the first mask 132a chucked in position to contact the substrate 121 a. Although the mask 132a is displayed as being evenly chucked against the first substrate 121 a, certain areas of the mask can be chucked with greater pressure than others. For example, portions of the first mask 132a over areas of the first substrate 121 a currently receiving deposition material from the evaporation source 100 can be chucked with greater pressure than other portions of the first mask 132a. With the first mask 132a in position, a layer of organic material can be deposited on the first substrate 121 a by a translational movement of the evaporation source 100 as indicated by arrow 101 B moving from the first position 1 1 in Figure 1A to the second position 12 in Figure 1 B and then to the third position 13 in Figure 1 C. While the first substrate 121 a is deposited with the layer of organic material through the first mask 132a, the second substrate 121 b, can be exchanged for a new substrate. Figure 1 B shows a second transportation track 124b to aid in exchanging the second substrate 121 b. As the second substrate 121 b is not in position in Figure 1 B, the second substrate carrier 150b and the second magnetic chuck 151 b are not activated for chucking and the mask 132a is shown spaced apart from where the substrate 121 b would fit into second transportation track 124b.

[0024] After the first substrate 121 a has been deposited with the layer of organic material, the distribution pipe 106 of the evaporation source 100 is rotated as indicated by arrow 101 C in Figure 1 C from the third position in Figure 1 C to the fourth position 14 in Figure 1 D. During deposition of the organic material on the first substrate 121 a, the second substrate 121 b is then chucked to the second substrate carrier 150b. The second mask 132b is then positioned and aligned with relation to the second substrate 121 b followed by chucking the second mask 132b to the second magnetic chuck 151 b over the second substrate 121 b. Accordingly, after the rotation shown arrow 101 C in Figure 1 C, the second substrate 121 b can be coated with a layer of organic material through the second mask 132b as indicated by arrow 101 D in Figure 1 D. While the second substrate 121 b is coated with the organic material, the first mask 132a can be unchucked from the first magnetic chuck 151 a. Consequently, the first mask 132a is shown spaced apart from a first transportation track 124a that is used to aid in exchanging the first substrate 121 a for a new substrate. With the first mask 132a being unchucked, the first substrate 121 a can then be removed from the chamber 1 10.

[0025] According to embodiments described herein, the first substrate 121 a and second substrate 121 b are coated with organic material in a substantially vertical position. As mentioned above, Figures 1A to 1 D are top views of the process chamber 1 10 and of the corresponding devices in the process chamber 1 10, such as the evaporation source 100. The distribution pipe 106 can be a vapor distribution showerhead, and in some embodiments distribution pipe 106 can be a linear vapor distribution showerhead. Thereby, the distribution pipe 106 can provide a line source extending essentially vertically. According to embodiments described herein, "essentially vertically" refers primarily to the substrate orientation and allows for a deviation from the vertical direction of 10 degrees or less. This deviation recognizes that in some embodiments, a substrate carrier with some deviation from the vertical orientation might result in a more stable substrate position. Furthermore "essentially vertical" is considered different from horizontal substrate orientation. The surface of the substrate, such as first substrate 121 a, can be coated by the evaporation source 100 primarily along a vertical dimension (i.e., the Y direction) of the substrate and a translational movement along the horizontal dimension (i.e., the X direction) as illustrated by the evaporation source 100 moving from the first position 1 1 to the second position 12 and the third position 13. However, though described in reference to an essentially vertical position for an exemplary vertical process chamber, this configuration and/or chamber is not intended to be limiting. Embodiments described herein are equally amenable to horizontal chambers or chambers which can process more or fewer substrates.

[0026] Embodiments described herein particularly relate to deposition of organic materials, such as depositions for organic light-emitting diode (OLED) display manufacturing and on large area substrates, but the embodiments can be useful on other processes as well. According to some embodiments, large area substrates may have a size of at least 0.174 m². The carriers can support between about 1 .4 m² to about 9 m² of substrates, such as about 2 m² to about 8 m² or in some embodiments even up to 12 m². The rectangular area of the carrier on which the substrates are supported, for which the embodiments described here are provided, is about the same or slightly larger than the size of the large area substrates. In some embodiments, the substrate thickness can be from 0.1 to 1 .8 mm. However, in some embodiments the substrate thickness can be about 0.9 mm or below, such as 0.5 mm or 0.3 mm, and the holding arrangement and devices can be adapted for such substrate thicknesses. The substrate may be made from any material suitable for material deposition. For instance, the substrate may be made from a material selected from the group consisting of glass (for instance soda-lime glass, borosilicate glass etc.), metal, polymer, ceramic, compound materials, carbon fiber materials or any other material or combination of materials which can be coated by a deposition process.

[0027] In some embodiments, the first magnetic chuck 151 a and the second magnetic chuck 151 b can employ permanent magnets to allow independent chucking and unchucking of the masks 132a, 132b, without affecting the chucking of the respective substrates 121 a, 121 b. In other embodiments, electromagnets can be used for the magnets in the mask chucking assemblies 151 a, 151 b. In still other embodiments, a mix of permanent magnets and electromagnets can be used for the magnets in the mask chucking assemblies 151 a, 151 b.

[0028] In any of the embodiments described herein, the magnets (either permanent magnet, electromagnet, or combination of both) can be arranged in a Halbach array. Used herein, a Halbach array refers to an arrangement of magnets that augments the magnetic field on one side of the array while reducing or cancelling the field to near zero on the other side. In some embodiments, the reduced magnetic field is only partially reduced, and is not reduced to near zero. Employing embodiments with magnets arranged in a Halbach array has an advantage of concentrating the magnetic field on one side of the array resulting in a stronger magnetic field on that side than if all of the magnets were arranged in the same orientation, such as where like poles of the magnets all face the same direction, or an alternating north pole/south pole configuration. Magnets in a Halbach array can be oriented, so that each magnet is out of phase with each adjacent magnet in the array. Figures 4 to 7 provide additional details of embodiments of mask chucking assemblies employing Halbach arrays.

[0029] Figure 2 illustrates a top view of a deposition apparatus 200 for depositing organic material in a process chamber 240 including the substrate carriers 150a, 150b and the mask chucking assemblies 151 a, 151 b, according to one embodiment. Process chamber 240 could be a vacuum process chamber. An evaporation source 230 is provided in the process chamber 240 on a track or linear guide 224. The linear guide 224 is configured for the translational movement of the evaporation source 230. According to different embodiments, which can be combined with other embodiments described herein, a drive for the translational movement can be provided in the evaporation source 230, at the track or linear guide 224, within the process chamber 240, or a combination thereof. Figure 2 shows a valve 205, for example a gate valve. The valve 205 allows for a vacuum seal to an adjacent process chamber (not shown in Figure 2). The valve 205 can be opened for transport one or more substrates, such as substrates 121 a and 121 b, or one or more masks, such as masks 132a and 132b, into and out of the process chamber 240.

[0030] In some embodiments, a maintenance process chamber 210 is provided adjacent to the process chamber 240. The process chamber 240 and the maintenance process chamber 210 can be connected with a valve 207. The valve 207 is configured for opening and closing a vacuum seal between the process chamber 240 and the maintenance process chamber 210. The evaporation source 230 can be transferred to the maintenance process chamber 210 while the valve 207 is in an open state. Thereafter, the valve 207 can be closed to provide a vacuum seal between the process chamber 240 and the maintenance process chamber 210. If the valve 207 is closed, the maintenance process chamber 210 can be vented and opened for maintenance of the evaporation source 230 without breaking the vacuum in the process chamber 240.

[0031 ] Two substrates 121 a, 121 b can be supported on respective transportation tracks within the process chamber 240. Further, two tracks for providing masks 132a, 132b thereon can be provided. Thereby, coating of the substrates 121 a, 121 b can be masked by respective masks 132a, 132b. According to typical embodiments, the masks 132a, 132b are provided in the mask frames 131 a, 131 b to hold the masks 132a, 132b in a predetermined position. The masks 132a, 132b are chucked into position over the substrate 121 a, 121 b using the respective chucking assemblies 151 a, 151 b. In some embodiments, the chucking assemblies 151 a, 151 b can act independently to chuck the substrate 121 a, 121 b and the masks 132a, 132b, such that the masks 132a, 132b can be positioned over each respective substrate 121 a, 121 b without affecting the positioning of the substrates 121 a, 121 b and without mechanical control of the masks 132a and 132b. For example, in some embodiments, each chucking assembly 151 a, 151 b can include an electrostatic chuck to chuck each respective substrate 121 a, 121 b and a magnetic chuck to chuck each respective mask 132a, 132b.

[0032] According to some embodiments, substrates 121 a, 121 b can be supported by substrate carriers 150a, 150b, which can be connected to respective alignment units 212a and 212b. The alignment units 212a and 212b are actuators that can adjust the position of the substrates 121 a, 121 b relative to the respective masks 132a, 132b in order to provide for proper alignment between the substrates 121 a, 121 b and the respective masks 132a, 132b. This proper alignment is important during deposition of the organic material and other forms of display manufacturing. In some embodiments, the masks 132a, 132b and/or the mask frames 131 a, 131 b can be connected to the respective alignment units 212a, 212b. Thereby, the alignment units 212a, 212b can position the masks 132a, 132b relative to the respective substrates 121 a, 121 b or position the masks 132a, 132b as well as the respective substrates 121 a, 121 b relative to each other.

[0033] When the substrates 121 a, 121 b are held on the substrate carriers 150a, 150b, the substrates 121 a, 121 b can be described as having a horizontal dimension 125, a thickness dimension 126, and a vertical dimension (not shown in the top view of Figure 2). The X direction can be essentially parallel to the horizontal dimension 125. The Y direction can be essentially parallel to the vertical dimension. The Z direction can be essentially parallel to the thickness dimension 126. The surface of each substrate 121 a, 121 b forms a plane in the X-Y plane. Each alignment unit 212a, 212b can provide for relative alignment of the respective masks 132a, 132b and/or substrates 121 a, 121 b in at least the X and Y directions. Each mask 132a, 132b can have a masking surface in the X-Y plane that is essentially parallel to the surface of each substrate 121 a, 121 b to be processed.

[0034] In some embodiments, the alignment units 212a, 212b can also provide for alignment of the substrates 121 a, 121 b and/or masks 132a, 132b in the Z direction. In one embodiment, each mask 132a, 132b can be held stationary in the process chamber 240, and each alignment unit 212a, 212b can align the substrates 121 a, 121 b in the X direction, the Y direction and the Z direction to each respective mask 132a, 132b.

[0035] As shown in Figure 2, the linear guide 224 can provide for fixed translational movement of the evaporation source 230 along the X direction allowing for the evaporation source to deposit material on the vertical dimension of the substrates 121 a, 121 b as the evaporation source translates along the horizontal dimension 125 of the substrates 121 a, 121 b. In some embodiments, the evaporation source 230 deposits material on only one of the substrates 121 a, 121 b at a time, but in other embodiments, the evaporation source can simultaneously deposit material on both substrates 121 a, 121 b.

[0036] Deposition apparatus 200 can include a respective substrate transportation track (not shown) for transportation of each of the substrates 121 a, 121 b. Each transportation track can extend along the X direction parallel to the horizontal dimension of each substrate 121 a, 121 b. In some embodiments, each substrate transportation track allows movement of a respective substrate carrier 150a, 150b into and out of the process chamber 240. In other embodiments, the transportation track enables transfer of the substrates 121 a, 121 b onto a fixed substrate support within the process chamber 240.

[0037] In some embodiments, mask supporting tracks(not shown) are provided for supporting the mask frames 131 a, 131 b and thereby the masks 132a, 132b. The mask supporting tracks can ease transfer of the masks 132a, 132b into and out of the process chamber 240 for various reasons, such as when a new mask is needed or an existing mask needs to be cleaned. The masks 132a, 132b can remain attached to the mask frames 131 a, 131 b during transfer, or in some embodiments the masks 132a, 132b and mask frames 131 a, 131 b can be separated during transfer. Some embodiments can include two transportation tracks for each of the substrates 121 a, 121 b and two mask supporting tracks within the process chamber 240.

[0038] In other embodiments, the masks 132a, 132b as well as the respective mask frames 131 a, 131 b can be moved onto the transportation tracks of the substrates 121 a, 121 b to ease transfer of the masks 132a, 132b into and out of the process chamber 240. The costs of ownership of a deposition apparatus 200 can be reduced if the substrates 121 a, 121 b, the masks 132a, 132b and the mask frames 131 a, 131 b can all be transferred into and out of the process chamber 240 using the same two tracks, such as the transportation tracks for the substrates 121 a, 121 b. One or more actuators or robotic devices can be used to facilitate transfer of the masks 132a, 132b and mask frames 131 a, 131 b onto the transportation tracks.

[0039] Once the masks 132a, 132b and the respective substrates 121 a, 121 b are aligned with one another, the substrate carriers 150a, 150b can bring the substrates 121 a, 121 b into close proximity to the masks 132a, 132b. During the deposition process, an organic material is being propelled at the substrates 121 a, 121 b from the evaporation source 230. This organic material is deposited through openings in the masks 132a, 132b, onto the substrates 121 a, 121 b. The openings provide the subsequent pattern of the deposited material on the substrates 121 a, 121 b. If the masks 132a, 132b are positioned too far from the respective substrates 121 a, 121 b, the organic material can be deposited imprecisely through the openings in the masks 132a, 132b leading to poor resolution or failure of the final product. If the masks 132a, 132b make too much contact or uncontrolled contact with the respective substrates 121 a, 121 b, the masks 132a, 132b can cause physical damage to the substrates 121 a, 121 b. This physical damage can be exacerbated by multiple alignment processes between the substrates 121 a, 121 b and the masks 132a, 132b. By using the substrate carriers 150a, 150b as described herein, the three dimensional position of the mask can be more finely controlled allowing for better deposition with minimal risk of substrate damage during processing.

[0040] Figure 2 illustrates an exemplary embodiment of the evaporation source 230. The evaporation source 230 includes a support 102. The support 102 is configured for the translational movement along the linear guide 224. The support 102 supports an evaporation crucible 104 and a distribution pipe 208 provided over the evaporation crucible 104. Thereby, the vapor generated in the evaporation crucible 104 can move upwardly and out of the one or more outlets of the distribution pipe 208. According to embodiments described herein, the distribution pipe 208 can also be considered a vapor distribution showerhead, for example a linear vapor distribution showerhead.

[0041] Figure 2 further illustrates a shield assembly having at least one shield 202. Typically, as shown in Figure 2, embodiments can include two side shields 202. Thereby, the spray from the distribution pipe 208 can be confined and directed towards the substrate. A spray from the distribution pipe 208 in a direction perpendicular to the normal spray direction can be avoided or used in an idle mode only. In light of the fact that it can be easier to block the vapor beam of organic material as compared to switching off the vapor beam of organic material, the distribution pipe 208 may also be rotated towards one of the side shields 202 in order to avoid vapor exiting the evaporation source 230 during an operation mode where vapor emission is not desired.

[0042] Figure 3 depicts an exploded view of one embodiment of a substrate carrier 300. The substrate carrier 300 can be a component of the substrate carriers 150a, 150b described above. The substrate carrier 300 includes a support base 304, an electrode assembly 306 disposed on or in the support base 304, and an encapsulating member 302 disposed on the electrode assembly 306, which together form a body 31 1 of the substrate carrier 300. The support base 304 defines a bottom surface 312 of the substrate carrier 300 while the encapsulating member 302 defines a substrate supporting surface 313 of the substrate carrier 300. Although not shown, the body 31 1 may include lift pin holes extending there through. The support base 304 can be operable to move the substrate carrier 300 into and out of a process chamber, such as the process chamber 240. For example, the support base 304 can include a guide rail (not shown) to aid in transporting the substrate carrier 300. The guide rail can be configured to interface with a transfer mechanism or a drive system in the process chamber. In other embodiments, the support base could interface with a conveyor or track, such as second transportation track 124b of Figure 1 B.

[0043] In the embodiment of Figure 3, the support base 304 has a rectangular- like shape having a periphery (defined by sides 314) that substantially matches the shape and size of electrode assembly 306, the encapsulating member 302, as well as the substrates 121 a, 121 b. It is noted that the support base 304, the electrode assembly 306 and the encapsulating member 302 may have an alternative shape or geometry selected as needed to accommodate the geometry of a workpiece, such as the substrates 121 a, 121 b. For example, although the substrate carrier 300 is shown with a rectangular shape, it is contemplated that the shape of the substrate carrier 300 may alternatively have other geometric forms to accommodate different substrates, such as circular geometric forms to accommodate a circular substrate.

[0044] In one embodiment, the support base 304 may be fabricated from an insulating material, such as a dielectric material or a ceramic material. The support base 304 can have a rigid structure. Suitable examples of the ceramic materials or dielectric materials include polymers (e.g., polyimide), silicon oxide (e.g., quartz or glass), aluminum oxide (AI₂O₃), aluminum nitride (AIN), yttrium containing materials, yttrium oxide (Y₂O₃), yttrium-aluminum-garnet (YAG), titanium oxide (TiO), titanium nitride (TiN), silicon carbide (SiC) and the like. Optionally, the support base 304 may be a metal or metallic body having a dielectric layer disposed on the surface of the support base 304 facing the electrode assembly 306.

[0045] The electrode assembly 306 is disposed on or in the support base 304 and includes at least two distributed electrodes 308, 31 0. Each electrode 308, 310 may be charged with different polarities when a chucking voltage is applied thereto, thus generating an electrostatic force. The electrodes 308, 310 are configured to distribute the electrostatic force along a distance at least two times with width of the substrate carrier 300. Each electrode 308, 31 0 may have a plurality of geometric forms interleaved or interposed among a plurality of similar or different other geometric forms of the other electrode. As shown in Figure 3, a plurality of electrode fingers 320 of electrode 308 are interleaved with plurality of electrode fingers 322 of electrode 310. The interleaved fingers 320, 322 of the distributed electrodes 308, 31 0 provide a local electrostatic attraction distributed across a large area of the substrate carrier 300 which in the aggregation provides a high chucking force while using less chucking power. The electrode fingers 320, 322 may be formed to have different shapes, lengths, and geometries. In one example, one or both of the electrode fingers 320, 322 may be formed from interconnected electrode islands 324. Interconnections 326 between electrode islands 324 may be in the plane of the electrodes 308, 310 as shown in Figure 3, or out of plane, such as in the form of jumpers and/or vias. In one embodiment, each electrode finger 320, 322 has a width 316 of between about 0.25 mm and about 10 mm. [0046] In one embodiment, the electrode assembly 306 may be fabricated from a metallic material, such as aluminum silicon alloy, having a coefficient of thermal expansion similar to the adjacent encapsulating member 302 and the support base 304. In one embodiment, the coefficient of thermal expansion of the electrode assembly 306 is between about 4 μιη/(ιη*Κ) and about 6 μιη/(ιη*Κ), and is generally within about 20 percent of the coefficient of thermal expansion of the encapsulating member 302.

[0047] Between each of the electrode fingers 320 of the first electrode 308, spaces 328 are defined to receive electrode fingers 322 of the second electrode 310. The spaces 328 may be an air gap, filled with a dielectric spacer material, or filled with at least one of the support base 304 or encapsulating member 302.

[0048] Vias 332, 334 may be formed through the support base 304 to couple the first and the second electrodes 308, 310 to a chucking power source (not shown). In some embodiments, an optional battery 330 may be disposed in the support base 304 and connected to the first and the second electrodes 308, 310 to provide power for chucking the substrates 121 a, 121 b. The battery 330 may be a lithium ion battery and may have terminal connections (not shown) on the exterior of the support base 304 for recharging the battery 330 without removal from the support base 304.

[0049] The encapsulating member 302 is disposed on the support base 304 sandwiching the electrode assembly 306, to form the body 31 1 of the substrate carrier 300 as a unitary structure. The encapsulating member 302 is positioned on the electrode assembly 306 to provide an insulating surface on which the substrates 121 a, 121 b are chucked. The encapsulating member 302 may be fabricated from a material having thermal properties, such as a coefficient of thermal expansion, substantially matching that of the underlying electrode assembly 306. In some embodiments, the material used to fabricate the encapsulating member 302 is also used to fabricate the support base 304.

[0050] After the encapsulating member 302, the electrode assembly 306 and the support base 304 are stacked together, a bonding process, such as an annealing process, is performed to fuse the encapsulating member 302, the electrode assembly 306 and the support base 304 together, making a laminated structure that forms the body 31 1 of the substrate carrier 300. As the encapsulating member 302, the electrode assembly 306 and the support base 304 may operate in a high temperature environment, such as greater than 300 degrees Celsius, the materials used to fabricate these three components may be selected from heat resistance materials, such as ceramic materials or glass materials that can sustain high thermal treatment during the annealing process. In one embodiment, the encapsulating member 302 and the support base 304 may be fabricated from a ceramic material, a glass material, or a composite of ceramic and metal material, providing good strength and durability as well as good heat transfer properties. The materials selected to fabricate the encapsulating member 302 and the support base 304 may have a coefficient of thermal expansion substantially matching the coefficient of thermal expansion of the intermediate electrode assembly 306 to reduce thermal expansion mismatch, which may cause stress or failure under high thermal loads. In one embodiment, the coefficient of thermal expansion of the encapsulating member 302 is between about 2 μιη/(ιη*Κ) and about 8 μιη/(ιη*Κ). Ceramic materials suitable for fabricating the encapsulating member 302 and the support base 304 may include, but are not limited to, silicon carbide, aluminum nitride, aluminum oxide, yttrium containing materials, yttrium oxide (Y₂O₃), yttrium-aluminum-garnet (YAG), titanium oxide (TiO), or titanium nitride (TiN). In another embodiment, the encapsulating member 302 and the support base 304 may be fabricated from a composite material includes a different composition of a ceramic and metal, such as metal having dispersed ceramic particles.

[0051 ] During operation, a charge may be applied to the first electrode 308 and an opposite charge may be applied to the second electrode 310 to generate an electrostatic force. During chucking of the substrate, the electrostatic force generated by the electrodes 308, 310 securely holds the substrate, such as substrates 121 a, 121 b, to the substrate supporting surface 313 of the encapsulating member 302. As the power supplied from the chucking power source is turned off, the charges present at the interface 318 between the electrodes 308, 310 may be maintained over a long period of time, thus allowing the substrates 121 a and 121 b to remain chucked to the substrate carrier 300 after power has been removed. To release the substrate held on the substrate carrier 300, a short pulse of power in the opposite polarity is provided to the electrodes 308, 310 to remove the charge present in the interface 318.

[0052] Figure 4 depicts a chucking assembly 400, according to one embodiment. The chucking assembly 400 includes a substrate carrier 402 and a magnetic chuck 404. The magnetic chuck 404 may be utilized in the process chamber 1 10 in place of the magnetic chucks 151 a, 151 b. The substrate carrier 402 can be configured to adhere and release a substrate 420. In one embodiment, the substrate carrier 402 is substantially similar to the substrate carrier 300, described with reference to Figure 3. The magnetic chuck 404 can be coupled to a support base of the substrate carrier 402, such as support base 304 of substrate carrier 300. The magnetic chuck 404 is depicted here as a rectangular shape. However, the magnetic chuck 404 can be of any shape such that it can deliver the magnetic field of the magnets in the magnetic chuck 404 to clamp the mask 430 over the substrate 420 held to the substrate carrier 402.

[0053] The magnetic chuck 404 can include a plurality of magnets arranged in a one or more Halbach arrays, shown as Halbach arrays 406a-406j, contained within a chuck body 408. Further details on arrangement of the magnets in the one or more Halbach arrays are provide in reference to Figures 5A to 7. The chuck body 408 can completely surround the Halbach arrays 406a-406j. The chuck body 408 can further have an optional actuator 410 and a chucking surface 412. In operation, the strong side of the magnetic field generated by the Halbach array is on the chucking surface side of the chuck body 408. The optional actuator 410 is operable to move the chuck body 408, and thus control the distance between the chucking surface 412 of the magnetic chuck 404 and the substrate carrier 402. In some embodiments, the optional actuator 410 can move the magnetic chuck 404 closer to the mask 430. The chucking surface 412 is a surface through which a magnetic chucking force is applied and which can draw the mask 430 against the substrate 420 disposed on the substrate carrier 402. The chucking surface 412 can be a flat surface, as depicted in Figure 4.

[0054] The substrate 420 has a supported surface 421 chucked to the substrate carrier 402 and a process surface 422 on which material is deposited during processing. The substrate carrier 402 can chuck the supported surface 421 of the substrate 420 using an electrostatic force as described above in reference to Figure 3. The mask 430 is positioned in front of and aligned with the process surface 422 of substrate 420. The magnetic field of the magnetic chuck 404 can then be brought into magnetic connection with the mask 430. Magnetic connection used herein refers to a position or arrangement of the magnets in the one or more Halbach arrays, which causes the magnetic field of the magnetic chuck 404 to attract the mask 430.

[0055] In some embodiments, the magnetic connection between the magnetic chuck 404 and the mask 430 is accomplished by reducing and increasing the distance between the chucking surface 412 of the magnetic chuck 404 and the mask 430. These changes in distance can be accomplished by moving the magnetic chuck 404 and/or the mask 430. In embodiments in which the magnetic chuck is integrated with the substrate carrier 402, the carrier 402 can have one or more actuators to reposition the magnetic chuck 404 within the carrier 402 closer to the mask 430. In some embodiments, the magnets in the Halbach arrays 406a-406j can be repositioned in the chuck body 408. In some embodiments, some or all of the magnets in the Halbach arrays 406a-406j can be electromagnets, where the current applied to the electromagnets can be reversed to change direction of the magnetic fields. In some of the embodiments using electromagnets, the current can be increased and decreased to control the strength of the magnetic field.

[0056] In embodiments where the distance between the magnetic chuck 404 and the mask 403 is changed, the proximity of the magnets in the Halbach arrays 406a- 406j to the mask 430 controls the magnetic pull of the magnetic field from the magnets on the mask 430. The magnetic force from the magnets in the Halbach arrays 406a-406j in the magnetic chuck 404 brings at least a portion of the mask 430 into position over or in contact with the substrate 420. A layer (not shown) is then deposited through the mask 430 on the substrate 420. Once the layer is deposited, the magnetic chuck 404 or the magnets within the chuck 404 are then repositioned, or in the case of electromagnets the current can be reduced, so that the magnetic field is no longer secures the mask 430 to the substrate 420 allowing removal of the mask 430.

[0057] In Figures 5A to 7, the following letters and symbols are used to indicate the location of the magnetic poles of a magnet. An "N" indicates the magnet is oriented with its north pole facing out of the Figure. An "S" indicates the magnet is oriented with its south pole facing out of the Figure. An arrow indicates the direction in which the north pole of the magnet is oriented relative to the plane of the two dimensional Figure.

[0058] Figures 5A to 5C depict a front schematic view of a magnetic chuck 504 including a Halbach array 510, according to one embodiment. The Halbach array 510 includes a plurality of magnets 51 1 -518. The magnetic chuck 504 includes a chucking surface 522, which can be similar to the chucking surface 412 described in reference to Figure 4. In some embodiments, magnets 51 1 -518 can be permanent magnets, each having a shape of a long magnetic rod or tube. Each rod or tube can have a long dimension 528 that spans substantially all of one of the dimensions of the chucking surface 522, such as an edge 525.

[0059] The chucking surface 522 is shown as being transparent in order to show the orientation of the magnets 51 1 -518 with respect to the chucking surface 522, but such transparency is not required. The magnets 51 1 -518 can be recessed with respect to the chucking surface 522 in a similar way to how the Halbach arrays 406a-406j were shown recessed from the chucking surface 412 in Figure 4.

[0060] In each Figure 5A-5C the poles of at least some of the magnets 51 1 -518 are oriented differently with respect to the chucking surface 522. Arranging the magnets 51 1 -518 in different orientations can create an augmented magnetic field relative to the chucking surface 522 to chuck a mask in one orientation (see Figure 5A) and can create a reduced or canceled magnetic field relative to the chucking surface 522 to dechuck the mask in other orientations (see Figures 5B and 5C).

[0061 ] Figure 5A shows the magnets 51 1 -518 arranged in a chucking state with the magnets 51 1 -518 arranged in first orientations 51 1 1-518 in the Halbach array 510. Each magnet 51 1 -518 has a north pole oriented in one of four directions relative to the chucking surface 522. When the magnets 51 1 -518 are arranged in the first orientations 51 1 -518 , each outwardly facing magnet, (e.g., magnet 513) having a first pole facing outward towards the chucking surface 522, is adjacent to one or two other magnets (e.g., magnets 512, 514) having respective first poles facing the outwardly facing magnet. This orientation creates a strong magnetic field directed out of the chucking surface 522 enabling the mask (not shown) to be chucked. The mask can have similar features to the masks described above, such as masks 132a, 132b, or 430.

[0062] Magnetic chuck 504 can further include a rotation mechanism 530. The rotation mechanism 530 can be an actuator, such as a pneumatic actuator, solenoid, motor, or other suitable mechanism. The rotation mechanism can be used to rotate at least some of the magnets 51 1 -518 to create an augmented magnetic field relative to the chucking surface 522 to chuck a mask in one orientation (see Figure 5A) and can create a reduced or canceled magnetic field relative to the chucking surface 522 to dechuck the mask in other orientations (see Figures 5B and 5C). The rotation mechanism 530 can be coupled to the magnets 51 1 -518 through a plurality of gears 541 -548. The rotation mechanism 530 and plurality of gears 541 - 548 can rotate the magnets 51 1 -518 around rotational axes (e.g., rotational axis 551 ) which parallel edges 525, 526 of the chucking surface 522 as well as the long dimension 528 of the magnets 51 1 -518. In some embodiments, the rotation mechanism 530 is directly connected to a main gear 540, which is coupled to the plurality of gears 541 -548.

[0063] In some embodiments, the gears 541 -548 can have varying shapes, such as varying elliptical shapes, in order to stagger the rotation of the magnets 51 1 -518 in reference from locations on the chucking surface 522, such as a center 524, or one of the edges 525, 526. In some embodiments, the plurality of gears 541 -548 are operable to cause the rotation of the magnets closest to the center 524, such as magnets 514, 515, to lead the rotation of the magnets 513, 516, which can lead the rotation of the magnets 512, 517, which can lead the rotation of the magnets 51 1 , 518 at the edges 525, 526. Thus, the magnets closer to the center 524 (e.g., magnets 514, 515) can rotate faster than the magnets further from the center (e.g., magnets 513, 516). In other embodiments, the order of rotation can be reversed with the magnets 51 1 , 518 at the edges 525, 526 leading the other magnets in rotation, and the magnets 514, 515 trailing the other magnets in rotation. Thus, the magnets closer to the edge 525 (e.g., magnets 513, 516) can rotate faster than the magnets further from the center (e.g., magnets 514, 515).

[0064] In other embodiments, the rotation can be staggered from one edge to an opposite edge. For example, the rotation can be staggered from the left edge 525 to the right edge 526, so that the rotation of each magnet is slightly ahead of the rotation of the magnet to the right with the rotation of magnet 51 1 leading the most and the rotation of magnet 518 trailing the most.

[0065] In still other embodiments, the rotation of each magnet 51 1 -518 can be individually controllable allowing additional sequences of rotation to be explored. For example, each magnet 51 1 -518 can be coupled to a separate actuator, such as a separate servo or a separate pneumatic actuator. In some embodiments the rotation mechanism 530 and the plurality of gears 541 -548 are components of the magnetic chuck 504. In other embodiments the rotation mechanism 530 and the plurality of gears 541 -548 are separate devices and not part of the magnetic chuck 504. For embodiments in which the magnetic chuck (e.g., magnetic chuck 504) is integrated with a substrate carrier (e.g., substrate carrier 300), the rotation mechanism 530 can also be integrated with the substrate carrier (e.g., substrate carrier 300) or the rotation mechanism 530 can be a separate component in the process chamber (e.g., process chamber 1 10). For embodiments in which the magnetic chuck (e.g., magnetic chuck 504) is a separate component from a substrate carrier (e.g., substrate carrier 300), the rotation mechanism 530 can be a separate component in the process chamber (e.g., process chamber 1 10). [0066] In some embodiments, the rotation mechanism 530 is not coupled to all of the magnets 51 1 -518. In such embodiments, the rotation mechanism 530 is coupled to at least the magnets having a north pole oriented in two of the four directions, where the two directions differ by about 180 degrees. For example, the rotation mechanism 530 may only be coupled to magnets 512, 514, 516, and 518, which each have a north pole oriented in the left or right direction in the Figure, and left and right differ by 180 degrees. Figure 5C provides additional detail on an embodiment in which the rotation mechanism 530 is only coupled to magnets having a north pole oriented in two of the four directions.

[0067] Figure 5B shows the magnets 51 1 -518 arranged in a dechucking state with the magnets 51 1 -518 arranged in second orientations 51 12-5182 in the Halbach array 510. Each magnet 51 1 -518 has a north pole oriented in one of four directions relative to the chucking surface 522. When the magnets 51 1 -518 are arranged in the second orientations 51 12-5182, each outwardly facing magnet, (e.g., magnet

512) having a first pole (e.g., south pole of magnet 512) facing outward towards the chucking surface 522, is adjacent to one or two other magnets (e.g., magnets 51 1 ,

513) having respective opposite poles (e.g., north poles of magnets 51 1 , 513) facing the outwardly facing magnet (e.g., magnet 512). This orientation results in a reduced or near zero magnetic field directed out of the chucking surface 522 enabling the mask to be dechucked.

[0068] To change the orientation of the magnets 51 1 -518 from the first orientations 51 1 1-5181 to the second orientations 51 12-5182, the rotation mechanism 530 is coupled to all of the magnets 51 1 -518 in the Halbach array 510. In embodiments employing more than one Halbach array, one or more rotation mechanisms can be coupled to all of the magnets in each array. The rotation mechanism 530 can then rotate each magnet 51 1 -518 by about 90 degrees, alternating the direction of rotation for each magnet 51 1 -518 in the array. As an example of alternating the direction of rotation from the first orientations 51 11-5181 to second orientations 51 12-5182, magnet 51 1 can rotate counterclockwise when observing the rotation from a bottom edge 527 of the chucking surface 522, and magnet 512 can rotate clockwise when observing the rotation from the bottom edge 527. To return the magnets 51 1-518 to a chucking state, the rotation mechanism 530 can (1 ) reverse the rotation by 90 degrees to return each magnet to its first orientation 51 ₁-518₁ , (2) continue the alternating rotation of each magnet 51 1-518 by an additional 90 degrees to create a new chucking orientation, or (3) continue the alternating rotation by an additional 270 degrees in the same direction for each magnet 51 1-518 to return each magnet 51 1-518 to its first orientation 51 1₁-518 . In some embodiments, less than all of the magnets 51 1-518 are rotated to dechuck the mask.

[0069] Figure 5C shows the magnets 51 1-518 arranged in another dechucking state with all odd numbered magnets fixed in first orientations 51 1₁, 513i, 515i, 517i and all even numbered magnets changing to third orientations 512₃, 514₃, 5163, and 5183 in the Halbach array 510. Each magnet 51 1 -518 has a north pole oriented in one of four directions relative to the chucking surface 522. When all odd numbered magnets are arranged in the first orientations 51 1 , 513i, 515 , 517 and all even numbered magnets are arranged in third orientations 512₃, 514₃, 5163, 5183, each outwardly facing magnet (e.g., magnet 513 having a first pole, such as its north pole facing outward towards the chucking surface 522) is adjacent to one or two other magnets (e.g., magnets 512, 514) having respective opposite poles (e.g., the south poles of magnets 512, 514) facing the outwardly facing magnet (e.g., magnet 513). This orientation results in a reduced or near zero magnetic field directed out of the chucking surface 522 enabling the mask to be dechucked.

[0070] To change the orientation of the even numbered magnets from the first orientations 512-,, 514-,, 516₁, 518₁ to the third orientations 512₃, 514₃, 516₃, 518₃, the rotation mechanism 530 may be coupled to only the even numbered magnets. The rotation mechanism 530 can then rotate each even numbered magnet 512, 514, 516, 518 by about 180 degrees. To return the magnets 51 1-518 to a chucking state, the rotation mechanism 530 can reverse the rotation by 180 degrees or continue the rotation in the same direction by an additional 180 degrees for the even numbered magnets 512, 514, 516, 518. In some embodiments, the odd numbered magnets are rotated and the even numbered magnets remain in the first orientation. [0071 ] Figures 6A to 6B depict a front schematic view of a magnetic chuck 610 including a plurality of Halbach arrays 61 1 -614 arranged in a series, according to one embodiment. Each Halbach array 61 1 -614 includes a plurality of magnets 601 - 608. In some embodiments, each Halbach array 61 1 -614 can extend from a first edge 625 of the magnetic chuck 610 to a second edge 626 of the magnetic chuck 610. The magnetic chuck 610 includes a chucking surface 622, which can be similar to the chucking surface 412 described in reference to Figure 4. In some embodiments, magnets 601 -608 can be permanent magnets, each having a cylindrical shape with the height of the cylinders substantially perpendicular to the chucking surface 622 or with the height of the cylinders being substantially parallel to one of the edges of the chucking surface 622, such as edge 625. In some embodiments, the cylinder can be disposed in other orientations relative to the chucking surface 622 or the edges, such as edge 625. Other embodiments can have magnets 601 -608 shaped in the form of rods, blocks, or tubes, such as a rectangular tube.

[0072] The chucking surface 622 is shown as being transparent in order to illustrate the orientation of the magnets 601 -608 with respect to the chucking surface 622, but such transparency is not required. The magnets 601 -608 can be recessed with respect to the chucking surface 622 similar to the Halbach arrays 406a-406j are shown recessed from the chucking surface 412 in Figure 4.

[0073] Figure 6A shows the magnets 601 -608 arranged in a chucking state with the magnets 601 -608 in each Halbach array 61 1 -614 arranged in first orientations 6011-608-1. This orientation creates a strong magnetic field directed out of the chucking surface 622 enabling a mask to be chucked. The mask can have similar features to the masks described above, such as masks 132a, 132b, or 430.

[0074] Magnetic chuck 610 can further include one or more rotation mechanisms (not shown) similar to the rotation mechanism 530 depicted in Figure 5. The one or more rotation mechanisms can be coupled to at least the magnets in each Halbach array 61 1 -614 having a north pole oriented in two of the four directions in which the north pole of each magnet 601 -608 faces. In some embodiments, the magnetic chuck 610 includes one rotation mechanism, which rotates each corresponding magnet 601 -608 in each Halbach array 61 1-614 in unison. A connecting rod or other connection can be used to ensure the corresponding magnets rotate in unison. In other embodiments, a separate rotation mechanism can be used for each array allowing for some of the Halbach arrays 61 1-614 to be in a chucking state and some of the Halbach arrays 61 1-614 to be in a dechucking state or an intermediate state. In embodiments employing one rotation mechanism or separate rotation mechanisms for each Halbach array 61 1-614, the rotation of each magnet coupled to a rotation mechanism can be staggered from center to edge, edge to center, or edge similarly to the staggering of rotation discussed in reference to magnetic chuck 504 above.

[0075] In some embodiments, the rotational axis of the magnets is parallel to one of the edges (e.g., edge 625) of the chucking surface 622, and gears similar to gears 541-548 coupled to the one or more rotation mechanisms can be used to accomplish the rotation. In other embodiments, the rotational axis of the magnets 601-608 is perpendicular to the chucking surface 622.

[0076] In still other embodiments, the rotation of each magnet 601-608 of each Halbach array 61 1-614 can be individually controllable allowing additional sequences of rotation to be explored. For example, each magnet 601-608 of each Halbach array 61 1 -614 can be coupled to a separate actuator, such as a separate servo or a separate pneumatic actuator.

[0077] Figure 6B shows the magnets 601-608 arranged in a dechucking state with all odd numbered magnets remaining in first orientations 6011 , 603i, 605i, 607i and all even numbered magnets changing to second orientations 602₂, 604₂, 606₂, and 608₂ in each Halbach array 61 1-614. Having the odd numbered magnets in the first orientation and the even numbered magnets in the second orientation results in a canceled or near zero magnetic field directed out of the chucking surface 622 enabling the mask to be dechucked.

[0078] To change the orientation of the even numbered magnets from the first orientations 602! , 604! , 6O6₁ , 6O8₁ to the second orientations 602₂, 604₂, 606₂, 608₂, the one or more rotation mechanisms may be coupled to only the even numbered magnets. The one or more rotation mechanisms can then rotate each even numbered magnet 602, 604, 606, 608 by about 180 degrees. To return the magnets 601 -608 to a chucking state, the one or more rotation mechanisms can reverse the rotation by 180 degrees or continue the rotation in the same direction by an additional 180 degrees for the even numbered magnets 602, 604, 606, 608. In some embodiments, the odd numbered magnets are rotated and the even numbered magnets remain in the first orientation. Magnetic mask 610 could similarly be operable to rotate all of the magnets 601 -608 in one or more of the Halbach arrays 61 1 -614 by about 90 degrees to change from the chucking state to the dechucking state similarly to what was described in reference to Figure 5B above.

[0079] Using multiple Halbach arrays as opposed to one Halbach array can provide greater operational flexibility. For example, if separate rotation mechanisms are used for separate Halbach arrays, then some Halbach arrays can be in a chucking state, a dechucking state, or an intermediate state. Separate control could be provided to each rotation mechanism allowing individual control on when each array is switched to a chucking, dechucking, or intermediate state. Furthermore, multiple Halbach arrays could allow for magnets of varying magnetic strength to be used to clamp different areas of the mask. For example, to clamp a center of the mask with greater force, stronger magnets could be used for the magnets closer to the center of the mask relative to the strength of magnets further from the center of the mask.

[0080] Figure 7 shows a schematic top view of magnetic chuck 710 including a Halbach array 720, according to one embodiment. In contrast to magnetic chucks 504 and 610, which use rotation to change between chucking and dechucking states, magnetic chuck 710 changes the position of movable magnets 71 1 -719 relative to fixed magnets 721 -728 to adjust the magnetic field strength. When movable magnets 71 1 -719 are placed into position between fixed magnets 721 -728, a Halbach array is formed creating a strong magnetic field directed out of a chucking surface 732 enabling a mask 730 to be chucked. To dechuck the mask 730, the movable magnets can be moved away from the fixed magnets 721 -728 and the chucking surface 732. One or more actuators 704 can be used to change the positions of the movable magnets 71 1 -719 individually, in groups, or all of the magnets 71 1 -719 together. In some embodiments, the mask 730 can be dechucked by sliding the movable magnets 71 1 -719 away from the fixed magnets 721 -729 as well as the chucking surface 732 and then repositioning each movable magnet 71 1 - 719 adjacent to a next fixed magnet 721 -729. For example, movable magnet 712, which is adjacent to fixed magnets 721 , 722 in the chucking state can be repositioned between fixed magnets 722, 723 in the dechucking state. Repositioning all of the movable magnets similarly to movable magnet 712 results in a reduced or near zero magnetic field directed out of the chucking surface 732 enabling the mask 730 to be dechucked.

[0081 ] In some embodiments, the flexible plate 702 can be used to move the movable magnets 71 1 -719. The flexible plate 702 can be curved inward so that the movable magnets 71 1 -719 in the center of the flexible plate 702 are closer to the chucking surface 732 in order to progressively chuck the mask 730 from the center of the mask 730 to the edges of the mask 730 as the movable magnets 71 1 -719 are moved into a chucking position. The inwardly curved flexible plate also allows for the mask 730 to be progressively dechucked in an edge to center sequence. In other embodiments, the flexible plate 702 can be curved outward so that the movable magnets 71 1 -719 at the center of the flexible plate 702 are furthest away from the chucking surface 732 resulting in the opposite effect creating progressive edge to center chucking and progressive center to edge dechucking.

[0082] Referring to Figures 2, 5A to 5C, and 8, a method 800 is described for chucking a mask to a substrate in a processing chamber. Although the method is described in conjunction with reference to the systems of Figures 5A to 5C, persons skilled in the art would understand that any magnetic chuck configured to perform the method steps, in any order, is within the scope of the embodiments disclosed. Method 800 is described as being executed in the process chamber 240 using the substrate carrier 150a and the magnetic chuck 504 instead of the first magnetic chuck 151 a. Although method 800 is described using the magnetic chuck 504 and the substrate carrier 150a in the process chamber 240, method 800 can also be executed with other magnetic chucks, with other substrate carriers, or in other process chambers. For example, method 800 can also be executed using the magnetic chuck 610 and the substrate carrier 300 in the process chamber 1 10.

[0083] At block 802, the first substrate 121 a is disposed on a substrate supporting surface of the substrate carrier 150a and is transferred into the process chamber 240.

[0084] At block 804, a mask is chucked to the substrate. The mask could be chucked in accordance with any of the embodiments described herein. In some embodiments, the mask can be chucked as soon as the substrate is placed into position within a process chamber requiring no rotation or movement of magnets within a Halbach array. In other embodiments, at least some magnets in a Halbach array can be moved with or without rotation to chuck the mask. For example, at least some of a plurality of magnets 51 1 -518 arranged in the Halbach array 510 in the magnetic chuck 504 can be rotated. The rotation can occur with the magnetic chuck 504 being proximate to the substrate supporting surface in order to chuck the mask 132a to the substrate 121 a disposed on the substrate carrier 150a. Alternatively, the rotation could occur with the magnetic chuck 504 being further away from the substrate supporting surface 150a and then the magnetic chuck could be moved proximate to the substrate supporting surface in order to chuck the mask 132a to the substrate 121 a disposed on the substrate carrier 150a. In some embodiments, the magnets 51 1 -518 are all rotated by about 90 degrees as described above in reference to Figure 5B. In other embodiments, the magnets in the plurality of magnets 51 1 -518 oriented in two of the four directions in the Halbach array 510 can be rotated by about 180 degrees as described above in reference to Figure 5C.

[0085] In embodiments having magnetic chucks with more than one Halbach array, such as magnetic chuck 610, then magnets in more than one of the Halbach arrays can be rotated at block 804. In some embodiments, at least some of the plurality of magnets 51 1 -518 magnets closer to a center of the magnetic chuck 504, such as the center 524 of the chucking surface 522, are rotated faster than magnets closer to an edge of the magnetic chuck 504, such as the edge 525 of the chucking surface 522. The rotation of the magnets can be staggered in numerous ways as described above, such as staggering the rotation from center to edge, edge to center, or edge to edge. In an embodiment using magnetic chuck 710, movable magnets 71 1 -719 can be placed into position between fixed magnets 721 -728, creating a strong magnetic field directed out of a chucking surface 732 enabling a mask 730 to be chucked to the substrate. In embodiments using electromagnets no movement or rotation of the magnets may be required as the chucking can be accomplished by energizing the electromagnets with the appropriate current.

[0086] At block 806, a layer is deposited through the mask 132a onto the substrate 121 a. Evaporation source 230 can be used to deposit the layer onto the substrate 121 a. Linear guide 224 can provide translational movement of the evaporation source 230, so the layer can be deposited on different areas of the substrate 121 a. Magnets in one or more Halbach arrays can rotate to adjust the chucking force across different areas of the substrate during the deposition. It is contemplated that the layer may be deposited through the mask using a chemical vapor deposition or other deposition process.

[0087] At block 808, the mask is dechucked from substrate. The mask could be dechucked in accordance with any of the embodiments described herein. In some embodiments, at least some of the magnets in a Halbach array can be moved with or without rotation to dechuck the mask. For example, at least some of a plurality of magnets 51 1 -518 arranged in the Halbach array 510 in the magnetic chuck 504 can be rotated in order to dechuck the mask 132a from the substrate 121 a disposed on the substrate carrier 150a. In some embodiments, the magnets 51 1 -518 are all rotated by about 90 degrees as described above in reference to Figure 5B. In other embodiments, the magnets in the plurality of magnets 51 1 -518 oriented in two of the four directions in the Halbach array 510 can be rotated by about 180 degrees as described above in reference to Figure 5C. [0088] In embodiments having magnetic chucks with more than one Halbach array, such as magnetic chuck 610, then magnets in more than one of the Halbach arrays can be rotated at block 806. In some embodiments, at least some of the plurality of magnets 51 1 -518 magnets closer to a center of the magnetic chuck 504, such as the center 524 of the chucking surface 522, are rotated faster than magnets closer to an edge of the magnetic chuck 504, such as the edge 525 of the chucking surface 522. The rotation of the magnets can be staggered in numerous ways as described above, such as staggering the rotation from center to edge, edge to center, or edge to edge. In an embodiment using magnetic chuck 710, movable magnets 71 1 -719 can be removed from the position between fixed magnets 721 - 728, resulting in a canceled or reduced magnetic field directed out of a chucking surface 732 enabling a mask 730 to be dechucked from the substrate. In embodiments using electromagnets no movement or rotation of the magnets may be required as the dechucking can be accomplished by deenergizing the electromagnets, reducing the current supplied to the electromagnets, or changing the direction of the current applied to at least some of the electromagnets.

[0089] After dechucking the mask from the substrate at block 808, the substrate can be removed from the chamber allowing for the process to be repeated for a new substrate. If at least some magnets in a Halbach array were moved to dechuck the mask from the substrate at block 808, then at least some magnets in the Halbach array can be moved as described above to recreate the chucking state when the new substrate is placed into position in the process chamber.

[0090] Each of the magnetic chucks 404, 504, 610, 710 can include more or less magnets than shown in the Figures. The embodiments showing only one Halbach array, such as magnetic chucks 504, 710 can include additional Halbach arrays. The embodiments including multiple Halbach arrays, such as magnetic chucks 404, 610 can include more or less Halbach arrays than the number of arrays shown in the Figures.

[0091] Each of the magnetic chucks 404, 504, 610, 710 can fully function in each of the process chambers 1 10, 240 independent of any substrate carrier (e.g., carrier 402) including functioning with all of the components in all of the chambers, such as the alignment units 212a, 212b, the valves 205, 207, the masks 132a, 132b, and the mask frames 131 a, 131 b. The alignment units 212a, 212b can be operable to align each magnetic chuck 404, 504, 61 0, 71 0 with each substrate carrier 150a, 150b, 300, 402 as well as aligning the substrates with the respective masks for embodiments in which the magnetic mask chuck is not part of the carrier. Each of magnetic chucks 404, 504, 610, 710 can be used with each of the substrate carriers 150a, 150b, 300, 402 as a separate device or integrated with each of the carriers. In embodiments in which the magnetic chuck is integrated with a substrate carrier the plurality of magnets in the one or more Halbach arrays can be oriented relative to a chucking surface (e.g., chucking surface 412) or relative to a substrate supporting surface (e.g., substrate supporting surface 313). In some embodiments, the chucking surface and the substrate supporting surface can be the same surface. Each of the magnetic chucks 404, 504, 610, 71 0 can also function with positioning devices, such as optional actuator 410. For embodiments in which the magnetic chuck is separate from the substrate carrier, the magnetic chuck can remain in the process chamber as substrates and/or substrate carriers are transferred into and out of the process chamber.

[0092] Each of the magnetic chucks 404, 504, 610, 710 can have a chuck body, such as chuck body 408, fabricated from an insulating material, such as a dielectric material or a ceramic material. Suitable examples of the ceramic materials or dielectric materials include polymers (e.g., polyimide), silicon oxide materials (e.g., such as quartz or glass), aluminum oxide (AI₂O₃), aluminum nitride (AIN), yttrium containing materials, yttrium oxide (Y₂O₃), yttrium-aluminum-garnet (YAG), titanium oxide (TiO), titanium nitride (TiN), silicon carbide (SiC) and the like. Optionally, each of the chuck bodies may be a metal or metallic body. In some embodiments, the chuck body may be fabricated from a ferromagnetic or non-magnetic body. In some embodiments, the chuck body can also be the electrostatic chuck body.

[0093] Each of the magnetic chucks 404, 504, 610, 710 includes Halbach arrays, such as Halbach arrays 406a-406j, in which all of the magnets in the Halbach arrays can be permanent magnets composed of a ferromagnetic material, such as aluminum-nickel-cobalt (Alnico), ceramic, rare-earth, Iron-Chromium-Cobalt, or combinations thereof. In other embodiments, all of the magnets in the Halbach arrays 406a-406j can be electromagnets. In still other embodiments, some of the magnets in the Halbach arrays 406a-406j can be permanent magnets and some of the magnets in the Halbach arrays 406a-406j can electromagnets.

[0094] In embodiments using electromagnets, a controller and a power source can be used to energize the electromagnets. A rotational mechanism may not be needed for the electromagnets. In some embodiments, the polarity of an electromagnet can be easily switched by reversing the current flowing through the electromagnet making embodiments using electromagnets, especially suitable for embodiments which switch the polarity of some of the magnets by 180 degrees to change between the chucking state and the dechucking state. An advantage of some embodiments of magnetic chucks using electromagnets can be a lack of moving parts that can create dust and cause additional maintenance, such as rotating magnets. Another advantage of embodiments of magnetic chucks using electromagnets is that each electromagnet can be individually energized and deenergized by the controller allowing precise control of the chucking and dechucking across the chucking surface.

[0095] The magnetic chucks described herein enable a mask to be magnetically clamped to a substrate, which improves product quality and can reduce equipment cost. Magnetically clamping the mask can spread an evenly distributed and lower clamping force over a target area of the substrate when compared to mechanical clamping systems that concentrate higher forces at the location of the mechanical clamps. This lower and evenly distributed clamping force can prevent contact contamination or physical damage to substrates often caused by the concentrated forces used by mechanical clamping.

[0096] The magnetic chucks using Halbach arrays provide additional advantages when compared to other embodiments of magnetic chucks. Magnets oriented in a Halbach array can generate higher magnetic forces to clamp a mask than the same magnets oriented in other classical arrangements, such as an alternating north south configuration. This allows for smaller or less magnets to be included in the magnetic chuck, which can save on equipment costs as well as reduce the size of the magnetic chuck.

[0097] Furthermore, as described above magnets oriented in a Halbach array can be easily rotated to a chucking state creating a strong magnetic field to chuck the mask and then rotated to a dechucking state resulting in a reduced or near zero magnetic field directed out towards the mask enabling the mask to be dechucked. Other embodiments of magnetic chucks not using a Halbach array would require the distance between the magnets and the mask to be increased and decreased in order to chuck and dechuck the mask. Increasing and decreasing this distance would result in additional equipment costs because of the additional space in the magnetic chuck that would be needed or the additional space and equipment in the chamber to move the mask or magnetic chuck. Rotation of the magnets in the Halbach array allows the magnetic chuck to have a smaller footprint, which not only provides an equipment cost savings, but also will allow the magnetic chucks using Halbach arrays to be utilized in more existing processing chambers as compared to other magnetic chucks. Additionally, embodiments using permanent magnets have very low power requirements to chuck and dechuck the mask because the only power used is for the rotation of some of the magnets by about 180 degrees or all of the magnets by about 90 degrees.

[0098] Although the magnetic chuck 710 does not rotate the magnets to change from the chucking state to the dechucking state, the distance that the magnets must move is much lower than the distance that magnets would need to move in other magnetic chucks. The distance is lower because the movable magnets in the magnetic chuck 710 only need to move far away enough, so that the movable magnets can slide past the fixed magnets as they are repositioned into a dechucking orientation.

[0099] While the foregoing is directed to typical embodiments, other and further embodiments may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims

What is claimed is:

1 . A processing system for chucking a mask to a substrate comprising:

a process chamber; and

a magnetic chuck disposed in the process chamber, the magnetic chuck comprising:

a chucking surface;

a plurality of magnets oriented in one or more Halbach arrays relative to the chucking surface, wherein each magnet has a north pole oriented in one of four directions; and

one or more rotation mechanisms coupled to change the direction of the north pole of at least one of the magnets.

2. The processing system of claim 1 , wherein the one or more rotation mechanisms are coupled to the magnets having the north pole oriented in two of the four directions, wherein the two of the four directions differ by about 180 degrees.

3. The processing system of claim 1 , wherein the one or more rotation mechanisms are coupled to all of the plurality of magnets in the one or more Halbach arrays.

4. The processing system of claim 3, wherein the plurality of magnets comprises magnetic tubes, the magnetic tubes each having a long dimension parallel to a rotational axis of the magnets coupled to the one or more rotation mechanisms.

5. The processing system of claim 1 , wherein the one or more rotation mechanisms are operable to rotate a first magnet of the plurality of magnets faster than a second magnet of the plurality of magnets.

6. The processing system of claim 5, wherein the first magnet is closer to an edge of the chucking surface than the second magnet.

7. The processing system of claim 1 , wherein the one or more Halbach arrays comprises a series of Halbach arrays, wherein each array extends from a first edge of the maqnetic chuck to a second edge of the magnetic chuck.

8. A substrate carrier for use in a process chamber, the substrate carrier comprising:

a support base operable to move the substrate carrier into and out of a process chamber;

an electrode assembly disposed on the support base to electrostatically chuck a substrate to a substrate supporting surface, the substrate supporting surface disposed on the electrode assembly; and

a magnetic chuck integrated with the support base, the magnetic chuck comprising:

a plurality of magnets oriented in one or more Halbach arrays relative to the substrate supporting surface, wherein each magnet has a north pole oriented in one of four directions; and

9. The substrate carrier of claim 8, wherein the one or more rotation mechanisms are coupled to the magnets having the north pole oriented in two of the four directions, wherein the two of the four directions differ by about 180 degrees.

10. The substrate carrier of claim 8, wherein the plurality of magnets comprises magnetic tubes, the magnetic tubes each having a long dimension parallel to a rotational axis of the magnets coupled to the one or more rotation mechanisms.

1 1 . The substrate carrier of claim 8, wherein the one or more rotation mechanisms are operable to rotate a first magnet of the plurality of magnets faster than a second magnet of the plurality of magnets.

12. A method for chucking a mask to a substrate in a process chamber, the method comprising:

transferring a substrate disposed on a substrate supporting surface of a substrate carrier into a process chamber;

chucking a mask to the substrate; depositing a layer through the mask onto the substrate; and moving at least some of a plurality of magnets arranged in one or more Halbach arrays in a magnetic chuck proximate the substrate supporting surface to dechuck the mask from the substrate disposed on the substrate carrier.

13. The method of claim 12, wherein moving at least some of the plurality of magnets comprises:

rotating at least some of the magnets in the plurality of magnets by about 180 degrees.

14. The method of claim 12, wherein moving at least some of the plurality of magnets comprises:

rotating all of the magnets by about 90 degrees.

15. The method of claim 12, further comprising:

moving at least some of the plurality of magnets to chuck the mask to the substrate disposed on the substrate carrier.