IP Library Granted Patent US 9,736,920
Granted Patent B2
US 9,736,920 · App. 14/616,089 · Granted Aug 15, 2017

Apparatus and method for plasma ignition with a self-resonating device

Inventors: Shaun T. Smith (Malden, MA); Steven R. Walther (Andover, MA); Chen Wu (Foster City, CA)
Assignee: MKS Instruments, Inc.
H05H1/46H01J37/32082H01J37/32174H01J37/32192H01J37/32247H01J37/32311H05H2001/4607H05H2001/4652
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Quick Facts
Patent No.
US 9,736,920
App. No.
14/616,089
Granted
Aug 15, 2017
Kind
B2
Abstract

Methods and apparatus for igniting a process plasma within a plasma chamber are provided. One or more self-resonating devices are positioned within a plasma chamber relative to a plasma generation volume within the plasma chamber. The plasma generation volume is defined by the plasma chamber. Each of the self-resonating devices generates an ignition plasma. The ignition plasmas cause a partial ionization of an ignition gas. The partially ionized ignition gas allows for ignition of a process plasma by applying an electric field to the plasma generation volume.

Claims (37)

1. A method for igniting a process plasma, the method comprising:

flowing an ignition gas into a plasma chamber;

providing at least one self-resonating device in the plasma chamber and a power transformer coupled to the plasma chamber;

using the at least one self-resonating device to form at least one ignition plasma within the plasma chamber, the at least one ignition plasma causing at least partial ionization of the ignition gas; and

using the power transformer to inductively couple power to the plasma chamber, including to the at least one ignition plasma in the plasma chamber, and ignite the process plasma within the plasma chamber,

wherein the at least one self-resonating device enables partial ionization of the ignition gas using reduced power during ignition of the process plasma.

2. The method of claim 1 wherein the self-resonating device resonates with a radio frequency or microwave frequency.

3. The method of claim 1 further comprising positioning the at least one self-resonating device adjacent to a plasma generation volume within the plasma chamber, the plasma generation volume being a region within which the process plasma forms.

4. The method of claim 3 further comprising positioning a first self-resonating device of the at least one self-resonating device at an inlet of the plasma chamber and a second self-resonating device at an outlet of the plasma chamber.

5. The method of claim 3 further comprising positioning a first self-resonating device of the at least one self-resonating device and a second self-resonating device at an equidistance along the plasma channel.

6. The method of claim 1 further comprising operating the at least one self-resonating device at a frequency between 100 megahertz and 10 gigahertz.

7. The method of claim 1 further comprising operating the at least self-resonating device at a frequency between 300 megahertz and 3 gigahertz.

8. The method of claim 1 wherein the at least one self-resonating device is a coaxial resonator, ring resonator, or any combination thereof.

9. The method of claim 1 wherein the at least one self-resonating device is a microstrip resonator, stripline resonator, or any combination thereof.

10. The method of claim 1 wherein the process plasma is ignited with an average field between approximately 1 to 10 kilovolts per meter.

11. The method of claim 1 wherein the ignition plasma is sustained with a voltage less than 100 Vrms.

12. The method of claim 1 wherein a peak voltage of the ignition plasma is less than 300 Vrms.

13. The method of claim 1 further comprising supplying the at least one self-resonating device a power less than 50 Watts.

14. The method of claim 1 wherein a pressure within the plasma chamber is less than 50 torr.

15. A plasma source for generating a plasma, the plasma source comprising:

a plasma ignition gas source that flows a plasma ignition gas into a plasma chamber;

at least one self-resonating device in the plasma chamber that generates at least one ignition plasma within the plasma chamber, the at least one ignition plasma causing at least partial ionization of the plasma ignition gas;

a power source in direct electrical communication with the plasma chamber; and

a power transformer coupled to the plasma chamber configured to ignite the process plasma within the plasma chamber by coupling power from the power source to the plasma chamber, including to the at least one ignition plasma in the plasma chamber,

wherein the at least one self-resonating device enables partial ionization of the ignition gas using reduced power during ignition of the process plasma.

16. The plasma source of claim 15 further comprising positioning the at least one self-resonating device adjacent to a plasma generation volume inside the plasma chamber, the plasma generation volume being a region within which the process plasma forms.

17. The plasma source of claim 16 wherein a first self-resonating device of the at least one self-resonating device and a second self-resonating device are positioned an equidistance along the plasma generation volume.

18. The plasma source of claim 16 wherein a first self-resonating device of the at least one self-resonating device is positioned at an inlet of the plasma chamber and a second self-resonating device is positioned at an outlet of the plasma chamber.

19. The plasma source of claim 15 wherein the at least one self-resonating device operates at a microwave frequency or a radio frequency.

20. The plasma source of claim 15 wherein the at least one self-resonating device operates at a frequency between 100 megahertz and 10 gigahertz.

21. The plasma source of claim 15 wherein the at least one self-resonating device operates at a frequency between 300 megahertz and 3 gigahertz.

22. The plasma source of claim 15 wherein the at least one self-resonating device is a coaxial resonator, ring resonator, or any combination thereof.

23. The plasma source of claim 15 wherein the process plasma is ignited with an average field of 10 kilovolts per meter.

24. The plasma source of claim 15 wherein the one or more ignition plasmas is sustained with a voltage less than 100 Vrms.

25. The plasma source of claim 15 wherein a peak voltage of the ignition plasma is less than 300 Vrms.

26. The plasma source of claim 16 wherein the at least one self-resonating device is supplied a power less than 50 Watts.

27. The plasma source of claim 16 wherein a pressure within the plasma chamber is less than 50 torr.

Assignments (9)
RELEASE OF SECURITY INTEREST Recorded Aug 24, 2022
From: BARCLAYS BANK PLC
To: MKS INSTRUMENTS, INC.; NEWPORT CORPORATION; ELECTRO SCIENTIFIC INDUSTRIES, INC.
Reel/Frame 063009/0001 →
RELEASE OF SECURITY INTEREST Recorded Aug 24, 2022
From: BARCLAYS BANK PLC
To: MKS INSTRUMENTS, INC.; NEWPORT CORPORATION; ELECTRO SCIENTIFIC INDUSTRIES, INC.
Reel/Frame 062739/0001 →
SECURITY INTEREST Recorded Aug 19, 2022
From: MKS INSTRUMENTS, INC.; NEWPORT CORPORATION; ELECTRO SCIENTIFIC INDUSTRIES, INC.
To: JPMORGAN CHASE BANK, N.A., AS COLLATERAL AGENT
Reel/Frame 061572/0069 →
CORRECTIVE ASSIGNMENT TO CORRECT THE REMOVE U.S. PATENT NO.7,919,646 PREVIOUSLY RECORDED ON REEL 048211 FRAME 0312. ASSIGNOR(S) HEREBY CONFIRMS THE PATENT SECURITY AGREEMENT (ABL). Recorded Jan 14, 2021
From: ELECTRO SCIENTIFIC INDUSTRIES, INC.; MKS INSTRUMENTS, INC.; NEWPORT CORPORATION
To: BARCLAYS BANK PLC, AS COLLATERAL AGENT
Reel/Frame 055668/0687 →
PATENT SECURITY AGREEMENT (ABL) Recorded Feb 1, 2019
From: ELECTRO SCIENTIFIC INDUSTRIES, INC.; MKS INSTRUMENTS, INC.; NEWPORT CORPORATION
To: BARCLAYS BANK PLC, AS COLLATERAL AGENT
Reel/Frame 048211/0312 →
RELEASE OF SECURITY INTEREST Recorded Feb 1, 2019
From: DEUTSCHE BANK AG NEW YORK BRANCH
To: MKS INSTRUMENTS, INC.; NEWPORT CORPORATION
Reel/Frame 048226/0095 →
SECURITY AGREEMENT Recorded May 4, 2016
From: MKS INSTRUMENTS, INC.; NEWPORT CORPORATION
To: DEUTSCHE BANK AG NEW YORK BRANCH
Reel/Frame 038663/0265 →
SECURITY AGREEMENT Recorded May 4, 2016
From: MKS INSTRUMENTS, INC.; NEWPORT CORPORATION
To: BARCLAYS BANK PLC; BARCLAYS BANK PLC
Reel/Frame 038663/0139 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 3, 2015
From: SMITH, SHAUN; WALTHER, STEVEN R.; WU, CHEN
To: MKS INSTRUMENTS, INC.
Reel/Frame 035328/0125 →
Continuity (1)
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