IP Library Granted Patent US 12,315,697
Granted Patent B2
US 12,315,697 · App. 17/785,873 · Granted May 27, 2025

Method and apparatus for use in generating plasma

Inventors: Sean Michael Carley (Gloucester, GB); Sven Gauter (London, GB)
Assignee: Dyson Technology Limited
H01J37/3211C23C14/3471C23C14/358H01J37/32651
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 12,315,697
App. No.
17/785,873
Granted
May 27, 2025
Kind
B2
Abstract

A method of generating a plasma is provided. The method uses a plasma antenna having a length, the method including driving an electrical conductor of the plasma antenna with RF frequency current to generate plasma both at a first location and at a second location spaced apart from the first location in a direction along the length of the antenna, there being a region adjacent to the antenna between the first location and the second location at which the generation of plasma is curtailed as a result of at least one shield member.

Claims (36)

1. A method of generating a plasma with the use of a plasma antenna having a length, the method including driving an electrical conductor of the plasma antenna with RF frequency current to generate plasma both at a first location and at a second location spaced apart from the first location in a direction along the length of the antenna, there being a region adjacent to the antenna between the first location and the second location at which the generation of plasma is curtailed as a result of at least one shield member;

wherein the at least one shield member restricts the generation of plasma at a further region that is on the opposite side of the first location from the second location, in the direction along the length of the antenna, or on the opposite side of the second location from the first location, in the direction along the length of the antenna.

2. The method according to claim 1 , wherein the plasma generated at one or both of the first location and the second location extends circumferentially around the antenna by more than 300 degrees.

3. The method according to claim 1 , wherein the plasma generated at one or both of the first location and the second location extends circumferentially around the antenna by less than 270 degrees.

4. The method according to claim 1 , wherein the at least one shield member restricts the generation of plasma circumferentially around the antenna by more than 300 degrees.

5. The method according to claim 1 , wherein the at least one shield member restricts the generation of plasma on circumferentially around the antenna by less than 270 degrees.

6. The method according to claim 1 , wherein the at least one shield member restricts the generation of plasma at one or both of the first location and the second location.

7. The method according to claim 1 , wherein the at least one shield member restricts the generation of plasma at a further region that is on the opposite side of the first location from the second location, in the direction along the length of the antenna, or on the opposite side of the second location from the first location, in the direction along the length of the antenna.

8. The method according to claim 1 , wherein the at least one shield member comprises material that has a relative magnetic permeability of less than 100.

9. The method according to claim 1 , wherein the at least one shield member is in the form of a partial or complete Faraday cage.

10. The method according to claim 1 , wherein the at least one shield member comprises an electromagnetic-shielding electrically conductive material.

11. The method according to claim 1 , wherein the at least one shield member is held at a fixed potential.

12. The method according to claim 1 , wherein the at least one shield member comprises dielectric material.

13. The method according to claim 1 , wherein the antenna creates a magnetic field which is enhanced and/or focussed by a plasma focussing member, which comprises ferromagnetic material.

14. The method according to claim 1 , wherein the antenna is at least partly contained within an air-tight tube of material.

15. The method according to claim 14 , wherein the at least one shield member is mounted externally of the air-tight tube of material.

16. The method according to claim 1 , wherein the length of the antenna between the first and second locations is linear.

17. The method according to claim 1 , wherein the method includes generating plasma with the use of at least two lengths of plasma antenna being spaced laterally apart from each other.

18. The method according to claim 1 , wherein the method includes confining the plasma so as to cause interaction between the plasma and a target.

19. A plasma antenna for use in the method of claim 1 , the antenna being provided together with said at least one shield member, the antenna and said at least one shield member together forming a plasma antenna assembly.

20. A plasma reactor comprising one or more plasma antenna assemblies according to claim 19 .

21. The plasma reactor according to claim 20 , wherein the plasma antenna is configured to generate a plasma remote from a sputter target.

22. A deposition apparatus comprising one or more plasma antenna assemblies according to claim 19 .

23. A method of depositing a material on a substrate, the method comprising:

generating a plasma remote from one or more sputter targets suitable for plasma sputtering using a plasma antenna having a length, by driving an electrical conductor of the plasma antenna with RF frequency current to generate plasma both at a first location and at a second location spaced apart from the first location in a direction along the length of the antenna, there being a region adjacent to the antenna between the first location and the second location at which the generation of plasma is curtailed as a result of at least one shield member,

generating sputtered material from the one or more sputter targets using the plasma; and

depositing the sputtered material onto the substrate.

24. The method according to claim 23 , wherein the step of generating sputtered material from the target or targets using the plasma includes confining and/or controlling, with the use of an electric field and/or a magnetic field, the plasma in such a way that the plasma sputters material from a target.

25. The method according to claim 23 , wherein the plasma has uniform density at the target as a result, at least in part, of the use of the at least one shield member.

26. An electronic device comprising a component which comprises a layer of material deposited using the method of claim 23 .

27. The electronic device according to claim 26 , wherein the component includes the substrate onto which the layer of material has been deposited.

28. A plasma antenna assembly, the assembly comprising an antenna and a housing, wherein

the antenna has a length,

the antenna is configured, when powered by RF frequency current, to generate plasma both at a first location and at a second location spaced apart from the first location in a direction along the length of the antenna, and

the housing has at least one shield member which is arranged such that there is a region adjacent to the antenna between the first location and the second location at which, in use, the generation of plasma is inhibited as a result of said at least one shield member;

wherein the at least one shield member is configured to restrict the generation of plasma at a further region that is on the opposite side of the first location from the second location, in the direction along the length of the antenna, or on the opposite side of the second location from the first location, in the direction along the length of the antenna.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 4, 2022
From: CARLEY, SEAN MICHAEL; GAUTER, SVEN
To: DYSON TECHNOLOGY LIMITED
Reel/Frame 060716/0615 →
Priority Claims (1)
GB 1918481 · Dec 16, 2019 · national
Continuity (1)
Related Publication 20230028207A1 · Jan 26, 2023
References Cited (87)
US 4725449A · Ehlers et al. · 1988 [cited by applicant]
US 4841409A · Kalwar · 1989 [cited by applicant]
US 5560776A · Sugai et al. · 1996 [cited by applicant]
US 5587226A · Leung et al. · 1996 [cited by applicant]
US 5795429A · Ishii et al. · 1998 [cited by applicant]
US 5994236A · Ogle · 1999 [cited by applicant]
US 6080271A · Fujii · 2000 [cited by applicant]
US 6181069B1 · Tonotani et al. · 2001 [cited by applicant]
US 6251792B1 · Collins et al. · 2001 [cited by applicant]
US 6806653B2 · Strang · 2004 [cited by examiner]
US 6863773B1 · Emmerich et al. · 2005 [cited by applicant]
US 10790122B2 · Hong · 2020 [cited by examiner]
US 11515122B2 · Lane · 2022 [cited by examiner]
US 20030087488A1 · Fink et al. · 2003 [cited by applicant]
US 20030095072A1 · Kwon et al. · 2003 [cited by applicant]
US 20030228416A1 · Iwamaru · 2003 [cited by applicant]
US 20040011466A1 · Matsumoto et al. · 2004 [cited by applicant]
US 20040027293A1 · Miyake et al. · 2004 [cited by applicant]
US 20040060662A1 · Yeom et al. · 2004 [cited by applicant]
US 20070193512A1 · Deguchi et al. · 2007 [cited by applicant]
US 20070235327A1 · Vukovic · 2007 [cited by applicant]
US 20080050537A1 · Godyak · 2008 [cited by applicant]
US 20080067430A1 · Hershkowitz · 2008 [cited by examiner]
US 20080272700A1 · Lin et al. · 2008 [cited by applicant]
US 20100078320A1 · Stowell · 2010 [cited by examiner]
US 20100116790A1 · Spitzl · 2010 [cited by applicant]
US 20100206846A1 · Nishimura et al. · 2010 [cited by applicant]
US 20110018443A1 · Kou et al. · 2011 [cited by applicant]
US 20110076420A1 · Stowell · 2011 [cited by applicant]
US 20110080094A1 · Setsuhara et al. · 2011 [cited by applicant]
US 20120211166A1 · Yevtukhov et al. · 2012 [cited by applicant]
US 20120293070A1 · Kurunczi et al. · 2012 [cited by applicant]
US 20130047923A1 · Kato · 2013 [cited by examiner]
US 20130193848A1 · Biloiu et al. · 2013 [cited by applicant]
US 20140196849A1 · Nguyen et al. · 2014 [cited by applicant]
US 20150024609A1 · Milligan et al. · 2015 [cited by applicant]
US 20150091442A1 · Mai et al. · 2015 [cited by applicant]
US 20160071704A1 · Benveniste et al. · 2016 [cited by applicant]
US 20160079042A1 · Likhanskii et al. · 2016 [cited by applicant]
US 20160233047A1 · Tang et al. · 2016 [cited by applicant]
US 20180308661A1 · Collins et al. · 2018 [cited by applicant]
CN 101460002A · 2009 [cited by applicant]
CN 102573265A · 2012 [cited by applicant]
DE 4136297A1 · 1993 [cited by applicant]
EP 0468758A1 · 1992 [cited by applicant]
EP 1860680A1 · 2007 [cited by applicant]
GB 2576539A · 2020 [cited by applicant]
JP 2000345351A · 2000 [cited by applicant]
JP 2003086581A2 · 2003 [cited by applicant]
JP 2004055600A · 2004 [cited by applicant]
JP 2009140899A · 2009 [cited by applicant]
JP 2011181292A2 · 2011 [cited by applicant]
JP 2012038568A2 · 2012 [cited by applicant]
JP 2018014170A2 · 2018 [cited by applicant]
KR 20040010220A · 2004 [cited by applicant]
KR 20070079870A · 2007 [cited by applicant]
KR 100753868B1 · 2007 [cited by applicant]
KR 20080024624A · 2008 [cited by applicant]
KR 20080024693A · 2008 [cited by applicant]
KR 20090018544A · 2009 [cited by applicant]
KR 20090033718A · 2009 [cited by applicant]
KR 1020090076159A · 2009 [cited by applicant]
KR 20090073327A · 2009 [cited by applicant]
KR 20090076159A · 2009 [cited by applicant]
KR 20090079696A · 2009 [cited by applicant]
KR 20110012167A · 2011 [cited by applicant]
KR 20110027396A · 2011 [cited by applicant]
KR 20120060017A · 2012 [cited by applicant]
KR 20120090345A · 2012 [cited by applicant]
KR 20140125121A · 2014 [cited by applicant]
KR 20170104063A · 2017 [cited by applicant]
KR 20170110001A · 2017 [cited by applicant]
KR 20180104348A · 2018 [cited by applicant]
RU 2601947C2 · 2016 [cited by applicant]
RU 2642493C1 · 2018 [cited by applicant]
WO 2002084700A1 · 2002 [cited by applicant]
WO 2005057607A2 · 2005 [cited by applicant]
WO 2007117122A1 · 2007 [cited by applicant]
WO 2011131921A1 · 2011 [cited by applicant]
WO 2018173892A1 · 2018 [cited by applicant]
WO 2021123729A1 · 2021 [cited by applicant]
Office Action received for Japanese Patent Application No. 2022-536797, mailed on Jul. 4, 2023, 10 pages (6 pages of English Translation and 4 pages of Original Document). [cited by applicant]
International Search Report and Written Opinion received for PCT Patent Application No. PCT/GB2020/053114, mailed on Mar. 9, 2021, 11 pages. [cited by applicant]
Examination Report and Search Report received for Patent Application No. GB 1918480.3, mailed on Jun. 29, 2022, 4 pages. [cited by applicant]
International Search Report and Written Opinion received for PCT Patent Application No. PCT/GB2020/053112, mailed on Mar. 4, 2021, 12 pages. [cited by applicant]
International Search Report and Written Opinion received for PCT Patent Application No. PCT/GB2020/053113, mailed on Mar. 5, 2021, 12 pages. [cited by applicant]
Search Report received for Patent Application No. GB 1918481.1, mailed on May 29, 2020, 1 page. [cited by applicant]