CN106486335A - 利用二次等离子体注入的等离子体蚀刻系统及方法 - Google Patents

利用二次等离子体注入的等离子体蚀刻系统及方法 Download PDF

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CN106486335A
CN106486335A CN201610724716.5A CN201610724716A CN106486335A CN 106486335 A CN106486335 A CN 106486335A CN 201610724716 A CN201610724716 A CN 201610724716A CN 106486335 A CN106486335 A CN 106486335A
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T·Q·特兰
S·朴
Z·翁
D·卢博米尔斯基
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Abstract

本申请公开了利用二次等离子体注入的等离子体蚀刻系统及方法。一种等离子体处理装置包括：第一等离子体源；第一平面电极；气体分配设备；等离子体阻挡筛网；以及工件卡盘。所述第一等离子体源产生第一等离子体产物，所述第一等离子体产物从所述第一等离子体源离开，穿过所述第一平面电极中的第一孔隙。所述第一等离子体产物继续穿过所述气体分配设备中的第二孔隙。所述等离子体阻挡筛网包括具有第四孔隙的第三板，并且面对所述气体分配设备，使得所述第一等离子体产物穿过所述多个第四孔隙。所述工件卡盘面对所述等离子体阻挡筛网的第二侧，从而在所述等离子体阻挡筛网与所述工件卡盘之间限定工艺腔室。所述第四孔隙具有足够小的大小，以便阻挡所述工艺腔室中产生的等离子体到达所述气体分配设备。

Description

利用二次等离子体注入的等离子体蚀刻系统及方法
技术领域
本公开涉及等离子体处理系统。
背景技术
在等离子体处理中，等离子体形成电离和/或能量激发物质，以与可为例如半导体晶片的工件相互作用。为了形成和/或维持等离子体，一个或多个射频(RF)和/或微波发生器通常产生振荡电场和/或磁场。在一些晶片处理系统中，等离子体是在与所处理的一个或多个晶片相同的位置中产生的；在其他情况下，等离子体在一个位置中产生，并移动至晶片受处理的另一位置。所产生的等离子体通常包含高能和/或高腐蚀性物质和/或高能电子，使得产生它们的设备有时因与高能物质和/或电子接触发生劣化。例如，暴露于高能物质和/或电子的材料可能被蚀刻和/或溅射，从而产生经蚀刻和/或经溅射的材料，所述蚀刻和/或溅射材料可绕各种表面移动并且可反应或沉积在各种表面上。
发明内容
在一个实施方式中，一种用于等离子体处理的装置包括：第一等离子体源；第一平面电极；气体分配设备；等离子体阻挡筛网；以及工件卡盘。所述第一等离子体源产生第一等离子体产物。所述第一平面电极包括限定从其中穿过的多个第一孔隙的第一板，所述第一平面电极的第一侧设置为相对于所述第一等离子体源，使得所述第一等离子体产物从所述第一等离子体源离开，穿过所述多个第一孔隙到达所述第一平面电极的第二侧。所述气体分配设备包括限定从其中穿过的多个第二孔隙的第二板，所述气体分配设备的第一侧设置为面对所述第一平面电极的第二侧，使得所述第一等离子体产物继续穿过所述多个第二孔隙到达所述气体分配设备的第二侧。所述等离子体阻挡筛网包括限定从其中穿过的多个第四孔隙的第三板，所述等离子体阻挡筛网的第一侧设置为面对所述气体分配设备的第二侧，使得所述第一等离子体产物穿过所述多个第四孔隙到达所述等离子体阻挡筛网的第二侧。所述工件卡盘面对所述等离子体阻挡筛网的第二侧，使得在所述等离子体阻挡筛网与所述工件卡盘之间限定工艺腔室。所述第四孔隙具有足够小的大小，以便阻挡所述工艺腔室中产生的等离子体到达所述气体分配设备。
在一个实施方式中，等离子体处理腔室包括工件保持器和平面电极。所述平面电极跨其中心区域限定以一定厚度分开的平行且相对的第一平面表面和第二平面表面。第二平面表面设置为面对所述工件夹具工件保持器。所述平面电极限定从其中穿过的多个孔隙。所述孔隙中的每者以第一孔隙部分和第二孔隙部分表征。所述第一孔隙部分限定孔轴以及垂直于所述孔轴的第一孔隙较短侧向尺寸，所述第一孔隙部分从所述第一平面表面延伸穿过所述厚度的至少一半。所述第二孔隙部分限定第二孔隙较短侧向尺寸，所述第二孔隙较短侧向尺寸小于所述第一孔隙较短侧向尺寸，并且从所述第二平面表面延伸穿过所述厚度的不到一半。所述第一孔隙部分和所述第二孔隙部分轴向邻接，以将所述孔隙形成为从所述第一平面表面至所述第二平面表面的连续孔隙。
在一个实施方式中，用于等离子体处理的装置包括：气源；第一平面电极；第二平面电极；第一电源；等离子体阻挡筛网；工件卡盘；以及第二电源。所述第一平面电极包括限定从其中穿过的多个第一孔隙的第一板，所述第一平面电极的第一侧设置为相对于所述气源，使得来自于所述气源的气体穿过所述多个第一孔隙到达所述第一平面电极的第二侧。所述第二平面电极包括限定从其中穿过的多个第二孔隙的第二板，所述第二平面电极的第一侧设置为面对所述第一平面电极的第二侧。所述第一电源将射频(RF)功率耦合在所述第一平面电极和所述第二平面电极上。第一等离子体是用所述气体在所述第一平面电极与所述第二平面电极之间产生的，并且来自于所述第一等离子体的第一等离子体产物通过所述多个第二孔隙到达所述第二平面电极的第二侧。所述等离子体阻挡筛网包括限定从其中穿过的多个第三孔隙的第三板，所述等离子体阻挡筛网的第一侧设置为面对所述第二平面电极的第二侧，使得所述第一等离子体产物穿过所述多个第三孔隙到达所述等离子体阻挡筛网的第二侧。所述工件卡盘面对所述等离子体阻挡筛网的第二侧，从而在所述等离子体阻挡筛网与所述工件卡盘之间限定工艺腔室。所述第二电源将射频(RF)功率耦合在所述等离子体阻挡筛网和所述工件卡盘上，从而会用所述气体在所述等离子体阻挡筛网和所述工件卡盘之间产生第二等离子体。
附图简述
参考与下文所简述的附图结合的以下具体实施方式，可理解本公开，其中相同元件符号在若干附图中指示类似部件。应当注意，出于清楚例示目的，附图中的某些元件可不按比例来绘制。特定物项实例可用后缀有括号内的第二数字的数字指称(例如，等离子体阻挡筛网270(1)、270(2)等等)，而未后缀短划线的数字是指任何此类物项(例如，等离子体阻挡筛网270)。在示出多个物项的情况下，为了清楚例示，仅对一些实例加上标签。
图1示意性地示出根据一个实施方式的等离子体处理系统的主要元件。
图2以截面图示意性地示出根据一个实施方式的等离子体处理系统的主要元件。
图3示出根据一个实施方式的作为图2的等离子体处理系统的部分的等离子体阻挡筛网的一部分。
图4示出根据一个实施方式的另一等离子体阻挡筛网的一部分。
图5是根据一个实施方式的对与等离子体阻挡筛网的第二孔隙部分的较短侧向尺寸的选择有关的数据建模的图。
图6以放大图示意性地示出图2中指出的区域。
图7以截面图示意性地示出根据一个实施方式的另一等离子体处理系统的主要元件。
另外实施方式以及特征在以下描述中部分阐明，并且部分在查阅本说明书后将对技术人员为部分显而易见的，或者可通过本发明的实践来了解。本发明的特征以及优点可借助于本说明书中描述的器械、组合和方法来实现和达成。
具体实施方式
图1示意性地示出根据一个实施方式的等离子体处理系统100的主要元件。系统100被描绘为单晶片半导体晶片等离子体处理系统，但是对本领域中的技术人员将显而易见的是，本文的技术和原理也适用于任何类型等离子体产生系统(例如，不一定处理晶片或半导体的系统)。处理系统100包括用于晶片接口115、用户接口120、等离子体处理单元130、控制器140、一个或多个电源150和一个或多个射频(RF)发生器165的外壳110。处理系统100由各种设施支持，所述设施可包括气体155、外部电源170、真空160和任选地其他物质。为了清楚例示，并未示出处理系统100内的内部管道和电连接。
处理系统100被示为所谓的间接等离子体处理系统，所述间接等离子体处理系统在第一位置处产生等离子体并将等离子体和/或等离子体产物(例如，离子、分子碎片、带电物质等等)引向发生处理的第二位置。因此，在图1中，等离子体处理单元130包括等离子体源132，它为工艺腔室134供应等离子体和/或等离子体产物。工艺腔室134包括一个或多个工件保持器135，晶片接口115将工件50(例如，半导体晶片，然而，也可以是不同类型工件)放在所述工件保持器上，以待处理。在操作中，将气体155引入到等离子体源132中，并且RF发生器165中的至少一者供应功率以在等离子体源132内点燃第一等离子体。在等离子体源132内，可存在有施加RF功率并产生等离子体的多个区域。等离子体和/或等离子体产物从等离子体源132穿过扩散器板137到工艺腔室134。可将另外的气体添加到工艺腔室134中的等离子体和/或等离子体产物，还可在工艺腔室134内提供RF功率来产生另一等离子体。在工艺腔室134中处理工件50。
因此，一般来说，在等离子体处理系统内的一个、两个或更多个位置处点燃等离子体，并且本文所公开的技术可适应于点燃和/或使用在单个或多个位置处形成的等离子体的等离子体处理系统。某些电子器件制造商会偏好能够以多种配置来灵活地点燃和/或使用等离子体的系统，使得每个系统可适用于对应多种处理需要。
图2以截面图示意性地示出根据一个实施方式的等离子体处理系统200的主要元件。等离子体处理系统200是图1的等离子体处理单元130的实例。等离子体处理系统200包括等离子体源210和工艺腔室205，所述等离子体源和工艺腔室也可产生等离子体，如下论述。在图2的取向中，气体和/或等离子体产物大体流动方向是向下的，并且这个方向在本文中可以称为“下游”，而图2的取向中相反向上方向可以称为“上游”。另外，图2中示出的装置的大部分可为围绕中心轴201圆柱形对称的，其中相关联的方向被限定为径向方向202和方位方向203。这种方向约定可以用于本文，但是本领域的技术人员应当理解，许多本文所述原理并不限于圆柱形对称的系统。
如图2所示，等离子体源210可将气体、和/或由上游远程等离子体源电离的气体作为等离子体源气体212引入通过RF电极215。RF电极215电连系至第一气体扩散器220和面板225，用于将源气流重新定向，使得气流均匀地分布于等离子体源210(在图2的视图中，从左至右均匀)。应当注意，本文中的所有扩散器或筛网可表征为电极，因为任何此类扩散器或筛网可连系至特定电位。绝缘体230使RF电极215(包括面板225)与保持电接地的扩散器235电气绝缘。扩散器235用作背对RF电极215的面板225的第二电极。面板225、扩散器235和绝缘体230的表面限定第一等离子体产生空腔，当等离子体源气212存在并且RF能量通过RF电极215提供在面板225处时，在所述第一等离子体产生空腔中产生第一等离子体245。RF电极215、面板225和扩散器235可由任何导体形成，并且在一个实施方式中，由铝(或铝合金，诸如已知“6061”合金类型)形成。面板225和扩散器235的直接面对等离子体245的表面可涂布有例如氧化钇(Y2O3)或氧化铝(Al2O3)的陶瓷层，以便抵抗等离子体245中产生的通电等离子体产物所造成的轰击。面板225和扩散器235的不一定直接暴露于等离子体下但暴露于等离子体所产生的反应气体和/或自由基的其他表面可涂布有陶瓷层(例如，氧化钇、氧化铝)或合适的钝化层(例如，阳极化层，或化学产生的氧化铝层)，以便实现化学耐性。绝缘体230可为任何的绝缘体，并且在一个实施方式中，它由陶瓷形成。
等离子体245中产生的等离子体产物通过扩散器235，这再次有助于促使等离子体产物均匀分布，并且可有助于电子温度控制。在通过扩散器235后，等离子体产物通过任选的气体分配设备260，以促成均匀性。(某些实施方式并不包括气体分配设备260；参见例如图7。)任选的气体分配设备260也保持为电接地的。完全穿过任选的气体分配设备260的孔隙的直径为扩散器235内的孔隙的直径的至少3倍。另外，气体分配设备260包括另外气体通道250，所述另外气体通道可以用于在一种或多种另外气体155(2)进入工艺腔室205(也就是说，气体155(2)仅从气体分配设备260的远离扩散器235的一侧汇集)时，将这些气体向等离子体产物引导。任选的气体分配设备260还可由铝或铝合金制成，并且正如上文论述的面板225和扩散器235那样，可至少部分涂布有用于实现化学耐性的钝化层，或可涂布有陶瓷层。
气体155(1)、155(2)和/或来自于等离子体245的等离子体产物进入气室空腔265，随后通过等离子体阻挡筛网270(1)到达工艺腔室205。等离子体阻挡筛网270(1)可以形成在0.15至1.0英寸的范围内的厚度，并且形成许多较小孔隙，这些孔隙被配置成允许来自上游源的气体以及等离子体产物通过，以便进入工艺腔室205，同时基本阻挡来自上游部件的下游等离子体以及等离子体产物，如下文中详细论述。在一个实施方式中，等离子体阻挡筛网270可有利地在其中心区域形成每平方英寸至少10个孔隙，并且在某些实施方式中，可以形成每平方英寸30或更多个孔隙。类似任选的气体分配设备260，等离子体阻挡筛网270(1)也保持为电接地的。类似以上论述的面板225和扩散器235，等离子体阻挡筛网270(1)的直接暴露于等离子体下的表面有利地涂布有陶瓷(例如，氧化铝或氧化钇)，而未直接暴露于等离子体的表面也可涂布陶瓷，并有利地至少涂布有钝化层，以实现对反应气体和活化物质的化学耐性。如上所述那样来产生的所有气体和/或等离子体产物与工件50在工艺腔室205内相互作用，并且可以在工艺腔室205内产生另外等离子体275。当在工艺腔室205内期望等离子体时，由于扩散器235被保持为电接地的(并且当存在时，任选的气体分配设备260)，用于形成等离子体275的RF功率被施加到工件保持器135。DC偏压还可以施加到工件保持器135，以便操控等离子体275中产生的离子，从而促成对工件50的定向(各向异性)蚀刻，如下论述。工件保持器135可与RF和/或DC偏压源可切换地连接，以便在所选时间而非其他时间上、在工艺腔室205内产生等离子体。工件保持器135可与如用于在面板225与扩散器235之间形成等离子体245的相同RF功率源连接，或者可与不同RF功率源连接。
等离子体阻挡筛网270(1)的使用、选择是否通过将RF功率和/或DC偏压提供至工件保持器135来产生等离子或不产生此类等离子体的能力以及本文所述其他特征提供处理系统200的应用灵活性。例如，在第一时间上，处理系统200可以在其中等离子体未在工艺腔室205内产生的模式下操作。在第一时间上，处理系统200的上游部分提供的气体和/或等离子体产物可以提供各向同性蚀刻，并且工件保持器135可保持为处于DC接地(但是可在工件保持器135的空间部分上提供DC偏移，以便实现静电晶片卡紧)。在第二时间上，处理系统200可以在其中等离子体在工艺腔室205内产生的模式下操作，并且它的等离子体产物可由等离子体阻挡筛网与工件保持器135之间的DC偏压操控。在第二时间上，DC偏压所操控的等离子体产物可以提供各向异性蚀刻，例如以便去除工件上的较广表面沉积、同时留下侧壁，或将工件中的较深沟槽内的材料清除。等离子体阻挡筛网270(1)的特征在图3和图4中更详细地示出，同时图2中的指示为A的部分的放大图在图6中详细示出。
图3示出等离子体阻挡筛网270的一部分，诸如图2的等离子体阻挡筛网270(1)。等离子体阻挡筛网270限定平行且相对的平面表面268和269，并且限定延伸穿过等离子体阻挡筛网270的多个孔隙271，如图2所示。第一平面表面268和第二平面表面269表征等离子体阻挡筛网270的中心部分；然而，在中心部分外，等离子体阻挡筛网可较厚或较薄，以便提供等离子体处理系统200的其他结构的附接点。孔隙271专门用于允许大量等离子体产物以最小的壁效应通过其中，但是阻挡来自等离子体处理系统200的其他部分的等离子体275中的等离子体，其中等离子体会对其他部件造成损坏。图3示出单个孔隙271的特征，其特征为第一孔隙部分272和第二孔隙部分273，如图所示。第一孔隙部分272可为圆柱形的，这可促进制造，但是也可限定其他形状，例如具有矩形或六边形截面。任何此类截面可沿第一孔隙部分272的竖直深度H1保持相对恒定(给定等离子体阻挡筛网270(1)的取向，如图2和图3所示)，并且视为限定孔轴(例如，竖直孔轴，如图2和图3所示)。第一孔隙部分272在侧向方向(例如，垂直于孔轴的方向)的较短侧向尺寸示为W1。本文中的“较短侧向尺寸”表示表征具有竖直侧的孔隙的任何侧向尺寸中的最大那个(例如，如果第一孔隙部分272是圆柱形的，那么较短侧向尺寸W1是圆柱体的直径，如果第一孔隙部分272是矩形的，那么较短侧向尺寸W1是矩形边的较小那个等等)。类似地，第二孔隙部分273的竖直深度示为H2，而第二孔隙部分273在侧向方向的较小侧向尺寸示为W2。H1和H2的总和是在平面表面268和269之间等离子体阻挡筛网270的厚度。
现在参考图2和图3两者，尺寸H1、W1、H2和W2被选择成在来自于上方(在图2所示取向上)的等离子体产物通过孔隙271时，最小化壁效应，而且还会阻挡等离子体275产物到达任选的气体分配设备260(如果存在)和/或等离子体处理系统200的其他上游部件。研究表明(参见图5)，即使当孔隙271设有高度非常短的第二孔隙部分273时，适当宽度W2也将显著降低第一孔隙部分272内和上方电子密度。电子密度可以用于估计任何等离子体产物将通过孔隙271并对上游部件造成影响的程度。在本文中的实施方式中，宽度W2小于0.050"，而高度H2在0.050"与0.100"之间。对于机械的完整性，H1通常大于H2，并且在本文中的实施方式中，H1通常为0.10"或更大。W1不如W2那么关键，但是较大W1会减少壁效应(例如，离子的再组合、激活物质的去激活等等)，以便保持穿过孔隙271的等离子体产物的活性。W1可为例如0.02"至0.25"。
图4示出等离子体阻挡筛网270'的一部分，它是图3的等离子体阻挡筛网270的修改例。等离子体阻挡筛网270'限定多个孔隙271'，类似孔隙271，所述孔隙271'专门用于允许大量等离子体产物以最小的壁效应通过其中，但是阻挡来自等离子体处理系统200的其他部分的等离子体275中的等离子体。图4示出单个孔隙271'的特征，其特征为第一孔隙部分272和第二孔隙部分273'，如图所示。第一孔隙部分272在特性上与图3中示出的相同特征相同，并类似地，由此可为圆柱形的，这可促成制造，但是第一孔隙部分272还可限定其他形状，例如矩形或六边形截面。第二孔隙部分273'限定邻接第一孔隙部分272的圆柱形的上部部分276以及从上部部分276向外朝第二平面表面269张开的下部部分277。下部部分277可实际为圆锥形的，如图4所示，或者可仅仅从竖直方向向外弯曲。相对于孔轴成15度至65度的角度θ可以是有利的，如下论述。因此，上部部分276可表征为具有直径，并且所述下部部分277的直径在下部部分277邻接平面表面269的位置处大于上部部分276的直径。上部部分276和下部部分277轴向邻接，以使孔隙271'贯穿等离子体阻挡筛网270'。
形成孔隙271'使其包括圆锥形的下部部分277已发现对制造具有高质量的等离子体阻挡筛网270、将氧化铝或氧化钇继续涂布在面对着有源等离子体的表面(诸如第二平面表面269以及第二孔隙部分273、273'的侧表面)上来说是有利的。第一平面表面268以及第一孔隙部分272的侧壁还任选地涂布有氧化铝或氧化钇。如本领域的技术人员所已知，某些沉积技术(溅射)趋于高度定向，也就是说，要沉积的物质趋于在直线上从源行进，并附着到所述物质遇到的第一事物。这使得其难以在狭窄孔隙(诸如图3中的第二孔隙部分273)内提供有均匀厚度且较高密度的膜。提供圆锥形或其他渐缩边缘部分(诸如图4的下部部分277)不仅允许在渐缩边缘上实现改进沉积，而且还返回至上部部分276，因为上部部分276的内壁的每一个点会相对于可沉积材料的位置“形成”更广泛的角度。出于这个原因，还应了解，当下部部分277存在时，上部部分276的某些深宽比(例如，上部部分276的深度H3相对于上部部分276的宽度W2的深宽比，如图4所示)以及因此所形成的相应角度θ可以是有利的。当下部部分277提供通向溅射源的相对开放入口时，在0.5至4.0的范围内的深宽比可有利地提供相对于上部部分276的表面上的每一个点的广泛角度。
图5示出对支持选择图3和图4的第二孔隙部分273、273'的较短侧向尺寸的数据建模的图300。在图300中，水平轴线是对位置建模，其中导体(例如，工件保持器135和晶片50)假定呈现约4厘米，结构空隙(例如，具有等离子体275在其中的工艺腔室205)从约4厘米至几乎7厘米(注意，在图300中，示为折线)，并且等离子体阻挡筛网270界定从约7厘米延伸到图300的末端。竖直轴线指示在实心导体与工件保持器之间的等离子体区域内的建模电子密度。建模假定等离子体利用He在1Torr的压力和200W的功率下点燃。图300示出具有第二孔隙部分273的若干较小侧向尺寸的等离子体阻挡筛网270的建模电子密度数据。在约102至较低103的范围内的电子密度视为表示基本无等离子体的区域，也就是说，电子和/或其他等离子体产物数量是低至可忽略的。电子密度在等离子体区域内较高，并且在等离子体阻挡筛网270处降低。使用图3中示出的标注，所建模的所有等离子体阻挡筛网270假定H2在0.050"至0.100"的范围内，W1在0.100"至0.150"的范围内，并且H2在0.300"至0.400"的范围内。空心圆圈数据310是具有在0.100"至0.150"的范围内的W2的第二孔隙部分273，实心三角数据320是具有在0.050"至0.100"的范围内的W2的第二孔隙部分273，并且实心矩形数据330是具有在0.020"至0.050"的范围内的W2的第二孔隙部分273。
数据310和320表明，具有标注相应W2的第二孔隙的等离子体阻挡筛网270将会降低传输到相邻区域(例如，延伸到图300的右侧的区域，或者在图2中的等离子体阻挡筛网270(1)上方的区域)的电子密度，但将无法对其进行有效阻挡。数据330表明，具有在0.020"至0.050"的范围内的W2的等离子体阻挡筛网270将会几乎完全阻挡来自于相邻上游区域的等离子体。虽然在阻挡来自于上游区域的有源等离子体的方面是有效的，但是等离子体阻挡筛网270并不阻挡来自于上游等离子体的等离子体产物、和/或气体在下游方向上通过。
图6示意性地示出图2中指出的区域A。如图2中所示，工件50示为在工艺腔室205内的工件保持器135上。气体155和/或先前所形成的等离子体产物流过等离子体阻挡筛网270(1)，进入工艺腔室205，在所述工艺腔室中，另外等离子体275形成。如上指出，等离子体阻挡筛网270(1)被保持为电接地的。RF能量以及DC偏压被施加到工件保持器135，以向等离子体275提供能量。由于在工艺腔室205内存在反应物质和离子轰击源两者，因此工艺腔室205的内表面设有能够阻挡来自于此类源的攻击的材料(一般来说，但不限于，陶瓷)。材料还可选择用来管理电场分布(就DC意义和AC意义两者而言)，以便最大化递送到等离子体275中的RF功率。例如，工件保持器135可涂布有铝或氮化铝，并且等离子体阻挡筛网270(1)可涂布有氧化铝或氧化钇。任选陶瓷隔件350和/或任选陶瓷泵送内衬370可以用于减小工件保持器135的边缘的侧向电场。陶瓷隔件350以及陶瓷泵送内衬370是环形的，使得它们围绕工艺腔室205周边延伸，但不跨过工艺腔室205的中心区域，并且有利地由低损耗角正切值的材料(诸如高纯度氧化铝、氮化硅和/或碳化硅)制成。具有在0.1至0.0001的范围内的损耗角正切值的材料提供有用结果，而具有在0.005至0.001的范围内的低损耗角正切值的材料在合理成本下展现较高性能范围。等离子体阻挡筛网270(1)和陶瓷隔件350两者的部分设置在接地的升降板390的一部分的顶部，如图所示，并且从其获得机械支撑。升降板390与等离子体阻挡筛网270(1)、陶瓷隔件350和其他上覆结构机械连接，以便使得能够出于组装和/或维修目的，将所有此类结构从工件保持器135附近升降。等离子体阻挡筛网270(1)通过接触升降板390来电接地。陶瓷隔件350的厚度受控制成在等离子体阻挡筛网270(1)与陶瓷隔件350之间留下间隙360，以便确保陶瓷隔件350不会中断围绕工艺腔室205周边在方位角方向上等离子体阻挡筛网270(1)与升降板390的连续接触。
形成低损耗角正切值的材料的陶瓷隔件350和陶瓷泵送内衬370是相对昂贵的(相较例如从具有陶瓷涂层的铝来制造此类物项)，但是减小工件保持器135的边缘的电场效应，并且当等离子体275在工艺腔室205内产生时，减少反射RF功率。相较用于相同位置中的等效铝质部件，取代的陶瓷隔件350和陶瓷泵送内衬370还减少了与离子轰击有关的污染。陶瓷隔件350和陶瓷泵送内衬370的使用因此促成等离子体以及工艺的稳定性，并且减少污染。电场在图6中使用点线箭头示意性地例示；初级电场在工件保持器135/工件50与等离子体阻挡筛网270(1)之间。使工件保持器135/工件50与等离子体阻挡筛网270(1)之间的电场在某个方向上强力且均匀是有利的，因为电场操控各向异性蚀刻所涉及的离子。也就是说，为了清除竖直沟槽的底部的材料，对离子进行操控的电场需要对应为竖直的。较弱的场存在于工件保持器135与接地的升降板390之间，穿过陶瓷隔件350和陶瓷泵送内衬370。这些电场是由将插置在工件保持器135与升降板390之间的陶瓷隔件350和陶瓷泵送内衬370的介电材料减弱。减弱工件保持器135边缘处的侧向电场具有两个益处；(1)电场的方向性以及因此蚀刻的方向性维持朝向工件50边缘外部，并且(2)较弱电场产生比较高的场更少的溅射。
图7以截面图示意性地示出根据一个实施方式的等离子体处理系统400的主要元件。等离子体处理系统400是图1的等离子体处理单元130的实例。类似图2的等离子体处理系统200，等离子体处理系统400使得能够在工件50的相邻位置形成等离子体275。等离子体处理系统400包括就结构和功能来说与图2的等离子体处理系统200中出现的那些相同的许多部件，不同之处在于，缺少等离子体处理系统200中示出的任选的气体分配设备260。另外，等离子体处理系统400包括与图2中示出的等效物项不同配置的等离子体阻挡筛网270(2)以及在扩散器235与等离子体阻挡筛网270(2)之间的绝缘体280。
类似等离子体处理系统200，绝缘体230使RF电极215(包括面板225)与保持电接地的扩散器235电气绝缘。扩散器235用作背对RF电极215的面板225的第二电极。面板225、扩散器235和绝缘体230的表面限定第一等离子体产生空腔，当等离子体源气212存在并且RF能量通过RF电极215提供在面板225处时，在所述第一等离子体产生空腔中产生第一等离子体245。等离子体阻挡筛网270(2)也保持成电接地的，但是绝缘体280允许等离子体阻挡筛网270(2)与扩散器235隔离以提供独立RF接地回程路径。等离子体阻挡筛网270(2)内的孔隙被配置成类似等离子体阻挡筛网270(1)中的那些，也就是说，它们形成类似于图3和图4中示出的那些孔隙的形状，具有类似尺寸，使得上游等离子体产物可以通过，但是有源等离子体275受到扩散器235以及其他上游部件阻挡。
本文中的实施方式可以重新布置，并且可以形成各种形状。例如，图2和图7中示出的许多部件(诸如RF电极215、扩散器220和235、气体分配设备260、面板225、绝缘体230、等离子体阻挡筛网270等等)可以是绕中心轴基本径向对称的，以便处理作为工件50的圆形半导体晶片。然而，此类特征可为符合用作等离子体源的任何形状。用于将气体和/或等离子体产物引入和分配的特征(诸如扩散器、面板等等)的准确数量和放置方式也可改变。此外，以类似于包括气体通道250的气体分配设备260在来自于等离子体245的等离子体产物进入工艺腔室205时将气体155(2)添加到所述等离子体的方式，等离子体处理系统200的其他部件可配置成在气体通过系统到达工艺腔室205时，将气体155添加到其他气体和/或等离子体产物或与它们混合。还如图2、图6和图7表明，许多系统部件将会在等离子体处理单元中心区域内形成穿孔平面形状，以便将均匀工艺条件提供到平面工件，但是出于结构目的，也可在等离子体处理单元边缘处形成不同形状，诸如凸缘、厚度变化、实心无孔表面等等。中心区域范围在一个实施方式中可以改变，以便适应不同工件大小，尤其但不限于作为工件的晶片的直径。当工件是晶片时，中心区域通常将会涵盖延伸每个此类系统部件的半径至少一半的区域。
具体细节在以上描述中给出，以便提供对实施方式的透彻理解。然而，应当理解，实施方式可在没有这些具体细节的情况下实践。例如，所熟知的工艺、结构和技术可示出为没有不必要的细节，以便避免模糊实施方式。虽然本公开的原理在上文中已经结合特定的装置和方法进行描述，但是应当清楚理解，这个描述仅以举例方式进行，而不限制本公开的范围。
应当了解，所示布置仅是示例性的；其他实施方式可在构造方面大为不同，包括引入源气体量、电极和绝缘体布置方式、等离子体和/或等离子体产物产生后的处理方式和沟槽在绝缘体中形成方式。预见的是，本文公开的技术和装置可适用于这些以及其他布置，其中导电材料在使用过程中堆积，并且由此形成漏泄和/或排放路径。
如本文以及随附的权利要求书中所用，单数形式“一个”、“一种”和“所述”包括复数指代对象，除非上下文清楚地另外指明。因此，例如，提及“一种工艺”包括多种此类工艺，并且提及“电极”包括指称本领域的技术人员所已知的一个或多个电极以及其等效物，等等。另外，术语“包括”和“包含”在用于本说明书以及随附的权利要求书时，旨在指明存在陈述特征、整数、部件或步骤，但是它们并不排除一个或多个其他特征、整数、部件、步骤、动作或分组的存在或添加。

Claims (20)

1.一种等离子体处理装置，所述等离子体处理装置包括：
第一等离子体源，所述第一等离子体源产生第一等离子体产物；
第一平面电极，所述第一平面电极包括限定从其中穿过的多个第一孔隙的第一板，所述第一平面电极的第一侧设置为相对于所述第一等离子体源，使得所述第一等离子体产物从所述第一等离子体源离开，穿过所述多个第一孔隙到达所述第一平面电极的第二侧；
气体分配设备，所述气体分配设备包括限定从其中穿过的多个第二孔隙的第二板，所述气体分配设备的第一侧设置为面对所述第一平面电极的第二侧，使得所述第一等离子体产物继续穿过所述多个第二孔隙到达所述气体分配设备的第二侧；
等离子体阻挡筛网，所述等离子体阻挡筛网包括限定从其中穿过的多个第四孔隙的第三板，所述等离子体阻挡筛网的第一侧设置为面对所述气体分配设备的第二侧，使得所述第一等离子体产物穿过所述多个第四孔隙到达所述等离子体阻挡筛网的第二侧；以及
卡盘，所述卡盘面对所述等离子体阻挡筛网的所述第二侧，所述等离子体阻挡筛网与所述卡盘在其间限定工艺腔室；
其中所述第四孔隙具有足够小的大小，以便阻挡所述工艺腔室中产生的等离子体到达所述气体分配设备。
2.根据权利要求1所述的装置，其特征在于，所述等离子体阻挡筛网所限定的所述第四孔隙中的每一个的特征为：
第一孔隙部分，所述第一孔隙部分从所述等离子体阻挡筛网的所述第一侧延伸，并且限定孔轴以及垂直于所述孔轴的第一孔隙较短侧向尺寸，以及
第二孔隙部分，所述第二孔隙部分从所述等离子体阻挡筛网的所述第二侧延伸，并且限定约0.05英寸或更小的第二孔隙较短侧向尺寸，并且所述第二孔隙较短侧向尺寸小于所述第一孔隙较短侧向尺寸；
其中所述第一孔隙部分和所述第二孔隙部分轴向邻接，以从所述等离子体阻挡筛网的所述第一侧延伸到所述第二侧，从而形成所述第四孔隙。
3.根据权利要求2所述的装置，其特征在于，所述等离子体阻挡筛网在所述等离子体阻挡筛网面对着所述卡盘的区域内限定每平方英寸至少10个所述第四孔隙。
4.根据权利要求2所述的装置，其特征在于：
所述第二孔隙部分限定其邻接所述第一孔隙部分处的所述第二孔隙较短侧向尺寸；
所述第二孔隙部分的至少一部分从所述孔轴向外朝所述第二侧张开；并且
至少所述等离子体阻挡筛网的所述第二侧、以及所述第二孔隙部分的表面包括陶瓷涂层。
5.根据权利要求1所述的装置，其特征在于，至少所述等离子体阻挡筛网被保持为电接地的，并且围绕所述工艺腔室的周边与支撑结构电连接；并且
所述卡盘可切换地连接至射频(RF)功率源或从射频(RF)功率源脱离，使得当连接所述RF功率源时，在所述工艺腔室内产生所述等离子体。
6.根据权利要求5所述的装置，其进一步包括陶瓷环，所述陶瓷环围绕所述工艺腔室的所述周边设置，使得所述陶瓷环插置在所述卡盘与所述支撑结构之间。
7.根据权利要求6所述的装置，其特征在于：
所述等离子体阻挡网筛中的部分以及所述陶瓷环设置在所述支撑结构的一部分的顶部，并且
所述陶瓷环的厚度受控制以在所述陶瓷环与所述等离子体阻挡网筛之间提供间隙。
8.根据权利要求6所述的装置，其特征在于，所述陶瓷环包含具有在0.0001至0.1的范围内的损耗角正切值的材料。
9.根据权利要求1所述的装置，其特征在于，所述气体分配设备还进一步限定气体通道，所述气体通道从所述气体分配设备周边延伸到限定在所述气体分配设备的所述第二侧而不在所述气体分配设备的所述第一侧的多个第三孔隙，使得引入所述气体通道中的工艺气体出现在所述气体分配设备的所述第二侧上。
10.一种等离子体处理腔室，所述等离子体处理腔室包括：
工件保持器；以及
平面电极；
所述平面电极跨其中心区域限定以一定厚度分开的平行且相对的第一平面表面和第二平面表面，所述第二平面表面设置为面对所述工件夹具工件保持器，
所述平面电极限定从其中穿过的多个孔隙，其中所述孔隙中的每者的特征为：
第一孔隙部分，所述第一孔隙部分限定孔轴以及垂直于所述孔轴的第一孔隙较短侧向尺寸，所述第一孔隙部分从所述第一平面表面延伸穿过所述厚度的至少一半，以及
第二孔隙部分，所述第二孔隙部分：
限定第二孔隙较短侧向尺寸，所述第二孔隙较短侧向尺寸小于所述第一孔隙较短侧向尺寸，并且
从所述第二平面表面延伸穿过所述厚度的不到一半；
其中所述第一孔隙部分和所述第二孔隙部分轴向邻接，以使所述孔隙为从所述第一平面表面至所述第二平面表面的连续孔隙。
11.根据权利要求10所述的等离子体处理腔室，其特征在于：
所述厚度在0.15至1.0英寸的范围内；
所述第一孔隙部分限定在0.02至0.25英寸的范围内的所述第一孔隙较短侧向尺寸，并且
所述第二孔隙部分限定垂直于所述孔轴的0.01至0.05英寸的所述第二孔隙较短侧向尺寸。
12.根据权利要求10所述的等离子体处理腔室，其特征在于：
所述平面电极包含铝，并且
至少所述第二平面表面、以及所述第二孔隙部分的表面包括包含氧化钇的涂层。
13.根据权利要求12所述的等离子体处理腔室，其特征在于，所述孔隙的每一个的所述第二孔隙部分限定：
上部部分，所述上部部分轴向邻接所述第一孔隙部分，以及
下部部分，所述下部部分轴向邻接所述上部部分，并且从所述孔轴向外朝所述第二平面表面张开。
14.根据权利要求13所述的等离子体处理腔室，其特征在于：
所述上部部分是圆柱形的，通过作为所述第二孔隙较短侧向尺寸的直径表征，并且轴向邻接所述第一孔隙部分；
所述下部部分是圆锥形的，围绕所述孔轴对称，并且轴向邻接所述圆柱形的上部部分；并且
在所述圆锥形的下部部分中，所述平面电极的表面在所述圆锥形的下部部分邻接所述圆柱形的上部部分的每一个点处偏离所述孔轴成25度至65度的角度，使得所述下部部分的侧向尺寸在所述圆锥形的下部部分邻接所述第二平面表面的位置处大于所述圆柱形的上部部分的所述直径。
15.根据权利要求14所述的等离子体处理腔室，其特征在于，所述上部部分的深度与所述直径的深宽比在0.5至4.0的范围内。
16.根据权利要求10所述的等离子体处理腔室，其特征在于：
所述平面电极是基本盘形的，并且其特征为限定中心轴和半径；
所述平面电极的中心区域限定为所述平面电极的在距所述中心轴的一半半径范围内的部分；并且
所述平面电极在所述中心区域内限定每平方英寸至少10个所述孔隙。
17.根据权利要求16所述的等离子体处理腔室，其特征在于，所述平面电极在所述中心区域内限定每平方英寸至少30个所述孔隙。
18.一种等离子体处理装置，所述等离子体处理装置包括：
气源；
第一平面电极，所述第一平面电极包括限定从其中穿过的多个第一孔隙的第一板，所述第一平面电极的第一侧设置为相对于所述气源，使得来自于所述气源的气体穿过所述多个第一孔隙到达所述第一平面电极的第二侧；
第二平面电极，所述第二平面电极包括限定从其中穿过的多个第二孔隙的第二板，所述第二平面电极的第一侧设置为面对所述第一平面电极的所述第二侧；
第一电源，所述第一电源将射频(RF)功率耦合在所述第一平面电极和所述第二平面电极上，其中
第一等离子体是用所述气体在所述第一平面电极与所述第二平面电极之间产生的，并且
来自于所述第一等离子体的第一等离子体产物穿过所述多个第二孔隙到达所述第二平面电极的第二侧；
等离子体阻挡筛网，所述等离子体阻挡筛网包括限定从其中穿过的多个第三孔隙的第三板，所述等离子体阻挡筛网的第一侧设置为面对所述第二平面电极的所述第二侧，使得所述第一等离子体产物穿过所述多个第三孔隙到达所述等离子体阻挡筛网的第二侧；
卡盘，所述卡盘面对所述等离子体阻挡筛网的所述第二侧，从而在所述等离子体阻挡筛网与所述卡盘之间限定工艺腔室；以及
第二电源，所述第二电源将射频(RF)功率耦合在所述等离子体阻挡筛网和所述卡盘上，其中第二等离子体是用所述气体在所述等离子体阻挡筛网和所述卡盘之间产生的。
19.根据权利要求18所述的装置，其特征在于，所述等离子体阻挡筛网所限定的所述第三孔隙中的每一个的特征为：
第一孔隙部分，所述第一孔隙部分从所述等离子体阻挡筛网的所述第一侧延伸，并且限定孔轴以及垂直于所述孔轴的第一孔隙较短侧向尺寸，以及
第二孔隙部分，所述第二孔隙部分从所述等离子体阻挡筛网的所述第二侧延伸，并且限定约0.05英寸或更小的第二孔隙较短侧向尺寸，并且所述第二孔隙较短侧向尺寸小于所述第一孔隙较短侧向尺寸；
其中所述第一孔隙部分和所述第二孔隙部分轴向邻接，以从所述等离子体阻挡筛网的所述第一侧延伸到所述第二侧，从而形成所述第三孔隙。
20.根据权利要求19所述的装置，其特征在于：
所述第二孔隙部分限定其邻接所述第一孔隙部分处的所述第二孔隙较短侧向尺寸；
所述第二孔隙部分的至少一部分从所述孔轴向外朝所述等离子体阻挡筛网的所述第二侧张开；并且
至少所述等离子体阻挡筛网的所述第二侧、以及所述第二孔隙部分的表面包括陶瓷涂层。
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