CN109103125A - 半导体处理设备以及用于校准半导体处理设备的方法 - Google Patents

半导体处理设备以及用于校准半导体处理设备的方法 Download PDF

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CN109103125A
CN109103125A CN201810612758.9A CN201810612758A CN109103125A CN 109103125 A CN109103125 A CN 109103125A CN 201810612758 A CN201810612758 A CN 201810612758A CN 109103125 A CN109103125 A CN 109103125A
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S·拉贾贝鲁
J·托尔
R·麦克卡特尼
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Abstract

公开了一种半导体处理设备。所述半导体处理设备可包括:反应室,所述反应室包括:由竖直侧壁连接的上室壁和下室壁,所述室壁由上游入口法兰和下游出口法兰接合,其中所述室的纵向方向从所述入口法兰延伸到所述出口法兰;以及设置在至少所述上室壁的外表面上的多个肋材,所述多个肋材横向于所述室的所述纵向方向而定向。所述半导体处理设备还可包括:至少一个加热元件阵列,所述至少一个加热元件阵列安置在所述反应室上方;以及至少一个可变定位装置,所述至少一个可变定位装置连接到所述至少一个加热元件阵列并且被配置成相对于所述多个肋材的位置可控制地调整所述至少一个加热元件阵列的位置。还公开了校准半导体处理设备的方法。

Description

半导体处理设备以及用于校准半导体处理设备的方法
技术领域
本公开大体上涉及一种半导体处理设备以及用于校准半导体处理设备的方法。
背景技术
可使用高温反应室将各种材料层沉积到半导体衬底上。可将例如硅衬底的半导体衬底放置在反应室内部的衬底支架上。可将衬底和支架两者都加热到所需设定点温度。在实例衬底处理工艺中,可使反应气体越过被加热的衬底,从而致使反应材料的薄层化学气相沉积(CVD)到衬底上。在整个后续沉积、掺杂、光刻、蚀刻和其它工艺中,将这些层制成为集成电路。
可仔细地控制各个工艺参数以确保沉积层的高质量。一个此类工艺参数的实例是衬底温度均匀性。例如,在CVD期间,沉积气体可在特定的规定温度范围内反应以沉积到衬底上。遍及衬底的温度均匀性变化可能会引起沉积速率变化以及不合需要的层厚度非均匀性。因此,重要的是,在处理开始之前准确地控制衬底温度均匀性以使衬底达到所需温度和温度均匀性,并且在整个工艺期间维持所需温度和均匀性。
在某些应用中,可将例如被配置成用于CVD的石英反应室的反应室内的压力减小到远低于周围环境压力的水平。在此类减压应用中,石英反应室可包括圆柱形或球形室,这是因为此类石英反应室的弯曲表面可较好地适于承受由减压工艺引起的向内引导的力。然而,当出于化学气相沉积目的而定位平坦衬底时,在沉积气体平行于衬底而流动的情况下,可能需要使室壁平行于衬底的平坦表面,以在衬底表面上获得均匀沉积。均匀沉积对于获得将由此类衬底制造的高合格率的可接受产品可能至关重要。然而,与大小和厚度相似的向外凸起的室壁相比,当工艺包括减压时,包括平坦室壁的石英反应室可能会向内塌陷。
为了处置平坦室壁上的向内引导的力,可在壁的外部上设置角撑板或肋材,所述角撑板或肋材大体上垂直于与其接合的壁而延伸,如可在1990年5月1日发布的标题为“用于半导体处理的耐压热反应器系统(PRESSURE RESISTANT THERMAL REACTOR SYSTEM FORSEMICONDUCTOR PROCESSING)”的第4,920,918号美国专利中所见,所有专利以引用的方式并入本文中并且成为本说明书的部分。此类石英反应室设计的一个缺点是,与平坦室壁相比,即使石英可使由辐射灯加热器提供的辐射灯能量基本上透过,肋材片段也会呈现厚得多的石英区域并且可在很大程度上折射灯能量,由此衰减到达反应室内的衬底的某些片段的灯能量。此能量衰减会在衬底上造成较冷区域(即,阴影)。衬底表面上的此类温度非均匀性会降低可被沉积的膜的质量,尤其是对于温度敏感的工艺条件。
用于晶片沉积的标称相同的CVD工具可包括工具之间的一些差异。例如,用于CVD工艺的反应室可各自具有特性热环境,这又可能会影响沉积工艺期间的晶片温度。反应室可由石英材料制造,并且用于石英反应室的制造和返工的工艺可能会引起石英反应室的特征变化,例如,引起临界尺寸、材料质量、折射性质等等变化。另外,反应室内和周围的组件可能会在位置和最佳功能上变化,从而增加了额外差异。反应室的变化对于大批量制造可能是不合需要的,在大批量制造中,多个反应室可执行相同工艺配方并且预期到工艺结果基本上相同。例如,对于CVD工艺,所得的沉积层被预期为具有均匀的厚度、载流子迁移率、折射率、应力等等。
为了解决可能由于CVD工具的变化而出现的问题,可采用被称为“工具间匹配”的系统和工艺。然而,现有“工具间匹配”系统和工艺可能受到限制、耗时、成本过高,并且可能不会提供热校准多个化学气相沉积系统的有效方法。
发明内容
根据本公开的至少一个实施例,公开一种半导体处理设备。所述半导体处理设备可包括:反应室,所述反应室包括:由竖直侧壁连接的上室壁和下室壁,所述室壁由上游入口法兰和下游出口法兰接合,其中所述室的纵向方向从所述入口法兰延伸到所述出口法兰。所述反应室可进一步包括设置在至少所述上室壁的外表面上的多个肋材,所述多个肋材横向于所述室的所述纵向方向而定向。所述半导体处理设备还可包括:至少一个加热元件阵列,所述至少一个加热元件阵列安置在所述反应室上方;以及至少一个可变定位装置,所述至少一个可变定位装置连接到所述至少一个加热元件阵列并且被配置成相对于所述多个肋材的位置可控制地调整所述至少一个加热元件阵列的位置。
本公开还可包括一种校准半导体处理设备的方法,并且所述方法可包括:提供反应室,所述反应室包括:由竖直侧壁连接的上室壁和下室壁,所述室壁由上游入口法兰和下游出口法兰接合,其中所述室的纵向方向从所述入口法兰延伸到所述出口法兰。提供反应室可进一步包括:提供设置在至少所述上室壁的外表面上的多个肋材,所述多个肋材横向于所述室的所述纵向方向而定向。所述校准半导体处理设备的方法可进一步包括:提供至少一个加热元件阵列,所述至少一个加热元件阵列安置在所述反应室上方;以及调整至少一个可变定位装置,所述至少一个可变定位装置连接到所述至少一个加热元件阵列以相对于所述多个肋材的位置可控制地调整所述加热元件阵列的位置。
附图说明
尽管本说明书以具体地指出并且明显地要求本发明的实施例的权利要求书结束,但是当结合附图阅读时,可以从本公开的实施例的某些实例的描述中更容易地确定本公开的实施例的优势,在附图中:
图1是如可用于本公开的半导体处理设备的半导体反应室的透视图,在所述室的外表面上具有多个肋材;
图2是本公开的半导体处理设备的部分的横截面示意性绘示;
图3A是上部加热外壳的平面图,包括安置在反应室上方的加热元件阵列,所述加热元件阵列基本上平行于反应室的纵向方向而安置;
图3B是上部加热外壳的平面图,包括安置在反应室上方的加热元件阵列,所述加热元件阵列基本上垂直于反应室的纵向方向而安置;
图4是本公开的半导体处理设备的部分的剖视横截面图;
图5是如本公开的实施例中所公开的实例上部加热外壳的示意性绘示;
图6是本公开的上部加热外壳的内部配置的部分的实例分解示意性绘示;以及
图7是绘示处于打开位置的上部加热外壳的本公开的半导体处理设备的透视图。
应了解,图中的元件仅为简单和清晰起见而进行绘示,且不一定按比例绘制。例如,图中的一些元件的尺寸可以相对于其它元件放大以有助于提高对本公开的所绘示实施例的理解。
具体实施方式
尽管下文公开某些实施例和实例,但本领域的技术人员将理解,本发明延伸超出了具体公开的实施例和/或本发明的用途和显而易见的修改以及其等效物。因此,希望本发明所公开的范围不应受下文所描述的具体公开实施例的限制。
如本文所使用,术语“衬底”可以指可以使用的,或其上可以形成装置、电路或膜的任何下层材料。
本公开的实施例可包括半导体处理设备以及被配置成用于化学气相沉积工艺的特定半导体处理设备。本公开的半导体处理设备可包括石英反应室,石英反应室可以在减压下操作并且因此可包括多个肋材,多个肋材加固反应室并且在减压下操作时防止不希望的内爆。本公开的半导体处理设备可允许通过提供一个或多个可变定位装置增加对石英反应室内的温度均匀性和热环境的控制,一个或多个可变定位装置被配置成用于相对于构成石英反应室的多个肋材的位置可控制地调整加热元件阵列的位置。相对于构成石英反应室的多个肋材可控制地定位和重新定位加热元件阵列的能力允许半导体处理设备的热校准和多个半导体处理设备的热匹配,以及允许改进遍及提供在石英反应室内的至少一个衬底的上表面的温度均匀性差。
在本公开的具体实施例中,被提供用于化学气相沉积工艺的石英反应室可包括已经历翻新工艺的石英反应室。更详细地说,一旦石英反应室已多次用于化学气相沉积工艺,就可能需要处理以将石英反应室恢复回其原始状态(或尽可能接近其原始状态)。用于恢复石英反应室的工艺通常被称为“翻新工艺”,并且可包括但不限于热处理和化学处理。例如,石英反应室翻新工艺可包括用于消除石英反应室的表面中的微裂纹的“火抛光”工艺,并且另外,还可使石英反应室在高温炉(例如,1100℃)中退火以减轻石英反应室中的应力。尽管石英反应室的翻新使石英反应室能够长时段被利用和再利用,但是翻新工艺也可能会改变石英反应室的临界尺寸,这又可能会改变在化学气相沉积工艺期间定位在石英反应室上方的加热元件阵列的相对位置。本公开的半导体处理设备和方法使能够使用翻新的石英反应室,而不会降低石英反应室和关联室元件的热特性,即,热均匀性。
图1绘示可用于减压化学气相沉积工艺的反应室100的非限制性实例实施例。反应室100可用作本公开的(图2的)半导体处理设备200的部分。参考图1和图2,反应室100可包括细长的大体上扁平的配置。图1的非限制性实例反应室100可包括具有外表面102A和内表面102B的上壁102,以及具有外表面和内表面104B的下壁104A。上室102和下室壁104由竖直侧壁106和108连接。室壁102、104、106和108可由上游入口法兰110和下游出口法兰112接合。上游和下游与通过反应室100的工艺气流的方向相关,并且在本公开中与前部和后部以及与向前和向后同义。
替代地,反应室100可具有除了图1所绘示的扁平配置之外的配置。例如,反应室100可具有帐篷形横截面形状,其中上壁102和/或下壁104具有峰顶。在另一实施例中,上壁102/下壁104可以是圆形,从而向反应室100提供大体上卵形的横截面形状。应了解,在其它实施例中,反应室100的上壁102/下壁104可被形成为具有除了上文所论述的形状之外的其它形状,以及其组合。
在一些实施例中,反应室高度小于反应室宽度。在这方面,反应室100的纵向方向从入口法兰110延伸到出口法兰112,或沿着截面线114-114而延伸。侧向方向在侧壁106和108之间延伸,或横向于截面线114-114而延伸。高度方向垂直于纵向轴和侧向轴两者。在本公开的一些实施例中,反应室100具有约760mm的长度、约490mm的宽度,以及约160mm的高度。
在一些实施例中,上壁102和下壁104两者都包括具有矩形形状的薄平板状元件。多个肋材116从上壁102的外表面102A延伸,并且多个肋材118从下壁104的外表面104A延伸。所有肋材116和118都横向于图1的截面线114-114纵长地定向,横向于反应室100的纵向方向而定向。如图2所展示,肋材116中的每个肋材可定位在肋材118中的对应肋材正上方并且与所述对应肋材对准。因此,肋材116和118包括多对上肋材和下肋材。在图1和图2所绘示的一些实施例中,十二对肋材与提供在基座202上方和下方的大致八对肋材一起被利用,基座202安置在(图2的)反应室100内。然而,在其它实施例中,取决于反应室100的所需结构完整性,可使用更多对或更少对肋材。在本公开的一些实施例中,上肋材116和下肋材118的对应对彼此可能不对准。因此,取决于反应室100的结构完整性的所需水平,上肋材116和下肋材118可有利地以邻近肋材之间的不同定向、对准和/或间隔熔合到反应室。
图2绘示包括图1的半导体反应室100的半导体处理设备200的横截面图,并且绘示安置在反应室100上方的至少一个加热元件阵列204。在本公开的一些实施例中,至少一个加热元件阵列204可包括上部加热阵列,并且可容纳在上部加热外壳206中(如图2中由虚线100所绘示)。图2的半导体处理设备200还可包括安置在反应室100下方并且容纳在下部加热外壳210中的额外加热元件阵列208。安置在反应室100下方的额外加热元件阵列208可与安置在反应室100上方的加热元件阵列204基本上相同。
在一些实施例中,安置在反应室100上方的至少一个加热元件阵列204可包括多个辐射加热灯。作为本公开的半导体设备的非限制性实例实施例,图3A示意性地绘示包括多个肋材116、入口法兰110和出口法兰112的反应室100的平面图。图3A还绘示上部加热外壳206,上部加热外壳206安置在反应室100上方并且包括加热元件阵列204。在一些实施例中,多个辐射加热灯204包括多个细长管型灯,所述灯以平行关系隔开并且还与通过下层反应室100的反应气体流动路径基本上平行。换句话说,在本公开的一些实施例中,多个辐射加热灯204属于基本上平行于反应室的纵向方向而安置的多个细长管型灯,即,多个辐射加热灯204基本上垂直于多个肋材116的方向而定向。在上部加热元件阵列包括基本上平行于反应室的纵向方向而安置的多个辐射加热灯的实施例中,安置在反应室下方的下部加热元件阵列还可包括可基本上垂直于反应室的纵向方向而安置的多个细长管型灯,即,上部多个辐射加热灯和下部多个辐射加热元件彼此基本上垂直。
作为本公开的半导体设备的另一非限制性实例实施例,图3B示意性地绘示包括多个肋材116、入口法兰110和出口法兰112的反应室100的平面图。图3B还绘示上部加热外壳206,上部加热外壳206安置在反应室100上方并且包括加热元件阵列204。在一些实施例中,多个辐射加热灯204包括多个细长管型灯,所述灯以平行关系隔开并且还与通过下层反应室100的反应气体流动路径基本上垂直。换句话说,在本公开的一些实施例中,多个辐射加热灯204属于基本上垂直于反应室的纵向方向而安置的细长管型灯,即,多个辐射加热灯204基本上平行于多个肋材116的方向而定向。在上部加热元件阵列包括基本上垂直于反应室的纵向方向而安置的多个辐射加热灯的实施例中,安置在反应室下方的下部加热元件阵列还可包括可基本上平行于反应室的纵向方向而安置的多个细长管型灯,即,上部多个辐射加热灯和下部多个辐射加热元件彼此基本上垂直。
如图3A和图3B两者所绘示,多个辐射加热灯204属于彼此基本上平行且邻近而安置的细长管型。在本公开的一些实施例中,可能需要改变阵列内的个别加热灯的相对位置。例如,在本公开的一些实施例中,重新定位个别辐射加热灯204`可在反应室100内提供更均匀的温度分布,因此,本公开的设备允许调整个别辐射加热灯之间的距离。作为非限制性实例实施例,图3A绘示彼此基本上平行并且彼此隔开被标记为d的距离的辐射加热灯204`和204``。因此,在本公开的一些实施例中,取决于反应室100内所需要的所需热分布,可增大或减小辐射加热灯204`和204``之间的距离d。
多个辐射加热灯204可属于相似配置。每个细长管型加热元件可包括高强度钨丝灯,所述灯具有含有例如碘的卤素气体的透明石英封套。灯产生呈全谱光的形式的辐射热能,所述辐射热能透射通过反应室壁,例如上室壁102,而无明显的吸收。如在半导体处理设备的领域中所知,响应于如图2所绘示的接近于安置在反应室100内的衬底212而布置的温度传感器,各个辐射加热灯的功率可独立地或以分组区形式被控制。
如图2以及图3A和图3B所绘示的多个灯204和208被绘示为未展示详细支撑结构。然而,本领域的技术人员将容易认识到相对于例如上室壁102的室壁安装灯的多种方式。在本公开的一些实施例中,安置在反应室100上方的至少一个加热元件阵列204可安置在上部加热外壳206内。图2所展示的上部加热外壳206属于简化形式,并且本文将提供上部加热外壳206的进一步绘示和论述。然而,应注意,在一些实施例中,上部加热外壳206可附接到反应室外壳,反应室外壳可支撑反应室100。
在一些实施例中,每个个别辐射加热灯包括在其相对端中的每个端上的一体形成的轴向延伸凸耳,以及从每个凸耳延伸以接纳提供在导电体的端处的连接器的合适连接销布置。
返回参考图2,安置在反应室100上方的至少一个加热元件阵列204可连接到至少一个可变定位装置,至少一个可变定位装置被配置成相对于多个肋材的位置可控制地调整至少一个加热元件阵列的位置。在本公开的一些实施例中,至少一个加热元件阵列连接到至少两个可变定位装置,例如,如图2中由可变定位装置214和216所绘示。在一些实施例中,至少一个加热元件阵列连接到至少三个可变定位装置,例如,如图3A和图3B中由可变定位装置214、216和302所绘示。
如由图2的非限制性实例半导体处理设备200所展示,至少一个可变定位装置214被配置成在基本上平行于反应室100的纵向方向的方向上可控制地调整至少一个加热元件阵列204的位置。换句话说,可变定位装置在x轴上定位和重新定位辐射加热灯阵列,如图2所绘示。应了解,连接到至少一个加热元件阵列204的可变定位装置214可通过上部加热外壳206而连接,并且可包括安置在可变定位装置214与个别辐射加热灯204之间的另外连接材料。
在另一实例实施例中,至少一个可变定位装置216被配置成相对于反应室100的上室壁102的位置以及尤其关于安置在反应室100内的基座202可控制地调整至少一个加热元件阵列204的高度的位置。换句话说,可变定位装置在z轴上定位和重新定位辐射加热灯阵列,如图2所绘示。应了解,连接到至少一个加热元件阵列204的可变定位装置216可通过上部加热外壳206而连接,并且可包括安置在可变定位装置216与个别辐射加热灯204之间的另外连接材料。
在又一实例实施例中,(图3A或图3B的)至少一个可变定位装置302被配置成在基本上垂直于反应室100的纵向方向的方向上可控制地调整至少一个加热元件阵列204的位置。换句话说,可变定位装置302在y轴上定位和重新定位辐射加热灯阵列204,如图3A所绘示。同样,应了解,连接到至少一个加热元件阵列204的可变定位装置302可通过上部加热外壳206而连接,并且可包括安置在可变定位装置302与个别辐射加热灯204之间的另外连接材料。
多个可变定位装置可用于可控制地调整至少一个加热元件阵列的位置和高度,例如,可变定位装置可包括测微计(手动或由电机致动)、差示测微计或压电致动器中的至少一个。
本公开的可变定位装置可被配置成提供至少一个加热元件阵列在多个方向上的所需放置。例如,本公开的至少一个可变定位装置可允许至少一个加热元件阵列在包括但不限于平行于反应室的纵向方向、垂直于反应室的纵向方向的一个或多个方向上的位移,并且还可相对于反应室的上室壁的位置可控制地调整至少一个加热元件阵列的高度。
在本公开的一些实施例中,至少一个可变定位装置可被配置成提供不超过约2厘米或不超过约1厘米或甚至不超过约0.5厘米的最少一个加热元件阵列的位移。另外,至少一个可变定位装置可被配置成提供小于0.1毫米或小于0.01毫米或甚至小于0.001毫米的位移准确度。
本公开的半导体处理设备可包括额外元件。如图2所绘示,本公开的半导体处理设备可进一步包括衬底支架,衬底支架包括安置在至少一个加热元件阵列204下方的反应室100内的基座202,基座202被配置成支撑至少一个衬底212,其中包括基座202的衬底支架具有衬底212可旋转所围绕的中心轴。至少一个衬底212可由可包括基座202的衬底支架支撑,基座202包括不能使辐射热能透过的材料,例如石墨或碳化硅,如在半导体处理设备的领域中所知。如图2所展示,基座202和衬底212由支撑结构固持在反应室100内的所需高度处。基座202可支撑在连接到可旋转轴件224的上端的合适支架222的臂220上,可旋转轴件224延伸通过从反应室104的底壁悬垂的管226。基座202被展示为与支撑板226的上表面大致齐平。这有助于将衬底212定位在反应室100的基座202的顶上。关于内部室支撑组合件的另外细节以及关于半导体处理室的其它细节可在2000年7月25日发布的第6,093,252号美国专利中找到,整个专利以引用的方式并入本文中并且成为本说明书的部分。
本公开的半导体处理设备允许更大程度地控制反应室100内的热环境。在一些实施例中,至少一个加热元件阵列被配置成提供小于1.5℃的遍及至少一个衬底的表面的温度均匀性差,或被配置成提供小于0.5℃的遍及至少一个衬底的表面的温度均匀性差,或甚至被配置成提供小于0.25℃的遍及至少一个衬底的表面的温度均匀性差。在一些实施例中,至少一个衬底可包括化学气相沉积工艺主要在其上进行的暴露上表面。在一些实施例中,至少一个衬底可包括直径大于25毫米或大于100毫米或大于200毫米或大于300毫米或甚至大于450毫米的衬底。
在本公开的一些实施例中,可通过结合安置在反应室上方的加热元件阵列而利用一个或多个反射器来进一步改进反应室内的热均匀性以及尤其是遍及其上安置衬底的基座的热均匀性。在某些实施例中,一个或多个反射器可包括单件反射器,即,反射器可由单件材料制造。在本公开的一些实施例中,单件反射器可包括多个抛物线区段,多个抛物线区段中的每个个别抛物线区段安置在辐射加热元件上方并且邻近于辐射加热元件。在替代实施例中,多个非抛物线区段可安置在辐射加热元件上方并且邻近于辐射加热元件。
更详细地说,图4绘示通过图2的半导体处理设备200的参考线228-228的横截面图,并且提供通过本公开的半导体处理设备的反应室100和相关组件的详细视图。图4绘示安置在反应室100内的基座202以及从反应室100的底壁104悬垂的管226,可通过管226提供用于基座202的旋转的机构(未展示)。被绘示为处于闭合位置的上部加热外壳206安置在反应室100上方,上部加热外壳206包括与反应室外壳404接触的上部加热外壳壁402。单件反射器408安置在上部加热外壳206内并且通过托架406而连接到上部加热外壳206。单件反射器408包括多个抛物线区段410,每个个别抛物线区段410安置在个别辐射加热灯206上方并且邻近于个别辐射加热灯206。在本公开的一些实施例中,每个辐射加热灯206位于与所述辐射加热灯相关联的对应抛物线区段的焦点处,使得照射在所述抛物线区段上的辐射热能将向下反射到下层基座和关联衬底上。
在本公开的一些实施例中,一个或多个可变定位装置可被配置成在辐射加热灯与单件反射器以及尤其是多个抛物线区段的焦点之间提供可调整距离。辐射加热元件和多个抛物线区段的焦点的相对位置的此类调整使辐射加热元件能够定位在对应抛物线元件的焦点处,并且可遍及多个沉积系统实现此类相对定位,使得多个沉积系统能够在反应室内提供基本上相同的热环境。在替代实施例中,可调整安置在反应室上方的加热元件阵列的相对高度的一个或多个可变定位装置可连接到加热元件阵列和单件反射器两者,使得加热元件阵列的相对高度的任何调整会维持单件反射器相对于加热元件阵列的位置。
单件反射器还可包括从单件反射器的下表面延伸直到单件反射器的上表面的多个开口412。在一些实施例中,延伸通过单件反射器的每个个别开口可安置在个别抛物线元件内,并且每个开口可基本上平行于抛物线元件的焦点而延伸以紧接于单件反射器的外围边缘。多个开口可用于允许空气从反应室100上方流动到上部加热外壳206的内部,并且此类空气流动可允许辐射加热元件和反应室的冷却。
在本公开的一些实施例中,单件反射器408可由单件材料制造,例如,由单件金、铝、镍、铜、金属化聚酯薄膜或多层介电材料制造。
图5中更详细地展示上部加热外壳206,图5将上部加热外壳206绘示为处于闭合(向下)位置。上部加热外壳206可包括一个或多个可变定位装置214和302,一个或多个可变定位装置214和302可以可控制地定位和重新定位安置在上部加热外壳206内的加热元件阵列。在图5所绘示的非限制性实例实施例中,可变定位装置214和302可用于在x轴和y轴两者上调整加热元件阵列的位置,即,平行于和垂直于下层反应室的纵向方向而调整加热元件阵列的位置。上部加热外壳206还可包括上部加热外壳壁402,并且其上可安置一个或多个光学高温计的高温计支座502连接到上部加热外壳壁402。在图5所绘示的非限制性实例实施例中,高温计支座502连接到两个高温计504A和504B,两个高温计504A和504B可被配置成用于感测在反应室内部和在反应室外部的预定位置处的温度。例如,高温计504A可被配置成用于感测反应室内的温度以及尤其是用于感测安置在反应室内的基座上的衬底的温度,而高温计504B可被配置成用于感测石英反应室的外部温度。
定位装置506A和506B也安置在高温计支座502上,定位装置506A和506B可用于实现关联高温计504A和504B的精确定位。作为非限制性实例实施例,连接到高温计504A和504B的定位装置506A和506B可包括测微计,测微计可被配置成用于在x轴和y轴两者上定位和重新定位高温计504A和504B。上部加热外壳206还可包括一个或多个高温计冷却块508,一个或多个高温计冷却块508与高温计504A和504B热接触,并且提供散热片功能以实现高温计504A和504B的冷却。上部加热外壳206还可包括一个或多个升降盖托架510,一个或多个升降盖托架510可用于升高和降低上部加热外壳。
图6绘示上部加热外壳206,其中移除了上部加热外壳壁并且从上部加热外壳206内移除了各种其它辅助组件以使能够观察上部加热外壳206的功能性。例如,上部加热外壳206的内部可包括安置在辐射加热元件阵列(未展示)上方的单件反射器408,单件反射器408包括从单件反射器的上表面向下延伸到单件反射器的下表面的空气流动开口412,多个空气流动开口412用于对多个辐射加热元件和下层石英反应室提供冷却。单件反射器408还可包括同样也可从单件反射器的上表面延伸通过到单件反射器的下表面的额外开口602。通过单件反射器的额外开口可用于通过单件反射器从安置在上部加热外壳壁(如先前在图5中所展示)上的先前所论述的高温计引导光探针。
如图6所绘示的上部加热外壳206的内部可进一步包括xy载台604,xy载台604可连接到单件反射器408(以及关联辐射加热元件阵列)和一个或多个可变定位装置两者,作为非限制性实例,一个或多个可变定位装置可包括用于调整辐射加热元件阵列在x轴上的定位的测微计214,并且可进一步包括用于调整辐射加热元件阵列在y轴上的位置的测微计302。
除了可变定位装置214和302之外,上部加热外壳206的内部还可包括额外可变定位装置216A和216B。在本公开的一些实施例中,可变定位装置216A和216B可包括调整螺钉,调整螺钉连接到xy载台604和单件反射器408(以及关联辐射加热元件阵列)。在非限制性实例实施例中,调整螺钉可顺时针转动以增大辐射加热元件阵列与上室壁和安置在下方的基座之间的距离,并且相反地,调整螺钉可逆时针转动以减小辐射加热元件阵列与上室壁和安置在下方的基座之间的距离。在本公开的一些实施例中,三个单独调整螺钉可连接到xy载台604以在z轴上定位和重新定位加热元件阵列,即,调整辐射加热元件阵列与上室壁以及尤其是与反应室内所公开的基座的相对高度。在一些实施例中,调整螺钉可包括下突出部处的球头,所述球头可安置在xy载台604的上表面上所安置的v形槽中并且径向地向内指向,以确保当组合件在加热和冷却过程期间扩展和收缩时,单件反射器中心保持在同一位置处。
上部加热外壳206可进一步包括用于将上部加热外壳连接到反应室外壳的一个或多个铰接机构。例如,图6绘示铰接机构606A和606B,其中铰接机构606A和606B的第一表面附接到上部加热外壳206,并且铰接机构606A和606B的第二表面可附接到反应室外壳。因此,在本公开的一些实施例中,至少一个加热元件阵列安置在上部加热外壳中,并且上部加热外壳通过一个或多个铰接机构而连接到反应室外壳。
在本公开的一些实施例中,一个或多个铰接机构在固定位置中连接到反应室外壳,即,上部加热外壳与反应室外壳之间的连接处于固定的非可变位置,使得上部加热外壳中的辐射加热元件阵列相对于构成反应室的多个肋材的位置的任何变化是通过调整连接到加热元件阵列的至少一个可变定位装置而实现。换句话说,加热元件阵列的位置变化不应来自上部加热外壳相对于反应室的升高和降低动作。因此,在一些实施例中,一个或多个铰接机构可被配置成用于相对于反应室100升高和降低上部加热外壳206。例如,在一些实施例中,一个或多个铰接机构进一步被配置成用于以相对于多个肋材的小于0.25毫米的位置公差将上部加热外壳206重新定位在降低位置(即,闭合位置)中。例如,图7绘示本公开的半导体处理设备200,其中上部加热外壳206处于打开位置。上部加热外壳包括在安置在反应室外壳702中的反应室100上方的上部加热元件阵列204,上部加热元件阵列204处于打开位置,即,升高位置。如图7所绘示,半导体处理设备200进一步包括用于将上部加热外壳206附接到反应室外壳702的铰接机构606。
本公开的实施例还可提供用于校准半导体处理设备的方法。例如,在一些实施例中,上部辐射加热元件阵列可平行于构成石英反应室的多个肋材而安置,并且多个肋材可能会在安置在反应室内的衬底上造成“阴影”,这可能会在下层衬底上产生温度低于平均衬底温度的区域。另外,多个肋材可能会造成多个加热灯的辐射能量的“漏光”,这可能会在下层衬底上产生温度高于平均衬底温度的区域。因此,遍及安置在基座上的衬底的温度可具有特性温度分布,特性温度分布可取决于上部加热元件阵列和多个肋材的相对位置。在本公开的一些实施例中,可针对特定工艺调谐特性温度分布,例如,作为非限制性实例,可调谐温度分布,使得存在从衬底边缘到衬底中心的温度梯度。
在例如利用包括多个肋材的石英反应室和上部加热元件阵列的化学气相沉积系统的现有技术半导体处理设备的操作和维护期间,可能有必要将上部加热外壳从闭合位置升高直到打开位置并且再次返回。在用于升高和降低上部加热外壳的操作期间,加热元件阵列相对于构成石英反应室的多个肋材的相对位置可能会变化,并且设备的特性温度分布可能会被修改。因此,本公开的实施例可提供用于进行以下操作的方法:维持多个肋材与上部加热元件阵列之间的相对位置,由此在延长的操作和维护期间保持半导体处理设备的特性温度分布。
另外,为了实现遍及包括多个石英反应室的多个半导体处理设备的“工具间匹配”,可能需要遍及多个半导体处理设备复制特性温度分布,以确定使用相同工艺配方的多个设备产生基本上相同的沉积结果。因此,需要用于匹配多个半导体处理设备的热环境的方法。
在一些实施例中,校准半导体处理设备的方法可包括提供反应室,反应室包括由竖直侧壁连接的上室壁和下室壁,室壁由上游入口法兰和下游出口法兰接合,其中反应室的纵向方向从入口法兰延伸到出口法兰。本公开的方法的反应室还可包括设置在至少上室壁的外表面上的多个肋材,多个肋材横向于反应室的纵向方向而定向。校准半导体处理设备的方法还可包括提供安置在反应室上方的至少一个加热元件阵列。在一些实施例中,校准半导体处理设备的方法还可包括调整连接到至少一个加热元件阵列的至少一个可变定位装置以相对于多个肋材的位置可控制地调整加热元件阵列的位置。
在一些实施例中,用于本公开的半导体工艺设备中的反应室可包括翻新的反应室,即,反应室可包括已经历如本文所描述的翻新工艺的石英反应室。在翻新石英反应室的过程期间,可修改石英反应室的临界尺寸,因此,当翻新的石英反应室再用于本公开的半导体处理设备内时,可能有必要相对于反应室的多个肋材调整上部加热元件阵列的位置以提供所需特性温度分布。
在一些实施例中,所述方法可包括将至少一个加热元件阵列选择为包括多个辐射加热灯。在一些实施例中,多个辐射加热灯属于基本上平行于反应室的纵向方向而安置的细长管型。在替代实施例中,多个辐射加热灯属于基本上垂直于反应室的纵向方向而安置的细长管型。
本公开的实施例可包括用于维持上部加热阵列与构成石英反应室的多个肋材之间的相对位置的方法。因此,在一些实施例中,所述方法可包括选择至少一个可变定位装置以在基本上平行于反应室的纵向方向的方向上可控制地调整至少一个加热元件阵列的位置。另外,在一些实施例中,所述方法可包括选择至少一个可变定位装置以在基本上垂直于反应室的纵向方向的方向上可控制地调整至少一个加热元件阵列的位置。在另外实施例中,所述方法可包括选择至少一个可变定位装置以相对于反应室的上室壁的位置可控制地调整至少一个加热元件阵列的高度。
在本公开的方法的一些实施例中,至少一个加热元件阵列连接到至少两个可变定位装置。例如,上部加热元件阵列可连接到第一可变定位装置和第二可变定位装置,其中第一可变定位装置在基本上平行于反应室的纵向方向的方向上可控制地调整加热元件阵列的位置,并且第二可变定位装置在基本上垂直于反应室的纵向方向的方向上可控制地调整加热元件阵列的位置。
在本公开的方法的一些实施例中,至少一个加热元件阵列连接到至少三个可变定位装置。例如,上部加热元件阵列可连接到第一可变定位装置、第二可变定位装置和第三可变定位装置,其中第一和第二可变定位装置可在x-y轴上调整加热元件阵列的位置,并且第三可变定位装置可相对于反应室的上室壁的位置可控制地调整最少至少一个加热元件阵列的高度。
在一些实施例中,所述方法可进一步包括选择至少一个可变定位装置以提供不超过约2厘米或不超过约1厘米或不超过约0.5厘米的至少一个加热元件阵列的位移。
应注意,两个或多于两个可变定位装置可用于在一个特定方向上调整加热元件阵列的位置。例如,两个或多于两个可变定位装置可用于相对于反应室的上室壁的位置可控制地调整至少一个加热元件阵列的高度。
校准半导体处理设备的方法可进一步包括提供安置在至少一个加热元件阵列下方的反应室内的衬底支架,衬底支架被配置成支撑至少一个衬底,其中衬底支架具有衬底支架旋转所围绕的中心轴。在额外实施例中,所述方法可包括提供单件反射器,单件反射器包括邻近于至少一个加热元件阵列而安置的多个抛物线区段。
校准半导体处理设备的方法可进一步包括将至少一个加热元件阵列选择为安置在上部加热外壳中,以及通过一个或多个铰接机构将上部加热外壳连接到反应室。所述方法还可包括将一个或多个铰接机构选择为在固定位置中连接到反应室外壳。一个或多个铰接机构的固定定位允许通过相对于反应室升高和降低上部加热外壳来重新定位上部加热外壳,其中重新定位上部加热外壳包括以相对于多个肋材的小于0.25毫米的位置公差将上部加热外壳重新定位到降低位置。
在本公开的一些实施例中,反应室可包括翻新的石英反应室,并且在翻新工艺期间,构成反应室的多个肋材可能会偏离在任何翻新工艺之前确定的标称位置,即,针对新的未使用的反应室确定多个肋材的标称位置。可通过测量从入口法兰110(参看图2)(或替代地,出口法兰112)到多个肋材116中的每个肋材的距离来确定多个肋材中的每个肋材的标称位置。一旦已确定多个肋材中的每个肋材的标称位置,就可在确定反应室需要翻新工艺以前利用反应室。
一旦已对反应室完成翻新工艺,本公开的方法就可通过测量从入口法兰到多个肋材中的每个肋材的距离并且计算多个肋材中的每个肋材与先前记录的标称位置的偏离距离而继续。所述方法可通过计算多个肋材的平均偏离距离而继续。可例如利用蚀刻工艺以在反应室上产生标记,即,在入口法兰上产生标记,而将多个肋材的平均偏离距离记录在反应室自身上。本公开的方法可通过将连接到至少一个加热元件阵列的至少一个可变定位装置的位置调整基本上等于平均偏离距离的量而继续。因此,本公开的方法允许确定多个肋材的平均偏离距离并且调整加热元件阵列的位置,以补偿多个肋材的任何此类平均偏离距离。
如本文所描述的校准半导体处理设备的方法可减小遍及安置在反应室内的衬底的温度非均匀性。例如,在一些实施例中,至少一个加热元件阵列被配置成提供小于1.5℃的遍及至少一个衬底的表面的温度均匀性差,或小于0.4℃的遍及至少一个衬底的表面的温度均匀性差,或甚至小于0.25℃的遍及至少一个衬底的表面的温度均匀性差。在一些实施例中,至少一个衬底可包括直径大于25毫米或大于100毫米或大于200毫米或大于300毫米或甚至大于450毫米的衬底。
上文所描述的本公开的实例实施例不限制本发明的范围,这是因为这些实施例仅仅是本发明的实施例的实例,本发明由所附权利要求书和其法定等效物限定。任何等效实施例都意图在本发明的范围内。实际上,除了本文中所展示和描述的例如所描述元件的替代适用组合等内容以外,对于本领域的技术人员来说,本公开的各种修改也将从描述变得显而易见。此类修改和实施例也意图属于所附权利要求书的范围内。

Claims (42)

1.一种半导体处理设备,包括:
反应室,所述反应室包括:
由竖直侧壁连接的上室壁和下室壁,所述室壁由上游入口法兰和下游出口法兰接合,其中所述室的纵向方向从所述入口法兰延伸到所述出口法兰;以及
设置在至少所述上室壁的外表面上的多个肋材,所述多个肋材横向于所述室的所述纵向方向而定向;
至少一个加热元件阵列,所述至少一个加热元件阵列安置在所述反应室上方;以及
至少一个可变定位装置,所述至少一个可变定位装置连接到所述至少一个加热元件阵列并且被配置成相对于所述多个肋材的位置可控制地调整所述至少一个加热元件阵列的位置。
2.根据权利要求1所述的设备,其中所述至少一个加热元件阵列包括多个辐射加热灯。
3.根据权利要求2所述的设备,其中所述多个辐射加热灯属于基本上平行于所述室的所述纵向方向而安置的细长管型。
4.根据权利要求2所述的设备,其中所述多个辐射加热灯属于基本上垂直于所述室的所述纵向方向而安置的细长管型。
5.根据权利要求1所述的设备,其中所述至少一个可变定位装置被配置成在基本上平行于所述反应室的所述纵向方向的方向上可控制地调整所述至少一个加热元件阵列的位置。
6.根据权利要求1所述的设备,其中所述至少一个可变定位装置被配置成在基本上垂直于所述反应室的所述纵向方向的方向上可控制地调整所述至少一个加热元件阵列的位置。
7.根据权利要求1所述的设备,其中所述至少一个可变定位装置被配置成相对于所述反应室的所述上室壁的位置可控制地调整所述至少一个加热元件阵列的高度。
8.根据权利要求1所述的设备,其中所述至少一个加热元件阵列连接到至少两个可变定位装置。
9.根据权利要求1所述的设备,其中所述至少一个加热元件阵列连接到至少三个可变定位装置。
10.根据权利要求1所述的设备,进一步包括:
安置在所述至少一个加热元件阵列下方的所述反应室内的衬底支架,所述衬底支架被配置成支撑至少一个衬底;并且
其中所述衬底支架具有所述衬底支架旋转所围绕的中心轴。
11.根据权利要求10所述的设备,其中所述至少一个加热元件阵列被配置成提供小于1.5℃的遍及所述至少一个衬底的表面的温度均匀性差。
12.根据权利要求10所述的设备,其中所述至少一个加热元件阵列被配置成提供小于0.4℃的遍及所述至少一个衬底的表面的温度均匀性差。
13.根据权利要求10所述的设备,其中所述至少一个加热元件阵列被配置成提供小于0.25℃的遍及所述至少一个衬底的表面的温度均匀性差。
14.根据权利要求1所述的设备,其中所述至少一个可变定位装置被配置成提供不超过约2厘米的所述至少一个加热元件阵列的位移。
15.根据权利要求1所述的设备,其中所述反应室包括翻新的反应室。
16.根据权利要求1所述的设备,进一步包括单件反射器,所述单件反射器包括邻近于所述至少一个加热元件阵列而安置的多个抛物线反射器。
17.根据权利要求1所述的设备,进一步包括安置在所述反应室下方的额外加热元件阵列。
18.根据权利要求1所述的设备,其中所述至少一个加热元件阵列安置在上部加热外壳中,并且所述上部加热外壳通过一个或多个铰接机构而连接到反应室外壳。
19.根据权利要求18所述的设备,其中所述一个或多个铰接机构在固定位置中连接到所述反应室外壳。
20.根据权利要求19所述的设备,其中所述一个或多个铰接机构被配置成用于相对于所述反应室升高和降低所述上部加热外壳,并且其中所述一个或多个铰接机构中的至少一个铰接机构进一步被配置成用于以相对于所述多个肋材的小于0.25毫米的位置公差将所述上部加热外壳重新定位在降低位置中。
21.根据权利要求1所述的设备,其中所述多个辐射加热灯属于彼此基本上平行且邻近而安置的细长管型,其中所述个别辐射加热灯之间的距离是可调整的。
22.一种校准半导体处理设备的方法,包括:
提供反应室,所述反应室包括:
由竖直侧壁连接的上室壁和下室壁,所述室壁由上游入口法兰和下游出口法兰接合,其中所述反应室的纵向方向从所述入口法兰延伸到所述出口法兰;以及
设置在至少所述上室壁的外表面上的多个肋材,所述多个肋材横向于所述反应室的所述纵向方向而定向;
提供至少一个加热元件阵列,所述至少一个加热元件阵列安置在所述反应室上方;以及
调整至少一个可变定位装置,所述至少一个可变定位装置连接到所述至少一个加热元件阵列以相对于所述多个肋材的位置可控制地调整所述加热元件阵列的位置。
23.根据权利要求22所述的方法,进一步包括将所述反应室选择为包括翻新的反应室。
24.根据权利要求22所述的方法,进一步包括将所述至少一个加热元件阵列选择为包括多个辐射加热灯。
25.根据权利要求24所述的方法,其中所述多个辐射加热灯属于基本上平行于所述反应室的所述纵向方向而安置的细长管型。
26.根据权利要求24所述的方法,其中所述多个辐射加热灯属于基本上垂直于所述反应室的所述纵向方向而安置的细长管型。
27.根据权利要求24所述的方法,进一步包括选择所述至少一个可变定位装置以在基本上平行于所述反应室的所述纵向方向的方向上可控制地调整所述至少一个加热元件阵列的位置。
28.根据权利要求24所述的方法,进一步包括选择所述至少一个可变定位装置以在基本上垂直于所述反应室的所述纵向方向的方向上可控制地调整所述至少一个加热元件阵列的位置。
29.根据权利要求24所述的方法,进一步包括选择所述至少一个可变定位装置以相对于所述反应室的所述上室壁的位置可控制地调整所述至少一个加热元件阵列的高度。
30.根据权利要求24所述的方法,其中所述至少一个加热元件阵列连接到至少两个可变定位装置。
31.根据权利要求24所述的方法,其中所述至少一个加热元件阵列连接到至少三个可变定位装置。
32.根据权利要求24所述的方法,进一步包括:
提供安置在所述至少一个加热元件阵列下方的所述反应室内的衬底支架,所述衬底支架被配置成支撑至少一个衬底;
其中所述衬底支架具有所述衬底支架旋转所围绕的中心轴。
33.根据权利要求32所述的方法,其中所述至少一个加热元件阵列被配置成提供小于1.5℃的遍及所述至少一个衬底的表面的温度均匀性差。
34.根据权利要求32所述的方法,其中所述至少一个加热元件阵列被配置成提供小于0.4℃的遍及所述至少一个衬底的表面的温度均匀性差。
35.根据权利要求32所述的方法,其中所述至少一个加热元件阵列被配置成提供小于0.25℃的遍及所述至少一个衬底的表面的温度均匀性差。
36.根据权利要求22所述的方法,进一步包括选择所述至少一个可变定位装置以提供不超过约2厘米的所述至少一个加热元件阵列的位移。
37.根据权利要求22所述的方法,进一步包括提供单件反射器,所述单件反射器包括邻近于所述至少一个加热元件阵列而安置的多个抛物线区段。
38.根据权利要求22所述的方法,进一步包括将所述至少一个加热元件阵列选择为安置在上部加热外壳中,以及通过一个或多个铰接机构将所述上部加热外壳连接到反应室外壳。
39.根据权利要求38所述的方法,进一步包括将所述一个或多个铰接机构选择为在固定位置中连接到所述反应室外壳。
40.根据权利要求39所述的方法,进一步包括通过相对于所述反应室升高和降低所述上部加热外壳来重新定位所述上部加热外壳,其中重新定位所述上部加热外壳包括以相对于所述多个肋材的小于0.25mm的位置公差将所述上部加热外壳重新定位到降低位置。
41.根据权利要求24所述的方法,其中所述多个辐射加热灯属于彼此基本上平行且邻近而安置的细长管型,其中所述个别辐射加热灯之间的距离是可调整的。
42.根据权利要求22所述的方法,进一步包括:
测量从所述入口法兰到所述多个肋材中的每个肋材的距离;
计算所述多个肋材中的每个肋材与标称位置的偏离距离;
计算所述多个肋材的平均偏离距离;以及
将连接到所述至少一个加热元件阵列的所述至少一个可变定位装置的位置调整等于所述平均偏离距离的量。
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