CN1516749A - 电化学粗化的铝半导体加工装置表面 - Google Patents
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Abstract
发现一种均匀、可控的用于电化学粗化含铝表面的方法,该表面用在半导体加工设备中。通常含铝表面为铝或铝合金。本方法包括将含铝表面浸渍在体积浓度大约在1%到大约5%之间的盐酸溶液中,随即施用电荷密度大约在80amps/ft.2到大约250amps/ft.2的电荷约4分钟到约25分钟。可以加入一种螯合剂以增强粗化过程。该电化学粗化法可以用在常见的铝合金上,其包括但不限于6061和LP。电化学粗化提供光滑的起伏表面,其不会截留颗粒,并提供扩大的表面面积,用于粘附半导体加工副产物。粗化的表面提供一种用于随后的阳极化的极好的表面。
Description
发明领域
本发明涉及一种用在半导体加工腔室中的电化学粗化的铝表面。本发明还涉及一种电化学粗化铝表面的方法。通常将该粗化的表面阳极化,以制得用在半导体加工中的精巧的(finished)表面。
发明背景
半导体制造工艺,例如蚀刻和沉积工艺,利用了多种多样的加工气体和基片材料。通常使用真空将高挥发性的加工过程中的副产物从加工腔室中移除。不易挥发的副产物可能粘附在加工腔室的内表面上,或可能再沉积在被加工的半导体基片的表面上。大多数半导体制造商宁愿使再沉积副产物沉积到加工腔室表面(而不是基片上)。然后定期清理加工腔室的表面。从加工腔室的停工期来看,频繁清理加工腔室是昂贵的。加工腔室表面能够粘附的再沉积副产物越多,越不需要频繁的清理。
半导体加工腔室的内表面通常是铝的。一个现有技术中的半导体加工腔室包括阳极化的铝表面,其被打磨至表面粗糙度仅有4Ra,其基本上为镜面精度(mirror finish)。然而,当遇到高温和在许多半导体加工工艺中所用的加工条件时,这种高度抛光的、阳极化的铝表面会在阳极化层出现许多微小的裂纹,被称为裂痕纹线(craze lines);这些在图1中被示出。由于裂痕纹线100通常在从阳极化层到在基底铝之下的边界层的各方向上都不渗透,它们倾向于在阳极化层上横向伸展,形成蛛网图案。在氟基(fluorine-based)的蚀刻过程中,阳极化铝表面与氟气体反应,导致裂痕纹线充满了自钝化氟化物。尽管在氟基的蚀刻过程中裂痕纹不会干扰加工腔室的运转,但它们缺乏装饰性,而且加工腔室的使用者往往担心含氟物质会穿过阳极化保护层并腐蚀下方的铝表面。此外,在非氟基环境(例如在氯基蚀刻过程中)并未充满自钝化氟化物,而且阳极化表面最终会失去作用,使得下方的铝受到含氯物质的腐蚀。
在许多半导体加工过程中,会生成那些没有足够挥发性以便被加工腔室的真空系统除去的副产物。在许多情况下,需要提供一种在加工腔室内的、副产物能够粘附在上面的表面,由此,副产物在加工过程中不会落到半导体工件上,导致污染。
一种提高半导体加工副产物在半导体加工腔室中的铝表面上的粘合的方法是提供一种在加工过程中生成的副产物能够粘附在其上的粗化表面。通常,铝半导体腔室表面已经通过珠光处理(bead blasting)的方法被粗化。但是,珠光处理经常为手工操作,其很难控制均匀度及重复性。进一步而言,如图2所示,珠光处理通常在铝上形成非常尖锐、粗糙的表面200。粗化铝的尖端可以卷曲,形成钩形突起202,其可以折断或截留包括珠光处理颗粒本身的颗粒204。结果,珠光处理介质可以成为铝表面污染的一个来源。珠光处理不用作对一些较软的铝合金(例如1000系列)的粗化方法,因为珠光处理颗粒能够轻易嵌入延性金属。进一步的,由珠光处理形成的尖锐的表面可以使后续的阳极化过程变得复杂。
因此,有必要提供一种可用于所有铝合金的均匀并可控的粗化铝表面的方法。特别的,这种粗化方法应提供一种不截留颗粒的表面,其可免于粗糙及钩形表面形态,并易于阳极化。
发明内容
申请人发现了一种均匀、可控的方法以用来粗化在半导体加工腔室中使用的含铝表面。通常,含铝表面是铝或一种铝合金。申请人还测定,如果他们电化学粗化铝或铝合金表面,其可避免锯齿状(jagged)或钩形表面形貌。由电化学粗化形成的表面可以提供类似起伏的小山和山谷的形态。估计的由谷底到山顶的平均高度为大约16微米;估计的小山之间的平均距离为大约50微米,取决于铝的等级。通常,小山的高度在大约8微米到大约25微米之间,一座小山中心与另一座相邻小山中心之间的距离在大约30微米到大约100微米之间。
令人惊讶的,通过电化学粗化铝或铝合金表面方法获得小山和山谷形貌,降低了随后在整个粗化表面上阳极化产生的应力,因此,阳极化层不会在高达大约300℃的热循环过程中龟裂。另外,出乎意料,能够积聚在小山和山谷上(包括反映铝表面下面的阳极化表面)的再沉积副产物的量,已经彻底增加超过了可以在珠光处理表面积聚的副产物的量。结果,在用新的,电化学粗化的铝或铝合金阳极化表面清理之间的基片加工循环的次数比使用珠光处理铝阳极化表面的次数大五倍。
申请人的用于表面粗化的方法,可以用在普通的的铝和铝合金上,包括但不限于6061和LP(可从Alcan Alusuisse获得)。申请人的方法促进了光滑的、起伏的小山形的、阳极化的表面的形成,此表面不截留颗粒。进一步而言,申请人的电化学粗化含铝表面提供了增加的用于再沉积副产物收集的表面积。
附图的简要说明
图1显示了现有技术的阳极化铝表面100,其被打磨至表面粗糙度为4Ra。注意形成于铝表面的大量裂痕纹线102在随后暴露在加工条件下形成蛛网图案。
图2显示了已用珠光处理法粗化的现有技术的铝表面200。注意能够被折断或截留包括珠光处理颗粒自身的颗粒204的大量钩形突出物。
图3显示了已用申请人的电化学粗化法粗化的铝表面300。注意申请人的电化学粗化铝表面的光滑的、起伏的形态。
优选具体实施方案的详细说明
申请人的发明涉及一种电化学粗化含铝表面的方法。通常,含铝表面为铝或铝合金。铝一般与例如硅、铜、锌、镁、锰、铁、钛和镍的元素组成合金(仅为举例而非限制)。申请人的发明已经用在半导体加工腔室中,其具有电化学粗化的铝表面,特别是具有例如阳极化铝涂层的保护涂层的粗化表面。
申请人的用于电化学粗化含铝表面的方法包括,在大约45℃到大约80℃的温度下,将含铝表面浸渍在浓度为大约1体积百分比到大约5体积百分比的盐酸水溶液中,随后施用电荷密度为大约80amps/ft.2到大约250amps/ft.2的电荷约5分钟到约25分钟。可以将螯合剂(例如,举例但不限制,葡糖酸,可由VWR Scientific Products,WestChester,Pa处获得)加入到盐酸溶液中,以控制溶液化学和电导率。
根据申请人的方法的电化学粗化铝和铝合金的典型处理条件列在下面的表1中。
表1.电化学粗化铝和铝合金的典型工艺条件
工艺参数 | 典型工艺条件 | 优选工艺条件 | 最佳公知工艺条件 |
盐酸浓度(%体积) | 1-5 | 1-3 | 1-1.5 |
螯合剂(%体积) | 0.5-3 | 0.5-1.5 | 0.8-1.2 |
槽温度(℃) | 45-80 | 50-70 | 55-65 |
交流频率(Hz) | 60-120 | 80-100 | 85-95 |
电荷密度(amps/ft.2) | 80-250 | 120-250 | 150-250 |
时间(分钟) | 4-25 | 4-20 | 4-20 |
按照被粗化的特定铝合金的具体化学组成来调整加工条件。申请人已对一些可通过商业途径获得的铝合金进行了电化学粗化。在这些合金的电化学粗化过程中的具体的加工条件列在下面的表2中。
未经粗化的、机械加工的铝及铝合金,其表面粗糙度通常为大约12Ra到大约32Ra。在用申请人的电化学粗化法处理后,铝或铝合金表面的表面粗糙度通常为大约100Ra到大约200Ra,优选在大约110Ra到160Ra。
如图3中所示,申请人的铝及铝合金粗化法提供了一种表面300,其具有类似小的起伏小山302和山谷304的形态。由山谷304到小山302的估计平均高度为大约16微米,小山302之间的估计平均距离为大约50微米,取决于铝的等级。通常,小山302的高度在大约8微米到大约25微米之间,一座小山中心与另一座相邻小山中心之间的距离在大约30微米到大约100微米之间。申请人的电化学粗化的铝及铝合金表面提供扩大的用于再沉积副产物收集的表面区域,但是不截留颗粒。
表2.电化学粗化特定铝合金的工艺条件
合金 | 6061* | LP** |
工艺条件 | ||
盐酸浓度(%V) | 1.0-1.5 | 1.0-1.5 |
葡糖酸***(%V)(螯合剂) | 0.9-1.1 | 0.9-1.1 |
槽温度(℃) | 55-65 | 55-65 |
交流频率 | 85-95 | 85-95 |
电荷密度(amps/ft.2) | 175-250 | 175-250 |
时间(分钟) | 6-12 | 4-8 |
*可以由一些主要的铝制造商,例如Alcoa(匹兹堡,PA)、Alcan.Inc(蒙特利尔,加拿大)、和Reynolds Aluminum Supply Co.(Richmond,VA)处获得。
**由Alcan Alusuisse(Stegen,Germany)处获得。
***由VWR Scientific Products(West Chester,PA)处获得。
申请人的电化学粗化法特别有于其随后被抗等离子涂层所保护的粗化铝和铝合金表面,该表面用在例如蚀刻腔室或沉积腔室的半导体加工腔室中。申请人的方法特别有用于粗化一些与半导体加工副产物接触的设备表面。申请人的电化学粗化的铝或铝合金表面提供在小山和山谷中的凹穴(pockets),这些小山和山谷用于例如蚀刻副产物或CVD沉积副产物的半导体加工副产物的积聚,这些凹穴防止副产物再沉积到所加工的半导体的基片表面上。在整个用于粘附沉积副产物的铝或铝合金表面上,施用保护涂层是有帮助的。保护涂层的实施例包括阳极氧化物、火焰喷射沉积(flame spray-deposited)氧化铝及其它可以是导电的或非导电的陶瓷涂层。
特别的,在氟基蚀刻工艺中,蚀刻工艺中产生的氟和碳反应,生成易于粘附到电化学粗化的、阳极化铝表面上的聚合物。
申请人的电化学粗化的、阳极化的铝或阳极化的铝合金表面可以包括在用于蚀刻介电材料(包括无机绝缘材料,例如氧化硅、氮化硅、氧氮化硅和五氧化二钽,以及有机介电材料,例如一种有机低K介电材料)、金属(例如铝、铜、钛、钽、和钨)、和多晶硅的蚀刻室中,此为举例而非限制。
申请人的方法可以用于制造半导体加工腔室部件的粗化表面,这些部件例如腔壁衬垫(wall liners)、阴极衬垫(cathode liners)、狭缝阀门(slit valve doors)、狭缝阀衬垫、缓冲插入件(buffer inserts)、和气体分配盘,此为举例而非限制。
申请人的电化学粗化铝和铝合金表面的阳极化可以采用本领域内公知的传统铝阳极化技术进行,例如通过下列的Mil Standard No.A-8625F,此为举例而非限制。因为申请人的粗化方法降低了在铝和铝合金表面中的应力,所得阳极化表面不会形成裂痕纹线,甚至在对其施加因特殊半导体制造法所致的温度循环的时候。
其它类似火焰喷射沉积氧化铝和其它陶瓷涂层的保护性抗等离子涂层,可以采用本领域公知的技术沉积或施用在整个铝或铝合金表面上。陶瓷涂层,导电的或不导电的,可以施用在整个粗化的阳极化表面上。
上述的优选具体实施方案不是为了限制本发明的范围,熟知本领域的人能够根据本公开将这些实施例进行扩展以符合本发明的权利要求的主旨。
Claims (45)
1.一种半导体加工腔室,其具有至少一个含有电化学粗化的铝或铝合金的内表面。
2.如权利要求1所述的半导体加工腔室,其中所述至少一个内表面具有大约100Ra到大约200Ra的表面粗糙度。
3.如权利要求2所述的半导体加工腔室,其中所述表面粗糙度在大约110Ra到大约160Ra之间。
4.如权利要求1所述的半导体加工腔室,其中所述电化学粗化铝或铝合金表面,当放大时外观如起伏的小山和山谷。
5.如权利要求4所述的半导体加工腔室,其中所述小山的高度在大约8微米到大约25微米之间。
6.如权利要求4或权利要求5所述的半导体加工腔室,其中一座小山的中心到一相邻小山中心之间的距离为大约30微米到大约100微米。
7.如权利要求1所述的半导体加工腔室,其中所述电化学粗化铝或铝合金表面位于一涂层下,该涂层选自阳极化涂层、火焰喷射沉积的氧化铝涂层、陶瓷涂层、以及具有涂布于其上的陶瓷涂层的阳极化涂层。
8.如权利要求1所述的半导体加工腔室,其中在蚀刻过程或沉积过程中产生的副产物粘附到所述的电化学粗化铝表面上。
9.如权利要求1所述的半导体加工腔室,其中所述半导体加工腔室选自蚀刻室或沉积室。
10.如权利要求9所述的半导体加工腔室,其中所述半导体加工腔室为蚀刻室,其用来蚀刻选自介电材料、金属和多晶硅的材料。
11.如权利要求9所述的半导体加工腔室,其中所述半导体加工腔室为蚀刻室,并且其中由蚀刻过程产生的氟和碳反应,生成粘附在所述电化学粗化铝表面上的聚合物。
12.一种用在半导体加工腔室中的加工部件,其中所述加工部件具有至少一个电化学粗化的铝或铝合金表面。
13.如权利要求12所述的加工部件,其中所述的电化学粗化铝或铝合金表面具有大约100Ra到大约200Ra的表面粗糙度。
14.如权利要求13所述的加工部件,其中所述表面粗糙度在大约110Ra到大约160Ra之间。
15.如权利要求12所述的加工部件,其中所述电化学粗化铝或铝合金表面,当放大时外观如起伏的小山和山谷。
16.如权利要求15所述的加工部件,其中所述小山的高度在大约8微米到大约25微米之间。
17.如权利要求15或权利要求16所述的加工部件,其中一座小山的中心到一相邻小山中心之间的距离为大约30微米到大约100微米。
18.如权利要求12所述的加工部件,其中所述电化学粗化铝或铝合金表面位于一涂层下,该涂层选自阳极化涂层、火焰喷射沉积的氧化铝涂层、陶瓷涂层、以及具有涂布其上的陶瓷涂层的阳极化涂层。
19.如权利要求12所述的加工部件,其中在蚀刻过程或沉积过程中产生的副产物粘附到所述的电化学粗化铝或铝合金表面上。
20.如权利要求12所述的加工部件,其中所述加工部件用在选自蚀刻腔室和沉积腔室的半导体加工腔室中。
21.如权利要求20所述的加工部件,其中所述半导体加工腔室为蚀刻腔室,其用来蚀刻选自介电材料、金属和多晶硅的材料。
22.如权利要求20所述的加工部件,其中所述半导体加工腔室为蚀刻腔室,并且其中由蚀刻过程产生的氟和碳反应,生成粘附在所述电化学粗化表面上的聚合物。
23.如权利要求12所述的加工部件,其中所述加工部件选自:腔壁衬垫、阴极衬垫、狭缝阀门、狭缝阀衬垫、缓冲插入件、和气体分配盘。
24.一种半导体加工设备表面,其中所述表面含有电化学粗化的铝或铝合金。
25.如权利要求24所述的半导体加工设备表面,其中所述表面的表面粗糙度为大约100Ra到大约200Ra之间。
26.如权利要求25所述的半导体加工设备表面,其中所述表面粗糙度在大约110Ra到大约160Ra之间。
27.如权利要求24所述的半导体加工设备表面,其中所述电化学粗化铝或铝合金表面,当放大时外观如起伏的小山和山谷。
28.如权利要求27所述的加工部件半导体加工设备表面,其中所述小山的高度在大约8微米到大约25微米之间。
29.如权利要求27或权利要求28所述的半导体加工设备表面,其中一座小山的中心到一相邻小山中心之间的距离为大约30微米到大约100微米。
30.如权利要求24所述的半导体加工设备表面,其中所述表面位于一涂层下,该涂层选自阳极化涂层、火焰喷射沉积氧化铝涂层、陶瓷涂层、以及具有涂布于其上的陶瓷涂层的阳极化涂层。
31.如权利要求24所述的半导体加工设备表面,其中在蚀刻过程或沉积过程中产生的副产物粘附到所述的电化学粗化的表面上。
32.如权利要求31所述的半导体加工设备表面,其中由蚀刻过程产生的氟和碳反应,生成粘附到所属表面上的聚合物。
33.如权利要求24所述的半导体加工设备表面,其中所述表面在一个设备部件上,该设备部件选自:腔壁衬垫、阴极衬垫、狭缝阀门、狭缝阀衬垫、缓冲插入件、和气体分配盘。
34.一种用于电化学粗化含铝或铝合金的表面的方法,包括步骤为:
a)在大约45℃到大约80℃的温度间,将所述表面浸渍在浓度为大约1体积百分比到大约5体积百分比的盐酸溶液中;并
b)施用电荷密度为大约80amps/ft.2到大约250amps/ft.2的电荷约4分钟到约25分钟。
35.如权利要求34所述的方法,其中所述盐酸溶液体积的浓度在大约1%到大约3%之间。
36.如权利要求35所述的方法,其中所述盐酸溶液的温度在大约50℃到大约70℃之间。
37.如权利要求34所述的方法,其中所述盐酸溶液进一步含有螯合剂,其中所述螯合剂的体积浓度在大约0.5%到大约3%之间。
38.如权利要求37所述的方法,其中所述螯合剂为葡糖酸。
39.如权利要求34所述的方法,其中所述电荷密度大约在120amps/ft.2到大约250amps/ft.2之间。
40.如权利要求34所述的方法,其中所述时间大约在4分钟到大约20分钟之间。
41.如权利要求34所述的方法,其中所述含铝表面是一种铝合金,选自6061和LP。
42.如权利要求41所述的方法,其中所述盐酸溶液体积浓度大约在1%到大约1.5%之间;其中所述盐酸溶液的温度在大约55℃到大约65℃之间;且其中所述电荷密度大约在175amps/ft.2到大约250amps/ft.2之间。
43.如权利要求42所述的方法,其中所述盐酸溶液进一步含有葡糖酸螯合剂,其体积浓度大约在0.9%到大约1.1%之间。
44.如权利要求43所述的方法,其中在所述电流密度存在的期间,所述时间段大约为6分钟到大约12分钟,且铝合金为6061。
45.如权利要求43所述的方法,其中在所述电流密度存在的期间,所述时间段为大约4分钟到大约8分钟,且铝合金为LP。
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2002
- 2002-07-22 KR KR10-2003-7015103A patent/KR20040030619A/ko not_active Application Discontinuation
- 2002-07-22 WO PCT/US2002/023287 patent/WO2003012162A1/en not_active Application Discontinuation
- 2002-07-22 CN CNB028121333A patent/CN1267578C/zh not_active Expired - Fee Related
- 2002-07-22 EP EP02768339A patent/EP1415016A1/en not_active Withdrawn
- 2002-07-26 TW TW091116827A patent/TWI223347B/zh not_active IP Right Cessation
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2004
- 2004-06-10 US US10/866,470 patent/US20040224171A1/en not_active Abandoned
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CN102080205A (zh) * | 2009-11-05 | 2011-06-01 | 欧瑞康太阳能(处贝区市)公司 | 通过铝铸造制成的真空处理室 |
US8347941B2 (en) | 2009-11-05 | 2013-01-08 | Oerlikon Solar Ag, Trubbach | Vacuum processing chamber manufactured by aluminum casting |
Also Published As
Publication number | Publication date |
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TWI223347B (en) | 2004-11-01 |
WO2003012162A1 (en) | 2003-02-13 |
EP1415016A1 (en) | 2004-05-06 |
CN1267578C (zh) | 2006-08-02 |
KR20040030619A (ko) | 2004-04-09 |
US20040224171A1 (en) | 2004-11-11 |
US20030047464A1 (en) | 2003-03-13 |
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