JP6782320B2 - 基板処理方法 - Google Patents

基板処理方法 Download PDF

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JP6782320B2
JP6782320B2 JP2019062296A JP2019062296A JP6782320B2 JP 6782320 B2 JP6782320 B2 JP 6782320B2 JP 2019062296 A JP2019062296 A JP 2019062296A JP 2019062296 A JP2019062296 A JP 2019062296A JP 6782320 B2 JP6782320 B2 JP 6782320B2
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gas
substrate
oxygen
pattern structure
substrate processing
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JP2019186541A (ja
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セウン ウー チョイ
セウン ウー チョイ
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エーエスエム アイピー ホールディング ビー.ブイ.
エーエスエム アイピー ホールディング ビー.ブイ.
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Description

本発明は、基板処理方法に係り、さらに具体的には、薄膜層の特性を改善させることができる基板処理方法に関する。
基板上において、薄膜に対して、蒸着及びエッチングを行う基板処理過程において、基板各部分の均一度を一定に維持することは、半導体素子の収率(yield)を高めるために非常に重要である。特に、プラズマ工程において、活性ラジカルによる下部膜損傷が発生してしまうが、基板の各部分別に、損傷程度が異なるという場合が生じる。そのような損傷の不均一性により、薄膜及び素子の特性が、位置別に均一ではなくなってしまう。すなわち、全体的に損傷均一度が低下する場合、素子の収率管理に大きい影響を及ぼすことになる。
特開2016−027551号公報
本発明が解決しようとする課題は、基板上に均一な特性の薄膜を蒸着する方法を開示し、具体的には、プラズマ蒸着工程において、基板上各部分別に、プラズマ密度を制御し、基板上各部分別に、薄膜特性を均一に制御することができる方法を提供することである。
本発明の技術的思想による実施形態の一側面によれば、基板処理方法は、 パターン構造物が形成された基板上に、第1ガスを供給する段階と、前記第1ガスをパージする段階と、前記第1ガスと反応性を有する第2ガス及び第3ガスを、プラズマ雰囲気下で供給し、前記パターン構造物上に薄膜を形成する段階と、前記第2ガスをパージする段階と、を含み、前記薄膜を形成する段階の間、前記第2ガスは、ガス供給ユニットの少なくとも中心ガス流入口を介して供給され、前記第3ガスは、前記ガス供給ユニットの前記中心ガス流入口と離隔された追加ガス流入口を介して供給され、前記第3ガスは、前記第1ガス及び前記第2ガスと異なるガスであり、Arのイオン化エネルギーより高いイオン化エネルギーを有し、前記プラズマ雰囲気下で、前記第2ガスは、イオン化され、前記第3ガスは、イオン化されず、前記第1ガスは、第1温度で、前記第2ガスとは反応し、前記第1ガスは、前記第1温度で、前記第3ガスとは反応しない
本発明によれば、プラズマ蒸着工程において、基板中心部と基板エッジ部との間の周辺領域に、反応ガス及びキャリアガスよりイオン化エネルギーが高いガスを供給することにより、周辺部領域でのラジカル発生が、中心部とエッジ部とに比べ、相対的に抑制され、周辺部での下部膜損失を制御することにより、基板全体的に下部膜損失均一度が向上する。
本発明の技術的思想による実施形態による基板処理方法を概略的に示したフローチャートである。 本発明の技術的思想による他の実施形態による基板処理方法を概略的に示した断面図である。 本発明の技術的思想による実施形態による基板処理方法が適用されるガス供給ユニット、及びそれを含む基板処理装置を概略的に示す図面である。 本発明の技術的思想による実施形態による基板処理方法が適用されるガス供給ユニット、及びそれを含む基板処理装置を概略的に示す図面である。 本発明の技術的思想による実施形態による基板処理方法が適用されるガス供給ユニット、及びそれを含む基板処理装置を概略的に示す図面である。 本発明の技術的思想による実施形態による基板処理方法が適用されるガス供給ユニット、及びそれを含む基板処理装置を概略的に示す図面である。 基板上のSOH膜上にSiO膜を蒸着するとき、プラズマラジカルによる下部SOH膜の損傷程度を示す図面である。 27MHz、600ワットのプラズマ条件下において、基板上のSOH構造物上に、SiO膜を蒸着するとき、基板の各領域別にSOH損失程度を示す図面である。 他の実施形態として、NOの代わりに、Nガスを供給したとき、基板上において、SOH損失の均一性が変わることを示す図面である。 本発明の技術的思想による他の実施形態による基板処理方法を概略的に示した断面図である。
以下、添付された図面を参照し、本発明の実施形態について説明する。本発明の実施形態は、当該技術分野において当業者に、本発明をさらに完全に説明するために提供されるものであり、以下の実施形態は、さまざまに異なる形態にも変形され、本発明の範囲は、以下の実施形態に限定されるものではない。むしろ、それら実施形態は、本開示を、さらに忠実であって完全なものにし、当業者に本発明の思想を完全に伝達するために提供されるのである。
本明細書で使用された用語は、特定実施形態について説明するために使用され、本発明を制限するためではない。本明細書で使用されているように、単数形態は、文脈上、取り立てての場合を確かに指すものではないならば、複数の形態を含んでもよい。また、本明細書で使用される場合である「含む(comprise)」及び/または「含む(comprising)」は、言及した形状、数、段階、動作、部材、要素、及び/またはそれらグループの存在を特定するものであり、1以上の他の形状、数、動作、部材、要素、及び/またはグループの存在または付加を排除するものではない。本明細書で使用されているように、用語「及び/または」は、当該列挙された項目のうちいずれか一つ、及び1以上の全ての組み合わせを含む。
本明細書において、第1、第2のような用語は、多様な部材、領域及び/または部位について説明するために使用されるが、それらの部材、部品、領域、層及び/または部位は、それら用語によって限定されるものではないということは、自明である。それら用語は、特定順序、上下または優劣を意味するものではなく、1つの部材、領域または部位を、他の部材、領域または部位と区別するためにのみ使用される。従って、以下で説明する第1の部材、領域または部位は、本発明の教えからはずれなくとも、第2の部材、領域または部位を指すことができる。
本明細書において、「ガス」は、蒸発された固体及び/または液体を含んでもよく、単一ガス、またはガスの混合物によっても構成される。本明細書において、ガス供給ユニットを介して反応チャンバに導入された工程ガスは、前駆体ガス及び付加性ガスを含んでもよい。前記前駆体ガス及び前記付加性ガスは、典型的には、混合ガスとして、または別途に、反応空間にも導入される。前記前駆体ガスは、不活性ガスのようなキャリアガスとも共に導入される。前記付加性ガスは、反応物ガス及び不活性ガスのような希釈ガスを含んでもよい。前記反応物ガス及び前記希釈ガスは、混合され、または別途に反応空間にも導入される。該前駆体は、2以上の前駆体からも構成され、該反応物ガスは、2以上の反応物ガスからも構成される。前記前駆体は、基板上に化学吸着(chemisorption)され、誘電体膜のマトリックス主要構造を構成する、典型的には、メタロイド(metalloid)または金属元素を含むガスであり、堆積のための前記反応物ガスは、前記ガスが、前記基板上において、原子層または単層(monolayer)を固定するために励起されるとき、基板上に化学吸着された前記前駆体と反応するガスである。「化学吸着」は、化学的飽和吸着を指す。前記工程ガス以外のガス、すなわち、前記ガス供給ユニットを介して、通過せずに導入されたガスが、前記反応空間をシーリング(sealing)するためにも使用され、それは、不活性ガスのようなシールガス(seal gas)を含む。一部実施形態において、「膜(film)」は、全体ターゲットまたは関連表面を被覆させるように、実質的にピンホールなしに、厚み方向に垂直した方向に連続的に延長される層、または単に、ターゲットまたは関連表面を被覆する層を指す。一部実施形態において、「層(layer)」は、表面上に形成されたある厚みを有する構造物、または膜の同義語、または非膜(non-film)構造物を指す。膜または層は、ある特性を有する不連続的単一膜または単一層、または多重の膜または層によっても構成され、隣接した膜または層の境界は、明らかでもあり、明らかではなくもあり、物理的、化学的、及び/またはある他の特性、形成工程またはシーケンス、及び/または隣接した膜または層の機能または目的に基づいても設定される。
本明細書において、「同一物質」という表現は、主要構成成分が同一であるということを意味すると解釈されなければならない。例えば、第1層と第2層は、いずれもシリコン窒化層であり、同一物質から形成される場合、第1層は、SiN、SiN、Si及びSiを含む群からも選択され、第2層も、前記群からも選択されるが、その具体的な膜質は、第1層と異なってもいる。
さらには、本明細書において、遂行可能な範囲が、定例的な作業に基づいて決定されるということにより、ある2つの変数が、前記変数の遂行可能な範囲を構成することができ、ある指示された範囲は、終了点を含んだり排除したりすることができる。さらには、ある指示された変数値(それらが、「約(about)」と指示されていても、されていなくても)は、正確な値または近似値を指し、等価物を含んでもよく、また一部実施形態において、平均値、中央値、代表値、多数値などを指すことができる。
条件及び/または構造が特定されていない本明細書において、当業者は、慣例的な実験の問題として、本明細書の見地から、そのような条件及び/または構造を容易に提供することができる。全ての開示された実施形態において、1つの実施形態で使用されたある構成要素は、意図された目的のために、ここに、明示的に、必然的にまたは本質的に開示されたものを含み、それに等価的なある構成要素に代替され、さらに、本発明は、装置及び方法にも同一に適用される。
以下、本発明の技術的思想による実施形態について、概略的に図示する図面を参照して説明する。図面において、例えば、製造技術及び/または公差によって、図示された形状の変形が予想される。従って、本発明の実施形態は、本明細書に図示された領域の特定形状に制限されたものであると解釈されるものではなく、例えば、製造上、もたらされる形状変化を含むものである。
図1は、本発明の技術的思想による実施形態による基板処理方法を概略的に示したフローチャートである。
図1を参照すれば、パターン構造物が形成された基板上に、第1物質が供給される(S10)。該第1物質は、例えば、ソース物質でもあり、追って供給される第2物質と反応性を有する物質を含んでもよい。該第1物質は、ガスでもあり、選択的な実施形態において、液体でもあり、それ以外に、ガスと液体との間の状態の物質でもある。該第1物質は、パターン構造物が形成された基板上にも供給される。従って、該第1物質は、パターン構造物の上下面、及び上面と下面とを連結する側面の上にも塗布される。
その後、基板上に第2物質が供給される(S20)。該第2物質は、例えば、反応物質でもあり、パターン構造物は、該反応物質と反応性を有する物質を含んでもよい。例えば、前記パターン構造物は、フォトレジストを含んでもよい。該第2物質は、ガスでもあり、選択的な実施形態において、液体でもあり、それ以外に、ガスと液体との間の状態の物質でもある。該第2物質は、プラズマ雰囲気下でも供給される。また、第2物質は、供給ユニット(例えば、ガス供給ユニット)を介して、少なくとも基板中心近辺にも供給される。例えば、該第2物質は、供給ユニットの中心流入口を介して、基板中心部分にも供給される(S23)。さらには、該第2物質は、供給ユニットの他の流入口を介して、基板中心以外の部分にも供給される。
該第2物質が供給される間、該第2物質と異なる遮断物質も基板上に供給される(S20)。該遮断物質は、反応物質が基板のエッジ近辺に集中する現象(及び、それにより、基板上のパターン構造物のエッジ近辺が多く損傷される現象)を防止する機能を遂行することができる。該遮断物質は、第1物質及び第2物質と異なる物質を含んでもよい。
例えば、該遮断物質は、第1物質のイオン化エネルギー、及び第2物質のイオン化エネルギーより高いイオン化エネルギーを有することができる。選択的な実施形態において、該遮断物質は、非活性ガスのイオン化エネルギーより高いイオン化エネルギーを有することができる。そのような高いイオン化エネルギーを有する遮断物質の供給を介して、基板上のパターン構造物のエッジ近辺でのラジカル生成が抑制される。従って、前記ラジカルと反応性を有するパターン構造物の損傷が防止される。
前述のように、該遮断物質は、基板エッジ近辺での反応物質の集中(及び、それによるラジカル生成)を遮断するために供給される物質である。そのために、例えば、該遮断物質は、供給ユニットの中心ガス流入口と離隔された追加ガス流入口を介しても供給される(S25)。追加ガス流入口は、供給ユニットの中心ガス流入口と、供給ユニットのエッジとの間に位置することができる。該遮断物質により、基板エッジの流量が増加する。従って、エッジ近辺の反応物質のラジカル密度が、相対的に低下する。一方、該遮断物質が基板エッジに供給されることにより、基板中心近辺の反応物質のラジカル密度に対する遮蔽効果が生じうる。従って、基板中心近辺の反応物質のラジカル密度が上昇する。
図2は、本発明の技術的思想による他の実施形態による基板処理方法を概略的に示したフローチャートである。該実施形態による基板処理方法は、前述の実施形態による基板処理方法の変形例でもある。以下、実施形態間の重複説明は、省略する。
図2を参照すれば、まず、パターン構造物が形成された基板上に、第1ガスが供給される(S50)。例えば、該パターン構造物は、酸素と反応する物質を含んでもよく、前記反応により、該パターン構造物の一部が除去される。他の実施形態において、該パターン構造物は、酸素以外の物質(例えば、窒素)と反応する物質を含んでもよい。例えば、該パターン構造物は、スピンオンハードマスク(SOH)を含んでもよい。
該第1ガスは、前述のように、ソースガスであり、該第1ガスが反応空間に供給されれば、該第1ガスは、基板上にも吸着される。その後、該第1ガスがパージされる(S60)。該第1ガスは、基板上に形成しようとする薄膜の構成成分を含んでもよい。例えば、基板上に、シリコン酸化膜を形成しようとする場合、該第1ガスは、シリコン含有ガスでもある。
該第1ガスがパージされた後、第2ガス及び第3ガスが供給される(S70)。該第2ガス及び該第3ガスは、プラズマ雰囲気下でも供給される。前記プラズマ雰囲気の温度は、100℃以下でもあり、さらに具体的な例として、50℃以下でもある。前記プラズマの周波数は、例えば、27Mhzでもあり、該プラズマの電力は、600Wでもある。しかし、本発明は、前述のパラメータに制限されるものではなく、多様なパラメータによっても調節されるということに留意する。
該第2ガスは、該第1ガスと反応性を有する反応ガスでもある。一方、該第3ガスは、該第1ガスと反応しないガスでもある。基板上に吸着された第1ガスが、該第2ガスの供給により、該第2ガスと反応することにより、パターン構造物上に薄膜が形成される。基板上に吸着された第1ガスは、該第3ガスとは反応しないために、パターン構造物上に形成された薄膜は、該第3ガスの成分を含まない。
該第3ガスは、該第1ガス及び該第2ガスと異なるガスでもある。薄膜に、該第3ガスの成分を含めないために、該第3ガスは、高いイオン化エネルギーを有する物質によっても選択される。例えば、該第3ガスは、該第1ガスのイオン化エネルギー、及び/または該第2ガスのイオン化エネルギーより高いイオン化エネルギーを有することができる。選択的な実施形態において、該第3ガスは、非活性ガスのイオン化エネルギーより高いイオン化エネルギーを有することができる。それにより、薄膜形成段階の間、プラズマ雰囲気下で、該第2ガスは、イオン化され、一方、該第3ガスは、イオン化されない。
例えば、該第1ガスがシリコン含有ガスによって形成しようとする薄膜が、シリコン酸化膜である場合、該第2ガスは、酸素含有ガスでもあり、該第3ガスは、窒素含有ガスでもある。例えば、該第3ガスは、亜酸化窒素ガス及び窒素ガスのうち少なくとも一つを含んでもよい。
その場合、シリコン酸化膜を形成する間、基板のパターン構造物上に吸着されたシリコン含有ガスは、酸素含有ガスとは反応し、窒素含有ガスとは反応しない。それは、窒素含有ガスが、シリコン含有ガスのイオン化エネルギー、及び酸素含有ガスのイオン化エネルギーより高いエネルギーを有するからである。すなわち、プラズマ雰囲気下において、酸素含有ガスだけがイオン化されることにより、基板上に吸着されたシリコン含有ガスと反応し、シリコン酸化膜が形成され、シリコン窒化膜及び/またはシリコン酸窒化膜は、形成されない。
一例において、該第2ガスが酸素ガスであり、該第3ガスが亜酸化窒素ガスである場合、酸素ガスと亜酸化窒素ガスとの流量比は、1:0.625ないし1:1.25でもある。例えば、酸素ガスが供給される流量が160sccmである場合、亜酸化窒素ガスの流量は、100sccmないし200sccmでもある。他の例において、該第2ガスが酸素ガスであり、該第3ガスが窒素ガスである場合、酸素ガスと窒素ガスとの流量比は、1:0.625ないし1:1.25でもある。例えば、酸素ガスが供給される流量が160sccmである場合、窒素ガスの流量は、100sccmないし200sccmでもある。しかし、本発明は、前述のパラメータに制限されるものではなく、多様なパラメータによっても調節されるということに留意する。
たとえ、前述の実施形態がシリコン酸化膜を形成するための工程を基準に説明されたとしても、それは本発明を制限するものではないということに留意する。本発明は、任意の酸化膜を形成するための工程でもあり、その場合、該第2ガスは、酸素成分を含み、該第3ガスは、窒素成分を含んでもよい。他の実施形態において、本発明は、任意の窒化膜を形成するための工程でもある。
選択的な実施形態において、プラズマ雰囲気の温度パラメータは、該第3ガスの反応性を制限する要素にもなる。例えば、該プラズマ雰囲気は、第1温度にも設定されるが、その場合、該第1ガス(すなわち、パターン構造物上に吸着された第1ガス)は、第1温度で第2ガスと反応し、一方、該第1ガスは、第1温度で該第3ガスと反応しない。前記第1温度は、例えば、100℃以下の温度でもある。
例えば、100℃以下の温度条件のプラズマ雰囲気で供給される酸素ガスは、基板のパターン構造物上に吸着されたシリコン含有ガスと反応し、シリコン酸化膜を形成することができる。一方、100℃以下の温度条件のプラズマ雰囲気で供給される窒素ガス及び/または亜酸化窒素ガスは、基板のパターン構造物上に吸着されたシリコン含有ガスと反応しない。
薄膜を形成する段階の間、該第2ガスは、ガス供給ユニットの少なくとも中心ガス流入口を介しても供給される(S73)。一方、該第3ガスは、ガス供給ユニットの中心ガス流入口と離隔された追加ガス流入口を介しても供給されることができる(S75)。該第3ガスが追加ガス流入口を介して供給されることにより、基板エッジの流量が増加し、それにより、基板中心近辺のラジカル密度が上昇する。それは、基板中心部分の損傷増加に帰結される。
さらに具体的には、プラズマ雰囲気下において、パターン構造物と反応性を有する第2ガスが供給される場合、該第2ガスのラジカルが、パターン構造物と反応することにより、パターン構造物が除去される。そのようなパターン構造物の損傷は、第2ガスが供給される位置によっても影響を受けるが、反応に関与しない第3ガスが供給される位置によっても影響を受ける。特に、第3ガスが、追加ガス流入口を介して供給される場合、エッジでパターン構造物と反応することができるラジカルの生成が抑制され、従って、基板エッジに位置するパターン構造物の損傷が低減される。
例えば、該第1ガスがシリコン含有ガスであり、該第2ガスが酸素含有ガスであり、該第3ガスが窒素含有ガスである場合、酸素含有ガスは、少なくとも中心ガス流入口を介しても供給される。窒素含有ガスは、ガス供給ユニットの中心ガス流入口と離隔された追加ガス流入口を介しても供給される。
その場合、窒素含有ガスが、前記追加ガス流入口を介して供給され、基板エッジの流量が増加する。そのような基板エッジの流量増加により、基板エッジ部分でのパターン構造物と反応するラジカル密度は、低下する。一方、基板エッジの流量増加により、基板中心近辺でのパターン構造物と反応するラジカル密度は、上昇する。結果として、基板エッジ部分でのパターン構造物の損傷は、低減され、基板中心近辺でのパターン構造物の損傷は、増加し、結果として、両者が均一にもなる。
選択的な実施形態において、酸素含有ガスは、中心ガス流入口だけではなく、追加ガス流入口を介しても供給される。すなわち、基板中心近辺とエッジ近辺とのパターン構造物の損傷偏差を調節するために、追加ガス流入口を介して、パターン構造物と反応性を有する第2ガス(例えば、酸素含有ガス)を供給することもでき、パターン構造物と反応性を有さない第3ガス(例えば、窒素含有ガス)を供給することもできる。
該第2ガス及び該第3ガスが供給され、パターン構造物上に薄膜が形成された後、該第2ガス及び該第3ガスがパージされる。それにより、パターン構造物上に薄膜を形成するための1サイクルが完了して、前記サイクルは、所定回数反復される。前記サイクルが反復されることにより、パターン構造物上に形成された薄膜の厚みが増大する。
パターン構造物上に形成された薄膜は、ダブルパターニング工程またはクワドループルパターニング工程にも利用される。すなわち、追っての工程において、パターン構造物は、除去され、パターン構造物の側壁に形成された前記薄膜が、マスクの役割を行い、基板がパターニングされる。
前述の実施形態で説明したように、パージガスの供給は、ガスを転換する過程において、断続的に行われる。例えば、該第1ガスパージのためのパージガスは、第1ガスの供給段階と、該第2ガス及び該第3ガス供給段階との間に、断続的に供給される。また、該第2ガス及び該第3ガスのパージのためのパージガスは、該第2ガス及び該第3ガス供給段階と、次のサイクルでの第1ガスの供給段階との間にも供給される。
選択的な実施形態において、パージガスの供給は、薄膜形成工程全般にわたり、連続して遂行される。例えば、該第1ガスパージのためのパージガスは、工程過程において、継続して供給される。その場合、該第1ガス供給段階後、該第2ガス及び該第3ガスの供給段階まで、所定期間の間、他のガスを供給しないことにより、該第1ガスパージが行われる。また、該第2ガス及び該第3ガスの供給段階後、次のサイクルの第1ガス供給段階まで所定期間の間、他のガスを供給しないことにより、該第2ガス及び該第3ガスパージが行われる。
パージガスと同様に、該第3ガスの供給も、断続して行われる。例えば、該第3ガスは、該第2ガス供給段階と、次サイクルでの該第1ガス供給段階との間にも供給される。また、該第3ガスの供給は、連続しても行われる。言い換えれば、該第3ガスは、薄膜形成工程全般にわたって連続しても供給される。
図3は、本発明の技術的思想による実施形態による基板処理方法が適用されるガス供給ユニット、及びそれを含む基板処理装置を概略的に示す。
図3を参照すれば、基板処理装置は隔壁110、ガス供給ユニット120、RFロッド130及び排気通路140を含んでもよい。本明細書で説明された基板処理装置の例として、半導体基板またはディスプレイ基板の蒸着装置を有することができるが、本発明は、それに制限されるものではないということに留意する。該基板処理装置は、薄膜形成のための物質堆積を行うのに必要ないかなる装置でもあり、物質のエッチングないし研磨のための原料が均一に供給される装置を指すこともできる。以下では、便宜上、該基板処理装置が、半導体基板蒸着装置であるということを前提に説明する。
隔壁110は、反応器の構成要素でもある。言い換えれば、隔壁110構造により、基板の処理(例えば、蒸着、エッチング、研磨)のための反応空間が形成される。例えば、隔壁110は、反応器側壁及び/または反応器上壁を含んでもよい。隔壁110において、反応器上壁部分は、ガス供給チャネル150を提供することができ、前記ガス供給チャネル150を介して、ソースガス、パージガス及び/または反応ガスが供給される。
ガス供給ユニット120は、ガス供給チャネル150にも連結される。ガス供給ユニット120は、反応器にも固定される。例えば、ガス供給ユニット120は、固定部材(図示せず)を介して、隔壁110にも固定される。ガス供給ユニット120は、反応空間(160)内の被処理体にガスを供給するようにも構成される。例えば、ガス供給ユニット120は、シャワーヘッドアセンブリでもある。
ガス供給ユニット120内部には、ガス供給チャネル150と連通するガスフローチャネル170が形成される。ガスフローチャネル170は、ガス供給ユニット120のガスチャネル125(上部)と、ガス供給ユニット120のガス供給プレート127(下部)との間にも形成される。たとえ図面には、ガスチャネル125とガス供給プレート127とが別個の構造に図示されているにしても、ガスチャネル125とガス供給プレート127は、一体化された構造にも形成される。
ガスチャネル125は、ガス供給チャネル150と連結された中心注入口を提供することができる。該中心注入口は、ガスフローチャネル170と連結され、従って、ガスフローチャネル170は、中心注入口を介して、ガス供給チャネル150と連結される。
前述のように、隔壁110には、ガス供給チャネル150が形成される。前記ガス供給チャネル150に追加し、第1貫通ホール180が、隔壁110の少なくとも一部を貫通するようにも形成される。例えば、第1貫通ホール180は、隔壁110において、反応器上壁を貫通するようにも形成される。望ましい実施形態において、第1貫通ホール180の直径は、ガス供給チャネル150の直径よりも小さい。
第2貫通ホール185は、ガス供給ユニット120の少なくとも一部を貫通するようにも形成される。例えば、第2貫通ホール185は、ガスチャネル125を貫通し、ガスフローチャネル170と連結されるようにも形成される。従って、第1貫通ホール180が、第2貫通ホール185を介して、前記ガスフローチャネル170と連通することができる。
第2貫通ホール185は、ガスフローチャネル170の中心とエッジとの間にも配置される。特に、第2貫通ホール185は、ガスフローチャネル170のエッジから離隔されても配置される。そのような第2貫通ホール185の位置構造を介して、基板の特定部分(すなわち、第2貫通ホール185が配置された部分と相応する部分)での薄膜蒸着が制御される。
例えば、第2貫通ホール185を介して供給されたガスは、基板の中心とエッジとの間の部分に蒸着される薄膜下部のパターン構造物の損傷程度に影響を及ぼす。前記ガスが高いイオン化エネルギーを有する遮断ガスである場合、基板の中心とエッジとの間のパターン構造物の損傷は、低減される。
シャワーヘッド構造は、一般的に、中心部分を介して反応ガスが供給され、エッジを介して排気される構造を採用するが、そのような構造により、基板エッジ部分のパターン構造物の損傷と、基板中心部分のパターン構造物の損傷とが均一ではなくなるという問題が生じうる。しかし、本発明によれば、別途のガス供給通路を追加し、それを介して、反応空間の中心部分とエッジとの間に遮断ガスが供給される。そのように供給された遮断ガスは、反応空間の周辺部でのラジカル生成を制限する遮蔽効果(blocking effect)を誘導することができ、結果として、基板の周辺部に形成されたパターン構造物の損傷が低減される。従って、基板の中心とエッジとの間に生じるパターン構造物の損傷偏差問題が改善される。
選択的な実施形態において、第2貫通ホール185は、中心注入口の中心から一定間隔離隔された円周に沿って、複数個配置される。他の選択的な実施形態において、第2貫通ホール185は、中心注入口の中心から一定間隔離隔された円周に沿い、連続しても配置される。その場合、ガスチャネル125は、前記第2貫通ホール185によって分離された複数の部品からも構成される。
第2貫通ホール185は、ガス供給プレート127に対して(または、ガスフローチャネル170に対して)、垂直方向、または傾いた方向に、ガスチャネル125を貫通するようにも形成される。例えば、第2貫通ホール185は、ガス供給プレート127の延長方向(すなわち、水平方向)に対して、ガス供給プレート127の中心に向かい、15〜45°の角度で貫通するようにも形成される。言い換えれば、ガスチャネル125を貫通する第2貫通ホール185の貫通角度を調節することにより、基板上そして薄膜下部に位置するパターン構造物のプラズマによる損傷の均一度が制御される。
例示的な実施形態において、第2貫通ホール185は、ガス供給プレート127の延長方向(すなわち、水平方向)に対して、30°の角度で貫通するようにも形成される。その場合、第2貫通ホール185は、ガスチャネル125の第1面(例えば、上部表面)上において第1径を有する第1円周に沿い、配置または形成され、第2貫通ホール185は、前記ガスチャネル125の第2面(例えば、下部表面)上において第2径を有する第2円周に沿い、配置または形成され、前記第1径と前記第2径は、異なりもする。
そのように、第2貫通ホール185の個数、形状及び配列位置、及び第2貫通ホール185に供給されるガスの種類、流量などを調節することにより、パターン構造物の損傷均一度がさらに精密に制御され、結果として、所望の形態と所望の品質の薄膜が蒸着される。
選択的な実施形態において、第1貫通ホール180と第2貫通ホール185との間に、バッファ空間190がさらに形成される。前記バッファ空間190は、第1貫通ホール180を介して供給されたガスが、第2貫通ホール185に均一に供給されるように、ガスを一時的に保有する役割を行うことができる。従って、前記バッファ空間190の直径ないし幅は、第1貫通ホール180の直径ないし幅より大きく、第2貫通ホール185の直径ないし幅よりも大きい。また、バッファ空間190は、ガス供給チャネル150の中心から一定間隔離隔された円周に沿い、連続しても形成される。
該基板処理装置は、ガス供給チャネル150と連結された第1ガス供給部(図示せず)、及び第1貫通ホール180と連結された第2ガス供給部(図示せず)をさらに含んでもよい。また、該基板処理装置は、前記第1ガス供給部及び前記第2ガス供給部を制御するように構成された制御部(図示せず)をさらに含んでもよい。一実施形態において、前記制御部は、前記第1ガス供給部及び前記第2ガス供給部を独立的に制御するようにもさらに構成される。例えば、該第1ガス供給部は、ソースガス及び/または反応ガスを供給するようにも構成され、該第2ガス供給部は、遮断ガスを供給するようにも構成される。
該基板処理装置は、RFロッド130をさらに含んでもよい。RFロッド130は、隔壁110の少なくとも一部を貫通し、前記ガス供給ユニット120とも連結される。RFロッド130は、外部のプラズマ供給部(図示せず)とも連結される。図面には、2個のRFロッド130が図示されているが、本発明は、それに制限されるものではなく、少なくとも1個以上のRFロッド130を設け、反応空間160に供給されるプラズマパワーの均一性を向上させることができる。
該基板処理装置は、隔壁110の下部面と接触するように構成されたサセプタ200をさらに含んでもよい。サセプタ200は、サセプタ支持部210によっても支持され、サセプタ支持部210は、上下動及び回転運動を行うことができる。サセプタ支持部210の上下動により、サセプタ200が隔壁110から離隔されたり、隔壁110と接触したりすることにより、反応空間160が開閉される。
該基板処理装置は、排気部(図示せず)をさらに含んでもよい。反応空間160において、基板との化学反応後に残存する残留ガスは、前記排気部により、排気通路140を介して外部に排気される。
図4は、本発明の技術的思想による他の実施形態によるガス供給ユニット、及びそれを含む基板処理装置を概略的に示す。該実施形態によるガス供給ユニット及び基板処理装置は、前述の実施形態によるガス供給ユニット及び基板処理装置の変形例でもある。以下、該実施形態間での重複説明は、省略する。
図4を参照すれば、基板処理装置は、隔壁110、及び隔壁110内に実質的に水平に正しく位置しているガス供給ユニット120、隔壁110内のガス供給ユニット120と実質的に平行に対向するように位置したサセプタ200を含んでもよい。
隔壁110内に設けられ、真空ポンプに連結された排気通路140は、隔壁110内の反応空間160の残留ガスを真空排出させるのにも利用される。
ガス供給ユニット120は、シャワーヘッドでもあり、該シャワーヘッドのベースは、原料ガスを噴出させるように形成された多数の微細孔220を含んでもよい。該シャワーヘッドは、ガス供給チャネル150を介して、原料ガス供給タンクにも連結される。高周波(RF)電源は、一側電極として機能するシャワーヘッドと電気的にも連結される。
サセプタ200は、支持台によって支持され、他側電極として機能することができる。サセプタ200の表面には、半導体基板のような被処理基板がローディングされ、前記被処理基板は、真空吸着などによっても固定される。
また、前述のように、第2貫通ホール185は、シャワーヘッドの上部部分の少なくとも一部を貫通するようにも形成される。従って、第1貫通ホール180が、第2貫通ホール185を介して、シャワーヘッドのガスフローチャネル170と連通することができる。
図5は、本発明の技術的思想による他の実施形態によるガス供給ユニット、及びそれを含む基板処理装置を概略的に示す。該実施形態によるガス供給ユニット及び基板処理装置は、前述の実施形態によるガス供給ユニット及び基板処理装置の変形例でもある。以下、該実施形態間の重複説明は、省略する。
図5を参照すれば、隔壁110を含む第1蓋240及び第2蓋250は、サセプタ200と共に反応空間160を形成することができる。さらに具体的には、反応空間160の下部は、サセプタ200により、反応空間160の上部は、第1蓋240により、反応空間160の両側面は、第2蓋250によっても形成される。
該基板処理装置が蒸着装置である場合、第1蓋240は、シャワーヘッドを含んでもよい。第2蓋250は、反応側壁W及び排気通路140を含んでもよい。
該基板処理装置の排気構造は、下流排気構造によっても構成され、そのとき、前記下流排気構造は、第2蓋250によっても具現される。その場合、蒸着に利用されるガスは、第1蓋240のシャワーヘッドを介して、被処理基板に噴射され、その後、第2蓋250の排気通路140を介して、下流排気される。
また、前述のように、第2貫通ホール185は、ガス供給ユニット120の上部部分の少なくとも一部を貫通するようにも形成される。従って、第1貫通ホール180が、第2貫通ホール185を介して、シャワーヘッドのガスフローチャネル170と連通することができる。
図6は、本発明の技術的思想による他の実施形態によるガス供給ユニット、及びそれを含む基板処理装置を概略的に示す。該実施形態によるガス供給ユニット及び基板処理装置は、前述の実施形態によるガス供給ユニット及び基板処理装置の変形例でもある。以下、該実施形態間の重複説明は、省略する。
前述のように、本発明においては、基板上に蒸着される薄膜の各部分別に、特性を制御する方法を開示する。本発明によれば、基板上にガスを供給するガス供給手段を具備した反応器において、基板上にプラズマを利用した薄膜蒸着がなされる。さらに具体的には、前記ガス供給手段は、シャワーヘッドであり、前記プラズマを利用した薄膜蒸着は、プラズマ原子層蒸着法(PEALD)、プラズマ化学気相蒸着法(PECVD)、パルストプラズマ化学気相蒸着法(pulsed PECVD)そしてサイクリックパルストプラズマ化学気相蒸着法(cyclic pulsed PECVD)のうち一つ、あるいは前記方法の適切な組み合わせでもあり、あるいは前記方法の適切な変形でもある。
図6を参照すれば、反応器1は、反応器壁2とサセプタ3とが面接触を介して、反応空間13を形成する。ガスは、反応器中心に位置した第1ガス流入口4、周辺部に位置した第2ガス供給ポート8、第2ガス流入口5,6,7、及びその下部に位置したシャワーヘッド11ホール(図示せず)を介して反応空間13に供給される。
反応空間13に供給されたガスは、サセプタ3上にローディングされた基板(図示せず)表面と反応した後、排気チャネル14、排気ホール15、排気通路16及び排気ポート18を介して排気される。前記第2ガス流入口5,6,7は、反応器壁2、バックプレート9、ガスチャネル10を貫通し、ガスフローチャネル12とも連結される。例えば、ガスチャネル10を貫通する第2ガス流入口7は、基板表面を基準に、多様な角度にも形成される。それにより、基板上の特定部分に供給されるガスの流量が制御され、基板上の特定部分に蒸着される薄膜の特性が制御される。
前記反応器壁を貫通する第2ガス流入口5は、前記反応器の一面を貫通することができる。他の第2ガス流入口6,7は、反応器の中心を基準に、環状にも配置され、それにより、基板周辺部に均一に第2ガスが供給される。
図7は、図6の反応器において、PEALD方法により、基板上のSOH(フォトレジストの一種)膜上にSiO膜を蒸着するとき、プラズマラジカルによる下部SOH膜の損傷程度を示す。該損傷程度は、前記蒸着されたSiO膜を湿式エッチング(wet etch)して測定した。
図7を参照すれば、図7の横軸は、直径300mm基板の中心から両方向に各位置を示し、縦軸は、プラズマALD方式でSiO膜を蒸着したとき、前述の図6の第2ガス供給通路を介して供給される酸素あるいは非活性ガス(例えば、Ar)の流量によるSOH下部膜の損失程度を示す。図6の反応器において、第2ガス流入口を介して、それぞれ酸素を50sccm、250sccm、Arを600sccm、1,000accm供給したが、ガスの種類及び流量にかかわらず、全基板にかけてSOH膜の損失形態及び程度は同じようであった。
さらに具体的には、図7を参照すれば、SOH下部膜の損失均一度(SOH loss uniformity)は、全基板にかけて一定ではなく、基板のエッジ部において、SOH膜の損失程度が大きかった。それは、プラズマ工程時、反応空間にかけてプラズマラジカル密度が一定ではなく、前記基板のエッジ部でのラジカル密度が特に高いということを意味する。従って、本発明においては、前記エッジ部でのラジカル密度を制御することにより、全体的にSOH損失均一度を高めることができる方法を開示する。
前記基板周辺部(基板中心部と基板エッジ部との間の領域)でのラジカル密度を制御したり低くしたりするために、本発明においては、ラジカル生成を抑制するガスを供給した。本発明の一実施形態によれば、SOH膜上に、プラズマを利用し、SiO膜を蒸着するとき、前記第2ガス流入口を介して、窒素を含むガスを供給した。具体的には、前記第1ガス流入口を介して、ソースガス、酸素反応ガス、及びArキャリアガスあるいはパージガスが供給されるとき、前記第2ガス流入口を介して窒素ガスを供給する。窒素ガスのイオン化エネルギーは、1,503MJ/mol、Arガスのイオン化エネルギーは1,520.6KJ/mol、そして酸素ガスのイオン化エネルギーは、493.4KJ/molであり、窒素ガスの解離エネルギーが、他ガスの解離エネルギーよりはるかに大きい。従って、窒素を供給するとき、アルゴンあるいは酸素を供給する場合に比べ、プラズマ発生が抑制される。窒素以外にも、前記キャリアガスあるいはパージガスそして反応ガスよりイオン化エネルギーの高いガスが、前記第2ガス流入口を介しても供給される。
そのように、本発明の技術的思想によれば、基板の中心部に比べ、第2ガス流入口に対応する基板上の周辺部でのラジカル発生を抑制することにより、周辺部領域でのSOH損失が防止され、全体的に、さらに均一なSOH損失均一度が達成される。
Figure 0006782320
図8を参照すれば、酸素ガスは、Arガスと共に供給され、第2ガス流入口を介して基板周辺部に供給される窒素含有ガス(例えば、NO)の量によるSOH損失を測定したとき、窒素含有ガスの流量が増加するほど、基板周辺部でのSOH損失が低減するということが分かる。すなわち、酸素及びArガスだけを供給したときには、基板上でのSOH損失の均一性が良好ではなかったが、Arの代わりに、窒素含有ガスの比率を高めたときには、基板周辺部でのプラズマ生成が抑制され、従って、ラジカルによるSOH侵食が低減される。結果として、SOH損失の均一性が全般的に制御され、だんだんと改善されるということが分かる。また、図8を参照すれば、窒素ガスの供給量が増加するほど、基板エッジ部でのSOH損失は低減するが、中心部のSOH損失は、むしろ増加するということを示すが、それは、基板周辺部に供給された窒素ガスが、中心部に供給された酸素ガスを取り囲むことにより、相対的に中心部での酸素ラジカルの密度が上昇し、SOH損失が増大すると理解することができる。従って、基板周辺部に供給される窒素含有ガスの流量を適切に調節することにより、基板中心部のラジカル密度を調節することができ、SOH損失、あるいは下部膜変形の均一度(uniformity)が適切に制御されるということを示す。
図9は、さらに他の実施形態であり、NOの代わりに、Nガスを供給したとき、基板上において、SOH損失の均一性が変わるということを示す。図9を参照すれば、N2ガスを、第1ガス流入口及び第2ガス流入口を介して、反応空間の周辺部に供給したとき、エッジの窒素ガス(EN:edge N)の流量により、SOH損失の均一性が制御されるということが分かる。
図10は、本発明の技術的思想による他の実施形態による基板処理方法を概略的に示した断面図である。該実施形態による基板処理方法は、前述の実施形態による基板処理方法の変形例でもある。以下、該実施形態間の重複説明は、省略する。
図10を参照すれば、反応空間の中心に配置された第1ガス流入口を介して、Siソースガス、酸素ガスそしてArガスが反応空間に供給され、反応空間の周辺に配置された第2ガス流入口を介して、窒素あるいは二酸化窒素が、反応空間の周辺領域に供給される。酸素ガスは、第1ガス流入口を介して、図10のように、パルス形態にも供給され、連続しても供給される。本発明によれば、基板の周辺領域には、窒素ガスの相対的比率が高く、基板の中心部とエッジ部とに比べ、ラジカル発生率が相対的に低くなる。従って、周辺部でのSOH損失が低減され、全体的にSOH損失均一度が向上する(図8及び図9を参照)。
そのように、本発明によれば、プラズマ蒸着工程において、基板中心部と基板エッジ部との間の周辺領域に、反応ガス及びキャリアガスよりイオン化エネルギーが高いガスを供給することにより、周辺部領域でのラジカル発生が、中心部とエッジ部とに比べ、相対的に抑制され、周辺部での下部膜損失を制御することにより、基板全体的に下部膜損失均一度が向上する。
本発明について明確に理解させるために添付された図面の各部位の形状は、例示的なものであると理解されなければならない。図示された形状以外の多様な形状に変形されるということに留意しなければならないのである。
以上で説明した本発明は、前述の実施形態、及び添付された図面に限定されるものではなく、本発明の技術的思想を外れない範囲内で、さまざまな置換、変形及び変更が可能であるということは、本発明が属する技術分野において当業者において、明白であろう。
本発明の基板処理方法は、例えば、半導体素子収率関連の技術分野に効果的に適用可能である。
1 反応器
2 反応器壁
3,200 サセプタ
4 第1ガス流入口
5,6,7 第2ガス流入口
8 第2ガス供給ポート
9 バックプレート
10,125 ガスチャネル
11 シャワーヘッド
12,170 ガスフローチャネル
13,160 反応空間
14 排気チャネル
15 排気ホール
16,140 排気通路
18 排気ポート
110 隔壁
120 ガス供給ユニット
125 ガスチャネル
127 ガス供給プレート
130 RFロッド
150 ガス供給チャネル
180 第1貫通ホール
185 第2貫通ホール
190 バッファ空間
210 サセプタ支持部
220 微細孔
240 第1蓋
250 第1蓋

Claims (18)

  1. パターン構造物が形成された基板上に、第1ガスを供給する段階と、
    前記第1ガスをパージする段階と、
    前記第1ガスと反応性を有する第2ガス及び第3ガスを、プラズマ雰囲気下で供給し、前記パターン構造物上に薄膜を形成する段階と、
    前記第2ガスをパージする段階と、を含み、
    前記薄膜を形成する段階の間、前記第2ガスは、ガス供給ユニットの少なくとも中心ガス流入口を介して供給され、前記第3ガスは、前記ガス供給ユニットの前記中心ガス流入口と離隔された追加ガス流入口を介して供給され、
    前記第3ガスは、前記第1ガス及び前記第2ガスと異なるガスであり、Arのイオン化エネルギーより高いイオン化エネルギーを有し、
    前記プラズマ雰囲気下で、前記第2ガスは、イオン化され、前記第3ガスは、イオン化されず、
    前記第1ガスは、第1温度で、前記第2ガスとは反応し、前記第1ガスは、前記第1温度で、前記第3ガスとは反応しない、基板処理方法。
  2. 前記第3ガスが前記追加ガス流入口を介して供給され、基板エッジの流量が増加し、それにより、基板中心近辺のラジカル密度が上昇することを特徴とする請求項1に記載の基板処理方法。
  3. 前記第3ガスは、窒素成分を含むことを特徴とする請求項2に記載の基板処理方法。
  4. 前記第3ガスは、亜酸化窒素ガス及び窒素ガスのうち少なくとも一つを含むことを特徴とする請求項3に記載の基板処理方法。
  5. 前記第2ガスは、酸素成分を含み、前記第3ガスは、窒素成分を含み、
    前記薄膜は、100℃以下の温度条件で形成された酸化膜であることを特徴とする請求項1に記載の基板処理方法。
  6. 前記第2ガスは、酸素であり、前記第3ガスは、亜酸化窒素であり、
    前記プラズマ雰囲気において、前記酸素ガスと前記亜酸化窒素ガスとの流量比は、1:0.625ないし1:1.25であることを特徴とする請求項5に記載の基板処理方法。
  7. 前記第2ガスは、酸素であり、前記第3ガスは、窒素であり、
    前記プラズマ雰囲気において、前記酸素ガスと前記窒素ガスとの流量比は、1:0.625ないし1:1.25であることを特徴とする請求項5に記載の基板処理方法。
  8. 前記プラズマ雰囲気下において、前記パターン構造物の損傷が生じることを特徴とする請求項1に記載の基板処理方法。
  9. 前記パターン構造物の損傷は、前記追加ガス流入口を介して供給される前記第3ガスによって変化することを特徴とする請求項8に記載の基板処理方法。
  10. 前記パターン構造物は、スピンオンハードマスク(SOH)を含むことを特徴とする請求項8に記載の基板処理方法。
  11. 前記パターン構造物上に形成された前記薄膜を利用して遂行されるダブルパターニング工程またはクワドループルパターニング工程をさらに含むことを特徴とする請求項1に記載の基板処理方法。
  12. 前記第3ガスは、前記第1ガス及び前記第2ガスのイオン化エネルギーより高いイオン化エネルギーを有することを特徴とする請求項1に記載の基板処理方法。
  13. 酸素と反応するパターン構造物が形成された基板上に、シリコン含有ガスを供給する段階と、
    前記シリコン含有ガスをパージする段階と、
    酸素含有ガス及び窒素含有ガスを100℃以下のプラズマ雰囲気下で供給し、前記パターン構造物上にシリコン酸化膜を形成する段階と、
    前記酸素含有ガスをパージする段階と、を含み、
    少なくとも前記シリコン酸化膜を形成する段階の間、前記酸素含有ガスは、ガス供給ユニットの少なくとも中心ガス流入口を介して供給され、前記窒素含有ガスは、前記ガス供給ユニットの前記中心ガス流入口と離隔された追加ガス流入口を介して供給され、
    前記プラズマ雰囲気下で、前記酸素含有ガスは、イオン化され、前記窒素含有ガスは、イオン化されず、
    前記シリコン含有ガスは、第1温度で、前記酸素含有ガスとは反応し、前記シリコン含有ガスは、前記第1温度で、前記窒素含有ガスとは反応しない、基板処理方法。
  14. 前記酸素と反応するパターン構造物は、スピンオンハードマスクであり、
    前記酸素含有ガスは、酸素であり、前記窒素含有ガスは、亜酸化窒素であり、
    前記プラズマ雰囲気において、前記酸素ガスと前記亜酸化窒素ガスとの流量比は、1:0.625ないし1:1.25であることを特徴とする請求項13に記載の基板処理方法。
  15. 前記シリコン酸化膜を形成する段階の間、前記基板の前記パターン構造物上に吸着されたシリコン含有ガスは、酸素含有ガスとは反応し、窒素含有ガスとは反応しないことを特徴とする請求項13に記載の基板処理方法。
  16. 前記窒素含有ガスが前記追加ガス流入口を介して供給され、基板エッジの流量が増加し、
    前記基板エッジの流量増加により、基板エッジ部分でのパターン構造物と反応するラジカル密度は低下し、
    前記基板エッジの流量増加により、基板中心近辺でのパターン構造物と反応するラジカル密度は上昇し、
    結果として、基板エッジ部分でのパターン構造物の損傷と、基板中心近辺でのパターン構造物の損傷とが均一になることを特徴とする請求項13に記載の基板処理方法。
  17. 反応物質と反応するパターン構造物が形成された基板上に、ソース物質を供給する段階と、
    プラズマ雰囲気下で、供給ユニットの少なくとも中心ガス流入口を介して、前記反応物質を供給する段階と、を含み、
    前記反応物質を供給する段階の間、前記反応物質と異なる遮断物質が、前記供給ユニットの前記中心ガス流入口と離隔された追加ガス流入口を介して供給され、
    前記遮断物質により、基板エッジの流量が増加し、それにより、基板中心近辺の反応物質のラジカル密度が上昇し、
    前記プラズマ雰囲気下で、前記反応物質は、イオン化され、前記遮断物質は、イオン化されず、
    前記ソース物質は、第1温度で、前記反応物質とは反応し、前記ソース物質は、前記第1温度で、前記遮断物質とは反応しない、基板処理方法。
  18. 前記遮断物質は、Arのイオン化エネルギーより高いイオン化エネルギーを有することを特徴とする請求項17に記載の基板処理方法。
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US20190304776A1 (en) 2019-10-03
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