KR102501472B1 - 기판 처리 방법 - Google Patents
기판 처리 방법 Download PDFInfo
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- KR102501472B1 KR102501472B1 KR1020180037762A KR20180037762A KR102501472B1 KR 102501472 B1 KR102501472 B1 KR 102501472B1 KR 1020180037762 A KR1020180037762 A KR 1020180037762A KR 20180037762 A KR20180037762 A KR 20180037762A KR 102501472 B1 KR102501472 B1 KR 102501472B1
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- H01L21/324—Thermal treatment for modifying the properties of semiconductor bodies, e.g. annealing, sintering
Abstract
기판 상에 형성되는 박막 하부의 패턴 구조물의 손상이 위치별로 균일하게 유지될 수 있는 기판 처리 방법이 개시된다. 기판 처리 방법은, 반응 물질과 반응하는 패턴 구조물이 형성된 기판 상에 소스 물질을 공급하는 단계 및 플라즈마 분위기 하에서 공급 유닛의 적어도 중심 유입구를 통해 상기 반응 물질을 공급하는 단계를 포함하고, 상기 반응 물질을 공급하는 단계 동안, 상기 반응 물질과 다른 차단 물질이 상기 공급 유닛의 상기 중심 기체 유입구와 이격된 추가 기체 유입구를 통해 공급된다.
Description
본 발명은 기판 처리 방법에 관한 것으로, 보다 구체적으로는 박막 층의 특성을 개선시킬 수 있는 기판 처리 방법에 관한 것이다.
기판 상에 박막을 증착 및 식각을 하는 기판 처리 과정에 있어서, 기판 각 부분의 균일도를 일정하게 유지하는 것은 반도체 소자의 수율(yield)을 높이기 위해 매우 중요하다. 특히 플라즈마 공정에 있어 활성 라디칼에 의한 하부막 손상이 발생하게 되는데, 기판의 각 부분별로 손상 정도가 달라지는 경우가 발생한다. 이러한 손상의 불균일성으로 인해 박막 및 소자의 특성이 위치별로 균일하지 않게 될 수 있다. 즉, 전체적으로 손상 균일도가 저하될 경우 소자의 수율 관리에 큰 영향을 미치게 된다.
따라서 본 발명은 기판 상에 균일한 특성의 박막을 증착하는 방법을 개시하며 구체적으로는 플라즈마 증착 공정에 있어 기판 상 각 부분별로 플라즈마의 밀도를 제어하여 기판상 각 부분별 박막의 특성을 균일하게 제어할 수 있는 방법을 제공하고자 한다.
본 발명의 기술적 사상에 따른 실시예들의 일 측면에 따르면, 기판 처리 방법은 패턴 구조물이 형성된 기판 상에 제1 기체를 공급하는 단계; 상기 제1 기체를 퍼지하는 단계; 상기 제1 기체와 반응성을 갖는 제2 기체 및 제3 기체를 플라즈마 분위기 하에서 공급하여 상기 패턴 구조물 상에 박막을 형성하는 단계; 및 상기 제2 기체를 퍼지하는 단계를 포함하고, 상기 박막을 형성하는 단계 동안, 상기 제2 기체는 기체 공급 유닛의 적어도 중심 기체 유입구를 통해 공급되고, 상기 제3 기체는 상기 기체 공급 유닛의 상기 중심 기체 유입구와 이격된 추가 기체 유입구를 통해 공급되며, 상기 제3 기체는 상기 제1 기체 및 상기 제2 기체와 다른 기체이며, 비활성 기체의 이온화 에너지보다 높은 이온화 에너지를 가질 수 있다.
상기 기판 처리 방법의 일 예에 따르면, 상기 제3 기체가 상기 추가 기체 유입구를 통해 공급되어 기판 가장자리의 유량이 증가되고, 그에 따라 기판 중심 부근의 라디칼 밀도가 증가될 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 제3 기체는 질소 성분을 포함할 수 있다. 예를 들어, 상기 제3 기체는 아산화 질소 기체 및 질소 기체 중 적어도 하나를 포함할 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 제2 기체는 산소 성분을 포함하고, 상기 제3 기체는 질소 성분을 포함하며, 상기 박막은 섭씨 100도 이하의 온도 조건에서 형성된 산화막일 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 제2 기체는 산소이고, 상기 제3 기체는 아산화질소이며, 상기 플라즈마 분위기에서 상기 산소 기체와 상기 아산화질소 기체의 유량비는 1:0.625 내지 1:1.25일 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 제2 기체는 산소이고, 상기 제3 기체는 질소이며, 상기 플라즈마 분위기에서 상기 산소 기체와 상기 질소 기체의 유량비는 1:0.625 내지 1:1.25일 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 플라즈마 분위기 하에서 상기 패턴 구조물의 손상이 발생할 수 있다. 상기 패턴 구조물의 손상은 상기 추가 기체 유입구를 통해 공급되는 상기 제3 기체에 의해 변화할 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 패턴 구조물은 스핀 온 하드마스크(SOH)를 포함할 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 기판 처리 방법은 상기 패턴 구조물 상에 형성된 상기 박막을 이용하여 수행되는 더블 패터닝 공정 또는 쿼드러플 패터닝 공정을 더 포함할 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 플라즈마 분위기 하에서, 상기 제2 기체는 이온화되고, 상기 제3 기체는 이온화되지 않을 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 제1 기체는 제1 온도에서 상기 제2 기체와는 반응하고, 상기 제1 기체는 상기 제1 온도에서 상기 제3 기체와는 반응하지 않을 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 제3 기체는 상기 제1 기체 및 상기 제2 기체의 이온화 에너지보다 높은 이온화 에너지를 가질 수 있다.
본 발명의 기술적 사상에 따른 실시예들의 다른 측면에 따르면, 기판 처리 방법은 산소와 반응하는 패턴 구조물이 형성된 기판 상에 실리콘 함유 기체를 공급하는 단계; 상기 실리콘 함유 기체를 퍼지하는 단계; 산소 함유 기체 및 질소 함유 기체를 섭씨 100도 이하의 플라즈마 분위기 하에서 공급하여 상기 패턴 구조물 상에 실리콘 산화막을 형성하는 단계; 및 상기 산소 함유 기체를 퍼지하는 단계를 포함하고, 적어도 상기 실리콘 산화막을 형성하는 단계 동안, 상기 산소 함유 기체는 기체 공급 유닛의 적어도 중심 기체 유입구를 통해 공급되고, 상기 질소 함유 기체는 상기 기체 공급 유닛의 상기 중심 기체 유입구와 이격된 추가 기체 유입구를 통해 공급될 수 있다.
상기 기판 처리 방법의 일 예에 따르면, 상기 산소와 반응하는 패턴 구조물은 스핀 온 하드마스크이고, 상기 산소 함유 기체는 산소이고, 상기 질소 함유 기체는 아산화질소이며, 상기 플라즈마 분위기에서 상기 산소 기체와 상기 아산화질소 기체의 유량비는 1:0.625 내지 1:1.25일 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 실리콘 산화막을 형성하는 단계 동안, 상기 기판의 상기 패턴 구조물 상에 흡착된 실리콘 함유 기체는 산소 함유 기체와는 반응하고 질소 함유 기체와는 반응하지 않을 수 있다.
상기 기판 처리 방법의 다른 예에 따르면, 상기 질소 함유 기체가 상기 추가 기체 유입구를 통해 공급되어 기판 가장자리의 유량이 증가하고, 상기 기판 가장자리의 유량 증가로 인해 기판 가장자리 부분에서의 패턴 구조물과 반응하는 라디칼 밀도는 감소하며, 상기 기판 가장자리의 유량 증가로 인해 기판 중심 부근에서의 패턴 구조물과 반응하는 라디칼 밀도는 증가하고, 결과적으로 기판 가장자리 부분에서의 패턴 구조물의 손상과 기판 중심 부근에서의 패턴 구조물의 손상이 균일해질 수 있다.
본 발명의 기술적 사상에 따른 실시예들의 또 다른 측면에 따르면, 기판 처리 방법은 반응 물질과 반응하는 패턴 구조물이 형성된 기판 상에 소스 물질을 공급하는 단계; 및 플라즈마 분위기 하에서 공급 유닛의 적어도 중심 유입구를 통해 상기 반응 물질을 공급하는 단계를 포함하고, 상기 반응 물질을 공급하는 단계 동안, 상기 반응 물질과 다른 차단 물질이 상기 공급 유닛의 상기 중심 기체 유입구와 이격된 추가 기체 유입구를 통해 공급되며, 상기 차단 물질에 의해 기판 가장자리의 유량이 증가되고, 그에 따라 기판 중심 부근의 반응 물질의 라디칼 밀도가 증가될 수 있다.
상기 기판 처리 방법의 일 예에 따르면, 상기 차단 물질은 비활성 기체의 이온화 에너지보다 높은 이온화 에너지를 가질 수 있다.
도 1은 본 발명의 기술적 사상에 의한 실시예들에 따른 기판 처리 방법을 개략적으로 나타낸 흐름도이다.
도 2는 본 발명의 기술적 사상에 의한 다른 실시예들에 따른 기판 처리 방법을 개략적으로 나타낸 단면도이다.
도 3 내지 도 6은 본 발명의 기술적 사상에 의한 실시예들에 따른 기판 처리 방법이 적용되는 기체 공급 유닛 및 이를 포함하는 기판 처리 장치를 개략적으로 나타낸다.
도 7은 기판 상의 SOH 막 위에 SiO2 막을 증착할 때 플라즈마 라디칼에 의한 하부 SOH 막의 손상 정도를 보여준다.
도 8은 27MHz, 600 와트(watt)의 플라즈마 조건 하에서 기판 상의 SOH 구조물 상에 SiO2 막을 증착할 때 기판의 각 영역별로 SOH 손실 정도를 보여주고 있다.
도 9는 또 다른 실시예로서, N2O대신 N2기체를 공급했을 때 기판 상에서 SOH 손실의 균일성이 변하는 것을 보여주고 있다.
도 10은 본 발명의 기술적 사상에 의한 다른 실시예들에 따른 기판 처리 방법을 개략적으로 나타낸 단면도이다.
도 2는 본 발명의 기술적 사상에 의한 다른 실시예들에 따른 기판 처리 방법을 개략적으로 나타낸 단면도이다.
도 3 내지 도 6은 본 발명의 기술적 사상에 의한 실시예들에 따른 기판 처리 방법이 적용되는 기체 공급 유닛 및 이를 포함하는 기판 처리 장치를 개략적으로 나타낸다.
도 7은 기판 상의 SOH 막 위에 SiO2 막을 증착할 때 플라즈마 라디칼에 의한 하부 SOH 막의 손상 정도를 보여준다.
도 8은 27MHz, 600 와트(watt)의 플라즈마 조건 하에서 기판 상의 SOH 구조물 상에 SiO2 막을 증착할 때 기판의 각 영역별로 SOH 손실 정도를 보여주고 있다.
도 9는 또 다른 실시예로서, N2O대신 N2기체를 공급했을 때 기판 상에서 SOH 손실의 균일성이 변하는 것을 보여주고 있다.
도 10은 본 발명의 기술적 사상에 의한 다른 실시예들에 따른 기판 처리 방법을 개략적으로 나타낸 단면도이다.
이하, 첨부된 도면을 참조하여 본 발명의 실시예들을 설명하기로 한다.
본 발명의 실시예들은 당해 기술 분야에서 통상의 지식을 가진 자에게 본 발명을 더욱 완전하게 설명하기 위하여 제공되는 것이며, 아래의 실시예들은 여러 가지 다른 형태로 변형될 수 있으며, 본 발명의 범위가 아래의 실시예들로 한정되는 것은 아니다. 오히려, 이들 실시예는 본 개시를 더욱 충실하고 완전하게 하며 당업자에게 본 발명의 사상을 완전하게 전달하기 위하여 제공되는 것이다.
본 명세서에서 사용된 용어는 특정 실시예를 설명하기 위하여 사용되며, 본 발명을 제한하기 위한 것이 아니다. 본 명세서에서 사용된 바와 같이 단수 형태는 문맥상 다른 경우를 분명히 지적하는 것이 아니라면, 복수의 형태를 포함할 수 있다. 또한, 본 명세서에서 사용되는 경우 "포함한다(comprise)" 및/또는 "포함하는(comprising)"은 언급한 형상들, 숫자, 단계, 동작, 부재, 요소 및/또는 이들 그룹의 존재를 특정하는 것이며, 하나 이상의 다른 형상, 숫자, 동작, 부재, 요소 및/또는 그룹들의 존재 또는 부가를 배제하는 것이 아니다. 본 명세서에서 사용된 바와 같이, 용어 "및/또는"은 해당 열거된 항목 중 어느 하나 및 하나 이상의 모든 조합을 포함한다.
본 명세서에서 제1, 제2 등의 용어가 다양한 부재, 영역 및/또는 부위들을 설명하기 위하여 사용되지만, 이들 부재, 부품, 영역, 층들 및/또는 부위들은 이들 용어에 의해 한정되어서는 안됨은 자명하다. 이들 용어는 특정 순서나 상하, 또는 우열의 의미하지 않으며, 하나의 부재, 영역 또는 부위를 다른 부재, 영역 또는 부위와 구별하기 위하여만 사용된다. 따라서, 이하 상술할 제1 부재, 영역 또는 부위는 본 발명의 가르침으로부터 벗어나지 않고서도 제2 부재, 영역 또는 부위를 지칭할 수 있다.
본 개시서에서, "기체(가스)"는 증발된 고체 및/또는 액체를 포함할 수 있으며, 단일 기체 또는 기체들의 혼합물로 구성될 수 있다. 본 개시서에서, 기체 공급 유닛을 통하여 반응 챔버로 도입된 공정 기체는 전구체 기체 및 부가성 기체를 포함할 수 있다. 상기 전구체 기체 및 상기 부가성 기체는 전형적으로 혼합 기체로서 또는 별도로 반응 공간으로 도입될 수 있다. 상기 전구체 기체는 불활성 기체와 같은 캐리어 기체와 함께 도입될 수 있다. 상기 부가성 기체는 반응물 기체 및 불활성 기체와 같은 희석 기체를 포함할 수 있다. 상기 반응물 기체 및 상기 희석 기체는 혼합하여 또는 별도로 반응 공간으로 도입될 수 있다. 전구체는 둘 이상의 전구체들로 구성될 수 있으며, 그리고 반응물 기체는 둘 이상의 반응물 기체들로 구성될 수 있다. 상기 전구체는 기판 상에 화학흡착된 그리고 유전체 막의 매트릭스의 주요 구조를 구성하는 전형적으로 메탈로이드(metalloid) 또는 금속 원소를 함유하는 기체며, 퇴적을 위한 상기 반응물 기체는 상기 기체가 상기 기판 상에서 원자층 또는 단층(monolayer)을 고정하기 위해 여기될 때 기판 상에 화학흡착된 상기 전구체와 반응하는 기체이다. "화학흡착(chemisorption)"은 화학적 포화 흡착을 지칭한다. 상기 공정 기체 외의 기체, 즉 상기 기체 공급 유닛을 통하여 통과하지 않고 도입된 기체가 상기 반응 공간을 실링(sealing)하기 위해 사용될 수 있으며, 이것은 불활성 기체와 같은 시일 기체(seal gas)를 포함한다. 일부 실시예들에서, "막(film)"은 전체 타겟 또는 관련된 표면을 피복하도록 실질적으로 핀홀들 없이 두께 방향에 수직한 방향으로 연속적으로 연장되는 층, 또는 단순히 타겟 또는 관련된 표면을 피복하는 층을 지칭한다. 일부 실시예들에서 "층(layer)"은 표면 상에 형성된 어떠한 두께를 갖는 구조물, 또는 막의 동의어, 또는 비막(non-film) 구조물을 지칭한다. 막 또는 층은 어떠한 특성들을 갖는 불연속적 단일 막 또는 층, 또는 다중의 막들 또는 층들로 구성될 수 있으며, 그리고 인접한 막들 또는 층들 사이의 경계는 분명하거나 또는 분명하지 않을 수 있으며, 그리고 물리적, 화학적, 및/또는 어떤 다른 특성들, 형성 공정들 또는 시퀀스, 및/또는 인접한 막들 또는 층들의 기능들 또는 목적들에 기초하여 설정될 수 있다.
본 개시서에서, "동일한 물질"이라는 표현은, 주요 구성 성분이 동일함을 의미하는 것으로 해석되어야 한다. 예를 들어, 제1 층과 제2 층은 모두 실리콘 질화층이고 동일한 물질로 형성될 경우, 제1 층은 Si2N, SiN, Si3N4, 및 Si2N3을 포함하는 그룹으로부터 선택될 수 있고, 제2 층 역시 상기 그룹으로부터 선택될 수 있으나 그 구체적인 막일은 제1 층과 상이할 수 있다.
부가적으로, 본 개시서에서, 실행 가능한 범위가 정례적인 작업에 기초하여 결정될 수 있다는 것에 따라서 어떠한 두 가지의 변수가 상기 변수의 실행가능한 범위를 구성할 수 있으며, 어떠한 지시된 범위는 종료점들을 포함하거나 배제할 수 있다. 부가적으로, 어떠한 지시된 변수들의 값들은(그것들이 "약(about)"으로 지시되었거나 아니거나 상관없이) 정확한 값들 또는 근사값들을 지칭할 수 있으며, 등가물을 포함할 수 있으며, 그리고 일부 실시예들에서 평균값, 중앙값, 대표값, 다수값 등을 지칭할 수 있다.
조건들 및/또는 구조들이 특정되지 않은 본 개시서에서, 통상의 기술자는 관례적인 실험의 문제로서, 본 개시서의 견지에서 이러한 조건들 및/또는 구조들을 용이하게 제공할 수 있다. 모든 개시된 실시예들에서, 하나의 실시예에서 사용된 어떠한 구성 요소는 의도된 목적들을 위해, 여기에 명시적으로, 필연적으로 또는 본질적으로 개시된 것들을 포함하여, 그것에 등가적인 어떠한 구성 요소들로 대체될 수 있다, 나아가, 본 발명은 장치들 및 방법들에 동일하게 적용될 수 있다.
이하, 본 발명의 기술적 사상에 따른 실시예들을 개략적으로 도시하는 도면들을 참조하여 설명한다. 도면들에 있어서, 예를 들면, 제조 기술 및/또는 공차에 따라, 도시된 형상의 변형들이 예상될 수 있다. 따라서, 본 발명의 실시예는 본 명세서에 도시된 영역의 특정 형상에 제한된 것으로 해석되어서는 아니 되며, 예를 들면 제조상 초래되는 형상의 변화를 포함하여야 한다.
도 1은 본 발명의 기술적 사상에 의한 실시예들에 따른 기판 처리 방법을 개략적으로 나타낸 흐름도이다.
도 1을 참조하면, 패턴 구조물이 형성된 기판 상에 제1 물질이 공급된다(S10). 제1 물질은 예를 들어 소스 물질일 수 있으며, 추후 공급되는 제2 물질과 반응성을 갖는 물질을 포함할 수 있다. 제1 물질은 기체일 수 있고, 선택적인 실시예에서 액체일 수도 있으며, 이외에 기체와 액체 사이의 상태의 물질일 수도 있다. 제1 물질은 패턴 구조물이 형성된 기판 상에 공급될 수 있다. 따라서 제1 물질은 패턴 구조물의 상면과 하면, 그리고 상면과 하면을 연결하는 측면 상에 도포될 수 있다.
이후, 기판 상에 제2 물질이 공급된다(S20). 제2 물질은 예를 들어 반응 물질일 수 있으며, 패턴 구조물은 반응 물질과 반응성을 갖는 물질을 포함할 수 있다. 예를 들어, 상기 패턴 구조물은 포토레지스트를 포함할 수 있다. 제2 물질은 기체일 수 있고, 선택적인 실시예에서 액체일 수도 있으며, 이외에 기체와 액체 사이의 상태의 물질일 수도 있다. 제2 물질은 플라즈마 분위기 하에서 공급될 수 있다. 또한 제2 물질은 공급 유닛(예를 들어, 기체 공급 유닛)을 통해 적어도 기판 중심 부근에 공급될 수 있다. 예를 들어, 제2 물질은 공급 유닛의 중심 유입구를 통해 기판 중심 부분에 공급될 수 있다(S23). 추가적으로, 제2 물질은 공급 유닛의 다른 유입구를 통해 기판 중심 외의 부분에도 공급될 수 있다.
제2 물질이 공급되는 동안 제2 물질과 다른 차단 물질도 기판 상에 공급될 수 있다(S20). 차단 물질은 반응 물질이 기판의 가장자리 부근에 집중되는 현상(및 그에 따라 기판 상의 패턴 구조물의 가장자리 부근이 많이 손상되는 현상)을 방지하는 기능을 수행할 수 있다. 차단 물질은 제1 물질 및 제2 물질과 다른 물질을 포함할 수 있다.
예를 들어, 차단 물질은 제1 물질의 이온화 에너지 및 제2 물질의 이온화 에너지보다 높은 이온화 에너지를 가질 수 있다. 선택적인 실시예에서, 차단 물질은 비활성 기체의 이온화 에너지보다 높은 이온화 에너지를 가질 수 있다. 이러한 높은 이온화 에너지를 갖는 차단 물질의 공급을 통해 기판 상의 패턴 구조물의 가장자리 부근에서의 라디칼 생성이 억제될 수 있다. 따라서, 상기 라디칼과 반응성을 갖는 패턴 구조물의 손상이 방지될 수 있다.
전술한 바와 같이, 차단 물질은 기판 가장자리 부근에서의 반응 물질의 집중(및 그로 인한 라디칼 생성)을 차단하기 위해 공급되는 물질이다. 이를 위해, 예를 들어 차단 물질은 공급 유닛의 중심 기체 유입구와 이격된 추가 기체 유입구를 통해 공급될 수 있다(S25). 추가 기체 유입구는 공급 유닛의 중심 기체 유입구와 공급 유닛의 가장자리 사이에 위치할 수 있다. 차단 물질에 의해, 기판 가장자리의 유량이 증가될 수 있다. 따라서 가장자리 부근의 반응 물질의 라디칼 밀도가 상대적으로 감소할 수 있다. 다른 한편으로, 차단 물질이 기판 가장자리에 공급됨으로써 기판 중심 부근의 반응 물질의 라디칼 밀도에 대한 차폐 효과가 발생할 수 있다. 따라서, 기판 중심 부근의 반응 물질의 라디칼 밀도가 증가될 수 있다.
도 2는 본 발명의 기술적 사상에 의한 다른 실시예들에 따른 기판 처리 방법을 개략적으로 나타낸 단면도이다. 이 실시예들에 따른 기판 처리 방법은 전술한 실시예들에 따른 기판 처리 방법의 변형예일 수 있다. 이하 실시예들간 중복되는 설명은 생략하기로 한다.
도 2를 참조하면, 먼저 패턴 구조물이 형성된 기판 상에 제1 기체가 공급된다(S50). 예를 들어 패턴 구조물은 산소와 반응하는 물질을 포함할 수 있고, 상기 반응에 의해 패턴 구조물의 일부가 제거될 수 있다. 다른 실시예에서, 패턴 구조물은 산소 이외의 물질(예를 들어 질소)와 반응하는 물질을 포함할 수도 있다. 예를 들어, 패턴 구조물은 스핀 온 하드마스크(SOH)를 포함할 수 있다.
제1 기체는 전술한 바와 같이 소스 기체로서, 제1 기체가 반응 공간으로 공급되면 제1 기체는 기판 상에 흡착될 수 있다. 이후, 제1 기체가 퍼지된다(S60). 제1 기체는 기판 상에 형성하고자 하는 박막의 구성 성분을 포함할 수 있다. 예를 들어, 기판 상에 실리콘 산화막을 형성하고자 하는 경우, 제1 기체는 실리콘 함유 기체일 수 있다.
제1 기체가 퍼지된 이후, 제2 기체 및 제3 기체가 공급된다(S70). 제2 기체 및 제3 기체는 플라즈마 분위기 하에서 공급될 수 있다. 상기 플라즈마 분위기의 온도는 섭씨 100도 이하일 수 있고, 보다 구체적인 예에서 섭씨 50도 이하일 수 있다. 상기 플라즈마의 주파수는 예를 들어 27Mhz일 수 있고, 플라즈마의 전력은 600W일 수 있다. 그러나 본 발명은 전술한 파라미터에 제한되지 않고 다양한 파라미터로 조절될 수 있음에 유의한다.
제2 기체는 제1 기체와 반응성을 갖는 반응 기체일 수 있다. 반면에, 제3 기체는 제1 기체와 반응하지 않는 기체일 수 있다. 기판 상에 흡착된 제1 기체가 제2 기체의 공급에 의해 제2 기체와 반응함으로써, 패턴 구조물 상에 박막이 형성될 수 있다. 기판 상에 흡착된 제1 기체는 제3 기체와는 반응하지 않기 때문에, 패턴 구조물 상에 형성된 박막은 제3 기체의 성분을 포함하지 않을 수 있다.
제3 기체는 제1 기체 및 제2 기체와 다른 기체일 수 있다. 박막에 제3 기체의 성분이 포함되지 않도록 하기 위해, 제3 기체는 높은 이온화 에너지를 갖는 물질로 선택될 수 있다. 예를 들어, 제3 기체는 제1 기체의 이온화 에너지 및/또는 제2 기체의 이온화 에너지보다 높은 이온화 에너지를 가질 수 있다. 선택적인 실시예에서, 제3 기체는 비활성 기체의 이온화 에너지보다 높은 이온화 에너지를 가질 수 있다. 그에 따라 박막 형성 단계 동안, 플라즈마 분위기 하에서, 제2 기체는 이온화되고, 반면에 제3 기체는 이온화되지 않을 수 있다.
예를 들어, 제1 기체가 실리콘 함유 기체이고 형성하고자 하는 박막이 실리콘 산화막인 경우, 제2 기체는 산소 함유 기체일 수 있고, 제3 기체는 질소 함유 기체일 수 있다. 예를 들어, 제3 기체는 아산화 질소 기체 및 질소 기체 중 적어도 하나를 포함할 수 있다.
이 경우, 실리콘 산화막을 형성하는 동안, 기판의 패턴 구조물 상에 흡착된 실리콘 함유 기체는 산소 함유 기체와는 반응하고 질소 함유 기체와는 반응하지 않을 수 있다. 이는 질소 함유 기체가 실리콘 함유 기체의 이온화 에너지 및 산소 함유 기체의 이온화 에너지보다 높은 에너지를 갖기 때문일 수 있다. 즉, 플라즈마 분위기 하에서 산소 함유 기체만이 이온화됨으로써 기판 상에 흡착된 실리콘 함유 기체와 반응하여 실리콘 산화막이 형성될 수 있고, 실리콘 질화막 및/또는 실리콘 산질화막은 형성되지 않을 수 있다.
일 예에서, 제2 기체가 산소 기체이고 제3 기체가 아산화질소 기체인 경우, 산소 기체와 아산화질소 기체의 유량비는 1:0.625 내지 1:1.25일 수 있다. 예를 들어, 산소 기체가 공급되는 유량이 160 sccm인 경우, 아산화질소 기체의 유량은 100sccm 내지 200 sccm일 수 있다. 다른 예에서, 제2 기체가 산소 기체이고 제3 기체가 질소 기체인 경우, 산소 기체와 질소 기체의 유량비는 1:0.625 내지 1:1.25일 수 있다. 예를 들어, 산소 기체가 공급되는 유량이 160 sccm인 경우, 질소 기체의 유량은 100sccm 내지 200 sccm일 수 있다. 그러나 본 발명은 전술한 파라미터에 제한되지 않고 다양한 파라미터로 조절될 수 있음에 유의한다.
비록 전술한 실시예들이 실리콘 산화막을 형성하기 위한 공정을 기준으로 설명되었지만, 이는 본 발명을 제한하지 않음에 유의한다. 본 발명은 임의의 산화막을 형성하기 위한 공정일 수 있고, 이 경우 제2 기체는 산소 성분을 포함하고, 제3 기체는 질소 성분을 포함할 수 있다. 다른 실시예에서, 본 발명은 임의의 질화막을 형성하기 위한 공정일 수도 있을 것이다.
선택적인 실시예에서, 플라즈마 분위기의 온도 파라미터는 제3 기체의 반응성을 제한하는 요소가 될 수 있다. 예를 들어, 플라즈마 분위기는 제1 온도로 설정될 수 있는데, 이 경우 제1 기체(즉, 패턴 구조물 상에 흡착된 제1 기체)는 제1 온도에서 제2 기체와 반응하고, 반면에 제1 기체는 제1 온도에서 제3 기체와 반응하지 않을 수 있다. 상기 제1 온도는 예를 들어 섭씨 100도 이하의 온도일 수 있다.
예를 들어, 섭씨 100도 이하의 온도 조건의 플라즈마 분위기에서 공급되는 산소 기체는 기판의 패턴 구조물 상에 흡착된 실리콘 함유 기체와 반응하여 실리콘 산화막을 형성할 수 있다. 반면에 섭씨 100도 이하의 온도 조건의 플라즈마 분위기에서 공급되는 질소 기체 및/또는 아산화실소 기체는 기판의 패턴 구조물 상에 흡착된 실리콘 함유 기체와 반응하지 않을 수 있다.
박막을 형성하는 단계 동안, 제2 기체는 기체 공급 유닛의 적어도 중심 기체 유입구를 통해 공급될 수 있다(S73). 반면에 제3 기체는 기체 공급 유닛의 중심 기체 유입구와 이격된 추가 기체 유입구를 통해 공급될 수 있다(S75). 제3 기체가 추가 기체 유입구를 통해 공급됨으로써 기판 가장자리의 유량이 증가되고, 그에 따라 기판 중심 부근의 라디칼 밀도가 증가될 수 있다. 이는 기판 중심 부분의 손상의 증가로 귀결될 수 있다.
보다 구체적으로, 플라즈마 분위기 하에서 패턴 구조물과 반응성을 갖는 제2 기체가 공급되는 경우 제2 기체의 라디칼이 패턴 구조물과 반응함으로써 패턴 구조물이 제거될 수 있다. 이러한 패턴 구조물의 손상은 제2 기체가 공급되는 위치에 의해 영향을 받을 수도 있지만, 반응에 관여하지 않는 제3 기체가 공급되는 위치에 의해 영향을 받을 수도 있다. 특히, 제3 기체가 추가 기체 유입구를 통해 공급될 경우 가장자리에서 패턴 구조물과 반응할 수 있는 라디칼의 생성이 억제될 수 있고, 따라서 기판 가장자리에 위치하는 패턴 구조물의 손상이 감소할 수 있다.
예를 들어, 제1 기체가 실리콘 함유 기체이고, 제2 기체가 산소 함유 기체이며, 제3 기체가 질소 함유 기체인 경우, 산소 함유 기체는 적어도 중심 기체 유입구를 통해 공급될 수 있다. 질소 함유 기체는 기체 공급 유닛의 중심 기체 유입구와 이격된 추가 기체 유입구를 통해 공급될 수 있다.
이 경우, 질소 함유 기체가 상기 추가 기체 유입구를 통해 공급되어 기판 가장자리의 유량이 증가할 수 있다. 이러한 기판 가장자리의 유량 증가로 인해, 기판 가장자리 부분에서의 패턴 구조물과 반응하는 라디칼 밀도는 감소할 수 있다. 반면에, 기판 가장자리의 유량 증가로 인해, 기판 중심 부근에서의 패턴 구조물과 반응하는 라디칼 밀도는 증가할 수 있다. 결과적으로 기판 가장자리 부분에서의 패턴 구조물의 손상은 감소하고, 기판 중심 부근에서의 패턴 구조물의 손상은 증가할 수 있고, 결과적으로 양자가 균일해질 수 있다.
선택적인 실시예에서, 산소 함유 기체는 중심 기체 유입구뿐만 아니라 추가 기체 유입구를 통해서도 공급될 수 있다. 즉, 기판 중심 부근과 가장자리 부근의 패턴 구조물의 손상의 편차를 조절하기 위해, 추가 기체 유입구를 통해 패턴 구조물과 반응성을 갖는 제2 기체(예를 들어, 산소 함유 기체)를 공급할 수도 있고, 패턴 구조물과 반응성을 갖지 않는 제3 기체(예를 들어, 질소 함유 기체)를 공급할 수도 있다.
제2 기체 및 제3 기체가 공급되어 패턴 구조물 상에 박막이 형성된 후, 제2 기체 및 제3 기체가 퍼지된다. 이로써 패턴 구조물 상에 박막을 형성하기 위한 일 사이클이 완료되며, 상기 사이클은 소정 횟수 반복될 수 있다. 상기 사이클이 반복됨으로써 패턴 구조물 상에 형성된 박막의 두께가 증가할 수 있다.
패턴 구조물 상에 형성된 박막은 더블 패터닝 공정 또는 쿼드러플 패터닝 공정에 이용될 수 있다. 즉, 추후 공정에서 패턴 구조물은 제거되고 패턴 구조물의 측벽에 형성된 상기 박막이 마스크의 역할을 수행하여 기판이 패터닝될 수 있다.
전술한 실시예들에서 설명한 바와 같이, 퍼지 기체의 공급은 기체를 전환하는 과정에서 단속적으로 수행될 수 있다. 예를 들어, 제1 기체의 퍼지를 위한 퍼지 기체는, 제1 기체의 공급 단계와 제2 기체 및 제3 기체 공급 단계 사이에 단속적으로 공급될 수 있다. 또한 제2 기체 및 제3 기체의 퍼지를 위한 퍼지 기체는, 제2 기체 및 제3 기체 공급 단계와 다음 사이클에서의 제1 기체의 공급 단계 사이에 공급될 수 있다.
선택적인 실시예에서, 퍼지 기체의 공급은 박막 형성 공전 전반에 걸쳐 연속적으로 수행될 수 있다. 예를 들어, 제1 기체의 퍼지를 위한 퍼지 기체는 공정 과정에서 계속적으로 공급될 수 있다. 이 경우 제1 기체 공급 단계 이후 제2 기체 및 제3 기체 공급 단계까지 소정의 기간 동안 다른 기체를 공급하지 않음으로써, 제1 기체의 퍼지가 수행될 수 있다. 또한 제2 및 제3 기체의 공급 단계 이후 다음 사이클의 제1 기체 공급 단계까지 소정의 기간 동안 다른 기체를 공급하지 않음으로써, 제2 기체 및 제3 기체의 퍼지가 수행될 수 있다.
퍼지 기체와 마찬가지로, 제3 기체의 공급 역시, 단속적으로 수행될 수 있다. 예를 들어, 제3 기체는, 제2 기체 공급 단계와 다음 사이클에서의 제1 기체의 공급 단계 사이에 공급될 수 있다. 또한, 제3 기체의 공급은 연속적으로 수행될 수도 있다. 다시 말해, 제3 기체는 박막 형성 공전 전반에 걸쳐 연속적으로 공급될 수 있다.
도 3은 본 발명의 기술적 사상에 의한 실시예들에 따른 기판 처리 방법이 적용되는 기체 공급 유닛 및 이를 포함하는 기판 처리 장치를 개략적으로 나타낸다.
도 3을 참조하면, 기판 처리 장치는 격벽(110), 기체 공급 유닛(120), RF 로드(130), 및 배기 통로(140)를 포함할 수 있다. 본 명세서에서 설명된 기판 처리 장치의 예로서 반도체 또는 디스플레이 기판의 증착 장치를 들 수 있으나, 본 발명은 이에 제한되지 않음에 유의한다. 기판 처리 장치는 박막 형성을 위한 물질의 퇴적을 수행하는데 필요한 여하의 장치일 수도 있고, 물질의 식각 내지 연마를 위한 원료가 균일하게 공급되는 장치를 지칭할 수도 있다. 이하에서는 편의상 기판 처리 장치가 반도체 증착 장치임을 전제로 설명하기로 한다.
격벽(110)은 반응기의 구성요소일 수 있다. 다시 말해, 격벽(110) 구조에 의해 기판의 처리(예를 들어, 증착, 식각, 연마)를 위한 반응 공간이 형성될 수 있다. 예를 들어, 격벽(110)은 반응기 측벽 및/또는 반응기 상벽을 포함할 수 있다. 격벽(110) 중 반응기 상벽 부분은 기체 공급 채널(150)을 제공할 수 있고, 상기 기체 공급 채널(150)을 통해 소스 가스, 퍼지 가스, 및/또는 반응 가스가 공급될 수 있다.
기체 공급 유닛(120)은 기체 공급 채널(150)에 연결될 수 있다. 기체 공급 유닛(120)은 반응기에 고정될 수 있다. 예를 들어, 기체 공급 유닛(120)은 고정 부재(미도시)를 통해 격벽(110)에 고정될 수 있다. 기체 공급 유닛(120)은 반응 공간(160) 내의 피처리체에 기체를 공급하도록 구성될 수 있다. 예를 들어, 기체 공급 유닛(120)은 샤워헤드 어셈블리일 수 있다.
기체 공급 유닛(120) 내부에는 기체 공급 채널(150)과 연통하는 기체 흐름 채널(170)이 형성될 수 있다. 기체 흐름 채널(170)은 기체 공급 유닛(120)의 기체 채널(125)(윗부분)과 기체 공급 유닛(120)의 기체 공급 플레이트(127)(아랫 부분) 사이에 형성될 수 있다. 비록 도면에는 기체 채널(125)과 기체 공급 플레이트(127)가 별개의 구조로 도시되었지만, 기체 채널(125)과 기체 공급 플레이트(127)는 일체화된 구조로 형성될 수도 있다.
기체 채널(125)은 기체 공급 채널(150)과 연결된 중심 주입구를 제공할 수 있다. 중심 주입구는 기체 흐름 채널(170)과 연결될 수 있고, 따라서 기체 흐름 채널(170)은 중심 주입구를 통해 기체 공급 채널(150)과 연결될 수 있다.
전술한 바와 같이, 격벽(110)에는 기체 공급 채널(150)이 형성될 수 있다. 상기 기체 공급 채널(150)에 추가로, 제1 관통 홀(180)이 격벽(110)의 적어도 일부를 관통하도록 형성될 수 있다. 예를 들어, 제1 관통 홀(180)은 격벽(110) 중 반응기 상벽을 관통하도록 형성될 수 있다. 바람직한 실시예에서, 제1 관통 홀(180)의 직경은 기체 공급 채널(150)의 직경보다 작을 수 있다.
제2 관통 홀(185)은 기체 공급 유닛(120)의 적어도 일부를 관통하도록 형성될 수 있다. 예를 들어, 제2 관통 홀(185)은 기체 채널(125)을 관통하여 기체 흐름 채널(170)과 연결되도록 형성될 수 있다. 따라서, 제1 관통 홀(180)이 제2 관통 홀(185)을 통해 상기 기체 흐름 채널(170)과 연통할 수 있다.
제2 관통 홀(185)은 기체 흐름 채널(170)의 중심과 가장자리 사이에 배치될 수 있다. 특히, 제2 관통 홀(185)은 기체 흐름 채널(170)의 가장자리로부터 이격되어 배치될 수 있다. 이러한 제2 관통 홀(185)의 위치 구조를 통하여, 기판의 특정 부분(즉, 제2 관통 홀(185)이 배치된 부분과 상응하는 부분)에서의 박막 증착이 제어될 수 있다.
예를 들어, 제2 관통 홀(185)을 통해 공급된 기체는 기판의 중심과 가장자리 사이의 부분에 증착되는 박막 하부의 패턴 구조물의 손상 정도에 영향을 미칠 수 있다. 상기 기체가 높은 이온화 에너지를 갖는 차단 가스인 경우, 기판의 중심과 가장자리 사이의 패턴 구조물의 손상은 감소할 수 있다.
샤워헤드 구조는 일반적으로 중심 부분을 통해 반응 기체가 공급되고 가장자리를 통해 배기되는 구조를 채용하는데, 그러한 구조로 인해 기판 가장자리 부분의 패턴 구조물의 손상과 기판 중심 부분의 패턴 구조물의 손상이 균일하지 않게 되는 문제가 발생할 수 있다. 그러나 본 발명에 따르면 별도의 기체 공급 통로를 추가하여, 이를 통해 반응 공간의 중심 부분과 가장자리 사이에 차단 기체가 공급될 수 있다. 이렇게 공급된 차단 기체는 반응 공간의 주변부에서의 라디칼 생성을 제한하는 차폐 효과(blocking effect)를 유도할 수 있고, 결과적으로 기판의 주변부에 형성된 패턴 구조물의 손상이 감소될 수 있다. 따라서 기판의 중심과 가장자리 사이에 발생하는 패턴 구조물의 손상의 편차 문제가 개선될 수 있다.
선택적인 실시예에서, 제2 관통 홀(185)은 중심 주입구의 중심으로부터 일정 간격 이격된 원주를 따라 복수 개 배치될 수 있다. 또 다른 선택적인 실시예에서, 제2 관통 홀(185)은 중심 주입구의 중심으로부터 일정 간격 이격된 원주를 따라 연속적으로 배치될 수도 있다. 이 경우 기체 채널(125)은 상기 제2 관통 홀(185)에 의해 분리된 복수의 부품으로 구성될 수도 있다.
제2 관통 홀(185)은 기체 공급 플레이트(127)에 대하여(또는 기체 흐름 채널(170)에 대하여) 수직 방향으로 또는 경사진 방향으로 기체 채널(125)을 관통하도록 형성될 수 있다. 예를 들어, 제2 관통 홀(185)은, 기체 공급 플레이트(127)의 연장 방향(즉, 수평 방향)에 대하여, 기체 공급 플레이트(127)의 중심을 향하여 15~45 도의 각도로 관통하도록 형성될 수 있다. 다시 말해, 기체 채널(125)을 관통하는 제2 관통 홀(185)의 관통 각도를 조절함으로써, 기판 상에 그리고 박막 하부에 위치하는 패턴 구조물의 플라즈마에 의한 손상의 균일도가 제어될 수 있다.
예시적인 실시예에서, 제2 관통 홀(185)은 기체 공급 플레이트(127)의 연장 방향(즉, 수평 방향)에 대하여 30 도의 각도로 관통하도록 형성될 수 있다. 이 경우, 제2 관통 홀(185)은 기체 채널(125)의 제1 면(예를 들어, 상부 표면) 상에서 제1 지름을 갖는 제1 원주를 따라 배치 또는 형성될 수 있고, 제2 관통 홀(185)은 상기 기체 채널(125)의 제2 면(예를 들어, 하부 표면) 상에서 제2 지름을 갖는 제2 원주를 따라 배치 또는 형성되며, 상기 제1 지름과 상기 제2 지름은 다를 수 있다.
이와 같이, 제2 관통 홀(185)의 개수, 형상, 및 배열 위치와 제2 관통 홀(185)에 공급되는 기체의 종류, 유량 등을 조절함으로써, 패턴 구조물의 손상 균일도가 보다 정밀하게 제어될 수 있고, 결과적으로 원하는 형태와 원하는 품질의 박막이 증착될 수 있다.
선택적인 실시예에서, 제1 관통 홀(180)과 제2 관통 홀(185) 사이에 버퍼 공간(190)이 더 형성될 수도 있다. 상기 버퍼 공간(190)은 제1 관통 홀(180)을 통해 공급된 기체가 제2 관통 홀(185)에 균일하게 공급될 수 있도록 기체를 일시적으로 보유하는 역할을 수행할 수 있다. 따라서, 상기 버퍼 공간(190)의 직경 내지 폭은, 제1 관통 홀(180)의 직경 내지 폭보다 크고, 제2 관통 홀(185)의 직경 내지 폭보다도 클 수 있다. 또한, 버퍼 공간(190)은 기체 공급 채널(150)의 중심으로부터 일정 간격 이격된 원주를 따라 연속으로 형성될 수 있다.
기판 처리 장치는 기체 공급 채널(150)과 공급된 제1 기체 공급부(미도시) 및 제1 관통 홀(180)과 연결된 제2 기체 공급부(미도시)를 더 포함할 수 있다. 또한, 기판 처리 장치는 상기 제1 기체 공급부 및 상기 제2 기체 공급부를 제어하도록 구성된 제어부(미도시)를 더 포함할 수 있다. 일 실시예에서, 상기 제어부는 상기 제1 기체 공급부 및 상기 제2 기체 공급부를 독립적으로 제어하도록 더 구성될 수 있다. 예를 들어, 제1 기체 공급부는 소스 기체 및/또는 반응 기체를 공급하도록 구성될 수 있고, 제2 기체 공급부는 차단 기체를 공급하도록 구성될 수 있다.
기판 처리 장치는 RF 로드(130)를 더 포함할 수 있다. RF 로드(130)는 격벽(110)의 적어도 일부를 관통하여 상기 기체 공급 유닛(120)과 연결될 수 있다. RF 로드(130)는 외부의 플라즈마 공급부(미도시)와 연결될 수 있다. 도면에는 2개의 RF 로드(130)가 도시되어 있는데, 본 발명은 그에 제한되지 않고, 적어도 1개 이상의 RF 로드(130)를 설치하여 반응 공간(160)에 공급되는 플라즈마 파워의 균일성을 향상시킬 수 있다.
기판 처리 장치는 격벽(110)의 하부 면과 접촉하도록 구성된 서셉터(200)를 더 포함할 수 있다. 서셉터(200)는 서셉터 지지부(210)에 의해 지지될 수 있고, 서셉터 지지부(210)는 상하 및 회전 운동을 할 수 있다. 서셉터 지지부(210)의 상하 운동에 의해 서셉터(200)가 격벽(110)으로부터 이격되거나 격벽(110)과 접촉함으로써, 반응 공간(160)이 개방되거나 폐쇄될 수 있다.
기판 처리 장치는 배기부(미도시)를 더 포함할 수 있다. 반응 공간(160)에서, 기판과의 화학반응 이후 잔존하는 잔류 기체는, 상기 배기부에 의해, 배기 통로(140) 통해 외부로 배기될 수 있다.
도 4는 본 발명의 기술적 사상에 의한 다른 실시예들에 따른 기체 공급 유닛 및 이를 포함하는 기판 처리 장치를 개략적으로 나타낸다. 이 실시예들에 따른 기체 공급 유닛 및 기판 처리 장치는 전술한 실시예들에 따른 기체 공급 유닛 및 기판 처리 장치의 변형예일 수 있다. 이하 실시예들간 중복되는 설명은 생략하기로 한다.
도 4를 참조하면, 기판 처리 장치는 격벽(110) 및 격벽(110) 내에 실질직으로 수평하게 똑바로 위치해 있는 기체 공급 유닛(120), 격벽(110) 내의 기체 공급 유닛(120)과 실질적으로 평행하게 마주보도록 위치한 서셉터(200)를 포함할 수 있다.
격벽(110) 내에 마련되어 진공펌프로 연결된 배기 통로(140)는 격벽(110) 내 반응 공간(160)의 잔류 기체를 진공 배출시키는데 이용될 수 있다.
기체 공급 유닛(120)은 샤워헤드일 수 있고, 샤워헤드의 베이스는 원료가스를 분출하도록 형성된 다수의 미세공(220)을 포함할 수 있다. 샤워헤드는 기체 공급 채널(150)을 통해 원료가스 공급 탱크에 연결될 수 있다. 고주파(RF) 전원은 일측 전극으로서 기능하는 샤워헤드와 전기적으로 연결될 수 있다.
서셉터(200)는 지지대에 의해 지지되며, 타측 전극으로서 기능할 수 있다. 서셉터(200)의 표면에는 반도체 기판과 같은 피처리 기판이 로딩될 수 있고, 상기 피처리 기판은 진공 흡착 등에 의해 고정될 수 있다.
또한, 전술한 바와 같이, 제2 관통 홀(185)은 샤워헤드의 상부 부분의 적어도 일부를 관통하도록 형성될 수 있다. 따라서, 제1 관통 홀(180)이 제2 관통 홀(185)을 통해 샤워헤드의 기체 흐름 채널(170)과 연통할 수 있다.
도 5는 본 발명의 기술적 사상에 의한 다른 실시예들에 따른 기체 공급 유닛 및 이를 포함하는 기판 처리 장치를 개략적으로 나타낸다. 이 실시예들에 따른 기체 공급 유닛 및 기판 처리 장치는 전술한 실시예들에 따른 기체 공급 유닛 및 기판 처리 장치의 변형예일 수 있다. 이하 실시예들간 중복되는 설명은 생략하기로 한다.
도 5를 참조하면, 격벽(110)을 포함하는 제1 덮개(240) 및 제2 덮개(250)는 서셉터(200)와 함께 반응 공간(160)을 형성할 수 있다. 보다 구체적으로, 반응 공간(160)의 하부는 서셉터(200)에 의해, 반응 공간(160)의 상부는 제1 덮개(240)에 의해, 반응 공간(160)의 양 측면은 제2 덮개(250)에 의해 형성될 수 있다.
기판 처리 장치가 증착 장치인 경우, 제1 덮개(240)는 샤워헤드를 포함할 수 있다. 제2 덮개(250)는 반응 측벽(W) 및 배기 통로(140)를 포함할 수 있다.
기판 처리 장치의 배기 구조는 하류 배기 구조로 구성될 수 있고, 이 때 상기 하류 배기 구조는 제2 덮개(250)에 의해 구현될 수 있다. 이 경우 증착에 이용되는 기체는 제1 덮개(240)의 샤워헤드를 통해 피처리 기판으로 분사되고 이후 제2 덮개(250)의 배기 통로(140)를 통해 하류 배기될 수 있다.
또한, 전술한 바와 같이, 제2 관통 홀(185)은 기체공급 유닛(125)의 상부 부분의 적어도 일부를 관통하도록 형성될 수 있다. 따라서, 제1 관통 홀(180)이 제2 관통 홀(185)을 통해 샤워헤드의 기체 흐름 채널(170)과 연통할 수 있다.
도 6은 본 발명의 기술적 사상에 의한 다른 실시예들에 따른 기체 공급 유닛 및 이를 포함하는 기판 처리 장치를 개략적으로 나타낸다. 이 실시예들에 따른 기체 공급 유닛 및 기판 처리 장치는 전술한 실시예들에 따른 기체 공급 유닛 및 기판 처리 장치의 변형예일 수 있다. 이하 실시예들간 중복되는 설명은 생략하기로 한다.
전술한 바와 같이, 본 발명에서는 기판 상에 증착되는 박막의 각 부분별로 특성을 제어하는 방법을 개시한다. 본 발명에 따르면, 기판 상에 기체를 공급하는 기체 공급 수단을 구비한 반응기에서 기판상에 플라즈마를 이용한 박막 증착이 이루어진다. 더욱 구체적으로는 상기 기체 공급 수단은 샤워헤드이며 상기 플라즈마를 이용한 박막 증착은 플라즈마 원자층 증착법(PEALD), 플라즈마 화학기상 증착법(PECVD), 펄스드 플라즈마 화학기상 증착법(Pulsed PECVD) 그리고 사이클릭 펄스드 플라즈마 화학 기상 증착법(Cyclic pulsed PECVD)중의 하나 혹은 상기 방법들의 적절한 조합일 수 있고 혹은 상기 방법들의 적절한 변형일 수 있다.
도 6을 참조하면, 반응기(1)는 반응기 벽(2)과 서셉터(3)가 면접촉을 통해 반응 공간(13)을 형성한다. 기체는 반응기 중심에 위치한 제1 기체 유입구(4)와 주변부에 위치한 제2 기체 공급 포트(8)와 제2 기체 유입구(5,6,7) 및 그 하부에 위치한 샤워헤드(11) 홀들(showerhead holes, 미도시)를 통해 반응 공간(13)으로 공급된다.
반응 공간(13)으로 공급된 기체는 서셉터(3) 상에 로딩된 기판(미도시) 표면과 반응한 후, 배기 채널(14), 배기 홀(15), 배기 통로(16) 및 배기 포트(18)를 통해 배기된다. 상기 제2 기체 유입구(5,6,7)는 반응기 벽(2), 백플레이트(9), 기체 채널(10)을 관통하여 기체 흐름 채널(12)과 연결될 수 있다. 예를 들어, 기체 채널(10)을 관통하는 제 2기체 유입구(7)는 기판 표면을 기준으로 다양한 각도로 형성될 수 있다. 그에 의해 기판 상의 특정 부분에 공급되는 기체의 유량이 제어될 수 있고, 기판 상의 특정 부분에 증착되는 박막의 특성이 제어될 수 있다.
상기 반응기 벽을 관통하는 제2 기체 유입구(5)는 상기 반응기의 일면을 관통할 수 있다. 다른 제2 기체 유입구(6,7)는 반응기의 중심을 기준으로 환형으로 배치될 수 있고, 그에 의해 기판의 주변부에 균일하게 제2 기체가 공급될 수 있다.
도 7은 도 6의 반응기에서 PEALD 방법으로 기판상의 SOH(Spin-On-Hardmask, Photo Resist의 한 종류) 막 위에 SiO2 막을 증착할 때 플라즈마 라디칼에 의한 하부 SOH 막의 손상 정도를 보여준다. 하기 손상 정도는 상기 증착된 SiO2막을 습식 식각(wet etch) 하여 측정하였다.
도 7을 참조하면, 도 7의 가로축은 지름 300mm 기판의 중심에서 양쪽 방향으로 각 위치를 나타내고 세로축은 플라즈마 ALD 방식으로 SiO2막을 증착했을 때 상기 도 6의 제2 기체 공급통로를 통해 공급되는 산소 혹은 비활성기체(예를 들어 Ar)의 유량에 따른 SOH 하부막의 손실 정도를 나타낸다. 도 6의 반응기에서 제2 기체 유입구를 통해 각각 산소 50sccm, 250sccm, Ar 600sccm, 1000accm을 공급했으나, 기체의 종류 및 유량에 관계없이 전 기판에 걸쳐 SOH막의 손실 형태 및 정도는 비슷하였다.
보다 구체적으로, 도 7을 참조하면, SOH 하부막의 손실 균일도(SOH loss uniformity)는 전 기판에 걸쳐 일정하지 않고 기판의 가장자리부에서 SOH 막의 손실 정도가 컸다. 이것은 플라즈마 공정 시 반응 공간에 걸쳐 플라즈마 라디칼 밀도가 일정하지 않고 상기 기판의 가장자리부에서의 라디칼 밀도가 특히 높다는 것을 의미한다. 따라서 본 발명에서는 상기 가장자리부에서의 라디칼 밀도를 제어함으로써, 전체적으로 SOH 손실 균일도(SOH loss uniformity)를 높일 수 있는 방법을 개시하고자 한다.
상기 기판 주변부(기판 중심부와 기판 가장자리부 사이의 영역)에서의 라디칼의 밀도를 제어하기 위해 혹은 낮추기 위해서, 본 발명에서는 라디칼 생성을 억제하는 기체를 공급하였다. 본 발명의 한 실시예에 따르면, SOH 막 상에 플라즈마를 이용하여 SiO2막을 증착할 때, 상기 제2 기체 유입구를 통해 질소를 포함하는 기체를 공급하였다. 구체적으로는 상기 제1 기체 유입구를 통해 소스 기체, 산소 반응기체와 Ar 캐리어 기체 혹은 퍼지기체가 공급될 때, 상기 제2 기체 유입구를 통해서 질소 기체를 공급한다. 질소기체의 이온화 에너지는 1,503MJ/mol, Ar기체의 이온화 에너지는 1,520.6KJ/mol 그리고 산소기체의 이온화 에너지는 493.4KJ/mol로서, 질소 기체의 해리 에너지가 다른 기체의 해리 에너지보다 훨씬 크다. 따라서, 질소를 공급할 때 아르곤 혹은 산소를 공급하는 경우 비해 플라즈마 발생이 억제될 수 있다. 질소 외에도 상기 캐리어 기체 혹은 퍼지기체 그리고 반응기체보다 이온화 에너지가 높은 기체가 상기 제2 기체 유입구를 통해 공급될 수 있다.
이와 같이, 본 발명의 기술적 사상에 따르면, 기판의 중심부에 비해 제2 기체 유입구에 대응하는 기판 상의 주변부에서의 라디칼 발생을 억제함으로써, 주변부 영역에서의의 SOH 손실이 방지될 수 있고, 전체적으로 보다 균일한 SOH 손실 균일도(SOH loss uniformity)가 달성될 수 있다.
도 8은 27MHz, 600 와트(watt)의 플라즈마 조건 하에서 기판 상의 SOH 구조물 상에 SiO2 막을 증착할 때 기판의 각 영역별로 SOH 손실 정도를 보여주고 있다. 기판은 300mm 지름을 갖고 있으며 가로축의 중심, 즉 기판 중심을 기준으로 양쪽으로 각각 150mm씩 각 위치별로 SOH 손실을 측정했다. 세로축은 SOH 손실의 정도를 옹스트롬 단위로 측정한 것을 나타낸다.
도 8을 참조하면, 산소 기체는 Ar 기체와 함께 공급되며 제2 기체 유입구를 통해 기판 주변부로 공급되는 질소 함유기체(예를 들어, N2O)의 양에 따른 SOH 손실을 측정했을 때, 질소 함유 기체의 유량이 증가할수록 기판 주변부에서의 SOH 손실이 감소함을 알 수 있다. 즉, 산소와 Ar 기체만을 공급했을 때에는 기판 상에서의 SOH 손실의 균일성이 좋지 않았지만, Ar 대신 질소 함유기체의 비율을 증가시킬 때에는 기판 주변부에서의 플라즈마 생성이 억제되고 따라서 라디칼에 의한 SOH의 침식이 감소될 수 있다. 결과적으로 SOH 손실의 균일성이 전반적으로 제어될 수 있으며 점차 개선됨을 알 수 있다. 또한 도 8을 보면 질소 기체의 공급량이 증가할 수록 기판 가장자리부에서의 SOH 손실은 감소하지만 중심부의 SOH 손실은 오히려 증가함을 보여주는데, 이는 기판 주변부에 공급된 질소 기체가 중심부에 공급된 산소기체를 둘러쌈으로써 상대적으로 중심부에서의 산소 라디칼의 밀도가 증가하고 SOH 손실이 증가하는 것으로 이해할 수 있다. 따라서 기판 주변부로 공급되는 질소 함유 기체의 유량을 적절히 조절함으로써 기판 중심부의 라디칼 밀도를 조절할 수 있고 SOH 손실 혹은 하부막 변형의 균일도(uniformity)가 적절히 제어될 수 있음을 보여 준다.
도 9는 또 다른 실시예로서, N2O대신 N2기체를 공급했을 때 기판 상에서 SOH 손실의 균일성이 변하는 것을 보여주고 있다. 도 9를 참조하면, N2기체를 제1 기체 유입구 및 제2 기체 유입구를 통해 반응 공간의 주변부로 공급했을 때 가장자리의 질소 기체(edge N2; EN)의 유량에 따라 SOH 손실의 균일성(uniformity)이 제어될 수 있음을 알 수 있다.
도 10은 본 발명의 기술적 사상에 의한 다른 실시예들에 따른 기판 처리 방법을 개략적으로 나타낸 단면도이다. 이 실시예들에 따른 기판 처리 방법은 전술한 실시예들에 따른 기판 처리 방법의 변형예일 수 있다. 이하 실시예들간 중복되는 설명은 생략하기로 한다.
도 10을 참조하면, 반응 공간의 중심에 배치된 제1 기체 유입구를 통해서 Si 소스 기체, 산소 기체 그리고 Ar기체가 반응공간으로 공급되며, 반응 공간의 주변에 배치된 제2 기체 유입구를 통해서 질소 혹은 이산화 질소가 반응공간의 주변 영역으로 공급된다. 산소 기체는 제1 기체 유입구를 통해 도 10에서와 같이 펄스 형태로 공급될 수도 있고, 연속적으로 공급될 수도 있다. 본 발명에 따르면, 기판의 주변 영역에는 질소 기체의 상대적 비율이 높아 기판의 중심부와 가장자리부에 비해 라디칼 발생률이 상대적으로 작아진다. 따라서, 주변부에서의 SOH 손실이 줄어들어 전체적으로 SOH 손실 균일도가 향상될 수 있다(도 8 및 도 9 참조)
이와 같이, 본 발명에 따르면, 플라즈마 증착 공정에 있어 기판 중심부와 가장자리부 사이의 주변영역에 반응기체와 캐리어 기체보다 이온화 에너지가 높은 기체를 공급함으로써, 주변부 영역에서의 라디칼 발생이 중심부와 가장자리부에 비해 상대적으로 억제될 수 있고, 주변부에서의 하부 막 손실을 제어함으로써, 기판 전체적으로 하부막 손실 균일도가 향상될 수 있다.
본 발명을 명확하게 이해시키기 위해 첨부한 도면의 각 부위의 형상은 예시적인 것으로 이해하여야 한다. 도시된 형상 외의 다양한 형상으로 변형될 수 있음에 주의하여야 할 것이다.
이상에서 설명한 본 발명이 전술한 실시예 및 첨부된 도면에 한정되지 않으며, 본 발명의 기술적 사상을 벗어나지 않는 범위 내에서 여러 가지 치환, 변형 및 변경이 가능하다는 것은, 본 발명이 속하는 기술분야에서 통상의 지식을 가진 자에게 있어 명백할 것이다.
Claims (20)
- 패턴 구조물이 형성된 기판 상에 제1 기체를 공급하는 단계;
상기 제1 기체를 퍼지하는 단계;
상기 제1 기체와 반응성을 갖는 제2 기체 및 제3 기체를 플라즈마 분위기 하에서 공급하여 상기 패턴 구조물 상에 박막을 형성하는 단계; 및
상기 제2 기체를 퍼지하는 단계를 포함하고,
상기 박막을 형성하는 단계 동안, 상기 제2 기체는 기체 공급 유닛의 적어도 중심 기체 유입구를 통해 공급되고, 상기 제3 기체는 상기 기체 공급 유닛의 상기 중심 기체 유입구와 이격된 추가 기체 유입구를 통해 공급되며,
상기 제3 기체는 상기 제1 기체 및 상기 제2 기체와 다른 기체이며, 비활성 기체의 이온화 에너지보다 높은 이온화 에너지를 갖는, 기판 처리 방법. - 청구항 1에 있어서,
상기 제3 기체가 상기 추가 기체 유입구를 통해 공급되어 기판 가장자리의 유량이 증가되고, 그에 따라 기판 중심 부근의 라디칼 밀도가 증가되는, 기판 처리 방법. - 청구항 2에 있어서,
상기 제3 기체는 질소 성분을 포함하는, 기판 처리 방법. - 청구항 3에 있어서,
상기 제3 기체는 아산화 질소 기체 및 질소 기체 중 적어도 하나를 포함하는, 기판 처리 방법. - 청구항 1에 있어서,
상기 제2 기체는 산소 성분을 포함하고, 상기 제3 기체는 질소 성분을 포함하며,
상기 박막은 섭씨 100도 이하의 온도 조건에서 형성된 산화막인, 기판 처리 방법. - 청구항 5에 있어서,
상기 제2 기체는 산소이고, 상기 제3 기체는 아산화질소이며,
상기 플라즈마 분위기에서상기 산소 기체와 상기 아산화질소 기체의 유량의 부피비는 1:0.625 내지 1:1.25인, 기판 처리 방법. - 청구항 5에 있어서,
상기 제2 기체는 산소이고, 상기 제3 기체는 질소이며,
상기 플라즈마 분위기에서상기 산소 기체와 상기 질소 기체의 유량의 부피비는 1:0.625 내지 1:1.25인, 기판 처리 방법. - 청구항 1에 있어서,
상기 플라즈마 분위기 하에서 상기 패턴 구조물의 손상이 발생하는, 기판 처리 방법. - 청구항 8에 있어서,
상기 패턴 구조물의 손상은 상기 추가 기체 유입구를 통해 공급되는 상기 제3 기체에 의해 변화하는, 기판 처리 방법, - 청구항 8에 있어서,
상기 패턴 구조물은 스핀 온 하드마스크(SOH)를 포함하는, 기판 처리 방법. - 청구항 1에 있어서,
상기 패턴 구조물 상에 형성된 상기 박막을 이용하여 수행되는 더블 패터닝 공정 또는 쿼드러플 패터닝 공정을 더 포함하는, 기판 처리 방법. - 청구항 1에 있어서,
상기 플라즈마 분위기 하에서, 상기 제2 기체는 이온화되고, 상기 제3 기체는 이온화되지 않는, 기판 처리 방법. - 청구항 1에 있어서,
상기 제1 기체는 제1 온도에서 상기 제2 기체와는 반응하고,
상기 제1 기체는 상기 제1 온도에서 상기 제3 기체와는 반응하지 않는, 기판 처리 방법. - 청구항 1에 있어서,
상기 제3 기체는 상기 제1 기체 및 상기 제2 기체의 이온화 에너지보다 높은 이온화 에너지를 갖는, 기판 처리 방법. - 산소와 반응하는 패턴 구조물이 형성된 기판 상에 실리콘 함유 기체를 공급하는 단계;
상기 실리콘 함유 기체를 퍼지하는 단계;
산소 함유 기체 및 질소 함유 기체를 섭씨 100도 이하의 플라즈마 분위기 하에서 공급하여 상기 패턴 구조물 상에 실리콘 산화막을 형성하는 단계; 및
상기 산소 함유 기체를 퍼지하는 단계를 포함하고,
적어도 상기 실리콘 산화막을 형성하는 단계 동안, 상기 산소 함유 기체는 기체 공급 유닛의 적어도 중심 기체 유입구를 통해 공급되고, 상기 질소 함유 기체는 상기 기체 공급 유닛의 상기 중심 기체 유입구와 이격된 추가 기체 유입구를 통해 공급되는, 기판 처리 방법. - 청구항 15에 있어서,
상기 산소와 반응하는 패턴 구조물은 스핀 온 하드마스크이고,
상기 산소 함유 기체는 산소이고, 상기 질소 함유 기체는 아산화질소이며,
상기 플라즈마 분위기에서 상기 산소 기체와 상기 아산화질소 기체의 유량의 부피비는 1:0.625 내지 1:1.25인, 기판 처리 방법. - 청구항 15에 있어서,
상기 실리콘 산화막을 형성하는 단계 동안, 상기 기판의 상기 패턴 구조물 상에 흡착된 실리콘 함유 기체는 산소 함유 기체와는 반응하고 질소 함유 기체와는 반응하지 않는, 기판 처리 방법. - 청구항 15에 있어서,
상기 질소 함유 기체가 상기 추가 기체 유입구를 통해 공급되어 기판 가장자리의 유량이 증가하고,
상기 기판 가장자리의 유량 증가로 인해 기판 가장자리 부분에서의 패턴 구조물과 반응하는 라디칼 밀도는 감소하며,
상기 기판 가장자리의 유량 증가로 인해 기판 중심 부근에서의 패턴 구조물과 반응하는 라디칼 밀도는 증가하고,
결과적으로 기판 가장자리 부분에서의 패턴 구조물의 손상과 기판 중심 부근에서의 패턴 구조물의 손상이 균일해지는, 기판 처리 방법. - 반응 물질과 반응하는 패턴 구조물이 형성된 기판 상에 소스 물질을 공급하는 단계; 및
플라즈마 분위기 하에서 공급 유닛의 적어도 중심 유입구를 통해 상기 반응 물질을 공급하는 단계를 포함하고,
상기 반응 물질을 공급하는 단계 동안, 상기 반응 물질과 다른 차단 물질이 상기 공급 유닛의 상기 중심 유입구와 이격된 추가 기체 유입구를 통해 공급되며,
상기 차단 물질에 의해 기판 가장자리의 유량이 증가되고, 그에 따라 기판 중심 부근의 반응 물질의 라디칼 밀도가 증가되는, 기판 처리 방법. - 청구항 19에 있어서,
상기 차단 물질은 비활성 기체의 이온화 에너지보다 높은 이온화 에너지를 갖는, 기판 처리 방법.
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