KR20050005360A - Manufacturing apparatus for large-size LCD substrate using plasma - Google Patents

Abstract

PURPOSE: An apparatus for manufacturing a large-sized LCD(Liquid Crystal Display) using plasma is provided to enhance stability of RF(Radio Frequency) power and supply maximum power, thereby enhancing stability and uniformity of plasma and improving uniformity of deposition process or etching process. CONSTITUTION: Plasma electrodes(50,51) are spaced from a processing chamber wall(10) at the shortest distance of 12 millimeter, wherein the processing chamber wall is grounded. And, the plasma electrodes are spaced from a chamber lid(11) at the shortest distance of 12 millimeter, wherein the chamber lid is grounded. Herein, insulators for preventing discharge are disposed between the plasma electrodes and the grounded processing chamber or between the plasma electrodes and the grounded chamber lid.

Description

Manufacturing apparatus for large-size LCD substrate using plasma

The present invention relates to a large-area LCD substrate manufacturing apparatus using a plasma, and more particularly to a large-area LCD substrate manufacturing apparatus using a capacitive coupled plasma (CCP).

In general, in order to manufacture LCD substrates, processes such as thin film deposition, etching, and cleaning must be repeated several times to hundreds of times. Since these processes require a high degree of precision, they are specially manufactured in a process chamber that can maintain a vacuum atmosphere. Is done.

There are many ways to perform this process, but in general, chemical vapor deposition (CVD), which has good uniformity and step coverage, is commonly used, and among them, low temperature deposition and thin film formation rate may be performed. Plasma Enhanced CVD (PECVD) using plasma has been widely used due to its rapid advantages.

The large-area LCD substrate manufacturing apparatus using plasma, in addition to the PECVD apparatus for thin film deposition, is used for treating LCD substrates using plasma, such as an etcher performing an etching process using plasma, a dry cleaner using plasma, and the like. It includes a device.

However, PECVD is a device for performing a thin film deposition process using PECVD method, etc. Etchers, dry cleaners, etc. is a device for performing an etching or cleaning process using a plasma, but each process is using a plasma and is performed in the same device In some cases, since the general process order is similar, the following description will focus on the PECVD apparatus.

1 is a schematic configuration diagram of a conventional PECVD apparatus, which will be briefly described in the process order with reference to the drawings.

First, when the LCD substrate 30 is seated on the upper surface of the susceptor 20 installed in the process chamber by a robot arm (not shown), the reaction gas flows into the process chamber through the gas supply pipe 60 and is injected. The injected gas is changed into the plasma 40 state by the RF power supplied from the RF (Radio Frequency) oscillator 80 through the impedance matcher 70 and the plasma electrode 50, and the plasma 40 state. The reaction gas is deposited or reacted on the LCD substrate 30, the reaction gas remaining after the process is completed is discharged to the exhaust pipe 120 by a vacuum motor (not shown).

Meanwhile, the space 90 formed between the upper portion of the plasma electrode 50 and the chamber lid 11 is an atmospheric pressure region, and the space 110 below the plasma electrode 50 is a vacuum region, and both spaces are formed on the insulator 100. It is isolated by a vacuum, the vacuum O-ring (not shown) is provided between the insulator 100 and the process chamber wall 10 and between the insulator 100 and the plasma electrode 50 to maintain the vacuum of the process chamber internal space 110. do. The insulator 100 may electrically insulate the plasma electrode 50 from the process chamber 10 wall.

On the other hand, the plasma electrode 50 may be formed integrally with the shower head for gas injection, may be formed integrally with the susceptor 20, or may be formed on both the shower head and the susceptor 20.

In the susceptor 20, a heater (not shown) for preheating the LCD substrate 30 is embedded, and an upper surface of the susceptor 20 and a lower surface of the plasma electrode 50 are formed to form a uniform thin film. Usually, the interval of about 5 to 40 mm is maintained.

Looking at the path through which RF power is supplied in the PECVD apparatus, RF power supplied from the RF oscillator 80 is applied to the plasma electrode 50 through the impedance matcher 70. At this time, since the RF power moves along the surface of the plasma electrode 50 due to the skin effect, the RF power moves from the edge of the lower surface of the plasma electrode 50 to the center, and thus, the standing wave of the RF power stands on the lower surface of the plasma electrode 50. wave is formed.

On the other hand, the RF power supplied to the plasma electrode 50 discharges the reaction gas to generate the plasma 40, and then passes through the grounded susceptor 20 and the process chamber wall 10 to the impedance matcher 70, Return to the RF oscillator 80.

At this time, the generated plasma 40 is heated by RF power, and the plasma 40 may be stably and uniformly maintained only when RF power is stably supplied. In recent years, as the size of the LCD substrate becomes larger, the size of the plasma electrode 50 also increases in proportion. Therefore, in order to improve the stability and uniformity of the plasma, increasing the stability of the applied RF power has become a more important problem.

Generally speaking, large area LCD substrate refers to more than 600,000mm ^{2 in} terms of area. For reference, the approximate size of LCD substrate by generation is shown in Table 1.

TABLE 1

division glass size (mm) Short axis (mm) Major axis (mm) Area (mm ² ) 4th generation 730 x 920 730 920 671,600 5th generation 1100 x 1250 1100 1250 1,375,000 6th generation 1500 x 1850 1500 1850 2,775,000 7th generation 1870 x 2200 1870 2200 4,114,000 8th generation 2200 x 2550 2200 2550 5,610,000

As the LCD substrate becomes larger in area, the RF power required to generate the plasma 40 must be increased. In the case of the fifth generation LCD substrate, an RF power of about 5-6 kw is required, which is roughly converted into RF power per unit area. It becomes about 300-500 mW / cm <^2> . Therefore, in the case of the 6th generation or the 7th generation, even if the RF power per unit area applied to the plasma electrode 50 is at least equal to 5th generation, the 6th generation requires about 10-13kw, and the 7th generation requires about 20kw RF power. Of course, more generations require more RF power.

However, when the RF power is increased in this way, the RF voltage is also increased between the plasma electrode 50 and the process chamber wall 10 or between the plasma electrode 50 and the chamber lead 11, so that RF power is supplied. The likelihood of being lost or discharged in the middle of the path also increases.

If a part of the RF power is lost or discharged during supply, the RF power applied to the plasma electrode 50 becomes unstable, so that the reaction gas is not discharged into the plasma 40 or the generated plasma 40 is unstable. The phenomenon of degradation occurs.

The discharge occurs because the dielectric strength of the medium is finite. Generally, since the dielectric strength of air is about 3 kV / cm, discharge occurs when a voltage of 3 kV or more is applied at intervals of about 10 mm. As shown in FIG. 2, since the shortest distance a between the plasma electrode 50 and the process chamber wall 10 is usually only about 6 mm, discharge often occurs therebetween.

Referring to FIG. 1, a path through which RF power is discharged during supply, the first path is a process chamber wall 10 in which RF power passed from the RF oscillator 80 to the impedance matcher 70 is grounded at the plasma electrode 50. Is discharged to the impedance matching unit 70 and the RF oscillator 80 again. In this case, not only the discharge to the process chamber wall 10 but also the discharge may occur between the upper portion of the plasma electrode 50 and the chamber lead 11.

In the case of the PECVD apparatus using the CCP, the plasma electrode can be integrally formed with the susceptor 20. In the second path, when the plasma electrode is formed on the susceptor 20, RF power is applied to the susceptor 20 side. It is a path that is discharged to the process chamber wall 10 grounded at and returned to the RF oscillator again. 3 shows the distance b between the plasma electrode formed on the susceptor 20 and the process chamber wall 10.

In order to generate stable plasma, the RF power supplied through the plasma electrode should be stabilized. The impedance (Z ₁ or Z ₂ ) in the first or second path where the RF power is discharged is the impedance of the normal path without discharge. If less than or similar to (Z), RF power is discharged through the first or second path or power loss occurs.

FIG. 4 simulates the distribution of the RF electric field formed on the LCD substrate 30 when the distance between the plasma electrode 50 and the process chamber wall 10 is typically 6 mm in the PECVD apparatus for the 6th generation LCD substrate. The results are shown. In FIG. 4, the contour lines for dividing the areas of A, B, C, D, and E represent areas up to 0.5% of the difference from the maximum value of the RF electric field in each area. Non-uniformity of 2.5% is shown, and although not shown in the figure, a non-uniformity appears up to 3% near the susceptor edge in the simulation. Experimentally, it is shown that the nonuniformity of the RF electric field and the nonuniformity of the plasma are about 1 to 5, so the nonuniformity of the plasma is about 15% in this case.

As can be seen from the above, as the size of LCD substrate becomes larger, it becomes more important to improve the stability and uniformity of plasma on the LCD substrate, while the possibility of leakage of RF power due to the discharge phenomenon also increases, thereby preventing discharge or power leakage. It is urgent to prepare a plan that can be done.

An object of the present invention is to provide a large-area LCD substrate manufacturing apparatus using a plasma that can prevent the discharge of the RF power supplied from the RF oscillator.

1 is a schematic configuration diagram of a conventional PECVD apparatus

2 is an enlarged partial view of portion A of FIG.

3 is an enlarged partial view of portion B of FIG.

4 is a RF electric field distribution diagram in the conventional PECVD apparatus

5 to 7 are schematic diagrams showing the distance between the plasma electrode and the ground and the floating capacitance in the PECVD apparatus;

8 is an RF electric field distribution diagram according to an embodiment of the present invention

9 is a configuration diagram in which an insulator is inserted between an electrode and a chamber according to another embodiment of the present invention.

10 is a schematic diagram of a Paschen curve

Explanation of symbols on the main parts of the drawings

10: process chamber wall 11: chamber lid

20: susceptor 30: LCD substrate

40: plasma 50: showerhead plasma electrode

51: susceptor plasma electrode 60: gas supply pipe

70: impedance matcher 80: RF oscillator

90: space between chamber lead and plasma electrode

100: insulator 110: process chamber internal space

120 exhaust pipe 200 discharge insulator

The present invention provides a large area LCD substrate manufacturing apparatus using a plasma having a shortest distance of 12 mm or more between the plasma electrode and the grounded process chamber wall or between the plasma electrode and the grounded chamber lead.

In addition, the present invention provides a large-area LCD substrate manufacturing apparatus using a plasma having a relationship of Cew / Ces <1.4 between the capacitance Ces between the plasma electrode and the susceptor and the capacitance Cew between the plasma electrode and the ground.

More specifically, the grounding provides a large area LCD substrate manufacturing apparatus using a plasma including a grounded process chamber wall and a grounded chamber lead.

Another embodiment of the present invention provides a large area LCD substrate manufacturing apparatus using plasma in which at least one discharge preventing insulator is inserted between the plasma electrode and the grounded process chamber wall or between the plasma electrode and the grounded chamber lead. The plasma electrode provides a large-area LCD substrate manufacturing apparatus using a plasma formed in at least one of the shower head or susceptor, and provides a large-area LCD substrate manufacturing apparatus using plasma having a thickness of the discharge preventing insulator is 3mm or more, The material of the discharge preventing insulator provides a large-area LCD substrate manufacturing apparatus using a plasma made of one or more selected from Al ₂ O ₃ , Teflon, Vespel, Ultem.

Another embodiment of the present invention, the product of the pressure of the space formed between the plasma electrode and the chamber lead and the shortest distance between the plasma electrode and the chamber lead belongs to any one range selected from less than 0.3mmHgcm or more than 7mmHgcm. Provided is a large area LCD substrate manufacturing apparatus using plasma.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings, and like reference numerals will be used to refer to like parts.

One embodiment of the present invention is to increase the impedance between the plasma electrode and the grounded process chamber wall or the grounded chamber lead to prevent RF power loss and discharge, between the plasma electrode and the grounded process chamber wall or between the plasma electrode and the grounded process chamber wall. Since the capacitive reactance between grounded chamber leads is 1 / ωC (ω: angular frequency, C: capacitance), the impedance can be increased by reducing the capacitance (C).

Therefore, in one embodiment of the present invention, the shortest distance between the plasma electrode and the grounded process chamber wall or between the plasma electrode and the grounded chamber lead is 12 mm or more in order to reduce capacitance. Then, even under high RF power of 10kW or more used in the large-area LCD manufacturing apparatus of 6th generation or more, power leakage does not occur due to discharge, and as a result, RF power applied to the plasma electrode is stabilized and plasma stability is increased. do.

5 to 7 illustrate the positions to which the intervals according to the present invention are applied according to the position of the plasma electrode, and FIG. 5 illustrates that the plasma electrode 50 is integrally formed with the shower head. And the shortest distance between the process chamber wall 10 and between the plasma electrode 50 and the chamber lead 11 is 12 mm or more.

6 shows that the plasma electrode 51 is formed integrally with the susceptor 51, and keeps the shortest distance between the plasma electrode 51 and the process chamber wall 10 at 12 mm or more.

FIG. 7 is provided with both the showerhead plasma electrode 50 and the susceptor plasma electrode 51. Between the showerhead plasma electrode 50 and the process chamber wall 10, the showerhead plasma electrode 50 and the chamber lead. The shortest distance between the portions 11 and between the susceptor plasma electrode 51 and the process chamber wall 10 is maintained at 12 mm or more.

FIG. 8 illustrates the LCD substrate 30 when the shortest distance between the plasma electrodes 50 and 51 and the process chamber wall 10 or the chamber lead 11 is 12 mm in the 6th generation LCD manufacturing apparatus as shown in FIGS. 5 to 7. The simulation results of the distribution of the RF electric field formed on the top surface shows a non-uniformity of about 1.5%. Compared with the conventional RF electric field distribution of FIG. 4, only the regions A, B, and C are shown, and it can be seen that the electric field difference between the center and the edge is smaller than in the case of the conventional case in which the regions D and E are represented. As described above, since the nonuniformity of the RF electric field and the nonuniformity of the plasma have a relationship of about 1 to 5, in this case, the nonuniformity of the plasma is about 7.5%. This is about 2 times the plasma uniformity improvement compared to the previous method.

Another embodiment of the present invention provides a large-area LCD substrate manufacturing apparatus using a plasma having a stray capacitance Cew between the plasma electrode and the ground and a capacitance Ces between the plasma electrode and the susceptor with Cew / Ces <1.4. do.

Here, the stray capacitance Cew between the plasma electrode and the ground is the capacitance Cew ₁ between the plasma electrode 50 and the grounded chamber lead 11 shown in FIGS. 5 to 7, and the plasma electrode 50 is grounded. It means that the capacitance Cew ₂ between the process chamber walls 10 and the capacitance Cew ₃ between the susceptor plasma electrode 51 and the grounded process chamber wall 10 are added together. The above capacitance is merely an example, and of course, the capacitance between all unshown gaps between the plasma electrode and the ground is also applicable.

Unnecessary increase in stray capacitance leads to a decrease in impedance, which leads to destabilization of plasma and deterioration of uniformity due to power loss and unnecessary discharge. Therefore, it is necessary to reduce the impedance by reducing the floating capacitance.

Table 2 shows the distance between the electrode and the susceptor at the 5th generation LCD substrate (1100mm x 1250mm) as 25mm and the plasma electrode and ground when RF power 5,300W with frequency 13.56MHz is applied to the process chamber in the pressure atmosphere of 0.8 to 2 torr Experimentally calculated stray capacitance Cew ₂ between the process chamber walls.

Here, it can be seen that the gap between the plasma electrode and the grounded process chamber wall is 678.5 pF when the gap is 6 mm, and 339.3 pF when the gap is 12 mm. At this time, since the capacitance Ces between the plasma electrode and the susceptor is 486.8 pF, it can be seen that the relationship of Cew ₂ / Ces ≒ 1.4 is established when the interval is 6 mm.

TABLE 2

Table 2 calculates only the capacitance (Cew ₂ ) in the gap between the plasma electrode and the grounded process chamber wall, but the discharge or power leakage is between the plasma electrode and the grounded chamber lead, the susceptor plasma electrode and the grounded process chamber. Since it also occurs between the walls, capacitances Cew _{1 and} Cew ₃ in this area must be taken into account.

In addition, in Table 2, it can be seen that when the interval is set to 12 mm, Cew ₂ /Ces≒0.7 is significantly lowered under the same conditions.

Cew includes Cew _1, Cew _{2, and} Cew ₃ , and Cew ₂ / Ces must have a value of about 1.4, so that plasma can be generated stably and uniformly, and as the spacing increases, the decrease in stray capacitance becomes noticeable. Cew <1.4 Ces, that is, it must be satisfied that the Cew / Ces <1.4 conditions, it can be seen that a stable and uniform plasma can be generated in a large-area LCD substrate manufacturing apparatus of more than 5 generations.

Another embodiment of the present invention is to insert a discharge preventing insulator between the plasma electrode and the grounded process chamber wall or between the plasma electrode and the grounded chamber lead. When the discharge preventing insulator is inserted, it is possible to prevent the discharge because the insulation breakdown voltage caused by the RF electric field increases, that is, the dielectric strength.

9 illustrates that a discharge preventing insulator 200 is inserted between the showerhead plasma electrode 50 and the process chamber wall 10. When the discharge preventing insulator 200 is used, discharge or power leakage can be prevented even when the thickness d of the discharge preventing insulator 200 reaches about 3 mm due to the increase in dielectric strength.

However, FIG. 9 is merely an example, and the present invention may be applied to all intervals indicated by arrows in FIGS. 5 to 7. Therefore, between the showerhead plasma electrode 50 and the grounded process chamber wall 10, between the showerhead plasma electrode 50 and the grounded chamber lead 11 or the susceptor plasma electrode 51 and the grounded process chamber wall ( 10) a discharge preventing insulator 200 may be inserted between the two. In addition, since the discharge preventing insulator 200 can be installed between any structure in the plasma electrode and the process chamber, there is no particular limitation on the installation position.

The material for the discharge preventing insulator 200 is selected from aluminum oxide (Al ₂ O ₃ ), Teflon, Vespel, and Ultem. Vespel is a powder of aromatic polyimide resin formed by high technology. It is not only excellent in heat resistance and abrasion resistance, but also has insulation strength of about 22 kV / mm and excellent plasma resistance. Ultem refers to polyetherimide and has excellent flame resistance and chemical resistance.

Yet another embodiment of the present invention provides a method of preventing discharge by adjusting the pressure in the space 90 between the showerhead plasma electrode 50 and the chamber lid 11 in FIG. FIG. 10 illustrates a Paschen curve, which schematically illustrates a correlation between dischargeable pressure, distance between electrodes, and voltage (V), in which an upper portion of the curve is a dischargeable region and a lower portion is discharged. That is not an area.

That is, since the horizontal axis represents the product of the pressure and the distance between the electrodes, for example, a voltage difference of 1 kV exists and is present in the dischargeable area, the distance between the electrodes is difficult to change once the system is installed. Discharge can be prevented by using a method of increasing or decreasing the pressure in the space 90 between the chamber 50 and the chamber lid 11. When there is a voltage difference of 1 kV, the discharge is prevented when the product of the pressure of the space formed between the plasma electrode and the chamber lead and the shortest distance between the plasma electrode and the chamber lead is 0.3 mmHgcm or less or 7 mmHgcm or more.

According to the present invention, it is possible to increase the stability of the RF power applied to the plasma electrode and to supply the maximum power, thereby increasing the stability and uniformity of the plasma, and further improving the process uniformity in the deposition process or the etching process.

Claims (8)

Large area LCD substrate manufacturing apparatus using plasma having a shortest distance of 12 mm or more between the plasma electrode and the grounded process chamber wall or between the plasma electrode and the grounded chamber lead Large-area LCD substrate manufacturing apparatus using plasma having a Cew / Ces <1.4 relationship between the capacitance Ces between the plasma electrode and the susceptor and the capacitance Cew between the plasma electrode and the ground The method of claim 2, The ground is a large-area LCD substrate manufacturing apparatus using a plasma comprising a grounded process chamber wall and a grounded chamber lead Large area LCD substrate manufacturing apparatus using plasma in which at least one discharge preventing insulator is inserted between the plasma electrode and the grounded process chamber wall or between the plasma electrode and the grounded chamber lid The method according to any one of claims 1 to 4, The plasma electrode is a large-area LCD substrate manufacturing apparatus using a plasma formed in one or more of the shower head or susceptor The method of claim 4, wherein Large area LCD substrate manufacturing apparatus using a plasma of the discharge prevention insulator is 3mm or more The method of claim 4, wherein The material of the discharge preventing insulator is a large-area LCD substrate manufacturing apparatus using a plasma made of one or more selected from Al ₂ O ₃ , Teflon, Vespel, Ultem. A large area LCD substrate manufacturing apparatus using plasma belonging to any one of 0.3 mmHgcm or less or 7 mmHgcm or more, the product of the pressure of the space formed between the plasma electrode and the chamber lead and the shortest distance between the plasma electrode and the chamber lead.