TW563200B - Low contamination plasma chamber components and methods for making the same - Google Patents

Low contamination plasma chamber components and methods for making the same Download PDF

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TW563200B
TW563200B TW090131841A TW90131841A TW563200B TW 563200 B TW563200 B TW 563200B TW 090131841 A TW090131841 A TW 090131841A TW 90131841 A TW90131841 A TW 90131841A TW 563200 B TW563200 B TW 563200B
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plasma
coating
reactor
substrate
polymer
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TW090131841A
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Christopher C Chang
Robert J Steger
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Lam Res Corp
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J37/00Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
    • H01J37/32Gas-filled discharge tubes
    • H01J37/32431Constructional details of the reactor
    • H01J37/32458Vessel
    • H01J37/32477Vessel characterised by the means for protecting vessels or internal parts, e.g. coatings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
    • H01L21/18Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
    • H01L21/30Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
    • H01L21/302Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to change their surface-physical characteristics or shape, e.g. etching, polishing, cutting
    • H01L21/306Chemical or electrical treatment, e.g. electrolytic etching
    • H01L21/3065Plasma etching; Reactive-ion etching
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00Aeronautics or air transport
    • Y02T50/60Efficient propulsion technologies, e.g. for aircraft
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    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/26Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
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    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/26Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263Coating layer not in excess of 5 mils thick or equivalent
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/26Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264Up to 3 mils
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31678Of metal
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31678Of metal
    • Y10T428/31681Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31721Of polyimide

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
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  • Computer Hardware Design (AREA)
  • Manufacturing & Machinery (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
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  • Coating By Spraying Or Casting (AREA)
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Description

563200 A7 B7 五、發明説明(2 ) 為了達成較大的電路密度,現代的積體電路大小具有愈 來愈嚴苛的設計規則,因此,已不斷縮小特徵尺寸亦即導 線寬度或相鄰導線之間隔(譬如溝道)^為了形成現代的積 體電路之狹窄的導體線,需要高度異向性的蝕刻。蝕刻異 向性係指相較於側向蝕刻速率之垂直蝕刻速率,為了對於 垂直側壁形成高的深寬比特徵,垂直蝕刻速率必須明顯大 於側向触刻速率。電漿蝕刻中,時常利用側壁鈍化技術達 成垂直輪廓,這些技術一般包含在蝕刻期間將一聚合物形 成物種(通常為譬如Ch、CHF3、C4F8之氟碳化物)導入反應 室内,蚀刻期間所形成的聚合物係優先沉積在所蝕刻特徵 的側壁上,藉以減少基材的側向蝕刻並增加蝕刻異向性。 但在蝕刻程序期間,聚合物沉積物亦可形成於暴露在電漿 之蝕刻室的各種元件内表面上。隨著時間經過,這些聚合 物沉積物可脫落或剥離而變成電漿反應器中的一種粒子污 染來源。 電漿反應器内所形成的聚合物沉積物通常包含碳化合 物的鏈分子,當聚合物接觸及黏附至待處理基材時將會污 染該部份的基材並因此降低晶粒的良率。聚合物沉積物可 累積在所有的室表面(特別是在處理氣體入口管鄰近處之 室殼體表面上)以及與基材表面相對之氣體配送板或室蓋 的底側。室的内表面上所沉積之聚合物可移徙暴基材上形 成一基材的瑕疵,在重覆的電漿處理循環期間,因為反應 器元件的熱循環而使聚合物顆粒污染更加嚴重^反應器元 件的電漿暴露表面之反覆加熱與冷卻將可因為聚合物沉積 -5- 563200 Λ 7 _ Β7 五、發明説明(3 ) 物與反應器表面之間的CTE (熱膨脹係數)差異而導致所黏 附的聚合物沉積物產生脫落或掉離。亦可利用電漿中之反 應劑物種的轟擊除去聚合物沉積物。 由於積體電路不斷降低實體尺寸及操作電壓,其相關的 製造良率更易受到粒子污染的影響。因此在製造較小實體 尺寸的積體電路裝置時,需令顆粒污染的程度小於先前認 為可接受的程度,已採用各種方法來降低電漿反應器中的 粒子污染,譬如請見美國專利5, 366, 585 ; 5, 391, 275 ; 5, 401, 319; 5, 474, 649; 5, 851, 343; 5, 916, 454; 5, 993, 594 ;6, 120, 640 ; 6, 155, 203號。 為了降低粒子污染,可定期清理電漿反應器以移除聚合 ,物沉積物,電漿清理程序揭露於美國專利5, 486, 235 ; 5, 676, 759 ; 5, 685, 916號。此外,通常定期以新的反應器 部份取代電漿反應器部份。 需要提供可降低反應器室内部的粒子污染程度之電衆 反應器,使用這些部份將有助於改善良率及/或延長需要清 理或更換電漿反應器元件前之時間長度。 發明概論 本發明人已經揭露:可將一種譬如陶瓷或高溫聚合物等 塗覆材料電漿喷灑在反應器的電漿暴露表面上,藉以降低 電漿反應器中的污染粒子。經過電漿喷灑的材料係形成一 塗層,此塗層具有所需要的表面粗糙特徵以促進聚合物沉 積物的黏附。聚合物沉積物在室表面上之改良的黏附將可 降低沉積物脫落或剝離室表面的傾向,藉以降低反應器中 -6 - 本紙張尺度適丨丨 1中㈣家樣準(CNS) Α视格(21G X 29了公费)-------- 563200 A7 _____ B7 五、發明説明(4 ) 足顆粒汙染的程度。藉由改良聚合物沉積物在電漿反應器 元件上之黏附,可能間隔較久才需要清理或更換反應器元 件’故降低了電漿反應器的操作成本。 根據本發明之一項實施例,提供一種製造電漿反應器元 件足方法,此反應器元件具有在使用期間暴露於電漿之一 或多個表面。此方法包括將一塗覆材料電裝噴灑在元件之 一電衆暴露表面上,以形成具有表面粗糙特徵之一塗層以 促進聚合物沉積物的黏附。 根據本發明之另一項實施例,提供具有在處理期間暴露 於電漿的一或多個表面之一種電漿反應器的一元件。元件 係包括位於一電漿暴露表面上之一電漿喷灑塗層,塗層具 有可促進聚合物沉積物黏附之表面粗糙特徵。 根據本發明之另一項實施例,亦提供一種電漿反應器以 及一種用於處理基材之方法,此電漿反應器包括一或多個 上述元件,此方法包括以一電漿接觸此基材的一暴露表面。 圖式簡簞說明 參照圖式詳細描述本發明,其中類似元件具有類似的編 號,圖中: 圖1顯示一種習知的電漿噴灑程序; 圖2顯示根據本發明採用電漿喷灑反應器元件之一種金 屬蝕刻室; 圖3顯示根據本發明採用電漿噴灑反應器元件之一種高 密度氧化物蝕刻室;及 圖4為對於圖3的蝕刻室之根據本發明的一項實施例之 本紙浪疋度通爪中國國家慄準(CMS) A4規洛(210X 297公釐) 563200
AT
一種氣體配送板的俯視圖。 較—佳實施例的評知 本發明所提供之改良係為降低譬如半導體(譬如梦坤 化鎵等)—晶圓、平板顯示器基材及類似物等基材之粒子污染 特疋β之本發明係對於在具有電漿暴露表面的電漿處 理室中所使用的元件提供可促進聚合物黏附之表面粗縫特 徵。將-稜譬如陶資或聚合材料等塗覆材料電漿噴灑在表 面積上,藉以形成粗糙化表面。對於處理期間暴露於電漿 之任何電漿反應器元件均可使用本發明之電漿噴灑元件, 適當的元件警如包拾:室襯整、擒圈'氣體配送板、聚焦圏 、電漿限制圈、軸架及襯墊支撐部。 本發明足反應器元件可由金屬材料或陶瓷材料製成,適 當的金屬材料包括鋁,有待電漿噴灑塗覆的鋁表面可為裸 露狀(除了 一先天氧化物層以外)或經陽極化處理。或者, 反應器元件可由陶瓷材料製成,此等陶瓷材料譬如為:氧化 铭、二氧化硬、石英、二氧化飲、二氧化锆、氧化記、碳 化鈥、碳化錘、碳切、碳化硼、氮化銘、氮化鈥、氮化 矽及/或氮化硼。可藉由譬如將陶瓷粉末熱壓及燒結成體塊 等任何習知的陶瓷製造技術來製造陶瓷元件。 本發明中,在處理期間暴露於電漿之反應器元件的任意 或所有表面係塗覆有一種譬如陶瓷或高溫聚合物等電漿喷 灑材料,根據本發明之電漿喷灑塗覆材料係對於反應器内 表面提供表面粗糙特徵,藉以促進蝕刻期間在電漿室中形 成之聚合物沉積物的黏附。本發明中,本發明塗層較佳具 -8 - 本紙张疋度適用中S固家櫺準(C· Α4規格(210X297公货)----^-:~ 563200 A7 一___B7 五、發明説明(7 ) 各種結合機構可能出現在塗層/基材介面上以及電漿噴 灑塗層的組成粒子之間,一般具有機械互鎖及擴散結合兩 者作用。可能出現的結合機構係包括:機械鍵接或互鎖;擴 散結合;及其他黏劑、化學及物理結合機構(譬如范德瓦力 (Van der Waal s forces))。電漿喷灑塗層之結合及後續構 成之影響因素係包括:基材表面的清潔度;可供結合的表面 積;表面拓樸形狀或表面輪廓;粒子及基材的溫度(熱能) :時間(反應速率及冷卻速率等);粉末粒子的速度(動能) ;基材及粉末粒子的物理或化學性質;及程序中可能發生 的任何物理及化學反應。 本發明中,可使用譬如清理及砂礫及珠粒喷擊等表面製 備技術提供與電漿喷灑塗層相結合之更高化學及物理活性 的元件表面。藉由砂礫或珠粒喷擊,可供結合的表面積會 增大藉以提高塗層結合強度。對於氧化鋁室元件,待塗覆 …表面較佳以無污染的氧化鋁媒體進行砂礫噴擊。然後可清 理粗Μ化表面,藉由譬如以空氣或C0 2喷擊表面及/或以一 種酸性溶液清洗表面等任何適當技術來移除鬆散粒子。此 處理所生成之基材的粗糙化表面輪廓係有助於促進塗層與 基材的鍵接或互鎖。 一旦已經施加電漿喷灑塗層之後,可利用任何適當的技 術來清理塗層的暴露表面,適當的清理技術包括以空氣或 C〇2噴擊表面及/或超音波清理,可重覆這些清理步驟以在 電漿處理基材期間使用元件之前達成元件表面所需要的表 面清潔或調節程度。 -10- 本紙浪义度通州中國a家樣準(CMS) A4規格(210X297公*) 563200 A7 B7 五 發明説明(8 ) 電漿噴灑具有可喷灑譬如耐火金屬及陶瓷等極高融點 材料之優點,譬如,已經使用陶瓷的電漿喷灑塗層對於各 種電漿反應器元件作為保護性塗層,譬如請見美國專利 5, 560, 780 ; 5, 879, 523 ; 5, 993, 594 ; 6, 120, 640號。此外 ’已經對於譬如聚醯亞胺等高融點熱塑性及熱固性聚合物 發展出電漿噴灑程序。 本發明中,電漿喷灑塗層可能為可抵抗電漿侵蚀之任何 材料,譬如,任何適合作為反應器元件之陶瓷材料只要可 進行電漿噴灑即亦可能作為塗層使用。當塗層為一種陶瓷 材料時,塗層較佳為與埋置元件相同的材料。由於元件與 塗層使用相同的材料,可盡量降低或消除位於塗層及元件 之間的熱膨脹係數(CTE)差異,這些CTE值差異會在使用時 的反應器元件循環期間導致塗層材料產生脫落。當塗層為 氧化鋁時,較佳以2至5密耳(0· 002至0· 005吋)厚度的塗層 施加至元件。 塗層亦可為一種聚合性材料,當塗層為一種聚合物時, 此聚合物應能以電漿喷灑以在元件上形成一緊密黏性塗層 ,一種較佳的高溫聚合物為譬如維思沛® (VESPEL® :杜邦 (DuPont)的註冊商標)的聚醯亞胺,聚醯亞胺塗層較佳以1〇 至30密耳(0· 010至〇· 030吋)厚度施加至元件。 在基材的電漿蝕刻中,將特徵蝕刻成譬如矽晶圓等基材 上的各種材料層,受蝕刻的材料通常係包括金屬及譬如氧 化物(譬如Si〇2)等介電材料,此等蝕刻程序中,可使用一 氣體配送板來控制氣體流在基材平面上方的反應器體積中 -11 - 本紙張尺度適川中® S家橾準(cNS) Λ4規格(210 X 297公釐) 563200 A7 B7 五、發明説明(9 之空間分佈。聚合物累積在電漿反應器中時特別會產生問 通’在電漿反應器中轉合至射頻(RJT)源的一個天線係將氣 體增能成為處理室中的一電漿狀態。此類型的電漿反應器 揭露於美國專利 4, 948, 458 ; 5, 198, 718 ; 5, 241,245 ; 5, 304, 279; 5, 401,350; 5, 531, 834; 5, 464, 476; 5, 525, 159
,5’529, 657; 5, 580, 385號。這些系統中,天線藉由一介 電構件與處理室内部相分離,介電構件譬如為一介電窗、 氣禮配送板、環氧樹脂的包封層或類似物等,並經由介電 構件將射頻能供應至室中。可對於譬如蝕刻、沉積、阻抗 剝除等多種不同的半導體處理應用使用這些處理系統。 裝
在一上述類型電漿反應器中之半導體晶圓的一種氧化 物或金屬蚀刻期間,聚合物沉積物可能累積在反應器内表 面上且其中包括朝向晶圓之氣體配送板或介電構件的暴露 表面。當聚合物累積加深時,聚合物容易脫落或剝離介電 構件’當介電構件直接位於基材及夾塊上方時,聚合物粒 子會直接落在基材或下方的夾塊上,這些聚合物粒子可將 瑕疵帶入基材中而降低良率。或者,粒子可移徙至夾塊表 面造成夾塊夾固之問題。 一般係定期停止蝕刻程序並清理内表面室(譬如使用一 種乾式蝕刻處理)以降低粒子污染的程度,然而,不恰當或 不完全的清理實際上卻會增加室中的粒子污染程度《並且 ,清理時所需的“停工時間,,造成的延遲亦代表生產良率的 嚴重損失。因此,需要控制蝕刻室内表面上之聚合物沉積 ,藉以達成高的生產良率並維持電漿反應器中的基材產出。 -12- 本紙張尺度適川中a a家樣準(CNS) A4規格(210 X 297公登} 563200
A7 B7 發明説明(10 ) 一種上述類型的示範性金屬蝕刻反應器係為已知得自 加州福瑞蒙特的LAM研究公司(LAM Research Corporat ion) 的TCPTM 9600電漿反應器之一變壓耦合電漿反應器,圖2顯 示TCPTM 9600電漿反應器的簡圖,圖2顯示一個包括一電漿 處理室152之反應器150。在室152#方配置有一天線156以 產生電漿,圖2的範例中藉由一平面性線圈實施此天線156 。通常以一射頻產生器158經由一匹配網路(未圖示)將射頻 線圈156增能。室152内設有一蓮蓬頭154,此蓮蓬頭154較 佳包括複數個孔,這些複數個孔可將譬如蝕刻劑源氣體等 氣態源材料釋入蓮蓬頭與晶圓170之間的射頻感應電漿區。 亦可從内建在室152壁中之孔口釋出氣態源材料,當蝕 刻通過鋁或一種合金時,蝕刻劑源化學物譬如包括:譬如 Cl2及BCb等鹵素,對於側壁鈍化亦可能使用其他蝕刻劑化 學物(譬如CH4、HBr、HC1、CHCh)以及聚合物形成物種(譬 如碳氫化合物、氟碳化物、氫氟碳化物等),可能連同選用 的惰性及/或非反應性氣體一起使用這些氣體。 使用時,將一晶圓170導入由室壁172所界定並位於一基 材支撐部162上之室152中,基材支撐部162作為一下或第二 電極。較佳藉由一射頻產生器164(通常亦經由一匹配網路) 將晶圓予以偏壓,晶圆上可含有製成的複數個積體電路, 積體電路可譬如包括諸如PLA、FPGA、AS 1C等邏輯裝置或諸 如隨機存取記憶體(RAM)、動態隨機存取記憶體(DRAM)、同 步動態隨機存取記憶體(SDRAM)或唯讀記憶體(ROM)等記憶 體裝置。當施加射頻功率時,反應性物種(由蝕刻劑源氣體 563200 A7 B7 五、發明説明(H ) 所構成)係蚀刻晶圓17 0的暴露表面,可能為揮發性的副產 at!則經由一出口孔口 1 6 6排出,完成處理之後,可切刻晶圓 將積體電路分成個別的晶片。 本發明中,一電漿限制圈(未圖示)、室壁172、一室襯 塾(未圖示)及/或蓮蓬頭154之電漿暴露表面可設有一電漿 嘴灑塗層160,此電漿喷灑塗層16〇具有可促進聚合物黏附 之表面粗糙特徵。此外,基材支撐部168的電漿暴露表面亦 可根據本發明設有一電漿喷灑塗層(未圖示),利用此方式 ’限制住高密度電漿之實質所有表面係均具有可促進聚合 物黏附之表面粗糙特徵,可利用此方式顯著降低反應器内 的顆粒污染。 本發明的反應器元件亦可使用於一種高密度的氧化物 蚀刻程序中,一種示範性氧化物蝕刻反應器係為得自加州 福球蒙特的LAM研究公司(LAM Research Corporation)的 TCP 9100TMf漿蝕刻反應器。在TCP 9100τ1應器中,氣體 配送板為直接位於TCPTM窗下的一個圓形板,TCPTM窗亦為位 於一半導體晶圓上方的一平行平面中之反應器頂部上的真 空密封表面。氣體配送圈從一供源將氣體饋送入氣體配送 板所界定的體積中,氣體配送板包含延伸通過板之具有指 定直徑的一陣列的孔,通過氣體配送板之孔具有可改變的 S間分佈以使所蚀刻的層(譬如晶圓上之一光阻層、一個二 氧化矽層及一底層材料)具有最佳的蝕刻均勻度,氣體配送 板具有可改變的剖面形狀以操縱進入反應器的電漿中之射 頻功率的分佈。氣體配送板材料係由一種介電材料所製成 -14· 本紙張尺度遴用中國函家標準(CNS> A4規格(210X 297公查) 563200 A7 _ B7 五、發明説明(12~) — ’使得此射頻功率能夠耦合通過氣體配送板進入反應器内 。並且,氣體配送板的材料需很能抵抗環境中的化學嘴賤 姓刻(譬如氧或氫氟碳化物氣體電漿),藉以避免產生相關 的崩溃及生成粒子。 圖3顯示根據本發明一項實施例之氧化物蚀刻所用的一 真空處理室,真空處理室1〇包括一基材固持件丨2及一聚焦 圈14,此基材固持件12係為一底部電極的形式以對於一基 材13提供一靜電夾力並對於所支撐的一基材提供一射頻偏 壓,此聚焦圈14係用於將電漿限制在基材上方的一區域中 。基材可能以一種譬如氦氣等熱傳氣體從後方冷卻,一能 量源將射頻能感應式耦合至室10以提供一高密度電漿,此 能量源係在譬如由一適當射頻源及一適當射頻阻抗匹配電 路供應動力之一扁平螺旋線圈形式的一天線18室中維持一 、度(10至1012離子/立方公分)電漿。室包括用於將室 内部保持在一理想壓力(譬如50毫托耳以下且一般為1至20 毫托耳)之適當的真空泵送裝置。具有均勻厚度之一大致平 面性的介電窗20係設置於天線18及處理室1〇内部之間並形 成處理室10頂部上之真空壁。一常稱為蓮蓬頭22的氣體配 送板係設置於窗20下方並包括複數個開口(譬如未圖示的 圓孔)以將氣禮供應部23所供應的處理氣體輸送至處理室 10 ^ —錐形襯墊30係從氣體配送板延伸而圍繞基材固持件 12,天線18可具有一通路24,一種溫度控制流體經由入口 及出口導管25、26通過此通路24 ^然而,亦可利用譬如將 在天線及窗上方吹送空氣、令一冷卻媒體通過窗及/或氣禮 -15- 本紙張尺度適用中噚8家標準(CNS) Α4規格(210 X 297公釐) 563200 A7 _B7__ 五、發明説明(13 ) 配送板或與窗及/或氣體配送板呈熱傳式接觸等其他技術 來冷卻天線18及/或窗20。 操作時,一晶圓係位於基材固持件12上且通常由一靜電 夾件、一機械夾件或其他夾持機構固持在位置中。然後, 令處理氣體通過窗20與氣體配送板22之間的一間隙,藉以 將處理氣體供應至真空處理室10,適當的氣體配送板配置 (亦即蓮蓬頭)係揭露於共同所有的美國專利5, 824, 6G5 ; 5, 863, 376 ; 6, 048, 798號。 氣體配送板可具有各種設計,圖4顯示其中一項範例, 圖4所示的氣髏配送板40係包括89個孔41及接近中心的四 個浮雕部42,藉以提供一路徑將處理氣體供應至氣體配送 板與介電窗之間。 如圖3所示,氣體配送板22、室襯墊30及/或聚焦圈14之 電漿暴露表面係具有陶瓷或聚合性材料之電漿喷灑塗層32 ’此等電漿喷灑塗層32具有可促進聚合物黏附的表面粗糙 特徵’可利用此方式顯著降低反應器内的顆粒污染。 在後續使用時,根據本發明之反應器元件的内表面可變 成為受到聚合物沉積物所塗覆。根據本發明之另一項實施 例,可從反應器移除元件,故可從元件實體地移除既有的 電漿喷灑塗層及任何累積的沉積物並施加一新的電漿噴灑 塗層。可利用譬如研磨或喷砂等方式來移除舊塗層,·可利 用此方式重新使用反應器元件。 進行一種膠帶測試以決定本發明之電漿喷灑塗層的黏附 性質,在一 TCP 9600TM金屬蝕刻反應器中安裝並使用一個 -16- 本紙*尺度適用中國國家樣準(CNS> A4規格(210 X 297公釐)

Claims (1)

  1. 563200 Λ Q 第090131841號專利申請案 B8
    中文申請專利範圍替換本(92年2月) 漂 六、申請專利範圍 1· 一種電漿反應器元件之製造方法,該電漿反應器元件具 有使用期間暴露於電漿的一或多個表面,該方法包含將 一塗覆材料電漿噴灑至該元件的一電漿喷灑表面上以 形成一塗層,該塗層具有可促進聚合物沉積物的黏附之 表面粗縫特徵。 2 ·如申請專利範圍第1項之方法,其進一步包含以下步驟: 將該元件的電漿暴露表面加以粗糙化;及 在电聚貪丨麗•亥塗覆材料之前清理該粗縫化的表面。 3 ·如申請專利範圍第1項之方法,其進一步包含清理該電 漿嘴灑塗層的暴露表面。 4·如申請專利範圍第1項之方法,其中該塗覆材料為一陶 瓷或一聚合材料。 5.如申請專利範圍第1項之方法,其中該元件具有貫穿的 開口’該方法進一步包含在電漿噴灑該塗層之前先塞住 該等開口。 6 ·如申請專利範圍第1項之方法,其進一步包含從一電聚 反應室移除該元件,並在將該塗層電漿噴灑至該經清理 表面上之前移除任何既有的塗層及/或黏附的聚合物沉 積物藉以清理該電漿暴露表面。 7.如申請專利範圍第4項之方法,其中該電漿喷灑塗層係 為具有2至5密耳厚度之一種陶瓷材料。 8·如申請專利範圍第4項之方法,其中該元件及該塗覆材 料包含相同的陶瓷材料。 9.如申請專利範圍第4項之方法,其中該塗覆材料為一種
    563200 A8 B8 C8 D8 六、申請專利範園 聚酿亞胺。 10·如申請專利範圍第9項之方法,其中該塗層具有10至30 密耳的厚度。 11 ·如申請專利範圍第1項之方法,其中該元件選自包括下 列各物之群組:一電漿限制圈、一聚焦圈、一軸架、一 室壁、一室襯墊及一氣體配送板。 12·如申請專利範圍第2項之方法,其中該粗糙化步驟係包 含以珠粒嘴擊該元件的表面。 13·如申請專利範圍第之方法,其中該塗層具有介於15〇 與190微吋之間之算數平均表面粗糙值(Ra)。 14·種屯漿反應器之元件,該元件具有在處理期間暴露於 該電漿的一或多個表面,該元件包含位於一電漿暴露表 面上之i漿噴灑塗層,其中該塗層具有可促進聚合物 》匕積物的沉積之表面粗縫特徵〇 15·如申請專利範圍第14項之元件,其中該元件由-金屬材 料或一陶瓷材料製成。 16·如申β請專利範圍第15項之元件,其中該元件係包含具有 一陽極化或非陽極化的電漿暴露表面之鋁。 17·如申請專利範圍第14項夕 胃< 7C件’其中該元件係由選自包 括下列各物之群組之一種陶 搜陶瓷材料所製成:氧化鋁、氧 化釔、二氧化锆、碳化碎、 ^ 鼠化矽、碳化硼及氮化硼。 18·如申請專利範圍第14項 件其中該元件選自包括下 列各物心群組··一電漿隈制 —戚—包聚限制圈、—聚焦圈、一軸架、-至土'至襯墊及一氣體配送板。 -2 -
    .如申請專利範圍第14項之元 聚合材料。 干其中邊塗層為一陶瓷或 …19項之元件,其中該塗層係為選自包 二 〈群組之一種陶瓷材料:氧化鋁、氧化釔、 21.4 L #、碳切、氮切、碳化侧及氮化·。 I清專利範Ιϋ第2G項之方法,其中該.元件及該塗覆材 竹包含相同的陶瓷材料。 22·如申請專利範圍第20項之元件,其中該塗層具有2至5 密耳的厚度。 申明專利範圍第19項之兀件,其中該塗層為一種聚醯 亞胺。 4.如申4專利範圍第23項之元件,其中該塗層具有1〇至3〇 在、耳的厚度。 5·如申叫專利範圍第14項之元件,其中該塗層具有至 190微吋之算數平均表面粗糙值(Ra)。 26. —種電漿反應器,其包含至少一元件,該元件具有在處 理期間暴露於該電漿的一或多個表面,及位於一電漿暴 露表面上之電漿噴灑塗層,其中該塗層具有可促進聚合 物沉積之表面粗糙特徵。 27· —種處理一基材之方法,該方法係於一電漿反應器中進 行’該電漿反應器包含一元件,該元件具有在處理期間 暴露於該電漿的一個或多個表面,及位於一電漿暴露表 面上之電漿喷灑塗層,其中該塗層具有可促進聚合物沉 積之表面粗链特徵,該方法包含:以一電漿接觸該基材 -3- 563200
    的一暴露表面之步驟。 28.如申請專利範圍第27項之方法,其進一步包含以下步驟· 將該基材定位在該反應器的一基材支撐部上; 將一處理氣體導入該反應器中; 將射頻能施加至該處理氣體以在鄰近該基材的一暴 露表面處產生一電漿;及 以一電漿蝕刻該暴露的基材表面。 29·如申請專利範圍第28項之方法,其中該處理氣體包含至 少一種的聚合物形成物種。 30.如申請專利範圍第27項之方法,其中該基材的暴露表 包含一金屬材料或一氧化物^ 面 〜氣靉配 氣體配适 31.如申請專利範圍第28項之方法,其中該元件為 送板’該方法進一步包含將該處理氣體經由該 板中的開口導入該反應器中。 -4-本紙張尺度適用中國國家標準(CNS) A4規格(210X 297公釐)
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US6805952B2 (en) 2004-10-19
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KR20030066769A (ko) 2003-08-09
WO2002057506A2 (en) 2002-07-25
EP1346076B1 (en) 2017-03-22
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JP2010199596A (ja) 2010-09-09
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CN1489641A (zh) 2004-04-14
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US20040224128A1 (en) 2004-11-11
JP2004523894A (ja) 2004-08-05
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