TWI849834B - 用於高壓處理腔室的氣體分配系統 - Google Patents

用於高壓處理腔室的氣體分配系統 Download PDF

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TWI849834B
TWI849834B TW112113014A TW112113014A TWI849834B TW I849834 B TWI849834 B TW I849834B TW 112113014 A TW112113014 A TW 112113014A TW 112113014 A TW112113014 A TW 112113014A TW I849834 B TWI849834 B TW I849834B
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奇偉 梁
史林尼法斯D 奈馬尼
席恩S 康
艾德柏 坎
怡利 葉
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美商微材料有限責任公司
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Abstract

本案揭示了一種高壓處理系統,用於處理基板上的層。系統包含:第一腔室;支座,支座用於將基板固持於第一腔室中;第二腔室,第二腔室鄰接第一腔室;前級,前級用於從第二腔室移除氣體;真空處理系統,真空處理系統經配置以將第二腔室內的壓力降低至接近真空;閥組件,閥組件在第一腔室與第二腔室之間,用於將第一腔室內的壓力隔離自第二腔室內的壓力;氣體分配系統,氣體分配系統經配置以在第一腔室與第二腔室隔離的同時將第一腔室內的壓力提升至至少10個大氣壓;排氣系統,排氣系統包含排氣線以從第一腔室移除氣體;以及共同外殼,共同外殼圍繞第一氣體分配模組與第二氣體分配模組兩者。

Description

用於高壓處理腔室的氣體分配系統
本發明相關於用於積體電路製造的高壓處理腔室。
微電子電路與其他微型裝置,一般而言由基板製成,諸如矽基板或其他半導體材料的基板。在基板上施加多個金屬層,以形成微電子部件或其他微型部件,或提供電性連結。這些金屬層(例如銅)被由一系列的光刻、電鍍、蝕刻、研磨或其他作業,鍍上基板並形成部件與交互連結。
為了取得所需的材料性質,基板通常經過退火製程,其中基板通常被快速加熱至約200至500°C。基板可在一段相對短的時間,例如60至300秒內被保持在這些溫度下。基板隨後被快速冷卻,而整體製程通常僅需要數分鐘。退火可用於改變基板上的材料層性質。退火亦可用於活性化摻雜劑、在基板上的薄膜之間驅動摻雜劑、改變膜對膜介面或膜對基板介面、使經沈積薄膜緻密化、或修復離子植入所造成的傷害。
隨著微電子裝置與交互連結的特徵尺寸縮小,可允許的缺陷率大大地降低。一些缺陷來自污染物粒子。其他缺陷可來自基板的某些區域的不完全處理,例如沒有在溝槽底部長成薄膜。
過去已使用了各種退火腔室。在單一基板處理設備中,這些退火腔室通常將基板放置在加熱元件與冷卻元件之間(或之上),以控制基板的溫度輪廓。然而,取得精確的、可重複的溫度輪廓以及可接受的缺陷位準,可呈現工程上的挑戰。
在一個範例中,提供一種高壓處理系統,用於處理基板上的層。系統包含:第一腔室;支座,支座用於將基板固持於第一腔室中;第二腔室,第二腔室鄰接第一腔室;前級,前級用於從第二腔室移除氣體;真空處理系統,真空處理系統經配置以將第二腔室內的壓力降低;閥組件,閥組件在第一腔室與第二腔室之間,用於將第一腔室內的壓力隔離自第二腔室內的壓力;氣體分配系統,氣體分配系統經配置以將一或更多種氣體引入第一腔室,並在氣體位於第一腔室中的同時且在第一腔室與第二腔室隔離的同時將第一腔室內的壓力提升至至少10個大氣壓; 控制器,控制器經配置以操作氣體分配系統與閥組件;排氣系統,排氣系統包含排氣線以從第一腔室移除氣體;以及共同外殼,共同外殼圍繞第一氣體分配模組與第二氣體分配模組兩者。氣體分配系統包含第一氣體分配模組以在第一壓力下(至少10個大氣壓)分配第一氣體,以及第二氣體分配模組以在第二壓力下(小於第一壓力但大於1個大氣壓)分配第一氣體或成分不同於第一氣體的第二氣體。
實施例可包含下列特徵之一或更多者。
可配置第二排氣系統以從共同外殼移除氣體。第二排氣系統可經配置以從外殼引導氣體至前級。第一與第二遞送線可將第一與第二氣體分配模組耦接至第一腔室。可配置包封殼體以將從第一與第二遞送線洩漏的氣體轉向至前級。共同外殼可與包封殼體流體性地隔離。
在另一範例中,一種用於處理基板上的層的高壓處理系統包含:第一腔室;支座,支座用於將基板固持於第一腔室中;第二腔室,第二腔室鄰接第一腔室;前級,前級用於從第二腔室移除氣體;真空處理系統,真空處理系統經配置以將第二腔室內的壓力降低至接近真空;閥組件,閥組件在第一腔室與第二腔室之間,用於將第一腔室內的壓力隔離自第二腔室內的壓力;氣體分配系統,氣體分配系統經配置以將一或更多種氣體引入第一腔室,並在氣體位於第一腔室中的同時且在第一腔室與第二腔室隔離的同時將第一腔室內的壓力提升至至少10個大氣壓;排氣系統,排氣系統包含排氣線以從第一腔室移除氣體;以及控制器。氣體分配系統包含第一氣體分配模組以在第一壓力下(至少10個大氣壓)分配第一氣體,以及第二氣體分配模組以在第二壓力下(小於第一壓力但大於1個大氣壓)分配第一氣體或成分不同於第一氣體的第二氣體。控制器經配置以操作氣體分配系統、閥組件、真空處理系統與排氣系統,使得閥組件將第一腔室隔離自第二腔室,隨後第二氣體分配模組將第一腔室從低於1個大氣壓的一壓力提升至第二壓力,隨後第二氣體分配模組被隔離自第一腔室,且隨後第一氣體分配模組將第一腔室從第二壓力提升至第一壓力。
實施例可包含下列特徵之一或更多者。
第一氣體分配模組可包含幫浦,幫浦經配置以在將第一氣體分配至第一腔室之前,提升第一氣體的壓力。第二氣體分配模組可使用質量流量控制器、液體流量計或液體流量控制器,以將氣體引導至第一腔室。第一腔室中可定位第一壓力感測器,而第二腔室中可定位第二壓力感測器。控制器可經配置以使排氣系統減少第一腔室中的壓力,並使真空處理系統減少第二腔室中的壓力。控制器可經配置以比較來自第一壓力感測器與第二壓力感測器的測量結果,並控制排氣系統與真空處理系統,使得第一腔室中的壓力高於第二腔室中的壓力。
在另一範例中,一種操作高壓處理系統的方法,包含以下步驟:將第一腔室與第二腔室調整至第一壓力,第一壓力小於一個大氣壓;在第一腔室與第二腔室之間的隔離閥為打開的同時,將基板從第二腔室移送入第一腔室;在隔離閥為關閉的同時,將第一腔室從第一壓力減少至第二壓力,並將第二腔室從第一壓力減少至第三壓力;由第二氣體分配模組將第一腔室加壓至第四壓力,第四壓力高於大氣壓力並小於10個大氣壓;由第一氣體分配模組將第一腔室加壓至第五壓力,第五壓力高於10個大氣壓;在第一腔室位於第五壓力下的同時,處理基板;對第一腔室抽氣;以及打開隔離閥並將基板從第一腔室移除。
實施例可包含下列特徵之一或更多者。
將第一腔室加壓至第五壓力之步驟可包含:供應第一氣體至第一腔室,且將第一腔室加壓至第四壓力之步驟可包含:供應具有不同成分的第二氣體至第一腔室。第一氣體可包含H 2或NH 3之至少一者。由第二氣體分配模組將第一腔室加壓之步驟可包含:由在第一氣體分配模組與第一腔室之間的遞送線中的高壓隔離閥,將第一氣體分配模組隔離自第一腔室;以及藉由打開在第二氣體分配模組與第一腔室之間的遞送線中的低壓隔離閥,流體性地耦接第二氣體分配模組與第一腔室。由第一氣體分配模組將第一腔室加壓之步驟可包含:由低壓隔離閥將第二氣體分配模組隔離自第一腔室;以及藉由打開高壓隔離閥流體性地耦接第一氣體分配模組與第一腔室。
第三壓力可小於第二壓力。可比較來自第一腔室中的第一壓力感測器與第二腔室中的第二壓力感測器的測量結果,並繼續減少第一腔室與第二腔室中的壓力,直到第一腔室中的壓力高於第二腔室中的壓力為止。對第一腔室抽氣之步驟可包含:將第一腔室中的壓力降低至第六壓力,第六壓力小於第一壓力。第六壓力可大於第三壓力。
實施例可包含下列優點之一或更多者。
可更安全地在腔室中建立高壓。可偵測洩漏。
可在基板上更均勻地處理或形成層。此外,高壓處理亦可進行在低壓下無法進行的化學反應。
在附加圖式與下面的說明中揭示一或更多個具體實施例的細節。根據說明書、圖式以及申請專利範圍,將可顯然理解其他特徵、目的與優點。
如前述,一些缺陷可因基板某些區域的不完全處理而造成。然而,高壓處理(例如退火或沈積)可提升基板上處理的一致性。特定而言,退火可發生在高壓環境中,在使用退火製程形成層時(例如藉由熱氧化或其他製程,其中化學物質擴散到設置在基板上的材料中並與其反應),高壓可幫助提升基板上材料層的表面覆蓋的徹底性。例如,層在溝槽中的處理形成的問題可被減少。因此,在基板上可更均勻地處理或形成層。此外,高壓處理(例如退火或沈積)亦可進行在低壓下無法進行的化學反應。
另一議題為,在溫度超過約70° C下,某些材料(諸如銅)將在暴露至氧時快速氧化。若銅或其他材料氧化,則基板可不再能被使用,或者在進一步處理之前必需先將氧化層移除。這些都是對於有效率地進行製造所無法接受的選項。因此,一個設計因素為將基板隔離自氧,特別是在基板溫度超過約70° C時。因為氧當然會存在於周遭空氣中,在退火期間避免銅氧化也可呈現工程挑戰。如本文所述,基板可被移送於高壓處理腔室與低壓(例如接近真空)環境中的不同的處理腔室之間,以避免基板被污染與氧化。
另一個考量是壓力。非常高的壓力可提升所產生的基板的一致性與品質。然而,具有高壓(例如高於10 atm、高於15 atm或上至20 atm)的系統存在高度的破裂與失控風險。具有增強安全特徵的系統,有益於使用在這種超高壓處理中。
第1圖圖示整合多腔室基板處理系統,此系統適合用於執行物理氣相沈積、化學氣相沈積及(或)退火製程的至少一個具體實施例。一般而言,多腔室基板處理系統包含至少一個高壓處理腔室(例如能夠操作在高於10大氣壓的壓力下以執行高壓製程,諸如沈積或退火)以及至少一個低壓處理腔室(例如能夠操作在低壓(例如低於1個大氣壓)之下以執行低壓製程,諸如蝕刻、沈積或熱處理)。在一些實施例中,多腔室處理系統為具有中央移送腔室的群集工具,中央移送腔室位於低壓且可從中央移送腔室訪問多個處理腔室。
本文所述之製程與系統的一些具體實施例,相關於沈積用於特徵定義的材料層(例如金屬與金屬矽化物阻障)。例如,第一金屬層被沈積在矽基板上並經過退火以形成金屬矽化物層。第二金屬層隨後被沈積在金屬矽化物層上以填充特徵。形成金屬矽化物層的退火製程可由多個退火作業執行。
第1圖為處理平臺100的一個具體實施例的示意俯視圖,包含兩個移送腔室102、104、分別位於移送腔室102、104中的移送機器人106、108、以及設置在兩個移送腔室102、104上的處理腔室110、112、114、116、118、130。第一與第二移送腔室102、104為中央真空腔室,與鄰接的處理腔室110、112、114、116、118、130介面連接。
第一移送腔室102與第二移送腔室104係由穿越腔室120分隔開,穿越腔室120可包含冷卻腔室或預熱腔室。在第一移送腔室102與第二移送腔室104操作在不同壓力下時,在處理基板期間內穿越腔室120亦可被抽氣或通氣。例如,第一移送腔室102可操作在約100毫托與約5托之間(諸如約40毫托)的壓力下,且第二移送腔室104可操作在約1x10 -5托與約1x10 -8托之間(諸如約1x10 -7托)的壓力下。
由經編程控制器122操作處理平臺100。控制器122可控制移送機器人106、108以在腔室之間移送基板,並可使處理平臺100的每一腔室執行個別的作業以處理基板。
第一移送腔室102耦接於兩個去氣腔室124、兩個裝載閘腔室128、反應預清洗腔室118、至少一個物理氣相沈積腔室110、以及穿越腔室120。預清洗腔室可為購於美國加州聖塔克拉拉市的應用材料公司的PreClean II腔室。透過裝載閘腔室128將基板(未圖示)裝載入處理平臺100。例如,工廠介面模組132(若存在)將負責接收來自人類操作者或自動化基板處理系統的一或更多個基板(例如基板盒)或封閉式基板艙。工廠介面模組132可開啟基板盒或基板艙(若可應用),並移動基板自/至裝載閘腔室128。處理腔室110、112、114、116、118、130從移送腔室102、104接收基板、處理基板、並允許基板被移送回移送腔室102、104。在被裝載入處理平臺100之後,在去氣腔室124與預清洗腔室118中分別循序對基板去氣並清洗。
每一處理腔室由隔離閥隔離自移送腔室102、104,隔離閥允許處理腔室操作在與移送腔室102、104不同的真空位準下,並防止處理腔室中使用的任何氣體被引入移送腔室。裝載閘腔室128亦由隔離閥隔離自移送腔室102、104。每一裝載閘腔室128具有門,門向外部環境開啟,例如向工廠介面模組132開啟。在正常作業中,從工廠介面模組132通過門將裝載了基板的盒放入裝載閘腔室128,並關閉門。裝載閘腔室128隨後被抽氣至與移送腔室102相同的壓力,並打開裝載閘腔室128與移送腔室102之間的隔離閥。移送腔室102中的機器人被移入定位,且一個基板被從裝載閘腔室128移除。裝載閘腔室128裝配了升降機機制,以在一個基板被從盒移除時,升降機移動盒中的基板堆疊以放置另一基板於移送平面中,使得基板可被放置在機械刃上。
移送腔室102中的移送機器人106隨著基板旋轉,使得基板對齊處理腔室位置。處理腔室中的任何有毒氣體被沖出、壓力位準被設為與移送腔室相同、並開啟隔離閥。移送機器人106接著將基板移入處理腔室,其中基板被舉離機器人。移送機器人106隨後從處理腔室縮回,並關閉隔離閥。處理腔室隨後經過一系列的作業,以對基板執行所指定的製程。在完成時,處理腔室被調回與移送腔室102相同的環境,並開啟隔離閥。移送機器人106將基板從處理腔室移除,且隨後將基板移至另一處理腔室以進行另一作業,或將基板再放回裝載閘腔室128以在基板盒整體已被處理後移出處理平臺100。
移送機器人106、108分別包含機械臂107、109,機械臂107、109支撐並於不同的處理腔室之間移動基板。移送機器人106在去氣腔室124與預清洗腔室118之間移動基板。基板隨後可被移送至長間距(long throw)PVD腔室110,以在基板上沈積材料。
第二移送腔室104耦接至處理腔室116、112、114、130群集。處理腔室116、112可為用於依操作者所需來沈積材料(諸如鎢)的化學氣相沈積(CVD)腔室。經PVD處理的基板被從第一移送腔室102,經由穿越腔室120移入第二移送腔室104。此後,移送機器人108移動基板於處理腔室116、112、114、130之一或更多者之間,以進行處理所需的材料沈積與退火。
當然,前述實施例僅為示例性的;每一移送腔室可具有不同數量的處理腔室(例如一至五個腔室);處理腔室可具有不同的功能分配;系統可具有不同數量的移送腔室(例如僅有單一移送腔室);以及移送腔室可被整體省略,且系統可僅具有單一個獨立式處理腔室。
第2圖圖示說明受控制的高壓處理系統200,高壓處理系統200創建高壓環境以處理基板,並在基板被移送於處理腔室之間時對基板創建低壓環境。受控制的高壓處理系統200包含高壓內側第一腔室202與低壓外側第二腔室204。
第一腔室202可對應於處理平臺100的處理腔室110、112、114、116、118、130中之一者,且第二腔室204可對應於處理平臺100的移送腔室102、104中之一者。或者在一些實施例中,處理腔室110、112、114、116、118、130中之一者包含第一腔室202與第二腔室204兩者。第一腔室202可對應於內側腔室,且第二腔室204可對應於圍繞內側腔室的外側腔室。
可獨立於第二腔室204中的壓力,來控制第一腔室202內的壓力。若第一與第二腔室202、204不同於移送腔室,則可獨立於移送腔室內的壓力來控制第一與第二腔室202、204的壓力。受控制的高壓處理系統200進一步包含氣體分配系統206、真空處理系統208以及控制器210。在一些範例中,處理平臺100的控制器122可包含控制器210。
第一腔室202經配置(例如密封與加強)以容納非常高的壓力(例如至少10個大氣壓的壓力,例如40-80 atm的壓力)。相對的,第二腔室204經配置(例如密封與加強)以容納非常低的壓力(例如低於1個大氣壓的壓力,例如下至約100毫托的壓力)。第二腔室204的低壓環境,可禁止基板或基板上沈積的材料的污染及(或)氧化。
第二腔室204鄰接於第一腔室202。在一些實施例中,第二腔室204亦圍繞第一腔室202(若第二腔室204未圍繞第一腔室,則第二腔室仍可被視為外側腔室,因為基板將穿越第二腔室以到達第一腔室)。在一些實施例中,第二腔室204實質上圍繞(例如至少80%的)第一腔室202。
如前述,第二腔室204可對應於移送腔室(例如移送腔室102或移送腔室104),移送腔室於不同的處理腔室之間接收基板。或者,第二腔室204可為位於第一腔室202與移送腔室102(或移送腔室104)之間的個別腔室。
內側(例如第一)腔室202包含基板支座218(例如底座)以支撐工件(諸如基板10),工件欲被處理(例如經受退火或在其上沈積材料層)。支座218被定位或可被定位在第一腔室202內。在一些實施例中,基板10直接位在底座的平坦頂表面上。在一些實施例中,基板位在從底座凸起的升舉銷上。
第一腔室202與第二腔室204之間的第一閥組件212,使第一腔室202內的壓力隔離自第二腔室204內的壓力。第一腔室202內的高壓環境可因此被密封隔離自第二腔室204內的低壓環境。第一閥組件212可開啟以使基板10能被從第二腔室204(或通過第二腔室204)移送進入第一腔室202,或使基板能被從第一腔室202移送進入第二腔室204(或通過第二腔室204)。
第二腔室204與外部環境(例如移送腔室)之間的第二閥組件213,使第二腔室204內的壓力隔絕自第二腔室204外側的壓力。
氣體分配系統206經配置以加壓第一腔室202。特定而言,氣體分配系統206可分配處理氣體至第一腔室202並在第一腔室中建立高壓,例如於至少10大氣壓的壓力,例如高於15 atm、高於20 atm、高於30 atm、上至50 atm、上至60 atm、上至70 atm、上至80 atm。處理氣體可例如在退火製程期間內與基板10(例如基板10上的層)反應,或作為要沈積到基板上的材料的來源。
在一些實施例中,氣體分配系統206包含第一氣體分配模組242以分配第一氣體至第一腔室202,以及第二氣體分配模組244以分配第一氣體或具有不同於第一氣體的成分的第二氣體至第一腔室202。第一氣體分配模組242經配置以於高壓(例如於10至80 bar的壓力)分配第一氣體至第一腔室202。相對的,第二氣體分配模組244經配置以於低壓(例如於少於1 bar)分配氣體。
分配模組242、244連接至設施供應,或連接至供應各別氣體的氣體槽。分配模組242、244由各自的遞送線252、254連接至第一腔室202。至第一氣體分配模組242的遞送線252可包含高壓隔離閥232,且至第二氣體分配模組244的遞送線254可包含低壓隔離閥234。
可於高於大氣壓力但相較於第一腔室中的最終壓力而言仍為相對低的壓力下,將第一氣體供應至第一氣體分配模組242。例如,可於40至80 psi(約2.7至5.4 atm)的壓力下,將第一氣體分配至第一氣體分配模組242。第一氣體分配模組242包含幫浦(例如增壓幫浦)。幫浦提升入送第一氣體(諸如(例如)氫氣)的壓力。幫浦可提升壓力約二至二十倍,在一些情況中高達80 atm。
可於高於大氣壓力但相較於第一腔室中的最終壓力而言仍為相對低的壓力下,將氣體供應至第二氣體分配模組244。例如,亦可於40至80 psi(約2.7至5.4 atm)的壓力下,將氣體分配至第二氣體分配模組244。然而,第二氣體分配模組244不需要包含幫浦。相對的,可使用習知的質量流量控制器、液體流量計或液體流量控制器,以將氣體引導至第一腔室202。
第一氣體分配模組242與第二氣體分配模組244可被包含在共同外殼246內。在一些實施例中,外殼246內部被與下面所論述的其他包封容器流體隔離。排氣系統248可用於對外殼246的內部抽氣。這可防止在氣體分配系統發生洩漏時,腐蝕性或爆炸性的氣體集聚在外殼內。在一些實施例中,包封組裝包含多個零件,每一零件為包含壓力的外殼,其圍繞並封裝相應的氣體分配模組。例如,第一氣體分配模組242可被封裝在第一外殼中,第二氣體分配模組244在外殼中。排氣系統248可被耦接至前級214,或被耦接至個別的真空系統。
第一氣體包含處理氣體,例如H 2、NH 3、O 2或O 3。在一些實施例中,第一氣體為實質上純淨的處理氣體。或者,第一氣體可包含處理氣體與惰性氣體(例如氬氣)兩者。
如前述,來自第二氣體分配模組244的氣體的成分可與第一氣體相同,或可為不同的第二氣體。第二氣體亦可為實質上純淨的處理氣體,或處理氣體與惰性氣體的結合。在一些實施例中,第二氣體包含水,例如第二氣體可為水蒸汽,諸如乾燥或過熱蒸汽。
高壓處理系統200包含前級214,前級214將第二腔室204連接至真空處理系統208。外側隔離閥216被沿著前級214設置,以將第二腔室204內的壓力隔離自真空處理系統208的壓力。外側隔離閥216可被操作以調整第二腔室204內的壓力,以及釋放第二腔室204內的氣體。外側隔離閥216可被結合真空處理系統208操作,以調節第二腔室204內的壓力。
真空處理系統208經配置以降低第二腔室204的壓力至幾乎真空的壓力,例如少於1毫托。特定而言,真空處理系統208可將第二腔室204內的壓力降至幾乎真空,從而產生適當的低壓環境以用於移送基板。在作業期間內,在第一腔室202中達到的超高壓力(例如高於10 atm、高於15 atm)需要第二腔室204中的相應較高壓力(低於約1 atm(例如約0.85 atm或640托))。
在一些實例中,真空處理系統208包含乾線幫浦。為了容許異常高的壓力(例如防止由洩漏所造成的高壓穿透乾線幫浦),氣體在抵達乾線幫浦之前被擴展。在一些實例中,氣體流過大直徑擴散器(例如20吋乘以5呎高的擴散器)。
氣體分配系統206包含排氣線211以從第一腔室202排出第一氣體,藉以將第一腔室202減壓。在一些實施例中,排氣線被耦接至排氣系統(例如前級214與真空處理系統208)或個別的真空系統來源。排氣線211可包含內側排氣隔離閥230,內側排氣隔離閥230可被關閉以將第一腔室202隔離自排氣系統。
為了提升安全性,處理系統200可包含包封組件。包封組件可包含至少一包封殼體260,包封殼體260在遞送線252、254進入要被流體連接至第一腔室202的第二腔室204處包圍遞送線252、254。此外,每一遞送線252、254可被包圍在各自的導管256、258中,導管256、258延伸於外殼246與包封殼體260之間。
包封組件亦可包含包封排氣線268。包封排氣線268包圍包封殼體260與排氣系統之間的排氣線211。包封排氣線268也將包封殼體260流體連接至排氣系統(例如至前級214與真空處理系統208)或個別的真空系統來源。因此,在遞送線252、254中(或來自遞送線與第二腔室204的接點)的任何洩漏,被抽吸通過包封殼體260並流至排氣系統。
遞送線252、254之每一線具有減壓線,減壓線在包封殼體260內具有減壓閥252a、254a。由減壓線釋放的任何積累在遞送線252、254內的壓力,將流入包封殼體260並從處理系統200移除(例如藉由包封排氣線268),或在一些實例中經由連接至排氣系統的個別排氣管道移除。
處理系統200亦包含將第一腔室202耦接至減壓閥276的減壓線。減壓閥276可被定位在第二腔室204中。在此情況中,若第一腔室202中的壓力超過可允許位準,則由減壓閥276釋放的氣體將流入第二腔室204且被透過前級214移除。或者,減壓閥276可被定位在包封殼體260中。在此情況中,由減壓閥276釋放的氣體將被透過排氣線211移除。
因此,所有加壓部件可被保持在包封組件內,使得處理系統200可處理非期望的洩漏、破裂或突破,而不用將加壓氣體暴露至大氣。
處理系統200中包含多個氣體感測器280。特定而言,氣體感測器280可為氫感測器。氣體感測器280被整合入可能的洩漏位置中,例如在包封殼體260內與包封排氣線268內。若任何氣體感測器280偵測到氣體洩漏(例如氫洩漏),則控制器210將偵測來自氣體感測器280的訊號,並將關閉氣體分配模組242、關閉第一氣體分配模組242內的幫浦、或採取其他適當的行動。回應於由一或更多個氣體感測器280偵測到的洩漏,遞送線252、254中的隔離閥亦可被關閉。
此外,處理系統200可包含一或更多個壓力感測器282。例如,第一腔室202中可有第一壓力感測器282,而第二腔室204中可有第二壓力感測器282。壓力感測器282耦接至控制器210。
第3圖圖示說明一種操作處理系統200以處理基板的方法。處理系統200開始於打開第一閥組件212、第二閥組件213。由機器人106或108通過開啟第一閥組件212、第二閥組件213與第二腔室204,將基板插入第一腔室202(於作業302)。控制器可操作機器人以將基板10載入第一腔室202,並將基板10放置到底座上。
第一與第二腔室202、204被真空系統抽氣至第一壓力(例如100至300毫托),且隨後在基板10的移送期間內維持在低壓(於作業304)。這可幫助防止基板10氧化。
第一閥組件212被關閉(於作業306)。可選的,亦可關閉第二閥組件213。
使用真空系統以進一步將第一腔室202抽氣至低於第一壓力的第二壓力,並將第二腔室抽氣至低於第二壓力的第三壓力(於作業308)。例如,第一與第二壓力兩者可為1至50毫托。第一壓力可為100至300毫托,且第二壓力可為1至50毫托。
第一與第二腔室202、204中的壓力被由壓力感測器282測量,且控制器可接收來自壓力感測器282的訊號。
若第一腔室202、第二腔室204任一者中的壓力超過洩漏臨限值,則此可指示氣體正從外部環境洩漏入腔室。在此情況中,可中止對基板的處理。
此外,控制器可比較測得的壓力(於作業310)。若第一腔室中的壓力P1與第二腔室中的壓力P2之間的差異未超過臨限值,則可繼續對腔室抽氣。
一旦第一腔室202、第二腔室204到達所需壓力,則關閉內側排氣隔離閥230並打開低壓隔離閥234(於作業312)。這將第一腔室202隔離自排氣系統,但將第一腔室202耦接至第二氣體分配模組244。
接著,第二氣體分配模組244將第一氣體或第二氣體分配至第一腔室202(於作業314)。這將第一腔室202中的壓力提升至高於第一壓力的第四壓力。第四壓力可高於大氣壓力,例如為40至80 psi的壓力。可使用常見的流速率控制(例如不需要壓力伺服控制演算法)來執行由第二氣體分配模組244分配氣體。
一旦第一腔室202已被升高至第四壓力,則關閉低壓隔離閥234並打開高壓隔離閥232(於作業316)。這將第一腔室202隔離自第二氣體分配模組244,例如以避免隨後作業中的高壓對第二氣體分配模組244造成傷害。這亦將第一腔室202耦接至第一氣體分配模組242。
接著第一氣體分配模組242將第一氣體分配至第一腔室202(於作業318)。這將第一腔室202中的壓力提升至高於第四壓力的第五壓力。如前述,第五壓力可為10至80大氣壓。第一氣體分配模組242的氣體分配,可由控制器210使用壓力伺服控制演算法來控制。
控制器可比較第一腔室202內的測得的壓力P1與所需的處理壓力PP(於作業320)。若第一腔室中的壓力P1小於所需處理壓力PP,則可繼續對第一腔室202加壓。
一旦第一腔室202已升至第五壓力,則關閉高壓隔離閥232(於作業322)。這使第一腔室202隔離自第一氣體分配模組242。
現在在第一腔室202中處理基板10(於作業324)。處理可持續一設定時間,例如由控制器中的定時器測量。第一氣體可為與基板10上的層反應的退火氣體。或者,氣體可包含要沈積到基板10上的材料。第一腔室202中的適當溫度與壓力條件,可使得材料退火或沈積發生。在處理期間內(例如退火或沈積),控制器可操作支座218中的一或更多個加熱元件219,以對基板10加熱,以協助處理基板10上的材料層。
在對基板10上材料層的處理完成時,關閉外側隔離閥216,並打開內側隔離閥230(於作業326)。這只將第一腔室202耦接至排氣系統,同時保持密封第二腔室204。
內側腔室被抽氣至第六壓力(於作業328)。第六壓力可小於第一壓力但大於第三壓力,例如約等於第二壓力。因此,壓力位於接近真空的壓力,使得第一腔室202與第二腔室204之間的壓力差為小的。
同樣的,控制器可比較所測得的壓力(於作業330)。若第一腔室中的壓力P1與第二腔室中的壓力P2之間的差異未超過臨限值,則可繼續對腔室抽氣。
一旦第一腔室202到達第六壓力,則打開第一閥組件212(於作業332)。此外,第二隔離閥若為關閉,則亦可將其打開。接著打開外側排氣隔離閥116。因為內側與外側排氣共享相同的前級,在內側排氣期間內保持關閉外側排氣隔離閥,可保護升舉銷和加熱器波紋管免受損壞。
最後,可使用機器人106或108將基板10從第一腔室202移除,且在需要時移送至隨後的處理腔室。
第6圖圖示說明受控制的高壓處理系統200',高壓處理系統200'創建高壓環境以處理基板,並在基板被移送於處理腔室之間時對基板創建低壓環境。處理系統200'可相同於處理系統200,除了第二氣體分配模組244'為可在高壓下(例如在10至80 bar的壓力下)將第二氣體分配至第一腔室202的高壓氣體分配模組之外。第二氣體為液體蒸汽,例如水蒸汽。遞送線254中的閥234'為第二高壓隔離閥。
第5圖圖示說明一種操作處理系統200或200'以處理基板的方法。此程序類似於參照第3圖所說明的程序,除了下面所論述的以外。
特定而言,操作處理系統200或200'的方法,在單一作業中而非在多個階段中在第一腔室202中供應氣體以到達高壓。因此,可僅使用處理系統200的第一氣體分配模組242、或僅使用處理系統200'的第一氣體分配模組242、或僅使用處理系統200'的第二氣體分配模組244'、或使用處理系統200'的第一氣體分配模組242與第二氣體分配模組244'兩者但操作第二氣體分配模組244'以模擬第一氣體分配模組242(例如同時開關氣體分配模組的隔離閥等等),來執行此程序。
特定而言,關閉內側排氣隔離閥230(於作業312'),並打開高壓隔離閥232及(或)234'(於作業316')。第一氣體分配模組242及(或)第二氣體分配模組244',將第一氣體及(或)第二氣體分配至第一腔室202(於作業318')。這將第一腔室202中的壓力從第二壓力提升至第五壓力。如前述,第五壓力可為10至80大氣壓。第一氣體分配模組242的氣體分配,可由控制器210使用壓力伺服控制演算法來控制。
分配至第一腔室202的氣體可包含H 2或NH 3,例如若僅使用處理系統200的第一氣體分配模組242或僅使用處理系統200'的第一氣體分配模組242。或者,分配至第一腔室202的氣體可包含液體蒸汽(例如水蒸汽),例如若僅使用處理系統200'的第二氣體分配模組244'。或者,分配至第一腔室202的氣體可包含水蒸汽與另一處理氣體的混合物,例如若使用處理系統200'的第一氣體分配模組242與第二氣體分配模組244'兩者。
第4圖圖示說明高壓處理系統200(或200')中第一腔室202與第二腔室204的可能配置。高壓處理系統200進一步包含第一腔室202與第二腔室204之間的第一閥組件212。此實施例可讓第二腔室204作為移送腔室的部分(例如在均等壓力中)。
第二腔室204可由內側壁420與外側壁424之間的容積來界定。此外,基板10可被支撐在(提供基板支座218的)底座418上。一或更多個元件219(例如電阻式加熱器)可被嵌入底座418。基板可直接位於底座418上,或位於延伸穿過底座的升舉銷組件430上。
由臂425形成第一閥組件212,臂425可相對於第一腔室202的內側壁420與基座422移動。特定而言,第一閥組件212包含第一腔室202與第二腔室204之間的狹縫閥423。狹縫閥423包含狹縫423a與臂425。狹縫423a延伸穿過第一腔室402的內側壁420中之一者。臂425的垂直端425a定位在第一腔室202之外,同時臂425的水平端425b定位在第一腔室202內。臂425的垂直端425a可被定位在第二腔室204內,並由定位在第二腔室204內的致動器驅動。或者,臂425的垂直端425a被定位在第二腔室204外,並由也定位在第二腔室204外的致動器428驅動。
臂425延伸通過狹縫423a,並可被相對於內側壁420移動,使得臂425可被移動至與內側壁420形成密封的位置。致動器428被耦接至臂425的垂直端425a,並相對於內側壁420驅動臂425的水平端425b。臂425可垂直移動以覆蓋或露出狹縫423a。特定而言,臂425的垂直端425a可為凸緣(或包含凸緣),凸緣實質平行於內側壁420的鄰接內側表面而延伸。臂425亦可被橫向驅動,使得臂425的水平端425b可接合或脫開內側壁420。臂425亦可延伸通過外側壁424中的孔426。
第一閥組件212可在打開位置與關閉位置之間移動。在第一閥組件212位於打開位置時,臂425的水平端425b與內側壁420(例如內側壁420的內側表面)橫向間隔開。此外,臂425的水平端425b被垂直定位,以露出狹縫423a。狹縫423a因此提供開口以致能第一腔室202與第二腔室204之間的流體連通,並亦致能基板10被移入移出第一腔室202(例如藉由上文論述的機器人)。
在第一閥組件212位於關閉位置時,臂425的水平端425b覆蓋狹縫423a並接觸內側壁420之一者,藉以形成密封而將第一腔室202隔離自第二腔室204。在加壓時,凸緣或水平端425b接觸內側壁420界定第一腔室202的內側表面。沿著水平端425b的周圍在接觸內側壁420的表面上放置O形環,在第一腔室402被加壓時幫助加強包封的密封程度。
底座418中的加熱元件219加熱第一腔室202中的氣體(例如上至250°C)。為了防止O形環受傷害,臂425可包含內部氣體管道480。內部氣體管道480被從冷卻氣體供應484供應,並為讓冷卻氣體流過臂425的導管。內部氣體管道480可延伸通過水平端425b,或通過水平端425b與垂直端425a兩者。內部氣體管道與冷卻氣體供應484可經配置,使得在第一閥組件212位於打開位置時,沒有氣體從冷卻氣體供應484提供,而在移送基板時防止冷卻氣體流入。
已說明了本發明的數個具體實施例。然而應瞭解到,可進行各種修改,而不脫離本發明的精神與範圍。例如,儘管上文說明由鈷或鎳薄膜層形成金屬矽化物層,但在一些實施例中可使用其他材料。例如,其他材料可包括鈦、鉭、鎢、鉬、鉑、鐵、鈮、鈀及其組合,以及其他合金,包括鎳鈷合金、鈷鎢合金、鈷鎳鎢合金、摻雜的鈷和鎳合金、或鎳鐵合金,以形成如本文所述的金屬矽化物材料。
儘管上文是在退火或沈積系統的背景內容中進行說明,但取決於所提供的氣體,高壓腔室可用於蝕刻系統。或者,高壓腔室可被填充惰性氣體,且高壓腔室可被單純用於在高壓下進行熱處理。本文所說明的處理平臺可包含其他類型的處理腔室。例如,處理平臺可包含蝕刻腔室,以將圖樣蝕刻到基板表面上。
處理平臺的不同的腔室中之每一者,可具有不同的壓力環境,範圍從接近真空到多於50個大氣壓。腔室之間的隔離閥(例如真空閥),可隔離彼此的壓力,使得每一腔室內可維持這些不同的壓力環境。
因此,存在位於下列申請專利範圍的範圍內的其他具體實施例。
10:基板 100:處理平臺 102:腔室 104:腔室 106:機器人 107:機械臂 108:機器人 109:機械臂 110:處理腔室 112:處理腔室 114:鄰接處理腔室 116:鄰接處理腔室 118:預清洗腔室 120:穿越腔室 122:控制器 124:去氣腔室 128:裝載閘腔室 130:處理腔室 132:工廠介面模組 200:高壓處理系統 202:高壓內側第一腔室 204:低壓外側第二腔室 206:氣體分配系統 208:真空處理系統 210:控制器 211:排氣線 212:第一閥組件 213:第二閥組件 214:前級 216:外側隔離閥 218:基板支座 219:加熱元件 230:內側排氣隔離閥 232:高壓隔離閥 234:低壓隔離閥 242:分配模組 244:分配模組 246:外殼 248:排氣系統 252:遞送線 252a:減壓閥 254:遞送線 254a:減壓閥 256:導管 258:導管 260:包封殼體 268:包封排氣線 276:減壓閥 280:氣體感測器 282:壓力感測器 288:氣體感測器 300:系統 302:作業 304:作業 306:作業 308:作業 310:作業 311:排氣系統 312:作業 312:作業 314:作業 316:作業 318:作業 320:作業 322:作業 324:作業 326:作業 328:作業 330:作業 352:遞送線 354:遞送線 356:遞送線 360:包封殼體 368:包封排氣線 369:排氣管道 372:幫浦 402:第一腔室 418:底座 420:內側壁 422:基座 423:狹縫閥 423a:狹縫 424:外側壁 425:臂 425a:垂直端 425b:水平端 426:孔 428:致動器 430:升舉銷組件 480:內部氣體管道 484:冷卻氣體供應
第1圖為處理平臺的示意圖。
第2圖為具有增強安全特徵的高壓處理系統的示意圖。
第3圖為圖示說明用於操作高壓處理系統的方法的流程圖。
第4圖為具有增強安全特徵的高壓處理系統的另一實施例的示意圖。
第5圖為圖示說明用於操作高壓處理系統的方法的流程圖。
第6圖為用於高壓處理系統的腔室的示意側視圖。
在各種圖式中,類似的元件符號指示類似的元件。
國內寄存資訊 (請依寄存機構、日期、號碼順序註記) 無
國外寄存資訊 (請依寄存國家、機構、日期、號碼順序註記) 無
10:基板
100:處理平臺
102:腔室
104:腔室
106:機器人
107:機械臂
108:機器人
109:機械臂
110:處理腔室
112:處理腔室
114:鄰接處理腔室
116:鄰接處理腔室
118:預清洗腔室
120:穿越腔室
122:控制器
124:去氣腔室
128:裝載閘腔室
130:處理腔室
132:工廠介面模組

Claims (20)

  1. 一種高壓處理系統,用於處理一基板上的一層,該高壓處理系統包含:一第一腔室;一第二腔室,該第二腔室鄰接該第一腔室;一閥組件,該閥組件在該第一腔室與該第二腔室之間,該閥組件經配置以將該第一腔室隔離自該第二腔室;一氣體分配系統,該氣體分配系統經配置以:在該第一腔室被保持與該第二腔室隔離的情況下,將該第一腔室加壓至一第一壓力,該第一壓力至少為約10大氣壓;以及在該第一腔室被保持與該第二腔室隔離的情況下,將該第一腔室減壓至一第二壓力,該第二壓力在大於約1大氣壓且小於該第一壓力的一範圍內;以及第一與第二遞送線,該等第一與第二遞送線將該氣體分配系統耦接至該第一腔室。
  2. 如請求項1所述之高壓處理系統,其中該第一遞送線與該第二遞送線進入該第二腔室的一第一側並流體連接至該第一腔室。
  3. 如請求項2所述之高壓處理系統,該高壓處理系統進一步包含: 一前級,該前級經配置以從該第二腔室移除氣體,該前級連接至該第二腔室的與該第一側相對的一第二側。
  4. 如請求項3所述之高壓處理系統,該高壓處理系統進一步包含:一第一排氣系統,該第一排氣系統包含一排氣線,且該第一排氣系統經配置以從該第一腔室移除氣體,其中該排氣線經由該第二腔室的該第一側連接至該第一腔室。
  5. 如請求項4所述之高壓處理系統,其中該氣體分配系統包含一第一氣體分配模組與一第二氣體分配模組,且其中該高壓處理系統進一步包含:一共同外殼,該共同外殼圍繞該第一氣體分配模組與該第二氣體分配模組;以及一第二排氣系統,該第二排氣系統經配置以將氣體從該共同外殼引導至該前級。
  6. 如請求項5所述之高壓處理系統,該高壓處理系統進一步包含一包封殼體,該包封殼體經配置以將從該等第一與第二遞送線洩漏的氣體轉向至該前級。
  7. 如請求項1所述之高壓處理系統,該高壓處理系統進一步包含: 一控制器,該控制器經配置以:操作該閥組件以使該第一腔室隔離自該第二腔室;操作該氣體分配系統以將該第一腔室加壓至該第一壓力;以及操作該氣體分配系統以將該第二腔室加壓至該第二壓力。
  8. 如請求項7所述之高壓處理系統,其中該控制器進一步經配置以:使一排氣系統在該第一腔室中產生一第三壓力,該第三壓力小於該第一壓力;使一真空處理系統在該第二腔室中產生一第四壓力,該第四壓力小於該第二壓力;比較來自該第一腔室中的一第一壓力感測器與該第二腔室中的一第二壓力感測器;以及控制該排氣系統與該真空處理系統以維持該第三壓力大於該第四壓力。
  9. 如請求項1所述之高壓處理系統,其中該氣體分配系統進一步經配置以:遞送一第一氣體進入該第一腔室;和遞送一第二氣體進入該第二腔室。
  10. 如請求項9所述之高壓處理系統,其中該氣體分配系統包含一幫浦,該幫浦經配置以在將該第 一氣體分配至該第一腔室之前,提升該第一氣體的壓力。
  11. 一種操作一高壓處理系統的方法,該方法包含以下步驟:使一第一腔室與一第二腔室具有一第一壓力,該第一壓力小於1大氣壓;在一隔離閥為關閉的同時,將該第一腔室從該第一壓力減少至一第二壓力,並將該第二腔室從該第一壓力減少至一第三壓力;由一氣體分配系統將該第一腔室加壓至一第四壓力,該第四壓力高於大氣壓力並小於10大氣壓;由該氣體分配系統將該第一腔室加壓至一第五壓力,該第五壓力大於10大氣壓;以及在該第一腔室處於該第五壓力的同時處理一基板。
  12. 如請求項11所述之方法,該方法包含以下步驟:在位於該第一腔室與該第二腔室之間的該隔離閥為開啟的同時,將該基板從該第二腔室運輸到該第一腔室中;回應於完成該基板的該處理而將該第一腔室排氣;以及回應於排氣該第一腔室而開啟該隔離閥並將該基板 從該第一腔室移除。
  13. 如請求項12所述之方法,其中將該第一腔室排氣之步驟包含以下步驟:將該第一腔室中的一壓力降低至一第六壓力,該第六壓力小於該第一壓力。
  14. 如請求項13所述之方法,其中該第六壓力大於該第三壓力。
  15. 如請求項11所述之方法,其中將該第一腔室加壓至該第五壓力之步驟包含以下步驟:供應一第一氣體至該第一腔室,且其中加壓該第一腔室至該第四壓力之步驟包含以下步驟:供應具有不同成分的一第二氣體至該第一腔室。
  16. 如請求項15所述之方法,其中該第一氣體包含H2或NH3中的至少一個。
  17. 如請求項11所述之方法,其中將該第一腔室加壓至該第四壓力之步驟包含以下步驟:使該氣體分配系統的一第一氣體分配模組隔離自該第一腔室;和使該氣體分配系統的一第二氣體分配模組流體耦接至該第一腔室。
  18. 如請求項17所述之方法,其中將該第一腔室加壓至該第五壓力之步驟包含以下步驟:使該第二氣體分配模組隔離自該第一腔室;和 使該第二氣體分配模組流體耦接至該第一腔室。
  19. 如請求項11所述之方法,其中該第三壓力小於該第二壓力。
  20. 如請求項11所述之方法,該方法進一步包含以下步驟:比較來自該第一腔室中的一第一壓力感測器以及來自該第二腔室中的一第二壓力感測器的測量結果;以及基於該等測量結果的該比較,控制該第一腔室中的一壓力與該第二腔室中的一壓力。
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