US20210159052A1 - Processing Chamber With Multiple Plasma Units - Google Patents
Processing Chamber With Multiple Plasma Units Download PDFInfo
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- US20210159052A1 US20210159052A1 US17/101,074 US202017101074A US2021159052A1 US 20210159052 A1 US20210159052 A1 US 20210159052A1 US 202017101074 A US202017101074 A US 202017101074A US 2021159052 A1 US2021159052 A1 US 2021159052A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J37/00—Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
- H01J37/32—Gas-filled discharge tubes
- H01J37/32009—Arrangements for generation of plasma specially adapted for examination or treatment of objects, e.g. plasma sources
- H01J37/32422—Arrangement for selecting ions or species in the plasma
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- C—CHEMISTRY; METALLURGY
- C23—COATING 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
- C23C—COATING 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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/448—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for generating reactive gas streams, e.g. by evaporation or sublimation of precursor materials
- C23C16/452—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for generating reactive gas streams, e.g. by evaporation or sublimation of precursor materials by activating reactive gas streams before their introduction into the reaction chamber, e.g. by ionisation or addition of reactive species
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- C—CHEMISTRY; METALLURGY
- C23—COATING 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
- C23C—COATING 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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/455—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
- C23C16/45523—Pulsed gas flow or change of composition over time
- C23C16/45525—Atomic layer deposition [ALD]
- C23C16/45527—Atomic layer deposition [ALD] characterized by the ALD cycle, e.g. different flows or temperatures during half-reactions, unusual pulsing sequence, use of precursor mixtures or auxiliary reactants or activations
- C23C16/45536—Use of plasma, radiation or electromagnetic fields
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- C—CHEMISTRY; METALLURGY
- C23—COATING 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
- C23C—COATING 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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/50—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges
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- C—CHEMISTRY; METALLURGY
- C23—COATING 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
- C23C—COATING 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
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/50—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges
- C23C16/505—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges using radio frequency discharges
- C23C16/509—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating using electric discharges using radio frequency discharges using internal electrodes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J37/00—Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
- H01J37/32—Gas-filled discharge tubes
- H01J37/32009—Arrangements for generation of plasma specially adapted for examination or treatment of objects, e.g. plasma sources
- H01J37/32357—Generation remote from the workpiece, e.g. down-stream
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
- H01L21/67005—Apparatus not specifically provided for elsewhere
- H01L21/67011—Apparatus for manufacture or treatment
- H01L21/67017—Apparatus for fluid treatment
- H01L21/67028—Apparatus for fluid treatment for cleaning followed by drying, rinsing, stripping, blasting or the like
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
- H01L21/67005—Apparatus not specifically provided for elsewhere
- H01L21/67011—Apparatus for manufacture or treatment
- H01L21/67017—Apparatus for fluid treatment
- H01L21/67063—Apparatus for fluid treatment for etching
- H01L21/67069—Apparatus for fluid treatment for etching for drying etching
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- H05H1/00—Generating plasma; Handling plasma
- H05H1/24—Generating plasma
- H05H1/46—Generating plasma using applied electromagnetic fields, e.g. high frequency or microwave energy
- H05H1/4645—Radiofrequency discharges
- H05H1/4652—Radiofrequency discharges using inductive coupling means, e.g. coils
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J2237/00—Discharge tubes exposing object to beam, e.g. for analysis treatment, etching, imaging
- H01J2237/32—Processing objects by plasma generation
- H01J2237/327—Arrangements for generating the plasma
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J2237/00—Discharge tubes exposing object to beam, e.g. for analysis treatment, etching, imaging
- H01J2237/32—Processing objects by plasma generation
- H01J2237/33—Processing objects by plasma generation characterised by the type of processing
- H01J2237/332—Coating
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J2237/00—Discharge tubes exposing object to beam, e.g. for analysis treatment, etching, imaging
- H01J2237/32—Processing objects by plasma generation
- H01J2237/33—Processing objects by plasma generation characterised by the type of processing
- H01J2237/335—Cleaning
Definitions
- Embodiments of the disclosure generally relate to semiconductor processes and apparatus. More particularly, embodiments relate to processing apparatus and processes that include both remote and direct plasma units.
- Integrated circuits are made possible by processes which produce patterned material layers on a substrate.
- Producing patterned material on a substrate requires controlled methods for removal of exposed material.
- Chemical etching is used for a variety of purposes, including transferring a pattern in photoresist into underlying layers, thinning layers, or thinning lateral dimensions of features already present on the surface. Sometimes it is necessary to have an etch process that etches one material faster than another facilitating, for example, a pattern transfer process.
- Incoming substrates often have residue on them from previous processing, from native oxide formation on a metal, and etch residue from via hole formation.
- any residue and/or native oxide must be removed.
- Remote plasma and direct plasma alone, are incapable of removing the residue and native oxide inside the structure effectively. Remote plasma radicals do not reach the structure trench well due to its lifetime, and direct plasma does not clear the side walls of a structure due to the directionality.
- a processing chamber comprises: a lid and at least one sidewall defining an internal volume; a remote plasma unit in the internal volume; a direct plasma unit in the internal volume; and at least one electrode, wherein one of the remote plasma unit or the direct plasma unit generates a remote plasma and the other of the remote plasma unit or the direct plasma unit generates a direct plasma.
- a processing method comprises: exposing a substrate to a remote plasma and exposing a substrate to a direct plasma.
- a non-transitory computer readable medium including instructions, that, when executed by a controller of a processing chamber, causes the processing chamber to perform operations of: exposing a substrate to a remote plasma; and exposing the substrate to a direct plasma.
- FIG. 1A illustrates a process flow diagram for a method according to one or more embodiments
- FIG. 1B illustrates a process flow diagram for a method according to one or more embodiments
- FIG. 2 illustrates schematic diagram of a processing tool according to one or more embodiments
- FIG. 3 illustrates schematic diagram of a processing tool according to one or more embodiments.
- substrate and “wafer” are used interchangeably, both referring to a surface, or portion of a surface, upon which a process acts. It will also be understood by those skilled in the art that reference to a substrate can also refer to only a portion of the substrate, unless the context clearly indicates otherwise. Additionally, reference to depositing on a substrate can mean both a bare substrate and a substrate with one or more films or features deposited or formed thereon.
- a “substrate” as used herein, refers to any substrate or material surface formed on a substrate upon which film processing is performed during a fabrication process.
- a substrate surface on which processing can be performed include materials such as silicon, silicon oxide, silicon nitride, strained silicon, silicon on insulator (SOI), carbon doped silicon oxides, amorphous silicon, doped silicon, germanium, gallium arsenide, glass, sapphire, and any other materials such as metals, metal nitrides, metal alloys, and other conductive materials, depending on the application.
- Substrates include, without limitation, semiconductor wafers.
- Substrates may be exposed to a pretreatment process to polish, etch, reduce, oxidize, hydroxylate, anneal, UV cure, e-beam cure and/or bake the substrate surface.
- any of the film processing steps disclosed may also be performed on an underlayer formed on the substrate as disclosed in more detail below, and the term “substrate surface” is intended to include such underlayer as the context indicates.
- the exposed surface of the newly deposited film/layer becomes the substrate surface.
- a processing chamber is configured to contain a semiconductor substrate in a processing region of the chamber.
- the processing chamber includes a remote plasma unit and a direct plasma unit, wherein one of the remote plasma unit or the direct plasma unit generates a remote plasma and the other of the remote plasma unit or the direct plasma unit generates a direct plasma.
- the combination of a remote plasma unit and a direct plasma unit is used to remove, treat, residue on a substrate from previous processing and/or from native oxide formation.
- FIG. 1A illustrates a process flow diagram of a method 100 according to one or more embodiments.
- a substrate is optionally placed into a processing chamber.
- a substrate is exposed to a remote plasma.
- the substrate is exposed to a direct plasma.
- exposing the substrate to the remote plasma and exposing the substrate to a direct plasma occurs sequentially.
- the substrate is first exposed to the remote plasma and is thereafter is exposed to the direct plasma.
- exposing the substrate to the remote plasma and exposing the substrate to a direct plasma occurs simultaneously.
- FIG. 1B illustrates a process flow diagram of a method 100 according to one or more embodiments.
- a substrate is optionally placed into a processing chamber.
- a substrate is exposed to a direct plasma.
- the substrate is exposed to a remote plasma.
- exposing the substrate to the direct plasma and exposing the substrate to a remote plasma occurs sequentially.
- the substrate is first exposed to the direct plasma and is thereafter exposed to the remote plasma.
- exposing the substrate to the direct plasma and exposing the substrate to a remote plasma occurs simultaneously.
- exposing the substrate to the remote plasma and exposing the substrate to a direct plasma treats or cleans the substrate.
- the substrate comprises at least one feature.
- the at least one feature may comprise any feature known to the skilled artisan, including, but not limited to a trench, a via, or a peak.
- the treating or cleaning removes one or more of a residue, e.g. from prior processing, and/or a native oxide.
- the treating or cleaning removes one or more of a residue, e.g. from prior processing, and/or a native oxide.
- the method further comprises exposing the substrate to at least one precursor to deposit a film on the substrate vis a vis a plasma enhanced chemical vapor deposition (PECVD) process or a plasma enhanced atomic layer deposition process (PEALD). Any appropriate precursor known to the skill artisan may be used to form a film on the substrate.
- PECVD plasma enhanced chemical vapor deposition
- PEALD plasma enhanced atomic layer deposition process
- FIG. 2 illustrates a processing tool 200 according to one or more embodiments.
- the processing tool 200 comprising a processing chamber 201 .
- the processing chamber comprises a lid 202 and at least one side wall 204 .
- the lid 202 and the at least one sidewall 204 define an internal volume 205 of the processing chamber 201 .
- the processing tool 200 comprises a remote plasma unit 206 within the internal volume 205 of the processing chamber 201 .
- a direct plasma unit 208 is within the internal volume 205 of the processing chamber 201 .
- one of the remote plasma unit 206 generates a remote plasma and the direct plasma unit 208 generates a direct plasma.
- the generation of the remote plasma and the generation of the direct plasma occurs sequentially. In some embodiments, the generation of the remote plasma occurs first, and the generation of the direct plasma occurs thereafter. In other embodiments, the generation of the direct plasma occurs first and the generation of the remote plasma occurs thereafter. In one or more embodiments, the generation of the remote plasma and the generation of the direct plasma occurs simultaneously.
- an ion filter 212 separates the remote plasma unit 206 and the direct plasma unit 208 .
- the ion filter 212 is used to filter ions from the plasma effluents during transit from the remote plasma unit 206 to the substrate processing region 215 .
- the ion filter 212 functions to reduce or eliminate ionically charged species traveling from the remote plasma unit 206 to the substrate 230 .
- uncharged neutral and radical species may pass through at least one aperture 218 in the ion filter 212 to react at the substrate 230 . It should be noted that complete elimination of ionically charged species in the reaction region 215 surrounding the substrate 230 is not always the desired goal.
- ionic species are required to reach the substrate 230 in order to perform etch and/or deposition processes.
- the ion filter 212 helps control the concentration of ionic species in the reaction region 215 at a level that assists the treat/clean and/or deposition process.
- the processing tool comprises at least one electrode within the processing chamber. In one or more embodiments, the at least one electrode is located within the internal volume 205 of the processing chamber 201 . In the embodiment illustrated in FIG. 2 , at least one electrode 210 is positioned in electrical communication with the remote plasma unit 206 .
- the processing chamber 201 comprises a pedestal 214 .
- the pedestal 214 is configured to support a semiconductor substrate 230 in a processing region 215 .
- the pedestal 214 may have a heat exchange channel (not illustrated) through which a heat exchange fluid flows to control the temperature of the substrate 230 .
- the substrate 230 temperature can be cooled or heated to maintain relatively low temperatures, such as from about ⁇ 20° C. to about 400° C.
- the heat exchange fluid comprises one or more of ethylene glycol or water.
- the pedestal 214 is resistively heated in order to achieve relatively high temperatures, such as from about 100° C.
- the pedestal 214 is configured to rotate.
- the pedestal 214 comprises an electrode 216 within the interior of the pedestal 214 , and the pedestal 214 is powered by RF generator 250 and matched by RF match 240 .
- the pedestal 214 is comprised of a metallic material and is, itself, an electrode.
- At least one power source, e.g. RF generator, 250 is electrically connected via a first RF match 240 and a second RF match 245 to the processing chamber 201 .
- two RF generators 250 are electrically connected to the processing chamber 201 .
- a first RF generator 250 is electrically connected to a pedestal electrode 216
- a second RF generator 255 is electrically connected to a top electrode 210 .
- a plasma is generated using a radio frequency (RF) powered remote plasma unit 206 and/or direct plasma unit 208 .
- RF radio frequency
- AC alternating current
- the RF amplifier operates at a reference frequency (13.56 MHz, for example), drives current through an output-matching network, and then through a power measurement circuit to the output of the power supply.
- the output match is usually designed to be connected a generator that is optimized to drive particular impedance, such as, for example, 50 ohms, in order to have the same characteristic impedance as the coaxial cables commonly used in the industry. Power flows through the matched cable sections, is measured by the match controller, and is transformed through the load match.
- the load match is usually a motorized automatic tuner, so the load match operation incurs a predetermined time delay before the system is properly configured.
- power is then channeled into a plasma excitation circuit that drives two electrodes in an evacuated processing chamber.
- a processing gas is introduced into the evacuated processing chamber, and when driven by the circuit, plasma is generated. Since the matching network or the load match is motorized, the response time from the matching network is typically on the order of one second or more.
- the plasma power is in a range of from about 10 W to about 1000 W, including from about 200 W to about 600 W. In some embodiments, the plasma power is less than or equal to about 1000 W, or less than or equal to about 6500 W.
- the plasma frequency may be any suitable frequency.
- the plasma has a frequency in a range of about 200 kHz to 30 MHz.
- the plasma frequency is less than or equal to about 20 MHz, less than or equal to about 10 MHz, less than or equal to about 5 MHz, less than or equal to about 1000 kHz, or less than or equal to about 500 kHz.
- the plasma frequency is greater than or equal to about 210 kHz, greater than or equal to about 250 kHz, greater than or equal to about 600 kHz, greater than or equal to about 750 MHz, greater than or equal to about 1200 kHz, greater than or equal to about 2 MHz, greater than or equal to about 4 MHz, greater than or equal to about 7 MHz, greater than or equal to about 12 MHz, greater than or equal to about 15 MHz, or greater than or equal to about 25 MHz.
- the plasma has a frequency of about 13.56 MHz, or about 350 kHz, or about 400 kHz, or about 27 MHz, or about 40 MHz, or about 60 MHz.
- a controller 220 may be provided and coupled to various components of the processing tool 200 to control the operation thereof.
- the controller 220 can be a single controller that controls the entire processing tool 200 , or multiple controllers that control individual portions of the processing tool 200 .
- the processing tool 200 may include separate controllers for each of the processing chamber 202 , remote plasma unit 206 , direct plasma unit 208 , and power source 250 .
- the processing chamber 201 further comprises a controller 220 .
- the controller 220 controls the ignition of the plasma by the remote plasma unit 206 and/or the direct plasma unit 208 within the processing chamber 201 .
- the controller 220 includes a central processing unit (CPU) 222 , a memory 224 , inputs/outputs (I/O) 226 , and support circuits 228 .
- the controller 220 may control the processing tool 200 directly, or via computers (or controllers) associated with particular process chamber and/or support system components.
- the controller 220 may be one of any form of general-purpose computer processor that can be used in an industrial setting for controlling various chambers and sub-processors.
- the memory 224 or computer readable medium of the controller 220 may be one or more of readily available memory such as non-transitory memory (e.g. random access memory (RAM)), read only memory (ROM), floppy disk, hard disk, optical storage media (e.g., compact disc or digital video disc), flash drive, or any other form of digital storage, local or remote.
- RAM random access memory
- ROM read only memory
- floppy disk e.g., hard disk
- optical storage media e.g., compact disc or digital video disc
- flash drive e.g., compact disc or digital video disc
- the support circuits 228 are coupled to the CPU 222 for supporting the processor in a conventional manner. These circuits include cache, power supplies, clock circuits, input/output circuitry and subsystems, and the like.
- One or more processes may be stored in the memory 224 as software routine that, when executed or invoked by the processor, causes the processor to control the operation of the processing tool 200 or individual processing units (e.g. remote plasma unit 206 and direct plasma unit 208 ) in the manner described herein.
- the software routine may also be stored and/or executed by a second CPU (not shown) that is remotely located from the hardware being controlled by the CPU 222 .
- Some or all of the processes and methods of the present disclosure may also be performed in hardware.
- the process may be implemented in software and executed using a computer system, in hardware as, e.g., an application specific integrated circuit or other type of hardware implementation, or as a combination of software and hardware.
- the software routine when executed by the processor, transforms the general purpose computer into a specific purpose computer (controller) that controls the chamber operation such that the processes are performed.
- the controller 220 has one or more configurations to execute individual processes or sub-processes to perform the method.
- the controller 220 can be connected to and configured to operate intermediate components to perform the functions of the methods.
- the controller 220 can be connected to and configured to control one or more of the remote plasma unit 206 , the direct plasma unit 208 , the pedestal 214 , the at least one electrode, or other components.
- FIG. 3 illustrates a processing tool 300 according to one or more embodiments.
- the processing tool 300 comprises a processing chamber 301 .
- the processing chamber comprises a lid 302 and at least one side wall 304 .
- the lid 302 and the at least one sidewall 304 define an internal volume 305 of the processing chamber 301 .
- the processing tool 300 comprises a remote plasma unit 306 within the internal volume 305 of the processing chamber 301 .
- a direct plasma unit 308 is within the internal volume 305 of the processing chamber 301 .
- one of the remote plasma unit 306 generates a remote plasma and the direct plasma unit 308 generates a direct plasma.
- the generation of the remote plasma and the generation of the direct plasma occurs sequentially. In some embodiments, the generation of the remote plasma occurs first, and the generation of the direct plasma occurs thereafter. In other embodiments, the generation of the direct plasma occurs first and the generation of the remote plasma occurs thereafter. In one or more embodiments, the generation of the remote plasma and the generation of the direct plasma occur simultaneously.
- an ion filter 312 separates the remote plasma unit 306 and the direct plasma unit 308 .
- the ion filter 312 is used to filter ions from the plasma effluents during transit from the remote plasma unit 306 to the substrate processing region 315 .
- the ion filter 312 functions to reduce or eliminate ionically charged species traveling from the remote plasma unit 306 to the substrate 330 .
- uncharged neutral and radical species may pass through at least one aperture 318 in the ion filter 312 to react at the substrate 330 . It should be noted that complete elimination of ionically charged species in the reaction region 315 surrounding the substrate 330 is not always the desired goal.
- ionic species are required to reach the substrate 330 in order to perform etch and/or deposition processes.
- the ion filter 312 helps control the concentration of ionic species in the reaction region 315 at a level that assists the treat/clean and/or deposition process.
- the ion filter 312 comprises a showerhead.
- the processing tool comprises at least one electrode within the processing chamber.
- the at least one electrode is located within the internal volume 305 of the processing chamber 301 .
- at least one electrode 316 is positioned in electrical communication with the pedestal 314 .
- the processing chamber 301 comprises a pedestal 314 .
- the pedestal 314 is configured to support a semiconductor substrate 330 in a processing region 315 .
- the pedestal 314 may have a heat exchange channel (not illustrated) through which a heat exchange fluid flows to control the temperature of the substrate 330 .
- the substrate 330 temperature can be cooled or heated to maintain relatively low temperatures, such as from about ⁇ 20° C. to about 400° C., or from about 0° C. to about 400° C.
- the heat exchange fluid comprises one or more of ethylene glycol or water.
- the pedestal 314 is resistively heated in order to achieve relatively high temperatures, such as from about 100° C. to about 1100° C., or from about 200° C. to about 750° C., through the use of an embedded resistive heater element (not illustrated).
- the pedestal 314 is configured to rotate.
- the pedestal 314 comprises an electrode 316 within the interior of the pedestal 314 , and the pedestal 314 is powered by RF generator 350 and matched by RF match 340 .
- the pedestal 314 is comprised of a metallic material and is, itself, an electrode.
- At least one power source, e.g. RF generator, 350 is electrically connected via an RF match 340 to the processing chamber 301 .
- two RF generators are electrically connected to the processing chamber 301 .
- a first RF generator 350 is electrically connected to a pedestal electrode 316
- a second RF generator 355 is electrically connected to an inductively coupled plasma (ICP) coil 370 .
- ICP inductively coupled plasma
- a plasma is generated using a radio frequency (RF) powered remote plasma unit 306 and direct plasma unit 308 .
- RF radio frequency
- AC alternating current
- the RF amplifier operates at a reference frequency (13.56 MHz, for example), drives current through an output-matching network, and then through a power measurement circuit to the output of the power supply.
- the output match is usually designed to be connected a generator that is optimized to drive particular impedance, such as, for example, 50 ohms, in order to have the same characteristic impedance as the coaxial cables commonly used in the industry. Power flows through the matched cable sections, is measured by the match controller, and is transformed through the load match.
- the load match is usually a motorized automatic tuner, so the load match operation incurs a predetermined time delay before the system is properly configured.
- power is then channeled into a plasma excitation circuit that drives two electrodes in an evacuated processing chamber.
- a processing gas is introduced into the evacuated processing chamber, and when driven by the circuit, plasma is generated. Since the matching network or the load match is motorized, the response time from the matching network is typically on the order of one second or more.
- the plasma power is in a range of about 10 W to about 1000 W, including from about 200 W to about 600 W. In some embodiments, the plasma power is less than or equal to about 1000 W, or less than or equal to about 6500 W.
- the plasma frequency may be any suitable frequency.
- the plasma has a frequency in a range of about 200 kHz to 30 MHz.
- the plasma frequency is less than or equal to about 20 MHz, less than or equal to about 10 MHz, less than or equal to about 5 MHz, less than or equal to about 1000 kHz, or less than or equal to about 500 kHz.
- the plasma frequency is greater than or equal to about 210 kHz, greater than or equal to about 250 kHz, greater than or equal to about 600 kHz, greater than or equal to about 750 MHz, greater than or equal to about 1200 kHz, greater than or equal to about 2 MHz, greater than or equal to about 4 MHz, greater than or equal to about 7 MHz, greater than or equal to about 12 MHz, greater than or equal to about 15 MHz, or greater than or equal to about 25 MHz.
- the plasma has a frequency of about 13.56 MHz, or about 350 kHz, or about 400 kHz, or about 27 MHz, or about 40 MHz, or about 60 MHz.
- a controller 320 may be provided and coupled to various components of the processing tool 300 to control the operation thereof.
- the controller 320 can be a single controller that controls the entire processing tool 300 , or multiple controllers that control individual portions of the processing tool 300 .
- the processing tool 300 may include separate controllers for each of the processing chamber 301 , remote plasma unit 306 , direct plasma unit 308 , and power source 350 .
- the processing chamber 301 further comprises a controller 320 .
- the controller 320 controls the ignition of the plasma by the remote plasma unit 306 and/or the direct plasma unit 308 within the processing chamber 301 .
- the controller 320 includes a central processing unit (CPU) 322 , a memory 324 , inputs/outputs (I/O) 326 , and support circuits 328 .
- the controller 320 may control the processing tool 300 directly, or via computers (or controllers) associated with particular process chamber and/or support system components.
- the controller 320 may be one of any form of general-purpose computer processor that can be used in an industrial setting for controlling various chambers and sub-processors.
- the memory 324 or computer readable medium of the controller 320 may be one or more of readily available memory such as non-transitory memory (e.g. random access memory (RAM)), read only memory (ROM), floppy disk, hard disk, optical storage media (e.g., compact disc or digital video disc), flash drive, or any other form of digital storage, local or remote.
- RAM random access memory
- ROM read only memory
- floppy disk e.g., hard disk
- optical storage media e.g., compact disc or digital video disc
- flash drive e.g., compact disc or digital video disc
- the support circuits 328 are coupled to the CPU 322 for supporting the processor in a conventional manner. These circuits include cache, power supplies, clock circuits, input/output circuitry and subsystems, and the like.
- One or more processes may be stored in the memory 324 as software routine that, when executed or invoked by the processor, causes the processor to control the operation of the processing tool 300 or individual processing units (e.g. remote plasma unit 306 and direct plasma unit 308 ) in the manner described herein.
- the software routine may also be stored and/or executed by a second CPU (not shown) that is remotely located from the hardware being controlled by the CPU 322 .
- Some or all of the processes and methods of the present disclosure may also be performed in hardware.
- the process may be implemented in software and executed using a computer system, in hardware as, e.g., an application specific integrated circuit or other type of hardware implementation, or as a combination of software and hardware.
- the software routine when executed by the processor, transforms the general purpose computer into a specific purpose computer (controller) that controls the chamber operation such that the processes are performed.
- the controller 320 has one or more configurations to execute individual processes or sub-processes to perform the method.
- the controller 320 can be connected to and configured to operate intermediate components to perform the functions of the methods.
- the controller 320 can be connected to and configured to control one or more of the remote plasma unit 306 , the direct plasma unit 308 , the pedestal 314 , the at least one electrode 316 , the ICP coil 370 , or other components.
- One or more embodiments are directed to a non-transitory computer readable medium including instructions, that, when executed by a controller of a processing chamber, cause the processing chamber to perform the operations of exposing a substrate to a remote plasma and exposing a substrate to a direct plasma.
- the non-transitory computer readable medium includes instructions, that, when executed by the controller of the processing chamber, cause the processing chamber to perform the operation of exposing the substrate to at least one precursor to form a film on the substrate.
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- General Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
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- Condensed Matter Physics & Semiconductors (AREA)
- General Physics & Mathematics (AREA)
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- Computer Hardware Design (AREA)
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JP2022529565A JP2023503578A (ja) | 2019-11-27 | 2020-11-23 | 複数のプラズマユニットを有する処理チャンバ |
US17/101,074 US20210159052A1 (en) | 2019-11-27 | 2020-11-23 | Processing Chamber With Multiple Plasma Units |
PCT/US2020/061759 WO2021108294A2 (fr) | 2019-11-27 | 2020-11-23 | Chambre de traitement à unités multiples de plasma |
KR1020227021126A KR20220103781A (ko) | 2019-11-27 | 2020-11-23 | 다수의 플라즈마 유닛들을 갖는 프로세싱 챔버 |
US17/844,245 US11955319B2 (en) | 2019-11-27 | 2022-06-20 | Processing chamber with multiple plasma units |
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US201962941148P | 2019-11-27 | 2019-11-27 | |
US202062960293P | 2020-01-13 | 2020-01-13 | |
US17/101,074 US20210159052A1 (en) | 2019-11-27 | 2020-11-23 | Processing Chamber With Multiple Plasma Units |
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US17/844,245 Division US11955319B2 (en) | 2019-11-27 | 2022-06-20 | Processing chamber with multiple plasma units |
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US (2) | US20210159052A1 (fr) |
JP (1) | JP2023503578A (fr) |
KR (1) | KR20220103781A (fr) |
TW (1) | TW202135125A (fr) |
WO (1) | WO2021108294A2 (fr) |
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- 2020-11-23 JP JP2022529565A patent/JP2023503578A/ja active Pending
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Also Published As
Publication number | Publication date |
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WO2021108294A2 (fr) | 2021-06-03 |
WO2021108294A3 (fr) | 2021-07-08 |
KR20220103781A (ko) | 2022-07-22 |
JP2023503578A (ja) | 2023-01-31 |
US20220319813A1 (en) | 2022-10-06 |
TW202135125A (zh) | 2021-09-16 |
US11955319B2 (en) | 2024-04-09 |
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