Classifications

• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10P—GENERIC PROCESSES OR APPARATUS FOR THE MANUFACTURE OR TREATMENT OF DEVICES COVERED BY CLASS H10
  • H10P72/00—Handling or holding of wafers, substrates or devices during manufacture or treatment thereof
  • H10P72/04—Apparatus for manufacture or treatment
  • H10P72/0431—Apparatus for thermal treatment
• • 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
  • C23C16/4401—Means for minimising impurities, e.g. dust, moisture or residual gas, in the reaction chamber
  • C23C16/4404—Coatings or surface treatment on the inside of the reaction chamber or on parts thereof
• • 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
• • 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
  • H01J37/32431—Constructional details of the reactor
  • H01J37/32715—Workpiece holder
  • H01J37/32724—Temperature
• • H—ELECTRICITY
  • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
  • H10P—GENERIC PROCESSES OR APPARATUS FOR THE MANUFACTURE OR TREATMENT OF DEVICES COVERED BY CLASS H10
  • H10P72/00—Handling or holding of wafers, substrates or devices during manufacture or treatment thereof
  • H10P72/04—Apparatus for manufacture or treatment
  • H10P72/0402—Apparatus for fluid treatment
  • H10P72/0418—Apparatus for fluid treatment for etching
  • H10P72/0421—Apparatus for fluid treatment for etching for drying etching

Definitions

• the present invention is directed to reactors and in particular reactors for processing objects with films such as semiconductor wafers.
• reactors which can accomplish various steps associated with the definition ofthefunctionalityofthe semiconductor chip.
• Such reactors can, for example, perform deposition and etching processes through the use of various gases which are part of the fabrication process.
• gases which are part of the fabrication process.
• gaseous input materials as well as materials from the substrate being etched and combinations thereof can be deposited on the internal surface present in the reactor itself.
• Such surfaces include reactor walls, reactor electrodes, the reactor chuck and the like.
• Each processing tool depending on the processing run, will have a regular scheduled down period during which the internal surfaces of the reactor will be cleaned and parts such as electrodes will be repaired and/or replaced.
• the deposits which form on the various surfaces found in the reactor are known to have a detrimental effect to the fabrication of the semiconductor wafer product in the reactor.
• deposits and layers on surfaces of the reactor can be thick and have poor reactor surface adhesion qualities.
• the deposits or layers may not be very durable. All this potentially leads to the flaking or spaulding off of portions of the deposits or layers from the surfaces of the reactor.
• flaking or spaulding can interfere with the uniform processing of the surface of the wafer.
• materials which flake or spauld from the surface of a reactor can redeposit on the surface of the wafer being processed, potentially damaging the functionality being fabricated on the wafer.
• the present invention is directed to overcoming the problems associated with prior reactors.
• the present invention includes apparatus and method for ensuring that any materials that are deposited on the internal surfaces of the reactor are thin and more durable than those deposited by prior art reactors and that such deposits adhere more readily to the internal surfaces of the reactor. Accordingly, it is an object of the invention to provide an apparatus and method which ensures that any layers or deposits on the internal surfaces of the reactor are thin, durable and adhere well to the surface of the reactor so that the deposits do not flake or spauld, potentially interfering with the process of defining the various layers which are being fabricated on a wafer.
• embodiments of the present invention can be used in the construction and fabrication of semiconductor chips as well as in the construction and fabrication of any other product.
• Such other products can include thin film read/write heads for a disk drive which requires the fabrication of circuitry on a substrate or which requires the fabrication of layers.
• any construct having layers with features of submicron dimensions can benefit from the present invention.
• a further object of the present invention is to provide one or more electrodes, in particular the top electrode, of a reactor with a heater in order to ensure that the deposits and materials on the electrode adhere well to the electrode.
• Still a further object of the invention is to provide the reactor with a reactor chamber and surfaces which are textured in order to encourage adherence of materials deposited thereon so that such materials do not flake or spauld off, interfering with the processing of a wafer.
• Fig. 1 is a schematical plan sectional view of an electrode with heaters.
• Fig. 2 is a cross sectional view of the electrode of Fig. 1.
• Figs. 3a, 3b, and 3c are cross-sections of textured surfaces of embodiments of the invention.
• Fig. 4 is a cross-section of another textured surface of an embodiment of the invention.
• Fig. 5 is a cross-section of still a further textured surface of an embodiment of the invention.
• Fig. 6 is a graph depicting a reduction in deposit thickness and halogen content as the electrode temperature is increased.
• Fig. 7 is a side sectional view of a reactor surface which has been precoated.
• Fig. 8 is a side view of a reactor with a shield protecting a reactor surface such as an electrode.
• Reactor embodiment of the present invention can include heated electrode, deposition shield and/or other surfaces.
• Figs. 1 and 2 depict plan and cross-sectional views of an upper electrode 20 for a reactor, and in particular of an etch reactor.
• the upper electrode has bores 22 provided therein which can receive heating elements 24.
• the heating elements 24 are preferably cartridge heaters with an internal thermocouple.
• the third element 26 is a cartridge heater used as a thermocouple in orderto sense the temperature.
• the heaters are resistive type heaters. It is to be understood that other heaters can be employed and be within the spirit and scope of the invention. It is to be understood that the same technique can be used to heat electrode shields, and other surfaces and walls of the reactor.
• the upper electrode (and/or the electrode opposite to the electrode or chuck holding a wafer to be processed) is preferably heated to a maximum temperature of about 300 to about 350 degrees C.
• the maximum temperature is preferably about 400 to about 500 degrees C.
• the upper electrode would be floating at a maximum temperature of about 100 degrees C.
• reaction gases, materials from the wafer and combination thereof can be deposited on the various internal surface of the reactor and chamber, such as for example, the electrode.
• the deposits are thinner, more adherent and more durable than is experienced when such reaction materials are deposited on non-heated surfaces.
• the deposited layer on the electrode and other surfaces is more likely to be mostly platinum and not combinations of platinum with other gases such as chlorine and oxygen.
• Such other gases de-absorb or boil off from the surfaces in order to leave a more thin, durable and adhesive platinum layer.
• This layer accordingly sticks better to the surface of the electrode and does not easily flake or spauld off. Accordingly, there is less of a likelihood that any materials deposited on the electrode will flake off from the electrode and ruin the substrate being processed.
• non-volatile material such as, by way of example only, platinum (Pt), Iridium (Ir), barium strontium titanate (BST), lead zirconium titanate (PZT), bismuth strontium tantalate (SBT), Iridium
• Embodiment with a Textured Upper, Lower and Side Electrodes and Other Textured Surfaces can be textured such that layers that are deposited thereon have less likelihood of flaking or spaulding off, potentially contaminating the reaction.
• Such structures are particularly useful for etching non-volatile materials as described hereinabove.
• Such surface texturing promotes adhering of the deposits to the surface. Texturing can be as effective with capacitively coupled reactors. Further, inductively coupled reactors can also benefit from a texturing technique.
• Texturing can take a variety of shapes and forms, both regular and irregular.
• the Figs. 3, 4, and 5 demonstrate several different representative embodiments for texturing.
• the first embodiments (Figs. 3a, 3b, and 3c ) show surfaces 30, 32, 34 which are scalloped.
• the scallops presented are convex in shape toward the reactor chamber. Alternating the scallops can be concave toward the reactor chamber much as presented in Fig. 5.
• Such surface can be provided on the electrodes, shields for the electrode, and also on the various surfaces found inside of a reactor chamber.
• Figs. 4 and 5 include texturing which have a series of peaks 40, 50.
• the effect of this texturing in some instances can be measured by the aspect ratio of the width between peaks to the depth of the valley between the peaks.
• the aspect ratio would be:
• a textured surface With a relatively low aspect ratio, in other words, with the width much less than the depth, it can be expected that such a textured surface would be better able to capture any deposited material than a texture where the width between peaks is much greater than the depth. Additionally, a textured surface also increases the surface area upon which materials can be deposited and collected.
• This embodiment with the textured surfaces as well as the embodiment with the heated electrode as indicated above prevent flaking, spaulding, delaminating, cracking and the accumulation of dust, all of which can interfere with the wafer fabrication process.
• FIG. 7 Another embodiment (Fig. 7) of the invention for use especially with such non-volatile films includes the pre-coating of the various surfaces 55 of the reaction chamber in order to promote chemical adhesion.
• Such pre-coating 60 can be done with Titanium (Ti) or Titanium Nitride (TiN).
• the surface found in the reactor chamber can be pre-coated with materials which are the same as or compatible with the non-volatile films which are being etched.
• Such materials can also include Platinum (Pt), Iridium (Ir), Iridium Oxide (lrO 2 ), Barium Strontium Titanate (BST), Strontium Bismuth Tantalate (SBT), Strontium Titanate (STO), Ruthenium (Ru), Ruthenium Oxide (RuO 2 ), and Lead Zirconium Titanate (PZT).
• the sidewalls of the reactor and in particular the sidewalls of the reactor liners can be provided with a matt finish which also promotes good chemical adhesion.
• a matt finish is defined as follows: General texturing of a surface to facilitate the adhesion of various materials. The matting is constructed in such a way as to maximize the surface area penetrated while minimizing spaulding of the deposited film.
• coating or pre-conditioning internal surfaces of the reactor chamber can prevent spaulding, flaking, and delaminating of any materials deposited on the surfaces, beneficially effecting the processing of semiconducting wafers or other substrates
• Fig. 8 shows a shield 70 which has been located adjacent to an upper electrode 80.
• the shield can either be heated, textured, or pre- coated, or a combination of the above and be within the spirit and scope of the invention. Texturing can include grooves, channels, perforations and/or screened surfaces.
• the present invention advantageously uses heated and/or textured and/or pre-coated surfaces that are internal to a reactor chamber in order to ensure that materials deposited thereon adhere and do not flake, spauld or become delaminated, contaminating the process.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Plasma & Fusion (AREA)
• Physics & Mathematics (AREA)
• Analytical Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Materials Engineering (AREA)
• Mechanical Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• General Chemical & Material Sciences (AREA)
• Drying Of Semiconductors (AREA)
• Chemical Vapour Deposition (AREA)
• Physical Or Chemical Processes And Apparatus (AREA)

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• 2000
  • 2000-11-21 JP JP2001542603A patent/JP5054874B2/ja not_active Expired - Fee Related
  • 2000-11-21 WO PCT/US2000/031987 patent/WO2001040540A1/en not_active Ceased
  • 2000-11-21 EP EP00980631.6A patent/EP1252359B1/en not_active Expired - Lifetime
  • 2000-11-21 AU AU17863/01A patent/AU1786301A/en not_active Abandoned
• 2001
  • 2001-06-22 US US09/888,365 patent/US7439188B2/en not_active Expired - Fee Related
• 2008
  • 2008-09-02 US US12/203,022 patent/US20080318432A1/en not_active Abandoned

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