WO2009144456A1

WO2009144456A1 - Thermal gradient enhanced chemical vapour deposition (tge-cvd)

Info

Publication number: WO2009144456A1
Application number: PCT/GB2009/001326
Authority: WO
Inventors: Kenneth Teo; Nalin Rupesinghe
Original assignee: Aixtron Ag
Priority date: 2008-05-28
Filing date: 2009-05-27
Publication date: 2009-12-03
Also published as: KR20110025185A; EP2294244A1; TWI461568B; JP5674645B2; EP2294244B1; JP2011522119A; TW201005120A

Abstract

A chemical vapor deposition (CVD) apparatus is configured for thermal gradient enhanced CVD operation by the inclusion of multiple heaters, positioned so as to provide a desired thermal gradient profile across a vertical dimension of a substrate or other work piece within the chamber. So configured, the chamber may also be used for controlled growth of thin films via diffusion through intermediate films, either top down or bottom parallel to the direction of the thermal gradient.

Description

THERMAL GRADIENT ENHANCED CHEMICAL VAPOUR DEPOSITION (TGE-CVD)

RELATED APPLICATIONS

[0001] This is a NONPRO VISIONAL and claims the priority benefit of U.S. Provisional Patent Application 61/056,619, filed 28 May 2008, which is incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to methods and systems for thermal gradient enhanced chemical vapor deposition.

BACKGROUND

[0003] The generally accepted growth mechanism for nanotubes and nanowires is the diffusion of gas through a catalyst. One of the factors controlling the rate of diffusion of the gas is the thermal gradient across the catalyst or substrate {see, e.g., R.T.K. Baker, "Catalytic Growth of Carbon Filaments", Carbon, v. 27, pp. 315-329 (1989); and R. S. Wagner, in Whisker Technology, A. P. Levitt Ed., p. 47 (Wiley, New York, 1970)). Hence, for the growth of nanotubes and nanowires, especially in a vertical direction above a substrate, it is important to control the thermal gradient vertically. [0004] Referring to Figure 1, in a hot wall apparatus 10, a heater 12 surrounds a chamber 14 and heats the chamber, and a substrate 16 within the chamber, to a growth temperature. The gases flow horizontally through the chamber and over the substrate 16 to promote growth. The chamber and the substrate are at the same temperature and, hence, it is not possible to form a vertical temperature gradient across the wafer. [0005] Referring to Figure 2, in a heated substrate apparatus 20, a substrate 22 is placed on a heater 24 in a chamber 26. The substrate is then heated up to the growth temperature. The gases are introduced into the chamber 26 from above (e.g., via gas distributor 28), which cools the top surface of the substrate, and are removed via exhaust 30. This forms a negative temperature gradient because the top side of the wafer is colder than the bottom side of the wafer, which is in contact with the heater. The negative temperature gradient can impede the growth of nanotubes and nanowires. In some cases, a plasma is used to decompose the gases above the substrate, however, the problem of the negative temperature gradient still exists.

[0006] Referring to Figure 3, in hot filament chemical vapour deposition, an apparatus 20' similar to that used in connection with the heated substrate apparatus 20 is used, except that a thin wire or filament 32 is introduced in chamber 26 between the gas distributor and the substrate 22. The thin wire or filament is used to decompose the gases before they reach the substrate. The thin wire or filament is often operated at temperatures in excess of 1000 ⁰C. The wire is often thin and has less than 50% area coverage in order to reduce the heating effects on the substrate. The distance between the wire and the substrate is also fixed.

SUMMARY OF THE INVENTION

[0007] In one embodiment, the present invention provides a vapour deposition apparatus that includes a chamber configured for chemical vapour deposition of a film on a substrate and which has included therein a lower heater configured to support said substrate and an upper heater disposed a vertical distance above the lower heater. The upper heater has holes therethrough to allow reaction gases to pass vertically from a gas distributor within the chamber towards the substrate. In some instances, area coverage of the upper heater is greater than 50%. Also, either or both of the upper heater and the bottom lower may be configured for vertical motion with respect to one another in order to facilitate adjustment of the vertical distance between the heaters. In some cases, the upper heater is integrated with the gas distributor.

[0008] A further embodiment of the invention provides a vapour deposition apparatus that includes a chamber configured for chemical vapour deposition of a film on a substrate and having included therein a lower heater configured to support said substrate and an upper heater disposed a vertical distance above the lower heater, the upper heater being positioned above a gas distributor having holes therethrough to allow reaction gases to pass vertically towards the substrate.

[0009] Still another instantiation of the vapour deposition apparatus, provides a chamber configured for chemical vapour deposition of a film on a substrate and having included therein a lower heater configured to support said substrate and an upper heater disposed a vertical distance above the lower heater, the upper heater being positioned circumferentially around a gas distributor having holes therethrough to allow reaction gases to pass vertically towards the substrate. [0010] In any or all of the foregoing embodiments, the bottom heater may include a cooling element. Likewise, either or both of the upper and lower heaters may be configured for the application of a voltage to create a plasma.

[0011] A method consistent with an embodiment of the invention involves establishing a thermal gradient between an upper heater and a lower heater within a vacuum chamber in which a substrate is positioned in the vicinity of the lower heater and introducing reaction gasses vertically into the chamber to create depositions on the substrate. The upper heater may be maintained higher or lower in temperature than the lower heater and the reaction gasses may be evacuated from the chamber using a vacuum pump after being made to flow vertically through holes in the upper heater prior to encountering a top surface of the substrate.

[0012] These and other features and embodiments of the present invention are described further below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present invention is illustrated by way of example, and not limitation, in the figures of the accompanying drawings, in which:

[0014] Figure 1 illustrates a conventional apparatus in which substrates are heated by way of heating elements surrounding a chamber.

[0015] Figure 2 illustrates a conventional chamber configured with a single substrate heating element.

[0016] Figure 3 illustrates a chamber configured for conventional, hot filament, chemical vapour deposition (CVD) on a substrate.

[0017] Figure 4 illustrates an apparatus configured in accordance with one embodiment of the present invention, eemploying both top and bottom heating elements in a chamber configured for growing nano-structures on substrates.

[0018] Figures 5 A and 5B illustrate alternative configurations of apparatus configured for thermal gradient enhanced CVD in accordance with embodiments of the present invention. [0019] Figures 6A and 6B are images taken of sample wafers, showing the growth of nano- structures in apparatus configured in accordance with embodiments of the present invention.

DETAILED DESCRIPTION

[0020] Described herein are methods and systems for thermal gradient enhanced chemical vapor deposition (TGE-CVD). In various instantiations, the present invention provides a CVD (or other form of deposition) chamber which includes both an upper and lower heater or heating element. The lower heater (which, during operation, may be maintained at a temperature of between 20 - 1000 ⁰C) may be configured to support a substrate or other work piece, and the upper heater (which, during operation, may be maintained at a temperature of between 20 - 1000 °C) is disposed a certain distance (e.g., 5 - 75 mm) above the lower heater. In some instances, the upper heater may have holes running therethrough, to allow reaction gases to pass vertically from a gas distributor within the chamber towards the substrate. For example, the upper heater may be integrated with the gas distributor. [0021] Either or both of the upper and/or lower heater(s) may be configured for vertical motion relative to one another. This facilitates adjustment of the vertical distance between the heaters. Further, the area coverage of the upper heater may be greater than 50%. [0022] An alternative instantiation involves a CVD (or other form of deposition) chamber having included therein a lower heater configured to support a substrate and an upper heater disposed a vertical distance above the lower heater, and above a gas distributor. This arrangement allows reaction gases to pass unimpeded in a vertical direction towards the substrate.

[0023] Still another instantiation provides an apparatus that includes a CVD chamber. Included in the CVD chamber is a lower heater configured to support a substrate and an upper heater disposed a vertical distance above the lower heater, and being positioned circumferentially around a gas distributor having holes therethrough to allow reaction gases to pass vertically towards the substrate. In some instances, the lower heater may include a cooling element. Further, either or both of the upper and lower heaters may be configured for the application of a voltage to create a plasma.

[0024] Regardless of the physical instantiation, systems configured in accordance with the present invention are able to establish a thermal gradient between an upper heater and a lower heater within a vacuum chamber in which a substrate is positioned (usually, though not necessarily in the vicinity of the lower heater). Reaction gasses are introduced vertically into the chamber to create depositions on the substrate and the temperature gradient is preserved by maintaining one of the heaters higher in temperature than the other. [0025] Now referring to Figure 4, an apparatus 34 configured for thermal gradient enhanced CVD in accordance with an embodiment of the present invention is illustrated. The substrate 22 is placed on a bottom heater 38 within chamber 26. This may be done using a conventional vacuum robotic wafer handler as is known in the art. A top heater 36, with holes 37 therethrough to allow the reaction gases to pass vertically from the gas distributor 28 to the substrate 22, is suspended above the substrate 22. The area coverage of the top heater is preferably greater than 50%, to maximise the efficiency of the top heater in creating a vertical thermal gradient within the chamber. Either or both of the top heater 36 or the bottom heater 38 may be moved vertically in order to facilitate the adjustment of the vertical distance between the heaters.

[0026] The difference in temperature between the heaters, as well as the distance between the heaters, can be used to control the thermal gradient across the vertical dimension of substrate 22. For example, if the top heater is higher in temperature than the bottom heater, a positive thermal gradient (from the top of the substrate to the bottom of the substrate) is formed. On the other hand, if the bottom heater is higher in temperature than the top heater, a negative thermal gradient (from the top of the substrate to the bottom of the substrate) is formed. [0027] A variety of different chamber/heater configurations may be employed. For example, Figure 5A shows a configuration in which the apparatus 34' includes a top heater 36' (which may be moveable or fixed) that is integrated with a gas distributor 40. Gas distributor 40 may be configured as a showerhead, with multiple gas exit ports or injectors to provide gasses in the direction of the substrate. In this particular instance, the top heater 36' is positioned above the showerhead 40, but other embodiments may incorporate these elements in different fashions. For example, the heater element may be positioned circumferentially around the showerhead or centrally therein.

[0028] Yet a further embodiment is illustrated in Figure 5B. In this implementation, the apparatus 34" includes a bottom heater 38, which itself includes a cooling element 42. Both the bottom heater 38 and the cooling element 42 may be moveable (either collectively or independently of one another) so as to maintain a constant temperature of the substrate 22 if there is excessive radiative heating from the top heater 36 in situations where the top heater is moved into close proximity with the substrate to create a large thermal gradient. Additionally, in any of the above-described configurations, voltages can be applied to the top and/or bottom heaters to create a plasma.

[0029] Figures 6A and 6B are images taken of sample wafers, each at 650 ⁰C, and illustrate the growth of nano-structures in apparatus configured in accordance with embodiments of the present invention. In Figure 6A, the growth was conducted in a negative thermal gradient environment, in which the top heater had a temperature lower than the bottom heater. In Figure 6B, the growth was conducted in a positive thermal gradient environment, in which the top heater had a temperature greater than the bottom heater. [0030] It should be appreciated that many details of an apparatus suitable for performing the nano-structure growth operations described herein have not been presented in detail so as not to unnecessarily obscure the features of the present invention. Such details would, of course, be required for an operational system, but are known in the art. For example, U.S. Patent 5,855,675, assigned to the assignee of the present invention and incorporated herein by reference, provides a good discussion of features which may included in an apparatus that also includes dual heaters in accordance with the present invention. In general, such a commercial apparatus may be organized as a cluster-tool-based processing system operating substantially within a vacuum chamber. A wafer transfer apparatus may be positioned to operate from the center of the vacuum chamber and be adapted to place and retrieve, by rotation and extension, substrates, typically semiconductor wafers, from and to processing chambers configured in the manner described above and appended at points around the periphery of substantially circular vacuum transfer chamber. Wafers may be moved from an outside environment into the vacuum chamber through a load-lock, then through one or more processing chambers, and finally back to the outside environment through an unload lock. Gases used in processing may be introduced via a gas feed and control unit through conduit(s) and manifolds, such as the showerhead manifold discussed above. Alternatively, other gas distributor manifolds may be used.

[0031] The processing chambers are typically maintained at atmospheric pressure or below atmospheric pressure through the use of vacuum pumps fluidly coupled to the chamber exhausts. This avoids contamination by atmospheric gases and other particles. During processing in one of the processing chambers, vacuum pumping may be throttled to control process chamber pressure without using excessive quantities of process gases. Such throttling may be accomplished in a number of ways, including by valves having controllable openings. In a typical process cycle, after processing is complete, gases are valved off and the throttling mechanism is opened to allow maximum pumping speed in the processing chamber. The purpose is to reduce the gas pressure in the processing chamber to a value close to that in the substrate transfer chamber. Then, the processed wafer may be removed from the chamber.

[0032] A drive assembly mounted below a processing chamber may be used to raise and lower an internal pedestal on which the substrate support (e.g., the bottom heater) is attached. Alternatively, the bottom heater may be included within such a pedestal. Usually though, the pedestal apparatus will have a heated hearth for supporting and providing heat to a wafer to be processed. When the pedestal is in a lowermost position wafers may be inserted into the chamber and released to lie upon the hearth, and, after the transfer apparatus withdraws, the pedestal may be raised, moving the supported wafer up into a processing position to be processed. The procedure may be reversed when the wafer is to be removed from the processing chamber. Vacuum integrity may be maintained for the overall assembly while allowing vertical freedom of motion for the pedestal by means of a bellows. It will be apparent to those of ordinary skill in the art that there are other mechanisms by which the pedestal assembly may be translated in a vertical fashion, and there are a variety of alterations that might be made without departing from the scope of the invention. There are, for example, a number of different extensible drives that might be used, such a air cylinders, air-oil systems, hydraulic systems, and the like. [0033] Thus, means for thermal gradient enhanced chemical vapor deposition have been described. Although discussed with reference to several illustrated embodiments, the present invention is not intended to be limited by the examples provided in these illustrations. For example, the methods and system of the present invention may also be used for controlled growth of thin films via diffusion through intermediate films, either top down or bottom parallel to the direction of the thermal gradient.

Claims

1. An apparatus, comprising: a chamber configured for chemical vapour deposition of a film on a substrate and having included therein a lower heater configured to support said substrate and an upper heater disposed a vertical distance above the lower heater, the upper heater having holes therethrough to allow reaction gases to pass vertically from a gas distributor within the chamber towards the substrate.

2. The apparatus of claim 1, wherein area coverage of the upper heater is greater than 50%.

3. The apparatus of claim 1 or 2, wherein either or both of the upper heater and the bottom lower are configured for vertical motion with respect to one another in order to facilitate adjustment of the vertical distance between the heaters.

4. The apparatus of claim 1, 2 or 3, wherein the upper heater is integrated with the gas distributor.

5. An apparatus, comprising: a chamber configured for chemical vapour deposition of a film on a substrate and having included therein a lower heater configured to support said substrate and an upper heater disposed a vertical distance above the lower heater, the upper heater being positioned above a gas distributor having holes therethrough to allow reaction gases to pass vertically towards the substrate.

6. An apparatus, comprising: a chamber configured for chemical vapour deposition of a film on a substrate and having included therein a lower heater configured to support said substrate and an upper heater disposed a vertical distance above the lower heater, the upper heater being positioned circumferentially around a gas distributor having holes therethrough to allow reaction gases to pass vertically towards the substrate.

7. The apparatus of any one preceding claim, wherein the bottom heater includes a cooling element.

8. The apparatus of any one preceding claim, wherein either or both of the upper and lower heaters is configured for the application of a voltage to create a plasma.

9. A method, comprising establishing a thermal gradient between an upper heater and a lower heater within a vacuum chamber in which a substrate is positioned in the vicinity of the lower heater and introducing reaction gasses vertically into the chamber to create depositions on the substrate.

10. The method of claim 9, wherein the upper heater is maintained higher in temperature than the lower heater.

11. The method of claim 9, wherein the lower heater is maintained higher in temperature than the upper heater.

12. The method of any one of claims 9, 10 or 11, further comprising evacuating the reaction gasses from the chamber using a vacuum pump.

13. The method of any one of claims 9 to 11, wherein the reaction gasses are made to flow vertically through holes in the upper heater prior to encountering a top surface of the substrate.