WO2024258641A1 - Substrate support - Google Patents
Substrate support Download PDFInfo
- Publication number
- WO2024258641A1 WO2024258641A1 PCT/US2024/032096 US2024032096W WO2024258641A1 WO 2024258641 A1 WO2024258641 A1 WO 2024258641A1 US 2024032096 W US2024032096 W US 2024032096W WO 2024258641 A1 WO2024258641 A1 WO 2024258641A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- substrate support
- gas
- support component
- conductor
- plug
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Ceased
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Classifications
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- 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
- H10P72/70—Handling or holding of wafers, substrates or devices during manufacture or treatment thereof for supporting or gripping
- H10P72/76—Handling or holding of wafers, substrates or devices during manufacture or treatment thereof for supporting or gripping using mechanical means, e.g. clamps or pinches
- H10P72/7604—Handling or holding of wafers, substrates or devices during manufacture or treatment thereof for supporting or gripping using mechanical means, e.g. clamps or pinches the wafers being placed on a susceptor, stage or support
- H10P72/7616—Handling or holding of wafers, substrates or devices during manufacture or treatment thereof for supporting or gripping using mechanical means, e.g. clamps or pinches the wafers being placed on a susceptor, stage or support characterised by a coating, a hardness or a material
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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
- H01J37/32431—Constructional details of the reactor
- H01J37/3244—Gas supply means
- H01J37/32449—Gas control, e.g. control of the gas flow
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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
- H01J37/32431—Constructional details of the reactor
- H01J37/32715—Workpiece holder
- H01J37/32724—Temperature
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- 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
- H10P72/70—Handling or holding of wafers, substrates or devices during manufacture or treatment thereof for supporting or gripping
- H10P72/72—Handling or holding of wafers, substrates or devices during manufacture or treatment thereof for supporting or gripping using electrostatic chucks
- H10P72/722—Details of electrostatic chucks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- 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
- H01J2237/334—Etching
Definitions
- BACKGROUND Semiconductor fabrication can involve various processes performed on a substrate. These processes can take place in one or more processing chambers. For example, deposition processes can be performed to deposit layers of films of various materials on the substrate. In another example, plasma etching can be used in semiconductor processing to selectively etch one or more layers using a plasma formed from particular etching gas chemistries.
- Integrated circuits can be formed using semiconductor fabrication techniques from layer structures including multiple (e.g., two or more) layer compositions. As scaling of integrated circuits continues to move towards smaller features and increased aspect ratios, there is a growing need for precision fabrication of layer structures.
- a substrate refers to a wafer or another carrier structure, e.g., a glass plate.
- a wafer can include a semiconductor material, e.g., Silicon, GaAs, InP, or another semiconductor-based wafer material.
- a wafer can include an insulator material, for example, silicon-on-insulator (SOI), diamond, etc.
- SOI silicon-on-insulator
- the substrate includes film(s) formed on a surface of the wafer/carrier structure.
- the film(s) can be, for example, dielectric, conductive, or insulating films.
- the film(s) can be formed on the surface of the wafer using various deposition techniques, for example, spin- coating, atomic layer deposition (ALD), chemical vapor deposition (CVD), metal-organic chemical vapor deposition (MOCVD), molecular beam epitaxy (MBE), or other similar techniques for forming thin film layers on a wafer or another carrier structure.
- ALD atomic layer deposition
- CVD chemical vapor deposition
- MOCVD metal-organic chemical vapor deposition
- MBE molecular beam epitaxy
- the fabrications tools described in this specification are plasma-based etching tools, where etch processes can be performed on the formed layers on the surface of the wafer/carrier structure and/or on the wafer.
- an integrally formed insulator body comprising a first surface and a second surface opposite the first surface, where the first surface is configured to retain a first body of the substrate support comprises an electrically conductive material, the second surface is configured to affix the insulator body to a second body of the substrate support, wherein the second body comprises an electrically conductive material, and a thickness of the insulator body exceeds an arcing threshold between the first body and the second body when the insulator body is arranged between the first body and the second body.
- the integrally formed insulator body includes one or more gas conduits within the insulator body extending from the first surface to the second surface and forming a gas flow path from the first surface to the second surface.
- Each of the one or more gas conduits includes a gas conductance plug embedded within a first portion of the gas conduit and having at least a threshold gas conductance through the gas conductance plug, and where the gas conductance plug obstructs an electrical discharge path between the first body and the second body when the insulator body is arranged with respect to the first body and the second body.
- implementations of this aspect include corresponding methods of manufacture, data structures embodied in a machine-readable medium for designing, manufacturing, or testing a design, and corresponding systems, computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.
- a conductor body including an edge portion and a center portion, where the conductor body is configured to support an electrostatic chuck on a first surface of the conductor body.
- the conductor body includes one or more cooling channels embedded within the conductor body and configured to facilitate coolant flow within at least one of the edge portion and the center portion of the conductor body.
- the one or more cooling channels include cooling fins, where the cooling fins include a first cross-section geometry oriented perpendicular to the coolant flow, and where the cooling fins include a second geometry having a threshold surface area parallel to the coolant flow.
- the conductor body includes a first gas conduit embedded in the conductor body configured to facilitate gas flow through the conductor body and couple into one or more second gas conduits of the electrostatic chuck, when the electrostatic chuck is supported by the first surface.
- the conductor body includes one or more isolation features integrally formed within the conductor body and oriented to reduce a threshold cross-talk between the edge portion of the conductor body and the center portion of the conductor body.
- implementations of this aspect include corresponding methods of manufacture, and data structures embodied in a machine-readable medium for designing, manufacturing, or testing a design, and corresponding systems, computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.
- the subject matter described in this specification can be implemented in these and other implementations so as to realize one or more of the following advantages.
- Using additive manufacturing (AM) techniques to manufacture substrate supports can overcome challenges in the methods to manufacture the substrate supports and components of the substrate supports, improve yield and increase complexity, as well as open up material possibilities.
- AM additive manufacturing
- AM can be used to introduce features (e.g., complex shapes and/or internal geometries) otherwise unavailable or cost-prohibited by traditional, non- AM techniques, e.g., embedded sensors, complex internal channels/conduits, etc..
- AM techniques can be used to introduce new material compositions, e.g., alloys, formed using powder composites in order to achieve desired material properties.
- a ceramic/metallic blend of powders may be used to form a new material composition for AM-based components.
- refurbishments/modification can be used to update an existing component rather than fabricating a completely new component to incorporate a new feature.
- the remaining disclosure will identify specific processes for etch-based fabrication tools using the disclosed technology, it will be readily understood that the systems and methods are equally applicable to a variety of other fabrication tools and chambers. Accordingly, the technology should not be considered to be so limited as for use with the described etching fabrication tools alone.
- the disclosure will discuss one possible system and chamber that can be used with the present technology before describing systems and methods or operations of exemplary process sequences according to some implementations of the present technology.
- characterization device 172 includes an optical emission spectroscopy device configured to monitor a signal, e.g., emitted light of a plasma, within a processing region of the processing chamber 100.
- a signal can be a primary or highest intensity wavelength of emitted light.
- Characteristics of the emitted light (e.g., wavelength and intensity) from the plasma within the processing region can depend in part on an etching gas mixture used to generate the plasma as well as a layer composition of the layer being etched.
- each etching gas mixture and corresponding layer composition being etched can have a respective signal signature. Emitted wavelengths that are unique or distinguishing for each etching gas mixture and corresponding layer composition can be monitored to determine an etching condition of the layer being etched.
- FIG.3A shows a schematic cross section of an example substrate support 300 including an insulator body 302, conductor body 304, ground plate 306 and ESC 308.
- the insulator body 302 can include embedded regions within the insulator body, e.g., region 310, having internal geometries. Characteristics of the embedded regions can be selected to have at least a threshold impedance between the radio-frequency (RF) hot (e.g., voltage biased) components and grounded components of the substrate support as well as a threshold internal structural strength.
- RF radio-frequency
- a substrate support 300 can have at least a first creepage path 312 and a second creepage path 314 between the conductor body 304 and ground plate 306 during operation of the processing chamber.
- a minimum thickness of the insulator body can be selected to be equal to or greater than the creepage path.
- thickness of the insulator body 302 along a creepage path, e.g., creepage path 312 can be scaled by about 3.175 cm of insulating material thickness per 10 kV of voltage difference between RF hot components and grounded components of the substrate support.
- the thickness of insulating material can provide at least a threshold impedance during operation of the processing chamber and reduce a likelihood of arcing between the RF hot and grounded components.
- a creepage path can be greater than about 5 cm such that a thickness of insulating material along the creepage path is needed to (substantially) prevent arcing.
- additive manufacturing techniques can be used to form the insulator body as an integral body (e.g., in a layer-by-layer process) and without requiring multiple separately formed sheets of insulating material to be affixed together, for example, as depicted in FIGS.4A and 4B.
- FIGS.4A and 4B show various views of an insulator body 402 formed as an integral body using AM techniques.
- FIG.4C depicts two example structures for internal geometries 404a, 404b which form at least a portion of the insulator body 402.
- AM techniques can facilitate forming regions of internal geometries, e.g., as depicted in FIGS.3C, 4C, which may otherwise be unattainable by conventional manufacturing techniques.
- the insulator body of the substrate support includes one or more gas conduits to facilitate gas flow through the insulator body and into other components of the substrate support, e.g., into the conductor body (facilities plate and cooling base) and ESC.
- FIG. 3B depicts an example schematic view of gas conduits 320 for gas flow through the insulator body 302.
- a gas conduit 320 includes a gas conductance plug 322, e.g., a porous plug, that obstructs an electrical discharge path between an RF hot portion of the substrate support and a grounded portion of the substrate support, e.g., between a facilities plate and ground plate, while still allowing a specified gas flow rate through the gas conduit 320.
- FIGS.5A-5J show example schematic views of various gas conductance plug designs.
- a portion 502 of the gas conductance plug 500 is formed of a porous material, e.g., ceramic material, to facilitate a flow of gas (e.g., helium) but can prevent a backflow of other gases, contaminants, etc., through the gas conductance plug.
- the gas conductance plug includes an outer ceramic portion 504.
- the gas conductance plug can obstruct (e.g., prevent, substantially reduce) an electrical discharge path 506 through the gas conduit to prevent arcing within the process chamber to the ground plate.
- Gas conductance plug can obstruct a line-of-sight from an electrically charged (e.g., RF hot) facilities plate to ground but maximize a gas flow through the plug.
- gas conductance plug 510 can include internal features 512 that create a convoluted gas flow path and obstruct line-of-sight of an electrical arc path.
- a gas conductance plug defines a convoluted gas flow path having a gas conductance from one end of the gas conductance plug to a second end of the gas conductance plug.
- the convoluted path can define a longest gas flow path for a given gas flow rate.
- a higher flow gas conductance plug can provide a higher helium pressure to the ESC, e.g., for low temperature substrate applications.
- additive manufacturing (AM) techniques can be used to form one or more features and/or components of the insulator body.
- AM techniques can be used to form the gas conductance plugs from a same or different material than the surrounding insulator body.
- AM techniques can be used to form gas conductance plug that are integrally formed with the insulator body.
- a desired gas flow through a gas conduit can be selected during a design process for an AM formed insulator body based on internal structure of the gas conduit, e.g., of the gas conductance plug.
- the features (e.g., gas conductance plugs, outer/inner sleeves, etc.) of the gas conduits can be formed using AM techniques to have a different gas flow, e.g., a higher gas flow, than gas conduits facilitating gas flow to an inner cooling zone of the ESC.
- AM techniques can be used to rapidly design and deploy different designs for the gas conductance plugs.
- AM techniques can be used to form a gas conductance plug that substantially reduces or eliminates a radial gap between a porous center portion of the gas conductance plug and a ceramic sleeve surrounding the porous center portion. Reducing or eliminating the radial gap can obstruct a potential arcing path through the radial gap.
- FIG.6A shows an example schematic view of a gas conduit including gas conductance plugs.
- a gas conduit 600 within insulator body 602 includes a first portion 604 including a gas conductance plug 606 having a first diameter associated with the porous material and a second portion 608 including gas conduit 610 having a second diameter.
- a diameter 612 of the gas conduit 610 can be smaller than a diameter 614 of the gas conductance plug.
- the gas conduit 610 can facilitate flow of gas from a ground plate 622 to a first surface of the gas conductance plug 606.
- the first portion 604 of gas conduit 600 includes an outer sleeve 618 surrounding the gas conductance plug 606.
- the second portion 608 of gas conduit 600 includes a ceramic portion 620 surrounding gas conduit 610.
- Gas conduit 600 extends from a first surface of the insulator body 602 in contact with the ground plate 622 to a second surface of the insulator body 602 in contact with the conductor body 624 (e.g., facilities plate and cooling base).
- the gas conduit 600 facilitates a gas flow 626 from the ground plate 622 through the insulator body 602 and into the conductor body 624.
- a gas flow path through the insulator body can include one or more gas conduits.
- FIGS.6B and 6C show example schematic views of gas flow paths including gas conductance plugs.
- a gas flow path 628 can include one gas flow conduit, e.g., gas conduit 630 as depicted in FIG.6B, or a gas flow path 629 can include two or more gas conduits, e.g., three gas conduits 632 as depicted in FIG.6C.
- a number of gas conduits can be selected to adjust a gas flow 634 through the gas conductance plug of the gas flow path. For example, a larger number of gas conduits can facilitate a higher gas flow through the gas conductance plug than a smaller number of gas conduits.
- additive manufacturing e.g., 3D printing
- additive manufacturing processes can be used to facilitate a design space for manufacturing a unified facilities plate and cooling base as an integral (e.g., unified) body, e.g., referred to here as a “conductor body” or “conductive body.”
- a unified facilities plate and cooling base e.g., referred to here as a “conductor body” or “conductive body.”
- various subcomponents and/or integrated and/or embedded features of the conductor body can be enabled by additive manufacturing techniques, one or more of which may not be otherwise achievable by traditional manufacturing techniques.
- An integrally formed conductor body including the functionality of the facilities plate and cooling base as described with reference to FIG.1, can reduce fabrication steps which can result in reduced leaking/failure points in the support structure.
- features of the facilities plate and cooling base which would otherwise require vacuum brazing between components of the cooling base and/or e-beam welding of cooling channels can be formed instead using AM techniques.
- using AM techniques to form an integral conductor body can reduce the need for seals, e.g., O-ring seals, gaskets, and fixtures, e.g., dowel pins, screws, fixtures etc., required to affix subcomponents of the substrate support together.
- An integrally formed conductor body can have improved electrical RF performance and/or thermal performance in comparison to two or more subcomponents affixed together, e.g., by reducing a number of interfaces and welded/brazed unions.
- an integrally formed conductor body 700 can include features embedded 702 within the body of the conductor body.
- features of the conductor body for example, channels, gas conduits, isolation features, electrical connections, through-holes, etc., can be formed during an AM process and without requiring welding/brazing steps, as described in further detail below. Additionally, a complexity of the internal structures can be increased using AM techniques in comparison to traditional forms of manufacturing.
- FIG.7C shows a schematic view of complex cooling channels for an edge portion 704 and cooling channels for a center portion 706 embedded within the conductor body 700 which can be formed in a layer-by-layer process using additive manufacturing techniques.
- a conductor body includes cooling channels having internal features, e.g., cooling fins.
- FIGS.8A-8F show example cross-sectional schematic views of various cooling channels 802, 804, 806, 808, 810, 812 integrally formed in a conductor body 800.
- the cooling fins e.g., cooling fin 801, can include a first cross-sectional geometry (perpendicular to flow of coolant) and a second geometry (parallel to a flow of coolant).
- the geometry of the cooling fins parallel to the flow of the coolant can be selected to achieve at least a threshold (e.g., optimize) amount of heat exchange between the cooling fins and the coolant as the coolant flows through the cooling channel.
- a threshold e.g., optimize
- Multiple different cooling fin geometries can be utilized to improve heat transfer efficiency in multiple different regions of the conductor body.
- the geometry of the cooling channels can be selected such that the cooling mechanism is contact- dominated by an exposed surface area of the cooling fins within the cooling channels.
- an integrally formed conductor body can include isolation features embedded within the conductor body and formed integrally with the conductor body, e.g., by additive manufacturing.
- FIG.9 shows an example schematic view of isolation features 902, 904 embedded within a conductor body 900.
- the isolation features 902, 904 can be arranged within the body of the conductor body 900 and with respect to the cooling channels 906.
- An isolation feature can be, for example, a thermal isolation feature configured to reduce thermal cross-talk between regions of the conductor body.
- a thermal break or a thermal choke can be used, for example, to improve center-to-edge temperature uniformity (e.g., tunability).
- an isolation feature can be a capacitance isolation feature. Thermal isolation features can also be used to reduce a thermal mass of the conductor body, yield improved thermal response.
- isolation features can be formed integrally and can be embedded within the conductor body, without requiring additional manufacturing steps (e.g., subtractive manufacturing).
- a portion of the substrate support can be coated with a protective coating, e.g., as depicted in FIG.10A.
- the protective coating 1000 can be applied to surfaces that are exposed to the plasma during fabrication processes, e.g., to an exposed surface of the conductor body 1002.
- Protective coating can be a ceramic coating having anti-arcing properties. Ceramic coating can be made of, for example, alumina.
- the protective coating can be formed on a surface of the substrate support, using additive manufacturing techniques (e.g., using plasma spray coating).
- integrated features of the conductor body enabled by additive manufacturing techniques includes forming the conductor body from two or more different materials.
- conductor body 1010 can include a 3D printed ceramic insulator 1012 (e.g., alumina insulator) integrated into the conductor body for gas conduits 1016.
- 3D printed ceramic insulator 1012 e.g., alumina insulator
- bonding 1014 between subcomponents of different materials can be eliminated.
- additive manufacturing e.g., three-dimensional printing (or 3-D printing), may be used to produce (or make) the substrate support and components described herein.
- a computer (CAD) model of the required part is first made and then a slicing algorithm maps the information for every layer.
- CAD computer
- a layer starts off with a thin distribution of powder spread over the surface of a powder bed.
- a chosen binder material then selectively joins particles where the object is to be formed.
- a piston which supports the powder bed and the part-in-progress is lowered in order for the next powder layer to be formed.
- the same process is repeated followed by a final heat treatment to make the object. Since 3-D printing can exercise local control over the material composition, microstructure, and surface texture, various (and previously inaccessible) geometries may be achieved with this method.
- a substrate support and components of a substrate support as described herein may be represented in a data structure readable by a computer rendering device or a computer display device.
- FIG.13 is a schematic representation of a computer system with a computer-readable medium according to one embodiment.
- the computer-readable medium may contain a data structure that represents one or more components of the substrate support, e.g., a conductor body, isolator body, ESC, etc.
- the data structure may be a computer file, and may contain information about the structures, materials, textures, physical properties, or other characteristics of one or more articles.
- the data structure may also contain code, such as computer executable code or device control code that engages selected functionality of a computer rendering device or a computer display device.
- the data structure may be stored on the computer-readable medium.
- the computer readable medium may include a physical storage medium such as a magnetic memory, floppy disk, or any convenient physical storage medium.
- the physical storage medium may be readable by the computer system to render the article represented by the data structure on a computer screen or a physical rendering device which may be an additive manufacturing device, such as a 3D printer.
- additive manufacturing techniques can be used in combination with other manufacturing techniques, e.g., subtractive manufacturing.
- subtractive manufacturing can be used to modify/remove portions of the substrate support and additive manufacturing can be used to add/modify portions of the substrate support.
- the combination of techniques can be used during the initial process to manufacture or to modify/refurbish/regrow an existing substrate support or components of a substrate support to repair damage or change a configuration of the features.
- additive manufacturing techniques can be used to regrow/refurbish portions of a substrate support, e.g., to repair operational damage or manufacturing damage, and/or to add features.
- additive manufacturing techniques can be used to form the substrate support and/or components of the processing chamber using two or more material compositions, e.g., simultaneously or sequentially.
- Different material compositions can include, for example, AlN and Al 2 O 3 .
- Different material compositions can include, for example, different porosity or another material structural difference of a same material composition.
- porous plugs can be formed of a different material composition (or having a different material structure of the same material composition) than the insulator material of the substrate support.
- additive manufacturing techniques can include ceramic-based additive manufacturing including a binder, e.g., a polymer binder, to form a slurry including a ceramic powder and where a photosensitizer can be included in the slurry that is sensitized (e.g., is curable by) to a wavelength of light.
- a photopolymerization technique using ultraviolet (UV) light can be used to form a ceramic green body, which can then be consolidated into a ceramic part from the green body using a sintering process.
- UV ultraviolet
- additive manufacturing techniques can include coating process, where layers of a body are formed in a layer-by-layer process using coating techniques, e.g., plasma spray coating, screen printing, etc.
- Plasma spray coating process can be used to coat an exposed surface from a powder, e.g., a ceramic powder, metal powder, or a combination of ceramic and metallic powder.
- Screen printing can be used to form, for example, metal-based electrodes as described in this specification.
- a sintering (e.g., firing) process can be used to consolidate the ceramic powder/particles (e.g., remove porosity and densify the ceramic material) of a green state ceramic part.
- a sintering process can be performed at a high temperature below a melting point of the ceramic material(s) where the material of the separate particles diffuse towards neighboring power particles to form a densified ceramic body.
- the sintering process includes a pre-heat process to remove organic materials, e.g., polymer(s), lubricant, binders, etc.
- the sintering process includes a cooling process to cool down the ceramic parts to reduce cracking/stress formation.
- a rapid sintering process e.g., a flash sintering process, can be performed on set of green ceramic layers of a green ceramic body.
- a sintering process can be alternated with a forming/AM process, where a set number of layers are formed by AM and then sintered in sequence before another set of layers are formed by AM on the exposed surface of the body.
- portions of the ceramic body are formed in a green state and sintered in succession, where an end result of the process is a densified ceramic body.
- a refurbished part can be sintered such that the regrown layers of the refurbishing process are densified, e.g., to match characteristics of the original part.
- FIG.11 is a flow diagram of an example process 1100 for manufacturing a substrate support component for substrate processing.
- process 1100 will be described with respect to an additive manufacturing system that performs at least some steps of the process.
- An additive manufacturing system forms multiple layers in a layer-by-layer process to form an integral insulator body including a first surface and a second surface opposite the first surface, where a thickness of the insulator body exceeds an arcing threshold between a first body retained by the first surface and a second body supportive of the second surface (1102).
- the additive manufacturing system can receive, from a computer system, a data structure representative of the insulator body, and use the data structure to form the multiple layers of the insulator body.
- the insulator body e.g., insulator body 302
- the insulator body can include one or more thicknesses, e.g., 312 and 314, between the first body and the second body, each thickness being at least a threshold thickness based on a respective creepage path.
- the insulator body can be formed as a unified structure, e.g., without needing fixtures or other attachment features to affix two or more separate insulator sub-components together to form the insulator body.
- the additive manufacturing system forms, during the forming of the integral insulator body, multiple layers including one or more gas conduits within the insulator body extending from the first surface to the second surface and forming a gas flow path from the first surface to the second surface (1104).
- the one or more gas conduits e.g., gas conduit 320, can be formed during the AM process of forming the insulator body, e.g., where features are embedded in the layer-by-layer process according to the data structure representative of the insulator body used by the additive manufacturing system to form the features.
- the additive manufacturing system forms, during the forming of the integral insulator body, multiple layers including one or more gas conductance plugs embedded within first portions of the one or more gas conduits and having at least a threshold gas conductance through the gas conductance plug (1106).
- Each of the gas conductance plugs e.g., gas conductance plugs depicted in FIGS.5A-5J, can be made of a different material composition (e.g., a different ceramic) and/or having different structural characteristics than the ceramic body (e.g., a different porosity, internal structure).
- the forming of the layers including the gas conductance plug can include additive manufacturing techniques including forming the layer include two different material compositions simultaneously or sequentially.
- the conductor body e.g., conductor body 700
- the conductor body can be formed as a unified structure, e.g., without needing fixtures or other attachment features to affix two or more separate sub-components (e.g., a facilities plate and a cooling base) together to form the conductor body.
- One or more features e.g., cooling channels, gas conduits, and/or isolation features, can be formed during the AM process of forming the conductor body, e.g., where features are embedded in the layer-by-layer process according to the data structure representative of the conductor body used by the additive manufacturing system to form the features.
- Isolation features e.g., isolation features 902, 904, can be formed during the AM process to form the conductor body to reduce a cross-talk between an edge portion and a center portion of the conductor body, e.g., to improve thermal uniformity across the conductor body and, consequently, thermal uniformity across an ESC affixed to the conductor body and substrate retained by the ESC during a fabrication process.
- FIG.13 is a block diagram of an example computer system 1300 that can be used to perform operations described above. For example, such as operations performed by the controller 165.
- the system 1300 includes a processor 1310, a memory 1320, a storage device 1330, and an input/output device 1340.
- the processor 1310 is capable of processing instructions for execution within the system 1300.
- the processor 1310 is a single-threaded processor.
- the processor 1310 is a multi-threaded processor.
- the processor 1310 is capable of processing instructions stored in the memory 1320 or on the storage device 1330.
- the memory 1320 stores information within the system 1300.
- the memory 1320 is a computer-readable medium.
- the memory 1320 is a volatile memory unit.
- the memory 1320 is a non-volatile memory unit.
- the storage device 1330 is capable of providing mass storage for the system 1300.
- the storage device 1330 is a computer-readable medium.
- the storage device 1330 can include, for example, a hard disk device, an optical disk device, a storage device that is shared over a network by multiple computing devices (e.g., a cloud storage device), or some other large capacity storage device.
- the input/output device 1340 provides input/output operations for the system 1300.
- the input/output device 1340 can include one or more of a network interface device, e.g., an Ethernet card, a serial communication device, e.g., and RS-232 port, and/or a wireless interface device, e.g., and 802.11 card.
- the input/output device can include driver devices configured to receive input data and send output data to peripheral devices 1360, e.g., keyboard, printer and display devices.
- peripheral devices 1360 e.g., keyboard, printer and display devices.
- FIG.13 implementations of the subject matter and the functional operations described in this specification can be implemented in other types of digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them.
- computing devices such as controller 165 and processes performed by controller 165 such as controlling switching of etching gasses of a plasma processing chamber
- computing devices can be implemented in digital electronic circuitry, in tangibly- embodied computer software or firmware, in computer hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them.
- the subject matter and the actions and operations described in this specification can be implemented as or in one or more computer programs, e.g., one or more modules of computer program instructions, encoded on a computer program carrier, for execution by, or to control the operation of, data processing apparatus.
- the carrier can be a tangible non-transitory computer storage medium.
- the carrier can be an artificially-generated propagated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal, which is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus.
- the computer storage medium can be or be part of a machine-readable storage device, a machine-readable storage substrate, a random or serial access memory device, or a combination of one or more of them.
- a computer storage medium is not a propagated signal.
- data processing apparatus encompasses all kinds of apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, or multiple processors or computers.
- Data processing apparatus can include special-purpose logic circuitry, e.g., an FPGA (field programmable gate array), an ASIC (application-specific integrated circuit), or a GPU (graphics processing unit).
- the apparatus can also include, in addition to hardware, code that creates an execution environment for computer programs, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of one or more of them.
- a computer program can be written in any form of programming language, including compiled or interpreted languages, or declarative or procedural languages; and it can be deployed in any form, including as a stand-alone program, e.g., as an app, or as a module, component, engine, subroutine, or other unit suitable for executing in a computing environment, which environment can include one or more computers interconnected by a data communication network in one or more locations.
- a computer program can, but need not, correspond to a file in a file system.
- a computer program can be stored in a portion of a file that holds other programs or data, e.g., one or more scripts stored in a markup language document, in a single file dedicated to the program in question, or in multiple coordinated files, e.g., files that store one or more modules, sub-programs, or portions of code.
- the processes and logic flows described in this specification can be performed by one or more computers executing one or more computer programs to perform operations by operating on input data and generating output.
- the processes and logic flows can also be performed by special-purpose logic circuitry, e.g., an FPGA, an ASIC, or a GPU, or by a combination of special-purpose logic circuitry and one or more programmed computers.
- the subject matter described in this specification can be implemented on one or more computers having, or configured to communicate with, a display device, e.g., a LCD (liquid crystal display) monitor, or a virtual-reality (VR) or augmented-reality (AR) display, for displaying information to the user, and an input device by which the user can provide input to the computer, e.g., a keyboard and a pointing device, e.g., a mouse, a trackball or touchpad.
- a display device e.g., a LCD (liquid crystal display) monitor, or a virtual-reality (VR) or augmented-reality (AR) display
- VR virtual-reality
- AR augmented-reality
- a computer can interact with a user by sending documents to and receiving documents from a device that is used by the user; for example, by sending web pages to a web browser on a user’s device in response to requests received from the web browser, or by interacting with an app running on a user device, e.g., a smartphone or electronic tablet.
- a computer can interact with a user by sending text messages or other forms of message to a personal device, e.g., a smartphone that is running a messaging application, and receiving responsive messages from the user in return.
- a personal device e.g., a smartphone that is running a messaging application
- This specification uses the term “configured to” in connection with systems, apparatus, and computer program components. That a system of one or more computers is configured to perform particular operations or actions means that the system has installed on it software, firmware, hardware, or a combination of them that in operation cause the system to perform the operations or actions. That one or more computer programs is configured to perform particular operations or actions means that the one or more programs include instructions that, when executed by data processing apparatus, cause the apparatus to perform the operations or actions.
- That special-purpose logic circuitry is configured to perform particular operations or actions means that the circuitry has electronic logic that performs the operations or actions. While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what is being claimed, which is defined by the claims themselves, but rather as descriptions of features that can be specific to particular implementations of particular inventions. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple implementations separately or in any suitable subcombination.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Analytical Chemistry (AREA)
- Container, Conveyance, Adherence, Positioning, Of Wafer (AREA)
- Drying Of Semiconductors (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Elimination Of Static Electricity (AREA)
Abstract
Description
Claims
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| KR1020257034555A KR20250169211A (en) | 2023-06-14 | 2024-05-31 | Substrate support |
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| US18/209,649 | 2023-06-14 |
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| WO2024258641A1 true WO2024258641A1 (en) | 2024-12-19 |
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| US20240312770A1 (en) * | 2023-03-16 | 2024-09-19 | Applied Materials, Inc. | Apparatus and methods for controlling substrate temperature during processing |
Citations (5)
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| JP2020107762A (en) * | 2018-12-27 | 2020-07-09 | 東京エレクトロン株式会社 | Plasma processing apparatus and plasma processing method |
| US20220181127A1 (en) * | 2019-05-07 | 2022-06-09 | Lam Research Corporation | Electrostatic chuck system |
| US20220216086A1 (en) * | 2021-01-06 | 2022-07-07 | Ngk Insulators, Ltd. | Member for semiconductor manufacturing apparatus and method for manufacturing the same |
| US20230019718A1 (en) * | 2018-06-04 | 2023-01-19 | Applied Materials, Inc. | Substrate support pedestal |
| US20230170241A1 (en) * | 2021-11-29 | 2023-06-01 | Applied Materials, Inc. | Porous plug for electrostatic chuck gas delivery |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US8270141B2 (en) * | 2009-11-20 | 2012-09-18 | Applied Materials, Inc. | Electrostatic chuck with reduced arcing |
| US10586718B2 (en) * | 2015-11-11 | 2020-03-10 | Applied Materials, Inc. | Cooling base with spiral channels for ESC |
| TWI827502B (en) * | 2017-06-19 | 2023-12-21 | 美商應用材料股份有限公司 | Electrostatic chuck for high temperature processing chamber and forming method thereof |
| KR102891158B1 (en) * | 2019-10-24 | 2025-11-25 | 램 리써치 코포레이션 | Manufacturing semiconductor equipment modules using additive manufacturing |
| US12322634B2 (en) * | 2020-12-31 | 2025-06-03 | Entegris, Inc. | Electrostatic chuck prepared by additive manufacturing, and related methods and structures |
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- 2024-05-31 WO PCT/US2024/032096 patent/WO2024258641A1/en not_active Ceased
- 2024-06-06 TW TW113120959A patent/TWI911754B/en active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20230019718A1 (en) * | 2018-06-04 | 2023-01-19 | Applied Materials, Inc. | Substrate support pedestal |
| JP2020107762A (en) * | 2018-12-27 | 2020-07-09 | 東京エレクトロン株式会社 | Plasma processing apparatus and plasma processing method |
| US20220181127A1 (en) * | 2019-05-07 | 2022-06-09 | Lam Research Corporation | Electrostatic chuck system |
| US20220216086A1 (en) * | 2021-01-06 | 2022-07-07 | Ngk Insulators, Ltd. | Member for semiconductor manufacturing apparatus and method for manufacturing the same |
| US20230170241A1 (en) * | 2021-11-29 | 2023-06-01 | Applied Materials, Inc. | Porous plug for electrostatic chuck gas delivery |
Also Published As
| Publication number | Publication date |
|---|---|
| KR20250169211A (en) | 2025-12-02 |
| TW202507927A (en) | 2025-02-16 |
| TWI911754B (en) | 2026-01-11 |
| US20240420932A1 (en) | 2024-12-19 |
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