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US20100101728A1 - Plasma process apparatus - Google Patents

Plasma process apparatus Download PDF

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Publication number
US20100101728A1
US20100101728A1 US12/531,510 US53151008A US2010101728A1 US 20100101728 A1 US20100101728 A1 US 20100101728A1 US 53151008 A US53151008 A US 53151008A US 2010101728 A1 US2010101728 A1 US 2010101728A1
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US
United States
Prior art keywords
plasma
gas
chamber
plasma process
pipe
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.)
Abandoned
Application number
US12/531,510
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English (en)
Inventor
Masahide Iwasaki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tokyo Electron Ltd
Original Assignee
Tokyo Electron Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from JP2007088407A external-priority patent/JP5438260B2/ja
Priority claimed from JP2007088653A external-priority patent/JP5522887B2/ja
Application filed by Tokyo Electron Ltd filed Critical Tokyo Electron Ltd
Priority to US12/531,510 priority Critical patent/US20100101728A1/en
Assigned to TOKYO ELECTRON LIMITED reassignment TOKYO ELECTRON LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: IWASAKI, MASAHIDE
Publication of US20100101728A1 publication Critical patent/US20100101728A1/en
Priority to US14/257,040 priority patent/US9887068B2/en
Priority to US15/844,736 priority patent/US10734197B2/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • H01J37/32192—Microwave generated discharge
    • 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
    • C23C16/511—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 microwave discharges
    • 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
    • H01J37/32192—Microwave generated discharge
    • H01J37/32211—Means for coupling power to the plasma
    • H01J37/32229—Waveguides
    • 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
    • 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

Definitions

  • the present invention relates to a microwave plasma process apparatus that utilizes microwaves so as to carry out a predetermined plasma process, specifically to a microwave plasma process apparatus that supplies microwave power to plasma in a process chamber through electromagnetic wave coupling.
  • radio frequency (RF) waves and microwaves are used so as to discharge or ionize a process gas in a vacuum process chamber.
  • An RF plasma apparatus mainly employs capacity coupling where a pair of electrodes is located, one electrode in parallel with the other leaving an appropriate gap between the electrodes in the process chamber.
  • the RF waves are applied to one of the electrodes through a capacitor while the other electrode is grounded.
  • it is difficult to produce high density plasma at relatively low pressures in the RF plasma apparatus.
  • it is disadvantageous in that device elements on a wafer are more frequently damaged during the plasma process because the RF plasma inherently has high electron temperatures.
  • the microwave plasma apparatus is advantageous in that the microwaves can produce high density plasma with low electron temperatures at relatively low pressures. Additionally, the microwave plasma apparatus has another advantage in that the microwave plasma can be efficiently produced in a two-dimensional large area at a wider pressure range when a planar microwave introduction window through which the microwaves are introduced into the chamber is employed. Moreover, the microwave plasma apparatus may have a simple configuration as a whole because a magnetic field is not required (see Patent Document 1).
  • Patent Document 1 WO2005/045913 A1 (FIG. 1(A), FIG. 2)
  • microwave plasma is generated from a process gas by introducing microwaves and the process gas into the process chamber
  • the ways of introducing the microwaves and the process gas may be important factors that determine plasma characteristics and apparatus performance.
  • a first configuration has a shower plate serving as the microwave introduction window that opposes a susceptor.
  • the process gas is ejected downward through plural gas ejection holes uniformly distributed in the shower plate.
  • a second configuration has one or plural gas ejection holes formed in a side wall of the chamber in order to eject the process gas inward to a plasma region in the chamber.
  • the plasma density tends to be lower, which leads to a low etching rate when the plasma process apparatus is an etcher, and an inefficient process as a whole.
  • the shower plate having plural gas ejection holes provides a pathway through which the microwaves (electromagnetic waves) pass.
  • such a configuration may cause a problem of contamination or the like.
  • the process gas may be introduced into the process chamber through a gas ejection hole formed (pierced) through a dielectric window, which corresponds to a ceiling surface of the process chamber and opposes the susceptor.
  • the dielectric window serves as a microwave introduction window, that is, as a microwave propagation path, there exists an electric field inside the dielectric window. Therefore, the process gas is exposed to the microwave electric field when flowing through the dielectric window, and thus may be ionized in a gas conduit in the dielectric window or near the gas ejection hole, which causes abnormal discharging. Such abnormal discharging may affect the dielectric window, so that the dielectric window is deteriorated or damaged in a relatively short period of time, and may impair process performance.
  • the present invention has been made in order to eliminate at least one of the above-mentioned disadvantages, and provides a plasma process apparatus that can prevent abnormal discharging in a microwave transmission line or radiation path, or a process gas ejection portion, so that plasma excellent in plasma density uniformity and controllability can be realized, thereby improving performance or quality of the plasma process.
  • the present invention may provide a plasma process apparatus in which plasma conditions or the plasma process can easily and efficiently be monitored.
  • a first aspect of the present invention provides a plasma process apparatus that processes a substrate utilizing plasma.
  • the plasma process apparatus includes a process chamber that houses a substrate subjected to a predetermined plasma process and may be evacuated to a reduced pressure; a microwave generator that generates microwaves for generating plasma; a waveguide pipe that transmits the microwaves from the microwave generator to the process chamber; a waveguide pipe/coaxial pipe converter connected to one end of the waveguide pipe; a coaxial pipe that forms a line through which the microwaves are transmitted from the waveguide pipe-coaxial pipe converter to the process chamber, wherein an inner conductive body of the coaxial pipe has a hollow portion; and a first process gas supplying portion that supplies a process gas into the process chamber through the hollow portion of the inner conductive body of the coaxial pipe.
  • the microwaves output from the microwave generator propagate through the microwave transmission line including the waveguide pipe, the waveguide pipe/coaxial pipe converter, and the coaxial pipe, and are introduced into the process chamber, while the process gas from the process gas supplier flows through the hollow portion of the inner conductive body of the coaxial pipe, circumventing a microwave propagation path, and is introduced into the process chamber.
  • the process gas is ionized by the microwaves so as to generate plasma in the process chamber. Utilizing the plasma, the substrate is processed.
  • the plasma process apparatus may further include a susceptor on which the substrate is placed in the process chamber, and a dielectric window for introducing the microwaves into the process chamber, where the dielectric window serves as a ceiling surface opposing the susceptor.
  • the microwaves propagate as surface waves along a lower surface of the dielectric window, and the plasma is generated by the surface waves.
  • the dielectric window may be provided with a gas ejection opening that is in communication with the hollow portion of the inner conductive body, where the process gas can be ejected from the gas ejection opening into the process chamber.
  • the dielectric window may be one of constituent elements of a planar antenna to which an end portion of the coaxial pipe is connected.
  • This planar antenna may be a slot antenna in order to efficiently generate high density plasma.
  • the planar antenna may include a radial line slot antenna in order to generate a large area, or large diameter plasma.
  • the waveguide pipe-coaxial pipe converter converts the transmission mode in the waveguide pipe to a TEM mode in the coaxial pipe.
  • the waveguide pipe may be square-shaped, where one end portion of the inner conductive body protrudes into the square-shaped waveguide pipe, and the protruding end portion becomes thicker along the protruding direction in the waveguide pipe-coaxial pipe converter.
  • the hollow portion penetrates the inner conductive body of the coaxial pipe so as to allow a process gas to enter the hollow portion from an inlet opening made in the protruding end portion of the inner conductive portion and to be ejected from a hole directed toward the interior of the process chamber.
  • the inner conductive body of the coaxial pipe may include a coolant conduit through which a coolant may flow.
  • the plasma process apparatuses with at least one of the above-stated additional features may be provided with a second process gas supplying portion that introduces a process gas into the chamber.
  • the second process gas supplying portion may include a side wall eject hole from which the process gas is ejected toward a center portion of the process chamber.
  • a first flow rate control portion that controls the flow rate of the process gas introduced into the process chamber through the first process gas supplying portion; and a second flow rate control portion that controls the flow rate of the process gas introduced into the process chamber through the second process gas supplying portion.
  • the plasma process apparatus may include a radio frequency wave generator that applies radio frequency waves to the susceptor in order to generate a self bias voltage in the susceptor, or a magnetic field producing portion that surrounds the process chamber so as to produce a magnetic field around the process chamber, thereby causing electron cyclotron resonance in the plasma in the process chamber.
  • a second aspect of the present invention provides a plasma process apparatus in which a substrate subjected to a predetermined plasma process is housed in a process chamber that may be evacuated to a reduced pressure and plasma is generated from a process gas introduced into the process chamber by introducing microwaves so as to perform the predetermined plasma process on the substrate.
  • the plasma process apparatus includes a microwave transmission line that transmits the microwaves from a microwave generator to the process chamber, wherein a predetermined section of the microwave transmission line, the section including one end portion of the microwave transmission line, is formed of a coaxial line, and wherein an inner conductive body of the coaxial line is formed of a hollow pipe through which the process gas is introduced into the process chamber.
  • a third aspect of the present invention provides a plasma process apparatus in which a substrate subjected to a predetermined plasma process is housed in a process chamber that may be evacuated to a reduced pressure and plasma is generated from a process gas introduced into the process chamber by introducing microwaves so as to perform the predetermined plasma process on the substrate.
  • the plasma process apparatus includes a microwave transmission line that transmits the microwaves from a microwave generator to the process chamber, wherein a predetermined section of the microwave transmission line, the section including one end portion of the microwave transmission line, is formed of a coaxial line whose inner conductive body is formed of a hollow pipe, and a monitor portion that monitors through the hollow pipe the plasma process performed in the process chamber.
  • the microwaves output from the microwave generator propagate through the microwave transmission line and are introduced into the process chamber, and the microwaves ionize the process gas so as to generate plasma in the process chamber.
  • the substrate is processed with the plasma.
  • the plasma conditions or the plasma process in the process chamber can be monitored in-situ through the hollow portion of the inner conductive body of the coaxial pipe that may constitute at least one portion of the microwave transmission line by the monitor portion.
  • the monitor portion includes a plasma emission measurement portion that spectroscopically measures emission of the plasma in the process chamber, an optical thickness measurement portion that measures the thickness of a film on the substrate held on a susceptor in the process chamber, or a temperature sensor that measures temperature inside the process chamber.
  • a fourth aspect of the present invention provides a plasma process apparatus that utilizes plasma so as to perform a predetermined process on a substrate.
  • the plasma process apparatus includes a process chamber that houses a substrate subjected to the predetermined plasma process and may be evacuated to a reduced pressure; a microwave generator that generates microwaves for generating plasma; a dielectric window through which the microwaves are introduced to the process chamber; a microwave transmission line that transmits the microwaves from the microwave generator to the dielectric window; and a first process gas supplying portion including a gas conduit that penetrates the dielectric window to the process chamber in order to supply a process gas into the process chamber, the gas conduit being electrically conductive and grounded.
  • the process gas from a process gas supplier of the first process gas supplying portion flows through the gas conduit, which is grounded, and the dielectric window. Therefore, the process gas is not exposed to an electric field due to the microwaves, and thus abnormal discharging can be prevented.
  • the gas conduit may penetrate one portion of the dielectric window, or plural of the gas conduits may penetrate corresponding plural portions of the dielectric window in the plasma process apparatus according to the fourth aspect.
  • the gas conduit preferably penetrates substantially the center of the dielectric window when the gas conduit penetrates one portion of the dielectric window, and the plural portions are preferably located symmetrically in relation to substantially the center of the dielectric window.
  • a gas ejection portion of the gas conduit may protrude into the process chamber from the dielectric window, and specifically the gas ejection portion of the gas conduit is preferably at a distance 10 mm or more from the dielectric window in the plasma process apparatus according to the fourth aspect.
  • the gas ejection portion can be located out of a plasma generation region, or in a plasma diffusion region, so as to prevent abnormal discharging around the gas ejection portion.
  • the plasma process apparatus may include a susceptor on which the substrate is placed in the process chamber, wherein the dielectric window serves as a ceiling surface opposing the susceptor.
  • the plasma process apparatus may preferably be provided with a radio frequency wave generator in order to apply radio frequency waves in order to generate a self bias voltage in the susceptor and thus attract ions in the plasma.
  • the dielectric window is one of constituent elements of a planar antenna in the plasma process apparatus according to the fourth aspect with at least one of the above-stated additional features.
  • the planar antenna may include a radial line slot antenna.
  • the microwave transmission line includes a coaxial pipe whose end portion is connected to the planer antenna.
  • the gas conduit is formed in an inner conductive body in the plasma process apparatus according to the fourth aspect with at least one of the above-stated additional features.
  • the inner conductive body preferably includes a hollow portion that may be used to allow gas to flow therethrough, the hollow portion extending along a center axis of the inner conductive body.
  • the gas conduit is preferably in communication with the hollow portion and extends into the process chamber through a through hole made in the dielectric window.
  • the microwave transmission line includes a waveguide pipe one of whose ends is connected to the microwave generator; a waveguide pipe/coaxial pipe converter that couples another end of the waveguide pipe with one end of the coaxial pipe in order to convert one transmission mode of electromagnetic waves in the waveguide pipe to another transmission mode in the coaxial pipe.
  • the microwaves output from the microwave generator propagate through the waveguide pipe, the waveguide pipe/coaxial pipe converter, and the coaxial pipe and are introduced into the process chamber, while the process gas from the process gas supplying portion flows through the gas conduit, which is grounded, including the inner conductive body of the coaxial pipe, without being exposed to the electric field due to the microwaves and is introduced into the process chamber,
  • the plasma process apparatus further includes a second process gas supplying portion that introduces the process gas into the chamber.
  • the second process gas supplying portion may include a side wall eject hole from which the process gas is ejected toward a center portion of the process chamber.
  • the plasma process apparatus according to the fourth aspect further includes a first flow rate control portion that controls a flow rate of the process gas introduced into the process chamber by the first process gas supplying portion; and a second flow rate control portion that controls a flow rate of the process gas introduced into the process chamber by the second process gas supplying portion.
  • a fifth aspect of the present invention provides a plasma process apparatus that utilizes plasma so as to perform a predetermined process on a substrate.
  • the plasma process apparatus includes a process chamber that houses a substrate subjected to the predetermined plasma process; an evacuation portion that evacuates the process chamber to a reduced pressure; a gas supplying line for supplying a process gas into the process chamber, the gas supplying line being electrically conductive and grounded; a microwave generator that generates microwaves for generating plasma; a dielectric window through which the microwaves are introduced to the process chamber, the dielectric window extending around the gas supplying line; and a microwave transmission line that transmits the microwaves from the microwave generator to the dielectric window.
  • the process gas from a process gas supplier of the process gas supplying portion flows through the gas supplying line, and is introduced into the process chamber, while the microwaves output from the microwave generator propagate through the microwave transmission line, and are introduced into the process chamber through the dielectric window extending around the gas supplying line.
  • the process gas ejected from a gas ejection opening of one end of the gas supplying line diffuses in the chamber, and is ionized near the dielectric window by the microwaves.
  • the end of the gas supplying line preferably protrudes from the dielectric window into the process chamber.
  • a plasma process apparatus that can prevent abnormal discharging in a microwave transmission line or radiation path, or a process gas ejection portion, is provided, so that plasma excellent in plasma density uniformity and controllability can be realized, thereby improving performance or quality of the plasma process.
  • a plasma process apparatus in which plasma conditions or a plasma process can easily be monitored may also be provided.
  • FIG. 1 is a schematic cut-open view of a plasma process apparatus according to a first embodiment of the present invention
  • FIG. 2 schematically shows a primary portion of the plasma process apparatus shown in FIG. 1 ;
  • FIG. 3 is a plan view of a slot antenna used in the plasma process apparatus shown in FIG. 1 ;
  • FIG. 4 is a schematic cut-open view of a modification example of the plasma process apparatus according to the first embodiment of the present invention.
  • FIG. 5 is a schematic cut-open view of another modification example of the plasma process apparatus according to the first embodiment of the present invention.
  • FIG. 6 is a schematic cut-open view of a plasma process apparatus according to a second embodiment of the present invention.
  • FIG. 7 schematically shows a primary portion of the plasma process apparatus shown in FIG. 6 ;
  • FIG. 8 shows an experimental result of electron density distribution along a direction from a dielectric window to a susceptor in the plasma process apparatus shown in FIG. 6 ;
  • FIG. 9 shows an experimental result of electron temperature distribution along a direction from a dielectric window to a susceptor in the plasma process apparatus shown in FIG. 6 ;
  • FIG. 10 is a schematic cut-open view of a modification example of the plasma process apparatus according to the second embodiment of the present invention.
  • FIG. 1 is a schematic cut-open view of a microwave plasma etching apparatus 1 according to a first embodiment of the present invention.
  • the microwave plasma etching apparatus 1 which is configured as a planar SWP type plasma process apparatus, has a cylinder-shaped chamber (process chamber) 10 made of metal such as aluminum or stainless steel.
  • the chamber 10 is grounded for security reasons.
  • a susceptor 12 In a lower center portion of the chamber 10 , there is a susceptor 12 on which a semiconductor wafer W (referred to as a wafer W below) is placed.
  • the susceptor 12 is horizontally supported by a cylindrical supporting portion 14 extending upward from the bottom of the chamber 10 .
  • the cylindrical supporting portion 14 is made of an insulating material.
  • the susceptor 12 is shaped into a circular plate and made of, for example, aluminum, serving also as a lower electrode to which radio frequency waves are applied.
  • a ring-like evacuation pathway 18 is provided between the inner wall of the chamber 10 and another cylindrical supporting portion 16 that extends upward from the bottom of the chamber 10 and along the outer circumferential surface of the cylindrical supporting portion 14 .
  • the cylindrical supporting portion 16 is electrically conductive.
  • a ring-like baffle plate 20 is arranged at a top portion (or an inlet portion) of the evacuation pathway 18 , and an evacuation port 22 is provided below the evacuation pathway 18 .
  • plural of the evacuation ports 22 are preferably provided at equal angular intervals along a circumferential direction.
  • Each of the evacuation ports 22 is connected to an evacuation apparatus 26 through an evacuation pipe 24 .
  • the evacuation apparatus 26 may have a vacuum pump such as a turbo molecular pump (TMP), which can evacuate the chamber 10 to a desired reduced pressure.
  • TMP turbo molecular pump
  • a gate valve 28 is attached on an outer wall of the chamber 10 . The gate valve 28 opens and closes a transport opening through which the wafer W is transported into or out from the chamber 10 .
  • the susceptor 12 is electrically connected to a radio frequency power supply 30 that applies an RF bias voltage to the susceptor 12 through a matching unit 32 and a power feeding rod 34 .
  • the power supply 30 outputs, at a predetermined electric power level, radio frequency waves having a relatively low frequency of, for example, 13.56 MHz. Such a low frequency is suitable to control the energy of ions to be attracted to the wafer W on the susceptor 12 .
  • the matching unit 32 includes a matching element for matching output impedance of the power supply 30 with impedance of a load including the electrode (susceptor), the plasma produced in the chamber 10 , and the chamber 10 .
  • the matching element has a blocking condenser for generating self bias.
  • An electrostatic chuck 36 is provided on the upper surface of the susceptor 12 .
  • the electrostatic chuck 36 holds the wafer W by electrostatic force on the susceptor 12 .
  • the electrostatic chuck 36 has an electrode 36 a formed of an electroconductive film and a pair of insulating films 36 b , 36 c that sandwich the electrode 36 a .
  • a DC power supply 40 is electrically connected to the electrode 36 a via a switch 42 .
  • the DC voltage applied to the electrostatic chuck 36 from the DC power supply 40 produces a Coulomb force, which in turn holds the wafer W onto the electrostatic chuck 36 .
  • a focus ring 38 is provided in order to surround the wafer W.
  • a cooling medium chamber 44 is provided inside the susceptor 12 .
  • the cooling medium chamber 44 has a ring-shape extending in a circumferential direction.
  • a cooling medium or cooling water at a predetermined temperature is supplied to the cooling medium chamber 44 through conduits 46 , 48 from a chiller unit (not shown) so as to circulate through the cooling medium chamber 44 and the conduits 46 , 48 .
  • a thermal conduction gas such as He gas is supplied between the wafer W and the electrostatic chuck through a gas supplying pipe 50 from a thermal conduction gas supplying portion (not shown).
  • the chamber 10 is provided with elevatable lift pins (not shown) that vertically penetrate the susceptor 12 and raise/lower the wafer W when the wafer W is loaded into or unloaded from the chamber 10 .
  • the lift pins may be driven by an elevation mechanism (not shown).
  • a planar antenna 55 is provided above the susceptor 12 in order to introduce the microwaves into the chamber 11 .
  • the planar antenna 55 includes a circular quartz plate 52 as a dielectric window and a circular radial line slot antenna (RLSA) 54 .
  • the quartz plate 52 is hermetically attached to the chamber 10 and serves as a ceiling surface of the chamber 11 that opposes the susceptor 12 .
  • the RLSA 54 is located on the upper surface of the quartz plate 52 , and has plural slots distributed along concentric circles.
  • the RLSA 54 is electromagnetically coupled to a microwave transmission line 58 via a slow wave plate 56 formed of a dielectric material, for example, quartz.
  • the microwave transmission line 58 has a waveguide pipe 62 , a waveguide pipe/coaxial pipe converter 64 , and a coaxial pipe 66 , and transmits the microwaves output from a microwave generator 60 to the RLSA 54 .
  • the waveguide pipe 62 is formed of, for example, a square pipe, and transmits the microwaves in a TE mode from the microwave generator 60 through the waveguide pipe-coaxial pipe converter 64 .
  • the waveguide pipe/coaxial pipe converter 64 couples the waveguide pipe 62 with the coaxial pipe 66 , and converts the TE mode microwaves in the waveguide pipe 62 to TEM mode microwaves in the coaxial pipe 66 .
  • the converter 64 preferably has a larger diameter at an upper portion connected to the waveguide pipe 62 , and a smaller diameter at a lower portion connected to an inner conductor 68 of the coaxial pipe 66 in order to avoid a concentrated electromagnetic field, which may be present at high power transmission levels.
  • the converter 64 is preferably shaped into an inverted cone (or a door knob) as shown in FIGS. 1 and 2 .
  • the converter 64 may be referred to as an inverted cone portion 68 a for simplicity of explanation below.
  • the coaxial pipe 66 extends vertically downward from the converter 64 to an upper center portion of the chamber 10 and is coupled with the RLSA 54 .
  • the coaxial pipe 66 has an outer conductor 70 and the inner conductor 68 .
  • the outer conductor 70 is connected to the waveguide pipe 62 at the upper end and extends downward so as to reach the slow wave plate 56 .
  • the inner conductor 68 is connected to the converter 64 at the upper end and extends downward so as to reach the RLSA 54 .
  • the microwaves propagate in the TEM mode between the inner conductor 68 and the outer conductor 70 .
  • the microwaves output from the microwave generator 60 are transmitted through the microwave transmission line 58 including the waveguide pipe 62 , the converter 64 , and the coaxial pipe 66 , and are supplied to the RLSA 54 passing through the slow wave plate 56 . Then, the microwaves are spread in a radial direction in the slow wave plate 56 and emitted toward the chamber 10 through the slots of the RLSA 54 .
  • the microwaves emitted through the slots propagate along the lower surface of the quartz plate 52 as surface waves, and ionize gas near the lower surface of the quartz plate 52 , thereby generating plasma in the chamber 10 .
  • An antenna back surface plate 72 is provided on the upper surface of the slow wave plate 56 .
  • the antenna back surface plate 72 is made of, for example, aluminum.
  • the antenna back surface plate 72 contains fluid conduits 74 to which a chiller unit (not shown) is connected so that a cooling medium or cooling water at a predetermined temperature is circulated through the conduits 74 and pipes 76 , 78 .
  • the antenna back surface plate 72 serves as a cooling jacket that absorbs heat generated in the quartz plate 52 and transfers the heat to the outside.
  • a gas conduit 80 is provided so as to go through the inner conductor 68 of the coaxial pipe 66 in this embodiment.
  • a first gas supplying pipe 84 ( FIG. 1 ) is connected at one end to an upper opening of the gas conduit 80 and at the other end to a process gas supplier 82 .
  • a gas ejection opening 86 is formed at the center portion of the quartz plate 52 and open to the chamber 10 .
  • a first process gas introduction portion 88 having the above configuration, the process gas from the process gas supplier 82 flows through the first gas supplying pipe 84 and the gas conduit 80 in the coaxial pipe 66 , and is ejected from the gas ejection opening 86 toward the susceptor 12 located below the gas ejection opening 86 .
  • the ejected process gas is spread outward in a radial direction in the chamber 10 , partly because the process gas is pulled toward the evacuation pathway 18 surrounding the susceptor 12 by the evacuation apparatus 26 .
  • the first gas supplying pipe 84 is provided with a mass flow controller (MFC) 90 and an on-off valve 92 in the middle.
  • MFC mass flow controller
  • a second process gas introduction portion 94 is provided in addition to the first process gas introduction portion 88 in order to introduce the process gas to the chamber 10 .
  • the second process gas introduction portion 94 includes a buffer chamber 96 , plural side ejection holes 98 , and a gas supplying pipe 100 .
  • the buffer chamber 98 is shaped into a hollow ring that extends inside the side wall portion of the chamber 10 and along a circumferential direction of the side wall portion, and is located slightly lower than the quartz plate 52 .
  • the plural side ejection holes 98 are open toward the plasma region in the chamber 10 , arranged at equal angular intervals along an inner wall of the chamber 10 , and in gaseous communication with the buffer chamber 96 .
  • the gas supplying pipe 100 connects the buffer chamber 96 to the process gas supplier 82 .
  • the gas supplying pipe 100 is provided with an MFC 102 and an on-off valve 104 in the middle.
  • the process gas from the process gas supplier 82 is introduced into the buffer chamber 96 in the side wall portion of the chamber 10 through the second process gas supplying pipe 100 .
  • Pressure in the buffer chamber 96 filled with the process gas becomes uniform along the circumferential direction of the buffer chamber 96 , which allows the process gas to be uniformly and horizontally ejected from the plural ejection holes 98 toward the plasma region in the chamber 10 .
  • the process gas ejected from the gas ejection opening 86 located at the center of the quartz plate 52 is spread in an outward radial direction and flows toward the evacuation pathway 18 as stated above, the process gas ejected from the side ejection holes 98 is not affected to a great extent by the evacuation apparatus 26 in this embodiment. Therefore, the plasma can be uniformly distributed above the wafer W on the susceptor 12 .
  • the process gases introduced into the chamber 10 respectively from the first process gas introduction portion 88 and the second process gas introduction portion 94 may be the same, or different.
  • Flow rates of the gases can be controlled by the MFCs 90 and 102 , respectively, or the gases are introduced into the chamber at a predetermined flow rate ratio, so that the gases and thus the plasma are uniformly distributed in the radial direction.
  • the inner conductor 68 is made of, for example, aluminum.
  • the gas conduit 80 penetrates the inner conductor 68 along a center axis of the inner conductor 68 .
  • a cooling medium conduit 106 is formed in parallel with the gas conduit 80 .
  • the cooling medium conduit 106 includes an incoming path 106 a and an outgoing path 106 b that are divided by a vertical partition (not shown).
  • a pipe 108 is connected to the incoming path 106 a of the cooling medium conduit 106 .
  • the opposite end of the pipe 108 is connected to a chiller unit (not shown).
  • a pipe 110 is connected to the outgoing path 106 b of the cooling medium conduit 106 .
  • the opposite end of the pipe 110 is connected to the same chiller unit.
  • the gas conduit 80 is fitted, as shown in FIG. 2 .
  • the opening 54 a is located in coaxial alignment with the gas ejection opening 86 of the quartz plate 52 .
  • the electromagnetic waves (microwaves) radiated from the RLSA 54 do not reach the gas ejection opening 86 , and thus no discharging takes place in the gas ejection opening 86 .
  • the gas ejection opening 86 may be branched into plural holes in the quartz plate 52 . The plural holes may be located within a certain range in the radial direction of the quartz plate 52 .
  • FIG. 3 shows a slot pattern in the RLSA 54 in this embodiment.
  • the RLSA 54 has plural slots distributed in concentric circles. Specifically, two kinds of slots 54 b , 54 c whose longitudinal directions are substantially at right angles are distributed in alternating concentric circles. These concentric circles are arranged at radial intervals depending on wavelengths of the microwaves propagating in the radial direction of the RLSA 54 .
  • the microwaves are converted into circularly polarized planar waves having two polarization components intersecting with each other, and the planar waves are radiated from the RLSA 54 .
  • the RLSA 54 configured as described above is advantageous in that the microwaves may be uniformly radiated into the chamber 10 ( FIG. 1 ) from substantially the entire region of the antenna, and suitable to generate nonuniform and stable plasma.
  • a controlling portion composed of, for example, a microcomputer in the microwave plasma etching apparatus 1 according to the first embodiment of the present invention.
  • the gate valve 28 is opened, and a wafer W subjected to the etching process is transferred into the chamber 10 and placed on the electrostatic chuck 36 .
  • etching gases generally, mixed gases
  • the chamber 10 is evacuated by the evacuation apparatus 26 so that the inner pressure of the chamber 10 becomes at a set pressure.
  • the RF power source 30 is activated in order to output the RF waves at a predetermined power level to the susceptor 12 through the matching element 32 and the power feeding rod 34 .
  • the switch 42 is turned on in order to apply the DC voltage from the DC voltage supplier 44 to the electrode 36 a of the electrostatic chuck 36 , by which the wafer W is firmly held on the electrostatic chuck 36 .
  • the microwave generator 60 is turned on in order to apply the microwaves to the RLSA 54 through the microwave transmission line 58 , and thus the microwaves are introduced into the chamber 10 from the RLSA 54 through the quartz plate 52 .
  • the etching gases introduced into the chamber 10 from the gas ejection opening 86 of the first process gas introduction portion 88 and the side ejection holes 98 of the second process gas introduction portion 94 diffuse below the quartz plate 52 and are ionized by the microwave energy radiated from the surface waves (microwaves) propagating along the lower surface of the quartz plate 52 , and thus the surface plasma is generated. Then, the plasma generated below the quartz plate 52 diffuses downward so as to etch a film on the wafer W in an isotropic manner with radicals in the plasma, or to vertically etch the film by irradiation of ions in the plasma.
  • the microwave plasma etching apparatus 1 as the microwave plasma etching apparatus, high density plasma is generated through surface wave excitation, so that the electron temperature of the plasma near the wafer W on the susceptor 12 is as low as about 0.7 through about 1.5 eV. Therefore, ion irradiation energy is reduced, thereby alleviating damage to the film to be etched.
  • the microwave energy is introduced in a large area through the RLSA 54 , the plasma etching apparatus can easily process large size wafers.
  • the gas conduit 80 is made to pass through the inner conductor 68 of the axial pipe 66 , which is an end portion of the microwave transmission line 58 , and the process gas is introduced into the chamber 10 from the gas ejection opening 86 through the gas conduit 80 , plasma density uniformity and thus over-the-wafer uniformity of the etching rate can be improved without any adverse effects of reduced antenna performance and abnormal discharging.
  • the microwave plasma etching apparatus 1 since the microwave plasma etching apparatus 1 generates the microwave plasma without applying a magnetic field to the chamber 10 , the need for a magnetic field generation mechanism including a permanent magnet, a magnetic coil, or the like can be eliminated, so that the microwave plasma etching apparatus has a simple configuration. Even so, the plasma etching apparatus according to the embodiment may be another type of plasma etching apparatus employing, for example, Electron Cyclotron Resonance (ECR).
  • ECR Electron Cyclotron Resonance
  • an ECR plasma process apparatus includes a magnet field generation mechanism 112 having a permanent magnet or a magnetic coil around the chamber 10 .
  • the magnetic field generation mechanism 112 can apply a magnetic field to a plasma generation space in the chamber 10 so that the frequency of the microwaves is equal to the electron cyclotron frequency at any point in the plasma generation space, by which high density plasma can be generated.
  • the magnetic field may be 875 Gauss in the case of 2.45 GHz.
  • the second process gas introduction portion 94 ( FIG. 1 ) can be omitted, as shown in FIG. 4 , while the first process gas introduction portion 88 is employed in order to introduce the process gas from the upper center portion (the gas ejection opening 86 ) of the chamber 10 .
  • a hollow space formed in the inner conductor 68 of the coaxial pipe 66 which corresponds to the gas conduit 80 in FIG. 2 , may be used for other purposes in other embodiments according to the present invention.
  • a monitor portion 114 is located above the inverse cone portion 68 a , and the hollow space of the inner conductor 68 serves as an optical measurement line through which the plasma process is monitored by the monitor portion 114 .
  • the plasma spectrum may be observed by the monitor portion 114 through an optical fiber probe (not shown) that is inserted into the hollow space located at the upper center portion of the chamber 10 , and analyzed by spectrometry.
  • the end point can be known when a peak intensity of a particular emission originating from a particular gas specie is increased or decreased.
  • the hollow space of the inner conductor 68 may be used as a light path through which a laser beam propagates, in order to measure the thickness of an antireflection film or a resist film on the wafer W.
  • a temperature sensor having the thermocouple at the distal end may be inserted through the hollow space of the inner conductor 68 in order to measure a temperature at and around the upper center portion of the chamber 10 .
  • the inner conductor 68 of the coaxial pipe 66 may have different conduits from the conduit 80 .
  • a plural pipe configuration employing, for example, a double pipe may be employed in the inner conductor 68 of the coaxial pipe 66 , instead of the gas conduit 80 .
  • each pipe of the plural pipes can be used as an independent line (a gas supplying line, a measurement line, or the like).
  • a third process gas introduction portion may be provided to the plasma etching apparatus 1 according to this embodiment of the present invention, in addition to or instead of the first and the second process gas introduction portions 88 , 94 , in order to introduce the process gasses into the chamber 10 .
  • the microwaves may be introduced into chamber not through an antenna but through a duct, which may be referred to as a microwave injection method.
  • the microwave transmission line 58 may be differently configured.
  • another transmission line may be inserted between the microwave generator 60 and the waveguide pipe 62 having a square-shaped opening.
  • a circular pipe may be used instead of the waveguide pipe 62 .
  • the inverse cone portion 68 a of the converter 64 may be made into a ridge guide shape instead of the door knob shape.
  • a circular waveguide pipe may be electromagnetically coupled to the chamber 10 without employing the converter 64 .
  • FIG. 6 is a schematic cut-open view of the plasma process apparatus 2 according to the second embodiment of the present invention. While the plasma process apparatus 2 according to the second embodiment is operated, when etching the wafer W in substantially the same manner as the plasma process apparatus 1 according to the first embodiment, the plasma process apparatus 2 is different in a gas ejection configuration at the top center portion of the chamber 10 from the plasma process apparatus 1 according to the first embodiment of the present invention. The following explanation is focused on the difference.
  • the gas conduit 80 goes through the inner conductor 68 of the coaxial pipe 66 , and the top portion of the gas conduit 80 is connected to the process gas supplier 82 through the first gas supplying pipe 84 , which places the gas conduit 80 in gaseous communication with the first gas supplying pipe 84 .
  • a conductive injector portion 110 is connected to the lower portion of the inner conductor 68 so as to be in gaseous communication with the gas conduit 80 .
  • the injector portion 110 penetrates the quartz plate 52 and protrudes downward from the lower surface of the quartz plate 52 .
  • the injector portion 110 has a gas ejection opening 110 a at the bottom end, through which the process gas is ejected into the chamber 10 .
  • a first process gas introduction portion 88 having such a configuration, the process gas supplied at a predetermined pressure from the process gas supplier 82 flows through the first gas supplying pipe 84 , the gas conduit 80 , and the injector portion 110 in this order, and is ejected into the plasma region in the chamber 10 from the gas ejection opening 110 a of the injector portion 110 .
  • the first process gas supplying pipe 84 has a mass flow controller (MFC) 90 and an open/close valve 92 .
  • MFC mass flow controller
  • the inner conductor 68 of the coaxial pipe 66 is made of, for example, aluminum, and has the gas conduit 80 penetrating the inner conductor 68 along a center axis of the inner conductor 68 .
  • the injector portion 110 is also made of, for example, aluminum, and has a gas conduit 112 in gaseous communication with the gas conduit 80 in the inner conductor 68 of the coaxial pipe 66 .
  • the first gas supplying pipe 84 may be made of a metal (or conductor), or a resin (or insulator).
  • the injector portion 110 is composed of an upper half portion 114 having a large diameter and a lower half portion 116 having a small diameter.
  • the upper half portion 114 is fitted into a concave portion 118 formed in the quartz plate 52 , and the lower half portion 116 is inserted into a through hole 120 that extends from the center bottom of the concave portion 118 through the lower surface of the quartz plate 52 .
  • a seal member 122 such as an O ring is sandwiched by the upper half portion 114 and the bottom surface of the concave portion 118 , and thus hermetically seal the upper half portion 114 relative to the concave portion 118 (the quartz plate 52 ).
  • the coaxial pipe 66 and the injector portion 110 are preferably arranged along a normal line passing through a center of axial symmetry, or the center of RLSA 54 (the chamber 10 and the susceptor 12 ).
  • an upper portion of the injector portion 110 contacts an opening 54 a of the RLSA 54 . Therefore, the injector portion 110 can be grounded via the RLSA 54 and the chamber 10 , or through the inner conductor 68 of the coaxial pipe 66 , the outer conductor 70 , the antenna back surface plate 72 , and the chamber 10 in this order.
  • the lower half portion 116 having the smaller diameter protrudes downward from the through hole 120 of the quartz plate 52 into the chamber 10 .
  • a protrusion distance d of the lower half portion 116 (or, the distance between the gas ejection opening 110 a and the lower surface of the quartz plate 52 ) may be about 10 mm or more, for reasons described below.
  • the gas conduit 80 goes through the inner conductor 68 of the axial pipe 66 , which is an end portion of the microwave transmission line 58 .
  • the conductive injector portion 110 which is in gaseous communication with the gas conduit 80 , is connected to the lower end portion of the inner conductor 68 and grounded along with the inner conductor 68 .
  • the injector portion 110 penetrates the RLSA 54 and the quartz plate 52 so as to protrude into the chamber 10 .
  • plasma characteristics such as the plasma generation efficiency, plasma density distribution and the like can be stably maintained, thereby improving the process performance. Additionally, the quartz plate 52 is prevented from being deteriorated or damaged, thereby lengthening the operational service life of the quartz plate 52 .
  • the injector portion 110 protrudes into the chamber 10 by an appropriate distance d, discharging can be prevented at the gas ejection opening 110 a in this embodiment.
  • the process gas molecules near the lower surface are ionized so that the microwave plasma is highly concentrated near the lower surface of the quartz plate 52 .
  • the surface wave energy is rapidly reduced only a slight distance away from the lower surface of the quartz plate 52 .
  • a region of reduced surface wave energy is called a plasma diffusion region where active species generated in the plasma can only diffuse. Namely, when the gas ejection opening 110 a of the injector portion 110 is located away from the lower surface of the quartz plate 52 and in the plasma diffusion region, the ionization of the process gas is effectively prevented at the gas ejection opening 110 a.
  • FIG. 8 shows an experimental result of a plasma density distribution along a vertical direction (Z) in the microwave plasma process apparatus 2 according to the second embodiment of the present invention.
  • FIG. 9 shows an experimental result of a plasma temperature distribution along a vertical direction (Z) in the microwave plasma process apparatus 2 according to the second embodiment of the present invention. From these figures, it is understood that any position at a distance about 10 mm or more from the dielectric window (the quartz plate 52 ) is in the plasma diffusion region. This is the reason why the protrusion distance d of the gas ejection opening 110 a is determined to be about 10 mm or more However, when the protrusion distance d becomes larger, it becomes difficult for the process gas ejected from the gas ejection opening 110 a to flow upward and reach the quartz plate 52 .
  • the protrusion distance d is preferably about 30 mm or less.
  • the gas ejection opening 110 a of the injector portion 110 is preferably located at a distance about 20 mm or more from the wafer W on the susceptor 12 , considering whether the lower end of the injector portion 110 hinders the transfer of the wafer W into and out from the chamber 10 , affects the microwave distribution and RF bias applied to the susceptor 12 , which may affect an etching rate, and whether the distance over which the process gas can diffuse above the wafer W is sufficient enough to obtain a desired process gas distribution.
  • FIG. 7 shows that the process gas is ejected downward from the gas ejection opening 110 a
  • the process gas may be ejected horizontally from the lower end portion of the injector portion 110 , or in a radial direction of the chamber 10 .
  • a plural pipe configuration employing, for example, a double pipe may be employed in the inner conductor 68 of the coaxial pipe 66 .
  • each pipe of the plural pipes can be used as an independent line (a gas supplying line, a measurement line, or the like).
  • the gas conduit 80 located in the inner conductor 68 of the coaxial pipe 66 in order to introduce the process gas through the quartz plate (ceiling plate) 52 is used as part of the gas supplying line of the first process gas introduction portion 88 , the through hole of the quartz plate 52 through which the gas supplying line (especially the injector portion 110 ) goes can be as short as possible, thereby reducing the probability of abnormal discharging.
  • the gas supplying line in the first process gas introduction portion 88 may be modified so that the gas supplying line does not go through the inner conductor 68 of the coaxial pipe 66 .
  • the first gas supplying pipe 84 may be inserted from a side wall of the quartz plate 52 through an opening made in a side wall of the chamber 10 and horizontally extended in the quartz plate 52 , and may be bent at the center portion of the quartz plate 52 so as to protrude downward from the lower surface of the quartz plate 52 as shown in FIG. 10 .
  • the first gas supplying pipe 84 may be connected to a side opening made in the injector portion 110 inside the quartz plate 52 .
  • at least a portion of the first gas supplying pipe 84 is made of an electrically conductive material and grounded through the side wall of the chamber 10 .
  • the first gas supplying pipe 84 which is connected at one end to the process gas supplier 82 , may go through the antenna back surface plate 72 , the slow wave plate 56 , the RLSA 54 , and the quartz plate 52 in this order, rather than the inner conductor 68 of the coaxial pipe 66 , although not shown.
  • the first gas supplying pipe 84 may protrude at the other end downward from the lower surface of the quartz plate 52 .
  • the other end of the first gas supplying pipe 84 may be connected to the side opening made in the injector portion 110 inside the quartz plate 52 .
  • plural of the injector portions 110 may be axially symmetrically provided in a ring shape.
  • a third process gas introduction portion may be provided to the plasma etching apparatus 2 according to this embodiment of the present invention, in addition to or instead of the first and the second process gas introduction portions 88 , 94 , in order to introduce the process gasses into the chamber 10 .
  • the second process gas introduction portion 94 FIG. 1
  • the first process gas introduction portion 88 is employed in order to introduce the process gas from the upper center portion (the gas ejection opening 86 ) of the chamber 10 .
  • the microwaves may be introduced into the chamber not through an antenna but through a duct, which may be referred to as a microwave injection method.
  • the microwave transmission line 58 may be differently configured.
  • another transmission line may be inserted between the microwave generator 60 and the waveguide pipe 62 having a square-shaped opening.
  • a circular pipe may be used instead of the waveguide pipe 62 .
  • the converter 64 may include a member in a ridge guide shape, instead of the inverse cone portion 68 a in the door knob shape.
  • a circular waveguide pipe may be electromagnetically coupled to the chamber 10 without employing the converter 64 .
  • the microwave plasma etching apparatus 2 since the microwave plasma etching apparatus 2 according to the second embodiment of the present invention generates the microwave plasma without applying a magnetic field to the chamber 10 , the need for a magnetic field generation mechanism including a permanent magnet, a magnetic coil, or the like can be eliminated, so that the microwave plasma etching apparatus 2 has a simple configuration. Even so, the plasma etching apparatus according to an embodiment of the present invention may be another type of plasma etching apparatus employing, for example, Electron Cyclotron Resonance (ECR), as described in reference to FIG. 4 in the first embodiment.
  • ECR Electron Cyclotron Resonance
  • Embodiments according to the present invention are not limited to the microwave plasma etching apparatus in the above embodiment, but may be a plasma chemical vapor deposition (CVD) apparatus, a plasma oxidation apparatus, a plasma nitriding apparatus, a plasma sputtering apparatus, or the like.
  • a substrate subjected to a plasma process is not limited to the semiconductor wafer, but may be various substrates for use in fabricating a flat panel display, a photomask, a CD substrate, a printed substrate, or the like.

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US20140290860A1 (en) 2014-10-02
US9887068B2 (en) 2018-02-06
KR101173268B1 (ko) 2012-08-10
KR20110089208A (ko) 2011-08-04
KR101333112B1 (ko) 2013-11-26
US10734197B2 (en) 2020-08-04
CN101647101A (zh) 2010-02-10
TWI386997B (zh) 2013-02-21
KR101119627B1 (ko) 2012-03-07
US20180108515A1 (en) 2018-04-19
TW200845199A (en) 2008-11-16
KR20100003293A (ko) 2010-01-07
CN101647101B (zh) 2012-06-20
KR20120034117A (ko) 2012-04-09

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