Abstract: An exemplary embodiment providing one or more improvements includes a wafer tilt detection apparatus for use with a wafer processing or manufacturing device that applies a process to the wafer and which utilizes an endpoint signal for determining control of the process applied to the wafer. The wafer tilt apparatus uses the endpoint signal in establishing when the wafer was in a tilted orientation during processing.

Abstract: A new methodology of monitoring process drift and chamber seasoning is presented based on the discovery of the strong correlation between chamber surface condition and free radical density in a plasma. Lower free radical density indicates either there is a significant process drift in the case of production wafer etching or that the chamber needs more seasoning before resuming production wafer etching. Free radical density in the plasma is monitored through measuring the emission intensities of free radicals in the plasma by an optical spectrometer. A timely detection of the extent of process drift and chamber seasoning can help to minimize the chamber downtime and improve its throughput significantly. Such method can also be implemented in existing production wafer etching or chamber seasoning practices in an in-situ, real-time, and non-intrusive manner.

Abstract: In a technique for fabricating an integrated circuit to include an active device structure which supports an electrical interconnect structure, a photoresist layer is used prior to forming an electrical interconnect structure on the active device structure. The photoresist and related residues are removed by exposing the photoresist and exposed regions of the active device structure to one or more reactive species that are generated using a gas mixture including hydrogen gas, as a predominant source of the reactive species, in a plasma source such that the photoresist and residues are continuously exposed to hydrogen-based reactive species. An associated system architecture is described which provides for a substantial flow of hydrogen gas in the process chamber.

Abstract: A new methodology of monitoring process drift and chamber seasoning is presented based on the discovery of the strong correlation between chamber surface condition and free radical density in a plasma. Lower free radical density indicates either there is a significant process drift in the case of production wafer etching or that the chamber needs more seasoning before resuming production wafer etching. Free radical density in the plasma is monitored through measuring the emission intensities of free radicals in the plasma by an optical spectrometer. A timely detection of the extent of process drift and chamber seasoning can help to minimize the chamber downtime and improve its throughput significantly. Such method can also be implemented in existing production wafer etching or chamber seasoning practices in an in-situ, real-time, and non-intrusive manner.

Abstract: A method and apparatus for reducing the sensitivity of semiconductor processing to chamber conditions is provided. Process repeatability of common processes are affected by changing surface conditions which alter the recombination rates of processing chemicals to the chamber surfaces. In one aspect of the invention, a composition of one or more etchants is selected to optimize the etch performance and reduce deposition on chamber surfaces. The one or more etchants are selected to minimize buildup on the chamber surfaces, thereby controlling the chamber surface condition to minimize changes in etch rates due to differing recombination rates of free radicals with different surface conditions and achieve etch repeatability. In another embodiment, the etchant chemistry is adjusted to reduce the change to internal surface conditions after a cleaning cycle. In another embodiment, a process recipe is selected to reduce the sensitivity of the etch process to the chamber conditions.

Abstract: The present invention includes a method for forming fluorinated carbon polymer films (C-films) on substrates, and methods of using the C-films as sacrificial layers to form unique structures on the substrates. In one embodiment of the present invention, a C-film is formed on a substrate by exposing the substrate to a plasma of a process gas including a fluorocarbon or hydrofluorocarbon gas and a hydrogen-containing inorganic gas such as HBr or HCl. A method of using the C-film to form one or more structures on a substrate comprises the steps of depositing the C-film over a layer of materials on the substrate, removing a first part of the C-film from a part of the layer of material, etching the layer of material, and removing a second part of the C-film.

Abstract: The present invention includes a method of using plasma polymers to form microstructures on substrates. The method includes the steps of forming a polymer film on a substrate having one or more layers of materials thereon in a plasma of a first process gas; removing a first part of polymer film in a plasma of a second process gas; etching the one or more layers of materials in a plasma of a third process gas; and removing a second part of the polymer film in a plasma of a fourth process gas. During the etching of the one or more layers of materials, the second part of the polymer film protects selected portions of the one or more layers of materials from being removed by the plasma of the third process gas.

Abstract: The present invention provides a process of etching polysilicon gates using a silicon dioxide hard mask. The process includes exposing a substrate with a polysilicon layer formed thereon to a plasma of a process gas, which includes a base gas and an additive gas. The base gas includes HBr, Cl2, O2, and the additive gas is NF3 and/or N2. By changing a volumetric flow ratio of the additive gas to the base gas, the etch rate selectivity of polysilicon to silicon dioxide may be increased, which allows for a thinner hard mask, better protection of the gate oxide layer, and better endpoint definition and control. Additionally, when the polysilicon layer includes both N-doped and P-doped regions, the additive gas includes both NF3 and N2, and by changing a volumetric flow ratio of NF3 to N2, the etching process may be tailored to provide optimal results in N/P loading and microloading.

Abstract: A method for operating a plasma reactor having a secondary chamber that is a neutral species source for the main chamber. The method in one embodiment of the invention consists of determining the desired increase in main chamber neutral particle density to be contributed by the secondary chamber for a given main chamber ion density range, and then to maintain the main chamber source power below a level beneath which the secondary chamber is capable of supplying the desired main chamber neutral density contribution.

Abstract: Conventional methods of etching TiSix use Cl2 or HBr as the plasma etchant. However, these methods can lead to undesirable residues, due to the presence of silicon nodules in the TiSix The present invention overcomes the residue problem by adding a fluorine containing gas to the plasma etchant, which is then able to effectively etch the Si nodules at an etch rate which is approximately the same as the etch rate of the TiSix, so that the undesirable residue is not formed. A method of etching TiSix is provided, wherein the surface of the TiSix is exposed, typically through a patterned mask, to a plasma etchant. The plasma etchant comprises (i) at least one fluorine containing gas, such as SF6, NF3, CxFy, and compatible mixtures of such gases; and (ii) a gas selected from the group consisting of HBr, Cl2, and combinations thereof.

Abstract: The present invention provides an apparatus and method, for plasma assisted processing of a workpiece, which provides for separate control of species density within a processing plasma. The present invention has a processing chamber and at least one collateral chamber. The collateral chamber is capable of generating a collateral plasma and delivering it to the processing chamber. To control the densities of the particle species within the processing chamber the present invention may have: a filter interposed between the collateral chamber and the processing chamber, primary chamber source power, several collateral chambers providing separate inputs to the processing chamber, or combinations thereof. Collateral plasma may be: filtered, combined with primary chamber generated plasma, combined with another collateral plasma, or combinations thereof to separately control the densities of the species comprising the processing plasma.

Abstract: A method for etching metal silicide layers 22a, 22b and polysilicon layers 24a, 24b on a substrate 20 with high etching selectivity, and anisotropic etching properties, is described. In the method, the substrate 20 is placed in a plasma zone 55, and process gas comprising chlorine, oxygen and optionally helium gas, is introduced into the plasma zone. A plasma is formed from the process gas to etch the metal silicide layer 22 at high etching selectivity relative to etching of the polysilicon layer 24, while providing substantially anisotropic etching of the metal silicide and polysilicon layers. Preferably, the plasma is formed using combined inductive and capacitive plasma sources.