PLASMA PROCESSING APPARATUS WITH REDUCED EFFECTS OF PROCESS CHAMBER ASYMMETRY
Plasma processing apparatus that provide an asymmetric plasma distribution within the processing apparatus are provided herein. In some embodiments, a plasma processing apparatus may include a process chamber having a processing volume with a substrate support disposed therein; and a first RF coil disposed above the substrate support to couple RF energy into the processing volume, wherein an electric field generated by RF energy moving along the first RF coil is asymmetric about a central axis of the substrate support. In some embodiments, a pump port is disposed asymmetrically with respect to the processing volume to remove one or more gases from the processing volume. In some embodiments, the first RF coil is asymmetrically disposed about the central axis of the substrate support.
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This application claims benefit of U.S. provisional patent application Ser. No. 61/407,882, filed Oct. 28, 2010, which is herein incorporated by reference.
BACKGROUND1. Field
Embodiments of the present invention generally relate to substrate processing equipment, and more specifically to plasma enhanced substrate processing apparatus.
2. Description of the Related Art
Some substrate process chambers may have a pumping port asymmetrically disposed with respect to a processing volume of the process chamber. Such process chambers may further include inductively or capacitively coupled electrodes to ignite a plasma in the processing volume. Inductive coils or capacitive electrodes are typically symmetrically disposed about the process chamber, for example proximate an upper portion of the process chamber, to provide a uniform electric field, and therefore, a more uniform plasma within the process chamber. However, the inventors have observed that the asymmetric location of the pump port with respect to the processing volume can result in plasma non-uniformities in the process chamber, which can undesirably result in non-uniform processing of a substrate within the process chamber. For example, the inventors have observed that severe processing non-uniformities may result in etch processes performed at higher operating pressures (for example, greater than about 25 millitorr (mTorr)). Attempts to mitigate the effects of such pumping asymmetry have included baffles or flow diversion. However, the inventors have observed that these resolutions undesirably limit flow conductance within the process chamber and may reduce the available processing window.
Therefore, the inventors have provided an improved plasma processing apparatus that may reduce at least some of the effects of pumping asymmetry while maintaining flow conductance and process window.
SUMMARYEmbodiments of plasma processing apparatus that provide an asymmetric plasma distribution within the processing apparatus are provided herein. In some embodiments, a plasma processing apparatus may include a process chamber having a processing volume with a substrate support disposed therein, and a first RF coil disposed above the substrate support to couple RF energy into the processing volume, wherein an electric field generated by RF energy moving along the first RF coil is asymmetric about a central axis of the substrate support. In some embodiments, a pump port is disposed asymmetrically with respect to the processing volume to remove one or more gases from the processing volume. In some embodiments, the first RF coil is asymmetrically disposed about the central axis of the substrate support. In some embodiments, the first RF coil includes at least one conductor winding about the central axis of the substrate support and toward a periphery of the processing volume from a first end disposed proximate the central axis of the substrate support to a second end. In some embodiments, the plasma processing apparatus includes a second RF coil disposed above the processing volume. In some embodiments, the first RF coil is an outer coil asymmetrically disposed about the central axis of the substrate support and the second RF coil is an inner coil symmetrically disposed about the substrate support.
In some embodiments, a plasma processing apparatus may include a process chamber having a processing volume with a substrate support disposed therein and a ceiling disposed above the substrate support; an outer RF coil disposed proximate the ceiling external to the processing volume to couple RF energy into the processing volume, wherein the outer RF coil includes at least one first conductor asymmetrically disposed about the central axis of the substrate support; an inner RF coil proximate the ceiling external to the processing volume to couple RF energy into the processing volume, wherein the inner RF coil includes a second conductor symmetrically disposed about the central axis of the substrate support; and a pump port disposed asymmetrically with respect to the processing volume, wherein the electric field is weaker above a first portion of the processing volume proximate the pump port than above a second portion of the processing volume opposing the pump port.
In some embodiments, a plasma processing apparatus may include a process chamber having a processing volume with a substrate support disposed therein; a pump port disposed asymmetrically with respect to the processing volume; and a plasma generator. In some embodiments, the plasma generator may include a signal generator; and an electrode coupled to the signal generator to create an electric field within the processing volume upon application of energy from the signal generator, wherein the electric field has an asymmetric geometry relative to a central axis of the substrate support.
Other and further embodiments of the present invention are described below.
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
Embodiments of plasma processing apparatus that provide an asymmetric plasma distribution within the processing apparatus are provided herein. In some embodiments, the inventive apparatus may advantageously overcome asymmetry within a process chamber without adversely affecting processing within the process chamber. For example, at least some embodiments of the present invention may advantageously overcome asymmetry within the process chamber without adversely affecting flow conductance and/or the process window of the process chamber. Embodiments of the inventive apparatus may be beneficial to any plasma assisted substrate processes, such as etch, deposition, or the like. Non-limiting examples of suitable processes include deep silicon (Si) etch processes used in forming microelectromechanical systems (MEMS) devices or thru silicon via (TSV) applications.
The reactor 100 comprises a process chamber 110 having a processing volume 115 with a substrate support 116 disposed therein, and a plasma generator to create and/or maintain a plasma within the processing volume 115, or that can be delivered to the processing volume 115, during use. In some embodiments, the chamber 110 may be supplied with a dome-shaped dielectric ceiling 120 (also referred to as a dielectric window) disposed above a conductive body (wall) 130. Alternatively, the ceiling 120 may have other geometries such as, for example, substantially flat. The processing volume 115 may be enclosed within the conductive body 130 and the ceiling 120. A pump port 125 may be disposed asymmetrically with respect to the processing volume 115 to remove one or more gases from the processing volume 115. For example, the pump port 125 may be disposed to one side of the processing volume 115 such that, during use, asymmetric regions of high and low pressure form within the processing volume 115 (such as regions of low pressure in regions of the processing volume 115 proximate the pump port 125, regions of high pressure remote from the pump port 125, and regions of intermediate pressure disposed between the regions of high and low pressures. As used herein, high pressure, low pressure, and intermediate pressure are intended to be relative terms with respect to each other and not in absolute terms of any particular pressure. The variant pressures within the processing volume may cause variant gas flow rates within the processing volume, which may undesirably affect the processing results on a substrate disposed within the processing volume 115. The variant pressure and gas flow rates may undesirably push/pull or otherwise affect the position of the plasma within the processing volume, which may lead to non-uniform process results. Alternatively or in combination, other chamber components, such as a slit valve 102 for transferring a substrate into and out of the process chamber 110, and/or the geometry of the process chamber 110 itself may be the cause or may contribute to any flow asymmetry in the process chamber 110 that may be mitigated by use of the inventive apparatus disclosed herein. Although described herein primarily in connection with flow asymmetries within the process chamber, embodiments of the present invention may also be used to compensate for other asymmetries that affect the plasma or processing within the process chamber as well.
The plasma generator may be any suitable plasma generator such as a radio frequency (RF) plasma generator, a microwave plasma generator, a remote plasma generator, or the like. In some embodiments, the plasma generator comprises a signal generator 118 coupled to an electrode. The signal generator 118 generally provides energy at frequency suitable to form and/or maintain a plasma in the process chamber, or remote from the process chamber, from process gases being supplied to the processing volume 115 of the process chamber 110. For example, in some embodiments, the signal generator 118 may provide a signal at a frequency of about 50 kHz to about 2.45 GHz (e.g., in the RF to microwave spectrum). The plasma generator is configured to provide an asymmetric plasma within the process chamber that can compensate for the asymmetric pressure/flow conditions within the chamber. The signal generator 118 may be coupled to the electrode through a first matching network 119 to minimize reflected power during use.
In some embodiments, the electrode may be an antenna 111 comprising at least one RF coil. The antenna 111 may be disposed above the substrate support 116. In some embodiments, such as illustrated in
Embodiments of the antenna 111 are shown in more detail in
In some embodiments, the antenna 111 may include the first RF coil 112 disposed above the substrate support 116 as illustrated in
The first portion 117 of the processing volume 115 proximate the pump port 125 may be a region of low pressure due to proximity to the pump port 125. The second portion 121 of the process volume 115 which opposes the first portion 117 may be a region of high pressure due to the location of the second portion 121 at the farthest distance from the pump port 125. The third portion 123 of the processing volume 115, located between the first portion 117 and the second portion 121 may be a region of intermediate pressure, higher than the pressure in the first portion 117 and lower than the pressure in the second portion 121. Accordingly, in some embodiments, the asymmetry of the electric field discussed above may be configured to be weakest above the first portion 117 and strongest above the opposing second portion 121.
The asymmetric electric field produced by flowing RF energy along the first RF coil 112 may be resultant from the first RF coil 112 being asymmetrically disposed about the central axis 113 of the substrate support. For example, in some embodiments, the first RF coil 112 may comprise at least one conductor 129 (
In some embodiments, and as illustrated in
The inventors have unexpectedly discovered that even if the at least one conductor 129 was symmetric (not shown), an improvement in process uniformity can be achieved by disposing the outermost winding 135 internally from the periphery of the processing volume 115. For example, in conventional processing apparatus, the outermost winding of a symmetrically conductor coil is typically disposed proximate the periphery of a processing volume of the processing apparatus. However, the inventors discovered that by moving the outermost winding of a symmetrical conductor coil away from the periphery of the processing apparatus, process uniformity in an etch process unexpectedly improved by about 25 percent. The inventors have further discovered that by introducing an asymmetry into the at least one conductor 129, a further improvement in process uniformity can be achieved.
For example, as illustrated in
The at least one conductor 129, illustrated as a coil winding asymmetrically about the central axis 113 in
In some embodiments, where a plurality of conductors 129 are used, a distance between adjacent conductors 129 may be constant along respective corresponding lengths of the adjacent conductors. For example, a distance 147 between adjacent conductors 129 may be constant along the respective lengths of the adjacent conductors 129.
In some embodiments, and as shown in
In some embodiments, as shown in
In some embodiments, and as illustrated in
Although illustratively described herein in terms of an inductively coupled processing apparatus, in some embodiments, the electrode may be configured to capacitively couple energy to the process chamber. For example, in some embodiments, the electrode may be a plate electrode (not shown) or the like having a geometry such that energy is coupled to the process chamber in desired regions, or such that more energy is coupled to the process chamber in regions where a higher density plasma is desired and less energy is coupled to the process chamber where a lower density plasma is desired. In some embodiments, for example when providing a signal having a microwave frequency, the electrode may be omitted and a waveguide may be provided to route the microwave energy to a desired location to energize the process gases and form a plasma.
The position of the electrode, or waveguide, may be configured such that the plasma is created or provided in one or desired locations. For example,
Returning to
The controller 140 may be one of any form of general-purpose computer processor that can be used in an industrial setting for controlling various chambers and sub-processors. The controller 140 generally comprises a central processing unit (CPU) 144, a memory 142, and support circuits 146 for the CPU 144 and facilitates control of the components of the chamber 110 and, as such, of the etch process, as discussed below in further detail. The memory 142, or computer-readable medium, of the CPU 144 may be one or more of readily available memory such as random access memory (RAM), read only memory (ROM), floppy disk, hard disk, or any other form of digital storage, local or remote. The support circuits 146 are coupled to the CPU 144 for supporting the processor in a conventional manner. These circuits can include cache, power supplies, clock circuits, input/output circuitry and subsystems, and the like. Methods of operation of the inventive apparatus may be stored in the memory 142 as a software routine. The software routine may also be stored and/or executed by a second CPU (not shown) that is remotely located from the hardware being controlled by the CPU 144.
In operation, a semiconductor substrate 114 is placed on the substrate support 116 and process gases are supplied from a gas panel 138 through entry ports 126 and form a gaseous mixture 151. The gaseous mixture 151 is ignited into a plasma 155 in the chamber 110 by applying power from the signal generator 118 and biasing power source 122 to the first and second RF coils 112, 148 and the cathode 116, respectively. The pressure within the interior of the chamber 110 is controlled using a throttle valve 127 and a vacuum pump 136. Typically, the chamber wall 130 is coupled to an electrical ground 134. The temperature of the wall 130 may be controlled using any suitable heat transfer mechanism, such as liquid-containing conduits, resistive heaters, or the like (not shown) that are placed proximate to or within the wall 130.
The temperature of the substrate 114 is controlled by stabilizing a temperature of the substrate support 116. In some embodiments, helium gas from a gas source 154 is provided via a gas conduit 156 to channels (not shown) formed in the substrate support surface under the substrate 114. The helium gas is used to facilitate heat transfer between the substrate support 116 and the substrate 114. During processing, the substrate support 116 may be heated by a resistive heater (not shown) within the pedestal to a steady state temperature and then the helium gas facilitates uniform heating of the substrate 114. Using such thermal control, the substrate 114 may be maintained at a temperature of about −30 to about 60 degrees Celsius.
Thus, embodiments of plasma processing apparatus are provided herein. In some embodiments, the inventive apparatus may advantageously overcome asymmetry within a process chamber, for example flow asymmetries due to an asymmetrically disposed pump port with respect to a processing volume of the process chamber, without adversely affecting flow conductance and/or the process window of the process chamber. Embodiments of the inventive apparatus may be beneficial to any plasma assisted substrate processes, such as etch, deposition, or the like. Non-limiting examples of suitable processes include deep silicon (Si) etch processes used in forming MEMS devices or thru silicon via (TSV) applications.
While the foregoing is directed to illustrative embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof.
Claims
1. A plasma processing apparatus, comprising:
- a process chamber having a processing volume with a substrate support disposed therein; and
- a first RF coil disposed above the substrate support to couple RF energy into the processing volume, wherein an electric field generated by RF energy moving along the first RF coil is asymmetric about a central axis of the substrate support.
2. The plasma processing apparatus of claim 1, comprising:
- a pump port to remove one or more gases from the processing volume, wherein the pump port is disposed asymmetrically with respect to the processing volume.
3. The plasma processing apparatus of claim 2, wherein the first RF coil is configured such that the electric field produced during use is weaker above a first portion of the processing volume proximate the pump port than above a second portion of the processing volume opposing the pump port.
4. The plasma processing apparatus of claim 2, wherein the electric field is weaker above a first portion of the processing volume proximate the pump port than above a third portion of the processing volume adjacent to the first portion of the processing volume.
5. The plasma processing apparatus of claim 2, wherein the first RF coil is asymmetrically disposed about the central axis of the substrate support.
6. The plasma processing apparatus of claim 2, wherein the first RF coil further comprises:
- at least one conductor winding about the central axis of the substrate support and toward a periphery of the processing volume from a first end disposed proximate the central axis of the substrate support to a second end.
7. The plasma processing apparatus of claim 6, wherein an outermost winding of the at least one conductor is disposed internally from the periphery of the processing volume.
8. The plasma processing apparatus of claim 7, wherein the at least one conductor further comprises:
- a first winding; and
- a second winding adjacent to the first winding, wherein a distance between the first winding and the second winding varies.
9. The plasma processing apparatus of claim 8, wherein the distance is largest above a first portion of the processing volume proximate the pump port.
10. The plasma processing apparatus of claim 2, wherein the first RF coil further comprises:
- a plurality of conductors winding about the central axis of the substrate support and toward a periphery of the processing volume from respective first ends of the plurality of conductors disposed proximate the central axis of the substrate support to respective second ends of the plurality of conductors.
11. The plasma processing apparatus of claim 10, wherein at least one of the plurality of conductors is disposed asymmetrically about the central axis of the substrate support.
12. The plasma processing apparatus of claim 10, wherein each of ones of the plurality of conductors are disposed asymmetrically about the central axis of the substrate support and wherein each of ones of the plurality of conductors are disposed symmetrically with respect to each other.
13. The plasma processing apparatus of claim 12, wherein a distance between any two adjacent conductors is constant along respective lengths of the adjacent conductors.
14. The plasma processing apparatus of claim 1, further comprising:
- a second RF coil disposed above the substrate support to couple RF energy into the processing volume.
15. The plasma processing apparatus of claim 14, wherein the first RF coil is an outer coil and the second RF coil is an inner coil symmetrically disposed about the central axis of the substrate support.
16. The plasma processing apparatus of claim 15, wherein the second RF coil further comprises:
- at least one conductor winding about the central axis of the substrate support and toward a periphery of the processing volume from a first end disposed proximate the central axis of the substrate support to a second end.
17. The plasma processing apparatus of claim 1, wherein the process chamber further comprises:
- a dome disposed above the substrate support, wherein the first RF coil is disposed about the dome external to the processing volume.
18. A plasma processing apparatus, comprising:
- a process chamber having a processing volume with a substrate support disposed therein and a ceiling disposed above the substrate support;
- an outer RF coil disposed proximate the ceiling external to the processing volume to couple RF energy into the processing volume, wherein the outer RF coil includes at least one first conductor asymmetrically disposed about the central axis of the substrate support;
- an inner RF coil about the ceiling external to the processing volume to couple RF energy into the processing volume, wherein the inner RF coil includes a second conductor symmetrically disposed about the central axis of the substrate support; and
- a pump port disposed asymmetrically with respect to the processing volume, wherein the electric field is weaker above a first portion of the processing volume proximate the pump port than above a second portion of the processing volume opposing the pump port.
19. The plasma processing apparatus of claim 18, wherein the outer RF coil further comprises:
- a plurality of conductors winding about the central axis of the substrate support and toward a periphery of the processing volume from respective first ends of the plurality of conductors disposed proximate the central axis of the substrate support to respective second ends of the plurality of conductors, and wherein an outermost winding of the plurality of conductors is disposed internally from the periphery of the processing volume.
20. A plasma processing apparatus, comprising:
- a process chamber having a processing volume with a substrate support disposed therein;
- a pump port disposed asymmetrically with respect to the processing volume; and
- a plasma generator comprising: an signal generator; and an electrode coupled to the signal generator to create an electric field within the processing volume upon application of energy from the signal generator, wherein the electric field has an asymmetric geometry relative to a central axis of the substrate support.
Type: Application
Filed: Sep 22, 2011
Publication Date: May 3, 2012
Applicant: APPLIED MATERIALS, INC. (Santa Clara, CA)
Inventors: Robert CHEBI (San Carlos, CA), Alan CHESHIRE (Glasgow), Stanley DETMAR (Mountain View, CA), Gabriel ROUPILLARD (Stockholm)
Application Number: 13/240,451
International Classification: C23F 1/08 (20060101);