A segmented transformer coupled plasma (TCP) coil is provided as a source for generating a uniform plasma in a plasma reactor. The segmented TCP is divided into two or more segment coils which, when connected to an RF source, produces a circulating flow of electrons to cause a magnetic field in the plasma. Because the segmented TCP employs multiple segment coils, a plasma is generated that is more spatially uniform than the plasma produced by a monolithic coil. This is implemented using a power distributing component that allows the RF current to be distributed in the segment coils such that a uniform plasma density can be obtained in an area spanned by the coils. For instance, variable shunts, switchable shunts, and disconnect switches can be used to vary the RF currents in the individual coils.
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20. A method of generating a plasma having a substantially uniform density in a plasma reaction chamber, the method comprising the steps of:
introducing a process gas into the plasma reaction chamber;
supplying an excitation coil for the plasma with a radio frequency current resonant to the coil, the coil responding to the radio frequency current to produce a radio frequency field that excites the gas to a plasma, the coil comprising at least a first coil segment and a second coil segment connected in a radio frequency circuit, the coil being disposed proximate an exterior surface of a window of the chamber; and
selectively controlling the maximum amplitude of radio frequency current flowing through the first and second coil segments in a manner such that the plasma has a uniform plasma density in an area spanned by the first and second coil segments.
0. 50. An apparatus for generating plasma, the apparatus comprising:
a plasma reaction chamber having a window forming a magnetic/electrical field path into the chamber and a process gas supply for introducing process gas into the chamber;
a coil comprising at least an inner coil segment and an outer coil segment, the inner and outer coil segments being connected in series and disposed proximate an exterior surface of the window of the chamber so electromagnetic fields from said inner and outer coil segments are coupled through the window into the chamber;
a radio frequency source for coupling r.f. energy to the coil, the radio frequency source being effective to resonate a radio frequency current in the inner and outer coil segments; and
a power distributing component connected to one of the coil segments for controlling the flow of radio frequency current from the source through the inner and outer coil segments so different maximum radio frequency current amplitudes selectively flow from the source through the inner and outer coil segments at the same time to cause the process gas introduced into the chamber to be excited into a plasma having a relatively uniform plasma density in an area spanned by the inner and outer coil segments.
1. An apparatus for generating plasma, the apparatus comprising:
a plasma reaction chamber having a window forming a magnetic/electrical held path into the chamber and a process gas supply for introducing process gas into the chamber;
a coil comprising at least a first coil segment and a second coil segment, the first and second coil segments being connected in series and disposed proximate an exterior surface of the window of the chamber so electromagnetic fields from said first and second coil segments are coupled through the window into the chamber;
a radio frequency source for coupling r.f. energy to the coil arrangement, the radio frequency source being effective to resonate a radio frequency current in the first and second coils coil segments; and
a power distributing component connected to one of the coil segments fee controlling the flow of radio frequency current from the source through the first and second coil segments so different maximum radio frequency current amplitudes selectively flow from the source through the first and second coil segments at the same time to cause the process gas introduced into the chamber to be excited into a plasma having a relatively uniform plasma density in an area spanned by the first and second coil segments.
29. A method of exciting plasmas in a plasma reaction chamber supplied with a process gas, the plasmas having differing characteristics at different times but being excited so they have substantially uniform density, the process gas being excited into a plasma by a coil coupling a radio frequency electromagnetic field into the chamber, the coil having spatially disparate plural segments relative to the excited plasma, the method comprising:
during a first interval while the excited plasma has a first characteristic, effectively arranging the segments in a first way and supplying radio frequency current to the coil so the radio frequency electromagnetic field coupled by the coil to the plasma has a first spatial configuration and amplitude to cause the plasma to have a first substantially uniform density,; and
during a second interval white the excited plasma has a second characteristic, effectively arranging the segments in a second way and supplying radio frequency current to the coil so the radio frequency electromagnetic field coupled by the coil to the plasma has a second spatial configuration and amplitude to cause the plasma to have a second substantially uniform density, the first and second characteristics, ways, and configurations differing.
26. An apparatus for generating plasma, the apparatus comprising:
a plasma reaction chamber having a window forming a magnetic/electrical field path into the chamber and a process gas supply for introducing process gas into the chamber;
a radio frequency source arrangement; and
a coil arrangement comprising a first coil segment and a second coil segment, the first and second coil segments being disposed proximate an exterior surface of the window of the chamber so radio frequency fields from said first and second coil segments are coupled through the window into the chamber, each of the coil segments including an inner terminal, an outer terminal and an arcuate conductor portion having at least one turn extending between the inner and outer terminals, the first coil segment being inside the second coil segment the first and second coil segments being connected to the radio frequency source arrangement and arranged so a lower radio frequency maximum amplitude current from the source arrangement flows through the first coil segment than through the second coil segment, the radio frequency fields derived from the first and second coil segments interacting with the process gas introduced into the chamber so the process gas is excited to form a plasma having a relatively uniform plasma density in an area spanned by the first and second coil segments.
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27. The apparatus of claim 20 26 wherein the coil arrangement for causing a lower radio frequency maximum amplitude current to flow through the first coil segment than through the second coil segment includes a relatively low non-inductive impedance shunting the first coil segment.
28. The apparatus of claim 20 26 wherein the source arrangement includes a single radio frequency source, the first and second coil segments being connected in series across a pair of excitation terminals responsive to radio frequency current derived from the single radio frequency source, radio frequency current from the single source flowing through one of the excitation terminals, thence through both of the first and second coil segments, thence through the other excitation terminal.
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0. 39. The apparatus of claim 1, wherein the first coil segment and the second coil segment are arranged as an inner coil segment and an outer coil segment, respectively, of the coil.
0. 40. The apparatus of claim 1, wherein at least one of the first and second coil segments has a plurality of radially and circumferentially extending turns.
0. 41. The apparatus of claim 1, wherein both of the first and second coil segments have a plurality of radially and circumferentially extending turns.
0. 42. The apparatus of claim 41, wherein the first and second coil segments are connected in series by the power distributing component.
0. 43. The apparatus of claim 42, wherein the power distributing component is configured as a loop lacking a plurality of radially and circumferentially extending turns.
0. 44. The apparatus of claim 43, wherein the apparatus is configured such that resultant magnetic flux densities in the vicinity of first and second coil segments are greater than resultant magnetic flux density in the vicinity of the power distributing component.
0. 45. The apparatus of claim 26, wherein the arcuate conductor of at least one of the first and second coil segments has a plurality of radially and circumferentially extending turns.
0. 46. The apparatus of claim 26, wherein the arcuate conductors of the first and second coil segments have a plurality of radially and circumferentially extending turns.
0. 47. The apparatus of claim 46, wherein the coil arrangement further comprises a power distributing component connected in series between the first coil segment and the second coil segment.
0. 48. The apparatus of claim 47, wherein the power distributing component is configured as a loop lacking a plurality of radially and circumferentially extending turns.
0. 49. The apparatus of claim 48, wherein the apparatus is configured such that the coil arrangement is associated with a plurality of resultant magnetic flux densities, wherein resultant magnetic flux densities in the vicinity of first and second coil segments are greater than resultant magnetic flux density in the vicinity of the power distributing component.
0. 51. The apparatus of claim 50, wherein the power distributing component includes a circuit component connected in shunt with one of the inner or outer coil segments.
0. 52. The apparatus of claim 51, wherein the circuit component comprises an adjustable capacitor.
0. 53. The apparatus of claim 51, wherein the circuit component comprises a switch for selectively effectively connecting one or both of the inner and outer coil segments in series across a pair of excitation terminals connected to be responsive to radio frequency current derived from the radio frequency source.
0. 54. The apparatus of claim 50, wherein the power distributing component includes a component for selectively disconnecting the inner coil segment from the outer coil segment so radio frequency current flows from the radio frequency source through the outer coil segment but not through the inner coil segment while the component disconnects the inner coil segment from the outer coil segment and radio frequency current flows from the radio frequency source through the inner and outer coil segments while the component connects the inner coil segment to the outer coil segment.
0. 55. The apparatus of claim 50, wherein the inner and outer coil segments are coplanar.
0. 56. The apparatus of claim 50, wherein the inner and outer coil segments are concentrically arranged structures each including an inner terminal, an outer terminal and an arcuate conductor having at least one turn extending between the inner and outer terminals.
0. 57. The apparatus of claim 50, wherein the inner and outer coil segments are powered by a single radio frequency power source, the inner and outer coil segments being connected to each other and the single radio frequency power source so radio frequency current flows from the radio frequency power source through a first excitation terminal of the coil connected to the inner coil segment, thence through the coil to a second excitation terminal of the coil connected to the outer coil segment, thence back to the source, the first and second excitation terminals being at opposite ends of the coil.
0. 58. The apparatus of claim 50 wherein each of the inner and outer coil segments includes an inner terminal, an outer terminal and an arcuate conductor portion having at least one turn extending between the inner and outer terminals, the inner and outer coil segments being connected in series across a pair of excitation terminals connected to be responsive to r.f current derived from the radio frequency source.
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The present invention relates generally to a segmented coil for a transformer coupled plasma (TCP) source. More specifically, the present invention relates to a segmented coil configuration as a source for generating a plasma which can be used for treating semiconductor wafers in low pressure processing equipment.
Plasma generation is useful in a variety of semiconductor fabrication processes, for example enhanced etching, deposition, etc. Plasmas are generally produced from a low pressure gas by inducing an electron flow which ionizes individual gas molecules through the transfer of kinetic energy through individual electron-gas molecule collisions. The electrons are commonly accelerated in an electric field, typically a radio frequency (RF) electric field.
Numerous techniques have been proposed to accelerate the electrons in an RF electric field. For example, U.S. Pat. No. 4,948,458 discloses a plasma generating device in which electrons are excited in an RF field within a chamber using a single winding coil (SWC) that is parallel to the plane of a semiconductor wafer and the plasma. As shown in
A typical SWC is shown in detail
When processing semiconductor wafers in plasma gas environments, it is desirable to uniformly process the entire surface of the wafer. The single winding monolithic coil, such as that described, above does not provide the same uniformity at all operating pressures. For example, at one pressure the center of the wafer may be etched at a higher rate than remaining portions of the wafer while at another pressure the center of the wafer may be etched at a lower rate than remaining portions of the wafer. Other process parameters, such as RF power, gas species and flows, may also affect the rate at which the center is etched.
Several methods have been proposed to optimize plasma uniformity. For example, U.S. Pat. No. 4,615,755 discloses a plasma etching technique wherein uniformity of the wafer temperature is achieved by He backcooling of a wafer supported on a bowed electrode. By bowing the wafer away from the lower electrode with the cooling helium, cooling performance of the wafer is sacrificed in order to achieve etch uniformity. However, variations in the thickness of the wafer result in sub-standard control of the wafer bowing, thereby reducing the etch uniformity.
Another proposed solution for optimizing plasma uniformity is to adjust the process parameters. A problem with this proposed solution is that once process parameters are adjusted to obtain uniformity, only a small parameter range is typically available for optimizing other etch responses, such as profile.
Yet another proposed solution for optimizing plasma uniformity is to modify the reactor configuration by shaping the plasma window or by adding shrouds, spacers, or focus rings. The disadvantage of this approach is that such modifications are fixed and work best in a limited parameter range.
There is thus a need for a plasma generating coil that optimizes plasma uniformity but does not limit the parameter ranges needed for optimizing other etch responses.
The invention provides an apparatus for generating a transformer coupled plasma (TCP), the apparatus comprising a plasma reaction chamber into which a process gas is introduced, a coil comprising at least a first coil segment and a second coil segment connected in series and disposed proximate the chamber, and a radio frequency source coupled via RF circuitry to the segmented coil. The radio frequency source resonates a radio frequency current in the segmented coil and excites the process gas into a plasma within the chamber. Variable electrical components are connected across or between the first and second coils to selectively change the RF current in each segment coil relative to the other segments. The variable electrical components permit the segment coil currents to be adjusted to improve the spatial uniformity of RF power coupling in the plasma, thereby improving the plasma and process uniformity such as etching, deposition, etc., in the reaction chamber.
Preferably, each of the coil segments has an inner terminal, an outer terminal and an arcuate conductor portion having at least one turn extending between the inner and outer terminals.
According to various aspects of the invention, the variable electrical components have different configurations. For instance, an adjustable capacitor or a switch can be connected across a segment of the coil to shunt that segment from the rest of the segments. Alternatively, a switch can be connected in series between one segment and another to disconnect one of the segments from the RF circuitry.
The invention also provides a method of generating a transformer coupled plasma, the method comprising the steps of introducing a process gas into a plasma reaction chamber and resonating a radio frequency current in a coil comprising at least a first coil segment and a second coil segment connected in series and disposed proximate the chamber. The RF current excites the process gas into a plasma within the chamber. The method further comprises a step of varying the radio frequency current in each of the segments to improve the spatial uniformity of RF power coupling in the plasma and in turn improve the plasma and process uniformity such as etching, deposition, etc., in the reaction chamber.
The method is preferably carried out using the various a coil configuration as previously mentioned. Further, the plasma can be used to process one or more substrates such as semiconductor wafers. For instance, the reaction chamber can be sized to process a single semiconductor wafer at a time and a layer on the wafer can be etched or deposited by the plasma. During processing, the chamber is typically maintained at a wide range of pressures, such as less than 100 mTorr.
The invention relates to plasma processing of substrates, such as semiconductor wafers, flat panel displays, etc. In the case of processing such substrates, it is usually desired to provide a uniform plasma density above the exposed surface of the substrate to be processed. However, depending on the treatment to be performed on the substrate surface, non-uniform plasma density can occur above the surface. For instance, the plasma density may be greater at the substrate center than at the edge thereof or vice versa. The segmented coil of the present invention enable an adjustable RF current to be provided in each of plural segments of the TCP coil and thus achieve substantial improvement in uniformity compared to previously known coil arrangements.
The invention provides a segmented transformer coupled plasma (TCP) coil segment with at least a first coil and a second coil which, when connected to an RF source, efficiently generates a uniform plasma. Since the segmented TCP coil has multiple coil segments, variable electrical components can be connected to the individual coils, allowing RF current in each segment to be changed relative to the other segments. The current in each segment can thus be adjusted to improve the spatial uniformity of RF power deposition in the plasma and to in turn improve the plasma and etching uniformity in the plasma chamber.
The capacitor Ci is not an active element in impedance matching. Further, the capacitance of the capacitor Ci is not intended to be continually adjusted, but rather, the capacitor Ci is preset to a desired value, depending upon the particular process and uniformity required for the substrate undergoing processing.
A segmented TCP coil according to a second embodiment of the invention is illustrated in
The segmented TCP coil described in the embodiments above permits control of the plasma processing on different parts of the substrate undergoing treatment. For example, in plasma etching process, sufficient reduction of the center etch rate is obtained by reducing the current flowing through the first, i.e. inner coil segment. By controlling the etch rate on different parts of the wafer, a uniformly etched wafer surface can be obtained.
A plasma generating device employing the segmented TCP coil is depicted in
The segmented TCP coil described above permits efficient generation of a spatially uniform plasma without changing the configuration of the TCP window or limiting the parameter ranges needed to optimize other processing responses. Although particular embodiments of the invention have been described, it will be appreciated by those of ordinary skill in the art that the present Invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. For example, switches and capacitors can also be provided to shunt and/or disconnect the second coil as well as the first coil and three or more coils can be utilized to form the segmented coil. Furthermore, although a TCP segmented coil with coaxially arranged first and second coils has been illustrated, the number of coils is not hauled thereto, but may be any number and pattern which meets the demands of uniform plasma generation. The presently disclosed embodiments are therefore considered in all respects to be illustrative, and not restrictive. The scope of the invention is indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalence thereof are intended to be embraced therein.
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