This invention relates to ion treatment of workpieces and, more particularly, to a method and apparatus for charge neutralization during ion treatment of workpiece.
Ion beam and plasma processing of workpieces (substrates) may be performed for a variety of purposes including for ion implantation, surface texturing, and etching of a surface. Ion implantation in particular is a standard technique for introducing property-altering impurities into substrates. A desired impurity material is ionized in an plasma source, the ions are accelerated to form an ion beam of prescribed energy, and the ion beam is directed at the surface of the substrate. The energetic ions in the beam penetrate into the sub-surface of the substrate material and are embedded into the crystalline lattice of the substrate material to form a region of desired conductivity or material property.
One challenge for ion beam processing is the need to dissipate charge at a workpiece, which may occur during ion implantation of a workpiece because ions impinging on a substrate by nature carry charge. In the case of ion beams that comprise positive ions, positive charge may build up on the workpiece after exposure to an ion beam. In order for this charge to be dissipated, the workpiece holder may be grounded, thereby providing a conductive path for conducting the charge from the workpiece surface. However, if a workpiece itself is a poor conductor or an electrical insulator, the charge on the workpiece surface may have no conductive path to ground, thereby preventing the charge from being dissipated.
Neutralization of charge that builds up on a workpiece surface due to exposure to an ion beam may also be accomplished by providing charged species of opposite polarity to the charge on the workpiece. In typical known ion implantation systems that employ pulsed ion implantation using positive ions, including plasma immersion ion implantation, a plasma may be established proximate a workpiece holder and a periodic bias may be applied in pulses between the plasma and workpiece holder. During “on” periods positive ions may be attracted to the workpiece by providing a bias between the plasma and workpiece holder, wherein the potential at the workpiece holder is negative with respect to the plasma. At the same time, electrons in the plasma may be repelled from the workpiece holder due to its relatively negative potential with respect to the plasma. During “off” periods when the implantation system no longer sets the workpiece holder at a negative potential with respect to the plasma, electrons may drift towards the workpiece. However, the flux of electrons during these “off” periods may be insufficient to neutralize the surface of the workpiece and excessive positive charge may remain.
a illustrates a voltage pulse train 100 that includes a series of “on” periods 102 interrupted by “off” periods 104. During the “on” periods 102 a positive high voltage may be applied to a plasma source, while the workpiece is grounded, thereby setting the workpiece at a high negative potential (voltage) with respect to the plasma. Accordingly, positive ions may be attracted to the workpiece at a high energy of about 10 kV in the example shown in
While the circuitry 202 may produce a waveform generally as shown by voltage pulse train, an actual voltage waveform may differ from a desired waveform where the voltage is zero during “off” periods. For example, the high voltage switch 206 and second switch 208 may have an internal impedance that results in a small voltage drop. Thus, during the “off” periods 104 in which the plasma source is connected through second switch 208 to ground, the small internal impedance of second switch 208 may result in plasma source 210 not being directly grounded, but rather floating at a potential that may be several volts above zero. As illustrated in
In view of the above, it will be appreciated that it may be useful to provide improvements for neutralization of charge in systems that provide charged species of a predominant polarity, such as ion beam systems.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.
In one embodiment, a plasma processing system includes a plasma source for providing a plasma, a workpiece holder arranged to receive ions from the plasma, and a pulsed bias circuit operable to switch a bias voltage supplied between the plasma source and workpiece holder, between a high voltage state in which the plasma source is biased positively with respect to the workpiece and a low voltage state in which the plasma source is biased negatively with respect to the workpiece.
In another embodiment, a method of treating a workpiece in a processing system, comprises igniting a plasma using a plasma source, providing a workpiece to receive ions from the plasma source, and applying a voltage pulse train to the plasma source, the voltage pulse train comprising a high voltage state in which the plasma source is biased positively with respect to the workpiece and a low voltage state in which the plasma source is biased negatively with respect to the workpiece.
For a better understanding of the present disclosure, reference is made to the accompanying drawings, which are incorporated herein by reference and in which:
a illustrates a conventional voltage pulse train;
b shows an expanded view of the voltage pulse train of
a depicts one embodiment of a voltage pulse train;
b depicts another embodiment of a voltage pulse train; and
c depicts a further embodiment of a voltage pulse train.
Embodiments of a system and method are described herein in connection with ion processing of workpieces (substrates). In various embodiments, this system can be used with, for example, semiconductor substrates, bit-patterned media, solid-state batteries, or flat panels, or other substrates. Thus, the invention is not limited to the specific embodiments described below.
In various embodiments, a processing system includes a plasma source and switch circuitry for providing pulsed biasing of the plasma source with respect to a workpiece holder. The switch circuitry may provide a pulsed biasing that provides alternating pulses of ion beams and electrons to a workpiece (holder) in various embodiments. By providing a novel pulsed biasing circuit arrangement, a workpiece exposed to ions by pulsed ion processing of positive ions can be effectively neutralized by electrons supplied during off periods of the pulsed implantation process. In the discussion to follow, reference in the text and FIGs. may be made to a workpiece holder without explicit reference to a workpiece. However, it is to be understood that, unless otherwise indicated, it is implicit that a workpiece may be present in scenarios or arrangements that merely depict or describe a workpiece holder.
In various embodiments, plasma based ion implantation systems may employ plasma source to generate a plasma and separate circuitry to control biasing between the plasma and workpiece. In addition to use in plasma immersion ion implantation systems, the present embodiments may be employed in processing systems that situate an extraction plate between plasma and workpiece in order to provide a controllable ion beam having a unique set of properties.
The extraction plate 14 is used to extract ions 30 for implantation into a workpiece (substrate) 40, which may be grounded, as illustrated. The extraction plate 14 may be cooled. The plasma source 12 may be biased and a bias circuit as described below may be provided to provide a continuous or pulsed bias to the plasma source 12 to attract the ions 30. The extraction plate 14 may have at least one aperture 34, through which ions 30 are provided to the workpiece 40.
An ion beam extracted from a plasma using processing system 10 may be used to simultaneously provide to workpieces 40 ions 30 over a range of angles if desired without requiring complicated masking or lithography procedures. This ability to create a wide angular distribution of ions facilitates processing of workpieces having three dimensional features where it may be desirable to simultaneously provide ions incident on the features from different directions. Moreover, the exact angular distribution of ions 30 that are provided to workpiece 40 may be established according to a specific set of ion beam optics conditions (parameters) in processing system 10. Parameters that may affect the angular distribution of ions 30 include the shape and size of aperture 34, the implantation voltage, spacing between extraction plate 14 and workpiece 40, and plasma density. Thus, a specific set of parameters may establish a specific ion angular distribution of ions 30.
Processing system 10 also includes a pulsed bias circuit 42 that may provide pulses of voltage to created pulses of charged particles directed to workpiece(s) 40, as detailed below. Consistent with the present embodiments, the pulsed bias circuit 42 may produce a voltage waveform that provides a pulsed ion beam to workpiece during “on” periods of a pulse, as well as electrons that serve to neutralize workpiece 40 during “off” periods of the pulse. Also illustrated in
Included in pulsed bias circuit 400 is a high voltage circuit 404 and low voltage circuit 406. The high voltage circuit 404 may include, for example, a high voltage power supply 408, high voltage switch 412, and capacitor 416 and the low voltage circuit 406 may include a low voltage supply 410, low voltage switch 414, and capacitor 418.
Consistent with the present embodiments, the high voltage circuit 404 may set the voltage of plasma source 12 to be at a high positive potential with respect to workpiece holder 28. As illustrated, the high voltage circuit 404 includes a high voltage (HV) power supply 408, which may output a positive voltage of about 100 V or more, and in particular may output a positive voltage of 500 V to 50 kV. Accordingly, when the high voltage supply 408 is connected to plasma source 12, via high voltage switch 412, the plasma source 12 may attain a potential of about +100V to +50 kV, causing positive ions extracted from plasma source 12 to be accelerated towards workpiece holder 28 at energies ranging from 100 eV to 50 keV for singly charged ions. As detailed below, the high voltage circuit may 404 may operate to intermittently electrically connect and disconnect the high voltage supply 408 from plasma source 12, thereby pulsing the plasma source 12 intermittently at high voltage, which may drive pulses of ions toward the workpiece holder 28.
Consistent with the present embodiments, the low voltage circuit 406 may set the voltage of plasma source 12 at a small negative potential with respect to workpiece holder 28. As illustrated, the low voltage circuit 406 includes a low voltage supply 410, which may output a negative voltage of about −2 V or more, and in particular may output a negative voltage of −2 V to −100 V. Accordingly, when the low voltage supply 410 is connected to plasma source 12, via low voltage switch 414, the plasma source may attain a potential of about −2 V to −100 V, preventing ions in plasma source 12 from accelerating towards workpiece holder 28, while at the same time accelerating electrons in plasma source 12 toward the workpiece holder 28 at low energies, that is, energies less than or equal to about 100 eV. As detailed below, the low voltage circuit 406 may operate to intermittently electrically connect and disconnect the low voltage supply 410 from plasma source 12, thereby pulsing the plasma source 12 intermittently at a small negative voltage, which may drive electrons (not shown) in pulses toward the workpiece holder 28.
Referring now to
In order to prevent excessive positive charge from building up on workpiece holder 28, the pulsed bias circuit 400 may be intermittently switched to a second mode of operation, as illustrated in
In various embodiments, the controller 44 may direct the pulsed bias circuit 400 to alternate between the configurations depicted in
By alternating pulses of ions 420 and electrons 422, a processing system, such as processing system 10, operating in conjunction with the pulsed bias circuit 400, may effectively process a workpiece (see workpieces 40 in
In order to ensure effective switching back and forth between “on” states in which the high voltage switch 412 is closed, and “off” states in which the high voltage switch 412 is open, the pulsed bias circuit also includes a high voltage circuit capacitor 416 and low voltage circuit capacitor 418. The high voltage circuit capacitor 416 may store charge that can be discharged in a rapid pulse into plasma source 12 when high voltage switch 412 is closed. In this manner, the voltage may build up rapidly in plasma source 12, facilitating the ability of the high voltage supply 408 to rapidly bring the plasma source to the actual voltage set by the high voltage supply 408. This may be especially useful in processing systems in which the components of plasma source 12 are relatively massive and require substantial charge to adjust the potential to the desired voltage.
On the other hand, the low voltage circuit capacitor 418 may facilitate discharge of the plasma source 12 when the low voltage switch 414 is closed and the high voltage switch is open. Because a relatively large charge may be present on components of plasma source 12 during an “on” period, in order to effectively establish in a timely manner the negative voltage set by low voltage supply 410, it may be advantageous to quickly discharge plasma source 12 components.
The actual voltage attained by plasma source 12 during the “off” periods may differ from the voltage set by low voltage supply 410. Thus, due to internal circuit impedance, the plasma source 12 may remain at a potential that is slightly positive with respect to the nominal voltage, as discussed above. Accordingly, the present embodiments may adjust for this by setting the low voltage supply 410 to a greater negative voltage than actually desired for plasma source 12. For example, if it is desired to provide electrons with an energy of about 5 eV when incident on a workpiece 40, the low voltage supply 410 may be set at −10 V to account for a +5 V offset that may exist between the set voltage and voltage attained on plasma source 12. In this manner the potential of the plasma source 12 may actually reach about −5V, thereby accelerating negatively charged electrons through a field of 5 V between the plasma source 12 and ground potential at the workpiece holder 28.
In various embodiments, the pulse bias circuit 400 may adjust “on” periods, “off” periods, and the negative voltage set during “off” periods, among other factors, to optimize processing of a workpiece. For example, a workpiece may be processed using a first voltage pulse train that includes components such as a first “on” period, first “off” period, and first negative voltage, after which the accumulated charge at the workpiece may be monitored. Any of the aforementioned components of the voltage pulse train may be adjusted based upon the monitored accumulated charge.
In order to address this situation, the negative voltage applied during “off” portions 806 may be increased to attract a higher flux of electrons from a plasma source, thereby providing a faster neutralization of positive charge on a workpiece. However, this should be balanced with possible damage the increased electron energy may cause if the workpiece is a semiconductor substrate for building electronic devices.
b illustrates another way of increasing the neutralization of a workpiece. In the embodiment of
c depicts another embodiment in which the voltage pulse train 822 may comprise the same duty cycle (50%) as in
However, if the duration of the “off” portion in which a negative voltage is applied to the plasma source is sufficiently long, a workpiece 40 may develop a negative charge due to excessive exposure to electrons, after which electrons may no longer by accelerated from the plasma source. Thus, depending on various other operating parameters, including plasma power, gas pressure and plasma source voltage, an optimum range for the duration of “off” portion of a voltage pulse train may be defined.
The methods described herein may be automated by, for example, tangibly embodying a program of instructions upon a computer readable storage media capable of being read by machine capable of executing the instructions. A general purpose computer is one example of such a machine. A non-limiting exemplary list of appropriate storage media well known in the art includes such devices as a readable or writeable CD, flash memory chips (e.g., thumb drives), various magnetic storage media, and the like.
In particular, steps for providing voltage pulse trains to a plasma source may be performed at least partially by a combination of an electronic processor, computer readable memory, and/or computer readable program. The computer memory may be further configured to receive, display and store process history information associated with operation of a plasma system and as exemplified by the stored voltage values.
The present disclosure is not to be limited in scope by the specific embodiments described herein. Indeed, other various embodiments of and modifications to the present disclosure, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the present disclosure. Furthermore, although the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Thus, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein.
Number | Name | Date | Kind |
---|---|---|---|
6237527 | Kellerman et al. | May 2001 | B1 |
6528804 | Sullivan et al. | Mar 2003 | B1 |
7767986 | Dorai et al. | Aug 2010 | B2 |
20090004836 | Singh et al. | Jan 2009 | A1 |
20110143527 | Platow et al. | Jun 2011 | A1 |
20120228515 | Leavitt et al. | Sep 2012 | A1 |