The present disclosure relates to an etching apparatus and method for etching a wafer or substrate.
A semiconductor wafer is processed in a semiconductor manufacturer to form various integrated circuits (IC) in different regions of the wafer. The integrated circuit formed on the semiconductor substrate includes a plurality of semiconductor devices. Various semiconductor manufacturing processes are employed to form the semiconductor devices, including etching, lithography, ion implantation, thin film deposition, and thermal annealing.
During the manufacturing of semiconductor devices, unwanted layers (or particles) are often deposited on wafers from known or unknown sources. Such deposition may occur on various layers of a wafer, such as the substrate, photoresist layer, photo mask layer, and/or other layers of the wafer. Currently, manufacturers use some semiconductor tools (such as a shower head) to inject the process gases into the reaction chamber, so as to remove undesirable layers from wafers. Some semiconductor tools have multi-zone design of the gas injection to improve center-edge etching or deposition amount and its uniformity.
The disclosure can be more fully understood by reading the following detailed description of various embodiments, with reference to the accompanying drawings as follows:
In the following description, specific details are presented to provide a thorough understanding of the embodiments of the present disclosure. Persons of ordinary skill in the art will recognize, however, that the present disclosure can be practiced without one or more of the specific details, or in combination with other components. Well-known implementations or operations are not shown or described in detail to avoid obscuring aspects of various embodiments of the present disclosure.
The terms used in this specification generally have their ordinary meanings in the art and in the specific context where each term is used. The use of examples in this specification, including examples of any terms discussed herein, is illustrative only, and in no way limits the scope and meaning of the disclosure or of any exemplified term. Likewise, the present disclosure is not limited to various embodiments given in this specification.
It will be understood that, although the terms “first,” “second,” etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the embodiments. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
As used herein, the terms “comprising,” “including,” “having,” “containing,” “involving,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, implementation, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, uses of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, implementation, or characteristics may be combined in any suitable manner in one or more embodiments.
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For example, if a photo resist layer deposited at the bevel of the wafer or substrate W needs to be removed, the gas flow controller 18 can allow the auxiliary processing gas generator 16 that generates oxygen to exhaust out of the first gas inlets 142. If an oxide layer deposited at the bevel of the wafer or substrate W needs to be removed, the gas flow controller 18 can allow the auxiliary processing gas generator 16 that generates fluorine-based gas to exhaust out of the first gas inlets 142.
The number of the auxiliary processing gas generators 16 in
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The electrostatic chuck 14 further has a plurality of third gas inlets 146 for entrance of the thermal conduction gas. The distance between any of the third gas inlets 146 and the center of the adsorption surface 140 is smaller than the distance between any of the second gas inlets 144 and the center of the adsorption surface 140. Similarly, the thermal conduction gas exhausted out from the third gas inlets 146 of the electrostatic chuck 14 can also flow within the gap between the backside of the wafer or substrate W and the adsorption surface 140 of the electrostatic chuck 14.
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The numbers of the first gas inlets 142, the second gas inlets 144, and the third gas inlets 146 in
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The electrostatic chuck 34 further has a plurality of second gas inlets 344 and a plurality of third gas inlets 346. The second gas inlets 344 are for entrance of a thermal conduction gas. The third gas inlets 346 are for entrance of the thermal conduction gas. The distance between any of the second gas inlets 344 and the center of the adsorption surface 340 is smaller than the distance between any of the first gas inlets 342 and the center of the adsorption surface 340. Hence, the thermal conduction gas exhausted out from the second gas inlets 344 of the electrostatic chuck 34 can flow within the gap between the backside (i.e., the lower side) of the wafer or substrate W and the adsorption surface 340 of the electrostatic chuck 34. Thus, the electrostatic chuck 34 can adjust the wafer or substrate W to the predetermined temperature by the thermal conduction gas exhausted out from the second gas inlets 344 of the electrostatic chuck 34 in the form of thermal convection. The distance between any of the third gas inlets 346 and the center of the adsorption surface 340 is smaller than the distance between any of the second gas inlets 344 and the center of the adsorption surface 340. Similarly, the thermal conduction gas exhausted out from the third gas inlets 346 of the electrostatic chuck 34 can also flow within the gap between the backside of the wafer or substrate W and the adsorption surface 340 of the electrostatic chuck 34.
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Accordingly, besides the plasma excited from the first processing gas can etch the front side (i.e., the upper side) of the wafer or substrate W, the plasma excited from the second processing gas can achieve the purpose of fine tuning the behavior of the etching amount of the edge of the wafer or substrate W, or removing the polymer at the bevel of the wafer or substrate W.
For example, if a photo resist layer deposited at the bevel of the wafer or substrate W needs to be removed, the second processing gas exhausted out from the first annular gas inlet 542 can be oxygen. If an oxide layer deposited at the bevel of the wafer or substrate W needs to be removed, the second processing gas exhausted out from the first annular gas inlet 542 can be a kind of fluorine-based gas.
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In some embodiments of the present application, the temperature-adjusting module 56 includes a heater 560. The heater 560 of the temperature-adjusting module 56 is thermally connected to the electrostatic chuck 54 and electrically connected to the temperature controller 60. The temperature controller 60 is capable of driving the heater 560 to adjust the actual temperature of the electrostatic chuck 54 to the predetermined temperature when the actual temperature is lower than the predetermined temperature.
In some embodiments of the present application, the temperature-adjusting module 56 includes a chiller 562 (as shown in
In some embodiments of the present application, the temperature-adjusting module 56 includes the heater 560 and the chiller 562. The temperature controller 60 is capable of driving the heater 560 and the chiller 562 to adjust the actual temperature of the electrostatic chuck 54 to the predetermined temperature.
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Furthermore, the electrostatic chuck 54 further has a third annular gas inlet 546 for entrance of the thermal conduction gas. The third annular gas inlet 546 is communicated with the adsorption surface 540 of the electrostatic chuck 54, and is located between the second annular gas inlet 544 and the center of the adsorption surface 540. Similarly, the thermal conduction gas exhausted out from the third annular gas inlet 546 of the electrostatic chuck 54 can also flow within the gap between the backside of the wafer or substrate W and the adsorption surface 540 of the electrostatic chuck 54.
It should be pointed out that in some embodiments of the present disclosure, the second annular gas inlet 544 of the electrostatic chuck 54 is communicated with a first thermal conduction gas source. The thermal conduction gas exhausted out from the second annular gas inlet 544 has a first air pressure. The third annular gas inlet 546 of the electrostatic chuck 54 is communicated with a second thermal conduction gas source. The thermal conduction gas exhausted out from the third annular gas inlet 546 has a second air pressure different from the first air pressure. Hence, the first air pressure of the thermal conduction gas exhausted out from the second annular gas inlet 544 can be selectively adjusted to be larger than or smaller than the second air pressure of the thermal conduction gas exhausted out from the third annular gas inlet 546 as needed, so that the process flexibility of the etching apparatus 5 of the present application can be increased.
In some embodiment of the present application, the thermal conduction gas is an inert gas. The inert gas is a gas that does not undergo chemical reactions under a set of given conditions (i.e., dose not undergo chemical reactions with the first and second processing gases).
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S100: providing a process reaction chamber and an electrostatic chuck located in the process reaction chamber.
S102: placing the wafer or substrate on the electrostatic chuck.
S104: charging the electrostatic chuck, so as to adsorb the wafer or substrate on the electrostatic chuck.
S106: introducing a thermal conduction gas between the electrostatic chuck and the wafer or substrate.
S108: adjusting the electrostatic chuck to a predetermined temperature.
S110: introducing a first processing gas into the process reaction chamber.
S112: continuously generating an electric field to the process reaction chamber, so as to excite the first processing gas to generate a first plasma to etch the wafer or substrate.
S114: introducing a second processing gas toward at least a part of a circumference of the wafer or substrate through a gas inlet of the electrostatic chuck, so that the second processing gas is excited by the electric field to generate a second plasma to the part of the edge of the wafer or substrate.
The above illustrations include exemplary steps, but the steps are not necessarily performed in the order shown. Steps may be added, replaced, changed order, and/or eliminated as appropriate, in accordance with the spirit and scope of various embodiments of the present disclosure.
In some embodiments, an etching apparatus is disclosed for etching a wafer or substrate. The etching apparatus includes a process reaction chamber, a gas distribution plate, and an electrostatic chuck. The gas distribution plate is located in the process reaction chamber, and is used for entrance of a main processing gas. The electrostatic chuck is located in the process reaction chamber and has an adsorption surface. The wafer or substrate is located on the adsorption surface. The electrostatic chuck further has a plurality of first gas inlets for entrance of a plurality of auxiliary processing gases. Each of the first gas inlets is communicated with the adsorption surface and aligned with at least a part of the edge of the wafer or substrate. The gas distribution plate and the electrostatic chuck are located at two opposite sides of the process reaction chamber, respectively.
Also disclosed is an etching apparatus for etching a wafer or substrate. The etching apparatus includes a process reaction chamber, a gas distribution plate, and an electrostatic chuck. The gas distribution plate is located in the process reaction chamber, and is used for entrance of a first processing gas. The electrostatic chuck is located in the process reaction chamber and has an adsorption surface. The wafer or substrate is located on the adsorption surface. The electrostatic chuck further has a first annular gas inlet for entrance of a second processing gas. The first gas inlet is communicated with the adsorption surface and aligned with the entire edge of the wafer or substrate.
An etching method is also disclosed for etching a wafer or substrate. The etching method includes steps of: providing a process reaction chamber and an electrostatic chuck located in the process reaction chamber; placing the wafer or substrate on the electrostatic chuck; introducing a first processing gas into the process reaction chamber; continuously generating an electric field to the process reaction chamber, so as to excite the first processing gas to generate a first plasma to etch the wafer or substrate; and introducing a second processing gas toward at least a part of a circumference of the wafer or substrate through a gas inlet of the electrostatic chuck, so that the second processing gas is excited by the electric field to generate a second plasma to the part of the edge of the wafer or substrate.
According to the foregoing recitations of the embodiments of the disclosure, it can be seen that the etching apparatus and method for etching a wafer or substrate integrate the process gas at the edge area of the electrostatic chuck, so as to achieve the purpose of fine tuning the behavior of the etching amount of the edge of the wafer or substrate, or removing the polymer at the bevel of the wafer or substrate. Furthermore, the first air pressure of the thermal conduction gas exhausted out from the second gas inlet(s) can be selectively adjusted to be larger than or smaller than the second air pressure of the thermal conduction gas exhausted out from the third gas inlet(s) as needed, so that the process flexibility of the etching apparatus of the present application can be increased.
As is understood by one of ordinary skill in the art, the foregoing embodiments of the present disclosure are illustrative of the present disclosure rather than limiting of the present disclosure. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.