This invention relates generally to ion sources for partial pressure analyzers used in process monitoring, and more particularly to in-situ cleaning methods of ion sources for partial pressure analyzers used in process monitoring.
In semiconductor manufacturing, the transition to larger, more expensive wafers and smaller geometries inevitably requires close production control. The more accurately and quickly one can measure and control a process, the more profitable their investment becomes. Therefore, more and more processes are requiring reliable in-situ monitoring and control. Partial pressure analyzers (PPA), sometimes known as residual gas analyzers (RGA), typically in the form of a quadrupole mass spectrometer, are widely used for in-situ process monitoring in semiconductor manufacturing, especially in physical vapor deposition (PVD) processes. Among the uses of the PPA for chemical vapor deposition (CVD)/etch processes are following the process chemistry by monitoring the timing and concentration of input gases; monitoring the reaction products; eliminating the waste; and assessing the “health” of the process chamber (by checking for leaks, residual contaminants, contaminants during processing and proper functioning of the tool). To-date, most applications of PPAs for CVD/etch process focused on process development, process optimization and troubleshooting. Relatively few PPAs are employed as in-situ CVD/etch process monitors for actual production owing to PPA lifetime issues often encountered with those applications. First, CVD/etch chemicals are typically highly reactive or corrosive. Second, deposits can form in the ion source, making insulating surfaces conductive or conductive surfaces insulating, resulting in sensor malfunction. This is especially true on surfaces which receive energetic electron or ion bombardment. Third, the ion source is heated by the filament, sometimes resulting in significant pyrolysis of CVD precursors or etching by-products.
Typically, PPAs for CVD/etch applications employ a closed ion source (CIS), rather than the open ion source of a true RGA. Using a CIS minimizes exposure of sensor components and its vacuum chamber to the reactive or corrosive constituents present in these applications. Even so, the resulting lifetime for a PPA in CVD/etch is often still not sufficient for in-situ monitoring on a production line. Applicant has developed an ion source, having a replaceable liner described in U.S. Pat. No. 7,041,984, extending the time before the source itself needs to be replaced. However, it is still necessary to break vacuum of the PPA system in order to replace the liner, negatively impacting tool availability. Even more important, however, is that replacing only the anode liner may not solve the problem completely. Sensitivity decrease may also be caused by deposits on other parts of the ion source besides the anode cylinder, such as the focus lens plate and total pressure collector plate.
When reactive substances are sampled, an insulating film can be deposited on the inner surfaces of the ion source. When bombarded by charged particles, these deposits can charge up, effectively altering the bias voltages applied to these electrodes, thus affecting their function, typically resulting in a loss of sensitivity for the instrument. In some processes, conductive rather than insulating deposits can form. If these deposits form on critical insulator surfaces, sensor performances can be adversely affected by causing leakage currents to flow.
The sensitivity loss problem can be especially troublesome when the PPA is used to monitor a dielectric deposition process such as silicon tetranitride (Si3N4) CVD, when silicon nitride and/or oxides are easily deposited. Silicon etch processes that produce silicon tetrachloride (SiCI4) among other by-products result in the deposition of SiO2 films whenever sufficient moisture is present, as is often the case. With both of these processes, an insulating coating on the inside of the anode cylinder has been detected, especially opposite the electron entrance, resulting in severe sensitivity loss. Being an insulator, the deposited material will pick up a negative charge under electron bombardment, effectively decreasing the positive potential applied to the anode. The quadrupole mass filter is biased approximately six volts less positive than the anode. This difference in bias determines the kinetic energy of the ions as they travel through the quadrupole mass filter. As the negative charge on the anode builds up, eventually things will reach a point where the ions no longer have sufficient ion energy to transit through the quadrupole mass filter, resulting in a severe drop in sensitivity. A similar mechanism, this time involving positive ion bombardment, will occur on the focus and total pressure collector plates, although at a slower rate reflecting the much smaller currents involved. While this will not cause a decrease in the kinetic energy of the ions in the mass filter, it can sufficiently defocus the ion beam, therefore also resulting in a loss in sensitivity.
Plasma cleaning processes have long been used not only for in-situ cleaning of semiconductor production tools, but also in the manufacture of automotive bumpers, stainless steel syringe needles, angioplasty balloon catheters, plastic lenses, golf balls, and lawnmower distributor covers, to name just a few. Such cleaning processes involve the removal of impurities and contaminants from surfaces through the use of plasma created from gaseous species by applying a strong electric field. The excited gas forms energetic ions, electrons, atoms, free radicals and other reactive species. Contaminants on the metal, ceramic, glass, or wafer surfaces are desorbed as a result of energetic particle bombardment. Additionally, there will be some surface heating associated with these impacts. There are multiple effects from the plasma including removing organic contamination, removing substrate material by ablation (micro-etching), increasing surface area, removing a weak boundary layer, cross-linking or branching to strengthen surface cohesion, and modifying surface chemistry to improve chemical and physical interactions at the bonding interface. No volatile solvents are required for plasma cleaning, thus eliminating waste and residue.
U.S. Pat. No. 7,005,634 describes a mass spectrometer with the capability of in-situ plasma cleaning of the ion source. The ion source was based on a thermionic metal ion emitter, which subsequently ionizes the sample by metal ion attachment, rather then employing electron impact ionization. Various schemes for producing the plasma were presented in the patent disclosure. This plasma cleaning process was repeatedly performed subsequent to the mass spectrometry utilizing a suitable delay after the ionization process. However, because its ionization apparatus is based on the mechanism of ionizing gases by the attachment of metal ion emitter, it is not applicable to the electron impact ion source currently under discussion.
In brief, the in-situ cleaning method for partial pressure analyzers is based on inducing a hollow cathode discharge (HCD) inside the ion source. The HCD is formed by applying a high negative voltage to one or more parts of the ion source, including the anode electrode, the lens focus plate, and/or additional lens(es) plate(s).
According to one version, an ion source (CIS) apparatus with in-situ cleaning mode is provided, the ion source apparatus being attachable to a partial pressure analyzer (PPA). According to this version, the ion source apparatus comprises one or more inner surfaces, an anode electrode, a means of applying a high negative voltage to the anode electrode, and a means for electron emission. The in-situ cleaning mode provides for removal of contaminating deposits from the inner surfaces, by introducing into the ion source, a plasma producing gas producing positive ions, and applying the high negative voltage to the anode electrode, such that a hollow cathode discharge occurs within the anode electrode causing said positive ions to bombard one or more inner surfaces of the ion source and remove contaminating deposits.
The ion source apparatus further includes a focus lens plate and at least one additional lens(es) plate, wherein the high negative voltage is applied to one or more of the anode electrode, focus lens plate, and the at least one additional plate. In one preferred version, the at least one additional lens plate is a total pressure collector plate as found in a closed ion source (CIS) that is attachable to a partial pressure analyzer (PPA). However, the implementation of the hollow cathode discharge can be similarly applied to other electron impact ion sources, open or closed, which are defined minimally by a filament, anode and at least one lens (plate). Alternatively, non-electron impact ion sources can also apply the teachings described herein.
According to another version, there is provided a method of removal of contaminating deposits from an ion source, said ion source being attachable to a partial pressure analyzer (PPA), said ion source comprising an anode electrode, and a means for electron emission, said ion source having one or more inner surfaces, said method comprising one or more plasma cleaning cycles. According to the method, each of said plasma cleaning cycles comprises the steps of introducing a plasma producing gas into said ion source, said plasma producing gas producing positive ions, applying a high negative voltage to the anode electrode, so that a hollow cathode discharge occurs within said anode electrode causing said positive ions to bombard said one or more inner surfaces of said ion source and remove said contaminating deposits, removing said contaminating deposits from the ion source; and conditionally, upon satisfying a first condition, terminating the method.
In one preferred version, the ion source is a closed ion source that further includes a focus lens plate and a total pressure collector plate and wherein the high negative voltage is applied to one or more of the anode electrode, the focus lens plate, and the total pressure collector plate.
Alternatively, the ion source further comprises a focus lens plate and at least one additional plate, wherein the high negative voltage is applied to one or more of the anode electrode, the focus lens plate, and the at least one additional plate; and wherein a greater negative potential is applied to the focus lens plate and the at least one additional plate than is applied to the anode electrode, such that positive ions mainly bombard the focus lens plate and the at least one additional plate rather than the anode electrode. In this version, the at least one additional plate can be a total pressure collector plate.
According to one exemplary version, the high negative voltage is within the range of approximately −800 to −900V wherein the high negative voltage is one of direct current, current pulses, and/or radio frequency current.
The plasma producing gas according to described versions is one of argon, oxygen, hydrogen, and any combination thereof, though it will be readily apparent that other gases can be utilized. In one version, for example, the plasma producing gas is at least one of: nitrogen fluoride NF3, chlorine fluoride CIF3, carbon tetrafluoride CF4, and hexafluoroethane C2F6. In another version, the plasma producing gas is at least one of nitrogen fluoride NF3, chlorine fluoride CIF3, carbon tetrafluoride CF4, and hexafluoroethane C2F6, further combined with one of: argon, oxygen, and hydrogen.
With regard to the timing of the herein described method, the method can be performed at pre-determined intervals of process monitoring, when performance of the ion source has decreased by a pre-determined threshold value, or as an automated, in-situ process while said the ion source is otherwise idle.
In one version, the above-noted first condition is satisfied upon elapsing a pre-determined period of time. Alternatively, this condition is satisfied when a pre-determined value of the ion current measured by the PPA is reached.
These and other features and advantages will become readily apparent from the following Detailed Description, which should be read in conjunction with the accompanying drawings.
The in-situ cleaning method for partial pressure analyzers described herein is based on inducing a hollow cathode discharge (HCD) inside an ion source. The HCD is formed by applying a high negative voltage to one or more parts of the ion source, including the anode electrode, a lens focus plate, and other len(ses) plate, such as a total pressure collector plate.
For purposes of the following discussion, an exemplary form of ion source, a closed ion source (CIS) is herein referred to throughout the bulk of the discussion. It will be readily apparent, however as noted above, that the inventive concepts can equally be applied to other electron impact ion sources, such as open ion sources that are used in residual gas analyzers (RGAs). Furthermore, the present concepts can also be employed to cover non-electron impact ion sources, for example, such as those described in U.S. Pat. No. 7,005,634.
Electron emission means is provided by the filament 20 using a tungsten wire typically biased negatively with respect to the anode 10 during normal operation. It is heated by the current that passes through it. The emitted electrons are repelled by the electron repeller 30 and attracted by the anode electrode 10. The majority of the electrons pass through the slot 70 in the circumference of the anode. A fraction of the electrons collide with sample gas molecules inside the cylindrical anode electrode 10 and produce positive ions. The difference between the bias voltages on the filament 20 and the anode 10 determine the kinetic energy of the electrons. It is this kinetic energy that determines how the gas molecules will behave during the collision. The remaining electrons collide with the inside wall of the cylindrical anode electrode 10. The positive ions are attracted by the focus lens plate 50 (biased negative with respect to the anode 10) and are focused through the hole 62 in the total pressure collector plate 60 (also biased negative with respect to the anode 10) in the direction generally shown by the arrow 80 into the quadrupole mass filter (not shown in
A HCD can be formed within a CIS of the described configuration when a high negative potential is applied to one or more parts of the CIS, e.g., to the anode electrode, to the lens focus plate, and/or to the total pressure collector plate. The sputtering action of the HCD removes the insulating deposits from the inside of the cylindrical anode electrode and the surfaces of the focus and total pressure collector plates facing the anode, therefore restoring ion source performance and hence its lifetime before it must be replaced.
The plasma cleaning process of the present invention can be performed at pre-determined intervals of process monitoring or when the CIS performance has decreased by a pre-determined threshold value. While plasma cleaning can be performed on a CIS removed from the PPA, it can best be utilized as an automated, in-situ process while the PPA is otherwise idle.
The embodiment illustrated in
In accordance with the embodiment illustrated in
A skilled artisan would understand that applying a high negative voltage to one or more of anode electrode, focus lens plate, total pressure plate, or any combination thereof will be within the scope and the spirit of the present invention.
In on aspect, stable plasma can be obtained e.g., with argon (Ar) gas pressure in the range of 50 millitorr to 1 Torr (e.g., 100 millitorr). Using argon, deposit removal is accomplished only by sputter etching, a purely physical process.
In another aspect, other more reactive gases can be used either in addition to or in place of argon, depending on the nature of the process being monitored. Hydrocarbon deposits which can come, e.g., from vacuum pump lubricants, grease on o-rings, or photo-resist (PR) materials related to processes such as PR ashing and wafer degassing, can be removed using oxygen (O2) in the plasma producing gas, thus forming volatile products, e.g., water (H2O), carbon monoxide (CO), and carbon dioxide (CO2) gases that can be easily pumped away from the ion source. Other process chemistries might best be handled using hydrogen (H2) as the plasma producing gas. In severe contamination cases, typical semiconductor cleaning gases such as nitride trifluoride (NF3) chlorine trifluoride (CIF3), carbon tetrafluoride (CF4 or hexafluoro ethane (C2F6), either alone or in combination with argon, oxygen or hydrogen, can be employed. In addition, there may also be gases not typically used for semiconductor cleaning processes that could be used.
In a further aspect, one or more plasma cleaning cycles can be carried out, each cycle including applying a high negative voltage to one or more parts of the CIS, including the anode electrode, the lens focus plate, and the total pressure collector plate, followed by removal (e.g., by pumping away) of the contaminants from the ion source.
In another aspect the cleaning process can be completed upon elapsing of a pre-determined period of time.
in yet another aspect, a spectrum can be taken by the PPA after each plasma cleaning cycle, and the cleaning process can be completed when a pre-determined value of the ion current is reached, e.g., Ar+ current equal to 2.8E-10 A. The noted ion current is not measured during the plasma cleaning phase because the pressure is too high. Instead, the plasma cleaning operation must first be stopped and the pressure of the argon is then lowered to about 1E-4 Torr before the filament is turned on and the current is measured.
This application is based upon a provisional patent application entitled: IN-SITU ION SOURCE CLEANING FOR PARTIAL PRESSURE ANALYZERS USED IN PROCESS MONITORING, U.S. Ser. No. 60/959,335; filed Jul. 13, 2007, the entire contents of which are herein incorporated by reference.
Number | Date | Country | |
---|---|---|---|
60959335 | Jul 2007 | US |