The present invention relates generally to methods and apparatus that may be used for evaluating a plasma, and more specifically relates to such methods and apparatus providing improved evaluating of plasmas, particularly those for which previous measurement techniques have offered less than optimal results.
A number of systems have been used or considered for evaluating of plasmas formed in chambers or similar devices. In many circumstances the systems have been configured to measure relatively high temperature and/or high density plasmas. For example, systems such as Heavy Ion Beam Probes have been used for such purposes. While different configurations of Heavy Ion Beam Probe systems are known for evaluating different types of plasma devices, in general, such systems operate by directing an ionized beam through the plasma, where the ions will become “heavy ions” through electron impact within the plasma, thereby becoming “doubly ionized”. The doubly ionized particles will then be deflected by the magnetized plasma, and detected by an energy analyzer which can then discern the energy gained by the ions, and from that energy data identify the electric potential of the plasma at the point of ionization.
One limitation of such Heavy Ion Beam Probe systems is that the incident electron impact energy must be equal to or greater than the second stage ionization potential of the ions in the beam. Thus, a significant limitation on such Heavy Ion Beam Probe systems is that they are not suitable for use with relatively low temperature plasmas, for example, plasmas operating at approximately 1-2 eV. Such plasmas typically do not have enough sufficiently hot electrons to achieve significant second stage ionization in the ion beam, and thus signal levels are generally very low.
This limitation on such probe systems is significant particularly to industries such as the semiconductor manufacturing industry, which typically uses “cold plasmas,” that is plasmas with electron temperatures of approximately 2 electron volts or less. However, measurement of plasma characteristics is very important in the semiconductor industry because the plasma may have a significant impact on the semiconductor manufacturing process. Because of this need to measure these cold plasmas, the most common techniques currently used to measure the plasma in semiconductor systems have used Langmuir probes inserted into the plasma. With such probes, however, the measurements are less than optimal because the mere presence of the Langmuir probe disrupts the plasma to at least some degree. Additionally, the measurement may only be made at a single point in the plasma, and is often believed to be inaccurate.
An additional concern arises in some applications, and is exemplified in the semiconductor manufacturing industry, where the real need is to evaluate the plasma potential (voltage) and density across a geometrical dimension. For example, in semiconductor manufacturing, the vast majority of such manufacturing is done by depositing or otherwise forming a succession of patterned layers on a circular substrate such as a thin silicon wafer. Many forms of deposition operations and patterning operations, such as etching, involve the use of plasma mechanisms. The current conventional technology forms such layers on a 300 mm diameter wafer, and a critical factor in such manufacturing is the consistency of deposition or etching operations across the entire dimension of that wafer. Additionally, a varying plasma gradient across the wafer may create localized plasma charging resulting in damage to the structures formed, such as the gate oxide layer. Accordingly, for that industry, the currently-available techniques do not provide either a system capable of measuring the relatively cold plasmas that are typically of interest, or a mechanism for identifying any irregularities or discontinuities in plasma characteristics across the wafer dimension. While similar needs are believed to be experienced in other industries, the semiconductor manufacturing industry provides an accessible and understandable example of where currently-known plasma measurement methods and systems fail to provide capabilities that would be beneficial to the industry.
Accordingly, the present invention provides new methods and apparatus for evaluating plasmas which is capable of evaluating relatively cold plasmas, as well as hotter plasmas; and which in some examples provide additional capabilities of profiling plasmas across the dimension of the plasma.
The present invention utilizes a photon source to assist ionization of atoms used for evaluating at least one characteristic of a plasma. In the described examples of the invention, a beam of neutral atoms (“neutrals”) will be directed toward the plasma, and some portion of those neutrals will be excited, and in some preferred examples ionized, through interaction with photons from a photon source such as, in some examples, a laser. Through the combination of the photon interaction increasing the kinetic energy of the neutrals, and the interaction of the plasma on those neutrals or ions, the ions will experience a net energy increase. The subsequent measurement of these results of the energy of the ions allows evaluating one or more characteristics of the plasma. In some examples, the ionized beam neutrals will be evaluated by an energy analyzer, as described in more detail later herein.
The following detailed description refers to the accompanying drawings that depict various details of embodiments selected to show, by example, how the present invention may be practiced. The discussion herein addresses various examples of the inventive subject matter at least partially in reference to these drawings and describes the depicted embodiments in sufficient detail to enable those skilled in the art to practice the invention. However, many other embodiments may be utilized for practicing the inventive subject matter, and many structural and operational changes in addition to those alternatives specifically discussed herein may be made without departing from the scope of the inventive subject matter.
In this description, references to “one embodiment” or “an embodiment,” or to “one example” or “an example” mean that the feature being referred to is, or may be, included in at least one embodiment or example of the invention. Separate references to one or more examples or embodiments in this description are not intended to refer necessarily to the same embodiment; however, neither are such embodiments mutually exclusive, unless so stated or as will be readily apparent to those of ordinary skill in the art having the benefit of this disclosure. Thus, the present invention can include a variety of combinations and/or integrations of the embodiments described herein, as well as further embodiments as defined within the scope of all claims based on this disclosure, as well as all legal equivalents of such claims.
Referring now to the drawings in more detail, and particularly to
As depicted in
Several types of lasers may be suitable for use in various examples of systems constructed in accordance with the principles described herein, depending on the specific operating parameters for which those systems are intended. For the system intended for operation in the example environment identified for this example, and with the parameters identified above, laser 106 will preferably be a pulsed excimer laser operating at a wavelength (λ) of 193 nm, with an example pulse duration (ΔTp) of approximately 12 ns, and a pulse repetition rate frep of approximately 1 kHz. In one presently-defined embodiment, the laser will have a pulse energy (up) of approximately 11 mJ, and a beam cross-sectional area of approximately 18 mm2.
Ion gun 106 may again be of a number of different possible structures. In one currently-contemplated structure ion gun 106 will be a multi-stage Pierce-type extractor, having an Einzel lens. In one currently-identified structure, the ion gun will provide sodium (Na) ions with a beam energy (Eb) of approximately 10 keV, and a beam ion velocity (v) on the order of 2.9×105m/s. As will be described later herein, in some environments it may be desirable to use ions of a different element.
As can be seen in
As can be seen in
System 100 also includes a charge exchange chamber, or neutralizer, 118 configured to neutralize the charges on the sodium ions in the beam from ion gun 106. A neutralizer 118 may be of any suitable configuration to facilitate charge exchange of the ions. In one example, a source of neutral sodium gas may be provided within the chamber, whereby the neutral sodium atoms will facilitate a charge transfer with a substantial portion of the sodium ions. Downstream of neutralizer 118, there will be another steering mechanism 120, again such as a set of charged deflection plates. The purpose of this second steering mechanism is to deflect any remaining ions from the beam toward an ion dump, thereby leaving neutrals in the beam that will pass into chamber 102, and thus through the plasma therein. Where deflection plates 120 are used, again each plate may be approximately 3 inches square, with positively and negatively-charged plates placed to steer remaining charged ions to ion dump 122. Ion dump 122 may be just a grounded plate placed to collect the deflected positively-charged ions. As a result, the beam of atoms entering chamber 102 is generally limited to neutrals, except to the extent that the neutrals are ionized by the photons from the pulsed laser. As will be described in more detail later herein, because such laser energy is known, the energy gained by the neutrals by intersecting the plasma within chamber 102 may also be determined.
On the opposite side of chamber 102 is found energy analyzer 110, as discussed earlier herein. Again, a pressure housing 126 will couple energy analyzer 110 to chamber 102, such that energy analyzer 110 is also at a common pressure and in fluid communication with chamber 102. Energy analyzer 110 is preferably a Proca-Green-type analyzer, as is well-known in the art. Such analyzers use a pair of spaced, charged plates, indicated generally at 132a-b, to deflect ions in the beam in functional relation to the energy of those ions (also schematically depicted in
The described current ratio measurement at any selected time interval represents a measurement of the ion energy at that time interval, and is thus directly representative of the plasma energy at that time interval. The correlation of that time-based measurement to a distance measurement across the plasma may be accomplished as described below.
As is well known to those skilled in the art, energy analyzer 110 will require calibration. This is typically performed with the neutralizer turned off and with no plasma present. For the calibration and for the measurement itself, the currents detected on the two detector plates are monitored. As with an actual measurement as noted above, the incoming beam of ions will straddle the two plates, and the ratio of the currents will indicate the energy of the beam. For calibration, the gun voltage will be fixed, and the voltage of the analyzer will be varied. This will allow the determining in situ of two analyzer parameters known in the literature as “G” and “F,” representative of the geometric characteristics of the analyzer, as are empirically determined relative to the specific analyzer configuration at issue. The determination of such parameters are well-known in the art, and as one example, may be determined in accordance with the teachings of L. Solensten and K. A. Connor, “Heavy Ion Beam Probe Energy Analyzer For Measurement of Plasma Potential Fluctuations,” Rev. Sci. Instrum. Vol. 58, No. 4, 1987; which is hereby incorporated herein by reference to demonstrate the state of the prior art.
Once energy analyzer 110 is calibrated, the potential (V) at any point in time may then be determined by a relation such as the following:
Where:
In performing a plasma measuring operation, ion gun 106 and laser 104 will be actuated as described above to direct a beam of, in this example, sodium atoms through a plasma within chamber 102, and the ions charged as a result of the laser and the plasma will be detected by energy analyzer 110. In the course of that operation, the sodium ions in the accelerated beam will be neutralized by neutralizer 118, and the remaining charged ions removed by the second steering mechanism, such as deflection plates 126, before the atoms enter chamber 102 and encounter the plasma therein. The described laser pulse from laser 104 can excite, and preferably ionize, the entire beam of atoms, including within chamber 102, and for all practical purposes, virtually instantaneously. As a result, after such excitation, and preferably ionization, the first detected ions will likely be ions outside of the plasma, having already have passed through the plasma before interacting with the laser beam photons (depending upon the configuration of the system surrounding chamber 102). Subsequently, a string of ions will be detected, coming from the plasma sheath proximate the output port of chamber 102; followed by ions across the dimension of the plasma; followed by ions from the sheath proximate the input port; and then potentially outside of chamber 102 on the input side. For example, a hypothetical detector signal may be expected to look something like the hypothetical curve 200 depicted in
v=√{square root over ((2E/m))} eq. 2
The energy of the neutral beam is known from the energy imparted to the ions out of the ion gun, and the mass is known from the species of ions from the gun.
This type of profile can be very useful, for example, when designing a chamber, so as to identify irregularities or undesirable properties within the chamber, such as may be caused by various structures or configurations within the chamber. Additionally, it is contemplated that periodic measurements of the type described herein may be useful during the actual use of a chamber, such as in a semiconductor manufacturing process. As is well known to those skilled in the art, during such manufacturing operations a number of wafers will be processed, and the number of active and/or carrier gases may be introduced into a chamber, such as source gases for deposition processes and etching or otherwise reactive gases for etching or other removal processes. Typically, after multiple such cycles the chamber will experience build up of deposition products or byproducts on various surfaces, and over time this build-up can degrade performance of the chamber, in some cases by interfering with the generation or uniformity of the plasma that will be formed within the chamber. Accordingly, it is contemplated that at least for some types of chambers and/or operations, periodic measurements of the type described herein could identify when a chamber needs cleaning, repair or other remedial action.
Referring again to the curve of
ne=n0e(V/T
Where:
In applications in which it is desired to monitor a chamber actively used in semiconductor manufacturing, the use of sodium ions may be considered undesirable, as sodium, in many cases is considered a contaminant to the actual manufacturing operations. In such circumstances, therefore, it may often be preferable to use alternative ions, such as for example, calcium (Ca), germanium (Ge), magnesium (Mg) or aluminum (Al). When using these alternative ions, one point to be addressed will be the energy required to ionized the neutrals in the beam. In some cases, such as that of germanium, this may be possible with other commercially available lasers, such as, for example, a 157 nm laser. Other shorter-wavelength lasers would be suitable for use with these other ions. However, at the present time, those lasers are less cost-effective for general commercial practice of the described techniques.
Referring now to
As will be appreciated from consideration of
Referring now to
Many modifications and variations may be made in the techniques and structures described and illustrated herein, without departing from the spirit and scope of the present invention. For example, as is apparent from the preceding discussion, there may be other types of lasers that are suitable, and in some cases preferable, depending upon the atoms to be ionized and the specific configuration of a plasma monitoring system. Additionally, there may be alternative structures which may be assembled in order to produce atoms from ion gun 106 and the photons from laser 104 along a coincident path. Additionally, there may be additional excitation mechanisms used to elevate the energy state of certain atoms thereby further facilitating photon ionization of those atoms under appropriate conditions. Accordingly, it should be readily understood that the scope of the invention includes all of these and other variations which will be apparent to those skilled in the art having the benefit of the present disclosure.
Number | Name | Date | Kind |
---|---|---|---|
3287598 | Brooks | Nov 1966 | A |
3733248 | Chu et al. | May 1973 | A |
3755073 | Haught et al. | Aug 1973 | A |
3817622 | Billman et al. | Jun 1974 | A |
3833851 | Jobes, Jr. et al. | Sep 1974 | A |
4442354 | Hurst et al. | Apr 1984 | A |
4714834 | Shubaly | Dec 1987 | A |
4775789 | Albridge, Jr. et al. | Oct 1988 | A |
5153430 | Gammel et al. | Oct 1992 | A |
5270222 | Moslehi | Dec 1993 | A |
5365063 | Kaesdorf et al. | Nov 1994 | A |
5601654 | Springer | Feb 1997 | A |
5637188 | Amme et al. | Jun 1997 | A |
6068783 | Szetsen | May 2000 | A |
6184623 | Sugai et al. | Feb 2001 | B1 |
6326794 | Lundquist et al. | Dec 2001 | B1 |
6744211 | Sugai et al. | Jun 2004 | B2 |
7061184 | Kim et al. | Jun 2006 | B2 |
20090266984 | Hirano | Oct 2009 | A1 |
20100090106 | De Gorordo | Apr 2010 | A1 |
Number | Date | Country | |
---|---|---|---|
20100090106 A1 | Apr 2010 | US |