1. Technical Field
The present invention relates generally to semiconductor wafer processing, and more particularly to a method and apparatuses for providing electrical contact for plasma processing applications.
2. Related Art
Plasma processing applications, such as plasma doping (PLAD), are gaining favor as an attractive method for semiconductor device processing. PLAD, for example, offers advantages including the ability to achieve higher throughputs in semiconductor implant processing, while keeping the footprint much smaller than conventional beam-line implanters.
With PLAD applications, as the examples in
One challenge with PLAD is to provide arc-free performance. Arcing typically results when electrical contact to the wafer 10 is insufficient, and a potential difference at a gap (e.g., 26 in
Further, considerable amounts of electrical current are required to flow through the wafer under PLAD processing conditions when there are high plasma density requirements due to increased throughput needs. These currents lead to voltage gradients across the wafer due to the resistivity of the bulk material, the spreading resistance of any electrical contacts, and/or the contact resistance. Voltage gradients cause a non-uniform bias across the wafer due to finite contact regions through which the current is applied. If the resistivity and/or current is sufficiently large, the voltage gradient can ultimately impact dopant junction depth, thereby affecting sheet resistance. Large voltage gradients in the region of the backside of the wafer can also lead to localized damage to the backside of the wafer in the region of electrical contact.
In view of the foregoing, there is a need in the art that addresses at least one of the aforementioned shortcomings of the related art.
A method and apparatuses for providing improved electrical contact to a semiconductor wafer during plasma processing applications are disclosed. In one embodiment, an apparatus includes a wafer platen for supporting the wafer; and a plurality of electrical contact elements, each of the plurality of electrical contact elements are configured to provide a path for supplying a bias voltage from a bias power supply to the wafer on the wafer platen. The plurality of electrical contact elements are also geometrically arranged such that at least one electrical contact element contacts an inner surface region (e.g., region between a center of wafer and a distance approximately half of the radius of the wafer) and at least one electrical contact element contacts an outer annular surface region (e.g., region between an outer edge of wafer and a distance approximately half of the radius of the wafer).
A first aspect of the disclosure is directed to an apparatus for supporting a backside of a semiconductor wafer during plasma processing application, the backside geometrically defining an inner surface region and an outer annular surface region, the apparatus comprising: a wafer platen for supporting the wafer; and a plurality of electrical contact elements, each of the plurality of electrical contact elements are configured to provide a path for supplying a bias voltage from a bias power supply to the wafer on the wafer platen, the plurality of electrical contact elements being geometrically arranged such that at least one electrical contact element contacts the inner surface region and at least one electrical contact element contacts the outer annular surface region.
A second aspect of the disclosure is directed to a method of providing electrical contact during plasma processing using a platen for contact with a backside of a semiconductor wafer, the method comprising: placing at least one electrical contact element in contact with an inner surface region of the wafer; placing at least one electrical contact element in contact with an outer annular surface region of the wafer; and plasma processing the wafer.
A third aspect of the disclosure is directed to an apparatus for supporting a backside of a semiconductor wafer during plasma processing application, the apparatus comprising: a wafer platen for supporting the wafer; and a plurality of electrical contact elements coupled to the wafer platen, wherein at least one of the plurality of electrical contact elements is located less than a distance of approximately 50 mm from an adjacent electrical contact element.
The foregoing and other features of the invention will be apparent from the following more particular description of embodiments of the disclosure.
The embodiments of this invention will be described in detail, with reference to the following figures, wherein like designations denote like elements, and wherein:
A method and apparatuses for providing improved electrical contact to a semiconductor wafer during plasma processing applications are described herein.
Referring to the attached drawings,
In one embodiment, the geometry of wafer 102 is defined as including a first inner surface region 114 and a second outer annular surface region 116. As shown, wafer 102, generally being circular in plan, includes a geometry having a radius, R1, from a center, or centerline, (C.L.) of wafer 102. Dimension, R2, is approximately half of radius R1. In one embodiment, first portion 114 is defined as a region of wafer 102 between a center, CL, of the wafer 102 and approximately distance R2. Consequently, the second portion 116 may include a portion of wafer 102 defined as a region of wafer 102 between an outer edge 118 of wafer 102 and a distance, approximately R2.
In another embodiment, first inner surface region 114 and second outer annular surface region 116 may be defined as two portions of wafer 102 having equal areas. Thus, first inner surface region 114 may be defined as a region of wafer 102 between CL of wafer 102 and approximately distance 0.707R1. Second, outer annular surface region 116 may include a portion of wafer 102 defined as a region of wafer 102 between an outer edge 118 of wafer 102 and a distance, approximately 0.707 R1. It is understood, however, that the illustrated radial dimensions defining each region may vary, and are not considered limiting other than as recited in the attached claims. Improved attributes of wafers 102 manufactured in PLAD applications are obtained by placing a plurality of electrical contact elements 120 so that at least one electrical contact element 120A contacts first portion 114 and at least one electrical contact element 120B contacts second portion 116. In another embodiment, backside 104 of wafer 102 may be defined into other quantities of regions. For example, if N=quantity of regions that wafer 102 is apportioned, then N may exceed 2. In another embodiment, wafer 102 is defined by a plurality of outer annular surface regions 116. In this manner, electrical contact elements 120 may contact more than two outer annular surface regions 116.
Various configurations of electrical contact elements 120 and layouts thereof may be employed under aspects of the disclosure. For example, in
Bench testing was conducted on apparatuses of the related art and an embodiment of an apparatus under the disclosure. Under the bench testing, the impedance for various methods of electrically contacting a wafer produced the following data: for a three (3) pinned electrical contact apparatus (see e.g., 20 in FIG. 2(a) in U.S. Pat. No. 7,126,808), when a contact voltage of 64 volts and current of 240 or 250 milli-amps is applied across a wafer, the measured resistance across the wafer is found to be in a range of 256 to 266.7 ohms. Contrastingly, when a contact voltage of 13 volts and current of 700 milli-amps is applied across a wafer 102 supported by an apparatus 100, 200, 300, according to embodiments of the disclosure, with an aluminum electrical contact element 120, as in the embodiment shown in
Other embodiments of providing electrical contact are shown in plan in
In another embodiment, as shown in
In another embodiment, as shown in
In any event, the distribution, configuration, arrangement, and/or quantity of electrical contact elements 120 to backside 104 is such so as to minimize voltage distribution across wafer 102 for a worst case resistivity (i.e., highest) wafer 102 that may be implanted by apparatus 100, 200, 300. This voltage is kept to a value such that any impact on implanted dopant junction depth will be negligible and/or zero. Further, the distribution, configuration, arrangement, and/or quantity of electrical contact elements 120 to backside 104 is selected so to minimize contact resistance and/or spreading resistance across wafer 102. These resistance values are kept at a threshold that allows no appreciable voltage drop at the maximum current during implantation.
Various materials may be used for electrical contact elements 120. Material selection may be dependent on wafer 102 substrate material (p-type or n-type) and thickness of films on wafer 102 substrate. Material selection may be optimized for either p-type or n-type material or both p-type and n-type material to be implanted. For example, suitable materials for electrical contact elements 120 may include a metal or an alloy. Further, suitable materials for electrical contact elements 120 may include Titanium, Aluminum, Tungsten, Tantalum, Cobalt, Nickel, Silicon, Silicon Carbide and/or silicide formed used the aforementioned elements.
Another aspect of the disclosure includes providing different materials on different electrical contact elements 120. For example, the plurality of electrical contact elements 120 may be defined by a first group of electrical contact elements 120 and a second group of electrical contact elements 120, wherein the first group comprises a first material and the second group comprises a second material. In this manner, the first group of electrical contact elements 120 may, for example, comprise a material type “A” suited for p-type Si substrate, while the second group of electrical contact elements 120 may, for example, comprise a material type “B” suited for n-type Si substrate, or vice versa. The first group and second group may be different, similar, and/or identical quantities of electrical contact elements 120. For example, approximately half of the total quantity of electrical contact elements 120 may be comprised of a material that is suited for p-type Si substrate, while the other half of the total quantity of electrical contact elements 120 may be comprised of a material that is suited for n-type Si substrate. Such configurations would obviate the need for two different apparatuses for processing different wafer 120 substrates (e.g., p-type Si substrate, n-type Si substrate, etc.).
Another aspect of the disclosure includes providing an advantageous shape to an engagement end 402 of electrical contact element 120J, 120K, as shown in
As shown in
While this disclosure has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims.