Patent Application
20080194112
IBM® is a registered trademark of International Business Machines Corporation, Armonk, N.Y., U.S.A. Other names used herein may be registered trademarks, trademarks or product names of International Business Machines Corporation or other companies.
1. Field of the Invention
This invention relates generally to plasma etching of semiconductor devices, and more particularly, to a method and system for improving across-wafer etch uniformity.
2. Description of the Related Art
As semiconductor technology continues to advance, the demands on the manufacturing process of semiconductor devices increase as well. In particular, larger wafer sizes allow for an increased number of semiconductor chip devices for a given manufacturing run, thereby lowering unit costs of the individual semiconductor devices. Uniformity in layers and substrate features are a critical production requirement. However, as wafers sizes increase it becomes more difficult to insure a uniform process across the wafer surface. Etch processes generally exhibit variation (etch rate and/or critical dimension) as a function of the radial distance from the wafer center.
Etching chamber designs with dual zone temperature electrostatic chuck (“E-Chuck”) or dual zone gas feeds have contributed to minimize non-uniformity of wafer etch. However, as seen in
A method for improving across-wafer etch uniformity of semiconductor devices in an etching chamber, includes: introducing a first flow of gas mixtures from a central gas distribution plate manifold; introducing a second flow of separate gas mixtures from an auxiliary gas feed; controlling process parameters including one or more of: duration, and gas flow rates for the first and second flows of gas mixtures; wherein the central gas distribution plate manifold is positioned above the semiconductor wafer; wherein the auxiliary gas feed is positioned around the perimeter of the semiconductor wafer; and wherein the controlling of the process parameters of the central gas distribution plate manifold and the auxiliary gas feed is facilitated by independent controls.
A system for improving across-wafer etch uniformity in an etching chamber, includes: a central gas distribution plate manifold with a first flow of gas mixtures controlled by a first controller; an auxiliary gas feed with a second flow of gas mixtures controlled by a second controller; and wherein the central gas distribution plate manifold is positioned above a semiconductor wafer under process in the etching chamber; wherein the auxiliary gas feed is positioned around the perimeter of the semiconductor wafer; and wherein the first and second controllers independently control process parameters including one or more of: duration, and gas flow rates for each component of gases within each of the two gas mixtures for the first and second etching gas flows.
A plasma reaction chamber for processing of semiconductor wafers including: a gas distribution plate having a plurality of apertures sized, shaped, and positioned to deliver at least one gas to a central portion of a semiconductor wafer operatively positioned within the reaction chamber; a second gas distribution ring having a plurality of apertures sized, shaped, and positioned to deliver at least one gas to an outer radial portion of the semiconductor wafer; and wherein the flow of the at least one gas through the gas distribution plate and the gas distribution ring is independently controllable.
Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.
The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
Embodiments of the present invention provide a method and system for improving across-wafer etch uniformity of semiconductor devices by providing an edge proximity auxiliary gas feed design. The plasma etcher embodied in the present invention provides both a central gas distribution plate manifold, as well as a circumferential gas distribution ring manifold positioned proximate the outer edge of a wafer undergoing plasma etching. Gas flows through the two plasma gas distribution manifolds are independently controllable. Providing two independently controllable manifolds provides greater uniformity of the etching process across the entire surface of wafer.
Examples of applying embodiments of the present invention for gate etch critical dimension (CD) improvement are as follows:
The flow diagrams depicted herein are just examples. There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
While the preferred embodiments to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may male various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.
