The present invention will now be described with reference to the drawings wherein like reference numerals are used to refer to like elements throughout, and wherein the illustrated structures are not necessarily drawn to scale. The invention provides ion implantation systems to compensate for disadvantageous thermal conditions on a semiconductor workpiece, as well as methods for providing a workpiece to a fixed ion beam and/or a ribbon ion beam.
Although illustrated and described below in the context of exemplary low energy ion implantation systems, the invention may alternatively be employed in high or medium energy ion implanters, which may or may not include acceleration components.
Conventional high current and/or high-energy ion implantation applications typically result in an increase of workpiece temperature near the edge for a subsequent scan relative to a prior scan, thus causing non-uniform ion implantation results. The surface temperature of a workpiece is a function of the ion beam power and the technique used for ion beam scanning and/or workpiece scanning. Therefore, a need exists for a method for reducing a transient workpiece temperature during implantation.
Productivity in ion implantation systems is generally a function of several factors. For example, productivity can be quantified by a capability of the system to generate a particular amount of ion beam current, a ratio between a number of ions that are generated by the system to a number of ions actually implanted in the workpiece (e.g., a silicon wafer), or a ratio between an amount of time in which the workpiece is being implanted with ions and an amount of time taken for positioning the workpiece for ion implantation. The ratio of generated ions to ions actually implanted in the workpiece, for example, is generally referred to as “ion beam utilization”, as will be discussed hereafter.
For low dose ion implants (e.g., ion implantations having a dosage of less than approximately 1×1014 ions/cm2), a current of the ion beam typically ranges well below limitations in the capability of the ion implantation system, and the ion beam current can be increased in order to account for a potentially-low ion beam utilization. However, for high dose ion implants (e.g., ion implantations having a dosage of greater than approximately 1×1015 ions/cm2) as contemplated in the present invention, the ion beam current is typically at or near the maximum capability of the ion implantation system, and ion beam utilization has a much greater significance to the productivity of the system for optimal ion implantations. Such ion implantations are referred to as “beam current limited” implants, wherein the utilization of the ion beam is an important factor in determining the most advantageous usage of various types of ion implantation systems. For example, multiple-substrate ion implantation systems, or batch implanters, traditionally have a significantly higher ion beam utilization than single substrate systems, thus making the multiple-substrate systems the conventional tool of choice for high dose implants. However, single-substrate ion implantation systems, or serial systems, have various other advantages, such as contamination control, process lot size flexibility, and, in some configurations, incident beam angle control. Therefore, as contemplated by the inventors, it would be highly desirable for the single-substrate system to be utilized in a method that minimizes losses in productivity.
Therefore, the present invention is directed to an increase of thermal uniformity in a single-workpiece ion implantation system, wherein the workpiece transient temperature operating parameter is controlled by rotation of the workpiece between fixed beam scans. Rotating the workpiece between scans allows for the transient temperature of the workpiece surface to decay sufficiently for a more uniform ion implantation process to proceed along a scan axis.
In one embodiment of the present invention, several advantages over conventional methods using typical single-workpiece or single-wafer ion implantation systems are provided. For example, conventional single-workpiece ion implantation systems or serial implanters have generally fixed linear scan speeds and accelerations in one or more axes (e.g., in a slow-scan axis), and are not typically optimized for a uniform thermal continuum in a fixed ion beam. Control of transient thermal parameters during ion implantation reduces workpiece temperature.
Referring now to the figures, in accordance with one exemplary aspect of the present invention,
The beamline assembly 114, for example, comprises a beamguide 130 having an entrance near the source 120 and an exit with a resolving aperture 134, as well as a mass analyzer 134 that receives the extracted ion beam 110 and creates a dipole magnetic field to pass only ions of appropriate energy-to-mass ratio or range thereof (e.g., a mass analyzed ion beam 110 having ions of a desired mass range) through the resolving aperture 132 to the workpiece 105 on a workpiece scanning system 136 associated with the end station 116. Various beam forming and shaping structures (not shown) associated with the beamline assembly 114 may be further provided to maintain and bound the ion beam 110 when the ion beam is transported along a beam path to the workpiece 105 supported on the workpiece scanning system 136.
The end station 116 illustrated in
According to one exemplary aspect of the present invention, the single-workpiece ion implantation system 100 provides a generally stationary ion beam 110 (e.g., also referred to as a “spot beam” or “pencil beam”), wherein the workpiece scanning system 136 generally translates the workpiece 105 in two generally orthogonal axes with respect to the stationary ion beam.
The translation of the workpiece 205 through the ion beam 210 generally defines a first edge 230 (e.g., illustrated with reference to a notch 235 in
In accordance with the present invention, the disadvantageous thermal non-uniformity associated with the prior art is alleviated by a method 300 illustrated in
As illustrated in
After the initial mechanical scan (i.e., the first scan) of the workpiece 405 along the slow scan axis 415 (e.g., in the −y direction) of act 305 of
According to another example, such as when implanting hydrogen ions into the workpiece, the workpiece 405 is rotated a second predetermined amount (e.g., approximately 90 degrees) and placed in a third orientation 408C after the second scan, as illustrated in
As implied by the use of the term “reciprocating drive apparatus”, in one example, the drive apparatus of the present invention is operable to reciprocally translate or oscillate the workpiece 502 in a reversible motion along the first scan path 504, such that the workpiece translates alternatingly back and forth with respect to a generally stationary ion beam 505, wherein the apparatus can be utilized in an ion implantation process. Alternatively, the reciprocating drive apparatus 500 may be utilized in conjunction with various other processing systems, which may include other semiconductor manufacturing processes such as, for example, a step-and-repeat lithography system.
According to one aspect of the present invention, the reciprocating drive apparatus 500 comprises a motor 506 operably coupled to a scan arm 508 wherein the scan arm is further operable to support the workpiece 502 thereon. The motor 506, for example, comprises a rotor 510 and a stator 512, wherein the rotor and the stator are dynamically coupled and operable to individually rotate about a first axis 514. The rotor 510 is further operably coupled to a shaft 516, wherein the shaft generally extends along the first axis 514 and is operably coupled to the scan arm 508. In the present example, the rotor 510, shaft 516, and scan arm 508 are generally fixedly coupled to one another, wherein rotation of the rotor about the first axis 514 generally drives rotation of the shaft and scan arm about the first axis, thus generally translating the workpiece 502 along the first scan path 504. Alternatively, the rotor 510, shaft 516, and scan arm 508 may be otherwise coupled to one another, wherein the rotation of the rotor and/or shaft may drive a linear translation of the scan arm with respect to the first axis 514.
As can be appreciated, the system 500 is operable to reciprocate the workpiece 502 along scan path 504 that comprises a fast scan path. In addition, the entire system 500 is further operable to translate linearly along a second scan path or axis 518, that comprises the slow scan path. According to an aspect of the present invention, the system 500 is further operable to rotate the workpiece 502 a predetermined amount (e.g., between 0 and 360 degrees) about a workpiece axis 520 after one scan along the second scan path 518 prior to returning in the opposite direction along the second scan path. In the above manner, for example, when rotated 180 degrees, a first edge 522 of the workpiece remains the leading edge and a second edge 524 remains the lagging edge for the scans along the second scan path 518 in differing directions, thereby improving thermal uniformity in scan conditions.
According to one example, the first link 615 is rotatably coupled to the base portion 605 via a first joint 625, wherein the first link is operable to continuously rotate about a first axis 627 in a first rotational direction 628 (e.g., the first link is operable rotate clockwise or counter-clockwise with respect to the first joint). The second link 620 is further rotatably coupled to the first link 615 via a second joint 630, wherein the second joint is spaced a predetermined distance L from the first joint 625. The second link is further operable to continuously rotate about a second axis 632 in a second rotational direction 633 (e.g., the second link is operable to rotate clockwise or counter-clockwise with respect to the second joint). The first link 615 and the second link 620, for example, are further operable to rotate in separate, yet generally parallel first and second planes (not shown), respectively, wherein the first and second planes are generally perpendicular to the respective first and second axes 627 and 632. Furthermore, the first link 615 and second link 620 are operable to continuously rotate 360° in a respective first rotational path 634 and second rotational path 135 about the respective first joint 625 and second joint 630.
According to one exemplary aspect of the invention, the first rotational direction 628 is generally opposite the second rotational direction 633, wherein an end effector 640 associated with the second link 620 is operable to linearly translate along a first scan path 642 (e.g., a fast scan path) associated with the predetermined movement of the first link 615 and the second link. The end effector 640, for example, is operably coupled to the second link 620 via a third joint 645 associated with the second link, wherein the third joint is spaced the predetermined distance L from the second joint 630. The third joint 645, for example, is operable to provide a rotation 647 of the end effector 640 about a third axis 648. Furthermore, according to another example, the third joint 645 is further operable to provide a tilt (not shown) of the end effector 640, wherein, in one example, the end effector is operable to tilt about one or more axes (not shown) which are generally parallel to the second plane (not shown).
The end effector 640, for example, is further operable to secure the workpiece 646 thereto, wherein the movement of the end effector generally defines a movement of the workpiece. The end effector 640, for example, may comprise an electrostatic chuck (ESC), wherein the ESC is operable to substantially clamp or maintain a position of the workpiece 646 with respect to the end effector. It should be noted that while an ESC is described as one example of the end effector 640, the end effector may comprise various other devices for maintaining a grip of a payload (e.g., the workpiece), and all such devices are contemplated as falling within the scope of the present invention.
The predetermined movement of the first link 615 and second link 620, for example, can be further controlled in order to linearly oscillate the end effector 640 along the first fast scan path 642, wherein the workpiece (not shown) can be moved in a predetermined manner with respect to the ion beam (e.g., an ion beam coincident with the first axis 627). A rotation of the third joint 645, for example, can be further controlled, wherein the end effector 640 is maintained in a generally constant rotational relation with the first fast scan path 642 when traveling therealong. It should be noted that the predetermined distance L separating the first joint 625 and second joint 630, as well as the second joint and third joint 645, provides a general congruity in link length when measured between the respective joints. Such a congruity in length of the first link 615 and second link 620, for example, generally provides various kinematic advantages.
As illustrated in
It should be therefore noted that while the rotational directions 628 and 633 remain constant (i.e., unchanged), the movement of the end effector 640 and workpiece 665 oscillates along the first scan path 642, thus changing direction at the maximum positions 655 and 660. Such a change in direction of the end effector 640 (and hence, the workpiece 665) is associated with a change in velocity and acceleration of the end effector and workpiece. In ion implantation processes, for example, it is generally desirable for the end effector 640 to maintain a substantially constant velocity along the scan path 642 when the workpiece 665 passes through an ion beam (not shown), such as an ion beam which is generally coincident with the first axis 627. Such a constant velocity provides for the workpiece 665 to be generally evenly exposed to the ion beam throughout the movement through the ion beam. However, due to the oscillatory motion of the end effector 640, acceleration and deceleration of the end effector is inevitable; such as when the third joint 645 (e.g., associated with the end effector and workpiece 665) approaches the maximum positions 655 and 660 at either extent of the linear oscillation. Such an acceleration and deceleration near the maximum positions 655 and 660 (e.g., during scan path turn-around), should be maintained at reasonable levels in order to minimize inertial forces and associated reaction forces transmitted to the base portion 605 of the scanning mechanism 600. Variations in velocity of the end effector 640 during exposure of the workpiece 665 to the ion beam, for example, can lead to a non-uniform ion implantation across the workpiece.
Therefore, a generally constant velocity is desired for a predetermined range 668 associated with the movement of the workpiece 665 through the ion beam. For example, the predetermined range 168 is associated with the physical dimensions of the workpiece 665 (e.g., twice a diameter of the workpiece), such that the acceleration and deceleration of the end effector can be generally accommodated within the overshoot 667. Accordingly, once the workpiece 665 completely passes through the ion beam, the acceleration and deceleration of the end effector 640 will not substantially affect an ion implantation process or dose uniformity across the workpiece.
The present invention may be employed in conjunction with the system of
Although the invention has been illustrated and described with respect to one or more implementations, alterations and/or modifications may be made to the illustrated examples without departing from the spirit and scope of the appended claims. In particular regard to the various functions performed by the above described components or structures (blocks, units, engines, assemblies, devices, circuits, systems, etc.), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component or structure which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary implementations of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising”.
This application claims priority to and the benefit of U.S. Provisional Application Ser. No. 60/833,938 which was filed Jul. 28, 2006, entitled METHOD OF REDUCING TRANSIENT WAFER TEMPERATURE DURING IMPLANTATION, the entirety of which is hereby incorporated by reference as if fully set forth herein.
Number | Date | Country | |
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60833938 | Jul 2006 | US |