This disclosure relates to an optimization method, and in particular to an optimization method of a vacuum plating process.
Thin films made by vacuum plating systems have been widely used in various fields, such as semiconductor devices, solar cells, memory, photoconductive materials, and microelectromechanical materials. With different applications, it is necessary to adjust different process parameters, types of raw materials and additive amounts to meet the needs of various thin films. In order to obtain an optimal combination of parameters, a large number of experimental trials and errors are required, which are costly in terms of manpower, resources and time. Moreover, this trial-and-error method lacks the rules to effectively link process parameters to thin film properties, which makes it difficult to apply to other thin films or to make predictions. Therefore, how to improve the efficiency of thin film process control and the accuracy of prediction is an issue that needs to be improved.
The disclosure provides an optimization method for a vacuum plating process, capable of improving efficiency of optimization and accuracy of prediction.
The optimization method for the vacuum plating process of the disclosure includes following steps. A property of a thin film to be optimized is determined. According to the property of the thin film to be optimized, process parameters and a level of each of the process parameters are determined. M sets of experiments are designed, where M is a positive integer, M is positively related to a number of the process parameters, but M is not related to a number of the level of the process parameters. The M sets of experiments are performed to obtain M sets of test films and the property of each of the test films are measured or calculated. Process parameters used in the M sets of experiments and the property of the M sets of test films are fitted with a multi-dimensional quadratic transformation function to obtain a first fitting function. The first fitting function is dynamically modified using an iteration method to obtain a best fitting function. A multi-dimensional response surface diagram is illustrated using the best fitting function to determine an optimal process parameter combination.
Based on the above, the optimization method for the vacuum plating process of the disclosure can fit a small amount of experiment data to obtain an accurate fitting function by fitting the multi-dimensional quadratic transformation function and making dynamic iterative corrections. In this way, the efficiency of optimization and the accuracy of prediction may be effectively improved.
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In some embodiments, the value of the level of the each process parameter can be designed within its adjustable range. For example, the adjustable range of the process temperature in the vacuum plating system is between 25° C. and 800° C., then 200° C. and 500° C. can be set as two levels of process temperature. The setting of level can be selected according to the understanding of the process, the scope to be explored, etc., without special restrictions.
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In some embodiments, the multi-dimensional quadratic transformation function can be represented by the following formula (a):
where E is the property of the thin film to be optimized, n is the number of process parameters, fi and fj are process parameters, and c0, ci, cii, and cij are unknown coefficients. Therefore, for this embodiment, in order to fit the above formula (a), M is at least (n2+3n+2)/2. Compared with the traditional trial and error method, the number of experiments may be greatly reduced by fitting the above multi-dimensional quadratic transformation function.
In some embodiments, some items of the above formula (a) can be omitted to further reduce the number of experiments. For example, the linear term in formula (a) can be ignored, that is, the multi-dimensional quadratic transformation function can be expressed by the following formula (b):
where E is the property of the thin film to be optimized, n is the number of process parameters, fi and fj are process parameters, and c0, cii, and cij are unknown coefficients. Therefore, for this embodiment, in order to fit the above formula (b), M is at least (n2+n+2)/2.
In some embodiments, the experiment design method may adopt the Orthogonal Array Composite Design (OACD) method or other suitable design methods, but the disclosure is not limited thereto.
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In some embodiments, a determination coefficient (i.e., R2) can be used to determine the fit property of the fitting function. When the determination coefficient is closer to 1, it means that the fit property of the fitting function is better. When the determination coefficient is closer to 0, it means that the fit property of the fitting function is worse. The determination coefficient can be expressed as follows:
where SStot=Σi=1m(yi−yavg)2, SSres=Σi=1mei2,
where m is the total number of experiments, yi is the thin film property value actually measured in the ith set of experiments, yavg is the average of the thin film property values actually measured in all experiments, and ei is the difference between the thin film property value actually measured in the ith set of experiments and the thin film property value of the ith set of experiments predicted by the fitting function.
In some embodiments, as the number of iterations increases, the determination coefficient (i.e., R2) of the corresponding fitting function becomes closer to 1. That is, the determination coefficient (i.e., R2) of the second fitting function (or the determination coefficient of the best fitting function) is greater than the determination coefficient of the first fitting function. In some embodiments, if the determination coefficient of the second fitting function is smaller than the determination coefficient of the first fitting function (that is, the determination coefficient of the fitting function obtained after iteration is smaller than the determination coefficient of the fitting function obtained before iteration), it is necessary to confirm whether there is any abnormal condition in the experiment process. If the abnormal condition is ruled out, it is necessary to review the experimental design, for example, whether the selection of process parameters and the selection of level of each process parameter are appropriate, etc., to judge whether to redesign the experiment.
In some embodiments, multiple iterations can be performed until the determination coefficient (i.e., R2) of the obtained fitting function is greater than or equal to a target value, then the fitting function this time is the best fitting function. In some embodiments, the target value of the determination coefficient is, for example, 0.90, 0.95, 0.98, or other suitable values, but the disclosure is not limited thereto. In some embodiments, the best fitting function is obtained by fitting data from at least M+p experiments, where M is the number of initial experiment sets and p is the number of iterations.
In some embodiments, if the determination coefficient (i.e., R2) of the fitting function obtained by the kth iteration is smaller than the determination coefficient of the fitting function obtained by the k−1th iteration, or the best parameter combination obtained by the kth iteration is the same as the best parameter combination obtained by the k−1th iteration, the fitting function obtained by the k−1th iteration can be used as the best fitting function, where k is a positive integer.
In the embodiment where the multi-dimensional quadratic transformation function is represented by formula (a), the best fitting function can be represented by the following formula 1,
where E is the property of the thin film to be optimized, n is the number of process parameters, fi and fj are process parameters, and c0,0, ci,0, cii,0, and cij,0 are coefficients obtained by fitting the data of the M sets of experiments (i.e., the coefficients of the first fitting function),
In the embodiment where the multi-dimensional quadratic transformation function is represented by formula (b), the best fitting function can be represented by the following formula 2,
where E is the property of the thin film to be optimized, n is the number of process parameters, fi and fj are process parameters, c0,0, cii,0, and cij,0 are coefficients obtained by fitting the data of the M sets of experiments (i.e., the fitting coefficients of the first fitting function),
where c0,k, cii,k, and cij,k are fitting coefficients obtained by the kth iteration, c0,k-1, cii,k-1, and cij,k-1 are the fitting coefficients obtained by the k−1th iteration, and p is the number of iterations.
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In some embodiments, through the best fitting function, the coefficient magnitude of each process parameter can be compared and analyzed to understand the degree of influence of each process parameter on the thin film property. For example, the greater the absolute value of the coefficient corresponding to the process parameter, the greater the impact on the thin film property; conversely, the smaller the absolute value of the coefficient corresponding to the process parameter, the smaller the impact on the thin film property.
In some embodiments, the optimization method can be applied to various vacuum plating processes, such as physical vapor deposition, thermal evaporation, electron beam evaporation, ion beam assisted evaporation, molecular beam epitaxy, pulse laser coating chemical vapor deposition, plasma enhanced chemical vapor deposition, metal organic chemical vapor deposition and atomic layer deposition or other suitable vacuum plating process.
Below, the optimization method for the vacuum plating process of the disclosure is explained in detail through an experiment example. However, the following experiment example is not intended to limit the disclosure.
This experiment example aims to optimize the deposition rate of silicon nitride thin film formed by plasma enhanced chemical vapor deposition (PECVD) method, in which the reactants for forming silicon nitride thin film include N2 and SiH4. Five process parameters were selected for experiment design from Group 1 to Group 26, as shown in Table 1 below, in which the process parameters include RF power, reaction chamber pressure, substrate temperature, flow ratio of N2 and SiH4, and mass flow rate of N2, and each process parameter is set to three levels. After that, a silicon nitride thin film was prepared according to the experimental design of Group 1 to Group 26, and its deposition rate was measured, which are recorded in Table 1. The data from experiments 1 to 26 in the following table were then used to fit the multi-dimensional quadratic transformation function represented by formula (a) and to predict the optimal parameter combination. A silicon nitride thin film was prepared with this optimal process parameter combination and its deposition rate was measured, which is recorded in the 27th group of experiments in Table 1. Then, the data from group 1 to group 27 are then used to fit the multi-dimensional quadratic transformation function represented by formula (a), an iterative correction is performed, the optimal parameter combination obtained after the correction is the same as that analyzed in group 1 to group 26, and therefore the iteration is stopped. The best fitting function is obtained as follows, and its determination coefficient is 0.98:
A multi-dimensional response surface diagram is illustrated according to the best fitting function obtained above, as shown in
The obtained best fitting function shows that the mass flow rate of N2 and the reaction chamber pressure are the parameters that have a greater impact on the thin film deposition rate, while the interaction term between the flow ratio of N2 and SiH4 and the substrate temperature has the greatest impact on the thin film deposition rate.
In addition, from the three-dimensional surface diagrams in
It can be seen that this experiment example can obtain the fitting function that can well describe the deposition rate of silicon nitride thin film through 27 sets of experiment data and determine its optimal process parameter combination, which can improve the efficiency of the film process control, and if there are different needs for the deposition rate (e.g., a specific deposition rate), the corresponding process parameter combination can be quickly found through the obtained fitting function.
To sum up, the optimization method for the vacuum plating process of the disclosure can fit a small amount of experiment data to obtain an accurate fitting function by fitting the multi-dimensional quadratic transformation function and making dynamic iterative corrections. In this way, the efficiency of optimization and the accuracy of prediction may be effectively improved.
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed embodiments without departing from the scope or spirit of the disclosure. In view of the foregoing, it is intended that the disclosure covers modifications and variations provided that they fall within the scope of the following claims and their equivalents.
This application claims the priority benefit of U.S. provisional application Ser. No. 63/601,710, filed on Nov. 21, 2023. The entirety of the above-mentioned patent application is hereby incorporated by reference herein and made a part of this specification.
Number | Date | Country | |
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63601710 | Nov 2023 | US |