In general, the invention relates to systems and methods for generating ozone and plasma using electron beam technology.
Ozone and plasma generation technologies rely on the principle of supplying energy to an input gas, resulting in the formation of charge carriers (electrons and ions) as well as additional plasma species. The most commonly used method for generating and sustaining ozone and plasma for industrial applications is by applying an air electric field to the input gas. There are several methods for generating and applying an electric field for these applications. Typically, ozone a id plasma gene ion technologies are configured in such way that the electric field is generated in the same chamber in which the input process gas is reacted. There are fundamental limitations of generating the electric field in the same chamber as where the input process gas is dissociated into ozone or plasma. One limitation is that the reacted gas can modify the surface of the chamber in such a way as to alter the way in which the electric field is generated, resulting in a change in reaction efficacy. A second limitation is that the reacted gas can modify the surface of the chamber in such a way as to create additional unwanted particles. A third limitation is that it is difficult or impossible to precisely control how the electric field interacts with the process gas, limiting the flexibility of the process. Known processes for overcoming these limitations for ozone and plasma generation generally result in reduced efficacy, higher process variability, lower efficiency, increased system complexity, higher cost, and increased system maintenance.
Ozone generation technologies currently exist and have been in commercial operation or over 20 years. Applications include semiconductor manufacturing (including without limitation atomic layer deposition, oxide growth, photo-resist removal, and chemical vapor deposition) and water treatment. The typical configuration of ozone generation for semiconductor applications uses dielectric barrier discharge to create an electric field in a reaction chamber that initiates a dissociation reaction through electron acceleration within an input gas containing some concentration of oxygen. This initiates a capacitively coupled plasma and yields some concentration of ozone. In this type of arrangement, the electric field is created in the same chamber in which the input gas is reacted.
One common configuration for dielectric barrier discharge is metal to ceramic discharge cells. In order to increase the concentration of ozone produced in these types of embodiments, refractory metals such as tungsten are a choice of material for the metal surface. One limitation is the detrimental modification of the discharge surface as a result of resultant process gas (i.e. ozone) interaction with those surfaces. A result of this gradual detrimental modification is the gradual reduction in concentration of the ozone generated due to loss of the effective discharge surface. Conventional methods of ozone generation also require precise control of the discharge gap in the reaction zone and require cooling of the reaction zone as the ozone concentration is dependent on the temperature of the reaction zone volume and discharge surfaces. Precise gap control and cooling introduce complexity to the overall design of the system and variability in the resultant process gas across different systems. In addition, precise gap control allows for only limited control over the energy levels of the electrons.
The industry standard for plasma generation is based on either inductively coupled plasma generation or microwave plasma generation. Examples of industrial plasma generated in these methods include generation of fluorine based plasma, oxygen or nitrogen plasma, water plasma, argon or another inert gas plasma, and hydrogen plasma. These types of plasmas are used for a wide range of semiconductor and other industrial applications including without limitation: photoresist removal, passivation and residue removal, surface modification, nitridation, oxide etch, deposition, silicon etch, and remote plasma cleaning of reaction chamber. Common materials used in these plasma generation technologies include quartz, sapphire, and anodized aluminum for inductively coupled plasma. For capacitively coupled plasma, common materials include alumina or tungsten, and microwave plasma generation commonly uses sapphire or aluminum nitride.
Conventional methods of plasma generation generate a high electromagnetic field within the reaction chamber that accelerates electrons and initiates an avalanche of electron generation that breaks down an input process gas into a plasma. As a result of having the electromagnetic field present within the reaction chamber, the electromagnetic field influences the resultant plasma, causing direct interactions of the ions and charged particles with the walls of the chamber such as etching the walls and generating additional particles. These additional particles are problematic for semiconductor and other industries. Furthermore, conventional methods result in only partial control over the energy levels of the electrons.
As such, there remains a need in the art for improved systems and methods for ozone and plasma generation.
The systems and methods described herein include, among other things, systems and methods for providing ozone generators or plasma generators that generate an electric field in an electron generation chamber that is separate from a reaction chamber. An electron beam emitter in an electron generation chamber is configured to emit a beam of electrons. The electron generation chamber is separated from the reaction chamber by an electron permeable barrier that provides a window through which the beam of electrons passes. The barrier also seals the electron generation chamber to prevent non-electron material from passing out of the electron generation chamber and to maintain a differential pressure and a vacuum level. The electrons are generated, accelerated to the appropriate energy in the electron generation chamber, and transmitted through the barrier to the reaction chamber, where an input gas source introduces an input gas into the reaction chamber. The input gas may react with the beam of electrons inside the reaction chamber to form an output gas comprising a plasma or ozone, and the output gas passes from the reaction chamber to a wafer processing chamber.
in one embodiment, the system includes an electron beam emitter having an electron generation chamber. The electron beam emitter is configured to emit a beam of electrons and has a barrier at one end of the electron generation chamber. The barrier comprises an electron permeable material to provide a window through which the beam of electrons passes and which seals the electron generation chamber to prevent material from passing out of the electron generation chamber. The barrier maintains a differential pressure and a vacuum level. A reaction chamber is arranged proximate the barrier for receiving the beam of electrons and has a passage for allowing a gas to flow therethrough. An input gas source introduces an input gas into the reaction chamber, whereby the input gas may react with the beam of electrons inside the reaction chamber to form an output gas comprising a reactive gas in a form of plasma or a concentration of ozone. The output gas passes from the reaction chamber to a wafer processing chamber. By separating the electron generation chamber from the reaction chamber, the systems and methods described herein are understood to allow for better control over the distribution of electron energy levels by the electron beam emitter, thereby allowing for better control over the resultant output gas. In addition, several embodiments describe a number of physical features that provide further control over the distribution of electron energy levels. However, these embodiments are provided for illustration purposes only and are not to be deemed limiting to the scope of the invention.
More particularly, the systems and methods described herein include systems for generating a plasma or ozone, comprising an electron beam emitter having an electron generation chamber, configured to emit a beam of electrons, and having a barrier at one end of the electron generation chamber. The barrier may comprise an electron permeable material to provide a window through which the beam of electrons passes and which seals the electron generation chamber to prevent material from passing out of the electron generation chamber and maintains a differential pressure and a vacuum level. The system may also include a reaction chamber arranged proximate the barrier for receiving the beam of electrons and having a passage for allowing a gas to flow therethrough. Additionally, the system may have an input gas source for introducing an input gas into the reaction chamber. Typically the system allows the input gas to react with the beam of electrons inside the reaction chamber to form an output gas comprising a reactive gas in a form of plasma or a concentration of ozone, and the output gas passes from the reaction chamber to a wafer processing chamber.
Optionally, the system may further include a controller for controlling a current and an accelerating voltage of the electron beam emitter to manipulate characteristics of the beam of electrons to achieve a selected energy distribution inside the reaction chamber. Further optionally, the system may have a second electron beam emitter configured to emit a second beam of electrons that passes into the reaction chamber, and optionally a cooling channel configured to adjust the temperature inside the reaction chamber. A secondary electron generator may be added and arranged to block a path of the beam of electrons and generate secondary electrons. Other modifications may be made without departing from the scope thereof.
In another aspect, the invention provides methods for generating a plasma or ozone. The methods may include emitting, an electron beam emitter having an electron generation chamber, a beam of electrons across a barrier arranged at one end of the electron generation chamber, wherein the barrier comprises an electron permeable material, provides a window through which the beam of electrons passes, seals the electron generation chamber to prevent material from passing out of the electron generation chamber, and maintains a differential pressure and a vacuum level. The methods may also include the step of introducing, by an input gas source, an input gas into a reaction chamber arranged proximate the barrier for receiving the beam of electrons, whereby the input gas may react with the beam of electrons inside the reaction chamber to form an output gas comprising a plasma or a concentration of ozone. The output gas may be passed from the reaction chamber into a wafer processing chamber, or other suitable equipment.
The methods may further include controlling a current and an accelerating voltage of the electron beam emitter to manipulate beam characteristics to achieve a selected energy distribution inside the reaction chamber. Optionally, the method may further include emitting, by a second electron beam emitter, a second beam of electrons that passes into the reaction chamber. Further optionally, the method may include adjusting, by a cooling channel, the temperature inside the reaction chamber. The method may also include blocking, by a secondary electron generator, a path of the beam of electrons, thereby generating secondary electrons. Other modifications may be made without departing from the scope thereof.
The above and other features of the present disclosure, including its nature and its various advantages, will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings in which:
To provide an overall understanding of the systems and methods described herein, certain illustrative embodiments will now be described, including a system for constructing ozone or plasma generators that create an electric field in a separate chamber from the reaction chamber. For illustrative purposes, the systems and methods described herein are discussed with reference to providing gas to a wafer processing system. However, it will be understood by one of ordinary skill in the art that the systems and methods described herein may be adapted and modified as is appropriate for the application being addressed and that the systems and methods described herein may be employed for many suitable applications, and that the systems and methods may have other additions and modifications will not depart from the scope thereof.
The electron beam source 102 is an electron beam emitter, which is configured to emit a beam of electrons. Typically, the electron beam source 102 is a filament, such as a tungsten wire filament, but any suitable electron source, including a plate, grid or other element may be used. The beam of electrons is generated within the electron generation chamber that is kept at an appropriate level of vacuum, typically at pressures below 1E-4 Torr. A low pressure within the electron generation chamber may be necessary for the electron beam source 102 to generate a beam of electrons with high energy levels.
A controller may control the characteristics of the beam of electrons by manipulating a current and an accelerating voltage in such a way to achieve a desired energy distribution. For example, the controller may be a device external to the electron beam source 102, or the controller may be within the electron beam source 102. The controller may manipulate the electron beam current to be on the order of 100 mA, and the accelerating voltage to be on the order of 100 kV. The desired energy distribution may be selected based on what energy levels are required for a particular plasma mix and a required process gas. The energy is transmitted from the electron generation chamber 101 to the reaction chamber 104 through the vacuum window 103.
The pressure in the reaction chamber 104 is much higher (on the order of 1-10 Torr for plasma and 10-50 psi for ozone) than the pressure in the electron generation chamber 101 (below 1E-4 Torr). The reaction chamber 104 requires a higher pressure based on the process requirement for the output gas 106. The vacuum window 103 allows for this differential pressure between the two chambers.
Dimensions of the reaction chamber 104 are not fixed and may be driven primarily by the cost and throughput requirements. As an example, the dimensions of the reaction chamber 104 may be 500 mm×250 mm×100 mm, or some other set of suitable dimensions. Furthermore, the walls of the reaction chamber 104 may include more plasma resistant material, as the material is not restricted to dielectric materials or specific metals as is required and common in previous technologies. An advantage of device 100 over the previous technology is device 100 has fewer restrictions regarding the choice of material. For example, common vacuum compatible material such as stainless steel may be used in device 100.
Input process gas 105 is introduced by one or more input gas sources from two input channels 107 positioned on opposite ends of the reaction chamber 104. Examples of input gases are NF3, N2, O7, Ar, H20 vapor, H2, CF4, or He. The dimensions of the input channels are not critical parameters for the overall function of the device 100. The input process gas 105 travels along the length of the reaction chamber 104 towards the middle at a flow rate on the order of 10 SLM (Standard Liters a Minute). In addition, the device of
Depending on the type of reaction, the output gas 116 may include plasma or ozone and is passed from the reaction chamber through a output channel 109 in the middle of the reaction chamber 104 into a downstream site for an industrial process such as a wafer processing chamber. The dimensions of the output channel are not critical parameters for the overall function of the device 100. A solid feature (not labeled in
Device 100 overcomes the limitations of conventional methods of ozone or plasma generation and presents multiple advantages. First, as a result of separating the electron beam chamber 101 from the reaction chamber 104, the electric field in the electron beam chamber 101 is not affected by changes in surface properties of the reaction chamber 104. This effectively removes a primary cause for the decay in concentration of the output gas 106. Another advantage is that the device 100 enables significant control of the distribution of electron energy levels. This allows for the process parameters, such as flow rate and output gas concentration, to be optimized. These are key parameters for semiconductor and other industrial applications.
As a third advantage, the output gas 106 is less influenced by the electric field, reducing the interaction between the output gas 106 and the walls of the reaction chamber 104. Fourth, the device 100 does not require precise gap control, which adds to the complexity and variability in conventional devices. Thus, the device 100 produces more consistent resultant output gases. Fifth, the source of electromagnetic energy does not interact directly with gas ions and ionized particles in the plasma, thereby decreasing the number of particles created. Sixth, the design does not require dielectric material for the chamber walls, enabling the use of more plasma resistant materials, further decreasing the number of generated problematic particles. A seventh advantage is that, the shape of the reaction chamber has no limitations, allowing for use of a straight channel. This provides a straight flow path for unperturbed reactive gas flow that eliminates interaction with the walls and particle generation. This is not the case for conventional plasma sources such as inductively coupled sources, where the choice of channel shape is driven by the induction coupling requirement and results in a flow channel that results in wall damage and particle generation through flow-channel interaction. Finally, a wider range of material can be selected for constructing the reaction chamber walls, leading to possible savings in cost and allowing for a wider range of selected precursors for the input gas.
The devices of
In some embodiments, the electron generation chamber 101 is an ultra high vacuum level, and the reaction chamber 104 is a substantially higher pressure. For the electrons generated by the electron beam source 102 to pass through the barrier to enter the reaction chamber 104, the electrons need to achieve at least a minimum energy level. The energy distribution of the electrons within the reaction chamber 104 defines the flow rate and concentration of the resultant output process gas 106. One method for controlling this energy level is to use the two vacuum pumps 110 and 112 to create differential pressure that causes the process gas to flow through the system. In this case, there is no need for a vacuum window as described in relation to
As described in relation to
In the device of
In the device of
While various embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be under stood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.
This application claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application 61/423,693, entitled “Ozone and Plasma Generation Using Electron Beam Technology,” filed Dec. 16, 2010, which is incorporated herein in its entirety.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US11/65523 | 12/16/2011 | WO | 00 | 7/8/2013 |
Number | Date | Country | |
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61423693 | Dec 2010 | US |