Embodiments of the disclosure are directed to substrate support components. In particular, embodiments of the disclosure are directed to substrate supports with improved gas exchange.
In a semiconductor wafer processing chamber, such as an atomic layer deposition (ALD) chamber, wafer edge purging and backside pressure control are useful features. The primary functions of these features are to provide backside pressure control to improve temperature uniformity of the wafer and edge purging to prevent deposition on the backside and edge of the wafer.
In many ALD process chamber, a wafer chucked to a pedestal is moved back and forth between two or more process stations. Each portion of the deposition cycle includes a period of time in which the wafer is exposed to a dose of a reactive gas and a period of time in which the process station is purged to remove unreacted species.
Conventional edge purge can be accomplished by a couple different techniques. Gas can be delivered through a line in the pedestal and distributed to the edges underside of the wafer edge through either a recursive channel, a plenum near the circumference of the pedestal, or a combination of both. The purge techniques are limited in effectiveness based on how well the flow can be distributed around the edge of the wafer.
In many process environments, the wafer is positioned within a pocket formed in the substrate support. An active bevel purge can be incorporated into the pedestal but occupies a significant amount of space and can be difficult to employ with moving substrate supports. Without an active purge, there exists a dead-volume or recirculation zone between the wafer edge and the pocket in the substrate support. As wafers are moved between process stations, residual precursors can remain in this dead volume and lead to undesirable gas phase reactions on the wafer edge. These gas phase depositions can adversely affect the film composition, resistivity and/or conformality.
For both backside pressure control and edge purging, any features put into a pedestal will impact other design components and goals. For example, putting a gas distribution channel in a pedestal will have a negative impact on the temperature uniformity that can be achieved with that pedestal due to required design compromises.
Therefore, there is a need in the art for substrate support apparatus with improved edge purge.
One or more embodiments of the disclosure are directed to substrate support pedestals comprising a support body with a top surface and a bottom surface that define a thickness. The top surface has a support region bounded by an outer band and comprises one or more openings. The outer band comprises a plurality of spaced apart posts.
Additional embodiments of the disclosure are directed to processing chambers comprising a substrate support assembly and a plurality of gas distribution assemblies. The substrate support assemblies comprise a plurality of substrate support pedestals, each of the substrate support pedestals comprising a support body with a top surface and a bottom surface defining a thickness. The top surfaces have a support region bounded by an outer band and comprise one or more openings in the top surfaces. The outer bands comprise a plurality of spaced apart posts. The substrate support assembly is rotatable around a central axis. The plurality of gas distribution assemblies are spaced around an inside of the processing chamber. Each of the gas distribution assemblies is configured to direct a flow of gas toward the top surface of the support body.
Further embodiments of the disclosure are directed to processing methods comprising: providing a flow of gas to a support region of a substrate support pedestal, the substrate support pedestal comprising, a support body having a top surface and a bottom surface defining a thickness, the top surface having a support region bounded by an outer band and comprising one or more openings in the top surface, the outer band comprising a plurality of spaced apart posts; and evacuating the support region to provide a purge flow from the support region pas the spaced apart posts bounding the support region.
So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments. The embodiments as described herein are illustrated by way of example and not limitation in the figures of the accompanying drawings in which like references indicate similar elements.
Embodiments of the disclosure are directed to apparatus and methods for integrating backside pressure control and edge purge in a process chamber. In some embodiments, backside pressure control is achieved by creating a controlled leak through the seal band so that the backside pressure control gas will also function as the edge purge gas.
Some embodiments of the disclosure advantageously provide apparatus and methods to create or improve edge purge gas flow uniformity and/or efficiency. With a more uniform edge purge gas, the flow rate of the edge purge gas in some embodiments is reduced. Some embodiments advantageously eliminate annular dead volume around the edge of a wafer. Some embodiments maintain the benefits of a heater pocket to center and capture a wafer while improved purge efficiency.
Some embodiments of the disclosure provide a movable heater/substrate support which incorporate posts. The posts of some embodiments form a boundary for a support region of the substrate support that acts similarly to the pocket. For example, the support region bounded by posts of some embodiments minimizes local thermal effects without creating dead volumes around the wafer. In some embodiments, the outer band provides a physical barrier to keep the substrate centered on the support region within the band. In some embodiments, there is substantially no dead volume around the substrate. In some embodiments, the wafer edge becomes part of the active flow path, improving purge efficiency and cycle times. In some embodiments, the wafer edge is thermally and chemically less sensitive to centering or hand-off effects.
Referring to
In the illustrated embodiment, the gas distribution assembly 110 is part of the chamber top 104. However, the skilled artisan will recognize that the gas distribution assembly 110 can be separate from the chamber top 104 or located in a different portion of the interior volume 105 of the processing chamber 100. For example, in some embodiments, the gas distribution assembly provides a flow of gas from a sidewall 102 of the chamber 100 at an oblique angle relative to the top surface of the substrate support.
The top surface 204 of the support body 202 has a support region 210. The support region 210 is a portion of the top surface 204 designated to hold a substrate during processing. The support region 210 of some embodiments comprises one or more openings 212 in the top surface 204. The one or more openings 212 of some embodiments are in fluid communication with one or more of a vacuum source, a reactive gas source or a purge gas source.
The embodiments illustrated in the Figures show substrate support pedestals 200 for use with round substrates. However, the skilled artisan will recognize that the disclosure is not limited to round substrates and round support bodies 202 and that any suitable shape substrate and support body can be used.
The support region 210 is bounded by an outer band 220 comprising a plurality of spaced apart posts 225. As used in this specification and the appended claims, the term “band” refers to region with posts 225 with top surface 204 between. A “band” refers to the overall impression and arrangement of the posts 225, and does not imply any particular shape.
The spaced apart posts 225 of some embodiments provide substantially no barrier to gas flow from the support region 210. The cross-sectional width of the individual posts 225, measured tangentially to the band 220 at the angle of the post 225, is small compared to the area of the support region 210. In some embodiments, the combined cross-sectional widths of the spaced apart posts 225 is less than or equal to 50% of the circumference of the support region 210, or the average circumference of the band 220. In some embodiments, the combined cross-sectional widths of the spaced apart posts is less than or equal to 25%, 20%, 15%, 10%, 5%, 2% or 1% of the circumference of the support region 210, or the average circumference of the band 220.
Referring back to
The distance from the outer edge 208 of the pedestal to the band 220 can be any suitable distance. In some embodiments, the distance Do of the band 220 to the outer edge 208 of the pedestal is in the range of about 0.25 mm to about 10 mm, or in the range of about 0.5 mm to about 6 mm, or in the range of about 0.75 mm to about 4 mm, or in the range of about 1 mm to about 2 mm.
In some embodiments, the distance Di from the band 220 to the substrate 160 can be any suitable distance. In some embodiments, the distance Dii is measured from the inner edge 225i of the band 220 to the outer peripheral edge 161 of the substrate 160. The distance Dii can be any suitable distance. In some embodiments, the distance Dii is in the range of about 0.1 mm to about 5 mm, or in the range of about 0.2 mm to about 3 mm. In some embodiments, when a substrate 160 is present in the support region 210, the outer band 220 is spaced from the outer peripheral edge 161 of the substrate 160 by an average distance Dii in the range of about 0.1 mm to about 5 mm, or in the range of about 0.2 mm to about 3 mm, or in the range of about 0.5 mm to about 5 mm.
The shape of the posts 225 can be any suitable shape. In the illustrated embodiments, the posts 225 are cylindrical shaped components that extend a height HS from the top surface 204 of the body 202. In some embodiments, the height HS is in the range of about 0.2 mm to about 5 mm. In some embodiments, the sidewall of the post 225 closest to the substrate 160 extends substantially perpendicular to the top surface 204 of the support body 202. As used in this manner, the term “substantially perpendicular” means at an angle to the top surface 204 in the range of about 80° to about 110°.
The width Wb of the band 220 is defined as the distance between the inner face 225i and the outer face 225o. In some embodiments, the width Wb of the band 220 is in the range of about 0.5 mm to about 25 mm, or in the range of about 1 mm to about 20 mm, or in the range of about 2 mm to about 15 mm, or in the range of about 3 mm to about 10 mm.
The height HS of the band 220, as shown in
The shape of the posts 225 can vary to change the flow of gases passing the posts 225.
Referring back to
The pedestal shaft 250 of some embodiments comprises a gas line 255 that extends through the pedestal shaft 250 to an opening 213 in the support region 210. In some embodiments, there is a pedestal shaft 250 with a gas line 255 extending through the pedestal shaft to openings 213 support region 210 through openings 212.
In some embodiments, the support body 202 is an electrostatic chuck. As will be understood by the skilled artisan, an electrostatic chuck includes one or more electrode 260 which can be polarized to chuck a substrate to the support body 202. In some embodiments, the support body 202 includes one or more thermal element 265 within the thickness of the support body 202. The thermal elements 265 are connected to a power source (not shown) which can cause a change in the temperature of the support body 202. In some embodiments, the thermal elements 265 are heating coils. In some embodiments, the thermal elements 265 are cooling elements. In some embodiments, the thermal elements 265 comprise heating coils and cooling elements to control the temperature of the substrate.
Referring back to
In the embodiment illustrated in
In some embodiments, the substrate support pedestal 200 or processing chamber 100, or both, is connected to a controller 190. The controller 190 can be configured to control and/or receive information from one or more of the flow controller 170, pressure gauge 172, pump 174 or feedback circuit 176. In some embodiments, the feedback circuit 176 is a part of the controller 190.
In the processing chamber 100 of
Some embodiments of the processing chamber 100 include at least one controller 190 coupled to one or more of the processing chamber 100, pedestal 200, flow controller 170, pressure gauge 172, pump 174, feedback circuit 176, reaction space pressure gauge 108 or gas distribution assembly 110. In some embodiments, there are more than one controller 190 connected to the individual components and a primary control processor is coupled to each of the separate controller or processors to control the system. The controller 190 may be one of any form of general-purpose computer processor, microcontroller, microprocessor, etc., that can be used in an industrial setting for controlling various chambers and sub-processors.
The at least one controller 190 can have a processor 192, a memory 194 coupled to the processor 192, input/output devices 196 coupled to the processor 192, and support circuits 198 to communication between the different electronic components. The memory 194 can include one or more of transitory memory (e.g., random access memory) and non-transitory memory (e.g., storage).
The memory 194, or a computer-readable medium, of the processor may be one or more of readily available memory such as random access memory (RAM), read-only memory (ROM), floppy disk, hard disk, or any other form of digital storage, local or remote. The memory 194 can retain an instruction set that is operable by the processor 192 to control parameters and components of the system. The support circuits 198 are coupled to the processor 192 for supporting the processor in a conventional manner. Circuits may include, for example, cache, power supplies, clock circuits, input/output circuitry, subsystems, and the like.
Processes may generally be stored in the memory as a software routine that, when executed by the processor, causes the process chamber to perform processes of the present disclosure. The software routine may also be stored and/or executed by a second processor (not shown) that is remotely located from the hardware being controlled by the processor. Some or all of the method of the present disclosure may also be performed in hardware. As such, the process may be implemented in software and executed using a computer system, in hardware as, e.g., an application specific integrated circuit or other type of hardware implementation, or as a combination of software and hardware. The software routine, when executed by the processor, transforms the general purpose computer into a specific purpose computer (controller) that controls the chamber operation such that the processes are performed.
In some embodiments, the controller 190 has one or more configurations to execute individual processes or sub-processes to perform embodiments of the method. The controller 190 can be connected to and configured to operate intermediate components to perform the functions of the methods. For example, the controller 190 can be connected to and configured to control one or more of gas valves, actuators, motors, slit valves, vacuum control, etc.
The controller 190 or non-transitory computer readable medium of some embodiments has one or more configurations or instructions selected from: a configuration to move a substrate on a robot to the lift pins; a configuration to load and/or unload substrates from the system; a configuration to provide a flow of gas through the gas distribution assembly, a configuration to measure the reaction space pressure; a configuration to measure the pressure in the gas line; a configuration to control a flow controller to control a flow of backside gas to the gas line; a configuration to control the flow of gas to the pump from the gas line and flow controller to regulate the pressure in the gas line; a configuration to adjust the flow controller to maintain a uniform pressure within the gas line based on readings from the reaction space pressure gauge; a configuration to maintain a positive pressure in the inner pocket region relative to the reaction space; a configuration to control the electrostatic chuck and/or electrode within the support body; a configuration to control the thermal element to control the temperature of the support body.
In some embodiments, the non-transitory computer readable medium or controller includes instructions to flow a backside gas to a support region of the substrate support pedestal; a configuration to flow a process gas to the reaction space in the processing chamber; a configuration to determine a pressure differential between the support region and an outer region at an outside of the band or the pressure of the reaction space; and/or controlling the flow of backside gas to the support region to maintain a uniform flow of gas from the support region through the band.
Reference throughout this specification to “one embodiment,” “certain embodiments,” “one or more embodiments” or “an embodiment” means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. Thus, the appearances of the phrases such as “in one or more embodiments,” “in certain embodiments,” “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily referring to the same embodiment of the disclosure. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.
Although the disclosure herein has been described with reference to particular embodiments, those skilled in the art will understand that the embodiments described are merely illustrative of the principles and applications of the present disclosure. It will be apparent to those skilled in the art that various modifications and variations can be made to the method and apparatus of the present disclosure without departing from the spirit and scope of the disclosure. Thus, the present disclosure can include modifications and variations that are within the scope of the appended claims and their equivalents.
This application claims priority to U.S. Provisional Application No. 62/992,980, filed Mar. 21, 2020, the entire disclosure of which is hereby incorporated by reference herein.
Number | Date | Country | |
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62992980 | Mar 2020 | US |