1. Field of the Invention
The present invention relates to a slot array antenna and a plasma processing apparatus using the same. The slot array antenna or the plasma processing apparatus according to the present invention is suitably applicable, in particular, to a plasma processing apparatus using a rectangular-type antenna (e.g., a plasma processing apparatus to be used for manufacturing liquid crystal devices).
2. Related Background Art
The slot array antenna and plasma processing apparatus according to the present invention is generally applicable to general plasma processing procedures, including the production of materials for electronic devices such as semiconductors or semiconductor devices, and liquid crystal devices. For the convenience of explanation, however, only the background art relating to liquid crystal devices will be described here.
In general, the process for manufacturing liquid crystal devices involves subjecting a base material (such as wafer) to various kinds of treatments such as CVD (chemical vapor deposition), etching, and sputtering. A plasma processing apparatus has often been used for conducting such treatments. This is because, when a plasma processing apparatus is used, a substrate can be processed if the substrate is maintained at a low temperature.
(Patent Document 1)
JP-A (Japanese Unexamined Patent Publication) No. 2000-123997
The above-mentioned JP-A No. 2000-123997 (Patent Document 1) discloses a plasma processing apparatus, which may be used for manufacturing liquid crystal devices. In such a plasma processing apparatus, use of a slot array antenna is considered to be very promising and highly efficient antenna having a small transmission loss. Particularly promising is an apparatus having a single layer structure (wherein a power feeding waveguide is disposed in the same plane as a radiating waveguide) capable of permitting easy formation of an antenna structure, wherein power is supplied to the radiating waveguide via a window provided in the wall of the power feeding waveguide.
However, according to the present inventors' experiments, it has been found that, when using a conventional plasma processing apparatus having the above-mentioned structure, it is difficult to increase the plasma density in the plasma processing chamber.
The present invention provides an antenna and a plasma processing apparatus, which overcomes the above-mentioned problem encountered in the prior art.
The present invention also provides an antenna and a plasma processing apparatus, which can easily increase the plasma density in a plasma-processing chamber.
The present inventors have found that the conventional close or dense arrangement of slots in a radiating waveguide (i.e., at intervals which are sufficiently smaller than the wavelength of microwave) in order to obtain an exponential attenuation of electromagnetic field, may provide a disadvantage, especially when a material having a relatively large dielectric constant (e.g., one having a dielectric constant of 4 or more) is used in the radiating waveguide. The present inventors have further found it extremely effective in attaining the above object to constitute a radiating waveguide such that the slot interval “d” in the radiating waveguide is substantially the same as the wavelength λm of above-mentioned microwave in the radiating waveguide.
A plasma processing apparatus consistent with the present invention comprises a power feeding waveguide for feeding microwave power. The plasma processing apparatus further comprises a plurality of rectangular radiating waveguides connected to a plurality of windows which are disposed along the longitudinal direction of the power feeding waveguide. The plurality of windows are disposed so as to guide the microwave power from the plurality of windows to the outside of the antenna. Each of the radiating waveguides has a plurality of slots disposed along the longitudinal direction of the radiating waveguide. The interval “d” between the centers of gravity of slot pairs or slots is substantially the same as the wavelength λm of the microwave in the rectangular radiating waveguide.
The present invention may also provide a plasma processing apparatus comprising a plasma processing chamber for subjecting an object to a plasma treatment. The present invention may also provide an antenna for guiding microwave power into the plasma processing chamber so as to generate plasma in the plasma processing chamber. The antenna comprises a power feeding waveguide for feeding microwave power and a plurality of rectangular radiating waveguides connected to a plurality of windows. The plurality of windows are disposed alone the longitudinal direction of the power feeding waveguide, so as to guide the microwave power from the plurality of windows to the outside of the antenna. Each of the radiating waveguides has a plurality of slots disposed alone the longitudinal direction of the radiating waveguide. The interval “d” between the centers of gravity of slot pairs or slots is substantially the same as the wavelength λm of the microwave in the rectangular radiating waveguide.
Hereinbelow, the present invention will be described in detail with reference to the accompanying drawings, as desired. In the following description, “%” and “part(s)” representing a quantitative proportion or ratio are those based on mass, unless otherwise noted specifically.
The slot array antenna according to the present invention comprises: a power-feeding waveguide for feeding microwave power; and a plurality of radiating waveguides connected to a plurality of windows which are disposed along the longitudinal direction of the power-feeding waveguide so as to guide the microwave power from the plurality of windows to a plasma processing chamber. The plurality of radiating waveguides are generally disposed so that their longitudinal directions are substantially perpendicular to the longitudinal direction of the power-feeding waveguide. The present invention is characterized in that each of the above-mentioned radiating waveguides has a plurality of slots arranged along the longitudinal direction of the radiating waveguide, and the interval “d” between the plurality of slots is substantially the same as the wavelength λm of the above-mentioned microwave.
As mentioned previously however, when slots are arranged closely or densely (i.e., at intervals which are sufficiently smaller than the wavelength of microwave) in a radiating waveguide in order to obtain an exponential attenuation of electromagnetic field, such a structure may provide a disadvantage, especially when a material having a relatively large dielectric constant is used in the radiating waveguide.
(One Embodiment of Slot Array Antenna)
Referring to
Each of the radiating waveguides 3 has a plurality of slots 5 disposed along the longitudinal direction of the radiating waveguides 3, and the interval “d” between the plurality of slots 5 is set to a value which is substantially the same as the wavelength λm of the above-mentioned microwave. In
In the present invention, the interval “d” between the plurality of slots 5 is substantially the same as the wavelength λm of the above-mentioned microwave. More specifically, the ratio of the interval “d” between the plurality of slots 5 to the wavelength λm of the above-mentioned microwave, (d/λm), may preferably be in the range of 0.75–1.25, or more preferably in the range of 0.9–1.1.
In the present invention wherein such a structure of slots is adopted, even if a material having a relatively large dielectric constant is used in the inside of antenna means, it becomes easy to substantially suppress the attenuation of the electromagnetic field in the plasma processing chanter so that the plasma density in the plasma processing chamber may be maintained at a high level. According to the present inventors' investigation, maintenance of the plasma density at a high level may presumably be a phenomenon caused by the attenuation characteristic of the radiated electromagnetic field not being represented by an exponential function, but by (1/Z) (wherein Z is the distance from the antenna in the direction perpendicular to the antenna).
Further referring to
Further, in
(Connecting Portion)
Referring to
As shown in
In the structure as shown in
(1) Width w of the Coupling Window 4:
The width w is monotonically increased along the longitudinal direction of the power-feeding waveguide 2 from the power-feeding side toward the distal end. The mode of this increase may more preferably be monotone.
(2) Position h of the Cutout Portion 7:
The position h is monotonically increased along the longitudinal direction of the power feeding waveguide 2 from the power-feeding side toward the distal end. The mode of this increase may more preferably be monotone.
(3) x-coordinate p of the Sidewall Member 6:
Basically, the value of the x-coordinate p is also changed monotonically, but at the distal end, it becomes a specific value depending upon the combination structure so as to provide good impedance matching.
(4) z-coordinate q of the Sidewall Member 6:
Basically, the value of the z-coordinate q is also changed monotonically, but at the distal end, it becomes a specific value depending upon the combination structure so as to provide a good impedance matching.
(Examples of Preferred Structure)
Preferred examples of the values of the above-mentioned various parameters are as follows in Table 1:
(Conventional Antenna)
For the purpose of comparison, a conventional slot array antenna is schematically shown in
(Plasma Processing Apparatus)
The plasma processing apparatus according to the present invention is one comprising a plasma processing chamber for subjecting an object to be processed to a plasma treatment; and antenna means for guiding microwave power into the plasma processing chamber so as to generate plasma in the plasma processing chamber. In this apparatus, the antenna means is a slot array antenna (according to the present invention) having a structure as described hereinabove.
(One Embodiment of a Plasma Processing Apparatus)
On the top portion of the plasma processing chamber 15, a slot array antenna member 1 having the above-described structure is disposed such that the microwave is fed from the radiating waveguide 3 constituting the antenna member 1 into the plasma processing chamber 15 so as to generate plasma in a plasma generating region 16 in the plasma processing chamber 15 to thereby process the object 11 using to a predetermined plasma treatment.
(Constitution of Various Components)
Hereinbelow, the structure of various components constituting the antenna and the plasma processing apparatus shown in
(Power-feeding Waveguide)
The shape, size, structure, etc., of the power-feeding waveguide 2 are not particularly limited, but the power-feeding waveguide 2 may preferably be a rectangular waveguide. This is because, in an embodiment using such a rectangular waveguide, it is quite easy to reduce the cost by using a single microwave power supply.
Material of Waveguide
Material for the power-feeding waveguide 2, the radiating waveguide 3 and other members constituting the above-described antenna are not particularly limited, as long as microwave power can be supplied by using such antenna. In view of the reduction in the loss due to wall current and of the thermal conductivity, however, the material for these members may preferably be one comprising a copper base material with a silver plating.
(Dielectric Material for the Radiating Waveguide 3)
The dielectric material for constituting the radiating waveguide 3 is not particularly limited. In view of the ratio of the wavelength of the microwave and the chamber size (L/λm), this material may preferably be one having a dielectric constant which is not less than λ/5L (λ is the wavelength the microwave in vacuum, and L is the chamber size).
(Variable Coupling Window)
In the connecting portion (i.e., power-feeding portion) between the power-feeding waveguide 2 and the radiating waveguide 3 shown in
In addition, it is also possible that a “rod-shaped” member can be erected in the power-feeding portion of the radiating waveguide 3 so as to adjust the L component, to thereby achieve good load matching. In an embodiment wherein such a rod-shaped member is provided, the side wall plate 6 in the power-feeding waveguide 2 becomes omissible so that the related structure can be advantageously simplified thereby.
(Slots)
In the embodiment shown in
In other words, the shape of the slots may be of any known shapes. For example, the slots of any shape shown in the schematic plan view of
For example, the shape of the slot may be a staggered Λ(lambda)-shape along the center line as shown in the schematic plan view (a) of
In the case of a staggered Λ-shape as shown in
In the case of the staggered Λ-shape as shown in
Also in the case of the X-shaped slots as shown in
(Angle)
The angle of inclination of each slot relative to the center axis of the radiating waveguide may preferably be about 45°. When the angle θ in the staggered Λ-shaped slots is greater than 45°, the electromagnetic field tends to be radiated more strongly towards the power feeding side. When the angle θ is less than 45°, the electromagnetic field tends to be radiated more strongly towards the terminal end. Accordingly, it is possible to generate plasma due to “oblique propagation” by adjusting the angle θ.
When an individual slot in each pair is made shorter than the other slot of the pair, the electromagnetic field tends to be radiated more strongly towards the shorter slot. Accordingly, the “oblique propagation” can also be achieved by utilizing such characteristics.
(Standing Wave and Traveling Wave)
When the microwave in the radiating waveguide 3 is a standing (or stationary) wave as shown in
In this respect, it is preferred that a traveling wave be formed along the longitudinal direction of the radiating waveguide 3. This is because, when a standing wave is formed, as described above, the plasma intensity directly under the slots of the radiating waveguide 3 tends to become non-uniform along the longitudinal direction of the radiating waveguide 3.
In this respect, in the case of the staggered Λ-shaped slots as shown in
On the other hand, in the case of the X-shaped slots as shown in
(Sidewall Members)
In view of the impedance matching, etc., a sidewall member 6 in the form of an “adjusting pin” may be used in place of the “plate-shaped” member shown in
(Terminal End Portion)
At the terminal end of the radiating waveguide 3, a matching slot for suppressing the reflected power from the terminal end may be provided, as desired. When a matching slot is provided at the terminal end, it is possible to obtain an advantage that the traveling wave can be obtained (the reflected wave can be suppressed) in the waveguide.
(Other Embodiments of Antenna)
The radiating waveguide 31 may be provided in one-to-one correspondence with the windows 41 in the power-feeding waveguide 21. An example of this embodiment is shown in
Referring to
In the present invention, the slots having such a structure is adopted, and therefore, it becomes easy to suppress the attenuation of the electromagnetic field introduced to the plasma processing chamber, even when material having a relatively large dielectric constant is used in the antenna means. As a result, it becomes easy to maintain the plasma density at a high level in the plasma-processing chamber.
On the contrary, in the conventional slot array antenna as shown in
(Other Examples of Application)
The application or use of the antenna or the plasma processing apparatus according to the present invention is not particularly limited. In other words, the antenna or the plasma processing apparatus according to the present invention may be applied to any apparatus utilizing plasma such as, for example, a plasma etching apparatus, plasma CVD apparatus, or plasma LCD apparatus.
As described hereinabove, the present invention can provide a plasma processing apparatus wherein the plasma density can easily be enhanced.
Number | Date | Country | Kind |
---|---|---|---|
2002-314623 | Oct 2002 | JP | national |
Number | Name | Date | Kind |
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5579019 | Uematsu et al. | Nov 1996 | A |
6020858 | Sagisaka | Feb 2000 | A |
6158383 | Watanabe et al. | Dec 2000 | A |
6343565 | Hongoh | Feb 2002 | B1 |
6372084 | Hongo et al. | Apr 2002 | B1 |
6497783 | Suzuki et al. | Dec 2002 | B1 |
6535173 | Ou | Mar 2003 | B1 |
6713968 | Ishii et al. | Mar 2004 | B1 |
Number | Date | Country |
---|---|---|
53-149752 | Dec 1978 | JP |
7-106847 | Apr 1995 | JP |
A 2000-123997 | Apr 2000 | JP |
2000-286631 | Oct 2000 | JP |
2002-158216 | May 2002 | JP |
Number | Date | Country | |
---|---|---|---|
20040155829 A1 | Aug 2004 | US |