Patent Application
20240047194
The present disclosure relates to a substrate processing method and a substrate processing apparatus.
In a film forming apparatus that performs film formation on a substrate by chemical vapor deposition (CVD) or the like, the substrate is sufficiently heated by a heater in a stage on which the substrate is placed, and then a film forming reaction proceeds. In recent years, since there has been a demand for high-speed processing through high-temperature processing in order to improve productivity, substrates are heated rapidly, which may cause the substrates to warp. When a substrate is warped, misalignment or the like may be caused on the substrate during transportation, and when the substrate is placed on a stage, the peripheral edge of the substrate may come into contact with the stage, causing particles to be generated. Therefore, it is required to prevent a substrate from warping during substrate processing at a high temperature.
As a method for suppressing the warping of a substrate, a method including preheating in which the substrate is heated in advance before film formation processing is known (see, for example, Patent Documents 1 and 2). Patent Document 1 discloses a method of gradually heating a substrate with radiant heat from a heater in a stage in a state in which the substrate is supported by support pins, thereby relaxing thermal stress, and then further performing preheating by placing the substrate on the stage, thereby shortening a preheating time. Patent Document 2 discloses a method of placing a substrate on a stage and performing preheating by using plasma, thereby shortening a preheating time.
The present disclosure provides a technique for shortening a time required for preheating a substrate before film formation while suppressing warping of the substrate.
In view of the above problems, the present disclosure provides a substrate processing method including: a preparation process of placing a target substrate on a stage within a processing container; a first heating process of heating the target substrate with a heater by supplying a first gas into the processing container; a second heating process of stopping the supply of the first gas, supplying a second gas different from the first gas, and heating the target substrate with the heater; and a processing process of processing the target substrate by supplying the second gas and a third gas.
It is possible to shorten a time required for preheating a substrate before film formation while suppressing warping of the substrate.
Hereinafter, embodiments for executing the present disclosure will be described with reference to drawings. In the specification and drawings, constituent elements that are substantially the same will be denoted by the same reference numerals, and redundant descriptions will be omitted.
An example of a plasma processing apparatus for executing a film forming method of the present disclosure will be described.
The plasma processing apparatus 100 includes a processing container 101, a stage 102, a gas supply mechanism 103, an exhaust mechanism 104, a microwave plasma source 105, and a controller 106.
The processing container 101 is made of a metal material, for example, aluminum having an anodized surface, and has a substantially cylindrical shape. The processing container 101 includes a plate-shaped ceiling wall 111, a bottom wall 113, and a side wall 112 connecting the ceiling wall 111 and the bottom wall 113 to each other. The inner wall of the processing container 101 may be coated with yttria (Y2O3) or the like. The stage 102 is disposed within the processing container 101. The processing container 101 accommodates a wafer W such as a substrate.
The ceiling wall 111 includes a plurality of openings into which microwave radiation mechanisms 143 and gas introduction nozzles 123 (to be described later) of the microwave plasma source 105 are fitted. The side wall 112 includes a carry-in/out port 114 to carry a wafer W (a target substrate) into/out of a transport chamber (not illustrated) adjacent to the processing container 101. The carry-in/out port 114 is configured to be opened and closed by a gate valve 115. An exhaust pipe 116 is connected to the bottom wall 113.
The stage 102 has a disk shape and is made of a metal material, for example, aluminum having an anodized surface, or a ceramic material, for example, aluminum nitride (AlN). A wafer W is placed on the top surface of the stage 102. The stage 102 is supported by a support member 120, which is a metal cylinder extending upward from the center of the bottom of the processing container 101 via an insulating member 121.
In addition, inside the stage 102, lifting pins (not illustrated) configured to raise/lower the wafer W are provided to be capable of protruding/retracting with respect to the top surface of the stage 102. In addition, a heater 126 is provided inside the stage 102 as a heating mechanism. The heater 126 is powered by a heater power source 127 to generate heat. By controlling the output of the heater 126 based on a temperature signal from a sensor (e.g., a thermocouple) provided near the top surface of the stage 102, the wafer W is controlled to a predetermined temperature.
From the viewpoint of performing good plasma processing, the stage 102 is provided at a position at which the distance from the bottom surface of the ceiling wall 111, which is the microwave radiation surface of the microwave radiation mechanism 143, to the wafer W is preferably in the range of 40 to 200 mm.
A radio frequency power source 122 is electrically connected to the stage 102. When the stage 102 is made of ceramic, an electrode is provided on the stage 102, and the radio frequency power source 122 is electrically connected to the electrode. The radio frequency power source 122 applies radio frequency power as bias power to the stage 102. The frequency of the radio frequency power applied by the radio frequency power source 122 is preferably in the range of 0.4 to 27.12 MHz.
The gas supply mechanism 103 supplies various processing gases for performing film formation into the processing container 101. The gas supply mechanism 103 includes a plurality of gas introduction nozzles 123, a gas supply pipe 124, and a gas supplier 125. The gas introduction nozzles 123 are fitted into respective openings formed in the ceiling wall 111 of the processing container 101. The gas supplier 125 is connected to each gas introduction nozzle 123 via the gas supply pipe 124. The gas supplier 125 supplies various processing gases. For example, the gas supplier 125 includes a first gas source, a second gas source, and a third gas source. A first gas supplied by the first gas source is an inert gas, such as N2 gas, Ar gas, or He gas. Alternatively, Kr gas, Xe gas, Ne gas, or the like may be used as the first gas. A second gas supplied by the second gas source is a reducing gas, such as NH3 or N2. As the second gas, N2 gas is initially used to suppress warping of the substrate and switched to NH3 gas, which does not affect the quality of a film before a film forming process, and the NH3 gas is continuously used in the film forming process. A third gas supplied by the third gas source is SiH4 gas, SiH2Cl2 gas, or the like, which may be a raw-material gas. In addition, the gas supplier 125 is provided with a valve configured to perform supply and stop of a processing gas and a flow rate adjuster configured to adjust the flow rate of a processing gas.
An exhaust pipe 116 is connected to the bottom wall 113 of the processing container 101. The exhaust mechanism 104 is connected to the exhaust pipe 116. The exhaust mechanism 104 includes a vacuum pump and a pressure control valve and is capable of exhausting the interior of the processing container 101 through an exhaust pipe 116 by the vacuum pump. The pressure inside the processing container 101 is controlled by a pressure control valve (not illustrated) based on the value of a pressure gauge.
The microwave plasma source 105 is provided above the processing container 101. The microwave plasma source 105 introduces electromagnetic waves (microwaves) into the processing container 101 to generate plasma.
The microwave plasma source 105 includes a microwave output part 130 and an antenna unit 140. The antenna unit 140 includes a plurality of antenna modules. In
In
As long as a microwave power density can be appropriately controlled, a microwave plasma source 105 having a single microwave introducer having a size corresponding to the wafer W may be used.
The controller 106 is, for example, a computer including a processor, a storage, an input device, a display device, and the like. The controller 106 controls each part of the plasma processing apparatus 100. In the controller 106, an operator may perform a command input operation or the like in order to manage the plasma processing apparatus 100 by using the input device. In addition, in the controller 106, the operation situation of the plasma processing apparatus 100 may be visualized and displayed by the display device. Furthermore, the storage of the controller 106 stores control programs and recipe data for controlling various kinds of processing, which are executed in the plasma processing apparatus 100, by the processor. The processor of the controller 106 executes the control programs and controls each part of the plasma processing apparatus 100 according to the recipe data, whereby desired processing is executed in the plasma processing apparatus 100. For example, the controller 106 controls each part of the plasma processing apparatus 100 to execute processing for a film forming method according to the embodiment.
Preheating is performed, for example, before film formation processing by CVD, for the purpose of suppressing warping of a wafer W, obtaining stable film quality, and the like. In the present disclosure, a SiN film forming process using NH3 and SiH4 as raw material gases will be described. However, the processing gases are not limited thereto.
In the preheating in a SiN film forming process, the wafer W is gradually heated over time until the temperature of the wafer W is stabilized at a temperature suitable for film formation. As for the heating time, the heating is performed gradually over, for example, 120 seconds. It is known that warping of the wafer W can be suppressed to some extent by heating the wafer W gradually (over 120 seconds).
In addition, when the wafer W is placed on the stage 102, the wafer W may be attracted to the stage 102 due to the electrostatic force of the wafer W itself. When the wafer W is warped by being rapidly heated in a state in which the wafer W is attracted to the stage 102, the wafer W may bounce or crack. For this reason, in an adopted method in the related arts, a wafer W is pinned up with wafer support pins to provide a distance between the wafer W and the stage 102, and the wafer W is heated over time with radiant heat from the stage 102.
From the viewpoint of improving productivity (throughput: processing time per one wafer), it is desirable to shorten the preheating time and omit the pin-up operation of the wafer support pins.
Therefore, the present disclosure discloses a method for shortening a time required for preheating a substrate before film formation while suppressing the warp of the substrate, and describes the corresponding method.
In (i), N2 gas is supplied, and a first preheating is performed as a first heating process. In the first preheating, N2 gas is supplied into the processing container 101, and the pressure inside the processing container 101 is adjusted to a first pressure. The first pressure is predetermined as a pressure suitable for preheating a wafer W. The time required for the first preheating is set to T1 seconds.
In (ii), the supply of N2 gas is stopped, NH3 gas is supplied, and a second preheating is performed as a second heating process. In the second preheating, in the state in which the pressure inside the processing container 101 is adjusted to the first pressure as in the first preheating, the atmosphere in the processing container 101 is replaced with NH3 gas. The time required for the second preheating is set to T2 seconds.
In (iii), SiH4 gas is supplied in the state in which NH3 gas is supplied, and the pressure is stabilized at a second pressure lower than the first pressure. The time required for stabilization is set to T3 seconds. The second pressure is predetermined as a pressure suitable for film formation, that is, a pressure at which plasma is easily ignited. SiH4 gas including NH3 gas is an example of the third gas. The supply of SiH4 gas may be started between (iii) and (iv).
In (iv), a microwave power is turned on to form a film. The time required for film formation is set to T4 seconds. In (iv), a desired film is formed by supplying the second gas and the third gas. In the present disclosure, as an example, NH3 gas and SiH4 gas are supplied to form a SiN film.
A series of processes including preheating will be described more specifically with reference to
First, the controller 106 moves a wafer W from a transport chamber (not illustrated), which is maintained in a reduced pressure state by opening the gate valve 115, to the processing container 101 via the carry-in/out port 114 by a transport apparatus (not illustrated) (S1).
Then, the controller 106 raises wafer support pins (not illustrated) to receive the wafer W, carries out the transport apparatus, and then lowers the wafer support pins (not illustrated) to place the received wafer W on the stage 102 for preparation (S2).
Next, the controller 106 closes the gate valve 115 and adjusts the pressure inside the processing container 101 to the first pressure by supplying N2 gas from the gas supplier 125 into the processing container 101 at a predetermined flow rate and exhausting the interior of the processing container 101 (S3). The first pressure is preferably 20 to 667 Pa, for example, 333 Pa (2.5 Torr). After the start of the supply of the N2 gas, before the start of the supply, or at the same time as the start of the supply, the heating of the wafer W is started as the first preheating. Specifically, the stage 102 is heated by feeding power from the heater power source 127 to the heater 126, and the temperature of the wafer W is controlled to a desired temperature by the heat. The time for the first preheating is T1 seconds. The first preheating is a part of the preheating process for raising the temperature of the wafer W to a temperature suitable for film formation.
After the first preheating (after T1 seconds have elapsed), the controller 106 stops the supply of the N2 gas from the gas supplier 125 while maintaining the first pressure, and supplies NH3 gas from the gas supplier 125 into the processing container 101 at a predetermined flow rate (S4). This process is the second preheating. Switching from the first preheating to the second preheating is performed at a predetermined time based on, for example, evaluation results or the like. In addition, switching from the first preheating to the second preheating may be performed based on an output signal output to the heater 126 by the controller 106. The time for the second preheating is T2 seconds. The controller 106 performs control so that the temperature is raised to a temperature suitable for film formation by the first preheating and the second preheating (i.e., T1+T2 seconds (e.g., about 40 seconds)).
After the second preheating (after T2 seconds have elapsed), the controller 106 reduces the pressure inside the processing container 101 from the first pressure to a second pressure lower than the first pressure while maintaining the supply of NH 3 gas from the gas supplier 125 into the processing container 101. In addition, the controller 106 supplies, for example, SiH4 gas into the processing container 101 at a predetermined flow rate from the gas supplier 125 to stabilize the pressure inside the processing container 101 to the second pressure (S5). The time for this gas stabilization process prior to the film forming step may be set to, for example, 5 seconds or more and 50 seconds or less, preferably 10 seconds or more and 30 seconds or less. In addition, the second pressure is preferably 6.7 to 133 Pa, for example, 16 Pa (120 mTorr).
Then, after the pressure is stabilized in the gas stabilization step (after T3 seconds have elapsed, specifically after determining that the pressure monitoring result has been stabilized), the controller 106 turns on the microwave power to ignite plasma and starts film formation processing on the wafer W (S6). That is, microwaves from the microwave output part 130 are radiated to the space above the wafer W in the processing container 101 via the microwave radiation mechanism 143. An electromagnetic field is formed in the processing container 101 by the microwaves radiated to the processing container 101, and the NH3 gas and SiH4 are plasmatized. Then, a SiN film is uniformly formed on the surface of the wafer W by the action of active species in the plasma, mainly N radicals. The film to be generated varies depending on processing gases, and may be an insulating film containing oxygen or nitrogen, a dielectric film, a metal film, or the like, in addition to the SiN film. For example, when the raw-material gases are SiH4 and N2O, an oxide film of SiO2 (an insulating film) may be produced. In addition, for example, when the raw-material gases are SiH2Cl2 and NH3, a dielectric film of Si3N4 may be produced. Furthermore, for example, when the raw-material gases are WF6 and Si, a metal film of 2WSi may be produced.
After performing the film formation processing for a predetermined time, the controller 106 turns off the microwave power, stops the supply of SiH4 gas and the NH3 gas, and terminates the film formation processing (S7).
Thereafter, the wafer support pins (not illustrated) are raised in the reverse order of steps S1 and S2, and the wafer W is carried out by the transport apparatus (not illustrated) (S8).
The preheating of the present disclosure includes two steps: a first preheating process and a second preheating process. That is, the time required for preheating is the sum of the time T1 required for the first preheating process and the time T2 required for the second preheating process. Here, the degree of influence of the preheating time of the present disclosure on the quality of the film to be formed will be described.
The horizontal axis of
As shown in
Between condition D and condition E (T1=35 to 40 seconds or T2=0 to 5 seconds), it is expected that as the time T1 for supplying the N2 gas becomes longer, the RI will be lowered. In other words, it is expected that as the time T2 for supplying the NH3 gas becomes shorter, the RI will be lowered. In
When expressing the ratio of the second preheating time T2 to the first preheating time T1, the ratio at which warping is suppressed and appropriate film quality is obtained is 1:1 (T1=T2=20 seconds) to 7:1 (T1=35 seconds and T2=5 seconds).
In addition, it is considered that the reason why the RI becomes small when the time T2 for supplying NH3 gas is short (appropriate film quality is not obtained) is that N2 supplied by the first preheating remains in the processing container 101 during film formation processing.
With reference to
In addition, as a method for detecting the warping of a wafer W other than visual observation, there is a method focusing on a heater output. Specifically, it is a method of determining the warping of a wafer from values of output data of the heater power source 127 that feeds power to the heater 126 built in the stage 102. When warping occurs, the contact area between the stage 102 and the wafer W is reduced as illustrated in
This relationship is consistent with visual determination. Therefore, the presence or absence of warping can be determined by recording the heater output during preheating.
Considering the heater output from time t1 to t2, the heater output of NH3 gas is obviously smaller than those of Ar gas, He gas, and N2 gas. That is, it is shown that warping easily occurred in the preheating in the state in which NH3 gas was supplied, but in the preheating in the state in which any of Ar gas, He gas, or N2 gas supplied, warping was difficult to occur. These results are also consistent with visual determination. In this way, warping can be detected from the output data of the heater power source 127. From the above, it can be said that as the first gas, any one of Ar gas, He gas, and N2 gas, or a combination of these gases, in which warping is difficult to occur in a wafer W, is preferable.
Next, with reference to
The inflowing gas reaches the lower surface (rear surface) of the wafer W. However, since the plurality of protrusions 165 is formed on the surface of the stage 102, it is difficult for the gas to spread uniformly over the entire bottom surface (rear surface) of the wafer W. For example, since pressures are applied to the central portion of the stage 102 so that the gas inflows from each of the three through holes 162 and cancel each other, it is difficult for the gas to reach the central portion from any direction of the three through holes 162. Therefore, the gas inflowing upward from the bottoms of the through holes 162 tends to escape from the outer periphery of the wafer W. In addition, it is considered that the degree of ease of escaping from the outer periphery is affected by the viscosity coefficient of the gas.
In addition, as it becomes more difficult for the gas to reach the center of the stage 102 and as it becomes easier for the gas to escape from the outer periphery, a temperature difference is likely to occur between the central portion and the outer peripheral portion of the wafer W (lower at the center and higher at the outer periphery). That is, warping is likely to occur.
Descriptions will be made returning back to
From the results illustrated in
As described above, it is considered that when NH3 gas is supplied, since it is difficult for the NH3 gas to reach the central portion of the stage 102 and the NH3 gas easily escapes from the outer periphery, the heating of the wafer W becomes non-uniform, causing a temperature difference to occur between the central portion and the outer peripheral portion of the wafer W, and as a result, warping occurs in the wafer W. On the other hand, it is considered that since He gas, N2 gas, or Ar gas easily reaches the central portion of the stage 102 and it is difficult for the He gas, N2 gas or Ar gas to escape from the outer periphery, the heating of the wafer W becomes uniform, not causing a temperature difference between the central portion and the outer peripheral portion of the wafer W, and as a result, warping does not occur in the wafer W. From the above, as the first gas, it is preferable to use any one of Ar gas, He gas, and N2 gas, or a combination of these gases, in which warping is difficult to occur in the wafer W. However, in addition to He gas, N2 gas, or Ar gas, an inert gas having high viscous resistance may be applicable as the first gas.
As described above, the substrate processing method of the present disclosure makes it possible to uniformly heat the surface of a wafer W by performing a first preheating by using an inert gas (e.g., N2 gas or the like). Therefore, it is possible to suppress warping of the wafer W that may occur due to heating. In addition, since the warping is suppressed, it is not necessary to preheat the wafer W in a state in which the wafer W is pinned up and supported by the wafer support pins. Since warping is suppressed, the temperature can be raised in a short time, and the productivity (throughput) is improved.
In addition, since the film forming gas is switched during preheating, the substrate processing method can be applied regardless of the type of the film forming gas. In addition, since a purge line for purging a processing gas line (flow path) already installed in the plasma processing apparatus 100 is used to supply the inert gas (e.g., N2 gas), there is no need to add a new gas line.
Although the substrate processing apparatus has been described above based on the embodiments, the substrate processing apparatus according to the present disclosure is not limited to the embodiments, and various modifications and improvements are possible within the scope of the present disclosure. Matters described in the above-described multiple embodiments may be combined within a range in which the matters do not contradict each other.
In the present disclosure, a wafer W has been described as an example, but the object to be plasma-processed is not limited to the wafer W, and may be various substrates used in liquid crystal displays (LCDs) and flat panel displays (FPDs).
In addition, the preheating before CVD film formation processing has been described in the present disclosure, the preheating may also be used for preheating before various heat treatment processes, impurity introduction processes, or planarization processes. In addition, in the present disclosure, preheating for film formation processing by the plasma processing apparatus 100 has been described, but the preheating may also be used for preheating for etching and ashing. Furthermore, the film formation processing is not limited to a method using plasma, and sputtering, thermal oxidation, annealing with various lamps, and the like may be used.
This application claims priority based on Japanese Patent Application No. 2021-18135 filed with the Japan Patent Office on Feb. 8, 2021, and the entire disclosure of Japanese Patent Application No. 2021-18135 is incorporated herein in its entirety by reference.
100: plasma processing apparatus, 101: processing container, 102: stage, 103: gas source, 105: microwave plasma source, 106: controller, 111: lid, 122: radio frequency bias power source, U: processing space
| Number | Date | Country | Kind |
|---|---|---|---|
| 2021-018135 | Feb 2021 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2022/002674 | 1/25/2022 | WO |
