This U.S. non-provisional patent application claims priority under 35 U.S.C. § 119 to Korean Patent Application No. 10-2023-0101404, filed on Aug. 3, 2023, in the Korean Intellectual Property Office, the entire contents of which are hereby incorporated by reference.
Semiconductor processes may include various processes (e.g., photolithography, etching, deposition, etc.). A substrate may be used to manufacture a semiconductor device. Here, the substrate should be fixed on a stage in a process chamber to perform the semiconductor process as desired by an operator.
The present disclosure relates to substrate processing methods. In general, in some aspects, the subject matter of the present disclosure encompasses methods of processing a substrate, in which the methods include checking a fixed state of a substrate by measuring a heater voltage at a plasma induction electrode.
Implementations of the methods disclosed herein may include one or more of the following features. For example, in some implementations of the methods include checking a fixed state of a substrate regardless of a type of a plasma induction electrode.
In some implementations, of the methods include checking a fixed state of a substrate without measuring a change in gas leak.
In some implementations, the methods include checking a fixed state of a substrate at a high process temperature.
In some implementations, the methods include measuring a change in heater voltage at a plasma induction electrode according to a change in resistance according to a change in contact state between a substrate and a stage.
In general, in some aspects, the subject matter of the present disclosure is directed to methods of processing a substrate that include: locating a substrate in a substrate processing apparatus; fixing the substrate in the substrate processing apparatus; processing the substrate; and checking a fixed state of the substrate. The substrate processing apparatus may include a process chamber providing a process space, a stage supporting the substrate, a plasma induction electrode used to generate plasma and located in the stage, a first power source configured to supply RF power to the plasma induction electrode, a heater located in the stage and used to heat the stage, a second power source configured to supply AC power to the heater, and a monitoring unit electrically connected to the plasma induction electrode. The processing of the substrate may include heating the stage by supplying the AC power to the heater by the second power source. The checking of the fixed state of the substrate may include measuring AC-2 power of the AC power, which is transferred to the monitoring unit through the heater and the plasma induction electrode.
In general, in some aspects, the subject matter of the present disclosure is directed to methods of processing a substrate that include: locating a substrate in a substrate processing apparatus; fixing the substrate in the substrate processing apparatus; processing the substrate; and checking a fixed state of the substrate. The substrate processing apparatus may include a process chamber providing a process space, a stage supporting the substrate, a plasma induction electrode used to generate plasma, a first power source comprising a RF power source configured to supply RF power to the plasma induction electrode and an alternating current filter configured to filter the RF power, a heater located in the stage and used to heat the stage, a second power source configured to supply AC power to the heater, and a monitoring unit configured to measure a change in AC-2 power supplied from the second power source and passed through the heater, the plasma induction electrode and the alternating current filter. The checking of the fixed state of the substrate may include measuring the AC-2 power.
In general, in some aspects, the subject matter of the present disclosure is directed to methods of processing a substrate that include: fixing a substrate in a substrate processing apparatus; processing the substrate; checking a fixed state of the substrate; and checking an arcing state of the substrate. The substrate processing apparatus may include a process chamber providing a process space, a stage supporting the substrate, a plasma induction electrode located in the stage and used to generate plasma, a first power source comprising a RF power source electrically connected to the plasma induction electrode and configured to supply RF power, a heater located in the stage and used to heat the stage, a second power source comprising an AC power source configured to supply AC power to the heater, and a monitoring unit connected to the first power source and configured to analyze a state of a substrate. The processing of the substrate may include heating the stage by supplying the AC power to the heater by the AC power source. The checking of the fixed state of the substrate may include measuring AC-2 power transferred from the AC power source to the monitoring unit through the heater and the plasma induction electrode. The checking of the arcing state of the substrate may include measuring RF-2 power supplied from the RF power source and transferred to the monitoring unit through the substrate and the plasma induction electrode.
Hereinafter, implementations will be described in detail with reference to the accompanying drawings. The same reference numerals or the same reference designators may denote the same components or elements throughout the specification.
In semiconductor processing, if the substrate is not fixed on the stage, heat may not be uniformly transferred to the substrate, and thus a process (e.g., deposition or etching) may not be uniformly performed on the substrate. A state of fixation of the substrate (sometimes referred to as a fixed state of the substrate) may be changed by various factors such as a temperature and/or a pressure in the process chamber. Aspects of this disclosure provide processes and systems for measuring the state of fixation.
Hereinafter, a reference designator D1 may be referred to as a first direction, a reference designator D2 intersecting the first direction D1 and perpendicular to the first direction D1 may be referred to as a second direction, and a reference designator D3 intersecting both the first direction D1 and the second direction D2, and perpendicular to both the first direction D1 and the second direction D2, may be referred to as a third direction. The first direction D1 may be referred to as an upward direction, and a direction opposite to the first direction D1 may be referred to as a downward direction. In addition, each of the second direction D2 and the third direction D3 may be referred to as a horizontal direction.
Referring to
The process chamber 1 may provide a process space 1h. A process may be performed on the substrate W in the process space 1h. The process space 1h may be separated from an external space. The process space 1h may be in a substantial vacuum state while the process is performed on the substrate W. The process chamber 1 may have, but is not limited to, a cylindrical shape.
Referring to
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The cooling plate 73 may be located under the stage body 71. For example, the stage body 71 may be located on the cooling plate 73. The cooling plate 73 may provide a cooling hole (not shown). Cooling water may flow through the cooling hole. The cooling water in the cooling hole may absorb heat from the cooling plate 73.
The shower head 3 may be located in the process chamber 1. For example, the shower head 3 may be located in the process space 1h. The shower head 3 may be spaced upward from and apart from the stage 7. A gas supplied from the gas supply unit GS may be uniformly supplied into the process space 1h through the shower head 3.
The outer ring 51 may surround the shower head 3. For example, the outer ring 51 may be disposed outside the shower head 3 and may surround an edge of the shower head 3 when viewed in a plan view along the first direction D1. The outer ring 51 may be in contact with the shower head 3.
The heating liner ring 53 may surround the outer ring 51. For example, the heating liner ring 53 may be disposed outside the outer ring 51 and may surround an edge of the outer ring 51 when viewed in a plan view along the first direction D1. The heating liner ring 53 may support the outer ring 51. The heating liner ring 53 may include aluminum (Al) and yttrium oxide (Y2O3). More particularly, the heating liner ring 53 may have a shape in which aluminum (Al) is coated with yttrium oxide (Y2O3).
The plasma induction electrode PE may be used to generate plasma. More particularly, the plasma induction electrode PE may be supplied with RF power from the first power source 9 to generate the plasma. The plasma induction electrode PE may be located in the inside of the stage 7. The plasma induction electrode PE may have a plate shape. However, implementations are not limited thereto.
The heater HT may be located in the inside of the stage 7. The heater HT may be located under the plasma induction electrode PE. The heater HT may have a plate shape. However, implementations are not limited thereto. The heater HT may be supplied with AC power from the second power source PW1 to emit heat. The second power source PW1 may include an AC power source (not shown) for generating the AC power. A temperature of the stage 7 may be raised by the AC power. The temperature of the stage 7 may be raised to about 400° C. or more by the AC power supplied to the heater HT.
Referring to
The first power source 9 may be configured to apply RF power and DC power to the stage 7. The first power source 9 (e.g., as shown in
The second power source PW1 may be configured to supply AC power to the stage 7. More particularly, the second power source PW1 may be configured to supply the AC power to the heater HT in the stage 7. An amplitude of the AC power supplied by the second power source PW1 may be constant. However, implementations are not limited thereto.
The third power source PW2 may be electrically connected to the shower head 3. The third power source PW2 may be located above the process space 1h. The third power source PW2 may be configured to supply RF power capable of generating the plasma. More particularly, the third power source PW2 may convert the gas supplied from the shower head 3 into the plasma. The third power source PW2 may more effectively generate the plasma in conjunction with the second power source PW1.
The vacuum pump VP may be connected to the process space 1h. A vacuum pressure may be applied to the process space 1h by the vacuum pump VP while the process is performed on the substrate W.
The monitoring unit MN may be electrically connected to the first power source 9. The monitoring unit MN may be electrically connected to the plasma induction electrode PE. The monitoring unit MN may include a first monitoring unit MN1 and a second monitoring unit MN2 (see
The control unit CP may be electrically connected to the monitoring unit MN. The control unit CP may check a state of the substrate W by using information or data transmitted from the monitoring unit MN. More particularly, the control unit CP may check the fixed state and arcing of the substrate W together with the monitoring unit MN. This will be described below in detail.
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The AC power may include AC-2 power supplied from an AC power source and transferred to the monitoring unit MN through the heater HT, the E-layer E and the plasma induction electrode PE. The AC-2 power may be power obtained by filtering the RF power, supplied from the RF power source 92, by the alternating current filter 93. For example, the AC-2 power may be power supplied from the second power source PW1 and transferred to the monitoring unit MN through the heater HT, the E-layer E, the plasma induction electrode PE and the alternating current filter 93. An amplitude of a voltage of the AC power may be constant. An amplitude of a voltage of the AC-2 power may be changed depending on the fixed state of the substrate W. The temperature of the stage 7 may be changed to change the third resistance, and thus the voltage of the AC-2 power may be changed. In addition, the first resistance may be changed, and thus the voltage of the AC-2 power may also be changed (see
Referring to
The blocking capacitors 94, 95 and 96 may include a first blocking capacitor 95, a second blocking capacitor 94, and a third blocking capacitor 96. The first blocking capacitor 95 and the DC power source 91 may be connected in parallel to the plasma induction electrode PE. The first blocking capacitor 95 may prevent the first power source 9 from making a short circuit. The second blocking capacitor 94 and the third blocking capacitor 96 may be connected in series to the alternating current filter 93. However, implementations are not limited thereto. The first monitoring unit MN1 may be connected to the first power source 9 between the RF power source 92 and the alternating current filter 93. The second monitoring unit MN2 may be electrically connected to a place at which power passed through the plasma induction electrode PE passes through the alternating current filter 93 and the second blocking capacitor 94.
Referring to
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The processing of the substrate W (S4) may include heating the stage 7 by supplying the AC power to the heater HT by the second power source PW1. For example, the processing of the substrate W (S4) may include heating the stage 7 by supplying the AC power to the heater HT by the AC power source. The processing of the substrate W (S4) may further include supplying the RF power to the plasma induction electrode PE by the RF power source 92.
The filtering of the power, supplied from the RF power source 92, by the alternating current filter 93 (S41) and the measuring of the AC-2 power (S42) may include measuring the AC-2 power transferred from the AC power source to the monitoring unit MN through the heater HT, the plasma induction electrode PE and the alternating current filter 93.
The measuring of the RF-2 power transferred to the monitoring unit MN before reaching the alternating current filter 93 (S51) may include measuring the RF-2 power supplied from the RF power source 92 and transferred to the monitoring unit MN through the substrate W and the plasma induction electrode PE before reaching the alternating current filter 93.
The checking of whether the arcing occurs at the substrate W or not (S52) may include analyzing the RF-2 power.
Referring to
According some implementations of processing a substrate, the fixed state of the substrate may be checked regardless of DC power formed by plasma, which can be beneficial. For example, if a state of a substrate is checked using a leakage current of DC power at a stage, accuracy may be deteriorated by the DC power formed by the plasma. By contrast, a frequency of the voltage of the AC-2 power filtered at the plasma induction electrode by the alternating current filter may be different from a frequency of the DC power formed by the plasma, and thus the AC-2 power may not be affected by the DC power formed by the plasma. The change in the AC power applied to the heater and passing through the substrate and the plasma induction electrode may be analyzed to check the fixed state of the substrate regardless of the DC power formed by the plasma.
According to some implementations of processing a substrate, the fixed state of the substrate may be checked regardless of a type of the stage. The stage may include a mono-polar stage including a single plasma induction electrode or a bi-polar stage including two plasma induction electrodes. The mono-polar stage may be incompatible with a method of checking a fixed state of a substrate by using a change in capacitance between the stage and the substrate. However, the fixed state of the substrate on the mono-polar stage may be checked using the AC power applied to the heater.
According to some implementations of processing a substrate, the fixed state of the substrate may be checked and the arcing state of the substrate may also be checked. The RF-2 power supplied from the RF power source and passed through the substrate and the plasma induction electrode may be monitored and analyzed to check the arcing state of the substrate.
Advantages provided by some implementations according to this disclosure include at least the following. In implementations, the fixed state of the substrate may be checked by measuring the heater voltage at the plasma induction electrode. In some implementations, the fixed state of the substrate may be checked regardless of the type of the plasma induction electrode. In some implementations, the fixed state of the substrate may be checked without measuring a change in gas leakage. In some implementations, the fixed state of the substrate may be checked at a high process temperature. In some implementations, it is possible to measure a change in heater voltage at the plasma induction electrode according to a change in resistance according to a change in contact state between the substrate and the stage.
While this disclosure contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed. Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a combination can in some cases be excised from the combination, and the combination may be directed to a subcombination or variation of a subcombination.
While some implementations have been particularly shown and described, it will be understood by one of ordinary skill in the art that variations in form and detail may be made therein without departing from the spirit and scope of the attached claims.
Number | Date | Country | Kind |
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10-2023-0101404 | Aug 2023 | KR | national |