SURFACE PROCESSING APPARATUS

Abstract

A surface processing apparatus is provided for use in the surface processing of a substrate. The surface processing apparatus comprises a plasma source and processing chamber in which a substrate is mounted in use. The processing chamber is operatively connected to the plasma source and the surface processing apparatus is characterised by a transmission plate for the transmission of plasma in use between the plasma source and processing chamber. The transmission plate comprises one or more apertures wherein the physical form of the one or more apertures and/or the distribution of the one or more apertures is adapted to provide a predetermined processing pattern upon the surface of the substrate. Typically the design of the apertures is adapted to provide a substantially uniform deposition rate across a wafer substrate.

Description

BACKGROUND OF INVENTION

1. Field of Invention

The present invention relates to apparatus for the surface processing of a substrate, in particular apparatus that utilises high-density plasma to aid chemical vapour deposition or etching.

2. Description of the Related Art

Chemical vapour deposition (CVD) and plasma etching are well-known processing methods used in the semiconductor and integrated circuit industry. In a standard CVD process a semiconductor wafer is placed within a specialised reaction chamber and the surface of the wafer is exposed to various chemical substances, wherein the chemical substances are injected into the reaction chamber in gaseous form or within a carrier gas. The chemical substances typically comprise one or more volatile precursors, which react with and/or decompose upon the wafer substrate to alter the surface of the semiconductor wafer and provide the necessary processing in dependence on the chemistry of the substances involved. In many processes volatile gaseous by-products are also produced, which are removed using a gas flow through the reaction chamber. Surface reactions can either add new material or etch the existing surface. Common processing operations include the deposition of layers of material upon the wafer substrate and the etching of layers of material from the wafer substrate to form device components, electrical connections, dielectrics, charge barriers and other common circuit elements.

In recent times, plasma enhancement has been incorporated into CVD systems in order to enhance the quality and/or processing rate of the surface process. These plasma-enhanced CVD (PECVD) systems generally operate by the dissociation and ionisation of gaseous chemicals to increase the reactivity of the one or more chemical precursors. This enhanced reactivity due to energetic particles in the plasma increases the processing rate and allows lower processing temperatures to be used when compared to conventional CVD systems. Plasma enhancement is particularly useful for etching processes.

The plasma can be generated in situ within the reaction chamber using a parallel plate (PP) system or generated remotely from reaction chamber and/or substrate and then transported into the reaction chamber. A standard PP system is illustrated in FIG. 10: a first plate 104 is used as a platform upon which the wafer substrate 103 is mounted and a second plate 150 is located in a parallel plane above the first plate 104. Both plates are located within a single chamber 115 and process gas mixtures are injected into this chamber 115 through an array of holes 106 in the upper second plate 150 in an assembly called a showerhead. Typically, the second plate 150 is then driven with a radio frequency (RF) current source 160 and plasma 113 is generated, using the injected gas mixtures, in the space between the two plates. The showerhead holes 106 are as narrow as can be practically manufactured to limit intense parasitic plasmas forming inside the holes. The formation of any plasma within the gas mixture inlets would produce an intense local plasma, which perturbs the uniformity of processing and can degrade the gas injection apparatus. Each hole normally takes the form of a small tube, with a length to diameter ratio of at least 5:1.

With contemporary developments in the field of PECVD and plasma etching, the use of high-density (HD) plasmas is becoming increasingly viable. High-density plasma CVD (HDPCVD) or etching systems are typically those in which the generated ion or electron density is greater than 10¹¹ cm⁻³. This also raises the dissociation efficiency by an order of magnitude when compared to standard parallel plate systems. These enhanced plasma properties further increase the processing rate and/or quality of HDPCVD processes and offers potential advantages of lower hydrogen content films, high quality films at lower process temperatures, void-free gap filling of high aspect ratio features, and self-planarisation when compared with conventional PECVD.

A common implementation of HDPCVD utilises an inductively coupled plasma (ICP) source comprising a plasma generation chamber encircled by an inductively coupled coil. This coil is driven with a RF supply in order to generate an electric field within the plasma generation chamber, which in turn in creates and ignites a plasma cloud. A variety of RF frequencies can be used including low frequencies (below 55 kHz), high frequencies (13.56 MHz) or microwave frequencies (where the coil is replaced with a microwave cavity) (2.45 GHz). By locating the plasma source remotely to the processing chamber, ICP systems allow high-density plasma to be generated remotely without affecting the surface processes within the processing chamber.

Two or more gases or gas mixtures are typically injected into an ICP HDPCVD system: a first gas or gas mixture is injected into the ICP generation chamber and a second gas or gas mixture is injected into the substrate reaction chamber. The generated electric field accelerates the electrons of the first gas within the plasma generation chamber, which ionises individual gas molecules and allows for the transfer of kinetic energy within individual electron-gas molecule collisions. U.S. Pat. No. 5,792,272 provides an example of a HD ICP reactor as is known in the art.

There are, however, several problems with the use of HDPCVD. In typical CVD systems process uniformity has been achieved by controlling the flow dynamics of the chemical substances in order to generate a uniform species distribution across the reaction surface of the wafer substrate. In an HDPCVD system the distribution of gases inside the processing chamber is very difficult to control as the plasma interacts with the flow dynamics of any injected gas.

E. R. Keiter and M. J. Kushner discuss the problem of gas distribution in their paper “Radical and Electron Densities in a High Plasma Density-Chemical Vapour Deposition Reactor from a Three-Dimensional Simulation” published in the IEEE Transactions on Plasma Science, Vol. 27, No. 2, April 1999. FIG. 2 of this paper clearly illustrates how the uniformity of deposition is strongly influenced by the gas flow patterns in the low pressure reaction space, and especially the flow pattern of the gases compound bearing the primary material for the film, typically silane SiH₄ for silicon containing films.

The uniformity of thin film deposition is an important performance parameter, with current deposition processes aiming for an error of around ±3% across the diameter of the wafer substrate. This level of uniformity has been achieved in the prior art by either shaping the generated plasma using the associated RF induction coil or by using a particular arrangement of gas injectors.

EP-0870072-A1 teaches that a particular arrangement of gas injection nozzles in an annulus between the plasma source and the substrate can aid process uniformity. However, this increased uniformity is achieved through empirical adjustment of the nozzle geometry, which is cumbersome and requires complex modifications of the HDPCVD reactor apparatus. Additionally, by increasing the number of gas injection nozzles and altering the nozzle geometry complicated flow patterns can be set up within the processing chamber that can have an unpredicted effect on processing uniformity.

U.S. Pat. Nos. 5,800,621-A and 5,401,350 teach a method of adjusting the uniformity of an ICP source by configuring the arrangement of the RF induction coils. However, these methods require complicated modelling of the electric field parameters within the plasma source chamber and also typically have higher power demands and require more complicated electronic control.

Another problem that arises with the use of all CVD processes is that chemicals applied to the wafer substrate typically further coat most of the processing chamber as well. The ability to clean the chamber in situ by a plasma process is thus important for PECVD and HDPCVD systems. As many prior art techniques for improving the uniformity also complicate the processing apparatus they increase the difficulty of cleaning the chamber in situ and the ability to repair or replace components affected in this way.

Therefore, a flexible method of controlling the uniformity of a process in an ICP HDPCVD system is desired. Preferably this solution should not significantly alter the construction of such systems and allow for simply cleaning and maintenance.

SUMMARY OF INVENTION

According to a first aspect of the present invention there is provided a surface processing apparatus for use in the surface processing of a substrate, the surface processing apparatus comprising a plasma source; and a processing chamber in which a substrate is mounted in use, the processing chamber being operatively connected to the plasma source; the surface processing apparatus characterised by a transmission plate for the transmission of plasma in use between a plasma source and the processing chamber, the transmission plate comprising one or more apertures wherein the physical form of the one or more apertures and/or the distribution of the one or more apertures is adapted to provide a predetermined processing pattern upon the surface of the substrate.

The prior art teaches away from the use of a transmission plate because it is well known that excited and ionised plasma species are quickly quenched by contact with solid surfaces. Thus any technologies developed for use in altering generic gas flow are unsuitable for use in situations involving a plasma source and a connected processing chamber, due to the very different properties of the plasma species. Furthermore, whereas PECVD showerhead systems are designed to suppress plasma passing through the showerhead at all costs, the transmission plate is designed to allow active species to pass through the plate without significant quenching. By varying the fraction of plasma species that pass through different parts of the plate, a simple and effective means of optimising the uniformity of surface processing is provided.

By controlling the features of a transmission plate mounted between a plasma source and a processing chamber, the present invention allows the careful control of the processing upon the surface of the substrate. Typically, the transmission plate will be designed so that the physical form and/or distribution of the one or more apertures is such that a uniform processing rate is provided across the surface of the substrate. Such a plate is simple to remove and replace if different processing patterns are required or if the transmission plate needs to be cleaned and replaced. This is in contrast to the use of predetermined nozzle geometry or RF coil configurations, wherein the method of providing uniformity is intrinsically bound with the complete HDPCVD apparatus. With the present invention, a transmission plate can also be changed for use with different plasma species.

Preferably, the transmission plate comprises a plurality of circular apertures wherein the diameter of each circular aperture is greater than the thickness of the transmission plate. The ratio between the diameter of each aperture and the transmission plate thickness should typically be greater than 3:1. This then allows a transmission plate to be used without destroying the active species making up the plasma. Typically, the transmission plate will be circular in form in correspondence with a substantially cylindrical plasma source and processing chamber. In these cases the plasma source is typically axially aligned with the processing chamber, which is mounted below the plasma source.

In some embodiments the plurality of apertures are distributed in one or more concentric aperture rings upon the transmission plate, the centre(s) of the one or more concentric aperture rings being that of the transmission plate. In these cases either the angular spacing of the plurality of apertures within each concentric aperture ring or the radial spacing between each pair of concentric aperture rings is adapted to provide a predetermined processing pattern upon the surface of the substrate.

Preferably, the plasma source generates an inductively coupled plasma and comprises a plasma chamber and an RF driven inductively coupled coil. Common drive parameters for the RF source are a frequency of 13.56 MHz and a power of 1 to 3 kW.

Typically, the apparatus uses two gas or gas mixture supplies: a first gas or gas mixture supply to the plasma source and a second gas or gas mixture supply to the processing chamber. Typical surface processing of the substrate comprises deposition or removal of material on or from the surface of the substrate. In some embodiments the physical form of the one or more apertures and/or the distribution of the one or more apertures is adapted to provide a substantially uniform deposition or material removal rate across a width of the substrate.

To prevent the thermal degradation of the transmission plate, and to limit particles flaking from the transmission plate through thermal cycling, the thermal conductivity of the plate is typically greater than 100 W m-1 K-1 and the plate is thermally connected to an external chamber via a low thermal resistance path. The transmission plate can comprise either a metal or metal alloy plate. Alternatively a lower thermal conductivity material can be used with a lower thermal expansion coefficient, which can operate at higher temperatures, such as alumina ceramic. Where the transmission plate is to be used with chlorine-containing gas mixtures for etching, then alumina is preferred. It is also possible to use anodised aluminium or metal coated with a material more inert to the reactive plasma, such as plasma-sprayed alumina, to combine the beneficial effects of improved lateral heat conduction with inertness to the plasma.

According to a second aspect of the present invention there is provided a method for the fabrication of a transmission plate for use in the surface processing of a substrate mounted within a processing chamber, the transmission plate being mounted in use between a plasma source and the processing chamber and comprising one or more apertures to allow the transmission of plasma from the plasma source to the processing chamber, the method comprising the steps of:

• • a) measuring the processing rate of a surface process on the substrate with respect to the radius of the substrate, r, using the plasma source and the processing chamber without a transmission plate;
  • b) fitting a process rate function d(r) to the measured process rate;
  • c) calculating a plasma transmission function T(r) as a function of a radius from the centre of the transmission plate, such that d(r)×T(r) is a constant;
  • d) defining an aperture design for the physical form of the one or more apertures and/or the distribution of the one or more apertures such that a measured plasma transmission function for the transmission plate provides a best fit to the plasma transmission function T(r); and
  • e) fabricating a transmission plate using the aperture design defined in step d).

By following this method, new transmission plates can be quickly and easily generated in response to new or different processing conditions. According to a third aspect of the present invention there is provided a method of operating the apparatus as previously defined, the method comprising:

• • a) injecting a first gas or gas mixture into the plasma source on one side of the transmission plate;
  • b) injecting a second gas or gas mixture into the processing chamber of the other side of the transmission plate;
  • c) adjusting the gas flow ratio of the two injected gases in response to a measured processing rate.

Both gas mixtures can contain noble gases and both gas supplies may inject the same noble gas. This method further increases uniformity and the transmission plate limits the movement of undesired reactive gas species into the plasma source.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be better understood, some embodiments of the invention will now be described with reference to the accompanying drawings in which:

FIG. 1 illustrates a surface processing apparatus according to the present invention;

FIG. 2 illustrates a first possible transmission plate aperture configuration in accordance with the present invention;

FIG. 3 illustrates a second transmission plate aperture configuration in accordance with the present invention;

FIG. 4 illustrates a third transmission plate aperture configuration in accordance with the present invention;

FIG. 5 illustrates a fourth transmission plate aperture configuration in accordance with the present invention;

FIG. 6 is a graph illustrating the effect of transmission plate aperture configuration on deposition rate;

FIG. 7 is an illustration of a 3D model of a transmission plate according to the present invention;

FIG. 8 is a second illustration of a 3D model of a transmission plate for use in SiO_x deposition according to the present invention;

FIG. 9 is a graph illustrating the effect of deposition thickness when using the transmission plate as shown in FIG. 8;

FIG. 10 illustrates a prior art parallel plate PECVD system;

FIG. 11 is a graph illustrating the effect of changing the radius-to-thickness aspect ratio on transmission fraction;

FIG. 12 is a graph illustrating the fit between an actual and ideal plasma transparency measure, the transparency being measured across the radius of a transmission plate; and

FIG. 13 is a graph illustrating the effect of injecting argon gas above a transmission plate on deposition uniformity.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a schematic illustration of a high-density plasma chemical vapour deposition (HDPCVD) system. The system consists of two main components: a plasma source 1 and a processing chamber 2. The plasma source comprises a plasma chamber 8 constructed from a dielectric cylindrical tube with a vertical axis surrounded by an electrostatic shield 10. Typically, quartz or alumina is used as the dielectric. At the top of the cylindrical tube 8 is a set of gas inlets 9, which have an axially symmetric distribution and are used to inject a first gas or gas mixture into the plasma chamber used in the plasma generation. Beneficially, this first gas mixture includes a noble gas such as argon. This gas or gas mixture is ionised and excited within the plasma source 1, then transports to the processing chamber 2 by a combination of flow and diffusion.

Surrounding this plasma chamber 8 is a water-cooled radio frequency (RF) coil antenna 7 that forms an inductively coupled coil for use in generating the plasma within the plasma chamber 8. The RF coil 7 is connected to a 13.56 MHz, 3 kW RF generator via a matching unit (not shown). Effectively, the current passing through the RF coil 7 generates an RF magnetic flux along the axis of the plasma chamber 8 and this magnetic flux further induces an RF electric field inside the plasma chamber 8. The induced electric field accelerates electrons within the injected gas cloud producing high-density plasma within the plasma chamber. By controlling the inductively coupled RF coil 7, an operator can control the dissociation of the plasma and the density of the incident ions in the plasma chamber 8. The most intense plasma is represented in FIG. 1 by shaded region 13.

An inspection port 14 may be provided to observe the substrate surface by laser interferometry, provided the transmission plate has a suitably aligned hole. The top plate 16, side cover 15 and plasma source base plate 17 form an enclosure to contain RF radiation from the RF coil 7

Below the plasma source 1 is the processing chamber 2, which is axially aligned with the plasma chamber 8. The processing chamber 2 typically comprises a substrate table 4 made from a 205 mm diameter cooled or heated lower electrode with helium assisted heat transfer. This table can be electrically grounded, or powered by a separate RF supply to control the ion impact energy at the substrate surface. A wafer substrate 3 is placed upon this substrate table 4 and can be further held in place using a modular clamping mechanism 5. The processing chamber 2 is typically kept at low pressure or within a vacuum by evacuation using a turbomolecular pump backed by a mechanical pump, via a pumping port 11 mounted beneath the substrate table 4. In this example, the pumping port 11 is a 200 mm diameter high conductance pumping port. A ring of gas nozzles is provided in an annulus 6 at the top of the processing chamber 2, through which a gas or gas mixture is injected. In processes to deposit silicon compounds, the silicon-bearing gas such as silane is included in this gas mixture. Beneficially, a noble gas such as argon forms part of this mixture.

In use plasma 13 is generated within the plasma source 1 by providing the appropriate RF current to the ICP coil. In prior art systems, the plasma source 1 is directly connected to the processing chamber 2 and ion impact energy on the wafer substrate 3 is controlled by applying an RF bias to the substrate table 4. However, as is seen in the Keiter and Kushner paper discussed within the introduction, these prior art systems generate a non-uniform processing rate upon the wafer substrate 3.

Thus to provide uniformity, a transmission plate is mounted between the plasma source 1 and the processing chamber 2 and the plasma 13 is driven through the transmission plate 12, which modifies the electron distribution in the plasma cloud. In the present invention, the interruption of the plasma flow by the transmission plate alters the configuration of the flow.

A method for generating the form and/or the arrangement of the apertures on the transmission plate will now be described in relation to the apparatus of FIG. 1. First, a set surface process is selected and the apparatus of FIG. 1 is set up accordingly but with the transmission plate 12 removed from the assembly. A test wafer substrate 3 is then placed on the substrate table 4 and a plasma is generated in the plasma source 1. This plasma is then used to deposit material upon the wafer without a transmission plate being present and the resultant wafer substrate 3 is then analysed. Using a test wafer substrate 3 the deposition rate for the HDPCVD process can be measured without the beneficial effects of the transmission plate 12. From this data a graph of deposition rate against wafer radius can be plotted in a similar manner to FIGS. 6 and 9. Once the experimental data has been plotted a deposition rate function d(r) can be fitted to the data so that a deposit rate can be calculated at any radius r. Any known data fitting techniques can be used including but not limited to least mean square error methods applied to cubic spline or polynomic curves.

After the deposition rate function d(r) has been fitted then a transmission function T(r) for the transmission plate is calculated to generate a plasma transmission function through the transmission plate as a function of transmission plate radius r. Both these functions assume that the transmission plate and the substrate wafer are axially aligned. The transmission function T(r) is calculated so that d(r)×T(r)=1, i.e. the transmission function is calculated to be the inverse of the deposition rate function. Once a required transmission function T(r) has been calculated then a set of apertures can be generated or calculated to provide an actual plasma transmission distribution that best fits the transmission function T(r). This can either be done experimentally or theoretically, using standard plasma flow models and equations. For example, if the operating conditions are known then the velocity of a plasma as it moves towards the substrate table can be calculated to provide a plasma flux parameter in relation to the plasma flow. It can then be assumed that the transmission function T(r) is proportional to the plasma flux. By standard calculations the amount of aperture area per annular area of the transmission plate can be calculated and thus an aperture shape fitted to best match these area requirements.

An example of the function fitting described above is illustrated in FIG. 12. A transmission plate divided into 10 equal-width concentric bands is used as a starting point for the analysis of the required plasma transparency, a measure of plasma transmission, at a variety of radial positions. The ideal plasma transparency for each concentric band is shown in unfilled bars 121 and is derived from the deposition rate on a wafer substrate in the absence of a transmission plate. A design based on a series of simple rings of equal diameter holes, as illustrated in FIG. 2 and located across the 10 concentric bands, is then developed and the plasma transparency is calculated using equations known in the art. The design with a calculated plasma transparency that best fits the ideal transparency is then chosen. The transparency of the chosen design is shown in shaded bars 120 and provides a good fit to the ideal transparency required for a uniform surface process. There is only a lack of fit at the centre due to the required binary choice of inserting or omitting a single central hole.

Transmission plate variables that can be changed include, but are not limited to, the number of apertures per unit area, the shape of the aperture, the diameter of each aperture if circular apertures are used, the major and minor axes of each aperture if elliptical apertures are used, or any combination of the above. The number of apertures per unit area can further be defined using a concentric ring arrangement as illustrated in FIGS. 2 to 5, wherein the aperture density is dependent on the radial spacing of the concentric rings 30-35 and the concentric spacing of a set of circular apertures 21.

The development of an aperture design from a transmission function will generally involve constraints on aperture form. For example, if circular apertures are used the diameter of such apertures should be greater than the thickness of the transmission plate in order to ensure the efficiency of plasma flow through the transmission plate. Through experimental tests and modelling it has been found that an aperture diameter to plate thickness ratio of at least 3:1 provides a required transmission rate and prevents the destruction and recombination of active plasma species. The fraction of gas particles transmitted through a single circular hole of radius R in a plate of thickness h without contacting the wall has been calculated, and is shown in FIG. 11. This calculation assumes that the mean free path is long compared to the hole dimensions. Figure shows that at least 50% of the species are transmitted, without a potentially quenching encounter with the wall, if the aspect ratio of the hole (radius:thickness) is at least 3:1, and at least 30% if the aspect ratio is 1.5:1 If non-circular apertures are used with associated width and length parameters instead of a diameter parameter a similar aperture width to plate thickness and/or aperture length to plate thickness ratio should be obeyed.

Examples of possible transmission plate configurations designed using this method are illustrated in FIGS. 2 to 5. Each transmission plate comprises a circular disc 20 in which there are a plurality of circular apertures 21 that allow the passage of plasma from the plasma source 1 to the processing chamber 2. By removing certain apertures 23, 24, and 26, highlighted by the dark shading in FIGS. 3 to 5, within the design process described above the resultant processing rate can be altered from that achieved with no transmission plate 12 present.

FIG. 2 illustrates a basic aperture distribution comprising a central circular aperture 36 and six concentric aperture rings of increasing radii: first, outer concentric aperture ring 30 comprising 39 uniformly spaced circular apertures 21; second concentric aperture ring 31 also comprising 39 uniformly spaced circular apertures 21; third concentric aperture ring 32 comprising 28 uniformly spaced circular apertures 21; fourth concentric aperture ring 33 comprising 18 uniformly spaced circular apertures 21; fifth concentric aperture ring 34 comprising 12 uniformly spaced circular apertures 21; sixth concentric aperture ring 35 comprising 6 uniformly spaced circular apertures 21; and a central aperture 36. This pattern was derived using the method of transmission plate design described previously, with the further constraints of maximum transmission near the edge of the plate, a constant hole diameter of 10 mm, and an adequate amount of metal remaining for lateral heat conduction and mechanical stability.

The first three concentric aperture rings 30, 31, 32 have a first uniform radial spacing 40, i.e. the distance from the centre of the circular apertures in the first outer concentric ring 30 to the centre of the circular apertures in the second concentric ring 31 is equal to the distance from the centre of the circular apertures in the second concentric ring 31 to the centre of the circular apertures in the third concentric ring 32. The inner concentric aperture rings 33, 34, 35 and the central aperture 36 have a second uniform radial spacing 41, which is greater than the first uniform radial spacing 40. The angular spacing 42 of the circular apertures in the outer three concentric aperture rings 30, 31, 32 varies with the second concentric aperture ring 31 having the highest aperture density per concentric ring. The inner concentric aperture rings 33, 34, 35 also have a varied angular spacing, with the minimum angular spacing being greater than the largest angular spacing of the outer three concentric aperture rings 30, 31, 32, and the angular spacing of the circular apertures increasing as the radius of the concentric aperture rings decreases.

Typically, the circular disc 20 is manufactured from aluminium alloy no. 6082 with a thickness of between 3 to 5 millimetres. To allow a suitable transmission rate, the diameter of the circular apertures 21 is greater than the thickness of the plate, typically for the illustrated transmission plates the ratio of aperture diameter to plate thickness is greater than 3:1. Hence, using the aluminium alloy above, the diameter of the circular apertures is between 9 and 15 mm, with the diameter of all apertures preferably greater than 9 mm. However, an aperture diameter greater than 5 mm will begin to demonstrate favourable transmission characteristics.

The effect of each transmission plate configuration illustrated in FIGS. 2 to 5 when used, with the apparatus of FIG. 1, in the deposition of SiN_x is illustrated in the graph shown in FIG. 6. Line 61 illustrates how the deposition rate varies across the diameter of a 100 mm wide wafer when a transmission plate 12 is absent from the apparatus. It is clearly visible that the absence of a transmission plate, as is found in the prior art, causes more material to be deposited in the centre of the wafer than at the edges. This then generates a non-uniform deposition pattern that can have negative consequences for downstream semiconductor and integrated circuit processing.

The use of a transmission plate as illustrated in FIG. 2 improves the deposition rate profile across the wafer substrate, as illustrated by line 62 in FIG. 6. The differing radial and angular spacing of the six concentric aperture rings mean that a greater amount of plasma can be transmitted through the outer three concentric aperture rings 30, 31, 32 than through the inner concentric aperture rings 33 to 35. By varying these parameters the plasma transmission factor per concentric ring area can be altered, which in turn will alter the deposition rate within corresponding concentric areas of the wafer substrate 3, assuming the wafer substrate 3 is axially aligned with the transmission plate 12. For example, as the concentric aperture density is greatest within the second concentric aperture ring 31, the plasma flux per concentric unit area, assuming a uniform plasma density and velocity perpendicular to the transmission plate 12, would also be a maximum. In real world use, the plasma density will vary in the plasma chamber 8 across the diameter of the transmission plate 12 and thus the differing aperture densities, created by the arrangement of the circular apertures 21, help generate a more uniform plasma density on the processing chamber 2 side of the plate. However, the transmission plate 12 illustrated in FIG. 2 still generates some non-uniformity in deposition rate across the wafer substrate 3, and can be optimised further by iterating the design method, either experimentally or by further application of function fitting.

When the distribution of circular apertures 21 within the circular disc 20 of the transmission plate 12 is altered by removing the central aperture 23, as conceptually illustrated in FIG. 3, then the peak deposition rate at the centre of the substrate wafer is reduced as illustrated by line 63. This is because, as the centre aperture 23 is no longer present in the transmission plate 12, plasma present near the centre of the plasma chamber 8 can no longer be perpendicularly transmitted into the processing chamber 2, thus generating a dearth of plasma near the centre of the processing chamber 2 and reducing the rate of chemical reactions at the centre of wafer substrate 3 below the transmission plate.

By further altering the distribution of circular apertures 21, for example by selecting which apertures should remain in the circular disc 20 and which should be excluded, the deposition rate across the wafer can be further modified. The aperture distribution shown in FIG. 4 excludes the centre aperture 23 and removes the apertures of concentric aperture ring 35, conceptually illustrated by the shaded region 24. The resultant deposition rate profile with this configuration is further smoothed and is illustrated by line 65 in FIG. 6. However, this pattern is still non-optimal as it now overly reduces the deposition rate in the centre of the wafer substrate 3, producing a ‘m’ shape deposition rate profile. An optimal deposition rate pattern is then provided by the transmission plate of FIG. 5, which provides a substantially uniform deposition rate across the surface of the wafer as illustrated by line 64. In this configuration half of the circular apertures in the concentric aperture ring 35 remain and only the central aperture 23 and the shaded apertures 26 are removed. Experimental tests have further shown that a thickness uniformity of ±1.50% (with 7 mm edge exclusions) can be achieved in SiN_x depositions. All the transmission plates in these tests used a plate thickness of 3 mm and 10 mm diameter holes.

As well as or instead of selecting certain apertures to include or exclude from the transmission plate 12, the diameter of certain apertures could also be modified. For example, if the circular apertures 21 are arranged in a series of concentric circles, similar to the concentric aperture ring 24, the diameter of each set of apertures in each concentric ring could reduce as the radius of each concentric ring reduces. This would then have a similar effect to the distribution shown in FIG. 4 and FIG. 5, wherein the rate of aperture diameter change across the radius of the plate would alter the deposition rate across the substrate wafer 3. Alternatively, a similar design based on a series of concentric rings could use elliptically shaped apertures. The major axis of each aperture can be decremented as the radius of each concentric circle decreases resulting in a pattern with wide or long ellipses in the outer concentric circles and near circular ellipses in the more central concentric circles. This again will produce a modified deposition rate which can help provide a more uniform deposition.

While the above distributions and arrangements have been described in relation to the deposition of material on a wafer substrate 3, it is equally possible that the apparatus can be used in the etching or removal of material from a wafer substrate. In these cases, as is known in the art, the activated plasma 13 provides a means to activate and dissociate chemical precursors, which react to remove material upon the surface of the wafer substrate 3.

A three dimensional model of the arrangement of FIG. 5 is shown in FIG. 7. In use the transmission plate 12 is mounted at 3 points 70 near the edge of the plate to the upper surface or base plate 17 of an external chamber 15 of the plasma source 1. The mountings are constructed to provide a low thermal resistance path in order to retain the transmission plate 12 within 20° C. of the base plate 17 temperature. This was demonstrated with a temperature measurement at the centre of the plate while running a 3 kW plasma in the source. The plate temperature never exceeded 70 C. Aluminium alloy no. 6082 has a high level of thermal conductivity to conduct heat away from the areas of the transmission plate in contact with the plasma 13, and the plate is typically thermally coupled to a section of the external chamber made from a material of similar thermal conductivity to further dissipate the generated heat. By minimising the temperature variations of the transmission plate 12 more material can be deposited upon the wafer substrate 3 without particles flaking from the transmission plate 12. Also by controlling the temperature of the transmission plate the negative interaction between the transmission plate and the active plasma can be reduced. Other metals or metal alloys can be used in place of the aluminium alloy, although it is recommended that such a metal or metal alloy has a thermal conductivity above 100 W m⁻¹ K⁻¹. Alternatively, the transmission plate 12 can be constructed from alumina sheet or another ceramic. An alumina transmission plate experiences a larger temperature rise than an equivalent aluminium transmission plate, because the thermal conductivity of the alumina is about one tenth of the thermal conductivity of the aluminium. However, the thermal expansion coefficient of the alumina is about one third that of aluminium and thus the thermal expansion coefficient of the alumina is better matched to the insulating layers most commonly deposited, so thermal cycling does not produce severe flaking of deposited materials.

As the transmission plate 12 is only connected to the external chamber by three connecting points 70, the transmission plate 12 can be easily installed or removed for a variety of operations. For example, new distributions can be applied or plates can be replaced if they begin to show degradation. To clean the transmission plate 12 in situ when depositing SiO_x or SiN_x films, a fluorine-containing plasma can be used, which will remove any deposits that have built up upon the plate.

As discussed previously, the transmission plate 12 may need to be changed when using different processing techniques or different chemical depositions. For example the transmission plate illustrated in FIG. 7 is designed for use with SiN_x deposition, however, when using SiO_x deposition, less plasma activation is required to initiate deposition. Thus FIG. 8 illustrates a SiO_x transmission plate 82 for use in SiO_x deposition. The SiO_x transmission plate 82 comprises three concentric rings 85, 86, 87 of circular apertures 21 with no apertures being present in a central circular section 84 of the plate. The resultant north-south 91 and west-east 92 deposition levels across the substrate wafer when using this plate are shown in FIG. 9. When using the transmission plate illustrated in FIG. 8, a uniformity of ±1.43% (with 7 mm edge exclusions) can be generated across the 100 mm wafer substrate 3. This then halves the uniformity variation obtained using a non-modified transmission plate, as shown in FIG. 2, which is typically ±3.5%. Without a transmission plate the non-uniformity is even greater.

In empirical observations a total deposition thickness on the substrate of at least 5 microns and up to 20 microns has been demonstrated when using the transmission plate 12 without the film flaking from the transmission plate 12.

The presence of a transmission plate also makes it possible to tailor the steps of the surface process by choosing where to inject the different process gases. It is known that gases such as silanes must not be injected into the high-density plasma, i.e. into the plasma chamber 1, as these gases dissociate readily producing material that will adhere to the next surface they contact. The transmission plate 12 helps to limit the intrusion of such gases into the HDP region, keeping the plasma source region cleaner. Further, the injection of a noble gas above the plate will stream ions and excited species towards the substrate, while injection below the plate will serve to modify the diffusion of other species without adding so much extra ion bombardment. The noble gas injected above the transmission plate may also be the same noble gas injected with the gas mixture below the transmission plate. An example of the effect of this process is shown in FIG. 13. This Figure demonstrates the change in the uniformity of SiO₂ deposition with the injection of argon into the plasma source 1. Uniformity is measured as the difference between the maximum and minimum deposition rate, and this measure decreases as the flow of argon gas into the plasma source increases.

In summary, the present invention has been described in relation to a number of embodiments and provides numerous advantages over the prior art including:

• • the transmission plate 12 is easily demountable for changing to new transmission distributions;
  • the transmission plate 12 can be cleaned in situ by a fluorine-containing plasma when depositing SiO_x or SiN_x films;
  • the temperature of the transmission plate 12 can be controlled simply by making a good thermal connection to an external chamber at the transmission plate 12 mounting points.
  • a total deposition thickness of at least 5 microns and up to 20 microns has been demonstrated using the current invention without the film flaking from the transmission plate 12; and
  • the transmission plate 12 can be much simpler and economical compared to the complex gas nozzle and RF coil designs of prior art.

Claims

1. A surface processing apparatus for use in the surface processing of a substrate, the surface processing apparatus comprising: a plasma source; and a processing chamber in which a substrate is mounted in use, the processing chamber being operatively connected to the plasma source; the surface processing apparatus characterised by: a transmission plate for the transmission of plasma in use between the plasma source and processing chamber, the transmission plate comprising one or more apertures wherein the physical form of the one or more apertures and/or the distribution of the one or more apertures is adapted to provide a predetermined processing pattern upon the surface of the substrate.

2. The surface processing apparatus of claim 1, wherein the transmission plate comprises a plurality of circular apertures.

3. The surface processing apparatus of claim 2, wherein the diameter of each circular aperture is greater than the thickness of the transmission plate.

4. The surface processing apparatus of claim 3, wherein the ratio of aperture diameter to transmission plate thickness is greater than 3:1.

5. The surface processing apparatus of claim 2, wherein the diameter of each circular aperture is greater than 5 mm.

6. The surface processing apparatus of claim 5, wherein the diameter of each circular aperture is greater than 9 mm.

7. The surface processing apparatus of claim 1, wherein the transmission plate is circular in form.

8. The surface processing apparatus of claim 7, wherein a plurality of apertures are distributed in one or more concentric aperture rings upon the transmission plate, the centre(s) of the one or more concentric aperture rings being that of the transmission plate.

9. The surface processing apparatus of claim 8, wherein the concentric spacing of the plurality of apertures within each concentric aperture ring is adapted to provide a predetermined processing pattern upon the surface of the substrate.

10. The surface processing apparatus of claim 8, wherein a plurality of concentric aperture rings are arranged upon the transmission plate and the radial spacing between each pair of concentric aperture rings is adapted to provide a predetermined processing pattern upon the surface of the substrate.

11. The surface processing apparatus of claim 1, wherein the plasma source is an inductively coupled plasma.

12. The surface processing apparatus of claim 11, wherein the plasma source comprises a plasma chamber and an inductively coupled coil.

13. The surface processing apparatus of claim 12, wherein the inductively coupled coil is connected to a radio frequency (RF) source.

14. The surface processing apparatus of claim 13, wherein the RF source supplies an RF current at 13.56 MHz.

15. The surface processing apparatus of claim 1, further comprising a first gas supply to the plasma source and a second gas supply to the processing chamber.

16. The surface processing apparatus of claim 1, wherein the surface processing of the substrate comprises the deposition of material on the surface of the substrate.

17. The surface processing apparatus of claim 16, wherein the physical form of the one or more apertures and/or the distribution of the one or more apertures is adapted to provide a substantially uniform deposition rate across a width of the substrate.

18. The surface processing apparatus of claim 1, wherein the surface processing of the substrate comprises the removal of material from the surface of the substrate.

19. The surface processing apparatus of claim 18, wherein the physical form of the one or more apertures and/or the distribution of the one or more apertures is adapted to provide a substantially uniform material removal rate across a width of the substrate.

20. The surface processing apparatus of claim 1, wherein the thermal conductivity of the transmission plate is greater than 100 W m−1 K−1.

21. The surface processing apparatus of claim 1, wherein the transmission plate is thermally connected to the processing chamber via a low thermal resistance path.

22. The surface processing apparatus of claim 1, wherein the transmission plate comprises a metal or metal alloy plate.

23. The surface processing apparatus of claim 22, wherein the transmission plate comprises a metal or metal alloy plate coated with a layer resistant to attack by the plasma.

24. The surface processing apparatus of claim 1, wherein the transmission plate comprises a ceramic plate.

25. The surface processing apparatus of claim 24, wherein the transmission plate comprises an alumina plate.

26. The surface processing apparatus of claim 12, wherein the plasma chamber and the processing chamber comprise substantially cylindrical chambers.

27. The surface processing apparatus of claim 26, wherein the plasma chamber and processing chamber are axially aligned.

28. The surface processing apparatus of claim 1, wherein the plasma source is mounted above the processing chamber.

29. A method for the fabrication of a transmission plate for use in the surface processing of a substrate mounted within a processing chamber, the transmission plate being mounted in use between a plasma source and the processing chamber and comprising one or more apertures to allow the transmission of plasma from the plasma source to the processing chamber, the method comprising the steps of: a) measuring the processing rate of a surface process on the substrate with respect to the radius of the substrate, r, using the plasma source and the processing chamber without a transmission plate; b) fitting a process rate function d(r) to the measured process rate; c) calculating a plasma transmission function T(r) as a function of the radius from a centre of the transmission plate, such that d(r)×T(r) is a constant; d) defining an aperture design for the physical form of the one or more apertures and/or the distribution of the one or more apertures such that a measured plasma transmission function for the transmission plate provides a best fit to the plasma transmission function T(r); and e) fabricating a transmission plate using the aperture design defined in step d).

30. The method of claim 29, wherein the apertures defined in d) have a predetermined width to thickness ratio.

31. A method of operating a surface processing apparatus, the surface processing apparatus comprising: a plasma source; and a processing chamber in which a substrate is mounted in use, the processing chamber being operatively connected to the plasma source; the surface processing apparatus characterised by a transmission plate for the transmission of plasma in use between the plasma source and processing chamber, the transmission plate comprising one or more apertures wherein the physical form of the one or more apertures and/or the distribution of the one or more apertures is adapted to provide a predetermined processing pattern upon the surface of the substrate; the method comprising: a) injecting a first gas or gas mixture into the plasma source on one side of the transmission plate; b) injecting a second gas or gas mixture into the processing chamber of the other side of the transmission plate; c) adjusting the gas flow ratio of the two injected gases in response to a measured processing rate.

32. The method of claim 31, wherein the first and second mixtures gases include noble gases.

33. The method of claim 32, wherein the first and second gases are the same noble gas.

34. The method of claim 31, wherein the temperature of the transmission plate is kept within 20 degrees Celsius of the temperature of an external chamber.