U.S. patent application number 11/318122 was filed with the patent office on 2006-06-22 for plasma cleaning of deposition chamber residues using duo-step wafer-less auto clean method.
This patent application is currently assigned to LAM RESEARCH CORPORATION. Invention is credited to Brett C. Richardson, Vincent Wong.
Application Number | 20060130873 11/318122 |
Document ID | / |
Family ID | 23108156 |
Filed Date | 2006-06-22 |
United States Patent
Application |
20060130873 |
Kind Code |
A1 |
Richardson; Brett C. ; et
al. |
June 22, 2006 |
Plasma cleaning of deposition chamber residues using duo-step
wafer-less auto clean method
Abstract
A method involving plasma cleaning of deposit residues in
process chamber using duo-step wafer-less auto clean method is
detailed. Specifically, the method involves cleaning the processing
chamber by flowing a first gaseous composition with at least about
75% of fluorine-containing compound of the formula X.sub.yF.sub.z,
into a processing chamber and then forming a first etchant plasma
which removes silicon and silicon based byproducts from the
interior surfaces of the processing chamber. The method then
involves flowing a second gaseous composition into the processing
chamber with a composition of at least about 50% O.sub.2 and
forming a plasma from the second gaseous composition to provide a
second etchant plasma which removes carbon and carbon based
byproducts from the interior surfaces of the processing chamber. A
system configured to execute the two step cleaning process is also
provided.
Inventors: |
Richardson; Brett C.; (San
Ramon, CA) ; Wong; Vincent; (Pleasanton, CA) |
Correspondence
Address: |
MARTINE PENILLA & GENCARELLA, LLP
710 LAKEWAY DRIVE
SUITE 200
SUNNYVALE
CA
94085
US
|
Assignee: |
LAM RESEARCH CORPORATION
FREMONT
CA
|
Family ID: |
23108156 |
Appl. No.: |
11/318122 |
Filed: |
December 23, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10139042 |
May 3, 2002 |
7028696 |
|
|
11318122 |
Dec 23, 2005 |
|
|
|
60288678 |
May 4, 2001 |
|
|
|
Current U.S.
Class: |
134/1.1 ;
156/345.24 |
Current CPC
Class: |
B08B 7/0035 20130101;
B08B 3/06 20130101; H01J 37/32935 20130101; C23C 16/4405 20130101;
H01J 37/32862 20130101; H01J 37/32963 20130101; Y10S 438/905
20130101 |
Class at
Publication: |
134/001.1 ;
156/345.24 |
International
Class: |
B08B 6/00 20060101
B08B006/00 |
Claims
1. A plasma processing system for executing a two step in-situ
cleaning process, comprising: a processing chamber having: a gas
inlet for introducing a first cleaning gas and a second cleaning
gas, the first cleaning gas optimized to remove silicon based
byproducts deposited on inner surfaces of the processing chamber,
the second cleaning gas optimized to remove carbon based byproducts
on the inner surfaces of the processing chamber; and a top
electrode for creating a first plasma from the first cleaning gas
to perform a first step of the in-situ cleaning process and then a
second plasma from the second cleaning gas upon completion of the
first step; a variable conductance meter for controlling a pressure
inside the processing chamber independently of a flow rate of the
process gases, the variable conductance meter positioned on an
outlet of the processing chamber; an optical emission spectrometer
(OES) for detecting an endpoint for each step of the two step
in-situ cleaning process performed in the processing chamber, the
OES in communication with the processing chamber; and a pumping
system for evacuating the processing chamber between each step of
the two step cleaning process.
2. The plasma processing system of claim 1, wherein the first
cleaning gas is a fluorine containing compound and the second
cleaning gas is an oxygen containing compound.
3. The plasma processing system of claim 1, wherein the OES monitor
is configured to detect wavelengths corresponding to silicon based
byproducts for the first step of the in-situ cleaning process and
carbon based byproducts for a second step of the in-situ cleaning
process.
4. The plasma processing system of claim 1, wherein the two step
cleaning process is performed after each processing operation in
the processing chamber.
5. A plasma processing system for executing a two step in-situ
cleaning process, comprising: a processing chamber having a gas
inlet for introducing a first cleaning gas and a second cleaning
gas flowing a first gaseous composition into a processing chamber,
the first cleaning gas including at least about 75% of a
fluorine-containing compound of the formula X.sub.yF.sub.z; a
controller having process instructions causing the two step in-situ
cleaning process to proceed by: forming a plasma from the first
cleaning gas to provide a first etchant plasma which removes
silicon and silicon based compounds from interior surfaces of the
processing chamber; flowing the second cleaning gas into a
processing chamber after removal of the first gaseous composition,
the second cleaning gas including at least about 50% O.sub.2; and
forming a plasma from the second gaseous composition to provide a
second etchant plasma which removes carbon and carbon based
compounds from interior surfaces of the processing chamber.
6. The plasma processing system of claim 5, further comprising: a
top electrode for creating a first plasma from the first cleaning
gas to perform a first step of the in-situ cleaning process and
then a second plasma from the second cleaning gas upon completion
of the first step; a variable conductance meter for controlling a
pressure inside the processing chamber independently of a flow rate
of the process gases, the variable conductance meter positioned on
an outlet of the processing chamber; an optical emission
spectrometer (OES) for detecting an endpoint for each step of the
two step in-situ cleaning process performed in the processing
chamber, the OES in communication with the processing chamber; and
a pumping system for evacuating the processing chamber between each
step of the two step cleaning process.
7. A plasma processing system for executing a two step in-situ
cleaning process, comprising: a processing chamber having a gas
inlet for introducing a first process gas and a second process gas
into a processing chamber, the first process gas including at least
about 75% of a fluorine-containing compound of the formula
X.sub.yF.sub.z; a controller having process instructions causing
the two step in-situ cleaning process, the process instructions
including, process instructions for flowing the first process gas
with a fluorine-containing compound of the formula X.sub.yF.sub.z,
said fluorine-containing compound being optimized to remove silicon
and silicon compounds; process instructions for forming a plasma
from said first process gas; process instructions for flowing a
second process gas containing oxygen upon removal of the first
process gas, said second process gas being optimized to remove
carbon based compounds and an optional fluorine-containing compound
of the formula X.sub.yF.sub.z, said fluorine-containing compound
being optimized to remove silicon and silicon compounds; process
instructions for forming a plasma from said second process gas;
process instructions for maintaining a pressure in the processing
chamber between about 2 mTorr and about 100 mTorr; and process
instructions for monitoring said process for carbon-based compounds
on interior surfaces of said processing chamber for reaching a
predetermined level.
8. The method of claim 7 wherein the second etchant process gas is
essentially oxygen and a flow rate of the process gas is about 100
standard cubic centimeters per minute.
9. The method of claim 7, further including: process instructions
introducing the second process gas containing oxygen into the
processing chamber at a flow rate between about 100 standard cubic
centimeters per minute (sccm) and about 600 sccm; and process
instructions applying a TCP power between about 800 Watts and 1500
Watts.
10. The method of claim 9 wherein said second etchant process gas
containing oxygen is at least about 90% O.sub.2.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. application Ser.
No. 10/139,042 which claims priority to U.S. Provisional Patent
Application Ser. No. 60/288,678 filed May 4, 2001 and entitled
"Plasma Cleaning of Deposition Chamber Residues Using Duo-Step
Wafer-Less Auto Clean Method." These applications are herein
incorporated by reference. This application is related to (1) U.S.
patent application Ser. No. 10/138,980, filed on May 3, 2002, and
entitled "Endpoint Determination of Process Residues in Wafer-less
Auto Clean Process Using Optical Emission Spectroscopy," (2) U.S.
patent application Ser. No. 10/138,288, filed May 2, 2002, and
entitled "High Pressure Wafer-less Auto Clean for Etch
Applications". These applications are hereby incorporated by
reference.
FIELD OF THE INVENTION
[0002] This invention generally relates to an apparatus and method
of cleaning a processing chamber to remove previously deposited
chamber residues, which have accumulated on interior surfaces of
the apparatus. In particular, the invention relates to wafer-less
plasma cleaning methods for elimination of residues on interior
walls, or other components using a two step cleaning process.
BACKGROUND OF THE INVENTION
[0003] In a conventional plasma process, plasma is activated by
reactive gaseous species so that a desired film can be produced on
the substrate or removed from the substrate. The chemically
reactive species includes ions, neutral atoms, and molecules. When
a chemical process, such as plasma etching, is involved, reactive
species interact chemically or physically with the material to be
etched.
[0004] The chemically reactive species are chosen carefully so that
the species are specific to the surface of the substrate that it is
going to interact with. In general, the plasma is controlled by one
or more process parameters, such as: wafer temperature, chamber
surface temperature, pressure, reactant gas flow rate, reactant gas
mix, reactant gas concentration, gas injection distribution, plasma
ion density, and bias voltage. Often such process parameters are
optimized for the reactant species on dummy wafers. The
optimization of the process parameters and the choice of chemically
reactive species are done for the specific process in the form of
design of experiments (more often called a DOE).
[0005] Although care and caution is involved during the monitoring
of a chemical process, more often than not, undesired residues are
deposited on the inner surfaces of the process chambers where the
processes are taking place. The undesired residues, unfortunately,
get deposited in and around the walls of the processing chamber.
The build up of residues inside the processing chamber, over time,
not only make the processes unreliable and shifted from baseline,
but also result in degraded, defective substrates in the form of
defects. Without frequent cleaning procedures, impurities from the
residue build up can migrate onto the substrate. In addition,
process etch rates or deposition rates can vary over time due to
the changing chamber conditions from residue build-up resulting in
out of control process performance. Thus, the maintenance of the
processing equipment is important not only for higher yields and
better product performance of current products but also in the
development of future generation products.
[0006] An important technique to improve the overall quality and
efficiency in the processing of devices is to clean the chamber of
any deposits. Two methods of cleaning a process chamber are dry
etch cleaning and wet cleaning. In the former cleaning operation,
process gases are evacuated from the processing chamber and one or
more process cleaning gases are introduced. Energy is applied to
promote a reaction between the gases and any residues, which may
have accumulated on the processing chamber's interior surfaces.
Residues on the processing chamber's interior react with the
cleaning process gases, forming gaseous by-products which are then
exhausted from the processing chamber, along with unreacted
portions of the cleaning process gases. The cleaning process is
followed by the resumption of normal processing.
[0007] An alternative to dry etching i.e., the in-situ cleaning
procedure, in which the processing chamber remains sealed, is a wet
cleaning procedure that is performed by breaking the processing
chamber's vacuum seal and manually wiping down the chamber's
interior surfaces. A wet cleaning procedure is normally performed
to remove residues that are not entirely removed by the in-situ
cleaning process, and tend to accumulate over time. A solvent is
sometimes used to dissolve these residues. Once cleaned, the
processing chamber is sealed and normal processing is resumed.
[0008] Unfortunately, such cleaning operations affect a substrate
processing system's utilization in a variety of ways. For example,
system utilization is reduced by the time involved in performing
cleaning operations. When a wet clean is performed, opening the
processing chamber and physically wiping the chamber's interior
surfaces results in even more downtime because the processing
environment must subsequently be re-stabilized. The
re-stabilization of the chamber condition requires processing many
wafers to condition the chamber back to the pre-wet clean operating
chamber state without excessive residue build-up.
[0009] FIG. 1 is a flowchart diagram of the method operations for a
composite one step cleaning process for the removal of all chamber
deposition byproducts. The method initiates with operation 10 where
dummy wafers are processed to check for process readiness. The
method then advances to operation 12 where production wafers are
processed. Then, the method moves to operation 14 where the
etchants for both silicon based byproduct removal and carbon based
byproduct removal are combined to run a single step cleaning
operation. If there are more wafers to be processed, the production
wafers are rerun through operations 12 and 14. The method
operations of FIG. 1 can also be performed in wafer-less
conditions, in which case it is considered a one-step (composite)
wafer-less auto clean (WAC) process. Although in some instances,
there may be multiple steps, all these steps are still repeating
composite (both silicon based byproduct removal and carbon based
byproduct removal together) one-step wafer-less auto clean (WAC)
processes.
[0010] Although such a recipe has the advantage that the number of
process steps can be reduced or not, it fails to ensure complete
removal of different byproducts, such as carbon based organic
residues and semiconductor based silicon residues. In fact, the
removal rates for silicon and carbon deposition are in opposition
to each other. The process trends for silicon removal are based
primarily on fluorine-based chemistry while carbon removal are
based primarily on oxygen-based chemistry. As both fluorine-based
and oxygen-based chemistries are mixed together, the removal rates
of both silicon and carbon are not at optimal levels. As the
O.sub.2 concentration increases in the mixture above a certain
limit, the silicon removal rate becomes saturated and reduces
substantially. Rather both silicon and carbon rates are compromised
in a one step composite approach with an immediate removal rate.
Thus, the one step approach can not yield optimized removal rates
for silicon and carbon deposition. In the past, plasma cleans were
used for cleaning etch reactors and deposition reactors with the
wafer in the chamber to cover the electrode, but it has become more
common to do wafer-less plasma cleans. This has led to the use of a
wafer-less auto clean (WAC).
[0011] When a composite WAC recipe for both silicon and carbon
byproduct removal is used involving a specific mixture of separate
etchant gases for silicon removal and for carbon removal, it
suffers from non-optimized lower removal rates of both silicon and
carbon-based deposition byproducts. That is, the one step composite
WAC approach is not tuned to achieve complete by-product removal of
both the silicon and the carbon by-products. In effect, the one
step composite WAC approach compromises the effectiveness of the
removal of the byproducts for the convenience of using a single
all-encompassing WAC chemistry. Thus, the composite WAC recipe
removes both byproduct materials at a mid-range removal rate that
may remove too much of one byproduct and not enough of another
byproduct. Consequently, the chamber will be under-cleaned which
results in a build up of material, or the chamber will be
over-cleaned which results in the degradation of chamber parts and
a shortening of their lifetime. Moreover, when fluorine containing
cleaning gases are used with the composite WAC recipe, non volatile
aluminum fluoride compounds are formed which build up on the inner
surfaces of the chamber. The build up of these compounds causes
variability of the plasma processing operations performed in the
processing chamber. Eventually, the build up can flake off and
deposit onto a wafer being processed.
[0012] Another shortcoming of frequent cleaning operations is that
they tend to increase wear on the processing chamber components
when over-cleaning occurs resulting in decreased lifetime of the
components. In turn, the cost of consumables increases. Thus,
improved methods and apparatus for cleaning semiconductor process
chambers are needed. In particular, the cleaning methods and
apparatus should be capable of removing the residues created during
substrate processing operations, while reducing or eliminating the
subsequent formation of cleaning residues.
[0013] In view of the foregoing, what is needed is a semiconductor
processing chamber configured to optimize chamber byproduct removal
of silicon and carbon based byproducts, such that the removal of
the silicon based byproducts and the carbon based byproducts is
achieved in an efficient manner to provide a consistent environment
inside the chamber for each successive semiconductor substrate
being processed.
SUMMARY OF THE INVENTION
[0014] The present invention provides a method and apparatus
configured for removing silicon and carbon based deposition
byproducts using a two-step cleaning process where each step of the
cleaning process is optimized for removing a specific byproduct.
The first step of the two-step cleaning process is optimized for
removing silicon-based chamber byproducts while the second step of
the two-step cleaning process is optimized for the removal of
carbon-based deposition byproducts. It should be appreciated that
the present invention can be implemented in numerous ways,
including as an apparatus, a system, a device, or a method. Several
inventive embodiments of the present invention are described
below.
[0015] In one embodiment, the method for wafer-less auto clean
process (WAC) involves cleaning the processing chamber by flowing a
first gaseous composition into a processing chamber including at
least about 75% of a fluorine-containing compound of the formula
X.sub.yF.sub.z. Then, a plasma is formed from this first gaseous
composition to provide a first etchant plasma which removes silicon
and silicon based compounds from the interior surfaces of the
processing chamber. The next step involves flowing a second gaseous
composition into the same processing chamber, of a composition
including at least about 50% oxygen of chemical formula O.sub.2.
Then, a plasma is formed from the second gaseous composition to
provide a second etchant plasma which removes carbon and carbon
based compounds from interior surfaces of the processing
chamber.
[0016] In another embodiment of the present invention, the wafers
are processed by first cleaning interior surfaces of a process
chamber with a fluoride plasma including at least about 75% of a
fluorine-containing compound of the formula X.sub.yF.sub.z, with
the plasma being optimized to remove silicon and silicon compounds
and secondly, cleaning the interior surfaces of the process chamber
with an oxygen plasma including at least about 50% O.sub.2, such
that the oxygen plasma is optimized to remove carbon and carbon
compounds. The wafer can be processed in the process chamber after
the first and second cleaning processes.
[0017] In yet another embodiment, a process for cleaning the
interior surfaces of a processing chamber is provided. The process
steps for cleaning the interior surfaces of a processing chamber
for silicon and silicon compounds includes the steps of first
flowing an etchant process gas with a fluorine-containing compound
of the formula X.sub.yF.sub.z optimized to remove silicon and
silicon compounds. Then, a plasma is formed from the etchant
process gas with the fluorine-containing compound. A pressure
within the processing chamber is maintained at a pressure range
between about 2-100 mTorr. The process is monitored for silicon and
silicon compounds on interior surfaces of the processing chamber so
that a predetermined level can be ascertained.
[0018] The process steps for removing carbon based compounds
includes first flowing an etchant process gas containing oxygen,
and an optional fluorine-containing compound of the formula
X.sub.yF.sub.z, in trace amounts such that the fluorine-containing
compound is optimized to remove silicon and silicon compounds from
the previous process step in the two-step process. The plasma
formed from the etchant process gas containing oxygen is maintained
at a pressure range of about 10-100 mTorr inside the processing
chamber. The process for removing carbon-based compounds is
monitored on interior surfaces of the processing chamber so that a
predetermined level is reached.
[0019] In still yet another embodiment of the invention, a plasma
processing system for executing a two step in-situ cleaning process
is provided. The plasma system includes a processing chamber having
a gas inlet for introducing a first cleaning gas and a second
cleaning gas, the first cleaning gas optimized to remove silicon
based byproducts deposited on inner surfaces of the processing
chamber, the second cleaning gas optimized to remove carbon based
byproducts on the inner surfaces of the processing chamber. The
processing chamber also includes a top electrode for creating a
first plasma from the first cleaning gas to perform a first step of
the in-situ cleaning process and then a second plasma from the
second cleaning gas upon completion of the first step. A variable
conductance meter for controlling a pressure inside the processing
chamber independently of a flow rate of the process gases is
included. The variable conductance meter is positioned on an outlet
of the processing chamber. There is an electrostatic chuck for
wafer clamping and temperature control of the wafer. An optical
emission spectrometer (OES) for detecting an endpoint for each step
of the two step in-situ cleaning process performed in the
processing chamber is included. The OES is in communication with
the processing chamber. A pumping system for evacuating the
processing chamber between each step of the two step cleaning
process is included.
[0020] Other aspects and advantages of the invention will become
apparent from the following detailed description, taken in
conjunction with the accompanying drawings, illustrating by way of
example the principles of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0021] The present invention will be readily understood by the
following detailed description in conjunction with the accompanying
drawings, with like reference numerals designating like
elements.
[0022] FIG. 1 is a flowchart diagram of the method operations for a
composite one step cleaning process for the removal of all chamber
deposition byproducts.
[0023] FIG. 2 is a simplified cross-sectional schematic diagram of
a plasma etching system configured to execute a dual step cleaning
process in accordance with one embodiment of the invention.
[0024] FIG. 3 is a flowchart diagram of the method operations
performed for a dual step byproduct removal WAC technique in
accordance with one embodiment of the invention.
[0025] FIG. 4 is a more detailed flowchart diagram of the method
operation of removal of silicon byproduct of FIG. 3.
[0026] FIG. 5 is a more detailed flowchart diagram of the method
operation of removal of carbon byproducts of FIG. 3.
[0027] FIG. 6 is a graph depicting the effect of the WAC process on
the etch rate performance in accordance with one embodiment of the
invention.
[0028] FIG. 7 is a graph of etch rate repeatability using a
Polygate Release recipe where a WAC is performed after each wafer
in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] An invention is described for providing an optimized dual
step wafer-less auto clean method optimized for removing multiple
byproducts deposited onto walls of a semiconductor processing
chamber. It will be obvious, however, to one skilled in the art,
that the present invention may be practiced without some or all of
these specific details. In other instances, well known process
operations have not been described in detail in order not to
obscure the present invention. FIG. 1 is described in the
"Background of the Invention" section.
[0030] The basic concept of plasma etching is rather direct. A glow
discharge is utilized to produce chemically reactive species
(neutral atoms, radicals and ions) from a relatively inert
molecular gas. The etching gas is selected so as to generate
species that react chemically with the material to be etched, and
whose reaction product with the etched material is volatile so that
it can be removed from the processing chamber.
[0031] An ideal dry etch process based solely on chemical
mechanisms for material removal, can thus be broken down into six
steps: 1) reactive species are generated in a plasma, 2) these
species diffuse to the surface of the material being etched, 3) the
species are adsorbed on the surface, 4) a chemical reaction occurs
with the formation of a volatile byproduct 5) the byproduct is
released from the surface, and 6) the released species diffuses
into the bulk of the gas. If any of these steps fail to occur, the
overall etch cycle ceases. However, when the byproduct is released
from the surface it is possible that they are deposited on the
inner surface of the chamber. Thus, over time the inner surfaces of
the chamber can build up a layer of byproducts that may contaminate
a wafer being processed.
[0032] In plasma etching processes an RF diode configuration is
normally used to establish the glow discharge. The glow discharge
is used primarily as a source of energetic ions, which are used to
bombard target surfaces and cause sputtering. That is, the glow
discharge produces reactive species for chemically etching the
surfaces of interest. In plasma etching systems high frequency 13.6
MHz RF diode configurations are primarily used. If a 13.6 MHz
frequency is used for the applied RF power, this frequency is high
enough so that the ions require several RF cycles to traverse the
dark space between the bulk plasma region and the wafer region.
[0033] Knowledge about the potential distribution in plasma etching
systems is useful because the energy with which particles impinge
on the etched surface depends on the potential distribution. In
addition, plasma potential determines the energy with which ions
strike other surfaces in the chamber, and high-energy bombardment
of these surfaces can cause sputtering and consequent redeposition
of the sputtered material. Silicon-based residues are often formed
on the interior surfaces of a processing operation, such as in
deposition and etching operations involving silicon wafers. In
addition, carbon based residues can also be formed on the interior
surfaces when bombarding photoresists used as masks for patterning
of the devices.
[0034] The two step wafer-less auto clean (WAC) of the present
invention efficiently cleans these deposits and allows for a
consistent baseline environment for the beginning of each etch
operation. The two step WAC begins by forming a first plasma from
process etchant gases introduced into the processing chamber. The
first plasma is optimized to react with the silicon-based residues
to form volatile gases that may be removed from the chamber's
interior. Following the first plasma process, a second plasma is
formed from process etchant gases introduced into the processing
chamber. The second plasma is optimized to react with the
carbon-based residues to form gases that may be removed from the
chamber's interior.
[0035] Because silicon residues are more prevalent in the chamber,
the two step method can be configured to spend more time to ensure
removal of the silicon based byproducts and less time so that the
carbon based byproducts are removed without over-cleaning. Thus,
the two step process will not have a significant impact on the
wafer processing throughput of the system as compared to the
composite one step process. Additionally, the optimized two step
process provides for a more uniform chamber conditioning
environment inside the processing chamber between each operation.
Consequently, the repeatability of the etch operation from wafer to
wafer is enhanced because of the consistent environment provided
inside the processing chamber through the two step WAC technique.
That is, the build-up of byproducts on the inner surfaces of the
processing chamber, over time, is substantially eliminated allowing
for stable/repeatable etch rates from wafer to wafer and extended
mean time between cleaning (MTBC).
[0036] FIG. 2 is a simplified cross-sectional schematic diagram of
a plasma etching system configured to execute a dual step cleaning
process in accordance with one embodiment of the invention.
Exemplary plasma etch systems include the 2300 Poly VERSYS
Wafer-less Auto Clean System, also referred to as PolyWAC, and the
TCP 9400PTX both owned by the assignee. Plasma etching system 100
consists of several components, such as etching chamber 102 that is
evacuated to reduced pressure, a pumping system 104 for
establishing and maintaining the reduced pressure, pressure gauges
106 to monitor pressure in the chamber, a variable conductance
meter 108 between pumping system 104 and etching chamber 102 so
that the pressure and flow rate in the etching chamber can be
controlled independently. A radio frequency (RF) power supply 110
creates the glow discharge. Gas handler 112 meters and controls the
flow of reactant gases. Electrodes 114 can be used to strike a
plasma. Optical emission spectroscopy (OES) monitor 116 monitors
wavelengths specific to etching chamber 102 deposition removal
products and chamber deposition removal reactants. An electrostatic
chuck for temperature control and wafer clamping is also included.
It should be appreciated that in the past plasma cleans were used
for cleaning reactors with the wafer in the reactor chamber to
cover the electrode, but it has become more common to do wafer-less
plasma cleans. This has led to the use of a wafer-less auto clean
(WAC). In one embodiment, the operations are computer controlled to
automatically start the wafer-less plasma cleans at set wafer
processing intervals. For example, the WAC process can be run after
each wafer, after a lot of wafers or after some other suitable
interval. In another embodiment, the process parameters discussed
below are input as a recipe and the process parameters are
controlled by a control system, such as a programmable logic
controller that interfaces with the reaction chamber.
[0037] The WAC process has conventionally used a composite one-step
recipe focused on the removal of all chamber deposition byproducts
involving a mixture of etchant gases for the removal of both
silicon based byproducts and carbon based byproducts. However, a
composite WAC recipe for both silicon and carbon byproduct removal
suffers from lower removal rates of both silicon and carbon-based
deposition byproducts. In addition, aluminum fluoride compounds
left behind in the one step recipe adversely impact etch
operations.
[0038] As is known in the art, silicon-based residues are often
formed on the interior surfaces of a processing operation, such as
in deposition and etching operations involving silicon wafers.
Carbon based deposition products are also formed on the chamber
during processing operations due to carbon based photoresist, often
used as the mask for patterning devices. In general, the percentage
of silicon based byproducts to carbon based byproducts is not a 1:1
ratio, since silicon based byproducts are found in a greater amount
than carbon based byproducts. It will be apparent to one skilled in
the art that silicon based byproducts are the predominant chamber
deposition species in Polysilicon Etch equipment. The present
invention provides a method to clean the inner surfaces of
semiconductor processing chamber by forming a plasma from process
etchant gases specific and optimized to the byproduct to be
removed. That is, the cleaning process for the silicon based
byproducts is optimized to efficiently remove silicon based
byproducts, while the cleaning process for the carbon based
byproducts is optimized to efficiently remove carbon based
byproducts. In one embodiment, the targeted byproduct removal
process is a two step process where the first step uses SF.sub.6
chemistry, or other fluorine based chemistry, such as NF.sub.3, to
remove silicon based (inorganic) byproducts. The second step uses
oxygen (O.sub.2) based chemistry to remove carbon based (organic)
byproducts from the chamber walls. The cleaning process is
preferably performed after each wafer, however, any suitable
cleaning frequency may be used. Additionally, the O.sub.2 chemistry
of the second step assists in the purging of any fluorine in order
to substantially prevent the formation of aluminum fluoride
compounds in the aluminum processing chambers.
[0039] FIG. 3 is a flowchart diagram of the method operations
performed for a dual step byproduct removal WAC technique in
accordance with one embodiment of the invention. The method
initiates with operation 142 where silicon byproduct is removed. It
should be appreciated that operation 142 can be performed following
the processing of a wafer or multiple wafers or even following an
initial gas stability operation. Here, a fluorine based etchant gas
is introduced into the chamber and a plasma is struck. The fluorine
based plasma removes the silicon based (inorganic) byproducts from
the inner surfaces of the processing chamber. The method then moves
to operation 144 where a carbon based (organic) byproduct is
removed. Here, an oxygen based (O.sub.2) based etchant gas is
introduced into the chamber and a plasma is struck. It should be
appreciated that the decoupling of the two process steps allows for
each process to be optimized for the particular byproduct. As
mentioned above, when silicon is the predominant chamber deposition
species the time for each process step can be optimized. More
specifically, the time for the silicon cleaning step can be
lengthened while the time for the carbon cleaning step can be
shortened. Thus, the cleaning time does not substantially increase
from the cleaning time for the composite WAC process. It should be
appreciated that the operations can be performed for a specified
amount of time or the cleaning operations can be controlled through
software detection of an endpoint.
[0040] The method then advances to operation 146 where the
production wafers are processed in the chamber. As mentioned above,
multiple wafers may be processed in between cleaning operations or
a single wafer may be processed in between cleaning operations. The
processing performed on the production wafers could be any etch or
deposition process, such as Polygate, shallow trench isolation
(STI) applications and other suitable semiconductor processing
operations that can deposit material on the inner surfaces of the
processing chamber. The method then proceeds to decision operation
148 where it is determined if the processing for the wafer is
completed. If the processing is not complete, then the method
returns to operation 142. The process is repeated until all the
wafers have been completed. If it is determined that the processing
is complete then the method terminates.
[0041] FIG. 4 is a more detailed flowchart diagram of the method
operation of removal of silicon byproduct of FIG. 3. The method
initiates with operation 162 where a fluorine containing gaseous
mixture is introduced into a processing chamber. A suitable
processing chamber is the chamber described with reference to FIG.
2. Fluorine is used as an etchant for the removal of silicon based
compounds. In one embodiment, the fluorine etchant is a gaseous
composition that includes at least about 75% of a
fluorine-containing compound of the formula X.sub.yF.sub.z and is
introduced into a reaction chamber configured to support a
wafer-less auto clean (WAC) process, such as the processing chamber
of FIG. 2. The recipe for removing the silicon byproduct with the
fluorine etchant is optimized for process parameters such as:
temperature, pressure, reactant gas flow rate, transformer coupled
plasma power and bias voltage for maximum removal of silicon and
silicon based compounds from interior surfaces of the processing
chamber. Table 1 below provides process operating ranges for
process parameters in accordance with one embodiment of the
invention. It should be appreciated that the provided ranges may
vary with the different configurations of processing chamber.
Furthermore, the ranges of Table 1 are optimal ranges for a plasma
etch system, such as the 2300 Poly Wafer-less Auto Clean System or
TCP 9400 PTX etch system. As shown below, the flow rate of the
fluorine containing gaseous mixture, i.e., SF.sub.6, of operation
162 can range from about 50 standard cubic centimeters per minute
(sccm) to about 400 sccm in one embodiment of the invention. A
preferred range for the flow rate is between about 50 sccm and
about 100 sccm. TABLE-US-00001 TABLE 1 Parameter Optimal Range Mid
Range Wide Range Pressure 3 mT 2-5 mT <100 mT TCP Power 1000 W
800-1000 W 800-1500 W SF.sub.6 Flow 50 sccm 50-100 sccm 50-400
sccm
[0042] The method then advances to operation 164 where a plasma is
created from the fluorine containing gaseous mixture. The
processing parameters are provided with reference to Table 1. In
particular, the pressure can range between about 0 milliTorr (mT)
and about 100 mT, with a preferred range of between about 2 mT and
about 5 mT. The transformer coupled plasma (TCP) power is between
about 800 watts (W) and about 1500 W, with a preferred range of
between about 800 W and about 1000 W. One skilled in the art will
appreciate that the processing chamber may be configured as a
capacitively coupled chamber or an inductively coupled chamber. For
a capacitively coupled chamber the bottom power would preferably be
set to 0. Additionally, the fluorine containing gas can include a
mixture of SF.sub.6 and NF.sub.3. In one embodiment, the mixture is
a 1:1 ratio of the SF.sub.6 and NF.sub.3 gases. Alternatively, the
NF.sub.3 can replace the SF.sub.6. In another embodiment, the gas
mixture may contain a small percentage of O.sub.2 to assist in
breaking up any fluorine. Here, the O.sub.2 flow rate would be
between about 0% and about 10% of the SF.sub.6 or NF.sub.3 flow
rate. Preferably, there is no O.sub.2 flow rate.
[0043] The method of FIG. 4 then proceeds to operation 166 where
the WAC step for removal of silicon based byproducts is performed.
Here, the silicon clean step, as explained above, is executed with
the process parameters set as described above with reference to
Table 1. The method then advances to decision operation 168 where
it is determined if the silicon byproduct has been removed. In one
embodiment, the endpoint is determined by optical emission
spectroscopy (OES), such as through OES monitor 116 with reference
to FIG. 2.
[0044] FIG. 5 is a more detailed flowchart diagram of the method
operation of removal of carbon byproducts of FIG. 3. The method
initiates with operation 172 where an oxygen (O.sub.2) containing
gaseous mixture is introduced to a semiconductor processing
chamber. It should be appreciated that the O.sub.2 flow may or may
not contain a small percentage of a fluorine containing gas, such
as the fluorine containing gas etchants mentioned above with
reference to FIG. 4. The recipe for removing the carbon byproduct
with the oxygen etchant is optimized for process parameters such
as: temperature, pressure, reactant gas flow rate, TCP power and
bias voltage for maximum removal of carbon and carbon based
compounds from interior surfaces of the processing chamber. Table 2
below provides process operating ranges for process parameters for
a carbon clean where a small amount of a fluorine containing gas is
optional in accordance with one embodiment of the invention. It
should be appreciated that the provided ranges may vary with the
different configurations of the processing chamber. Furthermore,
the ranges of Table 2 are optimal ranges for a plasma etch system,
such as the 2300 Poly Wafer-less Auto Clean System. As shown below,
the flow rate of the oxygen containing gaseous mixture of operation
172 can range from about 100 standard cubic centimeters per minute
(sccm) to about 600 sccm with a preferred oxygen flow rate of about
100 sccm. TABLE-US-00002 TABLE 2 Optimal Parameter Range Mid Range
Wide Range Pressure 10 mT 10-40 mT <100 mT TCP Power 1000 W
800-1000 W 800-1500 W O.sub.2 Flow 100 sccm 100-500 sccm 100-600
sccm SF.sub.6 Flow (10% O.sub.2 10 sccm (0-10% O.sub.2 Flow (0-10%
O.sub.2 Flow Flow Max) Max) Max)
[0045] The method of FIG. 5 then advances to operation 174 where a
plasma is created from the oxygen containing gaseous mixture. The
processing parameters are provided with reference to Table 2. For
example, the pressure can range between about 0 milliTorr (mT) and
about 100 mT with a preferred pressure of about 10 mT. The
transformer coupled plasma (TCP) power is between about 800 watts
(W) and about 1500 W. One skilled in the art will appreciate that
the processing chamber may be configured as a capacitively coupled
chamber or an inductively coupled chamber. For a capacitively
coupled chamber the bottom power is preferably set to 0. The
fluorine containing gas can be introduced at a flow rate of between
about 0% and about 10% of the maximum flow rate of the oxygen
containing gas. It will be apparent to one skilled in the art that
while SF.sub.6 is listed as the fluorine containing gas, other
fluorine containing gases, such as NH.sub.3 can be substituted. In
one embodiment, the oxygen containing gas is introduced with an
inert gas into the processing chamber. For example, the oxygen
containing gas can be mixed with nitrogen, argon, helium, etc. In
this embodiment, the inert gas flow rate is between about 0% and
20% of the maximum flow rate of the oxygen containing gas.
[0046] The method of FIG. 5 then proceeds to operation 176 where
the WAC step for the removal of carbon based byproducts is
performed. Here, the carbon clean step, as explained above, is
executed with the process parameters set as described with
reference to Table 2 or Table 3. In decision operation 178 it is
determined if the carbon byproduct has been removed. In one
embodiment, the endpoint is determined by optical emission
spectroscopy (OES), such as through OES monitor 116 with reference
to FIG. 2.
[0047] As the addition of a fluorine containing gas is optional
during the carbon clean step, Table 3 lists the process parameters
for a carbon clean step in which only an oxygen containing gas is
used to create a plasma, in accordance with one embodiment of the
invention. It should be appreciated that the ranges provided in
Table 3 are substantially similar to the ranges provided in Table 2
above, except that Table 3 eliminates the fluorine containing gas.
TABLE-US-00003 TABLE 3 Parameter Optimal Range Mid Range Wide Range
Pressure 10 mT 10-40 mT <100 mT TCP Power 1000 W 800-1000 W
800-1500 W O2 Flow 100 sccm 100-500 sccm 100-600 sccm
[0048] It is preferred to perform the two step process with the
silicon clean step performed first and the carbon clean step
performed second. However, the order of the steps can be reversed.
The amount of the fluorine containing gas in the carbon-clean step
is limited so that the oxygen containing gas can effectively
prevent aluminum fluoride compounds from building up on the inner
surfaces of the processing chamber from the carbon clean step. The
one step WAC recipe leaves a deposit of aluminum fluoride on the
chamber surface.
[0049] As discussed above, the endpoints for the silicon clean step
and the carbon clean step can employ optical emission spectroscopy
(OES) to monitor wavelengths specific to chamber deposition removal
products and chamber deposition removal reactants. The specific
wavelengths for fluorine containing compounds are 309 nm
representative of SiF.sub.x species, 390 nm for SiF2, and 680 nm
for reactant fluorine (chemical symbol F). An initial base line
constitutes the wavelengths recorded from a clean chamber state and
used as threshold or nominal values for OES intensity. The
intensity of the specific wavelengths is noted for slope as a
function of time. When intensity curves for the specific
wavelengths shows zero slope, it is indicative of no additional
cleaning occurring and no change in the relative concentration of
the reactant or product species. In one embodiment, the WAC
endpoint time for the silicon based byproduct is reached when the
recommended wavelengths (390 nm, 309 nm or 680 nm) produce the
initial clean chamber intensities and intensity curve slope of zero
with time. The specific wavelength for oxygen containing compounds
(such as carbon monoxide or CO) is 520 nm. Therefore, the WAC
endpoint time for the carbon based compounds will be reached when
the 520 nm wavelength produces the initial clean chamber
intensities and intensity curve slope of zero with time. In the
case of carbon based compounds, the intensity slope is noted for
oxygen containing compounds since the etchants are oxygen based. It
should be appreciated that when fluorine containing compounds are
included in the carbon clean, then all the above listed wavelengths
can be monitored to determine an endpoint.
[0050] Table 4 summarizes the two step WAC recipe in accordance
with one embodiment of the invention. As mentioned above, the
endpoint times for the silicon clean times and the carbon clean
times can be determined based upon a signal for an OES monitor. The
OES monitor is configured to detect the appropriate wavelengths and
the signals are then compared to a baseline signal of a clean
chamber state. TABLE-US-00004 TABLE 4 Step Number 1 2 3A 3B Step
Type Stability Silicon Carbon Clean-2 Carbon Clean-2 Clean-1
(O.sub.2 only) (O.sub.2 + fluorine compound) Pressure 3 mT 3 mT 10
mT 10 mT TCP Power 0 1000 W 1000 W 1000 W Bias Voltage 0 0 0 0
O.sub.2 N/A N/A 100 sccm 100 sccm SF.sub.6 50 sccm 50 sccm 10 sccm
10 sccm Inert gas N/A N/A 20 sccm N/A Completion Stable Time Time
Time basis Time (sec) 30 17 6 6
[0051] One skilled in the art will appreciate that the stability
step conditions the environment inside the chamber so the
environment is stable and consistent prior to starting the silicon
clean step. As mentioned above the carbon clean step can be
performed with an oxygen containing compound only or with an oxygen
containing compound and a fluorine containing compound.
Additionally, an inert gas can be introduced with an oxygen
containing compound in step number 3A or 3B. Table 4 is shown for
exemplary purposes only and not meant to be limiting. In addition
to the process parameters varying between processing chamber
designs, values for the parameters within the ranges provided in
Tables 1-3 can also be substituted.
[0052] As shown by Table 4, the time allotted for the silicon clean
step and the carbon clean step can be tailored to the type of
process. That is, if the process deposits more silicon based
byproducts on the chamber walls, then the silicon clean step is
configured to remove the deposited by products without
over-cleaning or under-cleaning. In turn, a more consistent
environment is provided for substantially eliminating etch rate
drift due to varying chamber conditioning. Since the silicon based
deposition byproducts are more completely removed as compared to a
composite recipe, there is no longer a surface area larger than the
wafer for absorbing/desorbing reactant species during etching
operations. Similarly, since the carbon based byproducts tend to be
accumulated in a lesser amount than the silicon based byproducts,
the time allotted for the carbon clean step can be reduced in order
to efficiently clean the carbon based byproducts. Accordingly, the
overall cleaning time as compared to the one step composite process
is not significantly different. While Table 4 provides specific
times for each step, each of the steps can be controlled through
the detection of an endpoint by an OES monitor configured to detect
certain wavelengths. Here, the OES monitor would detect the
endpoint and output a signal to trigger the completion of the
respective cleaning step.
[0053] FIG. 6 is a graph depicting the effect of the WAC process on
the etchrate performance in accordance with one embodiment of the
invention. It is known that initial etch rates are lower from a
clean chamber until a sufficient number of conditioning wafers are
employed to stabilize the etch rate which in turn slowly drifts
over the course of the mean time between cleaning (MTBC) cycles.
Line 200 represents an oxide etch rate where a WAC is performed at
different time periods. A waferless autoclean is performed after
each wafer up to point 202. Then, 5 bare silicon wafers are
processed after point 202 without performing a WAC. As shown, there
is approximately a 27% increase in the oxide etch rate on a pattern
oxide wafers without a WAC vs. with a WAC after every wafer. That
is, the wafer etched following the 5 bare wafers performed without
a WAC, experiences a 27% increase in etch depth. It should be
appreciated that at point 204, the WAC is resumed after every
wafer.
[0054] Still referring to FIG. 6, the photoresist (PR) etch rate,
represented by line 206, is similarly impacted when compared with
and without WAC performed after every wafer being processed. That
is, between point 208 and 210, where 5 bare silicon wafers are
processed, there is approximately a 25% increase in the PR etch
rate. Likewise, once the WAC are resumed at point 210 the etch rate
stabilizes from wafer to wafer. Accordingly, performing the WAC
after every cycle provides a constant starting point for each etch
operation, thereby enabling minimal variation of the etch rate from
wafer to wafer. It should be appreciated that the WAC allows for
the repeatability of the etch rate, within a narrow range, for each
successive etch operation.
[0055] FIG. 7 is a graph of etch rate repeatability using a
Polygate Release recipe where a WAC is performed after each wafer
in accordance with one embodiment of the invention. Lines 212, 214,
216 and 218 represent poly main etch, poly over etch, oxide main
etch and photoresist main etch, respectively. The etch rate
repeatability and stability from the first wafer to the 25.sup.th
wafer was measured when a WAC was performed initially and after
each wafer was processed. The etch rate repeatability and stability
over the 25 wafers with a WAC performed between each wafer was
within 0.7% for the poly main etch, 2.6% for the poly over etch,
3.1% for the oxide main etch and 4.6% for the photoresist main
etch. Accordingly, by providing a consistent environment from wafer
to wafer, along with standardizing the starting conditions through
the performance of a WAC that is designed for optimization of each
of the silicon and carbon byproducts, tighter control over the etch
rates is accomplished. In turn, the critical dimensions defined
through the etching processes are controlled within suitable
ranges.
[0056] In summary, the two step cleaning process is optimized for
multiple byproducts to provide a consistent environment for
processing operations. The consistent environment allow for the
repeatability and reproducibility of the processing operations with
minimal wafer to wafer variation. Although the foregoing invention
has been described in some detail for purposes of clarity of
understanding, it will be apparent that certain changes and
modifications may be practiced within the scope of the appended
claims. Accordingly, the present embodiments are to be considered
as illustrative and not restrictive, and the invention is not to be
limited to the details given herein, but may be modified within the
scope and equivalents of the appended claims.
* * * * *