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Title:
APPARATUS FOR IMPROVING PLASMA DISTRIBUTION AND PERFORMANCE IN AN INDUCTIVELY COUPLED PLASMA
Document Type and Number:
WIPO Patent Application WO/2000/058995
Kind Code:
A2
Abstract:
A processing system (12) for processing a substrate (18) with a plasma (28) comprises a processing chamber (13) defining a processing space (14) and including a substrate support (17) therein for supporting a substrate (18) in the processing space (14) and a gas inlet (20) for introducing a process gas into said processing space (14). A plasma source is operable for creating a plasma (28) in the processing space (14) from process gas introduced therein. The plasma source comprises a dielectric window (24a) which interfaces with the processing chamber (12) proximate the processing space (14) and an inductive element (10) positioned outside of the chamber (12) and proximate the dielectric window (24a). The inductive element (10) is operable for coupling electrical energy through the dielectric window (24a) and into the processing space (14) to create a plasma (28) therein and comprises a variety of alternative designs for providing a dense, uniform plasma.

Inventors:
BRCKA JOZEF
CONSOLI PAUL LOUIS
Application Number:
PCT/US2000/007902
Publication Date:
October 05, 2000
Filing Date:
March 23, 2000
Export Citation:
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Assignee:
TOKYO ELECTRON LTD (JP)
TOKYO ELECTRON ARIZONA INC (US)
International Classes:
H05H1/46; B01J19/08; C23C14/34; C23C16/507; H01J37/32; H01L21/205; H01L21/302; H01L21/3065; (IPC1-7): H01J37/32
Domestic Patent References:
WO2000036632A22000-06-22
Foreign References:
US5648701A1997-07-15
EP0553704A11993-08-04
EP0813227A21997-12-17
US5368710A1994-11-29
EP0840350A21998-05-06
US5650032A1997-07-22
EP0838843A21998-04-29
US5800619A1998-09-01
EP0756309A11997-01-29
EP0820086A11998-01-21
US5122251A1992-06-16
Attorney, Agent or Firm:
Summe, Kurt A. (Herron & Evans L.L.P. 2700 Carew Tower Cincinnati, OH, US)
LLOYD WISE , TREGEAR & CO. (Commonwealth House 1-19 New Oxford Street London WC1A 1LW, GB)
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Claims:
AMENDED CLAIMS [received by the International Bureau on 6 December 2000 (06.12.00); original claims 19,28,56 and 58 amended; remaining claims unchanged (21 pages)]
1. A processing system for processing a substrate with a plasma, the system comprising: a processing chamber defining a processing space and including a substrate support therein for supporting a substrate in the processing space; a gas inlet for introducing a process gas into said processing space; a plasma source operable for creating a plasma in the processing space from process gas introduced therein, the plasma source comprising : a dielectric window having a generally planar surface, the dielectric window interfacing with the processing chamber proximate the processing space; an inductive element positioned outside of the chamber and proximate the dielectric window, the inductive element operable for coupling electrical energy through the dielectric window and into the processing space to create a plasma therein; the inductive element comprising a coil having multiple coil turns disposed successively along the length of the coil, at least one of said coil turns being oriented in a first plane, at least one of said coil turns being oriented in a second plane which is angled from the first plane.
2. The processing system of claim 1 wherein said first plane is oriented generally parallel to the planar surface of the dielectric window.
3. The processing system of claim 1 wherein said inductive element comprises another coil turn oriented in the first plane, the coil turn in the second plane being positioned generally between the coil turns in the first plane.
4. The processing system of claim 1 wherein said inductive element includes multiple coil turns oriented in the first plane.
5. The processing system of claim 1 wherein said inductive element includes multiple coil turns oriented in a plane which is angled from the first plane.
6. The processing system of claim 1 wherein at least one of said coil turns has a semicircular shape.
7. The processing system of claim 1 wherein at least one of said coil turns has a rectangular shape.
8. The processing system of claim 1 further comprising at least one coil turn oriented in a third plane angled between the first and second planes.
9. The processing system of claim 1 wherein said coil turn in the first plane which defines an inner coil end and an outer coil end, the coil turn in the second plane coupled to the outer coil end of the first plane coil turn.
10. The processing system of claim 1 wherein said coil turn in the first plane defines an inner coil end and an outer coil end, the coil turn in the second plane coupled to the inner coil end of the first plane coil turn.
11. The processing system of claim 1 wherein the inductive element further comprises a coil turn having a portion thereof oriented in the first plane and a portion thereof oriented in the second plane.
12. The processing system of claim 1 wherein said second plane is oriented to be generally perpendicular to the first plane.
13. The processing system of claim 1 wherein said processing chamber has a sidewall section formed of a dielectric material, the processing system further comprising: a second inductive element positioned proximate the sidewall section for further coupling electrical energy into the processing space through the sidewall section.
14. The processing system of claim 13 wherein said second inductive element comprises a coil wrapped around the chamber sidewall section.
15. The processing system of claim 13 wherein the first and second inductive elements are each coupled to an electrical energy source for coupling electrical energy into the processing space, the electrical energy sources being independently operable from one another for independently biasing the first and second inductive elements.
16. The processing system of claim 13 further comprising a Faraday shield positioned between said second inductive element and the processing space.
17. The processing system of claim 1 further comprising a Faraday shield positioned between the inductive element and the processing space.
18. The processing system of claim 1 further comprising a mount in the processing chamber configured for holding a target of material.
19. A processing system for processing a substrate with a plasma, the system comprising: a processing chamber defining a processing space and including a substrate support therein for supporting a substrate in the processing space; a gas inlet for introducing a process gas into said processing space; a plasma source operable for creating a plasma in the processing space from process gas introduced therein, the plasma source comprising: a dielectric window having a planar surface, the dielectric window interfacing with the processing chamber proximate the processing space; an inductive element positioned outside of the chamber and proximate the dielectric window, the inductive element operable for coupling electrical energy through the window and into the processing space to create a plasma therein; the inductive element comprising a coil having multiple coil turns, each coil turn comprising a predominant arcuate portion coupled to a linear portion, the predominant arcuate portions of first and second coil turns of the inductive element being oriented in spaced and generally parallel planes to form stacked coil turns, the stacked coil turns oriented generally parallel to said dielectric window planar surface.
20. The processing system of claim 19 wherein the inductive element comprises multiple sets of stacked coil turns.
21. The processing system of claim 19 wherein said processing chamber has a sidewall section formed of a dielectric material, the processing system further comprising: a second inductive element proximate the sidewall section for further coupling electrical energy into the processing space.
22. The processing system of claim 21 wherein said second inductive element comprises a coil wrapped around the chamber sidewall section.
23. The processing system of claim 21 wherein the first and second inductive elements are each coupled to an electrical energy source for coupling electrical energy into the processing space, the electrical energy sources being independently operable from one another for independently biasing the first and second inductive elements.
24. The processing system of claim 21 further comprising a Faraday shield positioned between said second inductive element and the processing space.
25. The processing system of claim 19 further comprising a Faraday shield positioned between the inductive element and the processing space.
26. The processing system of claim 19 wherein the inductive element further comprises a third coil turn oriented at an angle with respect to said stacked coil turns.
27. The processing system of claim 21 further comprising a mount in the processing chamber configured for holding a target of material.
28. A processing system for processing a substrate with a plasma, the system comprising: a processing chamber defining a processing space and including a substrate support therein for supporting a substrate in the processing space; a gas inlet for introducing a process gas into said processing space; a plasma source operable for creating a plasma in the processing space from process gas introduced threrein, the plasma source comprising: a dielectric window having a generally planar surface, the dielectric window interfacing with the processing chamber proximate the processing space; an inductive element positioned outside of the chamber and proximate the dielectric window, the inductive element operable for coupling electrical energy through the dielectric window and into the processing space to create a plasma therein; the inductive element comprising a plurality of repeated conductor segments arranged in a noncoil fashion and positioned in a circular pattern around a center of the inductive element the repeated conductor segments being oriented in planes generally parallel to the planar surface of said dielectric window.
29. The processing system of claim 28 wherein the repeated conductor segments are disposed to extend radially outwardly from a center of the inductive element.
30. The processing system of claim 28 wherein the repeated conductor segments form individual coils, the coils being arranged in a circular pattern around the center of the inductive element.
31. The processing system of claim 28 wherein the chamber comprises an end wall portion and a sidewall portion, the repeated conductor segments including horizontal segments oriented along an end wall portion of the chamber and vertical segments oriented along a sidewall portion of the chamber.
32. The processing system of claim 28 wherein said processing chamber has a sidewall section formed of a dielectric material, the system further comprising: a second inductive element positioned proximate the sidewall section for further coupling electrical energy into the processing space through the sidewall section.
33. The processing system of claim 32 wherein said second inductive element comprises a coil wrapped around the chamber sidewall section.
34. The processing system of claim 32 wherein the first and second inductive elements are each coupled to an electrical energy source for coupling electrical energy into the processing space, the electrical energy sources being independently operable from one another for independently biasing the first and second inductive elements.
35. The processing system of claim 32 further comprising a Faraday shield positioned between said second inductive element and the processing space.
36. The processing system of claim 28 further comprising a Faraday shield positioned between the inductive element and the processing space.
37. The processing system of claim 28 wherein the repeated conductor segments of the inductive element form a first layer of the element, the inductive element further comprising an additional layer of repeated conductor segments.
38. The processing system of claim 37 wherein said layers are generally coextensive.
39. The processing system of claim 32 further comprising a target mount in the processing chamber configured for holding a target of material.
40. A processing system for processing a substrate with a plasma, the system comprising : a processing chamber defining a processing space and including a substrate support therein for supporting a substrate in the processing space; the processing chamber having a sidewall portion and an endwall portion formed of a dielectric material ; a plasma source operable for creating a plasma in the processing space from process gas introduced therein, plasma source comprising: an inductive element positioned outside of the chamber and operable for coupling electrical energy into the processing space to create a plasma therein; the inductive element comprising a coil having multiple coil turns, each of the turns including a segment thereof oriented along said chamber sidewall portion and a segment thereof oriented along said chamber end wall portion for coupling energy simultaneously into the processing space through both the sidewall and end wall portions of the chamber.
41. The processing chamber of claim 40 wherein said inductive element comprises a coil having sets of coil turns, one set of turns being positioned generally along on one side of the chamber and another set of turns being positioned generally along another side of the chamber.
42. The processing system of claim 40 wherein the segment of the coil turn oriented along the chamber sidewall portion includes a section oriented in a first orientation and a section oriented in a second orientation which is angled from the first orientation.
43. The processing system of claim 42 wherein the first orientation is generally perpendicular to the second orientation.
44. The processing system of claim 40 wherein said processing chamber has a sidewall section formed of a dielectric material, the chamber sidewall section being positioned below said sidewall portion and endwall portion, the system further comprising: a second inductive element proximate the sidewall section for further coupling electrical energy into the processing space through the sidewall section.
45. The processing system of claim 44 wherein said second inductive element comprises the form of a coil wrapped around the chamber sidewall section.
46. The processing system of claim 44 wherein the first and second inductive elements are each coupled to an electrical energy source for coupling electrical energy into the processing space, the electrical energy sources being independently operable from one another for independently biasing the first and second inductive elements.
47. The system of claim 44 further comprising a Faraday shield positioned between said second inductive element and the processing space.
48. The system of claim 40 further comprising a Faraday shield positioned between the inductive element and the processing space.
49. The processing system of claim 40 further comprising a mount in the processing chamber configured for holding a target of material.
50. An element for coupling electrical energy into a processing chamber to generate a plasma from a process gas in the chamber, the element comprising: an electrically conductive element comprising a coil having multiple coil turns disposed successively along the length of the coil, at least one of the coil turns being oriented in a first plane, at least one of the coil tums being oriented in a second plane which is angled from said first plane.
51. The element of claim 50 further comprising another coil turn oriented in the first plane, the coil turn in the second plane being positioned generally between the coil turns in the first plane.
52. The element of claim 50 further comprising multiple coil turns oriented in the first plane.
53. The element of claim 50 further comprising multiple coil turns, each turn oriented in a plane generally parallel to said second plane.
54. The element of claim 50 further comprising at least one coil turn oriented in a third plane angled between the first and second planes.
55. The element of claim 50 wherein said second plane is oriented generally perpendicular to the first plane.
56. An element for coupling electrical energy into a processing chamber to generate a plasma from a process gas in the chamber, the element comprising: an electrically conductive element comprising a coil having multiple coil turns, each coil turn comprising a predominantly arcuate portion coupled to a linear portion, the predominantly arcuate portions of first and second coil turns of the element being oriented in spaced and generally parallel planes to form stacked coil tums ; the linear portions of the first and second coil turns being substantially coplanar and located in a plane which is generally parallel to the spaced and parallel planes containing the arcuate portions of the coil turns.
57. The element of claim 56 wherein the inductive element comprises multiple sets of stacked coil turns positioned adjacent to each other.
58. An element for coupling electrical energy into a processing chamber through a dielectric window defining a plane to generate a plasma from a process gas in the chamber, the element comprising: an electrically conductive element comprising a plurality of discrete, repeated conductor segments, the discrete, repeated segments arranged in a noncoil fashion and positioned in a circular pattern around a center wherein the circular pattern of the discrete segments leaves the center of the pattern generally open, the element configured to be oriented such that the repeated segments are oriented in planes generally parallel to the plane defined by the dielectric window.
59. The element of claim 58 wherein the repeated conductor segments are disposed to extend radially outwardly from a center of the electrically conductive element.
60. The element of claim 59 wherein the repeated conductor segments form individual coils, the coils being arranged in a circular pattern around the center of the inductive element.
61. The element of claim 59 wherein each of the individual coils are helical in shape and include approximately one and onehalf coil turns.
62. The element of claim 58 wherein the repeated conductor segments of the conductive element form a first layer of the element, the conductive element further comprising an additional layer of repeated conductor segments.
63. The element of claim 62 wherein the layers are generally co extensive.
64. An element for coupling electrical energy into a processing chamber having a sidewall portion and an end wall portion, the element operable to generate a plasma from a process gas in the chamber, the element comprising: an electrically conductive element comprising a coil having multiple coil turns, each of the turns including a segment thereof oriented for being positioned along a chamber sidewall portion and a segment thereof oriented for being simultaneously positioned along a chamber end wall portion for coupling electrical energy into the processing space through both the sidewall and end wall portions of the chamber.
65. The element of claim 64 wherein the conductive element comprises a coil having multiple coil turns arranged in sets of coil turns, at least one set of turns being oriented generally along one side of the chamber and another set of turns being oriented along another side of the chamber.
66. The element of claim 64 wherein the segment of the coil turn oriented along the chamber sidewall portion includes a section oriented in a first orientation and a section oriented in a second orientation which is angled from the first orientation.
67. The element of claim 66 wherein the first orientation is generally perpendicular to the second orientation.
Description:
INTERNATIONALSEARCHREPORT r---.,,,,-------) Internal Application No PCT/US00/07902 C.(Continuation)DOCUMENTSCONSIDEREDTOBERELEVANT CategoryCitationofdocument,withindication,whereappropriate,o ftherelevantpassagesRelevanttoclaimNo. XEP0840350A(APPLIEDMATERIALSINC)19,20,56 6May1998(1998-05-06) Yabstract21,22, figures6,17A,20,2124,26, 42,66 XUS5650032A(FORSTERJOHNCURTETAL)19,24,56 22July1997(1997-07-22) column3,line41-53;figures1,4,5 Y 21, 2Z, 26,42,66 AEP0838843A(APPLIEDMATERIALSINC)28,58 29April1998(1998-04-29) abstract figures30A-31C Yfigure2524,26, 42,66 Xfigures10-12,45,54-5740,64 AUS5800619A(BARNESMICHAELSETAL)28,58 1September1998(1998-09-01) abstract figures2-5 EWO0036632A(BENNETTPAULGEORGE;TRIKON28,58 HOLDINGSLTD(GB)) 22June2000(2000-06-22) abstract figures7,8,13,16-18,24 XEP0756309A(APPLIEDMATERIALSINC)40,64 29January1997(1997-01-29) Yabstract21,22, figures1-3,526,42,66 XEP0820086A(APPLIEDMATERIALSINC)40,64 21January1998(1998-01-21) abstract figure4 Y21,22 YUS5122251A(SHOJITATSUOETAL)26,42,66 16June1992(1992-06-16) abstract figures2-5 4 Int. ationalapplicationNo. INTERNATIONALSEARCHREPORTPCT/US00/07902 Box IObservationswherecertainclaimswerefoundunsearchable(Continu ationofitem1offirstsheet) ThisInternationalSearchReporthasnotbeenestablishedinrespecto fcertainclaimsunderArticle17(2)(a)forthefollowingreasons: 1.ClaimsNos.: becausetheyrelatetosubjectmatternotrequiredtobesearchedbythi sAuthority,namely: 2.ClaimsNos.: becausetheyrelatetopartsoftheInternationalApplicationthatdon otcomplywiththeprescribedrequirementstosuch anextentthatnomeaningfulInternationalSearchcanbecarriedout,s pecifically: 3.1 Claims Nos.: becausetheyaredependentclaimsandarenotdraftedinaccordancewit hthesecondandthirdsentencesofRule6.4(a). Box 11Observationswhereunityofinventionislacking(Continuationofi tem2offirstsheet) ThisinternationalSearchingAuthorityfoundmultipleinventionsin thisinternationalapplication,asfollows: seeadditionalsheet 1. As allrequiredadditionalsearchfeesweretimelypaidbytheapplicant, thisInternationalSearchReportcoversall searchableclaims. 2.As aitsearchableclaimscouldbesearchedwithouteffortjustifyingana dditionalfee,thisAuthoritydidnotinvitepayment ofanyadditionalfee. 3.! As on ! ysomeoftherequiredadditionalsearchfeesweretimelypaidbytheapp licant,thisInternationalSearchReport coversonlythoseclaimsforwhichfeeswerepaid,specificallyclaims Nos.: 4.Norequiredadditionalsearchfeesweretimelypaidbytheapplicant .Consequently,thisInternationalSearchReportis restrictedtotheinventionfirstmentionedintheclaims;itiscovere dbyclaimsNos.: RemarkonProtest2 Theadditionalsearchfeeswereaccompaniedbytheapplicant'sprotes t. 3Noprotestaccompaniedthepaymentofadditionalsearchfees.

FURTHER INFORMATION CONTINUED FROM PCT/ISA/210 This International Searching Authority found multiple (groups of) inventions in this international application, as follows: 1. Claims: 1-18,50-55 multiple coil turns, at least one turn in angled plane 2. Claims: 19-27,56,57 stacked coil turns, parallel to window 3. Claims: 28-39,58-63 repeated conductor segments arranged in non-coil fashion 4. Claims: 40-49,64-67 multiple coil turns at sidewall and end wall portions INTERNATIONALSEARCHREPORT| Inter. jnalApplicationNo mformation on patent family members PatentdocumentPublication Patent family Publication citedinsearchreportdate member(s)date US5648701A15-07-1997AU 5017293 A 29-03-1994 WO 9406263 A 17-03-1994 EP0553704A04-08-1993US 5280154 A 18-01-1994 DE 69302029 D 09-05-1996 DE 69302029 T 24-10-1996 JP 1969704 C 18-09-1995 JP 5275383 A 22-10-1993 JP 6080641 B 12-10-1994 EP0813227A17-12-1997US 5759280 A 02-06-1998 US 5800619 A 01-09-1998 CA 2207154 A 10-12-1997 JP 10125497 A 15-05-1998 US 6027603 A 22-02-2000 US 5975013 A 02-11-1999 US5368710A29-11-1994US 5226967 A 13-07-1993 AT 157197 T 15-09-1997 DE 69313275 D 25-09-1997 DE 69313275 T 04-12-1997 EP 0640244 A 01-03-1995 ES 2105263 T 16-10-1997 JP 7508125 T 07-09-1995 WO 9323874 A 25-11-1993 EP0840350A06-05-1998EP 0840349 A 06-05-1998 JP 10241894 A 11-09-1998 JP 10241895 A 11-09-1998 US 6095084 A 01-08-2000 US5650032A22-07-1997JP 8339897 A 24-12-1996 EP0838843A29-04-1998US 6054013 A 25-04-2000 JP 10189296 A 21-07-1998 US 6036878 A 14-03-2000 US5800619A01-09-1998CA 2207154 A 10-12-1997 EP 0813227 A 17-12-1997 JP 10125497 A 15-05-1998 US 5975013 A 02-11-1999 WO0036632A22-06-2000GB 2344930 A 21-06-2000 EP0756309A29-01-1997JP 3017944 B 13-03-2000 JP 9120898 A 06-05-1997 EP0820086A21-01-1998US 5897712 A 27-04-1999 JP 10106797 A 24-04-1998 US5122251A16-06-1992US 4990229 A 05-02-1991 AT 151569 T 15-04-1997 AU 1352192 A 07-09-1992 DE 69218924 D 15-05-1997 DE 69218924 T 15-01-1998 EP 0570484 A 24-11-1993 ES 2102497 T 01-08-1997 JP 6506084 T 07-07-1994 INTERNATIONALSEARCHREPORT------------------) Interr. nal ApplicationNo informationonpatenttamilymembers PCT/US00/07902 PatentdocumentPublicationPatentfamilyPublication citedinsearchreportdatemember(s)date US5122251AKR231221B15-11-1999 WO9214258A20-08-1992 US5421891A06-06-1995 US5429070A04-07-1995 EP0403418A19-12-1990 JP2103088C22-10-1996 JP3068773A25-03-1991 JP8014026B14-02-1996 US5091049A25-02-1992