CN104025280B - Method and apparatus for processing a substrate - Google Patents
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Abstract
Description
技术领域technical field
本发明的实施方式大体涉及半导体处理。Embodiments of the invention relate generally to semiconductor processing.
背景技术Background technique
一些传统的半导体制造工艺,例如退火工艺,可能需要处理腔室被维持在较高的温度和较低的压力下以执行处理。然而,本发明人已经观察到,在这样的温度和压力下执行处理,可能引起不期望的状况:基板上材料的升华或掺杂剂的扩散。例如,当将含硅基板退火时,在处理腔室内的氧(例如,水分、来自在处理腔室中执行的先前处理所剩余的材料、来自第一气源的泄漏物或类似物)可能会攻击基板的表面,形成氧化硅。然后氧化硅可凝结于处理腔室的表面上,例如,侧壁、反射板、高温计或类似者。为了保持处理的一致性,处理腔室需要定期维护以除去凝结的材料,从而降低了处理效率和产量。Some conventional semiconductor manufacturing processes, such as annealing processes, may require the processing chamber to be maintained at a higher temperature and lower pressure to perform processing. However, the inventors have observed that performing the process at such temperatures and pressures may give rise to undesired conditions: sublimation of material on the substrate or diffusion of dopants. For example, when annealing a silicon-containing substrate, oxygen (e.g., moisture, material left over from a previous process performed in the processing chamber, leakage from a first gas source, or the like) within the processing chamber may Attacks the surface of the substrate, forming silicon oxide. The silicon oxide may then condense on surfaces of the processing chamber, eg, sidewalls, reflective plates, pyrometers, or the like. To maintain consistent processing, processing chambers require regular maintenance to remove condensed material, reducing processing efficiency and throughput.
通常情况下,在诸如快速热处理(RTP)腔室之类的处理腔室中,具有低浓度的氧的气体可流向基板的前侧,以防止上述升华。然而,这种传统的处理腔室在基板的前侧与背侧之间的气体传导性方面通常具有较大的差异。这种气体传导性差异导致到达基板的背侧以防止材料从基板背侧升华的氧气量不足。Typically, in processing chambers such as rapid thermal processing (RTP) chambers, a gas with a low concentration of oxygen may flow towards the front side of the substrate to prevent the aforementioned sublimation. However, such conventional processing chambers typically have a large difference in gas conductance between the front and back sides of the substrate. This difference in gas conductivity results in an insufficient amount of oxygen reaching the backside of the substrate to prevent sublimation of the material from the backside of the substrate.
因此,本发明提供了用于处理基板的改进的方法和设备。Accordingly, the present invention provides improved methods and apparatus for processing substrates.
发明内容Contents of the invention
在此提供一种用于处理基板的方法和设备。在一些实施方式中,一种处理设置于处理腔室中的基板的方法可包括:在基板上执行处理,所述基板设置于处理腔室中,所述处理腔室具有基板支撑环和反射板,所述基板支撑环配置成支撑所述基板,所述反射板设置成接近所述基板的背侧;在所述基板上执行所述处理期间,经由一个或更多个通孔提供第一气体至所述基板的背侧,所述第一气体包括含氧气体或含氮气体之一,所述通孔设置于反射板中;以及将所述处理腔室维持在第一压力和第二压力下,所述第一压力接近所述基板的顶表面并且所述第二压力接近所述基板的底表面,其中所述第一压力大于所述第二压力而足以在处理期间防止所述基板从所述基板支撑环移位。A method and apparatus for processing a substrate is provided herein. In some embodiments, a method of processing a substrate disposed in a processing chamber may include performing processing on a substrate disposed in the processing chamber having a substrate support ring and a reflective plate , the substrate support ring is configured to support the substrate, the reflective plate is disposed close to the backside of the substrate; during performing the process on the substrate, a first gas is provided via one or more through holes to the backside of the substrate, the first gas includes one of an oxygen-containing gas or a nitrogen-containing gas, the through hole is provided in the reflection plate; and maintaining the processing chamber at a first pressure and a second pressure wherein the first pressure is close to the top surface of the substrate and the second pressure is close to the bottom surface of the substrate, wherein the first pressure is greater than the second pressure sufficiently to prevent the substrate from The substrate support ring is displaced.
在一些实施方式中,一种计算机可读介质上存储有指令,当执行这些指令时,产生一种将在处理腔室中执行的用于处理基板的方法。所述方法可包括任一个所述的实施方式。In some implementations, a computer readable medium has stored thereon instructions that, when executed, result in a method for processing a substrate to be performed in a processing chamber. The method may comprise any of the described embodiments.
在一些实施方式中,一种用于处理基板的设备可包括:处理腔室,所述处理腔室具有基板支撑环和反射板,所述基板支撑环配置成支撑所述基板,所述反射板设置成接近所述基板的背侧,所述反射板具有多个通孔;其中设置于所述反射板中的多个通孔中的至少一个通孔为入口,所述入口用以提供第一气体至接近所述基板的背侧的区域;其中设置于所述反射板中的多个通孔中的至少一个通孔为出口,所述出口用以产生这些气体的气流,所述气流流出所述基板的背侧。In some embodiments, an apparatus for processing a substrate may include a processing chamber having a substrate support ring configured to support the substrate and a reflective plate set close to the back side of the substrate, the reflection plate has a plurality of through holes; wherein at least one of the through holes in the reflection plate is an entrance, and the entrance is used to provide a first Gas to the area near the back side of the substrate; wherein at least one of the through holes in the reflecting plate is an outlet, and the outlet is used to generate a gas flow of these gases, and the gas flow flows out of the the backside of the substrate.
本发明其他的和更进一步的实施方式描述如下。Other and further embodiments of the invention are described below.
附图说明Description of drawings
可通过参照描绘于附图中的本发明的说明性实施方式来理解以上简要概述的并且下面将更加详细地讨论的本发明的实施方式。然而,应注意的是附图仅图示本发明的典型实施方式并且因此不应被视为对本发明范围的限制,因为本发明可允许其他等效的实施方式。Embodiments of the present invention, briefly summarized above and discussed in greater detail below, can be understood by reference to the illustrative embodiments of the invention depicted in the accompanying drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
图1图示了根据本发明的一些实施方式的用于处理基板的方法。Figure 1 illustrates a method for processing a substrate according to some embodiments of the invention.
图2A-B(统称为图2)图示了根据本发明的一些实施方式的基板在本发明的方法的各阶段的示意性侧视图。2A-B (collectively FIG. 2 ) illustrate schematic side views of substrates according to some embodiments of the invention at various stages of the methods of the invention.
图3图示了根据本发明的一些实施方式的适于执行本发明的方法的处理腔室的示意性侧视图。Figure 3 illustrates a schematic side view of a processing chamber suitable for carrying out the methods of the invention, according to some embodiments of the invention.
图4-5图示了根据本发明的一些实施方式的适于执行本发明的方法的处理腔室的一部分的示意性侧视图。4-5 illustrate schematic side views of a portion of a processing chamber suitable for performing the methods of the invention, according to some embodiments of the invention.
为了便于理解,已尽可能地使用相同的参考数字来标示各图共有的相同元件。这些附图并未按比例绘制并且为清楚起见可对这些附图进行简化。预期一个实施方式的元件和特征结构可有益地结合到其他实施方式中而无需进一步叙述。To facilitate understanding, identical reference numerals have been used wherever possible to designate identical elements that are common to the various figures. The figures are not drawn to scale and may be simplified for clarity. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.
具体实施方式detailed description
本发明的实施方式提供用于处理基板的方法和设备。本发明的实施方式可以有利地促进对接近基板背侧的环境条件的控制,以减少基板上材料的升华或掺杂剂的扩散,从而减少或防止材料在处理腔室表面上沉积,从而增加在清洁处理腔室所需的维护工作之前的生产时间,并提高处理效率。在一些实施方式中,本发明可提供用于在基板的背侧上沉积覆盖层(capping layer),从而进一步减少基板背侧的任何材料的升华或掺杂剂的扩散。Embodiments of the invention provide methods and apparatus for processing substrates. Embodiments of the present invention may advantageously facilitate the control of environmental conditions near the backside of the substrate to reduce sublimation of materials on the substrate or diffusion of dopants, thereby reducing or preventing deposition of materials on processing chamber surfaces, thereby increasing the Production time ahead of maintenance work required to clean process chambers and improve process efficiency. In some embodiments, the present invention may provide for depositing a capping layer on the backside of a substrate to further reduce sublimation of any material or diffusion of dopants on the backside of the substrate.
图1图示了根据本发明的一些实施方式的用于处理基板的方法100。图2A-B图示了根据本发明的一些实施方式的通过本发明的方法100的各阶段的基板200。方法100可以在任何适于半导体基板处理的处理腔室中执行,例如,诸如类似于以下针对图3所描述的处理腔室这样的处理腔室。FIG. 1 illustrates a method 100 for processing a substrate according to some embodiments of the invention. 2A-B illustrate a substrate 200 through various stages of the method 100 of the invention, according to some embodiments of the invention. Method 100 may be performed in any processing chamber suitable for semiconductor substrate processing, such as, for example, a processing chamber similar to that described below with respect to FIG. 3 .
方法100通常开始于102,在102处在基板上执行处理,所述基板设置于具有基板支撑环和反射板的处理腔室中,所述基板支撑环配置成用以支撑基板,所述反射板设置成接近基板的背侧。The method 100 generally begins at 102 where processing is performed on a substrate disposed in a processing chamber having a substrate support ring configured to support the substrate and a reflective plate placed close to the backside of the substrate.
参照图2,基板200可以是适于制造半导体装置的任何类型的基板。例如,基板200可以是掺杂的或者未掺杂的硅基板、III-V族化合物基板、硅锗(SiGe)基板、外延基板、绝缘体上硅(silicon-on-insulator,SOI)基板、显示器基板(诸如液晶显示器(LCD)、等离子体显示器、电致发光(EL)灯显示器)、发光二极管(LED)基板、太阳能电池阵列、太阳能电池板或类似物。在一些实施方式中,基板200可以是半导体晶片,诸如200mm或300mm的半导体晶片。Referring to FIG. 2, the substrate 200 may be any type of substrate suitable for manufacturing a semiconductor device. For example, the substrate 200 may be a doped or undoped silicon substrate, a III-V compound substrate, a silicon germanium (SiGe) substrate, an epitaxial substrate, a silicon-on-insulator (SOI) substrate, a display substrate (such as liquid crystal displays (LCD), plasma displays, electroluminescent (EL) lamp displays), light emitting diode (LED) substrates, solar cell arrays, solar panels, or the like. In some embodiments, the substrate 200 may be a semiconductor wafer, such as a 200mm or 300mm semiconductor wafer.
此外,在一些实施方式中,基板可包括完全或部分制造的半导体装置的一个或更多个部件。例如,在一些实施方式中,基板200可包括一个或更多个层、一个或更多个特征结构、一个或更多个完整或部分制造的结构或类似者。例如,在一些实施方式中,基板200可包括诸如氮化物层、氧化物层或类似者这样的层(在204处以虚线示出)。Furthermore, in some embodiments, a substrate may include one or more components of a fully or partially fabricated semiconductor device. For example, in some embodiments, substrate 200 may include one or more layers, one or more features, one or more fully or partially fabricated structures, or the like. For example, in some embodiments, substrate 200 may include layers such as nitride layers, oxide layers, or the like (shown in dashed lines at 204 ).
处理腔室可以是具有基板支撑环和反射板的任何类型的处理腔室,基板支撑环配置成用以支撑基板,反射板设置成接近基板的背侧。合适的处理腔室的实例包括任何的或处理腔室,或能够执行热处理(例如快速热处理(RTP))的任何其他处理腔室,所有处理腔室皆可从位于California(加利福尼亚)州Santa Clara(圣克拉拉)市的AppliedMaterials,Inc.(应用材料公司)取得。其它合适的处理腔室,包括那些可从其他制造商取得的处理腔室亦可根据本文中所提供的教导而被使用和/或改进。在一些实施方式中,处理腔室可类似于以下针对图3所描述的处理腔室。The processing chamber may be any type of processing chamber having a substrate support ring configured to support the substrate and a reflective plate positioned proximate to the backside of the substrate. Examples of suitable processing chambers include any or processing chamber, or any other processing chamber capable of performing thermal processing such as rapid thermal processing (RTP), all of which are available from Applied Materials, Inc., Santa Clara, California (California) ( Applied Materials Corporation). Other suitable processing chambers, including those available from other manufacturers, may also be used and/or modified in light of the teachings provided herein. In some embodiments, the processing chamber can be similar to the processing chamber described below with respect to FIG. 3 .
在基板上执行的处理可以是制造半导体装置所需要的任何处理,例如,诸如化学气相沉积(CVD)、物理气相沉积(PVD)或类似者这样的沉积处理,诸如干法蚀刻、湿法蚀刻或类似者这样的蚀刻处理,或诸如快速热退火(RTA)、氮化后退火(post nitridation anneal)、氧化后退火或类似者这样的退火处理。例如,根据本发明的实施方式的方法可有利地在约500摄氏度以上进行处理,其中基板背侧不与支撑件(诸如边缘环)直接接触。此外,根据本发明的实施方式的方法还可以有利地促进从基板的背侧进行测量(诸如使用光学技术的温度测量),并能同时尽量减少或消除任何随着时间的处理变化。The processing performed on the substrate may be any processing required for manufacturing a semiconductor device, for example, deposition processing such as chemical vapor deposition (CVD), physical vapor deposition (PVD) or the like, such as dry etching, wet etching, or Such an etching process, or an annealing process such as rapid thermal annealing (RTA), post nitridation anneal, post oxidation anneal, or the like. For example, methods according to embodiments of the present invention may advantageously be processed above about 500 degrees Celsius, where the backside of the substrate is not in direct contact with a support such as an edge ring. Furthermore, methods according to embodiments of the present invention may also advantageously facilitate measurements from the backside of the substrate, such as temperature measurements using optical techniques, while minimizing or eliminating any process variation over time.
本发明人已经观察到,一些处理(例如在快速热处理(RTP)腔室中进行的氮化后退火处理或氧化后退火处理)可能需要处理腔室被保持在较高的温度(例如约1000摄氏度或更高)和较低的压力(例如,小于约100托(Torr),或在一些实施方式中,小于约50托,或小于约10托)下以执行所述处理。然而,本发明人已经观察到,在这样的温度和压力下执行处理可能引起不期望的状况:基板200上材料的升华或掺杂剂的扩散。例如,在含硅基板的退火处理中,例如水分、来自在处理腔室中执行的先前处理所剩余的材料、来自第一气源的泄漏物或类似者可导致少量的氧存在于处理腔室内。例如,本发明人已经观察到,存在低浓度的氧、高处理温度和/或低氧气分压(至少部分地由低处理压力所引起),可能会导致氧化硅从基板升华。升华的硅氧化物材料之后可凝结于处理腔室的表面上,例如,侧壁、反射板、高温计或类似者。本发明人还观察到,在诸如快速热处理(RTP)腔室之类的处理腔室中,含氧气体可以流向基板的前侧以防止上述升华。例如,通过提供含氧气体至基板的前侧,氧的浓度和/或氧的分压增加,从而减少或消除材料(例如,氧化硅)从基板升华。然而,本发明人已经观察到,由于在传统的处理腔室中的流体传导性差异,导致到达基板200的背侧206以防止材料从基板200的背侧206升华的氧气量不足,所述流体传导性差异是关于沿着基板的前侧208的流体相比于沿着基板200的背侧206的流体之间的差异。The inventors have observed that some processes, such as post-nitridation annealing or post-oxidation annealing in a rapid thermal processing (RTP) chamber, may require the processing chamber to be maintained at a relatively high temperature, such as about 1000 degrees Celsius or higher) and lower pressure (eg, less than about 100 Torr (Torr), or in some embodiments, less than about 50 Torr, or less than about 10 Torr) to perform the process. However, the inventors have observed that performing processing at such temperatures and pressures may cause undesirable conditions: sublimation of materials on the substrate 200 or diffusion of dopants. For example, during the annealing process of a silicon-containing substrate, small amounts of oxygen may be present in the process chamber, such as moisture, material left over from previous processes performed in the process chamber, leaks from the first gas source, or the like . For example, the inventors have observed that the presence of low concentrations of oxygen, high processing temperatures, and/or low oxygen partial pressures (resulting at least in part from low processing pressures) may result in the sublimation of silicon oxide from the substrate. The sublimated silicon oxide material may then condense on surfaces of the processing chamber, such as sidewalls, reflectors, pyrometers, or the like. The inventors have also observed that in processing chambers such as rapid thermal processing (RTP) chambers, an oxygen-containing gas can flow towards the front side of the substrate to prevent the aforementioned sublimation. For example, by providing an oxygen-containing gas to the front side of the substrate, the concentration of oxygen and/or the partial pressure of oxygen is increased, thereby reducing or eliminating sublimation of material (eg, silicon oxide) from the substrate. However, the inventors have observed that due to differences in fluid conductance in conventional processing chambers, the amount of oxygen that reaches the backside 206 of the substrate 200 to prevent sublimation of material from the backside 206 of the substrate 200 is insufficient. The conductivity difference relates to the difference between the fluid along the front side 208 of the substrate as compared to the fluid along the back side 206 of the substrate 200 .
因此,接下来在104处,将包括含氧气体或含氮气体之一的第一气体提供至基板200的背侧206。在一些实施方式中,在执行处理期间,第一气体可经由一个或更多个通孔而被提供至基板的背侧,这些通孔设置在反射板中,反射板设置在基板的后面。通过提供第一气体至基板200的背侧206,发明人观察到接近基板背侧的环境条件(例如,压力、氧气分压、氧浓度或类似条件)可以得到控制,从而减少或消除基板200上材料的升华或掺杂剂的扩散(例如,如上面所述)。例如,在第一气体是含氧气体的实施方式中,本发明人观察到,提供含氧气体会增加接近基板200的背侧206处的氧浓度,从而防止硅从基板200升华,从而防止氧化硅在处理腔室的表面上形成和随后沉积。Accordingly, next at 104 , a first gas comprising one of an oxygen-containing gas or a nitrogen-containing gas is provided to the backside 206 of the substrate 200 . In some embodiments, during the performance of the process, the first gas may be provided to the backside of the substrate via one or more through holes disposed in a reflective plate disposed behind the substrate. By providing the first gas to the backside 206 of the substrate 200, the inventors have observed that environmental conditions (e.g., pressure, oxygen partial pressure, oxygen concentration, or the like) near the backside of the substrate can be controlled to reduce or eliminate Sublimation of material or diffusion of dopants (eg, as described above). For example, in embodiments where the first gas is an oxygen-containing gas, the inventors have observed that providing an oxygen-containing gas increases the oxygen concentration near the backside 206 of the substrate 200, thereby preventing the sublimation of silicon from the substrate 200, thereby preventing the oxidation of silicon. Formation and subsequent deposition on the surfaces of the processing chamber.
所述含氧气体或含氮气体可包括适于防止基板200上材料的升华或掺杂剂的扩散同时在处理环境中呈非反应性的任何气体或气体组合。例如,在第一气体包括含氧气体的实施方式中,第一气体可包括以下气体之一:氧气(O2)、氮氧化物(NOx)或类似气体。在第一气体包括含氮气体的实施方式中,第一气体可包括以下气体之一:氮气(N2)、氮氧化物(NOx)、氨(NH3)或类似气体。在一些实施方式中,含氧气体或含氮气体可以是与提供至基板前侧的气体相同的(例如,如上所述,含氧气体可以流向基板的前侧),或者在一些实施方式中,含氧气体或含氮气体可以是不同于提供至基板前侧的气体。The oxygen-containing gas or nitrogen-containing gas may include any gas or combination of gases suitable to prevent sublimation of materials on substrate 200 or diffusion of dopants while being non-reactive in the processing environment. For example, in embodiments where the first gas includes an oxygen-containing gas, the first gas may include one of the following: oxygen (O 2 ), nitrogen oxides (NO x ), or the like. In embodiments where the first gas includes a nitrogen-containing gas, the first gas may include one of nitrogen (N 2 ), nitrogen oxides (NO x ), ammonia (NH 3 ), or the like. In some embodiments, the oxygen-containing gas or nitrogen-containing gas can be the same gas that is provided to the front side of the substrate (e.g., the oxygen-containing gas can flow to the front side of the substrate as described above), or in some embodiments, The oxygen-containing gas or the nitrogen-containing gas may be different from the gas supplied to the front side of the substrate.
第一气体可以任意流量(flow rate)提供,所述流量适于提供足够量的含氧气体或含氮气体同时不会造成过大的压力差,过大的压力差在处理期间会造成基板200从支撑环移位。例如,可以使用下面的公式计算压力差:The first gas may be provided at any flow rate suitable to provide a sufficient amount of oxygen-containing gas or nitrogen-containing gas without creating an excessive pressure differential that would cause the substrate 200 to depress during processing. Displaced from the support ring. For example, the differential pressure can be calculated using the following formula:
Mw*g=(Pfs-Pfb)*Aw M w *g=(P fs -P fb )*A w
其中Mw是晶片(基板)的质量,g是重力,Pfs和Pfb分别是在基板前侧208和背侧206的压力,Aw为晶片的面积。例如,在基板是300mm的晶片的实施方式中,小于约2托的压力差适于提供第一气体同时不会造成基板200从支撑环移位。因此,在一些实施方式中,第一气体可设置为约50sccm至约500sccm的流量。在一些实施方式中,第一气体的流量也可以在一段时间内增加以防止朝向基板200的高压气体的初始爆裂(burst)。在这样的实施方式中,第一气体可以约10sccm至约50sccm的第一流量被提供并且在1秒至约5秒的一段时间内增加至约300sccm至约500sccm的第二流量。where Mw is the mass of the wafer (substrate), g is gravity, Pfs and Pfb are the pressure on the substrate front side 208 and backside 206, respectively, and Aw is the area of the wafer. For example, in embodiments where the substrate is a 300 mm wafer, a pressure differential of less than about 2 Torr is suitable for providing the first gas without causing displacement of the substrate 200 from the support ring. Accordingly, in some embodiments, the first gas may be set at a flow rate of about 50 seem to about 500 seem. In some embodiments, the flow rate of the first gas may also be increased for a period of time to prevent an initial burst of the high pressure gas towards the substrate 200 . In such embodiments, the first gas may be provided at a first flow rate of about 10 seem to about 50 seem and increased to a second flow rate of about 300 seem to about 500 seem over a period of 1 second to about 5 seconds.
在一些实施方式中,例如第一气体所需的流量将产生会导致基板200移位的压力差,可以将真空施加到设置在反射板中的所述一个或更多个通孔之一或更多者,以抵消施加到基板200的背侧206的压力。In some embodiments, for example, where the required flow rate of the first gas will create a pressure differential that will cause the substrate 200 to displace, a vacuum may be applied to one or more of the one or more through holes provided in the reflector plate. Many, to counteract the pressure applied to the backside 206 of the substrate 200 .
接着在106,可以任选地在基板200的背侧206上形成覆盖层202,如图2B所示。本发明人已经观察到,通过在基板200的背侧206上形成覆盖层202,可以进一步减少或消除基板200上材料的升华或掺杂剂的扩散(例如,如上面所述)。覆盖层202可包括任何工艺兼容的材料,所述材料适于防止基板200上的材料升华或掺杂剂的扩散(例如,如上面所述)同时不与基板200的材料反应,例如,氮化物层、氧化物层或类似材料。例如,在基板200是含硅基板200的实施方式中,覆盖层202可包括氮化硅(SiN)。Next at 106, a cover layer 202 may optionally be formed on the backside 206 of the substrate 200, as shown in FIG. 2B. The inventors have observed that by forming capping layer 202 on backside 206 of substrate 200, sublimation of materials on substrate 200 or diffusion of dopants (eg, as described above) can be further reduced or eliminated. Capping layer 202 may comprise any process compatible material suitable to prevent sublimation of materials on substrate 200 or diffusion of dopants (e.g., as described above) while not reacting with the materials of substrate 200, e.g., nitride layer, oxide layer or similar material. For example, in embodiments where the substrate 200 is a silicon-containing substrate 200, the capping layer 202 may comprise silicon nitride (SiN).
在108,为了形成覆盖层202,可由第一气体形成等离子体。等离子体可以形成于与用于处理基板200的相同的处理腔室中,或者在一些实施方式中,等离子体可以形成于与用于处理基板的所述处理腔室不同的处理腔室中,且随后提供至处理腔室(例如,远程等离子体)。At 108, to form the capping layer 202, a plasma may be formed from the first gas. The plasma may be formed in the same processing chamber as used to process the substrate 200, or in some embodiments, the plasma may be formed in a different processing chamber than the processing chamber used to process the substrate, and This is then provided to a processing chamber (eg, remote plasma).
可按以下方式形成等离子体:例如通过在适合的条件下在处理腔室(例如,用来处理基板的处理腔室或远程等离子体腔室)内将一些能量耦合至第一气体来点燃(igniting)第一气体以产生等离子体。在一些实施方式中,耦合至第一气体的能量可包括高达约3000瓦(W)的直流电能量。替代地或者结合地,在一些实施方式中,可以约2兆赫(MHz)至约3千兆赫(GHz)的频率供应高达约10,000W的RF能量。例如,在一些实施方式中,气源331可以是远程等离子体腔室,以在提供第一气体至处理腔室之前由所述第一气体形成等离子体。The plasma can be formed, for example, by igniting by coupling some energy to the first gas under suitable conditions within a processing chamber (e.g., a processing chamber used to process a substrate or a remote plasma chamber) The first gas to generate plasma. In some embodiments, the energy coupled to the first gas can include up to about 3000 watts (W) of direct current energy. Alternatively or in combination, in some embodiments, up to about 10,000 W of RF energy may be supplied at a frequency of about 2 megahertz (MHz) to about 3 gigahertz (GHz). For example, in some embodiments, the gas source 331 may be a remote plasma chamber to form a plasma from the first gas prior to providing the gas to the processing chamber.
除了上述情况之外,额外的处理参数可被用来点燃或维持等离子体。例如,在一些实施方式中,处理腔室可以维持在约10毫托(mTorr)至约5000毫托的压力下。此外,在一些实施方式中,处理腔室可以维持在约500摄氏度至约1100摄氏度的温度下。In addition to the above, additional processing parameters may be used to ignite or maintain the plasma. For example, in some embodiments, the processing chamber can be maintained at a pressure of about 10 milliTorr (mTorr) to about 5000 mTorr. Additionally, in some embodiments, the processing chamber may be maintained at a temperature of about 500 degrees Celsius to about 1100 degrees Celsius.
接着,在110,基板的背侧206可以暴露至形成于等离子体中的激发态物种,以在基板200的背侧206上形成覆盖层202。基板200的背侧206可暴露至激发态物种中持续任何所需的时间量,以形成达到所需厚度的覆盖层202。例如,在一些实施方式中,基板200的背侧206可暴露至等离子体中持续约10秒至约60秒的一段时间。在一些实施方式中,覆盖层202可形成为约5埃(angstrom)至约30埃的厚度。Next, at 110 , the backside 206 of the substrate may be exposed to excited species formed in the plasma to form a capping layer 202 on the backside 206 of the substrate 200 . The backside 206 of the substrate 200 may be exposed to the excited state species for any desired amount of time to form the capping layer 202 to a desired thickness. For example, in some embodiments, the backside 206 of the substrate 200 may be exposed to the plasma for a period of time ranging from about 10 seconds to about 60 seconds. In some embodiments, capping layer 202 may be formed to a thickness of about 5 angstroms to about 30 angstroms.
除了上述情况以外,可以利用额外的处理参数来形成覆盖层。例如,在一些实施方式中,处理腔室可以维持在约10毫托至约5000毫托的压力下。此外,在一些实施方式中,处理腔室可以维持在约200摄氏度至约1100摄氏度的温度下。In addition to the above, additional processing parameters may be utilized to form the capping layer. For example, in some embodiments, the processing chamber can be maintained at a pressure of from about 10 mTorr to about 5000 mTorr. Additionally, in some embodiments, the processing chamber may be maintained at a temperature of about 200 degrees Celsius to about 1100 degrees Celsius.
接着在104处提供第一气体(或任选地在106处形成覆盖层202),所述方法通常会结束,并可根据需要进一步处理基板200。例如,在一些实施方式中,可以在基板200上执行诸如附加层沉积、蚀刻、退火或类似处理这样的额外处理,例如,在基板200上形成半导体装置,或制备基板200用于以下应用中:包括但并不限于诸如光伏电池(PV)、发光二极管(LED)或显示器(例如,液晶显示器(LCD)、等离子体显示器、电致发光(EL)灯显示器或类似显示器)。Next, providing the first gas at 104 (or optionally forming the capping layer 202 at 106), the method generally ends and the substrate 200 can be further processed as desired. For example, in some embodiments, additional processing such as additional layer deposition, etching, annealing, or the like may be performed on the substrate 200, for example, to form a semiconductor device on the substrate 200, or to prepare the substrate 200 for use in the following applications: Examples include, but are not limited to, photovoltaic cells (PV), light emitting diodes (LED), or displays (eg, liquid crystal displays (LCD), plasma displays, electroluminescent (EL) lamp displays, or the like).
图3图示了根据本发明的一些实施方式的适于执行本发明的方法的处理腔室。处理腔室300可以是任何合适的处理腔室,例如,配置用于热处理,诸如快速热处理(RTP),或任何上述的处理腔室。Figure 3 illustrates a processing chamber suitable for carrying out the method of the present invention, according to some embodiments of the present invention. The processing chamber 300 may be any suitable processing chamber, eg, configured for thermal processing, such as rapid thermal processing (RTP), or any of the processing chambers described above.
基板200被安装于基板支撑件308上的处理腔室300内,并由灯头(lamphead)301加热,灯头301设置在与基板支撑件308相对的位置。灯头301产生的辐射被引导到基板200的前侧208。或者(图中未示出),灯头301可被配置成用以加热基板200的背侧206,例如,诸如通过被设置在基板200的下方,或通过引导辐射到基板200的背侧。辐射通过水冷式石英窗口组件314而进入处理腔室300。基板200的下方是反射板302,反射板302被安装在水冷式、不锈钢底座316上。底座316包括一个循环回路346,冷却剂通过循环回路346循环来冷却反射板302。在一些实施方式中,反射板302由铝制成并具有高反射率的表面涂层320。水可以通过底座316循环以保持反射板302的温度远低于加热的基板200的温度。或者可以相同或不同的温度提供其他的冷却剂。例如,防冻液(例如,乙二醇丙二醇或类似者)或其他传热流体可以通过底座316循环和/或底座316可以耦接至冷却器(chiller)(图中未示出)。基板200的底面或背侧和反射板302的顶部形成反射腔318。反射腔318提高了基板200的有效发射率。The substrate 200 is mounted in the processing chamber 300 on the substrate support 308 and heated by a lamphead 301 disposed opposite to the substrate support 308 . The radiation generated by the burner 301 is directed to the front side 208 of the substrate 200 . Alternatively (not shown), lamp head 301 may be configured to heat backside 206 of substrate 200 , such as by being disposed below substrate 200 , or by directing radiation onto the backside of substrate 200 , for example. Radiation enters the processing chamber 300 through a water-cooled quartz window assembly 314 . Below the substrate 200 is a reflector 302 mounted on a water-cooled, stainless steel base 316 . Base 316 includes a circulation loop 346 through which coolant circulates to cool reflector 302 . In some embodiments, the reflective plate 302 is made of aluminum and has a high reflectivity surface coating 320 . Water can be circulated through the base 316 to keep the reflective plate 302 at a temperature well below the temperature of the heated substrate 200 . Alternatively other coolants may be provided at the same or different temperature. For example, antifreeze (eg, ethylene glycol propylene glycol or the like) or other heat transfer fluid may be circulated through base 316 and/or base 316 may be coupled to a chiller (not shown). The bottom or backside of the substrate 200 and the top of the reflective plate 302 form a reflective cavity 318 . Reflective cavity 318 increases the effective emissivity of substrate 200 .
基板200局部区域的温度由多个温度探测器测量,诸如352a、352b和352c。每个温度探测器包括光管(light pipe)324,光管324穿过通孔327,通孔327从底座316的背侧延伸通过反射板302的顶部。光管324位于通孔327内,所以它的最上端与反射板302的上表面齐平或稍低于反射板302的上表面。光管324的另一端耦接至柔性光纤325,光纤325从反射腔318发送采样光(sampledlight)到高温计328。高温计328与温度控制器350连接,温度控制器350响应于测得的温度控制供应至灯头301的功率。所述灯可被分成多个区域。所述区域可以由控制器单独调节以允许在基板200的不同区域进行可控的辐射加热。The temperature of local regions of the substrate 200 is measured by a plurality of temperature probes, such as 352a, 352b, and 352c. Each temperature probe includes a light pipe 324 that passes through a through hole 327 that extends from the backside of the base 316 through the top of the reflective plate 302 . The light pipe 324 is located in the through hole 327 , so its uppermost end is flush with or slightly lower than the upper surface of the reflective plate 302 . The other end of the light pipe 324 is coupled to a flexible optical fiber 325 that sends sampled light from the reflective cavity 318 to the pyrometer 328 . The pyrometer 328 is connected to a temperature controller 350 which controls the power supplied to the lamp head 301 in response to the measured temperature. The lamp can be divided into multiple zones. The zones can be individually adjusted by the controller to allow controllable radiative heating of different zones of the substrate 200 .
除了如上所述的配置成用以容纳每个光管的通孔327之外,底座316和反射板302可包括一个或更多个附加的通孔(图示一个附加的通孔351),所述附加的通孔配置成用以容纳其他的机构(例如,升降销或类似机构)以方便处理。In addition to the through-holes 327 configured to accommodate each light pipe as described above, the base 316 and reflector plate 302 may include one or more additional through-holes (an additional through-hole 351 is shown), so The additional through-holes are configured to accommodate other mechanisms (eg, lift pins or the like) to facilitate handling.
在处理期间,第一气体可从气体面板(例如,气源229)流动,并在入口330(例如,第一入口)进入处理腔室300。入口330被设置在处理腔室300的一侧,并促进第一气体流动遍及基板200的表面。本发明人已经观察到,从入口330提供第一气体可能会导致从基板200的前侧208至背侧206的气体传导性差异。例如,当第一气体经由入口330而被提供至基板200的前侧208,第一气体以第一流动路径流动而直接遍及基板200的前侧208且第一气体以间接的第二流动路径流至基板200的背侧206。第一流动路径与第二流动路径之间的流体传导性差异导致到达基板的背侧206的第一气体的浓度低于到达基板200的前侧208的第一气体的浓度。本发明人已经观察到,这种低浓度的第一气体可导致处理程度的不足,例如,诸如如上所述基板200的背侧206上材料的升华或掺杂剂的扩散。During processing, a first gas may flow from a gas panel (eg, gas source 229 ) and enter processing chamber 300 at inlet 330 (eg, first inlet). The inlet 330 is provided at one side of the processing chamber 300 and facilitates the flow of the first gas across the surface of the substrate 200 . The inventors have observed that providing the first gas from the inlet 330 may result in a difference in gas conductance from the front side 208 to the back side 206 of the substrate 200 . For example, when a first gas is provided to the front side 208 of the substrate 200 via the inlet 330, the first gas flows in a first flow path directly across the front side 208 of the substrate 200 and the first gas flows in an indirect second flow path. to the backside 206 of the substrate 200 . The difference in fluid conductivity between the first flow path and the second flow path results in a lower concentration of the first gas reaching the backside 206 of the substrate than a concentration of the first gas reaching the front side 208 of the substrate 200 . The inventors have observed that such low concentrations of the first gas may result in insufficient processing, eg, sublimation of materials or diffusion of dopants such as described above on the backside 206 of the substrate 200 .
因此,在一些实施方式中,第一气体可通过接近基板背侧的第二入口被提供至基板200的背侧。例如,在一些实施方式中,第一气体可经由反射板302的一个或更多个通孔(例如,通孔327、351)而被提供至基板的背侧。Thus, in some embodiments, the first gas may be provided to the backside of the substrate 200 through a second inlet proximate to the backside of the substrate. For example, in some embodiments, the first gas may be provided to the backside of the substrate through one or more through holes (eg, through holes 327 , 351 ) of the reflective plate 302 .
在一些实施方式中,第一气体可经由气源331被提供至一个或更多个通孔327、351。虽然所示为分开的气源,但是气源229和气源331可以是相同的气源且具有独立的流量控制器,以根据需要提供第一气体至基板的前侧或背侧。在一些实施方式中,阀329可以被耦接至一个或更多个通孔,例如,阀329被设置于气源331与通孔327、351之间,以便引导第一气体至通孔327、351或排气装置(exhaust)之一。通过提供设置于气源331与通孔327、351之间的阀329,气源331可以保持在恒定的“导通(on)”状态,提供第一气体至通孔327、351或排气装置,从而保持了更均匀的压力并且减少在朝向通孔327、351启动第一气体流时由气源产生的高压力爆裂的情况。In some embodiments, the first gas may be provided to the one or more through holes 327 , 351 via a gas source 331 . Although shown as separate gas sources, gas source 229 and gas source 331 may be the same gas source with separate flow controllers to provide the first gas to the front or back side of the substrate as desired. In some embodiments, a valve 329 may be coupled to one or more of the through holes, for example, the valve 329 is disposed between the gas source 331 and the through holes 327, 351 in order to direct the first gas to the through holes 327, 351. 351 or one of the exhaust. By providing a valve 329 disposed between the gas source 331 and the through holes 327, 351, the gas source 331 can be kept in a constant "on" state, providing the first gas to the through holes 327, 351 or exhaust means , thereby maintaining a more uniform pressure and reducing the occurrence of high pressure bursts generated by the gas source when the first gas flow is initiated towards the through-holes 327,351.
通过经由一个或更多个通孔327、351提供第一气体,除了基板200上方的流动路径404外,如图4所示,在基板200下方产生流动路径402。本发明人已经观察到,提供流动路径402可以减少或消除从基板200的前侧208至背侧206的气流传导性差异,从而便于提供更高浓度的第一气体至基板200的背侧206,从而减少或消除了以上讨论的处理程度的不足。By providing the first gas through the one or more through holes 327 , 351 , in addition to the flow path 404 above the substrate 200 , as shown in FIG. 4 , a flow path 402 is created below the substrate 200 . The inventors have observed that providing the flow path 402 can reduce or eliminate the difference in gas flow conductance from the front side 208 to the back side 206 of the substrate 200, thereby facilitating the provision of a higher concentration of the first gas to the back side 206 of the substrate 200, The processing-level deficiencies discussed above are thereby reduced or eliminated.
在一些实施方式中,真空可被提供至接近基板200的背侧的区域。在一些实施方式中,真空可被提供至一个或更多个通孔(例如,通孔327),同时第一气体被提供至所述一个或更多个通孔的另一个通孔(例如,通孔351),从而产生从所述一个或更多个通孔的第一通孔(例如,通孔327)至所述一个或更多个通孔的第二通孔(例如,通孔351)的流动路径,例如,图5中所示的流动路径502。通过提供真空至一个或更多个通孔,可减少施加至基板200的背侧206的压力量,从而减少基板200的前侧208与背侧206之间的压力差,因此,减少基板200从基板支撑件(如上所述)移位的风险。在这样的实施方式中,泵333(例如诸如低真空泵(roughing pump)或真空泵)可耦接至所述一个或更多个通孔。在一些实施方式中,被施加真空的通孔可能会比其他通孔具有更大的直径,以防止对通往泵333的气流的限制。泵333和将泵耦接至所述一个或更多个通孔的导管具有足以提供以上讨论的压力差的传导性和功率。In some embodiments, a vacuum may be provided to an area near the backside of the substrate 200 . In some embodiments, a vacuum may be provided to one or more vias (e.g., via 327) while the first gas is provided to another one of the one or more vias (e.g., via 351), thereby creating a first via (eg, via 327) of the one or more vias to a second via (eg, via 351 ) of the one or more vias ) flow path, for example, the flow path 502 shown in FIG. 5 . By providing a vacuum to the one or more vias, the amount of pressure applied to the backside 206 of the substrate 200 can be reduced, thereby reducing the pressure differential between the frontside 208 and the backside 206 of the substrate 200, thereby reducing the amount of pressure that the substrate 200 experiences from the backside 206. Risk of displacement of the substrate support (as described above). In such embodiments, a pump 333 (eg, such as a roughing pump or vacuum pump) may be coupled to the one or more through holes. In some embodiments, the vias to which the vacuum is applied may have a larger diameter than the other vias to prevent restriction of airflow to the pump 333 . The pump 333 and the conduits coupling the pump to the one or more through holes are of sufficient conductivity and power to provide the pressure differential discussed above.
返回参照图3,基板支撑件308可被配置为固定的或可使基板200旋转。基板支撑件308包括支撑环334或边缘环,所述支撑环334或边缘环与基板200接触且环绕基板的外周边,从而使基板200除围绕外周边的小的环形区域之外的整个底面暴露。支撑环334也被称为边缘环,在本说明书之内这两个术语可以互换使用。为了尽量减少在处理期间在基板200的边缘可能会发生的热不连续性,支撑环334可由与基板200相同或相似的材料制成,例如硅。Referring back to FIG. 3 , the substrate support 308 may be configured to be stationary or to allow the substrate 200 to rotate. The substrate support 308 includes a support ring 334 or edge ring that contacts the substrate 200 and surrounds the outer perimeter of the substrate such that the entire bottom surface of the substrate 200 is exposed except for a small annular area around the outer perimeter. . The support ring 334 is also referred to as an edge ring, and the two terms are used interchangeably within this specification. To minimize thermal discontinuities that may occur at the edge of the substrate 200 during processing, the support ring 334 may be made of the same or similar material as the substrate 200, such as silicon.
在一些实施方式中,支撑环334可设置于可旋转的管状圆柱体(tubularcylinder)336上,管状圆柱体336涂有硅,以在高温计328的频率范围呈不透明。圆柱体336上的涂层作为挡板以阻挡来自外部源的辐射,外部源可能污染强度的测量。圆柱体336的底部由环状上轴承341保持,环状上轴承341设置于多个球轴承337上,多个球轴承337进而保持在固定的、环形的下轴承座圈(lower bearing race)339内。在一些实施方式中,球轴承337是由钢制成的并涂有硅氮化物以减少在操作期间颗粒的形成。在热处理期间,上轴承341被磁耦接至致动器(图中未示出),致动器使圆柱体336、支撑环334和基板200旋转。In some embodiments, the support ring 334 may be disposed on a rotatable tubular cylinder 336 coated with silicon to be opaque in the frequency range of the pyrometer 328 . The coating on the cylinder 336 acts as a baffle to block radiation from external sources that could contaminate the intensity measurements. The bottom of the cylinder 336 is held by an annular upper bearing 341 which rests on a plurality of ball bearings 337 which in turn are held in a fixed, annular lower bearing race 339 Inside. In some embodiments, ball bearings 337 are made of steel and coated with silicon nitride to reduce particle formation during operation. During thermal processing, the upper bearing 341 is magnetically coupled to an actuator (not shown in the figure), which rotates the cylinder 336, the support ring 334, and the base plate 200.
清洗环(purge ring)345被装配到腔室主体中而围绕圆柱体336。在一些实施方式中,清洗环345具有内部环形腔347,内部环形腔347打开朝向轴承341上方的区域。内部环形腔347通过通道349与气源(图中未示出)连接。在处理期间,清洗气体通过清洗环345流入所述腔室。A purge ring 345 is fitted into the chamber body around cylinder 336 . In some embodiments, the wash ring 345 has an inner annular cavity 347 that opens towards an area above the bearing 341 . The inner annular cavity 347 is connected to a gas source (not shown in the figure) through a channel 349 . During processing, purge gas flows into the chamber through purge ring 345 .
在一些实施方式中,支撑环334具有比圆柱体336的半径大的外半径,这样外半径向外延伸超出圆柱体336。超出圆柱体336的支撑环334的环形延伸部分与位于延伸部分下面的清洗环345共同作为挡板,挡板防止杂散光进入基板200的背侧的反射腔318。为了进一步减少杂散光进入反射腔318的可能性,支撑环334和清洗环345也可涂有能吸收灯头301所产生的辐射的材料(例如,黑色或灰色的材料)。In some embodiments, the support ring 334 has an outer radius that is larger than the radius of the cylinder 336 such that the outer radius extends outward beyond the cylinder 336 . The annular extension of the support ring 334 beyond the cylinder 336 together with the cleaning ring 345 below the extension acts as a baffle that prevents stray light from entering the reflective cavity 318 on the backside of the substrate 200 . To further reduce the possibility of stray light entering reflective cavity 318, support ring 334 and cleaning ring 345 may also be coated with a material (eg, a black or gray material) that absorbs radiation generated by lamp head 301 .
基板支撑件308可耦接至升降机构355,升降机构355能够相对于灯头301而升高和降低基板。例如,基板支撑件308可耦接至升降机构355,以使得在升降运动期间基板200与反射板302之间的距离是恒定的。The substrate support 308 may be coupled to a lift mechanism 355 capable of raising and lowering the substrate relative to the lamp head 301 . For example, the substrate support 308 may be coupled to the lift mechanism 355 such that the distance between the substrate 200 and the reflective plate 302 is constant during the lift motion.
在一些实施方式中,基板支撑件308可适于磁悬浮,并在处理腔室300内旋转(图中未示出)。基板支撑件308能够在处理期间旋转同时垂直地升高和降低,且亦可在处理之前、处理期间或处理之后升高或降低而不旋转。升高/降低和/或旋转基板支撑件通常需要移动部件,故由于移动部件的不存在或减少,这种磁悬浮和/或磁场的旋转可防止或减少颗粒的产生。In some embodiments, the substrate support 308 may be adapted to be magnetically levitated and rotated within the processing chamber 300 (not shown). The substrate support 308 can be rotated while being vertically raised and lowered during processing, and can also be raised or lowered without rotation before, during, or after processing. Raising/lowering and/or rotating the substrate support typically requires moving parts, so such magnetic levitation and/or rotation of the magnetic field may prevent or reduce particle generation due to the absence or reduction of moving parts.
因此,本发明已提供用于处理基板的方法和设备。本发明的实施方式提供了用于处理基板的方法。在一些实施方式中,本发明可促进足够的第一气体流流向基板的背侧,以减少在基板上的材料的升华或掺杂剂的扩散,从而防止材料在处理腔室的表面上沉积,从而提高处理效率。在一些实施方式中,本发明可提供在基板的背侧上沉积覆盖层,从而进一步减少在基板上的材料的升华或掺杂质的扩散。Accordingly, the present invention has provided methods and apparatus for processing substrates. Embodiments of the invention provide methods for processing substrates. In some embodiments, the present invention can facilitate sufficient flow of the first gas to the backside of the substrate to reduce sublimation of material on the substrate or diffusion of dopants, thereby preventing deposition of material on surfaces of the processing chamber, Thereby improving processing efficiency. In some embodiments, the present invention may provide for depositing a capping layer on the backside of the substrate to further reduce sublimation of material on the substrate or diffusion of dopants.
虽然上述内容涉及本发明的实施方式,但是在不偏离本发明的基本范围的情况下,也可设计本发明的其他和更进一步的实施方式。While the foregoing relates to embodiments of the invention, other and further embodiments of the invention may also be devised without departing from the essential scope of the invention.
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| PCT/US2013/021006 WO2013106552A1 (en) | 2012-01-13 | 2013-01-10 | Methods and apparatus for processing a substrate |
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| CN101589456A (en) * | 2007-01-26 | 2009-11-25 | 朗姆研究公司 | Bevel etcher with vacuum chuck |
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| US6139923A (en) * | 1996-02-09 | 2000-10-31 | Applied Materials, Inc. | Method and apparatus for reducing particle contamination in a substrate processing chamber |
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