CN104205308B - Dry-etching method - Google Patents
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- 238000000034 method Methods 0.000 title claims abstract description 89
- 238000001312 dry etching Methods 0.000 title claims abstract description 47
- 239000007789 gas Substances 0.000 claims abstract description 140
- 239000000758 substrate Substances 0.000 claims abstract description 104
- 238000005530 etching Methods 0.000 claims abstract description 78
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 70
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 70
- 239000010703 silicon Substances 0.000 claims abstract description 70
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 51
- 239000001301 oxygen Substances 0.000 claims abstract description 51
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 51
- 229910052736 halogen Inorganic materials 0.000 claims abstract description 23
- 150000002367 halogens Chemical class 0.000 claims abstract description 23
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 6
- 230000008676 import Effects 0.000 claims 10
- 230000006837 decompression Effects 0.000 claims 6
- 230000003628 erosive effect Effects 0.000 claims 3
- 239000000377 silicon dioxide Substances 0.000 claims 2
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 abstract description 18
- 229910052731 fluorine Inorganic materials 0.000 abstract description 18
- 239000011737 fluorine Substances 0.000 abstract description 18
- 238000000149 argon plasma sintering Methods 0.000 abstract description 4
- 238000004519 manufacturing process Methods 0.000 abstract description 4
- 239000010409 thin film Substances 0.000 abstract description 4
- 238000007599 discharging Methods 0.000 abstract description 2
- 239000007795 chemical reaction product Substances 0.000 description 12
- 239000010408 film Substances 0.000 description 9
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 6
- 230000015572 biosynthetic process Effects 0.000 description 6
- 229910001882 dioxygen Inorganic materials 0.000 description 6
- 150000002500 ions Chemical class 0.000 description 5
- 238000001039 wet etching Methods 0.000 description 5
- 238000004140 cleaning Methods 0.000 description 4
- 229910021420 polycrystalline silicon Inorganic materials 0.000 description 4
- 239000004215 Carbon black (E152) Substances 0.000 description 3
- 229930195733 hydrocarbon Natural products 0.000 description 3
- 150000002430 hydrocarbons Chemical class 0.000 description 3
- 229910052814 silicon oxide Inorganic materials 0.000 description 3
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 2
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000012433 hydrogen halide Substances 0.000 description 2
- 229910000039 hydrogen halide Inorganic materials 0.000 description 2
- 229910021421 monocrystalline silicon Inorganic materials 0.000 description 2
- 229920005591 polysilicon Polymers 0.000 description 2
- 238000009423 ventilation Methods 0.000 description 2
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 150000002222 fluorine compounds Chemical class 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011259 mixed solution Substances 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- LIVNPJMFVYWSIS-UHFFFAOYSA-N silicon monoxide Chemical class [Si-]#[O+] LIVNPJMFVYWSIS-UHFFFAOYSA-N 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
- H10F77/00—Constructional details of devices covered by this subclass
- H10F77/70—Surface textures, e.g. pyramid structures
- H10F77/703—Surface textures, e.g. pyramid structures of the semiconductor bodies, e.g. textured active layers
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10F—INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
- H10F10/00—Individual photovoltaic cells, e.g. solar cells
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
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- Drying Of Semiconductors (AREA)
- Photovoltaic Devices (AREA)
Abstract
本发明提供一种低成本的干蚀刻方法,其可高效制造具有纹理结构的硅基板,所述的纹理结构有效发挥防止光散射的效果,并在之后工序中形成规定的薄膜时也可覆盖良好地成膜。包含第一工序,其向配置了硅基板(W)的减压下的成膜室(12)内,导入含有含氟气体、含卤气体和氧气的第一蚀刻气体,施加放电用电力蚀刻硅基板表面;以及第二工序,其向配置了已在第一工序中蚀刻完了的硅基板的、减压下的成膜室内,导入含有含氟气体的第二蚀刻气体,施加放电用电力,进一步蚀刻硅基板表面。
The present invention provides a low-cost dry etching method, which can efficiently manufacture a silicon substrate with a textured structure, the textured structure can effectively prevent light scattering, and can also be well covered when forming a prescribed thin film in a subsequent process Film-forming. It includes a first step of introducing a first etching gas containing a fluorine-containing gas, a halogen-containing gas, and oxygen into a film-forming chamber (12) under reduced pressure in which a silicon substrate (W) is placed, and applying electric power for discharging to etch silicon. the substrate surface; and a second step of introducing a second etching gas containing a fluorine-containing gas into a film-forming chamber under reduced pressure in which the silicon substrate etched in the first step is disposed, applying electric power for discharge, and further Etch the surface of the silicon substrate.
Description
技术领域technical field
本发明涉及一种用于在硅基板表面上形成纹理结构的干蚀刻方法,特别是涉及一种用于在结晶系太阳能电池的制造工序中,在硅基板的表面上形成具有高效防止光散乱效果的纹理结构的干蚀刻方法。The present invention relates to a dry etching method for forming a textured structure on the surface of a silicon substrate, in particular to a dry etching method for forming a texture structure on the surface of a silicon substrate in the manufacturing process of a crystalline solar cell, which has the effect of preventing light scattering with high efficiency. dry etching method for textured structures.
背景技术Background technique
在使用单晶或多晶硅基板的结晶系太阳能电池中,一直以来都是通过以干蚀刻方法在硅基板表面上形成凹凸形状然后进行表面粗化(施以纹理结构),使入射到硅基板表面上的光的反射减低来实现光电转换效率的提高。再有,已知例如在专利文件1中,在将硅锭切片得到结晶系太阳能电池用的硅基板时,通过干蚀刻统一处理从去除切片时产生的硅基板的损伤层的工序到形成纹理结构的工序。In crystalline solar cells using single crystal or polycrystalline silicon substrates, conventional methods have been to dry-etch the surface of the silicon substrate to form concavities and convexities, and then roughen the surface (impart a textured structure) so that the light incident on the surface of the silicon substrate is reduced. The reflection of light is reduced to realize the improvement of photoelectric conversion efficiency. Furthermore, it is known that, for example, in Patent Document 1, when slicing a silicon ingot to obtain a silicon substrate for a crystalline solar cell, dry etching is used to perform a unified process from the process of removing the damaged layer of the silicon substrate generated during slicing to the formation of a textured structure. process.
在上述专利文件1中,在干蚀刻装置的处理室内,首先,为去除切片时产生的硅基板表面的损伤层,将例如氧气和去除损伤层用的SF6气体导入规定流量,从高频电源向保持硅基板的基台施加电力,对硅基板表面进行干蚀刻去除损伤层。接着向处理室内导入例如氧气和形成纹理用的Cl2气及NF3气,从高频电源向基台施加电力,对硅基板表面进行干蚀刻,以此在去除了损伤层的硅基板面形成纹理结构。In the above-mentioned patent document 1, in the processing chamber of the dry etching device, at first, in order to remove the damaged layer on the surface of the silicon substrate produced during slicing, for example oxygen and SF gas for removing the damaged layer are introduced into a predetermined flow rate, and the high-frequency power supply Power is applied to the base holding the silicon substrate, and the damaged layer is removed by dry etching on the surface of the silicon substrate. Next, oxygen gas, Cl 2 gas and NF 3 gas for forming textures are introduced into the processing chamber, power is applied from a high-frequency power supply to the base, and the surface of the silicon substrate is dry-etched, thereby forming a silicon substrate on the surface of the silicon substrate from which the damaged layer has been removed. Texture structure.
然而,如上所述,通过干蚀刻,在硅基板表面形成纹理结构时,在蚀刻后的硅基板表面堆积有蚀刻时生成的反应生成物。再有,硅表面变成凹凸不断的状态,其顶部和底部变成尖锐的锐利的部分(即,看剖面形状时,呈锯齿状)。此时,如果在之后的工序中在硅基板表面例如使用真空成膜装置形成防止反射膜,则其顶部和底部无法高效成膜,产生覆盖不好等问题。However, as described above, when a textured structure is formed on the surface of the silicon substrate by dry etching, reaction products generated during etching accumulate on the surface of the silicon substrate after etching. In addition, the silicon surface becomes uneven, and its top and bottom become sharp sharp parts (that is, jagged when viewed in cross-section). At this time, if an anti-reflection film is formed on the surface of the silicon substrate in a subsequent process, for example, using a vacuum film forming device, the top and bottom cannot be efficiently formed, resulting in problems such as poor coverage.
因此,提出了通过使用氟酸和硝酸的混合液等蚀刻液的湿蚀刻方法去除反应生成物,并对顶部和底部进行使其圆滑的磨圆加工。但是,为了进行磨圆加工另外需要湿蚀刻用的设备,不仅生产率不高,而且还需进行废液处理等,导致成本增加。Therefore, it has been proposed to remove the reaction product by wet etching using an etchant such as a mixed solution of hydrofluoric acid and nitric acid, and to round the top and bottom to make them smooth. However, additional equipment for wet etching is required for round grinding, which not only lowers productivity, but also requires waste liquid treatment, etc., resulting in an increase in cost.
现有技术文献prior art literature
专利文献patent documents
专利文献1:专利公开2011-35262号公报Patent Document 1: Patent Publication No. 2011-35262
发明内容Contents of the invention
发明要解决的技术问题The technical problem to be solved by the invention
鉴于以上内容,本发明要解决的技术问题是提供一种低成本的干蚀刻方法,其能高效制造具有纹理结构的硅基板,所述硅基板能够有效地发挥防止光散射的效果,并在之后的工序中形成规定的薄膜的情况下也能覆盖良好地成膜。In view of the above, the technical problem to be solved by the present invention is to provide a low-cost dry etching method, which can efficiently manufacture a silicon substrate with a textured structure, and the silicon substrate can effectively prevent light scattering, and then In the case of forming a predetermined thin film in the process, it can be formed into a film with good coverage.
解决技术问题的手段means of solving technical problems
为解决上述技术问题,本发明提供一种用于在硅基板表面形成纹理结构的干蚀刻方法,其特征在于:包含第一工序,其在配置有硅基板的减压下的成膜室内,导入含有含氟气体、含卤气体和氧气的第一蚀刻气体,施加放电用电力蚀刻硅基板表面;第二工序,其在配置了已在第一工序中蚀刻完毕的硅基板的减压下的成膜室内,导入含有含氟气体的第二蚀刻气体,施加放电用电力进一步蚀刻硅基板表面。In order to solve the above-mentioned technical problems, the present invention provides a dry etching method for forming a textured structure on the surface of a silicon substrate, which is characterized in that: it includes a first step, which is introduced into a film-forming chamber under reduced pressure in which a silicon substrate is arranged. The first etching gas containing fluorine-containing gas, halogen-containing gas, and oxygen is applied to etch the surface of the silicon substrate with electric power for electric discharge; the second process is formed under reduced pressure on which the silicon substrate that has been etched in the first process is placed. In the film chamber, the second etching gas containing fluorine-containing gas is introduced, and the electric power for discharge is applied to further etch the surface of the silicon substrate.
采用本发明,在第一工序中在硅基板表面形成有纹理结构。即向处理室中导入含有例如CF4等含氟气体(流量比20~60%)、Cl2等卤素气体或HBr等卤化氢气体一类的含卤气体(流量比25~70%)、氧气(流量比10~40%)的第一蚀刻气体,例如向在该处理室内保持硅基板的基板台施加高频电力。由此,在处理室内形成等离子体,等离子体中的活性种或离子种入射硅基板表面进行蚀刻。此时,堆积在基板表面上的硅氧化物或碳氢系的氟化物等发挥掩膜作用,硅表面被蚀刻为凹凸形状,表面粗化,呈纹理结构。According to the present invention, a textured structure is formed on the surface of the silicon substrate in the first process. That is, in the processing chamber, introduce halogen-containing gases (flow ratio 25-70%) such as CF 4 and other fluorine-containing gases (flow ratio 20-60%), Cl 2 and other halogen gases or hydrogen halide gases such as HBr (flow ratio 25-70%), oxygen The first etching gas (flow ratio: 10 to 40%) applies high-frequency power, for example, to a substrate stage holding a silicon substrate in the processing chamber. As a result, plasma is formed in the processing chamber, and active species or ion species in the plasma are incident on the surface of the silicon substrate for etching. At this time, the silicon oxide or hydrocarbon-based fluoride accumulated on the substrate surface acts as a mask, and the silicon surface is etched into a concave-convex shape, and the surface is roughened and has a textured structure.
接着,对在第二工序中形成在硅基板表面的纹理结构,在真空气氛中实施清洗处理以去除在第一工序的蚀刻时堆积在硅基板表面上的硅氧化物和碳氢系的氟化物等反应生成物。即向处理室内导入例如由CF4等含氟气体组成的第二蚀刻气体,向在该处理室内保持硅基板的基板台施加高频电力。由此,由等离子体中的活性种和离子种来去除堆积在硅基板表面上的反应生成物。此时,划出处理室的真空腔的壁面(包含防护板)也被清洗。此时蚀刻气体也可包含氧气。Next, the texture structure formed on the surface of the silicon substrate in the second step is cleaned in a vacuum atmosphere to remove silicon oxide and hydrocarbon-based fluoride deposited on the surface of the silicon substrate during the etching in the first step. and other reaction products. That is, a second etching gas composed of, for example, a fluorine-containing gas such as CF 4 is introduced into the processing chamber, and high-frequency power is applied to the substrate stage holding the silicon substrate in the processing chamber. Thus, the reaction products accumulated on the surface of the silicon substrate are removed by the active species and ion species in the plasma. At this time, the wall surface (including the shield plate) of the vacuum chamber defining the processing chamber is also cleaned. At this time, the etching gas may also contain oxygen.
如此在本发明中,通过干蚀刻分别进行纹理结构的形成和第一工序后硅基板表面的清洗,以此可在硅基板上高效制造纹理结构。此外,由于不使用湿蚀刻,所以可达到高生产率,且可以实现成本降低。In this way, in the present invention, the formation of the texture structure and the cleaning of the surface of the silicon substrate after the first process are performed separately by dry etching, so that the texture structure can be efficiently produced on the silicon substrate. Furthermore, since wet etching is not used, high productivity can be achieved, and cost reduction can be achieved.
在本发明中,优选进一步包含第三工序,其在配置了已在第二工序中蚀刻完的硅基板的减压下的成膜室内,导入以含氟气体和含卤气体中任意一种为主要成分且在其中添加了氧气的第三蚀刻气体,施加放电用电力进一步蚀刻硅基板表面。由此,对在硅基板表面形成的纹理结构继续实施磨圆加工。即向处理室中导入包含例如CF4等含氟气体(流量比40~95%)、氧气(流量比5~60%)的第三蚀刻气体,向在该处理室内保持硅基板的基板台施加高频电力。由此,等离子体中的活性种和离子种入射硅基板表面进行蚀刻,对在第一工序中形成的硅基板表面的纹理结构的顶部和底部进行磨圆加工。此时,添加氧气是为了通过调整氧气的流量,控制蚀刻速率得到最适合的形状。结果是可通过干蚀刻一直进行到对该纹理结构的磨圆加工,即便是在之后的工序中形成规定的薄膜的情况下,也可以覆盖良好地成膜。In the present invention, it is preferable to further include a third step of introducing any one of a fluorine-containing gas and a halogen-containing gas into a film-forming chamber under reduced pressure in which the silicon substrate etched in the second step is disposed. The third etching gas with oxygen added as its main component further etches the surface of the silicon substrate by applying electric power for discharge. Thereby, the rounding process is continuously performed on the textured structure formed on the surface of the silicon substrate. That is, the third etching gas including fluorine - containing gas (flow rate ratio: 40-95%) and oxygen gas (flow rate ratio: 5-60%) is introduced into the processing chamber, and applied to the substrate table holding the silicon substrate in the processing chamber. high frequency electricity. Thus, the active species and ion species in the plasma are incident on the surface of the silicon substrate to etch, and the top and bottom of the textured structure on the surface of the silicon substrate formed in the first step are rounded. At this time, the purpose of adding oxygen is to control the etching rate to obtain the most suitable shape by adjusting the flow rate of oxygen. As a result, dry etching can be performed up to the rounding of the texture structure, and even when a predetermined thin film is formed in a subsequent process, a film can be formed with good coverage.
在本发明中,优选在同一处理室内,不停止施加放电用电力,停止向该处理室内导入第一蚀刻气体中的含卤气体和氧气,从第一蚀刻气体切换到第二蚀刻气体,连续进行第一工序和第二工序。再有,优选在同一处理室内,不停止施加放电用电力,再次开始导入氧气,从第二蚀刻气体切换到第三蚀刻气体,连续进行第二工序和第三工序。通过在这样的同一处理室内进行统一的干蚀刻,可进一步实现生产率的提高和成本的降低。In the present invention, it is preferable that in the same processing chamber, the application of electric power for discharge is not stopped, the introduction of the halogen-containing gas and oxygen in the first etching gas into the processing chamber is stopped, and the first etching gas is switched to the second etching gas, and the process is continuously performed. The first process and the second process. In addition, it is preferable that in the same processing chamber, the application of electric power for discharge is not stopped, the introduction of oxygen gas is resumed, the second etching gas is switched to the third etching gas, and the second step and the third step are continuously performed. By performing unified dry etching in such a same processing chamber, further improvement in productivity and reduction in cost can be achieved.
在本发明中,优选还包含第三工序,其在配置了已在第一工序中蚀刻完的硅基板的减压下的成膜室内,导入以含氟气体和含卤气体中任意一种为主要成分并在其中添加了氧气的第三蚀刻气体,施加放电用电力,进一步蚀刻硅基板表面,通过第二工序进一步蚀刻已在第三工序中蚀刻完的硅基板表面。此时,通过干蚀刻分别进行纹理结构的形成、对该纹理结构的磨圆加工和第三工序后的硅基板表面的清洗,以此可在硅基板上高效制造纹理结构。此外,由于不使用湿蚀刻,所以可达到高生产率,且可实现成本降低。In the present invention, it is preferable to further include a third step of introducing any one of a fluorine-containing gas and a halogen-containing gas into a film-forming chamber under reduced pressure in which the silicon substrate etched in the first step is disposed. The main component is the third etching gas to which oxygen is added, and the electric power for discharge is applied to further etch the surface of the silicon substrate, and the surface of the silicon substrate etched in the third step is further etched by the second step. At this time, the formation of the texture structure, the rounding of the texture structure, and the cleaning of the surface of the silicon substrate after the third step are respectively performed by dry etching, so that the texture structure can be efficiently produced on the silicon substrate. Furthermore, since wet etching is not used, high productivity can be achieved, and cost reduction can be achieved.
在本发明中,也可在同一处理室内,不停止施加放电用电力,停止向该处理室内导入第一蚀刻气体中的含氟气体和含卤气体中的任意一种,从第一蚀刻气体切换到第三蚀刻气体,连续进行第一工序和第三工序。再有,也可在同一处理室内,不停止施加放电用电力,从第三蚀刻气体切换到第二蚀刻气体,连续进行第三工序和第二工序。通过在这样的同一处理室内进行统一的干蚀刻,以此可进一步实现生产率的提高和成本的降低。In the present invention, it is also possible to switch from the first etching gas to any one of the fluorine-containing gas and the halogen-containing gas in the first etching gas introduced into the processing chamber without stopping the application of electric power for discharge in the same processing chamber. Up to the third etching gas, the first step and the third step are continuously performed. In addition, the third process and the second process may be continuously performed in the same processing chamber without stopping the application of electric power for discharge, switching from the third etching gas to the second etching gas. By performing unified dry etching in the same processing chamber as described above, further improvement in productivity and reduction in cost can be achieved.
另外,也可通过具有流量控制装置的单一气体导入系统,进行第一工序及第三工序中的氧气导入,控制流量控制装置以将第一工序中的氧流量比控制在10~40%的范围内,将第三工序中的氧流量比控制在5~60%的范围内。此处,如果第一工序中的氧流量比(第一蚀刻气体中的氧气与导入处理室的第一蚀刻气体的总流量的流量比)在上述范围以外的话,则存在无法形成纹理结构的问题,另一方面,如果第三工序中氧流量比在上述范围以外,则存在蚀刻速率过快或过慢,无法控制蚀刻形状的问题。In addition, the oxygen introduction in the first process and the third process can also be carried out through a single gas introduction system with a flow control device, and the flow control device can be controlled to control the oxygen flow ratio in the first process in the range of 10 to 40%. Inside, the oxygen flow ratio in the third process is controlled within the range of 5-60%. Here, if the oxygen flow ratio in the first step (the flow ratio of the oxygen in the first etching gas to the total flow of the first etching gas introduced into the processing chamber) is out of the above range, there is a problem that a textured structure cannot be formed. , On the other hand, if the oxygen flow ratio in the third step is out of the above-mentioned range, there is a problem that the etching rate is too fast or too slow, and the etching shape cannot be controlled.
附图说明Description of drawings
图1是实施本发明实施方式的干蚀刻方法的干蚀刻装置的结构示意图。FIG. 1 is a schematic structural view of a dry etching device implementing a dry etching method according to an embodiment of the present invention.
图2(a)及(b)是本发明实施例1中得到的基板的SEM照片。2( a ) and ( b ) are SEM photographs of the substrate obtained in Example 1 of the present invention.
图3(a)~(c)是本发明实施例2中得到的基板的SEM照片。3( a ) to ( c ) are SEM photographs of the substrate obtained in Example 2 of the present invention.
具体实施方式detailed description
下面,参照附图说明本发明实施方式的干蚀刻方法,所述干蚀刻方法以结晶系太阳能电池中使用的单晶或多晶硅基板(下面只称为基板W)为处理对象,在其表面形成纹理结构。另外,结晶系太阳能电池的结构为公知的,所以此处省略对其的详细说明。Hereinafter, a dry etching method according to an embodiment of the present invention will be described with reference to the accompanying drawings. The dry etching method takes a single crystal or polycrystalline silicon substrate (hereinafter simply referred to as substrate W) used in a crystalline solar cell as the processing object, and forms a texture on the surface thereof. structure. In addition, the structure of a crystalline solar cell is well known, so a detailed description thereof will be omitted here.
图1示出了可实行本实施方式的干蚀刻方法的干蚀刻装置EM。下面将以后文提到的喷淋板朝向基板W的方向为下方,以基板W朝向喷淋板的方向为上方进行说明。FIG. 1 shows a dry etching apparatus EM capable of implementing the dry etching method of this embodiment. The following description will be made with the direction of the shower plate facing the substrate W as below and the direction of the substrate W facing the shower plate as above.
干蚀刻装置EM具有真空腔1,划分出成膜室12,所述真空腔1可经真空排气装置11减压并保持在规定的真空度,所述真空排气装置11具有回转泵、涡轮分子泵等。在成膜室12的下部空间设置有基板台2。在基板台2上连接有来自于高频电源3的输出31。在成膜室12的上部以与基板台2相对的方式设置有喷淋板4。喷淋板4由环状的支持壁13的下端保持,所述支持壁13突出设置在真空腔1的内壁面上,设置有气体导入系统5向由支持壁13和喷淋板4划分出来的空间41中导入蚀刻气体。The dry etching device EM has a vacuum chamber 1, which is divided into a film forming chamber 12. The vacuum chamber 1 can be decompressed and maintained at a specified vacuum degree through a vacuum exhaust device 11. The vacuum exhaust device 11 has a rotary pump, a turbine Molecular pump, etc. A substrate stage 2 is provided in a lower space of the film formation chamber 12 . An output 31 from a high-frequency power supply 3 is connected to the substrate stage 2 . A shower plate 4 is provided on an upper portion of the film forming chamber 12 so as to face the substrate stage 2 . The shower plate 4 is held by the lower end of the annular support wall 13, and the support wall 13 protrudes from the inner wall surface of the vacuum chamber 1, and a gas introduction system 5 is provided to the part divided by the support wall 13 and the shower plate 4. An etching gas is introduced into the space 41 .
气体导入系统5具有与空间41相连通的汇合通气管51,气体管道53a、53b、53c分别间隔质量流量控制器等具有关闭功能的流量控制装置52a、52b、52c而与汇合通气管51连接,并分别与第一~第三气源54a、54b、54c相连通。由此,可按气体种类进行流量控制并导入到处理室12中。在本实施方式中,连续实施第一工序、第二工序以及第三工序,第一气源54a的气体由CF4、NF3、SF6、CxHyFz等含氟气体组成,第二气源54b的气体由Cl2等卤素气体或HBr等卤化氢气体一类含卤气体组成,第二气源54b的气体由氧气组成。以下对使用上述干蚀刻装置EM的第一实施方式的蚀刻方法进行具体说明。The gas introduction system 5 has a confluence ventilation pipe 51 communicated with the space 41, and the gas pipelines 53a, 53b, 53c are respectively separated from flow control devices 52a, 52b, 52c with closing functions such as mass flow controllers and connected with the confluence ventilation pipe 51, And communicate with the first to third gas sources 54a, 54b, 54c respectively. Thus, the flow rate of the gas can be controlled and introduced into the processing chamber 12 according to the type of gas. In this embodiment, the first process, the second process, and the third process are continuously implemented. The gas in the first gas source 54a is composed of fluorine-containing gases such as CF 4 , NF 3 , SF 6 , and CxHyFz. The gas in the second gas source 54b The gas is composed of halogen gas such as Cl 2 or hydrogen halide gas such as HBr, and the gas of the second gas source 54b is composed of oxygen. The etching method of the first embodiment using the above-mentioned dry etching apparatus EM will be specifically described below.
首先,在处理室12达到规定真空度(例如10-5Pa)的状态下,通过图外的真空机器人传送基板W,并保持在基板台2上,接着,作为第一工序,通过气体导入系统5的各流量控制阀52a~52c,将来自第一~第三气源54a、54b、54c的第一蚀刻气体从空间41经喷淋板4导入到处理室12内。作为第一蚀刻气体,由作为含氟气体的CF4、作为含卤气体的Cl2以及氧气组成,而且,含氟气体与导入到处理室12内的气体总流量的流量比设在20~60%的范围内,含卤气体与所述气体总流量的流量比设在25~70%的范围内,氧气与所述气体总流量的流量比设在10~40%的范围内(此时,减压下的处理室12内的压力为30~250Pa)。各气体的流量比可根据处理室12的尺寸或其他工艺条件在上述范围内适当设置(在第三工序中也一样)。与此相结合,经高频电源3向基板台2施加放电用电力。适当设置此时的施加电力使电力密度变为0.5~1.8W/cm2。由此,在第一工序中在基板W表面上形成纹理结构。即在处理室12内形成等离子体,等离子体中的活性种或离子种入射到基板W表面进行蚀刻。此时由于堆积在基板表面的氧元素发挥掩膜的作用,硅表面被蚀刻为凹凸形状而粗化变为纹理结构。First, in the state where the processing chamber 12 has reached a predetermined degree of vacuum (for example, 10 -5 Pa), the substrate W is transported by a vacuum robot (not shown) and held on the substrate stage 2. The flow control valves 52 a to 52 c of 5 introduce the first etching gas from the first to third gas sources 54 a , 54 b , and 54 c from the space 41 through the shower plate 4 into the processing chamber 12 . As the first etching gas, it is composed of CF 4 as a fluorine-containing gas, Cl 2 as a halogen-containing gas, and oxygen, and the flow rate ratio of the fluorine-containing gas to the total flow of gas introduced into the processing chamber 12 is set at 20 to 60. %, the flow ratio of the halogen-containing gas to the total flow of the gas is set in the range of 25 to 70%, and the flow ratio of the oxygen to the total flow of the gas is set in the range of 10 to 40% (at this time, The pressure in the processing chamber 12 under reduced pressure is 30 to 250 Pa). The flow rate ratio of each gas can be appropriately set within the above-mentioned range according to the size of the processing chamber 12 or other process conditions (the same is true in the third step). In conjunction with this, electric power for discharging is applied to the substrate stage 2 via the high-frequency power supply 3 . The applied power at this time is appropriately set so that the power density becomes 0.5 to 1.8 W/cm 2 . Thus, a textured structure is formed on the surface of the substrate W in the first process. That is, plasma is formed in the processing chamber 12 , and active species or ion species in the plasma are incident on the surface of the substrate W for etching. At this time, since the oxygen element accumulated on the surface of the substrate acts as a mask, the silicon surface is etched into a concave-convex shape and roughened into a textured structure.
在将上述第一工序的蚀刻进行了规定时间后,作为第二工序接着实施清洗处理。即不停止高频电源3施加的放电用电力,关闭流量控制装置52b停止向处理室12内导入作为含卤气体的Cl2,并关闭流量控制装置52c停止向处理室12内导入氧气,由此从第一蚀刻气体切换到第二蚀刻气体。通过该第二工序,去除在上述第一工序的蚀刻时堆积在基板表面的硅氧化物或碳氢系的氟化物等反应生成物(也称“蚀刻残渣”)。与此同时也对划出处理室12的真空腔1的内壁面(包含防护板)进行清洗。After performing the etching in the above-mentioned first step for a predetermined time, a cleaning treatment is performed next as a second step. That is, the discharge power applied by the high-frequency power supply 3 is not stopped, the flow control device 52b is closed to stop introducing Cl 2 as a halogen-containing gas into the processing chamber 12, and the flow control device 52c is closed to stop introducing oxygen gas into the processing chamber 12, thereby Switching from the first etching gas to the second etching gas. This second step removes reaction products such as silicon oxides and hydrocarbon-based fluorides (also referred to as "etching residue") deposited on the surface of the substrate during etching in the first step. At the same time, the inner wall surface (including the protective plate) of the vacuum chamber 1 defining the processing chamber 12 is also cleaned.
在将上述第二工序的蚀刻进行了规定时间后,接着实施第二工序。即不停止高频电源3施加的放电用电力,关闭流量控制装置52c再次开始向处理室12内导入氧气,从第二蚀刻气体切换到第三蚀刻气体。此时,含氟气体相对于导入到处理室12内的气体总流量的流量比设在40~95%的范围内,氧气相对于该气体总流量的流量比设在5~60%的范围内(此时,减压下的处理室12内的压力设为20~150Pa)。After performing the etching in the above-mentioned second step for a predetermined time, the second step is then implemented. That is, the discharge power applied by the high-frequency power supply 3 is not stopped, the flow control device 52c is turned off, and the introduction of oxygen gas into the processing chamber 12 is restarted, switching from the second etching gas to the third etching gas. At this time, the flow ratio of the fluorine-containing gas relative to the total flow of the gas introduced into the processing chamber 12 is set in the range of 40 to 95%, and the flow ratio of oxygen to the total flow of the gas is set in the range of 5 to 60%. (At this time, the pressure in the processing chamber 12 under reduced pressure is 20 to 150 Pa).
通过该第三工序,对形成在基板W表面上的纹理结构进行磨圆加工。即通过入射到基板W表面的等离子体中的活性种或离子种,对第一工序中形成的硅基板表面的纹理结构的顶部和底部进行磨圆加工。此时,添加氧气是为了通过调整氧气的流量而控制蚀刻速率得到最适合的形状。另外,当纹理结构因第三工序而被反应生成物所覆盖时,也可设置为再次进行上述第二工序。Through this third step, the textured structure formed on the surface of the substrate W is rounded. That is, the top and bottom of the textured structure on the surface of the silicon substrate formed in the first step are rounded by the active species or ion species in the plasma incident on the surface of the substrate W. At this time, the purpose of adding oxygen is to control the etching rate by adjusting the flow rate of oxygen to obtain the most suitable shape. In addition, when the texture structure is covered with the reaction product in the third step, the above-mentioned second step may be performed again.
控制流量控制装置使第一工序的氧流量比在10~40%的范围内,第三工序的氧流量比在5~60%的范围内,由此可高效地进行第一工序的纹理结构形成以及第三工序的磨圆加工。另外,如果第一工序的氧流量比(氧气与导入到处理室内的第一蚀刻气体的总流量的流量比)在上述范围以外,则存在无法形成纹理结构的问题,另一方面,如果第三工序的氧流量比(氧气与导入到处理室12内的第三蚀刻气体的总流量的流量比)在上述范围以外,则存在蚀刻速率过快或过慢,无法控制蚀刻形状的问题。Control the flow control device so that the oxygen flow ratio of the first process is in the range of 10-40%, and the oxygen flow ratio of the third process is in the range of 5-60%, so that the texture structure formation of the first process can be efficiently carried out And the rounding process of the third process. In addition, if the oxygen flow ratio in the first step (the flow ratio of oxygen to the total flow of the first etching gas introduced into the processing chamber) is outside the above range, there is a problem that the texture cannot be formed. On the other hand, if the third If the oxygen flow ratio of the process (the flow ratio of oxygen to the total flow of the third etching gas introduced into the processing chamber 12) is outside the above range, the etching rate is too fast or too slow, and the etching shape cannot be controlled.
接着,对使用上述干蚀刻装置EM的第二实施方式的蚀刻方法进行说明。第二实施方式的蚀刻方法除将第二工序和第三工序的顺序颠倒外,都与上述第一实施方式的蚀刻方法相同。此处,优选通过不停止高频电源3施加的放电用电力而切换蚀刻气体,来在同一处理室中,按第一工序、第三工序、第二工序的顺序连续进行。对于各工序的气体流量等条件,由于与上述第一实施方式相同,所以此处省略详细说明。采用本实施方式,由于最后进行清洗,所以可可靠地保证磨圆加工后的纹理结构被反应生成物所覆盖。另一方面,由于第一工序中在基板表面形成的反应生成物包含硅,所以在第三工序的磨圆加工时该反应生成物也被蚀刻,因此存在通过第三工序直到得到需要的表面状态为止的处理时间比上述第一实施方式还长的情况。另外,也可考量太阳能电池的生产线上干蚀刻前后的工序和干蚀刻的各项条件等,适当选择第一实施方式和第二实施方式中的任意一种。Next, the etching method of the second embodiment using the dry etching apparatus EM described above will be described. The etching method of the second embodiment is the same as the etching method of the above-mentioned first embodiment except that the order of the second step and the third step is reversed. Here, it is preferable to continuously perform the first step, the third step, and the second step in the same processing chamber by switching the etching gas without stopping the discharge power applied by the high-frequency power supply 3 . Conditions such as the gas flow rate in each step are the same as those in the first embodiment described above, so detailed description thereof will be omitted here. According to this embodiment, since the cleaning is performed at the end, it can be reliably ensured that the texture structure after the rounding process is covered by the reaction product. On the other hand, since the reaction product formed on the surface of the substrate in the first step contains silicon, the reaction product is also etched during the rounding process in the third step, so there is a possibility that the third step may not be enough until the desired surface state is obtained. The processing time up to now is longer than that of the above-mentioned first embodiment. In addition, any one of the first embodiment and the second embodiment may be appropriately selected in consideration of steps before and after dry etching on a solar cell production line, various conditions of dry etching, and the like.
根据上述内容,通过单一的干蚀刻装置EM,进行纹理结构的形成和对该纹理结构的磨圆加工,由此发挥抑制光散射的效果,并在之后的工序中形成规定的薄膜的情况下,也可在硅基板上高效制造可覆盖良好地成膜的纹理结构。此外,由于不使用湿蚀刻,所以可实现高生产率,而且可实现成本降低。另外,可在上述第一工序之前在同一处理室12内进行去除将硅锭切片得到基板W时,切片时在基板W上产生的损伤层的工序。此时,干蚀刻的条件由于可使用上述以往例,所以此处省略对其的详细说明。From the above, when forming a texture structure and rounding the texture structure by a single dry etching apparatus EM, thereby exerting the effect of suppressing light scattering, and forming a predetermined thin film in a subsequent process, It is also possible to produce textured structures with good coverage and good film formation on silicon substrates efficiently. In addition, since wet etching is not used, high productivity can be achieved, and cost reduction can be achieved. In addition, a step of removing a damaged layer generated on the substrate W during slicing when the silicon ingot is sliced to obtain the substrate W may be performed in the same processing chamber 12 before the above-mentioned first step. At this time, since the above-mentioned conventional example can be used for the conditions of dry etching, a detailed description thereof will be omitted here.
接着,对使用图1所示的干蚀刻装置EM进行的实施例加以说明。在第一实施例中,对于基板使用以公知方法得到的多晶硅基板,第一工序的条件为:以CF4、Cl2和氧气作为第一蚀刻气体,该CF4:Cl2:氧气的流量设为300:1000:200sccm(此时的流量比为20:67:13%),蚀刻时的处理室12的压力设为60Pa,来自高频电源3的施加电力设为2kW,进行90秒钟所述处理。第二工序的条件为:以CF4作为第二蚀刻气体,该CF4的流量设为300sccm,蚀刻时的处理室12的压力设为60Pa,来自高频电源3的施加电力设为1.5kW,进行10秒钟所述清洗处理。第三工序的条件为:以CF4和氧气作为第三蚀刻气体,该CF4:氧气的流量设为300:50sccm(此时的流量比是86:14%),蚀刻时的处理室的压力设为60Pa,来自高频电源3的施加电力设为1.0kW,进行10秒钟所述处理。图2(a)中示出刚实施完第二工序后的基板的SEM照片,图2(b)中示出刚实施完第三工序后的基板的SEM照片。由此可知,通过干蚀刻可在硅基板上高效制造纹理结构。Next, an example performed using the dry etching apparatus EM shown in FIG. 1 will be described. In the first embodiment, a polysilicon substrate obtained by a known method is used as the substrate, and the conditions of the first process are: CF 4 , Cl 2 and oxygen are used as the first etching gas, and the flow rate of the CF 4 :Cl 2 :oxygen is set to 300:1000:200sccm (the flow ratio at this time is 20:67:13%), the pressure of the processing chamber 12 during etching is set to 60Pa, the applied power from the high-frequency power supply 3 is set to 2kW, and the process is performed for 90 seconds. described above. The conditions of the second step are: using CF 4 as the second etching gas, the flow rate of this CF 4 is set to 300 sccm, the pressure of the processing chamber 12 during etching is set to 60 Pa, and the applied power from the high-frequency power supply 3 is set to 1.5 kW, The washing process was performed for 10 seconds. The condition of the third process is: with CF 4 and oxygen as the third etching gas, the flow of this CF : oxygen is set to 300:50 sccm (the flow ratio at this time is 86:14%), the pressure of the processing chamber during etching It was set at 60 Pa, the applied electric power from the high-frequency power supply 3 was set at 1.0 kW, and the above-mentioned processing was performed for 10 seconds. FIG. 2( a ) shows a SEM photograph of the substrate immediately after the second step, and FIG. 2( b ) shows a SEM photograph of the substrate immediately after the third step. From this, it can be seen that a textured structure can be efficiently produced on a silicon substrate by dry etching.
在第二实施例中,作为基板使用以公知方法得到的多晶硅基板,按第一工序、第三工序、第二工序的顺序连续实施。此时,第一工序的条件是:以CF4、Cl2和氧气作为第一蚀刻气体,该CF4:Cl2:氧气的流量比设为60:30:10%,蚀刻时的处理室12的压力设在20~150Pa的范围内,来自高频电源3的施加电力设为29.5kW,处理时间设为75秒钟。第三工序的条件是:以CF4和氧气作为第三蚀刻气体,该CF4:氧气的流量比设为90:10%,蚀刻时的处理室的压力设在上述20~150Pa的范围内,来自高频电源3的施加电力设为15kW,处理时间设为15秒钟。第二工序的条件是:以CF4作为第二蚀刻气体,该CF4设为导入与第三工序同等的流量,蚀刻时的处理室12的压力设在上述20~150Pa的范围内,来自高频电源3的施加电力设为15kW,处理时间设为10秒钟。图3(a)中示出刚实施完第一工序后的基板的SEM照片,图3(b)中示出刚实施完第三工序后的基板的SEM照片,图3(c)示出刚实施完第二工序后的基板的SEM照片。由此,第一工序后基板表面整体被反应生成物所覆盖,第二工序后纹理结构的顶部及底部被磨圆,顶部残留有反应生成物(照片中为白色光亮部分),但第三工序后顶部的反应生成物被完全去除,可知通过干蚀刻可在硅基板上高效制造纹理结构。In the second example, a polysilicon substrate obtained by a known method was used as the substrate, and the first step, the third step, and the second step were sequentially carried out. At this time, the conditions of the first process are: CF 4 , Cl 2 and oxygen are used as the first etching gas, the flow ratio of the CF 4 :Cl 2 :oxygen is set to 60:30:10%, and the processing chamber 12 during etching The pressure was set in the range of 20 to 150 Pa, the applied power from the high-frequency power supply 3 was set to 29.5 kW, and the processing time was set to 75 seconds. The condition of the 3rd process is: with CF 4 and oxygen as the 3rd etching gas, this CF : the flow ratio of oxygen is set as 90: 10 %, the pressure of the treatment chamber during etching is set in the scope of above-mentioned 20~150Pa, The applied power from the high-frequency power source 3 was set to 15 kW, and the processing time was set to 15 seconds. The condition of the second process is: with CF 4 as the second etching gas, the CF 4 is set to introduce the same flow rate as that of the third process, and the pressure of the processing chamber 12 during etching is set in the above-mentioned range of 20-150Pa, from high The applied power of the frequency power source 3 was set to 15 kW, and the processing time was set to 10 seconds. Fig. 3 (a) shows the SEM photo of the substrate just after the first process has been implemented, Fig. 3 (b) shows the SEM photo of the substrate just after the third process has been implemented, and Fig. 3 (c) shows the SEM photo of the substrate just after the third process has been implemented. SEM photograph of the substrate after the second process. Therefore, after the first process, the entire surface of the substrate is covered by the reaction product, and after the second process, the top and bottom of the texture structure are rounded, and the reaction product remains on the top (white bright part in the photo), but the third process After the reaction product on the top was completely removed, it can be seen that the texture structure can be efficiently produced on the silicon substrate by dry etching.
以上,对本发明的实施方式进行了说明,但本发明并不被上述实施方式所限定。在上述实施方式中,以向基板台2施加电力为例对作为可实施本发明干蚀刻方法的干蚀刻装置EM进行了说明,但并不仅限于此,本发明的干蚀刻方法也可广泛适用于使用电感耦合放电的干蚀刻装置等其他形式的干蚀刻装置。As mentioned above, although embodiment of this invention was described, this invention is not limited to the said embodiment. In the above-mentioned embodiment, the dry etching apparatus EM capable of implementing the dry etching method of the present invention has been described by taking the application of power to the substrate stage 2 as an example. Other types of dry etching equipment such as dry etching equipment using inductively coupled discharge.
在上述实施方式中,是通过单一的干蚀刻处理装置EM实施第一工序、第二工序及第三工序,但也可将其单独实施,进而,以在第二工序中停止含卤气体的实施方式为例进行了说明,但也可停止含氟气体。再有,虽然上述实施方式中以含氟气体、含卤气体及氧气为彼此区别的气源,但也可以分别以含氟气体和氧气的混合气体、含卤气体和氧气的混合气体为气源。In the above-mentioned embodiment, the first process, the second process and the third process are implemented by a single dry etching processing apparatus EM, but they may be implemented separately, and further, the implementation of the halogen-containing gas is stopped in the second process. The method is described as an example, but it is also possible to stop the fluorine-containing gas. Furthermore, although in the above-mentioned embodiment, fluorine-containing gas, halogen-containing gas and oxygen are used as different gas sources, it is also possible to use a mixed gas of fluorine-containing gas and oxygen, a mixed gas of halogen-containing gas and oxygen as the gas source .
在上述实施方式中,以在第二工序中停止氧气的实施方式为例进行了说明,但也可控制流量控制装置52c,使第二工序的氧气的导入量低于第一工序。此时,含卤气体与导入处理室12内的气体总流量的流量比设在60~90%的范围内,氧气与该气体总流量的流量比设在10~40%的范围内(此时,减压下的处理室12内的压力设为40~150Pa)。In the above-mentioned embodiment, the embodiment in which oxygen gas is stopped in the second step has been described as an example, but the flow control device 52c may be controlled so that the amount of oxygen introduced in the second step is lower than that in the first step. At this time, the flow ratio of the halogen-containing gas to the total flow of gas introduced into the processing chamber 12 is set in the range of 60 to 90%, and the flow ratio of oxygen to the total flow of the gas is set in the range of 10 to 40% (at this time , the pressure in the processing chamber 12 under reduced pressure is set at 40 to 150 Pa).
附图标记说明Explanation of reference signs
EM、干蚀刻装置,12、处理室,2、基板台,3、高频电源,4、喷淋板,5、气体导入系统,52a~52c、质量流量控制器(流量控制装置)、53a~53c、气体管道,54a~54c、(含氟气体、含卤气体及氧气用的各)气源,W、基板(硅基板)。EM, dry etching device, 12, processing chamber, 2, substrate table, 3, high-frequency power supply, 4, shower plate, 5, gas introduction system, 52a~52c, mass flow controller (flow control device), 53a~ 53c, gas pipes, 54a-54c, (each for fluorine-containing gas, halogen-containing gas, and oxygen) gas sources, W, substrate (silicon substrate).
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