throbber
~· . ~ ...
`
`PATENT DAj~N 2 5 2000
`
`PATENT
`NUMBER
`
`...
`
`DATE
`·::'i /
`
`Ci.A~
`]/.':::. ·_ ..
`
`SUBCLASS
`"/ ) __ r:::__
`~--:_.
`
`I
`
`~::·L r·:-,t··,.-!1.., .. ! 'f
`
`c: r:.~ 1:::: E: !< ::
`
`c:: (.:! =·
`
`**CONTINUING DATA******~**************
`. .
`..
`...
`\_l L:: r:;_~ I F _,_ : .... _, ___ ,
`.. .........
`...
`'Tl···i I:-:-:-:~
`C:: T F'
`!:.:·i~·-·:i· .. 'L..!\l
`\·:.:·;
`J.·:·:::;
`I...il···
`WHICH IS A CON OF
`
`.............. LC?Y .....
`
`.
`
`..,
`I
`L.>·r; i
`/ ·
`:!. u ...... ::?:::-:: .. /
`0::::: /.· ";.:.::::-:·~(::. :: :::·:{:!. _!_::_:,
`08/567,224 12/04/
`
`{.':·:E·:-:!\1
`d (1rJ
`
`' \/;/?&' ;: . • \ ! .. L '·· i\i [ Ci hi' ' ' L L i
`
`\ ! \ ' ·•·
`
`---
`
`..
`
`i
`/
`I
`I
`
`!~-- () F-~ ··::: :i. i_::~ l -...1
`
`F:· I L.. I !..._.! Ci
`
`l . I C: E: j\_j :::-:-; E:::
`
`C:i F;~ (::·! i ..... ! ·r E::: ))
`
`:l. 0 .......
`
`:!. 0 / ~::;' -_:x
`
`***** SMALL ENTITY *****
`
`COUNTRY I DRWGS. I CLAIMS I CLAIMS I RECEIVED
`c:r:·j
`~~E- :.~j. f:::, (! :: 0 0
`:L
`
`-···,
`-l
`.!.-.:.i
`
`.L
`
`ATTORNEY'S
`DOCKET NO.
`
`F' L.. (:; ::::~ jYJ (::l
`
`:o I
`
`SUSTAINED BY INDUCTIVE
`
`Assistant Examiner
`
`+
`
`Sheets Drwg.
`
`..1\tirtJ;: St..rlE!I\'tH
`
`~"'
`
`\3
`
`ISSUE
`BATCH
`NUMBER
`
`l~. tl~
`
`' >""'·<f~'
`
`,....,, •
`
`• n <
`
`Label
`Area
`
`WARNING: The information disclosed herein may be restricted. Unaytl16rized disclosure may be prohibited
`by the United States Code Title 35, Sections 122, 18:t"'and 368. Possession outside the U.S.
`Patent & Trademark Office is restricted to authorized employees and contractors only.
`
`',··~~ .. -'•
`
`Form PT0-436A
`(Rev. 8192)
`
`SCAN 3C'Jonna! DrawingS t_strtsl sst_
`. Q~<~ "()\-
`.
`
`!SSUEfEt:··
`
`;>."'-
`
`(FACE)
`
`LAM Exh 1009-pg 1
`
`

`
`PATENT APPLICATION
`
`··--··-··---····-. ......
`
`I \\\1111\\\1\\1\1\\11\\\\1\\11111\111\1\111\11 II\\
`08866040
`. -
`CONTENTS REC~\\IED
`MAR 0 2. \9~
`
`Date:
`Received
`or
`Mailed
`
`GROUP 2100
`
`II
`1
`
`......
`
`')
`
`~·
`
`3. . · I
`/'"
`;/ 4
`···"''
`•
`,,,A"
`,,_."f~<!-t!,:'r~
`5.
`
`...
`
`~
`
`<1
`
`)'
`
`..__.. >j
`
`v
`
`I ,_,..
`
`··""-< "I.JY!'
`
`I
`
`f -,__-'-...)
`
`1 :!! \ I (I !...tH . .l?-1¢:'
`
`0
`
`' .. /
`lD)lLf\~']
`/ ;k -1 ( --1'7
`
`~
`
`lO ·_;}· c~
`y.-..o--?
`,
`..
`.r-s·~?z-
`o& /6q/97'
`G~~ Jiel -OrLl
`Ouf:;B )qq
`R/3! J9f
`9 ·-~7- cr 7
`L/~7/f9
`
`( --.-,------~...,
`
`-,--------~-----~ -· -------[-----·
`
`\'
`
`13.
`
`14.
`
`15.
`
`16.
`
`17.
`
`18.
`
`19.
`
`20.
`
`··&.- 21.
`
`22.
`
`23.
`
`24.
`
`25.
`
`26.
`
`2~.
`
`28.
`
`29~
`
`30.
`
`31.
`
`32.
`
`f~--
`
`1111 •
`
`1.• ~
`
`-·-·""
`
`(FRONT)
`
`LAM Exh 1009-pg 2
`
`

`
`United States Patent [19]
`Flamm
`
`US006017221A
`[11] Patent Number:
`[45] Date of Patent:
`
`6,017,221
`Jan. 25, 2000
`
`[54] PROCESS DEPENDING ON PLASMA
`DISCHARGES SUSTAINED BY INDUCTIVE
`COUPLING
`
`5,431,968
`5.534.231
`5,637,961
`
`7/1995 Miller et al..
`7/1996 savas.
`6/1997 Ishii et al. .
`
`[76] Inventor: Daniel L. Flamm, 476 Green View Dr.,
`Walnut Creek, Calif. 94596
`
`[21] App1_NO_;08/866,040
`
`[221
`
`Filed?
`
`May 30! 1997
`
`Related US. Application Data
`
`[63]
`
`Continuation-in-part of application No. 08/736,315, Oct. 23,
`1996, abandoned, which is a continuation of application No.
`08/567,224’ Dec 4’ 1995’ abandoned~
`7
`[51] Int. Cl. ................................................... .. H01L 21/00
`[52] US. Cl. ........................ .. 437/225; 437/228; 437/233;
`156/643; 156/192.25; 204/192.32
`[58] Field of Search .......................... .. 118/501; 156/643,
`156/345, 646, 659.1; 219/12141, 121.44;
`204/1921, 19212, 19225; 427/12; 216/2;
`437/225, 228, 233
`
`OTHER PUBLICATIONS
`
`Asmussen et al., “The Design of a Microwave Plasma
`Cavity,” Pr0c. ofIEEE, 62(1):109—117 (Jan. 1974).
`Eckert, “The Hundred Year History of Induction Dis
`charges,” 2”“Ann. Int’l Conf Plasma Chem. Tech., (1984).
`Fossheim et al., “Broadband tguning of helical resonant
`cavitites,” J. Phys. E. Sci. Instrum, 11:892—893 (1978).
`NiaZi et al. “Operation of a helical resonator plasma source,”
`Plasma Sources Sci. TechnoL, 3:482—495 (1994).
`Roppel et al., “Low temperature oxidation of silicon using a
`microwave plasma disk source,” J. Vac. sci. TechnoL,
`B4(1):295—298 (Jan/Feb. 1986).
`Zverev et a1‘, “Realization of a Filter With Helical COmpO_
`nents,” [RE THU“ On Component Parts) pp 99_11(), (Sap~
`1961)
`
`Primary Examiner—Laurie Scheiner
`Attorney, Agent, Or Firm—ToWnsend and TOWnScnd and
`CreW LLP
`
`[561
`
`References Cited
`
`[571
`
`ABSTRACT
`
`Us‘ PATENT DOCUMENTS
`
`3/1975 Gabriel .
`3,873,884
`1/1983 Steinberg et a1- -
`4,368,092
`4/1990 Flamm ct a1~ -
`4,918,031
`7/1990 Asmussen et al. ................... .. 156/643
`4,943,345
`8/1993 Johnson '
`5’234’529
`8/1993 Barnes et al. .
`5,241,245
`4/1994 Flamm .
`5,304,282
`5,361,016 11/1994 Ohkawa et al. ................. .. 315/111.41
`
`A process for fabricating a product 28, 119. The process
`comprises the steps of subjecting a substrate to a composi
`tion of entities, at least one of the entities emanating from a
`species generated by a gaseous discharge excited by a high
`frequency ?eld in which the vector sum of phase and
`anti-phase capacitive coupled voltages from the inductive
`coupling structure substantially balances.
`
`7 Claims, 13 Drawing Sheets
`
`LAM Exh 1009-pg 3
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 1 0f 13
`
`6,017,221
`
`FIG. 1
`
`LAM Exh 1009-pg 4
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 2 0f 13
`
`6,017,221
`
`0
`
`f/ /
`
`Q 5
`
`C 6
`
`/ l9 \L
`
`5
`
`M _ 6
`
`w M ...... \ 7
`
`D 5 B 5 5
`
`7 5
`
`5/ w w m
`
`/ .. 2 --|1|\ _
`
`\ B
`
`5 __
`
`/7 r @ 1.
`
`5
`
`
`
`IIIIIII/ . I , .............................. :l\_ F
`
`u .
`
`
`
`.................................. ..l/ A
`
`/ \ 1:.
`
`A \\v/_
`\\\\
`
`LAM Exh 1009-pg 5
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 3 0f 13
`
`6,017,221
`
`57
`WAC‘I /
`
`51
`
`53-]:
`
`55
`
`/-5.9
`
`WAC 2
`
`/57
`
`WAC
`
`FIG. 2B
`
`55
`
`5.1
`
`‘T 63
`
`FIG. 2C
`
`50/:
`
`LAM Exh 1009-pg 6
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 4 0f 13
`
`6,017,221
`
`PS1
`
`WAC 10
`
`_.____._..________..._____I
`_._._...__..._______.__.__.________________..
`
`______._....__._________1
`i
`WAC 1b
`
`WAC 20
`
`PS2
`
`@EEEEE'E-EE}}}1'_______________
`
`WAC 2b
`
`[52
`
`PM
`
`PA2
`
`V2
`
`PAn
`
`V3
`
`PSn
`
`@3333333I-I-I-I-I-3j-j-j-j-j-3§______________
`
`WAC nu
`
`i
`WAC nb
`
`FIG. 20
`
`LAM Exh 1009-pg 7
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 5 0f 13
`
`6,017,221
`
`mm .Ek
`
`LAM Exh 1009-pg 8
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 6 0f 13
`
`6,017,221
`
`l\ \ \\\\\\\\l
`
`130-\ I /// I] M119
`.113] §
`
`FIG. 3
`
`LAM Exh 1009-pg 9
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 7 0f 13
`
`6,017,221
`
`F
`
`125-\
`
`f“
`
`,/—114
`
`V
`o
`405
`F _______________ "—l O
`
`_
`
`l
`l
`o i
`
`I O
`i g
`i o
`
`405
`
`_
`
`1 4001
`1,94
`
`l 8
`3 i
`132—\o L _______________ __I o
`o
`o
`
`+ ‘404
`
`.130
`
`m’
`
`\
`\m
`
`i
`
`K
`""4
`
`‘
`
`115/ \Y &
`
`FIG. 4
`
`1%
`
`LAM Exh 1009-pg 10
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 8 0f 13
`
`6,017,221
`
`203 \
`
`r 205
`
`/- 200
`
`c
`l:
`
`c
`H
`
`LAM Exh 1009-pg 11
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 9 0f 13
`
`6,017,221
`
`mam.
`
`mm .SQ
`
`O,
`
`Rm 0
`
`LAM Exh 1009-pg 12
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 10 0f 13
`
`6,017,221
`
`$3265
`
`E250
`
`532x32 v
`
`003:;
`
`at 5 {0
`
`3323
`
`$3265
`
`E250
`
`LAM Exh 1009-pg 13
`
`

`
`U.S. Patent
`
`Jan. 25, 2000
`
`Sheet 11 0f 13
`
`6,017,221
`
`/500
`
`/502
`
`OOOOO/OOOCK W508
`
`0 00000000
`
`FIG. 5
`
`LAM Exh 1009-pg 14
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 12 0f 13
`
`6,017,221
`
`ooooo:oooooo
`
`I
`
`I
`
`
`
`+0 |__|0 O +0 0
`
`
`
`|__|0
`
`O
`
`
`
`III OI> Ill
`
`LAM Exh 1009-pg 15
`
`

`
`U.S. Patent
`
`Jan. 25,2000
`
`Sheet 13 of 13
`
`6,017,221
`
`LAM Exh 1009-pg 16
`
`LAM Exh 1009-pg 16
`
`

`
`1
`PROCESS DEPENDING ON PLASMA
`DISCHARGES SUSTAINED BY INDUCTIVE
`COUPLING
`
`CROSS REFERENCES TO RELATED
`APPLICATIONS
`
`This application is a continuation-in-part of application
`Ser. No. 08/736,315 ?led Oct. 23, 1996, noW abandoned,
`Which is a continuation of application Ser. No. 08/567,224
`?led Dec. 4, 1995, noW abandoned. All of these documents
`are hereby incorporated by reference for all purposes.
`
`BACKGROUND OF THE INVENTION
`
`This invention relates generally to plasma processing.
`More particularly, the invention is for plasma processing of
`devices using an inductive discharge. This invention is
`illustrated in an example With regard to plasma etching and
`resist stripping of semiconductor devices. The invention also
`is illustrated With regard to chemical vapor deposition
`(CVD) of semiconductor devices. But it Will be recogniZed
`that the invention has a Wider range of applicability. Merely
`by Way of example, the invention also can be applied in
`other plasma etching applications, and deposition of mate
`rials such as silicon, silicon dioxide, silicon nitride,
`polysilicon, among others.
`Plasma processing techniques can occur in a variety of
`semiconductor manufacturing processes. Examples of
`plasma processing techniques occur in chemical dry etching
`(CDE), ion-assisted etching (IAE), and plasma enhanced
`chemical vapor deposition (PECVD), including remote
`plasma deposition (RPCVD) and ion-assisted plasma
`enhanced chemical vapor deposition (IAPECVD). These
`plasma processing techniques often rely upon radio fre
`quency poWer (rf) supplied to an inductive coil for providing
`poWer to gas phase species in forming a plasma.
`Plasmas can be used to form neutral species (i.e.,
`uncharged) for purposes of removing or forming ?lms in the
`manufacture of integrated circuit devices. For instance,
`chemical dry etching generally depends on gas-surface
`reactions involving these neutral species Without substantial
`ion bombardment.
`In other manufacturing processes, ion bombardment to
`substrate surfaces is often undesirable. This ion
`bombardment, hoWever, is knoWn to have harmful effects on
`properties of material layers in devices and excessive ion
`bombardment ?ux and energy can lead to intermixing of
`materials in adjacent device layers, breaking doWn oxide
`and “Wear out,” injecting of contaminative material formed
`in the processing environment into substrate material layers,
`harmful changes in substrate morphology (e.g.
`amophotiZation), etc.
`Ion assisted etching processes, hoWever, rely upon ion
`bombardment to the substrate surface in de?ning selected
`?lms. But these ion assisted etching processes commonly
`have a loWer selectivity relative to conventional CDE pro
`cesses. Hence, CDE is often chosen When high selectivity is
`desired and ion bombardment to substrates are to be
`avoided.
`One commonly used chemical dry etching technique is
`conventional photoresist stripping, often termed ashing or
`stripping. Conventional resist stripping relies upon a reac
`tion betWeen a neutral gas phase species and a surface
`material layer, typically for removal. This reaction generally
`forms volatile products With the surface material layer for its
`removal. The neutral gas phase species is formed by a
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`55
`
`60
`
`65
`
`6,017,221
`
`2
`plasma discharge. This plasma discharge can be sustained by
`a coil (e.g., helical coil, etc.) operating at a selected fre
`quency in a conventional photoresist stripper. An example of
`the conventional photoresist stripper is a quarter-Wave heli
`cal resonator stripper, Which is described by US. Pat. No.
`4,368,092 in the name of Steinberg et al.
`Referring to the above, an objective in chemical dry
`etching is to reduce or even eliminate ion bombardment (or
`ion ?ux) to surfaces being processed to maintain the desired
`etching selectivity. In practice, hoWever, it is often difficult
`to achieve using conventional techniques. These conven
`tional techniques generally attempt to control ion ?ux by
`suppressing the amount of charged species in the plasma
`source reaching the process chamber. A variety of tech
`niques for suppressing these charged species have been
`proposed.
`These techniques often rely upon shields, baffles, large
`separation distances betWeen the plasma source and the
`chamber, or the like, placed betWeen the plasma source and
`the process chamber. The conventional techniques generally
`attempt to directly suppress charge density doWnstream of
`the plasma source by interfering With convective and diffu
`sive transport of charged species. They tend to promote
`recombination of charged species by either increasing the
`surface area (e. g., baffles, etc.) relative to volume, or increas
`ing ?oW time, Which relates to increasing the distance
`betWeen the plasma source and the process chamber.
`These baf?es, hoWever, cause loss of desirable neutral
`etchant species as Well. The baffles, shields, and alike, also
`are often cumbersome. Baf?es, shields, or the large separa
`tion distances also cause undesirable recombinative loss of
`active species and sometimes cause radio frequency poWer
`loss and other problems. These baf?es and shields also are
`a potential source of particulate contamination, Which is
`often damaging to integrated circuits.
`Baf?es, shields, spatial separation, and alike, When used
`alone also are often insuf?cient to substantially prevent
`unWanted parasitic plasma currents. These plasma currents
`are generated betWeen the Wafer and the plasma source, or
`betWeen the plasma source and Walls of the chamber. It is
`commonly knoWn that When initial charged species levels
`are present in an electrical ?eld, the charged species are
`accelerated and dissociative collisions With neutral particles
`can multiply the concentration of charge to higher levels. If
`suf?cient “seed” levels of charge and rf potentials are
`present, the parasitic plasma in the vicinity of the process
`Wafer can reach harmful charge density levels. In some
`cases, these charge densities may be similar to or even
`greater than plasma density Within the source plasma region,
`thereby causing even more ion ?ux to the substrate.
`Charge densities also create a voltage difference betWeen
`the plasma source and processing chamber or substrate
`support, Which can have an additional deleterious effect.
`This voltage difference enhances electric ?elds that can
`accelerate extraction of charge from the plasma source.
`Hence, their presence often induces increased levels of
`charge to be irregularly transported from the plasma source
`to process substrates, thereby causing non-uniform ion
`assisted etching.
`Conventional ion assisted plasma etching, hoWever, often
`requires control and maintenance of ion ?ux intensity and
`uniformity Within selected process limits and Within selected
`process energy ranges. Control and maintenance of ion ?ux
`intensity and uniformity are often difficult to achieve using
`conventional techniques. For instance, capacitive coupling
`betWeen high voltage selections of the coil and the plasma
`
`LAM Exh 1009-pg 17
`
`

`
`3
`discharge often cause high and uncontrollable plasma poten
`tials relative to ground. It is generally understood that
`voltage difference betWeen the plasma and ground can cause
`damaging high energy ion bombardment of articles being
`processed by the plasma, as illustrated by US. Pat. No.
`5,234,529 in the name of Johnson. It is further often under
`stood that rf component of the plasma potential varies in
`time since it is derived from a coupling to time varying rf
`excitation. Hence, the energy of charged particles from
`plasma in conventional inductive sources is spread over a
`relatively Wide range of energies, Which undesirably tends to
`introduce uncontrolled variations in the processing of
`articles by the plasma.
`The voltage difference betWeen the region just outside of
`a plasma source and the processing chamber can be modi?ed
`by introducing internal conductive shields or electrode ele
`ments into the processing apparatus doWnstream of the
`source. When the plasma potential is elevated With respect
`to these shield electrodes, hoWever, there is a tendency to
`generate an undesirable capacitive discharge betWeen the
`shield and plasma source. These electrode elements are often
`a source of contamination and the likelihood for contami
`nation is even greater When there is capacitive discharge (ion
`bombardment from capacitive discharge is a potential source
`of sputtered material). Contamination is damaging to the
`manufacture of integrated circuit devices.
`Another limitation is that the shield or electrode elements
`generally require small holes therein as structural elements.
`These small holes are designed to alloW gas to How there
`through. The small holes, hoWever, tend to introduce
`unWanted pressure drops and neutral species recombination.
`If the holes are made larger, the plasma from the source
`tends to survive transport through the holes and unWanted
`doWnstream charge ?ux Will often result. In addition, unde
`sirable discharges to these holes in shields can, at times,
`produce an even more undesirable holloW cathode effect.
`In conventional helical resonator designs, conductive
`external shields are interposed betWeen the inductive poWer
`(e.g., coil, etc.) and Walls of the vacuum vessel containing
`the plasma. Avariety limitations With these external capaci
`tive shielded plasma designs (e.g., helical resonator, induc
`tive discharge, etc.) have been observed. In particular, the
`capacitively shielded design often produces plasmas that are
`dif?cult to tune and even ignite. Alternatively, the use of
`unshielded plasma sources (e.g., conventional quarter-Wave
`resonator, conventional half-Wave resonator, etc.) attain a
`substantial plasma potential from capacitive coupling to the
`coil, and hence are prone to create uncontrolled parasitic
`plasma currents to grounded surfaces. Accordingly, the use
`of either the shielded or the unshielded sources using
`conventional quarter and half-Wave rf frequencies produce
`undesirable results.
`In many conventional plasma sources a means of cooling
`is required to maintain the plasma source and substrates
`being treated beloW a maximum temperature limit. PoWer
`dissipation in the structure causes heating and thereby
`increases the dif?culty and expense of implementing effec
`tive cooling means. Inductive currents may also be coupled
`from the excitation coil into internal or capacitive shields
`and these currents are an additional source of undesirable
`poWer loss and heating. Conventional capacitive shielding in
`helical resonator discharges utiliZed a shield Which Was
`substantially split along the long axis of the resonator to
`lessen eddy current loss. HoWever, such a shield substan
`tially perturbs the resonator characteristics oWing to
`unWanted capacitive coupling and current Which ?oWs from
`the coil to the shield. Since there are no general design
`
`10
`
`15
`
`25
`
`35
`
`45
`
`55
`
`65
`
`6,017,221
`
`4
`equations, nor are properties currently knoWn for resonators
`Which are “loaded” With a shield along the axis, sources
`using this design must be siZed and made to Work by trial
`and error.
`In inductive discharges, it is highly desirable to be able to
`substantially control the plasma potential relative to ground
`potential, independent of input poWer, pressure, gas com
`position and other variables. In many cases, it is desired to
`have the plasma potential be substantially at ground poten
`tial (at least offset from ground potential by an amount
`insigni?cantly different from the ?oating potential or intrin
`sic DC plasma potential). For example, When a plasma
`source is utiliZed to generate neutral species to be trans
`ported doWnstream of the source for use in ashing resist on
`a semiconductor device substrate (a Wafer or ?at panel
`electronic display), the concentration and potential of
`charged plasma species in the reaction Zone are desirably
`reduced to avoid charging damage from electron or ionic
`current from the plasma to the device. When there is a
`substantial potential difference betWeen plasma in the source
`and grounded surfaces beyond the source, there is a ten
`dency for unWanted parasitic plasma discharges to form
`outside of the source region.
`Another undesirable effect of potential difference is the
`acceleration of ions toWard grounded surfaces and subse
`quent impact of the energetic ions With surfaces. High
`energy ion bombardment may cause lattice damage to the
`device substrate being processed and may cause the chamber
`Wall or other chamber materials to sputter and contaminate
`device Wafers. In other plasma processing procedures,
`hoWever, some ion bombardment may be necessary or
`desirable, as is the case particularly for anisotropic ion
`induced plasma etching procedures (for a discussion of
`ion-enhanced plasma etching mechanisms See Flamm (Ch.
`2, pp.94—183 in Plasma Etching, An Introduction, D. M.
`Manos and D. L. Flamm, eds., Academic Press, 1989)).
`Consequently, uncontrolled potential differences, such as
`that caused by “stray” capacitive coupling from the coil of
`an inductive plasma source to the plasma, are undesirable.
`Referring to the above limitations, conventional plasma
`sources also have disadvantages When used in conventional
`plasma enhanced CVD techniques. These techniques com
`monly form a reaction of a gas composition in a plasma
`discharge. One conventional plasma enhanced technique
`relies upon ions aiding in rearranging and stabiliZing the
`?lm, provided the bombardment from the plasma is not
`suf?ciently energetic to damage the underlying substrate or
`the groWing ?lm. Conventional resonators and other types of
`inductive discharges often produce parasitic plasma currents
`from capacitive coupling, Which often detrimentally in?u
`ences ?lm quality, e.g., an inferior ?lm, etc. These parasitic
`plasma currents are often uncontrollable, and highly unde
`sirable. These plasma sources also have disadvantages in
`other plasma processing techniques such as ion-assisted
`etching, and others. Of course, the particular disadvantage
`Will often depend upon the application.
`To clarify certain concepts used in this application, it Will
`be convenient to introduce these de?nitions.
`Ground (or ground potential): These terms are de?ned as
`a reference potential Which is generally taken as the poten
`tial of a highly conductive shield or other highly conductive
`surface Which surrounds the plasma source. To be a true
`ground shield in the sense of this de?nition, the RF con
`ductance at the operating frequency is often substantially
`high so that potential differences generated by current Within
`the shield are of negligible magnitude compared to poten
`
`LAM Exh 1009-pg 18
`
`

`
`6,017,221
`
`5
`tials intentionally applied to the various structures and
`elements of the plasma source or substrate support assembly.
`HoWever, some realiZations of plasma sources do not incor
`porate a shield or surface With adequate electrical suscep
`tance to meet this de?nition. In implementations Where there
`is a surrounding conductive surface that is someWhat similar
`to a ground shield or ground plane, the ground potential is
`taken to be the ?ctitious potential Which the imperfect
`grounded surface Would have equilibrated to if it had Zero
`high frequency impedance. In designs Where there is no
`physical surface Which is adequately con?gured or Which
`does not have insuf?cient susceptance to act as a “ground”
`according to the above de?nition, ground potential is the
`potential of a ?ctitious surface Which is equi-potential With
`the shield or “ground” conductor of an unbalanced trans
`mission line connection to the plasma source at its RF feed
`point. In designs Where the plasma source is connected to an
`RF generator With a balanced transmission line RF feed,
`“ground” potential is the average of the driven feed line
`potentials at the point Where the feed lines are coupled to the
`plasma source.
`Inductively Coupled PoWer: This term is de?ned as poWer
`transferred to the plasma substantially by means of a time
`varying magnetic ?uX Which is induced Within the volume
`containing the plasma source. A time-varying magnetic ?uX
`induces an electromotive force in accord With MaXWell’s
`equations. This electromotive force induces motion by elec
`trons and other charged particles in the plasma and thereby
`imparts energy to these particles.
`RF inductive poWer source and bias poWer supply: In
`most conventional inductive plasma source reactors, poWer
`is supplied to an inductive coupling element (the inductive
`coupling element is often a multi-turn coil Which abuts a
`dielectric Wall containing a gas Where the plasma is ignited
`at loW pressure) by an rf poWer generator.
`Conventional Helical Resonator: Conventional helical
`resonator can be de?ned as plasma applicators. These
`plasma applicators have been designed and operated in
`multiple con?gurations, Which Were described in, for
`example, US. Pat. No. 4,918,031 in the names of Flamm et
`al., US. Pat. No. 4,368,092 in the name of Steinberg et al.,
`US. Pat. No. 5,304,282 in the name of Flamm, U.S. Pat. No.
`5,234,529 in the name of Johnson, US. Pat. No. 5,431,968
`in the name of Miller, and others. In these con?gurations,
`one end of the helical resonator applicator coil has been
`grounded to its outer shield. In one conventional
`con?guration, a quarter Wavelength helical resonator section
`is employed With one end of the applicator coil grounded
`and the other end ?oating (i.e., open circuited). A trimming
`capacitance is sometimes connected betWeen the grounded
`outer shield and the coil to “?ne tune” the quarter Wave
`structure to a desired resonant frequency that is beloW the
`native resonant frequency Without added capacitance. In
`another conventional con?guration, a half-Wavelength heli
`cal resonator section Was employed in Which both ends of
`the coil Were grounded. The function of grounding the one
`or both ends of the coil Was believed to be not essential, but
`advantageous to “stabiliZe the plasma operating character
`istics” and “reduce the possibility of coupling stray current
`to nearby objects.” See US. Pat. No. 4,918,031.
`Conventional resonators have also been constructed in
`other geometrical con?gurations. For instance, the design of
`helical resonators With a shield of square cross section is
`described in Zverev et al., IRE Transactions on Component
`Parts, pp. 99—110, Sept. 1961. Johnson (US. Pat. No.
`5,234,529) teaches that one end of the cylindrical spiral coil
`in a conventional helical resonator may be deformed into a
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`55
`
`60
`
`65
`
`6
`planar spiral above the top surface of the plasma reactor
`tube. U.S. Pat. No. 5,241,245 in the names of Barnes et al.
`teach the use of conventional helical resonators in Which the
`spiral cylindrical coil is entirely deformed into a planar
`spiral arrangement With no helical coil component along the
`sideWalls of the plasma source (this geometry has often been
`referred to as a “transformer coupled plasma,” termed a
`TCP).
`From the above it is seen that an improved technique,
`including a method and apparatus, for plasma processing is
`often desired.
`
`SUMMARY OF THE INVENTION
`The present invention provides a technique, including a
`method and apparatus, for fabricating a product using a
`plasma discharge. The present technique relies upon the
`control of the instantaneous plasma AC potential to selec
`tively control a variety of plasma characteristics. These
`characteristics include the amount of neutral species, the
`amount of charged species, overall plasma potential, the
`spatial eXtent and distribution of plasma density, the distri
`bution of electrical current, and others. This technique can
`be used in applications including chemical dry etching (e. g.,
`stripping, etc.), ion-enhanced etching, plasma immersion ion
`implantation, chemical vapor deposition and material
`groWth, and others.
`In one aspect of the invention, a process for fabricating a
`product is provided. These products include a varieties of
`devices (e.g., semiconductor, ?at panel displays, micro
`machined structures, etc.) and materials, e.g., diamonds, raW
`materials, plastics, etc. The process includes steps of sub
`jecting a substrate to a composition of entities. At least one
`of the entities emanates from a species generated by a
`gaseous discharge eXcited by a high frequency ?eld in Which
`the vector sum of phase and anti-phase capacitive coupled
`voltages (e.g., AC plasma voltage) from the inductive cou
`pling structure substantially balances. This process provides
`for a technique that is substantially free from stray or
`parasitic capacitive coupling from the plasma source to
`chamber bodies (e. g., substrate, Walls, etc.) at or near ground
`potential.
`In another aspect of the invention, another process for
`fabricating a product is provided. The process includes steps
`of subjecting a substrate to a composition of entities. At least
`one of the entities emanates from a species generated by a
`gaseous discharge eXcited by a high frequency ?eld in Which
`the vector sum of phase and anti-phase capacitive coupled
`voltages from the inductive coupling structure is selectively
`maintained. This process provides for a technique that can
`selectively control the amount of capacitive coupling to
`chamber bodies at or near ground potential.
`A further aspect of the invention provides yet another
`process for fabricating a product. This process includes steps
`of subjecting a substrate to a composition of entities. At least
`one of the entities emanates from a species generated by a
`gaseous discharge eXcited by a high frequency ?eld in Which
`the vector sum of phase and anti-phase capacitive coupled
`voltages from the inductive coupling structure is selectively
`maintained. A further step of selectively applying a voltage
`betWeen the at least one of the entities in the plasma source
`and a substrate is provided. This process provides for a
`technique that can selectively control the amount of capaci
`tive coupling to chamber bodies at or near ground potential,
`and provide for a driving voltage betWeen the entities and a
`substrate.
`Another aspect of the invention provides another process
`for fabricating a product. The process comprises steps of
`
`LAM Exh 1009-pg 19
`
`

`
`10
`
`15
`
`7
`subjecting a substrate to a composition of entities and using
`the resulting substrate for completion of the product. At least
`one of the entities emanates from a species generated by a
`gaseous discharge provided by a plasma applicator, e.g., a
`helical resonator, inductive coil, transmission line, etc. This
`plasma applicator has an integral current driven by capaci
`tive coupling of a plasma column to elements With a selected
`potential greater than a surrounding shield potential sub
`stantially equal to capacitive coupling of the plasma column
`to substantially equal elements With a potential beloW shield
`potential.
`In a further aspect, the invention provides an apparatus for
`fabricating a product. The apparatus has an enclosure com
`prising an outer surface and an inner surface. The enclosure
`houses a gaseous discharge. The apparatus also includes a
`plasma applicator (e.g., helical coil, inductive coil, trans
`mission line, etc.) disposed adjacent to the outer surface. A
`high frequency poWer source operably coupled to the plasma
`applicator is included. The high frequency poWer source
`provides high frequency to excite the gaseous discharge to
`provide at least one entity from a high frequency ?eld in
`Which the vector sum of phase and anti-phase capacitive
`current coupled from the inductive coupling structure is
`selectively maintained.
`In another aspect, the present invention provides an
`improved plasma discharge apparatus. This plasma dis
`charge apparatus includes a plasma source, a plasma appli
`cator (e.g., inductive coil, transmission line, etc.), and other
`elements. This plasma applicator provides a de-coupled
`plasma source. AWave adjustment circuit (e. g., RLC circuit,
`coil, transmission line, etc.) is operably coupled to the
`plasma applicator. The Wave adjustment circuit can selec
`tively adjust phase and anti-phase potentials of the plasma
`from an rf poWer supply. This rf poWer supply is operably
`coupled to the Wave adjustment circuit.
`The present invention achieves these bene?ts in the
`context of knoWn process technology. HoWever, a further
`understanding of the nature and advantages of the present
`invention may be realiZed by reference to the latter portions
`of the speci?cation and attached draWings.
`
`25
`
`35
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a simpli?ed diagram of a plasma etching
`apparatus according to the present invention;
`FIGS. 2A—2E are simpli?ed con?gurations using Wave
`adjustment circuits according to the present invention;
`FIG. 3 is a simpli?ed diagram of a chemical vapor
`deposition apparatus according to the present invention;
`FIG. 4 is a simpli?ed diagram of a stripper according to
`the present inv

This document is available on Docket Alarm but you must sign up to view it.


Or .

Accessing this document will incur an additional charge of $.

After purchase, you can access this document again without charge.

Accept $ Charge
throbber

Still Working On It

This document is taking longer than usual to download. This can happen if we need to contact the court directly to obtain the document and their servers are running slowly.

Give it another minute or two to complete, and then try the refresh button.

throbber

A few More Minutes ... Still Working

It can take up to 5 minutes for us to download a document if the court servers are running slowly.

Thank you for your continued patience.

This document could not be displayed.

We could not find this document within its docket. Please go back to the docket page and check the link. If that does not work, go back to the docket and refresh it to pull the newest information.

Your account does not support viewing this document.

You need a Paid Account to view this document. Click here to change your account type.

Your account does not support viewing this document.

Set your membership status to view this document.

With a Docket Alarm membership, you'll get a whole lot more, including:

  • Up-to-date information for this case.
  • Email alerts whenever there is an update.
  • Full text search for other cases.
  • Get email alerts whenever a new case matches your search.

Become a Member

One Moment Please

The filing “” is large (MB) and is being downloaded.

Please refresh this page in a few minutes to see if the filing has been downloaded. The filing will also be emailed to you when the download completes.

Your document is on its way!

If you do not receive the document in five minutes, contact support at support@docketalarm.com.

Sealed Document

We are unable to display this document, it may be under a court ordered seal.

If you have proper credentials to access the file, you may proceed directly to the court's system using your government issued username and password.


Access Government Site

We are redirecting you
to a mobile optimized page.





Document Unreadable or Corrupt

Refresh this Document
Go to the Docket

We are unable to display this document.

Refresh this Document
Go to the Docket