throbber
United States Patent [19] .
`Keller et al.
`
`[11] Patent Number:
`[45] Date of Patent:
`
`4,846,920
`Jul. 11, 1989
`
`[75]
`
`[73] Assignee:
`
`[54] PLASMA AMPLIFIED PHOTOELECTRON
`PROCESS ENDPOINT DETECTION
`APPARATUS
`Inventors: John H. Keller, Poughkeepsie; Gary
`S. Selwyn; Jyothi Singh, both of
`Hopewell Junction, all of N.Y.
`International Business Machine
`Corporation, Armonk, N.Y.
`[21] Appl. No.: 130,573
`[22] Filed:
`Dec. 9, 1987
`[51]
`Int. Cl.4 .................... C23C 14/00; HOlL 21/306;
`B44C 1/22; C23F 1/02
`[52] U.S. Cl. .................................... 156/345; 156/643;
`156/626; 156/627; 204/192.33; 204/298;
`427/10; 427/34; 118/620; 118/665
`[58] Field of Search .............. 204/298, 192.33, 192.32;
`156/643, 646, 345, 626, 627; 118/665, 620;
`427/10, 34
`
`[56]
`
`References Cited •
`U.S. PATENT DOCUMENTS
`4,579,623 4/1986 Suzuki ................................. 156/626
`4,602,981 7/1986 Chen ................................... 156/627
`4,615,761 10/1986 Tada et al. ...................... 156/345 X
`4,664,769 5/1987 Cuomo ............................. 204/192.1
`4,675,072 6/1987 Bennett et al. ................. 204/298 X
`4,687,930 8/1987 Tamura ............................... 250/309
`
`FOREIGN PATENT DOCUMENTS
`686529 5/1964 Canada .
`0061036 4/1984 Japan.
`
`OTHER PUB LI CA TIO NS
`IBM TDB vol. 20, No. 2 Jul. 1977, Geipel-End-Point
`Detection for Reactive Ion Etching.
`Primary Examiner-David L. Lacey
`Assistant Examiner-Thi Dang
`
`Attorney, Agent, or Firm-William T. Ellis
`[57]
`ABSTRACT
`A plasma processing apparatus and process endpoint
`detection method including a plasma chamber for pro(cid:173)
`cessing an item that has a first portion of a first material
`and a second portion of a second material, with the first
`and second materials having different work functions,
`and a structure for generating a plasma in the plasma
`chamber, with the plasma generating structure includ(cid:173)
`ing at least a pair of RF-power electrodes with one of
`them being excited by an RF excitation frequency. The
`apparatus further includes a structure for generating
`and ejecting electrons from the second material only
`when the second material is exposed to the plasma, and
`a structure for increasing the energies of these gener(cid:173)
`ated electrons and accelerating these electrons into the
`etching plasma with sufficient energy to generate sec(cid:173)
`ondary electrons in the plasma. The apparatus further
`includes a structure for receiving a plasma discharge
`voltage signal, a structure for filtering the discharge
`electrical voltage signal to remove the RF excitation
`frequency and any DC components therein, and a struc(cid:173)
`ture for amplifying the natural frequencies of excitation
`and decay of the plasma discharge voltage perturbation
`signal, to thereby detect the processing endpoint.
`In a preferred embodiment, the electron energy increas(cid:173)
`ing and accelerating structure includes a structure for
`generating an electrode voltage sheath, and a structure
`for generating the electrons within this voltage sheath
`to thereby accelerate the electrons into the plasma. The
`electron generating structure includes a structure for
`directing a beam of photons in a selected energy range
`onto the item to be processed, which energy range is
`not sufficient to eject photoelectrons from the first ma(cid:173)
`terial, but is high enough to generate photoelectrons
`from areas of exposed second material.
`
`35 Claims, 2 Drawing Sheets
`
`41-1)_
`
`40
`
`16
`
`36
`
`24 ' "
`/
`3T~ 38""'--26
`I
`I 35
`I../
`I
`34 I/
`
`30
`
`20
`
`48
`
`46
`
`32
`
`10
`
`12
`
`42
`
`1
`
`44
`
`SIGNAL
`PROCESSING
`UNIT
`
`ETCH
`SERVO
`CONTROL
`
`I
`I
`,------- -----------1 I
`IMPEDANCE I l
`~R_F_&_,__D_C_
`17
`I l
`FILTER &
`MATCHING
`AMPLIFIER
`NETWORK
`I 1
`NETWORK
`I I
`I I
`18
`-
`I I
`-------- ___7----------~~'-----~
`UV
`100
`LIGHT
`SOURCE
`OR LASER
`
`Page 1 of 11
`
`APPLIED MATERIALS EXHIBIT 1021
`
`

`

`0
`~
`0\
`~
`.a;..
`
`~
`
`~
`
`N
`~
`
`j,,,,l
`
`rJ)_ =-m.
`
`'°
`"' j,,,,l '° 00
`~
`~ a
`~ .......
`V-1
`~
`
`j,,,,l
`j,,,,l
`
`26
`
`32
`
`18
`
`\35
`//'>
`/
`
`OR LASER
`SOURCE
`LIGHT
`I UV
`---------7---------_::= L
`I I
`I I
`I I
`20 ----1 NETWORK
`I I
`MATCHING
`: I
`IMPEDANCE I 1
`I
`-------1-----------1 I
`I
`I
`I
`I/
`I
`34
`j____/
`I 35
`I
`34 I\_ 38
`
`f---~~6--I~;~--,:~:.,:_ -l
`
`1,
`
`7
`
`30
`
`,,,28
`//
`/
`
`/
`
`/
`
`/
`
`14\ ""
`
`"-' "-
`
`12
`
`1
`
`10
`
`"-
`
`40
`
`-
`
`----7
`
`4 6 ______.--/
`
`100
`
`42
`
`NETWORK
`AMPLIFIER
`FILTER &
`RF & DC
`
`I
`

`
`-----
`ONTROL
`_48
`SERVO
`--r=j-~cH ----}L__ -
`UNIT
`
`[
`
`PROCESSING
`
`SIGNAL
`
`44
`
`Fl G.1
`
`Page 2 of 11
`
`

`

`U.S. Patent
`
`Jul. 11, 1989
`
`Sheet 2 of 2
`
`4,846,920
`
`FIG.2
`
`FIG.3
`
`,. ... -.,. .. "-.
`
`,-
`.-··:..
`.,...
`__j,,," .. ,
`·-
`.. ,,____
`·~-·
`.,.,_.,., ..... -,._.,_..,. ,~-..·-
`•
`... ,...., ·~ , , . . . . - -~
`
`• ,·
`...
`
`: · .
`-·
`··.
`. . . . .. . . . _'.,._:···.
`
`. .,
`• •
`·:
`
`••
`
`.. ;
`
`• :
`.y
`
`500
`
`400
`
`300
`
`200
`
`100
`
`~ 0
`
`-100
`
`-200
`
`-300
`
`-400
`
`0
`
`2
`
`3
`
`4
`
`5
`
`6
`
`7
`
`8
`
`9
`
`10
`
`µ.S
`
`Page 3 of 11
`
`

`

`PLASMA AMPLIFIED PHOTOELECTRON
`PROCESS ENDPOINT DETECTION APPARATUS
`
`25
`
`5
`
`10
`
`BACKGROUND OF THE INVENTION
`The present invention relates generally to the field of
`material processing, and more particularly to a plasma
`apparatus and a method for detecting a process end-
`point.
`It is desirable to have a non-intrusive, sensitive etch
`endpoint apparatus and method to detect the exposure
`of a desired sublayer in an item being etched. Several
`techniques have been demonstrated for etch endpoint
`detection, including optical emission spectroscopy, 15
`plasma impedance monitoring, and laser interferometry.
`However, all of these techniques fail to provide suffi(cid:173)
`cient sensitivity when there is a very low pattern etch
`factor, i.e., a low percentage of the item's surface is
`exposed to the etching medium. Additionally, some of 20
`these techniques require considerable signal averaging
`to improve the signal-to-noise ratio. The use of these
`methods thus results in a slower response to etch plasma
`compositional changes and a slower response to end-
`point indicia in the plasma.
`The failure of the prior art techniques for detecting
`endpoint in the presence of very low pattern factors
`provide a significant impediment to the semiconductor
`industry drive for faster circuit devices. Such faster
`circuit devices require smaller component dimensions 30
`which often result in very low wafer pattern densities.
`At the same time, faster etch processes result in the need
`for more precise endpoint control with a fast endpoint
`detection response.
`Alternatively, it is desirable to be able to detect with 35
`precision the coverage of a low pattern factor area in a
`deposition process. Similar detection problems to those
`noted above are encountered in this type of processing.
`The invention as claimed is intended to remedy the
`above-described etch endpoint and deposition endpoint 40
`detection problems and limitations that arise when low
`pattern factors are present.
`The advantages offered by the present invention are
`that extremely low pattern factor endpoints can be
`detected with high resolution and a very fast response. 45
`This endpoint detection can be utilized when etching,
`for example, a top layer through to another layer there(cid:173)
`below, when those two layers have different work func(cid:173)
`tions. Likewise, this invention can be used when depos(cid:173)
`iting a top layer on to another layer, where those two 50
`layers have different work functions. Accordingly, this
`invention can be used to detect endpoint when etching
`or depositing a top layer of metal, semiconductor, or
`insulator material through or on to another layer there(cid:173)
`below of metal, semiconductor or insulator material 55
`which layer has a different work function. This inven(cid:173)
`tion is particularly advantageous in that it is essentially
`independent of the plasma composition, it has a high
`detection signal-noise ratio, and it is not highly wave-
`length sensitive.
`
`60
`
`SUMMARY OF THE INVENTION
`Briefly, one aspect of the invention comprises a
`plasma processing apparatus including
`a plasma chamber for processing an item that includes 65
`a first portion of a first material and a second por(cid:173)
`tion of a second material, with the first and second
`materials having different work functions;
`
`1
`
`4,846,920
`
`2
`means for generating a plasma in the plasma chamber,
`the plasma generating means including an RF-pow(cid:173)
`ered electrode excited by an RF excitation fre(cid:173)
`quency;
`means for generating and ejecting electrons only
`when the second material is exposed to the plasma;
`means for increasing the energies of the generated
`electrons and accelerating the electrons into the
`plasma, with sufficient energy to thereby generate
`a secondary electrons in the plasma;
`means for receiving a plasma RF discharge voltage
`signal;
`means for filtering the plasma RF discharge voltage
`signal to remove the RF excitation frequency
`therefrom; and
`means for amplifying the natural frequencies of the
`plasma discharge in response to the electron per(cid:173)
`turbation in the plasma discharge voltage signal to
`thereby detect the processing endpoint or a surface
`condition.
`In a preferred embodiment, the electron energy in(cid:173)
`creasing and accelerating means comprises means
`for generating an electrode voltage sheath, and
`means for generating the electrons within this volt(cid:173)
`age sheath to thereby accelerate the electrons into
`the plasma.
`In a further aspect of this embodiment, the electron
`generating means may comprise means for directing a
`beam of photons in a selected energy range onto the
`item, which energy range is not sufficient to eject pho(cid:173)
`toelectrons from the first material, but is high enough to
`generate photoelectrons from areas of exposed second
`material. This photon beam directing means may com(cid:173)
`prise means for generating laser pulses.
`In a further embodiment of the present invention, the
`filtering means may comprise a capacitor for blocking
`out any DC signal components, and notch filter means
`for removing the harmonics of the RF excitation signal.
`The present apparatus may further comprise means
`for integrating the filtered signal. In one embodiment,
`this integrating means may include means for detecting
`the filtered signal a predetermined time period after the
`occurrence of each laser pulse and integrating a plural(cid:173)
`ity of the detected filtered signals.
`In a further aspect of the present invention, a method
`is disclosed and claimed for detecting the endpoint in a
`plasma etching or deposition process. This method
`comprises the steps of
`disposing an item to be processed in a plasma cham(cid:173)
`ber, the item including a first portion of a first
`material and a second portion of a second material,
`with the first and second materials having different
`work functions;
`generating by means of an RF electrode excited by
`an RF excitation frequency a plasma in the
`plasma chamber to process the item;
`generating and ejecting electrons from the material
`only when the second material is exposed to the
`plasma;
`the
`the generated electrons into
`accelerating
`plasma with a sufficient energy to thereby gener(cid:173)
`ate secondary electrons in the plasma;
`receiving a plasma discharge voltage signal; and
`filtering and amplifying the plasma discharge volt(cid:173)
`age signal to monitor the natural frequencies of
`excitation and decay of the discharge plasma, to
`thereby determine the process endpoint or sur(cid:173)
`face condition.
`
`Page 4 of 11
`
`

`

`3
`BRIEF DESCRIPTION OF THE ORA WINGS
`FIG. 1 is a schematic block diagram of one embodi(cid:173)
`ment of the present invention.
`FIG. 2 is a schematic circuit diagram of a filter and
`amplifier network which may be utilized to implement
`the filter and amplifier block 42 of FIG. 1.
`FIG. 3 is a graphical representation of an integrated
`signal response obtained by utilizing the apparatus and
`method of the present invention.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENT
`The present invention is based on the use of the pho(cid:173)
`toelectric effect, i.e., the fact that when an energy beam 15
`is directed at a material surface where the energy per
`quantum is greater than the work function for that ma(cid:173)
`terial, then electrons will be ejected from that surface. It
`was recognized that in an etching process for etching,
`for example, a top layer of a first material through to a 20
`second layer therebelow of a second material, the work
`functions of those two materials will differ in almost
`every case. Likewise, in a deposition process, it was
`recognized that in the deposition of a top layer of a first
`material on to a second layer of a second material, the 25
`work functions of these two materials will --differ in
`almost every case. The present invention utilizes the
`electron-ejection effect in combination with this realiza(cid:173)
`tion of the differing work functions for these two layers
`of material on the item being processed to form an oper- 30
`able endpoint detection apparatus and method. Addi(cid:173)
`tionally, the invention resides in the use of means to
`increase the energy of electrons ejected when a given
`material is exposed and to accelerate those electrons
`into the plasma with sufficient energy to generate de- 35
`tectable secondary electrons. Finally, the present inven(cid:173)
`tion resides in the discovery that the response to these
`secondary electrons in the etching plasma may be de(cid:173)
`tected at the natural frequencies of excitation and decay
`of the plasma discharge. Accordingly, the RF plasma 40
`excitation frequency and its harmonics, and the DC
`components in the excitation signal may be removed by
`appropriate filtering, while the band of frequencies
`containing the natural frequencies of excitation and
`decay of the plasma discharge is amplified to obtain a 45
`highly enhanced signal/noise ratio.
`The present invention will first be described in the
`context of an etching system. However, the invention
`applies equally to deposition and other processing sys(cid:173)
`tems. Referring now to FIG. 1, there is shown a stan- 50
`dard dry etching chamber 10 with an electrode 12 upon
`which an item 14 to be etched is disposed. This item 14
`being etched may comprise, by way of example, a top or
`a first layer 28 of a first material disposed over a second
`layer 30 of a second material, with the first and second 55
`materials having different work functions. (In FIG. 1,
`the second layer comprises the studs 30.) In the example
`shown in FIG. 1, this item to be etched may be a wafer
`14. By way of example, and not by way of limitation, a
`typical dry etching chamber that may be utilized to 60
`perform reactive ion etching is described in the refer(cid:173)
`ence L. M. Ephrath, "Dry Etching for VLSI-A Re(cid:173)
`view", in Semiconductor Silicon 1981, (eds. H. R. Huff,
`Y. Takeishi and R. J. Kriegler), The Electrochemical
`Society, Pennington, N.J., Vol. 81-5, pp. 627 (1981). 65
`Such a chamber would have gas inlets in order to pro(cid:173)
`vide an appropriate etching gas mixture for the chamber
`10.
`
`4,846,920
`
`4
`The RF electrode 12 in the chamber 10 is connected
`by means of an electrical line 17 to a standard RF source
`of energy 18. The RF energy source 18 provides an
`excitation frequency to excite the gases in the chamber
`5 to form an etching plasma therein. The RF excitation
`frequency from the RF excitation signal source 18 is
`provided to the electrode 12 by means of an impedance
`matching network 20. By way of example, and not by
`way of limitation, this impedance matching network 20
`10 may be implemented by a standard LC or Pi circuit of
`the type shown in the reference A. /. Diefenderfer,
`Principles of Electronic Instrumentation, W. B. Saun(cid:173)
`ders Co, Philadelphia, Pa. (1979). A second electrode 22
`is disposed on the opposite side of the chamber from the
`electrode 12 and is connected by means of a line 24 to a
`reference potential 26. The RIE etching plasma is gen-
`erated in the volume between the electrodes 12 and 22.
`The invention further comprises means for generat(cid:173)
`ing and ejecting electrons only when a selected material
`is exposed to the etching plasma. In one embodiment,
`the means for generating electrons comprises means for ·
`directing a beam of energy of either photons or particles
`in a selected energy range onto the surface of the item
`14 being etched. This energy range is not sufficient to
`eject electrons from one of the first material layer 28 or
`the second material layer 30 on the item 14 being
`etched, but is high enough to eject electrons from the
`other of the first material layer 28 or the second material
`layer 30, to thereby eject electrons when the other
`material is exposed.
`In the embodiment shown in FIG. 1, the energy beam
`directing means comprises an energy beam source 32,
`an energy beam 34 following a path 35, and a window
`36 into the chamber 10 to permit application of the
`energy beam onto the surface of the item 14 being
`etched. In this embodiment, the energy beam source
`may be comprised simply of a laser or a UV light
`source. An ultraviolet wavelength laser such as an ex(cid:173)
`cimer laser, or a frequency-quadrupled Nd:V AG laser,
`or a frequency-doubled tunable dye laser may also be
`utilized, for example. Conveniently, the energy beam
`source should be a pulsed source or a continuous wave
`source that is appropriately chopped. The energy beam
`path 32 may include one or more mirrors 38, as re(cid:173)
`quired, in order to direct the energy beam through the
`window 36 and into the chamber 10. This energy beam
`may be focussed or unfocused, depending on the
`amount of area that is to be impinged on the item 14
`being etched. It may be desirable to also include a win(cid:173)
`dow 40 in the chamber 10 and an energy beam stop 41
`to receive the energy beam after it is reflected off of the
`surface of the item 14 to prevent the beam from making
`uncontrolled reflections within the chamber 10. It
`should be noted that the energy beam may be directed
`normal to the item 14 being etched, or it may be di(cid:173)
`rected at an oblique angle to the item 14 being etched. It
`should also be noted that the more oblique the angle of
`incidence of the energy beam onto the surface of the
`item 14, the more generalized will be the measurement
`for the endpoint.
`In the example of FIG. 1, when the energy beam 34
`strikes a metal, semiconductor, or insulator surface, it
`will eject photoelectrons if the photon energy exceeds
`the work function, U, of the material. The ejected pho(cid:173)
`toelectrons will have an energy, KEe, equal
`to:
`KEe=hv-U, where hv is the energy of the incident
`light. However, if the photon energy in the energy
`beam is less than the work function for the material,
`
`Page 5 of 11
`
`

`

`4,846,920
`
`6
`5
`cies. Additionally, these high energy photoelectrons
`then no photoelectrons will be ejected, regardless of the
`intensity of the energy beam. Accordingly, the energy
`can strike the opposite electrode 16 and produce sec-
`ondary electrons from that surface. The net result of
`of the energy beam is chosen so that it does not eject
`this generation of secondary electrons is the amplifica-
`electrons from one of the first or second materials on
`the item 14, but does eject electrons from the other of 5 tion of the photoelectron ejection phenomena.
`the first or second materials. By way of example, as-
`If laser pulses are utilized as the energy beam source
`sume that the first layer 28 of first material comprises a
`32 to produce the primary photoelectrons, a repetitious
`layer of an insulator such as glass, polyimide, or silicon
`perturbation of the plasma discharge impedance in the
`dioxide, while the second layer 30 of second material
`chamber results from the pulsed influx of high energy
`comprises a metal. The use of a laser which generates a 10 electrons following each laser shot (assuming an appro-
`UV light in the range of 230-250 nm results in a photon
`priate work function material has been exposed). This
`energy of between 5.4 to 4.9 eV, respectively. A typical
`amplified repetitious perturbation of the plasma dis-
`metal work function is 4.3 to 4.5 eV, while a typical
`charge impedance and voltage is caused by the sudden
`change in the current at the RF electrode as the high
`work function for an insulator such as silicon dioxide is
`on the order of 9-10 eV. Thus the direction of an ultra- 15 energy electrons are ejected into and amplified (by an
`violet energy beam to strike the first layer 28 of silicon
`increase in secondary ejections) by the plasma. Since
`dioxide will not eject photoelectrons. However, when
`the RF electrode 12 and the plasma are electrically
`small areas of metal become exposed during the etching
`coupled, this perturbation results in an oscillation which
`dampens out in time. It has been discovered that this
`process, these exposed metal areas will eject photoelec-
`trons with an energy of between 0.6 to 0.8 eV, depend- 20 amplified repetitious perturbation of the plasma dis-
`ing on the wavelength of the light and the exact value of
`charge voltage may be monitored electronically with a
`high signal/noise ratio, by filtering out the RF excita-
`the work function for the material. These photoelec-
`tion frequency (usually 13.56 MHz) along with any RF
`trons thus are characterized by a low kinetic energy and
`insufficient energy to produce secondary ions by colli-
`excitation frequency harmonics and DC components of
`sional processes.
`25 the signal detected at the RF powered electrode 12,
`However, the present invention further includes
`while amplifying the frequencies of excitation and
`means for increasing the energies of these low kinetic
`decay of the plasma discharge perturbation.
`In order to detect and measure this plasma perturba-
`energy photoelectrons and accelerating them with a
`tion, the RF electrode 12 may be connected to a filter
`sufficient energy into the etching plasma to generate
`secondary electrons in the plasma. In a preferred em- 30 and amplifier network 42 to remove unwanted frequen-
`bodiment, this photoelectron energy increasing and
`cies and to amplify desired frequencies. In this regard,
`accelerating means comprises means for generating an
`applicants have discovered that the major response
`electrode voltage sheath, and means for generating
`from this plasma perturbation is in the natural frequen-
`cies of excitation and decay of the plasma discharge (the
`these low kinetic energy photoelectrons within this
`voltage sheath to thereby accelerate the photoelectrons 35 inverse of the decay time constant). Accordingly, a
`into the plasma. In the embodiment shown in FIG. 1,
`series ofbandpass and blocking filters may be utilized to
`the photoelectron energy increasing and accelerating
`remove the RF fundamental excitation frequency, asso-
`means is implemented by disposing the item 14 being
`ciated RF excitation frequency harmonics, and the DC
`etched on the RF cathode electrode 12 or the RF anode
`self-biased voltage of the cathode 12. Note that in some
`electrode 16 during the etching operation. The sheath 40 applications, a set of LC networks may be combined
`voltage for these electrodes is determined by the input
`with a low pass filter and a DC blocking capacitor in
`electrode power density and the gas composition and
`order to accomplish the desired filtering function. In
`pressure in the etching chamber 10. For example, the
`other applications with high RF power, commercially
`RF cathode electrode 12 will typically generate a
`available blocking networks may be required. Means
`sheath voltage of 100 eV to 1 KeV either in a batch RIE 45 are also provided for amplifying the natural frequencies
`tool using a 0.25 W /cm 2 electrode power density at a
`of the excitation and decay of the plasma discharge in
`pressure of 50 mTorr, or in a single wafer etch tool
`the plasma discharge voltage signal, i.e., amplifying the
`using a 1-2W /cm2 electrode power density and at a
`photoelectric signal by tuning the amplification re-
`pressure of 0.5-4 Torr. The anode electrode 16 will
`sponse of the filter to match the excitation and decay
`typically have a sheath voltage of on the order of 50 frequencies.
`30-500 volts for those excitation levels. Thus, in the
`After the removal of the undesirable DC and RF
`example shown in FIG. 1 with the item 14 disposed on
`components from the electrode signal and the amplifica-
`the cathode electrode 12, any low kinetic photoelec-
`tion of the natural frequencies of decay of the plasma
`trons produced are ejected within the cathode sheath
`discharge voltage perturbation, this filtered and ampli-
`voltage disposed around the cathode electrode 12. Ac- 55 tied signal is applied to a signal processing unit 44. In
`cordingly, these low kinetic energy ejected photoelec-
`one embodiment, this signal processing unit may simply
`trons are accelerated by the strong potential field in the
`comprise an oscilloscope. For a quantitative measure-
`cathode sheath. The photoelectrons are accelerated
`ment, this signal processing unit 44 may comprise means
`across the sheath, gaining considerable kinetic energy
`for integrating the filtered and amplified signal in syn-
`from the electrostatic interaction of the electrons with 60 chronization with the laser pulses from he energy beam
`source 32. This synchronization can be obtained by
`the sheath field so that the photoelectrons are acceler-
`means of a synchronization signal via the line 46. In
`ated close to the sheath potential, which, as noted previ-
`ously, ranges from 100 eV to 1 KeV. Accordingly,
`essence, the signal processing unit operates in accor-
`dance with the synchronization signal on line 46 to
`these low kinetic photoelectrons are converted to high
`energy electrons which are accelerated into the plasma 65 detect the filtered signal at a series of predetermined
`times after the occurrence of each laser pulse, and then
`between the electrodes 12 and 16. In the plasma, these
`high energy electrons have sufficient energy to induce
`to integrate these detected filtered signals over a plural-
`secondary electrons from collisions with gas phase spe-
`ity of laser pulses. A typical signal processing unit
`
`Page 6 of 11
`
`

`

`4,846,920
`
`7
`which may be utilized to integrate the signal comprises
`a boxcar integrator circuit. Such a boxcar integrator
`could be set, for example, to detect the filtered and
`amplified signal over a series of selected time-windows
`occurring at a series of different selected times after a 5
`given laser pulse, and then to integrate each of these
`different time-window signals over a series of laser
`pulses. A standard time-window period might be, for
`example, 1 microsecond and the number of laser shots
`that may be integrated might be in the range of 5-100. 10
`Alternatively, the signal processing unit 44 may be
`implemented by means of a transient digitizer. In es(cid:173)
`sence, in this preferred embodiment the sudden appear(cid:173)
`ance of 100 KHz to 3 MHz damped oscillations in phase
`with the laser shots at the output of the signal process- 15
`ing unit 44 indicates that the endpoint has been reached
`and/or signals the appearance of the low work function
`material.
`The output from the signal processing unit 44 could
`be applied to an etch servo control unit 48 for control- 20
`ling an etching parameter (RF power, gas flow) in the
`chamber 10, or for stopping the etching process when a
`predetermined signal level is detected by the signal
`processing unit 44. Some form of threshold detection
`unit might be included in the control block 48 to facili- 25
`tate this operation. A similar servo control unit could be
`used to control a deposition parameter. Alternatively,
`the block 48 could simply comprise a chart recorder
`unit.
`Referring now to FIG. 3, there is shown a typical 30
`integrated plasma perturbation response as seen at the
`output of the signal processing unit 44 when low kinetic
`energy photoelectron pulses have been amplified by an
`etching plasma. It can be seen that in this graph, the
`time axis is in microseconds and the voltage axis is in 35
`millivolts. The points in the graph represent a series of
`integrated time-windows occurring after a series of
`laser pulses. 40 laser shots were integrated in order to
`form each point in the time graph.
`Referring now to FIG. 2, there is shown one example 40
`of a filter and amplifier network for removing various
`undesirable frequencies from the plasma discharge per(cid:173)
`turbation signal and for amplifying the frequencies of
`excitation and decay of the plasma discharge which
`may be utilized to implement the filter and amplifier 45
`network 40. In this embodiment, the electrode 12 is
`connected via line 16 to an optional capacitive divider
`network 50 for reducing the plasma discharge signal
`voltage to a desired voltage range. In the embodiment
`shown in FIG. 2, this divider network simply comprises 50
`the capacitors 52 and 54 connected in electrical series
`between the line 16 and a reference potential such as
`ground potential. A reduced voltage in the desired
`voltage range is taken from a node 56 disposed at the
`connecting point between the capacitors 52 and 54.
`The circuit further includes means for blocking any
`DC components in the plasma discharge signal. This
`DC blocking function is accomplished in FIG. 2 simply
`by connecting a DC blocking capacitor 58 to the node
`56 at one end thereof.
`The circuit further includes means for removing the
`fundamental RF excitation signal from the plasma dis(cid:173)
`charge impedance signal. In the embodiment shown in
`FIG. 2, this means is implemented simply by a notch
`filter 60 connected to the other end of the DC blocking 65
`capacitor 58 at node 59. The notch filter 60 comprises
`an inductor 62 connected in parallel to a capacitor 64,
`with the resulting notch filter designed to be in reso-
`
`55
`
`8
`nance with the RF drive frequency of approximately
`13.56 MHz. In the embodiment of the present invention
`shown in FIGS. 1 and 2, the notch filter 60, the DC
`blocking capacitor 58, the capacitive voltage divider
`network 50, the impedance matching network 20, and
`the RF signal source 18 are all disposed within a ground
`shield 100. Because of the potential for high RF volt(cid:173)
`ages at the notch filter 60, a wire wound inductor 62 is
`utilized in this filter.
`The circuit further includes means for amplifying the
`range of frequencies including the frequencies of decay
`of the plasma discharge perturbation. A variety of dif(cid:173)
`ferent amplifiers may be utilized to perform this amplifi(cid:173)
`cation function. In the embodiment shown in FIG. 2,
`this amplification function is accomplished by connect(cid:173)
`ing node 66, at the other end of the notch filter 60, to the
`reference potential via a capacitor 68. For frequency
`components in the filtered plasma discharge signal
`which are below the resonance frequency for the notch
`filter 60, the notch filter acts as an inductor. Accord(cid:173)
`ingly, the notch filter 60 in combination with the capaci(cid:173)
`tor 68 is designed to be in resonance for a band of these
`lower, frequencies to thereby increase or peak the am(cid:173)
`plitude of the signal in this frequency range. By way of
`example, the notch filter 60-capacitor 68 combination
`could be designed to amplify signal frequencies in the
`range of0.3-7 MHz, and preferably 1-5 MHz.
`In the alternative, if the drive frequency is below the
`perturbation frequencies to be amplified, then inductor
`elements could be substituted for the capacitors 68 and
`78 in FIG. 2 to effect signal amplification.
`The circuit may further include a second lower-volt(cid:173)
`age notch filter 70 disposed outside of the ground shield
`100 for removing any pick-up of the RF excitation fre(cid:173)
`quency fundamental in the low RF environment. This
`notch filter is connected at one end to the node 66, and
`again may comprjse a parallel-connected inductor 72
`and capacitor 74 designed to be in resonance at approxi(cid:173)
`mately 13.56 MHz. Again, the node 76 at the other end
`of the second notch filter 70 may be connected to the
`reference voltage via a capacitor 78 to form a second
`amplifier. The inductive notch filter 70 in combination
`with capacitor 78 again is designed to be in resonance
`for a band offrequencies below the 13.56 MHz notch of
`the filter 70 to thereby increase or peak the amplit

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