Apparatus for atomic layering etching
First Claim
1. A substrate processing system having a substrate processing chamber for etching a layer on a substrate, comprising:
- a substrate support configured to support a substrate in said substrate processing system;
a separating plate structure separating said substrate processing system into a plasma generating region and a substrate processing region, wherein said separating plate structure has a set of holes configured to permit at least some neutral metastables to migrate through said separating plate structure without colliding with the separating plate structure but substantially prevent energetic plasma species from migrating through the separating plate structure, and wherein the separating plate structure is grounded, wherein the separating plate structure, comprises;
a top plate, wherein the top plate is grounded, anda bottom plate between the top plate and the substrate support;
a plasma source for generating a plasma in said plasma generating region; and
a microprocessor, microcontroller, or computer with logic for;
introducing a first gas into said substrate processing system, said gas being an etchant gas suitable for etching said layer,allowing said first gas to be present in said substrate processing system for a period of time sufficient to cause adsorption of at least some of said first gas into said layer,substantially replacing said first gas in said substrate processing system with an inert gas,generating neutral metastables from said inert gas within said substrate processing region; and
etching said layer in said substrate processing region with said neutral metastables;
wherein said neutral metastables comprise atoms in an excited state.
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Abstract
A substrate processing system having a processing chamber for etching a layer on a substrate is provided. The system includes a chuck upon which the substrate is disposed during etching. The system also includes the chamber being divided into a plasma generating region and a substrate processing region by a separating plate structure. The system further includes a plasma source for generating plasma in the plasma generating region. The system further includes logic for introducing a first gas into the chamber, wherein the gas is suitable for etching the layer. The logic also allows the first gas to be present in the chamber for a period of time sufficient to cause adsorption of at least some of the first gas into the layer. The logic further replaces the first gas with an inert gas, generates metastables from the inert gas, and etches the layer with the metastables.
56 Citations
22 Claims
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1. A substrate processing system having a substrate processing chamber for etching a layer on a substrate, comprising:
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a substrate support configured to support a substrate in said substrate processing system; a separating plate structure separating said substrate processing system into a plasma generating region and a substrate processing region, wherein said separating plate structure has a set of holes configured to permit at least some neutral metastables to migrate through said separating plate structure without colliding with the separating plate structure but substantially prevent energetic plasma species from migrating through the separating plate structure, and wherein the separating plate structure is grounded, wherein the separating plate structure, comprises; a top plate, wherein the top plate is grounded, and a bottom plate between the top plate and the substrate support; a plasma source for generating a plasma in said plasma generating region; and a microprocessor, microcontroller, or computer with logic for; introducing a first gas into said substrate processing system, said gas being an etchant gas suitable for etching said layer, allowing said first gas to be present in said substrate processing system for a period of time sufficient to cause adsorption of at least some of said first gas into said layer, substantially replacing said first gas in said substrate processing system with an inert gas, generating neutral metastables from said inert gas within said substrate processing region; and etching said layer in said substrate processing region with said neutral metastables;
wherein said neutral metastables comprise atoms in an excited state. - View Dependent Claims (2, 3, 4, 5, 6, 11, 12, 13, 14, 20, 21, 22)
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7. A substrate processing system having a substrate processing chamber for etching a layer on a substrate, said substrate disposed on a chuck within said chamber during said etching, comprising:
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a separating plate structure separating said chamber into a plasma generating region and a substrate processing region, wherein said separating plate structure is grounded and configured with a set of aligned holes sized to permit neutral metastables to migrate through said separating plate structure but substantially prevent energetic plasma species from migrating through the separating plate structure, wherein said neutral metastables comprise atoms in an excited state, wherein the separating plate structure, comprises; a top plate, wherein the top plate is grounded, and a bottom plate between the top plate and the substrate support; a plasma source for generating a plasma in said plasma generating region; and a microprocessor, microcontroller, or computer with logic for; introducing a first gas into said chamber, said gas being an etchant gas suitable for etching said layer, allowing said first gas to be present in said chamber for a period of time sufficient to cause adsorption of at least some of said first gas into said layer, substantially replacing said first gas in said plasma processing region with an inert gas, generating a plasma from said inert gas in said plasma generating region, and etching said layer with neutral metastables from said plasma, wherein said etching is performed while substantially preventing migration of plasma charged species from said plasma to said layer. - View Dependent Claims (8, 9, 10)
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15. A substrate processing system having a substrate processing chamber for etching a layer on a substrate, said substrate processing chamber having a plasma generating region and a substrate processing region, said plasma generating region being separated from said substrate processing region by a separating plate structure, comprising:
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a separating plate structure separating said chamber into a plasma generating region and a substrate processing region, wherein said separating plate structure is grounded and configured with a set of aligned holes sized to permit neutral metastables to migrate through said separating plate structure but substantially prevent energetic plasma species from migrating through the separating plate structure, wherein said neutral metastables comprise atoms in an excited state, wherein the separating plate structure, comprises; a top plate, wherein the top plate is grounded, and a bottom plate between the top plate and the substrate support; a plasma source for generating a plasma in said plasma generating region; and a microprocessor, microcontroller, or computer with logic for; introducing a first gas into said substrate processing region of said chamber, said first gas being an etchant gas suitable for etching said layer, introducing an inert gas into said plasma generating region, allowing said first gas to be present in said substrate processing region of said chamber for a period of time sufficient to cause adsorption of at least some of said first gas into said layer while maintaining a pressure of said inert gas in said plasma generating region is greater than a pressure of said etchant gas in said substrate processing region, replacing at least 80% of said first gas in said substrate processing region of said chamber with said inert gas after said period of time expires, generating plasma in said plasma generating region of said chamber to generate metastables from said inert gas, and etching said layer with said metastables while maintaining a pressure in said substrate processing region below 10 mTorr. - View Dependent Claims (16, 17, 18, 19)
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Specification