Method and apparatus for monitoring plasma processing operations
First Claim
1. A method for monitoring a plasma process comprising a first plasma step and a second plasma step, said method comprising the steps of:
- loading a quantity of product into a processing chamber;
exposing said product in said processing chamber to a plasma;
obtaining data on optical emissions of said plasma in said processing chamber at least within a first wavelength range extending from about 250 nanometers to about 1,000 nanometers, at least at every 1 nanometer throughout said first wavelength range, and at least at every 1 second during at least a substantial portion of said exposing step;
selecting any first optical emissions endpoint indicator within said first wavelength range;
selecting any second optical emissions endpoint indicator within said first wavelength range;
performing said first plasma step on said product, wherein there is a first endpoint of said first plasma step which is when said first plasma step has produced a first predetermined result on said product, wherein said first optical emissions endpoint indicator comprises optical emissions at a first wavelength which is within said first wavelength range and which undergoes a change over time during said performing said first plasma step which is indicative of said first endpoint;
monitoring said first optical emissions endpoint indicator during at least a portion of said performing said first plasma step to identify an occurrence of said first endpoint;
performing said second plasma step on said product, wherein there is a second endpoint of said second plasma step which is when said second plasma step has produced a second predetermined result on said product, wherein said second predetermined result is different from said first predetermined result, wherein said second optical emissions endpoint indicator comprises optical emissions at a second wavelength which is within said second wavelength range and which undergoes a change over time during said performing said second plasma step which is indicative of said second endpoint; and
monitoring said second optical emissions endpoint indicator during at least a portion of said performing said second plasma step to identify an occurrence of said second endpoint, wherein said monitoring said first and second optical emissions endpoint indicator steps are each executed without requiring identification of any species within said plasma.
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Abstract
The invention generally relates to various aspects of a plasma process, and more specifically the monitoring of such plasma processes. One aspect relates in at least some manner to calibrating or initializing a plasma monitoring assembly. This type of calibration may be used to address wavelength shifts, intensity shifts, or both associated with optical emissions data obtained on a plasma process. A calibration light may be directed at a window through which optical emissions data is being obtained to determine the effect, if any, that the inner surface of the window is having on the optical emissions data being obtained therethrough, the operation of the optical emissions data gathering device, or both. Another aspect relates in at least some manner to various types of evaluations which may be undertaken of a plasma process which was run, and more typically one which is currently being run, within the processing chamber. Plasma health evaluations and process identification through optical emissions analysis are included in this aspect. Yet another aspect associated with the present invention relates in at least some manner to the endpoint of a plasma process (e.g., plasma recipe, plasma clean, conditioning wafer operation) or discrete/discernible portion thereof (e.g., a plasma step of a multiple step plasma recipe). A final aspect associated with the present invention relates to how one or more of the above-noted aspects may be implemented into a semiconductor fabrication facility, such as the distribution of wafers to a wafer production system.
48 Citations
23 Claims
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1. A method for monitoring a plasma process comprising a first plasma step and a second plasma step, said method comprising the steps of:
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loading a quantity of product into a processing chamber; exposing said product in said processing chamber to a plasma; obtaining data on optical emissions of said plasma in said processing chamber at least within a first wavelength range extending from about 250 nanometers to about 1,000 nanometers, at least at every 1 nanometer throughout said first wavelength range, and at least at every 1 second during at least a substantial portion of said exposing step; selecting any first optical emissions endpoint indicator within said first wavelength range; selecting any second optical emissions endpoint indicator within said first wavelength range; performing said first plasma step on said product, wherein there is a first endpoint of said first plasma step which is when said first plasma step has produced a first predetermined result on said product, wherein said first optical emissions endpoint indicator comprises optical emissions at a first wavelength which is within said first wavelength range and which undergoes a change over time during said performing said first plasma step which is indicative of said first endpoint; monitoring said first optical emissions endpoint indicator during at least a portion of said performing said first plasma step to identify an occurrence of said first endpoint; performing said second plasma step on said product, wherein there is a second endpoint of said second plasma step which is when said second plasma step has produced a second predetermined result on said product, wherein said second predetermined result is different from said first predetermined result, wherein said second optical emissions endpoint indicator comprises optical emissions at a second wavelength which is within said second wavelength range and which undergoes a change over time during said performing said second plasma step which is indicative of said second endpoint; and monitoring said second optical emissions endpoint indicator during at least a portion of said performing said second plasma step to identify an occurrence of said second endpoint, wherein said monitoring said first and second optical emissions endpoint indicator steps are each executed without requiring identification of any species within said plasma. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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Specification