High density plasma tool with adjustable uniformity and stochastic electron heating for reduced gas cracking

• US 6,262,538 B1
• Filed: 08/26/1999
• Issued: 07/17/2001
• Est. Priority Date: 08/26/1999
• Status: Expired due to Fees

• Current Assignee: International Business Machines Corporation
• Original Assignee: International Business Machines Corporation
• Inventors: Keller, John H.
• Primary Examiner(s): Philogene, Haissa
• Assistant Examiner(s): Alemu, Ephrem
• Application Number:
  US09/383,773
• Time in Patent Office: 691 Days
• Field of Search: 343/701, 343/895, 343/700.MS, 343/850, 343/853, 315/111.21, 315/111.41, 315/111.51, 315/111.71, 427/569, 427/571, 118/723.I, 118/723.IR, 118/723.AN, 156/345
• US Class Current: 315/111.21
• CPC Class Codes: H01J 37/32082 Radio frequency generated discharge H01J37/32357, H01J37/32366, H01J37/32394 and H01J37/32403 take precedence

Abstract

VHF/UHF power having a frequency of about 40 MHz or higher is applied across generally radial elements of an antenna and the phase of a standing wave component of the voltage in the generally radial elements is adjusted to provide relatively uniform density of a high density plasma across an area of at least the size of a semiconductor wafer being processed. Capacitive coupling of power to the plasma enhances the hot tail distribution of electron energies which is associated with low levels of gas cracking and the production of radicals such as fluorine which are not material-selective in semiconductor processing operations such as oxide etching. Accordingly, material-selectivity of processes may be maintained while the high density plasma accelerates the process to significantly improve tool throughput.

Claims

1. A method of controlling plasma density including the steps of

applying a VHF/UHF signal having a frequency equal to or greater than 40 MHz across generally radial antenna elements to produce a voltage having a standing wave component therein, and

adjusting a voltage profile of said standing wave component along said generally radial antenna elements to produce a substantially uniform plasma density by capacitive coupling power to said plasma in accordance with said voltage profile.

2. A method as recited in claim 1, wherein said voltage is a nearly travelling wave.

3. A method as recited in claim 1, wherein said voltage is a standing wave.

19. A method as recited in claim 1 wherein said voltage profile is generally larger at a distal end of said radial antenna elements than near an inner end of said radial antenna elements.

4. An antenna for coupling electrical power to a plasma including

a first plate having a plurality of generally radial elements,

a second plate electrically connected to outer ends of said generally radial elements,

a third plate forming a distributed capacitance with said second plate and electrically connected to inner ends of said generally radial elements, and

a capacitive impedance from said second plate to ground.

5. An antenna as recited in claim 4, wherein said second plate is annular and disposed between said first plate and said third plate.

6. An antenna as recited in claim 4, wherein said generally radial elements are curved.

7. An antenna as recited in claim 6, wherein radially opposed ones of said plurality of said generally radial elements as formed as S-shaped lamina.

8. An antenna as recited in claim 4, further including a variable capacitance to ground.

9. An antenna as recited in claim 8, wherein said variable capacitance is connected to said second plate.

10. A plasma tool including

an antenna having a plurality of generally radial elements,

means for applying VHF/UHF power of a frequency of about 40 MHZ or higher across said generally radial elements to establish a voltage thereon having a standing wave component, and

means for adjusting phase of said standing wave component to control a voltage profile along said generally radial elements to produce a substantially uniform plasma density by capacitive coupling power to said plasma in accordance with said voltage profile.

11. A plasma tool as recited in claim 10, wherein said means for applying VHF/UHF power produces a nearly travelling wave in said generally radial elements.

12. A plasma tool as recited in claim 10, wherein said means for applying VHF/UHF power produces a standing wave in said generally radial elements.

13. A plasma tool as recited in claim 10, wherein said antenna includes

a first plate having a plurality of generally radial elements,

a second plate electrically connected to outer ends of said generally radial elements, and

a third plate forming a distributed capacitance with said second plate and electrically connected to inner ends of said generally radial elements, and

a capacitive impedance from said second plate to ground.

14. A plasma tools as recited in claim 13, wherein said second plate is annular and disposed between said first plate and said third plate.

15. A plasma tool as recited in claim 13, wherein said generally radial elements are curved.

16. A plasma tool as recited in claim 15, wherein radially opposed ones of said plurality of said generally radial elements are formed as S-shaped lamina.

17. A plasma tool as recited in claim 13, wherein said antenna further includes a variable capacitance to ground.

18. A plasma tool as recited in claim 17, wherein said variable capacitance is connected to said second plate.

20. A plasma tool as recited in claim 10 wherein said voltage profile is generally larger at a distal end of said radial antenna elements than near an inner end of said radial antenna elements.