Patent ID: 8809196
Filing Date: 2014-08-19
Classification: H01L

Abstract:
1. A method of transferring a pattern to a substrate in a single-wafer plasma processing system, comprising: disposing a substrate comprising one or more mask layers overlying a thin film in said single-wafer plasma processing system; forming a feature pattern in said one or more mask layers; selecting a first process recipe including a first pressure of about 50 mTorr or less, a first etching chemistry comprising a first fluorocarbon-containing gas and a first oxygen-containing gas, a first fluorocarbon-containing gas flow rate of about 1-1000 sccm, a first oxygen-containing gas flow rate of about 1-1000 sccm, a first upper electrode RF bias of about 0-2000 W, a first upper electrode DC voltage of about 0 to about −2500 V, a first lower electrode RF bias of about 10-1000 W, and a first duration of time, and selecting a second process recipe including a second pressure of about 150 mTorr or greater, a second etching chemistry comprising a second fluorocarbon-containing gas and a second oxygen-containing gas, a second fluorocarbon-containing gas flow rate of about 1-1000 sccm, a second oxygen-containing gas flow rate of about 1-1000 sccm, a second upper electrode RF bias of about 0-2000 W, a second upper electrode DC voltage of about 0 to about −2500 V, a second lower electrode RF bias of about 10-1000 W, and a second duration of time, wherein said first process recipe is configured to reduce micro-loading in said feature pattern during a plasma etch transfer to said thin film and said second process recipe is configured to reduce feature roughness in said feature pattern during a plasma etch transfer to said thin film; and transferring said feature pattern in said one or more mask layers to said thin film by: wherein said performing said first plasma etching process and said performing said second plasma etching process are alternatingly repeated two or more cycles until said pattern is transferred to said thin film.