Abstract:
Embodiments disclosed herein relate to a substrate processing chamber component assembly with plasma resistant seal. In one embodiment, the semiconductor processing chamber component assembly includes a first semiconductor processing chamber component, a second semiconductor processing component, and a sealing member. The sealing member has a body formed substantially from polytetrafluoroethylene (PTFE). The sealing member provides a seal between the first and second semiconductor processing chamber components. The body includes a first surface, a second surface, a first sealing surface, and a second sealing surface. The first surface is configured for exposure to a plasma processing region. The second surface is opposite the first surface. The first sealing surface and the second sealing surface extend between the first surface and the second surface. The first sealing surface contacts the first semiconductor processing chamber component. The second sealing surface contacts the second semiconductor processing chamber component.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority from U.S. Provisional Application Serial No. 62/362,436, filed Jul. 14, 2016, which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND 
     Field 
       [0002]    Embodiments described herein generally relate to a substrate processing chamber component assembly with plasma resistant seal. 
       Description of the Related Art 
       [0003]    In the semiconductor industry, devices are fabricated by a number of manufacturing processes producing structures on an ever-decreasing size. Some manufacturing processes may generate particles, which frequently contaminate the substrate that is being processes, contributing to device defects. As device geometries shrink, susceptibility to defects increases and particle contaminant requirements become more stringent. Accordingly, as device geometries shrink, allowable levels of particle contamination may be reduced. 
         [0004]    Additionally, to maintain vacuum levels within semiconductor processing systems, seals are used at various locations. Conventional seal materials typically are not highly resistant to erosion, and thus, have a tendency to erode quickly if exposed to direct or remote plasma with sufficient energy. This causes particle generation which in turn results in defects and high levels of contamination, and eventually results in a failed vacuum seal. 
         [0005]    For more sensitive semiconductor applications, such as etching, erosive conditions are present inside the chamber due to the presence of corrosive gases and high energy plasma. Such an environment further limits the life of seals used with the processing chamber. 
         [0006]    Therefore, there is a need for improved seals for use in substrate processing systems. 
       SUMMARY 
       [0007]    Embodiments disclosed herein generally relate to a substrate processing chamber component assembly with plasma resistant seal. In one embodiment, the semiconductor processing chamber component assembly includes a first semiconductor processing chamber component, a second semiconductor processing component, and a sealing member. The sealing member has a body formed substantially from polytetrafluoroethylene (PTFE). The sealing member provides a seal between the first and second semiconductor processing chamber components. The body includes a first surface, a second surface, a first sealing surface, and a second sealing surface. The first surface is configured for exposure to a plasma processing region. The second surface is opposite the first surface. The first sealing surface extends between the first surface and the second surface. The first sealing surface contacts the first semiconductor processing chamber component. The second sealing surface extends between the first surface and the second surface. The second sealing surface contacts the second semiconductor processing chamber component. 
         [0008]    In another embodiment, a semiconductor processing chamber component assembly is disclosed herein. The semiconductor processing chamber component assembly includes an electrostatic chuck, a cooling base, and a sealing member. The sealing member has a body formed substantially from polytetrafluoroethylene (PTFE). The sealing member provides a seal between the electrostatic chuck and the cooling base. The body includes a first surface, a second surface, a first sealing surface, and a second sealing surface. The first surface is configured for exposure to a plasma processing region. The second surface is opposite the first surface. The first sealing surface extends between the first surface and the second surface. The first sealing surface contacts the electrostatic chuck. The second sealing surface extends between the first surface and the second surface. The second sealing surface contacts the cooling base. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments. 
           [0010]      FIG. 1  is a sectional side view illustrating a processing chamber having one or more sealing members, according to one embodiment. 
           [0011]      FIG. 2  is an enlarged view of the sealing member of  FIG. 1 , according to one embodiment. 
           [0012]      FIG. 3  is an enlarged view of the sealing member of  FIG. 2  positioned between a first processing chamber component and a second processing chamber component, according to one embodiment. 
           [0013]      FIG. 4  is an enlarged view of the sealing member of  FIG. 1 , according to one embodiment. 
           [0014]      FIG. 5  is an enlarged view of the sealing member of  FIG. 1 , according to one embodiment. 
       
    
    
       [0015]    For clarity, identical reference numerals have been used, where applicable, to designate identical elements that are common between figures. Additionally, elements of one embodiment may be advantageously adapted for utilization in other embodiments described herein. 
       DETAILED DESCRIPTION 
       [0016]      FIG. 1  is a sectional side view illustrating a processing chamber  100  having sealing members  150 , according to one embodiment. As shown, the processing chamber  100  is an etch chamber, capable of etching a substrate. Examples of processing chambers that may be adapted to benefit from the disclosure are Sym3® Processing Chamber, C3® Processing Chamber, and Mesa™ Processing Chamber, commercially available from Applied Materials, Inc, located in Santa Clara, Calif.. It is contemplated that other processing chambers including those from other manufacturers may be adapted to benefit from the disclosure. 
         [0017]    The processing chamber  100  may be used for various plasma processes. In one embodiment, the processing chamber  100  may be used to perform dry etching with one or more etching agents. For example, the processing chamber may be used for ignition of plasma from a precursor C x F y  (where x and y can be different allowed combinations, O 2 , NF 3 , or combinations thereof. Embodiments of the present disclosure may also be used in etching chromium for photomask applications, etching a profile, such as deep trench and through silicon vias (TSV), in a silicon substrate having oxide and metal layers disposed on the substrate  101 . 
         [0018]    The processing chamber  100  includes a chamber body  102  having sidewalls  104 , a bottom  106 , and a chamber lid  108 . The sidewalls  104 , bottom  106 , and chamber lid  108  define an interior volume  110 . The processing chamber  100  further includes a liner  112  disposed in the interior volume  110 . The liner  112  is configured to prevent the sidewalls  104  from damage and contamination from the processing chemistry and/or processing by-products. A slit valve door opening  114  is formed through the sidewall  104 . The slit valve door opening  114  is configured to allow passage of substrates and substrate transfer mechanism. A slit valve door  116  selectively opens and closes the slit valve door opening  114 . 
         [0019]    The processing chamber  100  further includes an electrostatic chuck  118  disposed in the interior volume  110 . The electrostatic chuck  118  is movably or fixedly positioned in the processing chamber  100 . The electrostatic chuck  118  is configured to support a substrate  101  during processing. The electrostatic chuck  118  includes a chuck body  120  and a chuck base  122 . The chuck body  120  and chuck base  122  may define a semiconductor processing chamber component assembly  170 . The chuck body  120  is secured to the chuck base by a bonding material  124 . The electrostatic chuck  118  further includes one or more sealing members  150 . The one or more sealing members  150  may be disposed around the bonding material  124  to protect the bonding material  124  from the processing environment. The one or more sealing members  150  are discussed in more detail below, in conjunction with  FIGS. 2-5 . 
         [0020]    The chuck body  120  may include one or more through holes (not shown) formed therethrough. The through holes are configured to allow lift pins  128  to pass therethrough to space the substrate  101  from the surface of the electrostatic chuck  118 . A lift  130  is configured to raise and lower lift pins  128  relative to the electrostatic chuck  118  during processing and loading/unloading the substrate  101 . The electrostatic chuck  118  may be coupled to a bias power source  132  for generating chucking force to secure the substrate  101  on the electrostatic chuck. 
         [0021]    One or more processing gases may be supplied to a plasma processing region  134  from a gas source  136  via an inlet  138 . The processing chamber  100  may further include a vacuum pump  140  in fluid communication with the plasma processing region  134 . The vacuum pump  140  is configured to pump the plasma processing region  134  and maintain a low pressure environment. 
         [0022]    The processing chamber  100  may further include an antenna assembly  142  disposed exterior to the chamber lid  108 . The antenna assembly  142  may be coupled to a radio-frequency (RF) power source  144  through a matching network  146 . During processing, the antenna assembly  142  is energized with RF power provided by the power source  144  to ignite a plasma of processing gases within plasma processing region  134  and to maintain the plasma during processing of the substrate  101 . 
         [0023]      FIGS. 2 and 3  are enlarged views of the sealing member  150 , according to one embodiment. The sealing member  150  generally includes a body  200 . The body  200  includes a first surface  202 , a second surface  204 , and a sealing surface  206 . The first surface  202  is exposed to a plasma processing region of the processing chamber  100 . The second surface  204  is opposite the first surface. In one embodiment, the second surface  204  is exposed to a component of the substrate processing chamber  100 . The sealing surface  206  extends between the first surface  202  and the second surface  204 . The sealing surface  206  is configured to contact a first component of the processing chamber  100 . For example, the sealing surface  206  is configured to contact the chuck body  120  and an opposite side contacting the chuck base  122  in the processing chamber  100 , such that a seal is formed between the chuck body  120  and the chuck base  122 . In addition to being used between the chuck body  120  and the chuck base  122  of the electrostatic chuck  118 , the sealing members  150  may be used in several other locations in the processing chamber  100 . For example, the sealing member  150  may be used in the chamber lid  108 , the liner  112 , the showerhead, nozzle, cathode, or other suitable locations in the processing chamber  100 . As shown in  FIG. 3 , generally, the sealing member  150  may be positioned between a first processing chamber component  302  and a second processing chamber component  304 . Collectively, the sealing member  150 , the first processing chamber component  302 , and the second processing chamber component  304  may define a semiconductor processing chamber component assembly  300 . 
         [0024]    Generally, the body  200  may be formed at least partially from polytetrafluoroethylene (PTFE). For example, the body  200  may include a first portion  208  and a second portion  210 . The first portion  208  includes at least the first surface  202 . The first portion  208  may be formed from PTFE. The PTFE in the first portion  208  has a higher erosion resistance compared to conventional FKM polymers and FFKM polymers used to form sealing members  150 . Thus, the first surface  202  exposed to the plasma processing region  134  is formed from a higher erosion resistance material and will withstand being exposed to the plasma better than conventional FKM and FFKM polymers. 
         [0025]    Additionally, conventional sealing members formed from FKM polymers and FFKM polymers typically compress about 15%-20% in size, or about 0.9 inches to 1 inch. The first portion  208  formed from PTFE only compresses about 1% in size, or about 0.1 inches to 0.2 inches. The compression of the PTFE is due to the vacuum compression force of the processing chamber  100 . The high compression force results in an enhanced seal for the PTFE sealing member  150 . For example, a compression force of up to 20-30 KN can be achieved in some processing chamber  100 . The second portion  210  may be formed from an FKM polymer or an FFKM polymer. For example, the second portion  210  may be formed from SiC, TiO 2 , Ba 2 SO 4 , MgO, or other suitable material. The sealing surface  206  may be comprised partially of the first portion  208  and the second portion  210 . Thus, the first portion  208  compresses less than the second portion  210  when in contact with the first component of the processing chamber. Therefore, when the sealing member  150  having body  200  is positioned between the first processing chamber component and the second processing chamber component, the first processing chamber component will be raised slightly higher on the side contacting the first portion  208  of the body  200  compared to the side of the first processing chamber component contacting the second portion  210  of the body  200 . For example, the body  200  may compress about 10-20 mm on the side contacting the first portion  208  of the body  200  and the body  200  may compress about 15-25 mm on the side contacting the second portion  210  of the body  200 . 
         [0026]    In one embodiment, the body  200  may be quadrilaterally shaped to increase the surface area that contacts the component of the processing chamber  100 . For example, the body  200  may have a rectangular shape that allows for a greater surface area of the sealing surface  206  to contact the first component of the processing chamber  100 . By increasing the surface area of the first component that the sealing surface  206  comes into contact with, an enhanced seal is formed between the sealing member  150  and the first component. Additionally, the body  200  may further include a surface finish  220 . The surface finish  220  may be in the range of 1-30 μinches. The surface finish  220  results in a smoother surface for the body  200 , which aids in achieving an enhanced seal with a processing chamber component. 
         [0027]      FIG. 4  is an enlarged view of the sealing member  150 , according to another embodiment. The sealing member  150  generally includes a body  400 . The body  400  includes at least a sealing surface  402 . The body  400  may be formed substantially from PTFE. In one embodiment, the body  400  is formed purely from PTFE. In another embodiment, the body  400  is formed substantially from PTFE and combined with an additive. For example, adequate additives may include, but are not limited to, SiC and polyamide. 
         [0028]      FIG. 5  is an enlarged view of the sealing member  150 , according to another embodiment. The sealing member  150  generally includes a body  500  formed substantially from PTFE. The body  500  may be substantially hollow. For example, the body  500  may be about 50% more hollow than the body  200  and the body  400  in  FIGS. 2-4 . The hollow body  500  is configured to increase the elastic properties of the PTFE material. In some embodiments, the sealing member  150  may include an elastic material injected into a hollow core  502  of the body  500 . For example, the elastic material may be an FKM or FFKM polymer. The elastic material injected in the hollow core  502  is configured to increase the elastic properties of the body  500 . 
         [0029]    While the foregoing is directed to specific embodiments, other and further embodiments may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.