Abstract:
A small, light-weight and highly maintainable etching system and an etching method for etching a large substrate with a homogeneous etching rate are provided. The etching system comprises an agitating electric field system disposed around the substrate, an agitating power source of high frequency, medium frequency or low frequency, agitating electrodes, amplifiers and a phase controller to agitate electrons or ions to increase the etching speed and the uniformity of the etching rate by promoting activation of reactive gas and uniformalizing a plasma density.

Description:
This is a continuation of U.S. application Ser. No. 08/688,019, filed Jul. 29, 1996, now U.S. Pat. No. 6,099,687. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to an etching system and an etching method for dry-etching a semiconductor film and an insulating film. 
     DESCRIPTION OF THE RELATED ART 
     Dry etching is essential for the production of highly integrated semiconductor integrated circuits and there are etching methods and etching systems utilizing reactive ion etching (RIE), magnetron enhanced RIE, electron cyclotron resonance (ECR) and the like. 
     FIG. 1 is a schematic diagram showing the principle of the magnetron enhanced RIE. Reactive gas  3  is fed into a vacuum container  1  via a gas flow controller  2  and is maintained at an adequate pressure by an exhaust flow control valve  4  and an exhaust system  5 . An anode  6  and a cathode  7  are provided within the vacuum container  1 . The cathode  7  also plays a role of a substrate table for supporting a substrate  8 . The cathode  7  is connected to an RF generator  10  via a matching device  9  to cause RF discharge between the anode  6  and the cathode  7 . Electromagnets  11  having different phases and opposing each other are disposed on the outside of the vacuum container  1  to facilitate the discharge within high vacuum. 
     While the etching method and etching system utilizing the magnetron enhanced RIE and electron cyclotron resonance have had no problem if the substrate has a size of about 6 inches in diameter or 6 inches square, the magnetron enhanced RIE has had a problem for a substrate having a size of 8, 10, 12 inches or more that a so-called bank of electrons is brought about, not effecting the original magnetron discharge that electrons drift and return. Accordingly, it becomes difficult to uniformalize the plasma density across the whole substrate and a bias of the plasma density is brought about. Depending on the bias, a specimen is often partially destroyed by ion damage or the like in an extreme case and a thin gate oxide film is likely to be damaged in particular. The ECR also has had a problem that the size and weight of the system cannot but be increased when substrates become large because a magnetic coil for ECR condition is used. Further, because the gas cannot be agitated within the plasma discharge and because the flow of the gas fed/exhausted into/from the plasma discharge must be controlled in high precision, a marked high precision gas feeding/exhausting method has been required, thus complicating and increasing the size of the system. 
     SUMMARY OF THE INVENTION 
     The present invention provides an etching method, for improving an uniformity of plasma density across the whole surface of a substrate, for enabling an uniform etching even for a substrate of 8 inches or more and for reducing damages of a substrate caused by a bias of plasma, and a configuration which allows a size and weight of a system which realizes the above method to be reduced in an RIE type etching system by providing electrodes for applying an electric field in parallel with the surface of the substrate, beside electrodes disposed so as to apply an electric field vertically to the surface of the substrate, and by not only drifting electrons/ions within the plasma in the direction parallel with the surface of the substrate but also by agitating only electrons or both electrons and ions by utilizing a phenomenon that although both electrons and ions move following a low frequency electric field when it is applied in parallel with the surface of the substrate, electrons can follow an RF electric field, but not ions, when it is applied in parallel with the surface of the substrate. 
     The plurality of electrodes disposed vertically to the surface of the substrate are connected with function generators, amplifiers for amplifying frequency generated by the function generators and a phase controller for controlling a phase of the function generator connected to the other electrode. An activation of reactive gas may be promoted, a plasma density may be uniformalized and an etching rate and etching uniformity may be improved by providing two sets of parallel plate type electrodes orthogonally in case of four electrodes for example and by applying an RF electric field having a Lissajous waveform from the two sets of the electrodes and by agitating mainly electrons. In case when there are six electrodes, an activation of reactive gas may be promoted, a plasma density may be uniformalized and an etching rate and etching uniformity may be improved by disposing the electrodes hexagonally, by applying an RF electric field between the set of electrodes opposing each other, by applying a low frequency electric field whose phase is shifted to the other four electrodes to move electrons by the RF electric field in the direction parallel to the surface of the substrate and to move positive and negative ions by the low frequency electric field in the direction parallel to the surface of the substrate to agitate the electrons and ions. Any number of the electrodes for applying the agitating electric field in the direction parallel to the surface of the substrate may be used so long as it is more than two in theory. It is a matter of course that the number may be an even or odd number. Further, the present invention allows a small and light-weight system to be constructed without requiring a magnetic coil like the ECR. 
     Further, an activation of reactive gas may be promoted more effectively, a plasma density may be uniformalized and an etching rate and etching uniformity may be improved because a force for accelerating positive ions in the direction vertical to the surface of the substrate by Lorentz&#39;s force acts by applying a magnetic field in parallel with the surface of the substrate on the outside of the electrodes for applying the electric field in parallel to the surface of the substrate for agitating electrons and ions, beside accelerating positive ions in the direction vertical to the surface of the substrate by an ion sheath. The effect becomes significant especially when the magnetic field is a rotary magnetic field and the electric field parallel to the surface of the substrate has a frequency and phase which are in synchronism with the rotation of the rotary magnetic field. The present invention requires no bulky and heavy magnetic coil like those used in the ECR condition, thus allowing a small and light-weight system to be constructed. 
     Further, because the present invention allows the same effect of agitating gas itself to be obtained without controlling a flow of the reactive gas on the surface of the substrate precisely like the known etching system by uniformalizing the plasma density by agitating ions and electrons by the electric field or the magnetic field or the electric field+the magnetic field, there is less limit on the gas feeding and exhausting methods. Therefore, when a pump which may be mounted upward, downward, horizontally or obliquely such as a magnetic levitation type turbo pump is used, it may be mounted at a location giving a high maintainability. Further, a so-called system down time which occurs when the system causes a failure or the like may be shortened considerably. Still more, concerning to feeding of gas, the present invention requires no complicated gas feeding structure in the anode or cathode like the prior art system. It is of course needless to say that it is preferable to control the feed and exhaust of the gas precisely. 
     The present invention may be readily applied to a known cluster type multi-chamber or a corridor type multi-chamber. When it is applied to the multi-chamber, it is particularly effective in a semiconductor manufacturing process in which cleanliness of an interface between films is important by providing an etching chamber, an ashing chamber and a film forming chamber as the reaction chambers in the system because a film may be etched in the etching chamber by using a resist patterned by photolithography as a mask, the resist may be removed in the ashing chamber and another film may be formed on the patterned film in the film forming chamber. An adhesiveness of another film formed on a film may be improved by sputter-cleaning the surface of the patterned film after ashing and before forming the other film. Still more, a defect such as a dangling bond may be terminated by performing hydrogen annealing with heat or plasma or heat+plasma to the patterned film after ashing and before forming another film and one having no so-called hydrogen shortness can be fabricated by forming a fine film such as a nitride film after that. 
     As described above, an activation of reactive gas may be promoted, a plasma density may be uniformalized and an etching rate and etching uniformity may be improved by etching with a plurality of electrodes for applying an electric field in parallel to the surface of the substrate or means for applying a magnetic field in parallel to the substrate, beside the electrodes for applying an electric field vertically to the surface of the substrate. Further, because the means is small and light-weight, it is possible to reduce the size of the system. Further, the present invention allows a system having a high maintainability and requiring no complicated structure to be constructed because the gas is agitated by the electric field or the electric field+magnetic field. 
     The specific nature of the present invention, as well as other objects, uses and advantages thereof, will clearly appear from the description and from the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     FIG. 1 is a schematic diagram showing a prior art magnetron RIE type etching system; 
     FIG. 2 is a structural diagram showing an etching system of a first embodiment of the present invention; 
     FIG. 3 is a section view along a line X-Y in FIG. 2; 
     FIG. 4 is a structural diagram showing an etching system of a second embodiment of the present invention; 
     FIG. 5 is a section view along a line X-Y in FIG. 4; 
     FIG. 6 is a structural diagram of an RIE type etching system of a third embodiment of the present invention; 
     FIG. 7 is a schematic structural diagram of a multi-chamber type etching system of a fourth embodiment; 
     FIG. 8 is a schematic structural diagram of a multi-chamber type etching system of a fifth embodiment; and 
     FIG. 9 is a schematic structural diagram of a multi-chamber type etching system of a sixth embodiment. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     First Embodiment 
     FIGS. 2 and 3 show a structure of a system of the present embodiment. FIG. 3 shows a section along a line X-Y in FIG. 2. A vacuum container  110  comprises a gas feeding system  120 , an exhaust system  130 , an etching power source  140 , an agitating electric field system  150  and an agitating magnetic field system  160 . 
     The gas feeding system  120  has a gas feeding port  121  for feeding reactive gas via a flow controller  122 . For the flow controller  122 , a mass-flow controller, a needle valve or the like is used. The reactive gas which has passed the gas feeding port  121  is blown out to a reaction space  170  via gas blowout pores  123  so that it spreads homogeneously in the space. The gas is rendered to diffuse within an anode  124  where the gas blowout pores  123  exist in order to blow out the gas homogeneously. 
     In the exhaust system  130 , exhaust ports  131  disposed around a substrate  180  so that the reactive gas fed from the gas feeding system  120  is exhausted homogeneously to flow the gas homogeneously on the surface of the substrate  180  are connected with an exhaust flow control valve  132  for maintaining the reaction space  170  at an approximately constant pressure by controlling the flow of the gas exhausted via the exhaust ports  131 . For the exhaust flow control valve  132 , one which can vary a conductance such as a butterfly valve, a variable orifice, a needle valve or the like is used. The exhaust flow control valve  132  is connected with an exhaust pump  133  to pull out the gas. For the exhaust pump  133 , one which conforms to the very purpose thereof has to be selected considering a type of the gas used, a flow amount of the gas used, a reaction pressure, a corrosivity of the gas used, a background pressure and the like such as a turbo pump, a mechanical pump, a rotary pump, a screw pump or the like among various vacuum pumps. 
     In the etching power source  140 , a cathode  141  which also plays a role of a supporting table of the substrate  180  is connected with a cathode power source  143  via a matching device  142 . For the cathode power source  143 , a high frequency power source of 13.56 MHz for example, a medium frequency power source of less than 1 MHz or a low frequency power source of less than 1 KHz is used. The purpose of the every power source is to lead ions generated in the reaction space  170  to the surface of the substrate. The agitating electric field system  150  is provided with agitating electrodes  151 , i.e. four electrodes  151   a ,  151   b ,  151   c  and  151   d  in the present embodiment. Each of the agitating electrodes  151  is connected with an agitating power source  152  via an amplifier  153 . While a power source in which the agitating power source  152  and the amplifier  153  are integrated may be used, the amplifier  153  is necessary in the present embodiment because a so-called function generator (frequency generator) is used to vary a frequency of the agitating power source  152  widely. For the agitating power source  152 , function generators  152   a ,  152   b ,  152   c  and  152   d  are used corresponding to the respective agitating electrodes  151 , i.e. the electrodes  151   a ,  151   b ,  151   c  and  151   d . A frequency band of each of the function generators  152   a  through  152   d  was from 0 to 15 MHz. The amplifiers  153  also include amplifiers  153   a ,  153   b ,  152   c  and  153   d  corresponding to the respective electrodes  151   a  through  151   d  and the function generators  152   a  through  152   d . A phase controller  154  for controlling a phase of each agitating power source  152  when a phase difference thereof needs to be related to each other is connected to the agitating power source  152 . That is, phase shifters  154   a ,  154   b ,  154   c  and  154   d  are connected to the function generators  152   a  through  152   d , respectively. 
     For the agitating magnetic field system  160 , magnets  161 , i.e. electromagnets  161   a ,  161   b ,  161   c  and  161   d  are used in the present embodiment. 
     The reactive gas fed in from the gas feeding port  121  via the flow controller  122  is diffused within the anode  124  and is led into the reaction space  170  from the gas blowout pores  123 . The reactive gas reached from the reaction space  170  to the surface of the substrate  180  flows to the exhaust ports  131 . The reaction space  170  is maintained at a desirable pressure by controlling a conductance of the exhaust flow control valve  132  located between the exhaust pump  133  and the exhaust ports  131 . 
     In the present embodiment, etching uniformity and shape were compared by using substrates on which 2 μm of a-Si is formed on Corning 7059 glasses of 150 mm×150 mm×1 mm, 200 mm×200 mm×1.1 mm, 350 mm×350 mm×1.1 mm and 500 mm×500 mm×1.1 mm as the substrate  180 . Mixed gas of SF 6  and Cl 2  was used as the reactive gas. The ratio of the gas was SF 6 /Cl 2 =2/8 to 10/0. 
     For the cathode  141 , four sizes of cathodes of 200×200 mm, 250 mm×250 mm, 400 mm×400 mm and 550 mm×550 mm were used corresponding to the sizes of the substrates  180  used in the experiment. For the cathode power source  143 , an RF generator of 13.56 MHz and a medium frequency power source of 500 KHz were used. The power of the power source was between 0.1 to 3 W/cm 2  and a distance between the cathode  141  and the anode  124  was fixed to 70 mm. 
     For the exhaust system  130 , one having 1800 liters/s of exhaust rate was used in order to be able to regulate the reaction pressure of the vacuum container  110  of about 75 liters to 50 to 300 mTorr. A total flow amount of the gas including the reactive gas was about 500 to 2000 SCCM. 
     In the agitating electric field system  150 , each of the phase shifters  154   a  through  154   d  were controlled so that the phase of the neighboring electrodes  151   a  through  151   d  is shifted by 90° each. The function generators  152   a  through  152   d  were operated in 1 KHz and 5 MHz. They were operated in 1 KHz to check an effect for agitating ions within a plane and 5 MHz to check an effect for agitating electrons within the plane. A power for the agitation was 0.3 to 1 W/cm 2 . 
     In the agitating magnetic field system  160 , static magnetic field and rotary magnetic field were generated by the electromagnets  161   a  through  161   d  so that while the field strength is 2000 gauss at the inner wall of the vacuum container  110 , it is reduced exponentially toward the middle of the container, thus having about 100 gauss in maximum on the substrate  180 . Although the rotary magnetic field is effective more or less as a result, the static magnetic field is also effective considerably as compared to a case without it. Accordingly, permanent magnets may be used instead of the electromagnets  161   a  through  161   d  when the static magnetic field will do, considering a size of the system and the like. 
     The result of the experiment shows that the etching rate and etching shape are decided almost by the condition of the etching power source  140  and the ratio of the reactive gas and that no effect of the agitating electric field system  150  and the agitating magnetic field system  160  can be seen. When typical conditions for performing anisotropic etching were SF 6 =1000 SCCM, Cl 2 =250 SCC M, 200 mTorr of pressure, 13.56 MHz of frequency of the cathode power source and 0.8 W/cm 2  of power, the etching rate of the a-Si was 6200 Å/min. in average. 
     However, concerning to the etching uniformity, an effect of the agitating electric field system  150  and the agitating magnetic field system  160  could be seen. Table 1 shows the effect as dispersion of the etching rates within the substrate plane. 
     
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Dispersion of Etching Rates within Substrate Plane 
               
             
          
           
               
                 CONDITION 
                 150 mm sq. 
                 200 mm sq. 
                 350 mm sq. 
                 500 mm sq. 
               
               
                   
               
             
          
           
               
                 With AMS 
                 ±4.0% 
                 ±4.5% 
                 ±5.5% 
                 ±7.3% 
               
               
                 With AMS 
               
               
                 With AMS 
                 ±4.0 
                 ±4.5 
                 ±5.1 
                 ±6.5 
               
               
                 W/O AES 
               
               
                 W/O AMS 
                 ±4.0 
                 ±4.2 
                 ±4.4 
                 ±4.8 
               
               
                 With AES 
               
               
                 W/O AMS 
                 ±4.0 
                 ±4.2 
                 ±4.4 
                 ±4.5 
               
               
                 With AES 
               
               
                   
               
               
                 AMS: Agitating Magnetic Field System  
               
               
                 AES: Agitating Electric Field System  
               
             
          
         
       
     
     The data in Table 1 showing the dispersion of the etching rates within the substrate plane was obtained by controlling each of the phase shifters  154   a  through  154   d  so that the phase of the neighboring electrodes is shifted by 90° each and by setting the function generators  152   a  through  152   d  in 5 MHz in the agitating electric field system  150 . No desirable result could be obtained when the frequency was 1 KHz because the chemical effect of the etching drops in the case of the mixed gas system because the type and mass of the ions differ significantly. A large effect could be obtained when a single system gas was used. 
     As it is apparent from the result of the experiment, the effect of the agitating electric field system  150  is large. Although no big difference can be seen with the substrate of 150 mm sq., its effect becomes remarkable when the substrate is 200 mm sq. or more. When a Si wafer of 2 inches in diameter on which MOS transistors are mounted on the whole surface of a substrate of 500 mm sq. is placed, plasma is generated by using helium gas instead of the reactive gas of the present embodiment and a number of elements of the transistor insulation-broken down was counted by taking out the substrate, the number of broken elements is only about a half when the agitating electric field system  150  exists as compared to a case without it, showing that ion damage caused by the bias of the plasma density is small. 
     Second Embodiment 
     While the system in which the flow of the gas is controlled precisely in the gas feeding system and the exhaust system has been used in the first embodiment, a system shown in FIGS. 4 and 5 is used in the second embodiment. FIG. 5 shows a section along a line X-Y in FIG. 4. A vacuum container  210  comprises a gas feeding system  220 , an exhaust system  230 , an etching power source  240 , an agitating electric field system  250  and an agitating magnetic field system  260 . 
     The gas feeding system  220  has a gas feeding port  221  for feeding reactive gas via a flow controller  222 . For the flow controller  222 , a mass-flow controller, a needle valve or the like is used. The reactive gas which has passed the gas feeding port  221  is blown out to a reaction space  270  via gas blowout pores  223 . No particular process for blowing it out homogeneously is provided. 
     In the exhaust system  230 , exhaust ports  231  disposed at the sides of a substrate  280  for exhausting the reactive gas fed from the gas feeding system  220  are connected with an exhaust flow control valve  232  for maintaining the reaction space  270  at an approximately constant pressure by controlling the flow of the gas exhausted via the exhaust ports  231 . Although the exhaust ports can be provided around the substrate  280  so that the gas flows homogeneously on the surface of the substrate  280 , the exhaust ports are not provided around the substrate  280  in this second embodiment. For the exhaust flow control valve  232 , one which can vary a conductance such as a butterfly valve, a variable orifice, a needle valve or the like is used. The exhaust flow control valve  232  is connected with an exhaust pump  233  to pull out the gas. For the exhaust pump  233 , one which conforms to the very purpose thereof has to be selected considering a type of the gas used, a flow amount of the gas used, a reaction pressure, a corrosivity of the gas used, a background pressure and the like such as a turbo pump, a mechanical pump, a rotary pump, a screw pump or the like among various vacuum pumps. 
     In the etching power source  240 , a cathode  241  which also plays a role of a supporting table of the substrate  280  is connected with a cathode power source  243  via a matching device  242 . For the cathode power source  243 , a high frequency power source of 13.56 MHz for example, a medium frequency power source of less than 1 MHz or a low frequency power source of less than 1 KHz is used. The purpose of the every power source is to lead ions generated in the reaction space  270  to the surface of the substrate. 
     The agitating electric field system  250  is provided with agitating electrodes  251 , i.e. four electrodes  251   a ,  251   b ,  251   c  and  251   d  in the present embodiment. Each of the agitating electrodes  251  is connected with an agitating power source  252  via an amplifier  253 . While a power source in which the agitating power source  252  and the amplifier  253  are integrated may be used, the amplifier  253  is necessary in the present embodiment because a so-called function generator (frequency generator) is used to vary a frequency of the agitating power source  252  widely. For the agitating power sources  252 , function generators  252   a ,  252   b ,  252   c  and  252   d  are used corresponding to the respective agitating electrodes  251 , i.e. the electrodes  251   a ,  251   b ,  251   c  and  251   d . A frequency band of each of the function generators  252   a  through  252   d  was from 0 to 15 MHz. The amplifiers  253  also include amplifiers  253   a ,  253   b ,  252   c  and  253   d  corresponding to the respective electrodes  251   a  through  251   d  and the function generators  252   a  through  252   d . A phase controller  254  for controlling a phase of each agitating power source  252  when a phase difference thereof needs to be related to each other is connected to the agitating power source  252 . That is, phase shifters  254   a ,  254   b ,  254   c  and  254   d  are connected to the function generators  252   a  through  252   d , respectively. 
     For the agitating magnetic field system  260 , magnets  261 , i.e. electromagnets  261   a ,  261   b ,  261   c  and  261   d  are used in the present embodiment. 
     The reactive gas fed in from the gas feeding port  221  via the flow controller  222  is diffused within the anode  224  and is led into the reaction space  270  from the gas blowout pores  223 . The reactive gas reached from the reaction space  270  to the surface of the substrate  280  flows to the exhaust ports  231 . The reaction space  270  is maintained at a desirable pressure by controlling a conductance of the exhaust flow control valve  232  located between the exhaust pump  233  and the exhaust ports  231 . 
     In the present embodiment, etching uniformity and shape were compared by using substrates on which 2 μn of a-Si is formed on Corning 7059 glasses of 150 mm×150 mm×1 mm, 200 mm×200 mm×1.1 mm, 350 mm×350 mm×1.1 mm and 500 mm×500 mm×1.1 mm as the substrate  280 . Mixed gas of SF 6  and Cl 2  was used as the gas. The ratio of the gas was SF 6 /Cl 2 =2/8 to 10/0. 
     For the cathode  241 , four sizes of cathodes of 200×200 mm, 250 mm×250 mm, 400 mm×400 mm and 550 mm×550 mm were used corresponding to the sizes of the substrates  280  used in the experiment. For the cathode power source  243 , an RF generator of 13.56 MHz and a medium frequency power source of 500 KHz were used. The power of the power source was between 0.1 to 3 W/cm 2  and a distance between the cathode  241  and the anode  224  was fixed to 70 mm. 
     For the exhaust system  230 , one having 1800 liters/s of exhaust rate was used in order to be able to regulate the reaction pressure of the vacuum container  210  of about 75 liters to 50 to 300 mTorr. A total flow amount of the gas including the reactive gas was about 500 to 2000 SCCM. In the agitating electric field system  250 , each of the phase shifters  254   a  through  254   d  were controlled so that the phase of the neighboring electrodes  251   a  through  251   d  is shifted by 90° each. The function generators  252   a  through  252   d  were operated in 1 KHz and 5 MHz. They were operated in 1 KHz to check an effect for agitating ions within a plane and 5 MHz to check an effect for agitating electrons within the plane. A power for the agitation was 0.3 to 1 W/cm 2 . 
     In the agitating magnetic field system  260 , static magnetic field and rotary magnetic field were generated by the electromagnets  261   a  through  261   d  so that while the field strength is 2000 gauss at the inner wall of the vacuum container  210 , it is reduced exponentially toward the middle of the container, thus having about 100 gauss in maximum on the substrate  280 . Although the rotary magnetic field is effective more or less as a result, the static magnetic field is also effective considerably as compared to a case without it. Accordingly, permanent magnets may be used instead of the electromagnets  261   a  through  261   d  when the static magnetic field will do, considering a size of the system and the like. 
     The result of the experiment shows that the etching rate and etching shape are decided almost by the condition of the etching power source  240  and the ratio of the reactive gas and that no effect of the agitating electric field system  250  and the agitating magnetic field system  260  can be seen. When typical conditions for performing anisotropic etching were SF 6 =1000 SCCM, Cl 2 =250 SCC M, 200 mTorr of pressure, 13.56 MHz of frequency of the cathode power source and 0.8 W/cm 2  of power, the etching rate of the a-Si was 6000 Å/min. in average. 
     However, concerning to the etching uniformity, an effect of the agitating electric field system  250  and the agitating magnetic field system  260  could be seen. Table 2 shows the effect as dispersion of etching rates within the substrate plane. 
     
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Dispersion of Etching Rates within Substrate Plane 
               
             
          
           
               
                 CONDITION 
                 150 mm sq. 
                 200 mm sq. 
                 350 mm sq. 
                 500 mm sq. 
               
               
                   
               
             
          
           
               
                 With AMS 
                 ±7.0% 
                 ±13.0% 
                 ±24.2% 
                 ±36.4% 
               
               
                 With AES 
               
               
                 With AMS 
                 ±7.0 
                 ±12.5 
                 ±21.2 
                 ±32.0 
               
               
                 W/O AES 
               
               
                 W/O AMS 
                 ±6.9 
                 ±8.5 
                 ±11.1 
                 ±15.3 
               
               
                 With AES 
               
               
                 W/O AMS 
                 ±6.9 
                 ±8.3 
                 ±10.5 
                 ±15.0 
               
               
                 With AES 
               
               
                   
               
               
                 AMS: Agitating Magnetic Field System  
               
               
                 AES: Agitating Electric Field System  
               
             
          
         
       
     
     The data in Table 2 showing the dispersion of the etching rates within the substrate plane was obtained by controlling each of the phase shifters  254   a  through  254   d  so that the phase of the neighboring electrodes is shifted by 90° each and by setting the function generators  252   a  through  252   d  in 5 MHz in the agitating electric field system  250 . No desirable result could be obtained when the frequency was 1 KHz because the chemical effect of the etching drops in the case of the mixed gas system because the type and mass of the ions differ significantly. A large effect could be obtained when a single system gas is used. 
     As it is apparent from the result of the experiment, the effect of the agitating electric field system  250  is large. Although no big difference can be seen with the substrate of 150 mm sq., its effect becomes remarkable when the substrate is 200 mm sq. or more. However, although the effect of the agitating electric field is large in the case of the present embodiment in which the flow of the gas is not considered at all, the uniformity of the etching rate within the substrate exceeds ±15% within 500 mm sq. Accordingly, it is actually necessary to control how to flow the gas by a certain degree. However, it is certain that the design margin of the system is wider when there is the agitating electric field system  250  when the size of the substrate and system increases. When a Si wafer of 2 inches in diameter on which MOS transistors are mounted on the whole surface of a substrate of 500 mm sq. is placed, plasma is generated by using helium gas instead of the reactive gas of the present embodiment and a number of elements of the transistor insulation-broken down was counted by taking out the substrate, the number of broken elements is only about a half when the agitating electric field system  250  exists as compared to a case without it, showing that ion damage caused by the bias of the plasma density is small. 
     Third Embodiment 
     FIG. 6 shows a third embodiment. While a vacuum container of the present embodiment is based on that of the first embodiment which is square as shown in FIG. 2, it is pentagonal in the present embodiment. A vacuum container  310  comprises an agitating electric field system and agitating magnetic field system. It also comprises an etching power source, a gas feeding system and an exhaust system similarly to the first embodiment, although not shown. 
     The gas feeding system has a gas feeding port for feeding reactive gas via a flow controller. For the flow controller, a mass-flow controller, a needle valve or the like is used. The reactive gas which has passed the gas feeding port is blown out to a reaction space via gas blowout pores so that it spreads homogeneously in the space. The gas is diffused within an anode where the gas blowout pores exist in order to blow it out homogeneously. 
     In the exhaust system, exhaust ports disposed around a substrate for exhausting the reactive gas fed from the gas feeding system homogeneously to flow the gas homogeneously on the surface of the substrate are connected with an exhaust flow control valve for maintaining the reaction space at an approximately constant pressure by controlling the flow of the gas exhausted via the exhaust ports. For the exhaust flow control valve, one which can vary a conductance such as a butterfly valve, a variable orifice, a needle valve or the like is used. The exhaust flow control valve is connected with an exhaust pump to pull out the gas. For the exhaust pump, one which conforms to the very purpose thereof has to be selected considering a type of the gas used, a flow amount of the gas used, a reaction pressure, a corrosivity of the gas used, a background pressure and the like such as a turbo pump, a mechanical pump, a rotary pump, a screw pump or the like among various vacuum pumps. 
     In the etching power source a cathode  341  which also plays a role of a supporting table of the substrate  380  is connected with a cathode power source via a matching device. For the cathode power source a high frequency power source of 13.56 MHz for example, a medium frequency power source of less than 1 MHz or a low frequency power source of less than 1 KHz is used. The purpose of the every power source is to lead ions generated in the reaction space to the surface of the substrate. 
     The agitating electric field system is provided with five agitating electrodes  351  in the present embodiment. The agitating electrodes  351  are connected with an agitating power source  352  via an amplifier  353  (although only one set is shown in the figure, all of the five electrodes are connected with them). While a power source in which the agitating power source  352  and the amplifier  353  are integrated may be used, the amplifier  353  is necessary in the present embodiment because a so-called function generator (frequency generator) is used to vary a frequency of the agitating power source  352  widely. For the agitating power sources  352 , function generators are used corresponding to the respective agitating electrodes  351 . A frequency band of each function generator was from 0 to 15 MHz. A phase controller  354  for controlling a phase of each agitating power source  352  when a phase difference thereof needs to be related to each other is connected to the agitating power source  352 . 
     For the agitating magnetic field system five magnets  361  are used as shown in figure in the present embodiment. 
     The reactive gas fed in from the gas feeding port via the flow controller is diffused within the anode and is led into the reaction space from the gas blowout pores. The reactive gas reached from the reaction space to the surface of the substrate flows to the exhaust ports. The reaction space is maintained at a desirable pressure by controlling a conductance of the exhaust flow control valve located between the exhaust pump and the exhaust ports. 
     In the present embodiment, etching uniformity and shape were compared by using Si wafers on which 2 μm of Al was formed and whose size were 6 inches, 8 inches and 12 inches in diameter as the substrate  380 . Mixed gas of SiCl 4 , Cl 2  and BCl 3  was used as the gas. The ratio of the gas was SiCl 4 /Cl 2 /BCl 3 =1/1/4 to 3/1/15. 
     For the cathode  341 , three cathodes of 180 mm, 230 mm and 350 mm in diameter were used corresponding to the sizes of the substrates  380  used in the experiment. For the cathode power source an RF generator of 13.56 MHz and a medium frequency power source of 500 KHz were used. The power of the power source was between 0.1 to 3 W/cm 2  and a distance between the cathode  341  and the anode  324  was fixed to 70 mm. 
     For the exhaust system one having 1800 liters/s of exhaust rate was used in order to be able to regulate the reaction pressure of the vacuum container  310  of about 50 liters to 50 to 300 mTorr. A total flow amount of the gas including the reactive gas was about 500 to 2000 SCCM. 
     As for the agitating electric field, each of the phase controllers  354  were controlled so that the phases of the neighboring electrodes are shifted by 72° each. The function generators were operated in 1 KHz and 5 MHz. They were operated in 1 KHz to check an effect for agitating ions within a plane and 5 MHz to check an effect for agitating electrons within the plane. A power for the agitation was 0.03 to 1 W/cm 2 . 
     As for the agitating magnetic field, static magnetic field and rotary magnetic field were generated by the electromagnets  361  so that while the field strength is 2000 gauss at the inner wall of the vacuum container  310 , it is reduced exponentially toward the middle of the container, thus having about 100 gauss in maximum on the substrate  380 . Although the rotary magnetic field is effective more or less as a result, the static magnetic field is also effective considerably as compared to a case without it. Accordingly, permanent magnets may be used instead of the electromagnets when the static magnetic field will do, considering a size of the system and the like. 
     The result of the experiment shows that the etching rate and etching shape are decided almost by the condition of the etching power source and the ratio of the reactive gas and that no effect of the agitating electric field system and the agitating magnetic field system can be seen. When typical conditions for performing anisotropic etching were SiCl 4 =80 SCCM, Cl 2 =80 SCCM, BCl 3 =720 SCCM, 100 mTorr of pressure, 13.56 MHz of frequency of the cathode power source and 0.8 W/cm 2  of power, the etching rate of Al was 5000 Å/min. in average. 
     However, concerning to the etching uniformity, an effect of the agitating electric field system and the agitating magnetic field system could be seen. Table 3 shows the effect as dispersion of etching rates within the substrate plane. 
     
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 3 
               
             
             
               
                   
               
               
                 Dispersion of Etching Rates within Substrate Plane 
               
             
          
           
               
                   
                 CONDITION 
                 6 inches φ 
                 8 inches φ 
                 12 inches φ 
               
               
                   
                   
               
             
          
           
               
                   
                 With AMS 
                 ±3.5% 
                 ±4.3% 
                 ±7.6% 
               
               
                   
                 W/O AES 
               
               
                   
                 With AMS 
                 ±3.5 
                 ±4.1 
                 ±7.4 
               
               
                   
                 W/O AES 
               
               
                   
                 W/O AMS 
                 ±3.4 
                 ±3.6 
                 ±4.8 
               
               
                   
                 With AES 
               
               
                   
                 W/O AMS 
                 ±3.4 
                 ±3.5 
                 ±4.5 
               
               
                   
                 With AES 
               
               
                   
                   
               
               
                   
                 AMS: Agitating Magnetic Field System  
               
               
                   
                 AES: Agitating Electric Field System  
               
             
          
         
       
     
     The data in Table 3 was obtained by controlling each of the phase shifters so that the phase of the neighboring electrodes is shifted by 72° each and by setting the function generators in 5 MHz for the agitating electric field system. A power of the agitating power source  352  was 0.5 W/cm 2 . No desirable result could be obtained when the frequency was 1 KHz because the chemical effect of the etching drops in the case of the mixed gas system because the type and mass of the ions differ significantly. A large effect could be obtained when a single system gas is used. 
     As it is apparent from the result of the experiment, the effect of the agitating electric field system is large. Although no big difference can be seen with the substrate of 6 inches in diameter, its effect becomes remarkable when the substrate is 8 inches in diameter or more. When a Si wafer on which MOS transistors are mounted on the whole surface of a substrate of 12 inches in diameter is placed, plasma is generated by using helium gas instead of the reactive gas of the present embodiment and a number of elements of the transistor insulation-broken down was counted by taking out the substrate, the number of broken elements is only about a half when the agitating electric field exists as compared to a case without it, showing that ion damage caused by the bias of the plasma density is small. 
     As it can be understood also from the present embodiment, the agitating electric field system brings about the effect regardless of a concrete number of the agitating electrodes so long as it is plural. It was found that the effect is remarkable especially when the substrate size is 8 inches or more in diameter. 
     Fourth Embodiment 
     FIG. 7 shows a schematic structure of an application to a multi-chamber, wherein a basic shape of a robot chamber  430  is square. 
     The structure shown in FIG. 7 comprises a loading chamber  410 , an unloading chamber  420 , the robot chambers  430 , an etching chamber  440 , an ashing chamber  450 , a treatment chamber  460  and film forming chamber  470 . Each of the chambers is connected via a gate valve which can close/open communication with the other chamber. 
     In the present embodiment, a process of patterning source and drain electrodes of a bottom gate type TFT with etching stopper SiNx on a glass substrate of 500 mm sq., of performing a hydrogen treatment and of forming a-SiNx film in the end as a protecting film was carried out. 
     The substrate set in the loading chamber  410  was conveyed to the etching chamber  440  by a robot in the robot chamber  431 . In the etching chamber  440  where there is the inventive etching system equipped with the agitating electric field system, Al which is the source and drain electrodes was etched by using the reactive gas of SiCl 4 , Cl 2  and BCl 3 . The etching conditions were set conforming to those of the third embodiment. After etching Al, n-type a-Si under Al was continuously etched by using SF 6  and Cl 2  gases and setting the conditions conforming to those of the first embodiment. 
     After etching, the substrate was conveyed to the ashing chamber  450  to ash and remove photoresist by oxygen plasma. Although the inventive system comprising the agitating electric field system might be used for the ashing, a normal parallel plate plasma reaction system was used because all the photoresist on the whole surface just needs to be removed. 
     After ashing, the substrate was conveyed to the treatment chamber  460  to perform sputter cleaning by Ar or the like when there exists residue of the photoresist or to perform plasma hydrogen treatment immediately when there is no residue. The hydrogen treatment was performed with conditions of 100 to 250° C. of substrate temperature, 200 to 800 SCCM of hydrogen and 0.2 to 0.8 W/cm 2  of RF power. It was effective to use the inventive agitating electric field system for the hydrogen treatment and because it was a single system gas in particular, a low frequency power source was effective to use as the agitating power source. Each of the phase shifters was controlled so that a phase of neighboring electrodes is shifted by 90° each and the function generator was operated in 1 KHz. A power of the agitating power source was 0.5 W/cm 2 . It was also found here that it is effective to comprise the agitating electric field system also in the process other than etching. 
     After finishing the treatment in the treatment chamber  460 , the substrate was conveyed to the film forming chamber  470  by a robot in the robot chamber  432 . SiNx is formed as a protecting film in the film forming chamber  470 . Forming conditions were 200 to 250° C. of substrate temperature, SiH 4 /NH 3 /N 2 =1/5/20, 500 to 1500 SCCM of total flow amount and 0.5 to 1.0 W/cm 2  of RF power. It was also effective to use the inventive agitating electric field system in the film forming chamber  470  and the RF generator was effective as the agitating power source. Each of the phase shifters was controlled so that a phase of neighboring electrodes is shifted by 90° each and the function generator was operated in 5 MHz. A power of the agitating power source was 0.5 W/cm 2 . It was also found here that it is effective to comprise the agitating electric field system also in the process other than etching. The substrate was conveyed to the unloading chamber  420  after forming the film. 
     Fifth Embodiment 
     FIG. 8 shows a schematic structure of an application to a multi-chamber, wherein a basic shape of a robot chamber  530  is pentagonal. It comprises a loading and unloading chamber  510 , the robot chambers  530 , an etching chamber  540 , an ashing chamber  550 , a treatment chamber  560  and film forming chamber  570 . Each of the chambers is connected via a gate valve which can close/open communication with the other chamber. 
     In the present embodiment, a process of patterning top wires on a Si wafer of 12 inches in diameter having a laminated structure, of performing a surface treatment and of forming an a-SiOx film as a protecting film in the end was carried out. 
     The substrate set in the loading and unloading chamber  510  was conveyed to the etching chamber  540  by a robot in the robot chamber  530 . In the etching chamber  540  where there is the inventive etching system equipped with the agitating electric field system, Al which is the wired electrode was etched by using the reactive gas of SiCl 4 , Cl 2  and BCl 3 . The etching conditions were set conforming to those of the third embodiment. 
     After etching, the substrate was conveyed to the ashing chamber  550  to ash and remove photoresist by oxygen plasma. Although the inventive system comprising the agitating electric field system might be used for the ashing, a normal parallel plate plasma reaction system was used because all the photoresist on the whole surface just needs to be removed. 
     After ashing, the substrate was conveyed to the treatment chamber  560  to perform sputter cleaning by Ar or the like when there exists residue of the photoresist or to perform plasma hydrogen treatment immediately when there is no residue. The hydrogen treatment was performed with conditions of 100 to 250° C. of substrate temperature, 200 to 800 SCCM of hydrogen and 0.2 to 0.8 W/cm 2  of RF power. It was effective to use the inventive agitating electric field system for the hydrogen treatment and because it was a single system gas in particular, a low frequency power source was effective to use as the agitating power source. Each of the phase shifters was controlled so that a phase of neighboring electrodes is shifted by 72° each and the function generator was operated in 1 KHz. A power of the agitating power source was 0.5 W/cm2. It was found here that it is effective to comprise the agitating electric field system also in the process other than etching. 
     After finishing the treatment in the treatment chamber  560 , the substrate was conveyed to the film forming chamber  570  by a robot in the robot chamber  530 . SiOx is formed as a protecting film in the film forming chamber  570 . Forming conditions were 200 to 250° C. of substrate temperature, TEOS/O 2 =1/10, 500 to 1500 SCCM of total flow amount and 0.5 to 1.0 W/cm 2  of RF power. It was also effective to use the inventive agitating electric field system in the film forming chamber  570  and the RF generator was effective as the agitating power source. Each of the phase shifters was controlled so that a phase of neighboring electrodes is shifted by 72° each and the function generator was operated in 5 MHz. A power of the agitating power source was 0.5 W/cm 2 . It was found here that it is effective to comprise the agitating electric field system also in the process other than etching. The substrate was conveyed to the unloading chamber  520  after forming the film. 
     Sixth Embodiment 
     FIG. 9 shows a schematic structure of an application to a multi-chamber, wherein a shape of a robot chamber  630  is hexagonal. It comprises a loading chamber  610 , an unloading chamber  620 , the robot chambers  630 , an etching chamber  640 , an ashing chamber  650 , a treatment chamber  660  and film forming chamber  670 . Each of the chambers is connected via a gate valve which can close/open communication with the other chamber. 
     In the present embodiment, a process of patterning source and drain electrodes of a bottom gate type TFT with etching stopper SiNx on a glass substrate of 500 mm sq., of performing a hydrogen treatment and of forming a-SiNx film in the end as a protecting film was carried out. 
     The substrate set in the loading chamber  610  was conveyed to the etching chamber  640  by a robot in the robot chamber  630 . In the etching chamber  640  where there is the inventive etching system equipped with the agitating electric field system, Al which is the source and drain electrodes was etched by using the reactive gas of SiCl 4 , Cl 2  and BCl 3 . The etching conditions were set conforming to those of the third embodiment. After etching Al, an n-type a-Si under Al was continuously etched by using SF 6  and Cl 2  gases and setting the conditions conforming to those of the second embodiment. 
     After etching, the substrate was conveyed to the ashing chamber  650  to ash and remove photoresist by oxygen plasma. Although the inventive system comprising the agitating electric field system might be used for the ashing, a normal parallel plate plasma reaction system was used because all the photoresist on the whole surface just needs to be removed. 
     After ashing, the substrate was conveyed to the treatment chamber  660  to perform sputter cleaning by Ar or the like when there exists residue of the photoresist or to perform plasma hydrogen treatment immediately when there is no residue. The hydrogen treatment was performed with conditions of 100 to 250° C. of substrate temperature, 200 to 800 SCCM of hydrogen and 0.2 to 0.8 W/cm 2  of RF power. It was effective to use the inventive agitating electric field system for the hydrogen treatment and because it was a single system gas in particular, a low frequency power source was effective to use as the agitating power source. Each of the phase shifters was controlled so that a phase of neighboring electrodes is shifted by 60° each and the function generator was operated in 1 KHz. A power of the agitating power source was 0.5 W/cm 2 . It was found here that it is effective to comprise the agitating electric field system also in the process other than etching. 
     After finishing the treatment in the treatment chamber  660 , the substrate was conveyed to the film forming chamber  670  by the robot in the robot chamber  630 . SiNx is formed as a protecting film in the film forming chamber  670 . Film forming conditions were 200 to 250° C. of substrate temperature, SiH 4 /NH 3 /N 2 =1/5/20, 500 to 1500 SCCM of total flow amount and 0.5 to 1.0 W/cm 2  of RF power. It was also effective to use the inventive agitating electric field system in the film forming chamber  670  and the RF generator was effective as the agitating power source. Each of the phase shifters was controlled so that a phase of neighboring electrodes is shifted by 60° each and the function generator was operated in 5 MHz. A power of the agitating power source was 0.5 W/cm 2 . It was found here that it is effective to comprise the agitating electric field system also in the process other than etching. The substrate was conveyed to the unloading chamber  620  after forming the film. 
     As it is apparent from the above description, the uniformity of the etching rate is improved for a substrate of 8 inches or more by having the agitating electric field system in the RIE type etching system as compared to the case without it. With the increase of size of the system, it can give a manufacturing margin with respect to precision control of gas flow in the system, thus allowing to create a small and light-weight system having a high maintainability. It can be also readily applied to a multi-chamber system. The same effect can be obtained in plasma treatments other than etching by having the agitating electric field system. 
     While preferred embodiments have been described, variations thereto will occur to those skilled in the art within the scope of the present inventive concepts which are delineated by the following claims.