Forming method of component and substrate processing system

A forming method of a component used in a plasma processing apparatus includes irradiating an energy beam to a source material of the component while supplying the source material based on a surface state of the component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application is a U.S. national phase application under 35 U.S.C. § 371 of PCT Application No. PCT/JP2019/018735 filed on May 10, 2019, which claims the benefit of Japanese Patent Application No. 2018-094129 filed on May 15, 2018, the entire disclosures of which are incorporated herein by reference.

TECHNICAL FIELD

The various embodiments described herein pertain generally to a forming method of a component and a substrate processing system.

BACKGROUND ART

With demands for high-aspect ratio etching and miniaturization, there is performed a plasma process in which a high frequency power for bias voltage generation is supplied at a high power level. Accordingly, the high aspect ratio etching and miniaturization can be realized by increasing the attraction of ions onto a substrate (see, for example, Patent Document 1).

SUMMARY

In one exemplary embodiment, a forming method of a component used in a plasma processing apparatus includes irradiating an energy beam to a source material of the component while supplying the source material based on a surface state of the component.

DETAILED DESCRIPTION

Hereinafter, exemplary embodiments for implementing the present disclosure will be described with reference to the drawings. Further, in the present specification and the drawings, substantially the same components will be denoted by the same reference numerals, and redundant descriptions thereof will be omitted.

[Plasma Processing Apparatus]First, an example of a plasma processing apparatus1will be described with reference toFIG.1. The plasma processing apparatus1according to the present exemplary embodiment is a parallel-plate capacitively-coupled plasma (CCP) processing apparatus. The plasma processing apparatus1has a plasma forming mechanism that configured to form plasma for etching a surface of a wafer W. Further, the plasma processing apparatus1is an example of a substrate processing system that has a component placed within a processing vessel10and processes a substrate, and the component is formed by irradiating an energy beam to a source material of the component while supplying the source material based on a surface state of the component.

The plasma processing apparatus1has the substantially cylindrical processing vessel10. An inner surface of the processing vessel10is alumite-treated (anodically oxidized). Within the processing vessel10, plasma processing such as etching, film formation, or the like is performed on the wafer W by plasma.

A placing table20has a base22and an electrostatic chuck21. The wafer W is placed on a top surface of the electrostatic chuck21. The base22is made of, e.g., Al, Ti, SiC, or the like.

The electrostatic chuck21is provided on the base22. The electrostatic chuck21has a structure in which an electrode film21ais embedded within an insulator21b. A DC power supply25is connected to the electrode film21avia a switch23. When the switch23is turned on and a DC voltage is applied from the DC power supply25to the electrode film21a, the wafer W is attracted to and held on the electrostatic chuck21by a Coulomb force.

An annular edge ring87is placed to surround a peripheral portion of the wafer W. The edge ring87is made of, e.g., Si and configured to converge plasma toward the surface of the wafer W within the processing vessel10to improve the efficiency of the plasma processing.

The placing table20is supported at a bottom portion of the processing vessel10by a support body14. A flow path24through which a temperature control medium (coolant, heat transfer medium) flows is formed within the base22. The coolant or the heat transfer medium, e.g., cooling water, brine or the like, output from a chiller circulates in order of a coolant inlet line24a, the flow path24, a coolant outlet line24b, and the chiller. The placing table20dissipates heat by the coolant circulated as described above to be cooled. The coolant and the heat transfer medium include fluid and gas.

A heat transfer gas such as helium gas (He) or argon gas (Ar) supplied from a heat transfer gas source passes through a gas supply line28and is supplied to a gap between a top surface of the electrostatic chuck21and a rear surface of the wafer W. With this configuration, the wafer W is controlled to a predetermined temperature by the coolant or the heat transfer medium circulating through the flow path24and the heat transfer gas supplied to the rear surface of the wafer W.

A first high frequency power supply32is connected to the placing table20via a first matching device33and is configured to apply a high frequency power HF for plasma formation with a first frequency (e.g., 40 MHz) to the placing table20. A second high frequency power supply34is connected to the placing table20via a second matching device35and is configured to apply a high frequency power LF for bias voltage generation with a second frequency lower (e.g., 13.56 MHz) than the first frequency to the placing table20. With this configuration, the placing table20also serves as a lower electrode. Although the high frequency power HF for plasma formation is applied to the placing table20in the present exemplary embodiment, the high frequency power HF may be applied to a shower head40.

The first matching device33is configured to match an output impedance of the first high frequency power supply32and a load impedance at a plasma side. The second matching device35is configured to match an internal impedance of the second high frequency power supply34and the load impedance at the plasma side.

The shower head40is disposed at a ceiling of the processing vessel10and closes the ceiling via a cylindrical shield ring42provided at an outer edge of the shower head40. The shower head40may be made of silicon. The shower head40also serves as a facing electrode (upper electrode) facing the placing table20(lower electrode). At a peripheral portion of the shower head40, a top shield ring41made of quartz (SiO2) is provided on a lower surface of the shield ring42.

An annular cover ring89and an annular insulator ring86are placed on a side surface of the placing table20and a peripheral portion of the edge ring87. The cover ring89and the insulator ring86may be made of quartz.

A gas inlet port45is formed in the shower head40. A diffusion space46is provided within the shower head40. A gas output from a gas source15is supplied and diffused into the diffusion space46through the gas inlet port45and then is supplied into a plasma processing space U within the processing vessel10through a plurality of gas supply holes47.

A gas exhaust port55is formed at a bottom surface of the processing vessel10. The processing vessel10is evacuated and decompressed by a gas exhaust device50connected to the gas exhaust port55. Accordingly, a pressure within the processing vessel10can be maintained at a predetermined vacuum level. A gate valve G is provided at a sidewall of the processing vessel10. The gate valve G is opened or closed when the wafer W is carried into and out of the processing vessel10.

An annular baffle plate81is provided at an upper portion of a gas exhaust path49that is formed above the gas exhaust port55to partition the plasma processing space U and a gas exhaust space D and also rectify the gas.

The plasma processing apparatus1includes a first controller60configured to control the overall operation of the plasma processing apparatus1. The first controller60includes a central processing unit (CPU)62, a read only memory (ROM)64and a random access memory (RAM)66. The CPU62executes a plasma processing such as etching or the like based on recipes stored in a storage such as the RAM66or the like. The recipes include information for controlling the plasma processing apparatus under the processing conditions, such as processing time, pressure (gas exhaust), high frequency power and voltage, various gas flow rates, temperature within the processing vessel (temperature of the upper electrode, temperature of the processing vessel side wall, temperature of the wafer W, temperature of the electrostatic chuck, etc.), temperature of the coolant, and the like. The recipes indicating such programs and processing conditions may be stored in a hard disk or a semiconductor memory. Alternatively, the recipes may be set at a predetermined region in a portable computer-readable storage medium, such as a CD-ROM, a DVD, or the like, to be readable.

When the plasma processing is performed in the plasma processing apparatus1configured as described above, opening/closing of the gate valve G is controlled. Then, the wafer W is carried into the processing vessel10and placed on the placing table20by moving lifter pins up and down. When the DC voltage is applied from the DC power supply25to the electrode film21a, the wafer W is attracted and held to the electrostatic chuck21.

The plasma forming mechanism includes the gas source15, the first high frequency power supply32and the second high frequency power supply34. The gas source15outputs and supplies a processing gas into the processing vessel10. The first high frequency power supply32applies the first high frequency power to the placing table20. The second high frequency power supply34applies the second high frequency power to the placing table20. Accordingly, the plasma forming mechanism forms plasma in the plasma processing space U. The plasma processing is performed on the wafer W by the action of the formed plasma.

After the plasma processing is performed, the DC voltage whose polarity is opposite to that of the voltage applied at the time of attracting the wafer W is applied from the DC power supply25to the electrode film21a, and charges on the wafer W are neutralized. The processed wafer W is separated from the electrostatic chuck21by moving the lifter pins up and down to be carried out to the outside of the processing vessel10when the gate valve G is opened.

Hereinafter, a configuration example of a 3D printer100will be described with reference toFIG.2.FIG.2illustrates an example of a configuration of the 3D printer100according to the exemplary embodiment. The 3D printer100according to the present exemplary embodiment is an example of a device configured to restore a component (a consumable component) consumed by the plasma. The device configured to restore the consumable component is not limited to the configuration of the 3D printer100illustrated inFIG.2.

In the present exemplary embodiment, the edge ring87will be described as an example of the consumable component to be restored by the 3D printer100. However, the consumable component is not limited thereto, and may be, e.g., the cover ring89, the insulator ring86, the top shield ring41, or the like. Also, the consumable component may be any component that is placed in the plasma processing apparatus1and can be separated (replaced) from the plasma processing apparatus1.

The 3D printer100can form a three-dimensional object in a chamber110. In the present exemplary embodiment, the edge ring87is formed as the three-dimensional object. Herein, a consumable part of the edge ring87is measured in advance and a three-dimensional shape of the consumable part of the edge ring87is restored by using the 3D printer100based on the measurement result, and, thus, the edge ring87is re-formed.

During the restoration, the edge ring87is placed on a placing surface of a stage102provided on a table103. The stage102can be moved up and down, for example, to be gradually lowered as the restoration of the edge ring87progresses.

In the present exemplary embodiment, powder of SiC serving as a source material is stored in a source material storage107. The source material just needs to be the same as the material of the edge ring87. For example, the edge ring87may be made of any one of quartz, Si, and tungsten. In this case, powder of quartz, Si or tungsten is stored in the source material storage107. Further, the source material is not limited to powder form, but may be in wire form. SiC powder B illustrated inFIG.2is supplied from the source material storage107and injected into the chamber110through a source material supply head105so as to be used to restore the consumption of the edge ring87. Desirably, the source material storage107and the source material supply head105are placed outside the chamber110.

While the SiC powder B is supplied into the chamber110, an energy beam is irradiated to melt the SiC powder B being supplied. In the present exemplary embodiment, a laser beam A (optical laser) is used as the energy beam to be irradiated. The laser beam A is output from a light source106and irradiated to a predetermined position determined by a laser scanning device104configured to perform a two-dimensional scanning. Desirably, the light source106and the laser scanning device104are placed outside the chamber110.

The laser scanning device104scans the laser beam A in at least two-dimensional (XY) direction above the stage102. For example, the laser scanning device104is controlled to move an irradiation spot of the laser beam A above the stage102based on a consumption state (consumption amount, consumption position (consumption area), consumption shape) of the edge ring87. Specifically, the laser scanning device104scans in the two-dimensional (XY) direction under the control of a second controller150as the restoration of the edge ring87progresses. For example, inFIG.2, the consumption state of the edge ring87is indicated by a dotted line E. The 3D printer restores the consumption of edge ring87to an original state of new product (i.e., a state indicated by the dotted line E).

At this time, the laser beam A irradiated from the laser scanning device104in the two-dimensional direction is irradiated to the irradiation spot above the stage102via a ceiling portion of the chamber110, e.g., a laser transmission window111provided right above the center of the stage102. The laser beam A heats the SiC powder B on the edge ring87(see C inFIG.2), melts and solidifies the powder B and forms a solidified layer D. The solidified layer D is stacked on a top surface of the edge ring87so that the edge ring87can be restored and re-formed.

The laser scanning device104and the source material supply head105are moved to a predetermined position as the second controller150drives a driver108. In the chamber110, a mechanism capable of supplying an inert gas and evacuating the inside of the chamber110may be provided.

The second controller150includes a CPU152, a ROM154and a RAM156. The second controller150controls the supply of the source material powder from the source material storage107and the source material supply head105and controls the moving up and down of the stage102. Further, the second controller150controls the turning on and off of the light source106and the scanning of the laser scanning device104and also controls the driver108. Accordingly, the second controller150controls the restoration of the edge ring87.

A control program executed by the CPU152is stored in, e.g., the ROM154. The CPU152controls the restoration of the edge ring87by executing the control program based on three-dimensional data stored in, e.g., the RAM156. Further, the control program may be stored in a fixed storage medium or may be stored in a detachable and computer-readable storage medium such as various flash memories or optical (magnetic) disks.

Furthermore, the second controller150includes a display158and an input device160such as a keyboard or a pointing device. The display158is used to display the restoration progress of the edge ring87. The input device160is used to input a control parameter for setting or an instruction such as the start and stop of the restoration of the edge ring87.

The consumption state of the edge ring87is measured by a non-contact type three-dimensional scanner200(hereinafter, simply referred to as “three-dimensional scanner200”). That is, the consumption state of the edge ring87is measured by the three-dimensional scanner200and the measured information is transmitted to the second controller150. The second controller150creates three-dimensional data which are restoration information based on the measured information and stores the created three-dimensional data in the RAM156.

Hereinafter, a process of measuring the consumption state of the edge ring87, which is performed by the three-dimensional scanner200before the restoration process, will be described.

First, a configuration example of the three-dimensional scanner200will be described with reference toFIG.3.FIG.3illustrates an example of a configuration of the three-dimensional scanner200according to the exemplary embodiment. The three-dimensional scanner200according to the present exemplary embodiment is an example of a device configured to measure the consumption state of the edge ring87, but is not limited to this configuration.

The three-dimensional scanner200includes a measurement stage203, an imaging unit201, a driver202and a detection controller204. The detection controller204includes a storage206and a three-dimensional measurement unit208. The edge ring87is placed on a placing surface of the measurement stage203. The consumption state of the edge ring87is indicated by a dotted line E.

The imaging unit201is placed facing the measurement stage203and configured to image the edge ring87. The driver202is configured to move the imaging unit201in a height direction or a horizontal direction in response to an instruction from the detection controller204. The imaging unit201scans the consumption state of the edge ring87in a three-dimensional manner and obtains image data.

The image data are transmitted to the detection controller204and then stored in the storage206. The three-dimensional measurement unit208is configured to create three-dimensional data from the three-dimensional consumption state (three-dimensional consumption amount, consumption position (consumption area), consumption shape) of the edge ring87based on a difference between the image data and the state of the edge ring87at the time when the edge ring87is a new product. The three-dimensional data are transmitted to the 3D printer100.

Hereinafter, an operation example of the three-dimensional scanner200will be described with reference toFIG.4.FIG.4is a flowchart showing an example of a three-dimensional data creation processing according to the exemplary embodiment. The present processing is started when the plasma processing is performed for a predetermined time period in the plasma processing apparatus1or when the edge ring87placed in the plasma processing apparatus1is consumed by a predetermined amount or more. The consumption amount of the edge ring87may be determined based on etching characteristics, such as an etching shape, an etching rate, etc., of the processed wafer W. The consumed edge ring87is separated from the plasma processing apparatus1and then transferred to the three-dimensional scanner200(process S10).

The edge ring87is placed on the placing surface of the measurement stage203. The imaging unit201scans the edge ring87in a three-dimensional manner (process S10). The image data of the scanned edge ring87are transmitted to the detection controller204.

The three-dimensional measurement unit208creates three-dimensional data indicating three-dimensional consumed amount, consumed position, consumed shape of the edge ring87based on the difference between the image data of the edge ring87and the state of the edge ring87at the time when the edge ring87is a new product (process S12). The three-dimensional measurement unit208transmits the created three-dimensional data to the 3D printer100(process S14), and the present processing is ended.

Accordingly, the 3D printer100obtains the three-dimensional data indicating the consumption state of the edge ring87and restores the consumed part of the edge ring87based on the three-dimensional data to re-form the edge ring87to an original state of new product.

Hereinafter, an operation example of the 3D printer100will be described with reference toFIG.5.FIG.5is a flowchart showing an example of a processing of restoring and forming a component according to the exemplary embodiment. When the present processing is started, the second controller150receives the three-dimensional data from the three-dimensional scanner200(process S20).

Then, the second controller150stores the three-dimensional data in the storage such as the RAM156or the like. The second controller150determines whether the consumption amount of the edge ring87exceeds a threshold value based on the three-dimensional data (process S22). If the second controller150determines that the consumption amount of the edge ring87does not exceed the threshold value, the edge ring87is consumed by a predetermined amount or less at this time. Therefore, the second controller150determines that restoration does not need to be performed and ends the present processing.

In the process S22, if the second controller150determines that the consumption amount of the edge ring87exceeds the threshold value, the second controller150determines that the edge ring87needs to be restored and then transfers the edge ring87to the 3D printer100and places the edge ring87on the stage102(process S24).

Then, the second controller150controls the driver108to move each of the source material supply head105and the laser scanning device104based on the three-dimensional data (process S26). Then, the second controller150irradiates the laser beam A while supplying the SiC powder B serving as the source material from the source material storage107(process S28). Accordingly, the SiC powder B is melted (see C inFIG.2) and solidified to form the solidified layer (see D inFIG.2) at a position determined based on the consumption state of the edge ring87.

Then, the second controller150determines whether the restoration of the consumed part of the edge ring87is completed (process S30). If the second controller150determines that the restoration of the consumed part of the edge ring87is not completed, the second controller150returns to the process S26and repeats the processing from the process S26to the process S30. In the process S30, if the second controller150determines that the restoration of the consumed part of the edge ring87is completed, the second controller150ends the present processing.

As described above, the forming method of the component, such as the edge ring87, according to the present exemplary embodiment includes the process of irradiating the energy beam to the source material of the component while supplying the source material based on three-dimensional data indicating a consumption state of the component.

Accordingly, the component, such as the edge ring87, can be restored. Therefore, even if the component, such as the edge ring87, is consumed by a predetermined amount or more, the component can be restored by the 3D printer100and provided again in the plasma processing apparatus1, and, thus, the component does not need to be replaced with a new one. Accordingly, it is possible to extend the lifetime of the component.

The consumption state of the component to be restored is measured by using the three-dimensional scanner200. After the measurement, the component is restored by irradiating the energy beam to the source material of the component while supplying the source material, based on the three-dimensional data indicating the consumption state of the component. Accordingly, it is possible to reduce the lead time required to manufacture the component.

However, the forming method of the component, such as the edge ring87, according to the present exemplary embodiment is not limited to the process of irradiating the energy beam to the source material of the component while supplying the source material based on three-dimensional data indicating the consumption state of the component. For example, if the edge ring87needs to be re-formed due to other reasons than the consumption of the component by the plasma, the component may be re-formed by irradiating the energy beam to the source material of the component while supplying the source material based on three-dimensional data indicating the surface state of the component.

In the present exemplary embodiment, a directed energy deposition 3D printer is described as an example of the 3D printer100configured to restore the edge ring87. In the directed energy deposition 3D printer, a component is restored by melting a source material in powder form or wire form in a space within the chamber110while supplying the source material, and depositing the melted source material at a predetermined position of the component. However, the 3D printer100is not limited to a 3D printer configured as described above.

For example, a powder bed fusion 3D printer may be used. In the powder bed fusion 3D printer, a component is restored by repeating an operation of spreading a source material in powder form on an entire surface of a stage, melting the source material with a laser beam, spreading the source material in powder form on the entire surface and melting the source material with a laser beam. Other 3D printers than the directed energy deposition 3D printer and the powder bed fusion 3D printer may be used in the method of restoring a component. Examples of the other 3D printers may include a binder jetting 3D printer, a sheet lamination 3D printer, a vat photopolymerization (stereolithography) 3D printer and a material extrusion (heat-melting lamination) 3D printer.

If the material of the component is a non-metal material such as resin or oxide, ultraviolet light and light in other frequency band may be used as the energy beam in the process of irradiating the energy beam while supplying the non-metal material by the 3D printer. Therefore, the forming method of the component according to the present exemplary embodiment enables the restoration of the component made of the non-metal material such as resin as well as the component made of the metal material. Examples of the 3D printer for the case where the material of the component is the non-metal material may include a material jetting 3D printer configured to solidify the non-metal material, which is jetted from an inkjet head, with the ultraviolet light and laminate the non-metal material.

The forming method of the component and the substrate processing system have been described above, but the forming method of the component and the substrate processing system of the present disclosure are not limited to the above-described exemplary embodiments and can be variously changed and modified without departing from the scope of the present disclosure. The contents described in the above-described exemplary embodiments may be combined without contradicting each other.

For example, in the above-described exemplary embodiments, the forming method of the edge ring87including the process of measuring the consumption state of the edge ring87and the process of irradiating the energy beam to the source material of the edge ring87while supplying the source material based on the measured consumption state of the edge ring87is described. However, the present disclosure is not limited thereto, and the method may include a process of measuring a surface state of the edge ring87and a process of irradiating the energy beam to the source material of the edge ring87while supplying the source material based on the measured surface state of the edge ring87.

The surface state of the component, such as the edge ring87, may include scratch or damage as well as the consumption of the edge ring87by the plasma. Even when the surface of the component is damaged or the like, the component can be restored or re-formed by measuring the surface state of the component including the damaged part and performing the forming method of the component according to the present disclosure based on the measurement result.

The plasma processing apparatus according to the present disclosure can be applied to any type of capacitively coupled plasma (CCP), inductively coupled plasma (ICP), radial line slot antenna, electron cyclotron resonance plasma (ECR) and helicon wave plasma (HWP).

In the present specification, the wafer W is described as an example of the substrate. However, the substrate is not limited thereto, but may include various substrates used for liquid crystal display (LCD) and flat panel display (FPD), CD substrates, print boards, or the like.

According to the exemplary embodiment as described above, consumable components can be restored.