Semiconductor processing chamber

Exemplary semiconductor processing systems may include a pedestal configured to support a semiconductor substrate. The pedestal may be operable as a first plasma-generating electrode. The systems may include a lid plate defining a radial volume. The systems may include a faceplate supported with the lid plate. The faceplate may be operable as a second plasma-generating electrode. A plasma processing region may be defined between the pedestal and the faceplate within the radial volume defined by the faceplate. The faceplate may define a plurality of first apertures. The systems may include a showerhead positioned between the faceplate and the pedestal. The showerhead may define a plurality of second apertures comprising a greater number of apertures than the plurality of first apertures.

TECHNICAL FIELD

The present technology relates to semiconductor systems, processes, and equipment. More specifically, the present technology relates to semiconductor processing systems and components.

BACKGROUND

Integrated circuits are made possible by processes which produce intricately patterned material layers on substrate surfaces. Producing patterned material on a substrate requires controlled methods for removal of exposed material. Chemical etching is used for a variety of purposes including transferring a pattern in photoresist into underlying layers, thinning layers, or thinning lateral dimensions of features already present on the surface. Often it is desirable to have an etch process that etches one material faster than another facilitating, for example, a pattern transfer process or individual material removal. Such an etch process is said to be selective to the first material. As a result of the diversity of materials, circuits, and processes, etch processes have been developed with a selectivity towards a variety of materials.

Etch processes may be termed wet or dry based on the materials used in the process. A wet HF etch preferentially removes silicon oxide over other dielectrics and materials. However, wet processes may have difficulty penetrating some constrained trenches and also may sometimes deform the remaining material. Dry etch processes may penetrate into intricate features and trenches, but may not provide acceptable top-to-bottom profiles. As device sizes continue to shrink in next-generation devices, the ways in which systems deliver precursors into and through a chamber may have an increasing impact. As uniformity of processing conditions continues to increase in importance, chamber designs and system set-ups may have an important role in the quality of devices produced.

SUMMARY

Exemplary semiconductor processing systems may include a pedestal configured to support a semiconductor substrate. The pedestal may be operable as a first plasma-generating electrode. The systems may include a lid plate defining a radial volume. The systems may include a faceplate supported with the lid plate. The faceplate may be operable as a second plasma-generating electrode. A plasma processing region may be defined between the pedestal and the faceplate within the radial volume defined by the faceplate. The faceplate may define a plurality of first apertures. The systems may include a showerhead positioned between the faceplate and the pedestal. The showerhead may define a plurality of second apertures comprising a greater number of apertures than the plurality of first apertures.

In some embodiments, the showerhead may be or include a dielectric material. The showerhead may define at least twice as many apertures as the faceplate. Each aperture of the plurality of second apertures may be offset from each aperture of the plurality of first apertures. A first subset of apertures of the plurality of second apertures may be characterized by a similar aperture pattern as the plurality of first apertures. Each aperture of the first subset of apertures may be offset from an associated aperture of the plurality of first apertures along an angle from a central axis through the showerhead. The first subset of apertures of the plurality of second apertures may include a similar number of apertures as a number of apertures in the plurality of first apertures.

A second subset of apertures of the plurality of second apertures may be characterized by a similar aperture pattern as the plurality of first apertures. Each aperture of the second subset of apertures may be offset from an associated aperture of the plurality of first apertures along a radius from a central axis through the showerhead. The second subset of apertures of the plurality of second apertures may be or include a similar number of apertures as a number of apertures in the plurality of first apertures. The processing system may also include an annular liner positioned within the radial volume defined by the lid plate. The annular liner may be characterized by a first surface facing the showerhead and a second surface opposite the first surface. The annular liner may define a protrusion extending about an exterior surface of the annular liner. The protrusion may be recessed from the first surface of the annular liner and may define a first ledge facing the first surface of the annular liner and a second ledge facing the second surface of the annular liner. The processing system may further include a first elastomeric element extending about the first ledge, and a second elastomeric element extending about the second ledge.

The first elastomeric element may extend proud of the first surface of the annular liner. The showerhead may be seated on the first elastomeric element. The processing system may also include a spacer seated on the lid plate, and the spacer may define a first recessed ledge. The second elastomeric element may be seated on the first recessed ledge of the spacer. The spacer may define a second recessed ledge radially outward of the first recessed ledge. The showerhead may define a plurality of notches about an exterior edge of the showerhead. The semiconductor processing system further include a plurality of alignment pins. Each alignment pin of the plurality of alignment pins at least partially may be disposed within a notch of the plurality of notches. Each alignment pin of the plurality of alignment pins may be seated on the second recessed ledge of the spacer.

An exterior of the faceplate may be characterized by an oxide coating. The showerhead may be characterized by a first surface facing the faceplate. The plurality of second apertures may extend from the first surface of the showerhead to a second surface of the showerhead opposite the first surface of the showerhead. Each aperture of the plurality of second apertures may be characterized by a profile limiting a linear path through the aperture in a direction orthogonal to the second surface of the showerhead. The first surface of the showerhead may be disposed within 2 mm from the faceplate.

Some embodiments of the present technology may encompass semiconductor processing systems. The systems may include a lid plate at least partially defining a radial volume for plasma processing. The systems may include a spacer seated on the lid plate and at least partially extending within the radial volume. The spacer may be characterized by a first surface and a second surface opposite the first surface. The spacer may be seated on the lid plate along the second surface of the spacer. The systems may include a faceplate seated on the first surface of the spacer and at least partially defining the radial volume from above. The faceplate may define a plurality of first apertures. The systems may include a gasbox. The faceplate may be disposed between the gasbox and the spacer. The gasbox may define a central aperture, and the gasbox may define a first channel within a first surface of the gasbox.

In some embodiments, the systems may also include a heater extending through the first channel. The first channel may be characterized by a spiral profile within the first surface of the gasbox. The heater may extend within the first channel for an integral number of turns. The systems may include a cover plate extending across the first channel defined within the first surface of the gasbox. The gasbox may further define a second channel within the first surface of the gasbox radially inward of the first channel. The gasbox may define a third channel within the first surface of the gasbox radially outward of the first channel. The semiconductor processing systems may include a first gasket disposed within the second channel within the first surface of the gasbox. The systems may include a second gasket disposed within the third channel within the first surface of the gasbox. The cover plate may form a seal between the first gasket and the second gasket.

The gasbox may be characterized by a second surface opposite the first surface, and the central aperture may flare at the second surface of the gasbox. The gasbox may define a recessed ledge from the first surface of the gasbox extending into the central aperture. The systems may include an insert seated on the recessed ledge within the central aperture. The insert may define one or more apertures providing access through the central aperture of the gasbox. The lid plate may define at least one aperture at least partially extending through the lid plate from a first surface of the lid plate on which the spacer is seated. The spacer may define at least one aperture, each aperture of the at least one aperture of the spacer axially aligned with an associated aperture of the at least one aperture of the lid plate. Each aperture of the at least one aperture of the spacer may be characterized by a diameter less than a diameter of the associated aperture of the at least one aperture of the lid plate at the first surface of the lid plate. The systems may include a jack member disposed within each aperture of the at least one aperture of the lid plate. A surface of each jack member may be characterized by a diameter greater than a diameter of each aperture of the at least one aperture of the spacer, and removal of the jack member may be configured to separate the spacer from the lid plate.

Some embodiments of the present technology may also encompass semiconductor processing systems. The systems may include a lid plate defining a first radial volume and a second radial volume laterally separated along the lid plate from the first radial volume. The systems may include a first lid stack seated on the lid plate and axially aligned with the first radial volume. The systems may include a first RF match, where the first lid stack may be disposed between the lid plate and the first RF match. The systems may include a second lid stack seated on the lid plate and axially aligned with the second radial volume. The systems may include a second RF match, where the second lid stack may be disposed between the lid plate and the second RF match.

In some embodiments, one or more components of the first lid stack and one or more components of the second lid stack may include an oxide coating. The first lid stack may include a first gasbox defining a central aperture. The second lid stack may include a second gasbox defining a central aperture. The systems may include a first outlet manifold positioned on the first gasbox along a first surface of the first outlet manifold. The first outlet manifold may define a central aperture extending partially through the first outlet manifold from the first surface of the first outlet manifold towards a second surface of the first outlet manifold opposite the first surface of the first outlet manifold. The central aperture of the first outlet manifold may provide fluid access to the central aperture of the first gasbox. The systems may include a first conductive pin electrically coupling the first RF match with the first outlet manifold.

The systems may include a second outlet manifold positioned on the second gasbox along a first surface of the second outlet manifold. The second outlet manifold may define a central aperture extending partially through the second outlet manifold from the first surface of the second outlet manifold towards a second surface of the second outlet manifold opposite the first surface of the first outlet manifold. The central aperture of the second outlet manifold may provide fluid access to the central aperture of the second gasbox. The systems may include a second conductive pin electrically coupling the second RF match with the second outlet manifold. The first gasbox and the second gasbox may each define a first channel within a first surface of a respective gasbox on which a respective outlet manifold is positioned. Each first channel may be characterized by a spiral profile within the first surface of the respective gasbox.

The systems may include a first heater extending through the first channel of the first gasbox, and a first RF filter may be coupled with the first heater. The systems may include a second heater extending through the first channel of the second gasbox, and a second RF filter may be coupled with the second heater. The systems may include a first gas block coupled with an exterior edge of the first outlet manifold. The first gas block may be coupled to provide fluid communication to the central aperture of the first outlet manifold. The systems may include a second gas block coupled with an exterior edge of the second outlet manifold. The second gas block may be coupled to provide fluid communication to the central aperture of the second outlet manifold. The systems may include a gas feedthrough extending through the lid plate and coupled with each of the first gas block and the second gas block. The semiconductor processing system may include two gas feedthroughs extending through the lid plate and coupled with each of the first gas block and the second gas block. The lid plate may define an aperture through which the gas feedthrough extends. The lid plate may be hingedly coupled with a chamber body of the semiconductor processing system. The chamber body may include an elastomeric element on which the gas feedthrough seats when the lid plate is closed upon the chamber body.

Such technology may provide numerous benefits over conventional systems and techniques. For example, the systems may protect against corrosion better than conventional designs. Additionally, the symmetric electrical designs may improve RF uniformity, which may improve plasma uniformity. These and other embodiments, along with many of their advantages and features, are described in more detail in conjunction with the below description and attached figures.

DETAILED DESCRIPTION

The present technology includes semiconductor processing systems, chambers, and components for performing semiconductor fabrication operations. Many dry etch operations performed during semiconductor fabrication may involve multiple precursors. When energized and combined in various ways, these etchants may be delivered to a substrate to remove or modify aspects of a substrate. Traditional processing systems may provide precursors, such as for etching, in multiple ways. One way of providing enhanced precursors or etchants is to provide all of the precursors through a remote plasma unit before delivering the precursors through a processing chamber and to a substrate, such as a wafer, for processing. An issue with this process, however, is that the different precursors may be reactive with different materials, which may cause damage to the remote plasma unit or any components that may be contacted by the radical effluents. For example, an enhanced fluorine-containing precursor may react with aluminum surfaces, but may not react with oxide surfaces. An enhanced hydrogen-containing precursor may not react with an aluminum surface, but may react with and remove an oxide coating. Thus, if the two precursors are delivered through a remote plasma unit together, they may damage any number of components.

The present technology may overcome these issues by utilizing components and systems configured to mix the precursors prior to delivering them into the chamber, where local plasmas may be generated to produce etchants. Chambers and systems according to some embodiments of the present technology may also include component configurations that maximize thermal conductivity through the chamber, and increase ease of servicing by coupling the components in specific ways. Several of the system components may also be coated or otherwise protected to limit reactivity and damage during fluid delivery through the chamber.

Although the remaining disclosure will routinely identify specific etching processes utilizing the disclosed technology, it will be readily understood that the systems and methods are equally applicable to deposition and/or cleaning processes as may occur in the described chambers. Accordingly, the technology should not be considered to be so limited as for use with etching processes alone.

FIG.1shows a top plan view of one embodiment of a processing system100of deposition, etching, baking, and/or curing chambers according to some embodiments. In the figure, a pair of front opening unified pods102may supply substrates of a variety of sizes that are received by robotic arms104and placed into a low pressure holding area106before being placed into one of the substrate processing chambers108a-f, positioned in tandem sections109a-c. A second robotic arm110may be used to transport the substrate wafers from the holding area106to the substrate processing chambers108a-fand back. Each substrate processing chamber108a-f, can be outfitted to perform a number of substrate processing operations including the dry etch processes described herein in addition to cyclical layer deposition, atomic layer deposition, chemical vapor deposition, physical vapor deposition, etch, pre-clean, degas, orientation, and other substrate processes.

The substrate processing chambers108a-fmay include one or more system components for depositing, annealing, curing and/or etching a dielectric, metal, or semiconductor film on the substrate wafer. In one configuration, two pairs of the processing chambers, e.g.,108c-dand108e-f, may be used to deposit dielectric material on the substrate, and the third pair of processing chambers, e.g.,108a-b, may be used to etch the deposited material. In another configuration, all three pairs of chambers, e.g.,108a-f, may be configured to etch a dielectric, metal, or semiconductor material on the substrate. Any of the tandem sections may be outfitted with processing systems described below. It will be appreciated that additional configurations of deposition, etching, annealing, and curing chambers for dielectric films are similarly encompassed by system100.

FIG.2shows a schematic cross-sectional view of an exemplary semiconductor processing system200according to some embodiments of the present technology. System200may be incorporated onto the mainframe illustrated inFIG.1, and may include some or all of the components illustrated in that figure. The image may include a partial view of a lid plate and lid stack, as well as associated components, but may include additional components as will be explained further below. System200may include a pair of adjacent processing chambers, or tandem processing chamber, which may include similar components to one another, and may share certain components of the system. The system may include a lid plate205, which may support lid stacks210aand210bfor the separate chambers. As will be described further below, lid plate205may define two radial volumes in some embodiments, and the lid stacks may each be aligned or coaxial with one of the radial volumes. For example, lid stack210amay be coaxial with a first radial volume defined by lid plate205, and lid stack210bmay be coaxial with a second radial volume defined by lid plate205. A box cover212, shown transparently to illustrate covered components, may provide RF sealing, and may at least partially house the lid stacks210.

The box cover212may also support additional components that may be described in more detail below. For example, each chamber of the system may include an individual RF match215aligned with a chamber. For example, first RF match215amay be axially aligned or coaxial with a central axis of lid stack210a, or the first processing chamber, and the lid stack210amay be disposed between the lid plate205and the first RF match215a. Similarly, second RF match215bmay be axially aligned or coaxial with a central axis of lid stack210b, or the second processing chamber of the system200, and the lid stack210bmay be disposed between the lid plate205and the second RF match215b. Box cover212may also support additional components, such as a separate RF filter217for each chamber. For example, each chamber may incorporate a heater that may interfere with the electrical signal for plasma processing. The heater may be operated via an RF filter as illustrated, and as will be described further below, to improve losses and interference with the plasma generation system. As illustrated, a first RF filter217amay be coupled with the box cover, and coupled with a heater of the lid stack210a. A second RF filter217bmay be coupled with the box cover, such as on an opposite end as illustrated, for example, and may be coupled with a heater of the lid stack210b. By utilizing coaxial RF match setups as will be described further below, improved RF delivery, reduced losses, and improved plasma uniformity may be produced by systems according to embodiments of the present technology.

FIG.3shows a schematic partial cross-sectional view of an exemplary processing chamber300according to some embodiments of the present technology. For example, the figure may illustrate one half of the system200described above, and may illustrate the associated components of one chamber of the system. For example, processing chamber300may include lid plate205, or what may be about half of the lid plate associated with one processing chamber, as well as one lid stack210disposed on the lid plate205. Lid plate205may be coupled with chamber body305, which may provide access to a pumping or exhaust system for extracting excess precursors or byproducts of processes performed. The chamber300may also include a pedestal310or other substrate support, which may be configured to support a semiconductor substrate312.

As noted above, processing system200, or each individual chamber300may be configured to perform plasma processing in embodiments of the present technology. For example, etch processes utilizing one or more halogen precursors, such as chlorine-containing or fluorine-containing precursors, may be delivered with one or more other reactive, neutral, or carrier precursors into a processing region315. A plasma may be generated in some embodiments within the processing region315, such as a capacitively-coupled plasma, which may produce radical effluents that react and etch materials on substrate312. The pedestal may operate as one of two plasma-generating electrodes in embodiments. One or more components of the lid stack may operate as a second plasma-generating electrode in embodiments. Although either the pedestal or the lid stack components may operate as the hot electrode, in some embodiments, a component of the lid stack may operate as the hot electrode, such as in electrical communication with the RF match, while the pedestal may be grounded.

When the pedestal may be operated as RF hot, the field strength near the chamber wall and at the edge of the electrode may be relatively high, which may increase plasma strength at the edges. This may increase an edge etch rate on the substrate, which may decrease uniformity of etching. When the polarity is reversed, and the lid stack operates as the RF hot electrode, increased field strength near the chamber wall may still produce increased radical effluents, but due to the relative distance from the substrate, these increased radicals may not impact the substrate as readily. This may increase uniformity of etching at the substrate, which may improve processing across a substrate.

Chamber300may include a number of components coupled to produce lid stack210. The lid stack may include one or more of a lid spacer320, a showerhead325, a liner327, a faceplate330, a blocker plate335, a gasbox340, a cover plate345, and an outlet manifold350. The components may be utilized to distribute a precursor or set of precursors through the chamber to provide a uniform delivery of etchants or other precursors to a substrate for processing, and/or may be used to protect chamber components as will be described below. In some embodiments, some of these components may be stacked plates each at least partially defining an exterior of chamber300.

As explained previously, chambers and components according to some embodiments of the present technology may be used to perform operations in which a bias plasma may be formed in processing region315. This operation may include aspects of etching including a physical bombardment of structures on a substrate, as well as a reactive etch performed by reactive plasma effluents produced in processing region315. The precursors may include halogen precursors, which may be configured to remove material from a substrate. Accordingly, components of the chamber may be exposed to both chemically reactive plasma effluents, such as fluorine, chlorine, or other halogen-containing effluents, as well as ions produced in the plasma, which may physically impact materials and components.

Systems and chambers according to embodiments of the present technology may also include configurations and coatings to limit plasma interaction with components. For example, faceplate330, which may be an additional showerhead, may conventionally have been exposed to both plasma effluents, such as bias plasma effluents contacting the surface facing the substrate and within apertures, as well as reactive effluents proceeding through apertures of the faceplate before interacting with substrate312. Other components noted above may also be exposed to one or both plasma effluents, including from backstreaming plasma effluents.

The plasma effluents may produce differing effects on the chamber components. For example, ions may be at least partially filtered from backstreaming by showerhead325from the chemically reactive plasma effluents produced in processing region315. However, the reactive effluents, such as chlorine-containing effluents, for example, may cause corrosion of exposed materials, such as by forming aluminum chloride. Over time, this process may corrode exposed metallic components, requiring replacement. Additionally, plasma species formed from a plasma in processing region315may have conventionally impacted components causing physical damage and sputtering that may erode components over time. Accordingly, any of the described components may have been susceptible to chemical corrosion as well as physical erosion from plasma effluents produced within one or more regions of the chamber.

Corrosion may be controlled in some ways by forming a coating over materials. For example, while aluminum may corrode from exposure to chlorine-containing or fluorine-containing materials, aluminum oxide, or other platings or coatings, may not corrode on contact with the precursors. Accordingly, any of the described components may be coated or protected by anodization, oxidation, electroless nickel plating, aluminum oxide deposited coatings, barium titanate, or any other material that may protect exposed conductive materials, such as aluminum, from chemical corrosion. Similarly, erosion may be controlled in some ways by forming a coating over materials. For example, high performance materials such as e-beam or plasma spray yttrium oxide, which may or may not include additional materials including aluminum or zirconium, for example, may protect the component from physical damage caused by plasma effluents. Damage to components may still occur, however, when a structure may be contacted by both corrosive plasma effluents as well as erosive plasma effluents.

Because chamber300may be configured to deliver halogen-containing precursors through each of the lid stack components, any one or more of these components may be coated or protected with any of the corrosion-resistant materials noted above. By limiting plasma generation to the processing region315, fewer components may include erosion-resistant coatings. Additionally, chamber300may include showerhead325, which may be or include a dielectric material, such as quartz, for example, and which may protect faceplate330from erosion due to ion bombardment. As will be explained below, apertures through the components may be configured together to limit or prevent interaction between plasma effluents and the faceplate330.

FIG.4shows a schematic isometric view of an exemplary lid plate205according to some embodiments of the present technology. Lid plate205may provide a support structure for lid stacks as previously explained. As illustrated, lid plate205may provide a partially or substantially planar component defining a first radial volume405and a second radial volume410, which may be laterally offset or separated from the first radial volume405. As illustrated above, the radial volume may at least partially define the plasma processing region radially, along with faceplate330and/or showerhead325from above, and pedestal310or a substrate support from below.

Lid plate205may support one or more of the components of the lid stack as noted above, and may support each of the tandem lid stacks as well as the RF matches and associated components. Lid plate205may be aluminum in some embodiments, and may or may not include any of the corrosion or erosion-resistant coatings described above. For example, in some embodiments, lid plate205may be configured or include components configured to limit or prevent fluid or material contact with the lid plate during processing operations. Consequently, lid plate205may not include coatings in some embodiments. This may be advantageous in some configurations as coating a single-piece lid plate that may be almost a meter in length or more, may be impractical or impossible for some coating systems.

FIG.5shows a schematic partial cross-sectional view of an exemplary lid stack500according to some embodiments of the present technology. The figure may illustrate an enhanced view of components identified in any of the previous figures, and may include any of the components, materials, or characteristics as previously described. The figure may show components of a portion of one of the processing chambers that may be supported on lid plate205, and it is to be understood that a second lid stack or processing chamber may include any or all of the components illustrated as a second version of the component described, as well as in different configurations, such as rotated, for example. For example, lid stack500may illustrate a portion of lid plate205, which may support the components. The supported components may include lid spacer320, liner327, showerhead325, faceplate330, blocker plate335, gasbox340, and cover plate345. As noted above, these may each be first components in some embodiments, with a second set of each of these components, as well as any other described elsewhere, incorporated as a second lid stack on lid plate205. Some or all of these components may be coupled together, such as with bolts, fasteners, screws, or other elements that may compressibly join the components, which may increase heat transfer through the lid stack as will be described below. The components may also include outlet manifold350, which may receive precursors as will be described further below.

The processing system may further include a power supply and/or RF match215electrically coupled with the processing chamber to provide electric power to the faceplate330, to generate a plasma in the processing region315as previously described. Each component of the lid stack may include an RF gasket or other electrical coupling component disposed between successive plates to maintain proper electrical coupling for the RF path. Several of the figures illustrate one or more channels formed in one or more surfaces of each component, which may be used to seat an RF gasket as well as elastomeric elements, such as o-rings, to provide a seal between adjacent system components. The power supply may be configured to deliver an adjustable amount of power to the chamber depending on the process performed. Such a configuration may allow for a tunable plasma to be used in the processes being performed. Unlike a remote plasma unit, which is often presented with on or off functionality, a tunable plasma may be configured to deliver a specific amount of power to the plasma processing region315. This in turn may allow development of particular plasma characteristics such that precursors may be dissociated in specific ways to enhance the etching profiles produced by these precursors.

In some embodiments, the plasma formed in substrate processing region315may be used to produce the radical precursors from an inflow of, for example, a chlorine-containing precursor or other precursor. An AC voltage typically in the RF range may be applied between the conductive top portion of the processing chamber, such as outlet manifold350, and through the lid stack components to the faceplate330to ignite a plasma in processing region315during deposition. An RF power supply may generate a high RF frequency of 13.56 MHz but may also generate other frequencies alone or in combination with the 13.56 MHz frequency, as well as any other frequencies up to 60 MHz or higher. The RF match may be connected with the chamber via a conductive pin510providing voltage to the processing chamber. The conductive pin may reside in a dielectric insulator and pin guide coupled with a surface of the outlet manifold350. As illustrated the RF match and conductive pin may be aligned with a central axis through the chamber or lid stack components, and may be coaxial in some embodiments, which may improve electrical delivery and produce more uniform plasma.

The outlet manifold350may be seated on a first surface342of gasbox340, and may contact the first surface of gasbox340along a first surface352of the outlet manifold350. Outlet manifold350may define a central aperture354extending partially through the outlet manifold from the first surface352. The central aperture354may extend partially or mostly through the outlet manifold, while not extending to or through a second surface356of the outlet manifold opposite the first surface352. Second surface356may be electrically coupled with the RF match215, such as via conductive pin510, and may be configured to distribute RF power through the lid stack components. Outlet manifold350may include one or more apertures358through a sidewall of the central aperture354, which may provide fluid access to the central aperture from a radial or exterior edge of the outlet manifold as will be described below.

Central aperture354of outlet manifold350may provide fluid access to gasbox340, and a central aperture344of the gasbox. Gasbox340may deliver fluids or precursors into a region defined by blocker plate335. Blocker plate335may have a number of apertures defined through the component to spread the precursors more uniformly outward within the chamber. For example, blocker plate335may define a number of relatively smaller apertures, which may produce a pressure drop across the component and increase residence time of a precursor allowing more lateral or radial delivery before proceeding through the lid stack. The blocker plate335may deliver the precursors to faceplate330, which may define a plurality of first apertures as will be described below. The faceplate330may deliver the precursors to showerhead325, which may further distribute the precursors to processing region315. In processing region315, a plasma may be generated from the precursors, which may produce ions that may contact internal components of the chamber. To reduce the interaction of plasma effluents with surfaces of components, such as lid spacer320, lid plate205, and faceplate330, a showerhead325and liner327may be included in some embodiments.

Lid spacer320may include a dielectric material, such as a ceramic material for example, which may electrically isolate the lid stack from the lid plate and/or chamber body to facilitate plasma generation in the processing volume described above. To protect lid spacer320, which may extend into the radial volume defined by the lid plate, the lid spacer may support additional components. For example, lid spacer320may be characterized by a first surface and a second surface, and may be seated on the lid plate along the second surface of the spacer. As will be explained below, lid spacer320may support the showerhead325and liner327in some embodiments. Faceplate330, as well as the overlying lid stack components, may be seated on the first surface of lid spacer320, which may maintain electrical isolation of these components that may be operating as a plasma-generating electrode in some embodiments.

FIG.6shows a schematic exploded isometric view of lid stack components according to some embodiments of the present technology. The figure may include showerhead325, liner327, and lid spacer320. As noted above, lid spacer320may support showerhead325and liner327to protect other chamber components from contact or impact by plasma effluent species. In some embodiments, showerhead325and liner327may be dielectric materials, such as quartz, for example, which may provide impact protection for the other lid stack and chamber components, as well as be resistant to corrosion from the etchant species generated. Because of the material properties of quartz, in some embodiments the showerhead325and the liner327, may not directly contact other chamber components, and may be spaced and maintained indirectly coupled and seated within the lid stack.

Showerhead325may define a plurality of apertures, which may be second apertures as will be described below. Showerhead325may also define one or more notches602on or about a radial outer edge of showerhead325. The notches602may be sized to accept an alignment pin as will be described below. Liner327may be an annular liner as illustrated, and may be characterized by a first surface604that may be facing showerhead325. Liner327may also be characterized by a second surface606opposite the first, and which may extend within the processing region in a direction from the faceplate to the pedestal at least to or beyond an edge of the lid spacer320. This may ensure protection of the lid spacer during processing operations.

As illustrated, liner327may define a protrusion610extending about an exterior surface of the annular liner. This protrusion may facilitate seating of both the liner and the showerhead in some embodiments. Protrusion610may be an integral portion of liner327, which may be a monolithic or single-piece component. The protrusion610may be recessed from first surface604of liner327. This may provide a first ledge612, such as on a first surface of protrusion610, facing the first surface of the annular liner, and a second ledge614, such as on a second surface of protrusion610opposite the first surface, facing the second surface of the liner. In some embodiments a first elastomeric element616may be positioned on, and extend about, first ledge612. A second elastomeric element618may be positioned on, and extend about, second ledge614. The first elastomeric element616and the second elastomeric element618may or may not be pressure sealing components during processing within the chamber. The elastomeric elements may additionally or instead ensure the showerhead325and liner327may have limited contact with other components.

FIG.7shows a schematic partial cross-sectional view of components according to some embodiments of the present technology, and may show a detailed view of showerhead325and liner327incorporated within the lid stack. As illustrated, lid spacer320may include a first surface702and a second surface704opposite the first surface. The lid spacer320may seat on the lid plate205along the second surface704, while the faceplate and other lid stack components may sit about the first surface702of the lid spacer. Lid spacer320may additionally define a portion extending vertically within the radial volume defined by the lid plate as previously described. The lid spacer320may define a first recessed ledge706along this portion. As previously described, showerhead325and liner327may be dielectric materials, such as quartz, in some embodiments. Quartz may crack when in contact with other components during processing conditions, and thus, in some embodiments the components may not directly contact other components of the lid stack.

As previously discussed, a first elastomeric element616and a second elastomeric element618may extend on surfaces of protrusion610and extend about the annular liner. The elastomeric elements may be bumper rings, for example, which may allow the liner and showerhead to be seated on other components. For example, liner327may rest on first recessed ledge706of lid spacer320along second elastomeric element618. The first recessed ledge706may extend radially about the processing region volume, and may be in contact with the elastomeric element618along the ledge. In some embodiments a radially outer edge of liner327may contact lid spacer320. In some embodiments, either or both of first elastomeric element616or second elastomeric element618may extend proud of protrusion610, and may extend radially outward from a radially outer edge of the protrusion610to limit or prevent contact between the protrusion610and the lid spacer320. First elastomeric element616may also extend proud of liner327, and may extend vertically beyond a first surface604of liner327. Accordingly, showerhead325may sit on first elastomeric element616, and may have limited contact with liner327, and in some embodiments may not contact liner327.

Lid spacer320may also define a second recessed ledge708radially outward from first recessed ledge706. Second recessed ledge708may recess from the first surface702of lid spacer320, and first recessed ledge706may recess from the first surface702and the second recessed ledge708. The extent of recess of first recessed ledge706from second recessed ledge708may be greater than a thickness of protrusion610of the liner327, such as a distance between first ledge612and second ledge614of the protrusion. The extent of recess may, however, be less than a distance including a diameter of each elastomeric element. Consequently, an entire distance extending from second elastomeric element618, protrusion610, and first elastomeric element616may be greater than a distance of first recessed ledge706from second recessed ledge708. This may allow showerhead325to be seated slightly above second recessed ledge708, and may limit or prevent contact between a radial edge of showerhead325and an exposed surface of lid spacer320. Second recessed ledge708may be characterized by a distance that is at least slightly greater than a thickness of showerhead325.

As a faceplate as previously described may be seated on first surface702of lid spacer320, a gap may be maintained between the faceplate and showerhead325. To maintain the gap, second recessed ledge708may be characterized by a distance of recess from first surface702greater than a thickness of the showerhead325as well as a distance by which first elastomeric element616extends beyond second recessed ledge708. Consequently, showerhead325may be maintained recessed below an uppermost portion of first surface702of lid spacer320on which a faceplate or lid stack components may be seated. This may then maintain a gap between the showerhead and the faceplate as will be described further below.

To limit movement of showerhead325, and to maintain alignment during successive placements, showerhead325may define a plurality of notches602as previously described. Notches602may extend radially inward from an external radial edge of showerhead325. A plurality of notches710may be formed along a radial sidewall at least partially defining second recessed ledge708of lid spacer320, which may be companion notches for each notch602on the showerhead325. Accordingly, in some embodiments the number of notches602and the number of notches710may be similar.

A plurality of alignment pins712may be seated in each of the notch sets to maintain alignment of the showerhead. Each alignment pin712may extend through a channel defined between each set of notch602and notch710about the showerhead. The alignment pins may be a material configured to limit damage to showerhead325, and may be a polyimide material such as vespel, or may be teflon, PEEK, or some other material that may limit or prevent contact between the showerhead and any hard materials that might contribute to cracking or damage. The alignment pins712may be seated on second recessed ledge708. Accordingly, although liner327may be contacted by elastomeric elements616and618, and although showerhead325may be contacted by first elastomeric element616and/or alignment pins712, the showerhead325and the liner327may be maintained separate from and may not contact lid spacer320, an associated faceplate as previously described, lid plate205, or any other component of the processing system in some embodiments.

During maintenance operations or tear down, the lid stack may be removed from the lid plate for accessing each lid stack plate for inspection or removal, such as for cleaning. Removal of the lid spacer320, showerhead325, and liner327may be performed with care to limit damage to potentially fragile components. As previously noted, lid spacer320may be a ceramic material, such as aluminum oxide, aluminum nitride, or any other ceramic or dielectric material. Forming threads, such as for screws or bolts or other jack members, may therefore be challenging without cracking or damaging the material. Accordingly, in some embodiments jack members may be incorporated with the lid plate to lift the lid spacer and from the lid plate.

As shown inFIG.7, lid plate205may define one or more apertures714at least partially extending from a first surface of the lid plate on which the lid spacer320may be seated. The aperture or apertures714may at least partially extend through the lid plate205from the first surface, and in some embodiments may be threaded to support a jack member716. The apertures714may be characterized by any profile, including a counterbore or countersink profile as illustrated, although straight apertures and other profiles are similarly encompassed. An associated aperture718may be defined through lid spacer320, and may fully extend from first surface702through second surface704of the lid spacer. As lid spacer320may be ceramic in some embodiments, aperture or apertures718may not be threaded, and may contain no additional components within the aperture, although the apertures may provide at least partial access to aperture or apertures714, as well as jack members716. Each aperture718may be axially aligned with an associated aperture714and/or jack member716of the lid plate205.

In some embodiments the apertures718of the spacer may be characterized by a diameter that may be less than or about the diameter of the apertures714through the lid plate205. Apertures718and apertures714may be characterized by a number of profiles, although the diameter of aperture718at least at second surface704may be less than the diameter of apertures714at the first surface of lid plate205. For example, a head or at least a surface of jack member716and an associated portion of aperture714, such as is illustrated, may be characterized by a larger diameter than a diameter of apertures718at second surface704of lid spacer320. Consequently, jack members716may be accessed through apertures718of the lid spacer, and operation of the jack members, such as by rotation from a direction of threading of apertures714, may draw the jack members from the apertures714, which may lift or separate lid spacer320from the lid plate205. As showerhead325and liner327may be seated on or with lid spacer320, removal of the lid spacer may also remove these components.

Turning toFIGS.8A-8Bare shown schematic plan views of components with projections according to some embodiments of the present technology.FIG.8Aillustrates a top view of a portion of a faceplate according to some embodiments of the present technology. The faceplate may define a plurality of first apertures805, which may be characterized by a number of profiles including a counterbore profile as shown, in which a diameter at a first surface, such as a surface facing a blocker plate or other lid stack component, may be larger than a diameter at a second surface opposite the first surface, such as a surface facing a showerhead or pedestal, or defining the processing region from above. Also shown is a projection of apertures807, which may exist through a showerhead positioned proximate the second surface of the faceplate. The projection is included to illustrate that apertures through the showerhead may not overlap with apertures of the faceplate in some embodiments. Similarly,FIG.8Billustrates a portion of a showerhead, such as a first surface, which may be facing a faceplate, and which may include any of the materials or characteristics of any showerhead described elsewhere. The showerhead may define a plurality of second apertures810, which may be characterized by any number of profiles as will be described further below. In some embodiments, the plurality of second apertures810may include a greater number of apertures than the plurality of first apertures805. Also shown is a projection of apertures812, which may exist through a faceplate positioned proximate the first surface of the showerhead. Again, the projection may illustrate examples in which the apertures through the faceplate may not overlap or align with apertures of the showerhead in some embodiments.

The plurality of first apertures805of the faceplate may be characterized by a first pattern as shown. Any of a variety of patterns of first apertures may be similarly encompassed by the present technology including a different number of apertures per ring, different geometric patterns of apertures including more random patterns, or other aperture configurations. The plurality of second apertures810of the showerhead may be characterized by a second pattern as shown, which may also include any of a variety of aperture patterns. In some embodiments, the second pattern may be at least in part based on the first pattern.

For example, in some embodiments the second pattern may include one or more adjustments from the first pattern. The second pattern may include one, two, or more sets of apertures characterized by the first pattern, where each aperture of the plurality of second apertures may be offset from each aperture of the plurality of first apertures. As one non-limiting example,FIG.8illustrates aperture patterns in which the first pattern and number of apertures is incorporated twice to produce the second pattern of apertures, as two subsets of the plurality of second apertures, where the plurality of second apertures is twice the number of apertures as the plurality of first apertures. A first subset of the plurality of second apertures may be characterized by a pattern like the first aperture pattern that has been offset from the first pattern in a first way. Additionally, a second subset of the plurality of second apertures may be characterized by a pattern like the first aperture pattern that has been offset from the first pattern in a second way. Thus, the first subset of second apertures and the second subset of second apertures may each include the same number of apertures as the plurality of first apertures.

For example, the first subset of apertures of the plurality of second apertures may include the first aperture pattern after an angular offset. Thus, each aperture of the first subset of apertures of the plurality of second apertures may pair with an aperture of the first apertures, and be offset from that associated aperture along an angle in either direction from a central axis through the showerhead. In the illustrations, aperture814, or alternatively aperture815, on the showerhead and aperture816on the faceplate may be the same aperture of the two patterns, where the angular offset has been applied to the first subset of apertures of the plurality of second apertures that includes aperture814. By applying this angular offset, the plurality of second apertures may include a first subset of apertures that may mimic the first pattern of apertures rotated an amount about a central axis through the components.

Similarly, the second subset of apertures of the plurality of second apertures may include the first apertures pattern after a radial offset. Thus, each aperture of the second subset of apertures of the plurality of second apertures may pair with an aperture of the first apertures, and be offset from that associated aperture along a radius in either direction from a central axis through the showerhead. In the illustrations, aperture818on the showerhead and aperture820on the faceplate may be the same aperture of the two patterns, where the radial offset has been applied to the second subset of apertures of the plurality of apertures that includes aperture818. By applying this radial offset, the plurality of second apertures may include a second subset of apertures that may mimic the first pattern of apertures inward or outward an amount along corresponding radii from the central axis through the components.

FIG.9shows a schematic partial cross-sectional view of components according to some embodiments of the present technology. The figure may provide a schematic representation of a faceplate905and a showerhead910according to some embodiments of the present technology. The faceplate905and showerhead910may be incorporated with a lid plate and lid stack as previously described. Faceplate905may include any of the features or characteristics of faceplates as described elsewhere. Additionally, showerhead910may include any of the features or characteristics of showerheads as described elsewhere.

The exemplary faceplate905includes a first pattern of first apertures908as discussed previously. The first apertures may be characterized by any number of profiles, including a counterbore as illustrated and extending from a first surface906to a second surface907of the faceplate. Showerhead910may include a number of different aperture patterns that may constitute a second pattern as discussed previously, and which may include a first subset and a second subset of apertures914. As shown, showerhead910may define apertures914that are offset from some or all apertures908of faceplate905. The apertures914may extend from first surface911to second surface912, although the outlet of apertures914at second surface912may not align with an inlet of apertures914in some embodiments. In some embodiments, each aperture914may be offset from each aperture908of the faceplate, although the offset may occur at first surface911or second surface912, as well as completely across the aperture from first surface911to second surface912.

As discussed previously, showerhead910may be positioned within the processing region between faceplate905and a pedestal, which together may operate to generate plasma within the processing region. Showerhead910may be configured to limit ionic bombardment on the second surface907of faceplate905, and may be or include a material, such as quartz, that may be more resistant to ionic bombardment. When plasma is produced, much ionic transmission may occur in a relatively linear direction parallel to a central axis through the chamber components. Consequently, by incorporating an aperture profile through showerhead910that may limit a linear path through the apertures914of the showerhead in a direction orthogonal to the second surface912of showerhead910, ions are likely to impinge on a surface of the aperture, and may not pass through to first surface911of showerhead910or to the faceplate905disposed beyond.

Any number of aperture profiles may be utilized in embodiments of the present technology, and apertures914a-914emay be only a few possible examples of aperture patterns encompassed by the present technology, and which may be selected or combined with other aperture profiles. For example, aperture914amay be characterized by an angular path from first surface911to second surface912, where the outlet at second surface912may be laterally offset from the inlet at first surface911to limit or prevent a linear path through the aperture. Apertures may be characterized by a number of angles, including angles extending in different directions through the showerhead or to different extents from other apertures, which may facilitate delivery into a processing region or improve uniformity.

Apertures914b, and similar apertures914e, may include a partially linear path through the aperture either from first surface911or to second surface912, while incorporating a partially angled portion extending to one surface, which may similarly limit a direct linear path through the aperture. Again, the apertures may be combined amongst the plurality of second apertures, and may be characterized by angled portions extending in a variety of directions relative to other apertures. Aperture914cmay be characterized by a profile including two angled sections, which may or may not include an aligned inlet and outlet of the aperture as illustrated. However, the extent of the angle may be such that a direct linear path through the aperture may be limited or prevented. Aperture914cmay similarly be combined with any other aperture designs, and again may include multiple apertures having similar or different angled profiles from one another.

Aperture914dmay illustrate a more complex aperture profile in which two vertical portions extending from each of the first surface911and the second surface912may be offset laterally from one another, and joined with an angled portion of the aperture, which may be angled to limit or prevent a direct linear path through the aperture. Again, any number of different angles may be utilized among apertures through the showerhead, and any of the exemplary configurations may be used alone or in combination to produce an aperture pattern that may affect fluid flow in any number of ways, while limiting or preventing ion impingement on the second surface907of faceplate905.

As discussed above, showerhead910may be spaced apart from faceplate905a distance D, which may occur from a configuration of an associated lid spacer and elastomeric elements, for example. The distance D may be minimized in some embodiments. For example, because in some embodiments faceplate905may be operated as a plasma-generating electrode to produce plasma in a processing region between the faceplate and the pedestal, plasma may be generated completely between the faceplate and the pedestal. However, if plasma may be generated between the showerhead and the faceplate, the showerhead will not prevent ionic bombardment on the second surface907of the faceplate. Additionally, contact between the showerhead and the faceplate may cause damage or fracture of the quartz showerhead.

Accordingly, in some embodiments a distance D between the showerhead and the faceplate may be limited to a distance to limit or prevent plasma generation between the components during operation, such as to control a mean-free path length before collision with the two components, which may prevent ionization. For example, in some embodiments, the showerhead910may be separated from the faceplate by 2 mm or less in order to prevent plasma generation, and may be separated from the faceplate by less than or about 1.8 mm, less than or about 1.6 mm, less than or about 1.4 mm, less than or about 1.2 mm, less than or about 1.0 mm, less than or about 0.9 mm, less than or about 0.8 mm, less than or about 0.7 mm, less than or about 0.6 mm, less than or about 0.5 mm, less than or about 0.4 mm, less than or about 0.3 mm, less than or about 0.2 mm, or less, although a gap may be maintained between the two components to limit or prevent physical contact between the components, and minimize a pressure drop within the gap between the two components.

Turning toFIG.10is shown a schematic a top isometric view of components according to some embodiments of the present technology. The figure may illustrate a portion of a lid plate205and a lid stack210, which may be similar to lid stack210aas discussed above. It is to be understood that the figure includes only a partial view, and the system may additionally include any of the components discussed elsewhere for semiconductor processing systems according to embodiments of the present technology. For example, lid plate205may define a second volume over which a second lid stack may be disposed, and which may include any component or any feature of any component described throughout the present disclosure, including with a variety of modifications, such as component rotation, for example.

The figure may illustrate a portion of a lid stack with the RF match and associated components removed, as well as with removal of the cover plate over the gasbox340shown. Beneath the gasbox340may be additional lid stack components including any of the components previously described. The figure may show a view of the first surface342of the gasbox including an inlet to central aperture344through the gasbox. Gasbox340may additionally define a first channel1010within the first surface of the gasbox. First channel1010may be characterized by a number of profiles, including a spiral or wound profile as illustrated. Disposed within the first channel1010may be a heater1015. As illustrated, heater1015may extend through a cover plate and be wound within the first channel1010. First channel1010may extend further than heater1015, which may accommodate expansion of heater1015during operation.

Heater1015may be configured to heat lid stack210in embodiments, and may conductively heat each lid stack component. Heater1015may be any kind of heater including a cable heater, or other device configured to deliver heat conductively to gasbox340, which may in turn heat each other lid stack component. In some embodiments, heater1015may be or include an electrical heater formed in a pattern defined by the first channel1010across the gasbox340, and around central aperture344as well as an outlet manifold as previously described. The heater may be a resistive element heater that may be configured to provide up to, about, or greater than about 2,000 W of heat, and may be configured to provide greater than or about 2,500 W, greater than or about 3,000 W, greater than or about 3,500 W, greater than or about 4,000 W, greater than or about 4,500 W, greater than or about 5,000 W, or more.

Heater1015may be configured to produce a variable chamber component temperature up to, about, or greater than about 50° C., and may be configured to produce a chamber component temperature greater than or about 75° C., greater than or about 100° C., greater than or about 150° C., greater than or about 200° C., greater than or about 250° C., greater than or about 300° C., greater than or about 350° C., greater than or about 400° C., greater than or about 450° C., greater than or about 500° C., greater than or about 550° C., greater than or about 600° C., or higher in embodiments. Heater1015may be configured to raise individual components, such as the faceplate, to any of these temperatures to facilitate processing operations. In some processing operations, heater1015may be adjusted to conductively raise the temperature of the substrate to any particular temperature noted above, or within any range of temperatures within or between any of the stated temperatures. To maintain temperature uniformity across the gasbox340, in some embodiments the heater may be wound within the first channel1010for an integral number of turns. For example, as illustrated, heater1015extends to a position on a radial outer turn that is substantially, or in some embodiments directly, in line with a position of the heater at the entrance or at an innermost radial turn. Accordingly, each area of the gasbox340is in contact with a similar area or amount of heater1015, which may improve temperature uniformity in some embodiments. An inlet may be formed through an overlying cover plate, which may allow the heater to be electrically coupled with an associated RF filter, as illustrated previously, such as withFIG.5.

Gasbox340may additionally define a second channel1020within first surface342of the gasbox. Second channel1020may be radially inward of first channel1010in some embodiments. Gasbox340may additionally define a third channel1025within first surface342of the gasbox. Third channel1025may be radially outward of first channel1010in some embodiments. While first channel1010may be incorporated to seat a heater as noted, second channel1020and third channel1025may be included to seal a cover plate about the gasbox.

FIG.11shows a schematic partial cross-sectional view of components according to some embodiments of the present technology, and may illustrate a partial cross-section of a gasbox and cover plate according to some embodiments of the present technology. The figure is intended only to provide additional details of particular components, which may be incorporated in any chamber or system described elsewhere, and which may include any aspect of components or systems described elsewhere. As illustrated, gasbox340may be characterized by a first surface342and a second surface343opposite the first. Within first surface342may be defined a first channel1010, within which heater1015may be disposed, as well as a second channel1020, and a third channel1025. As illustrated, in some embodiments second channel1020may be located radially inward of first channel1010, and third channel1025may be located radially outward of first channel1010.

A first gasket1110or elastomeric element may be disposed within second channel1020, and a second gasket1115or elastomeric element may be disposed within the third channel1025. Cover plate345may be seated at least partially across first surface342of gasbox340, and may extend at least across first channel1010, second channel1020, and third channel1025. Cover plate345may not extend fully radially inward, to provide access for an outlet manifold to be positioned on or in contact with the first surface342of the gasbox. The depth of first channel1010relative to the thickness of heater1015may be configured to reduce, limit, or prevent contact between heater1015and cover plate345. Cover plate345may contact first gasket1110and second gasket1115, and may form a seal between the two gaskets in some embodiments. By sealing across the first channel1010, and the heater seated within the first channel1010, cleaning operations may be performed less frequently of the first channel and the heater in some embodiments.

As noted above, gasbox340may be characterized by a first surface342and a second surface343opposite the first surface. A central aperture344may extend from first surface342to second surface343, which may provide fluid access to the other lid stack components and into the processing region of the chamber. To facilitate fluid distribution, central aperture344may be characterized by a flare1120or bevel at an outlet of the central channel extending to second surface343of the gasbox. Additionally, gasbox340may define a recessed ledge1125from the first surface342into the central aperture344. An insert may be seated on recessed ledge1125in some embodiments, which may be used to direct or adjust fluid flow into the processing chamber.

FIGS.12A-12Dshow schematic views of exemplary distributer inserts1200according to some embodiments of the present technology. Inserts1200may be seated on recessed ledge1125, and be used to increase mixing, or adjust fluid flow. For example, multiple precursors may be flowed into an outlet manifold overlying the gasbox. To increase mixing, an insert may reduce the aperture size or include multiple apertures providing access through the central aperture of the gasbox, which may facilitate mixing of the precursors as the precursors enter the processing chamber. For example, as illustrated inFIG.12A, insert1200amay include a single aperture1205a, which may increase residence time and mixing prior to delivery through the gasbox. Similarly, as illustrated inFIG.12B, insert1200bmay include multiple apertures1205b, which may also affect residence time and flow. Any number of aperture configurations may be utilized in this way.

Additionally, apertures may extend through an insert in any number of ways to further adjust fluid flow or mixing. For example, as illustrated inFIG.12C, one or more apertures1205c, which may be associated with any aperture configuration including one or more apertures, may be characterized by a substantially vertical profile through the insert. Additionally, as illustrated inFIG.12D, one or more apertures1205dmay be characterized by an angle extending through the insert, which may modify fluid flow, such as by causing an amount of swirl to precursors delivered into the processing chamber, which may further mix the materials. In embodiments the insert1200may be coated with any of the materials as previously described.

FIG.13shows a schematic partial isometric view of components according to some embodiments of the present technology. The figure may show a partial reversed view of systems and components previously described, which may illustrate additional system details.FIG.13illustrates a semiconductor processing system1300, which may include any component, characteristic, or material previously described. For example, system1300may include a lid plate205, which may be coupled with a chamber body305. Chamber body305may include pedestals, which may be raised to engage a substrate within the processing region defined by lid stack components and the lid plate205as previously described. On lid plate205may be a first lid stack210aand a second lid stack210b, which may include any of the components and configurations described previously.

For example, lid stack210amay include a first outlet manifold350a, and lid stack210bmay include a second outlet manifold350b, which may each be coupled with a respective RF match as previously described. As described above, outlet manifolds350may include a central aperture providing access to the respective lid stack through the gasbox, and may include one or more additional apertures extending to the central aperture from a radially exterior surface of the outlet manifold. In some embodiments, outlet manifold350aand outlet manifold350bmay be similar or identical, although the components may be reversed from one another to provide access to the additional apertures from a central location on the lid plate205. Precursors used in processing may be delivered through the lid plate205, and may be piped and split to the two processing chambers or lid stacks.

Each outlet manifold may include a gas block coupling the associated precursor piping with each outlet manifold. For example, the system1300may include a first gas block1310acoupled with an exterior edge of the first outlet manifold350a. The first gas block may provide fluid communication with the central aperture of the outlet manifold through the additional one or more apertures extending laterally or radially from an exterior surface to the central aperture. System1300may also include a second gas block1310bcoupled with an exterior edge or surface of the second outlet manifold350b. The second gas block may provide fluid communication with the central aperture of the outlet manifold through the additional one or more apertures extending laterally or radially from an exterior surface to the central aperture.

Although each outlet manifold350may be illustrated as being substantially cylindrical, a surface through which the additional apertures may be accessed, and with which gas block1310may be coupled, may be at least partially planarized or flattened to facilitate coupling of the components and limit leaks. The gas blocks may receive piping from one or more precursor sources, such as two precursor sources as illustrated. The precursors may be separately piped to the gas blocks, and may extend through the lid plate205with feedthroughs1315, which will be described further below.

FIG.13additionally illustrates an aspect of coupling between the lid plate205and the chamber body305according to some embodiments of the present technology. For example, in some embodiments, lid plate205, as well as the lid stacks, RF components, and associated piping supported by the lid plate205, may be coupled with chamber body305about hinges1320. Hinges1320may include leafs coupled with a first surface of lid plate205, and may provide pins extending outward from the lid plate. Chamber body305may include knuckles, bearings, or receptacles that may receive the pins and may allow the lid plate to hinge about the chamber body, providing access to the interior of the processing region for substrate delivery and removal, inspection and cleaning, or other maintenance.

FIG.14shows a schematic partial cross-sectional view of components according to some embodiments of the present technology, and may illustrate a cross-section through lid plate205and through a feedthrough1315as previously described. Lid plate205may define one or more apertures through the lid plate, and through which processing precursors may be delivered. Because processing chambers may deliver corrosive or reactive precursors, components or piping through the system may include coatings to protect the materials from damage. Lid plate205may be a single-piece design in some embodiments, and may extend up to a meter or more in length, which may challenge coating chambers. Accordingly, some embodiments of the present technology may limit interaction between precursors and lid plate205, such as with lid spacers and liners as previously described to protect interior surfaces, and by utilizing feedthroughs as illustrated.

Apertures1405extending through lid plate205may be sized to accommodate a feedthrough which may provide a channel for delivering precursors through the lid plate. The feedthroughs may be or include corrosion resistant materials, which may protect against damage from precursors being delivered, such as chlorine or fluorine-containing precursors. The materials may include any of the coatings or materials previously described, and may also include other corrosion resistant materials, such as steel, nickel, alloys, or other metals or materials that may be resistant to corrosion. The feedthroughs may extend through the lid plate completely, and may be piped with a split or otherwise coupled with each of the first gas block and second gas block as previously described. Depending on the number of precursors, multiple feedthroughs may extend through the lid plate and be coupled with each gas block, including the two feedthroughs and associated piping illustrated previously. The feedthroughs may be positioned through the lid plate and set with a jam nut and washers, such as belleville washers as illustrated, which may allow adjustable sealing of the feedthrough with a base plate sealing the feedthrough with the lid plate.

As previously explained, lid plate205may be hingedly coupled with the chamber body305, which may separate feedthroughs1315from an associated piping path, although in some embodiments flexible and or retractable piping solutions may be incorporated. In some embodiments, feedthroughs1315may land on elastomeric elements1410, such as o-rings, which may provide a sealing surface to receive feedthroughs when the lid plate is engaged with the chamber body. The gas feedthroughs may seat on the elastomeric elements1410when the lid plate is closed upon the chamber body, which may provide a seal between the components. By utilizing chamber systems and components according to embodiments of the present technology, component degradation and flaking may be reduced, and improved plasma processing may be afforded.

As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a plate” includes a plurality of such layers, and reference to “the precursor” includes reference to one or more precursors and equivalents thereof known to those skilled in the art, and so forth.