PROCESSING SYSTEM FOR SEMICONDUCTOR WAFERS

The present disclosure pertains to embodiments of a semiconductor processing system and method for treating a semiconductor wafer. The processing system comprises a reactor, a wafer handling assembly, and treatment unit disposed vertically adjacent to the wafer handling assembly. The system and method minimize a total floor space occupied by the system without sacrificing the processing capacity.

BACKGROUND OF THE DISCLOSED TECHNOLOGY

Field

The field generally relates to a semiconductor processing device, and more particularly to a system and method for processing a semiconductor wafer.

Background

A semiconductor processing typically utilizes a large area of production floor space within a clean room environment. In the production floor space, various semiconductor processing devices are arranged and the floor space can be scarce and costly. During semiconductor processing, a reactant vapor is fed into a process chamber to deposit a film on a wafer. Various types of pre- or post-deposition treatments can be applied in the process to improve film deposition properties. The treatment can be pre-deposition, post-deposition or cyclic (e.g., deposition-treatment-deposition-treatment). It is important to perform the deposition and other treatment processes using a small footprint. Accordingly, there remains a continuing need for improved semiconductor processing devices.

SUMMARY

In view of the above mentioned situation, one object of one or more aspects of the disclosed embodiments is to provide a semiconductor processing system for treating a wafer, in which the treatment unit is arranged where there is free space.

In one embodiment, a semiconductor processing system for treating a wafer may comprise a reactor configured to deposit a film on the wafer and a treatment unit for treating the film on the wafer. The system may further comprise a wafer handling robot configured to transfer the wafer to the reactor, for example in a vacuum state, and a wafer handling assembly may be configured to accommodate or interact with the wafer handling robot such that the robot arm may pick up and unload the wafer in the wafer handling assembly. The treatment unit may be disposed vertically over the wafer handling assembly. The wafer handling assembly may comprise a chamber in which the wafer is held by the wafer handling robot. The wafer handling robot may comprise an arm, a support or other structure that transfers the wafer. The wafer handling assembly may be a transfer module (TM), a loadlock module (LL), or an atmospheric module (ATM). The treatment unit may comprise a first process window on a side facing the wafer handling assembly while the wafer handling assembly comprises a second process window on a side facing the treatment unit. The first process window are aligned with the second process window, when the wafer handling assembly is disposed vertically over the transfer unit.

In another embodiment, a semiconductor processing system for treating a wafer may comprise a plurality of the reactors, a plurality of the wafer handling assemblies, and at least one of the wafer handling robot. One of the plurality of the wafer handling assemblies may be the transfer module (TM) comprising the wafter handling robot configured to transfer the wafer to a reactor of the plurality of the reactors for a treatment process. At least one of the plurality of the wafer handling assemblies may be the loadlock module (LL) configured to receive the wafer from ambient air pressure state and the wafer handling robot of the transfer module (TM) transfers the wafer in the loadlock module to the reactor in a vacuum state. At least one of the treatment unit is disposed vertically over at least one of the transfer module (TM) and the loadlock module (LL). The system may further comprise at least another one of the plurality of the wafer handling assemblies which can be an atmospheric transfer module (ATM) comprising the wafer handling robot configured to transfer the wafer to the loadlock module (LL). The treatment unit may be disposed vertically over the atmospheric transfer (ATM) or inside the atmospheric transfer (ATM). The plurality of reactors are arranged around the one of the plurality of wafer handling assemblies.

In yet another embodiment, a semiconductor processing system for treating a wafer may comprise a plurality of reactors, a plurality of treatment units for treating the film on the wafer. At least one of the plurality of treatment units is configured to deposit a film on a wafer or is configured for other processing such as etching. The system may further comprise a first wafer handling assembly comprising the wafer handling robot configured to transfer the wafer to a reactor of the plurality of reactors for a deposition process and a second wafer handling assembly, configured to hold the wafer and a third wafer handling assembly comprising the wafer handling robot configured to receive a wafer from ambient air and to transfer the wafer to the second wafer handling assembly. The plurality of treatment units are disposed vertically adjacent to at least one of the first wafer handling assembly and the second wafer handling assembly. The plurality of reactors may be arranged around the first wafer handling assemblies.

Another object of one or more aspects of the disclosed embodiments is to provide a method for treating a semiconductor wafer by a semiconductor processing system which comprises a reactor configured to deposit a film on a wafer, a treatment unit for treating a film and a wafer handling assembly configured to transfer the wafer to the reactor, the treatment unit being disposed vertically adjacent to the wafer handling assembly.

In one embodiment, the method may comprise providing the wafer to the wafer handling assembly, transferring the wafer to the reactor through the wafer handling assembly, and depositing a reactant vapor onto the wafer. The method may further comprise transferring the wafer to the wafer handling assembly and holding the wafer underneath treatment unit and conducting thermal annealing. The deposition steps and annealing step may be repeated.

DETAILED DESCRIPTION

Hereafter, an apparatus and a method of the present disclosed technology will be described in detail by way of various embodiments shown in the attached drawings. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one skill in the art.

In order to minimize a floor space occupied by a processing system, radiation sources for the treatment positioned next to a deposition chamber have been proposed in the past. However, this configuration has the practical problem that a process window will become impermeable to radiation, as the deposited material accumulates also on the window.

As indicated inFIG.1, system can include a plurality of reactors2and a plurality of treatment modules10disposed around a transfer module20(a). The treatment modules10can be configured to treat the wafers to improve the deposition of the film on the wafer. In the illustrated embodiment, the treatment modules10can treat the film on the wafer after deposition. In other embodiments, the treatment modules10may additionally or alternatively be configured to treat the wafer before deposition. The transfer module20(a) takes a wafer from the loadlock module20(b) and convey the wafer to the reactors2disposed around the transfer module20(a) so as to deposit a film on the wafer. The wafer having the film deposited thereon can then be conveyed to the treatment units10by the transfer module20(a). As the treatment unit10are also disposed around the transfer module20(a), as more treatment units10are added, the total floor space occupied by a horizontally integrated system increases which reduces processing capacity and yield. Accordingly, there is a need in the art to have a semiconductor processing system which occupies reduced or minimal floor space as compared to conventional systems.

FIG.2aandFIG.2bshow a typical semiconductor processing system with a plurality of (e.g., eight) reactors and wafer handling assemblies20, including, e.g., a transfer module (TM)20(a), a loadlock module20(b), and an atmospheric (ATM) module20(c), as described herein. With the disclosed system, the atmospheric transfer module (ATM)20(c) comprising a wafer handling robot (23) (seeFIG.5b), which takes wafer W from wafer storages5and loads the wafers W into loadlock module (LL)20(b) while exposed to ambient air or the cleanroom atmosphere. The wafer handling robot (23) of the transfer module (TM)20(a) takes the wafer W from the loadlock module (LL)20(b) in a vacuum state while exposed to a vacuum (or, in other embodiments, exposed to ambient air) and conveys the wafer W to the reactor2to deposit a film on the wafer W. In various embodiments disclosed herein (seeFIGS.3aet seq.), the wafer W is conveyed to at least one wafer handling assembly20disposed underneath a treatment unit10for treating the film on the wafer W. During the processing, the wafer W can be held in the loadlock module (LL)20(b) or transfer module (TM)20(a) while other wafers are being processed int the reactor2. Without reducing the processing capacity and increasing the total floor space occupied by the system, a free space indicated in the figures is utilized in the disclosed embodiments. As disclosed herein, the treatment units10can be provided in the free space over the wafer handling assemblies in order to reduce a lateral footprint of the treatment units10.

FIG.3aillustrates a semiconductor processing system1for treating a wafer W (not shown in the figure), which may comprise a reactor2configured to deposit a film on the wafer W and a treatment unit10for treating the film on the wafer W. The reactor2can be used for any suitable type of deposition process, such as Chemical Vapor Deposition (CVD) or Atomic Layer Deposition (ALD). The system1may further comprise a transfer module20(a) comprising the wafer handling robot (23) configured to transfer the wafer W to the reactor2in a vacuum state. The treatment unit10may be disposed vertically adjacent to (e.g., disposed vertically over) the transfer module20(a). As shown inFIG.5a, the treatment unit10may comprise a first process window11on a side facing the wafer handling assembly (bottom panel12thereof) while the wafer handling assembly20(a) comprises a second process window21on a side facing the treatment unit (top panel22thereof). The first process window11can be aligned with the second process window21, when the treatment unit10is disposed vertically over the wafer handling assembly20. The system1may be arranged on a utility enclosure4, in which electronics, gas and pumps lines are disposed. The system1may further comprise a wafer storage module5, which can comprise one or multiple wafer boats configured to store wafers before or after processing.

The treatment unit10may comprise a radiation source13configured to emit electromagnetic waves (e.g., ultraviolet (UV) radiation, infrared (IR) radiation, or any other suitable type of radiation) toward the first process window11to treat the film on the wafer W. The transfer module20(a) may comprise a wafer handling robot23configured to hold the wafer W being processed underneath the second process window21. SeeFIG.5b. The second process window21can be covered with or formed of an optically transparent material24for allowing the electromagnetic waves to pass therethrough. The radiation permeable material24may comprise fused silica in various embodiments.

The semiconductor processing system1may comprise a plurality of the reactors2, and the wafer handling assembly can comprise a plurality of wafer handling modules, including, e.g., a transfer module20(a), a loadlock module20(b), and an atmospheric (ATM) module20(c), as described herein. The transfer module20(a) may comprise the wafer handling robot (23) configured to transfer the wafer W to a reactor2of the plurality of the reactors for a treatment process in vacuum state. The loadlock module20(b) may be configured to receive the wafer W from ambient air pressure state and the wafer handling robot (23) of the transfer module (TM)20(a) transfers the wafer W to the reactor2.

A treatment unit10can be disposed over any or all of the wafer handling assemblies20disclosed herein. For example, a treatment unit10ca be disposed over at least one of the transfer module20(a), the loadlock module20(b) and the atmospheric module20(c). The number of the treatment units10and which of the wafer handling assemblies20to be equipped with the treatment units10may be determined based on process time for a film deposition and a post deposition treatment. As described herein, the present disclosed technology provides not only the system which occupies minimal or a reduced amount of floor space as compared conventional systems, but also a modular process system which can improve process capacity and reduce idling time of each component within the system1.

As shown inFIG.5b, the first process window11of the treatment unit10can be disposed vertically over the one of the plurality of the wafer handling assemblies20(a). The first process window11may be configured to cover a plurality of wafers at a time, while the second process window21of the one of the plurality of the wafer handling assemblies20(a) may be configured to cover a plurality of wafers at a time as well. SeeFIG.3b. Thus, the treatment unit10disposed vertically over the one of the plurality of the wafer handling assemblies20(a) can treat a plurality of wafers at a time.

FIG.3cshows an embodiment, in which the one of the plurality of the wafer handling assemblies (e.g., the transfer module20(a) comprises a plurality of the second process windows21on the top panel22. A corresponding treatment unit10can be disposed vertically over each of the plurality of second process windows21. Each of the treatment units10may be have different radiation sources13, which may emit the same or a different type of radiation from one another. AlthoughFIGS.3band3cindicate the configuration for treating four wafers W at a time, any suitable number of wafers W can be treated.

Turning to the embodiment ofFIG.4a, the treatment unit10may be disposed vertically adjacent to (e.g., disposed over) at least one of the plurality of the loadlock module20(b). As shown inFIG.4b, the first treatment unit10can be disposed over the transfer module20(a) and a second treatment unit can be disposed over each loadlock module20(b). The first treatment unit10may be configured to treat a plurality of (e.g., four) wafers W at a time and the second treatment unit can comprise a plurality of treatment units10, each of which is configured to treat a single wafer at a time. The transfer module20(a) may comprises a plurality of the second process windows21on the top panel22, and a treatment unit10may be disposed vertically over each of the second process windows21.FIG.4cshows an embodiment in which a plurality of (e.g., four) treatment units10are disposed over four corresponding regions of the transfer module20(a) to separately treat the wafers. A plurality of treatment units10can be disposed over two regions of the loadlock module20(b). Each of treatment units10disposed over the transfer module20(a) and loadlock module20(b) may have different radiation sources13so as to separately treat the plurality of wafers W. In other embodiments, a common radiation source can be used over the transfer module20(a) or the loadlock module20(b) so as to treat multiple wafers at a time.

FIG.5ashows a schematic side view of the semiconductor processing system1ofFIG.3ahaving the treatment unit10over the transfer module20(a). As indicated inFIG.5b, the first process window11of the treatment unit10can be aligned with the second process window21of the transfer module20(a). The transfer module20(a) may comprise a wafer handling robot23configured to hold the wafer W underneath the second process window21during a treatment process. Although the treatment unit10is disposed vertically over the transfer module20(a), the wafer handling robot23need not provide any vertical movement (Y direction inFIG.5b) to convey the wafer W to the treatment unit10, but may instead move the wafers W generally horizontally (X direction inFIG.5b) through the system1. The second process window21may be covered with or formed of an optically transparent material24for allowing the electromagnetic waves emitted from the radiation source13within the treatment unit10to pass therethrough. The radiation permeable material24may comprise fused silica in various embodiments.FIG.5aalso shows a utility enclosure4, in which electronics, gas and pumps lines are disposed, and an electronic junction box8,

FIG.6ashows a schematic side view of the semiconductor processing device ofFIG.4ain which the treatment unit10is disposed vertically over the loadlock module20(b). As shown inFIG.6b, the first process window11of the treatment unit10can be disposed vertically over and adjacent the second process window21of the loadlock20(b). The loadlock module20(b) may comprise a substrate support station33, which is configured to hold the wafer W in process underneath the second process window21. The wafer handling robot23in the transfer module20(a) may pick up the wafer W on the substrate support station33to transfer the wafer W to the reactor2.

FIG.6cshows a schematic side sectional view of the semiconductor processing device ofFIG.4b, in which the treatment unit10is disposed over the transfer module20(a) and the loadlock module20(b).

FIG.6dshows schematic side sectional view of the semiconductor processing device in accordance with another embodiment, in which the electronic junction box8on atmospheric transfer module (ATM)20(c) is replaced with the treatment unit10disposed over an atmospheric transfer module (ATM)20(c). The electronic junction box8can be disposed in another location of the system. Alternately, the treatment unit may be disposed inside of the atmospheric transfer module (ATM)20(c) and as noted above, the treatment unit10can perform a treatment on the wafer W in the ATM module20(c).

In the embodiment ofFIG.7a, the semiconductor processing device1may comprise a plurality of reactors2, at least one of which is configured to deposit a film on a wafer W, a plurality of treatment units10for treating the film on the substrate W, and a plurality of wafer handling assemblies20. The transfer module20(a) may comprise the wafer handling robot (23) configured to transfer the wafer W to a reactor of the plurality of reactors2for a treatment process. Intermediate transfer module20(d) may comprise wafer handling robot configured to transfer the wafer W to the transfer module20(a). At least one of the loadlock module20(b) are configured receive the wafer W from ambient air pressure state The wafer handling robot23of the intermediate transfer module (20d) configured to take the wafer W from the loadlock module20(b) and transfer the wafer W to the transfer module20(a) in vacuum state. The wafer handling robot23may be further configured to hold the wafer W in process underneath a process window of the intermediate transfer module (20d). The plurality of treatment units10may be disposed vertically over the intermediate transfer module20(d) or to another intermediate transfer module20(d) and the loadlock module20(b). The plurality of reactors2may be arranged around the transfer module20(a). As shown inFIG.1b, the plurality of treatment units10may be disposed vertically over the intermediate transfer module20(d) and the wafer handling robot23therein may further comprise a rotating table25configured to hold the plurality of wafers W. Each of treatment units10may be capable to have a different radiation source13from each other. AlthoughFIG.7bindicates the configuration for treating four wafers W at a time, the present disclosed technology is not limited to this embodiment and may be variously altered or changed as long as it does not depart from the gist of the present disclosed technology.

FIG.8is a flow chart generally illustrating a method for treating a semiconductor wafer W by the semiconductor processing system according to various embodiments. At block30, a wafer W is provided to the wafer handling assembly20. The wafer may be provided from another wafer handling assembly. At block31, the wafer handling assembly20can transfer the wafer W to the reactor2. At block32, a reactant vapor can be deposited on the wafer W to form a film thereon. At block33, the wafer W can be transferred to the wafer handling assembly20and held underneath the treatment unit10. At block34, a treatment process (e.g., a thermal annealing process) can be conducted by emitting electromagnetic waves from the radiation source13to the wafer W in order to improve filth property. In some embodiments, the deposition process and the treatment processes may be cyclically repeated. The order of the method in the flow chart needs not to be the same as that illustrated inFIG.8. The treatment unit can treat the wafer before or after the film deposition in various embodiments.

In each of the illustrated embodiments, the treatment unit(s)10are shown as being disposed vertically adjacent and over the wafer handling assembly20. In other embodiments, however, the treatment unit(s)10may be disposed vertically adjacent and underneath the wafer handling assembly20. For example, in some embodiments, the wafer W may be supported by a ring-shaped support with the bottom of the wafer W exposed to the treatment unit10underneath the wafer.