METHOD FOR DECONTAMINATION OF A CHAMBER USED IN VACUUM PROCESSES FOR DEPOSITION, ETCHING AND/OR GROWTH OF HIGH PURITY FILMS, PARTICULARLY APPLICABLE TO SEMICONDUCTOR TECHNOLOGY

Abstract: After introducing the products concerned with the process into the chamber and after creating a vacuum in said chamber, said chamber is decontaminated by a series of inflows of non-contaminating gas and subsequent emptying operations.

Description: This invention concerns a method for decontaminating chambers used in vacuum processes for deposition, etching or growth of high purity films, particularly applicable in semiconductor technology and, specifically, in processes for the deposition, etching and/or growth of films on semiconductor wafers. In the technology of semiconductor devices, use is preferably made, for deposition, etching or growth of films, of vacuum processes in order to reduce the presence of contaminating substances in the chambers where the processes take place, and consequently to improve the chemico-physical and stoichiometric characteristics of the films obtained. Use is made in particular of systems such as Low Pressure Chemical Vapor Deposition (LPCVD), Plasma Enhanced CVD (PECVD), evaporation, sputtering, Reactive Ion Etching (RIE), systems for etching in plasma, etc.. Known procedure, relating to a vacuum process for deposition or etching of films, generally begins with creation of a vacuum in the chamber until a certain minimum pressure level is reached - about 0.1-3.3 Pa (1-25 mTorr) - followed by decontamination of the chamber by allowing non-contaminating gas to flow in at low pressure - e.g. 26.4 Pa (200 mTorr) - for a previously set time (between 10 and 40 minutes). Then, having once more brought the vacuum down to a certain minimum value, the deposition or the etching processes begins. Although this method appreciably lessens the presence of undesired gases in the chamber (such as H, H₂, CO₂, OH, H₂O, etc.) it however fails to reduce it below certain limits. The method of decontamination subject of this present invention, aims at appreciably reducing - leaving unchanged the overall decontaminating time - the presence of most of the contaminants below the limit values rereferred to above, securing advantages as far as concerns the chemico-physical and stoichiometric characteristics of the products obtained thereby, such advantages being, for example, reduction of current leakage in insulating films, more efficient film gettering, reduction of the non-stoichiometric zones in the films, more uniform etching, greater possibility of reproducing the effects obtained by etching the films, etc.. For this purpose, after placing the products in the chamber for processing and before that is started, the method requires a vacuum, to a certain minimum level of pressure, to be created inside the chamber (hereinafter, for simplicity, this first step will be called "pumping"), and then its decontamination by flowing in non-contaminating gas at a pressure suitably higher than the above minimum level (hereinafter, for simplicity, this second step will be called "purging"), this method being characterized in that the flow of non-contaminating gas is intermittent, decontamination being achieved by a series of purgings, each purging being followed by a pumping. These and other characteristics of the invention will be made clearer by the description that follows and by the attached drawings illustrating an example of its realization of a non-limiting kind, in which the various figures show: Fig.1 : diagram of a known process of deposition or etching of films in a vacuum; Fig.2 : diagram of a process of deposition or etching of films according to the invention; Fig.3 : diagram of a unit functioning according to the process in Fig.2; Figs.4A and 4B : diagrams showing levels of contamination noted at the end of two decontamination processes executed by the known technique; Figs.5A and 5B : diagrams showing levels of contamination noted at the end of two decontamination processes executed according to the invention. The diagram in Fig.1 concerns an example of an already known process of deposition or etching of a film. According to this example, after the wafers have been placed in the chamber, at atmospheric pressure, where the process takes place, (said chamber consisting, for example, of a cylindrical body with quartz walls, heated from the outside), a vacuum is created by rotary pumps assisted if necessary by Roots pumps. When pressure has been reduced to about 3.3 Pa (25 mTorr), in roughly 10 minutes, the decontamination process begins (lasting for about 50 minutes), and, during this, nitrogen is flowed into the chamber. A system that regulates the opening of the N₂ outflow valves ensures that when pressure has risen to about 26.4 Pa (200 mTorr), it remains constant at that level for about 45 minutes. When this time has passed, the N₂ outflow valve is closed and the pump for creating and maintaining the vacuum reduces pressure once more. Pressure having fallen to about 1.6 Pa (12 mTorr), the valves controlling inflow of the gases used for deposition or etching of the film are opened and the process begins. The diagram in Fig.2 illustrates an example of a deposition or etching process according to the invention. In said process the initial stage consisting of placing wafers in the chamber and subsequent creation of a vacuum therein, is exactly the same as that for Fig.1. When pressure has fallen to about 3.3 Pa (25 mTorr), the decontamination process starts with flowing in N₂, lasting still about 50 minutes. Contrary to the preceding case, however, the N₂ inflow valve is alternately opened and closed at regular time intervals of about 2 minutes, giving rise to a series of 13 purgings and subsequent pumpings, and to a pressure graph rising and falling beween about 26.4 Pa (200 mTorr) and 3.3 Pa (25 mTorr), except for the last cycles of the series when minimum pressure drops to about 1.6 Pa (12 mTorr). The decontamination process is therefore followed by the process of deposition and/or etching of a film similary to what happens in the case of Fig.1. Fig.3 gives a schematic example of a layout of a low pressure system for deposition or etching of films according to the invention. The system comprises a chamber C in which the deposition process takes place, a pump P for creating and maintaining low pressure in C, a nitrogen container X, containers Y and Z for the reagent gases used during the deposition or etching process of the film, valves V1, V2, V3 and V4 for regulating gas flows, valves V5 and V6 for regulating gas flow out of chamber C, a gauge M for measuring pressure inside C and, finally a unit R for controlling and regulating gas flows and pressure in C. When the process starts the wafers are already inside C, the pump P is working and the door D to the chamber is closed as are all the valves V1, V2, ...,V6. Valve 6, a half-gate valve, is then opened and this connects the chamber C to the pump; said valve is kept open for about 5 minutes while the pressure falls from 100,320 Pa (760 Torr) to about 66 Pa (500 mTorr). At this point valve V6 is closed and valve 5 (gate valve) opened enabling a stronger vacuum to be obtained. After 5 more minutes when the pressure has fallen to about 3.3 Pa (25 mTorr), leaving valve V5 still open, valve V1 is opened allowing N₂ to enter the chamber. After about 2 minutes when pressure has risen to about 26.4 Pa (200 mTorr) - this value coinciding with the pressure chosen for carrying out the next deposition or the next etching - valve V1 is closed again and kept closed for another 2 minutes until pressure has once more dropped to the minimum level, i.e. about 3.3 Pa (25 mTorr). This first purging and pumping is followed by 12 purging and pumping cycles, all done in a substantially similar manner except for the last pumping when pressure falls to a minimum of about 1.6 Pa (12 mTorr), after which the decontamination process is completed and a start is made with the process of deposition or etching by opening valves V2, V4 and V3. To enable an evaluation to be made of the appreciable reduction of contaminants allowed by the invention, in Figs. 4A and 4B will be seen diagrams showing the concentrations recorded by a mass spectrometer (of the Residual Gas Analysis - RGA - type) after a decontamination process of the conventional kind, respectively carried out in a chamber for deposition of a polycrystal silicon film (Fig.4A) and in a chamber for deposition of a silicon nitride film (Fig.4B). Figs. 5A and 5B however show diagrams relating to the concentrations found in those same chambers when - other conditions and particularly the time taken being equal - decontamination is done according to the present invention (Fig.5A relating to the chamber for deposition of the polycrystal silicon film, and 5B to the chamber for deposition of silicon nitride film). In the case of Fig.5A the diagram brings out the decrease D in concentration of the various polluting substances, these valines being: D(H)=26.2%; D(H₂)=22.9%; D(O₂)=0%; D(OH)=27.8%; D(H₂O)=27.6%; D(CO₂)=0% while in the case of Fig.5B there was a decrease in the following values: D(H)=24%; D(H₂)=25%; D(O₂)=0%; D(OH)=27.9%; D(H₂O)=29.8%; D(CO₂)=0%. In the example of realization described above reference has been made to a particular low pressure system and to the use of nitrogen in the decontamination process. The same method can however be applied both in connection with all the possible gases normally used for the purpose, and in connection with the various vacuum systems operating at pressures in the region of 0.132 Pa [1 mTorr] (LPCVD,PECVD, evaporation, sputtering, RIE, for etching in plasma systems, etc.) or at pressures in the region of 132 Pa [1 Torr] (systems for the growth of epitaxial layers of silicon, etc.). Further, this example is not be considered as limited to semiconductor technology as it is obviously applicable to all the vacuum processes that concern deposition, etching or growth of high purity films.

Claims: Method for decontamination of a chamber used in vacuum processes for deposition, etching and/ or growth of high purity films, to be applied in particular to semiconductor technology, which requires, after the introduction into the chamber of products to be subjected to the process and before said process begins, the creation of a vacuum in said chamber by pumping until a predetermined minimum pressure value is reached and then its decontamination by flowing in non-contaminating gas at a pressure suitably higher than the above minimum value, characterized by the following steps: executing a first pumping until the pressure has been reduced at least to a first predetermined minimum value of about 3.3 Pa (25 mTorr), purging said chamber by flowing in the non-contaminating gas until a second pressure value is reached higher than said first minimum pressure value; interrupting the flowing of non-contaminating gas and executing a second pumping step until the pressure has been reduced at least to said first minimum value, repeating the above purging and pumping steps following the first pumping, such that the flow of said non-contaminating gas is intermittent and decontamination is realized by said series of purgins and pumpings steps. Method as in claim 1 characterized in that after the first pumping each purging and each pumping operation in the above series is started as soon as pressure inside the chamber has reached said first and respectively second value. Plant for vacuum processes of deposition, etching or growth of high purity films to be applied particularly to semiconductor technology which includes first means (P,V5,V6,R) capable, following introduction into a chamber of products to be subjected to the process and before said process starts, of creating a vacuum in said chamber by pumping until a predetermined minimum value of pressure is reached and also second means (X,V1,R) capable of subsequently purging the chamber by introduction of a flow of non-contaminating gas at a value of pressure suitably higher compared with the minimum value referred to above, characterized in that said first and second means successively cause a first pumping step until the pressure of said chamber has been reduced at least to a first predetermined minimum value of about 3.3 Pa (25 mTorr), a first purging step by flowing in non-contaminating gas until a second value of pressure is reached higher than said first minimum value, an interruption of said flowing in, a second pumping step at least until said first minimum pressure value is newly reached, repeating said first purging step and said second pumping step, decontamination being realized by a series of purgings each one followed by a pumping. Plant as in claim 3 characterized in that said first and second means regulate the above mentioned series of purgings and subsequent pumpings in such a way that each purging and pumping operation begins as soon as pressure inside the chamber has reached said first and respectively second value. Method as in claim 2 characterized in that said last pumping step is carried out at least until the pressure in the chamber reaches a value of 1.6 Pa (12 mTorr). Plant as in claim 4 characterized in that said first means regulate the last pumping in such a way that at least a final pressure of 1.6 Pa (12 mTorr) is reached.

Inventors: MOTTA, ANTONINO
Applicants: SGS-THOMSON MICROELECTRONICS S.R.L.
Application year: 1987
Main classification: C23C16
IPC codes: C30B25, C30B23, C23C16