Abstract:
Embodiments of the present invention provide a liner assembly including an inject insert. The inject insert enables tenability of flow parameters, such as velocity, density, direction and spatial location, across a substrate being processed. The processing gas across the substrate being processed may be specially tailored for individual processes with a liner assembly according to embodiment of the present invention.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of co-pending U.S. provisional patent application Ser. No. 62/046,400, filed Sep. 5, 2014 (Attorney Docket No. APPM/22327USL), which is herein incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    1. Field 
         [0003]    Embodiments of the present disclosure generally relate to an inject insert for use in semiconductor processing equipment. 
         [0004]    2. Description of the Related Art 
         [0005]    Some processes for fabricating semiconductor devices, for example rapid thermal processing, epitaxial deposition, chemical vapor deposition, physical vapor deposition, electron-beam curing, are performed at elevated temperatures. Usually substrates being processed are heated to a desired temperature in a processing chamber by one or more heat sources. The one or more heat source is typically mounted outside the chamber body so that the energy generated by the heat source radiates upon the substrate positioned within the chamber body. 
         [0006]    Processing gases are usually supplied to the chamber from a gas inlet, and are kept flowing in the chamber by a pumping system connected to chamber. Gas distribution in a conventional chamber is not uniform across the chamber. For example, gas distribution near the gas inlet is different from gas distribution near the pumping port, and gas distribution near the edge region is different from gas distribution near the center region. 
         [0007]    Further, some chambers may include multiple flow zones having different process gases or gas flow rates which feed into a single channel defined within the gas inlet. As a result of the “crosstalk” between the multiple flow zones feeding into a single gas inlet, attempts to tune the gas flow distribution within the processing chamber by varying the type of gas or gas flow rate in the different flow zones have unpredictable tuning results. 
         [0008]    Additionally, in operation, localized zones of cyclically flowing gas, known as “recirculation cells,” often form within the channels of inject inserts used in conventional gas manifolds. Recirculation cells result in degraded uniformity of the gas flow distribution within the processing chamber, which results in strong variations in epitaxially-grown films. 
         [0009]    Continuous rotation has been previously employed in an attempt to resolve some of the above non-uniformity issues. In theory, continuous rotation delivers a majority of the substrate to a variety of flow zones such that flow zone non-uniformity is minimized. Although, continuous rotation of the substrate may reduce the non-uniformity of gas distribution, the rotation alone may not be enough as the requirement for uniformity increases. The foregoing problems attributable to conventional gas inlets are amplified when the flow rate of the process gas is increased, which is desirable to increase the throughput of the CVD device. 
         [0010]    Therefore, there is a need for a thermal reactor with improved gas flow distribution. 
       SUMMARY 
       [0011]    Embodiments disclosed herein include an inject insert for use in a semiconductor processing chamber. In one embodiment, an inject insert can include a monolithic body with an inner connecting surface and an exterior surface to connect with a gas delivering device; a plurality of inject ports formed through the monolithic body, each forming an opening in the interior connecting surface and the exterior surface, and a plurality of inject inlets, each of the plurality of inject inlets being connected with at least one of the plurality of inject ports. The plurality of inject ports can create at least a first zone with a first number of inject ports of the plurality of inject ports; a second zone with a second number of inject ports of the plurality of inject ports, the second number of inject ports being different from the first number of inject ports; and a third zone with a third number of inject ports of the plurality of inject ports, the third number of inject ports being different from the first number of inject ports and the second number of inject ports. 
         [0012]    In another embodiment, an inject insert can include a monolithic body with an inner connecting surface to connect with a liner body and an exterior surface to connect with a gas delivering device; a plurality of inject ports formed through the monolithic body, each forming an opening in the interior connecting surface and the exterior surface, the plurality of inject ports creating at least; and a plurality of inject inlets, each of the plurality of inject inlets being connected with at least one of the plurality of inject ports, wherein at least a first inlet of the plurality of inject inlets comprises a first width, the first width being greater than an average width. 
         [0013]    In another embodiment, a liner assembly can include a liner body comprising an upper liner portion and a lower liner portion, the liner body having a plurality of liner ports formed therein; and an inject insert, the inject insert having a monolithic body with a substantially planar upper surface; a substantially planar lower surface; a curved inner connecting surface to connect with the liner body; an exterior surface to connect with a gas delivering device; and a plurality of inject ports formed therethrough, the plurality of inject ports creating at least a first zone with a first number of passages; a second zone with a second number of passages, the second number of passages being different from the first number of passages; and a third zone with a third number of passages, the third number of passages being different from the first number of passages and the second number of passages; and a plurality of inject inlets connected with at least one of the plurality of inject ports, wherein each of the plurality of inject ports fluidly connect with at least one of the plurality of liner ports through the plurality of inject inlets. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments. 
           [0015]      FIG. 1  is a schematic, cross sectional view of a process chamber according to embodiments described herein. 
           [0016]      FIG. 2A  depicts a schematic diagram of an inject insert in accordance with some embodiments. 
           [0017]      FIG. 2B  is a side view of an inject insert according to some embodiments. 
           [0018]      FIG. 3  is a cut away overhead view of an inject insert and gas line combination, according to some embodiments. 
           [0019]      FIG. 4  is a side view of a multi-tier inject insert, according to some embodiments. 
       
    
    
       [0020]    To facilitate understanding, identical reference numerals have been used, wherever possible, to designate identical elements that are common to the Figures. Additionally, elements of one embodiment may be advantageously adapted for utilization in other embodiments described herein. 
       DETAILED DESCRIPTION 
       [0021]    Embodiments disclosed herein describe a liner for use in semiconductor process systems. The inject insert connects with and incorporates at least  6  zones to allow for greater flow control. 
         [0022]    A variety of CVD chambers may be modified to incorporate the embodiments described herein. In one embodiment, the CVD chamber to be modified is the CVD chamber of the EPI CENTURA® CVD System, available from Applied Materials, Inc., of Santa Clara, Calif. The CENTURA® system is a fully automated semiconductor fabrication system, employing a single wafer, multi-chamber, modular design, which accommodates a wide variety of wafer sizes. In addition to the CVD chamber, the multiple chambers may include a pre-clean chamber, a wafer orienter chamber, a cooldown chamber, and a loadlock chamber. The CVD chamber presented herein is shown in schematic in  FIG. 1  is one embodiment and is not intended to be limiting of all possible embodiments. It is envisioned that other CVD chambers can be used in accordance with embodiments described herein, including chambers from other manufacturers. 
         [0023]      FIG. 1  is a cross sectional view of a processing chamber  100  according to one embodiment. The processing chamber  100  comprises a chamber body  102 , support systems  104 , and a chamber controller  106 . The chamber body  102  includes an upper portion  112  and a lower portion  114 . The upper portion  112  includes the area within the chamber body  102  between the upper dome  116  and the substrate  125 . The lower portion  114  includes the area within the chamber body  102  between a lower dome  130  and the bottom of the substrate  125 . Deposition processes generally occur on the upper surface of the substrate  125  within the upper portion  112 . The substrate  125  is supported by support posts  121  disposed beneath the substrate  125 . The substrate  125  may be any substrate used in the art for epitaxial deposition, such as a silicon or germanium containing substrate. Further, the substrate may be of varying sizes, such as a  300  mm diameter substrate or a  450  mm diameter substrate. 
         [0024]    An upper liner  118  is disposed within the upper portion  112  and is adapted to prevent undesired deposition onto chamber components. The upper liner  118  is positioned adjacent to a ring  123  within the upper portion  112 . The processing chamber  100  includes a plurality of heat sources, such as lamps  135 , which are adapted to provide thermal energy to components positioned within the processing chamber  100 . For example, the lamps  135  may be adapted to provide thermal energy to the substrate  125  and the ring  123 . The lower dome  130  may be formed from an optically transparent material, such as quartz, to facilitate the passage of thermal radiation therethrough. 
         [0025]    The chamber body  102  includes an inlet  120  and an exhaust port  122  formed therein. The inlet  120  may be adapted to provide a process gas  150  therethrough into the upper portion  112  of the chamber body  102 , while an exhaust port  122  may be adapted to exhaust a process gas  150  from the upper portion  112 . In such a manner, the process gas  150  may flow parallel to the upper surface of the substrate  125 . Thermal decomposition of the process gas  150  onto the substrate  125  to form an epitaxial layer on the substrate  125  is facilitated by the lamps  135 . 
         [0026]    A substrate support assembly  132  is positioned in the lower portion  114  of the chamber body  102 . The substrate support  132  is illustrated supporting a substrate  125  in a processing position. The substrate support assembly  132  includes a plurality of support pins  121  and a plurality of lift pins  133 . The lift pins  133  are vertically actuatable and are adapted to contact the underside of the substrate  125  to lift the substrate  125  from a processing position (as shown) to a substrate removal position. The components of the substrate lift assembly  132  can be fabricated from quartz, silicon carbide, graphite coated with silicon carbide or other suitable materials. 
         [0027]    The ring  123  can be removably disposed on a lower liner  140  that is coupled to the chamber body  102 . The ring  123  can be disposed around the internal volume of the chamber body  102  and circumscribes the substrate  125  while the substrate  125  is in a processing position. The ring  123  can be formed from a thermally-stable material such as silicon carbide, quartz or graphite coated with silicon carbide. The ring  123 , in combination with the position of the substrate  125 , can separate the volume of the upper potion  112 . The ring  123  can provide proper gas flow through the upper portion  112  when the substrate  125  is positioned level with the ring  123 . The separate volume of the upper portion  112  enhances deposition uniformity by controlling the flow of process gas as the process gas is provided to the processing chamber  100 . 
         [0028]    The support system  104  includes components used to execute and monitor pre-determined processes, such as the growth of epitaxial films in the processing chamber  100 . The support system  104  includes one or more of gas panels, gas distribution conduits, power supplies, and process control instruments. A chamber controller  106  is coupled to the support system  104  and is adapted to control the processing chamber  100  and support system  104 . The chamber controller  106  includes a central processing unit (CPU), a memory, and support circuits. Instructions resident in chamber controller  106  may be executed to control the operation of the processing chamber  100 . Processing chamber  100  is adapted to perform one or more film formation or deposition processes therein. For example, a silicon carbide epitaxial growth process may be performed within processing chamber  100 . It is contemplated that other processes may be performed within processing chamber  100 . 
         [0029]      FIGS. 2A and 2B  depict a liner  200  with an inject insert  220  according to embodiments described herein.  FIG. 2A  depicts a top view of the inject insert  220  in connection with the liner assembly  200 .  FIG. 2B  depicts a side view of the inject insert  220 . The liner assembly  200  includes a liner body  202  with an inner surface  204  and an outer surface  206 . The inner surface  204  forms the boundaries of a process region (not shown). A plurality of liner inlets  208 , which are depicted as dashed line circles, are formed through the inner surface  204  and outer surface  206  of the liner body  202 . The inject insert  220 , shown here with two inject inserts  220 , is fluidly connected with the plurality of liner inlets  208 . Gas supplied from a gas supply source (not shown) is introduced into the process region  206  through the inject insert  220  and then through the plurality of liner inlets  208 , whereby the plurality of liner inlets  208  can deliver one or more individual gas flows. The inject insert  220 , plurality of liner inlets  208  or both may be configured to provide individual gas flows with varied parameters, such as velocity, density, or composition. The plurality of liner inlets  208  are configured to direct the process gas in a generally radially inward direction, with the gas being delivered to a central area of the process region  206 . Each of the plurality of gas inlets  208  and the inject insert  220  may be used, individually or in combination, to adjust one or more parameters, such as velocity, density, direction and location, of the gas from the gas supply source. 
         [0030]    The inject insert  220  can be formed from a single piece of metal, ceramic or otherwise inert composition, such as aluminum or quartz. The inject insert  220  can have a substantially planar upper surface  222  and a substantially planar lower surface  224 . The inject insert  220  can have a number of inject ports  226  formed therein. The end portions of the inject insert  220  are shown here, with the middle portions omitted for simplicity. In this embodiment, the inject insert  220  is depicted as having seven (7) inject ports  226 . The inject ports  226  may be of any shape or size, such that the flow rate, flow velocity and other flow parameters may be controlled. Further, multiple inject ports  226  may connect with any number of the plurality of liner ports  208 . In one embodiment, a single port of the plurality of ports  208  is served by more than one of the inject ports  226 . In another embodiment, a multiple ports of the plurality of ports  208  is served by a single port of the inject ports  226 . The inject insert  220  has a connecting surface  228 . The connecting surface  228  may have a surface curvature such that the inject ports  226  penetrating through the inject insert  220  are fluidly sealed to the plurality of liner ports  208 . The inject insert  220  may have an exterior surface  230 . The exterior surface  230  may be configured to connect to one or more gas lines  301  or other gas delivering device. 
         [0031]    The inject ports  226  and the liner ports  208  create at least a first zone, a second zone and a third zone. The first zone has a first number of passages. The second zone has a second number of passages, the second number of passages being different from the first number of passages. The third zone has a third number of passages, the third number of passages being different from the first number of passages and the second number of passages. Larger substrates, due to their increased surface area, require tighter control of process parameters. Thus, by increasing the number of zones, the area that is controlled by a single zone is decreased allowing for finer tuning of process parameters. 
         [0032]      FIG. 3  depicts a cutaway overhead view of an inject insert  300 , according to one embodiment. The inject insert  300  may have the same or a similar composition to the inject insert  220  described with reference to  FIGS. 2A and 2B . The inject insert  300  has a plurality of inject ports  326  formed therein, such as seven inject ports  326 . As shown with relation to inject insert  220 , the end portions of the inject insert  300  are shown here, with the middle portions omitted for simplicity. The inject insert  300  can have one or more multi-connect gas lines, shown here as first multi-connect gas line  302 , second multi-connect gas line  304  and third multi-connect gas line  306 . The multi-connect gas lines  302 ,  304  and  306  are in connection with more than one of the plurality of inject ports  326  (also referred to as the connected ports). 
         [0033]    The multi connect gas lines  302 ,  304  and  306  can deliver either different gases or gases under differing conditions. In one embodiment, the first multi connect gas line  302  delivers a first gas to the connected ports, the second multi connect gas line  304  delivers a second gas to the connected ports and the third multi connect gas line  302  delivers a third gas to the connected ports. The first gas, the second gas and the third gas can be different gases from one another. In another embodiment, the first multi connect gas line  302  delivers a gas to the connected ports at a first pressure and/or a first temperature, the second multi connect gas line  304  delivers a gas to the connected ports at a second pressure and/or a second temperature, and the third multi connect gas line  302  delivers a gas to the connected ports at a third pressure and/or a third temperature. The first pressure, second pressure and the third pressure may be different from one another. As well, the first temperature, second temperature and the third temperature may be different from one another. Further any number of inject ports  326  may be connected to any number of multi-connect gas lines. In further embodiments, the one or more gas lines  301  and/or the multi-connect gas lines  302 ,  304  and  306  may connect with the same inject port  326 . 
         [0034]    Though one or more of the inject ports  326  are shown as connected through the one or more gas lines  301  and the multi-connect gas lines  302 ,  304  and  306 , the inject ports  326  may be interconnected within the inject insert  300  such that one or more of the multi-connect gas lines  302 ,  304  and  306  is unnecessary. In this case, a group of the inject ports  326  can branch internally to the inject insert  300 , shown by a branch  330 , such that the group of the inject ports  326  receive gas from a single gas line  301 . 
         [0035]    The inject insert  300  can further include a plurality of inject inlets, shown here as inject inlets  308   a - 308   j.  The inject inlets  308   a - 308   j  may be approximately equally spaced and positioned in the inject insert  300 . The inject inlets  308   a - 308   j  may have a varying width such that the inject inlet  308   a - 308   j  delivers a differing volume of gas at a proportionally changed velocity. When delivering gas through two inject ports  326  at a standard pressure, an increased width is expected to deliver gas to the process region at a decreased velocity but higher volume than a standard width. Under the same conditions as above, a decreased width is expected to deliver gas to the process region at an increased velocity but lower volume than a standard width. 
         [0036]    Shown here, inject inlet  308   a  has a width  312   a  which is increased as compared to the width  312   c  of the inject port  326 . Further, the inject inlet  308   a  has a graded increase, creating the appearance of a cone. Shown here, the increase of the width  312   a  of the inject inlet  308   a  results from a graded increase of 5 degrees from a center line  310 , as noted by the dashed line extending outward from the related inject port  326 . The graded increase may be more or less than 5 degrees. Further, a graded increase is not necessary for the formation of an increased in the width  312   a  In one embodiment, the width  312   a  is simply increased at a point prior to the inject inlet  308   a  forming a slightly larger cylinder in the inject port  326  (not shown). 
         [0037]    Though the center line  310  is only described with reference to the inject port  326 , it is understood that all bisymmetrical objects or formations as described herein have a center line. Further, though the center line  310  is only shown with relationship to inject inlet  308   a,  it is understood that each of the inject inlets  308   a - 308   g  have a related center line  310  which bisects each of the respective inject ports  326 . 
         [0038]    In another example, the inject inlet  308   b  has a width  312   b  which is decreased as compared to the standard width  312   c  of the inject ports  326 . As above, the inject inlet  308   b  has a graded decrease, creating the appearance of an inverted cone. Shown here, the decreased width  312   b  of the inject inlet  308   b  is formed from a graded decrease of 5 degrees from the center line  310 , as noted by the dashed line extending inward from the related inject port  326 . The graded decrease may be more or less than 5 degrees. 
         [0039]    Though the increased width  312   a,  the decreased width  312   b,  and the related graded increase and decrease are shown as symmetrical to the center line  310 , this is not intended to be limiting of embodiments described herein. A change in size and shape can be created with full freedom of position and rotation such that the gas can be delivered in any direction and at any angle desired by the end user. Further, the liner inlets  208  of  FIG. 2A and 2B  may have a design which either compliments or replicates the designs described with reference to inject inlets  308   a - 308   g.    
         [0040]      FIG. 4  depicts a side view of a multi-tier inject insert  400 , according to one embodiment. The multi-tier inject insert  400 , shown here with two rows of inject ports  426 , can have more than one row of inject ports  426  such that gas can be delivered to the process region more uniformly. As shown with relation to inject insert  220 , the end portions of the inject insert  400  are shown here, with the middle portions omitted for simplicity. The multi-tier inject insert  400  can have a substantially planar upper surface  422  and a substantially planar lower surface  424 . The multi-tier inject insert  400  can have a number of inject ports  426  formed therein per row. In this embodiment, the multi-tier inject insert  400  is depicted as having fourteen (14) inject ports  426 . In this embodiment, the number or shape of each of the inject ports  426  used in each of the corresponding rows may be of varying shapes, sizes and positions. 
         [0041]    Further, multiple inject ports  426  may connect with any number of the plurality of inject inlets (not shown). The inject inlets described with reference to  FIG. 4  are substantially similar to the inject inlets  308  described with reference to  FIG. 3 . The multi-tier inject insert  400  has a connecting surface  428 . The connecting surface  428  may have a surface curvature such that the inject ports  426  penetrating through the multi-tier inject insert  400  are fluidly sealed to the upper liner  118  and the lower liner (not shown). The multi-tier inject insert  400  has an exterior surface  430  which may be configured to connect to a gas line as described in  FIG. 3 . 
         [0042]    Tight control of both chemistry and gas flow is required for current and next generation semiconductor devices. Using the embodiments described above, control of both of the delivery of gas to the inject ports and flow of the gas from the inject ports through the inject inlets can be increased, leading to an increased control of process parameters for a majority of the substrate. Increased control of process parameters, including control of the velocity of the gases delivered to the chamber and the subsequent zone formation, will lead to improved epitaxial deposition and reduced product waste among other benefits. 
         [0043]    While the foregoing is directed to embodiments of the disclosed devices, methods and systems, other and further embodiments of the disclosed devices, methods and systems may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.