Abstract:
A plasma reactor is provided for achieving extension of etching parameters to reduce charge-up shape anomaly and to improve selectivity, uniformity and workability in a dry etching process. An RF power fluctuates in cycles, each one of the cycles including first and second subcycles ( 25 ), ( 26 ) with different frequencies. The RF power in the first subcycles ( 25 ) is higher in frequency than that in the second subcycles ( 26 ). A charge accumulated during the first subcycles ( 25 ) in which the RF power of high frequency is applied can be relieved during the second subcycles ( 26 ) in which the RF power of low frequency is applied. At the same time, deterioration in an etching rate occurring with the application of only the RF power of low frequency can be relieved by applying the RF power of high frequency during the first subcycles ( 25 ).

Description:
This application is a continuation of U.S. application Ser. No. 08/848,881, filed on May 1, 1997, now U.S. Pat. No. 6,471,821. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention is directed to a plasma reactor, especially to a dry etching apparatus. 
     2. Description of the Background Art 
     FIG. 20 is a sectional view generally showing an ECR (electron cyclotron resonance) etching apparatus which is a kind of conventional plasma processing apparatus. In a plasma production chamber  1 , plasma is produced from process gas by a μ wave  19  and transferred to a reaction chamber  2 . The plasma exposes wafers  7  biased by an RF power obtained by an RF power supply means  8 . 
     There are various parameters for controlling an etching process in the ECR etching apparatus, including shape and position of an ECR face  5  (which also depends on a magnetic field provided by coils  4 ), the RF power, the μ wave  19 , a method of electrostatic chuck for the wafers  7 , pressure from process gas or the like. 
     An apparatus of high integration and a fine structure has made it more and more difficult to achieve etching with high anisotropy, high selectivity and high uniformity. There are many cases that the present etching parameters are not enough to achieve a desirable etching. Anomalies in etching shape due to charge-up (referred to as “charge-up shape anomaly” hereinafter) has been raised as one of problems to prevent the formation of a fine structure in recent years. 
     FIGS. 21 and 22 are enlarged sectional views in the vicinity of the surface of a semiconductor wafer  101 , illustrating the charge-up shape anomaly. Each figure shows the behavior of ions (shown by circled “+”) and electrons (shown by circled “−”) when a fine pattern etching of the semiconductor wafer  101  is performed by means of a plasma etching. 
     In FIG. 21, an SiO2 film  13 , an Si film  14  and a resist pattern  15  are formed one after another on the surface of the semiconductor wafer  101 . The Si film  14  is etched with the resist pattern  15  as a mask. In this case, as etching proceeds, electrical neutrality is maintained by incidence of both ions and electrons on the surface of the resist pattern  15 . 
     In a fine pattern  16 , incidence of ions occurs perpendicular to the surface of the semiconductor wafer  101 . Thus, ions can reach to a bottom surface  18  of the fine pattern  16  with no collision with side walls  17 . On the other hand, electrons have no directional property to be incident on the side walls  17 , thereby having difficulty in reaching to the bottom surface  18 . 
     As shown in FIG. 21, when a conductive film such as the Si film  14  is etched, ions incident on the bottom surface  18  and electrons incident on the side walls  17  are recombined in the Si film  14  to be neutralized. Thus, electrical neutrality is maintained. On the other hand, when the bottom surface  18  moves downward due to the etching progress and exposes an insulating film such as the SiO2 film  13  as shown in FIG. 22, ions incident on the bottom surface  18  and electrons incident on the side walls  17  are not neutralized. Thus, the bottom surface  18  is positively charged up due to the ion incidence while the side walls  17  are negatively charged due to the electron incidence. 
     Therefore, the orbit of ions incident on the bottom surface  18  is bent by repulsion of positive charge on the bottom surface  18  and gravitation of negative charge on the side walls  17 . This causes local incidence of ions on the interface between the Si film  14  and the SiO2 film  13 , and then produces a V-shaped notch (reference character A shows notch amount). 
     To decrease such charge-up shape anomaly, a method for pulsing the μ wave  19  or the RF power (to repeat ON/OFF periods thereof) has been advocated. When both of the μ wave  19  and the RF power are in the ON period, normal discharge occurs, causing progress in charge-up in a fine pattern. On the contrary, when either of the μ wave  19  or the RF power is in the OFF period, incidence of electrons on the bottom surface  18  is made possible by no directional difference between ions and electrons, thereby dissolving charge-up. That is, charge-up proceeded during the ON period can be dissolved during the OFF period. 
     Such control over the movement of charged particles is very important not only for dissolution of shape anomalies but also for control of a selectivity ratio and uniformity. The method for pulsing conventional μ wave  19  and RF power is however limited, so that extension of pulse methods has been required for controlling broader etching parameters. 
     SUMMARY OF THE INVENTION 
     According to a first aspect of the present invention, a plasma reactor comprises a stage to which a frequency-modulated RF power is applied; and a reaction chamber containing plasma exposed to a sample mounted on the stage. 
     According to a second aspect of the present invention, a plasma reactor comprises a stage to which an RF power is applied; and a reaction chamber containing plasma exposed to a sample mounted on the stage, wherein the RF power fluctuates in cycles, each one of the cycles consisting of a plurality of first and second subcycles with the RF power of different amplitudes, wherein the plurality of first subcycles has different lengths, respectively. 
     According to a third aspect of the present invention, a plasma reactor comprises a stage to which an RF power is applied; and a reaction chamber containing plasma exposed to a sample mounted on the stage, wherein the RF power presents a waveform in which an AC waveform with a predetermined initial phase is intermittently superimposed on a DC value. 
     According to a fourth aspect of the present invention, an intermittently supplied μ wave produces the plasma. 
     According to the plasma reactor of the first aspect of the present invention, accumulation of charge occurring with the RF power of high frequency can be relieved with the RF power of low frequency. At the same time, deterioration in an etching rate, which is regarded as one of problems when only the RF power of low frequency is applied, can be relieved with the RF power of high frequency. 
     According to the plasma reactor in the second aspect of the present invention, in one cycle that the RF power fluctuates, the first subcycles have different lengths, respectively. Thus, charge-up can be relieved during one of the subcycles while deterioration in an etching rate can be suppressed during the other of the subcycles. 
     According to the plasma reactor in the third aspect of the present invention, an area more positive than DC components becomes larger than that more negative than DC components in the range of superimposition of RF components by setting the initial phase within the range of 180° to 360°. This results in improvement in a notch amount and a selectivity ratio. Further, the area more positive than DC components becomes smaller than that more negative than DC components in the range of superimposition of RF components by setting the initial phase within the range of 0° to 180°. This results in improvement in a CD gain and an etching rate. 
     According to the fourth aspect of the present invention, an intermittent introduction of the μ wave into the plasma reactor leads to reduction in a notch amount. Further, an intermittent application of the RF power to the stage leads to a remarkable effect in improving etching characteristics. 
     The object of this invention is to provide a plasma reactor capable of extending etching parameters for reducing charge-up shape anomaly in dry etching and for improving etching performance such as selectivity, uniformity and workability. 
     These and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a sectional view showing an ECR etching apparatus in accordance with a first preferred embodiment of the present invention. 
     FIG. 2 is a graph showing a waveform of an RF power in accordance with the first preferred embodiment of the present invention. 
     FIG. 3 is a graph showing a waveform of an RF power in accordance with a second preferred embodiment of the present invention. 
     FIGS. 4,  5  and  6  are timing charts showing correlation between ON/OFF periods of a pulsed RF power and a charge-up amount. 
     FIG. 7 is a timing chart showing correlation between ON/OFF periods of a pulsed RF power and a charge amount in accordance with a third preferred embodiment of the present invention. 
     FIG. 8 is a timing chart showing correlation between ON/OFF periods of a pulsed RF power and a charge amount in accordance with a fourth preferred embodiment of the present invention. 
     FIGS. 9A-9D are graphs showing a waveform of a voltage V in accordance with a fifth preferred embodiment of the present invention. 
     FIG. 10 is a graph showing the dependency of a notch amount on an initial phase. 
     FIG. 11 is a graph showing the dependency of a selectivity ratio on an initial phase. 
     FIG. 12 is a graph showing the dependency of a CD gain on an initial phase. 
     FIG. 13 is a sectional view illustrating the CD gain. 
     FIG. 14 is a graph showing the dependency of an etching rate on an initial phase. 
     FIG. 15 is a sectional view showing an ECR etching apparatus in accordance with a sixth preferred embodiment of the present invention. 
     FIGS. 16A-16B are graphs showing change in potential at a stage  6  on the basis of an initial phase. 
     FIG. 17 is a graph showing potential at the stage  6  when an RF power is continuously applied. 
     FIG. 18 is a graph showing a waveform of an RF power in accordance with a seventh preferred embodiment of the present invention. 
     FIG. 19 is a graph showing correlation between a delay time t  0  and a notch amount. 
     FIG. 20 is a sectional view showing a conventional ECR etching apparatus. 
     FIGS. 21 and 22 are sectional views illustrating charge-up shape anomaly. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     &lt;First Preferred Embodiment&gt; 
     FIG. 1 is a sectional view generally showing an ECR etching apparatus as a plasma reactor according to a first preferred embodiment of the present invention. A chamber in the ECR etching apparatus is roughly divided into a plasma production chamber  1  and a reaction chamber  2 . A reactive process gas is introduced into the chamber from an inlet  81  and is exhausted from an outlet  82 , so that a predetermined pressure is maintained. A microwave  19  of 2.45 GHz generated from a μ wave power  80  passes through a waveguide to be introduced into the chamber via a leading window  3 . 
     Since a magnetic field is applied in the chamber by coils  4 , an ECR resonance region (ECR surface) exists in the plasma production chamber  1  to produce an ECR plasma. The magnetic field generated by the coils  4  diverges from the plasma production chamber  1  to the reaction chamber  2 , so that the ECR plasma is carried to wafers  7  mounted on a stage  6 . This ECR plasma etches the wafers  7 . 
     Further, the stage  6  on which the wafers  7  are mounted is connected to an RF power source supply device  30  for supplying the RF power for etching, which will be described in detail later. Further, the wafers  7  are induced by static electricity generated by a power source  9  to contact with the stage  6  (referred to as electrostatic chuck) for cooling. 
     FIG. 2 is a graph showing a waveform of an RF power generated by the RF power supply device  30 . The frequency of the RF power applied in the first preferred embodiment is pulse-modulated. The RF power fluctuates in cycles, each one the cycles consisting of first and second subcycles  25 ,  26  with different frequencies. The graph indicates that the RF power in the first subcycle  25  is higher in frequency than that in the second subcycles  26 . 
     In general, the RF power of high frequency produces a high self-bias voltage. This increases an ion energy to remarkably raise an etching rate while increasing charge due to a heavy directional movement of ions. 
     On the contrary, the RF power of low frequency produces a low self-bias voltage. This prevents charge-up, but results in a low etching rate and small anisotropy. Thus, a continuous application of only the RF power of low frequency has not been put to practical use in general. 
     According to the first preferred embodiment, the RF power of high frequency and the RF power of low frequency are applied in turn. Thus, accumulation of charge during the first subcycle  25  in which the RF power of high frequency is applied can be relieved during the second subcycle  26  in which the RF power of low frequency is applied. Further, a decline in the etching rate, which is regarded as one of problems when only the RF power of low frequency is applied, can be relieved by applying the RF power of high frequency in the first subcycle  25 . 
     &lt;Second Preferred Embodiment&gt; 
     The alternating application of the RF power of high frequency and of low frequency is not necessarily in the form of pulse to obtain the same effect as described in the first preferred embodiment. If only the frequency fluctuates, the fluctuation does not have to be rapid. 
     FIG. 3 is a graph showing a waveform of an RF power according to a second preferred embodiment of the present invention. The ECR etching apparatus shown in FIG. 1 is applied as well in the second preferred embodiment. The RF power fluctuates in cycles. In each one of the cycles, the frequency of the RF power fluctuates with constant amplitude, showing a frequency-modulated waveform. In this case, the aforementioned effect can be obviously obtained. 
     &lt;Third Preferred Embodiment&gt; 
     It has been a well-known technique to apply pulsed RF power to the wafers  7 . According to the technique, charge accumulated during an ON period of the RF power is relieved during its OFF period, while an etching rate is increased during the ON period. 
     FIG. 4 is a timing chart showing correlation between ON/OFF periods of a conventional pulsed RF power and a charge amount (strength of a local electric field caused by accumulated charge). Cycles T 1  of the RF power fluctuating in cycles consist of an ON period  271  and an OFF period  281  of the same lengths. 
     When the OFF period  281  is long, accumulation of charge is relieved. However, etching progress stops due to disappearance of plasma during the period, reducing an etching rate in the etching period as a whole. Further, since the ON period  271  lasts long as well in such case, accumulation of charge reaches to a saturation value. Then, a long lasting charge-up period is apt to cause shape anomalies. 
     FIG. 5 is a timing chart showing correlation between a charge amount and ON/OFF periods of an RF power with cycles T 2  which consists of an ON period  272  and an OFF period  282  both shorter than the ON/OFF periods  271 ,  281 , in order to avoid the aforementioned problem discussed about FIG.  4 . In this case, charge accumulated during the ON period  272  is suppressed, so that less shape anomaly occurs. An early end of the ON period  272 , however, prevents an adequate rise of a self-bias potential, so that an etching rate is decreased as compared with the example shown in FIG.  4 . 
     FIG. 6 is a timing chart showing correlation between a charge-up amount and ON/OFF periods of an RF power with cycles T 3  which consists of an ON period  273 , and an OFF period  283  shorter than the ON period  273 , in order to avoid the aforementioned problem discussed about FIG.  5 . In this case, an etching rate can be increased during the ON period  273  without interfering with a rise of a self-bias potential. It is, however, impossible to sufficiently relieve accumulation of charge during the OFF period  283 , so that accumulated charge will reach to a saturation value (i.e. charge-up) after several cycles. 
     FIG. 7 is a timing chart showing correlation between ON/OFF periods of an RF power and a charge amount according to a third preferred embodiment of the present invention. The timing may be used in the ECR etching apparatus shown in FIG. 1 is applied as well in the third preferred embodiment. 
     The RF power applied in the third preferred embodiment fluctuates in cycles, each one of the cycles T 4  consisting of a group of first subcycles  284  and a group of second subcycles  274  with different amplitudes. The group of first subcycles  284  includes first subcycles  284   a  and  284   b  with amplitudes of zero and different lengths (both are OFF periods). The group of second subcycles  274  includes second subcycles  274   a  and  274   b  with the same amplitudes and lengths (both are ON periods). These subcycles  274   a ,  284   a ,  274   b  and  284   b  appear in turns. 
     As described above, the ON/OFF periods of the RF power are modulated by means of PCM (pulse code modulation). In other words, the length of the ON periods is constant while that of the OFF periods changes from long to short in cycles. 
     Since the cycles T 4  in which the RF power fluctuates include the OFF periods  284   a  and  284   b  of different length in this way, accumulation of charge can be relieved during the longer period thereof while a decline in the etching rate can be suppressed during the shorter period. In other words, it is possible to accumulate less charge as compared with the example shown in FIG. 4 and a high etching rate as compared with the example shown in FIG.  5 . 
     &lt;Fourth Preferred Embodiment&gt; 
     When an RF power fluctuates in cycles, it may be ON periods, not OFF periods, to have subcycles of different length. FIG. 8 is a timing chart showing correlation between ON/OFF periods of an RF power and a charge amount according to a fourth preferred embodiment of the present invention. The ECR etching apparatus shown in FIG. 1 is applied as well in the fourth preferred embodiment. 
     Cycles T 5  of the RF power consists of a group of first subcycles  275  and a group of second subcycles  285  with different amplitudes. The group of first subcycles  275  includes first subcycle  275   a ,  275   b  with the same amplitudes and different lengths (both are ON periods). The group of second subcycles  285  includes second subcycles  285   a ,  285   b  with amplitudes of zero and the same lengths (both are OFF periods). These subcycles  275   a ,  285   a ,  275   b  and  285   b  appear in turns. 
     As described above, the ON/OFF periods of the RF power are modulated by means of PWM (pulse width modulation). In other words, the length of the OFF periods is constant while that of the ON periods changes from long to short in cycles. 
     Since the cycles T 5  in which the RF power fluctuates include the ON periods  275   a ,  275   b  of different length in this way, accumulation of charge can be relieved during the shorter period thereof while a decline in an etching rate can be suppressed during the longer period. In other words, it is possible to accumulate less charge as compared with the example shown in FIG. 4 and a high etching rate as compared with the example shown in FIG.  5 . 
     &lt;Fifth Preferred Embodiment&gt; 
     FIG. 9 shows waveforms of an RF power according to a fifth preferred embodiment of the present invention. The waveforms maybe used in the ECR etching apparatus shown in FIG. 1 as well in the fifth preferred embodiment. In this case, the RF power supply device  30  can perform not only modulation of RE frequency and ON/OFF switching of the pulsed RF power but also superimposition of RF components on DC components. The combination of a random waveform generator, and a high-speed and wideband power amplifier can achieve such structure. 
     Suppose a time t to start an ON cycle in pulse of RF components is zero (t=0), a voltage applied to an output side of the RF power supply device  30  can be expressed as V=Asin (ωt +α)+V 0 , where A is amplitude of the RF power, ω is an angular frequency of the RF power, α is an initial phase, and V 0  is a central value of the voltage (DC components). If V 0 =−Asin(α), for example, the voltage V at a starting time becomes zero. 
     FIGS. 9A to  9 D show the voltage V of the RF power when α=0°, 90°, 180° and 270°, respectively, where each ON period in pulse includes only one cycle of RF components. As for the RF power, when RF components are superimposed in the form of pulse on DC components, change in the initial phase α for the RF components is effective for reduction in charge-up and control of a selectivity ratio. 
     FIG. 10 is a graph showing the dependency of a notch amount on an initial phase. Compared with the case that an RF power is not applied (shown by a broken line), the application of a pulsed RE power reduces a notch amount. The ratio of reduction depends on the value of an initial phase α. When the phase is 90°, the application of the RE power accelerates ions in the direction of a substrate while decelerating electrons and reducing an electron current. Thus, positive charge-up at the bottom portion of a pattern is not dissolved while negative charge accumulated on the side wall of the pattern is reduced, which results in little effect in improving notch. On the contrary, when the initial phase α is 270°, a retarding electrical field of electrons weakens and reduces accumulation of charge at the bottom portion of the pattern. Thus, notch prevention is remarkably improved. 
     FIG. 11 is a graph showing the dependency of a selectivity ratio on an initial phase. Compared with the case that an RF power is not applied (shown by a broken line), the selectivity ratio falls (deteriorates) due to the application of a pulsed RF power. The ratio of the fall depends on the value of an initial phase α. The initial phase α of 90° has the greatest fall of the selectivity ratio while the initial phase α of 270° has the least. 
     That is, in order to obtain good notch amount and selectivity ratio, it is desirable to set the initial phase α at the range of 180° to 360°, more preferably at 270° so that an area more positive than DC components is greater than that more negative than DC components in the range of the voltage V with RF components superimposed. 
     FIGS. 12 and 13 are a graph showing the dependency of a CD gain (critical dimension gain) on an initial phase, and a sectional view illustrating the CD gain, respectively. A film  102  provided on a substrate  101  is etched with a resist  103  as a mask. The CD gain can be found by the value of t 2 −t 1 , where the width of the resist  103  is t 1  and the width of the bottom portion of the film  102  to be etched is t 2 . Compared with the case that an RF power is not applied (shown by a broken line), the application of a pulsed RF power improves the CD gain. The ratio of the improvement depends on the value of an initial phase α. The initial phase α of 90°, for example, brings about the greatest improvement in the CD gain while the initial phase α of 270° brings about the least. 
     FIG. 14 is a graph showing the dependency of an etching rate on an initial phase. Compared with the case that an RF power is not applied (shown by a broken line), the application of a pulsed RF power increases an etching rate. The ratio of the increase depends on the value of an initial phase α. The initial phase α of 90°, for example, gives the greatest increase while the initial phase α of 270° gives the least. 
     That is, in order to obtain good CD gain and etching rate, it is desirable to set the initial phase α at the range of 0° to 180°, more preferably at 90° so that an area more positive than DC components becomes smaller than that more negative than DC components in the range of the voltage V with RF components superimposed. 
     As explained above, desirable etching characteristics can be obtained by controlling the initial phase α. Likewise, change in the initial voltage V 0  has effect in controlling accumulation of charge, a selectivity ratio, a CD gain and an etching rate. 
     &lt;Sixth Preferred Embodiment&gt; 
     As for an RF power, when RF components are superimposed in the form of pulse on DC components, the RF components may include a plurality of cycles. 
     FIG. 15 is a sectional view showing an ECR etching device applied in a sixth preferred embodiment of the preferred embodiment. Compared with the structure shown in FIG. 1, the structure of this preferred embodiment is different only in that the RF power supply device  30  is connected to the stage  6  via a blocking capacitor  29 . 
     FIGS. 16A and 16B are graphs showing change in potential of the stage  6  from the initial phase α of 0° to 90°, where the number of cycles k is 2. 
     Since the stage  6  is connected to the RF power supply device  30  via the blocking capacitor  29 , potential of the stage  6  with no application of the RF power is equal to a floating potential Vf. FIG. 17 is a graph showing potential of the stage  6  when the RF power is continuously applied. The amount that the maximum potential of the stage  6  goes over the floating potential Vf is smaller than that the minimum potential of the stage  6  goes below the floating potential Vf. As the number of cycles k is increased, change in potential of the stage  6  has less dependency on the initial phase α, getting closer to the graph shown in FIG.  17 . That is, the number of times to induce ions into the stage  6  increases. Thus, a constant initial phase α leads to an increase in an ion energy, reduction in a notch amount and a fall of a selectivity ratio. 
     As described above, it becomes possible to control a notch amount and a selectivity ratio by setting the number of cycles k or the initial phase α during the ON period of the pulsed RF power. Even if the RF power is continuously applied, an ion energy can be controlled by setting only a voltage or an electric power. However, further fine control can be achieved by control of the number of cycles k and the initial phase α. 
     &lt;Seventh Preferred Embodiment&gt; 
     FIG. 18 is a graph showing a waveform of an RF power according to a seventh preferred embodiment of the present invention. The waveforms maybe used in the ECR etching apparatus shown in FIG. 15 as well in the seventh preferred embodiment. A μ wave power source  80  generates a μ wave  19  in the form of pulse (intermittently). 
     An introduction of the pulsed μ wave  19  into a plasma reactor brings about reduction in a notch amount, which is taught, for example, by Jpn. J. Appl. Phys. 35(1996) p2450. According to this preferred embodiment, the plasma reactor not only generates plasma from the pulsed μ wave but also provides the pulsed RF power, which is described in the fifth and sixth preferred embodiments, with the stage  6 . The combination of such techniques has a remarkable effect in improving etching characteristics such as reduction in a notch amount. 
     FIG. 18 is a timing chart showing correlation between the μ wave  19  and the RF power. It becomes possible to control microscopic ion energy as well as a notch amount by controlling a delay time t 0 . The delay time t 0  is defined as how long the beginning of superimposition of RF components on DC components (floating potential Vf) delays from the beginning of intermittent ON period of the μ wave  19 . FIG. 19 is a graph showing correlation between the delay time t 0  and a notch amount, where a cycle of the μ wave is T (duty 50%) and the period of superimposition of the RF components on the DC components is τ (when initial phase α=0°). As it is obvious from the graph, a notch amount can be remarkably reduced by setting the timing of superimposition of the RF components on the DC components near the end of the OFF period of the μ wave. 
     The plasma density thins in such timing, which results in small amount of electrons. That is, when there is no difference in power of the RF components, each electron has maximum power. Thus, it is possible to obtain the most remarkable effect that the electrons are induced into the bottom portion of the pattern to offset charge. 
     Though only the ECR etching apparatuses are explained in the aforementioned preferred embodiments, the application of the present invention is not only limited to those apparatuses. The present invention is also applicable to all kinds of etching apparatuses for generating plasma separately from an RF power applied to a sample (e.g. etching apparatus using an induced coupled plasma, called as “ICP”). It is needless to say that control of the frequency of the RF power and a voltage is effective in controlling an ion energy and a notch amount. 
     While the invention has been described in detail, the foregoing description is in all aspects illustrative and not restrictive. It is understood that numerous other modifications and variations can be devised without departing from the scope of the invention.