Abstract:
An elevated temperature RF ion source system, comprising an ion source body, an RF antenna coil external to the ion source body, a vacuum enclosure surrounding both the outside surface of the ion source body and the RF antenna coil, at least one power supply, a gas delivery system operatively coupled to the ion source body, a vacuum condition between the outside surface of the ion source body and the RF antenna coil, the RF antenna coil operatively coupled to the at least one power supply, and a water cooling system operatively coupled to the RF antenna coil and the vacuum enclosure.

Description:
REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to and the benefit of U.S. Provisional Application Ser. No. 60/952,895 which was filed Jul. 31, 2007, entitled ELEVATED TEMPERATURE RF ION SOURCE, the entirety of which is hereby incorporated by reference as if fully set forth herein. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to radio frequency (RF) ion source semiconductor processing systems and more specifically to a system and method for ion implantation of substrates by employing an elevated temperature RF ion source. 
       BACKGROUND OF THE INVENTION 
       [0003]    The semiconductor industry employs ion implantation in the manufacture and processing of very large scale integrated circuits. Ion implantation is a process by which dopants are added to a workpiece, such as a semiconductor wafer by impacting accelerated charged atoms or molecules (positive or negative ions) against semiconductor substrates. One of the objectives of ion implantation is to introduce a desired atomic species into the target material, the semiconductor wafer or workpiece. 
         [0004]    Hot cathode DC arc ion sources have been the standard in semiconductor ion implantation. These sources have an internal cathode that is negatively biased with respect to the ion source body walls. Electrons are accelerated away from the cathode toward the walls of the ion source, ionizing gas molecules and thereby creating a plasma. The body of the ion source is typically supported inside of a vacuum system and therefore the source body is thermally isolated from the outside. Gases within the source body build up on the walls of the ion source if the source and/or source walls are not sufficiently hot. For example, if arsine (an arsenic hydrogen compound) is used, arsenic (As), that did not ionize, can plate out on the source walls as a contaminant. If the ion source body does not reach a high enough temperature, the Arsenic will remain on the walls and can contaminate future implantation when the system is changed over to a new gas, for example, phosphine (PH 3 ). However, ion sources for semiconductor ion implantation are generally operated at temperatures of 300-600 degrees Celsius (572-1112 degrees Fahrenheit) in order to avoid deposition on the ion source surfaces. 
         [0005]    Standard RF source design requires that the ion source wall temperature be in the range of approximately 20-100 degrees Celsius (68-212 degrees Fahrenheit). This incompatibility in temperature requirements has prevented the widespread use of RF sources in the semiconductor ion implant industry. 
         [0006]    In addition, current arc discharge DC ion sources can only run a few hundred hours or less before having to perform maintenance on the ion source. The cathode is worn out by the constant bombardment of ions and therefore has to be replaced. 
         [0007]    In view of the above problems associated with current arc discharge DC ion sources and RF ion beam sources with regard to semiconductor manufacture and processing, it would therefore be desirable to have a system and method which mitigates such issues. Thus, there exists a need for an improved system and method for ion sources used in semiconductor implantation. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention overcomes the limitations of the prior art mentioned supra. Consequently, the following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify key or critical elements of the invention nor delineate the scope of the invention. Its purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later. 
         [0009]    By way of illustration, and not limitation, the present invention is directed generally toward an elevated temperature RF ion source system, comprising an ion source body, an RF antenna coil external to the ion source body, a vacuum enclosure surrounding both the outside surface of the ion source body and the RF antenna coil. The system further comprises at least one power supply, a gas delivery system operatively coupled to the ion source body, and a vacuum condition between the outside surface of the ion source body and the RF antenna coil. The RF antenna coil operatively coupled to the at least one power supply, and a water cooling system operatively coupled to the RF antenna coil and the vacuum enclosure. 
         [0010]    According to another exemplary aspect of the present invention, an elevated temperature RF ion source system comprises an ion source body, an RF antenna partially internal to the ion source body, at least one insulation tube surrounding the RF antenna, and at least one power supply. The system further comprises at least one antenna support, a heater, a source flange, a cooling component, and a gas delivery component operatively coupled to the ion source body, the ion source body operably coupled to a vacuum component, the at least one antenna support centers the RF antenna within the at least one insulation tube. The at least one tube is internal to the ion source body, the RF antenna coil and the source flange are operatively coupled to the at least one power supply, and a cooling component is operatively coupled to the RF antenna coil and the vacuum enclosure. 
         [0011]    To the accomplishment of the foregoing and related ends, the invention comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is an exploded perspective view of an exemplary elevated temperature RF ion source system according to one aspect of the present invention. 
           [0013]      FIG. 2  is a perspective view of an exemplary elevated temperature RF ion source system according to another exemplary aspect of the invention. 
           [0014]      FIG. 3  is a perspective view of an ion source body of an ion implantation system in accordance with another exemplary aspect of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0015]    The present invention is directed generally towards a system and method for employing a high temperature RF ion source when manufacturing or processing semiconductors using an ion implantation system, for example. Accordingly, the present invention will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. It should be understood that the description of these aspects are merely illustrative and that they should not be taken in a limiting sense. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident to one skilled in the art, however, that the present invention may be practiced without these specific details. 
         [0016]    Referring now to the figures,  FIG. 1  and  FIG. 2  illustrate two different embodiments of ion source.  FIG. 1  illustrates an exploded perspective view of an elevated temperature RF ion source  100  where an RF antenna excitation coil  104  is external to a plasma chamber. Whereas,  FIG. 2  illustrates a perspective view of an elevated temperature RF ion source system  200 , wherein an RF antenna  204  is within a source body  202  surrounded by synthetic sapphire tubes (Al 2 O 3 )  302  that isolate and protect the antenna  204  from the plasma within the source body  202 . In accordance with one exemplary aspect of the present invention,  FIG. 1  illustrates the exemplary elevated temperature RF ion source system  100 , wherein the system is operable to provide plasma within an ion source body  102 . As stated above, various aspects of the present invention may be implemented in association with any type of ion implantation apparatus, including, but not limited, to the exemplary system  100  of  FIG. 1 . The elevated temperature RF ion source system  100  comprises the ion source body  102  that includes an alumina cone  106 , a molybdenum (Mo) front flange  108  and a molybdenum (Mo) back flange  110  and an extraction aperture  112  that forms a discharge chamber in which ion plasma (not shown) is initially formed before being directed to a workpiece location. In other words, the ion source body  102  can be defined as those components that are in contact with the ion plasma. It should be appreciated that the alumina cone  106  can be various shapes, for example, a cylinder, a half sphere, etc., and can be made of various materials, e.g., quartz, boron nitride or other refractory dielectrics. The RF antenna excitation coil  104 , surrounds the alumina cone  106  of the ion source body  102  and can be powered by a power supply (not shown) to create the plasma within the ion source body  102 . The extraction aperture  112  allows the ions to exit a discharge chamber and thereby direct an ion beam toward a workpiece. 
         [0017]    The ion source body assembly illustrated in  FIG. 1 , for example, can provide a water cooled source flange  114 , which regulates the temperature of the ion source body  102 . It should be noted, however, that other type cooling approaches may alternatively be employed, and fall within the scope of the present invention. 
         [0018]    According to one exemplary aspect of the present invention, the water cooled source flange  114  can be connected to the molybdenum front flange  108 , by employing support rods  116 . Gas lines  118  can supply gas to the ion source body  102  in order to form the plasma and water lines  120  are employed to cool various surfaces and the RF antenna excitation coil  104 . Without utilizing cooling, it is possible that the antenna  104  can fail (e.g., melt) and/or the RF losses can exceed an acceptable limit, becoming inefficient. 
         [0019]    An alternating current in the RF antenna excitation coil  104  creates an electromagnetic field within the ion source body  102  that generates a circulating current in the gas. The electromagnetic field breaks down the gas and the temperature of the ion source body  102  increases as plasma impinges on the inner walls, transferring energy thereto. The water cooled source flange  114  and the water cooled antenna excitation coil  104  remain close to room temperature (approximately 50 C) in one embodiment. There is very little thermal conduction through the supports rods  116  to the source flange  114  and, as discussed supra, the antenna  104  is separated from the aluminum cone  106  in vacuum, for example, by a 4 mm gap. Therefore, the ion source body  102  loses the majority of its heat through radiation heat loss, which allows the temperature to remain at an elevated level which can prevent gases from condensing on the internal walls of the ion source body  102 . Therefore the gases thereby do not become contaminants when changes are made to the source gas. In addition, unlike a cathode system, the RF antenna excitation coil  104  is external to the plasma creation area of the ion source body  102  and therefore the antenna is not damaged during plasma generation/collision. Therefore the system has far greater time between maintenance operations (1000&#39;s of hours versus 100&#39;s of hours or less). 
         [0020]    According to still another exemplary aspect of the present invention,  FIG. 2  is a perspective view of the elevated temperature RF ion source system  200 . The aluminum ion source body  202  employed in the system  200  is illustrated to aid in the understanding of generation of plasma, utilizing a radio frequency (RF) field. The RF antenna  204  can be made of, for example, a 3.18 millimeter (⅛ inch) outside diameter, a 0.813 mm (0.032 in.) wall thickness and copper tubing mounted within the aperture region (not shown) of the source body  202 . The source body  202  is conductively coupled to a water cooled source vacuum flange  206 . The RF antenna  204  can be precisely located inside the ion source body  202 , by utilizing antenna support plates  208  mounted on the top and bottom of the ion source body  202 . The antenna support plates  208 , for example, can be machinable ceramic, aluminum with ceramic inserts, alumina, quartz, etc. The copper tubing can be located, for example, in the center of a 10 mm (outside diameter) synthetic sapphire (Al 2 O 3 ) tube (not shown) having a wall thickness of 1 mm (0.039 inch), for example. The Sapphire tube  320  can be precisely located using, for example, feed through supports machined in the ion source body  202 , precision inserts in the ion source body  202 , etc. 
         [0021]    The synthetic sapphire tubes (Al 2 O 3 )  302  have high strength, hardness and chemical stability and are an excellent material at high temperature and severe environments, for example, fluorine attack. The ends of the tubes can be ground in order to ensure roundness and proper fit in the ion source body  202  locating holes. It is possible to have the ion source body  202 , a support flange  210 , a heater block  212  (shown as part of the source body  202 ) and the water cooled source vacuum flange  206  machined out of a single billet of, for example, aluminum in order to eliminate less conductive surface to surface thermal interfaces. 
         [0022]    In one exemplary embodiment of the present invention, the elevated temperature RF ion source system  200  can be employed to generate plasma for substrate ion implantation, as an ion source for other applications, and the like. The source vacuum flange  206  can be water cooled and maintained at a relatively constant temperature T 0 . The variation in T 0 , as the discharge power is varied can be assumed, for example, to be small compared to the difference between T 0  and the source temperature (T S ), 
         [0023]    The maximum power (P HMAX ) for a heater installed in a cavity  218  in the heater block  212  can be chosen to be equal to the maximum design discharge power (P DMAX ): 
         [0000]      ( P   MAX )=( P   DMAX )=( P   HMAX ) 
         [0024]    The source assembly in one embodiment is isothermal with a maximum design temperature of (T SMAX ). Support rods  214  can have a uniform length (L) and a cross sectional area (A) and the associated radiation losses in the rods  214  can be neglected in the first order and treated as a second order correction, for example. 
         [0025]    In order for the system to obtain maximum source power, the maximum power will equal the discharge power plus the heater power, (P MAX )=(P D )+(P H ), the source temperature can be maintained at a maximum value of T SMAX  and the heat conduction equation becomes: 
         [0000]    
       
         
           
             
               P 
               MAX 
             
             = 
             
               K 
                
               
                 
                   
                       
                   
                    
                   A 
                 
                 L 
               
                
               
                 ( 
                 
                   
                     T 
                     SMAX 
                   
                   - 
                   
                     T 
                     0 
                   
                 
                 ) 
               
             
           
         
       
     
         [0000]    Where K is the thermal conductivity of aluminum (K=250W/mK). Solving for the total support rod area: 
         [0000]    
       
         
           
             A 
             = 
             
               
                 
                   P 
                   MAX 
                 
                  
                 
                   ( 
                   L 
                   ) 
                 
               
               
                 K 
                  
                 
                   ( 
                   
                     
                       T 
                       SMAX 
                     
                     - 
                     
                       T 
                       0 
                     
                   
                   ) 
                 
               
             
           
         
       
     
         [0000]    For example, for a length, L=0.18 meters (0.59 feet) and the following chosen values below: 
         [0000]      P MAX =500 W 
         [0000]      T 0 =50° C. 
         [0000]      T SMAX =300° C. 
         [0000]    The rod area is calculated as follows: 
         [0000]    
       
         
           
             
               
                 
                   A 
                   = 
                     
                    
                   
                     
                       500 
                        
                       
                           
                       
                        
                       
                         W 
                          
                         
                           ( 
                           
                             0.18 
                              
                             
                                 
                             
                              
                             m 
                           
                           ) 
                         
                       
                     
                     
                       250 
                        
                       
                           
                       
                        
                       
                         W 
                         mK 
                       
                        
                       
                         ( 
                         
                           300 
                            
                           ° 
                            
                           
                               
                           
                            
                           
                             C 
                             . 
                             
                               - 
                               50 
                             
                           
                            
                           ° 
                            
                           
                               
                           
                            
                           
                             C 
                             . 
                           
                         
                         ) 
                       
                     
                   
                 
               
             
             
               
                 
                   = 
                     
                    
                   
                     1.44 
                     × 
                     
                       10 
                       
                         - 
                         3 
                       
                     
                      
                     
                       m 
                       2 
                     
                   
                 
               
             
             
               
                 
                   = 
                     
                    
                   
                     14.4 
                      
                     
                         
                     
                      
                     
                       
                         cm 
                         2 
                       
                        
                       
                         ( 
                         
                           0.0155 
                            
                           
                               
                           
                            
                           
                             ft 
                             2 
                           
                         
                         ) 
                       
                     
                   
                 
               
             
           
         
       
     
         [0026]    This is a reasonable cross sectional area for the source support rods, one bar  214  as illustrated in  FIG. 2 , or, for example, four, square, cross sectional bars, each 1.9 cm (0.748 inches) on a side. For multipurpose operation, with industry standard gases such as Arsine and Phosphine, the source (T S ) can be maintained, for example, at a constant 300° C. As the discharge power is varied, by varying the heater power (P H ) the system can maintain a constant total power (P MAX ) of 500 watts. A temperature measuring device (e.g., thermocouple, thermistor, resistance temperature detector (RTD), etc.), may be strategically mounted to the ion source body  202  block to monitor the temperature. A control system may then fine tune the heater power very accurately. For other fill gases a different source temperature may be desired, for example, in B 18 H 22  operation, a source temperature of T S  equal to approximately 150° C. is required to prevent B 18 H 22  condensation. For example, the source (discharge) power for B 18 H 22  can be less than approximately half of the full power estimate, and with T 0  of approximately 35° C., solving for the total power required: 
         [0000]    
       
         
           
             P 
             = 
             
               
                 KA 
                 L 
               
                
               
                 ( 
                 
                   
                     T 
                     s 
                   
                   - 
                   
                     T 
                     0 
                   
                 
                 ) 
               
             
           
         
       
       
         
           
             P 
             = 
             
               250 
                
               
                   
               
                
               
                 W 
                 mK 
               
                
               
                 
                   1.44 
                   × 
                   
                     10 
                     
                       - 
                       3 
                     
                   
                 
                 
                   0.18 
                    
                   
                       
                   
                    
                   m 
                 
               
                
               
                 
                   m 
                   2 
                 
                  
                 
                   ( 
                   
                     150 
                      
                     ° 
                      
                     
                         
                     
                      
                     
                       C 
                       . 
                       
                         - 
                         35 
                       
                     
                      
                     ° 
                      
                     
                         
                     
                      
                     
                       C 
                       . 
                     
                   
                   ) 
                 
               
             
           
         
       
       
         
           
             
               P 
               Total 
             
             = 
             
               230 
                
               
                   
               
                
               W 
             
           
         
       
     
         [0000]    The RF discharge power can be, for example, less than 100 W, so that the heater will have to supply around 130 W to provide a total power of 230 W. 
         [0027]    In yet another example, performing a second order thermal analysis on the radiation from the ion source body  102 : 
         [0000]    
       
         
           
             P 
             = 
             
               ∈ 
               
                 σ 
                  
                 
                     
                 
                  
                 
                   AT 
                   4 
                 
               
             
           
         
       
       
         
           
             σ 
             = 
             
               
                 
                   5.67 
                   × 
                   
                     10 
                     
                       - 
                       8 
                     
                   
                    
                   
                       
                   
                    
                   
                     W 
                     
                       
                         m 
                         2 
                       
                        
                       
                         K 
                         4 
                       
                     
                   
                 
                  
                 
                   
 
                 
                 ∈ 
               
               = 
               
                 0.06 
                  
                 
                     
                 
                  
                 
                   ( 
                   
                     polished 
                      
                     
                         
                     
                      
                     aluminum 
                   
                   ) 
                 
               
             
           
         
       
       
         
           
             T 
             = 
             
               573 
                
               
                   
               
                
               K 
             
           
         
       
       
         
           
             A 
             = 
             
               25 
               × 
               
                 10 
                 
                   - 
                   3 
                 
               
                
               
                 m 
                 2 
               
             
           
         
       
       
         
           
             P 
             = 
             
               9 
                
               
                   
               
                
               W 
             
           
         
       
     
         [0028]    This can be taken as negligible, for example, as assumed in the first order calculation. 
         [0029]    In yet another example, the conduction path area of the gas feed line  214  ( FIG. 2 ) can be calculated for a ¼ inch outside diameter, 0.032 inch wall thickness, and is approximately 0.16 cm 2  or about 1% of the design support area, in one embodiment. Thus the addition of two or three gas lines, for example, will have negligible effect on the thermal design. 
         [0030]    This approach to thermal design of an ion source has additional advantages over existing design approaches. For example, for a multispecies mode of operation (e.g., BF 3 , PH 3 , AsH 3 , B 18 H 22 , etc.), the ion source temperature is constant, independent of the beam current (function of discharge power) and therefore there are no thermal settling and/or drift problems when changing beam current or gases. Furthermore, warm-up times for cold starts may be reduced substantially as the source heater can be turned on as soon as the source is replaced in the system, even while the implanter is at atmospheric pressure. 
         [0031]    The ion source temperature, which can now be well controlled, can be utilized to create a hot multi-cusp discharge ion source. This general class of ion sources utilizes permanent magnets oriented with alternative polarities on the walls of the ion source  202  to create a magnetic field which can provide a degree of plasma confinement. This can reduce the power necessary to provide a desired plasma density and also allows operation at a lower pressure, reducing the gas flow requirements. Also a permanent magnet on a hot ion source without good temperature control is generally avoided as irreversible loss of magnetism may occur if the temperature becomes too high. With good temperature control according to the present invention, samarium cobalt magnets, which are available with maximum operating temperature as high as 550° C., can be used to make the high temperature source. 
         [0032]      FIG. 3  illustrates a perspective view of an exemplary ion source body  302  employed within an elevated temperature RF ion source system  300  with an extraction aperture removed. The exemplary ion source body assembly, for example, comprises the ion source body  302  wherein the RF antenna  304  resides, wherein sapphire tubes  320  enclose the RF antenna  304  within a plasma chamber  322  and provide a circumferential gap  328  between the outside of the antenna  304  and the inside of the sapphire tube  320  in one embodiment. It is to be appreciated that the ion source body  302  can utilize other materials than synthetic sapphire for the tube  320 , for example, quartz (SiO 2  ), boron nitride, or other refractory dielectrics. 
         [0033]    The antenna  304  can be precisely located by employing antenna support plates  322  at the top and bottom of the ion source body  302 . The plates  322  can be located precisely by utilizing, for example, alignment pins (not shown). The plates  322 , for example, can be manufactured from machinable ceramics, aluminum with ceramic inserts, and the like. The sapphire tubes  320  can have the ends ground precisely and fit up into precision holes in the ion source body  302  or precision inserts (not shown). In one embodiment the configuration, e.g., of the 3.18 mm (⅛ inch) O.D., copper tube, antenna  304  and the 8 mm ID sapphire tubes  320  provides a vacuum gap for thermal isolation of 2.41 mm. In addition, the sapphire tubes  320  may not need to provide a hermetic seal, but rather, may be designed to limit the gas flow out of the source  302 . 
         [0034]    In accordance with the present invention, the elevated temperature RF ion source system  300  can be maintained at any desired temperature between approximately 100° C. and 300° C. for a discharge power of less than approximately 100 W, for example for B 18 H 22  and multi-species low current operation, and at approximately 300° C. for multi-species high current operation with RF power up to 500 W. 
         [0035]    Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, circuits, etc.), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several embodiments, such feature may be combined with one or more other features of the other embodiments as may be desired and advantageous for any given or particular application.