Patent Publication Number: US-2022213959-A1

Title: Chamber body design architecture for next generation advanced plasma technology

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Division of application Ser. No. 14/693,254 filed on Apr. 22, 2015, which claims benefit of U.S. Provisional Application 62/108,052, filed on Jan. 26, 2015, each of which are is hereby incorporated by reference herein. 
    
    
     BACKGROUND 
     Field 
     Embodiments described herein generally relate to a modular two chamber design providing independent processing in each of the two chambers. More specifically, embodiments disclosed herein relate to etch plasma chamber technology and hardware design architecture that provides an independent variable gap process volume for multiple process regimes in a dual chamber architecture. 
     Description of the Related Art 
     As the technology nodes advance and reduced size device geometries requires etch plasma processing chambers with precise control of input parameters. Input parameters include electrical, radio frequency (RF), gas flow and thermal control. Symmetry in one or more of the input parameters is important to improve on-wafer uniformity and yield. The symmetry of the input parameters may be provided by improved chamber hardware. 
     Accordingly, there is a need in the art for an improved chamber and method of using the same. 
     SUMMARY 
     An apparatus for processing a substrate is disclosed and includes, in one embodiment, a twin chamber housing having two openings formed therethrough, a first pump interface member coaxially aligned with one of the two openings formed in the twin chamber housing, and a second pump interface member coaxially aligned with another of the two openings formed in the twin chamber housing, wherein each of the pump interface members include three channels that are concentric with a centerline of the two openings. 
     In another embodiment, an apparatus for processing a substrate is provided. The apparatus includes a twin chamber housing, a modular pumping interface having at least two separated interior volumes coupled to the twin chamber housing and providing two separate processing volumes within the twin chamber housing. 
     In another embodiment, a twin volume substrate processing chamber is provided. The twin volume substrate processing chamber includes a chamber body having a first opening and a second opening formed therethrough, a first pump interface member coaxially aligned with a centerline of the first opening, the first pump interface member having a plurality of first channels formed therein parallel to the centerline, and a second pump interface member coaxially aligned with a centerline of the second opening and fluidly separated from the first pump interface member, the second pump interface member having a plurality of second channels formed therein parallel to the centerline. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       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. 
         FIG. 1A  illustrates an isometric view of a twin chamber housing. 
         FIG. 1B  shows an exploded view of the twin chamber housing shown in  FIG. 1A . 
         FIG. 2A  is a top plan view of a chamber body. 
         FIG. 2B  is a side view of the chamber body of  FIG. 2A . 
         FIG. 2C  is a side cross-sectional view of the chamber body along lines  2 C- 2 C of  FIG. 2A . 
         FIG. 3A  is a top plan view of the twin chamber housing having the pump interface members axially aligned with the openings of the chamber body. 
         FIG. 3B  is an isometric view of one embodiment of a pump interface member. 
         FIG. 4A  is a cross-sectional plan view of the chamber body. 
         FIG. 4B  is an isometric cross-sectional view of the chamber body along lines  4 B- 4 B of  FIG. 4A . 
         FIG. 5  is a schematic cross-sectional view of a process chamber system according to one embodiment. 
         FIG. 6  is a schematic side cross-sectional view of a portion of two pump interface members coupled to one embodiment of a pump interface. 
         FIG. 7  is a schematic side cross-sectional view of a portion of two pump interface members coupled to another embodiment of a pump interface. 
         FIG. 8  is a schematic side cross-sectional view of a portion of two pump interface members coupled to another embodiment of a pump interface. 
     
    
    
     To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation. 
     DETAILED DESCRIPTION 
     Embodiments described herein generally relate to chamber hardware and associated methods having a symmetric flow design to pump out processed by-products from inside the chamber and maintain vacuum to enable improved flow conductance. Embodiments described herein also provide a chamber having a shorter mean free path for gas flow travel before the gas is pumped-out in an axial direction. Axially symmetric chamber hardware as provided herein helps in reducing on wafer skews and improves flow conductance. Embodiments disclosed herein include a twin chamber body design including a process portion and a flow block portion. The flow block portion provides axially-symmetric flow and is capable of providing variable process volumes for multiple applications and process regimes. The flow block design may also enable a modular design solution and/or cost effective manufacturing. 
       FIG. 1A  illustrates an isometric view of a twin chamber housing  100 .  FIG. 1B  shows an exploded view of the twin chamber housing  100  shown in  FIG. 1A . The twin chamber housing  100  includes a chamber body  105  having dual process volumes  110 A and  110 B. Each of the process volumes  110 A and  110 B may be bounded by a chamber sidewall  115  and a lid (not shown) that couples to a lid interface  120 . The twin chamber housing  100  also includes a modular pumping interface  125  which includes two pump interface members  130  that form a boundary of the process volumes  110 A and  110 B. The twin chamber housing  100  may be installed or retrofitted on existing semiconductor substrate manufacturing platforms where the PRODUCER® processing system, commercially available from Applied Materials, Inc., of Santa Clara, Calif. is utilized. Examples of platforms where the twin chamber processing housing  100  may be used include the CENTURA® platform available from Applied Materials, Inc., of Santa Clara, Calif. Embodiments of the twin chamber processing housing  100  may also be utilized on other suitably adapted processing systems or platforms having processing chambers disposed about a central transfer chamber, including those from other manufacturers. The twin chamber housing  100  as described herein may be coupled to a platform or processing system without increasing the footprint of the platform or processing system. 
     The twin chamber housing  100  includes separate dual process volumes  110 A and  110 B where individual semiconductor substrates may be processed by deposition of materials on the substrates, removal of material on the substrates, heating of the substrates, or other processes performed on the substrates. Each of the process volumes  110 A and  110 B may be fitted with showerheads and substrate supports (both not shown) to enable processes such as etching, deposition or other thermal processes. The process volumes  110 A and  110 B are environmentally separated such that processing parameters may be controlled in each process volume  110 A and  110 B separately. The twin chamber housing  100  may be made of aluminum or other process compatible metal. Each of the process volumes  110 A and  110 B may be sized to process substrates having a 200 millimeter (mm) diameter, 300 mm diameter, or 450 mm diameter. 
     The lid interface  120  may include a sealing member  135 , such as an o-ring, that facilitates sealing between a lid (not shown), that couples to the chamber body  105 . In some embodiments, a lid may be hingedly coupled to the chamber body  105 . In other embodiments, a lid may be coupled to the chamber body  105  utilizing fasteners coupled to threaded holes  140  formed in the chamber body  105 . Openings  145  are also formed in the chamber body  105  for transfer of substrates into and out of the process volumes  110 A and  110 B. 
     As shown in  FIG. 1B , each of the pump interface members  130  may include flanges  142 A and  142 B on opposing ends thereof. A first flange  142 A (upper flange) may include openings  145  formed therein to facilitate coupling of the individual pump interface members  130  to the chamber body  105 . A second flange  142 B (lower flange) may include openings  145  formed therein to facilitate coupling of the individual pump interface members  130  to a vacuum pump (not shown). The pump interface members  130  include slots  150  formed therein and the slots  150  are surrounded by individual pumping channels  155 . In the embodiment shown, each of the pump interface members  130  have three slots  150  and three pumping channels  155 . The slots  150  and/or the pumping channels  155  may be equally spaced relative to each other. 
     The twin chamber housing  100  includes a pair of first openings  160 A formed in the chamber body  105  and a set of second openings  160 B (corresponding to the pumping channels  155  of the pump interface members  130 ) that form the process volumes  110 A and  110 B (shown in  FIG. 1A ). The volumes of each of the pumping channels  155  may be substantially equal in some embodiments. “Substantially equal” as relating to the pumping channels  155  includes a volume metric that is identical or within about 1% to about 5% of each other. A centerline  165  of the twin chamber housing  100  is shared by each of the first openings  160 A and each of the pump interface members  130 . The pumping channels  155  are concentric or coaxial to the centerline  165 . Thus, the process volumes  110 A and  110 B, formed by the first openings  160 A and the plurality of second openings  160 B are axially symmetric, which enables enhanced pumping and/or conduction in each of the process volumes  110 A and  110 B. 
     Referring again to  FIG. 1A , the chamber body  105  includes openings  172  for coupling to a platform, such as the CENTURA® platform as described above. The chamber body  105  may also include a hinge feature  174  for coupling to a lid (not shown). The chamber body  105  may also include a view port  170  as well as a port  175  for a sensor, such as an endpoint detection device, for each of the process volumes  110 A and  110 B. A port  180  may also be included for a pressure sensing device for each of the process volumes  110 A and  110 B. 
       FIGS. 2A, 2B and 2C  are various views of the chamber body  105  of the twin chamber housing  100 .  FIG. 2A  is a top plan view of the chamber body  105 .  FIG. 2B  is a side view of the chamber body  105 .  FIG. 2C  is a side cross-sectional view of the chamber body  105  along lines  2 C- 2 C of  FIG. 2A . 
     As shown in  FIG. 2C , the chamber body  105  includes a door  200  that is movable within the opening  145 . The door  200  may interface with a transfer chamber (not show) on a platform, such as the CENTURA® platform as described above. The opening  145  may also include a liner assembly  205 . A fluid channel  210  may also be formed in the chamber body  105  for cooling the chamber body  105 . 
       FIG. 3A  is a top plan view of the twin chamber housing  100  having the pump interface members  130  axially aligned with the openings  160 A of the chamber body  105 . Each of the pumping channels  155  (the second openings  160 B) of the pump interface members  130  are concentric with the centerline  165 . 
       FIG. 3B  is an isometric view of one embodiment of a pump interface member  130 . The pump interface member  130  includes a plurality of pumping channels  155  adjacent to a slot  150 . The slots  150  may be utilized to install and/or service devices that may be used in the process volumes  110 A and  110 B (shown in  FIG. 1A ), such as a substrate support or pedestal. The slots  150  are open to atmospheric pressures and temperatures and may be used to provide control connections (electrical, hydraulic, pneumatic lines, etc.) to the substrate support or pedestal. 
     Each of the pumping channels  155  are enclosed by an inner sidewall  300  and an outer sidewall  305 . A first sealing interface  310 A, such as an o-ring, or an o-ring channel or groove, may be included to surround an atmospheric region  315  defined by the inner sidewall  300  and a bottom  320  of the pump interface member  130 . A second sealing interface  310 B, such as an o-ring, or an o-ring channel or groove, may be included to surround a perimeter of each of the pumping channels  155 . A plurality of coupling members  325  may be at least partially disposed in the slots  150 . The coupling members  325  may be used to fasten peripheral components, such as a substrate support or pedestal, or control connections (electrical, hydraulic, pneumatic lines, etc.) to the substrate support or pedestal, to the pump interface member  130 . 
       FIG. 4A  is a cross-sectional plan view of the chamber body  105  and  FIG. 4B  is an isometric cross-sectional view of the chamber body  105  along lines  4 B- 4 B of  FIG. 4A . 
     A fluid channel  210  is shown in the chamber body  105  that at least partially surrounds each of the first openings  160 A. The fluid channel  210  may be formed by gun drilling. As shown in  FIG. 4B , the fluid channel  210  may be coupled to a fluid source via an inlet  400  and an outlet  405 . 
       FIG. 5  is a schematic cross-sectional view of a process chamber system  500  according to one embodiment. The process chamber system  500  includes the twin chamber housing  100  according to embodiments described herein. However, only one side of the twin chamber housing  100  is shown in this cross-section. The process chamber system  500  may be configured to perform an etch process, but may also be utilized to perform a chemical vapor deposition process, an epitaxial deposition process, a through via silicon process, or other thermal process utilized in the manufacture of electronic devices on a substrate. 
     The process chamber system  500  includes the process volume  110 A consisting of the first opening  160 A and a plurality of pumping channels  155  of the pump interface member  130 . A substrate support or pedestal  505  is shown positioned at least partially in the atmospheric region  315  of the pump interface member  130  and the first opening  160 A. A gas distribution plate or showerhead  510  may be disposed in the first opening  160 A. The showerhead  510  may function as an anode electrode and a substrate supporting surface  515  of the pedestal  505  may function as a cathode in some embodiments. Gases may be provided to the process volume  110 A from a gas source  520  and distributed through the process volume  110 A by the showerhead  510 . A lid  512  may be coupled to the chamber body  105  to enclose the process volume  110 A. A vacuum pump  525  may be coupled to the pump interface member  130  and, in some embodiments, a symmetric valve body  530  is disposed between the vacuum pump  525  and the pump interface member  130 . The vacuum pump  525  may be a turbo-molecular pump and the valve body  530  may be a spherical flow valve. 
     In some embodiments, the pedestal  505  is coupled to a lift motor that moves the substrate supporting surface  515  of the pedestal  505  vertically (Z direction) relative to the showerhead  510 . The vertical movement of the supporting surface  515  may be used to adjust a gap between a substrate (not shown) disposed on the substrate supporting surface  515  of the pedestal  505  and the showerhead  510 . A height H of the pump interface member  130  may be chosen based on the vertical stroke of the pedestal  505 . If a pedestal having a shorter or longer stroke length (or no stroke length at all), the height H may be changed in order to enlarge or minimize volumes in the pumping channels  155 . 
       FIG. 6  is a schematic side cross-sectional view of a portion of two pump interface members  130  coupled to one embodiment of a pump interface  600 . The pump interface  600  includes an adapter housing  605  coupled to the pump interface members  130  and a single vacuum pump  525 . The adapter housing  605  includes an interior volume  610  that is in selective fluid communication with the process volumes  110 A and  1106  (shown in  FIG. 1A ) via the pumping channels  155 . The adapter housing  605  includes a first valve  615 A that is operable to control fluid communication between the process volume  110 A and the interior volume  610 . The adapter housing  605  also includes a second valve  615 B that is operable to control fluid communication between the process volume  1106  and the interior volume  610 . Each of the first valve  615 A and second valve  615 B may be selectively open and closed by a dedicated actuator  620 A and  620 B, respectively. Each actuator  620 A,  620 B may be coupled to a controller  625  that independently controls opening and closing of the valves  615 A and  615 B. In one embodiment, when the valves  615 A and  615 B are in an open state, one or both of the process volumes  110 A and  1106  are in fluid communication with the interior volume  610 . In another embodiment, when one of the valves  615 A or  615 B is closed, only the respective process volume ( 110 A or  1106 ) is in fluid communication with the interior volume  610 . In some embodiments, the valves  615 A and  615 B may be partially open to function as a throttle valve with each of the process volumes  110 A and  1106 . 
       FIG. 7  is a schematic side cross-sectional view of a portion of two pump interface members  130  coupled to another embodiment of a pump interface  700 . The pump interface  700  includes an adapter housing  705  coupled to the pump interface members  130  and a single vacuum pump  525 . The adapter housing  705  includes a first interior volume  710 A that is in selective fluid communication with the process volume  110 A (shown in  FIG. 1A ) and a central or third interior volume  710 C. The adapter housing  705  includes a second interior volume  710 B that is in selective fluid communication with the process volume  1106  (shown in  FIG. 1A ) and the third interior volume  710 C. The adapter housing  705  includes a first valve  715 A that is operable to control fluid communication between the process volume  110 A and the third interior volume  710 C. The adapter housing  705  also includes a second valve  715 B that is operable to control fluid communication between the process volume  1106  and the third interior volume  710 C. Each of the first valve  715 A and second valve  715 B may be selectively open and closed by a dedicated actuator  720 A and  720 B, respectively. Each actuator  720 A,  720 B may be coupled to a controller  625  that independently controls opening and closing of the valves  715 A and  715 B. In one embodiment, when the valves  715 A and  715 B are in an open state, one or both of the process volumes  110 A and  1106  are in fluid communication with the third interior volume  710 C. In another embodiment, when one of the valves  715 A or  715 B is closed, only the respective process volume ( 110 A or  1106 ) is in fluid communication with the third interior volume  710 C. In some embodiments, the valves  715 A and  715 B may be partially open to function as a throttle valve with each of the process volumes  110 A and  1106 . 
       FIG. 8  is a schematic side cross-sectional view of a portion of two pump interface members  130  coupled to another embodiment of a pump interface  800 . The pump interface  800  includes two adapter housings  805 A and  805 B having a respective interior volume  810 A,  810 B. Each adapter housing  805 A and  805 B is coupled to a dedicated vacuum pump  525 . The interior volume  810 A is in selective fluid communication with the process volume  110 A (shown in  FIG. 1A ), and the interior volume  810 B is in selective fluid communication with the process volume  1106  (shown in  FIG. 1A ). The adapter housing  805 A includes a first valve  815 A that is operable to be in selective fluid communication with the process volume  110 A via the pumping channels  155 . Likewise, the adapter housing  805 B includes a second valve  815 B that is operable to be in selective fluid communication with the process volume  1106  via the pumping channels  155 . Each of the first valve  815 A and the second valve  815 B are selectively open and closed by a dedicated actuator  820 A and  820 B, respectively. Each actuator  820 A,  820 B may be coupled to a controller  625  that independently controls opening and closing of the valves  815 A and  815 B. 
     Embodiments of the pump interfaces  600 ,  700  and  800  shown and described in  FIGS. 6-8  provide for independent vacuum application to each of the process volumes  110 A and  1106  of the twin chamber housing  100  of  FIG. 1A . The adapter housings  605 ,  705 , and  805 A and  805 B, may be utilized to provide independent flow regimes by actuation of respective valves. Thus, differential or similar pressures may be provided in each of the process volumes  110 A and  1106 . In some embodiments, one process volume (i.e.,  110 A or  1106 ) may be closed so that the other process volume may be used, which provides utilization of one chamber of the twin chamber housing  100 , if desired. 
     Embodiments of the twin chamber housing  100  as described herein include axially-symmetric positioning of process chamber hardware which may improve process flow uniformity/conductance inside the process volumes  110 A and  1106 . The modularity of the twin chamber housing  100  provides easy removal and attachment of pump interface members  130  of varying sizes (i.e., volumes and/or heights). For example, the pump interface members  130  may include a variable volume in the pumping channels  155  based on the manufactured height H ( FIG. 5 ) of the pump interface member  130 . The height H may be based on the stroke length of the pedestal  505 . Further, the pump interface members  130  of the twin chamber housing  100  provides three slots  150  and an atmospheric region  315  to accommodate components of a substrate support, RF/DC feeds, water lines, helium feed lines (for back side cooling), and the like. Mounting the symmetric pump interfaces  600 ,  700  or  800  and vacuum pump(s)  525  to the pump interface members  130  provides symmetric flow and conductance in each of the process volumes  110 A and  1106  of the twin chamber housing  100 . Further, footprint of the tool is substantially unchanged. 
     The twin chamber housing  100  as described herein also minimizes or eliminates gas conduction problems as well as providing good process control and on-wafer uniformity. The fundamental axial symmetry of the twin chamber housing  100  reduces on wafer skews and improves flow conductance inside the chamber. Further, the solution provided by the twin chamber housing  100  is simple, scalable, retrofit-able and process transparent. Manufacturing cost is minimized by simplifying the chamber body into two separate parts (one being the chamber body  105  and the other being the pump interface members  130 ), which reduces one or more of handling issues, finishing issues, tooling issues, and/or footprint issues. The variable chamber volume facilitated by the pump interface members  130  provides improved uniformity and control for the 16 nanometer (nm) node as well as future sustaining/applications expansion (less than 10 nm node). 
     While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.