Patent Publication Number: US-2023134862-A1

Title: Plasma reactor for inductively coupled plasma and method of assembling the same

Description:
TECHNICAL FIELD 
     The present invention relates to a technology for processing exhaust gas discharged from a process chamber of a semiconductor manufacturing facility using plasma, and more particularly, to a plasma reactor for processing exhaust gas discharged from a process chamber of a semiconductor manufacturing facility using inductively coupled plasma and a method of assembling the same. 
     BACKGROUND ART 
     Semiconductor devices are manufactured by repeatedly performing processes such as photolithography, etching, diffusion, and metal deposition on a wafer in a process chamber. During a semiconductor manufacturing process, various process gases are used, and after the process is completed, a residual gas in the process chamber contains various harmful components such as PFCs. The residual gas in the process chamber is discharged through an exhaust line by a vacuum pump after the process is completed, and the exhaust gas is purified by an exhaust gas processing device so that harmful components are not discharged as they are. 
     Recently, a technique of decomposing and processing harmful components using a plasma reaction has been widely used. As a prior art related to the present invention, Korean Patent Laid-open Publication No. 2019-19651 discloses a plasma chamber for processing exhaust gas using inductively coupled plasma. In inductively coupled plasma, when radio frequency power is applied to the antenna coil, a magnetic field is induced by a time-varying current flowing through the antenna coil, thereby generating plasma by an electric field generated inside the chamber. In general, a plasma reactor for inductively coupled plasma includes a chamber providing a space for generating plasma, a ferrite core coupled to surround the chamber, an antenna coil wound around the ferrite core, and an igniter for initial plasma ignition. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Technical Problem 
     The present invention provides an inductively coupled plasma reactor and a method of assembling the same. 
     Technical Solution 
     According to an aspect of the present invention, there is provided a plasma reactor for inductively coupled plasma including a ferrite core assembly including a ferrite core stacked body including a plurality of ferrite cores stacked and a first passage portion and a second passage portion arranged in parallel, and a ferrite core accommodating structure configured to accommodate the ferrite core stacked body, a first chamber body including a first base portion configured to provide a first internal space therein, a first A-extension pipe extending from the first base portion, communicating with the first internal space and accommodated in the first passage portion, and a second A-extension pipe extending from the first base portion, communicating with the first internal space and accommodated in the second passage portion, and a second chamber body including a second base portion configured to provide a second internal space therein, a first B-extension pipe extending from the second base portion, communicating with the second internal space and accommodated in the first passage portion to be connected to the first A-extension pipe, and a second B-extension pipe extending from the second base portion, communicating with the second internal space and accommodated in the second passage portion to be connected to the second A-extension pipe. 
     According to another aspect of the present invention, there is provided a method of assembling a plasma reactor for inductively coupled plasma, the method including preparing a ferrite core assembly including a ferrite core stacked body including a plurality of ferrite cores stacked and a first passage portion and a second passage portion arranged in parallel, and a ferrite core accommodating structure configured to accommodate the ferrite core stacked body, preparing a first chamber body including a first base portion configured to provide a first internal space therein, and a first A-extension pipe and a second A-extension pipe extending from the first base portion and communicating with the first internal space, preparing a second chamber body including a second base portion configured to provide a second internal space therein, and a first B-extension pipe and a second B-extension pipe extending from the second base portion and communicating with the second internal space, pre-assembling, wherein the first A-extension pipe and the first B-extension pipe are inserted to face each other and connected through the first passage portion and the second A-extension pipe and the second B-extension pipe are inserted to face each other and connected through the second passage portion, and coupling the first chamber body and the second chamber body. 
     Effects of the Invention 
     According to the present invention, all the objectives of the present invention described above can be achieved. Specifically, a ferrite core stacked body formed by accommodating a plurality of stacked ferrite cores in a ferrite core accommodating structure is provided, and because a first chamber body and a second chamber body are screwed to each other by a plurality of coupling rods, a plasma reactor for inductively coupled plasma is structurally robust and can be conveniently assembled and manufactured with improved workability. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view illustrating a plasma reactor for inductively coupled plasma according to an embodiment of the present invention. 
         FIG.  2    is an exploded perspective view of the plasma reactor for inductively coupled plasma shown in  FIG.  1   . 
         FIG.  3    is an exploded perspective view of a ferrite core assembly in the plasma reactor for inductively coupled plasma shown in  FIG.  2   . 
         FIG.  4    is a perspective view illustrating a ferrite core in the ferrite core assembly shown in  FIG.  3   . 
         FIG.  5    is a flowchart schematically illustrating a method of assembling the plasma reactor for inductively coupled plasma shown in  FIG.  1   , according to an embodiment of the present invention. 
     
    
    
     MODE OF THE INVENTION 
     Hereinafter, the configuration and operation of an embodiment of the present invention will be described in detail with reference to the drawings. 
     A plasma reactor for inductively coupled plasma according to an embodiment of the present invention is shown in a perspective view in  FIG.  1    and in an exploded perspective view in  FIG.  2   . Referring to  FIGS.  1  and  2   , a plasma reactor  100  for inductively coupled plasma according to an embodiment of the present invention includes a ferrite core assembly  110 , a first chamber unit  150   a  partially passing through the ferrite core assembly  110 , a second chamber unit  150   b  partially passing through the ferrite core assembly  110  and connected to the first chamber unit  150   a,  and a plurality of coupling rod members  190  and  195  connected between the two chamber units  150   a  and  150   b  to couple the two chamber units  150   a  and  150   b.  In the present embodiment, the plasma reactor  100  for inductively coupled plasma is installed in an exhaust pipe that discharges residual gas generated from a process chamber in a semiconductor manufacturing facility to process exhaust gas flowing along the exhaust pipe using inductively coupled plasma. The present invention does not limit the use and installation location of the plasma reactor  100  for inductively coupled plasma as described above. The plasma reactor  100  for inductively coupled plasma is operated by receiving appropriate power from a power source (not shown). 
       FIG.  3    shows the ferrite core assembly  110  in an exploded perspective view. Referring to  FIGS.  1 ,  2  and  3   , the ferrite core assembly  110  includes a ferrite core stacked body  140  and a ferrite core accommodating structure  120   a  accommodating the ferrite core stacked body  140 . 
     The ferrite core stacked body  140  is formed by sequentially stacking a plurality of ferrite cores  145  having the same shape and includes a first passage portion  142   a  and a second passage portion  142   b,  which are arranged in parallel on the ferrite core stacked body  140  and extend in parallel along a vertical direction in the drawing. The first passage portion  142   a  and the second passage portion  142   b  penetrate through the ferrite core stacked body  140  so that both ends of the upper and lower portions thereof are opened, and the side surfaces thereof are blocked. The ferrite core stacked body  140  is accommodated in the ferrite core accommodating structure  120   a.    
     In  FIG.  4   , the ferrite core  145  is shown in a perspective view. Referring to  FIGS.  3  and  4   , a plurality of ferrite cores  145  are stacked to form a ferrite core stacked body  140 . In the present embodiment, the ferrite core  145  will be described as being a ferrite core commonly used in an inductively coupled plasma device. The ferrite core  145  includes an annular portion  146  and a connection portion  148  crossing the inner region of the annular portion  146 . 
     The annular portion  146  has a rectangular annular shape, and includes opposing first and second long side portions  146   a  and  146   b  and opposing first and second short side portions  147   a  and  147   b.  Each of the first short side portion  147   a  and the second short side portion  147   b  connects opposite ends of the first long side portion  146   a  and the second long side portion  146   b  in a lengthwise direction so that the first long side portion  146   a,  the first short side portion  147   a,  the second long side portion  146   b  and the second short side portion  147   b  are continuously connected along the circumferential direction of the annular portion  146 . 
     The connection portion  148  extends in a straight line to connect the two opposite long side portions  146   a  and  146   b  of the annular portion  146 . Both ends of the connection portion  148  are connected to the longitudinal center portion of each of the two long side portions  146   a  and  146   b.  The inner region of the annular portion  146  is separated into a first through hole  149   a  and a second through hole  149   b  having a square shape by the connection portion  148 , respectively. In the ferrite core stacked body  140  formed by stacking a plurality of ferrite cores  145 , the first through holes  149   a  of each of the plurality of ferrite cores  145  are connected to the first ferrite core stacked body  140  to form a first passage portion  142   a  of the ferrite core stacked body  140 , and second through holes  149   b  of each of the plurality of ferrite cores  145  are connected to form a second passage portion  142   b  of the ferrite core stacked body  140 . 
     The ferrite core accommodating structure  120   a  provides an accommodation space  121  for accommodating the ferrite core stacked body  140  therein. The material of the ferrite core accommodating structure  120   a  is made of an electrical insulator. The ferrite core accommodating structure  120   a  includes a sidewall member  120  having both ends open, and a first finishing member  130   a  and a second finishing member  130   b  coupled to both open ends of the sidewall member  120 , respectively. The accommodation space  121  provided by the ferrite core accommodating structure  120   a  is formed in a shape and size corresponding to the outer shape of the ferrite core stacked body  140  to be accommodated, so that, when the ferrite core stacked body  140  is accommodated in the accommodation space  121  of the ferrite core accommodating structure  120   a,  the ferrite core stacked body  140  does not shake within the accommodation space  121  and maintains its shape steadily. 
     The side wall member  120  is an overall rectangular wall structure, and the upper and lower ends, which are both ends, are open in the drawing. The sidewall member  120  forms an accommodation space  121  therein, and surrounds side surfaces of the ferrite core stacked body  140  in a state in which the ferrite core stacked body  140  is accommodated in the accommodation space  121 . The side wall member  120  has a plurality of windows  122  through which the accommodation space  121  and the outside communicate with each other, and a region corresponding to the side of the ferrite core stacked body  140  accommodated in the accommodation space  121  through the plurality of windows  122  is exposed to the outside. The first finishing member  130   a  is coupled to the open upper end of the sidewall member  120 , and the second finishing member  130   b  is coupled to the open lower end of the sidewall member  120 . 
     The first finishing member  130   a  is coupled to the open upper end of the side wall member  120  through a fastening unit such as screwing. The first finishing member  130   a  has substantially the same shape as the ferrite core  145 , and the first finishing member  130   a  has a first A-opening  131   a  communicating with the first passage portion  142   a  of the ferrite core stacked body  140  and a second A-opening  132   a  communicating with the second passage portion  132   a  of the ferrite core stacked body  140 . A plurality of screw holes  133   a  for screwing with the side wall member  120  are formed in the first finishing member  130   a.  In addition, a plurality of screw holes  135   a  for screwing with the coupling rods  190  are formed on the side of the first finishing member  130   a.  The first finishing member  130   a  is in close contact with the uppermost ferrite core  145  of the ferrite core stacked body  140  in a state in which the ferrite core stacked body  140  is accommodated in the accommodation space  121 . 
     The second finishing member  130   b  is coupled to the open lower end of the sidewall member  120  through a fastening unit such as screwing. The second finishing member  130   b  has substantially the same shape as the ferrite core  145 , and the second finishing member  130   b  has a first B-opening portion  131   b  communicating with the first passage portion  142   a  of the ferrite core stacked body  140  and a second B-opening portion  132   b  communicating with the second passage portion  132   a  of the ferrite core stacked body  140 . A plurality of screw holes  133   b  for screwing with the side wall member  120  are formed in the second finishing member  130   b.  In addition, a plurality of screw holes  135   b  for screwing with the coupling rods  190  are formed on the side of the second finishing member  133   b.  The second finishing member  130   b  is in close contact with the lowermost ferrite core  145  of the ferrite core stacked body  140  in a state in which the ferrite core stacked body  140  is accommodated in the accommodation space  121 . 
     A plurality of ferrite cores  145  are accommodated in the accommodation space  121  through the open upper end of the side wall member  120  and stacked after the second finishing member  130   b  is coupled to the side wall member  120 , and the first finishing member  130   a  is coupled to the open upper end of the sidewall member  120  so that the ferrite core assembly  110  may be completed. 
     Referring to  FIGS.  1  and  2   , a first chamber unit  150   a  includes a first chamber body  160   a  and a plurality of first igniters (not shown) installed in the first chamber body  160   a.  The first chamber unit  150   a  is structurally coupled to the second chamber unit  150   b  by a plurality of coupling rods  190  and  195 . 
     The first chamber body  160   a  includes a first base portion  161   a,  and a first A-extension pipe  165   a  and a second A-extension pipe  167   a  extending from the first base portion  161   a.    
     The first base portion  161   a  provides a first internal space  162   a  therein, and a gas inlet  164   a  which communicates with the first internal space  162   a  and through which gas to be processed is introduced, is formed in the first base portion  161   a.  The first internal space  162   a  communicates with the first A-extension pipe  165   a  and the second A-extension pipe  167   a.  The first base portion  161   a  is in close contact with the first finishing member  130   a  of the ferrite core assembly  110 . Each of a plurality of first igniters (not shown) is inserted and installed in the first base portion  161   a.  A plurality of first screw coupling holes  166   a  through which the plurality of coupling rods  190  are screwed to each other, are formed on side surfaces of the first base portion  161   a.  In addition, a plurality of first screw through holes  163   a  through which the plurality of coupling rods  195  are screwed to each other, are formed on the first base portion  161   a.    
     The first A-extension pipe  165   a  and the second A-extension pipe  167   a  are formed to extend parallel to each other from the first base portion  161   a.  The first A-extension pipe  165   a  and the second A-extension pipe  167   a  communicate with the first internal space  162   a  of the first base portion  161   a,  and the end of the first A-extension pipe  165   a  and the end of the second A-extension pipe  167   a  are open. The first A-extension pipe  165   a  is accommodated in the first passage portion  142   a  of the ferrite core assembly  110 , and the second A-extension pipe  167   a  is accommodated in the second passage portion  142   b  of the ferrite core assembly  110 . The open end of the first A-extension pipe  165   a  and the open end of the second A-extension pipe  167   a  are connected to the second chamber unit  150   b.  The first chamber body  160   a  and the second chamber body  160   b  are connected to form a toroidal-shaped chamber. 
     Each of the plurality of first igniters (not shown) is installed at an appropriate position of the first base portion  161   a  of the first chamber body  160   a.    
     The second chamber unit  150   b  includes a second chamber body  160   b  and a plurality of second igniters (not shown) installed in the second chamber body  160   b.  The second chamber unit  150   b  is structurally coupled to the first chamber unit  150   a  by a plurality of coupling rods  190  and  195 . 
     The second chamber body  160   b  has substantially the same structure as the first chamber body  160   a,  and includes a second base portion  161   b,  a first B-extension pipe  165   b  and a second B-extension pipe  167   b  extending from the second base portion  161   b.    
     The second base portion  161   b  provides a second internal space (not shown) therein, and a gas outlet (not shown) which communicates with the second internal space (not shown) and through which the processed gas is discharged to the outside, is formed in the second base portion  161   b.  The second internal space (not shown) communicates with the second A-extension pipe  165   b  and the second B-extension pipe  167   b.  The second base portion  161   b  is in close contact with the second finishing member  130   b  of the ferrite core assembly  110 . Each of a plurality of second igniters (not shown) is inserted and installed in the second base portion  161   b.  A plurality of second screw coupling holes  166   b  through which the plurality of coupling rods  190  are screwed to each other, are formed on side surfaces of the second base portion  161   b.  In addition, a plurality of second screw through holes  163   b  through which the plurality of coupling rods  195  are screwed to each other, are formed on the second bae portion  161   b.    
     The first B-extension pipe  165   b  and the second B-extension pipe  167   b  are formed to extend parallel to each other from the second base portion  161   b.  The first B-extension pipe  165   b  and the second B-extension pipe  167   b  communicate with the second internal space (not shown) of the first base portion  161   b,  and the end of the first B-extension pipe  165   b  and the end of the second B-extension pipe  167   b  are open. The first B-extension pipe  165   b  is accommodated in the first passage portion  142   a  of the ferrite core assembly  110 , and the second B-extension pipe  167   b  is accommodated in the second passage portion  142   b  of the ferrite core assembly  110 . The first B-extension pipe  165   b  is connected to and communicates with the first A-extension pipe  165   a,  and the second B-extension pipe  167   b  is connected to and communicates with the second A-extension pipe  167   a,  and although not shown, a DC breaker (not shown) is positioned between the end of the first A-extension pipe  165   a  and the end of the first B-extension pipe  165   b  and between the end of the second A-extension pipe  167   a  and the end of the second B-extension pipe  167   b.    
     Each of the plurality of second igniters (not shown) is installed at an appropriate position of the second base portion  161   b  of the second chamber body  160   b.    
     The plurality of coupling rod members  190  and  195  are connected between the first chamber unit  150   a  and the second chamber unit  150   b  to couple the two chamber units  150   a  and  150   b.    
     The plurality of coupling rod members  190  and  195  include a plurality of first coupling rod members  190  and a plurality of second coupling rod members  195 . 
     The plurality of first coupling rod members  190  have a generally rectangular rod shape, and one side of both ends thereof is screwed to a side surface of the first base portion  161   a  of the first chamber body  160   a,  a side surface of the first finishing member  130   a  of the ferrite core assembly  140 , a side surface of the second base portion  161   b  of the second chamber body  160   b,  and a side surface of the second finishing member  130   b  of the ferrite core assembly  140 . To this end, a plurality of screw through holes  192  are formed on the side surfaces of the first coupling rod member  190 . That is, the first coupling rod member  190  includes a first screw coupling hole  166   a  formed on the first base portion  161   a,  a second screw coupling hole  166   b  formed on the second base portion  161   b,  a first screw hole  135   a  formed in the first finishing member  130   a,  and a second screw hole  135   b  formed in the second finishing member  130   b.  To this end, female screws are formed in the first and second screw coupling holes  166   a  and  166   b  and the first and second screw holes  135   a  and  135   b.    
     The plurality of second coupling rod members  190  have a generally circular rod shape, and are screwed to each other while being inserted between the first base portion  161   a  and the second base portion  161   b.  Female screw holes  196  are formed at both ends of the second coupling rod members  190 . Male screws to be inserted into the first screw hole  163   a  formed in the first base portion  161   a  and the second screw hole  163   b  formed in the second base portion  161   b  are coupled to the female screw holes  196  of the second coupling rod members  190 . 
       FIG.  5    is a flowchart illustrating a method of assembling the plasma reactor for inductively coupled plasma shown in  FIG.  1   , according to an embodiment. Referring to  FIG.  5   , the method of assembling the plasma reactor for inductively coupled plasma according to an embodiment of the present invention includes preparing a ferrite core assembly (S 11 ), preparing a first chamber (S 15 ), preparing a second chamber (S 18 ), pre-assembling (S 20 ), coupling (S 30 ), and assembling igniters (S 40 ). The method of assembling the plasma reactor for inductively coupled plasma shown in  FIG.  5    is a method of assembling the plasma reactor for inductively coupled plasma shown in  FIG.  1   , and thus will be described with reference to  FIGS.  1  to  4   . 
     In the preparing of the ferrite core assembly (S 11 ), the ferrite core assembly  110  having the configuration shown in  FIG.  2    is prepared. Referring to  FIG.  3   , the ferrite core assembly  110  having the configuration shown in  FIG.  2    may be completed when a plurality of ferrite cores  145  are accommodated in the accommodation space  121  through the open upper end of the sidewall member  120  and stacked after the second finishing member  130  is coupled to the sidewall member  120  and the first finishing member  130   a  is coupled to the open upper end of the sidewall member  120 . 
     In the preparing of the first chamber (S 15 ), the first chamber body  160   a  having the configuration shown in  FIG.  2    is prepared. 
     In the preparing of the second chamber (S 18 ), the second chamber body  160   b  having the configuration shown in  FIG.  2    is prepared. 
     In the pre-assembling (S 20 ), the ferrite core assembly  110  prepared through the preparing of the ferrite core assembly (S 11 ), the first chamber body  160   a  prepared through the preparing of the first chamber (S 15 ), and the second chamber body  160   b  prepared through the preparing of the second chamber (S 18 ) are pre-assembled. Specifically, in the pre-assembling (S 20 ), the first-A extension pipe  165   a  of the first chamber body  160   a  and the first B-extension pipe  165   a  of the second chamber body  160   b  are inserted to face each other and connected through the first passage portion  142   a  of the ferrite core assembly  110 , and the second A-extension pipe  167   a  of the first chamber body  160   a  and the second B-extension pipe  167   b  of the second chamber body  160   b  are inserted to face each other and connected through the second passage portion  142   b  of the ferrite core assembly  110 . 
     In the coupling (S 30 ), the ferrite core assembly  1100 , the first chamber body  160   a,  and the second chamber body  160   b  pre-assembled through the pre-assembling (S 20 ) are screwed to each other using a plurality of combining rods  190  and  195 . 
     In the assembling of igniters (S 40 ), a plurality of first igniters (not shown) are installed on the first chamber body  160   a,  and a plurality of second igniters (not shown) are installed on the second chamber body  160   b.    
     While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.