Patent Abstract:
A method for non-destructively evaluating the concentration of impurities in an epitaxial susceptor used in the processing of a semiconductor substrate. The method includes processing a semiconductor substrate of known impurity levels on the epitaxial susceptor, and measuring the impurity levels after epitaxial processing by drawing together at least a portion of the impurities and measuring the concentration of impurities that were drawn together. In one embodiment of the invention, a gettering layer is formed adjacent one or more surfaces of the substrate to getter impurities from the substrate into the gettering layer. The impurity concentration of the gettering layer is then measured and the results are used to determine at least a range of impurity concentrations that were transferred to the substrate from the epitaxial susceptor.

Full Description:
REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation-in-part of U.S. application Ser. No. 09/544,197 filed Apr. 6, 2000, the contents of which are hereby incorporated by reference in their entirety. 
    
    
     TECHNICAL FIELD 
     The present invention relates to semiconductor processing, and more particularly to measuring impurity concentrations in susceptors used to secure wafers in epitaxial reactors. 
     BACKGROUND OF THE INVENTION 
     Manufacturers of semiconductor integrated circuits are constantly striving to increase the performance and reduce the price of their products. One way to both increase the performance and reduce the price of an integrated circuit is to reduce the size of the integrated circuit. By reducing the size of a circuit, more circuits can be manufactured on a single semiconductor substrate, thereby reducing the unit cost of the circuit. In addition, reducing the size of a circuit typically increases its speed and reduces its power consumption. 
     One problem manufacturers encounter in attempting to reduce the size of their integrated circuits involves impurity contamination. For example, metallic contamination of a semiconductor substrate can cause excess leakage currents, poor voltage breakdown characteristics, and reduced minority carrier lifetimes. As the size of an integrated circuit decreases, the detrimental effect of impurities in the semiconductor is magnified. For extremely small circuits, even relatively low levels of contamination can be sufficient to render the circuit inoperative. Therefore, manufacturers take extraordinary measures to prevent impurity contamination in their manufacturing processes. 
     To optimize their contamination control practices, manufacturers often need to measure the concentration of impurities in their semiconductor substrates at various points during the manufacturing process. This allows manufacturers to determine which area(s) of their process are causing impurity contamination problems. However, as the levels of impurity concentration have decreased to very low levels, it has become more and more difficult to measure the impurity concentration. Indeed, semiconductor industry standards such as the National Semiconductor Roadmap call for impurity concentrations to be as low as 10 10  cm −3  in the near future. Since the atomic density of a typical semiconductor substrate such as silicon is approximately 10 22  cm −3 , impurity concentrations of 10 10  cm −3  can be very difficult to measure even with sophisticated measurement equipment. 
     For example, copper (Cu) and nickel (Ni) are two metallic impurities found in semiconductor substrates. Impurity concentrations of copper and nickel in heavily boron-doped substrates typically are measured by techniques such as Total Reflection X-Ray Fluorescence (TXRF) and Secondary Ion Mass Spectroscopy (SIMS), etc. The minimum detection limit of copper is approximately 10 17  cm −3  by TXRF (measured near the surface of the substrate) and approximately 10 15  cm −3  by SIMS. As a result, manufacturers have begun to search for new ways to measure impurity concentrations in semiconductor substrates. 
     As acceptable levels of metallic impurities are continually being reduced and new methods for measuring impurity concentrations are developed, manufacturers must understand and control the impurity concentrations of equipment used to manufacture semiconductor substrates, and in particular equipment that comes in physical contact with the semiconductor substrate. 
     One such apparatus of concern is the susceptor used in epitaxial deposition. During epitaxial deposition, the entire backside of the semiconductor substrate is in contact with the susceptor. Since the epitaxial deposition step is performed at relatively high temperatures of approximately 1000° C. or higher, any contaminants contained within the susceptor can migrate into the semiconductor wafer, which is very undesirable. It is therefore very important to use equipment that physically contacts the substrate wafer, such as a susceptor, that also has low concentrations of impurities. Unfortunately, reliable methods to determine the concentration of metallic impurities in this type of equipment are destructive. These destructive methods are undesirable because they prevent the ability to ensure that a part is fit for use because the susceptor must be destroyed to obtain the needed results. 
     The current method to protect from contamination migration is to put a protective layer, such as an oxide layer, on the back of the semiconductor substrate. This, however, is a very expensive process step, and does not add any value to the substrate other than protection. This oxide layer could be eliminated without risk of contamination if a method of determining the impurity concentration level of a susceptor could be achieved. As such, there is a need to be able to non-destructively determine the contamination levels of a susceptor. 
     SUMMARY OF THE INVENTION 
     The invention provides a method for evaluating the concentration of impurities in an epitaxial susceptor by measuring the concentrations of impurities of a semiconductor wafer that contacts the susceptor. The method includes running an epitaxial cycle with a monitor wafer having contamination levels below detection limits placed on the susceptor and running an epitaxial deposition cycle. At least a portion of the contaminants which have migrated from the susceptor to the monitor wafer are drawn together and measured. In one embodiment of the invention, a gettering layer is formed on the surface of the wafer that was in contact with the susceptor to getter impurities that have migrated from the susceptor. The impurity concentration of the gettering layer is then measured and the resulted are used to determine at least a range of impurity concentrations that were in the susceptor prior to the epitaxial deposition cycle. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be described in relation to the following drawings in which like reference numerals refer to like elements, and wherein: 
     FIG. 1 is a cross-sectional view of an epitaxial reactor including a susceptor; 
     FIG. 2 is a schematic flowchart diagram showing cross-sectional views of a semiconductor substrate that has been processed on an epitaxial reactor, the diagram illustrates a method according to the present invention for drawing together impurities transferred from the susceptor into the semiconductor substrate to a gettering layer formed on the substrate; 
     FIG. 3 is a flowchart illustrating a method of evaluating the concentration of impurities in a susceptor according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to FIG. 1, an epitaxial reactor is shown generally at  10 , including a susceptor assembly shown at  12 . The reactor  10  includes a reaction chamber  14  flanked on an upper side by an upper heat lamp array  16  and on a lower side by a lower heat lamp array  18 . Susceptor assembly  12  is positioned within reaction chamber  10 , and is configured to support semiconductor wafer  20  within reaction chamber  14 . 
     As shown in FIG. 1, susceptor assembly  12  includes several components, each of which are heated by the upper and lower heat lamp arrays  16  and  18  as the reaction chamber  14  is heated to a process temperature. Susceptor assembly  12  includes a susceptor  22 , typically of graphite construction, which acts to absorb heat energy from lamps  16  and  18 , and to evenly distribute the heat energy to wafer  20  during epitaxial deposition. Susceptor  22  typically includes a depression  36  on its top surface. During epitaxial growth, wafer  20  rests upon the susceptor  22 , contacting it only at the peripheral edge  38 . As shown in FIG. 1, susceptor  22  rests directly upon posts  32  of tripod  30 . Tripod  30  rests upon shaft  34 , which is configured to rotate under the influence of a motor (not shown). 
     In standard epitaxial operation, the reaction chamber is heated to a process temperature and a source gas containing semiconductor constituents is flowed from inlet  40  to outlet  42 , across a front side  46  of wafer  20  on its way through the reaction chamber. Typically, the semiconductor constituents are adsorbed onto the wafer surface at high temperature and diffuse across the surface to form the epitaxial layer. In the present invention, however, the purpose is not necessarily to form an epitaxial layer, but rather to simulate the formation steps such that impurities found within the susceptor  22  can migrate into the wafer  20 . As such, the front side  46  of wafer  20  contains a protective layer (not shown), such as an oxide layer, to protect the wafer from any impurities that may be found in the source gas. In addition, susceptor  22  inhibits epitaxial growth on the backside  44  of the wafer  20  by mechanically inhibiting gas flow to the backside of the wafer. The backside  44  of the wafer  20  is in full contact with the susceptor  22 . Therefore, any impurities within the susceptor  22  can migrate to the backside  44  of the wafer during the thermal cycle of epitaxial deposition. 
     In reactors such as  10 , the susceptor  22  is used to distribute heat to the wafer evenly. Epitaxial layer growth is most uniform when an even temperature is maintained across the entire wafer. Heat loss from the peripheral edge of the wafer is reduced and controlled by a saturn ring  23  disposed circumferentially around the outer edge of the susceptor  22 . The saturn ring  23  is comprised of a lower L-shaped ring  26  and an upper L-shaped ring  24  inversely laid on the lower L-shaped ring  26  such that a void  25  is created, wherein thermocouples (not shown) can be distributed to desired locations to monitor and control temperatures. The saturn ring  23  is supported by saturn ring posts  27 . 
     Preferably, the present invention is performed using a wafer containing as little metallic impurities as possible, and more preferably below the detection limit of metals. If the wafer used is above the detection limit for metallic impurities, its level of metallic impurities must be known before epitaxial simulation, and will be used to compare before simulation and after simulation impurity levels. 
     As shown in FIG. 2 a , after epitaxial simulation, the wafer  20  contains a protective layer  47  on the wafer front side  46 . The wafer  20  now contains metallic impurities  50  that have migrated from the susceptor (not shown) to the wafer  20 , and diffused into the body of wafer  20 . In FIG. 2 b , the wafer  20  is then subjected to the formation of a gettering layer  60  on the wafer backside  44  and optionally on the protective layer  47 , forming layer  62 . In the case where layer  62  is formed, it should be noted, however, that it performs no gettering interaction with the wafer  20 , or impurities  50  found therein. A typical manner for forming such a gettering layer is by low pressure chemical vapor deposition (LPCVD) of polycrystalline silicon. 
     To ensure the diffusion of impurities  50  within the wafer  20  into the gettering layer  60 , the wafer  20  may then be heated or annealed, as shown in FIG. 2 c . For example, the wafer  20  may be annealed in the range of 600° C. to 900° C. for one hour, followed by a slow cool down to approximately 400° to 500° C. The slow cool down allows sufficient time for the impurities  50  to diffuse to the gettering layer  60 . Upon completion of the annealing process, the impurities  50  have migrated from the wafer  20  into the gettering layer  60 . 
     The gettering layer  60  can then be analyzed by techniques such as Total Reflection X-Ray Flourescense (TXRF) and/or Secondary Ion Mass Spectroscopy (SIMS) using the techniques outlined in co-pending application Ser. No. 09/544,197. 
     As noted earlier, the process of the present invention can be used either by stripping the protective layer  47  from the wafer front side surface  46  before forming the gettering layers  60  and  62 , or by forming gettering layer  62  directly on the protective layer  47 . It is preferable to leave the protective layer  47  on the front side surface  46 , however. If the protective layer  47  remains on the front side surface  46 , all impurities  50  will migrate to the back side gettering layer  60 , whereas if the protective layer  47  is removed, impurities  50  can migrate to both gettering layers  60  and  62 . Theoretically, there will be equal amounts of impurities  50  gettered into each gettering layer  60  and  62 . In this case, the amount of impurities  50  detected by the analyzing techniques will be half the amount of the impurities  50  in the wafer  20 . When the impurity level is very low, the detection limit becomes an important factor, and a measurement result may be below the detection limit when both gettering layers  60  and  62  are used. On the other hand, an accurate measurement may be attainable if only gettering layer  60  is used. In this instance, all gettering will take place in layer  60 , thus providing the most concentrated level of impurities  50  and therefore the best opportunity for reaching the detection limit. After measuring the concentration of the localized impurities N L  found in the gettering layer using TXRF methods or the like, the concentration of bulk impurities N B  originally found in the substrate wafer can be found from:          N   B     =         N   L     *     T   layer         T   substrate                              
     Wherein T substrate  is the thickness of the substrate wafer and T laer  is the thickness of the gettering layer, considering substantially all impurities are drawn into the gettering layer. Pre-process bulk impurity levels can then be compared to bulk impurities measured after processing the wafer on the epitaxial susceptor, and appropriate actions taken from the information gathered. 
     An exemplary method for evaluating the impurity concentrations in an epitaxial susceptor is indicated generally in FIG.  3 . The method includes, at  210 , determining the “pre-process” bulk concentration of impurities in one or more semiconductor substrates. This may be performed by any suitable process, including the method described in co-pending application Ser. No. 09/544,197, TXRF, or SIMS, etc. Alternatively, this step may be omitted and the pre-process bulk impurity concentration may be presumed to be at a particular concentration. The one or more substrates are then processed through the semiconductor process, including a protective layer such as an oxide layer on one wafer surface and leaving bare silicon substrate on the other surface, as indicated at  220 . 
     A substrate wafer is then placed on the epitaxial susceptor using standard handling procedures and methods associated with the type of epitaxial reactor being monitored. The substrate wafer is placed on the susceptor such that the bare silicon substrate surface is facing toward, and in contact with the susceptor, and the surface containing the protective layer is facing away from the susceptor, as shown at  230 . The substrate wafer is then processed through an epitaxial deposition cycle representative of the thermal cycle used during standard deposition for that particular epitaxial reactor and process used during normal operating procedures, as shown in  240 . It is preferred that gas flows used in epitaxial deposition are incorportated into step  240 , to more closely simulate standard processing, but gas flows and constituents may be changed if so desired. Multiple substrate wafers can be singularly processed sequentially through steps  230  and  240  if desired, to obtain a statistically valid sampling in accordance with known statistical process control techniques. 
     The substrate wafer(s) can optionally have the protective layer stripped, as demonstrated in  250 . More preferably, however, the protective layer would not be stripped from the substrate wafer, thereby prohibiting impurities from migrating through the protective layer, and thereby increasing the sensitivity to impurity concentration measurements, as previously explained. 
     As indicated in  260 , a gettering layer is then formed on the substrate wafer using any standard technique, such as deposition of a polycrystalline silicon layer by LPCVD. If the protective layer is stripped as indicated in  250 , the gettering layer must be formed on both sides of the substrate wafer. Alternatively, if the protective layer is not stripped, the gettering layer must only be formed on the bare substrate silicon layer, and may be optionally formed on the protective layer, as dictated by cost and ease of manufacture. It should be noted that no inherent benefit will be gained by forming a gettering layer on the protective layer. The substrate wafer(s) is then annealed to promote gettering of the impurities into the gettering layer, as indicated in  270 . The impurity concentration in the gettering layer is then measured by suitable means, as indicated at  280 . Based on the impurity concentration in the gettering layer, the “post-process” bulk impurity concentration may be calculated using the equation presented above, as indicated in  290 . Finally, the concentration of impurities caused by the epitaxial susceptor is calculated based on the pre-process and post-process impurity concentrations, as indicated in  300 . Where substantially all of the impurities were gettered into the gettering layer, the concentration of impurities caused by the epitaxial susceptor may be calculated by subtracting the post-process impurity concentration from the pre-process impurity concentration. Appropriate decisions about the continued use of the susceptor may then be made. 
     Other embodiments of the present invention will be apparent to those skilled in the art from a consideration of this specification or practice of the invention disclosed herein. It is intended that the specification be considered in all aspects as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the forgoing description. All changes which come within the meaning and range of the equivalence of the claims are to be embraced within their scope.

Technology Classification (CPC): 8