Source: http://www.google.com/patents/US8175736?dq=7,453,150
Timestamp: 2015-04-19 01:48:48
Document Index: 558456086

Matched Legal Cases: ['Application No. 200480038051', 'Application No. 200480038051', 'Application No. 200480038051', 'Application No. 2006', 'Application No. 10', 'Application No. 10', 'Application No. 10']

Patent US8175736 - Method and system for performing a chemical oxide removal process - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsA processing system and method for chemical oxide removal (COR) is presented, wherein the processing system comprises a first treatment chamber and a second treatment chamber, wherein the first and second treatment chambers are coupled to one another. The first treatment chamber comprises a chemical...http://www.google.com/patents/US8175736?utm_source=gb-gplus-sharePatent US8175736 - Method and system for performing a chemical oxide removal processAdvanced Patent SearchPublication numberUS8175736 B2Publication typeGrantApplication numberUS 12/964,531Publication dateMay 8, 2012Filing dateDec 9, 2010Priority dateMar 17, 2003Also published asCN1961405A, CN1961405B, US7877161, US20040185583, US20110307089, WO2005062344A1Publication number12964531, 964531, US 8175736 B2, US 8175736B2, US-B2-8175736, US8175736 B2, US8175736B2InventorsMasayuki Tomoyasu, Merritt Funk, Kevin A. Pinto, Masaya Odagiri, Lemuel Chen, Asao Yamashita, Akira Iwami, Hiroyuki TakahashiOriginal AssigneeTokyo Electron LimitedExport CitationBiBTeX, EndNote, RefManPatent Citations (31), Non-Patent Citations (12), Classifications (42) External Links: USPTO, USPTO Assignment, EspacenetMethod and system for performing a chemical oxide removal process
US 8175736 B2Abstract
receiving pre-process metrology data for the substrate, wherein the pre-process metrology data defines an input state for the substrate and comprises CD data for at least one feature;
comparing the input state with the desired state, wherein the CD data is compared to the target CD data,
correlating a difference between the CD data and the target CD data with a trim amount,
processing the substrate to achieve the trim amount using the process recipe, the COR process including chemically treating the substrate by chemically altering exposed surface layers of a layer on the substrate and the PHT process including thermally treating the substrate to evaporate the chemically altered exposed surface layers of the layer on the substrate.
2. The method of processing a substrate as claimed in claim 1, wherein the CD data for at least one feature comprises isolated CD data for at least one isolated feature and nested CD data for at least one nested feature.
3. The method of processing a substrate as claimed in claim 2, wherein correlating a difference between the CD data and the target CD data with a trim amount comprises correlating a first difference between the isolated CD data and the target CD data and a second difference between the nested CD data and the target CD data with a trim amount.
4. The method of processing a substrate as claimed in claim 2, further comprising: performing a first trimming process based on the difference between the isolated CD data and the first target CD data; and performing a second trimming process based on the difference between the nested CD data and second target CD data.
5. The method of processing a substrate as claimed in claim 2, further comprising:
determining a second delta based on the difference between said nested CD data for the at least one nested feature and the target CD data; and
6. The method of processing a substrate as claimed in claim 1, wherein the layer on the substrate comprises a hard mask layer.
7. The method of processing a substrate as claimed in claim 1, the method further comprising:
8. The method of processing a substrate as claimed in claim 7, wherein the post-process metrology data comprises Optical Digital Profiling (ODP) data.
9. The method of processing a substrate as claimed in claim 8, wherein the post-process metrology data comprises Scanning Electron Microscope (SEM) data.
10. The method of processing a substrate as claimed in claim 9, further comprising: transferring the substrate from the COR module to the PHT module.
11. The method of processing a substrate as claimed in claim 1, wherein the pre-process metrology data comprises Optical Digital Profiling (ODP) data.
12. The method of processing a substrate as claimed in claim 1, wherein the pre-process metrology data comprises at least one to-be-controlled CD and the process recipe is determined by comparing the at least one to-be-controlled CD to a target CD.
13. The method of processing a substrate as claimed in claim 12, wherein the at least one to-be-controlled CD is larger than the target CD.
14. The method of processing a substrate as claimed in claim 13, wherein said process recipe comprises:
executing a chemical oxide removal (COR) process recipe for a COR module, wherein exposed surface layers of the layer on the substrate are chemically treated using a process gas to form a solid reaction product on at least one exposed surface layer of the layer on the substrate; and
executing a post heat treatment (PHT) process recipe for a PHT module, wherein the solid reaction product is evaporated, thereby trimming the chemically treated exposed surface layers of the layer on the substrate.
15. The method uf processing a substrate as claimed in claim 14, further comprising: repeating the COR process recipe executing and the PUT process recipe executing until the at least one to-be-controllcd CD is approximately equal to the target CD.
16. The method of processing a substrate as claimed in 15, further comprising:
17. The method of processing a substrate as claimed in claim 14, wherein the executing a COR process recipe comprises:
18. The method of processing a substrate as claimed in claim 17, wherein the process gas comprises a fluorine-containing gas and a nitrogen-containing gas.
19. The method of processing a substrate as claimed in claim 18, wherein the process gas comprises HF and NH3.
20. The method of processing a substrate as claimed in claim 17, wherein the temperature of the temperature controlled substrate holder in the chemical treatment chamber ranges from approximately 10� C. to approximately 50� C.
21. The method of processing a substrate as claimed in claim 17, wherein the temperature of the substrate mounted on the temperature controlled substrate holder in the chemical treatment chamber ranges from approximately 10� C. to approximately 50� C.
22. The method of processing a substrate as claimed in claim 17, wherein the chemical treatment chamber pressure ranges from approximately 1 mTorr to approximately 100 mTorr.
23. The method of processing a substrate as claimed in claim 17, further comprising controlling the temperature of the process gas in the gas distribution system within a range from approximately 30� C. to approximately 100� C.
24. The method of processing a substrate as claimed in claim 17, further comprising controlling the temperature of a chemical treatment chamber wall within a range from approximately 30� C. to approximately 100� C.
25. The method of processing a substrate as claimed in claim 14, wherein the executing a PHT process recipe comprises:
26. The method of processing a substrate as claimed in claim 25, wherein the temperature of the temperature controlled substrate holder in the thermal treatment chamber ranges from approximately 10� C. to approximately 50� C.
27. The method of processing a substrate as claimed in claim 25, wherein the temperature of the substrate mounted on the temperature controlled substrate holder in the thermal treatment chamber ranges from approximately 10� C. to approximately 50� C.
28. The method of processing a substrate as claimed in claim 25, wherein the thermal treatment chamber pressure ranges from approximately 1 mTorr to approximately 100 mTorr.
29. The method of processing a substrate as claimed in claim 25, wherein the temperature of the thermal treatment chamber ranges from approximately 10� C. to approximately 50� C.
30. The method of processing a substrate as claimed in claim 25, further comprising: positioning the substrate at a first distance from the temperature controlled upper assembly during a first time; and positioning the substrate at a second distance from the temperature controlled upper assembly during a second time.
31. The method of processing a substrate as claimed in claim 25, further comprising controlling the temperature of a thermal treatment chamber wall within a range from approximately 30� C. to approximately 100� C.
32. The method of processing a substrate as claimed in claim 14, wherein the process gas comprises a first gas and a second gas that are independently introduced to a processing space.
33. The method of processing a substrate as claimed in claim 13, wherein said process recipe includes:
34. The method of processing a substrate as claimed in claim 33, further comprising: examining a number of pre-qualified control recipes, wherein each control recipe has at least one pre-determined trim value; and selecting the pre-qualified control recipe having a pre-determined trim value approximately equal to the difference between post-process CD data and target CD data.
35. The method of processing a substrate as claimed in claim 1, further comprising: creating a lookup table containing a number of pre-qualified control recipes; and performing a table lookup to determine the process recipe.
36. The method of processing a substrate as claimed in claim 1, wherein the pre-process metrology data includes goodness-of-fit (GOF) data, and depth data.
37. The method of processing a substrate as claimed in claim 1, further comprising:
38. The method of processing a substrate as claimed in claim 1, wherein the process recipe is determined by executing a control strategy and a control plan.
39. A processing system for treating a substrate comprising:
a processing subsystem comprising a chemical oxidation removal (COR) module for chemically altering exposed surface layers of a layer on the substrate, a post heat treatment (PHT) module for thermally treating the chemically altered exposed surface layers of said layer on the substrate, and an isolation assembly coupled between the PHT module and the COR module;
a first integrated metrology module (IMM) coupled to the processing subsystem for providing pre-process metrology data that determines an input state for the substrate, wherein the pre-process metrology data comprises CD data for at least one feature; and
executes the process recipe to process the substrate to achieve the trim amount using the process recipe, the COR process including chemically treating the substrate in the COR module by chemically altering exposed surface layers of the layer on the substrate and the PHT process including thermally treating the substrate in the PHT module to evaporate the chemically altered exposed surface layers of the layer on the substrate.
40. The processing system for treating a substrate as claimed in claim 39, wherein the COR module further comprises a temperature controlled chemical treatment chamber, a temperature controlled substrate holder mounted within the chemical treatment chamber and configured to be substantially thermally insulated from the chemical treatment chamber, a vacuum pumping system coupled to the chemical treatment chamber, and a temperature controlled gas distribution system for introducing one or more process gases into the chemical treatment chamber.
41. The processing system for treating a substrate as claimed in claim 40, wherein the temperature controlled chemical treatment chamber comprises a wall heating element.
42. The processing system for treating a substrate as claimed in claim 40, wherein the temperature controlled gas distribution system comprises at least one gas distribution plate, the gas distribution plate comprising one or more gas injection orifices.
43. The processing system for treating a substrate as claimed in claim 40, wherein the temperature controlled substrate holder in the chemical treatment chamber comprises at least one of an electrostatic clamping system, a back-side gas supply system, and one or more temperature control elements.
44. The processing system for treating a substrate as claimed in claim 40, wherein the temperature controlled substrate holder in the chemical treatment chamber includes one or more temperature control elements.
45. The processing system for treating a substrate as claimed in claim 40, wherein the gas distribution system comprises a first gas distribution plenum and a first gas distribution plate having a first array of one or more orifices and a second array of one or more orifices for coupling a first gas to a process space through the first array of one or more orifices in the first gas distribution plate, and a second gas distribution plenum and a second gas distribution plate having passages therein for coupling a second gas to the process space through the passages in the second gas distribution plate and the second array of one or more orifices in the first gas distribution plate.
46. The processing system for treating a substrate as claimed in claim 45, wherein the first gas and the second gas are independently introduced to the process space.
47. The processing system for treating a substrate as claimed in claim 39, wherein the PHT module further comprises a temperature controlled thermal treatment chamber, a temperature controlled substrate holder mounted within the thermal treatment chamber and configured to be substantially thermally insulated from the thermal treatment chamber, and a vacuum pumping system coupled to the thermal treatment chamber.
48. The processing system for treating a substrate as claimed in claim 47, wherein the PHT module further comprises a substrate lifter assembly coupled to the thermal treatment chamber for vertically translating the substrate between a transfer plane and the substrate holder.
49. The processing system for treating a substrate as claimed in claim 39, wherein the control device further comprises means for controlling at least one of a chemical treatment chamber temperature, a chemical treatment gas distribution system temperature, a chemical treatment substrate holder temperature, a chemical treatment substrate temperature, a chemical treatment processing pressure, a chemical treatment gas flow rate, a thermal treatment chamber temperature, a thermal treatment substrate holder temperature, a thermal treatment substrate temperature, and a thermal treatment processing pressure.
50. The processing system for treating a substrate as claimed in claim 39, wherein the isolation assembly comprises at least one of a thermal insulation assembly, a gate valve assembly, and a transfer system.
51. The processing system as recited in claim 39, wherein the processing subsystem is coupled to a manufacturing system.
52. The processing system as recited in claim 39, wherein the control device also determines if the desired state has been achieved.
This application is a continuation of and claims the benefit of priority, under 35 USC �120 from U.S. Ser. No. 10/736,983, filed Dec. 17, 2003.
This application is related to co-pending U.S. Patent Application Ser. No. 60/454,597, entitled �Processing System and Method For Treating a Substrate�, filed on Mar. 17, 2003; co-pending U.S. Patent Application Ser. No. 60/454,642, entitled �Processing System and Method For Chemically Treating a Substrate�, filed on Mar. 17, 2003; co-pending U.S. Patent Application Ser. No. 60/454,641, entitled �Processing System and Method For Thermally Treating a Substrate�, filed on Mar. 17, 2003; and co-pending U.S. Patent Application Ser. No. 60/454,644, entitled �Method and Apparatus For Thermally Insulating Adjacent Temperature Controlled Chambers�, filed on Mar. 17, 2003. The entire contents of all of those applications are herein incorporated by reference in their entirety.
Also, the MES 110 can provide run-time configuration information to the TL controller 120 and/or the R2R controller 190. For example, settings, targets, limits, rules, and algorithms can be downloaded from the factory to the TL controller 120 and/or the R2R controller 190 as an �Advanced Process Control (APC) recipe�, an �APC system rule�, and �APC recipe parameters� at run-time.
Configurable items can be configured as a set of variable parameters sent from the factory system using Generic Equipment Model/SEMI Equipment Communications Standard (GEM SECS) communications protocol. For example, variable parameters can be passed as part of an �APC Recipe�. An APC recipe may contain more than one sub recipes and each sub recipe can contain variable parameters.
For example, the COR module can use a process gas comprising HF and NH3, and the processing pressure can range from approximately 1 to approximately 100 mTorr and, for example, can range from approximately 2 to approximately 25 mTorr. The process gas flow rates can range from approximately 1 to approximately 200 sccm for each specie and, for example, can range from approximately 10 to approximately 100 sccm. In addition, a uniform (three-dimensional) pressure field can be achieved. Additionally, the COR module chamber can be heated to a temperature ranging from 30� to 100� C. and, for example, the temperature can be approximately 40� C. Additionally, the gas distribution system can be heated to a temperature ranging from approximately 40� to approximately 100� C. and, for example, the temperature can be approximately 50� C. The substrate can be maintained at a temperature ranging from approximately 10� to approximately 50� C. and, for example, the substrate temperature can be approximately 20� C.
In addition, in the PHT module, the thermal treatment chamber can be heated to a temperature ranging from approximately 50� to approximately 100� C. and, for example, the temperature can be approximately 80� C. Additionally, the upper assembly can be heated to a temperature ranging from approximately 50� to approximately 100� C. and, for example, the temperature can be approximately 80� C. The substrate can be heated to a temperature in excess of approximately 100� C. Alternatively, the substrate can be heated in a range from approximately 100� to approximately 200� C., and, for example, the temperature can be approximately 135� C.
The R2R controller can select process models based on incoming material context. For example, the R2R controller can select process models based on the incoming material state and process recipe. The R2R controller can comprise means to verify that the system can calculate a valid R2R setting. For example, the R2R controller can comprise means to verify recipe parameter settings prior to lot start. The R2R controller can comprise means to use default settings of recipe set points. For example, when the R2R controller cannot provide recipe parameters for a particular wafer, the recipe parameters in the �nominal� recipe can be used.
The R2R controller inputs can include Instructions, substrate state, module physical state, process state, and/or controller parameters. In addition, the R2R controller inputs can include time constants for feed-forward/feedback loops, a reset event for accumulation, an IMM step, and ODP offset. Instructions can include targets, tolerances, computational commands, data collection plans, algorithms, models, coefficients, and/or recipes. The substrate state can include information from the substrate being processed (site, wafer, lot, batch state), profiles, and/or characteristics measured physically or electrically. The module physical state can include the current or last known recorded state of the module and components that will be used to process the substrate�RF hours, number of wafers, and/or consumable states. The process state can include the current or last known measured state from sensors of the processing environment, including trace data, and/or summary statistics. The controller parameters can include the last settings for the recipe/controller set points and process targets that created the substrate state, module physical state, and/or process state.
In 220, the desired process result can be determined. For example, the target CD can be compared to the pre-process metrology data. When the pre-process metrology data is less than the target CD, an error can be declared. When the pre-process metrology data is approximately equal to the target CD, a �null� condition can be declared. When the pre-process metrology data is greater than the target CD, a trim amount can be established. The trim amount to be removed during a process can be regarded as the desired result if the process model which contains the relationship between trim amount and recipe parameters has been verified.
Example Control Recipe Lookup table
First, the tool can move a wafer into a first buffer (load lock (LL)) module. The first buffer (load lock) module pumps down towards a vacuum; the tool can move the wafer to a second buffer (PHT) module; the GUI status screens are updated (showing wafer in LL). Next, the tool can move the wafer into a first process (COR) module; the TL controller (FDC component) can select a data collection (DC) strategy defined in a control strategy, and set up sensors; the status screens can be updated; module state can change; the tool performs a �Recipe Start� for the first process module; the status screens can be updated (module state can change to �wafer processing�). Then, the sensors can start recording; the recipe cycles through the processing steps; the first process module can send a �Recipe End� event; the sensors can stop recording;, the tool moves the wafer to a second buffer (PHT) module. Next, the TL controller (FDC component) can collect data file(s) from the tool and start processing the data based on the data collection plan filter; the TL controller (FDC component) can select an analysis strategy defined in the control strategy; process module and process state data; and update the database (i.e. module state and process state). Then, the status screens can be updated (module state can show wafer in LL/PHT; a �Recipe Start� for the second buffer (PHT) module; the status screens can be updated (module state can change �wafer processing�). Then, the sensors can start recording; the recipe cycles through the processing steps; the second buffer (PHT) module can send a �Recipe End� event; the sensors can stop recording; the tool moves wafer to the first buffer (load lock) module; the vacuum state changes from vacuum to atmosphere; the tool moves the wafer out of the first buffer (load lock) module; and the status screens are updated.
In one embodiment, �Control Strategies� can be used. For example, control strategies can be selected based on the system recipe. Each control strategy that matches the context can be executed. Control strategies can be evaluated on a �wafer by wafer� basis. Control strategies can contain one or more control plans. Control plans can contain the control model. When multiple control models are executed at the same time, outputs from the previous model may be used as inputs to the next model. There is at least one control plan for each process module being controlled.
An exemplary configuration procedure for run-to-run control of a process can be as follows: 1. Select the Recipe Range screen and configure it based on the default settings. 2. Switch to the Control Recipe screen, and configure it based on the Recipe Range configuration settings 3. Switch to the Control Plan screen and configure the Integration tab, Control tab, and Algorithm tab. 4. From the Control Plan�Algorithm tab page, switch to the Binning Table window and configure the bin table based on the Control Recipe configuration settings. 5. Switch to the Control Status screen and view the selected historical or running Control Plan status and the Control Wafer status.
Control Recipes and Control Plans will be removed. The
recipe range configuration cannot be edited, with the
exception of the description, when Protection is enabled.
when clicking the Edit button. The names such as
Null, Nominal, and Default are reserved for special
Cell Edit Counter
Step1-24
recipe step 1-24. Entered cell items are counted and
Users view the control strategy and click �Edit� to edit the
t = f(d, o)
Users view the control plan and click �Edit� to edit the existing
The Nominal Recipe�1st field displays the process recipe name of the R2R control chamber's first visit information that is included in the selected system recipe. The Nominal Recipe�2nd field displays the process recipe name of the R2R control chamber's second visit information that is included in the selected system recipe. The Route field displays the system recipe route according to the selected system recipe. The Chamber sequence buttons show the control chambers.
There are two radio buttons for choosing the Control CD calculation method either Step Average or Wafer Average. The Measurement Step field shows the IM Measurement Step. If the Step Average radio button is selected, users must specify the IM measurement step. If the Wafer Average radio button is selected, the measurement step with the description will be disabled and in �grayed out� mode. After a user selects the measurement step, the user can enter the description for the measurement step.
In FIG. 9C, an Algorithm Tab page is shown in accordance with an embodiment of the invention. For example, a simple bin algorithm can be a control recipe selection method that is based on trim etch amount. If the selected control recipe settings are the same as the process recipe on the process tool, the control variable's name is �Nominal� by default which can result in the use of the same tool process recipe which will trim the etch amount associated with it.
The Binning Table window can have three parts. The Bin Table Boundary input allows users to enter the bin table boundary. The Recipe Range filter allows users to view all the protected control recipes associated with the selected recipe range. Users must click the Control Recipe 1and Control Recipe 2cell to open the Control Recipe Selection window. After selecting from the list for both visits, the trim etch amount can be entered for each displayed control recipe. The software logic calculates the total etch amount for both visits.
The Control Recipe Viewer is at the bottom of the screen. The Control Recipe Viewer allows users to view the control recipe information and description. The description for the control recipe is displayed based on the information entered from the Control Recipe screen. When a user selects the cell of Control Recipe 1 or Control Recipe 2, the Control Recipe Selection window opens and allows users to select the control recipe. By default, the name �Nominal� and �Null� appears the first two cells. Here, Null means non-processing for this selected visit. If a new control recipe is added on the Control Recipe screen with the associated Recipe Range, users can click the control recipe cell to open the Control Recipe Selection window. Users then select the new control recipe in the Control Recipe Selection window.
Nominal Recipe - 1st
Nominal Recipe - 2nd
Init.CD
Selected - Control Recipe Selected Successfully.
Select Error - Control Recipe Selection Failure
Link Error - Telius-Ingenio Communication Failure
Data Error - Metrology Data Error
As illustrated in FIGS. 15 and 16, the chemical treatment system 1220 comprises a substrate holder 1240, and a substrate holder assembly 1244 that enables thermal control and processing of substrate 1242. The substrate holder 1240 and substrate holder assembly 1244 can comprise an electrostatic clamping system (or mechanical clamping system) in order to electrically (or mechanically) clamp substrate 1242 to the substrate holder 1240. Furthermore, substrate holder 1240 can, for example, further include a multi-zone temperature control system that can receive heat and transfer heat to a heat exchanger system (not shown), or when heating, can transfer heat from the heat exchanger system. Moreover, a heat transfer gas can, for example, be delivered to the back-side of substrate 1242 via a backside gas system to improve the gas-gap thermal conductance between substrate 1242 and substrate holder 1240. For instance, the heat transfer gas supplied to the back-side of substrate 1242 can comprise an inert gas such as helium, argon, xenon, krypton, a process gas such as CF4, C4F8, C5F8, C4F6, etc., or other gas such as oxygen, nitrogen, or hydrogen. Such a system can be utilized when temperature control of the substrate is required at elevated or reduced temperatures. For example, the backside gas system can comprise a multi-zone gas distribution system such as a two-zone (center-edge) system, wherein the back-side gas gap pressure can be independently varied between the center and the edge of substrate 1242. In other embodiments, the multi-zone temperature control system can comprise heating/cooling elements, such as resistive heating elements, or thermo-electric heaters/coolers. An exemplary thermo-electric element is one commercially available from Advanced Thermoelectric, Model ST-127-1.4-8.5M (a 40 mm by 40 mm by 3.4 mm thermo-electric device capable of a maximum heat transfer power of 72 W). Also additional heating/cooling elements can be located in the chamber wall of the chemical treatment chamber 1221.
Additionally, the substrate temperature can be monitored using a temperature-sensing device such as an optical fiber thermometer commercially available from Advanced Energies, Inc. (1625 Sharp Point Drive, Fort Collins, Colo., 80525), Model No. OR2000F capable of measurements from 50 to 2000 C and an accuracy of plus or minus 1.5 C, or a band-edge temperature measurement system as described in pending U.S. patent application Ser. No. 10/168544, filed on Jul. 2, 2002, the contents of which are incorporated herein by reference in their entirety.
Referring again to FIG. 17, thermal treatment system 1210 can further comprise a controller 1275 having a microprocessor, memory, and a digital I/O port capable of generating control voltages sufficient to communicate and activate inputs to thermal treatment system 1210 as well as monitor outputs from thermal treatment system 1210. Moreover, controller 1275 can be coupled to and can exchange information with substrate holder temperature control unit 1278, upper assembly temperature control unit 1286, upper assembly 1284, thermal wall temperature control unit 1281, vacuum pumping system 1280, and substrate lifter assembly 1290. For example, a program stored in the memory can be utilized to activate the inputs to the aforementioned components of thermal treatment system 1210 according to a process recipe. One example of controller 1275 is a DELL PRECISION WORKSTATION 610�, available from Dell Corporation, Austin, Tex.
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