Abstract:
The present invention provides a system, apparatus and method for improving the efficiency of a semiconductor processing system, such as a deposition system by decreasing or substantially eliminating the accumulation of by-products in the apparatus components of the semiconductor processing system. The present invention further relates to improving the efficiency of a foreline trap associated with a semiconductor processing system, wherein the trap removes substantially all of the by-products from the exhaust gas from the processing chamber. In addition, the present invention provides a system, apparatus and method for efficiently clearing traps of accumulated by-products from exhaust gas of a semiconductor processing system.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to new and useful systems, apparatus and methods in the field to semiconductor manufacturing.  
       BACKGROUND OF THE INVENTION  
       [0002]     Thin film deposition processes for depositing films of pure and compound materials are known. In recent years, the dominant technique for thin film deposition has been chemical vapor deposition (CVD). A variant of CVD, Atomic Layer Deposition (ALD) has been considered to be an improvement in thin layer deposition in terms of uniformity and conformity, especially for low temperature deposition.  
         [0003]     Generally, an ALD process comprises a series of conventional CVD processes, each producing a single-monolayer deposition, wherein each deposition step theoretically goes to saturation at a single molecular or atomic monolayer thickness, and then self-terminates. The deposition is the outcome of chemical reactions between reactive molecular precursors delivered to the system and a substrate. The net reaction must deposit the pure desired film and eliminate the “extra” atoms that compose the molecular precursors.  
         [0004]     In the case of CVD, the molecular precursors are fed simultaneously into the CVD reaction chamber. A substrate is kept at a temperature that is optimized to promote chemical reaction between the molecular precursors along with efficient desorption of by-products. Accordingly, the reaction proceeds to deposit the desired thin film.  
         [0005]     For ALD applications, the molecular precursors are introduced separately into the ALD reaction chamber. In particular, a first precursor, typically a metal bonded to an atomic or molecular ligand to make a volatile molecule, that reacts with the substrate, is introduced. The metal precursor reaction is normally followed by inert gas purging to clear the chamber prior to the introduction of the next precursor. Thus, in contrast to the CVD process, ALD is performed in a cyclic fashion with sequential alternating pulses of the precursors and purge gases. Typically, only one monolayer is deposited per operation cycle. Generally, ALD processes are conducted at pressures less than 1 Torr.  
         [0006]     ALD processes are commonly used in the fabrication and treatment of integrated circuit (IC) devices and other substrates where defined, ultra-thin layers are required. One problem related to ALD processes is the production of by-products that adhere to and otherwise cause deleterious processing effects in the deposition apparatus components. In particular, the by-products may deposit in the vacuum pump causing pump seizure, pump failure, and impure deposition. In addition, the by-products may adhere to the reaction chamber walls or other apparatus components, requiring the deposition process to be shut down while the by-products are removed, or the fouled components are replaced. The suspension of the production process as well as the cleaning or replacement of components is time consuming and costly.  
         [0007]     Such drawbacks also occur in CVD processes, but occur with greater frequency during ALD, because the intended reaction is a surface reaction on the substrate being treated. Therefore, in ALD processes, a majority of the supplied gas leaves the reaction chamber “unreacted”, and further mixes with gases from the previous and subsequent reaction steps. As a result, a significant volume of the unreacted gases may react outside the reaction chamber in locations such as in the process foreline and the pumps. This may result in higher unwanted non-chamber deposition rates, which leads to pump and foreline “clogging” and results in pump seizure or failure noted above.  
         [0008]     Various solutions have been attempted, but are also time-consuming, costly, or otherwise impractical for various reasons including space allocation. For example, one approach employs a valve at the exhaust of the reaction chamber that physically switches the exhaust flow alternately to one of two forelines and vacuum pumps. The valve operation is synchronized with the cycle times used to pulse different gases into the reaction chamber, in an attempt to avoid commingling of the gases in the chamber, forelines and pumps. However, this solution requires each pump exhaust to be routed separately to an abatement unit, adding significant processing cost. Further, portions of the reactant gases may still combine and react before they reach the chamber exhaust valve. Other solutions employ a foreline trap, to either trap the process by-products, or selectively trap one or more of the reactant species to avoid cross-reaction. These systems have not proved to be efficient. Another proposed solution, disclosed in JP 11181421 introduces CIF 3  or F 2  to react with by-products formed during CVD that adhere to pipe surfaces. However, this approach is unworkable for ALD systems where there are higher amounts of by-products exiting the reaction chamber.  
         [0009]     Another approach suggested by co-pending application, U.S. Ser. No. 11/018,641, incorporated by reference herein, provides a method, system and apparatus for improving the efficiency of a deposition system by decreasing or substantially eliminating the amount of by-products produced during the deposition system by providing a fluorine atmosphere in the deposition process, the atmosphere comprising molecular fluorine (F 2 ) or fluorine in the radical form (F*), and the fluorine atmosphere introduced to the apparatus in the foreline. However this approach will not work when hydrogen is added to the deposition process. This is because the fluorine will react preferentially with the hydrogen. Therefore, unless an excess of fluorine is added, there will be no fluorine left to create the desired fluorine atmosphere. The amount of excess fluorine needed depends on the amount of hydrogen added to the process, but could easily result in significant cost for the fluorine, equipment and energy.  
         [0010]     Therefore, there remains a need in the art to overcome the problems associated with by-product accumulation in the apparatus components of a deposition process.  
       SUMMARY OF INVENTION  
       [0011]     The present invention overcomes the problems noted above and provides a system, apparatus and method for improving the efficiency of a semiconductor processing system, such as a deposition system by decreasing or substantially eliminating the accumulation of by-products in the apparatus components of the semiconductor processing system.  
         [0012]     The present invention further relates to improving the efficiency of a foreline trap associated with a semiconductor processing system, wherein the trap removes substantially all of the by-products from the exhaust gas from the processing chamber.  
         [0013]     In addition, the present invention provides a system, apparatus and method for efficiently clearing traps of accumulated by-products from exhaust gas of a semiconductor processing system. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0014]      FIG. 1  is a schematic drawing of a trap for a semiconductor processing system.  
         [0015]      FIG. 2  is a schematic drawing showing one embodiment of the present invention employing multiple traps in series.  
         [0016]      FIG. 3  is a schematic drawing showing another embodiment of the present invention employing multiple traps in parallel series.  
         [0017]      FIG. 4  is a schematic drawing showing another embodiment of the present invention employing multiple traps in series and further including a fluorine source.  
         [0018]      FIG. 5A  is a schematic drawing showing a further embodiment of the present invention employing multiple traps in series with a fluorine source associated with each series of traps.  
         [0019]      FIG. 5B  is a schematic drawing showing a further embodiment of the present invention employing multiple traps in series with a single fluorine source operable with each series of traps.  
         [0020]      FIG. 6  is a schematic drawing showing another embodiment of the present invention employing multiple traps in series and having a fluorine source associated with each trap.  
         [0021]      FIG. 7A  is a schematic drawing showing another embodiment of the present invention employing multiple traps in series and having a fluorine source associated with each trap in each series.  
         [0022]      FIG. 7B  is a schematic drawing showing another embodiment of the present invention employing multiple traps in series and having a series of fluorine sources for associated with each series of traps.  
         [0023]      FIG. 8  is a schematic drawing showing a further embodiment of the present invention employing a single trap and having a reactive gas source and a fluorine source associated with the trap.  
         [0024]      FIG. 9A  is a schematic drawing showing a further embodiment of the present invention employing multiple traps in parallel and having a reactive gas source and a fluorine source associated with each trap.  
         [0025]      FIG. 9B  is a schematic drawing showing a further embodiment of the present invention employing multiple traps in parallel and having a single reactive gas source and a single fluorine source associated with the traps. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0026]     As noted above, the accumulation of by-products from a semiconductor manufacturing process, in the apparatus components of the processing system can cause equipment failure and also may require system shut-down to clean the components, resulting in substantial cost.  
         [0027]     Also as noted, various approaches have been attempted to overcome the problem of by-product accumulation. This includes employing a fore-line trap, which as noted, has not proved to be efficient.  
         [0028]     The present invention solves the problem of fore-line trap inefficiency. In particular, the present invention provides a semiconductor manufacturing system using a fore-line trap that can remove 99% or more of the by-products from the exhaust gas from the processing chamber. I addition, the present invention provides for means to clean the trap of accumulated by-products without requiring shut-down of the deposition system, resulting in significant cost savings. The present invention will be described in greater detail below, with reference to the drawing figures.  
         [0029]     In particular,  FIG. 1  shows a standard hot trap  10 , having an inlet  12 , an outlet  14 , an outer chamber  16 , an inner chamber  18  and baffles  20 . In operation, exhaust gas enters the hot trap  10 , through inlet  12 , flows through the outer chamber  16  and then into the inner chamber  18 . The baffles  20  are kept at a desired operating temperature, by an appropriate heating means, such as an electrical heating means  22 . The exhaust gas reacts with and accumulates on the hot baffles  20 , and the rest of the exhaust gas exits the hot tap  10 , through outlet  14 .  
         [0030]     There are two problems associated with the use of a hot trap  10 , as shown in  FIG. 1 . First, in order for the trap to be useful in a semiconductor processing system, the removal of by-products must be greater than 99%. In tests performed with respect to the present invention, a hot trap as shown in  FIG. 1 , operating at a baffle temperature of about 500° C. proved to be only about 70% efficient. Second, assuming the efficiency of the hot trap can be improved to more than 99%, a significant amount of by-product, as much as ten pounds a week, will accumulate in the trap, which must be removed and may cause costly cleaning and down time. The present invention addresses both of these issues.  
         [0031]     In order to increase the trap efficiency, the present invention provides a series of traps to increase the overall trap length. For example. if a particular trap having a length, L, provides 70% removal of by-products for a given set of process flows and chemistries, then by adding a second trap of the same configuration including length L, the total trapping efficiency can be increased to 91%. In particular, the first trap will remove 70% of the by-products and the second trap will remove 70% of the remaining 30% of the by-products that exit the first trap. More traps can be added to increase total trapping efficiency even further. The tables below show the number of lengths, L, and total trapping efficiencies assuming a single trap efficiency of 70% (Table 1), 50% (Table 2) and 90% (Table 3).  
                                           TABLE 1                           Single Trap Efficiency = 70%            Total Trap   Total Trapping   Effluent By-Product       Length   Efficiency (%)   Content (%)                    1L   70   30       2L   91   9       3L   97.3   2.7       4L   99.19   0.81       5L   99.757   0.243       6L   99.9271   0.0729                  
 
         [0032]    
       
         
               
             
               
               
               
             
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                   
               
               
                 Single Trap Efficiency = 50% 
               
             
          
           
               
                 Total Trap 
                 Total Trapping 
                 Effluent By-Product 
               
               
                 Length 
                 Efficiency (%) 
                 Content (%) 
               
               
                   
               
             
          
           
               
                 1L 
                 50 
                 50 
               
               
                 2L 
                 75 
                 25 
               
               
                 3L 
                 87.5 
                 12.5 
               
               
                 4L 
                 93.75 
                 6.25 
               
               
                 5L 
                 96.875 
                 3.125 
               
               
                 6L 
                 98.4375 
                 1.5625 
               
               
                 7L 
                 99.21875 
                 0.78125 
               
               
                   
               
             
          
         
       
     
         [0033]    
       
         
               
             
               
               
               
             
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                   
               
               
                 Single Trap Efficiency = 90% 
               
             
          
           
               
                 Total Trap 
                 Total Trapping 
                 Effluent By-Product 
               
               
                 Length 
                 Efficiency (%) 
                 Content (%) 
               
               
                   
               
             
          
           
               
                 1L 
                 90 
                 10 
               
               
                 2L 
                 99 
                 1 
               
               
                 3L 
                 99.9 
                 0.1 
               
               
                 4L 
                 99.99 
                 0.01 
               
               
                   
               
             
          
         
       
     
         [0034]     One embodiment of the present invention is shown in  FIG. 2 , wherein exhaust gases from a processing chamber  210 , pass through a series of hot traps  220 , prior to flowing through a vacuum pump  230 , and exiting as waste stream  240 . Four hot traps  220 , are shown in  FIG. 2 , but any number of traps necessary to meet the desired total trapping efficiency can be used. A single series path of hot traps is shown in  FIG. 2  and is acceptable for use when there is sufficient time between process runs in the processing chamber to allow for trap cleaning. In addition, as shown in  FIG. 2 , each trap in the series is of the same type and has the same parameters, including length, L, and trapping efficiency. The present invention also includes arrangements wherein the traps in the series are of different types, or have different parameters, such as different lengths. Any combination of traps in the series is acceptable, as long as the total trapping efficiency required for the system is met.  
         [0035]     Another embodiment according to the present invention is shown in  FIG. 3 , that is useful when there is not enough time to allow for cleaning of the traps, or when a more continuous operation is desired. In particular,  FIG. 3  shows two parallel series paths of hot traps, a first series of hot traps  320 , and a second series of hot traps  325 . The system shown in  FIG. 3  also includes a three way valve  315 , to allow the exhaust gas from the processing chamber  310 , to be switched from on series of traps to the other. This allows for continuous operation; for example, when the first series of traps  320  is receiving the exhaust gas and trapping by-products, the second series of traps  325 , can be cleaned, and vice versa. In either case, once the exhaust gas passes through a series of traps, it can then pass through the vacuum pump  330 , without significant by-product deposition and then on to the waste stream  340 . By using the system of the present invention, by-product buildup in the vacuum pump and other components can be avoided and the risk of pump seizure or failure, as well as system clogging can be nearly eliminated.  
         [0036]     Once again, while four traps are shown in each series of traps in  FIG. 3 , any number of traps can be used to meet the desired trapping efficiency. Generally, it is desirable that both of the parallel series of traps include the same number o traps, but the present invention includes alternative arrangements wherein the different series of traps include different numbers of traps. As noted above, any combination of traps in a series is acceptable, as long as the required total trapping efficiency is met. Normally, the required total trapping efficiency would be the same for both series, but such is not required by the present invention. Rather, the different series of traps can have different required total trapping efficiencies. While two parallel series of traps should be sufficient for the majority of semiconductor manufacturing systems to enable continuous operation, one or more additional series of traps can be added if necessary.  
         [0037]     The systems according to the present invention as shown in  FIGS. 2 and 3  solve the first problem noted above, i.e. increasing the total trapping efficiency of a hot trap. However, the second problem of cleaning the by-product accumulation from the hot traps in the systems shown in  FIGS. 2 and 3  would require dismantling and difficult cleaning operations or replacement of traps on a regular basis. Therefore, the present invention also provides a means to more easily clean the traps.  
         [0038]     In particular, one embodiment of the present invention, wherein traps can be cleaned is shown in  FIG. 4 , wherein exhaust gas from a processing chamber  410 , passes through a series of hot traps  420 , to remove more than 99% of the by-products prior to reaching a vacuum pump  430 , and being sent to waste stream  440 . The system shown in  FIG. 4  also includes a fluorine source  418 , to provide fluorine to the system that can etch the by-products and clean the traps  420 . The fluorine source  418 , can be any suitable source known in the industry, such as MKS Astron or MKS Astroni, or may be excess fluorine that has passed through the processing chamber  410 , during a chamber cleaning or other process. The fluorine provided to the system etches the by-products deposited in the hot traps  420 , and the effluent can then be processed by the vacuum pump  430 , without risk of further deposition and sent to the waste stream  440 . As noted above with respect to other embodiments, there can be any number of hot traps having the same or different parameters, as long as the required total trapping efficiency is accomplished.  
         [0039]      FIG. 5A  shows another embodiment of the present invention wherein two parallel series of hot traps, a first series of hot traps  520 , and a second series of hot traps  525 , are utilized to remove by-products from the exhaust gas of a processing chamber  510 . A three way valve  515  is provided to allow the exhaust gas to be switched from one series of hot traps to the other and to enable continuous operation. The system of  FIG. 5  also includes a fluorine source  518 , associated with hot traps  520 , and a fluorine source  528 , associated with hot traps  525 , that provides fluorine to the system to etch by-products from and clean the hot traps. The processed exhaust gas, as well as the fluorine gas and cleaned by-products are then sent through a vacuum pump  530  and out of the system as waste  540 . The fluorine sources can be any of those mentioned above and the hot traps can be provided in any of the configurations noted above, as long as the required total trapping efficiency is met.  FIG. 5B  show a further embodiment of the present invention, wherein a single fluorine source  518 , is used for both series of hot traps  520 , and  525 . This reduces the overall number of components necessary in the system, but otherwise operates in the same manner as described with respect to the embodiment of  FIG. 5A .  
         [0040]     The configurations shown in  FIGS. 4 and 5  will work adequately only if the hot traps have a high enough surface temperature. In particular, it has been found that molecular fluorine (F2) will not etch by-products from the surfaces of apparatus components. Rather, fluorine radicals (F*) are necessary. Further, at relatively low temperatures, F* will quickly recombine to F2 and therefore be unable to perform the cleaning operation. However, at high temperatures, F* can be maintained and cleaning operations can be successfully carried out. Further, once etching has been started, the heat of reaction may allow the reaction to continue, even with heaters turned off. In fact, in some instances, it may be necessary to provide cooling means. Therefore, when a high enough initial temperature is established, about 150° C. or higher, then the configurations of  FIGS. 4 and 5 , using a single fluorine source for each series of traps or for the entire system, is possible. In other words, a single fluorine source can be used for high temperature hot traps, and F* existence and reaction with the by-products, can be sustained throughout the series of traps.  
         [0041]     However, if surface temperatures in the hot traps are not hot enough or drop too low, the F* will quickly revert to F2 and not be able to carry out the cleaning operation. In general, F* would not survive past the first trap in a series. Therefore, it is necessary to provide multiple fluorine sources.  
         [0042]      FIG. 6  shows one embodiment of the present invention wherein a series of fluorine sources  618  are provided, one for each trap in the series of traps  620 . As in the embodiments described above, exhaust from a processing chamber  610 , passes through the series of traps  620 , and then sufficiently depleted of by-products, passes through the vacuum pump  630 , and out of the waste stream  640 . Each of the fluorine sources  618 , provides F* to an associated trap  620 . The F* cleans the deposited by-products from the traps and is also processed by the vacuum pump  630  and sent to the waste stream  640 . Any suitable number of traps, with the same or different operating parameters can be used in the arrangement shown in  FIG. 6 . Further, it may be possible to combine one or more of the fluorine sources  618 , and provide separate paths between the fluorine source  618 , and the individual traps  620 .  
         [0043]      FIG. 7A  depicts a further embodiment of the present invention, that also employs multiple fluorine sources. The arrangement shown in  FIG. 7A  includes two parallel series of traps, a first series of traps  720 , and a second series of traps  725 , that receive exhaust gas from a processing chamber  710 , as controlled by a three way valve  715 . This parallel arrangement may be required when a continuous process is desired or if there is insufficient time to perform the trap cleaning operation between process runs in the processing chamber  710 . In this configuration, a first series of fluorine sources  718 , provides F* to the first series of traps  720 , and a second series of fluorine sources  728 , provides F* to the second series of traps  725 . The exhaust stream and cleaning step exhaust are all sent through vacuum pump  730 , and into waste stream  740 . Any appropriate number and operating design for the traps, as discussed above with respect to other embodiments can be used. In operation, exhaust gas from processing chamber  710 , is provides to one series of traps while the other series of traps is being cleaned.  FIG. 7B  provides a further embodiment of the present invention where a single series of fluorine sources  718  is used to provide F* to both series of traps  720  and  725 . Operation and system arrangements are the same as described with respect to the embodiment shown in  FIG. 7A .  
         [0044]     The above embodiments will require the use of multiple traps to increase trapping efficiency and means to clean the traps of deposited by-products. In an alternative embodiment, the reaction of by-products is driven to completion, by injecting a gas to the trap. For example, ammonia gas can be added for many semiconductor processes to cause the reaction process to be completed in the trap. In this way, fouling of the pump and other apparatus components is avoided. Fluorine is then provided to the trap to clean the deposited by-products and remove them from the system. By using the reactive gas in the trap, the trapping efficiency is increased and the need to extend the overall length of the trap through the use of multiple traps is avoided.  
         [0045]     An embodiment according to the present invention employing a reactive gas is shown in  FIG. 8 , wherein exhaust gas from a processing chamber  810 , is sent through a trap  820 , to remove by-products, prior to exiting the system through vacuum pump  830 , as waste stream  840 . A reactive gas source  840 , and a fluorine source  818 , are also included. The reactive gas source  840 , provides a reactive gas, such as ammonia gas, to the trap  820 , in order to complete the reaction of the by-products in the trap  820 , and increase the trapping efficiency of the trap  820  to the desired level. Fluorine from fluorine source  818 , is then provided to the trap  820 , to etch the deposited by-products from the trap  820 . The components employed in this embodiment can be of any standard design, as described above with respect to other embodiments.  
         [0046]      FIGS. 9A and 9B  show further embodiments of the present invention employing two traps  920  and  925 , for processing the exhaust gas from processing chamber  910 . Providing two separate traps allows for continuous operation, as three way valve  915  provides a means to direct the exhaust gas to either of the traps  920  or  925 . In the embodiment shown in  FIG. 9A , each trap  920  and  925 , have a reactive gas source  940  and  945  respectively and a fluorine source  918  and  928 , respectively, associated therewith. In the embodiment shown in  FIG. 9B , as single reactive gas source  940 , and a single fluorine source  918 , service both traps  920  and  925 . In operation, when the reactive gas, such as ammonia gas, is provided to trap  920 , F* is provided to trap  925 , and vice versa. In this way, while one trap is removing by-products from the exhaust gas, utilizing the reactive gas to drive the reaction to completion, the other trap is being cleaned of deposits. All of the gases can then pass through the vacuum pump  930 , and out of the system as waste stream  940 . The components shown in  FIGS. 9A and 9B  can be of any standard design, the same or different, as described above with respect to other embodiments. Further, while completely separate or completely shared reactive gas and fluorine sources are shown, other arrangements are possible. For example, a single reactive gas source could be used for both traps, but separate fluorine sources, one for each trap could be included. Alternatively, separate reactive gas sources, one for each trap could be used, but a single shared fluorine source could be employed.  
         [0047]     In all cases, parallel paths are required only if the timing sequence of the processing chamber does not allow sufficient time for trap cleaning between processes. Further, in those embodiments where series of traps are provided, the number and configuration of the traps need only be that necessary to meet the required trapping efficiency. The injection of a reactive gas, such as ammonia, provides an alternate solution to the provision of series of traps. The embodiments described all show the traps up stream or ahead of a single pump. However, the pumping system could comprise multiple pumps in series or parallel configuration and the traps could be placed before all the pumps or between pumps. In addition, when parallel paths are employed, separate pumps could be used, for example, one pump could pump the treated exhaust gas and a second pump could pump the etched by-product and cleaning gas.  
         [0048]     The present invention solves the problems associated with buildup of deposited by-products in vacuum pumps and other apparatus components of a semiconductor processing system. The present invention employs traps to remove substantially all of the by-products from the exhaust gas of a vacuum processing unit and therefore avoids clogging and potential seizure or failure of pumps and other components of the system. In addition, the present invention provides means to clean the traps of accumulated by-product and alternatively to allow for continuous operation of the semiconductor processing system.  
         [0049]     It is anticipated that other embodiments and variations of the present invention will become readily apparent to the skilled artisan in the light of the foregoing description, and it is intended that such embodiments and variations likewise be included within the scope of the invention as set out in the appended claims.