Patent Description:
The present disclosure relates to substrate processing systems, and more particularly to substrate processing systems with pulse width modulated dose control.

The background description provided here is for the purpose of generally presenting the context of the disclosure.

Substrate processing systems may be used to treat substrates such as semiconductor wafers. Examples of substrate treatments include etching, deposition, photoresist removal, etc. During processing, the substrate is arranged on a substrate support such as an electrostatic chuck and one or more process gases may be introduced into the processing chamber.

The one or more processing gases may be delivered by a gas delivery system to the processing chamber. In some systems, the gas delivery system includes a manifold connected by one or more conduits to a showerhead that is located in the processing chamber. Most gas delivery systems deliver gases during periods that are longer than <NUM> or <NUM> seconds. Latency caused by mixing in the manifold, delivery through the conduits, and flow resistance of the showerhead makes it difficult to change gas mixtures quickly or to vary gas doses spatially or temporally. Furthermore, gas mixtures may react during travel through the gas delivery system. Some processes such as atomic layer etching (ALE), atomic layer deposition (ALD), etc. require different gas mixtures to be delivered to the processing chamber during very short intervals that are typically less than a second or a few seconds.

The following document are mentioned as a pertinent prior art illustration:.

Document <CIT> discloses a processing method for substrate which involves controlling time average for injections of process gas from first nozzle and second nozzle to control concentration of processes gas across substrate.

The following documents are mentioned as additional prior art illustration:.

A substrate processing system for treating a substrate includes a manifold and a plurality of injector assemblies located in a processing chamber. Each of the plurality of injector assemblies is in fluid communication with the manifold and includes a valve including an inlet and an outlet. A dose controller is configured to communicate with the valve in each of the plurality of injector assemblies and adjust a pulse width supplied to the valve in each of the plurality of injector assemblies based on at least one of manufacturing differences between the valves in each of the plurality of injector assemblies and non-uniformities of the valves in each of the plurality of injector assemblies to cause a desired dose to be supplied from the valve in each of the plurality of injector assemblies.

In other features, each of the plurality of injector assemblies further includes a pressure sensor sensing pressure at the valve in each of the plurality of injector assemblies. The dose controller is configured to adjust the respective pulse width for each valve based on the corresponding sensed pressure. Each of the plurality of injector assemblies further includes a temperature sensor sensing gas temperature at the valve in each of the plurality of injector assemblies. The dose controller is configured to adjust the respective pulse width for each valve based on the corresponding sensed gas temperature.

In other features, the dose controller is configured to vary the pulse widths based on corresponding locations of the plurality of injector assemblies relative to the substrate. The dose controller is configured to vary the pulse widths based on corresponding empirical data for the plurality of injector assemblies. A pressure regulator regulates a pressure inside the manifold. The dose controller is configured to adjust the pulse widths so as to cause the valves to provide approximately the same dose. The dose controller is configured to adjust the pulse widths so as to cause the valves to provide different doses. Each of the plurality of injector assemblies further includes a restricted orifice. Each of the plurality of injector assemblies further includes a bypass valve having an inlet connected to the inlet of the valve.

In other features, each of the plurality of injector assemblies further includes a pressure sensor sensing pressure at the corresponding valve in each of the plurality of injector assemblies. The dose controller is configured to adjust the pulse widths for the valves and the bypass valves based on the corresponding sensed pressures. Each of the plurality of injector assemblies further includes a temperature sensor sensing gas temperature at the corresponding valve in each of the plurality of injector assemblies. The dose controller is configured to adjust the pulse widths for the valves and the bypass valves based on the corresponding sensed gas temperatures.

In other features, the dose controller is configured to vary the respective pulse width based on a desired overlap of the valve and the bypass valve for each of the plurality of injector assemblies. The dose controller is configured to vary doses output by the plurality of injector assemblies to provide spatial skew.

A substrate processing system for treating a substrate includes a manifold and a plurality of injector assemblies located in a processing chamber. Each of the plurality of injector assemblies is in fluid communication with the manifold and includes a valve including an inlet and an outlet. A dose controller is configured to communicate with the valve in each of the plurality of injector assemblies, adjust a pulse width supplied to the valve in each of the plurality of injector assemblies to provide spatial dosing and at least one of compensate for upstream skew caused by a prior process and pre-compensate for downstream skew expected from a subsequent process.

In other features, each of the plurality of injector assemblies further includes a pressure sensor sensing pressure at the valve in each of the plurality of injector assemblies. The dose controller is configured to adjust the pulse widths based on the corresponding pressures. Each of the plurality of injector assemblies further includes a temperature sensor sensing gas temperature at the valve in each of the plurality of injector assemblies. The dose controller is configured to adjust the pulse widths based on the corresponding gas temperatures.

In other features, the dose controller is configured to vary the pulse widths based on at least one of manufacturing differences between the valves in each of the plurality of injector assemblies and non-uniformities of the valves in each of the plurality of injector assemblies. A pressure regulator regulates a pressure inside the manifold. Each of the plurality of injector assemblies further includes a restricted orifice. Each of the plurality of injector assemblies further includes a bypass valve having an inlet connected to an inlet of the valve. Each of the plurality of injector assemblies further includes a pressure sensor sensing pressure at the valve in each of the plurality of injector assemblies. The dose controller is configured to adjust the pulse widths of the valves and the bypass valves based on the corresponding pressures.

In other features, each of the plurality of injector assemblies further includes a temperature sensor sensing gas temperature at the valve in each of the plurality of injector assemblies. The dose controller is configured to adjust the pulse widths of the valves and the bypass valves based on the corresponding gas temperatures. The dose controller is configured to vary the pulse widths based on a desired overlap of the valve and the bypass valve for each of the plurality of injector assemblies.

In other features, the dose controller is configured to vary doses output by the plurality of injector assemblies to provide spatial skew.

A substrate processing system for treating a substrate includes N manifolds and Y groups of injector assemblies, wherein Y and N are integers greater than one. Each of the Y groups of injector assemblies includes N injector assemblies located in a processing chamber. Each of the N injector assemblies in each group of injector assemblies is in fluid communication with one of the N manifolds, respectively, and includes a valve including an inlet and an outlet. A dose controller is configured to control pulse widths output to the Y groups of injector assemblies to provide temporal dosing of the substrate.

In other features, the temporal dosing includes supplying a first gas mixture from a first one of the N manifolds using a first one of the Y groups of injector assemblies while concurrently supplying a second gas mixture from a second one of the N manifolds using a second one of the Y groups of injector assemblies.

In other features, each of the N injector assemblies further includes a pressure sensor sensing pressure at the valve in each of the N injector assemblies. The dose controller is configured to adjust the pulse widths based on the corresponding sensed pressures. Each of the N injector assemblies further includes a temperature sensor sensing gas temperature at the valve in each of the N injector assemblies. The dose controller is configured to adjust the pulse widths based on the corresponding gas temperatures.

In other features, the dose controller is configured to vary the pulse widths based on at least one of manufacturing differences between the valves in each of the N injector assemblies and non-uniformities of the valves in each of the N injector assemblies. A pressure regulator regulates a pressure inside the manifold.

In other features, each of the N injector assemblies further includes a restricted orifice. Each of the N injector assemblies further includes a bypass valve having an inlet connected to an inlet of the valve. Each of the N injector assemblies further includes a pressure sensor sensing pressure at the valve in each of the N injector assemblies. The dose controller is configured to adjust the pulse widths of the valves and the bypass valves based on the corresponding pressures.

In other features, each of the N injector assemblies further includes a temperature sensor sensing gas temperature at the valve in each of the N injector assemblies. The dose controller is configured to adjust the pulse widths of the valves and the bypass valves based on the corresponding gas temperatures.

In other features, the dose controller is configured to vary the pulse widths based on a desired overlap of the valve and the bypass valve for each of the N injector assemblies.

A substrate processing system for treating a substrate includes a manifold to supply a main gas flow and a plurality of injector assemblies located in a processing chamber. Each of the plurality of injector assemblies is in fluid communication with the manifold and includes a valve including an inlet and an outlet. A dose controller is configured to define R groups each including at least one of the plurality of injector assemblies, where R is an integer greater than one; communicate with the valves in each of the R groups; and split the main gas flow into R gas flows corresponding to R predefined flow ratios of the main gas flow by adjusting pulse widths that are output to the valves associated with the R groups, respectively. At least one of the R predefined flow ratios is different than another one of the R predefined flow ratios.

In other features, the dose controller is configured to vary the pulse widths based on at least one of manufacturing differences between the valves in each of the plurality of injector assemblies and non-uniformities of the valves in each of the plurality of injector assemblies. A pressure regulator regulates a pressure inside the manifold.

In other features, each of the plurality of injector assemblies further includes a restricted orifice. Each of the plurality of injector assemblies further includes a bypass valve having an inlet connected to an inlet of the valve. Each of the plurality of injector assemblies further includes a pressure sensor sensing pressure at the valve in each of the plurality of injector assemblies. The dose controller is configured to adjust the pulse widths of the valves and the bypass valves based on the corresponding pressures.

In other features, each of the plurality of injector assemblies further includes a temperature sensor sensing gas temperature at the valve in each of the plurality of injector assemblies. The dose controller is configured to adjust the pulse widths of the valves and the bypass valves based on the corresponding gas temperatures.

In other features, the dose controller is configured to vary the pulse widths based on a desired overlap of the valve and the bypass valve for each of the plurality of injector assemblies. The dose controller is configured to vary doses output by the plurality of injector assemblies to provide spatial skew.

A method for supplying fluid to a substrate processing system for treating a substrate includes arranging a plurality of injector assemblies, each including a valve including an inlet and an outlet, in a processing chamber; coupling the plurality of injector assemblies to a manifold; and adjusting a pulse width supplied to the valve in each of the plurality of injector assemblies based on at least one of manufacturing differences between the valves in each of the plurality of injector assemblies, and non-uniformities of the valves in each of the plurality of injector assemblies to supply a desired dose from the valve in each of the plurality of injector assemblies.

In other features, the method includes sensing pressure at the valve in each of the plurality of injector assemblies. The method includes adjusting the pulse widths further based on the corresponding pressures. The method includes sensing gas temperature at the valve in each of the plurality of injector assemblies. The method includes adjusting the pulse widths further based on the corresponding gas temperatures. The method includes varying the pulse widths further based on corresponding locations of the plurality of injector assemblies relative to the substrate.

In other features, the method includes varying the pulse widths further based on corresponding empirical data for the plurality of injector assemblies. The method includes regulating a pressure inside the manifold. The method includes adjusting the pulse width corresponding to each of the plurality of injector assemblies to provide approximately the same dose. The method includes adjusting the pulse width corresponding to each of the plurality of injector assemblies to provide different doses. Each of the plurality of injector assemblies further includes a restricted orifice. Each of the plurality of injector assemblies further includes a bypass valve having an inlet connected to an inlet of the valve.

In other features, the method includes sensing pressure at the valve in each of the plurality of injector assemblies and adjusting the pulse widths of the valves and the bypass valves further based on the corresponding pressures.

In other features, the method includes sensing gas temperature at the valve in each of the plurality of injector assemblies and adjusting the pulse widths of the valves and the bypass valves further based on the corresponding gas temperatures.

In other features, the method includes varying the pulse widths further based on a desired overlap of the valve and the bypass valve for each of the plurality of injector assemblies. The method includes varying doses output by the plurality of injector assemblies to provide spatial skew.

A method for supplying fluid in a substrate processing system for treating a substrate includes arranging a plurality of injector assemblies, each including a valve including an inlet and an outlet, in a processing chamber; coupling the plurality of injector assemblies to a manifold; and adjusting a pulse width supplied to the valve in each of the plurality of injector assemblies to provide spatial dosing and at least one of compensate for upstream skew caused by a prior process and pre-compensate for downstream skew expected from a subsequent process.

In other features, the method includes sensing pressure at the valve in each of the plurality of injector assemblies. The method includes adjusting the pulse widths further based on the corresponding pressures. The method includes sensing gas temperature at the valve in each of the plurality of injector assemblies. The method includes adjusting the pulse widths further based on the corresponding gas temperatures.

In other features, the method includes varying the pulse widths further based on at least one of manufacturing differences between the valves in each of the plurality of injector assemblies and non-uniformities of the valves in each of the plurality of injector assemblies. The method includes regulating pressure inside the manifold. In other features, each of the plurality of injector assemblies further includes a restricted orifice. In other features, each of the plurality of injector assemblies further includes a bypass valve having an inlet connected to an inlet of the valve.

In other features, the method includes sensing pressure at the valve in each of the plurality of injector assemblies and adjusting the pulse widths of the valves and the bypass valves further based on the corresponding pressures. The method includes sensing gas temperature at the valve in each of the plurality of injector assemblies and adjusting the pulse widths of the valves and the bypass valves further based on the corresponding gas temperatures.

A method for supplying fluid to a substrate processing system for treating a substrate includes arranging Y groups of injector assemblies in a processing chamber. Each of the Y groups of injector assemblies includes N injector assemblies. The method includes coupling each of the N injector assemblies of the Y groups of injector assemblies to one of N manifolds, respectively. Each of the N injector assemblies includes a valve including an inlet and an outlet, where Y and N are integers greater than one. The method includes controlling pulse widths output to the Y groups of injector assemblies to provide temporal dosing of the substrate.

In other features, providing the temporal dosing includes supplying a first gas mixture from one of the N manifolds using one of the Y groups of injector assemblies at the same time that a different gas mixture is supplied from another one of the N manifolds using another one of the Y groups of injector assemblies. The method includes sensing pressure at the valve in each of the N injector assemblies. The method includes adjusting the pulse widths further based on the corresponding pressures. The method includes sensing gas temperature at the valve in each of the N injector assemblies. The method includes adjusting the pulse widths further based on the corresponding gas temperatures.

In other features, the method includes varying the pulse widths further based on at least one of manufacturing differences between the valves in each of the N injector assemblies and non-uniformities of the valves in each of the N injector assemblies. The method includes regulating a pressure inside the manifold. Each of the N injector assemblies further includes a restricted orifice. Each of the N injector assemblies further includes a bypass valve having an inlet connected to an inlet of the valve.

In other features, the method includes sensing pressure at the valve in each of the N injector assemblies and adjusting the pulse widths of the valves and the bypass valves further based on the corresponding pressures. The method includes sensing gas temperature at the valve in each of the N injector assemblies and adjusting the pulse widths of the valves and the bypass valves further based on the corresponding gas temperatures.

In other features, the method includes varying the pulse widths further based on a desired overlap of the valve and the bypass valve for each of the N injector assemblies.

A method for supplying fluid to a substrate processing system for treating a substrate includes supplying a main gas flow using a manifold and arranging a plurality of injector assemblies in a processing chamber. Each of the plurality of injector assemblies is in fluid communication with the manifold and includes a valve including an inlet and an outlet. The method includes defining R groups each including at least one of the plurality of injector assemblies, where R is an integer greater than one; communicating with the valves in each of the R groups; and splitting the main gas flow into R gas flows corresponding to R predefined flow ratios of the main gas flow by adjusting pulse widths that are output to the valves associated with the R groups, respectively, wherein at least one of the R predefined flow ratios is different than another one of the R predefined flow ratios.

In other features, each of the plurality of injector assemblies further includes a pressure sensor sensing pressure at the valve in each of the plurality of injector assemblies. The method includes adjusting the pulse widths further based on the corresponding pressures. The method includes sensing gas temperature at the valve in each of the plurality of injector assemblies. The method includes adjusting the pulse widths further based on the corresponding gas temperatures.

In other features, the method includes varying the pulse widths further based on at least one of manufacturing differences between the valves in each of the plurality of injector assemblies and non-uniformities of the valves in each of the plurality of injector assemblies. The method includes regulating pressure inside the manifold. Each of the plurality of injector assemblies further includes a restricted orifice. Each of the plurality of injector assemblies further includes a bypass valve having an inlet connected to an inlet of the valve.

Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the invention which is defined by the appended claims.

To reduce latency, a gas delivery system according to the present disclosure supplies gas into the processing chamber using a plurality of gas injectors and a common gas supply manifold. The injectors are arranged at various locations inside the processing chamber above the substrate. There are often manufacturing differences between the same types of gas injectors from the same manufacturer. When the dose (or pulse width) of the injectors is relatively short, the manufacturing differences can cause significant dose variations and/or non-uniformity even when the same pulse width is used. Reducing manufacturing tolerances sufficiently to eliminate dosing differences between the valves has proven to be cost prohibitive.

The dose per pulse is also dependent upon a previous pulse width and/or flow rate. In systems performing ALD and ALE, precise dose control is required and very fast switching between different gas mixtures is performed. In some examples, the doses are supplied and the substrate is exposed to the doses during periods that are less than <NUM> seconds, <NUM> second, <NUM> seconds or even shorter durations. Furthermore, dose variations due to prior pulse widths or flow is unacceptable given the frequency of gas mixture switching.

Systems and methods according to the present disclosure allow injection of precise gas doses into a processing chamber using multiple injectors located inside of the processing chamber. The injectors can be operated with choked or unchoked flow conditions. When operated in choked flow conditions, flow from the injector is not affected by downstream pressure. When operated in unchoked flow conditions, flow from the injector may be affected by downstream pressure.

The pulse widths can be varied by a dose controller to compensate for manufacturing differences between injectors and/or for other non-uniformities. In some examples, the non-uniformities may arise due to dependencies on immediately prior injector doses and flows, etc. The dose controller can also be used to provide time varying gas concentrations, gas doses having spatial skew and/or gas doses having time-based skew.

When the injectors are operated in the choked flow condition, flow is not affected by downstream pressure. In this example, each of the injectors includes a variable flow restrictor (VFR) and a fixed flow restrictor (FFR). For example, a shut off valve and a restricted orifice can be used. The injectors are supplied by a common supply manifold. In some examples, manifold pressure is measured in the manifold and/or at the injectors with pressure sensors having a sampling rate that is higher than a switching frequency of the injectors. In some examples, manifold pressure is measured in the manifold and/or at the injectors with pressure sensors having a sampling rate that is at least <NUM> times higher than a switching frequency of the injectors. In some examples, gas temperature is measured at each of the injectors.

The pressures and temperatures for each of the injectors are output to a dose controller. The dose controller calculates pulse widths for the valve in each of the injectors to provide an accurate mass flow rate as determined by a flow setpoint and a flow function for the injector flow. The flow function is based on manifold pressure, gas temperature at the injector, geometrical parameters and/or empirical test data. In some examples, a pulse width for a dose is defined without gas state conditions and is based a combination of a desired dose, and/or empirical data. In some examples, pressure inside the manifold is actively controlled by a pressure regulator.

When the injectors are operated in an unchoked flow condition, flow may be affected by downstream pressure. In this example, the injectors include a valve and a bypass valve. In some examples, manifold pressure at the manifold or the valves is measured with pressure sensors having a high sampling rate. In some examples, gas temperature is measured at the injector.

The measured pressures and temperatures are output to a dose controller. The dose controller calculates pulse widths for the valves in each injector to provide an accurate mass flow rate as determined by a flow setpoint and a flow function for the injector flow. The flow function is based on manifold pressure, gas temperature at the injector, desired overlap between the valve and the bypass valve, geometrical parameters and/or empirical test data. In some examples, a pulse width for a dose is defined without gas state conditions and is based a combination of a desired dose, desired overlap between the valve and the bypass valve, geometrical parameters and/or empirical test data. In some examples, pressure inside the manifold is actively controlled by a pressure regulator.

Referring now to <FIG>, an example of a substrate processing system <NUM> according to the present disclosure is shown. The substrate processing system <NUM> includes a processing chamber <NUM>. A substrate support <NUM> such as an electrostatic chuck (ESC) is arranged in the processing chamber <NUM>. A substrate <NUM> is arranged on the substrate support <NUM> during processing.

A gas delivery system <NUM> includes gas sources <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-N (collectively gas sources <NUM>) that are connected to valves <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-N (collectively valves <NUM>) and mass flow controllers <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-N (collectively MFCs <NUM>). The MFCs <NUM> control flow of gases from the gas sources <NUM> to a manifold <NUM> where the gases mix. An output of manifold <NUM> is supplied via an optional pressure regulator <NUM> to a manifold <NUM>. An output of the manifold <NUM> is input to a multi-injector showerhead <NUM>. While the manifolds <NUM> and <NUM> are shown, a single manifold can be used.

In some examples, a temperature of the substrate support <NUM> may be controlled by resistive heaters <NUM> and/or coolant channels <NUM>. The coolant channels <NUM> supply cooling fluid from a fluid storage <NUM> and a pump <NUM>. Pressure sensors <NUM>, <NUM> may be arranged in the manifold <NUM> or the manifold <NUM>, respectively, to measure pressure. A valve <NUM> and a pump <NUM> may be used to evacuate reactants from the processing chamber <NUM> and/or to control pressure within the processing chamber <NUM>.

A controller <NUM> includes a dose controller <NUM> that controls dosing provided by the multi-injector showerhead <NUM>. The controller <NUM> also controls gas delivery from the gas delivery system <NUM>. The controller <NUM> controls pressure in the processing chamber and/or evacuation of reactants using the valve <NUM> and the pump <NUM>. The controller <NUM> controls the temperature of the substrate support <NUM> and the substrate <NUM> based upon temperature feedback from sensors (not shown) in the substrate support and/or sensors (not shown) measuring coolant temperature.

Referring now to <FIG>, two of the same type of injectors from the same manufacturer may have manufacturing differences and may not provide the same dose when the same pulse width is used - particularly for shorter pulse widths. If the two injectors (identified as injector <NUM> and injector <NUM> in <FIG>) are controlled with the same pulse width, they will produce different doses because injector <NUM> flows at a higher maximum rate (e.g. standard cubic centimeters per minute (sccm)) than injector <NUM>. According to the present disclosure, when the same dose is desired, different pulse widths are used when controlling injector <NUM> and injector <NUM>. As used herein, the term same dose refers to dosing within <NUM>%, <NUM>% or <NUM>%. A first pulse width output to injector <NUM> will be shorter than a second pulse width output to injector <NUM> to provide the same dose. In other words, the dose controller <NUM> compensates the pulse widths output to the injectors to account for manufacturing differences between injectors. Similar compensation can be made when the injectors are controlled to provide different dosing. In some examples, the injectors are bench tested to determine the differences in gas dosing. In other examples, the injectors are actuated individually and gas dosing is evaluated in situ in the processing chamber.

Referring now to <FIG> and <FIG>, the injectors can be arranged in zones and controlled to provide the same dose, the same dose timing, different doses and/or different dose timing. For example, differential dose timing can be used to create a gas wave across a substrate to be processed. In other words, gas doses can be supplied centrally and then sequentially in successive zones in a radially outer direction (or in an opposite direction from edge to center). In some examples, different doses for the individual injectors can be used to eliminate thickness non-uniformity.

In <FIG>, a plurality of injectors <NUM> (e.g. <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>) are arranged in P zones (e.g. Zone <NUM>, Zone <NUM>, Zone <NUM>, respectively), where P is an integer greater than zero. In <FIG>, the injectors <NUM> in the plurality of zones provide the same dose and the same dose timing. In <FIG>, the injectors <NUM> in the plurality of zones provide the same dose with offset timing. The injectors <NUM> in <FIG> are individually compensated to provide the same dose as described above.

In <FIG>, the injectors <NUM> in the plurality of zones provide different doses and start at the same time. In <FIG>, the injectors <NUM> in the plurality of zones provide different doses and end at the same time. The injectors <NUM> in <FIG> are individually compensated to provide the different doses as described above.

Referring now to <FIG>, various arrangements of the multi-injector showerhead <NUM> are shown. In <FIG>, the multi-injector showerhead <NUM> is shown to include injector assemblies <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively injector assemblies <NUM>) (where X is an integer greater than one). The injector assemblies <NUM> include pressure sensors <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively pressure sensors <NUM>), respectively, to sense a pressure at an inlet of variable flow restrictors (VFR) <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively VFRs <NUM>). A pulse width of the VFRs <NUM> is controlled by the dose controller <NUM> as will be described further below. The injector assemblies <NUM> further include temperature sensors <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively temperature sensors <NUM>) that sense gas temperature. In some examples, fixed flow restrictors (FFRs) <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively FFRs <NUM>) are connected to outlets of the VFRs <NUM>.

In <FIG>, the multi-injector showerhead <NUM> includes injector assemblies <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively injector assemblies <NUM>) (where X is an integer greater than one) including pressure sensors <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively pressure sensors <NUM>), respectively, to sense a pressure at an inlet of valves <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively valves <NUM>). A pulse width of the valves <NUM> is controlled by the dose controller <NUM> as will be described further below. The injector assemblies <NUM> further include temperature sensors <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively temperature sensors <NUM>) that sense gas temperature. In some examples, fixed orifices <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively fixed orifices <NUM>) are connected to an outlet of the valves <NUM>.

In <FIG>, the multi-injector showerhead <NUM> are shown to include injector assemblies <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively injector assemblies <NUM>) (where X is an integer greater than one) including pressure sensors <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively pressure sensors <NUM>), respectively. The pressure sensors <NUM> sense pressure at an inlet of valves <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively valves <NUM>) and bypass valves <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively bypass valves <NUM>). Pulse widths of the valves <NUM> and the bypass valves <NUM> are controlled by the dose controller <NUM> as will be described further below. The injector assemblies <NUM> further include temperature sensors <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively temperature sensors <NUM>) that sense gas temperature. In some examples, fixed orifices <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-X (collectively fixed orifices <NUM>) are arranged at an output of the valves <NUM>.

Referring now to <FIG>, there are other ways of implementing the multi-injector showerhead <NUM> of <FIG>. In <FIG>, an active showerhead <NUM> includes multiple injectors <NUM>. Examples of active showerheads <NUM> are shown and described further in commonly-assigned <CIT> -<NUM>). In <FIG>, an example of an injector <NUM> in the active showerhead <NUM> is shown to include a support layer <NUM>, an actuator layer <NUM>, a diaphragm layer <NUM>, a valve seat layer <NUM> and a gas distribution layer <NUM>. As can be appreciated, the active showerhead <NUM> includes multiple injectors. In some examples, the injectors of the active showerhead <NUM> are formed in substrate layers such as semiconductor wafers. The substrate layers can be formed and then bonded together to form the injector.

The actuator layer <NUM> includes an actuator <NUM> that selectively moves a diaphragm <NUM>. In some examples, the diaphragm includes an optional projection <NUM>. The diaphragm <NUM> is moved up-and-down as shown by arrows to allow gas flow or to prevent gas flow. The diaphragm layer <NUM> defines cavities <NUM> and <NUM>. The valve seat layer <NUM> defines cavities <NUM> and <NUM>. The gas distribution layer <NUM> defines an opening <NUM> and cavities <NUM> and <NUM>. In some examples, a filter <NUM> is arranged in the cavity <NUM>. Gas from a manifold or other gas source is supplied to the opening <NUM>. When the diaphragm <NUM> is open as shown in <FIG>, the gas flows through the cavity <NUM>, the cavity <NUM>, the cavity <NUM>, through the filter <NUM> (if used), and through the cavity <NUM> into the processing chamber. The actuator <NUM> moves the diaphragm <NUM> into a closed position by biasing a bottom surface thereof (the projection <NUM> if used) into an inlet <NUM>. In some examples, pressure and temperature sensors <NUM> and <NUM>, respectively, are used to measure pressure and temperature in the cavity <NUM>.

Referring now to <FIG>, methods for operating the injectors are shown. In <FIG>, a method <NUM> includes determining a desired gas dose for each injector of a plurality of injectors at <NUM>. At <NUM>, pressure is measured at the manifold or at the gas injector. At <NUM>, gas temperature is measured at the gas injector. At <NUM>, pulse width or duration is adjusted for each injector based on a flow relationship to provide the desired gas dose. The flow relationship is a function of measured pressure and temperature, overlap between bypass valve and the flow valve, geometrical parameters and/or empirical data.

In <FIG>, dose adjustment is performed in a method <NUM> without full knowledge of the gas state. At <NUM>, a desired gas dose for each injector is determined. At <NUM>, pulse width or duration is adjusted for each injector based on a flow relationship to provide the desired gas dose. The flow relationship is a function of overlap between bypass valve and the flow valve, geometrical parameters and/or empirical data.

In <FIG>, a method <NUM> includes determining a desired gas dose for each injector of a plurality of injectors at <NUM>. At <NUM>, pressure is measured at the manifold or at the gas injector. At <NUM>, gas temperature is measured at the gas injector. At <NUM>, pulse width or duration is adjusted for each injector based on a flow relationship to provide the desired gas dose. The flow relationship is a function of measured pressure and temperature, overlap between bypass valve and the flow valve, geometrical parameters and/or empirical data.

In <FIG>, dose adjustment is performed in a method <NUM> without full knowledge of the gas state. The method <NUM> includes determining a desired gas dose for each injector of a plurality of injectors at <NUM>. At <NUM>, pulse width or duration is adjusted for each injector based on a flow relationship to provide the desired gas dose. The flow relationship is a function of overlap between the bypass valve and the flow valve, geometrical parameters and/or empirical data.

Referring now to <FIG>, a substrate processing system <NUM> including one or more processing chambers including multiple injectors (such as those described above) that provide compensation for upstream and/or downstream substrate non-uniformity or skew (collectively referred to herein as skew). Skew data may correspond to substrate film with a center region that is thicker than an edge region, an edge region that is thicker than a center region, side to side variations, or other variations from a flat surface. The skew may be caused by an upstream process or anticipated skew that is expected from a downstream process. The skew data can be generated for the same substrate that is to be processed, test substrates, modelling, and/or one or more substrates that preceded the substrate to be processed. The skew data can be generated as a function of two or more substrates (such as an average, moving average, a statistical function, etc.).

A processing chamber <NUM> performs substrate treatment such as deposition, etching or other substrate treatment on a substrate. In some examples, the substrate treatment that is performed creates skew that is compensated during downstream processing. In some examples, a metrology station <NUM> is located downstream from the processing chamber <NUM> to perform one or more measurements on the substrate after processing and to generate metrology data for the substrate. In some examples, the metrology station <NUM> generates skew data based on film thickness measurements and/or generates a surface model for the substrate. The metrology station <NUM> outputs the metrology data to a processing chamber <NUM> that is located downstream. The processing chamber <NUM> includes multiple injectors and performs dose control as described herein to compensate for the skew. The processing chamber <NUM> uses the metrology data to determine the amount of compensation that is needed to offset the skew that was introduced by the processing chamber <NUM>. In other examples, the metrology station <NUM> is omitted and compensation is performed based on modeling, prior metrology measurements made during process setup or other data.

For example, the processing chamber <NUM> may perform deposition of film or etching of film. In some examples, the processing chamber <NUM> performs deposition of film that is thicker at the center or edge of the substrate. In some examples, the processing chamber <NUM> performs etching that removes more film at the center or edge of the substrate than is desired. The metrology data detects the skew and the dose controller associated with the processing chamber <NUM> compensates for the skew.

After the substrate is processed in the processing chamber <NUM>, the substrate may be further processed in a processing chamber <NUM> that is located downstream therefrom. After processing in the processing chamber <NUM>, metrology data is generated by the metrology station <NUM>. The metrology data is fed back to the processing chamber <NUM> to allow pre-compensation for downstream skew. In other examples, the metrology station <NUM> is omitted and compensation is performed based on modeling, prior metrology measurements made during setup or other data.

Referring now to <FIG>, the processing chamber <NUM> includes a controller <NUM> with a dose controller <NUM>. The dose controller <NUM> further includes a compensation module <NUM> that receives skew data from the metrology station <NUM>, a data store <NUM> or another data source. The compensation module <NUM> further receives a desired spatial map <NUM> for the incoming substrate. The compensation module <NUM> generates skew compensation data that is output to a dose mapping module <NUM>. The dose mapping module <NUM> compensates a base dose map <NUM> based on the skew compensation data from the compensation module <NUM>. For example, when additional or decreased etching or deposition is desired in a particular area, a local dose or duration of exposure to precursor or etching gas, respectively, can be increased or decreased relative to other areas. The dose mapping module <NUM> outputs a compensated dose map to an injector control module <NUM>, which controls the injectors accordingly.

Referring now to <FIG>, a method <NUM> for processing a substrate using multiple injectors that are controlled using skew data to compensate for skew of the incoming substrate is shown. At <NUM>, skew data for the substrate (such as a spatial map or set of parameters) are received for the incoming substrate (or for a typical or expected incoming substrate). At <NUM>, the skew data is compared to a desired spatial map or set of parameters. At <NUM>, compensation for upstream skew is determined. At <NUM>, a compensated dose map is generated based on the base dose map and the compensation.

Referring now to <FIG> and <FIG>, an example of a processing chamber including injectors that are controlled to pre-compensate for skew caused by one or more downstream processes is shown. In <FIG>, the processing chamber <NUM> includes a controller <NUM> with a dose controller <NUM>. The dose controller <NUM> includes a dose mapping module <NUM> that receives a desired skew <NUM> to pre-compensate the outgoing substrate for skew caused by one or more downstream processes. The dose mapping module <NUM> compensates a base dose map <NUM> based on the desired skew for the outgoing substrate to pre-compensate for downstream skew. The dose mapping module <NUM> outputs the compensated dose map to an injector control module <NUM>.

In <FIG>, an example of a system for generating the desired skew for the outgoing substrate is shown. The dose controller <NUM> further includes the metrology station <NUM> or a data store <NUM> that outputs a spatial map or a set of parameters to a compensation module <NUM>. The compensation module <NUM> further receives a desired spatial map for the downstream substrate at <NUM>. The compensation module <NUM> generates the desired skew for the outgoing substrate. As can be appreciated, the system shown in <FIG> can be combined with the system shown in <FIG>. Furthermore, the systems shown in <FIG> and <FIG> can be combined with the system shown in <FIG>.

Referring now to <FIG>, a method <NUM> for processing a substrate using injectors that compensate the outgoing substrate to offset skew caused by one or more downstream processes is shown. At <NUM>, skew data is received for one or more downstream processes. At <NUM>, the skew data is compared to a desired spatial map. At <NUM>, compensation is determined to pre-compensate for the skew of the one or more downstream processes. At <NUM>, a compensated dose map is generated based on a base dose map and compensation for the one or more downstream processes.

Referring now to <FIG>, the injectors can be addressed individually and/or arranged into groups to define various types of zones or zone shapes. For example, the groups may correspond to radial zones, pie-shaped zones and/or sliced zones. In <FIG>, the injectors are grouped into radial zones Z1, Z2, Z3 and Z4. While four radial zones are shown, additional or fewer numbers of radial zones can be used. In <FIG>, the injectors are grouped into the radial zones and/or into pie-shaped zones Q1, Q2, Q3 and Q4. While four pie-shaped zones are shown, additional or fewer pie-shaped zones can be used. In <FIG>, slices S1, S2,. , and S10 are shown that can be used in addition to or instead of the examples in <FIG>. In some examples, sides of the slices are parallel and abut adjacent slices. An angular orientation or angular offset of the slices can be varied as needed relative to a slot in the substrate or to a predetermined reference in the processing chamber. The slices may be used to accommodate side-to-side skew.

Referring now to <FIG> and <FIG>, examples of timing diagrams illustrating injector timing for spatial-based skew by individual injectors or groups of injectors is shown. One or more of the timing diagrams in <FIG> provide different injector dose control timing to individual injectors or groups of injectors. Individual injectors or groups of injectors associated with timing profile A have slowly decreasing pulse widths as a function of time. Individual injectors or groups of injectors associated with timing profiles B and C have pulse widths that decrease at a slightly faster rate as compared to timing profile A. Individual injectors or groups of injectors associated with timing profile D have fixed pulse widths during the corresponding periods. The variable pulse widths associated with the individual injectors or groups of injectors allow precise control of spatial and/or temporal dosing.

In <FIG>, the timing profiles can be used to produce different spatial patterns. Injectors or groups of injectors associated with timing profile D have fixed pulse widths during the corresponding periods. Injectors or groups of injectors associated with timing profiles B and C have about ½ the duration of the pulses in timing profile D. Injectors or groups of injectors associated with timing profile A have a similar pulse width as timing profiles B and C for some time periods and other time periods are skipped. The variable pulse widths associated with the individual injectors or groups of injectors allow precise control of spatial and/or temporal dosing.

Referring now to <FIG>, a portion of a processing chamber <NUM> is shown to include multiple manifolds <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-N (collectively manifolds <NUM>) and gas delivery systems <NUM>-<NUM>, <NUM>-<NUM>,. <NUM>-N (collectively gas delivery systems <NUM>) where N is an integer greater than one. The manifolds <NUM> supply different gas mixtures to groups of injector assemblies <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-Y (collectively groups of injector assemblies <NUM>) where Y is an integer greater than one. While one gas delivery system is shown per manifold, additional or fewer gas delivery systems can be used.

As will be described further below, the injector assemblies <NUM> can be configured to create temporal skew. Each of the groups of injector assemblies <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-Y includes N injectors <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-YN. Each of the N injectors in the groups of injector assemblies <NUM> is connected to one of the N manifolds <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-N, respectively. The arrangement allows the gas mixtures supplied to the N manifolds <NUM> to be delivered to each of the groups of injector assemblies <NUM>.

Referring now to <FIG>, each of the manifolds <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-N defines a plenum <NUM>-<NUM>, <NUM>-<NUM>,. , and <NUM>-N (collectively plenums <NUM>) and includes a plurality of through holes <NUM>. In some examples, the plenums <NUM> are generally shaped like a flat cylinder. To maintain separation of gas mixtures from the plenum <NUM>-<NUM>, posts <NUM> with corresponding aligned through holes <NUM> are arranged in lower plenums <NUM>-<NUM>. <NUM>-N to allow the gas mixture in the plenum <NUM>-<NUM> to travel through the through holes <NUM> and <NUM> to reach a corresponding injector without intermixing in the plenums <NUM>-<NUM>. A similar approach is used for other ones of the plenums <NUM>. While a specific arrangement of manifolds is shown, other manifold arrangements can be used.

Using the processing chamber shown in <FIG>, temporal skew can be performed. An example of temporal skew is shown in <FIG>. In first locations <NUM> (including one or more injector assemblies), the gas mixture is switched from a first gas mixture <NUM> to a second gas mixture <NUM> at time t1 and then to a third gas mixture <NUM> at time t3. In second locations <NUM> (including one or more injector assemblies), the gas mixture is switched from a first gas mixture <NUM> to a second gas mixture <NUM> at time t2 and then to a third gas mixture <NUM> at time t4. In third locations <NUM> (including one or more injector assemblies), the gas mixture is switched from a first gas mixture <NUM> to a second gas mixture <NUM> at time t3 and then to a third gas mixture <NUM> at time t4. In a fourth location <NUM> (including one or more injector assemblies), the gas mixture is switched from a first gas mixture <NUM> to a second gas mixture <NUM> at time t4 and then to a third gas mixture <NUM> at time t5.

For example, the first locations <NUM> may correspond to a central zone, and locations <NUM>-<NUM> may correspond to increasing radial zones around the central zone (although the same approach can be used for other groups of injectors having other shapes). As can be appreciated, the gas mixtures that are used will depend on the process and may include deposition gas mixtures, etch gas mixtures, purge gas, or other gas mixtures. For example, the gas mixture <NUM> may include a first precursor for an ALD or ALE process, the second gas mixture may include purge gas, and the third gas mixture may include a second precursor for the ALD or ALE process.

Referring now to <FIG>, a processing chamber <NUM> includes multiple injectors <NUM> that are grouped in various ways as described herein. The injectors <NUM> are controlled by a dose controller <NUM> to provide predefined ratios of a main flow rate. The main flow rate is supplied by a gas delivery system <NUM> including gas sources <NUM> and MFCs <NUM> to a manifold <NUM>. In the example shown in <FIG>, the injectors <NUM> are divided into R groups (GRP <NUM>, GRP <NUM>,. and GRP R) that are associated with R spatial areas of the substrate. Each of the R groups may include the same number or a different number of injectors.

In one example, it is desirable to supply two or more different ratios of a predetermined main flow rate to the R spatial areas of the substrate. For example, etch or deposition processes may require more etch gas or deposition precursor gas to be delivered at center or edge areas as compared to other areas of the substrate. Varying the pulse widths to the injectors in the R groups allows predetermined ratios of the main flow at the manifold <NUM> to be delivered to the R spatial areas without requiring flow splitters.

Traditionally, gas flowing from the manifold <NUM> would be split using the flow splitters. In some examples, the flow splitters include sonic nozzles. However, systems using flow splitters take a long time to reach steady state flow conditions. Therefore, flow splitters are difficult to use in processes requiring improved spatial control and/or fast gas exchanges such as ALD and ALE processes.

The injectors associated with the R groups are controlled using R pulse widths to provide R predetermined ratios of the main flow rate supplied to the manifold <NUM>, where R is an integer greater than zero.

For example, all of the R groups can be pulsed using the same pulse widths to supply the same dose (assuming the groups have the same number of injectors). Alternately, two or more different pulse widths can be used to vary the ratios for at least some of the R groups. For example, one of the R groups may be pulsed using ½ of the pulse width of others of the R groups to flow less to the one of the R groups and more to the others of the R groups. In another example, the pulse widths to all of the R groups are varied to provide an increasing spatial profile, a decreasing spatial profile, a bell-shaped profile, an inverted bell-shaped profile or other gas dosing profiles.

Referring now to <FIG>, a method <NUM> for splitting a main gas flow into R gas flows supplied to R spatial areas of a substrate is shown. At <NUM>, a ratio of a main gas flow to be delivered to each of the R spatial areas of the substrate is determined. At <NUM>, pulse widths for the injectors corresponding to the R spatial areas of the substrate are determined to provide the R ratios. At <NUM>, a main gas flow rate is supplied to the manifold. At <NUM>, the gas flow rate supplied to the manifold is split using the R pulse width values corresponding to the injectors in the R spatial areas.

Some embodiment variations may be considered as long as they do not go beyond the scope of the invention.

Spatial and functional relationships between elements (for example, between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "engaged," "coupled," "adjacent," "next to," "on top of," "above," "below," and "disposed. " Unless explicitly described as being "direct," when a relationship between first and second elements is described in the above disclosure, that relationship can be a direct relationship where no other intervening elements are present between the first and second elements, but can also be an indirect relationship where one or more intervening elements are present (either spatially or functionally) between the first and second elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean "at least one of A, at least one of B, and at least one of C.

In some implementations, a controller is part of a system, which may be part of the above-described examples. Such systems can comprise semiconductor processing equipment, including a processing tool or tools, chamber or chambers, a platform or platforms for processing, and/or specific processing components (a wafer pedestal, a gas flow system, etc.). These systems may be integrated with electronics for controlling their operation before, during, and after processing of a semiconductor wafer or substrate. The electronics may be referred to as the "controller," which may control various components or subparts of the system or systems. The controller, depending on the processing requirements and/or the type of system, may be programmed to control any of the processes disclosed herein, including the delivery of processing gases, temperature settings (e.g., heating and/or cooling), pressure settings, vacuum settings, power settings, radio frequency (RF) generator settings, RF matching circuit settings, frequency settings, flow rate settings, fluid delivery settings, positional and operation settings, wafer transfers into and out of a tool and other transfer tools and/or load locks connected to or interfaced with a specific system.

Broadly speaking, the controller may be defined as electronics having various integrated circuits, logic, memory, and/or software that receive instructions, issue instructions, control operation, enable cleaning operations, enable endpoint measurements, and the like. The integrated circuits may include chips in the form of firmware that store program instructions, digital signal processors (DSPs), chips defined as application specific integrated circuits (ASICs), and/or one or more microprocessors, or microcontrollers that execute program instructions (e.g., software). Program instructions may be instructions communicated to the controller in the form of various individual settings (or program files), defining operational parameters for carrying out a particular process on or for a semiconductor wafer or to a system. The operational parameters may, in some embodiments, be part of a recipe defined by process engineers to accomplish one or more processing steps during the fabrication of one or more layers, materials, metals, oxides, silicon, silicon dioxide, surfaces, circuits, and/or dies of a wafer.

The controller, in some implementations, may be a part of or coupled to a computer that is integrated with the system, coupled to the system, otherwise networked to the system, or a combination thereof. For example, the controller may be in the "cloud" or all or a part of a fab host computer system, which can allow for remote access of the wafer processing. The computer may enable remote access to the system to monitor current progress of fabrication operations, examine a history of past fabrication operations, examine trends or performance metrics from a plurality of fabrication operations, to change parameters of current processing, to set processing steps to follow a current processing, or to start a new process. In some examples, a remote computer (e.g. a server) can provide process recipes to a system over a network, which may include a local network or the Internet. The remote computer may include a user interface that enables entry or programming of parameters and/or settings, which are then communicated to the system from the remote computer. In some examples, the controller receives instructions in the form of data, which specify parameters for each of the processing steps to be performed during one or more operations. It should be understood that the parameters may be specific to the type of process to be performed and the type of tool that the controller is configured to interface with or control. Thus as described above, the controller may be distributed, such as by comprising one or more discrete controllers that are networked together and working towards a common purpose, such as the processes and controls described herein. An example of a distributed controller for such purposes would be one or more integrated circuits on a chamber in communication with one or more integrated circuits located remotely (such as at the platform level or as part of a remote computer) that combine to control a process on the chamber.

Without limitation, example systems may include a plasma etch chamber or module, a deposition chamber or module, a spin-rinse chamber or module, a metal plating chamber or module, a clean chamber or module, a bevel edge etch chamber or module, a physical vapor deposition (PVD) chamber or module, a chemical vapor deposition (CVD) chamber or module, an atomic layer deposition (ALD) chamber or module, an atomic layer etch (ALE) chamber or module, an ion implantation chamber or module, a track chamber or module, and any other semiconductor processing systems that may be associated or used in the fabrication and/or manufacturing of semiconductor wafers.

Claim 1:
A substrate processing system (<NUM>) for treating a substrate (<NUM>), comprising:
a manifold (<NUM>);
a plurality of injector assemblies (<NUM>-<NUM>, <NUM>-<NUM>,..., <NUM>-X / <NUM>-<NUM>, <NUM>-<NUM>,..., <NUM>-X) located in a processing chamber (<NUM>), wherein each of the plurality of injector assemblies is in fluid communication with the manifold and includes a valve (<NUM>-<NUM>, <NUM>-<NUM>,..., <NUM>-X / <NUM>-<NUM>, <NUM>-<NUM>,..., <NUM>-X) including an inlet and an outlet; and
a dose controller (<NUM>) configured to:
communicate with the valve in each of the plurality of injector assemblies;
adjust a pulse width supplied to the valve in each of the plurality of injector assemblies to provide spatial dosing and at least one of:
compensate for upstream skew caused by a prior process; and
pre-compensate for downstream skew expected from a subsequent process.