Patent Description:
Micro-electronic circuits and other micro-scale devices are generally manufactured from a substrate, such as a silicon or other semiconductor material substrate. Multiple metal layers are applied onto the substrate to form micro-electronic or other micro-scale components or to provide electrical connections. These metal layers, e.g., copper, are plated onto the substrate, and form the components and interconnects in a sequence of photolithographic, plating, etching, polishing, or other operations.

To achieve desired material properties the substrate is typically put through an annealing process in which the substrate is quickly heated, usually to about <NUM>-<NUM>. The substrate may be held at these temperatures for a relatively short time, e.g., <NUM>-<NUM> seconds. The substrate is then rapidly cooled, with the entire process usually taking only a few minutes. Annealing may be used to change the material properties of the layers on the substrate. It may also be used to activate dopants, drive dopants between films on the substrate, change film-to-film or film-to-substrate interfaces, densify deposited films, or to repair damage from ion implantation. <CIT> relates to a substrate-treating apparatus. <CIT> relates to a load lock system for supercritical fluid cleaning. <CIT> relates to apparatuses for high pressure gas annealing. <CIT> relates to multi-pressure workpiece processing. <CIT> relates to a chlorotrifluorine gas generator system.

As feature sizes for microelectronic devices and interconnects become smaller, the allowable defect rate decreases substantially. Some defects result from contaminant particles. Other defects can result from incomplete processing of certain regions of the substrate, e.g., failure to grow a film at the bottom of a trench.

Various annealing chambers have been used in the past. In single substrate processing equipment, these annealing chambers typically position the substrate between or on heating and cooling elements, to control the temperature profile of the substrate. However, achieving precise and repeatable temperature profiles, as well as an acceptable level of defects, can present engineering challenges.

In one aspect, a method of operating a high-pressure processing system according to claim <NUM> is provided. In a further aspect, a high-pressure processing system according to the independent system claim is provided.

In one example, a high-pressure processing system for processing a layer on a substrate is provided. The system includes a first chamber, a support to hold the substrate in the first chamber, a second chamber adjacent the first chamber, a foreline to remove gas from the second chamber, a vacuum processing system configured to lower a pressure within the second chamber, a valve assembly between the first chamber and the second chamber to isolate the pressure within the first chamber from the pressure within the second chamber, a gas delivery system configured to introduce one or more gases into the first chamber and to increase the pressure within the first chamber to at least <NUM> Torr (<NUM> atmospheres) while the gas is in the first chamber and while the first chamber is isolated from the second chamber, a controller configured to operate the gas delivery system and the valve assembly, an exhaust system comprising an exhaust line to remove gas from the first chamber, and a common housing surrounding both the first gas delivery module and the second gas delivery module. The gas delivery system includes a first gas delivery module to deliver a first gas at a first pressure that is at least <NUM> Torr (<NUM> atmospheres), and a second gas delivery module to deliver the first gas or a second gas of different composition at a second pressure that is less than the first pressure but greater than <NUM> Torr (<NUM> atmosphere).

Implementations may include one or more of the following features.

A second exhaust system may be configured to remove gas from the common housing. The second exhaust system may be configured to direct gas from the housing to the foreline. First and second delivery lines may couple the first and second gas delivery modules to the first chamber. A containment enclosure may be configured to divert gas leaking from the first and second delivery lines to the foreline. The common housing may be fluidically isolated from the containment enclosure.

In another example, a high-pressure processing system for processing a layer on a substrate includes a first chamber, a support to hold the substrate in the first chamber, a second chamber adjacent the first chamber, a foreline to remove gas from the second chamber, a vacuum processing system configured to lower a pressure within the second chamber to near vacuum, a valve assembly between the first chamber and the second chamber to isolate the pressure within the first chamber from the pressure within the second chamber, a gas delivery system configured to introduce one or more gases into the first chamber and to increase the pressure within the first chamber to at least <NUM> Torr (<NUM> atmospheres) while the gas is in the first chamber and while the first chamber is isolated from the second chamber, an exhaust system comprising an exhaust line to remove gas from the first chamber, and a controller. The gas delivery system includes a first gas delivery module to deliver a first gas at a first pressure that is at least <NUM> Torr (<NUM> atmospheres), and a second gas delivery module to deliver the first gas or a second gas of different composition at a second pressure that is less than the first pressure but greater than <NUM> Torr (<NUM> atmosphere). The controller is configured configured to operate the gas delivery system, valve assembly, vacuum processing system and exhaust system such that the valve assembly isolates the first chamber from the second chamber, then the second gas delivery module raises the first chamber from a pressure below <NUM> Torr (<NUM> atmosphere) to the second pressure, then the second gas delivery module is isolated from the first chamber, and then the first gas delivery module raises the first chamber from the second pressure to the first pressure.

The first gas delivery module may include a pump configured to increase pressure of the first gas before delivering the first gas to the first chamber. The second gas delivery module may use a mass flow controller, liquid flow meter or liquid flow controller to direct the gas to the first chamber. A first pressure sensor may be positioned in the first chamber and a second pressure sensor may be positioned in the second chamber. The controller may be configured to cause the exhaust system to reduce pressure in the first chamber and cause the vacuum processing system to reduce pressure in the second chamber. The controller may be configured to compare measurements from the first pressure sensor and the second pressure sensor and control the exhaust system and the vacuum processing system such that a pressure in the first chamber is higher than a pressure in the second chamber.

In another example, a method of operating a high-pressure processing system is provided that includes bringing a first chamber and a second chamber to a first pressure that is less than <NUM> Torr (one atmosphere), while an isolation valve between the first chamber and second chamber is open transporting a substrate from the second chamber into the first chamber, while the isolation valve is closed reducing the first chamber from the first pressure to a second pressure and reducing the second chamber from the first pressure to a third pressure, pressurizing the first chamber to a fourth pressure that is above atmospheric pressure and less than <NUM> Torr (<NUM> atmospheres) with a second gas delivery module, pressurizing the first chamber to a fifth pressure that is above <NUM> Torr (<NUM> atmospheres) with a first gas delivery module, processing the substrate while the first chamber is at the fifth pressure, evacuating first chamber, and opening the isolation valve and removing the substrate from the first chamber.

Pressuring the first chamber to the fifth pressure may include supplying a first gas to the first chamber, and pressurizing the first chamber to the fourth pressure may include supplying a second gas of different composition to the first chamber. The first gas may include at least one of H<NUM> or NH<NUM>. Pressurizing the first chamber with the second gas delivery module may include isolating the first gas delivery module from the first chamber with a high-pressure isolation valve in a delivery line between the first gas delivery module and the first chamber and fluidically coupling the second gas delivery module and the first chamber by opening a low-pressure isolation valve in a delivery line between the second gas delivery module and the first chamber. Pressurizing the first chamber with the first gas delivery module may include isolating the second gas delivery module from the first chamber with the low-pressure isolation valve and fluidically coupling the first gas delivery module and the first chamber by opening the high-pressure isolation valve.

The third pressure may be than the second pressure. Measurements from a first pressure sensor in the first chamber and a second pressure sensor in the second chamber may be compared and pressure may be continued to be reduced in the first chamber and second pressure until a pressure in the first chamber is higher than a pressure in the second chamber. Evacuating the first chamber may include lowering a pressure in the first chamber to a sixth pressure that is less than the first pressure. The sixth pressure may be greater than the third pressure.

Implementations may include one or more of the following advantages.

High pressure can be established in a chamber more safely. Leaks can be detected.

A layer can be treated or formed more uniformly across the substrate. In addition, high-pressure processing can also provide access to chemical reactions that are not available at lower pressures.

As noted above, some defects can result from incomplete processing of certain regions of a substrate. However, high-pressure processing (e.g., annealing or deposition) can improve consistency of processing across the substrate. In particular, annealing can occur in a high-pressure environment. Where a layer is formed using an annealing process, e.g., by thermal oxidation or other process in which chemistry diffuses into and reacts with the material disposed on substrate, the high pressure can help improve thoroughness of surface coverage of the layer of material on the substrate. For example, problems of treatment formation of a layer in a trench can be reduced. As a result, a layer can be treated or formed more uniformly across the substrate. In addition, high-pressure processing (e.g., annealing or deposition) can also provide access to chemical reactions that are not available at lower pressures.

Another issue is that certain materials, such as copper, will rapidly oxidize when exposed to oxygen, at temperatures over about <NUM>° C. If the copper or other material oxidizes, the substrate may no longer be useable, or the oxide layer must first be removed before further processing. These are both unacceptable options for efficient manufacturing. Accordingly, a design factor is to isolate the substrate from oxygen, particularly when the substrate temperature is over about <NUM>° C. Since oxygen is of course present in ambient air, avoiding oxidation of copper during annealing also can present engineering challenges. As described herein, the substrate can be transferred between the high-pressure processing chamber and different processing chambers in the low-pressure, e.g., near-vacuum, environment to avoid contamination and oxidation of the substrate.

Another consideration is pressure. Very high pressures can improve the consistency and quality of the substrates produced. However, systems that have high pressure (e.g., above <NUM> Torr (<NUM> atm), above <NUM> Torr (<NUM> atm), or up to <NUM> Torr (<NUM> atm)) are at high risk of breach and loss of containment. A system with enhanced safety features is beneficial for use of such ultra-high pressure processing.

<FIG> shows an integrated multi-chamber substrate processing system suitable for performing at least one embodiment of physical vapor deposition, chemical vapor deposition, and/or annealing processes. In general, the multi-chamber substrate processing system includes at least one high-pressure processing chamber, e.g., able to operate at pressures above <NUM> Torr (<NUM> atmospheres), to perform a high-pressure process such as deposition or annealing, and at least one low-pressure processing chamber, e.g., able to operate a low pressure, e.g., below <NUM> Torr (<NUM> atmosphere), to perform a low-pressure process such as etching, deposition, or thermal treatment. In some implementations the multi-chamber processing system is a cluster tool having a central transfer chamber that is at low pressure and from which multiple processing chambers can be accessed.

Some embodiments of the processes and systems described herein relate to depositing layers of material, e.g., metal and metal silicide barriers, for feature definitions. For example, a first metal layer is deposited on a silicon substrate and annealed to form a metal silicide layer. A second metal layer is then deposited on the metal silicide layer to fill the feature. The annealing process to form the metal silicide layer may be performed in multiple annealing operations.

<FIG> is a schematic top view of one embodiment a processing platform <NUM> including two transfer chambers <NUM>, <NUM>, transfer robots <NUM>, <NUM> positioned in the transfer chambers <NUM>, <NUM>, respectfully, and processing chambers <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, disposed on the two transfer chambers <NUM>, <NUM>. The first and second transfer chambers <NUM>, <NUM> are central vacuum chambers that interface with adjacent processing chambers <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>.

The first transfer chamber <NUM> and the second transfer chamber <NUM> are separated by pass-through chambers <NUM>, which may comprise cooldown or pre-heating chambers. The pass-through chambers <NUM> also may be pumped down or ventilated during substrate handling when the first transfer chamber <NUM> and the second transfer chamber <NUM> operate at different pressures. For example, the first transfer chamber <NUM> may operate between about <NUM> milliTorr and about <NUM> Torr, such as about <NUM> milliTorr, and the second transfer chamber <NUM> may operate between about <NUM>×<NUM>-<NUM> Torr and about <NUM>×<NUM>-<NUM> Torr, such as about <NUM>×<NUM>-<NUM> Torr.

The processing platform <NUM> is operated by a programmed controller <NUM>. The controller <NUM> can control the transfer robots <NUM>, <NUM> to transport the substrates between the chambers, and can cause each of the chambers of the processing platform <NUM> to perform individual operations to process the substrate.

The first transfer chamber <NUM> is coupled with two degas chambers <NUM>, two load lock chambers <NUM>, a reactive pre-clean chamber <NUM>, at least one physical vapor deposition chamber <NUM>, and the pass-through chambers <NUM>. The pre-clean chamber may be a PreClean II chamber, commercially available from Applied Materials, of Santa Clara, Calif. Substrates (not shown) are loaded into the processing platform <NUM> through load lock chambers <NUM>. For example, a factory interface module <NUM>, if present, would be responsible for receiving one or more substrates, e.g., cassettes of substrates, or enclosed pods of substrates, from either a human operator or an automated substrate handling system. The factory interface module <NUM> can open the cassettes or pods of substrates, if applicable, and move the substrates to and from the load lock chambers <NUM>. The processing chambers <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> receive the substrates from the transfer chambers <NUM>, <NUM>, process the substrates, and allow the substrates to be transferred back into the transfer chambers <NUM>, <NUM>. After being loaded into the processing platform <NUM>, the substrates are sequentially degassed and cleaned in degas chambers <NUM> and the pre-clean chamber <NUM>, respectively.

Each of the processing chambers are isolated from the transfer chambers <NUM>, <NUM> by an isolation valve which allows the processing chambers to operate at a different level of vacuum than the transfer chambers <NUM>, <NUM> and prevents any gasses being used in the processing chamber from being introduced into the transfer chamber. The load lock chambers <NUM> are also isolated from the transfer chamber <NUM>, <NUM> with isolation valves. Each load lock chamber <NUM> has a door which opens to the outside environment, e.g., opens to the factory interface module <NUM>. In normal operation, a cassette loaded with substrates is placed into the load lock chamber <NUM> through the door from the factory interface module <NUM> and the door is closed. The load lock chamber <NUM> is then evacuated to the same pressure as the transfer chamber <NUM> and the isolation valve between the load lock chamber <NUM> and the transfer chamber <NUM> is opened. The robot in the transfer chamber <NUM> is moved into position and one substrate is removed from the load lock chamber <NUM>. The load lock chamber <NUM> is equipped with an elevator mechanism so as one substrate is removed from the cassette, the elevator moves the stack of substrates in the cassette to position another substrate in the transfer plane so that it can be positioned on the robot blade.

The transfer robot <NUM> in the transfer chamber <NUM> rotates with the substrate so that the substrate is aligned with a processing chamber position. The processing chamber is flushed of any toxic gasses, brought to the same pressure level as the transfer chamber, and the isolation valve is opened. The transfer robot <NUM> then moves the substrate into the processing chamber where it is lifted off the robot. The transfer robot <NUM> is then retracted from the processing chamber and the isolation valve is closed. The processing chamber then goes through a series of operations to execute a specified process on the substrate. When complete, the processing chamber is brought back to the same environment as the transfer chamber <NUM> and the isolation valve is opened. The transfer robot <NUM> removes the substrate from the processing chamber and then either moves it to another processing chamber for another operation or replaces it in the load lock chamber <NUM> to be removed from the processing platform <NUM> when the entire cassette of substrates has been processed.

The transfer robots <NUM>, <NUM> include robot arms <NUM>, <NUM>, respectively, that support and move the substrate between different processing chambers. The transfer robot <NUM> moves the substrate between the degas chambers <NUM> and the pre-clean chamber <NUM>. The substrate may then be transferred to the long throw PVD chamber <NUM> for deposition of a material thereon.

The second transfer chamber <NUM> is coupled to a cluster of processing chambers <NUM>, <NUM>, <NUM>, <NUM>. The processing chambers <NUM>, <NUM> may be chemical vapor deposition (CVD) chambers for depositing materials, such as tungsten, as desired by the operator. The PVD processed substrates are moved from the first transfer chamber <NUM> into the second transfer chamber <NUM> via the pass-through chambers <NUM>. Thereafter, the transfer robot <NUM> moves the substrates between one or more of the processing chambers <NUM>, <NUM>, <NUM>, <NUM> for material deposition and annealing as required for processing.

Of course, all of the above is simply an exemplary implementation; each transfer chamber could have just a different number of processing chambers, e.g., one to five chambers, the processing chambers could have different distribution of functions, the system could have a different number of transfer chambers, e.g., just a single transfer chamber, and the transfer chambers could be omitted entirely and the system could have just a single stand-alone processing chamber.

<FIG> illustrates a controlled high-pressure processing system <NUM> that creates a high-pressure environment for processing a substrate and a low-pressure environment for the substrate when the substrate is being transferred between processing chambers. The controlled high-pressure processing system <NUM> includes a high-pressure inner first chamber <NUM> and low-pressure outer second chamber <NUM>.

The first chamber <NUM> can correspond to one of the processing chambers <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> of the processing platform <NUM>, and the second chamber <NUM> can correspond to one of the transfer chambers <NUM>, <NUM> of the processing platform <NUM>. Alternatively, in some implementations, one of the processing chambers <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> includes both the first chamber <NUM> and the second chamber <NUM>. The first chamber <NUM> can correspond to an inner chamber, and the second chamber <NUM> can correspond to an outer chamber surrounding the inner chamber.

The pressure within the first chamber <NUM> can be controlled independently of the pressure in the second chamber <NUM>. If the first and second chambers <NUM>, <NUM> are distinct from the transfer chambers, the first and second chambers <NUM>, <NUM> can have pressures that are controlled independently of the pressures within the transfer chambers. The controlled high-pressure system <NUM> further includes a gas delivery system <NUM>, a vacuum processing system <NUM>, and a controller <NUM>. In some examples, the controller <NUM> of the processing platform <NUM> can include the controller <NUM>.

The first chamber <NUM> is configured, e.g., sealed and reinforced, to accommodate very high pressures, e.g., a pressure of at least <NUM> Torr (<NUM> atmospheres), e.g., a pressure of <NUM> Torr - <NUM> Torr (<NUM>-<NUM> atm). In contrast, the second chamber <NUM> is configured, e.g., sealed and reinforced, to accommodate very low pressures, e.g., a pressure lower than <NUM> Torr (<NUM> atmosphere), e.g., a pressure down to about <NUM> mTorr. The low pressure environment of the second chamber <NUM> can inhibit contamination and/or oxidation of the substrate or the material deposited on the substrate.

The second chamber <NUM> is adjacent to the first chamber <NUM>. In some implementations, the second chamber <NUM> also surrounds the first chamber <NUM> (if the second chamber <NUM> does not surround the first chamber, the second chamber can still be considered an outer chamber in that the substrate would pass through the second chamber to reach the first chamber). In some implementations, the second chamber <NUM> substantially surrounds, e.g., at least <NUM>%, the first chamber <NUM>.

As noted above, the second chamber <NUM> can correspond to a transfer chamber, e.g., the transfer chamber <NUM> or the transfer chamber <NUM>, which receives the substrate between different processing chambers. Alternatively, the second chamber <NUM> can be a separate chamber located between the first chamber <NUM> and the transfer chamber <NUM> or the transfer chamber <NUM>.

The inner (e.g., first) chamber <NUM> includes a substrate support <NUM>, e.g., a pedestal, to support a workpiece, such as a substrate <NUM>, which is to be processed, e.g., subject to annealing or on which a layer of material is to be deposited. The support <NUM> is positioned or positionable within the first chamber <NUM>. In some implementations, the substrate <NUM> sits directly on a flat top surface of the pedestal. In some implementations, the substrate sits on lift pins that project from the pedestal.

A first valve assembly <NUM> between the first chamber <NUM> and the second chamber <NUM> isolates the pressure within the first chamber <NUM> from the pressure within the second chamber <NUM>. The high-pressure environment within the first chamber <NUM> can thus be separated and sealed from the low pressure environment within the second chamber <NUM>. The first valve assembly <NUM> is openable to enable the substrate <NUM> to be transferred from or through the second chamber <NUM> into the first chamber <NUM>, or to enable the substrate to be transferred from the first chamber <NUM> into or through the second chamber <NUM>.

A second valve assembly <NUM> between the second chamber <NUM> and an exterior environment, e.g., a transfer chamber isolates the pressure within the second chamber <NUM> from the pressure outside the second chamber <NUM>.

The gas delivery system <NUM> is configured to pressurize the first chamber <NUM>. In particular, the gas delivery system <NUM> can delivers the processing gas to the first chamber <NUM> and establishes a high pressure, e.g., at a pressure of at least <NUM> Torr (<NUM> atmospheres), e.g., above <NUM> Torr (<NUM> atm), above <NUM> Torr (<NUM> atm), above <NUM> Torr (<NUM> atm), up to <NUM> Torr (<NUM> atm), up to <NUM> Torr (<NUM> atm), up to <NUM> Torr (<NUM> atm), up to <NUM> Torr (<NUM> atm), in the first chamber. The processing gas can react with the substrate <NUM>, e.g., a layer on the substrate <NUM>, e.g., during an annealing process, or serve as a source for material to be deposited on the substrate.

In some implementations, the gas delivery system <NUM> includes a first gas delivery module <NUM> to deliver a first gas to the first chamber <NUM>, and a second gas delivery module <NUM> to deliver either the first gas or a second gas or different composition than the first gas to the first chamber <NUM>. The first gas delivery module <NUM> is configured to deliver the first gas a high pressure to the first chamber <NUM>, e.g., at pressures of <NUM> - <NUM> Torr (<NUM>-<NUM> bar). In contrast, the second gas delivery module <NUM> is configured to deliver gas at a low pressure, e.g., at less than <NUM> bar.

The delivery modules <NUM>, <NUM> are connected to facility supplies or gas tanks that supply the respective gases. The delivery modules <NUM>, <NUM> are connected to the chamber <NUM> by respective delivery lines <NUM>, <NUM>. The delivery line <NUM> to the first gas delivery module <NUM> can include a high-pressure isolation valve <NUM>, and the delivery line <NUM> to the second gas delivery module <NUM> can include a low-pressure isolation valve <NUM>.

The first gas can be supplied to the first gas delivery module <NUM> at a pressure that is above atmospheric pressure, but still relatively low compared to the eventual pressure in the first chamber. For example, the first gas can be delivered to the first gas delivery module <NUM> at a pressure of <NUM> - <NUM> Torr (about <NUM> to <NUM> atm). The first gas delivery module <NUM> includes a pump, e.g., a booster pump. The pump increases the pressure of the incoming first gas, such as for example, the hydrogen gas. The pump <NUM> can increase the pressure by a factor of about two to twenty, in some cases up as high as <NUM> Torr (<NUM> atm).

The gas can be supplied to the second gas delivery module <NUM> at a pressure that is above atmospheric pressure, but still relatively low compared to the eventual pressure in the first chamber. For example, the gas can also be delivered to the second gas delivery module <NUM> at a pressure of <NUM> - <NUM> Torr (about <NUM> to <NUM> atm). However, the second gas delivery module <NUM> need not include a pump. Rather, conventional mass flow controller, liquid flow meter or liquid flow controller can be used to direct the gas to the first chamber <NUM>.

The first gas delivery module <NUM> and the second gas delivery module <NUM> can be contained within a common housing <NUM>. In some implementations, the interior of the housing <NUM> is fluidly separated from other containment vessels discussed below. An exhaust system <NUM> can be used to evacuate the interior of the housing <NUM>. This can prevent build-up of corrosive or explosive gas within the housing in case of leaks from the gas delivery system. In some implementations, the containment assembly includes multiple parts each of which is a pressure-containing enclosure that surrounds and encapsulates a respective gas delivery module. For example, the first gas delivery module <NUM> can be enclosed in a first housing, the steam delivery module <NUM> in a housing. The exhaust system <NUM> can be coupled to the foreline <NUM>, or to a separate vacuum system.

The first gas includes a processing gas, e.g., H<NUM>, NH<NUM>, O<NUM> or O<NUM>. In some implementations, the first gas is a substantially pure processing gas. Alternatively, the first gas can include both a processing gas and an inert gas, e.g., argon.

As noted above, the gas from the second gas delivery module <NUM> can be the same composition as the first gas, or be a different second gas. The second gas can also be a substantially pure processing gas, or a combination of a processing gas and an inert gas. In some implementations, the second gas includes water, e.g., the second gas can be steam, such as dry or superheated steam.

The high-pressure system <NUM> includes a foreline <NUM> connecting the second chamber <NUM> to the vacuum processing system <NUM>. An outer isolation valve <NUM> is arranged along the foreline <NUM> to isolate the pressure within the second chamber <NUM> from the pressure of the vacuum processing system <NUM>. The outer isolation valve <NUM> can be operated to adjust the pressure within the second chamber <NUM> and to release gases within the second chamber <NUM>. The outer isolation valve <NUM> can be operated in conjunction with the vacuum processing system <NUM> to regulate the pressure within the second chamber <NUM>.

The vacuum processing system <NUM> is configured to lower the pressure of the second chamber <NUM> to be at near-vacuum pressure, e.g., less than <NUM> milliTorr. In particular, the vacuum processing system <NUM> can lowers the pressure within the second chamber <NUM> to near vacuum, thereby creating the appropriate low pressure environment for transfer of the substrate. During operation, the ultra-high pressures achieved in the first chamber <NUM> (e.g., above <NUM> Torr (<NUM> atm), above <NUM> Torr (<NUM> atm)) require a corresponding higher pressure in the second chamber <NUM> (below about <NUM> Torr (<NUM> atm) (e.g., approximately <NUM> atm or <NUM> Torr)).

In some instances, the vacuum processing system <NUM> includes a dry line pump. To accommodate unusually high pressure (e.g., prevent the high pressure caused by a leak from breaching the dry line pump) the gas is expanded before reaching the dry line pump. In some instances, the gas flows through a large diameter diffuser, e.g., <NUM> (<NUM> inch) by <NUM> (<NUM> feet) tall diffuser.

The gas delivery system <NUM> includes an exhaust line <NUM> to exhaust the first gas from the first chamber <NUM>, thereby depressurizing the first chamber <NUM>. In some implementations, the exhaust line is coupled to an exhaust system, e.g., the foreline <NUM> and the vacuum processing system <NUM>, or a separate vacuum system source. The exhaust line <NUM> can include an inner exhaust isolation valve <NUM> that can be closed to isolate the first chamber <NUM> from the exhaust system.

To increase safety, the system <NUM> can include a containment assembly. The containment assembly can include at least a containment enclosure <NUM> that encloses the delivery lines <NUM>, <NUM> where they enter the chamber <NUM> to be fluidically connected to the chamber <NUM>. In addition, each delivery line <NUM>, <NUM> can be enclosed in a respective conduit <NUM>, <NUM> that extend between the housing <NUM> and the enclosure <NUM>.

The containment assembly can also include a containment exhaust line <NUM>. The containment exhaust line <NUM> encloses the exhaust line <NUM> between the containment enclosure <NUM> and the exhaust system. The containment exhaust line <NUM> also fluidly connects the containment enclosure <NUM> to the exhaust system, e.g., to the foreline <NUM> and the vacuum processing system <NUM>, or the separate vacuum system source. Thus, any leak in the delivery lines <NUM>, <NUM>, or from the junction of the delivery lines and the second chamber <NUM>, is drawn through the containment enclosure <NUM> and vented to the exhaust system.

Each line delivery line <NUM>, <NUM> has a pressure relief line with a pressure relief valve 252a, 254a within the containment enclosure <NUM>. Any pressure buildup inside delivery lines <NUM>, <NUM>, <NUM> that is released by the pressure relief line will flow into the containment enclosure <NUM> and be removed from the system <NUM>, e.g., by containment exhaust line <NUM>, or in some instances via separate exhaust channels <NUM> connected to exhaust system <NUM>.

The system <NUM> also includes a pressure relief line that couples the first chamber <NUM> to a pressure relief valve <NUM>. The pressure relief valve <NUM> can be positioned in the second chamber <NUM>. In this case, if the pressure in the first chamber <NUM> exceeds permissible levels, gas that is released by the pressure relief valve <NUM> will flow into the outer chamber <NUM> and be removed through the foreline <NUM>. Alternatively, the pressure relief valve <NUM> can be positioned in the containment enclosure <NUM>. In this case, gas that is released by the pressure relief valve <NUM> will be removed through the exhaust line <NUM>.

Thus, all pressurized components can be contained within the containment assembly so that the system <NUM> can relieve unexpected leaks, ruptures, or breaches without ever exposing pressurized gas the atmosphere.

Multiple gas sensors <NUM> are included in the system <NUM>. In particular, the gas sensors <NUM> can be hydrogen sensors. A sensor <NUM> is integrated into possible leak locations, e.g., inside containment enclosure <NUM>, and inside exhaust line <NUM>. If any sensor <NUM> detects a gas leak, for example hydrogen leak, the controller <NUM> will detect the signal from the sensor <NUM> and will shut first off the gas delivery module <NUM>, shut off the pump within first gas delivery module <NUM>, or take other appropriate action. Isolation valves in the delivery lines <NUM>, <NUM> can also be closed in response to a leak being detected by one or more of the sensor <NUM>.

In addition, the system <NUM> can include on or more pressure sensors <NUM>. For example, there can be a first pressure sensor <NUM> in the first chamber <NUM> and a second pressure sensor <NUM> in the second chamber <NUM>. The pressure sensors <NUM> are coupled to the controller <NUM>.

A method of operating the system <NUM> to process a substrate is illustrated in <FIG>. The system <NUM> starts with the isolation valves <NUM>, <NUM> open. The substrate is inserted by a robot <NUM> or <NUM> through the open valves <NUM>, <NUM> and the second chamber <NUM> into the first chamber <NUM> (at operation <NUM>). The controller can operate the robot to carry the substrate <NUM> into the first chamber <NUM> and to place the substrate <NUM> on the pedestal.

The first and second chambers <NUM>, <NUM> are pumped down to a first pressure, e.g., <NUM>-<NUM> milliTorr, by the vacuum system, and then maintained at the low pressure during the transfer of the substrate <NUM> (at operation <NUM>). This can assist in prevention of oxidation of the substrate <NUM>.

The first isolation valve <NUM> is closed (at operation <NUM>). Optionally the second isolation valve <NUM> can be closed as well.

The vacuum system is used to further pump down the first chamber <NUM> to a second pressure that is lower than the first pressure, and to pump down the second chamber <NUM> to a third pressure that is lower than the second pressure (at operation <NUM>). For example, both the first and the second pressure can be <NUM>-<NUM> milliTorr. The first pressure can be <NUM>-<NUM> milliTorr and the second pressure can be <NUM>-<NUM> milliTorr.

The pressures in the first and second chambers <NUM>, <NUM> are measured by the sensors <NUM>, and the controller can receive signals from the sensors <NUM>.

If a pressure in either chamber <NUM>, <NUM> exceeds a leak threshold value, this can indicate that gas is leaking into the chamber from the external environment. In this case, processing of the substrate can be terminated.

In addition, the controller can compare the measured pressures (at operation <NUM>). If the difference between the pressure P1 in the first chamber and the pressure P2 in the second chamber does not exceed a threshold value, then the evacuation of the chambers can be continued.

Once the chambers <NUM>, <NUM> reach the desired pressures, the inner exhaust isolation valve <NUM> is closed and the low-pressure isolation valve <NUM> is opened (operation <NUM>). This isolates the first chamber <NUM> from the exhaust system, but couples the first chamber <NUM> to the second gas delivery module <NUM>.

Next, the second gas delivery module <NUM> delivers either the first gas or a second gas to the first chamber <NUM> (at operation <NUM>). This raises the pressure in the first chamber <NUM> to a fourth pressure that is above the first pressure. The fourth pressure can be above atmospheric pressure, e.g., a pressure of <NUM> - <NUM> Torr (<NUM>-<NUM> psi). Delivery of the gas by the second gas delivery module <NUM> can be performed using regular flow rate control, e.g., without a pressure servo control algorithm.

Once the inner chamber <NUM> has been elevated to the fourth pressure, the low-pressure isolation valve <NUM> is closed and the high-pressure isolation valve <NUM> is opened (at operation <NUM>). This isolates the first chamber <NUM> from the second gas delivery module <NUM>, e.g., to avoid damage to the second gas delivery module <NUM> due to the high pressures in the subsequent operations. This also couples the first chamber <NUM> to the first gas delivery module <NUM>.

Next, the first gas delivery module <NUM> delivers the first gas to the first chamber <NUM> (at operation <NUM>). This raises the pressure in the first chamber <NUM> to a fifth pressure that is above the fourth pressure. As noted above, the fifth pressure can be <NUM> - <NUM> Torr (<NUM>-<NUM> atmospheres). Delivery of the gas by the first gas delivery module <NUM> can be controlled by the controller <NUM> using a pressure servo control algorithm.

The controller can compare the measured pressure P1 inside the first chamber <NUM> to a desired processing pressure PP (at operation <NUM>). If the pressure P1 in the first chamber is less than the desired processing pressure PP, then pressurization of the first chamber <NUM> can be continued.

Once the inner chamber <NUM> has been elevated to the fifth pressure, the high-pressure isolation valve <NUM> is closed (at operation <NUM>). This isolates the first chamber <NUM> from the first gas delivery module <NUM>.

The substrate <NUM> is now processed in the first chamber <NUM> (at operation <NUM>). Processing can proceed for a set time, e.g., as measured by a timer in the controller. The first gas can be an annealing gas that reacts with the layer on the substrate <NUM>. Alternatively, the gas can include the material to be deposited onto the substrate <NUM>. The proper temperature and pressure conditions in the first chamber <NUM> can cause the annealing or deposition of the material to occur. During processing, e.g., annealing or deposition, the controller can operate the one or more heating elements <NUM> in the support <NUM> to add heat to the substrate <NUM> to facilitate processing of the layer of material on the substrate <NUM>.

When processing of the layer of material on the substrate <NUM> is complete, the outer isolation valve <NUM> is closed, and the inner isolation valve <NUM> is opened (at operation <NUM>). This couples just the first chamber <NUM> to the exhaust system, while the second chamber <NUM> remains sealed.

The inner chamber is pumped down to a sixth pressure (at operation <NUM>). The sixth pressure can be less than the first pressure but greater than the third pressure, e.g., about equal to the second pressure. Thus, the pressure is at a near-vacuum pressure such that the pressure differential between the first chamber <NUM> and the second chamber <NUM> is small.

Again, the controller can compare the measured pressures (at operation <NUM>). If the difference between the pressure P1 in the first chamber and the pressure P2 in the second chamber does not exceed the threshold value, then the evacuation of the chambers can be continued.

Once the inner chamber <NUM> has reached the sixth pressure, the first isolation valve <NUM> is opened (at operation <NUM>). In addition, if closed, the second isolation valve can be opened as well. Then the outer exhaust isolation valve <NUM> is opened. Because both inner and outer exhausts share the same foreline, keeping the outer exhaust isolation valve closed during inner exhausting can protect the lift pin and heater bellows from damage.

Finally, the substrate <NUM> can be removed from the first chamber <NUM> using the robot <NUM> or <NUM>, and, if necessary, transferred to a subsequent process chamber.

<FIG> illustrates a controlled high-pressure processing system <NUM>' that creates a high-pressure environment for processing a substrate and a low-pressure environment for the substrate when the substrate is being transferred between processing chambers. The system <NUM>' can be the same as the system <NUM>, except that the second gas delivery module <NUM>' is a high pressure gas delivery module that can deliver a second gas to the first chamber <NUM> at high pressures, e.g., at pressures of <NUM> - <NUM> Torr (<NUM>-<NUM> bar). The second gas is a liquid vapor, e.g., steam. The valve <NUM>' in the delivery line <NUM> is a second high pressure isolation valve.

A method of operating the system <NUM> or <NUM>' to process a substrate is illustrated in <FIG>. This process similar to the process described with reference to <FIG>, except as discussed below.

In particular, the method of operating the system <NUM> or <NUM>' supplies gas to reach a high pressure in the first chamber <NUM> in a single operation, rather than in multiple stages. Thus, this process could be performed using only the first gas delivery module <NUM> of the system <NUM>, or using only the first gas delivery module <NUM> of the system <NUM>', or using only the second gas delivery module <NUM>' of the system <NUM>', or using both the first gas delivery module <NUM> and the second gas delivery module <NUM>' of the system <NUM>' but operating the second gas delivery module <NUM>' to mimic the first gas delivery module <NUM> (e.g., the isolation valves of the gas delivery modules open and close at the same time, etc.).

In particular, the inner exhaust isolation valve <NUM> is closed (at operation <NUM>'), and the high-pressure isolation valve <NUM> and/or <NUM>' is opened (at operation <NUM>'). The first gas delivery module <NUM> and/or the second gas delivery module <NUM>' delivers the first gas and/or the second gas to the first chamber <NUM> (at operation <NUM>'). This raises the pressure in the first chamber <NUM> from the second pressure to the fifth pressure. As noted above, the fifth pressure can be <NUM> - <NUM> Torr (<NUM>-<NUM> atmospheres). Delivery of the gas by the first gas delivery module <NUM> can be controlled by the controller <NUM> using a pressure servo control algorithm.

The gas delivered to the first chamber <NUM> can include H<NUM> or NH<NUM>, e.g., if only the first gas delivery module <NUM> of the system <NUM> or only the first gas delivery module <NUM> of the system <NUM>' is used. Alternatively, the gas delivered to the first chamber <NUM> can include a liquid vapor, e.g., steam, e.g., if only the second gas delivery module <NUM>' of the system <NUM>' is used. Alternatively, the gas delivered to the first chamber <NUM> can include a mixture of stem and another process gas, e.g., if both the first gas delivery module <NUM> and the second gas delivery module <NUM>' of the system <NUM>' are used.

<FIG> illustrates a possible configuration for a first chamber <NUM> and second chamber <NUM> in a high-pressure processing system <NUM> (or <NUM>'). The high-pressure processing system <NUM> further includes the valve assembly <NUM> between the first chamber <NUM> and the second chamber <NUM>. This implementation can have the second chamber <NUM> be part of the transfer chamber, e.g., be in pressure equilibrium.

The second chamber <NUM> can be defined by volume between inner walls <NUM> and outer walls <NUM>. In addition, the substrate <NUM> is supportable on a pedestal <NUM> (that provides the substrate support <NUM>). One or more elements <NUM>, e.g., a resistive heater, can be embedded in the pedestal <NUM>. The substrate can sit directly on the pedestal <NUM>, or sit on a lift pin assembly <NUM> that extends through the pedestal.

The valve assembly <NUM> is formed by an arm <NUM> movable relative to the inner walls <NUM> and the base <NUM> of the first chamber <NUM>. In particular, the valve assembly <NUM> includes a slit valve <NUM> between the first chamber <NUM> and the second chamber <NUM>. The slit valve <NUM> includes a slit 423a and the arm <NUM>. The slit 423a extends through one of the inner walls <NUM> of the first chamber <NUM>. A vertical end 425a of the arm <NUM> is positioned outside of the first chamber <NUM> while a horizontal end 425b of the arm <NUM> is positioned within the first chamber <NUM>. The vertical end 425a of the arm <NUM> can be positioned within the second chamber <NUM> and be driven by an actuator positioned within the second chamber <NUM>. Alternatively, the vertical end 425a of the arm <NUM> is positioned outside of the second chamber <NUM> and is thus driven by an actuator <NUM> that is also positioned outside of the second chamber <NUM>.

The arm <NUM> extends through the slit 423a and is movable relative to the walls <NUM> so that the arm <NUM> can be moved to a position in which it forms a seal with the walls <NUM>. The actuator <NUM> is coupled to the vertical end 425a of the arm <NUM> and drives the horizontal end 425b of the arm <NUM> relative to the walls <NUM>. The arm <NUM> is movable vertically to cover or uncover the slit 423a. In particular, the vertical end 425a of the arm <NUM> can be or include a flange that extends substantially parallel to the adjacent inner surface of the inner wall <NUM>. The arm <NUM> can also be driven laterally so that the horizontal end 425b of the arm <NUM> can engage or disengage the wall <NUM>. The arm <NUM> can also extend through an aperture <NUM> in the outer wall <NUM>.

The valve assembly <NUM> is movable between an open position and a closed position. When the valve assembly <NUM> is in the open position, the horizontal end 425b of the arm <NUM> is spaced laterally apart from the wall <NUM>, e.g., the inner surface of the wall <NUM>. In addition, the horizontal end 425b of the arm <NUM> is positioned vertically so that the slit 423a is uncovered. The slit 423a thus provides an opening that enables fluidic communication between the first chamber <NUM> and the second chamber <NUM> and that also enables the substrate <NUM> to be moved in and out of the first chamber <NUM>, e.g., by a robot as discussed above.

When the valve assembly <NUM> is in the closed position, the horizontal end 425b of the arm <NUM> covers the slit 423a and contacts one of the walls <NUM>, thereby forming the seal to isolate the first chamber <NUM> from the second chamber <NUM>. When pressurized, the flange or horizontal end 425b contacts an inner surface of the wall <NUM> defining the first chamber <NUM>. An O-ring is placed along the circumference of the horizontal end 425b on the surface that contacts the wall <NUM>, helping to reinforcing the seal of containment when the first chamber <NUM> is pressurized.

The heating elements <NUM> in the pedestal <NUM> heat the gas in the first chamber <NUM>, e.g., to up to <NUM>. To prevent damage to the O-ring, the arm <NUM> can includes an internal gas channel <NUM>. The internal gas channel <NUM> is supplied from cooling gas supply <NUM> and is a conduit to let the cooling gas flow through the arm <NUM>. The internal gas channel <NUM> can extend through the horizontal end 425b, or through both the horizontal end 425b and the vertical end 425a. The internal gas channel and cooling gas supply <NUM> can be configured such that when the valve assembly <NUM> is in the open position no gas is available from the cooling gas supply <NUM>, preventing cooling gas flow when transfer of the substrate is occurring.

A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the scope of the invention as defined by the appended claims. For example, while the foregoing describes the formation of a metal silicide layer from a cobalt or nickel layer film, in some implementations, other materials can be used. For example, other materials can include titanium, tantalum, tungsten, molybdenum, platinum, iron, niobium, palladium, and combinations thereof, and other alloys including nickel cobalt alloys, cobalt tungsten alloys, cobalt nickel tungsten alloys, doped cobalt and nickel alloys, or nickel iron alloys, to form the metal silicide material as described herein.

Although described above in the context of an annealing or deposition system, depending on the gasses provided, the high-pressure chamber can be used for an etching system. Alternatively, the high-pressure chamber can be filled with an inert gas, and the high-pressure chamber can be used purely for heat treatment at high pressure. The processing platforms described herein can include other types of processing chambers. For example, a processing platform can include an etching chamber to etch patterns onto a surface of a substrate.

Each of the different chambers of a processing platform can have varying pressure environments, ranging from near-vacuum to more than <NUM> Torr (<NUM> atmospheres). The isolation valves, e.g., vacuum valves, between the chambers can isolate the pressures from one another such that these varying pressure environments can be maintained within each chamber.

Claim 1:
A method of operating a high-pressure processing system (<NUM>), the method comprising:
bringing a first chamber (<NUM>) and a second chamber (<NUM>) to a first pressure that is less than <NUM> Torr (one atmosphere);
while an isolation valve is closed, reducing the first chamber (<NUM>) from the first pressure to a second pressure and reducing the second chamber (<NUM>) from the first pressure to a third pressure;
pressurizing the first chamber (<NUM>) to a fourth pressure that is above atmospheric pressure and less than <NUM> Torr (<NUM> atmospheres) with a gas delivery system;
pressurizing the first chamber (<NUM>) to a fifth pressure that is above <NUM> Torr (<NUM> atmospheres) with the gas delivery system; and
processing a substrate (<NUM>) while the first chamber (<NUM>) is at the fifth pressure.