Method and apparatus for reducing pressure fluctuations within an ampoule of a chemical delivery system - Patents.com

Abstract

[0006] Methods and apparatus for reducing pressure fluctuations in a chemical delivery system for a process chamber are provided herein. In some embodiments, the chemical delivery system for a process chamber includes: a carrier gas supply; an ampoule fluidly coupled to the carrier gas supply via a first supply line, the ampoule configured to supply one or more process gases to the process chamber via a second supply line; an inlet valve disposed along the first supply line to control a flow of carrier gas from the carrier gas supply to the ampoule; and a first control valve disposed along a pressure regulation line, the pressure regulation line fluidly coupled to the first supply line at a T-junction location between the carrier gas supply and the inlet valve.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE Embodiments of the present disclosure relate generally to substrate processing equipment and, more specifically, to chemical delivery systems for substrate processing equipment. [Background technology]

[0002] Substrate processing equipment may include a solid-state chemical delivery system for providing one or more process gases to a process chamber, such as a chemical vapor deposition (CVD) chamber, an atomic layer deposition (ALD) chamber, an etch chamber, etc., for performing a suitable chemical process. The solid-state chemical delivery system typically includes a sublimation vessel, or ampoule, that contains a solid-state precursor. A carrier gas may be flowed through the ampoule to sublimate the solid-state precursor to form one or more process gases to be delivered to the process chamber. However, when the carrier gas is introduced into the ampoule, an initial pressure spike may cause the solid-state precursor to unintentionally mix with one or more process gases, and the solid-state precursor may contaminate the delivery line from the ampoule to the process chamber.

[0003] Accordingly, the inventors provide an improved solid chemical delivery system for reducing contamination. Summary of the Invention

[0004] Methods and apparatuses for reducing pressure fluctuations in a chemical delivery system for a process chamber are provided herein. In some embodiments, the chemical delivery system for a process chamber includes: a carrier gas supply; an ampoule fluidly coupled to the carrier gas supply via a first supply line, the ampoule configured to supply one or more process gases to the process chamber via a second supply line; an inlet valve disposed along the first supply line to control a flow of carrier gas from the carrier gas supply to the ampoule; and a first control valve disposed along a pressure regulation line, the pressure regulation line being fluidly coupled to the first supply line at a T-joint location between the carrier gas supply and the inlet valve.

[0005] In some embodiments, a chemical delivery system for a process chamber includes: a carrier gas supply; an ampoule fluidly coupled to the carrier gas supply via a first supply line, the ampoule configured to supply one or more process gases to the process chamber via a second supply line; a pressure switch disposed along the first supply line to control a pressure in the first supply line; an inlet valve disposed along the first supply line to control a flow of carrier gas from the carrier gas supply to the ampoule; and a first control valve and a metering valve disposed along a pressure regulation line, the pressure regulation line fluidly coupled to the first supply line at a Tee location between the carrier gas supply and the inlet valve, a first length of the pressure regulation line extending from the first control valve to the Tee location.

[0006] In some embodiments, a method of reducing pressure fluctuations in an ampoule for a process chamber includes: flowing a carrier gas from a carrier gas supply through a first supply line to a pressure regulation line, where the pressure regulation line redirects the flow of the carrier gas from the first supply line at a T-joint location; closing a first control valve disposed along the pressure regulation line; and opening an inlet valve disposed along the first supply line downstream of the T-joint location to flow the carrier gas to an ampoule.

[0007] Other and further embodiments of the present disclosure are described below.

[0008] Embodiments of the present disclosure, briefly summarized above and discussed in more detail below, can be understood by reference to example embodiments of the disclosure that are depicted in the accompanying drawings. The attached drawings, however, illustrate only typical embodiments of the disclosure and should not therefore be considered as limiting the scope, since the disclosure may admit of other equally effective embodiments. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic diagram of a chemical delivery system for a process chamber in accordance with at least some embodiments of the present disclosure. [Figure 2A] 1 is a graph of ampoule pressure versus time in accordance with at least some embodiments of the present disclosure. [Figure 2B] 1 is a graph of ampoule pressure versus time in accordance with at least some embodiments of the present disclosure. [Diagram 3] 1 is a flow chart of a method for reducing pressure fluctuations in an ampoule for a process chamber. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] For ease of understanding, wherever possible, the same reference numbers have been used to designate identical elements that are common to multiple figures. The figures are not drawn to scale and may be simplified for clarity. Elements and features of one embodiment may be beneficially incorporated in other embodiments without further detail.

[0011] A method and apparatus for reducing pressure fluctuations in a chemical delivery system for a process chamber is provided herein. The chemical delivery system includes a carrier gas supply for supplying a carrier gas to an ampoule of the chemical delivery system via a first supply line. The carrier gas is configured to sublimate a solid precursor disposed in the ampoule and form a mixture of the carrier gas and the sublimated precursor as one or more process gases that are delivered from the ampoule to the process chamber via a second supply line. The solid chemical delivery system may be a delivery system for a semiconductor substrate process chamber, such as a deposition chamber (CVD, ALD, etc.), an etch chamber, a cleaning chamber, etc.

[0012] The chemical delivery system includes a pressure regulation line extending from the first supply line upstream of the ampoule. The pressure regulation line advantageously stabilizes the pressure in the first supply line, thereby reducing pressure fluctuations in the ampoule as the carrier gas flows into the ampoule. The small pressure fluctuations in the ampoule advantageously minimize mixing of the solid precursor into the gaseous mixture of one or more process gases, which in turn reduces contamination of the second supply line by the solid precursor.

[0013] 1 is a schematic diagram of a chemical delivery system for a process chamber according to at least some embodiments of the present disclosure. The chemical delivery system 100 includes a carrier gas supply 102. The carrier gas supply 102 can store a carrier gas, which in some embodiments may be a non-reactive gas. In some embodiments, the carrier gas can be one or more of argon gas, nitrogen gas, helium gas, hydrogen gas, etc. The chemical delivery system 100 is configured to deliver the carrier gas from the carrier gas supply 102 to a process chamber 104. Other chemical delivery systems may have different elements and / or configurations, but the implementations discussed herein may still be applied to such other systems.

[0014] The ampoule 110 is fluidly coupled to the carrier gas supply 102 via a first supply line 112. The ampoule 110 can contain a solid precursor that sublimates as the carrier gas flows into the ampoule 110, resulting in a gaseous mixture of the sublimated precursor and the carrier gas. The solid precursor may be any suitable precursor, for example, a halide such as, but not limited to, hafnium tetrachloride (HfCl4). The ampoule 110 may be heated to promote sublimation of the solid precursor. In some embodiments, the solid precursor is in a granular form, including, for example, pellets or powder. The ampoule 110 is configured to supply one or more process gases from the ampoule 110 via a second supply line 128 to the process chamber 104. The process chamber 104 may be any suitable chamber for processing a substrate 120 disposed therein. The process chamber 104 can include a gas distribution plate 122 having one or more openings for distributing one or more process gases from the second supply line to the process chamber 104.

[0015] The first supply line 112 includes one or more control valves for controlling the flow or pressure of the carrier gas. For example, the first supply line 112 includes a mass flow controller 108 disposed downstream of the carrier gas supply 102 to control the mass flow rate of the carrier gas. In some embodiments, a pressure gauge 106 is disposed along the first supply line 112 to control the pressure in the first supply line 112. The pressure gauge 106 is disposed upstream of the ampoule 110. In some embodiments, the pressure gauge 106 is disposed downstream from the mass flow controller 108.

[0016] An inlet valve 116 is disposed along the first supply line 112 to control the flow of carrier gas from the carrier gas supply 102 to the ampoule 110. In some embodiments, an inlet isolation valve 124 is disposed along the first supply line 112 between the inlet valve 116 and the ampoule 110. In some embodiments, a bypass line 140 fluidly couples the first supply line 112 to the second supply line 128. In some embodiments, a bypass valve 132 is disposed along the bypass line 140 to allow carrier gas to flow from the carrier gas supply 102 to the process chamber 104 without flowing through the ampoule 110. In some embodiments, the bypass line 140 is disposed between the inlet valve 116 and the inlet isolation valve 124. The inlet isolation valve 124 may be normally open. The inlet isolation valve 124 may be closed when flow through the bypass line 140 is desired.

[0017] The pressure regulation line 136 is fluidly coupled to the first supply line 112 at a T-joint location 150 disposed between the carrier gas supply 102 and the inlet valve 116. In some embodiments, the end of the pressure regulation line 136 opposite the T-joint location 150 is coupled to a foreline 144 of the chemical delivery system 100. The foreline 144 is coupled to a vacuum pump 148. The first control valve 114 is disposed along the pressure regulation line 136. The first control valve 114 is any suitable open / close valve having a fast response. The first control valve 114 having a fast response time (i.e., about 100 milliseconds or less) advantageously minimizes pressure fluctuations within the ampoule 110 when the first control valve 114 is closed and the inlet valve 116 and the inlet isolation valve 124 are opened. In some embodiments, the first control valve 114 is an atomic layer deposition (ALD) valve commercially available from Swagelok® of Solon, Ohio.

[0018] In some embodiments, a metering valve 138 is disposed along the pressure regulation line 136. The metering valve 138 is generally a variable orifice valve for controlling the rate of conduction in the pressure regulation line 136. The metering valve 138 may be disposed upstream or downstream of the first control valve 114. In some embodiments, the metering valve 138 may be a manual valve. In some embodiments, the first control valve 114 has a faster response time than the metering valve 138. In some embodiments, a fixed orifice valve may be used in place of the metering valve 138.

[0019] A first length 152 of the pressure regulated line 136 extends from the first control valve 114 to the tee location 150. In some embodiments, a second length 160 of the pressure regulated line 136 extends from the first control valve 114 to the foreline 144. A first portion 154 of the first supply line 112 extends from the pressure gauge 106 to the tee location 150. A second portion 158 of the first supply line 112 extends from the tee location 150 to the inlet valve 116. In some embodiments, the metering valve 138 is advantageously configured to match the conductance in the first length 152 of the pressure regulated line 136 to the conductance in the second portion 158 of the first supply line 112 to minimize pressure fluctuations in the ampoule 110 when carrier gas flow is switched from the pressure regulated line to the ampoule 110.

[0020] The conductance in each of the multiple lines described herein can be a factor of the line length and the number of bends. In some embodiments, the first portion 154 of the first supply line 112 is about 25.0 inches to about 35.0 inches long. In some embodiments, the first portion 154 has about 3 to about 8 bends. In some embodiments, the second portion 158 of the first supply line 112 is about 30.0 inches to about 40.0 inches long. In some embodiments, the second portion 158 has about 7 to about 15 bends. In some embodiments, the first length 152 is about 28.0 inches to about 40.0 inches long. In some embodiments, the first length 152 has about 5 to about 12 bends. In some embodiments, the first length 152 of the pressure regulation line 136 is longer than the first portion 154 of the first supply line 112. In some embodiments, the second portion 158 of the first supply line 112 is longer than the first portion 154 of the pressure regulation line 136. In some embodiments, the second portion 158 of the first supply line 112 includes more bends than the first length 152 of the pressure regulation line 136. In some embodiments, the second length 160 is from about 10.0 inches to about 20.0 inches.

[0021] An outlet valve 118 is disposed along the second supply line 128 to control the flow of one or more process gases to the process chamber 104. In some embodiments, an outlet isolation valve 126 is disposed along the second supply line 128 between the ampoule 110 and the outlet valve 118. A bypass line 140 can extend from the first supply line 112 to the second supply line 128 between the outlet valve 118 and the outlet isolation valve 126. The outlet isolation valve 126 can be normally open. The outlet isolation valve 126 can be closed when flow through the bypass line 140 is desired.

[0022] In some embodiments, the filter 130 is disposed along the second supply line 128. In some embodiments, the filter 130 is disposed downstream of the outlet valve 118. The filter 130 is generally configured to collect contaminants, such as solid precursors, and prevent the contaminants from entering the process chamber 104. In some embodiments, the filter 130 is capable of filtering out particles of about 5 nanometers or larger.

[0023] and a vacuum valve disposed along the second supply line, where the vacuum valve is the same type of valve as the first control valve.

[0024] In some embodiments, a vacuum valve 134 is disposed along the second supply line 128 downstream of the ampoule 110. The vacuum valve 134 is coupled to the foreline 144 for selectively drawing a vacuum on the second supply line 128. In some embodiments, the vacuum valve 134 is the same type of valve as the first control valve 114. The vacuum valve 134 is advantageously a fast response valve to minimize pressure fluctuations within the ampoule when the vacuum valve 134 switches flow to the process chamber 104 to the foreline 144.

[0025] In some embodiments, a second control valve 190 is disposed between the outlet valve 118 and the process chamber 104. The second control valve 190 is generally a fast response valve such that the flow of one or more process gases through the second control valve 190 can be precisely controlled. In some embodiments, the second control valve 190 is configured to pulse one or more process gases to the process chamber 104. The second control valve 190 may be the same type of valve as at least one of the vacuum valve 134 or the first control valve 114. In some embodiments, the second control valve 190 is disposed between the vacuum valve 134 and the process chamber 104.

[0026] 2A illustrates a pressure versus time graph 200 of ampoule pressure according to at least some embodiments of the present disclosure. FIG. 2A illustrates an example pressure versus time graph for a chemical delivery system that does not include a pressure regulation line (i.e., pressure regulation line 136). At t0, inlet valve 116 is opened and carrier gas is flowed into ampoule 110. Without pressure regulation line 136, the pressure in ampoule 110 may rise to a peak pressure 202 before stabilizing to an average pressure 210. A first pressure differential 205 is the difference in pressure between peak pressure 202 and average pressure 210.

[0027] FIG. 2B illustrates a pressure versus time graph 201 of ampoule pressure according to at least some embodiments of the present disclosure. FIG. 2B illustrates an example pressure versus time graph for a chemical delivery system 100 including a pressure regulation line 136. At t0, the inlet valve 116 is opened and carrier gas is flowed into the ampoule 110. The pressure in the ampoule 110 may start at a peak pressure 220 before stabilizing to an average pressure 230. The second pressure differential 240 is the difference in pressure between the peak pressure 220 and the average pressure 230. Alternatively, the pressure in the ampoule 110 may start at an initial underpressure 250 and rise to an average pressure 260. The third pressure differential 270 is the difference in pressure between the average pressure 260 and the initial underpressure 250.

[0028] With pressure regulation line 136, the pressure in first supply line 112 downstream of inlet valve 116 approaches and becomes average pressure 260, causing the pressure in ampoule 110 to stabilize more quickly and with less pressure fluctuations. Second pressure differential 240 and third pressure differential 270 are advantageously less than first pressure differential 205, causing less contamination in second supply line 128.

[0029] 3 depicts a flow chart of a method 300 for reducing pressure fluctuations in an ampoule (i.e., ampoule 110) for a process chamber (i.e., process chamber 104). At 302, the method 300 includes flowing carrier gas from a carrier gas supply (i.e., carrier gas supply 102) through a first supply line (i.e., first supply line 112) to a pressure regulation line (i.e., pressure regulation line 136), where the pressure regulation line redirects the flow of carrier gas from the first supply line at a T-joint location (i.e., T-joint location 150). The pressure regulation line includes at least one of a metering valve (i.e., metering valve 138) or a first control valve (i.e., first control valve 114). The pressure regulation line may be coupled to a foreline (i.e., foreline 144).

[0030] At 304, a first control valve disposed along the pressure regulation line is closed. In some embodiments, the pressure in the pressure regulation line is regulated via a metering valve prior to closing the first control valve. In some embodiments, the pressure in the pressure regulation line is set to about 50 Torr to about 200 Torr. In some embodiments, the response time of the first control valve is less than about 100 milliseconds.

[0031] At 306, an inlet valve (i.e., inlet valve 116) disposed along the first supply line downstream of the T-joint location is opened to allow carrier gas to flow to the ampoule. In some embodiments, after opening the inlet valve, the ampoule is pressurized to about 50 Torr to about 200 Torr. In some embodiments, the first control valve is closed simultaneously with opening the inlet valve to advantageously reduce pressure fluctuations within the ampoule.

[0032] In some embodiments, one or more process gases, including a carrier gas or a mixture of a carrier gas and any other gas in the ampoule, are flowed from the ampoule through a second supply line (i.e., second supply line 128) to the process chamber. In some embodiments, the one or more process gases include a mixture of a carrier gas and sublimated material of a solid precursor disposed in the ampoule ... End The second supply line is filtered through a filter (i.e., filter 130) to limit particles that are in the second supply line. In some embodiments, the second supply line may be purged through a vacuum valve (i.e., vacuum valve 134).

[0033] While the forgoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof.

Claims

1. 1. A chemical delivery system for a process chamber, comprising: A carrier gas supply unit; an ampoule fluidly coupled to the carrier gas supply via a first supply line, the ampoule configured to supply one or more process gases to the process chamber via a second supply line; an inlet valve disposed along the first supply line for controlling flow of carrier gas from the carrier gas supply to the ampoule; a first control valve disposed along a pressure regulation line, the pressure regulation line fluidly coupled to the first supply line at a T-joint location between the carrier gas supply and the inlet valve; and wherein the pressure regulation line includes a metering valve. Chemical delivery systems.

2. 10. The chemical delivery system of claim 1, further comprising an outlet valve disposed along the second supply line to control flow of the one or more process gases to the process chamber.

3. 3. The chemical delivery system of claim 2, further comprising an inlet isolation valve disposed along the first supply line between the inlet valve and the ampoule, and an outlet isolation valve disposed along the second supply line between the ampoule and the outlet valve.

4. 4. The chemical delivery system of claim 3, further comprising a filter disposed along the second supply line.

5. The chemical delivery system of claim 4 , wherein the filter is disposed downstream of the outlet valve.

6. 6. The chemical delivery system of claim 1, further comprising a vacuum valve disposed along said second supply line, said vacuum valve being the same type of valve as said first control valve.

7. A chemical delivery system for a process chamber, comprising: A carrier gas supply unit; an ampoule fluidly coupled to the carrier gas supply via a first supply line, the ampoule configured to supply one or more process gases to the process chamber via a second supply line; an inlet valve disposed along the first supply line for controlling flow of carrier gas from the carrier gas supply to the ampoule; a first control valve disposed along a pressure regulation line, the pressure regulation line fluidly coupled to the first supply line at a T-joint location between the carrier gas supply and the inlet valve; and Equipped with a bypass line fluidly coupling the first supply line to the second supply line, and a bypass valve disposed along the bypass line. Chemical delivery systems.

8. 6. The chemical delivery system of claim 1, further comprising a vacuum valve disposed along the second supply line downstream of the ampoule.

9. A chemical delivery system for a process chamber, comprising: A carrier gas supply unit; an ampoule fluidly coupled to the carrier gas supply via a first supply line, the ampoule configured to supply one or more process gases to the process chamber via a second supply line; an inlet valve disposed along the first supply line for controlling flow of carrier gas from the carrier gas supply to the ampoule; a first control valve disposed along a pressure regulation line, the pressure regulation line fluidly coupled to the first supply line at a T-joint location between the carrier gas supply and the inlet valve; and Equipped with a pressure switch disposed along the first supply line to control pressure within the first supply line; a metering valve disposed along the pressure regulation line; a first length of the pressure regulation line extending from the first control valve to the tee location. Chemical delivery systems.

10. 10. The chemical delivery system of claim 9, wherein the first length of the pressure regulating line is longer than a first portion of the first supply line from the pressure switch to the T-joint location.

11. 11. The chemical delivery system of claim 10, wherein a second portion of the first supply line from the T-joint location to the inlet valve is greater than the first length of the pressure regulating line.

12. 12. The chemical delivery system of claim 11, wherein the second portion of the first supply line includes more bends than the first length of the pressure regulating line.

13. 10. The chemical delivery system of claim 9, wherein the metering valve is disposed between the Tee location and the first control valve.

14. 1. A method for reducing pressure fluctuations in an ampoule for a process chamber, comprising: flowing a carrier gas from a carrier gas supply through a first supply line to a pressure regulating line, the pressure regulating line redirecting the flow of the carrier gas from the first supply line at a T-joint location; closing a first control valve disposed along the pressure regulation line; opening an inlet valve disposed along the first supply line downstream of the Tee location to allow the carrier gas to flow to an ampoule; regulating pressure in the pressure regulation line via a metering valve prior to closing the first control valve; A method for reducing pressure fluctuations, comprising:

15. 15. The method of claim 14, further comprising flowing one or more process gases from the ampoule through a second supply line to a process chamber, the one or more process gases comprising a mixture of the carrier gas and sublimated material of a solid precursor disposed within the ampoule.

16. 16. The method of claim 15, further comprising filtering the one or more process gases in the second supply line to limit particles that are about 5.0 nanometers or larger.

17. 17. The method of any one of claims 14 to 16, wherein the first control valve is closed simultaneously with opening of the inlet valve.

18. 17. The method of any one of claims 14 to 16, wherein after opening the inlet valve, the ampoule is pressurized to about 50 Torr to about 200 Torr.

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