shower head for processing tools

Abstract

To provide a showerhead for process tool.SOLUTION: In one example, an apparatus includes a processing chamber; a substrate holder disposed in the processing chamber; and a showerhead disposed over the substrate holder. The showerhead includes a first zone disposed in a central region of the showerhead, the first zone including a first cavity, a plurality of first fluid exit holes aligned to output a fluid from the first cavity towards the substrate holder, a first flow path fluidly coupled to a fluid source, and a plurality of first fluid distribution pathways fluidly coupling the first flow path with the first cavity.SELECTED DRAWING: Figure 14

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 043,394, filed June 24, 2020, which is incorporated herein by reference.

[0002] The present invention relates generally to semiconductor manufacturing processing equipment, and in particular embodiments, to showerheads for processing tools. [Background technology]

[0003] In the semiconductor industry, various thin films are deposited using vapor deposition processes such as chemical vapor deposition (CVD). In a CVD process, different reactive gases come into contact with the surface on which the thin film is to be deposited. The gases react either thermally, as in atmospheric pressure CVD (APCVD) or subatmospheric pressure CVD (SACVD), or assisted with electrical energy at lower temperatures, as in plasma-enhanced CVD (PECVD). A CVD process called atomic layer deposition (ALD) has been used to deposit materials in controlled atomic layers.

[0004] The semiconductor industry uses gas-phase chemical etching processes using fluid vapors such as hydrogen fluoride, and gas-phase plasma etching processes that use gases such as fluorine- and chlorine-containing molecules to produce highly reactive fluorine and chlorine atoms to etch a variety of thin films. Atomic layer etching (ALE) uses highly reactive gaseous reactants to etch the surface of a thin film one atomic layer at a time.

[0005] As shown in FIGS. 1A and 1B, reactant fluids for thin film deposition or thin film etching are distributed through fluid outlet holes 102 in a showerhead 100 onto a substrate 112, such as a semiconductor wafer, in a deposition or etching tool.

[0006] 1A is a top view of a single wafer deposition or etching tool 116, showing a top view of a showerhead 100 (substrate not shown) above a substrate holder 110. Exhaust ports 118 surrounding the showerhead 100 remove fluids exiting the fluid exit holes 102.

[0007] 1B is a cross-sectional view of the showerhead 100 of FIG. 1A. Fluid (gas) pathways 106 couple the showerhead 100 to a fluid source 108. The fluid pathways 106 provide fluid to a cavity 104 within the showerhead 100. Fluid outlet holes 102 are aligned to output fluid from the cavity toward a substrate 112 on a substrate holder 110.

[0008] 2 is a top view of a batch deposition or etching tool 122. A substrate 112, such as a semiconductor wafer, is positioned near the circumference of a substrate holder 124. The substrate holder 124 rotates the substrate 112 under a wedge-shaped reactant showerhead 126 during CVD or ALD deposition, or during chemical vapor deposition, plasma, or ALE etching. An inert gas, such as nitrogen, is dispensed from wedge-shaped inert gas showerheads 128 on either side of the wedge-shaped reactant showerhead 126. The nitrogen exiting the wedge-shaped inert gas showerhead 128 and the fluid exiting the wedge-shaped reactant showerhead 126 are removed through exhaust ports 120. Summary of the Invention [Means for solving the problem]

[0009] According to one embodiment, an apparatus includes a processing chamber, a substrate holder disposed within the processing chamber, and a showerhead disposed above the substrate holder, the showerhead including a first zone disposed in a central region of the showerhead, the first zone including a first cavity, a plurality of first fluid outlet holes aligned to output fluid from the first cavity toward the substrate holder, a first flow path fluidly coupled to a fluid source, and a plurality of first fluid distribution paths fluidly coupling the first flow path with the first cavity.

[0010] According to one embodiment, an apparatus includes a processing chamber, a substrate holder disposed within the processing chamber, the substrate holder configured to support a plurality of wafers, and a showerhead system disposed above the substrate holder. The showerhead system includes a wedge-shaped showerhead disposed about a central region of the processing chamber. The wedge-shaped showerhead includes a first cavity within a central zone of the wedge-shaped showerhead, a plurality of first fluid outlet holes aligned to output fluid from the first cavity toward the substrate holder, a plurality of fluid distribution paths exiting the first cavity, and a first flow path fluidically coupling a fluid source with the plurality of fluid distribution paths.

[0011] According to one embodiment, a method for processing a substrate includes flowing a gas toward the substrate through a showerhead including: a first zone disposed in a central region of the showerhead, the first zone including a first cavity; a plurality of first fluid outlet holes aligned to output fluid from the first cavity toward the substrate; a first flow path fluidly coupled to a fluid source; and a plurality of first fluid distribution paths fluidly coupling the first flow path with the first cavity. The flowing includes filling the first cavity with gas through the first flow path and the plurality of first fluid distribution paths and directing the gas to exit the first cavity through the plurality of first fluid outlet holes.

[0012] For a more complete understanding of the present invention and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which: [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1A is a top view of a prior art single wafer showerhead, and FIG. 1B is a cross-sectional view of a prior art single wafer thin film deposition or thin film etch tool. [Figure 2] FIG. 2 is a top view of a prior art batch CVD deposition or thin film etch tool equipped with a wedge-shaped showerhead. [Figure 3]3A-3B illustrate a showerhead with fluid distribution paths for a single wafer deposition or etching tool, with FIG. 3A being a top view and FIG. 3B being a cross-sectional view of FIG. 3A, according to one embodiment. [Figure 4] 4A-4B illustrate a showerhead with fluid distribution paths for a single wafer deposition or etching tool, with FIG. 4A being a top view and FIG. 4B being a cross-sectional view of FIG. 4A, according to one embodiment. [Figure 5] 5A is a top view and FIG. 5B is a cross-sectional view of a multi-zone showerhead with fluid distribution paths for a single wafer deposition or etching tool, according to one embodiment. [Figure 6-1] FIG. 6A is a top view of a batch deposition or etching tool with a wedge-shaped showerhead having fluid distribution paths, according to one embodiment, where FIG. 6A shows a top view of the batch deposition or etching tool, FIG. 6B is a top view of the wedge-shaped showerhead, and FIG. 6C is a cross-sectional view of FIG. 6B. [Figure 6-2] FIG. 6A is a top view of a batch deposition or etching tool with a wedge-shaped showerhead having fluid distribution paths, according to one embodiment, where FIG. 6A shows a top view of the batch deposition or etching tool, FIG. 6B is a top view of the wedge-shaped showerhead, and FIG. 6C is a cross-sectional view of FIG. 6B. [Figure 7] 7A is a plan view and FIG. 7B is a cross-sectional view of a wedge-shaped multi-zone showerhead with fluid distribution paths for a batch wafer deposition or etching tool, according to one embodiment. [Figure 8] 8A is a top view and FIG. 8B is a cross-sectional view of the wedge-shaped multi-zone showerhead of FIG. 7A with a skirt according to one embodiment. [Figure 9] FIG. 9 is a perspective view showing simulated fluid flow from below a wedge-shaped showerhead to a single exhaust port in a batch deposition or etch tool, according to one embodiment. [Figure 10]FIG. 10 is a top view of a batch deposition or etching tool with dual exhaust ports, according to one embodiment. [Figure 11] FIG. 11 is a projection diagram showing simulated flow from under a wedge-shaped showerhead to dual exhaust ports in a batch deposition or etch tool, according to one embodiment. [Figure 12] 12A is a top view and FIG. 12B is a cross-sectional view of the wedge-shaped multi-zone showerhead of FIG. 7A with vacuum channels according to one embodiment. [Figure 13] 13A is a top view and FIG. 13B is a cross-sectional view of the wedge-shaped multi-zone showerhead of FIG. 8A with vacuum channels formed in the skirt according to one embodiment. [Figure 14] FIG. 14 is a flow diagram of processing steps for a method according to one embodiment illustrating deposition using a wedge-shaped showerhead with fluid distribution paths. DETAILED DESCRIPTION OF THE INVENTION

[0014] It is difficult to deposit thin films with uniform film properties, such as thickness, composition, and refractive index, across large substrates, such as 300 mm wafers. To deposit thin films uniformly using a showerhead, fluid is uniformly distributed from the showerhead's fluid outlet holes toward the surface of the substrate being processed.

[0015] Etching thin films uniformly across a wafer using vapor etching fluids or gaseous radicals generated from the fluid in a plasma is difficult and produces by-products that must be removed. To etch thin films uniformly using a showerhead, the fluid is uniformly distributed from fluid exit holes toward the surface of the thin film being etched. After deposition or etching, metrology measurements are taken across the wafer and correlation calculations are performed on the data to determine whether a statistically significant thickness pattern exists on the wafer.

[0016] For the fluid to exit the fluid exit holes uniformly, the fluid pressure above the holes must be uniform. The fluid pressure within the cavity must be high enough so that the fluid pressure above all fluid exit holes is the same. In prior art designs such as those shown in Figures 1-2, as the substrate size increases, the showerhead also becomes larger and the cavity size increases. To maintain uniform fluid pressure within the cavity across the increased number of fluid exit holes, the fluid pressure, fluid temperature, and fluid flow (flow rate) are increased. Higher fluid flow results in increased fluid usage, which increases fluid costs and post-processing chemical costs. Increased fluid usage can significantly increase manufacturing costs, especially for expensive precursor fluids such as those used in atomic layer deposition (ALD).

[0017] Embodiments of the present disclosure enable uniform thin film deposition and etching by modifying showerhead design, as described in more detail below. According to one embodiment, an apparatus includes a showerhead with fluid distribution paths for uniform deposition and to reduce the amount of fluid used by the process. According to one embodiment, an apparatus includes a wedge-shaped showerhead with fluid distribution paths for uniform deposition and etching while using less fluid. According to one embodiment, a method for deposition or etching includes flowing a fluid through the fluid distribution paths and filling a cavity in the wedge-shaped showerhead with a uniform pressure.

[0018] 3A and 3B are top and cross-sectional views of a single wafer deposition or etch showerhead according to an example embodiment.

[0019] The showerhead 300 includes a body portion made of, for example, stainless steel or other metal, depending on the corrosive properties of the fluid. Within the body portion is a hollow cavity 104 with fluid outlet holes 102 through which the fluid exits the cavity 104. The fluid outlet holes 102 uniformly cover the side of the showerhead 300 facing the substrate 112. A threaded opening on the side of the showerhead 300 opposite the fluid outlet holes 102 allows connection to a fluid source 108. Fluid from the fluid source 108 fills the cavity 104 and is distributed through the fluid outlet holes 102 toward the substrate 112. If the pressure of the fluid inside the showerhead 300 is sufficiently high, the pressure across all of the fluid outlet holes 102 is substantially the same for all of the fluid outlet holes 102. The pressure required to equalize the flow rate through the fluid outlet holes 136 in the showerhead 300 depends on the volume of the cavity 104 within the showerhead 300. If the cavity 104 is smaller, a lower pressure can be used to equalize the flow rate. -3 ~200cm -3 , for example 175cm -3 In this configuration, for example, when the chamber pressure is about 0.5 Torr to about 0.8 Torr, e.g., 0.6 Torr, by setting the pressure at about 1.6 Torr to about 2.6 Torr, a minimum pressure about 1 Torr to 2 Torr higher than the chamber pressure can be used.

[0020] The variation in pressure across the fluid outlet holes 102 may be 0.1% to 1% in one embodiment, and may be less than 5% in various embodiments, ensuring that the amount of fluid being dispensed through each fluid outlet hole 102 is substantially the same, so that during a deposition process, the composition and thickness of the film being deposited is uniform across the wafer, or during an etching process, the thickness of the film being etched is uniform across the wafer.

[0021] 3A and 3B show a showerhead 300 with multiple fluid distribution paths 130, 132, and 134 and multiple fluid distribution holes 136. As one example, the showerhead 300 of FIG. 3A has four fluid distribution paths 134 with twelve fluid distribution holes 136 around the perimeter region of the showerhead 300, two fluid distribution paths 132 with six fluid distribution holes 136 in the middle (donut) region of the showerhead 300, and one fluid distribution path 130 with one fluid distribution hole 136 in the center of the showerhead 300. This configuration provides more fluid to the outer regions of the showerhead 300 where the most fluid is distributed, a medium amount of fluid to the donut portion of the showerhead 300 where a medium amount of fluid is distributed, and a least amount of fluid to the center of the showerhead 300 where a least amount of fluid is distributed. By providing more fluid where more fluid is needed, substantially the same amount of fluid can be dispensed from all fluid outlet holes 102 while maintaining a lower pressure.

[0022] Accordingly, embodiments of the present disclosure improve deposition processes, such as chemical vapor deposition (CVD) and atomic layer deposition (ALD), for example, improving thin film deposition uniformity while reducing costs. Additionally, embodiments of the present disclosure improve etch uniformity while reducing the amount of hazardous by-products produced. Because there are more fluid outlet holes 102 in the peripheral region of the showerhead 300 than in the center of the showerhead 300, significantly more fluid exits through the periphery than from the intermediate and central regions of the showerhead 300. In contrast, conventional showerheads have a single fluid path 106 and use a single centrally located fluid distribution outlet to provide fluid to the entire fluid cavity 104 ( FIG. 1B ).

[0023] As previously mentioned, when fluids are dispensed at higher pressures from a showerhead, such as a conventional showerhead, significantly more fluid flows, resulting in significantly more fluid being used during a deposition or etching step and, in turn, generating significantly more exhaust gases that must be treated. Not only is the amount of fluid used reduced compared to conventional designs, but less effort is required to clean up waste products. Additionally, when fluids are dispensed at higher pressures from the showerhead, the showerhead is positioned at a greater distance from the substrate 112 to avoid imprinting the showerhead hole pattern on the deposited or etched thin film (a process defect). Embodiments of the present application avoid the post-processing costs and process defect design issues associated with conventional designs by controlling the reactant outflow from the showerhead 300 to flow more uniformly.

[0024] Thus, in various embodiments, the use of showerhead 300 with fluid distribution paths 130, 132, and 134 improves deposited or etched thin film across wafer uniformity, reduces fluid costs, and reduces by-product removal costs.

[0025] The fluid distribution channels 130, 132, and 134 are coupled to a fluid source 108 that stores fluid to be distributed onto the substrate 112. For clarity, additional components such as pumps, flow valves, control circuits, and other standard equipment are not shown. The fluid distribution channels 130, 132, and 134 are mini-cavities in that they store fluid but have a smaller volume than the cavity 104. The addition of a layer of fluid distribution channels 130, 132, and 134 on top of the cavity 104 with multiple fluid distribution holes 136 from the fluid distribution channels 130, 132, and 134 to the cavity 104 allows the fluid distribution channels 130, 132, and 134 to help maintain a more uniform fluid pressure within the cavity 104. Maintaining a uniform fluid pressure within the cavity 104 at a lower pressure allows for the use of a smaller cavity 104, which can be used with a reduced fluid flow rate while maintaining a uniform pressure across all fluid outlet holes 102. The uniform pressure distributes the fluid 114 evenly through all of the fluid outlet holes 102. Even at lower fluid flow rates, the fluid distribution paths 130, 132, and 134 allow a uniform pressure to be maintained within the smaller cavity 104 because more fluid enters the peripheral region due to the greater number of fluid distribution holes 136 located in the ceiling of the peripheral region of the cavity 104.

[0026] 4A-4B illustrate a showerhead with fluid distribution paths for a single wafer deposition or etching tool, with FIG. 4A being a top view and FIG. 4B being a cross-sectional view of FIG. 4A, according to one embodiment.

[0027] 4A-4B show further embodiments with multiple levels of fluid distribution paths. In certain embodiments, additional fluid distribution paths 430, 432, and 434 can be positioned above fluid distribution paths 130, 132, and 134 to further improve uniformity. Thus, for example, by using more fluid distribution paths 130, 132, and 134 with a greater number of fluid distribution holes 136 positioned in the peripheral region, more fluid can be distributed toward the peripheral region of cavity 104. In FIG. 4A , in one example, eight fluid distribution paths 134 with forty fluid distribution holes 136 provide fluid to the peripheral region of showerhead 400. Four fluid distribution paths 132 with twenty fluid distribution holes 136 provide fluid to the middle (donut) region of showerhead 400. One fluid distribution path 130 with four fluid distribution holes 136 provides fluid to the central region of showerhead 400. By providing multiple fluid distribution paths 130, 132, and 134, each with a similar number of fluid distribution holes 136 covering the ceiling of cavity 104, lower pressures can be used to maintain uniform fluid flow across fluid outlet holes 102.

[0028] To provide uniform fluid flow from the fluid source 108 to each of the 13 distribution paths in the configuration of FIG. 4A , additional layers of upper fluid distribution paths 430, 432, and 434 uniformly distribute fluid through upper fluid distribution holes 436 to the underlying layers of fluid distribution paths 130, 132, and 134. The upper layers of fluid distribution paths 430, 432, and 434 can be connected to the fluid source 108 through separate conduits 140, 142, and 144. Valves 150, 152, and 154, such as mass flow controller valves, can independently provide precise control of fluid flow to each of the upper fluid distribution paths 430, 432, and 434. Adding additional levels of fluid distribution paths can further reduce fluid usage by improving the uniformity of fluid dispensed from the fluid outlet holes 102 at lower pressures. This adds complexity and cost to the showerhead 400. Models correlating the number of fluid distribution paths versus cost versus film uniformity can be used to determine the optimal balance of these variables.

[0029] FIG. 5A is a top view and FIG. 5B is a cross-sectional view of a multi-zone showerhead 500 with fluid distribution paths 130 and fluid distribution holes 136 for a single wafer deposition or etching tool, according to one embodiment.

[0030] As shown in the configurations above, a single wafer showerhead can have multiple zones from which fluids are distributed and to which the fluid mixture and flow rate can be independently controlled. Each zone can have multiple fluid distribution paths to improve the uniformity of fluid distribution within each zone. In addition, multiple upper layers of fluid distribution paths can be provided above lower layers of fluid distribution paths to improve the uniformity of fluid provided to lower levels. During thin film deposition or etching, the uniformity of the target film across the substrate can be maintained by adjusting the values of one or more operating variables affecting the showerhead, including the chamber temperature, the fluid flow rate of the input fluid to each zone within the showerhead, the composition of the input fluid to each zone, the chamber fluid pressure for each zone, the ratio of the fluid flow rate of the first exhaust port compared to the second exhaust port, the number of fluid paths or fluid exit holes open in each zone, and / or the pressure of the fluid within each zone of the showerhead. In conventional single-wafer CVD (and ALD) deposition tools and single-wafer fluid vapor (and ALE) etch tools ( FIGS. 1A and 1B ), fluid is distributed through fluid outlet holes 102 across a showerhead 100 and exits the fluid deposition and etch tool through exhaust ports 118 surrounding the showerhead 100. The fluid flows radially across the semiconductor substrate 112, often resulting in a radial pattern with non-uniform thin film properties. To compensate for this radial non-uniformity, showerheads with multiple radial zones can be used, such as an inner zone 158, a middle zone 160, and an outer zone 162 as shown in FIGS. 5A and 5B .

[0031] To improve radial deposition or etching uniformity, the fluid mixture and flow rate may be independently controlled in each of the fluid paths 140, 142, 144 to the inner, intermediate, and outer zones 158, 160, and 162, respectively. By way of example, the fluid distribution path 130 includes distinct sections oriented in different directions, e.g., orthogonal sections in one case. In various embodiments, the cavities 103 and 105 in the inner zone 158 and outer zone 162 have smaller volumes than the cavity 104 in the intermediate zone 160. The fluid distribution path 130 and fluid distribution holes 136 provide significant benefits to the larger intermediate zone 160, but may provide less benefit to the smaller inner zone 158 and outer zone 162, and in some embodiments, may be omitted from these zones.

[0032] Figure 6A shows a top view of a batch deposition or etch tool with a wedge-shaped showerhead having fluid distribution paths, according to one embodiment, where Figure 6A shows a top view of the batch deposition or etch tool, Figure 6B shows a top view of the wedge-shaped showerhead, and Figure 6C is a cross-sectional view of Figure 6B. As described further herein, this exemplary embodiment improves thin film uniformity and reduces fluid costs in batch thin film deposition processes, such as CVD and ALD deposition, and reduces by-product removal costs in batch thin film etch processes.

[0033] Referring to FIG. 6A , a batch thin film deposition or etching tool includes a showerhead system having one or more wedge-shaped showerheads 600 disposed within a processing chamber. A substrate 112, such as a semiconductor wafer, is disposed near the circumference of a substrate holder 124. The substrate holder 124 rotates the substrate 112 beneath the one or more wedge-shaped showerheads 600 during a deposition or etching process, such as CVD or ALD deposition and fluid vapor or ALE etching. An inert gas, such as nitrogen, is distributed from wedge-shaped inert gas showerheads 128 on either side of each of the one or more wedge-shaped showerheads 600. The nitrogen exiting the wedge-shaped inert gas showerheads 128 and fluids exiting the one or more wedge-shaped showerheads 600 are removed through exhaust ports 120 (or multiple exhaust ports, as discussed in a further embodiment of FIG. 10 ) disposed along the periphery of the substrate holder 124.

[0034] Shown in the top view of FIG. 6B and the cross-sectional view of FIG. 6C are fluid distribution channels 130 with fluid distribution holes 136 coupled to a fluid distribution manifold 630 that distributes fluid to each fluid distribution channel 130. Fluid channels 106 couple the fluid distribution manifold 630 to a fluid source 108. The fluid distribution channels 130 distribute the fluid evenly within the cavities 104. Uniform fluid distribution allows for the use of smaller cavities 104 and lower fluid flow rates while still maintaining uniform pressure over all fluid outlet holes 102. At the same time, the uniform pressure distributes the fluid 114 evenly through all fluid outlet holes 102 toward the substrate 112. The substrate holder 124 rotates past the substrate 112 under each of one or more wedge-shaped showerheads 600 during deposition or etching. As the substrate 112 rotates, the fluid emerges from the fluid outlet holes 102 and flows 114 out from under each of one or more wedge-shaped showerheads 600, as shown in Figure 6C.

[0035] 7A shows a wedge-shaped multi-zone showerhead with fluid distribution paths 130, 132, and 134 for a batch wafer deposition or etch tool, according to one embodiment, where FIG. 7A is a top view and FIG. 7B is a cross-sectional view of FIG. 7A. This embodiment includes multiple zones to further improve radial uniformity across the wafer.

[0036] In a batch deposition or etching tool such as that shown in FIGS. 7A and 7B , fluid 114 is distributed through fluid outlet holes 102 and across the underside of a wedge-shaped showerhead 700 toward a substrate 112. The fluid 114 exits the batch deposition or etching tool 122 through exhaust ports 164 and 166 (see FIG. 10 , discussed below) on the exterior of the substrate holder 124. Nitrogen 168 from the ambient surrounding the wedge-shaped showerhead 700 can back-diffuse under the edges of the wedge-shaped showerhead 700. The back-diffusion of nitrogen 168 can dilute the fluid 114 and alter the thin film properties near the boundaries of the wedge-shaped showerhead 700. This can be particularly problematic at the apex 174 and base 170 of the wedge-shaped showerhead 700. Therefore, in certain embodiments, a wedge-shaped showerhead 700 with multiple zones 170, 172, and 174 having fluid distribution paths 130, 132, and 134 is used to improve thin film uniformity.

[0037] In various embodiments, a different fluid mixture 107, 108, and 109 may be provided to each zone 170, 172, and 174. The microprocessor 733 may send signals to the respective valves 150, 152, and 154 in the fluid lines to independently adjust the flow rate of each of the fluid mixtures 107, 108, 109 to each of the zones 170, 172, and 174. The microprocessor may send signals to the respective temperature controllers of the zones 170, 172, and 174 to independently control the temperature of each of the zones 170, 172, and 174.

[0038] In various embodiments, the fluid mixtures 107, 108, 109 and fluid flow rates can be independently controlled by valves 150, 152, and 154 in the fluid paths 144, 146, and 148 to the zones 170, 172, and 174, respectively. Typically, the cavities 103 and 105 in the inner zone 174 and the outer zone 170 are significantly smaller in volume than the cavity 104 in the middle zone 172. While the fluid distribution paths 132 and fluid distribution holes 136 provide significant benefits to the larger middle zone 172, the fluid distribution paths 134 may provide less benefit to the smaller inner zone 174, and the fluid distribution paths 130 may provide less benefit to the smaller outer zone 170. In some multi-zone showerheads, the inner fluid distribution paths 130 and the outer fluid distribution paths 134 can be omitted.

[0039] As shown in the above configuration, the wedge-shaped showerhead can have multiple zones from which fluids are distributed and to which the fluid mixture and flow rate can be independently controlled. Each zone can have multiple fluid distribution paths to improve the uniformity of fluid distribution within each zone. In addition, multiple upper layers of fluid distribution paths can be provided above lower layers of fluid distribution paths to improve the uniformity of fluid provided to lower levels. During thin film deposition or etching, the uniformity of the target film across the substrate can be maintained by adjusting the values of one or more operating variables affecting the showerhead, including the chamber temperature within each zone, the fluid flow rate of the input fluid to each zone of the showerhead, the composition of the input fluid to each zone, the chamber fluid pressure within each zone, the ratio of the fluid flow rate of the first exhaust port compared to the second exhaust port, the number of fluid paths or fluid exit holes open in each zone, and / or the pressure of the fluid within each zone of the showerhead.

[0040] FIG. 8A illustrates a wedge-shaped multi-zone showerhead 800 with a skirt 180 according to one embodiment, where FIG. 8A is a top view and FIG. 8B is a cross-sectional view of FIG. 8A.

[0041] Thin film deposition uniformity can be improved by adding a skirt 180 that surrounds the fluid exit holes 102 and extends from the underside of the wedge-shaped showerhead 700 toward the substrate holder 124, as shown in FIGS. 8A and 8B. In one embodiment, the skirt 180 is shaped like a ring and conforms to the wedge-shaped showerhead 700. The skirt 180 can be machined from the same billet of material as the showerhead by simply recessing the central surface containing the fluid injection holes 102. Ideally, in certain embodiments, it would be preferable to position the showerhead surface with the fluid holes 102 in close proximity (within 1-3 millimeters) to the substrate 124 without the skirt 180. However, this configuration can result in thickness streaks on the substrate corresponding to the gas holes in the showerhead. In certain embodiments, adding the skirt 180 can avoid thickness streaks. The skirt 180 also improves thin film composition uniformity, especially near the periphery of the wedge-shaped showerhead 700 , by reducing backflow of ambient nitrogen 168 under the edge of the wedge-shaped showerhead 700 .

[0042] The length of the skirt 180 can range from approximately 1 mm to 10 mm. In various embodiments, the length of the skirt 180 can range from approximately 1 mm to 3 mm. In an exemplary configuration, the distance from the wedge-shaped showerhead 700 to the underlying substrate holder 124 is approximately 3 mm, the length of the skirt 180 is approximately 2 mm, and the distance from the skirt 180 to the substrate holder 124 is approximately 1.5 mm. These distances can be adjusted depending on the fluid flow to achieve the best film uniformity. FIG. 9 is a projection diagram illustrating the simulated flow of fluid 114 from beneath the wedge-shaped showerhead 700 to the single exhaust port 120 in a batch deposition or etching tool 122. The fluid 114 is distributed from the fluid outlet holes 102 on the underside of the wedge-shaped showerhead 700. The fluid 114 and ambient nitrogen are pulled toward the single exhaust port 120. The fluid 114 flows non-uniformly across the underside of the wedge-shaped showerhead 700. The uniformity of the deposited thin film can be improved by improving the uniformity of the flow of fluid 114 across the underside of the wedge-shaped showerhead 700.

[0043] 10 is a top view of a batch deposition or etching tool 122 with dual exhaust ports 164 and 166. The batch deposition or etching tool 122 can be a CVD deposition tool in one embodiment, an ALD deposition tool in another embodiment, a fluid vapor etching tool in another embodiment, a plasma etching tool in another embodiment, or an ALE etching tool in yet another embodiment. The first exhaust port 164 and the second exhaust port 166 are located near each corner of the base of the wedge-shaped showerhead 700 to simultaneously exhaust fluid from both sides of the wedge-shaped showerhead 700. Instead of fluid flowing unidirectionally between the base of the wedge-shaped showerhead 700 and the substrate holder 124 on its way to the single exhaust port 120 with the first and second exhaust ports 164 and 166, the fluid 114 flowing from both sides of the wedge-shaped showerhead 700 can be balanced to improve thin film deposition or etching uniformity.

[0044] FIG. 11 is a projection diagram showing simulated fluid flow from a wedge-shaped showerhead 700 to first and second exhaust ports 164 and 166. The first and second exhaust ports 164 and 166 are located near the corners of the base of the wedge-shaped showerhead 700. Fluid 114 is uniformly extracted from underneath the wedge-shaped showerhead 700 on both sides. The more uniform flow of fluid 114 from between the substrate 112 and the wedge-shaped showerhead 700 produces a deposited or etched film with improved film uniformity. In FIG. 11 , fluid 114 from a first gas channel between the first wedge-shaped inert gas showerhead 128a and a portion along a first side of the wedge-shaped showerhead 700 enters the first exhaust port 164. Fluid 114 from the second gas channel between the second wedge-shaped inert gas showerhead 128b and a portion along a second side of the wedge-shaped showerhead 700 enters the second exhaust port 166. The exhaust ports 164 and 166 are different sizes because the two exhaust ports are connected by a passage. The conductance of this passage is important when determining the opening size of the exhaust port 164. The exhaust port 166 is designed as large as it can accommodate, and then the exhaust port 164 is sized to balance the flow. The exhaust port 164 is typically a standard exhaust outlet connected directly to the foreline and vacuum pump. Therefore, a smaller opening for the exhaust port 164 is needed to balance the flow with the port 166. The balanced removal of fluid 114 and nitrogen from both sides of the wedge-shaped showerhead 700 improves the uniformity of the flow of fluid 114 below the wedge-shaped showerhead 700, improving the uniformity of the deposited or etched film.

[0045] Figure 12A shows a wedge-shaped multi-zone showerhead with vacuum channels 171 according to one embodiment, where Figure 12A is a top view and Figure 12B is a cross-sectional view of Figure 12A. This embodiment includes additional vacuum channels 171 and can be combined with the embodiments described in Figures 6A-6B, 7A-7B, 8A-8B, or 10.

[0046] 12A and 12B, thin film deposition or etch uniformity can be further improved by adding vacuum channels 171 around the lower end of the wedge-shaped multi-zone showerhead 1200. The vacuum channel openings face the substrate holder 124 and are aligned to remove the fluid 114 and nitrogen 168 from between the wedge-shaped multi-zone showerhead 1200 and the underlying substrate holder 124. Removing a significant portion of the nitrogen 168 before it back-diffuses under the end of the wedge-shaped multi-zone showerhead 1200 reduces dilution of the fluid 114 in this region, improving thin film deposition or etch uniformity. The vacuum channels 171 also provide more uniform removal of the fluid from between the wedge-shaped multi-zone showerhead 1200 and the substrate holder 124. The more uniform removal of the fluid after it is dispensed from the fluid outlet holes 102 improves the uniformity of the fluid 114 flow under the wedge-shaped multi-zone showerhead 1200, allowing for more uniform thin film deposition or etch.

[0047] In an alternative embodiment shown in FIGS. 13A and 13B , the vacuum channel 171 can be incorporated into the skirt 180 to form an integrated skirt / vacuum channel 188. This reduces area and cost over the previous embodiment having separate vacuum channels 171 and skirt 180. FIG. 13A is a top view, and FIG. 13B is a cross-sectional view of FIG. 13A . In this embodiment, the skirt / vacuum channel 188 performs the dual function of blocking back-diffusion of nitrogen 168 and is also a vacuum channel 171. In this configuration, the skirt / vacuum channel 188 is hollow and includes openings positioned to remove fluid and nitrogen from between the substrate holder 124 and the underside of the showerhead 1300. Both blocking back-diffusion of nitrogen 168 and evacuating a significant amount of back-diffusing nitrogen reduces thin film non-uniformities at the boundaries of the showerhead 1300 as a result of fluid dilution by nitrogen. Additionally, the skirt / vacuum channels 188 improve the uniformity of fluid flow between the showerhead 1300 and the substrate holder 124 by continuously removing the fluid as it emerges from the fluid exit holes 102. More uniform fluid flow during deposition also improves thin film composition, and more uniform fluid flow during deposition or etching improves thin film thickness uniformity.

[0048] In various embodiments, the thin film CVD deposition methods described herein achieve more uniform thin film properties, such as thickness and composition, across the area where the thin film is deposited, and can do so at reduced cost and reduced post-processing costs. Additionally, in various embodiments, the thin film etching methods described herein achieve more uniform etched thin film thickness across the wafer, combined with reduced cost and reduced post-processing costs. Methods provided by embodiments of the present disclosure may include modifications to the fluid flow paths, showerheads, and vacuum pumping systems in thin film deposition or etching tools. In one configuration, a monolayer of silicon is deposited using chlorosilane-containing gases in an atomic layer deposition (ALD) tool. The chlorosilane-containing gases include trichlorosilane (SiClH, TCS), dichlorosilane (SiClH, DCS), and hexachlorodisilane (SiCl, HCDS).

[0049] The main steps of the method for depositing a CVD thin film or an ALD monolayer are listed in the flow diagram of FIG.

[0050] In a first method block 180, a showerhead of a CVD or ALD tool is modified to reduce the size of a first cavity in the showerhead and to include a gas distribution channel with gas distribution holes for uniformly distributing gas within the first cavity.

[0051] In a second block 182, a showerhead with multiple zones is created. In an exemplary configuration, an inner zone with a second cavity is located in a first peripheral region of the first zone, and an outer zone with a third cavity is located in a second peripheral region of the first zone. Separate gas paths for individually controlling gas flow are coupled between the gas source and the second zone and between the gas source and the third zone.

[0052] In a third block 184, gas is flowed through a first gas path, through the gas distribution channel and gas distribution holes to fill the first cavity, and directed to exit the first cavity through a plurality of first gas outlet holes towards the substrate.

[0053] In a fourth block 186, gas is flowed through a second gas path to fill the second cavity and directed out of the second cavity toward the substrate through a plurality of second gas outlet holes. If advantageous, a second distribution channel can be added to the second cavity. Typically, the second cavity is smaller than the first cavity. The gas flow rate in the second zone can be adjusted differently from the flow rate in the first zone to improve the uniformity of the CVD thin film or ALD monolayer. Typically, the gas flow rate in the second outer zone is adjusted slightly higher than the flow rate in the first zone to counteract nitrogen back-diffusion and improve thin film uniformity.

[0054] In fifth block 188, gas is flowed through a third gas passage to fill the third cavity and directed out of the third cavity toward the substrate through a plurality of third gas outlet holes. A third gas distribution channel can be added to the third cavity if advantageous. Typically, the third cavity is smaller than the first cavity. The gas flow rate in the third zone can be adjusted differently from the flow rate in the first zone to improve the uniformity of the CVD thin film or ALD monolayer. Typically, the gas flow rate in the third zone is adjusted slightly higher than the flow rate in the first zone to counteract nitrogen back-diffusion and improve thin film uniformity.

[0055] In a sixth block 190, which may be performed optionally to improve thin film uniformity, a first vacuum port is positioned near a first corner of the base of the wedge-shaped showerhead, and a second vacuum port is positioned near a second corner of the base. Valves on vacuum lines to the vacuum ports are adjusted to balance the flow rate of gas from under the first side of the wedge-shaped showerhead to the first vacuum port and the flow rate of gas from under the second side of the wedge-shaped showerhead to the second vacuum port. A seventh block 192 is controlling one or more operating variables of the showerhead by adjusting the value of one or more operating variables, including chamber temperature, fluid flow rate of input fluid to each zone in the showerhead, composition of fluid flow to each zone in the showerhead, chamber fluid pressure in each zone, ratio of fluid flow rate of the first exhaust port compared to the second exhaust port, and number of open fluid paths or fluid exit holes, and / or pressure of fluid within each zone of the showerhead, wherein controlling the one or more operating variables of the showerhead is configured to maintain uniformity of the target film on the substrate.

[0056] Thus, embodiments of the present disclosure enable uniform etching or deposition. After deposition or etching, metrology measurements are taken across the wafer, and correlation calculations are performed on the data to determine whether a statistically significant thickness pattern exists on the wafer. If a pattern is detected, operational variables affecting the showerhead are adjusted to eliminate the pattern. The operational variables include chamber temperature, local temperature of the fluid distribution paths, fluid flow rates to each zone within the showerhead, chamber fluid pressure within each zone, the ratio of fluid flow rates through the first exhaust port compared to the second exhaust port, and the number of open fluid paths or fluid exit holes, and / or the pressure of the fluid within each zone of the showerhead. Thus, embodiments of the present invention include a process control scheme in which a first feature is formed by processing a substrate in a processing tool including the showerhead described above in various embodiments. The first feature can be, for example, a structure formed after an etching process or a deposition process. The first feature, for example, the surface roughness, critical dimension, or height of the first feature, is measured using an in-line or other metrology tool, including an optical, electronic, or electromagnetic tool such as a profilometer, scatterometer, electron microscope, or X-ray. Based on the measurement, it is determined whether the metric falls within a process window for the processing tool, e.g., whether it falls within a target for that process flow. If the metric is outside the process window, the first flow rate of the first fluid into the first cavity, the second flow rate of the second fluid into the second cavity, the first fluid pressure in the first cavity, the second fluid pressure in the second cavity, the exhaust flow through the exhaust port of the processing tool, the first zone temperature of the first zone, or the second chamber temperature of the second zone are adjusted to bring the metric of the subsequent wafer within the target process window. Thus, subsequent features are processed after the adjustment.

[0057] Exemplary embodiments of the present application are summarized below: Other embodiments may also be understood from the entire specification and claims filed herewith.

[0058] Example 1. An apparatus includes a processing chamber, a substrate holder disposed within the processing chamber, and a showerhead disposed above the substrate holder. The showerhead includes a first zone disposed in a central region of the showerhead, the first zone including a first cavity, a plurality of first fluid outlet holes aligned to output fluid from the first cavity toward the substrate holder, a first flow path fluidly coupled to a fluid source, and a plurality of first fluid distribution paths fluidly coupling the first flow path with the first cavity.

[0059] Example 2. The apparatus of Example 1, further comprising: a second zone disposed in a peripheral region of the showerhead, the second zone comprising a second cavity; a plurality of second fluid outlet holes aligned to output fluid from the second cavity toward the substrate holder; and a second flow path fluidly coupled to the fluid source and independent from the first flow path.

[0060] Example 3. The device of Example 1 or 2, wherein the second zone further comprises a plurality of second fluid distribution paths fluidly coupling the second flow path with the second cavity.

[0061] Example 4. The apparatus of one of Examples 1-3, further comprising a skirt disposed around a perimeter of the showerhead and extending toward the substrate holder.

[0062] Example 5. The apparatus of one of Examples 1-4, wherein the skirt extends from the showerhead above the substrate holder to a distance of 1 mm to 10 mm.

[0063] Example 6. The apparatus of one of Examples 1-5, wherein the skirt includes a vacuum channel disposed around a peripheral region of the showerhead, and the plurality of fluid inlet holes are aligned to admit fluid away from the substrate holder.

[0064] Example 7. The apparatus of any one of Examples 1-6, further comprising a vacuum channel disposed around a peripheral region of the showerhead, the plurality of fluid inlet holes being aligned to admit fluid away from the substrate holder.

[0065] Example 8. The apparatus of any one of Examples 1-7, wherein the apparatus is an atomic layer deposition apparatus.

[0066] Example 9. An apparatus includes a processing chamber, a substrate holder disposed within the processing chamber, the substrate holder configured to support a plurality of wafers, and a showerhead system disposed above the substrate holder. The showerhead system includes a wedge-shaped showerhead disposed about a central region of the processing chamber. The wedge-shaped showerhead includes a first cavity within a central zone of the wedge-shaped showerhead, a plurality of first fluid outlet holes aligned to output fluid from the first cavity toward the substrate holder, a plurality of fluid distribution paths exiting the first cavity, and a first flow path fluidically coupling a fluid source with the plurality of fluid distribution paths.

[0067] Example 10. The apparatus of Example 9, further comprising: a peripheral zone disposed in a peripheral region of the central zone; the peripheral zone including a second cavity; a plurality of second fluid outlet holes aligned to output fluid from the second cavity toward the substrate holder; and a second flow path fluidly coupled to the fluid source and independent of the first flow path.

[0068] Example 11. The apparatus of any one of Examples 9 or 10, further comprising a skirt disposed around a perimeter of the showerhead and extending toward the substrate holder.

[0069] Example 12. The apparatus of one of Examples 9-11, wherein the skirt includes a vacuum channel disposed around a peripheral region of the showerhead, and the plurality of fluid inlet holes are aligned to admit fluid away from the substrate holder.

[0070] Example 13. The apparatus of any one of Examples 9-12, further comprising a vacuum channel disposed around a perimeter of the showerhead, the plurality of fluid inlet holes being aligned to admit fluid away from the substrate holder.

[0071] Example 14. The apparatus of any one of Examples 9-13, wherein the processing chamber further includes a dual vacuum port, the dual vacuum port including a first vacuum port positioned near a first wide corner of the wedge-shaped showerhead and a second vacuum port positioned near a second wide corner of the wedge-shaped showerhead.

[0072] Example 15. The apparatus of one of Examples 9-14, wherein the apparatus is an atomic layer deposition apparatus.

[0073] Example 16. A method for processing a substrate includes flowing a gas toward the substrate through a showerhead including: a first zone disposed in a central region of the showerhead, the first zone including a first cavity; a plurality of first fluid outlet holes aligned to output fluid from the first cavity toward the substrate; a first flow path fluidly coupled to a fluid source; and a plurality of first fluid distribution paths fluidly coupling the first flow path with the first cavity. The flowing includes filling the first cavity with gas through the first flow path and the plurality of first fluid distribution paths, and directing the gas to exit the first cavity through the plurality of first fluid outlet holes.

[0074] Example 17. The method of Example 16, further comprising: flowing gas through a second zone of the showerhead toward the substrate, the second zone being disposed in a peripheral region of the first zone, the second zone including a second cavity, the plurality of second fluid outlet holes being aligned to output fluid from the second cavity toward the substrate, the second flow path being fluidly coupled to the fluid source and independent of the first flow path, wherein the flowing comprises filling the second cavity with gas through the second flow path and directing the gas to exit the second cavity through the plurality of second fluid outlet holes.

[0075] Example 18. The method of any one of Examples 16 or 17, wherein the flow rate of the gas exiting the second fluid exit hole is greater than the flow rate of the gas exiting the first fluid exit hole.

[0076] Example 19. The method of one of Examples 16-18, wherein the showerhead is part of an atomic layer deposition tool, and the method further comprises treating the substrate in the atomic layer deposition tool.

[0077] Example 20. The method of one of Examples 16-19, wherein treating the substrate in an atomic layer deposition tool includes depositing an atomic layer of silicon, and the gas is a chlorosilane-containing precursor gas.

[0078] While the present invention has been described with reference to exemplary embodiments, this specification is not intended to be construed in a limiting sense. Various modifications and combinations of those exemplary embodiments, as well as other embodiments of the present invention, will become apparent to those skilled in the art upon reference to this specification. It is therefore intended that the appended claims cover any and all such modifications or embodiments. [Explanation of symbols]

[0079] 100, 300, 400, 1300 shower head 102 Fluid outlet hole 103, 104 hollow 106 Fluid Path 107, 109 Fluid mixture 108 Fluid source 110, 124 Substrate holder 112 PCB 114 Fluid 116 Wafer deposition or etching tools 118, 120 exhaust port 122 Batch deposition or etching tools 126 Reactant showerhead 128, 128a, 128b Inert gas showerhead 130, 132, 134 Fluid distribution pathway 136 Fluid distribution hole 140, 142, 144 conduit 150, 152, 154 valves 158, 174 inner zone 160, 172 Intermediate Zone 162, 170 outer zone 164 First exhaust port 166 Second exhaust port 168 Nitrogen 180 skirt 188 Skirt / Vacuum Channel 430, 432, 434 Upper fluid distribution path 434 Upper fluid distribution hole 500 Multi-Zone Shower Head 600, 700 wedge-shaped shower head 630 Fluid Distribution Manifold 733 microprocessor 800, 1200 wedge-shaped multi-zone shower head

Claims

1. 1. An apparatus comprising: a processing chamber; a substrate holder disposed within the processing chamber; a showerhead disposed above the substrate holder, the showerhead comprising: a first zone disposed in a central region of the showerhead, the first zone including a first cavity; a plurality of first fluid outlet holes aligned to output fluid from the first cavity toward the substrate holder; a first fluid path fluidly coupled to a first fluid source; and a plurality of first fluid distribution paths fluidly coupling the first flow paths to the first cavity, each of the first fluid distribution paths having a mini-cavity for storing the fluid; a shower head including: a skirt disposed around a perimeter of the showerhead and extending toward the substrate holder; Equipped with the mini-cavities are arranged in a first compartment oriented in a first direction and in a second compartment oriented in a second direction; The device, wherein the second section is orthogonal to the first section, and the first section and the second section form a distorted cross shape in a top view.

2. moreover, a second zone disposed in a peripheral region of the showerhead, the second zone including a second cavity; a plurality of second fluid outlet holes aligned to output the fluid from the second cavity toward the substrate holder; a second fluid flow path fluidly coupled to a second fluid source and independent of the first fluid flow path; The apparatus of claim 1 , comprising:

3. moreover, a plurality of first cavities disposed in the first zone; a respective plurality of first fluid outlet holes aligned to output the fluid from each of the plurality of first cavities toward the substrate holder; a plurality of first fluid channels fluidly coupled to the first fluid source; one of a first plurality of fluid distribution paths fluidly coupling each of the first plurality of flow paths to each of the first plurality of cavities; a plurality of second cavities disposed in the second zone; a respective plurality of second fluid outlet holes aligned to output the fluid from each of the plurality of second cavities toward the substrate holder; a plurality of second fluid paths fluidly coupled to the second fluid source and independent of the first fluid path and the plurality of first fluid paths; The apparatus of claim 2 , comprising:

4. moreover, a third zone disposed in an intermediate region of the showerhead, the intermediate region being disposed between the central region and the peripheral region, the third zone including a third cavity; a plurality of third fluid outlet holes aligned to output the fluid from the third cavity toward the substrate holder; a third fluid flow path fluidly coupled to a third fluid source, the third fluid flow path being independent of the first fluid flow path and the second fluid flow path; The apparatus of claim 2 , comprising:

5. The apparatus of claim 2 , wherein the second fluid source is the same as the first fluid source.

6. The apparatus of claim 2 , wherein the second zone further comprises a plurality of second fluid distribution paths fluidly coupling the second flow paths to the second cavities.

7. 10. The apparatus of claim 1, wherein the skirt extends from the showerhead above the substrate holder to a distance between 1 mm and 10 mm.

8. 10. The apparatus of claim 1, wherein the skirt has a vacuum channel disposed around a peripheral region of the showerhead and aligned with a plurality of fluid inlet holes, the fluid being directed away from the substrate holder.

9. 10. The apparatus of claim 1, further comprising a vacuum channel disposed around a peripheral region of the showerhead and aligned with a plurality of fluid inlet holes, the fluid being directed away from the substrate holder.

10. The apparatus of claim 1 , wherein the apparatus is an atomic layer deposition apparatus.

11. 1. An apparatus comprising: a processing chamber; a substrate holder disposed within the processing chamber, the substrate holder configured to support a plurality of wafers; a showerhead system disposed above the substrate holder, a wedge-shaped showerhead disposed about a central region of the processing chamber, a first cavity in a central zone of the wedge-shaped showerhead; a plurality of first fluid outlet holes aligned to output fluid from the first cavity toward the substrate holder; a plurality of fluid distribution paths that discharge into the first cavity, each of the plurality of fluid distribution paths having a mini-cavity for storing the fluid; and a first flow path fluidly coupling a first fluid source to the plurality of fluid distribution paths; a wedge-shaped shower head having a shower head system including: a skirt disposed around a perimeter of the wedge-shaped showerhead and extending toward the substrate holder; Equipped with the mini-cavities are arranged in a first compartment oriented in a first direction and in a second compartment oriented in a second direction; The device, wherein the second section is orthogonal to the first section, and the first section and the second section form a distorted cross shape in a top view.

12. moreover, a peripheral zone disposed in a peripheral region of the central zone, the peripheral zone including a second cavity; a plurality of second fluid outlet holes aligned to output the fluid from the second cavity toward the substrate holder; a second fluid flow path fluidly coupled to a second fluid source and independent of the first fluid flow path; The apparatus of claim 11 , comprising:

13. 13. The apparatus of claim 12, wherein the skirt has a vacuum channel disposed around a peripheral region of the showerhead and aligned with a plurality of fluid inlet holes, the fluid being directed away from the substrate holder.

14. moreover, 13. The apparatus of claim 12, further comprising a vacuum channel disposed around a perimeter of the showerhead and aligned with a plurality of fluid inlet holes, the fluid being directed away from the substrate holder.

15. the processing chamber further having dual vacuum ports; a first vacuum port located near a first wide corner of the wedge-shaped showerhead; 13. The apparatus of claim 12, wherein a second vacuum port is located near a second wide corner of the wedge-shaped showerhead.

16. The apparatus of claim 12 , wherein the apparatus is an atomic layer deposition apparatus.

17. 1. An apparatus comprising: a processing chamber; a substrate holder disposed within the processing chamber; a showerhead disposed above the substrate holder, a first flow path fluidly coupled to a first fluid source holding a first fluid; a first plurality of mini-cavities, each of which is fluidly coupled to the first fluid source via the first flow path and configured to store the first fluid, the first plurality of mini-cavities having a first compartment oriented in a first direction and a second compartment oriented in a second direction, the second direction being orthogonal to the first direction, the first compartment and the second compartment forming a distorted cross shape in a top view; a shower head having a a first cavity, each of the first plurality of mini-cavities having one of a first plurality of fluid distribution holes, the first fluid being output into the first cavity; a plurality of first fluid outlet holes arranged to output the first fluid from the first cavity toward the substrate holder; An apparatus having:

18. the first plurality of mini-cavities vary in size; 20. The apparatus of claim 17, wherein one of the first plurality of mini-cavities in a central region of the showerhead is smaller than one of the first plurality of mini-cavities in a peripheral region of the showerhead.

19. 20. The apparatus of claim 17, wherein the showerhead is a wedge-shaped showerhead.

20. The showerhead further comprises: a second plurality of mini-cavities, each of the second plurality of mini-cavities fluidly coupled to the first fluid source via the first flow path and configured to store the first fluid, each of the first plurality of mini-cavities fluidly coupled to the first fluid source via one of the second plurality of mini-cavities; and 20. The apparatus of claim 17, wherein each of the second plurality of mini-cavities has one of a second plurality of fluid distribution holes for outputting the first fluid to a respective one of the associated first plurality of mini-cavities.

21. The showerhead further comprises: an upper cavity fluidly coupled to the first fluid source via the first flow path and configured to store the first fluid; 20. The apparatus of claim 17, wherein each of the first plurality of mini-cavities is fluidly coupled to the first fluid source via the upper cavity.

22. The showerhead further comprises: a second flow path fluidly coupled to a second fluid source holding a second fluid; a second plurality of mini-cavities, each of the second plurality of mini-cavities fluidly coupled to the second fluid source via the second flow path and configured to store the second fluid; a second cavity, each of the second plurality of mini-cavities having one of the second plurality of fluid distribution holes, into which the second fluid is output; a plurality of second fluid outlet holes arranged to output the second fluid from the second cavity toward the substrate holder, the first cavity being disposed above a central region of the substrate holder and the second cavity being disposed above a peripheral region of the substrate holder; 22. The apparatus of claim 21, comprising:

23. 3. The apparatus of claim 2, further comprising a microprocessor configured to independently control the temperature in each of the first and second zones.

Images