Model-based purge gas flow

By adjusting purge gas flow rates using machine learning models, the method optimizes semiconductor processing to improve throughput and uniformity by minimizing undesired deposition in processing chambers.

JP7796220B2Active Publication Date: 2026-01-08APPLIED MATERIALS INC
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Patent Information

Application Number
JP2024524649
Authority / Receiving Office
JP · JP
Patent Type
Patents
Current Assignee / Owner
Priority Date
2022-01-04
Filing Date
2022-07-13
Publication Date
2026-01-08
Estimated Expiration
2042-07-13

AI Technical Summary

Technical Problem

Existing semiconductor processing methods face challenges in achieving optimal purge gas flow rates to prevent undesired film deposition in processing chambers, leading to increased maintenance, reduced throughput, and process variability due to either insufficient or excessive purge gas flow.

Method used

A method involving a variable purge gas flow rate adjustment based on geometric hardware configuration and process recipe, utilizing machine learning models to optimize gas flow rates and minimize undesired deposition, thereby improving throughput and uniformity.

Benefits of technology

The method enhances deposition uniformity and reduces maintenance downtime by effectively controlling purge gas flow, ensuring consistent process conditions across different hardware configurations and recipes.

✦ Generated by Eureka AI based on patent content.

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Patent Text Reader

Abstract

An embodiment herein provides a method for processing a semiconductor substrate. The method described herein includes receiving a first input corresponding to a first geometric hardware configuration of a processing chamber, receiving a second input corresponding to a first process recipe of the processing chamber, determining a first purge gas flow rate for the processing chamber based on the first input and the second input, measuring a deposition characteristic of the processing chamber via a first sensor, determining a second purge gas flow rate different from the first purge gas flow rate based on the first input, the second input, and the measured deposition characteristic, and flowing a purge gas at the second purge gas flow rate during a deposition process.
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Description

[Technical Field]

[0001] The present disclosure relates generally to methods for processing semiconductor substrates, and more particularly to the deposition, modification, or removal of semiconductor film material on a substrate. In particular, the present disclosure relates to a method and apparatus for determining purge gas flow in a processing chamber. [Background technology]

[0002] Semiconductor substrates are processed for a wide variety of applications, including the fabrication of integrated and microdevices. One method of processing a substrate involves depositing a material, such as a semiconductor or conductive material, on the upper surface of the substrate. The deposition, modification, or removal of semiconductor material on a substrate primarily relies on the flow of purge and process gases across the surface of the substrate. During deposition operations, process and purge gases, such as inert gases, simultaneously flow into a processing chamber, such as an epitaxial growth (EPI) chamber. One purpose of the purge gas is to reduce the possibility that the process gas will expand beyond the substrate into areas of the processing chamber and deposit an undesired film layer on the chamber surface. Undesired film layers result in increased, avoidable maintenance and a subsequent reduction in overall throughput. For example, these sporadic, undesired depositions can result in coatings on the backside of the substrate support, coatings on optically transparent surfaces, and / or coatings and / or condensation between liners or around lifting and rotating mechanisms inside the processing kit, which can ultimately lead to particle problems and process variability. If there is no purge gas or the purge gas flow is too low, additional particle problems can also occur if unevacuated precursor or process particles are exposed to air during substrate transfer.

[0003] If the purge gas flow rate is too low, the purge gas will not sufficiently reduce the likelihood of the process gas reaching these hard-to-clean areas of the processing chamber and prevent the above problems. However, if the purge gas flow rate is too high, the purge gas will dilute the process gas and displace it, slowing the deposition process, reducing throughput and potentially creating non-uniformities across the substrate during the deposition process, resulting in process variations.

[0004] Therefore, there is a need for a method to improve purge gas flow into a processing chamber. Summary of the Invention

[0005] In one embodiment, a method for processing a semiconductor substrate is provided, the method including receiving a first input corresponding to a first geometric hardware configuration of a processing chamber, receiving a second input corresponding to a first process recipe for the processing chamber, running a first deposition process in the processing chamber using the first process recipe at a first purge gas flow rate, measuring a deposition characteristic of the first deposition process via a first sensor, determining a second purge gas flow rate different from the first purge gas flow rate based on the first input, the second input, and the measured deposition characteristic, and running the second deposition process at the second purge gas flow rate.

[0006] In another embodiment, a method is provided that includes receiving a first input corresponding to a first hardware configuration of a processing chamber, receiving a second input corresponding to a first process recipe for the processing chamber, running a first deposition process in the processing chamber using the first process recipe at a first purge gas flow rate, measuring a deposition characteristic of the first deposition process at a first location via a first sensor, determining a second purge gas flow rate different from the first purge gas flow rate based on the first input, the second input, and the measured deposition characteristic, running a second deposition process in the processing chamber using the second purge gas flow rate, measuring the deposition characteristic of the second deposition process at the first location via the first sensor, and determining a third purge gas flow rate different from the second purge gas flow rate based on a change in the measured deposition characteristic.

[0007] In yet another embodiment, a non-transitory computer-readable medium is provided that includes instructions that, when executed by a processor, cause the processor to receive a first input corresponding to a first geometric hardware configuration of a processing chamber, receive a second input corresponding to a first process recipe for the processing chamber, run a first deposition process in the processing chamber using the first process recipe at a first purge gas flow rate, measure a deposition characteristic of the first deposition process via a first sensor, determine a second purge gas flow rate different from the first purge gas flow rate based on the first input, the second input, and the measured deposition characteristic, and run the second deposition process at the second purge gas flow rate.

[0008] In a manner in which the above-mentioned features of the present disclosure can be understood in detail, a more particular description of the present disclosure, briefly summarized above, can be had by reference to embodiments, some of which are illustrated in the accompanying drawings. It should be noted, however, that the accompanying drawings illustrate only exemplary embodiments, and that the present disclosure is open to other equally effective embodiments and therefore should not be considered limiting in scope. [Brief explanation of the drawings]

[0009] [Figure 1A] 1 is a schematic cross-sectional view of a processing chamber that can be used to practice various embodiments of the present disclosure. [Figure 1B] 1B is a schematic cross-sectional view of the processing chamber of FIG. 1A rotated 90 degrees clockwise. [Figure 2] FIG. 10 illustrates a method for adjusting a purge gas flow rate according to an embodiment of the present disclosure. [Figure 3A] FIG. 10 shows a graphical comparison of measured deposition characteristics of a bottom window in a processing chamber as a function of both different hardware configurations and different purge gas flow rates. [Figure 3B] FIG. 10 shows a graphical comparison of measured deposition characteristics of a bottom window in a processing chamber as a function of both different hardware configurations and different purge gas flow rates. [Figure 3C] FIG. 10 shows a graphical comparison of measured deposition characteristics on a substrate in a processing chamber as a function of both different hardware configurations and different purge gas flow rates. [Figure 3D] FIG. 10 shows a graphical comparison of measured deposition characteristics of the backside of a substrate support in a processing chamber as a function of both different hardware configurations and different purge gas flow rates. [Figure 3E] 3A-3D show a comparative table of measured deposition characteristics of a portion of a substrate support backside, a substrate, and a window in a chamber as a function of both different hardware configurations and different purge gas flow rates. [Figure 4] FIG. 2 is a schematic diagram of a controller according to some embodiments of the present disclosure. [Figure 5] FIG. 1 illustrates a processing system according to an embodiment of the present disclosure. [Figure 6] 1 is a schematic cross-sectional view of another processing chamber that can be used to practice various embodiments of the present disclosure. [Figure 7] 1 is a schematic cross-sectional view of yet another processing chamber that can be used to practice various embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0010] For ease of understanding, where possible, like reference numerals will be used to refer to like elements common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

[0011] The present disclosure relates to methods for purging a processing chamber. The methods provided herein can increase throughput and deposition uniformity, reduce total production downtime, and shorten cleaning durations.

[0012] Instead of a constant purge gas flow rate, embodiments of the present disclosure provide a variable purge gas flow rate that can be adjusted for variations in geometric hardware configuration and process recipe. As used herein, the phrase "process recipe" refers to a finite number of process conditions for performing a predetermined operation on a substrate, such as a semiconductor wafer. According to embodiments of the present disclosure, adjusting the purge gas flow rate does not substantially dilute the process gas on the substrate, but effectively reduces the likelihood that the process gas will expand beyond the substrate into hard regions of the processing chamber and deposit an undesirable film layer. This ultimately results in fewer avoidable maintenance operations (hereinafter, shorter production downtime) and increased throughput. Furthermore, by adjusting the purge gas flow rate during or prior to a deposition operation, the methods described herein can improve overall process uniformity, such as center-to-edge (CE) deposition response uniformity.

[0013] FIG. 1A is a schematic cross-sectional view of a processing chamber 100 that can be used to implement various considerations in this disclosure. FIG. 1B is a schematic plan view of the processing chamber of FIG. 1A. The processing chamber 100 is utilized to grow an epitaxial film on a substrate, such as a substrate 102. The substrate 102 may be, for example, a 300 mm wafer formed of silicon. However, other substrates are contemplated. The processing chamber 100 is an epitaxial (EPI) chamber, although other chambers, such as a rapid thermal processing (RTP) chamber or an etch chamber, are also contemplated (see FIGS. 6 and 7).

[0014] The processing chamber 100 includes an upper body 156, a lower body 148 disposed below the upper body 156, and a flow module 112 disposed between the upper body 156 and the lower body 148. Optionally, cooling channels may be disposed within the upper body 156 and / or the lower body 148. Collectively, the upper body 156, the flow module 112, and the lower body 148 form a chamber body. In some embodiments, the chamber body may be constructed of a process-resistant material such as aluminum or stainless steel. Disposed within the chamber body are a substrate support 106, an upper window 108, a lower window 110, a plurality of upper lamps 141, and a plurality of lower lamps 143. In some embodiments, the upper window 108 and / or the lower window 110 comprise transparent quartz. The substrate support 106 is disposed between the upper window 108 and the lower window 110. In some embodiments, the substrate support 106 is formed from a material with high thermal resistance (e.g., black quartz or aluminum nitride), or a ceramic or graphite material coated with a silicon material such as silicon carbide. The substrate support 106 can be formed from any material that can withstand a high temperature environment, such as the high temperature environment of a chemical vapor deposition (CVD) process. In some embodiments, the substrate support 106 is an annular ring. In other embodiments, the substrate support 106 is a disk / plate-like shape that protects the bottom surface of the substrate from unwanted deposition during the deposition process. During operation, the processing chamber 100 creates a flow of precursors across the top surface 150 of the substrate 102.

[0015] A plurality of upper lamps 141 are disposed between the upper window 108 and the lid 154. The plurality of upper lamps 141 form an upper lamp assembly 147. The lid 154 includes a plurality of sensors 153 disposed therein for measuring the temperature within the process chamber 100. A plurality of lower lamps 143 are disposed between the lower window 110 and the floor 152. The plurality of lower lamps 143 form a lower lamp assembly 145. In some embodiments, the upper lamp assembly 147 and / or the lower lamp assembly 145 can be disposed about 3 centimeters (cm) or less from the substrate support 106, such as about 2 cm or less above the substrate support 106. In some embodiments, the lamps 141 and / or 143 can be disposed more than 3 cm from the substrate support 106. The lamps 141 and / or 143 can be disposed above and / or below the substrate support 106. In some embodiments, the cooling channel 146 acts as a heat sink to cool the lower lamp assembly 145 and / or the upper lamp assembly 147 .

[0016] A process volume 136 is formed between the upper window 108 and the lower window 110. The process volume 136 includes a substrate support 106 disposed therein. The substrate 102 is disposed on top of the substrate support 106 during processing. The operating pressure within the process chamber 100 can be reduced to subatmospheric pressure before introducing process gases through the inlet port 180. An optional edge ring 125 surrounds the substrate support 106. The edge ring 125 may be part of or in contact with the substrate support 106. In some embodiments, the substrate 102 is disposed on top of the edge ring 125. The process chamber 100 further includes a preheat ring 133. The preheat ring 133 is configured to be disposed around the substrate support 106 while the substrate support 106 is in the processing position. In some embodiments, overlapping substrate supports are utilized such that a gap 188 between the preheat ring 133 and the substrate support 106 is minimized. The overlap can be achieved by additional substrate support components coupled to the substrate support 106. The gap 188 can be from about 0 mm to about 5 mm, such as from about 0.5 mm to about 4.5 mm, such as from about 1 mm to about 4 mm, or from about 2 mm to about 3 mm. In some embodiments, the gap 188 can be non-uniform or asymmetric (e.g., when the substrate support is non-uniform or asymmetric, such as elliptical). In some embodiments, as shown in FIG. 1A, the preheat ring 133 is coupled to a liner 163 disposed on the interior surface of the flow module 112 such that an outer or lower surface of the preheat ring 133 is coupled to an inner or upper surface of the liner 163. In some embodiments, the preheat ring 133 can be substantially “L” shaped. In some embodiments, a “gap” exists within the annular preheat ring 133 at one or more exhaust outlets 116, as shown in FIG. 3A.

[0017] The substrate support 106 is mounted on a shaft 118. The shaft is connected to a motion assembly 121. The motion assembly 121 includes one or more actuators and / or adjustment devices that provide movement and / or adjustment of the shaft 118 and / or the substrate support 106 within the process volume 136. The motion assembly 121 includes a rotary actuator 122 that rotates the shaft 118 and / or the substrate support 106 about a longitudinal axis A of the processing chamber 100. In some embodiments, the rotor actuator 122 can be configured to rotate the substrate 102 at a rotational spin rate of about 2 Hz or greater, such as about 4 Hertz (Hz) or greater. In some embodiments, the rotor actuator 122 can be configured to rotate the substrate 102 at a rotational spin rate of about 1 Hz or less, such as about 0.5 Hz or less. In some embodiments, the motion assembly 121 further includes a vertical actuator 124 for raising and lowering the substrate support 106 in the z-direction. The motion assembly includes a tilt adjustment device 126 used to adjust the planar orientation of the substrate support 106, and a lateral adjustment device 128 used to adjust the left-right position of the shaft 118 and substrate support 106 within the process volume 136. In some embodiments, the substrate support 106 may be stationary. In other embodiments, the substrate support 106 may rotate about a vertical axis (e.g., the x-axis).

[0018] The substrate support 106 may further include lift pin holes 107 disposed therein. The lift pin holes 107 are sized to accommodate lift pins 132 for placing the substrate 102 on the substrate support 106 and / or lifting the substrate 102 from the substrate support 106 either before or after a deposition process is performed, respectively. The lift pins 132 may rest against lift pin stops 134 when the substrate support 106 is lowered from the processing position to the transfer position.

[0019] The flow module 112 includes multiple process gas inlets 114, multiple flow module purge gas inlets 164, and one or more exhaust gas outlets 116. One or more cooling channels 146 are disposed below the multiple process gas inlets 114. As shown in FIG. 1A, one cooling channel 146 is shown below the multiple process gas inlets 114 and above the slit valve 135, and another cooling channel 146 is shown below the multiple flow module purge gas inlets 164. The cooling channel 146 may be annular. Slit purge gas can flow from a slit inlet (not shown) in the slit valve 135 and exit through either one or more exhaust gas outlets 116 or a slit outlet (not shown) in the slit valve 135. Additionally, holes or slits in the liner 163 can allow gas to exhaust to the gas outlet 116. It is contemplated that the positions of the slit inlet and slit outlet can be switched depending on the configuration selected. In some embodiments, the rotating purge gas may flow from a rotating inlet (not shown) at the bottom of the processing chamber 100 around the shaft 118 and exit through one or more exhaust gas outlets 116. In some embodiments, each of the different purge gases may be exhausted through an exhaust vent, such as a slit or hole in the liner 163, before reaching one or more gas outlets 116.

[0020] The liner 163 is disposed on the interior surface of the flow module 112 and protects the flow module 112 from reactive gases used during the deposition process. A liner purge gas can flow between the liner 163 and the chamber body and exit through one or more exhaust gas outlets 116. The flow module purge gas, slit purge gas, rotational purge gas, and / or liner purge gas can be an inert gas such as one or more of helium, hydrogen, nitrogen, and argon. The flow module purge gas, slit purge gas, rotational purge gas, and / or liner purge gas can further include an etchant to affect the selectivity of the deposited film or the cleaning area being purged. In some embodiments, the liner 163 is divided into an upper liner and a lower liner, and the lower liner has holes formed along its interior surface to form a vented lower liner, allowing gases in the lower portion of the chamber to be vented directly to an exhaust, such as the exhaust pump 157. The vented lower liner can have from about 1 to about 30 holes, such as from about 5 to about 20 holes, and each hole can be from about 1 mm to about 6 mm, such as from about 3 mm to about 4 mm. The purpose of the flow module purge gas, slit purge gas, liner purge gas, and rotational purge gas is to create a localized positive pressure to prevent precursor and / or process gas concentrations from increasing in the area through which each purge gas flows and to facilitate maintaining chamber cleaning both during and between processing operations, such as deposition operations. In some embodiments, the flow module purge gas flow rate and the slit purge gas flow rate can have a more dominant impact on process conditions on the substrate. As used herein, “purge gas” can refer to any one or combination of the flow module purge gas, slit purge gas, liner purge gas, and rotational purge gas flowing from the multiple flow module purge gas inlets 164.As used herein, "purge gas flow rate" and variations of "purge gas flow rate" such as "first purge gas flow rate" or "second purge gas flow rate" can refer to any one or combination of flow module purge gas flow rate, slit purge gas flow rate, liner purge gas flow rate, and rotational purge gas flow rate.

[0021] The process gas inlet 114 is positioned so that gas flows parallel to the top surface 150 of the substrate 102, while the flow module purge gas inlet 164 is positioned so that purge gas flows directly beneath the substrate support 106. The process gas inlet 114 is fluidly connected to a process gas source 151. The flow module purge gas inlet 164 is fluidly connected to a purge gas source 162. In some embodiments, the purge gas source 162 is fluidly connected to an inlet at the base of the shaft 118, as shown in phantom in FIG. 1A. The one or more exhaust gas outlets 116 are fluidly connected to an exhaust pump 157. The process gas source 151 and the purge gas source 162 can each be configured to deliver one or more precursors or process gases into the process volume 136. The precursor and / or process gases may include one or more of dichlorosilane (DCS), trichlorosilane (TCS), or higher order silanes such as disilane (DS), trisilane, and tetrasilane, and metal-organic precursors such as trimethylaluminum (TMA) and tetraethyl orthosilicate (TEOS). However, other gases are also contemplated. As shown in FIG. 1A, a controller 120 is in communication with the processing chamber 100 and is used to control processes such as those described herein.

[0022] The processing chamber 100 is configured to receive the substrate 102 through a slit valve 135. The slit valve 135 may be coupled to a transfer chamber having a transfer robot therein. The slit valve 135 allows the substrate 102 to be loaded into and removed from the processing volume 136 of the processing chamber 100 through an opening (e.g., using a robot end effector of the transfer robot). A door (not shown) closes and seals the opening (not shown), thereby allowing the environment of the processing volume 136 to be controlled independently of ambient conditions outside the processing chamber 100.

[0023] Various gas inlets, such as the multiple process gas inlets 144 and the multiple flow module purge gas inlets 164, can be configured to provide individual or multiple gas flows with varying gas parameters, such as velocity, density, or composition. In some embodiments, as shown in FIG. 1B, the one or more exhaust outlets 116 are positioned 180 degrees from the multiple process gas inlets 114 and the multiple flow module purge gas inlets 164 in a cross-flow configuration. In the cross-flow configuration, the slit valve 135 can be positioned 90 degrees clockwise (as shown in FIG. 1B) or 90 degrees counterclockwise from the one or more exhaust outlets 116. In some embodiments, the slit valve 135 can be positioned below the inlet (e.g., the slit valve 135 can be positioned 0 degrees from the inlet location). The processing chamber 100 can further include an additional gas inlet (not shown) to provide optional cross-flow gas, which facilitates tuning of deposition uniformity. As shown in FIG. 1B, the additional gas inlet is positioned 180 degrees from the slit valve 135. However, it is contemplated that the additional gas inlet and the slit valve 135 can be aligned with one another (e.g., located on the same side of the processing chamber 100). In some embodiments, the one or more exhaust outlets 116 are positioned 180 degrees from the slit valve 135 and 270 degrees counterclockwise from the multiple process gas inlets 114 and the multiple flow module purge gas inlets 164 in a rotational configuration. In this rotational configuration, when the substrate 102 is rotated counterclockwise, the gas flow sweeps at least 270 degrees around the interior of the processing chamber 100 before being exhausted through the one or more exhaust outlets 116. However, the one or more exhaust outlets 116, the additional gas inlet, the multiple process gas inlets 114, the slit valve 135, and the multiple flow module purge gas inlets 164 can be positioned in a variety of optional locations relative to one another. In some examples, the outlet port 190 is at the same height as the inlet port 180 in the XY plane.

[0024] FIG. 2 illustrates a method 200 for adjusting a purge gas flow rate according to some embodiments of the present disclosure. In operation 210, the controller 120 receives a first input. The first input can be entered by a user or selected from a library or database of information stored by the controller 120. The first input corresponds to a first geometric hardware configuration of the processing chamber 100. In some embodiments, the first geometric hardware configuration includes one or more of the following: flow type, preheat ring position, substrate support position, inlet location, slit valve and outlet location, non-vented or vented liner, circular or elliptical preheat ring, overlapping substrate support, dome or liner replacement, and any other new or replaced hardware in the processing chamber. The first geometric hardware configuration of the first input can take into account the life and / or current aging of one or more hardware components. For example, a newly replaced hardware component may be identical to the previous hardware component, but may have a different level of wear and initial machining tolerances, resulting in a changed required purge gas flow rate. In some examples, the first input may refer to a library or database of values ​​related to chamber hardware or hardware characteristics such as dimensions.

[0025] In operation 220, the controller 120 receives a second input. The second input may be entered by a user or may be selected and referenced by the controller 120 from a library or database of information stored in memory. The second input corresponds to a first process recipe for the processing chamber. In some embodiments, the first process recipe includes at least one process condition, such as a chamber temperature, a chamber pressure, a purge gas flow rate, a process gas flow rate, a substrate support rotation speed, a substrate support vertical position, a duration, and / or a gas composition.

[0026] In operation 230, the first and second inputs are used to determine a first purge gas flow rate. In one example, the purge gas flow rate per recipe includes a “default” setting, and the purge gas flow rate, timing, and / or composition are associated with the “default” setting. The default purge gas setting can be determined empirically and stored in a memory or database for recall when a desired hardware configuration and / or recipe is selected. In another example, the first purge gas flow rate is determined by a machine learning (ML) model 404 that selects a flow rate based on the first and second inputs from a library or catalog of prior laboratory data. For example, the ML model 404 determines the first purge gas flow rate and displays the determined value to the user, or the ML model 404 determines the first purge gas flow rate and automatically adjusts the purge gas flow rate to match the determined value.

[0027] In operation 240, one or more first sensors are used to measure a first deposition characteristic of the substrate or other chamber component. In some embodiments, the first deposition characteristic may be thickness, color, mass fraction, total area, CE change, transmittance, transparency, reflectance, roughness, and / or emissivity. The one or more first sensors may include a single or multiple color pyrometer, a wideband optical spectrometer, an optical reflectometer, a camera, a thermal camera, another device for physical sensor feedback, or any combination thereof. The one or more first sensors are outside the lower window 110 and the upper window 108 so that the one or more first sensors have a direct line of sight to the desired target area. For example, one or more optical spectrometers and / or one or more thermal cameras may be aimed at or through the lower window 110 at multiple locations where thicker deposition is expected, and / or one or more pyrometers may be aimed through the lower window 110 at the backside of the substrate support 106. In one example, signals from one or more optical spectrometers can be correlated with a loss in transmittance or increased blockage of portions of the lower window 110, indicating coating evolution. In situ image analysis of images from one or more cameras can similarly be correlated with coating evolution on the lower window 110. Metrology data (e.g., physical sensor feedback) from one or more first sensors can be used by the ML model 404 or other neural network for supervised or unsupervised self-learning to adjust purge gas flow rates to achieve improved and / or desired processing results, such as deposition uniformity and increased throughput. For example, the purge gas flow rate can be adjusted by the ML model after comparing predicted backside coatings with measured backside coatings and correcting for excessive deposition on chamber components or uneven / undesired deposition on substrates.

[0028] In operation 250, the first input, the second input, and the measured deposition characteristic are used to determine a second purge gas flow rate. In some embodiments, the second purge gas flow rate is determined by a machine learning (ML) model 404 (e.g., the ML model 404 determines the first purge gas flow rate and displays the determined value to a user, or the ML model 404 determines the first purge gas flow rate and automatically adjusts the purge gas flow rate to match the determined value). The second purge gas flow rate can be different from the first purge gas flow rate, and the difference between the second purge gas flow rate and the first purge gas flow rate can be based in whole or in part on the measured deposition characteristic. As previously discussed, the first purge gas flow rate and the second purge gas flow rate can refer to a flow module purge gas, a slit purge gas, a rotational purge gas, and / or a liner purge gas.

[0029] The ML model 404 (shown in FIG. 4) is particularly advantageous in that the model is configured for multiple purge gas variables and configured to make a single correction based on these variables. In conventional systems, a change to one variable, such as a rotational purge, can have unintended consequences in other chamber locations, creating new problems. Such conventional systems tend to force operators to “chase” configurations, in that a first change in process conditions can have unintended consequences elsewhere in the chamber, which can necessitate a second change in process conditions, which can necessitate a third change, and so on. However, the ML model 404 can learn to anticipate these changes and make the necessary adjustments to eliminate this tracking issue. It is further contemplated that the ML model 404 can include or interact with a “digital twin” of the processing chamber. The digital twin is configured according to the first input of operation 210. Fluid dynamics simulations can be performed on the digital twin based on the revisions suggested by the ML model 404 to determine the effects of fluid flow within the digital twin and, conversely, within the actual processing chamber.

[0030] The use of a digital twin eliminates "trial and error" or "chasing" against the physical processing chamber to determine improved and / or optimal process conditions, such as purge flow rates. It is contemplated that the digital twin and / or ML model 404 can be updated based on feedback from one or more sensors within the physical processing chamber, thereby improving results. Any such feedback is valuable in ensuring an accurate digital twin model. Furthermore, such feedback facilitates updating the digital twin due to deviations in hardware component specifications from input values. For example, the physical dimensions of hardware components may change due to iterative processing within the physical chamber, and thus the digital twin model may not accurately reflect the physical model. Feedback provided by sensors within the physical chamber can identify deviations from the digital twin (e.g., the digital twin purge gas recipe may indicate that no deposition is occurring at the bottom window while the physical chamber sensor still indicates deposition forming at the bottom window), and the ML model 404 can then "learn" to account for these deviations and improve the physical chamber processing by providing updated process recipe parameters.

[0031] Optionally, operations 240-250 are repeated so that multiple measurements of the deposition characteristics can be compared. In some embodiments, a contrast curve analysis can be created to compare the measured deposition characteristics as a function of purge gas flow rate. In some embodiments, operations 240-250 are repeated one or more times during a process, such as a deposition process, and the purge gas flow rate is adjusted in real time either by the ML model 404 or manually.

[0032] Graphical comparisons of measured deposition characteristics for different hardware configurations, process recipes, and / or purge gas flow rates can be made, as shown in Figures 3A-3E. In Figures 3A-3E, the process recipe was held constant to compare deposition characteristics as a function of different hardware configurations and purge gas flow rates. As illustrated, small changes in physical components can result in large differences in deposition characteristics. However, the ML model 404 of the present disclosure can account for these changes to reduce unwanted deposition in undesired locations.

[0033] 3A-3B are graphical comparisons of measured deposition on a lower window in a processing chamber as a function of both different hardware configurations (see bars on the graph) and different purge gas flow rates (see x-axis labels). Hardware configuration A (left bar, HWC-A) includes a first preheat ring, and hardware configuration B (right bar, HWC-B) includes a second preheat ring. In some embodiments, the first preheat ring and / or the second preheat ring may be symmetric or asymmetric. As used herein, symmetric and asymmetric can refer to uniformity or non-uniformity. As can be seen in FIG. 3A, hardware configuration A exhibits a thinner measured deposition compared to hardware configuration B for each purge gas flow rate. Thus, in the case of FIG. 3A, adjusting the purge gas flow rate can include increasing the purge gas flow rate to thin the measured deposition on the lower window of the processing chamber where deposition is undesirable. Clearly, different hardware configurations will result in more or less deposition on surface features when using the same process recipe. However, aspects of the present disclosure can take these differences into account to reduce undesirable results.

[0034] In Figures 3B-3D, hardware configurations A-G include first, second, third, fourth, and fifth preheat rings and first, second, third, fourth, and fifth liners, respectively. In some embodiments, one or more of the first, second, third, fourth, and fifth preheat rings may be symmetric or asymmetric, and one or more of the first, second, third, fourth, and fifth liners may be vented liners. As can be seen in Figure 3B, hardware configuration B generally results in increased deposition on the lower window for all purge gas flow rates. Meanwhile, hardware configurations C, D, and E each exhibit a thicker relative deposition than the other two for different purge gas flow rates. Furthermore, as the purge gas flow rate increases, the measured deposition becomes thinner for all hardware configurations. Thus, in the case of FIG. 3B , adjusting the purge gas flow rate can involve either decreasing or increasing the purge gas flow rate depending on the hardware configuration of the processing chamber utilized to thin the measured deposition on the lower window of the processing chamber where deposition is undesirable. Therefore, different hardware configurations coupled with different recipe conditions indicate different purge gas flow rates to avoid unacceptably thick deposition characteristics on the lower window in the processing chamber where deposition is undesirable. The particular purge gas flow rate indicated to avoid unacceptably thick deposition characteristics is a lower threshold purge gas flow rate for the lower window. Unacceptably thick deposition characteristics depend on the desired accuracy of the thin film application process and the application of the thin film itself. For example, a reduction in the transparency of quartz of more than about 5% and / or a change in the emissivity of the substrate of more than about 0.1% can be considered unacceptable.

[0035] FIG. 3C is a graphical comparison of measured deposition on substrates in processing chambers as a function of both different hardware configurations (see bars on the graph) and different purge gas flow rates (see x-axis labels). As can be seen from FIG. 3C, different hardware configurations each exhibit thicker or thinner deposition than other hardware configurations for different purge gas flow rates. Furthermore, as the purge gas flow rate increases, the measured deposition decreases. Thus, in the case of FIG. 3C, adjusting the purge gas flow rate can include decreasing the purge gas flow rate to increase the measured deposition on substrates in processing chambers where deposition is desired. Therefore, different hardware configurations coupled with different recipe conditions require different amounts of slit purge gas flow to avoid unacceptably thin deposition on substrates in processing chambers where deposition is desired. This specific amount of purge gas flow required to avoid unacceptably thin deposition is the upper threshold for acceptable purge gas flow rates. The unacceptably thin deposition characteristic depends on the desired accuracy of the thin film application process and the application of the thin film itself. For example, a reduction in deposition on a substrate of more than about 5% can be considered unacceptable.

[0036] An unacceptably thin deposition on a substrate in a processing chamber can also involve substantial problems with deposition uniformity. The substantial problems with deposition uniformity on a substrate depend on the desired accuracy of the thin film application process. For example, a non-uniformity of more than about 1% on a substrate can be considered unacceptable.

[0037] FIG. 3D is a graphical comparison of measured deposition on the backside of a substrate support in a processing chamber as a function of both different hardware configurations (see bars on the graph) and different purge gas flow rates (see x-axis labels). As can be seen from FIG. 3D, hardware configuration B exhibits a higher, or increased, measured deposition compared to the other hardware configurations for each purge gas flow rate, with increased purge gas flow rates generally resulting in thinner deposition for all hardware configurations. Meanwhile, hardware configurations C, D, and E each exhibit a thicker relative deposition than the other two for different purge gas flow rates. Thus, in the case of FIG. 3D, adjusting the purge gas flow rate can include increasing the purge gas flow rate to thin the measured deposition to avoid unacceptably thick deposition on the backside of the substrate in the processing chamber, where deposition is undesirable. This particular purge gas flow rate required to avoid unacceptably thick deposition is also a lower threshold for the required purge gas flow rate for the backside of the substrate support. In the case where there are multiple lower threshold required purge gas flow rates for different chamber parts or different portions of chamber parts, the lowest or smallest lower threshold required purge gas flow rate can be selected as the overall lower threshold purge gas flow rate for the processing chamber. In other embodiments, each of the different purge gas types and sources described can each have an individually determined purge gas flow rate.

[0038] FIG. 3E is a comparison table of measured deposition characteristics of the backside of the substrate support, the substrate, and the lower window in the chamber according to the graphs in FIGS. 3A-3D. The process recipe was kept constant for each hardware configuration. As can be seen from FIG. 3E, increasing the purge gas flow rate results in a decrease in the deposition characteristics of the substrate, the backside of the substrate support, and the lower window. To shorten processing time, increase deposition uniformity on the substrate, and increase overall chamber throughput, it is advantageous to improve the deposition characteristics on the substrate. However, to reduce cleaning time and avoidable maintenance and increase overall chamber throughput, it is also advantageous to reduce the deposition characteristics of the backside of the substrate support and the lower window. This tradeoff affects the purge gas flow rate (e.g., increasing the purge gas flow rate will increase deposition on the substrate (advantageous) and increase deposition on other chamber components (disadvantageous)).

[0039] For example, in FIG. 3E, the deposition characteristic value for the substrate is shown via the mass fraction ratio of DCS to the total amount of gas. In some examples, the lower threshold for the deposition characteristic value for the substrate may be 0.50, and the upper threshold deposition characteristic value for the backside and window portion of the substrate support may be 0.05. This would mean that for hardware configurations B and D, the purge flow rate should be at least 18 standard liters per minute (slm) to remain below the upper threshold deposition characteristic value for the backside and lower window of the substrate support and prevent unacceptable amounts of deposition on the backside and lower window of the substrate support. Similarly, for hardware configurations B and D, the purge flow rate should not exceed 18 slm to remain above the lower threshold deposition characteristic value for the substrate and retain a sufficiently high amount of deposition on the substrate. Thus, in this example, a purge flow rate of 18 slm is an acceptable value for hardware configurations B and D, and the process recipe would be utilized with both hardware configurations.

[0040] The deposition characteristics measured by the methods described above can reveal a sensitivity to the probability of coating a process chamber part, which is a measure of the concentration of precursor or process gas in proximity to the process chamber part and can be indicated by a number of physical sensor feedbacks, such as those disclosed herein.

[0041] As discussed, the controller 120 includes an ML model 404 that is trained on historical and simulated models of the hardware configuration, process recipe, and known or measured deposition characteristics. Upon determining the deposition characteristics by metrology measurements, such as via any of the sensors described herein, the trained ML model determines the simulated model to adjust the purge gas flow rate, and optionally causes the adjusted purge gas flow rate to be implemented. It is contemplated that for any intermediate values ​​or models, the ML model 404 may use regression or interpolation analysis or may be represented.

[0042] In some embodiments, the ML model 404 is a component of a larger system or process for generating an adjusted purge gas flow rate. In these embodiments, some or all of the simulated model generated by the ML model 404 is utilized. In some embodiments, the modified simulated model is selected by a table lookup based on a known process recipe, a known hardware configuration, and / or known or measured deposition characteristics of the processing chamber. In these embodiments, the table lookup determines the simulated model to select from a library of simulated models configured to adjust the purge gas flow rate of the processing chamber for known hardware configurations, process recipes, and / or deposition characteristics.

[0043] According to certain embodiments, the ML model 404 may be supervised or unsupervised machine learning. In some embodiments, the ML model 404 is a classifier such as a neural network, a deep learning neural network, a k-means classifier, a random forest walk, or the like that can receive inputs, such as a hardware configuration, a process recipe, such as an initial process recipe, and / or metrology data (e.g., measured deposition properties) of a substrate, such as the substrate 102, being processed by a tool, such as the processing chamber 100, or other chamber components, such as the bottom window 110 or the backside of the substrate support 106.

[0044] FIG. 4 depicts a schematic diagram of a controller according to some embodiments of the present disclosure. As shown in FIG. 4, the controller 120 receives design data 408, including hardware configuration data, and generates a purge gas flow rate prediction 406. The design data 408 can include or accompany process recipe data 412, including information about process conditions of a processing chamber. For example, the design data 408 can be provided to the ML model during operation 210, and the process recipe data 412 can be provided to the ML model during operation 220. Upon classifying the provided data, the ML model 404 generates a purge gas flow rate prediction 406, which is provided to a tool 432, such as the processing chamber 100. The ML model 404 also receives metrology data (e.g., deposition characteristics) 416 generated by a metrology tool, such as one or more sensors described herein. In some embodiments, the metrology tool can include more than one metrology tool and / or measure multiple deposition characteristics. In some embodiments, the metrology tool measures one or more deposition characteristics in real time while a substrate is being processed. Upon classifying the measured deposition property data, the ML model 404 generates a further purge gas flow rate prediction 406 that is provided to a tool 432, such as the processing chamber 100. In some embodiments, the ML model 404 provides the purge gas flow rate prediction 406 to the tool 432 in real time while processing a substrate, such as by automatically adjusting the purge gas flow rate to match the further purge gas flow rate prediction 406.

[0045] The controller 120 further includes an ML training component 420 for training the ML model 404. The ML training component 420 can receive historical data 424, simulated data 428, or both to train the ML model 404. The historical data 424 and simulated data 428 can include hardware configuration data, process recipe data, and / or metrology data, such as deposition characteristic data. In this context, the simulated data 428 can be a simulated model of predicted deposition characteristics based on known or discovered correlations between hardware configuration, process recipe conditions, and metrology data. The historical data 424 can include historical hardware configuration and / or process recipe data from a previous processing chamber, and / or metrology data (e.g., deposition characteristic data) from previously measured substrates and / or other chamber parts, such as a lower window or substrate support backside. In some embodiments, the ML model 404 is trained offline or at a point before processing is performed, such as prior to operations 210 and 220. In some embodiments, training may occur during processing, such as during acts 210-250.

[0046] The ML training component 420 trains the ML model 404 using historical data 424 and / or simulated data 428. Once trained, the ML model 404 can receive the data described above and generate purge gas flow rate predictions 406 that are provided to a tool 432, such as the processing chamber 100. The ML model 404 can continually store and update records and / or information regarding different process recipes and hardware configurations that have been tested, and the data can be saved in the historical data 424. The ML training component 420 constantly increases the accuracy of the ML model 404.

[0047] FIG. 5 depicts a processing system 500 according to some embodiments of the present disclosure. The processing system 500 is an example of the controller 120 according to certain embodiments and may be used in place of the controller 120 described above. FIG. 5 depicts an exemplary processing system 500 that may operate the embodiment systems described herein to implement embodiments according to the flowcharts and methods described herein. The processing system 500 includes a central processing unit (CPU) 502 coupled to a data bus 516. The CPU 502 is configured to process computer-executable instructions stored, for example, in memory 508 or storage 510, to cause the processing system 500 to perform method embodiments described herein, for example, on the system embodiments described herein with respect to FIGS. 1A-3E. The CPU 502 is included as representative of a single CPU, multiple CPUs, a single CPU with multiple processing cores, and other forms of processing architectures capable of executing computer-executable instructions.

[0048] Processing system 500 further includes input / output (I / O) device(s) 512 and an interface 504 that allows processing system 500 to interface with input / output devices 512, such as a keyboard, a display, a mouse device, a pen input, and other devices that can interact with processing system 500. It should be noted that processing system 500 can connect to external I / O devices (e.g., an external display device) via physical and wireless connections.

[0049] Processing system 500 further includes a network 514 interface that provides the processing system with access to an external network 514, thereby providing access to external computing devices. Processing system 500 further includes memory 508, which in this example includes a receiving component 518, a generating component 520, a controlling component 522, a measuring component 524, and a determining component 526 for performing the operations described herein. While shown in FIG. 5 as a single memory 508 for simplicity, it should be noted that the various aspects stored in memory 508 may be stored in different physical memories, including memory remote from processing system 500, but all accessible by CPU 502 via an internal data connection, such as bus 516.

[0050] Storage 510 further includes hardware configuration design data 528, process recipe data 530, deposition characteristic data 532, machine learning (ML) model data 534, ML training data 536, purge gas flow rate data 538, and adjusted purge gas flow rate data 540 for performing the operations described herein. As will be appreciated by those skilled in the art, storage 510 can include other data and aspects. As with memory 508, while FIG. 5 depicts a single storage 510 for simplicity, the various aspects stored in storage 510 can be stored on different physical storage devices, all accessible to CPU 502 via an internal data connection, such as bus 516, or an external connection, such as network interface 506. Those skilled in the art will recognize that one or more elements of processing system 500 can be located remotely and accessed via network 514.

[0051] FIG. 6 is a schematic cross-sectional view of another processing chamber 600 that can be used in some embodiments. The processing chamber 600 can be an RTP chamber. In some embodiments, the processing chamber 600 is set up in a cross-flow configuration as shown in FIG. 6, whereby the outlet 640 is at 180 degrees from the inlet 620. Multiple lamps 650 are positioned above a transparent top window 645 coupled to an upper body 644 of the processing chamber 600. In some embodiments, the upper body is formed of an opaque material (e.g., aluminum or steel). The substrate 602 is positioned on an annular substrate support 604 above a chill plate 624 in the processing volume 610 of the processing chamber 600. The annular substrate support is positioned on an edge ring 615 that is positioned on a support cylinder 625. The support cylinder 625 is configured to rotate the annular substrate support 604. In some embodiments, purge gas can flow from the floor 601 of the processing chamber 600. Multiple reflectors 608 are coupled to the substrate side of the chill plate 624. In some embodiments, a stationary member 655 is coupled to the lower body 654 of the processing chamber 600. The stationary member 655 may be an annular member.

[0052] FIG. 7 is a schematic cross-sectional view of yet another processing chamber 700 that can be used in some embodiments. The processing chamber 700 includes a showerhead 710 located inside a process volume 720 of the processing chamber 700. A substrate support pedestal 730 is configured to support a substrate 702 during processing. In some embodiments, an induction heater coil 740 is housed within the substrate support pedestal 730. An annular purge gas inlet 750 radially surrounds a substrate support shaft 735 in the floor 704 of the processing chamber 700. The substrate support shaft 735 is configured to support the substrate support pedestal 730. In some embodiments, the substrate support shaft 735 is configured to rotate the substrate support pedestal and / or the substrate. In some embodiments, purge gas from the purge gas inlet 750 can be exhausted 360 degrees throughout the processing chamber 700 via an exhaust vent.

[0053] It is contemplated that the above-described method can be integrated into an ML platform, whereby a first input corresponding to a first hardware configuration, a second input corresponding to a first process recipe, and one or more measured deposition characteristics can be used to adjust the purge gas flow rate into the chamber. As noted above, an excessively high purge gas flow rate can reduce the total precursor or process gas concentration across the substrate due to dilution. This can adversely affect (e.g., slow) the growth rate of the semiconductor material, waste excess purge gas, and adversely affect the process. Alternatively, an excessively low purge gas flow rate can allow the process or precursor gas to get into areas that are difficult to clean, potentially depositing undesirable layers on parts of the processing chamber other than the substrate.

[0054] Aspects of the present disclosure contemplate the use of digital replicas of physical processing chambers, such as the processing chambers described herein. The digital replica is a digital simulation stored in memory that corresponds to a physical processing chamber. The digital replica reflects the physical characteristics of the actual physical chamber, such as physical dimensions, materials, and so on. The digital replica facilitates prediction of operation within the physical chamber. The operation of the physical chamber is simulated using one or more rules, algorithms, physics models, fluid flow models, and so on. The digital replica can predict data such as deposition characteristics within the physical chamber based on a mathematical and physical understanding of the process conditions input into the digital replica's algorithm. For example, the digital replica can predict deposition characteristics on the backside of a substrate (within the physical chamber) based on values ​​of process gas flow rates and purge gas flow rates into the physical chamber. In some embodiments, the digital replica can generate multiple distinct predicted metrology outputs. For example, the digital replica receives data indicating fluid flow rates (e.g., purge gas flow rates and process gas flow rates) of the physical chamber and mathematically calculates more than a single solution or outputs metrology data. The digital replica processing chamber can automatically reject predicted output metrology data that is outside of acceptable ranges or otherwise violates the rules of the digital replica software. In some embodiments, the digital replica processing chamber works in conjunction with a machine learning model. This configuration is known as a physics-informed machine learning model (PIMLM) or physics-informed neural network (PINN).

[0055] The machine learning model can be utilized to update algorithms, rules, or other results output by the digital replica to refine and / or increase the accuracy of the digital replica simulation. Furthermore, the machine learning model can additionally or alternatively recommend hardware configurations and / or process conditions to achieve desired results in the physical chamber. The machine learning model can operate in conjunction with the digital replica to provide improved processing in the physical chamber. For example, the machine learning model can operate in conjunction with the digital replica to provide outputs for achieving desired process conditions (e.g., deposition characteristics) when hardware configurations, process recipes, etc., are changed. Other advantageous effects are also contemplated.

[0056] The foregoing description is provided to enable any person skilled in the art to practice the various embodiments described herein. The examples discussed herein are not intended to limit the scope, applicability, or embodiments set forth in the claims. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments. For example, changes may be made in the function and arrangement of the elements discussed without departing from the scope of the disclosure. The various examples may omit, substitute, or add various procedures or components where appropriate. For example, described methods may be performed in an order different from that described, and various steps may be added, omitted, or combined. Also, features described in connection with some examples may be combined in some other examples. For example, an apparatus may be implemented, or a method may be practiced using any number of aspects set forth herein. Additionally, the scope of the disclosure is intended to encompass such apparatuses or methods implemented using other structure, functionality, or structure and functionality in addition to or other than the various aspects of the disclosure set forth herein. It should be understood that any aspect of the disclosure disclosed herein may be embodied by one or more elements of a claim.

[0057] The methods disclosed herein include one or more operations or actions for achieving the method. Method operations and / or actions may be interchanged with one another without departing from the scope of the claims. In other words, unless a specific order of operations or actions is specified, the order and / or use of specific operations and / or actions may be changed without departing from the scope of the claims. Furthermore, various operations of the methods described above may be performed by any suitable means capable of performing the corresponding functions. This means may include various hardware and / or software component(s) and / or modules, including, but not limited to, circuits, application-specific integrated circuits (ASICs), or processors. Typically, where operations are illustrated in figures, these operations may have corresponding counterpart means-plus-function components with similar numbering.

[0058] While the foregoing 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, the scope of which is determined by the claims appended hereto.

Claims

1. 1. A method for processing a semiconductor substrate, comprising: receiving a first input corresponding to a first process recipe for a processing chamber; determining a first purge gas flow rate based on the first input and a hardware configuration of the processing chamber; performing a first deposition process in the processing chamber using the first process recipe at the first purge gas flow rate; measuring a deposition characteristic of the first deposition process via a first sensor; determining a second purge gas flow rate different from the first purge gas flow rate based on the first input, the hardware configuration of the processing chamber, and the measured deposition characteristics; performing a second deposition process at the second purge gas flow rate; A method comprising:

2. The method of claim 1 , wherein the first purge gas flow rate is further determined using a model corresponding to the processing chamber.

3. The method of claim 1 , wherein the first sensor comprises an optical spectrometer, a camera, or a pyrometer.

4. The method of claim 1 , wherein the hardware configuration includes a non-vented or vented liner, a circular or elliptical preheat ring, and / or a substrate support overlapping the preheat ring.

5. 10. The method of claim 1, wherein the determining the second purge gas flow rate is accomplished by a machine learning model, the machine learning model comparing the measured deposition characteristic to a desired deposition characteristic and providing the second purge gas flow rate based on a difference between the measured deposition characteristic and the desired deposition characteristic.

6. The method of claim 5 , wherein said determining said first purge gas flow rate is accomplished by referencing a database based on user input.

7. The method of claim 5 , wherein the first process recipe is updated to include the second purge gas flow rate.

8. 6. The method of claim 5, wherein the machine learning model includes a digital twin model configured according to the hardware configuration of the processing chamber, and wherein a fluid dynamics simulation is performed on the digital twin model based on revisions suggested by the machine learning model.

9. The method of claim 1 , wherein the measured deposition property comprises thickness, mass fraction, transmittance, transparency, emissivity, or any combination thereof.

10. The method of claim 1 , wherein the measured deposition property is a measured deposition property of a substrate, a backside of a substrate support, or a bottom window in the processing chamber.

11. The method of claim 1 , wherein measuring the deposition characteristic of the processing chamber via the first sensor occurs more than once throughout the first deposition process.

12. 10. The method of claim 1, wherein the purge gas is a flow module purge gas, a slit purge gas, a rotational purge gas, or a liner purge gas.

13. receiving a first input corresponding to a first hardware configuration of a processing chamber; receiving a second input corresponding to a first process recipe for the processing chamber; performing a first deposition process in the processing chamber using the first process recipe at a first purge gas flow rate; measuring a deposition characteristic of the first deposition process at a first location via a first sensor; determining a second purge gas flow rate different from the first purge gas flow rate based on the first input, the second input, and the measured deposition characteristic; performing a second deposition process in the processing chamber using the second purge gas flow rate; measuring a deposition characteristic of the second deposition process at the first location via the first sensor; determining a third purge gas flow rate different from the second purge gas flow rate based on the change in the measured deposition characteristic; A method comprising:

14. The method of claim 13 , wherein the measured deposition property comprises a film thickness.

15. The method of claim 13 , wherein the measured deposition property is a measured deposition property of a substrate, a backside of a substrate support, or a bottom window in the processing chamber.

16. 1. A non-transitory computer-readable medium having instructions that, when executed by a processor, cause the processor to: receiving a first input corresponding to a first process recipe for a processing chamber; determining a first purge gas flow rate based on the first input and a hardware configuration of the processing chamber; performing a first deposition process in the processing chamber using the first process recipe at the first purge gas flow rate; measuring a deposition characteristic of the first deposition process via a first sensor; determining a second purge gas flow rate different from the first purge gas flow rate based on the first input, the hardware configuration of the processing chamber, and the measured deposition characteristics; performing a second deposition process at the second purge gas flow rate; A non-transitory computer-readable medium for causing

17. 20. The non-transitory computer-readable medium of claim 16, wherein the first purge gas flow rate is further determined using a model corresponding to the processing chamber.

18. 17. The non-transitory computer-readable medium of claim 16, wherein the purge gas is a liner purge gas.

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