Showerhead faceplate with flow apertures configured for hollow cathode discharge suppression - Patents.com

Abstract

The showerhead faceplate has a bottom surface facing a plasma generation region and a top surface facing a plenum to which process gas is supplied during operation of the substrate processing system. The faceplate includes apertures formed through the bottom surface and openings formed through the top surface. Each of the apertures is formed to extend through a portion of the entire thickness of the faceplate and intersect with at least one of the openings to form a corresponding flow path for process gas through the faceplate. Each of the apertures has a cross-section in at least one direction having a hollow cathode discharge-suppressing dimension. Each of the openings has a cross-section with a minimum cross-sectional dimension greater than the hollow cathode discharge-suppressing dimension.

Description

[Technical Field]

[0001] The present disclosure relates to the fabrication of semiconductor devices. [Background technology]

[0002] Many modern semiconductor chip fabrication processes involve the generation of a plasma from which ions and / or radicals are derived and used to directly or indirectly affect changes on the surface of a substrate exposed to the plasma. For example, various plasma-based processes can be used to etch material from, deposit material on, or modify material already present on a substrate surface. Plasma is often generated by supplying a process gas to a plasma processing region and applying radio frequency (RF) power to the process gas, which excites and converts the process gas into the desired plasma within the plasma processing region. The characteristics of the plasma are affected by many process parameters, including, but not limited to, the material composition of the process gas, the flow rate of the process gas, the distribution and pressure of the process gas, the geometric features of the plasma processing region and surrounding structures, the temperature of the process gas and surrounding materials, the frequency and magnitude of the applied RF power, and a bias voltage applied to attract charged components of the plasma to the wafer, among other parameters. It is within this context that the present disclosure arises. Summary of the Invention

[0003] In some embodiments, a showerhead for delivering process gas to a plasma generation region in a substrate processing system is disclosed. The showerhead includes a faceplate having a bottom surface and a top surface. The bottom surface of the faceplate faces the plasma generation region during operation of the substrate processing system. The top surface of the faceplate faces one or more plenums to which one or more process gases are supplied during operation of the substrate processing system. The faceplate has an overall thickness measured between the bottom surface and the top surface of the faceplate. The faceplate includes apertures formed through the bottom surface of the faceplate. The faceplate includes openings formed through the top surface of the faceplate. Each of the apertures is formed to extend through a portion of the overall thickness of the faceplate and intersect at least one of the openings to form a corresponding flow path for the process gas through the faceplate. Each of the apertures has a cross-section oriented parallel to the bottom surface of the faceplate. The cross-section of each of the apertures has a hollow cathode discharge suppression dimension in at least one direction. Each of the openings has a cross-section oriented parallel to the top surface of the faceplate. Each of the openings has a minimum cross-sectional dimension that is greater than a hollow cathode discharge suppression dimension.

[0004] In some embodiments, a faceplate for a showerhead for delivering process gas to a plasma generating region in a substrate processing system is disclosed. The faceplate includes a disk having a bottom surface and a top surface. The bottom surface of the disk is configured to face the plasma generating region during operation of the substrate processing system. The top surface of the disk is configured to face one or more plenums to which one or more process gases are supplied during operation of the substrate processing system. The disk has an overall thickness measured between the bottom surface and the top surface of the disk. The disk includes apertures formed through the bottom surface of the disk. The disk includes openings formed through the top surface of the disk. Each of the apertures is formed to extend through a portion of the overall thickness of the disk and intersect with at least one of the openings to form a corresponding flow path for the process gas through the disk. Each of the apertures has a cross-section oriented parallel to the bottom surface of the disk. The cross-section of each of the apertures has a hollow cathode discharge suppression dimension in at least one direction. Each of the openings has a cross-section oriented parallel to the top surface of the disk. Each of the openings has a minimum cross-sectional dimension that is greater than a hollow cathode discharge suppression dimension.

[0005] In some embodiments, a method for manufacturing a faceplate of a showerhead for delivering process gas to a plasma generating region in a substrate processing system is disclosed. The method includes providing a disk having a bottom surface and a top surface. The bottom surface of the disk is configured to face the plasma generating region during operation of the substrate processing system. The top surface of the disk is configured to face one or more plenums to which one or more process gases are supplied during operation of the substrate processing system. The disk has an overall thickness measured between the bottom surface and the top surface of the disk. The method also includes forming apertures through the bottom surface of the disk. Each of the apertures has a cross-section oriented parallel to the bottom surface of the disk. The cross-section of each of the apertures is formed to have a hollow cathode discharge-suppressing dimension in at least one direction. The method also includes forming openings through the top surface of the disk to intersect at least one of the apertures in the disk and form a corresponding flow path for the process gas through the disk. Each of the openings has a cross-section oriented parallel to the top surface of the disk. Each of the openings is formed to have a minimum cross-sectional dimension greater than the hollow cathode discharge-suppressing dimension. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a cross-sectional side view of an exemplary substrate processing system used to perform a plasma process to modify a substrate, according to some embodiments.

[0007] [Figure 2A] FIG. 2A is a bottom view of a faceplate according to some embodiments.

[0008] [Figure 2B] FIG. 2B is a side cross-sectional view of a faceplate corresponding to view AA of FIG. 2A, according to some embodiments.

[0009] [Figure 2C]FIG. 2C is an enlarged vertical cross-sectional view of the area identified in FIG. 2B, according to some embodiments.

[0010] [Figure 3A] FIG. 3A is a bottom view of faceplate 152A, according to some embodiments.

[0011] [Figure 3B] FIG. 3B is a top view of faceplate 152A, according to some embodiments.

[0012] [Figure 3C] FIG. 3C is a see-through view of faceplate 152A, showing the arrangement of parallel slots and the arrangement of holes relative to each other, according to some embodiments.

[0013] [Figure 3D] FIG. 3D is a side cross-sectional view of faceplate 152A corresponding to view point AA referenced in FIG. 3C, according to some embodiments.

[0014] [Figure 3E] FIG. 3E is an enlarged vertical cross-sectional view of the area identified in FIG. 3D, according to some embodiments.

[0015] [Figure 3F] FIG. 3F is an enlarged vertical cross-sectional view of faceplate 152A corresponding to view point BB referenced in FIG. 3E, according to some embodiments.

[0016] [Figure 3G] FIG. 3G is a bottom isometric view of the faceplate 152A illustrated in FIGS. 3A-3F, according to some embodiments.

[0017] [Figure 3H] FIG. 3H is a bottom isometric view of a portion of faceplate 152A, according to some embodiments.

[0018] [Figure 3I] FIG. 3I is a bottom view of a portion of faceplate 152A, according to some embodiments.

[0019] [Figure 3J] FIG. 3J is a top isometric view of a portion of faceplate 152A, according to some embodiments.

[0020] [Figure 3K] FIG. 3K illustrates a faceplate 152B having holes arranged in a square grid array, according to some embodiments.

[0021] [Figure 3L] FIG. 3L illustrates a faceplate 152C having holes arranged in a rectangular grid array, according to some embodiments.

[0022] [Figure 3M] FIG. 3M illustrates a faceplate 152D having holes arranged in a diamond lattice array, according to some embodiments.

[0023] [Figure 3N] FIG. 3N illustrates a faceplate 152E having holes arranged in a parallelogram lattice array, according to some embodiments.

[0024] [Figure 3O] FIG. 3O illustrates a faceplate 152F having holes arranged in a customized pattern, according to some embodiments.

[0025] [Figure 3P] FIG. 3P is an isometric top view of faceplate 152F, according to some embodiments.

[0026] [Figure 3Q] FIG. 3Q is a bottom view of a portion of faceplate 152F, according to some embodiments.

[0027] [Figure 4A-1] FIG. 4A-1 is a bottom view of a portion of a modified faceplate 152G that includes rectangular cross-sectional shaped apertures formed separately at each hole location, according to some embodiments.

[0028] [Figure 4A-2] FIG. 4A-2 is a vertical cross-sectional view through a hole in a modified faceplate 152G corresponding to view AA in FIG. 4A-1, according to some embodiments.

[0029] [Figure 4A-3] FIG. 4A-3 is a vertical cross-sectional view through a hole in a modified faceplate 152G corresponding to view point BB in FIG. 4A-1, according to some embodiments.

[0030] [Figure 4B] FIG. 4B illustrates rectangular cross-sectional shaped apertures formed separately at each hole location in a modified faceplate 152H, where the apertures are non-parallel and regularly oriented relative to one another, according to some embodiments.

[0031] [Figure 4C] FIG. 4C illustrates rectangular cross-sectional shaped apertures formed separately at each hole location in a modified faceplate 152I, where the apertures are non-parallel and randomly oriented relative to one another, according to some embodiments.

[0032] [Figure 5A-1] FIG. 5A-1 is a bottom view of a portion of a modified faceplate 152J that includes curved cross-sectionally shaped apertures formed separately at each hole location, according to some embodiments.

[0033] [Figure 5A-2]FIG. 5A-2 is a vertical cross-sectional view through a hole in a modified faceplate 152J corresponding to view AA in FIG. 5A-1, according to some embodiments.

[0034] [Figure 5B] FIG. 5B is a bottom isometric view of a portion of a modified faceplate 152J1 in which holes are arranged in the customized pattern shown in FIGS. 3O and 3P, according to some embodiments.

[0035] [Figure 5C] FIG. 5C shows apertures of curved cross-sectional shapes formed separately at each hole location in the modified faceplate 152K1 and having various azimuthal orientations around the axis of the corresponding hole, according to some embodiments.

[0036] [Figure 5D] FIG. 5D is a bottom isometric view of a portion of a modified faceplate 152K2, according to some embodiments.

[0037] [Figure 6A-1] FIG. 6A-1 illustrates bracket cross-sectional shaped apertures formed separately at each hole location in a modified faceplate 152L, according to some embodiments.

[0038] [Figure 6A-2] FIG. 6A-2 is a vertical cross-sectional view through a hole in a modified faceplate 152L corresponding to view AA in FIG. 6A-1, according to some embodiments.

[0039] [Figure 6B] FIG. 6B shows bracket cross-sectional shaped apertures formed separately at each hole location in the modified faceplate 152M and having various azimuthal orientations around the axis of the corresponding hole, according to some embodiments.

[0040] [Figure 7A-1]FIG. 7A-1 illustrates circular cross-sectional shaped apertures formed separately at each hole location in a modified faceplate 152N, according to some embodiments.

[0041] [Figure 7A-2] FIG. 7A-2 is a vertical cross-sectional view through a hole in a modified faceplate 152N corresponding to view AA in FIG. 7A-1, according to some embodiments.

[0042] [Figure 7B-1] FIG. 7B-1 illustrates multiple apertures with circular cross-sectional shapes per hole in a modified faceplate 152O, according to some embodiments.

[0043] [Figure 7B-2] FIG. 7B-2 is a vertical cross-sectional view through a hole in the modified faceplate 152O corresponding to view AA in FIG. 7B-1, according to some embodiments.

[0044] [Figure 7C] FIG. 7C is a bottom isometric view of a portion of a modified faceplate 152O, according to some embodiments.

[0045] [Figure 8A] FIG. 8A is a top view of a modified faceplate 152P having holes arranged in a Vogel pattern, according to some embodiments.

[0046] [Figure 8B] FIG. 8B is an enlarged view of a portion of the modified faceplate 152P referenced in FIG. 8A that includes rectangular cross-sectionally shaped apertures, according to some embodiments.

[0047] [Figure 8C] FIG. 8C is a close-up view of a portion of a modified faceplate 152P that includes apertures with curved cross-sectional shapes, according to some embodiments.

[0048] [Figure 8D] FIG. 8D is a close-up view of a portion of a modified faceplate 152P including bracket cross-sectional shaped apertures, according to some embodiments.

[0049] [Figure 8E] FIG. 8E is a close-up view of a portion of a modified faceplate 152P that includes apertures with circular cross-sectional shapes, according to some embodiments.

[0050] [Figure 9A] FIG. 9A is a transparent view of a modified faceplate 152Q that includes a Vogel pattern of grooves formed through the bottom surface of the faceplate that intersects with a Vogel pattern of holes formed through the top surface of the faceplate, according to some embodiments.

[0051] [Figure 9B] FIG. 9B is a close-up view of a portion of a modified faceplate 152Q, according to some embodiments.

[0052] [Figure 10A] FIG. 10A is a transparent view of a modified faceplate 152R including a first Vogel pattern of bottom grooves formed through the bottom surface of the faceplate to intersect with a second Vogel pattern of top grooves formed through the top surface of the faceplate, according to some embodiments.

[0053] [Figure 10B] FIG. 10B is a cross-sectional view of an aperture formed by the intersection of a bottom groove and a top groove, according to some embodiments.

[0054] [Figure 11A]FIG. 11A is a top view of a modified faceplate 152S including a radial spoke pattern of bottom grooves formed through the bottom surface of the faceplate to intersect with a corresponding radial spoke pattern of top grooves formed through the top surface of the faceplate, according to some embodiments.

[0055] [Figure 11B] FIG. 11B is a side cross-sectional view of an aperture formed by the intersection of a bottom groove and a top groove, according to some embodiments.

[0056] [Figure 12A] FIG. 12A is a see-through view of a modified faceplate 152T that includes a concentric circular pattern of bottom grooves formed through the bottom surface of the faceplate that intersects with a radial spoke pattern of top grooves formed through the top surface of the faceplate, according to some embodiments.

[0057] [Figure 12B] FIG. 12B is a vertical cross-sectional view corresponding to view AA referenced in FIG. 12A, in which an aperture is shown at the intersection of the bottom and top grooves, according to some embodiments.

[0058] [Figure 13] FIG. 13 is a flowchart of a method for manufacturing a showerhead for delivering process gases to a plasma generating region in a substrate processing system, according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0059] FIG. 1 is a vertical cross-sectional view of an exemplary substrate processing system 100 used to perform a plasma process to modify a substrate 101, according to some embodiments. The system 100 includes a process chamber 102 having an upper chamber body 102A and a lower chamber body 102B. A center column 118 is defined within the lower chamber body 102B and configured to support a pedestal 140. In some embodiments, the pedestal 140 is a powered electrode. The pedestal 140 provides a substrate support surface on which the substrate 101 is positioned for processing. The pedestal 140 is electrically coupled to a power source 104 via a matching network 106. The power source 104 is controlled by a control module 110, e.g., a controller. The control module 110 is configured to operate the substrate processing system 100 by executing process inputs and control instructions 108. The process input and control instructions 108 may include process recipes and control specifications for process parameters such as power levels, timing parameters, process gases (e.g., precursors), flow rates of process gases, mechanical movement of the substrate 101, pressure, temperature within the process chamber 102, etc., to direct the performance of a plasma-based fabrication process on the substrate 101, such as depositing / forming a film on the substrate 101 via atomic layer deposition (ALD) or plasma-enhanced chemical vapor deposition (PECVD) methods and / or etching material from the substrate 101, among other methods.

[0060] The center column 118 also includes lift pins 120 controlled by a lift pin control system 122. The lift pins 120 are used to raise and lower the substrate 101 relative to the pedestal 140, allowing an end effector of a robotic substrate handling system to capture and release the substrate 101. The lift pin control system 122 is controlled by the control module 110. The substrate processing system 100 further includes a gas supply manifold 112 connected to a process gas source 114, e.g., a gas supply from a facility. Depending on the substrate 101 processing being performed, the control module 110 controls the delivery of the process gas 114 to a showerhead 150 via the gas supply manifold 112. In some embodiments, such as the example shown in FIG. 1, the showerhead 150 is configured as a "chandelier showerhead." The showerhead 150 includes one or more plenum regions 151 and a faceplate 152. The faceplate 152 includes multiple passages for process gases to travel from the plenum region 151 and reach the plasma processing region 154 between the faceplate 152 and the pedestal 140. The faceplate 152 is configured to distribute the process gases throughout the plasma processing region 154. In some embodiments, during operation, radio frequency (RF) power is supplied from the power source 104 through the matching network 106 to an electrode on the pedestal 140, and the showerhead 150 is electrically connected to a reference ground potential, such that RF power is transmitted through the plasma processing region 154 and converts the process gases into a plasma within the plasma processing region 154.

[0061] In some embodiments, the plenum region 151 of the showerhead 150 is defined by a single plenum region. In some embodiments, the plenum region 151 of the showerhead 150 includes an inner plenum region and an outer plenum region, with the outer plenum region configured to circumscribe the inner plenum region. In these embodiments, process gases are provided within a process window that is controlled in part by controlling the flow of process gases into the inner and / or outer plenums of the showerhead 150. Valves and mass flow control (MFC) mechanisms can be configured to ensure that the correct process gases are delivered to predetermined locations / plenums during the performance of a plasma-based fabrication process on the substrate 101. The valves and MFC mechanisms can be controlled by the control module 110. From the plasma processing region 154, spent process gases and volatile by-product materials, if present, flow to an outlet (not shown) and exit the process chamber 102. A vacuum source (not shown) (e.g., a one- or two-stage dry mechanical pump and / or turbomolecular pump) draws spent process gases and volatile by-product materials through an outlet. The vacuum source can also function to maintain an appropriately low pressure within the process chamber 102.

[0062] In some embodiments, the substrate processing system 100 may include a carrier ring 153 configured to surround an outer region of the pedestal 140. The carrier ring 153 is configured to rest on a carrier ring support region that is stepped down from a substrate support region at the center of the pedestal 140. The carrier ring 153 includes an outer edge side of its disk structure, e.g., an outer radius, and a substrate edge side of its disk structure, e.g., an inner radius, that is closest to where the substrate 101 is located. The substrate edge side of the carrier ring 153 includes a plurality of contact support structures configured to lift the substrate 101 when the carrier ring 153 is lifted by the forks 180. Movement of the carrier ring 153 is controlled by the carrier ring lift and rotation control module 124 in response to signals provided by the control module 110 to which the carrier ring lift and rotation control module 124 is connected. For example, the carrier ring lift and rotation control module 124 may be used to lift the carrier ring 153 along with the substrate 101 to move the substrate 101 into and out of a process chamber 102, for example, in a single station system. Alternatively, the carrier ring lift and rotation control module 124 can be used to rotate the carrier ring 153 along with the substrates 101 to another station, for example in a multi-station system.

[0063] Various embodiments are disclosed herein for the showerhead 150, and more particularly for modified configurations of the faceplate 152 of the showerhead 150. It should be understood that the substrate processing system 100 of FIG. 1 is provided by way of example. The embodiments disclosed herein for modified configurations of the showerhead 150 and faceplate 152 can be used in essentially any plasma processing chamber in which a showerhead 150 or an equivalent version is used to distribute process gas to a region where the process gas is converted into plasma. Thus, it should be understood that the embodiments disclosed herein can be used with many variations of the substrate processing system 100, as well as other types of plasma-based substrate processing / fabrication systems.

[0064] FIG. 2A is a bottom view of a faceplate 152, according to some embodiments. The faceplate 152 includes an arrangement of through-holes 201 (representative), which are illustrated as small circles in FIG. 2A. The example in FIG. 2A shows the through-holes 201 (representative) arranged in a square grid array. FIG. 2B is a vertical cross-sectional view of the faceplate 152 corresponding to view AA in FIG. 2A, according to some embodiments. FIG. 2C is an enlarged vertical cross-sectional view of the region 203 identified in FIG. 2B, according to some embodiments. As shown in FIG. 2C, the faceplate 152 has a thickness D1 in the vertical, or z-direction. In various embodiments, the thickness D1 of the faceplate 152 is configured so that the faceplate 152 provides sufficient thermal performance and maintains structural integrity during processing. In some embodiments, the thickness D1 of the faceplate 152 is in the range of about 0.25 inches to about 2 inches. In some embodiments, the thickness D1 of the faceplate is about 0.375 inches. However, it should be understood that in some embodiments, the thickness of faceplate 152 can be less than 0.25 inches or more than 2 inches. In some embodiments, through-holes 201 have a circular shape in the horizontal direction, i.e., in the x-y plane. In these embodiments, each of through-holes 201 (representative) has a diameter D2 measured in the horizontal direction, i.e., in the x-y plane. In some embodiments, diameter D2 is in the range of about 0.02 inches to about 0.08 inches. In some embodiments, diameter D2 is about 0.08 inches. In some embodiments, diameter D2 is in the range of about 0.02 inches to about 0.04 inches. In some embodiments, diameter D2 is about 0.04 inches.

[0065] In some embodiments, the faceplate 152 is formed of aluminum, such as 6061 aluminum or 3003 aluminum, among others. In some embodiments, the faceplate 152 is formed of a ceramic material, such as aluminum oxide (Al2O3), aluminum nitride (AIN), or yttria (YO3), among other ceramic materials. Also, in some embodiments, the faceplate 152 is formed of stainless steel. It should be understood that in various embodiments, the faceplate 152 can be formed of essentially any material: a) a material that is chemically compatible with the process gas chemistries and materials present in the plasma processing region 154 during processing; b) a material that has sufficient mechanical strength to maintain structural integrity in the presence of pressure differentials that may exist between the top and bottom surfaces of the faceplate 152 during processing; c) a material that has sufficient thermal properties to meet thermal performance requirements during processing; and d) a material that has sufficient electrical properties to meet electrical performance requirements during processing. Also, in some embodiments, the bottom of faceplate 152 facing plasma processing region 154 can be coated with a coating such as a metal oxide, e.g., aluminum oxide (Al2O3), among other coating materials. In various embodiments, the coating material applied to the bottom surface of faceplate 152 must remain adhered to faceplate 152 during processing and must be chemically compatible with the process gas chemistries and materials present in plasma processing region 154 during processing.

[0066] Referring to FIG. 2C , during processing, hollow cathode discharges (HCDs) 205 can form within the through-holes 201 near the bottom surface of the faceplate 152, depending on the process conditions, e.g., pressure and RF power, as well as the geometric shape and size of the through-holes 201. The specific combination of process conditions determines the critical dimension for hollow cathode discharge suppression. Concave features larger than the critical dimension allow the plasma sheath to form robust HCDs, while concave features smaller than the critical dimension do not support the formation of significant HCDs. Some processes, such as ashable hard mask (AHM) processes, require pressures greater than about 11 Torr or about 13 Torr and RF powers greater than 9 kilowatts (kW) at high frequency and / or greater than 3 kW at low frequency. In these and other processes, as the pressure and / or RF power increase during processing, HCDs 205 can occur in through-holes 201 having a cylindrical shape with a diameter D2 set to about 0.08 inches or greater. When HCDs 205 form in the through-holes 201 of the faceplate 152, the local plasma density around the HCDs 205 can be disrupted, which can adversely affect process uniformity across the substrate 101. Additionally, the local formation of HCDs 205 in the through-holes 201 of the faceplate 152 can generate electrical arcing at the location of the HCDs 205, which can damage the substrate 101 and cause non-uniformity in the process results on the substrate 101. Therefore, it is important to avoid the formation of HCDs 205 within the through-holes 201 of the faceplate 152 to reduce / eliminate process non-uniformity and electrical arcing.

[0067] One approach to reducing the formation of HCDs 205 is to reduce the diameter D2 of the through-holes 201 below the HCD formation limit. However, there is a practical limit to how much the diameter D2 of the through-holes 201 can be reduced using conventional drilling fabrication methods. Also, as the diameter D2 of the through-holes 201 decreases, the total number of through-holes 201 must increase to maintain the required overall process gas flow conductance through the faceplate 152 and maintain the required pressure drop across the faceplate 152 (between the plenum region 151 and the plasma processing region 154). Because the process gas flow conductance through a given through-hole 201 is a function of the flow area of ​​the given through-hole 201 and the friction associated with the flow boundary layer along the sides of the given through-hole 201, the total number of required through-holes 201 increases nonlinearly (nearly exponentially) as the diameter D2 decreases below about 0.08 inches. In addition, process uniformity can be sensitive to the pressure drop across the faceplate 152. Therefore, when adjusting the size and number of through-holes 201 in faceplate 152, it is important to maintain the same pressure drop across faceplate 152.

[0068] It has been demonstrated that in some processes, such as the AHM process, in which the faceplate 152 has a flat bottom and includes 3,870 cylindrical through-holes 201, HCDs 205 still occur within through-holes 201 with a diameter D2 set at approximately 0.02 inches. It has also been demonstrated that the through-hole diameter D2 needs to be approximately 0.012 inches, or approximately 0.01 inches, or even smaller to avoid HCD 205 formation at higher process pressures and RF powers, such as those present in the AHM process. And, if the cylindrical through-hole 201 diameter D2 is set at 0.012 inches, then for a given downstream pressure and flow through the showerhead 150, more than 50,000 through-holes 201 are required to match a specified overall process gas flow conductance through the faceplate 152 and match a specified pressure drop across the faceplate 152. However, it is impractical to manufacture the faceplate 152 using conventional drilling techniques to form 50,000 through-holes 201 with a diameter D2 set at 0.012 inches. One reason for this is that drill bit breakage becomes a significant issue when drilling holes with a diameter less than approximately 0.02 inches. And, if a drill bit breakage occurs when drilling any of the large number (e.g., 50,000) of through-holes 201, the faceplate 152 would likely be damaged and rendered unusable. It should be understood that the successful fabrication of the faceplate 152 is limited by the shape, size, and quantity of the through-holes 201 when attempting to make the through-holes 201 small enough to limit HCD 205. Not only is the required quantity of through-holes 201 prohibitive, but the required diameter D2 of the through-holes 201 also limits the “drilling yield” because the drill bit may be prone to breakage during drilling and to forming / machining less accurate through-holes 201.

[0069] The through-spindle cooling technique can be used to assist in drilling holes having diameters up to approximately 0.02 inches. In the through-spindle cooling technique, the drill bit includes coolant channels through which coolant flows during drilling, thereby preventing overheating and corresponding mechanical failure of the drill bit. While the through-spindle cooling technique enables faster and more consistent drilling of through holes 201 without damaging the drill bit, the through-spindle cooling technique cannot be utilized for drill bits having a size less than 0.02 inches. Therefore, a regular (non-through-spindle cooled) drill bit must be used to form through holes 201 having a diameter D2 less than 0.02 inches. Furthermore, for diameters D2 less than 0.02 inches, the through holes 201 must be drilled using a peck-drilling process to deal with material chips generated during the drilling process. Furthermore, using a small-diameter (less than 0.02 inches) drill bit that is not through-spindle cooled for peck drilling further increases the likelihood of drill bit breakage.

[0070] While it may be possible to mechanically drill circular through-holes 201 with diameters D2 smaller than the critical dimension required to suppress HCD formation, fabricating the faceplate 152 would be prohibitively expensive and have low yields to drill enough through-holes 201 to maintain sufficiently high process gas flow conductance and uniformity. For example, to match the process gas flow conductance of a faceplate 152 having 3,870 through-holes 201, each with a diameter D2 of 0.02 inches, tens of thousands of through-holes 201, each with a diameter D2 of approximately 0.012 inches, would need to be drilled through the faceplate 152. Given that through-holes 201 with diameters D2 less than approximately 0.02 inches cannot be drilled using through-spindle cooling techniques, the time required to drill each through-hole 201 with a diameter D2 of approximately 0.012 inches would be slower. Additionally, without the use of through-spindle cooling techniques, if a large number of through-holes 201 are drilled, the risk of breaking the drill bit and destroying the faceplate 152 increases significantly, correspondingly reducing the yield of the faceplate 152. This, combined with increased processing time, makes the cost per faceplate 152 prohibitively high. Recognizing that the limit for mechanical drilling at diameter D2 is approximately 0.02 inches, and that the diameter D2 of the through-holes 201 needs to be less than approximately 0.012 inches to avoid the formation of HCDs 205 at expected increased pressure and RF power process settings, an alternative configuration of faceplate 152 is disclosed herein that does not require drilling of through-holes 201 through the entire thickness D1 of the faceplate 152.

[0071] Various embodiments of modified faceplates (152A-152T) of the showerhead 150, i.e., modifications to the faceplate 152, are disclosed herein to eliminate HCD formation within the modified faceplates (152A-152T). Each of the modified faceplates (152A-152T) has a defined geometric configuration that eliminates HCD formation within the process gas passages on the plasma side (bottom) of the modified faceplates (152A-152T) in the presence of higher process pressures and higher process RF powers, such as those present in AHM processes and other processes. For HCD suppression, a concern is the minimum cross-sectional size of the process gas passages, i.e., flow apertures, on the plasma side (bottom) of the modified faceplates (152A-152T). The modified faceplates (152A-152T) disclosed herein include small apertures formed on the plasma side of the modified faceplates (152A-152T) to provide process gas flow to the plasma processing region 154. These small apertures can have various cross-sectional shapes in the plane of the plasma side of the modified faceplates (152A-152T), such as rectangular, curved, circular, and bent cross-sectional shapes, among other cross-sectional shapes. Each small aperture formed on the plasma side of the modified faceplates (152A-152T) has an HCD suppression dimension in at least one direction. The HCD suppression dimension is small enough to prevent HCD formation within the aperture in the presence of higher process pressures and higher process RF powers. For example, in some embodiments, the HCD suppression dimension of the aperture is about 0.012 inches or less.

[0072] Small apertures formed on the plasma side of the modified faceplates (152A-152T) intersect with larger openings formed through the plenum side (top surface) of the modified faceplates (152A-152T). To enable reliable and efficient manufacturing of the modified faceplates (152A-152T), the smaller apertures, which are more difficult to manufacture, are formed and extend a limited distance to the plasma side of the modified faceplates (152A-152T). Then, larger holes, which are easier to manufacture, are formed extending from the plenum side of the modified faceplates (152A-152T) through most of the entire thickness of the modified faceplates (152A-152T) to intersect one or more of the smaller apertures, thereby forming fluid passageways through the modified faceplates (152A-152T) for the flow of process gases. Thus, the smaller cross-sectional sizes and shallow depths of the apertures formed in the plasma side of the modified faceplates (152A-152T) are maintained within the range manufacturable using methods less suited to full-thickness drilling, such as mechanical drilling / machining methods, or laser drilling / cutting methods, and / or other cutting methods (e.g., waterjet cutting, plasma cutting, etc.), and / or wire electrical discharge machining (EDM) methods (e.g., sinker EDM, wire EDM, etc.), among other fabrication methods. And, the larger cross-sectional sizes and deeper depths of the openings formed in the plenum side of the modified faceplates (152A-152T) are maintained within the range manufacturable using mechanical drilling and / or machining and / or laser cutting methods, among other fabrication methods.

[0073] The distribution of small apertures formed within the plasma side of the modified faceplates (152A-152T) provides a substantially uniform distribution of process gas flow to the plasma processing region 154. Also, by defining the number and geometric specifications, e.g., cross-sectional opening area, length, depth, etc., of the small apertures, the process gas flow conductance to the plasma processing region 154 provided by the modified faceplates (152A-152T) is substantially matched to the process gas flow conductance of existing showerhead designs to substantially match process performance, e.g., process gas flow uniformity, pressure drop across the faceplate, etc. Larger openings formed through the plenum side of the modified faceplates (152A-152T) can be configured to reduce the depth (cut / machined depth) of the small apertures on the plasma side of the modified faceplates (152A-152T) while providing process gas flow conductance matching and pressure drop matching to existing showerhead designs.

[0074] By using small apertures with shallow depths on the plasma side of the modified faceplates (152A-152T) in combination with intersecting larger, deeper openings formed through the plenum side of the modified faceplates (152A-152T), the modified faceplates (152A-152T) can be more easily fabricated with lower process gas flow restrictions, while the bulk of the modified faceplates (152A-152T) can be thickened to provide adequate thermal and mechanical performance. Additionally, modified faceplates (152A-152T) that utilize small apertures of shallow depth on the plasma side of the modified faceplates (152A-152T) in combination with intersecting larger and deeper openings formed through the plenum side of the modified faceplates (152A-152T) can be more easily adjusted to deliver desired process gas flow conductances over a much wider range compared to faceplates 152 that utilize a similar number of drilled holes in a uniform cross section formed through the entire thickness of the faceplate 152.

[0075] FIG. 3A is a bottom view of a faceplate 152A according to some embodiments. The faceplate 152A includes an arrangement of parallel slots 301 formed to extend across the bottom surface 302 of the faceplate 152A. The slots 301 are illustrated in FIG. 3A as horizontal lines extending across the bottom surface 302 of the faceplate 152A. The slots 301 form bottom apertures through which process gases can enter the plasma processing region 154. FIG. 3B is a top view of the faceplate 152A according to some embodiments. FIG. 3B shows holes 303 formed to extend through the top surface 304 of the faceplate 152A to a depth within the faceplate 152 where the holes 303 intersect the slots 301. The holes 303 are illustrated in FIG. 3B as small circles distributed across the top surface 304 of the faceplate 152A. In the example of FIG. 3B, the holes 303 are arranged in a hexagonal lattice array. However, in other embodiments, the holes 303 can be arranged in other patterns, such as a square lattice array, a rectangular lattice array, a diamond lattice array, a parallelogram lattice array, a Vogel pattern, or another pattern. The holes 303 form top apertures through which process gases flow to reach the slots 301 (bottom apertures). FIG. 3C is a see-through view of the faceplate 152A, showing the arrangement of the parallel slots 301 and the arrangement of the holes 303 relative to one another, according to some embodiments. At a certain depth within the faceplate 152A, each of the holes 303 intersects with one of the slots 301 to form a fluid passage through the faceplate 152A through which process gases can flow into the plasma processing region 154.

[0076] FIG. 3D is a vertical cross-sectional view of faceplate 152A corresponding to view AA referenced in FIG. 3C, according to some embodiments. FIG. 3E is an enlarged vertical cross-sectional view of region 305 identified in FIG. 3D, according to some embodiments. As shown in FIG. 3E, faceplate 152A has an overall thickness 306 measured in the vertical direction, i.e., the z-direction, between top surface 304 and bottom surface 302 of faceplate 152A. In various embodiments, overall thickness 306 of faceplate 152A is configured so that faceplate 152A provides sufficient thermal performance and maintains structural integrity during processing. In some embodiments, overall thickness 306 of faceplate 152A is in the range of about 0.25 inches to about 2 inches. In some embodiments, overall thickness 306 of faceplate 152A is about 0.375 inches. However, it should be understood that in some embodiments, overall thickness 306 of faceplate 152A can be less than 0.25 inches or greater than 2 inches.

[0077] Holes 303 extend a distance 307 into faceplate 152A from top surface 304 of faceplate 152A. Distance 307 is a portion of the overall thickness 306 of faceplate 152A. Slots 301 also extend a distance 308 into faceplate 152A from bottom surface 302 of faceplate 152A. Distance 308 is at least large enough to allow slots 301 to intersect with holes 303 that are spatially aligned with slots 301. Thus, shallow slots 301 are formed across the plasma side (bottom surface) of faceplate 152A, with each slot 301 forming a plurality of small apertures for intersecting with deeper, larger holes 303 formed through the plenum side (top surface) of faceplate 152A. It should be appreciated that distance 308 is small enough to allow reliable and economical fabrication of slots 301. Thus, holes 303 (top openings) are formed to extend through a portion (distance 307) of the overall thickness 306 of faceplate 152A and intersect with at least one of slots 301 (bottom apertures) to form a corresponding flow path for process gases through faceplate 152A.

[0078] In some embodiments, distance 308, i.e., the depth of slot 301, is in the range of about 0.001 inches to about 0.03 inches. In some embodiments, distance 308 is about 0.03 inches. In some embodiments, distance 308 is greater than 0.03 inches. In some embodiments, distance 308 is about 50% or less of the overall thickness 306 of faceplate 152A. In some embodiments, distance 308 is about 10% or less of the overall thickness 306 of faceplate 152A.

[0079] The exemplary faceplate 152A includes 109 slots 301 and 7,043 holes 303. However, it should be understood that in various embodiments, the faceplate 152A can include any number of slots 301 and any number of holes 303 as needed to have a predetermined process gas flow distribution to the plasma processing region 154, a predetermined pressure drop across the faceplate 152A, and a predetermined process gas flow conductance through the faceplate 152A while maintaining sufficient mechanical and thermal performance of the faceplate 152A.

[0080] In some embodiments, holes 303 have a circular shape in the horizontal direction, i.e., the x-y plane. In these embodiments, holes 303 each have a diameter 309 measured in the horizontal direction, i.e., the x-y plane. In some embodiments, diameter 309 is in the range of about 0.02 inches to about 0.09 inches. In some embodiments, diameter 309 is about 0.02 inches or greater. In some embodiments, diameter 309 is about 0.04 inches or greater. In some embodiments, diameter 309 is about 0.08 inches or greater. In some embodiments, diameter 309 is about 0.1 inches or greater. It should be understood that diameter 309 may be larger than the diameter at which HCD is expected to occur, since slots 301 are sized to prevent HCD. It should also be understood that diameter 309 may be specified to facilitate fabrication of holes 303. Additionally, in various embodiments, a given hole 303 may be sized to intersect either one slot 301 or multiple slots 301. In some embodiments, the diameter 309 is sized to achieve a desired process flow conductance through the faceplate 152A. Also, in various embodiments, the spatial distribution of the holes 303 can be defined differently to achieve a desired process gas flow uniformity to the plasma processing region 154 and accommodate the formation of a total number of holes 303 necessary to achieve a target total process gas flow conductance through the faceplate 152A and a target pressure drop across the faceplate 152A. In some embodiments, the center-to-center spacing between adjacent holes 300 is approximately 0.16 inches. However, it should be understood that in other embodiments, the center-to-center spacing between adjacent holes 300 can be less than or greater than approximately 0.16 inches.

[0081] FIG. 3F is an enlarged vertical cross-sectional view of faceplate 152A corresponding to view point BB referenced in FIG. 3E , according to some embodiments. FIG. 3F shows that each slot 301 is formed to have a slot opening distance 311 measured horizontally, i.e., in the x-y plane, in a direction perpendicular to the parallel direction in which slot 301 is oriented. Slot opening distance 311 defines an HCD suppression dimension of the bottom aperture formed by slot 301. More specifically, slot opening distance 311 is sized small enough to prevent HCD formation in slot 301. It should be understood that the cross-section of a given bottom aperture in the x-y plane need have an HCD suppression dimension in only one direction to be effective in preventing HCD formation in the given bottom aperture. For example, slot opening distance 311 is sized small enough to prevent HCD formation in slot 301, but only in one direction. However, in some embodiments, the cross-section of a given bottom aperture in the x-y plane can have HCD suppression dimensions in multiple directions. For example, if a given bottom aperture has a circular cross section in the xy plane, the diameter of the cross section of the given bottom aperture defines the HCD suppression dimension.

[0082] It should be understood that the slot opening distance 311 required to prevent HCD formation in the slot 301 depends at least on the process pressure and the process RF power. Thus, for some processes with higher process pressures and / or higher process RF powers, a smaller slot opening distance 311 may be required to prevent HCD formation in the slot 301. However, for some processes with lower process pressures and / or lower process RF powers, a larger slot opening distance 311 may still be effective in preventing HCD formation in the slot 301. In some embodiments, the slot opening distance 311 is in a range from about 0.005 inches to about 0.04 inches. In some embodiments, the slot opening distance 311 is in a range from about 0.008 inches to about 0.018 inches. In some embodiments, the slot opening distance 311 is in a range up to about 0.008 inches. In some embodiments, the slot opening distance 311 is in a range up to about 0.08 inches. In some embodiments, the slot opening distance 311 is in a range up to about 0.1 inches. In some embodiments, slot opening distance 311 is in the range of up to about 0.2 inches. In some embodiments, slot opening distance 311 is about 0.08 inches. In some embodiments, slot opening distance 311 is about 0.01 inches. Again, the upper limit of slot opening distance 311 is process dependent, i.e., dependent on the process pressure and / or RF power, since the likelihood of HCD formation in a given slot 301 is process dependent. Additionally, a given slot 301 has an aspect ratio (width to depth) defined by the ratio of (distance 311 / distance 308). In some embodiments, the aspect ratio of a given slot 301 is about 1 or less. In some embodiments, the aspect ratio of a given slot 301 is about 0.3 or less. In some embodiments, the aspect ratio of a given slot 301 is about 0.1 or less.

[0083] FIG. 3G is a bottom isometric view of the faceplate 152A illustrated in FIGS. 3A-3F, according to some embodiments. FIG. 3H is a bottom isometric view of a portion of the faceplate 152A, according to some embodiments. FIG. 3I is a bottom view of a portion of the faceplate 152A, according to some embodiments. FIG. 3J is a top isometric view of a portion of the faceplate 152A, according to some embodiments. In some embodiments, the faceplate 152A is formed of aluminum, such as 6061 aluminum or 3003 aluminum, among other aluminum materials. In some embodiments, the faceplate 152A is formed of a ceramic material, such as aluminum oxide (Al2O3), aluminum nitride (AlN), or yttria (Y2O3), among other ceramic materials. Also, in some embodiments, the faceplate 152A is formed of stainless steel. It should be understood that in various embodiments, the faceplate 152A can be formed of essentially any material: a) chemically compatible with process gas chemistries and materials present in the plasma processing region 154 during processing; b) mechanically strong enough to maintain structural integrity in the presence of pressure differentials that may exist between the top and bottom surfaces of the faceplate 152A during processing; c) thermal properties sufficient to meet thermal performance requirements during processing; and d) electrical properties sufficient to meet electrical performance requirements during processing. Also, in some embodiments, the bottom surface 302 of the faceplate 152A, which faces the plasma processing region 154, can be coated with a coating such as a metal oxide, e.g., aluminum oxide (Al2O3), among other coating materials. In various embodiments, the coating material applied to the bottom surface 302 of the faceplate 152A must remain adhered to the faceplate 152A during processing and must be chemically compatible with the process gas chemistries and materials present in the plasma processing region 154 during processing.

[0084] In some embodiments, the slots 301 can be formed in the faceplate 152A by a sawing process, for example, using a split saw. In some embodiments, the slots 301 can be formed in the faceplate 152A by an EDM process, such as wire EDM or sinker EDM. In some embodiments, the slots 301 can be formed in the faceplate 152A by a cutting process, such as waterjet cutting, plasma cutting, or other types of cutting processes. In some embodiments, the slots 301 can be formed in the faceplate 152A by a machining process. It should be understood that the amount of material removed from the faceplate 152A when forming the slots 301 is less than the amount of material that would be removed from the faceplate 152A if uniform diameter through-holes were formed through the faceplate 152A in place of the slots 301 to achieve the same overall process gas flow conductance through the faceplate 152A. Thus, by using slots 301 to define apertures in the bottom surface of faceplate 152A, the total amount of material removed from faceplate 152A is reduced, providing a corresponding improvement in the time and cost of fabricating faceplate 152A.

[0085] In some embodiments, faceplate 152A is monolithically formed such that slots 301 and holes 303 are formed within the material of a single monolithic plate. In some embodiments, faceplate 152A is formed as a combination of plates. For example, in some embodiments, faceplate 152A includes a lower plate and an upper plate, where the lower plate has a thickness equal to distance 308 and the upper plate has a thickness equal to distance 307. In these embodiments, slots 301 are formed within the lower plate and holes 303 are formed within the upper plate. In these embodiments, the upper and lower plates are fastened together such that slots 301 and holes 303 align to form faceplate 152A. Also, in these embodiments, the upper and lower plates are fastened together in thermal and electrical contact with each other to form faceplate 152A. In some embodiments, faceplate 152A is a replaceable component within showerhead 150.

[0086] As mentioned above, in various embodiments, the holes 303 can be arranged in many different patterns and still be aligned to intersect with the slots 301. FIG. 3K illustrates a faceplate 152B having holes 303 arranged in a square grid array, according to some embodiments. FIG. 3K is a see-through view of the faceplate 152B, showing the arrangement of the parallel slots 301 visible relative to one another and the arrangement of the square grid array of holes 303. At a certain depth within the faceplate 152B, each of the holes 303 intersects with a corresponding one of the slots 301 to form a fluid passageway through the faceplate 152B through which process gases can enter the plasma processing region 154.

[0087] 3L illustrates a faceplate 152C having holes 303 arranged in a rectangular grid array, according to some embodiments. FIG. 3L is a see-through view of the faceplate 152C, showing the arrangement of the parallel slots 301 relative to one another and the arrangement of the rectangular grid array of holes 303. At a certain depth within the faceplate 152C, each of the holes 303 intersects with a corresponding one of the slots 301 to form a fluid passage through the faceplate 152C through which process gases can enter the plasma processing region 154.

[0088] 3M illustrates a faceplate 152D having holes 303 arranged in a diamond lattice array, according to some embodiments. FIG. 3M is a see-through view of the faceplate 152D, showing the arrangement of the parallel slots 301 relative to one another and the diamond lattice arrangement of the holes 303. At a certain depth within the faceplate 152D, each of the holes 303 intersects with a corresponding one of the slots 301 to form a fluid passageway through the faceplate 152D through which process gases can enter the plasma processing region 154.

[0089] 3N illustrates a faceplate 152E having holes 303 arranged in a parallelogram lattice array, according to some embodiments. FIG. 3N is a see-through view of the faceplate 152E, showing the arrangement of the parallel slots 301 relative to one another and the arrangement of the parallelogram lattice array of holes 303. At a certain depth within the faceplate 152E, each of the holes 303 intersects with a corresponding one of the slots 301 to form a fluid passageway through the faceplate 152E through which process gases can enter the plasma processing region 154.

[0090] FIG. 3O illustrates a faceplate 152F having holes 303 arranged in a customized pattern, according to some embodiments. FIG. 3O is a see-through view of the faceplate 152F, showing the arrangement of the parallel slots 301 and the customized pattern of holes 303 visible relative to one another. At a certain depth within the faceplate 152F, each of the holes 303 intersects with a corresponding one of the slots 301 to form a fluid passage through the faceplate 152F, through which process gases can enter the plasma processing region 154. FIG. 3P is an isometric top view of the faceplate 152F, according to some embodiments. FIG. 3Q is a bottom view of a portion of the faceplate 152F, according to some embodiments.

[0091] In various embodiments, each aperture, e.g., slot 101, formed in the bottom surface 302 of the modified faceplate (152A-152T) that is in fluid communication with a corresponding hole 303 can have one of many different cross-sectional shapes. More specifically, in various embodiments, the cross-sectional shape of a given aperture formed in the bottom surface 302 of the modified faceplate (152A-152T) of the showerhead 150 can be any shape suitable for providing a desired shape of a “jet” of process gas flow through the given aperture and into the plasma processing region 154. For example, a given aperture can have a variety of cross-sectional shapes, such as a rectangular cross-sectional shape, a curved cross-sectional shape, a circular cross-sectional shape, a bent cross-sectional shape, among other cross-sectional shapes, to achieve a desired shape of the process gas “jet” through the given aperture within the plane of the bottom surface 302 of the modified faceplate (152A-152T). Additionally, in some embodiments, the apertures formed in the bottom surface 302 of the modified faceplate (152A-152T) can have the same cross-sectional shape across the bottom surface 302 of the modified faceplate (152A-152T). And, in some embodiments, the apertures formed in the bottom surface 302 of the modified faceplate (152A-152T) can have different cross-sectional shapes across the bottom surface 302 of the modified faceplate (152A-152T). Regardless of the cross-sectional shape of the aperture across the bottom surface 302 of the modified faceplate (152A-152T), each aperture formed in the bottom surface 302 of the modified faceplate (152A-152T) has an HCD-suppressing dimension in at least one direction. Additionally, in various embodiments, the apertures formed in the bottom surface 302 of the modified faceplate (152A-152T) can be adjusted so that the overall process gas flow conductance through the modified faceplate (152A-152T) substantially matches a target overall process gas flow conductance value.In some embodiments, the target overall process gas flow conductance value through the modified faceplate (152A-152T) substantially matches the overall process gas flow conductance value of the previous faceplate design used in the previous plasma processing operation. In some embodiments, depending on process requirements, the target overall process gas flow conductance value through the modified faceplate (152A-152T) may be higher or lower than the overall process gas flow conductance value of the previous faceplate design.

[0092] FIG. 4A-1 is a bottom view of a portion of a modified faceplate 152G including rectangular cross-sectional apertures 401 formed separately at the locations of each hole 303, according to some embodiments. It should be understood that FIG. 4A-1 shows a see-through view of the faceplate 152G, so that the slots 401 and holes 303 are visible relative to one another. FIG. 4A-2 is a vertical cross-sectional view through holes 303 of the modified faceplate 152G corresponding to view point AA in FIG. 4A-1, according to some embodiments. FIG. 4A-3 is a vertical cross-sectional view through holes 303 of the modified faceplate 152G corresponding to view point BB in FIG. 4A-1, according to some embodiments. In the faceplate 152G, the apertures 401 are essentially only portions of the slots 101 that occur at the locations of holes 303 in the faceplate 152A of FIG. 3C. Each aperture 401 has an HCD suppression dimension 403 measured in a direction across the shortest span of the aperture 401. 4A-2 , HCD suppression dimension 403 depends at least on the process pressure and the process RF power. Thus, for some processes with higher process pressures and / or higher process RF powers, HCD suppression dimension 403 may need to be smaller to prevent HCD formation within aperture 401. However, for some processes with lower process pressures and / or lower process RF powers, HCD suppression dimension 403 may be larger and still be effective in preventing HCD formation within aperture 401. In various embodiments, HCD suppression dimension 403 is within a range of about 0.005 inches to about 0.04 inches, or within a range of about 0.008 inches to about 0.018 inches, or up to about 0.008 inches, or up to about 0.08 inches, or up to about 0.1 inches, or up to about 0.2 inches, or about 0.08 inches, or about 0.01 inches. Again, the upper limit of HCD suppression dimension 403 is process dependent, i.e., process pressure and / or RF power dependent, since the likelihood of HCD formation within a given aperture 401 is process dependent. Additionally, a given aperture 401 has an aspect ratio (width to depth) defined by the ratio of (HCD suppression dimension 403 / distance 308).In various embodiments, the aspect ratio of a given aperture 401 is about 1 or less, or about 0.3 or less, or about 0.1 or less. In various embodiments, aperture 401 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., waterjet cutting, plasma cutting, or other type of cutting process).

[0093] FIG. 4A-1 illustrates rectangular cross-sectional apertures 401 oriented parallel to one another. However, in some embodiments, the apertures 401 can be oriented non-parallel to one another. In various embodiments, the non-parallel orientation of the apertures 401 can be regular or random. FIG. 4B illustrates rectangular cross-sectional apertures 401 formed separately at the location of each hole 303 in a modified faceplate 152H, where the apertures 401 are oriented non-parallel and regular to one another, according to some embodiments. It should be understood that FIG. 4B shows a see-through view of the faceplate 152H, such that the apertures 401 and holes 303 are visible relative to one another. FIG. 4C illustrates rectangular cross-sectional apertures 401 formed separately at the location of each hole 303 in a modified faceplate 152I, where the apertures 401 are oriented non-parallel and random to one another, according to some embodiments. It should be understood that FIG. 4C shows a transparent view of faceplate 152I, so that aperture 401 and hole 303 are visible relative to one another.

[0094] In modified faceplates 152G, 152H, and 152I, holes 303 are arranged in a hexagonal lattice array, like holes 303 in faceplate 152A of Figure 3C. However, it should be understood that in other embodiments, holes 303 in modified faceplates 152G, 152H, and 152I can be arranged in another pattern, such as the square lattice array shown in Figure 3K, or the rectangular lattice array shown in Figure 3L, or the diamond lattice array shown in Figure 3M, or the parallelogram lattice array shown in Figure 3N, or essentially any other customized pattern, such as the customized pattern shown in Figure 3O.

[0095] FIG. 5A-1 is a bottom view of a portion of a modified faceplate 152J including a curved cross-sectional aperture 501 formed separately at the location of each hole 303, according to some embodiments. It should be understood that FIG. 5A-1 shows a see-through view of the faceplate 152J, so that the slots 501 and holes 303 are visible relative to one another. FIG. 5A-2 is a vertical cross-sectional view through holes 303 of the modified faceplate 152J corresponding to view point AA in FIG. 5A-1, according to some embodiments. In the faceplate 152J, each of the apertures 501 has a curved cross-sectional shape in the plane of the bottom surface 302 of the faceplate 152J, which is C-shaped. The example in FIG. 5A-1 also shows two apertures 501 per hole 303. In some embodiments, the apertures 501 are defined such that the “jet” of process gas flowing out of the pair of apertures 501 corresponding to a given hole 303 is substantially axisymmetric in shape. Each aperture 501 has an HCD suppression dimension 503 measured across the shortest span of the aperture 501 .

[0096] In the modified faceplate 152J of FIG. 5A-1, the holes 303 are arranged in a hexagonal lattice array, like the holes 303 in the faceplate 152A of FIG. 3C. However, it should be understood that in other embodiments, the holes 303 in the modified faceplate 152J can be arranged in another pattern, such as the square lattice array shown in FIG. 3K, or the rectangular lattice array shown in FIG. 3L, or the diamond lattice array shown in FIG. 3M, or the parallelogram lattice array shown in FIG. 3N, or essentially any other customized pattern, such as the customized pattern shown in FIG. 3O. For example, FIG. 5B is a bottom isometric view of a portion of a modified faceplate 152J1 in which the holes 303 are arranged in the customized pattern shown in FIGS. 3O and 3P, according to some embodiments.

[0097] HCD suppression dimension 503 depends at least on the process pressure and the process RF power. Thus, for some processes with higher process pressures and / or higher process RF powers, HCD suppression dimension 503 may need to be smaller to prevent HCD formation within aperture 501. However, for some processes with lower process pressures and / or lower process RF powers, HCD suppression dimension 503 may be larger and still be effective in preventing HCD formation within aperture 501. In various embodiments, HCD suppression dimension 503 is in the range of about 0.005 inches to about 0.04 inches, or in the range of about 0.008 inches to about 0.018 inches, or up to about 0.008 inches, or up to about 0.08 inches, or up to about 0.1 inches, or up to about 0.2 inches, or about 0.08 inches, or about 0.01 inches. Again, the upper limit of the HCD suppression dimension 503 is process-dependent, i.e., dependent on the process pressure and / or RF power, because the likelihood of HCD formation within a given aperture 501 is process-dependent. Additionally, a given aperture 501 has an aspect ratio (width to depth) defined by the ratio of (HCD suppression dimension 503 / distance 308). In various embodiments, the aspect ratio of a given aperture 501 is about 1 or less, or about 0.3 or less, or about 0.1 or less. In various embodiments, the aperture 501 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., waterjet cutting, plasma cutting, or other type of cutting process).

[0098] In the modified faceplate 152J, each pair of apertures 501 per hole 303 is similarly oriented relative to each hole 303. More specifically, each pair of apertures 501 for a given hole 303 has a particular azimuthal orientation about the axis 310 of the given hole 303, with the axis 310 of the given hole 303 extending in the z-direction down the center of the given hole 303. In the modified faceplates 152J and 152J1, each pair of apertures 501 per hole 303 across the faceplates 152J and 152J1 has substantially the same azimuthal orientation about the axis 310 of the corresponding hole 303. However, in some embodiments, the apertures 501 can be defined such that pairs of apertures 501 for different holes 303 have different azimuthal orientations about the axis 310 of the corresponding hole 303.

[0099] FIG. 5C illustrates curved cross-sectional apertures 501 formed separately at the location of each hole 303 in the modified faceplate 152K1, with varying azimuthal orientations around the axis 310 of the corresponding hole 303, according to some embodiments. It should be understood that FIG. 5C shows a see-through view of the faceplate 152K1, so that the apertures 501 and holes 303 are visible relative to one another. In some embodiments, varying azimuthal orientations of different pairs of apertures 501 around the axis 310 of the corresponding hole 303 can be defined to avoid imparting directional characteristics to the process gas flow. FIG. 5D is a bottom isometric view of a portion of the modified faceplate 152K2, according to some embodiments. Both the modified faceplates 152K1 and 152K2 include curved cross-sectional apertures 501 formed separately at the location of each hole 303. The modified faceplate 152K1 has holes 303 arranged according to a hexagonal lattice pattern, as shown in FIG. 3B. The modified faceplate 152K2 has holes 303 arranged according to a customized grid pattern, as shown in Figures 3O and 3P.

[0100] FIG. 6A-1 illustrates bracket cross-sectional apertures 601 formed separately at the location of each hole 303 in a modified faceplate 152L, according to some embodiments. It should be understood that FIG. 6A-1 shows a see-through view of the faceplate 152L, such that the apertures 601 and holes 303 are visible relative to one another. FIG. 6A-2 illustrates a vertical cross-sectional view through holes 303 in the modified faceplate 152L, corresponding to view point AA in FIG. 6A-1, according to some embodiments. The modified faceplate 152L includes two apertures 601 per hole 303. Each aperture 601 has an HCD suppression dimension 603 measured in a direction across the shortest span of the aperture 601. In FIG. 6A-1, the HCD suppression dimension 603 depends at least on the process pressure and the process RF power. Thus, for some processes with higher process pressures and / or higher process RF powers, HCD suppression dimension 603 may need to be smaller to prevent HCD formation within aperture 601. However, for some processes with lower process pressures and / or lower process RF powers, HCD suppression dimension 603 may be larger and still be effective in preventing HCD formation within aperture 601. In various embodiments, HCD suppression dimension 603 is in the range of about 0.005 inches to about 0.04 inches, or in the range of about 0.008 inches to about 0.018 inches, or up to about 0.008 inches, or up to about 0.08 inches, or up to about 0.1 inches, or up to about 0.2 inches, or about 0.08 inches, or about 0.01 inches. Again, the upper limit of HCD suppression dimension 603 is process dependent, i.e., process pressure and / or RF power dependent, since the likelihood of HCD formation within a given aperture 601 is process dependent. Additionally, a given aperture 601 has an aspect ratio (width to depth) defined by the ratio of (HCD suppression dimension 603 / distance 308). In various embodiments, the aspect ratio of a given aperture 601 is about 1 or less, or about 0.3 or less, or about 0.1 or less.In various embodiments, the aperture 601 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., waterjet cutting, plasma cutting, or other type of cutting process).

[0101] In the example of FIG. 6A-1 , each pair of apertures 601 per hole 303 is similarly oriented relative to each hole 303. More specifically, each pair of apertures 601 for a given hole 303 has a particular azimuthal orientation about the axis 310 of the given hole 303. In the example of FIG. 6A-1 , each pair of apertures 601 per hole 303 across the faceplate 152L has substantially the same azimuthal orientation about the axis 310 of the corresponding hole 303. However, in some embodiments, the apertures 601 can be defined such that pairs of apertures 601 for different holes 303 have different azimuthal orientations about the axis 310 of the corresponding hole 303.

[0102] 6B illustrates bracket cross-sectional shaped apertures 601 formed separately at the location of each hole 303 in a modified faceplate 152M, with varying azimuthal orientations about the axis 310 of the corresponding hole 303, according to some embodiments. It should be understood that FIG. 6B shows a transparent view of the faceplate 152M, such that the apertures 601 and holes 303 are visible relative to one another. In some embodiments, the varying azimuthal orientations of different pairs of apertures 601 about the axis 310 of the corresponding hole 303 can be defined to avoid imparting directionality to the process gas flow.

[0103] In modified faceplates 152L and 152M, holes 303 are arranged in a hexagonal lattice array, like holes 303 in faceplate 152A of Figure 3C. However, it should be understood that in other embodiments, holes 303 in modified faceplates 152L and 152M can be arranged in another pattern, such as a square lattice array as shown in Figure 3K, or a rectangular lattice array as shown in Figure 3L, or a diamond lattice array as shown in Figure 3M, or a parallelogram lattice array as shown in Figure 3N, or essentially any other customized pattern, such as the customized pattern shown in Figure 3O.

[0104] FIG. 7A-1 illustrates circular cross-sectional apertures 701 formed separately at the location of each hole 303 in a modified faceplate 152N, according to some embodiments. It should be understood that FIG. 7A-1 shows a see-through view of the faceplate 152N, such that the apertures 701 and holes 303 are visible relative to one another. FIG. 7A-2 illustrates a vertical cross-sectional view through holes 303 in the modified faceplate 152N, corresponding to view point AA in FIG. 7A-1, according to some embodiments. The modified faceplate 152N includes a single aperture 701 per hole 303. In some embodiments, the aperture 701 for a given hole 303 is substantially centered within the given hole 303 and is in fluid communication with the given hole 303. In some embodiments, the aperture 701 for a given hole 303 is not centered within the given hole 303, but is in fluid communication with the given hole 303.

[0105] FIG. 7B-1 illustrates multiple circular cross-sectional apertures 701 per hole 303 in a modified faceplate 152O, according to some embodiments. It should be understood that FIG. 7B-1 shows a see-through view of the faceplate 152O, so that the apertures 701 and holes 303 are visible relative to one another. FIG. 7B-2 illustrates a vertical cross-sectional view through a hole 303 in the modified faceplate 152O, corresponding to view point AA in FIG. 7B-1, according to some embodiments. In various embodiments, any number of two or more apertures 701 can be positioned in fluid communication with a given hole 303. The exemplary embodiment of FIG. 7B-1 shows six apertures 701 per hole 303. In some embodiments, there are up to 16 circular cross-sectional apertures 701 per hole 303. In some embodiments, multiple apertures 701 in fluid communication with a given hole 303 can be positioned in a symmetric pattern about the axis 310 of the given hole 303, with the axis of the given hole 303 extending in the z-direction down the center of the given hole 303. In the modified faceplate 152O, the six apertures 701 of a given hole 303 are positioned symmetrically about the axis 310 of the given hole 303. Also, in some embodiments, multiple apertures 701 in fluid communication with a given hole 303 can be positioned in an asymmetric pattern about the axis of the given hole 303. Each aperture 701 has an HCD suppression dimension 703 that is the diameter of the circular cross-sectional shape of the aperture 701. FIG. 7C is a bottom isometric view of a portion of a modified faceplate 152O, according to some embodiments.

[0106] In modified faceplates 152N and 152O, HCD suppression dimension 703 depends at least on the process pressure and the process RF power. Thus, for some processes with higher process pressures and / or higher process RF powers, HCD suppression dimension 703 may need to be smaller to prevent HCD formation within aperture 701. However, for some processes with lower process pressures and / or lower process RF powers, HCD suppression dimension 703 may be larger and still be effective in preventing HCD formation within aperture 701. In various embodiments, HCD suppression dimension 703 is in the range of about 0.005 inches to about 0.04 inches, or in the range of about 0.008 inches to about 0.018 inches, or up to about 0.008 inches, or up to about 0.08 inches, or up to about 0.1 inches, or up to about 0.2 inches, or about 0.08 inches, or about 0.01 inches. Again, the upper limit of the HCD suppression dimension 703 is process-dependent, i.e., dependent on the process pressure and / or RF power, because the likelihood of HCD formation within a given aperture 701 is process-dependent. Additionally, the given aperture 701 has an aspect ratio (width to depth) defined by the ratio of (HCD suppression dimension 703 / distance 308). In various embodiments, the aspect ratio of the given aperture 701 is about 1 or less, or about 0.3 or less, or about 0.1 or less. In various embodiments, the aperture 701 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., waterjet cutting, plasma cutting, or other type of cutting process).

[0107] In modified faceplates 152N and 152O, holes 303 are arranged in a hexagonal lattice array, like holes 303 in faceplate 152A of Figure 3C. However, it should be understood that in other embodiments, holes 303 in modified faceplates 152N and 152O can be arranged in another pattern, such as a square lattice array as shown in Figure 3K, or a rectangular lattice array as shown in Figure 3L, or a diamond lattice array as shown in Figure 3M, or a parallelogram lattice array as shown in Figure 3N, or essentially any other customized pattern, such as the customized pattern shown in Figure 3O.

[0108] 8A is a top view of a modified faceplate 152P having holes 303 arranged in a Vogel pattern, according to some embodiments. The Vogel pattern corresponds to a mathematical representation of the geometric arrangement of sunflower seed patterns, i.e., the Vogel model, developed by Helmut Vogel. The Vogel model of sunflower seed arrangement requires very specific rotation angles between successive points.

number

number

number

[0109] For example, in some embodiments, rectangular cross-sectionally shaped apertures 401, as described above with respect to modified faceplates 152G, 152H, and 152I, can be formed through bottom surface 302 of modified faceplate 152P and fluidly connected to holes 303 arranged in a Vogel pattern. Figure 8B is an enlarged view of a portion 801 of modified faceplate 152P, referenced in Figure 8A, including rectangular cross-sectionally shaped apertures 401, according to some embodiments. It should be understood that Figure 8B shows a see-through view of a portion of faceplate 152P, such that the Vogel pattern of holes 303 and apertures 401 are visible relative to one another.

[0110] In some embodiments, curved cross-sectionally shaped apertures 501, as described above with respect to modified faceplates 152J, 152J1, 152K1, and 152K2, can be formed through bottom surface 302 of modified faceplate 152P and fluidly connected to Vogel patterned holes 303. Figure 8C is an enlarged view of a portion 801 of modified faceplate 152P including curved cross-sectionally shaped apertures 501, according to some embodiments. It should be understood that Figure 8C shows a see-through view of a portion of faceplate 152P, such that Vogel pattern of holes 303 and apertures 501 are visible relative to one another.

[0111] In some embodiments, bracket cross-sectional shaped apertures 601, as described above with respect to modified faceplates 152L and 152M, can be formed through bottom surface 302 of modified faceplate 152P and fluidly connected to Vogel patterned holes 303. Figure 8D is an enlarged view of a portion 801 of modified faceplate 152P including bracket cross-sectional shaped apertures 601, according to some embodiments. It should be understood that Figure 8D shows a see-through view of a portion of faceplate 152P, such that the Vogel pattern of holes 303 and apertures 601 are visible relative to one another.

[0112] In some embodiments, circular cross-sectionally shaped apertures 701, as described above with respect to modified faceplates 152N and 152O, can be formed through bottom surface 302 of modified faceplate 152P and fluidly connected to holes 303 arranged in a Vogel pattern. Figure 8E is an enlarged view of a portion of modified faceplate 152P including circular cross-sectionally shaped apertures 701, according to some embodiments. It should be understood that Figure 8E shows a transparent view of a portion of faceplate 152P, such that the Vogel pattern of holes 303 and apertures 701 are visible relative to one another.

[0113] FIG. 9A is a see-through view of a modified faceplate 152Q including a Vogel pattern of grooves 901 formed through a bottom surface of the faceplate 152Q that intersects with a Vogel pattern of holes 303 formed through a top surface of the faceplate 152Q, according to some embodiments. It should be understood that FIG. 9A shows a see-through view of the faceplate 152Q, such that the grooves 901 and holes 303 are visible relative to one another. The holes 303 are illustrated as circles, and the grooves 901 are illustrated as solid lines passing through the circles representing the holes 303. FIG. 9B is an enlarged view of a portion 902 of the modified faceplate 152Q, according to some embodiments. It should be understood that FIG. 9B shows a see-through view of the faceplate 152Q, such that the grooves 901 and holes 303 are visible relative to one another. At a certain depth within the faceplate 152Q, each of the holes 303 intersects with a corresponding one of the grooves 901 to form a fluid passage through the faceplate 152Q through which process gases can enter the plasma processing region 154. In various embodiments, the grooves 901 can be defined similarly to the slots 301 of FIG. 3A . For example, the holes 303 extend a distance 307 from the top surface 304 of the faceplate 152Q into the faceplate 152Q. And, the grooves 901 extend a distance 308 from the bottom surface 302 of the faceplate 152Q into the faceplate 152Q. The distance 308 is at least large enough for the grooves 901 to intersect with the holes 303 that are spatially aligned with the grooves 901. Thus, shallow depth grooves 901 are formed across the plasma side (bottom) of faceplate 152Q, with each groove 901 forming a plurality of small apertures to intersect with larger holes 303 of greater depth formed through the plenum side (top) of faceplate 152Q. It should be appreciated that distance 308 is set small enough to allow reliable and economical fabrication of grooves 901. Holes 303 (top apertures) are thus formed to extend through a portion (distance 307) of the overall thickness 306 of faceplate 152Q to intersect with at least one of grooves 901 (bottom apertures) to form a corresponding flow path for process gases through faceplate 152Q.In various embodiments, distance 308, i.e., the depth of groove 901, is in the range of about 0.001 inches to about 0.03 inches, or about 0.03 inches, or greater than 0.03 inches. In some embodiments, distance 308, i.e., the depth of groove 901, is about 50% or less of the overall thickness 306 of faceplate 152Q. In some embodiments, distance 308, i.e., the depth of groove 901, is about 10% or less of the overall thickness 306 of faceplate 152Q.

[0114] Each trench 901 has an HCD suppression dimension 903 measured in a direction across the shortest span of the trench 901. In Figures 9A and 9B, the HCD suppression dimension 903 depends at least on the process pressure and the process RF power. Thus, for some processes with higher process pressures and / or higher process RF powers, the HCD suppression dimension 903 may need to be smaller to prevent HCD formation in the trench 901. However, for some processes with lower process pressures and / or lower process RF powers, the HCD suppression dimension 903 may be larger and still be effective in preventing HCD formation in the trench 901. In various embodiments, the HCD suppression dimension 903 is in the range of about 0.005 inches to about 0.04 inches, or in the range of about 0.008 inches to about 0.018 inches, or up to about 0.008 inches, or up to about 0.08 inches, or up to about 0.1 inches, or up to about 0.2 inches, or about 0.08 inches, or in the range of about 0.01 inches. Again, the upper limit of the HCD suppression dimension 903 is process-dependent, i.e., dependent on the process pressure and / or RF power, since the likelihood of HCD formation in a given trench 901 is process-dependent. Additionally, a given trench 901 has an aspect ratio (width to depth) defined by the ratio of (HCD suppression dimension 903 / distance 308). In various embodiments, the aspect ratio of a given trench 901 is about 1 or less, or about 0.3 or less, or about 0.1 or less. In various embodiments, the grooves 901 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., water jet cutting, plasma cutting, or other type of cutting process).

[0115] In some embodiments, the holes 303 formed through the top surface of the modified faceplates 152A-152Q can be replaced with openings of various shapes and sizes, so long as the openings: 1) intersect with the apertures formed through the bottom surface of the modified faceplates 152A-152Q, 2) provide adequate process gas flow conductance through the modified faceplates 152A-152Q, 3) provide adequate pressure drop across the modified faceplates 152A-152Q, 4) provide adequate process gas flow uniformity across the modified faceplates 152A-152Q, 5) provide adequate mechanical performance of the modified faceplates 152A-152Q, and 6) provide adequate thermal performance of the modified faceplates 152A-152Q.

[0116] It should be understood that in various embodiments, the holes 303 and / or apertures (e.g., 401, 501, 601, 701) can be arranged in various configurations based on a Vogel pattern. For example, in some embodiments, the holes 303 and / or apertures (e.g., 401, 501, 601, 701) can be arranged in different zones, one or more of which are arranged in separately defined Vogel patterns. An example of such a showerhead hole configuration based on a Vogel pattern is described in U.S. Patent Application No. 16 / 006,591, filed June 12, 2018, entitled "Chemical Vapor Deposition Shower Head for Uniform Gas Distribution."

[0117] FIG. 10A is a see-through view of a modified faceplate 152R including a first Vogel pattern of bottom grooves 1001 formed through a bottom surface of the faceplate 152R that intersects with a second Vogel pattern of top grooves 1003 formed through a top surface of the faceplate 152R, according to some embodiments. The second Vogel pattern of top grooves 1003 runs in an opposite direction relative to the first Vogel pattern of bottom grooves 1001. It should be understood that FIG. 10A shows a see-through view of the faceplate 152R, such that the first Vogel pattern of bottom grooves 1001 and the second Vogel pattern of top grooves 1003 are visible relative to one another. The bottom grooves 1001 are shown in FIG. 10A as thin lines. The top grooves 1003 are shown in FIG. 10A as thick lines. At a certain depth within the faceplate 152R, each of the top grooves 1003 intersects with a corresponding bottom groove 1001 to form a fluid passage through the faceplate 152R through which process gases can enter the plasma processing region 154. Figure 10B is a cross-sectional view of an aperture 1005 formed by the intersection of a bottom groove 1001 and a top groove 1003, according to some embodiments.

[0118] In various embodiments, the bottom grooves 1001 can be defined similarly to the slots 301 of FIG. 3A . For example, the top grooves 1003 extend a distance 307 from the top surface 304 of the faceplate 152R into the faceplate 152R. And, the bottom grooves 1001 extend a distance 308 from the bottom surface 302 of the faceplate 152R into the faceplate 152R. The distance 308 is at least large enough for the bottom grooves 1001 to intersect with the top grooves 1003 where they intersect each other. Thus, shallow depth bottom grooves 1001 are formed across the plasma side (bottom surface) of the faceplate 152R, and each bottom groove 1001 forms a plurality of small apertures 1005 for intersecting with larger top grooves 1003 of greater depth formed through the plenum side (top surface) of the faceplate 152R. It should be appreciated that the distance 308 is small enough to allow reliable and economical fabrication of the bottom grooves 1001. Accordingly, each of the top grooves 1003 is formed to extend through a portion (distance 307) of the overall thickness 306 of the faceplate 152R and intersect with a plurality of the bottom grooves 1001 to form corresponding flow paths for process gases through the faceplate 152R. In various embodiments, the distance 308, i.e., the depth of the bottom grooves 1001, is within a range of about 0.001 inches to about 0.03 inches, or about 0.03 inches, or greater than 0.03 inches. In some embodiments, the distance 308, i.e., the depth of the bottom grooves 1001, is about 50% or less of the overall thickness 306 of the faceplate 152R. In some embodiments, the distance 308, i.e., the depth of the bottom grooves 1001, is about 10% or less of the overall thickness 306 of the faceplate 152R.

[0119] Each bottom trench 1001 has an HCD suppression dimension 1007 measured in a direction across the shortest span of the bottom trench 1001. In the exemplary faceplate 152R, the HCD suppression dimension 1007 depends at least on the process pressure and the process RF power. Thus, in some processes with higher process pressures and / or higher process RF powers, the HCD suppression dimension 1007 of the bottom trench 1001 may need to be smaller to prevent HCD formation in the bottom trench 1001. However, in some processes with lower process pressures and / or lower process RF powers, the HCD suppression dimension 1007 may be larger and still be effective in preventing HCD formation in the bottom trench 1001. In various embodiments, the HCD suppression dimension 1007 of the bottom trench 1001 is in the range of about 0.005 inches to about 0.04 inches, or in the range of about 0.008 inches to about 0.018 inches, or up to about 0.008 inches, or up to about 0.08 inches, or up to about 0.1 inches, or up to about 0.2 inches, or about 0.08 inches, or about 0.01 inches. Again, the upper limit of the HCD suppression dimension 1007 of the bottom trench 1001 is process dependent, i.e., process pressure and / or RF power dependent, since the likelihood of HCD formation in a given bottom trench 1001 is process dependent. Additionally, a given bottom trench 1001 has an aspect ratio (width to depth) defined by the ratio of (HCD suppression dimension 1007 / distance 308). In various embodiments, the aspect ratio of a given bottom groove 1001 is about 1 or less, or about 0.3 or less, or about 0.1 or less. In various embodiments, the bottom groove 1001 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., water jet cutting, plasma cutting, or other type of cutting process).

[0120] In various embodiments, the width dimension, i.e., the short horizontal cross-sectional dimension, of the top surface groove 1003 is in the range of about 0.02 inches to about 0.09 inches, or about 0.02 inches or more, or about 0.04 inches or more, or about 0.08 inches or more, or about 0.1 inches or more. It should be understood that the width dimension of the top surface groove 1003 can be larger than the size at which HCD is expected to occur, since the bottom surface groove 1001 is sized to prevent HCD. It should also be understood that the width dimension of the top surface groove 1003 can be specified to facilitate fabrication of the top surface groove 1003. In various embodiments, the top surface groove 1003 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., waterjet cutting, plasma cutting, or other type of cutting process).

[0121] 11A is a top view of a modified faceplate 152S including a radial spoke pattern of bottom grooves 1101 formed through a bottom surface of the faceplate 152S that intersects with a corresponding radial spoke pattern of top grooves 1103 formed through a top surface of the faceplate 152S, according to some embodiments. It should be understood that FIG. 11A shows a see-through view of the faceplate 152S, such that the radial spoke pattern of the bottom grooves 1101 and the radial spoke pattern of the top grooves 1103 are visible relative to one another. The bottom grooves 1101 are shown in FIG. 11A as thin lines. The top grooves 1103 are shown in FIG. 11A as substantially rectangular areas that overlap with the thin lines of the bottom grooves 1101. At a certain depth within the faceplate 152S, each of the top grooves 1103 intersects with a corresponding bottom groove 1101 to form a fluid passage through the faceplate 152S through which process gases can enter the plasma processing region 154. Figure 11B is a side cross-sectional view of an aperture 1105 formed by the intersection of a bottom groove 1101 and a top groove 1103, according to some embodiments.

[0122] In various embodiments, the bottom grooves 1101 can be defined similarly to the slots 301 of FIG. 3A . For example, the top grooves 1103 extend a distance 307 from the top surface 304 of the faceplate 152S into the faceplate 152S. And, the bottom grooves 1101 extend a distance 308 from the bottom surface 302 of the faceplate 152S into the faceplate 152S. The distance 308 is at least large enough for the bottom grooves 1101 to intersect with corresponding top grooves 1103 where they overlap. Thus, the shallow depth bottom grooves 1101 are formed across the plasma side (bottom surface) of the faceplate 152S, and each bottom groove 1101 forms an aperture 1105 for intersecting with a corresponding larger top groove 1103 of greater depth formed through the plenum side (top surface) of the faceplate 152S. It should be appreciated that the distance 308 is small enough to allow reliable and economical fabrication of the bottom grooves 1101. Thus, each of the top grooves 1103 is formed to extend through a portion (distance 307) of the overall thickness 306 of the faceplate 152S to intersect with one or more corresponding bottom grooves 1101 to form corresponding flow paths for process gases through the faceplate 152S. In various embodiments, the distance 308, i.e., the depth of the bottom grooves 1101, is within a range of about 0.001 inches to about 0.03 inches, or about 0.03 inches, or greater than 0.03 inches. In some embodiments, the distance 308, i.e., the depth of the bottom grooves 1101, is about 50% or less of the overall thickness 306 of the faceplate 152S. In some embodiments, the distance 308, i.e., the depth of the bottom grooves 1101, is about 10% or less of the overall thickness 306 of the faceplate 152S.

[0123] Each bottom trench 1101 has an HCD suppression dimension 1107 measured in a direction across the shortest span of the bottom trench 1101. In the exemplary faceplate 152S, the HCD suppression dimension 1107 depends at least on the process pressure and the process RF power. Thus, in some processes with higher process pressures and / or higher process RF powers, the HCD suppression dimension 1107 of the bottom trench 1101 may need to be smaller to prevent HCD formation in the bottom trench 1101. However, in some processes with lower process pressures and / or lower process RF powers, the HCD suppression dimension 1107 may be larger and still be effective in preventing HCD formation in the bottom trench 1101. In various embodiments, the HCD suppression dimension 1107 of the bottom trench 1101 is in the range of about 0.005 inches to about 0.04 inches, or in the range of about 0.008 inches to about 0.018 inches, or up to about 0.008 inches, or up to about 0.08 inches, or up to about 0.1 inches, or up to about 0.2 inches, or about 0.08 inches, or about 0.01 inches. Again, the upper limit of the HCD suppression dimension 1107 of the bottom trench 1101 is process dependent, i.e., process pressure and / or RF power dependent, since the likelihood of HCD formation in a given bottom trench 1101 is process dependent. Additionally, a given bottom trench 1101 has an aspect ratio (width to depth) defined by the ratio of (HCD suppression dimension 1107 / distance 308). In various embodiments, the aspect ratio of a given bottom groove 1101 is about 1 or less, or about 0.3 or less, or about 0.1 or less. In various embodiments, the bottom groove 1101 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., water jet cutting, plasma cutting, or other type of cutting process).

[0124] In various embodiments, the width dimension, i.e., the short horizontal cross-sectional dimension, of the top surface groove 1103 is in the range of about 0.02 inches to about 0.09 inches, or about 0.02 inches or more, or about 0.04 inches or more, or about 0.08 inches or more, or about 0.1 inches or more. It should be understood that the width dimension of the top surface groove 1103 can be larger than the size at which HCD is expected to occur, since the bottom surface groove 1101 is sized to prevent HCD. It should also be understood that the width dimension of the top surface groove 1103 can be specified to facilitate fabrication of the top surface groove 1103. In various embodiments, the top surface groove 1103 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., waterjet cutting, plasma cutting, or other type of cutting process).

[0125] FIG. 12A is a see-through view of a modified faceplate 152T including a concentric circular pattern of bottom grooves 1201 formed through the bottom surface of the faceplate 152T that intersects with a radial spoke pattern of top grooves 1203 formed through the top surface of the faceplate 152T, according to some embodiments. It should be understood that FIG. 12A shows a see-through view of the faceplate 152T, such that the concentric circular pattern of bottom grooves 1201 and the radial spoke pattern of top grooves 1203 are visible relative to one another. The bottom grooves 1201 are shown in FIG. 12A as thin lines. The top grooves 1203 are shown in FIG. 12A as shaded areas. At a certain depth within the faceplate 152T, each of the top grooves 1203 intersects with several bottom grooves 1201 to form fluid passageways through the faceplate 152T through which process gases can enter the plasma processing region 154. FIG. 12B is a vertical cross-sectional view corresponding to view AA referenced in FIG. 12A, in which aperture 1205 is shown at the intersection of bottom groove 1201 and top groove 1203, according to some embodiments.

[0126] In various embodiments, the bottom grooves 1201 can be defined similarly to the slots 301 of FIG. 3A . For example, the top grooves 1203 extend a distance 307 from the top surface 304 of the faceplate 152T into the faceplate 152T. And, the bottom grooves 1201 extend a distance 308 from the bottom surface 302 of the faceplate 152T into the faceplate 152T. The distance 308 is at least large enough for the bottom grooves 1201 to intersect with the top grooves 1203 where they intersect with one another. Thus, the shallow depth bottom grooves 1201 are formed across the plasma side (bottom surface) of the faceplate 152T, and each bottom groove 1201 forms an aperture 1205 for intersecting with each of the deeper depth top grooves 1203 formed through the plenum side (top surface) of the faceplate 152T. It should be appreciated that distance 308 is small enough to allow reliable and economical fabrication of bottom grooves 1201. Accordingly, each of top grooves 1203 is formed to extend through a portion (distance 307) of the overall thickness 306 of faceplate 152T and intersect with one or more bottom grooves 1201 to form a flow path for process gases through faceplate 152T. In various embodiments, distance 308, i.e., the depth of bottom groove 1201, is within a range of about 0.001 inches to about 0.03 inches, or about 0.03 inches, or greater than 0.03 inches. In some embodiments, distance 308, i.e., the depth of bottom groove 1201, is about 50% or less of the overall thickness 306 of faceplate 152T. In some embodiments, distance 308, i.e., the depth of bottom groove 1201, is about 10% or less of the overall thickness 306 of faceplate 152T.

[0127] Each bottom trench 1201 has an HCD suppression dimension 1207 measured in a direction across the shortest span of the bottom trench 1201. In the exemplary faceplate 152T, the HCD suppression dimension 1207 depends at least on the process pressure and the process RF power. Thus, in some processes with higher process pressures and / or higher process RF powers, the HCD suppression dimension 1207 of the bottom trench 1201 may need to be smaller to prevent HCD formation in the bottom trench 1201. However, in some processes with lower process pressures and / or lower process RF powers, the HCD suppression dimension 1207 may be larger and still be effective in preventing HCD formation in the bottom trench 1201. In various embodiments, the HCD suppression dimension 1207 of the bottom trench 1201 is in the range of about 0.005 inches to about 0.04 inches, or in the range of about 0.008 inches to about 0.018 inches, or up to about 0.008 inches, or up to about 0.08 inches, or up to about 0.1 inches, or up to about 0.2 inches, or about 0.08 inches, or about 0.01 inches. Again, the upper limit of the HCD suppression dimension 1207 of the bottom trench 1201 is process dependent, i.e., process pressure and / or RF power dependent, since the likelihood of HCD formation in a given bottom trench 1201 is process dependent. Additionally, a given bottom trench 1201 has an aspect ratio (width to depth) defined by the ratio of (HCD suppression dimension 1207 / distance 308). In various embodiments, the aspect ratio of a given bottom groove 1201 is about 1 or less, or about 0.3 or less, or about 0.1 or less. In various embodiments, the bottom groove 1201 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., water jet cutting, plasma cutting, or other type of cutting process).

[0128] In various embodiments, the width dimension, i.e., the short horizontal cross-sectional dimension, of the top surface groove 1203 is in the range of about 0.02 inches to about 0.09 inches, or about 0.02 inches or more, or about 0.04 inches or more, or about 0.08 inches or more, or about 0.1 inches or more. It should be understood that the width dimension of the top surface groove 1203 can be larger than the size at which HCD is expected to occur, since the bottom surface groove 1201 is sized to prevent HCD. It should also be understood that the width dimension of the top surface groove 1203 can be specified to facilitate fabrication of the top surface groove 1203. In various embodiments, the top surface groove 1203 can be formed by an EDM process (e.g., sinker EDM or wire EDM), or a machining process, or a laser drilling process, or a cutting process (e.g., waterjet cutting, plasma cutting, or other type of cutting process).

[0129] In view of the foregoing, in some embodiments, a showerhead (e.g., 150) for delivering process gases to a plasma generating region (e.g., 154) in a substrate processing system (e.g., 100) is disclosed. The showerhead includes a faceplate (e.g., 152A-152T) having a bottom surface (e.g., 302) and a top surface (e.g., 304). The bottom surface of the faceplate faces the plasma generating region during operation of the substrate processing system. The top surface of the faceplate faces a plenum (e.g., 151) through which process gases are supplied during operation of the substrate processing system. The faceplate has an overall thickness (e.g., 306) measured between the bottom surface and the top surface of the faceplate. The faceplate includes an aperture formed through the bottom surface of the faceplate. The faceplate also includes an opening formed through the top surface of the faceplate. Each of the apertures is formed to extend through a portion of the total thickness of the faceplate (e.g., 308) and intersect with at least one of the openings to form a corresponding flow path for process gases through the faceplate. In some embodiments, the portion of the total thickness of the faceplate is in the range of about 0.001 inches to about 0.03 inches. In some embodiments, each of the openings is formed to extend through at least 50% of the total thickness of the faceplate (e.g., 307). In some embodiments, each of the openings is formed to extend through at least 90% of the total thickness of the faceplate (e.g., 307). Each of the apertures has a cross-section oriented parallel to the bottom surface of the faceplate. The cross-section of each of the apertures has a hollow cathode discharge-suppressing dimension in at least one direction. Each of the openings has a cross-section oriented parallel to the top surface of the faceplate. Each of the openings has a minimum cross-sectional dimension that is greater than the hollow cathode discharge-suppressing dimension. In some embodiments, the hollow cathode discharge suppression dimension is in the range of about 0.005 inches to about 0.04 inches. In some embodiments, the hollow cathode discharge suppression dimension is in the range of about 0.008 inches to about 0.018 inches.

[0130] In some embodiments, the openings formed through the top surface of the faceplate are formed as circular holes, hi some embodiments, the openings are arranged in any of a hexagonal lattice array, a square lattice array, a rectangular lattice array, a diamond lattice array, a parallelogram lattice array, a Vogel pattern, or a customized pattern.

[0131] In some embodiments, the apertures formed through the bottom surface of the faceplate are formed as slots extending through the bottom surface of the faceplate. In some embodiments, each of the slots extends continuously across the bottom surface of the faceplate, and the slots are oriented parallel to one another. In some embodiments, each of the slots is formed separately at each location of the opening. In some embodiments, each of the slots has a substantially rectangular cross-sectional shape oriented parallel to the bottom surface of the faceplate. In these embodiments, the slots can be oriented parallel to one another, regularly relative to one another, or randomly relative to one another.

[0132] In some embodiments, each of the slots has a curved cross-sectional shape oriented parallel to the bottom surface of the faceplate. In these embodiments, each opening intersects a separate pair of slots in the faceplate. In some embodiments, the curved cross-sectional shape is either C-shaped or bracket-shaped.

[0133] In some embodiments, the apertures formed through the bottom surface of the faceplate each have a circular cross-sectional shape in an orientation parallel to the bottom surface of the faceplate. In some embodiments, the openings are arranged in a Vogel pattern, and the apertures are formed as grooves extending through the bottom surface of the faceplate. In these embodiments, the grooves are formed in the Vogel pattern so as to intersect with the openings.

[0134] In some embodiments, the openings are formed as a first set of grooves extending through the top surface of the faceplate and the apertures are formed as a second set of grooves extending through the bottom surface of the faceplate. In these embodiments, the first set of grooves are formed in a first Vogel pattern and the second set of grooves are formed in a second Vogel pattern, the first and second Vogel patterns traversing each other in opposite directions.

[0135] In some embodiments, the openings are formed as a first set of grooves extending through the top surface of the faceplate and the apertures are formed as a second set of grooves extending through the bottom surface of the faceplate. In these embodiments, the first set of grooves are formed in a radial spoke pattern and the second set of grooves are also formed in a radial spoke pattern so as to intersect with the first set of grooves.

[0136] In some embodiments, the openings are formed as a first set of grooves extending through the top surface of the faceplate and the apertures are formed as a second set of grooves extending through the bottom surface of the faceplate. In these embodiments, the first set of grooves are formed in a radial spoke pattern and the second set of grooves are formed in a concentric circular pattern that intersects with the first set of grooves.

[0137] In some embodiments, a faceplate (e.g., 152A-152T) for a showerhead (e.g., 150) for delivering process gas to a plasma generation region (e.g., 154) in a substrate processing system (e.g., 100) is disclosed. The faceplate includes a disk having a bottom surface (e.g., 302) and a top surface (e.g., 304). The bottom surface of the disk faces the plasma generation region during operation of the substrate processing system. The top surface of the disk faces a plenum (e.g., 151) through which process gas is supplied during operation of the substrate processing system. The disk has an overall thickness (e.g., 306) measured between the bottom and top surfaces of the disk. The disk includes apertures formed through the bottom surface of the disk. The disk also includes openings formed through the top surface of the disk. Each of the apertures is formed to extend through a portion of the overall thickness of the disk (e.g., 308) and intersect with at least one of the openings to form a corresponding flow path for the process gas through the disk. Each of the apertures has a cross-section oriented parallel to the bottom surface of the disk. Each of the apertures has a cross-section with a hollow cathode discharge-suppressing dimension in at least one direction. Each of the openings has a cross-section oriented parallel to the top surface of the disk. Each of the openings has a minimum cross-sectional dimension that is greater than the hollow cathode discharge-suppressing dimension.

[0138] FIG. 13 is a flowchart of a method for fabricating a faceplate (e.g., 152A-152T) of a showerhead (e.g., 150) for delivering process gases to a plasma generation region (e.g., 154) in a substrate processing system (e.g., 100), according to some embodiments. The method includes operation 1301 for providing a disk having a bottom surface (e.g., 302) and a top surface (e.g., 304). The bottom surface of the disk is configured to face the plasma generation region during operation of the substrate processing system. The top surface of the disk is configured to face a plenum to which process gases are supplied during operation of the substrate processing system. The disk has an overall thickness (e.g., 306) measured between the bottom and top surfaces of the disk. The method also includes operation 1303 for forming openings through the top surface of the disk. Each of the openings has a cross-section oriented parallel to the top surface of the disk. Each of the openings is formed to have a minimum cross-sectional dimension greater than a hollow cathode discharge suppression dimension. The method also includes an operation 1305 for forming an aperture through a bottom surface of the disk to intersect with at least one of the apertures in the disk to form a corresponding flow path for the process gas through the disk. Each of the apertures has a cross section oriented parallel to the bottom surface of the disk. The cross section of each of the apertures is formed to have a hollow cathode discharge suppression dimension in at least one direction.

[0139] The various modified faceplates 152A-152T disclosed herein provide HCD suppression under various process conditions by intersecting small apertures of shallow depth formed through the bottom surface (plasma side) of the faceplate with larger openings formed through the top surface (plenum side) of the faceplate. The horizontal cross-section of the small apertures formed through the bottom surface of the faceplate has an HCD-suppressing dimension in at least one direction. The shallow depth of the small apertures formed through the bottom surface of the faceplate also allows for the formation of the small apertures using various fabrication techniques, such as EDM processes (e.g., sinker EDM or wire EDM), machining processes (e.g., drilling), laser drilling processes, or cutting processes (e.g., waterjet cutting, plasma cutting, or other types of cutting processes), among other processes. The shallow depth of the small apertures formed through the bottom surface of the faceplate also allows for faster material removal when forming the small apertures, allowing for lower process gas flow restrictions through the small apertures.

[0140] The various modified faceplates 152A-152T disclosed herein enable maintaining high process gas flow conductance and uniformity through the modified faceplate comparable to that achieved with existing showerhead designs. More specifically, the geometry and number of small apertures formed through the bottom surface of the modified faceplate and the geometry and number of larger openings formed through the top surface of the modified faceplate can be defined as maintaining high process gas flow conductance and uniformity through the modified faceplate comparable to that achieved with existing showerhead designs. Additionally, the various modified faceplates 152A-152T disclosed herein provide suppression of HCD formation under essentially all process conditions, including AHM process conditions. More specifically, the HCD suppression dimensions of the apertures formed through the bottom surface of the modified faceplate can be configured to ensure that HCD formation does not occur under planned process conditions of pressure and RF power. Additionally, the various modified faceplates 152A-152T disclosed herein can be economically fabricated on a production scale.

[0141] While the foregoing disclosure includes some details for clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. For example, it should be understood that one or more features from any embodiment disclosed herein can be combined with one or more features of any other embodiment disclosed herein. Thus, the present embodiments should be considered illustrative rather than limiting, and the claims should not be limited to the details set forth herein, but may be modified within the scope and equivalents of the described embodiments.

[0142] The present disclosure includes the following application examples: [Application example 1] 1. A showerhead for delivering process gas to a plasma generating region in a substrate processing system, comprising: a faceplate having a bottom surface and a top surface, the bottom surface of the faceplate facing the plasma generation region during operation of the substrate processing system, the top surface of the faceplate facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the faceplate having an overall thickness measured between the bottom surface and the top surface of the faceplate; Equipped with the faceplate includes apertures formed through the bottom surface of the faceplate, the faceplate includes openings formed through the top surface of the faceplate, each of the apertures extending through a portion of the overall thickness of the faceplate and intersecting at least one of the openings to form a corresponding flow path for process gas through the faceplate; each of the apertures has a cross section oriented parallel to the bottom surface of the faceplate, the cross section of each of the apertures having a hollow cathode discharge suppressing dimension in at least one direction; each of the openings has a cross section oriented parallel to the top surface of the faceplate, and each of the openings has a minimum cross-sectional dimension greater than the hollow cathode discharge-suppressing dimension; Shower head. [Application example 2] The shower head according to Application Example 1, The showerhead, wherein each of the openings is formed to extend through at least 50% of the total thickness of the faceplate. [Application example 3] The shower head according to Application Example 1, The showerhead, wherein each of the openings is formed to extend through at least 90% of the total thickness of the faceplate. [Application example 4] The shower head according to Application Example 1, The showerhead, wherein the portion of the total thickness of the faceplate is in the range of about 0.001 inches to about 0.03 inches. [Application example 5] The shower head according to Application Example 1, The showerhead, wherein the hollow cathode discharge suppression dimension is within a range of about 0.005 inches to about 0.04 inches. [Application Example 6] The shower head according to Application Example 1, The showerhead, wherein the hollow cathode discharge suppression dimension is within a range of about 0.008 inches to about 0.018 inches. [Application Example 7] The shower head according to Application Example 1, The opening is formed as a circular hole. [Application Example 8] The showerhead according to Application Example 7, The showerhead, wherein the openings are arranged in one of a hexagonal lattice array, a square lattice array, a rectangular lattice array, a diamond lattice array, a parallelogram lattice array, a Vogel pattern, or a customized pattern. [Application Example 9] The showerhead according to Application Example 8, The showerhead, wherein the aperture is formed as a slot extending through the bottom surface of the faceplate. [Application Example 10] The shower head according to Application Example 9, The showerhead, wherein each of the slots extends continuously across the bottom surface of the faceplate, and the slots are oriented parallel to one another. [Application Example 11] The shower head according to Application Example 9, The slots are formed separately at the locations of the openings. [Application Example 12] The showerhead according to Application Example 11, The showerhead, wherein each of the slots has a substantially rectangular cross-sectional shape in an orientation parallel to the bottom surface of the faceplate, and the slots are oriented parallel to each other, regularly relative to each other, or randomly relative to each other. [Application Example 13] The showerhead according to Application Example 11, The showerhead, wherein each of the slots has a curved cross-sectional shape oriented parallel to the bottom surface of the faceplate, and each opening intersects a separate pair of slots in the faceplate. [Application Example 14] The showerhead according to Application Example 13, The showerhead, wherein the curved cross-sectional shape is either C-shaped or bracket-shaped. [Application Example 15] The showerhead according to Application Example 8, The showerhead, wherein each of the apertures has a circular cross-sectional shape in an orientation parallel to the bottom surface of the faceplate. [Application Example 16] The showerhead according to Application Example 7, the openings are arranged in a Vogel pattern, the apertures are formed as grooves extending through the bottom surface of the faceplate, the grooves being formed in the Vogel pattern to intersect the openings. [Application Example 17] The shower head according to Application Example 1, the openings are formed as a first set of grooves extending through the top surface of the faceplate and the apertures are formed as a second set of grooves extending through the bottom surface of the faceplate, the first set of grooves being formed in a first Vogel pattern and the second set of grooves being formed in a second Vogel pattern, the first and second Vogel patterns traversing each other in opposite directions. [Application Example 18] The shower head according to Application Example 1, the openings are formed as a first set of grooves extending through the top surface of the faceplate, the apertures are formed as a second set of grooves extending through the bottom surface of the faceplate, the first set of grooves are formed in a radial spoke pattern, and the second set of grooves are also formed in the radial spoke pattern so as to intersect with the first set of grooves. [Application Example 19] The shower head according to Application Example 1, the openings are formed as a first set of grooves extending through the top surface of the faceplate and the apertures are formed as a second set of grooves extending through the bottom surface of the faceplate, the first set of grooves being formed in a radial spoke pattern and the second set of grooves being formed in a concentric circular pattern that intersect with the first set of grooves. [Application Example 20] 1. A faceplate for a showerhead for delivering process gas to a plasma generating region in a substrate processing system, comprising: a disk having a bottom surface and a top surface, the bottom surface of the disk facing the plasma generation region during operation of the substrate processing system, and the top surface of the disk facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the disk having an overall thickness measured between the bottom surface and the top surface of the disk; Equipped with the disk includes apertures formed through the bottom surface of the disk, the disk includes openings formed through the top surface of the disk, each of the apertures extending through a portion of the overall thickness of the disk and intersecting at least one of the openings to form a corresponding flow path for process gas through the disk; each of the apertures has a cross section oriented parallel to the bottom surface of the disk, the cross section of each of the apertures having a hollow cathode discharge suppressing dimension in at least one direction; each of the openings having a cross section oriented parallel to the top surface of the disk, and each of the openings having a minimum cross-sectional dimension greater than the hollow cathode discharge-suppressing dimension; Faceplate. [Application Example 21] 1. A method for manufacturing a faceplate of a showerhead for delivering process gases to a plasma generating region in a substrate processing system, comprising: providing a disk having a bottom surface and a top surface, the bottom surface of the disk facing the plasma generation region during operation of the substrate processing system, and the top surface of the disk facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the disk having an overall thickness measured between the bottom surface and the top surface of the disk; forming apertures through the bottom surface of the disk, each of the apertures having a cross section oriented parallel to the bottom surface of the disk, the cross section of each of the apertures being formed to have a hollow cathode discharge suppressing dimension in at least one direction; forming openings through the top surface of the disk to intersect with at least one of the apertures in the disk to form a corresponding flow path for process gas through the disk, each of the openings having a cross section oriented parallel to the top surface of the disk, each of the openings formed to have a minimum cross-sectional dimension greater than the hollow cathode discharge suppression dimension; A method comprising: The claims are as follows:

Claims

1. 1. A showerhead for delivering process gas to a plasma generating region in a substrate processing system, comprising: a faceplate having a bottom surface and a top surface, the bottom surface of the faceplate facing the plasma generation region during operation of the substrate processing system, the top surface of the faceplate facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the faceplate having an overall thickness measured between the bottom surface and the top surface of the faceplate; Equipped with the faceplate includes apertures formed through the bottom surface of the faceplate, the faceplate includes openings formed through the top surface of the faceplate, each of the apertures extending through a portion of the overall thickness of the faceplate and intersecting at least one of the openings to form a corresponding flow path for process gas through the faceplate; each of the apertures has a cross section oriented parallel to the bottom surface of the faceplate, the cross section of each of the apertures having a hollow cathode discharge suppression dimension in at least one direction, each of the apertures having an aspect ratio of 0.1 or less, the aspect ratio being the hollow cathode discharge suppression dimension divided by a depth of the aperture, the apertures being formed as slots extending through the bottom surface of the faceplate, the slots being separately formed at the locations of the openings; each of the openings has a cross section oriented parallel to the top surface of the faceplate, each of the openings has a minimum cross-sectional dimension greater than the hollow cathode discharge suppression dimension, the openings are formed as circular holes, and the openings are arranged in any of a hexagonal lattice array, a square lattice array, a rectangular lattice array, a diamond lattice array, a parallelogram lattice array, or a Vogel pattern; Shower head.

2. 10. The showerhead of claim 1, The showerhead, wherein each of the openings is formed to extend through at least 50% of the total thickness of the faceplate.

3. 10. The showerhead of claim 1, The showerhead, wherein each of the openings is formed to extend through at least 90% of the total thickness of the faceplate.

4. 10. The showerhead of claim 1, The showerhead, wherein the portion of the overall thickness of the faceplate is in a range from about 0.001 inches to about 0.03 inches.

5. 10. The showerhead of claim 1, The showerhead, wherein the hollow cathode discharge suppression dimension is in the range of about 0.005 inches to about 0.04 inches.

6. 10. The showerhead of claim 1, The showerhead, wherein the hollow cathode discharge suppression dimension is in the range of about 0.008 inches to about 0.018 inches.

7. 10. The showerhead of claim 1, The slots are oriented parallel to one another.

8. 10. The showerhead of claim 1, The showerhead, wherein each of the slots has a substantially rectangular cross-sectional shape in a direction parallel to the bottom surface of the faceplate.

9. 10. The showerhead of claim 1, The showerhead, wherein each of the slots has a curved cross-sectional shape in a direction parallel to the bottom surface of the faceplate, and each opening intersects with a separate pair of slots in the faceplate.

10. 10. The showerhead of claim 9, The showerhead, wherein the curved cross-sectional shape is either a C-shape or a bracket-shape.

11. A showerhead for delivering process gas to a plasma generating region in a substrate processing system, comprising: a faceplate having a bottom surface and a top surface, the bottom surface of the faceplate facing the plasma generation region during operation of the substrate processing system, the top surface of the faceplate facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the faceplate having an overall thickness measured between the bottom surface and the top surface of the faceplate; Equipped with the faceplate includes apertures formed through the bottom surface of the faceplate, the faceplate includes openings formed through the top surface of the faceplate, each of the apertures extending through a portion of the overall thickness of the faceplate and intersecting at least one of the openings to form a corresponding flow path for process gas through the faceplate; each of the apertures has a cross section oriented parallel to the bottom surface of the faceplate, the cross section of each of the apertures having a hollow cathode discharge suppressing dimension in at least one direction, each of the apertures having an aspect ratio of 0.1 or less, the aspect ratio being the hollow cathode discharge suppressing dimension divided by a depth of the aperture, each of the apertures having a circular cross-sectional shape in a direction parallel to the bottom surface of the faceplate; each of the openings has a cross section oriented parallel to the top surface of the faceplate, each of the openings has a minimum cross-sectional dimension greater than the hollow cathode discharge suppression dimension, the openings are formed as circular holes, and the openings are arranged in any of a hexagonal lattice array, a square lattice array, a rectangular lattice array, a diamond lattice array, a parallelogram lattice array, or a Vogel pattern.

12. A showerhead for delivering process gas to a plasma generating region in a substrate processing system, comprising: a faceplate having a bottom surface and a top surface, the bottom surface of the faceplate facing the plasma generation region during operation of the substrate processing system, the top surface of the faceplate facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the faceplate having an overall thickness measured between the bottom surface and the top surface of the faceplate; Equipped with the faceplate includes apertures formed through the bottom surface of the faceplate, the faceplate includes openings formed through the top surface of the faceplate, each of the apertures extending through a portion of the overall thickness of the faceplate and intersecting at least one of the openings to form a corresponding flow path for process gas through the faceplate; each of the apertures has a cross section oriented parallel to the bottom surface of the faceplate, the cross section of each of the apertures having a hollow cathode discharge suppression dimension in at least one direction, each of the apertures having an aspect ratio of 0.1 or less, the aspect ratio being the hollow cathode discharge suppression dimension divided by the depth of the aperture; each of the openings has a cross section oriented parallel to the top surface of the faceplate, each of the openings has a minimum cross-sectional dimension greater than the hollow cathode discharge suppression dimension, the openings are formed as circular holes, the openings are arranged in a Vogel pattern, and the apertures are formed as grooves extending through the bottom surface of the faceplate, the grooves being formed in the Vogel pattern to intersect the openings.

13. A showerhead for delivering process gas to a plasma generating region in a substrate processing system, comprising: a faceplate having a bottom surface and a top surface, the bottom surface of the faceplate facing the plasma generation region during operation of the substrate processing system, the top surface of the faceplate facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the faceplate having an overall thickness measured between the bottom surface and the top surface of the faceplate; Equipped with the faceplate includes apertures formed through the bottom surface of the faceplate, the faceplate includes openings formed through the top surface of the faceplate, each of the apertures extending through a portion of the overall thickness of the faceplate and intersecting at least one of the openings to form a corresponding flow path for process gas through the faceplate; each of the apertures has a cross section oriented parallel to the bottom surface of the faceplate, the cross section of each of the apertures having a hollow cathode discharge suppression dimension in at least one direction, each of the apertures having an aspect ratio of 0.1 or less, the aspect ratio being the hollow cathode discharge suppression dimension divided by the depth of the aperture; each of the openings has a cross section oriented parallel to the top surface of the faceplate, each of the openings has a minimum cross-sectional dimension greater than the hollow cathode discharge suppression dimension, the openings are formed as a first set of grooves extending through the top surface of the faceplate and the apertures are formed as a second set of grooves extending through the bottom surface of the faceplate, the first set of grooves are formed in a first Vogel pattern and the second set of grooves are formed in a second Vogel pattern, and the first and second Vogel patterns traverse each other in opposite directions.

14. A showerhead for delivering process gas to a plasma generating region in a substrate processing system, comprising: a faceplate having a bottom surface and a top surface, the bottom surface of the faceplate facing the plasma generation region during operation of the substrate processing system, the top surface of the faceplate facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the faceplate having an overall thickness measured between the bottom surface and the top surface of the faceplate; Equipped with the faceplate includes apertures formed through the bottom surface of the faceplate, the faceplate includes openings formed through the top surface of the faceplate, each of the apertures extending through a portion of the overall thickness of the faceplate and intersecting at least one of the openings to form a corresponding flow path for process gas through the faceplate; each of the apertures has a cross section oriented parallel to the bottom surface of the faceplate, the cross section of each of the apertures having a hollow cathode discharge suppression dimension in at least one direction, each of the apertures having an aspect ratio of 0.1 or less, the aspect ratio being the hollow cathode discharge suppression dimension divided by the depth of the aperture; each of the openings has a cross section oriented parallel to the top surface of the faceplate, each of the openings has a minimum cross-sectional dimension greater than the hollow cathode discharge suppression dimension, the openings are formed as a first set of grooves extending through the top surface of the faceplate and the apertures are formed as a second set of grooves extending through the bottom surface of the faceplate, the first set of grooves are formed in a radial spoke pattern and the second set of grooves are also formed in the radial spoke pattern so as to intersect with the first set of grooves.

15. A showerhead for delivering process gas to a plasma generating region in a substrate processing system, comprising: a faceplate having a bottom surface and a top surface, the bottom surface of the faceplate facing the plasma generation region during operation of the substrate processing system, the top surface of the faceplate facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the faceplate having an overall thickness measured between the bottom surface and the top surface of the faceplate; Equipped with the faceplate includes apertures formed through the bottom surface of the faceplate, the faceplate includes openings formed through the top surface of the faceplate, each of the apertures extending through a portion of the overall thickness of the faceplate and intersecting at least one of the openings to form a corresponding flow path for process gas through the faceplate; each of the apertures has a cross section oriented parallel to the bottom surface of the faceplate, the cross section of each of the apertures having a hollow cathode discharge suppression dimension in at least one direction, each of the apertures having an aspect ratio of 0.1 or less, the aspect ratio being the hollow cathode discharge suppression dimension divided by the depth of the aperture; each of the openings has a cross section oriented parallel to the top surface of the faceplate, each of the openings has a minimum cross-sectional dimension greater than the hollow cathode discharge suppression dimension, the openings are formed as a first set of grooves extending through the top surface of the faceplate and the apertures are formed as a second set of grooves extending through the bottom surface of the faceplate, the first set of grooves being formed in a radial spoke pattern and the second set of grooves being formed in a concentric circular pattern that intersect the first set of grooves.

16. 1. A faceplate for a showerhead for delivering process gas to a plasma generating region in a substrate processing system, comprising: a disk having a bottom surface and a top surface, the bottom surface of the disk facing the plasma generation region during operation of the substrate processing system, and the top surface of the disk facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the disk having an overall thickness measured between the bottom surface and the top surface of the disk; Equipped with the disk includes apertures formed through the bottom surface of the disk, the disk includes openings formed through the top surface of the disk, each of the apertures extending through a portion of the overall thickness of the disk and intersecting at least one of the openings to form a corresponding flow path for process gas through the disk; each of the apertures has a cross section oriented parallel to the bottom surface of the disk, the cross section of each of the apertures having a hollow cathode discharge suppression dimension in at least one direction, each of the apertures having an aspect ratio of 0.1 or less, the aspect ratio being the hollow cathode discharge suppression dimension divided by a depth of the aperture, the apertures being formed as slots extending through the bottom surface of the faceplate, the slots being separately formed at the locations of the openings; each of the openings has a cross section oriented parallel to the top surface of the disk, each of the openings having a minimum cross-sectional dimension greater than the hollow cathode discharge suppression dimension, the openings being formed as circular holes, and the openings being arranged in any of a hexagonal lattice array, a square lattice array, a rectangular lattice array, a diamond lattice array, a parallelogram lattice array, or a Vogel pattern; Faceplate.

17. 1. A method for manufacturing a faceplate of a showerhead for delivering process gases to a plasma generating region in a substrate processing system, comprising: providing a disk having a bottom surface and a top surface, the bottom surface of the disk facing the plasma generation region during operation of the substrate processing system, and the top surface of the disk facing one or more plenums to which one or more process gases are supplied during operation of the substrate processing system, the disk having an overall thickness measured between the bottom surface and the top surface of the disk; forming apertures through the bottom surface of the disk, each of the apertures having a cross section oriented parallel to the bottom surface of the disk, the cross section of each of the apertures being formed to have a hollow cathode discharge suppression dimension in at least one direction, each of the apertures having an aspect ratio of 0.1 or less, the aspect ratio being the hollow cathode discharge suppression dimension divided by a depth of the aperture; forming openings through the top surface of the disk to intersect with at least one of the apertures in the disk to form a corresponding flow path for process gas through the disk, each of the openings having a cross section oriented parallel to the top surface of the disk, each of the openings formed to have a minimum cross-sectional dimension greater than the hollow cathode discharge suppression dimension; Including, the apertures are formed as slots extending through the bottom surface of the disk, the slots being formed separately at the locations of the openings, the openings being formed as circular holes, and the openings being arranged in one of a hexagonal lattice array, a square lattice array, a rectangular lattice array, a diamond lattice array, a parallelogram lattice array, or a Vogel pattern; method.

Images