Non-Planar Film Deposition With Cyclic Etch for Thickness Uniformity
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Solution Overview
Problem
Existing film deposition methods for semiconductor elements with high aspect ratio structures often result in non-uniform film thickness, leading to overhangs, columnar or porous structures, and increased resistance, which negatively affect element reliability.
Innovation Solution
A film deposition method involving a cyclic process of depositing a film on non-planar substrates with varying surfaces and then etching to adjust thickness deviations, ensuring uniformity across different surfaces, using techniques like atomic layer deposition and etching to achieve equal or reduced thickness differences between surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional film deposition method is applied to a trench structure, then the film deposition process is simple and fast, but the film thickness becomes non-uniform and overhangs are formed
Solution Approach 1:
The patent applies periodic action by implementing cyclic deposition-etching sequences. The deposition process is divided into multiple cycles where material is deposited and then partially removed through etching, gradually building uniform thickness. This periodic approach transforms a single complex deposition into manageable iterative steps, achieving uniform film thickness on high aspect ratio structures while controlling the process complexity through systematic repetition.
Solution Approach 2:
The patent utilizes parameter changes by varying deposition and etching conditions across different cycles. By adjusting deposition thickness, etching duration, and process parameters in each cycle, the method adapts to achieve uniform film formation. The parameters are dynamically modified based on the evolving film structure, allowing precise control over final film uniformity while managing process complexity through parameter optimization.
2Reliability
If a conventional film deposition method is used on high aspect ratio substrates, then the process is simple, but overhangs and voids are formed reducing element reliability
Solution Approach 1:
The cyclic deposition-etching process uses periodic action to prevent defect formation. By repeatedly depositing and selectively removing material, the process ensures complete trench filling without overhang formation. This iterative approach maintains high element reliability by eliminating voids and ensuring uniform coverage, while the systematic cycle structure keeps the process efficient and manageable.
Solution Approach 2:
The patent applies the extraction principle by selectively removing excess material through etching steps. After each deposition cycle, the etching process extracts material from overhanging regions and uneven surfaces, preventing defect formation. This selective removal ensures that only the desired uniform film remains, significantly improving element reliability by eliminating overhangs and voids that would otherwise compromise structure integrity.
3Manufacturing precision
If film deposition is performed on non-planar surfaces, then complete coverage is achieved, but thickness deviation increases
Solution Approach 1:
The cyclic deposition-etching method uses periodic action to address thickness deviation on non-planar surfaces. Each cycle deposits material to achieve coverage, then selectively removes excess from elevated regions through etching. This repeated cycle gradually equalizes thickness across the non-planar surface while maintaining complete area coverage, transforming the challenge of surface irregularity into a controlled iterative process.
Solution Approach 2:
The patent applies parameter changes by adjusting deposition and etching conditions to accommodate non-planar surfaces. By modifying process parameters such as deposition rate, etching selectivity, and cycle duration, the method adapts to the specific surface topology. These parameter adjustments ensure uniform thickness achievement while maintaining complete surface coverage, resolving the contradiction between coverage and uniformity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method ensures uniform film deposition on non-planar substrates, reducing the formation of overhangs and voids, thereby enhancing the reliability and electrical characteristics of semiconductor elements.
Implementation Method 1
depositing a film having a thickness deviation on the first surface, the second surface, and the inclined surface
Implementation Method 2
etching the film deposited on the first surface, the second surface, and the inclined surface
Data Source
AI summary
A film deposition method may include preparing a non-planar substrate including a first surface, a second surface, and an inclined surface between the first surface and the second surface; depositing a film having a thickness deviation on the first surface, the second surface, and the inclined surface; and etching the film deposited on the first surface, the second surface, and the inclined surface. A height of the second surface may be different than a height of the first surface.


