Plasma Processing Apparatus Sheath Potential Stabilization

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Solution Overview

Problem

In plasma processing, particles generated during the process can adhere to semiconductor wafers, leading to defects and reduced yield, as existing methods like stopping direct-current power supply can cause sheath potential fluctuations, exacerbating particle adhesion.

Innovation Solution

A plasma processing apparatus with a controller that ramps down direct-current voltage and sequentially stops radio-frequency power supplies to prevent particle adhesion, using a capacitive coupling type plasma processing apparatus with dual-frequency superimposed power and a specific power control sequence to stabilize the sheath potential.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If direct-current power supply is stopped immediately after plasma process completion, then particle adhesion prevention is attempted, but sheath potential fluctuates drastically causing particles to adhere to the wafer

Engineering Contradiction:
Improveparticle adhesionVSAvoidsheath potential stability
Core Design Contradiction:
Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies preliminary action by ramping down the direct-current power supply before stopping the radio-frequency power supplies. This preparatory step gradually reduces the sheath potential, preventing drastic fluctuations that would otherwise cause particle adhesion to the wafer. The controller executes this sequence by first reducing DC power to a predetermined level, then stopping RF power supplies in a controlled manner.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent implements dynamics by transitioning from a static power supply state to a dynamic ramp-down process. The direct-current power supply is not stopped abruptly but is gradually reduced over time, allowing the sheath potential to adapt smoothly. This dynamic adjustment prevents sudden potential changes that would attract particles to the wafer surface.

Inventive Principle:
Principle #15Dynamics

2Productivity

If radio-frequency power supplies are stopped immediately, then process time is reduced, but particle adhesion increases due to sudden sheath potential change

Engineering Contradiction:
Improveprocess timeVSAvoidparticle adhesion
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by executing a controlled power-down sequence. Before stopping the radio-frequency power supplies, the system first ramps down the direct-current power supply to a predetermined level. This preparatory step ensures that when RF power is subsequently stopped, the sheath potential does not fluctuate drastically, thereby preventing particle adhesion while maintaining efficient process timing.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent implements periodic action through a structured multi-stage power supply cessation sequence. The controller systematically stops power supplies in a specific order and timing: first ramping down DC power, then stopping RF power supplies at predetermined intervals. This periodic, controlled approach balances process efficiency with particle adhesion prevention.

Inventive Principle:
Principle #19Periodic action

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

Effectively reduces particle adhesion to semiconductor wafers by stabilizing the sheath potential and controlling the power supply sequence, resulting in significantly fewer particles adhering to the wafer compared to traditional methods.

Implementation Method 1

a first radio-frequency power source configured to supply a first radio-frequency power for generating plasma on one of the pedestal and the opposite electrode

Methodology Applied
Scientific EffectPlasma generation: Plasma

Implementation Method 2

a second radio-frequency power source configured to supply a second radio-frequency power for generating a bias voltage on the pedestal

Methodology Applied
Scientific EffectBias voltage generation: Electromagnetic Induction

Data Source

PatentUS10043637B2Plasma processing apparatus and particle adhesion preventing method
Publication Date: 2018.08.07 TOKYO ELECTRON LTD
  • US10043637B2 patent drawing
  • US10043637B2 patent drawing
  • US10043637B2 patent drawing

AI summary

A plasma processing apparatus includes: a process chamber configured to accommodate a substrate such that a plasma process is performed in the process chamber; a pedestal on which the substrate is disposed; an opposite electrode opposite to the pedestal; a first radio-frequency power source configured to supply a first radio-frequency power for generating plasma on one of the pedestal and the opposite electrode; a second radio-frequency power source configured to supply a second radio-frequency power for generating a bias voltage on the pedestal, the second radio-frequency power being lower in frequency than the first radio-frequency power; a direct-current power source configured to supply a direct-current voltage to the opposite electrode; and a controller configured to control the first radio-frequency power source, the second radio-frequency power source, and the direct-current power source.