Pulsed Plasma Etching of Multilayer Films for Recess Shape Control

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Solution Overview

Problem

Existing plasma etching methods for substrates with multilayer films of silicon oxide and silicon nitride struggle to precisely control the depth and width of recesses, leading to unwanted expansion of recesses during etching.

Innovation Solution

An etching method using a plasma processing apparatus that alternately etches silicon oxide and silicon nitride films with intermittent or periodic pulses of source radio frequency power and electric bias, ensuring precise control over the etching process by using different process gases for each film type.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional plasma etching methods are used on multilayer films, then the etching process can be completed, but the depth and width of recesses cannot be precisely controlled, leading to unwanted expansion of recesses

Engineering Contradiction:
Improvecontrol precision of recess depth and widthVSAvoidunwanted expansion of recesses
Core Design Contradiction:
Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent applies periodic action by intermittently or periodically supplying pulses of source radio frequency power and pulses of electric bias during the etching process. This periodic supply allows precise control over plasma generation and ion attraction, enabling accurate control of recess depth and width while preventing unwanted expansion. The periodic pulsing creates controlled etching cycles that maintain dimensional accuracy.

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent employs parameter changes by using different process gases for etching different film types (silicon oxide versus silicon nitride). This change in process gas parameters enables selective and precise etching of each layer, improving control over the final recess dimensions and preventing expansion while achieving the desired depth profile.

Inventive Principle:
Principle #35Parameter changes

2Length of moving object

If deeper recesses are formed in the multilayer film, then the etching depth increases, but the width of the recesses expands uncontrollably

Engineering Contradiction:
Improvedepth of recessVSAvoidwidth of recess
Core Design Contradiction:
Length of moving objectVSArea of stationary object

Solution Approach 1:

The periodic supply of source radio frequency power and electric bias creates controlled etching cycles that advance the recess depth while maintaining width control. The intermittent pulsing allows precise progression into deeper regions without lateral expansion, as each pulse cycle carefully manages plasma density and ion directionality to etch vertically rather than laterally.

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent applies local quality by using different process gases tailored for etching specific film types at different locations in the multilayer structure. This localized approach ensures that each region is etched with optimal gas chemistry, maintaining precise width control while achieving the required depth, preventing uniform expansion across the recess width.

Inventive Principle:
Principle #3Local quality

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

This method effectively increases the depth of recesses while suppressing the expansion of their width, maintaining the desired shape and dimensions of the etched features.

Implementation Method 1

etching one or more first films among the plurality of first films by generating plasma from a first process gas in the chamber

Methodology Applied
Scientific EffectPlasma: Plasma

Implementation Method 2

a pulse of an electric bias for attracting ions from the plasma in the chamber to the substrate

Methodology Applied
Scientific EffectIon bombardment: Ion Beam

Data Source

PatentUS20240212982A1Etching method and plasma processing apparatus
Publication Date: 2024.06.27 TOKYO ELECTRON LTD
  • US20240212982A1 patent drawing
  • US20240212982A1 patent drawing
  • US20240212982A1 patent drawing

AI summary

A disclosed etching method includes (a) preparing a substrate on a substrate support in a chamber. The substrate includes a multilayer film including a plurality of first films and a plurality of second films that are alternately stacked with the plurality of first films, and a mask disposed on the multilayer film. The etching method further includes (b) etching one or more first films among the plurality of first films. The etching method further includes (c) etching one or more second films among the plurality of second films. In each of the (b) and (c), a pulse of a source radio frequency power for plasma generation and a pulse of an electric bias for ion attraction are intermittently or periodically supplied.