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I. INTRODUCTION over, the capacitive power of the l-R plasma source is de-
The use of inductive plasma sources has spread widely in posited mainly within the plasma source, while conventional
the last decade as high density plasma etching/deposition sources deposit an essential portion of the capacitive power
tools.1,2 However, they have some drawbacks, including ~a! outside the source in a processing chamber.
capacitive coupling of the inductor-plasma wafer, which pro- The l-R plasma source has not yet been well character-
duces a secondary capacitive plasma over the wafer and ized in terms of plasma and process parameters. We present
brings about wall sputtering and wafer damage; ~b! azi- here some results on plasma diagnostics in the source area, in
muthal discharge nonuniformity; ~c! too narrow a pressure the vicinity of the wafer, and on the surface of a process
and power process window; and ~d! difficult discharge igni- chamber and wafer in high power industrial scale oxygen
tion. discharges. The ashing processes are also estimated for 200
A novel internally balanced rf inductive plasma source and 300 mm single wafer ashes having 2.7 and 4.5 kW nomi-
has been developed3 and realized commercially as a single nal rf power generators.
wafer quasidownstream oxygen asher, l-Strip 3000.1 ~l-
Strip is a product of MC Electronics.! It operates in a full II. EXPERIMENTAL DETAILS
wave helical resonant or a lambda-resonator ~l-R! mode and
represents a rf plasma source utilizing a standing wave struc- The l-R reactor was described previously.3 A basic con-
ture in order to overcome known drawbacks and extend the figuration of the reactor is shown in Fig. 1 for scaling pur-
applicability of inductive plasma sources for 300 mm wafer poses. These reactors consist of a quartz discharge tube in-
processing. serted into a water cooled copper coil representing a
The plasma phenomena in the 2 kW rf power l-R oper- transmission line having total electric length of one full wave
ating in a 0.001–100 Torr pressure range have been at resonance plasma loaded conditions. Roughly, the length
reported.4,5 The l-R plasma source, having three separate of copper winding is about 11 m. The coil and the tube are
inductive zones, has substantially a three dimensional exci- enclosed by a cylinder water cooled copper shield. The top
tation structure keeping the discharge volume about constant flanges and the chambers are made of aluminum. Flat wafer
over a wide range of pressure and power in comparison with platens made of Al are mounted 120–140 mm below the
known inductive sources. The positions of each inductive bottom ground end of the coils. They can be heated up to
zone capable of generating of a separate plasma toroid is 300 °C by resistive heaters in both chambers.
strictly defined by the standing wave pattern of the rf current The rf power at 27.12 MHz frequency in the range of
along the coil of a one-lambda shorted spiral transmission 0.005–4.5 kW was supplied directly to the resonator by a 50
line. The discharge structure of the novel plasma source can- V coaxial cable. Three different power sources were used:
not be obtained from conventional inductive sources: none of 27.12 MHz, 2.7 and 4.5 kW rf power generators ~Kyosan,
them has multiple inductive excitation zones with opposite Japan!, and a 2.25 kW maximum rf power wide band tube
inductive currents within the same inductor volume. More- amplifier IFI-410 with a sign wave signal generator HP-
8648A. The l-R plasma source operates without a matching
a!
Author to whom correspondence should be addressed; electronic mail: network with an energy efficiency virtually up to 100%, ne-
100510.3707@compuserve.com glecting the power losses in a coaxial cable. The resonator
3164 J. Vac. Sci. Technol. A 16„6…, Nov/Dec 1998 0734-2101/98/16„6…/3164/6/$15.00 ©1998 American Vacuum Society 3164
3165 Vinogradov, Menagarishvili, and Yoneyama: A novel lambda balanced inductive plasma source 3165
at the center plane of the lambda coil at the zero rf voltage axial positions. The distance R 0 2R, where R 0 is an inside
standing wave node. The visible diameter of the toroidal tube radius, is measured from the quartz wall surface in order
channel is about 3–4 cm. The toroid contacts the quartz wall. to determine, more precisely, sharp sheath profiles. The high-
The rest of the discharge volume inside the coil radiates very est plasma potential in the discharge of about 22–23 V is
weakly. There is no visible emission in the downstream characteristic for the plasma toroid at about 5–15 mm from
chamber at all. The side inductive toroids typical for l-R the wall. The axial area inside a toroid represents a potential
discharge in Ar cannot be launched in oxygen in the 330- well of about 5 V in depth. It is generated due to the pump-
mm-inner diam ~i.d.! tube even at about 3.5–4 kW rf power. ing of fast electrons into this area from the toroid. This phe-
A weak plasma emission in the side inductive zones can be nomenon is very similar to the formation of low electric
observed at 4.5 kW in the smaller plasma source. There are potential on the surface of the discharge tube. There must be
two main reasons: ~1! oxygen discharges under 0.5–2 Torr
corresponding ambipolar diffusion of positive ions from the
pressure dissipate more than 50% of the specific plasma
toroid into the potential well. They must recombine in this
power into gas heating due to intrinsic mechanisms of energy
zone with negative ions delivering a lot of detached elec-
dissipation;11 ~2! negative ion formation through electron
trons. The electron energy distribution function should reveal
capture drastically decreases the electric conductivity neces-
specific features of this phenomenon.6
sary for efficient inductive coupling.1 The specific power
must be high enough to generate the necessary level of cir- A marked change in both the plasma and floating poten-
cular inductive current to overcome high electron and energy tial is seen near the quartz wall. The plasma potential itself is
losses and support a high level of electrical conductivity for not very informative unless the surface potential of the
efficient rf power coupling in the inductive zones. It can be boundary wall is known. Here we have measured the floating
explained in the same way as the transition from the capaci- potential up to the wall surface in several cases. Hence, the
tive to the inductive mode in any conventional inductive sheath voltage can be derived. The plasma floating potential
source.1 The situation may occur where the central toroid is minimal at the 159 mm axial position corresponding to the
efficiently absorbs an increasing power, not allowing power position of maximum standing wave rf voltage distributed
to reach the side toroids. The detailed mechanism of power along the coil.3 The tube surface potential is most negative
distribution between the internal plasma structures and be- here. The maximum dc sheath voltage is about 30–33 V. It is
tween the capacitive and inductive modes is presently un- obviously a low voltage sheath which cannot produce notice-
clear. All three plasma toroids easily appear in 2 Torr Ar able sputtering at the discharge tube surface.
discharge at only about 0.5 kW rf power. At 20 Torr Ar The mechanism of capacitive current balance is mainly
pressure 2 toroids exist at 1 kW power and the third one responsible for a drastic decrease of sheath voltage in the
appears at about 1.2 kW. l-R discharge in comparison with conventional inductive
Figure 2 shows radial distributions of plasma space V pl plasma sources. The plasma of the l-R discharge has enough
and floating V f potentials in a plasma source at different high electric conductivity provided by the central inductive
toroid to essentially shunt the area between the two opposite
phase capacitive voltage halves of the coil. That is why the
capacitive currents are not ‘‘looking’’ for a ground surface
below the plasma source but substantially cancel one another
inside the plasma source.
In the case of l-R discharge the specific coil-plasma ca-
pacitance is essentially low since the coil is separated from
the tube/plasma by a 30–50 mm distance thus representing a
high impedance current generator with respect to the plasma
load. The main portion of the rf capacitive voltage drops
between the coil and the tube wall but not inside the dis-
charge vessel. In addition, the l-R supplies antiphase cur-
rents to the plasma. Thus, the in-phase working capacitance
of the coil is only 50% of the total coil-plasma capacitance.
Furthermore, the l-R coil is at least 4–20 times longer than
any conventional inductor, including a quarter wave helical
resonator, if the same excitation frequency is used. Hence,
the surface density of the capacitive current inductor plasma
at the tube wall is also decreased 4–20 times for the same
total power absorbed in a discharge.
There is a very thin quartz wall between the coil and
plasma. It does not increase the coil-plasma capacitance by
FIG. 2. Plasma space ~a! and floating potential ~b! distributions in a central
plasma toroid of a 235 mm i.d. l-R plasma source: 1.4 Torr oxygen, 3 slm, introducing a high dielectric constant material like a thick
2 kW. The distance from the wafer platen ~in mm! is indicated. flat window. Furthermore, the inductive portion of the l-R is
1
oids depends on the gas type, pressure, and rf power. The M. A. Liberman and A. J. Liechtenberg, Principles of Plasma Discharges
discharge has typically about 97%–99% energy efficiency and Materials Processing ~Wiley, New York, 1994!.
2
High Density Plasma Sources, edited by O. A. Popov ~Noyes, Park
operating without a matchbox. Ridge, NJ, 1995!.
The highest plasma potential in the oxygen discharge un- 3
G. K. Vinogradov and S. Yoneyama, Jpn. J. Appl. Phys., Part 2 35,
der typical ashing conditions of the l-R asher is 20–22 V. L1130 ~1996!.
4
The maximum dc potential difference between the plasma G. K. Vinogradov and S. Yoneyama, Proceedings of 13th Symposium on
and the discharge tube surface is 30–33 V. There is no sput- Plasma Processing, Tokyo, January 1996 ~unpublished!.
5
G. K. Vinogradov and S. Yoneyama, Proceedings of the 43rd National
tering of the discharge tube in the capacitively balanced l-R
Symposium of the American Vacuum Society, Philadelphia, PA, 1996
plasma source. ~unpublished!.
The parameters of the afterglow plasma in the down- 6
G. K. Vinogradov, V. M. Menagarishvili, and S. Yoneyama, J. Vac. Sci.
stream chamber are similar to those of the conventional Technol. A 16, 1444 ~1998!.
7
downstream asher. The density of plasma electrons about 10 G. K. Vinogradov, G. J. Imanbaev, and D. I. Slovetsky, High Energy
mm from the wafer surface is on the order of 5 Chem. 19, 455 ~1985!.
8
L. Schott, in Plasma Diagnostics, edited by W. Lochte-Holtgreven ~AIP,
3107 cm23. The positive ion flux on the wafer surface is New York, 1995!.
<731012 cm22 s21. The wafer surface floating potential is 9
A. I. Maksimov, A. F. Sergienko, and D. I. Slovetsky, Fiz. Plasmy 4, 347
only about 3–5 V over 200 and 300 mm wafers. The stan- ~1978!.
10
dard process examination with chargeup MOS wafer moni- Yu. A. Ivanov, Yu. A. Lebedev, and L. S. Polak, in Methods of Contact
tors having antenna ratios of up to 700 000 and oxide thick- Diagnostics in Plasma Chemistry, edited by L. S. Polak ~Nauka,
Moskow, 1981! ~in Russian!.
nesses of about 90 Å did not detect any damage during 5 min 11
V. V. Rybkin, A. B. Bessarab, and A. I. Maximov, Teplofiz. Vys. Temp.
discharge processing. 34, 181 ~1996! ~in Russian!.
The ashing rate and uniformity of the 300 mm lambda- 12
R. R. J. Gagne and A. Cantin, J. Appl. Phys. 43, 2639 ~1972!.
resonator oxygen asher are about the same as or even exceed 13
R. L. F. Boyd and J. B. Thompson, Proc. R. Soc. London London A252,
the parameters of the 200 mm asher. 102 ~1959!.
14
H. Amemiya, B. M. Annaratone, and J. E. Allen, Proceedings of the 3rd
Presented at the 44th National Symposium of the American Vacuum Soci- International Conference on Reactive Plasmas and 14th Symposium on
ety, San Jose, CA, 20–24 October 1997. Plasma Processing, Nara-ken, Japan, 1997, p. 239.