US20050109460A1 - Adjustable gas distribution system - Google Patents
Adjustable gas distribution system Download PDFInfo
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- US20050109460A1 US20050109460A1 US10/856,584 US85658404A US2005109460A1 US 20050109460 A1 US20050109460 A1 US 20050109460A1 US 85658404 A US85658404 A US 85658404A US 2005109460 A1 US2005109460 A1 US 2005109460A1
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- Prior art keywords
- insert
- passageway
- outlet
- gas distribution
- outlets
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/455—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
- C23C16/45563—Gas nozzles
- C23C16/45565—Shower nozzles
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/455—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
- C23C16/45563—Gas nozzles
- C23C16/45574—Nozzles for more than one gas
Definitions
- the present invention relates generally to the field of semiconductor equipment and processing. More specifically, the present invention relates to an adjustable gas distribution apparatus useful in semiconductor fabrication.
- Wafer processing reactor systems and methods are widely used in the manufacture of semiconductors and integrated circuits.
- One particular type of wafer processing system utilizes chemical vapor deposition (CVD) to deposit films or layers on the surface of a substrate as a step in the manufacture of semiconductors and integrated circuits.
- CVD chemical vapor deposition
- it is often required to modify a gas dispersion device from a simple basic design that imparts changes necessary to achieve a desired end result. Examples of such systems are shown for instance in U.S. Pat. Nos. 6,415,736, 6,410,089, 6,284,673, 6,050,506, 6,184,986 and 6,126,753, among others.
- Atomic layer deposition is an alternative to CVD processes to deposit very thin films.
- ALD can be performed at comparatively lower temperatures which is compatible with the industry's trend toward lower temperatures, has high precursor utilization efficiency, and can produce conformal thin film layers. More advantageously, ALD can control film thickness on an atomic scale, and can be used to “nano-engineer” complex thin films.
- each reactant gas is introduced independently into a reaction chamber through, for example a showerhead, so that no gas phase intermixing occurs.
- a monolayer of a first reactant is physi- or chemisorbed onto a substrate surface. Excess first reactant is evacuated from the reaction chamber preferably with the aid of an inert purge gas.
- a second reactant is then introduced to the reaction chamber and reacted with the first reactant to form a monolayer of the desired thin film via a self-limiting surface reaction.
- the self-limiting reaction stops once the initially adsorbed first reactant fully reacts with the second reactant.
- Excess second reactant is evacuated, preferably with the aid of an inert purge gas.
- a desired film thickness is obtained by repeating the deposition cycle as necessary. The film thickness can be controlled to atomic layer accuracy by simply counting the number of deposition cycles.
- adjustable gas distribution apparatus useful in semiconductor fabrication.
- the adjustable gas distribution apparatus of the present invention allows one to alter the size and/or direction of gases exiting the gas distribution apparatus and thus selectively tailor the configuration of the apparatus to achieve a desired end response.
- the present invention provides a gas distribution apparatus comprising a plurality of outlets and at least one replaceable insert placed in at least one of the outlets.
- the insert is provided with a passageway adapted to alter the size of and/or the direction of gases exiting the at least one of the outlets.
- the insert can be placed in the outlet by threading. Alternatively, the insert can be placed in the outlet by press fit.
- the insert is provided with a passageway that is substantially straight and cylindrical.
- the passageway may have a first portion with a smaller diameter and a second portion with a larger diameter to selectively alter the size of the outlet passage in the gas distribution apparatus.
- the insert is provided with a main passageway and plurality of secondary passageways branched and angled from the main passageway.
- the angle between the main and branch passageways is in the range from about 10 to about 90 degrees. In one embodiment, the angle between the main and branch passageways is about 90 degrees.
- the present invention provides a gas distribution apparatus comprising a unitary body having a surface facing a processing region and a plurality of outlet passages formed within the unitary body and extending through the surface for providing gases into the processing region. At least one replaceable insert is placed in at least one of the outlet passages to allow altering the size of at least one of the outlet passages and/or the direction of gases exiting the at least one of the outlet passages into the processing region.
- FIG. 1 is external view of a showerhead showing a plurality of through outlet holes in which one or more replaceable inserts of the present invention can be installed.
- FIG. 2 shows an internal gas distribution network within the showerhead as illustrated in FIG. 1 .
- FIG. 3 is a front view of a screw type insert according to one embodiment of the present invention.
- FIG. 4 is a top view of the screw type insert illustrated in FIG. 3 according to one embodiment of the present invention.
- FIG. 5 is a cross-sectional view along line A-A of the screw type insert illustrated in FIG. 4 according to one embodiment of the present invention.
- FIG. 6 is a partial cross-sectional view of a showerhead installed with the insert illustrated in FIGS. 3-5 according to one embodiment of the present invention.
- FIG. 7 is a front view of a press-fit type insert having multiple branch passageways angled from a main passageway according to one embodiment of the present invention.
- FIG. 8 is a top view of the press-fit type insert illustrated in FIG. 7 according to one embodiment of the present invention.
- FIG. 9 is a cross-sectional view along line B-B of the press-fit type insert illustrated in FIG. 8 according to one embodiment of the present invention.
- FIG. 10 is a partial cross-sectional view of a showerhead installed with the press-fit type insert illustrated in FIGS. 7-9 according to one embodiment of the present invention.
- FIG. 11 is a front view of a press-fit type of insert having multiple branch passageways perpendicular to a main passageway according to one embodiment of the present invention.
- FIG. 12 is a top view of the press-fit type insert illustrated in FIG. 11 according to one embodiment of the present invention.
- FIG. 13 is a cross-sectional view along line C-C of the press-fit type insert illustrated in FIG. 12 according to one embodiment of the present invention.
- FIG. 14 is a partial cross-sectional view of a showerhead installed with the press-fit type insert illustrated in FIGS. 11-13 according to one embodiment of the present invention.
- FIG. 15 is a front view of a press-fit type insert showing details of press fit engagement region according to one embodiment of the present invention.
- FIG. 16 is a top view of the press-fit type insert illustrated in FIG. 15 according to one embodiment of the present invention.
- FIG. 17 is a cross-sectional view along line D-D of the press-fit type insert illustrated in FIG. 16 according to one embodiment of the present invention.
- FIG. 18 is a partial cross-sectional view of a showerhead showing engagement details between the press-fit type insert illustrated in FIGS. 15-17 and the outlet in the showerhead according to one embodiment of the present invention.
- FIG. 19 is a front view of a press-fit type insert showing details of press fit engagement region according to one embodiment of the present invention.
- FIG. 20 is a top view of the press-fit type insert illustrated in FIG. 19 according to one embodiment of the present invention.
- FIG. 21 is a front view of a screw type insert showing multiple passageways according to one embodiment of the present invention.
- FIG. 22 is a top view of the screw type insert illustrated in FIG. 21 according to one embodiment of the present invention.
- FIG. 23 is a cross-sectional view along line F-F of the screw type insert illustrated in FIG. 22 according to one embodiment of the present invention.
- FIG. 24 is a partial cross-sectional view of a showerhead installed with the screw type insert illustrated in FIGS. 21-23 according to one embodiment of the present invention.
- the adjustable gas distribution apparatus of the present invention comprises a plurality of gas outlets and one or more inserts installed in one or more of the outlets which allow altering of the size of the outlets and/or the direction of gases exiting the gas distribution apparatus and thus selectively tailoring the gas flow velocity and pattern to specific process requirements.
- FIG. 1 shows a showerhead 10 in which one or more inserts of the present invention can be used.
- the showerhead 10 shown in FIG. 1 is for illustrative purpose only and not intended to limit the scope of the invention in any way.
- the inserts described below can be used in any other gas distribution apparatus where adjustment of flow velocity and/or direction of gases exiting the apparatus is desired.
- a plurality of channels, passages or holes are created to form an internal gas distribution network in a member.
- the member can be a single unitary block within which an internal gas distribution network is formed.
- the member can also be comprised of several individual blocks, within each of which a plurality of channels, passages or holes are formed. These individual blocks are then connected and assembled as a unit, for example by a plurality of bolts.
- the channels, passages or holes can be formed by any suitable machining methods such as drillings, reaming and electrical discharge machining, etc.
- FIG. 1 shows an external view of a showerhead 10 .
- FIG. 2 shows an internal gas distribution network 12 formed within the showerhead 10 .
- a plurality of horizontal channels 14 are formed in a unitary cylindrical member 16 .
- the unitary member 16 can be comprised of an aluminum, steel, or nickel-based alloy block, or any other suitable materials. These horizontal channels 14 converge at a converging point 18 and extend radially and outwardly to the periphery surface 20 of the cylindrical member 16 .
- the periphery surface 20 is closed.
- the horizontal channels 14 can be formed by drilling from the periphery surface 20 . The unnecessary openings on the periphery surface are closed, for example by sealing plugs after the channels 14 are formed.
- a vertical inlet passage 22 is formed and connected with the converging point 18 .
- the inlet passage 18 extends upwardly and through the upper surface 24 of the unitary member 16 and connected to a gas source (not shown). Gases are introduced through the inlet passage 22 and distributed into the horizontal channels 14 via the converging point 18 .
- a plurality of outlet passages or holes 26 are formed along the path of the horizontal channels 14 . These outlet holes 26 extend downwardly and through the bottom surface 28 of the unitary member 16 . For clarity and simplicity, only some outlet holes are shown in FIGS. 1 and 2 . It should be noted that numerous horizontal channels and outlet passages or holes along the horizontal channels can be formed. Various patterns and configurations of outlet holes can be designed according to process specifications. The diameter of the outlet holes can be uniform throughout the bottom surface of the showerhead. Alternatively, the diameters of the outlet holes may differ. For example, the diameter of the outlet holes can be larger in the inner region and smaller in the outer region of the showerhead bottom surface to provide uniform back pressure. Any or all of the through outlet holes in the showerhead may include an insert described below to allow modification of the outlet size or diameter and/or the directions of gases exiting the showerhead.
- the insert is designed to be installed onto, for example, a showerhead as illustrated in FIGS. 1 and 2 , to provide a known diameter passageway leading from the internal gas distribution network within the showerhead to the process chamber or region.
- the insert may be a small precision machined part.
- the insert can be made of the same material as the showerhead body. Alternatively, the insert is made of a different material to capitalize on differences in physical properties that is desirable, such as different coefficients of thermal expansion to improve sealing between the insert and the showerhead body when used at elevated temperatures.
- the insert is provided with passageways by any suitable machining method such as drilling, reaming, electrical discharge machining, and the like.
- FIGS. 3 to 6 show a screw type insert 30 according to one embodiment of the invention.
- the insert 30 is provided with threads 32 for engaging the insert 30 with an outlet passage 26 which, in this embodiment, is also provided with threads for receiving the insert 30 .
- the installation is accomplished by screwing the insert 30 into the showerhead outlet 26 until the insert is sufficiently seated to ensure that the gases from the upstream side, i.e., outlet passages, find no route except that through the precision passageway in the insert 30 .
- a cylindrical passageway 34 is formed in the insert 30 and extends through the bottom surface 36 of the insert 30 . When installed, the insert passageway 34 is coaxial and in fluid communication with the outlet passage 26 .
- the diameter of the insert passageway 34 can be varied to tailor gas flow velocity to specific process requirements.
- the insert passageway may have a first portion 38 with a smaller diameter proximate to the gas distribution channel 14 and a second portion 39 with a larger diameter distal to the distribution channel 14 .
- the smaller diameter in the first portion 38 provides a metering function to create uniform back pressure.
- the larger diameter in the second portion 39 allows the reduction of a “jetting” effect of the gas stream and facilitate installation and removal of the insert 30 .
- FIGS. 7 to 10 show a press fit type insert 40 according to another embodiment of the invention. Press fit installation alleviates the need for threaded joining.
- a main passageway 42 is formed in the insert 40 and branched into a plurality of secondary passageways 44 .
- four branch passageways 44 are formed.
- the branch passageways 44 extend through the side surface 46 of the insert 40 .
- Each of the branch passageways 44 are angled from the main passageway 42 in the range from about 10 to 89 degrees.
- the insert main passageway 42 is coaxial with the outlet passage 26 .
- the insert 40 extends out of the bottom surface 28 of the showerhead 10 so that the openings of the branch passageways 42 on the side surface 46 of the insert 40 are positioned outside of the plane of the bottom surface 28 of the showerhead 10 to direct gases into a processing region.
- gases exit the branch passageways 44 in a direction non-perpendicular to the bottom surface 28 of the showerhead 10 or non-perpendicular to a substrate in a process region, for example, in an angle from about 10 to about 89 degrees with respect to the bottom surface 28 .
- This flow pattern minimizes prior art problems of “spotting,” or varying deposition thickness that matches the outlet spacing.
- the gas flow direction or flow pattern can be altered by selectively choosing the angle between the branch passageways 44 and the main passageway 42 .
- FIGS. 11-14 show another press-fit type insert 50 according to one embodiment of the present invention.
- the insert 50 shown in FIGS. 11-14 has a main passageway 52 and four branch passageways 54 intersecting with the main passageway 52 in 90 degrees.
- gases from distribution channels 14 exit the openings of the branch passageways 54 in a direction parallel to the bottom surface 28 of the showerhead 10 .
- FIGS. 15 to 20 show in detail the engagement of a press-fit type insert 60 of the present invention with the outlet 26 in the showerhead 10 .
- the outer diameter (D2) of the insert 60 is slightly larger than the outer diameter (D1) in the non-engagement region 64 .
- a preliminary insert can be sized so that the section in the engagement region is substantially shorter than the section in the non-engagement region (L2 ⁇ L1) to ease installation and removal of the insert. Threading 70 can be provided in the preliminary insert to facilitate installation and removal of the insert 60 .
- the preliminary insert may be removed and replaced with a final insert 72 that has a larger engagement section as illustrated in FIGS. 19 and 20 .
- the engagement section is substantially longer than the non-engagement section (L2>L1).
- a large engagement region between an insert and an outlet minimizes internal gaps or pocket volume and ensure enhanced sealing between the insert and the showerhead.
- FIGS. 21 to 24 show another screw type insert 80 according to one embodiment of the invention.
- the insert 80 has a hexagonal section 82 and cylindrical section 84 .
- the cylindrical section 84 is provided with threads 86 for engaging the insert 80 with the outlet 26 in the showerhead 10 , which is also provided with threads for receiving the insert 80 .
- a main passageway 88 is formed within the cylindrical section 84 and extends into the hexagonal section 82 .
- the main passageway 88 is branched in the hexagonal section 82 into multiple horizontal passageways 90 which extend radially and outwardly.
- the horizontal passageways 90 extend through the side surfaces 92 of the hexagonal section 82 to direct gases into a processing region.
- the hexagonal configuration also provides a tool engagement means for installation and removal of the insert 80 .
- the hexagonal section 82 of the insert extends out of the bottom surface 28 of the showerhead 10 .
- the insert 80 main passageway 88 is coaxial with the outlet passage 26 in the showerhead 10 . Gases flow through the main passageway 88 and change flow directions from vertical to horizontal with respect to the bottom surface 28 of the showerhead 10 as indicated by the arrows in FIG. 24 .
- the inserts of the invention can be placed in any selected outlets to alter the size and/or direction of the gases exiting the apparatus.
- Process results can be used as feedback to change the corresponding inserts to achieve the desired end response.
- the resulting configuration can then be used as is, or used to provide the design criteria to replicate the showerhead in a fixed, non-adjustable version that may be preferred in a production environment in which a minimum of process variables is desired.
Abstract
The present invention provides a gas distribution apparatus comprising a plurality of outlets and at least one replaceable insert placed in at least one of the outlets. The insert is provided with a passageway adapted to alter the size of the at least one of the outlets and/or the direction of gases exiting the at least one of the outlets. The insert is provided with passageway that may be substantial straight and cylindrical. The passageway may have a first portion with a smaller diameter and a second portion with a larger diameter to selectively alter the size of the outlet passage in the gas distribution apparatus. Alternatively, the insert is provided with a main passageway and plurality of secondary passageways branched and angled from the main passageway. The angle between the main and branch passageways is in the range from about 10 to about 90 degrees. In one embodiment, the angle between the main and branch passageways is about 90 degrees.
Description
- This application claims the benefit of and priority to U.S. Provisional Application No. 60/475,079 filed May 30, 2003, the disclosure of which is hereby incorporated by reference in its entirety.
- The present invention relates generally to the field of semiconductor equipment and processing. More specifically, the present invention relates to an adjustable gas distribution apparatus useful in semiconductor fabrication.
- Wafer processing reactor systems and methods are widely used in the manufacture of semiconductors and integrated circuits. One particular type of wafer processing system utilizes chemical vapor deposition (CVD) to deposit films or layers on the surface of a substrate as a step in the manufacture of semiconductors and integrated circuits. As described in the prior art, in chemical vapor deposition in semiconductor device fabrication (or other chemical reactors in which reaction products are desired to deposit or form in certain geometric manifestations), it is often required to modify a gas dispersion device from a simple basic design that imparts changes necessary to achieve a desired end result. Examples of such systems are shown for instance in U.S. Pat. Nos. 6,415,736, 6,410,089, 6,284,673, 6,050,506, 6,184,986 and 6,126,753, among others.
- Atomic layer deposition (ALD) is an alternative to CVD processes to deposit very thin films. ALD can be performed at comparatively lower temperatures which is compatible with the industry's trend toward lower temperatures, has high precursor utilization efficiency, and can produce conformal thin film layers. More advantageously, ALD can control film thickness on an atomic scale, and can be used to “nano-engineer” complex thin films. In an ALD process cycle, each reactant gas is introduced independently into a reaction chamber through, for example a showerhead, so that no gas phase intermixing occurs. A monolayer of a first reactant is physi- or chemisorbed onto a substrate surface. Excess first reactant is evacuated from the reaction chamber preferably with the aid of an inert purge gas. A second reactant is then introduced to the reaction chamber and reacted with the first reactant to form a monolayer of the desired thin film via a self-limiting surface reaction. The self-limiting reaction stops once the initially adsorbed first reactant fully reacts with the second reactant. Excess second reactant is evacuated, preferably with the aid of an inert purge gas. A desired film thickness is obtained by repeating the deposition cycle as necessary. The film thickness can be controlled to atomic layer accuracy by simply counting the number of deposition cycles.
- In many CVD or ALD applications, a simple basic geometry of outlet holes in a gas distribution apparatus does not achieve the required deposition thickness specifications. It has been demonstrated that a constant array of outlet holes or “pitch” does not necessarily create a uniform deposition on a wafer. It is therefore desirable to alter the outlet hole pattern or size to create the desired end effect. One prior art approach is to alter the location and/or size of the outlets to achieve the desired deposition pattern. This approach has had limited success however, as it does not allow for adjustment if further changes are necessary, such as in utilizing the same apparatus for more than one particular process or recipe which may be effected by the outlet configuration. Therefore, further development in gas distribution apparatus useful in CVD and ALD are needed.
- An adjustable gas distribution apparatus useful in semiconductor fabrication is provided. The adjustable gas distribution apparatus of the present invention allows one to alter the size and/or direction of gases exiting the gas distribution apparatus and thus selectively tailor the configuration of the apparatus to achieve a desired end response.
- In one aspect, the present invention provides a gas distribution apparatus comprising a plurality of outlets and at least one replaceable insert placed in at least one of the outlets. The insert is provided with a passageway adapted to alter the size of and/or the direction of gases exiting the at least one of the outlets. The insert can be placed in the outlet by threading. Alternatively, the insert can be placed in the outlet by press fit.
- In one embodiment, the insert is provided with a passageway that is substantially straight and cylindrical. The passageway may have a first portion with a smaller diameter and a second portion with a larger diameter to selectively alter the size of the outlet passage in the gas distribution apparatus.
- In another embodiment, the insert is provided with a main passageway and plurality of secondary passageways branched and angled from the main passageway. The angle between the main and branch passageways is in the range from about 10 to about 90 degrees. In one embodiment, the angle between the main and branch passageways is about 90 degrees.
- In another aspect, the present invention provides a gas distribution apparatus comprising a unitary body having a surface facing a processing region and a plurality of outlet passages formed within the unitary body and extending through the surface for providing gases into the processing region. At least one replaceable insert is placed in at least one of the outlet passages to allow altering the size of at least one of the outlet passages and/or the direction of gases exiting the at least one of the outlet passages into the processing region.
- Other objects and advantages of the present invention become apparent upon reading of the detailed description of the invention provided below and upon reference to the drawings in which:
-
FIG. 1 is external view of a showerhead showing a plurality of through outlet holes in which one or more replaceable inserts of the present invention can be installed. -
FIG. 2 shows an internal gas distribution network within the showerhead as illustrated inFIG. 1 . -
FIG. 3 is a front view of a screw type insert according to one embodiment of the present invention. -
FIG. 4 is a top view of the screw type insert illustrated inFIG. 3 according to one embodiment of the present invention. -
FIG. 5 is a cross-sectional view along line A-A of the screw type insert illustrated inFIG. 4 according to one embodiment of the present invention. -
FIG. 6 is a partial cross-sectional view of a showerhead installed with the insert illustrated inFIGS. 3-5 according to one embodiment of the present invention. -
FIG. 7 is a front view of a press-fit type insert having multiple branch passageways angled from a main passageway according to one embodiment of the present invention. -
FIG. 8 is a top view of the press-fit type insert illustrated inFIG. 7 according to one embodiment of the present invention. -
FIG. 9 is a cross-sectional view along line B-B of the press-fit type insert illustrated inFIG. 8 according to one embodiment of the present invention. -
FIG. 10 is a partial cross-sectional view of a showerhead installed with the press-fit type insert illustrated inFIGS. 7-9 according to one embodiment of the present invention. -
FIG. 11 is a front view of a press-fit type of insert having multiple branch passageways perpendicular to a main passageway according to one embodiment of the present invention. -
FIG. 12 is a top view of the press-fit type insert illustrated inFIG. 11 according to one embodiment of the present invention. -
FIG. 13 is a cross-sectional view along line C-C of the press-fit type insert illustrated inFIG. 12 according to one embodiment of the present invention. -
FIG. 14 is a partial cross-sectional view of a showerhead installed with the press-fit type insert illustrated inFIGS. 11-13 according to one embodiment of the present invention. -
FIG. 15 is a front view of a press-fit type insert showing details of press fit engagement region according to one embodiment of the present invention. -
FIG. 16 is a top view of the press-fit type insert illustrated inFIG. 15 according to one embodiment of the present invention. -
FIG. 17 is a cross-sectional view along line D-D of the press-fit type insert illustrated inFIG. 16 according to one embodiment of the present invention. -
FIG. 18 is a partial cross-sectional view of a showerhead showing engagement details between the press-fit type insert illustrated inFIGS. 15-17 and the outlet in the showerhead according to one embodiment of the present invention. -
FIG. 19 is a front view of a press-fit type insert showing details of press fit engagement region according to one embodiment of the present invention. -
FIG. 20 is a top view of the press-fit type insert illustrated inFIG. 19 according to one embodiment of the present invention. -
FIG. 21 is a front view of a screw type insert showing multiple passageways according to one embodiment of the present invention. -
FIG. 22 is a top view of the screw type insert illustrated inFIG. 21 according to one embodiment of the present invention. -
FIG. 23 is a cross-sectional view along line F-F of the screw type insert illustrated inFIG. 22 according to one embodiment of the present invention. -
FIG. 24 is a partial cross-sectional view of a showerhead installed with the screw type insert illustrated inFIGS. 21-23 according to one embodiment of the present invention. - An adjustable gas distribution apparatus useful in semiconductor fabrication is provided. In general, the adjustable gas distribution apparatus of the present invention comprises a plurality of gas outlets and one or more inserts installed in one or more of the outlets which allow altering of the size of the outlets and/or the direction of gases exiting the gas distribution apparatus and thus selectively tailoring the gas flow velocity and pattern to specific process requirements.
- Referring to the drawings where like components are designated by like reference numerals, the present adjustable gas distribution apparatus is described in more detail.
-
FIG. 1 shows ashowerhead 10 in which one or more inserts of the present invention can be used. It should be noted that theshowerhead 10 shown inFIG. 1 is for illustrative purpose only and not intended to limit the scope of the invention in any way. The inserts described below can be used in any other gas distribution apparatus where adjustment of flow velocity and/or direction of gases exiting the apparatus is desired. Generally, in a showerhead, a plurality of channels, passages or holes are created to form an internal gas distribution network in a member. The member can be a single unitary block within which an internal gas distribution network is formed. The member can also be comprised of several individual blocks, within each of which a plurality of channels, passages or holes are formed. These individual blocks are then connected and assembled as a unit, for example by a plurality of bolts. The channels, passages or holes can be formed by any suitable machining methods such as drillings, reaming and electrical discharge machining, etc. - In particular,
FIG. 1 shows an external view of ashowerhead 10.FIG. 2 shows an internalgas distribution network 12 formed within theshowerhead 10. A plurality ofhorizontal channels 14 are formed in a unitarycylindrical member 16. Theunitary member 16 can be comprised of an aluminum, steel, or nickel-based alloy block, or any other suitable materials. Thesehorizontal channels 14 converge at a convergingpoint 18 and extend radially and outwardly to theperiphery surface 20 of thecylindrical member 16. Theperiphery surface 20 is closed. Thehorizontal channels 14 can be formed by drilling from theperiphery surface 20. The unnecessary openings on the periphery surface are closed, for example by sealing plugs after thechannels 14 are formed. Avertical inlet passage 22 is formed and connected with the convergingpoint 18. Theinlet passage 18 extends upwardly and through theupper surface 24 of theunitary member 16 and connected to a gas source (not shown). Gases are introduced through theinlet passage 22 and distributed into thehorizontal channels 14 via the convergingpoint 18. - A plurality of outlet passages or
holes 26 are formed along the path of thehorizontal channels 14. These outlet holes 26 extend downwardly and through thebottom surface 28 of theunitary member 16. For clarity and simplicity, only some outlet holes are shown inFIGS. 1 and 2 . It should be noted that numerous horizontal channels and outlet passages or holes along the horizontal channels can be formed. Various patterns and configurations of outlet holes can be designed according to process specifications. The diameter of the outlet holes can be uniform throughout the bottom surface of the showerhead. Alternatively, the diameters of the outlet holes may differ. For example, the diameter of the outlet holes can be larger in the inner region and smaller in the outer region of the showerhead bottom surface to provide uniform back pressure. Any or all of the through outlet holes in the showerhead may include an insert described below to allow modification of the outlet size or diameter and/or the directions of gases exiting the showerhead. - The insert is designed to be installed onto, for example, a showerhead as illustrated in
FIGS. 1 and 2 , to provide a known diameter passageway leading from the internal gas distribution network within the showerhead to the process chamber or region. The insert may be a small precision machined part. The insert can be made of the same material as the showerhead body. Alternatively, the insert is made of a different material to capitalize on differences in physical properties that is desirable, such as different coefficients of thermal expansion to improve sealing between the insert and the showerhead body when used at elevated temperatures. The insert is provided with passageways by any suitable machining method such as drilling, reaming, electrical discharge machining, and the like. - FIGS. 3 to 6 show a
screw type insert 30 according to one embodiment of the invention. Theinsert 30 is provided withthreads 32 for engaging theinsert 30 with anoutlet passage 26 which, in this embodiment, is also provided with threads for receiving theinsert 30. The installation is accomplished by screwing theinsert 30 into theshowerhead outlet 26 until the insert is sufficiently seated to ensure that the gases from the upstream side, i.e., outlet passages, find no route except that through the precision passageway in theinsert 30. Acylindrical passageway 34 is formed in theinsert 30 and extends through thebottom surface 36 of theinsert 30. When installed, theinsert passageway 34 is coaxial and in fluid communication with theoutlet passage 26. Gases from theinternal distribution network 12 exit theshowerhead 10 via theinsert 30 in a direction perpendicular to thebottom surface 28 of theshowerhead 10. The diameter of theinsert passageway 34 can be varied to tailor gas flow velocity to specific process requirements. For example, the insert passageway may have afirst portion 38 with a smaller diameter proximate to thegas distribution channel 14 and asecond portion 39 with a larger diameter distal to thedistribution channel 14. The smaller diameter in thefirst portion 38 provides a metering function to create uniform back pressure. The larger diameter in thesecond portion 39 allows the reduction of a “jetting” effect of the gas stream and facilitate installation and removal of theinsert 30. - FIGS. 7 to 10 show a press
fit type insert 40 according to another embodiment of the invention. Press fit installation alleviates the need for threaded joining. Amain passageway 42 is formed in theinsert 40 and branched into a plurality ofsecondary passageways 44. In this embodiment, fourbranch passageways 44 are formed. The branch passageways 44 extend through theside surface 46 of theinsert 40. Each of thebranch passageways 44 are angled from themain passageway 42 in the range from about 10 to 89 degrees. After theinsert 40 is installed, the insertmain passageway 42 is coaxial with theoutlet passage 26. Theinsert 40 extends out of thebottom surface 28 of theshowerhead 10 so that the openings of the branch passageways 42 on theside surface 46 of theinsert 40 are positioned outside of the plane of thebottom surface 28 of theshowerhead 10 to direct gases into a processing region. In this embodiment, gases exit the branch passageways 44 in a direction non-perpendicular to thebottom surface 28 of theshowerhead 10 or non-perpendicular to a substrate in a process region, for example, in an angle from about 10 to about 89 degrees with respect to thebottom surface 28. This flow pattern minimizes prior art problems of “spotting,” or varying deposition thickness that matches the outlet spacing. By modifying the flow directions, the downward momentum of the gas stream entering the process region is reduced, and as a result gases are more evenly distributed in the process region. Accordingly, the gas flow direction or flow pattern can be altered by selectively choosing the angle between thebranch passageways 44 and themain passageway 42. -
FIGS. 11-14 show another press-fit type insert 50 according to one embodiment of the present invention. As compared to theinsert 40 illustrated inFIGS. 7-10 , theinsert 50 shown inFIGS. 11-14 has amain passageway 52 and fourbranch passageways 54 intersecting with themain passageway 52 in 90 degrees. When theinsert 50 is installed, gases fromdistribution channels 14 exit the openings of the branch passageways 54 in a direction parallel to thebottom surface 28 of theshowerhead 10. - FIGS. 15 to 20 show in detail the engagement of a press-
fit type insert 60 of the present invention with theoutlet 26 in theshowerhead 10. In theengagement region 62, the outer diameter (D2) of theinsert 60 is slightly larger than the outer diameter (D1) in thenon-engagement region 64. In a testing or trial stage, a preliminary insert can be sized so that the section in the engagement region is substantially shorter than the section in the non-engagement region (L2<L1) to ease installation and removal of the insert. Threading 70 can be provided in the preliminary insert to facilitate installation and removal of theinsert 60. Once the desired insert passageway size is determined, the preliminary insert may be removed and replaced with afinal insert 72 that has a larger engagement section as illustrated inFIGS. 19 and 20 . In thefinal insert 72, the engagement section is substantially longer than the non-engagement section (L2>L1). A large engagement region between an insert and an outlet minimizes internal gaps or pocket volume and ensure enhanced sealing between the insert and the showerhead. - FIGS. 21 to 24 show another
screw type insert 80 according to one embodiment of the invention. Theinsert 80 has ahexagonal section 82 andcylindrical section 84. Thecylindrical section 84 is provided withthreads 86 for engaging theinsert 80 with theoutlet 26 in theshowerhead 10, which is also provided with threads for receiving theinsert 80. Amain passageway 88 is formed within thecylindrical section 84 and extends into thehexagonal section 82. Themain passageway 88 is branched in thehexagonal section 82 into multiplehorizontal passageways 90 which extend radially and outwardly. Thehorizontal passageways 90 extend through the side surfaces 92 of thehexagonal section 82 to direct gases into a processing region. The hexagonal configuration also provides a tool engagement means for installation and removal of theinsert 80. Once theinsert 80 is installed, thehexagonal section 82 of the insert extends out of thebottom surface 28 of theshowerhead 10. Theinsert 80main passageway 88 is coaxial with theoutlet passage 26 in theshowerhead 10. Gases flow through themain passageway 88 and change flow directions from vertical to horizontal with respect to thebottom surface 28 of theshowerhead 10 as indicated by the arrows inFIG. 24 . - Advantageously, the inserts of the invention can be placed in any selected outlets to alter the size and/or direction of the gases exiting the apparatus. Process results can be used as feedback to change the corresponding inserts to achieve the desired end response. The resulting configuration can then be used as is, or used to provide the design criteria to replicate the showerhead in a fixed, non-adjustable version that may be preferred in a production environment in which a minimum of process variables is desired.
- As described above, an adjustable gas distribution apparatus has been provided by the present invention. The foregoing description of specific embodiments of the invention have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications, embodiments, and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.
Claims (23)
1. A gas distribution apparatus, comprising:
a body having a surface facing a processing region,
a plurality of outlet passages formed within the body and extending through the surface for providing gases into the processing region; and
at least one replaceable insert placed in at least one of the outlet passages, said insert is provided with a passageway adapted to alter the size of the at least one of the outlet passages and/or the direction of gases exiting the at least one of the outlet passages into the processing region.
2. The apparatus of claim 1 wherein said insert passageway is substantially cylindrical.
3. The apparatus of claim 1 wherein the insert passageway comprises a first portion having a smaller diameter and a second portion having a greater diameter.
4. The apparatus of claim 1 wherein said insert passageway is coaxial with the passage of the outlet placed with the insert.
5. The apparatus of claim 1 wherein the insert passageway comprises a first portion coaxial with the passage of the outlet placed with the insert and a plurality of second portions branched and angled from the first portion for directing the gases into the processing region.
6. The apparatus of claim 5 wherein said second portions of the insert passageway are angled from the first portion in the range from about 10 to about 90 degrees.
7. The apparatus of claim 5 wherein said second portions of the insert passageway are perpendicular to the first portion.
8. The apparatus of claim 5 wherein said second portions of the insert passageway are in parallel to the surface of the unitary body.
9. The apparatus of claim 1 wherein said outlet passages are substantially cylindrical.
10. The apparatus of claim 9 wherein said outlet passages comprises a first portion having a smaller diameter and a second portion having a greater diameter.
11. The apparatus of claim 1 wherein the insert is placed in the outlet passage by press fit.
12. The apparatus of claim 1 wherein the outlet passage and insert are provided with threads and the insert is placed in the outlet passage by threading.
13. The apparatus of claim 12 , wherein the insert comprises means for engaging installment tools.
14. A gas distribution apparatus, comprising a plurality of outlets and at least one replaceable insert placed in at least one of the outlets, said insert is provided with a passageway adapted to alter the size of and/or the direction of gases exiting the at least one of the outlets.
15. The apparatus of claim 14 wherein the insert passageway is substantially cylindrical.
16. The apparatus of claim 14 wherein the insert passageway is coaxial with the outlet placed with the insert.
17. The apparatus of claim 15 wherein the insert passageway comprises a first portion having a smaller diameter and a second portion having a greater diameter.
18. The apparatus of claim 14 wherein the insert passageway comprises a first portion coaxial with the outlet placed with the insert and a plurality of second portions branched and angled from the first portion.
19. The apparatus of claim 18 wherein said second portions of the insert passageway are angled from the first portion in the range from about 10 to about 90 degree.
20. The apparatus of claim 18 wherein said second portions of the insert passageway are perpendicular to the first portion.
21. The apparatus of claim 14 wherein the insert is placed in the outlet by press fit.
22. The apparatus of claim 14 wherein the outlet and insert are provided with threads and the insert is placed in the outlet by screwing.
23. The apparatus of claim 22 , wherein the insert is provided with means for engaging installation tools.
Priority Applications (1)
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US10/856,584 US20050109460A1 (en) | 2003-05-30 | 2004-05-27 | Adjustable gas distribution system |
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US47507903P | 2003-05-30 | 2003-05-30 | |
US10/856,584 US20050109460A1 (en) | 2003-05-30 | 2004-05-27 | Adjustable gas distribution system |
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US20050109460A1 true US20050109460A1 (en) | 2005-05-26 |
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US10/856,584 Abandoned US20050109460A1 (en) | 2003-05-30 | 2004-05-27 | Adjustable gas distribution system |
US11/142,087 Abandoned US20050217580A1 (en) | 2003-05-30 | 2005-05-31 | Gas distribution system |
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US11/142,087 Abandoned US20050217580A1 (en) | 2003-05-30 | 2005-05-31 | Gas distribution system |
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EP (2) | EP1629522A4 (en) |
JP (2) | JP2007525822A (en) |
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CN (2) | CN101068950A (en) |
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WO (2) | WO2004109761A2 (en) |
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Also Published As
Publication number | Publication date |
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KR20060011887A (en) | 2006-02-03 |
EP1629527A2 (en) | 2006-03-01 |
WO2004109761A2 (en) | 2004-12-16 |
WO2004112092A3 (en) | 2005-09-15 |
CN101068950A (en) | 2007-11-07 |
EP1629522A2 (en) | 2006-03-01 |
WO2004109761A3 (en) | 2006-12-14 |
EP1629522A4 (en) | 2008-07-23 |
US20050217580A1 (en) | 2005-10-06 |
CN1830069A (en) | 2006-09-06 |
JP2006526900A (en) | 2006-11-24 |
US6921437B1 (en) | 2005-07-26 |
TW200507023A (en) | 2005-02-16 |
TW200510564A (en) | 2005-03-16 |
WO2004112092A2 (en) | 2004-12-23 |
JP2007525822A (en) | 2007-09-06 |
KR20060003909A (en) | 2006-01-11 |
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