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Title: PLASMA%20MATERIALS%20PROCESSING:


1
PLASMA MATERIALS PROCESSING CREATING HIGH
VALUE Mark J. Kushner Iowa State University 104
Marston Hall Ames, IA 50011 mjk_at_iastate.edu http/
/uigelz.ece.iastate.edu January 2005
ISU_0105_01
2
ACKNOWLEDGEMENTS
  • Dr. Alex V. Vasenkov (now at CFD Research Corp.)
  • Dr. Gottlieb Oherlein (U of Maryland)
  • Dr. Arvind Sankaran (now at Novellus Systems)
  • Dr. Pramod Subramonium (now at Novellus Systems)
  • Dr. Rajesh Dorai (now at Varian Semiconductor
    Equipment)
  • Mr. Ananth Bhoj
  • Mr. Ramesh Arakoni
  • Funding Agencies
  • 3M Corporation
  • Semiconductor Research Corporation
  • National Science Foundation
  • SEMATECH
  • CFDRC Inc.

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Physics
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AGENDA
  • Introduction to Plasmas
  • Extremes in Physics and Applications
  • Plasmas for functionalization of polymers
    (0.05/m2)
  • Polymers for selectivity in plasma etching
    (1000/cm2)
  • Challenges for adapting commodity processes for
    high value materials.
  • Concluding Remarks

Iowa State University Optical and Discharge
Physics
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PLASMAS 101 INTRODUCTION
  • Plasmas (ionized gases) are often called the
    fourth state of matter.
  • Plasmas account for gt 99.9 of the mass of the
    known universe (dark matter aside).
  • X-ray view of the sun, a plasma.

http//www.plasmas.org/basics.htm
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Physics
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PARTIALLY IONIZED PLASMAS
  • A gas (collection of atoms or molecules) is
    neutral on a local and global basis.
  • An energetic free electron collides with an atom,
    creating a positive ion and another free electron.

Iowa State University Optical and Discharge
Physics
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PARTIALLY IONIZED PLASMAS
  • The resulting partially ionized gas is not
    neutral on a microscopic scale, but is neutral
    on a global scale.
  • An air plasma N2, O2, N2, O2, O-, e where e
    ltlt Neutrals
  • A plasma that ionizes itself at the same rate
    electrons and ions neutralize is self
    sustaining.

Iowa State University Optical and Discharge
Physics
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TECHNOLOGICAL PLASMAS
  • Technological plasmas have electron temperatures
    of a few eV and electron densities of 1010-1014
    cm-3. The gas usually remains cool.

Iowa State University Optical and Discharge
Physics
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ELECTRONS AS AN ENERGY TRANSFER MEDIUM
  • Electrons transfer power from the "wall plug" to
    internal modes of atoms / molecules dissociating
    and exciting them, very much like combustion.
  • These activated species can them be used to make
    a product.

Iowa State University Optical and Discharge
Physics
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COLLISIONAL LOW TEMPERATURE PLASMAS
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PLASMAS FOR MODIFICATION OF SURFACES
  • Plasmas are ideal for producing reactive species
    (radicals, ions) for modifying surface
    properties.
  • Two of the most technologically (and
    commercially) important uses of plasmas add or
    remove molecules from surfaces to selectively
    achieve desired functionality (mechanical or
    chemical)
  • .
  • Functionalization of polymers (high pressure)
  • Etching for microelectronics fabrication (low
    pressure)

Iowa State University Optical and Discharge
Physics
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EXTREMES IN CONDITIONS, VALUES, APPLICATIONS
Web Treatment of Films
Microelectronics
  • High pressure
  • High throughput
  • Low precision
  • Modify cheap materials
  • Commodity
  • Low pressure
  • Low throughput
  • High precision
  • Grow expensive materials
  • High tech

Iowa State University Optical and Discharge
Physics
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CREATING HIGH VALUE COMMODITY PROCESSES
  • Can commodity processes be used to fabricate high
    value materials?
  • Where will, ultimately, biocompatible polymeric
    films fit on this scale? Artificial skin for
    0.05/cm2 or 1000/cm2?

Iowa State University Optical and Discharge
Physics
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LOW COST, COMMODITY FUNCTIONALIZATION OF POLYMERS
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SURFACE ENERGY AND FUNCTIONALITY OF POLYMERS
  • Most polymers, having low surface energy, are
    hydrophobic.
  • For good adhesion and wettability, the surface
    energy of the polymer should exceed of the
    overlayer by ?2-10 mN m-1.

Iowa State University Optical and Discharge
Physics
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PLASMA SURFACE MODIFICATION OF POLYMERS
  • To improve wetting and adhesion of polymers
    atmospheric plasmas are used to generate
    gas-phase radicals to functionalize their
    surfaces.
  • Massines et al. J. Phys. D 31, 3411 (1998).

Iowa State University Optical and Discharge
Physics
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POLYMER TREATMENT APPARATUS
  • Filamentary Plasma 10s 200 mm

Iowa State University Optical and Discharge
Physics
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COMMERCIAL CORONA PLASMA EQUIPMENT
  • Sherman Treaters
  • Tantec, Inc.

Iowa State University Optical and Discharge
Physics
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FUNCTIONALIZATION OF THE PP SURFACE
  • Untreated PP is hydrophobic.
  • Increases in surface energy by plasma treatment
    are attributed to the functionalization of the
    surface with hydrophilic groups.
  • Carbonyl (-CO) ? Alcohols (C-OH)
  • Peroxy (-C-O-O) ? Acids ((OH)CO)
  • The degree of functionalization depends on
    process parameters such as gas mix, energy
    deposition and relative humidity (RH).

Iowa State University Optical and Discharge
Physics
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PLASMA PRODUCED WETTABILITY
  • Increases in wettability with plasma treatment
    result from formation of surface hydrophilic
    groups such as C-O-O (peroxy), CO (carbonyl).
  • Polyethylene, Humid-air
  • Polypropylene, Air corona
  • Akishev, Plasmas Polym. 7, 261 (2002).
  • Boyd, Macromol., 30, 5429 (1997).

Iowa State University Optical and Discharge
Physics
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REACTION PATHWAY
Iowa State University Optical and Discharge
Physics
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GLOBAL_KIN AND SURFACE KINETICS
  • Reaction mechanisms in pulsed atmospheric air
    plasma treatment of polymers have been
    investigated with global kinetics and surface
    models.
  • GLOBAL_KIN
  • 2-Zone homogeneous plasma chemistry (bulk plasma,
    boundary layer)
  • Plug flow
  • Multilayer surface site balance model
  • Circuit module
  • Boltzmann derived f(?)

Iowa State University Optical and Discharge
Physics
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REACTION MECHANISM FOR HUMID-AIR PLASMA
  • Initiating radicals are O, N, OH, H
  • Gas phase products include O3, N2O, N2O5, HNO2,
    HNO3.

Iowa State University Optical and Discharge
Physics
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POLYPROPYLENE (PP) POLYMER STRUCTURE
  • Three types of carbon atoms in a PP chain
  • Primary bonded to 1 C atom
  • Secondary bonded to 2 C atoms
  • Tertiary bonded to 3 C atoms
  • The reactivity of an H-atom depends on the type
    of C bonding. Reactivity scales as
  • HTERTIARY gt HSECONDARY gt HPRIMARY

Iowa State University Optical and Discharge
Physics
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PP SURFACE REACTION MECHANISM INITIATION
  • The surface reaction mechanism has initiation,
    propagation and termination reactions.
  • INITIATION O and OH abstract H from PP to
    produce alkyl radicals and gas phase OH and H2O.

Iowa State University Optical and Discharge
Physics
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PP SURFACE REACTION MECHANISM PROPAGATION
  • PROPAGATION Abundant O2 reacts with alkyl groups
    to produce stable peroxy radicals. O3 and O
    react to form unstable alkoxy radicals.

Iowa State University Optical and Discharge
Physics
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PP SURFACE REACTIONS PROPAGATION / AGING
  • PROPAGATION / AGING Peroxy radicals abstract H
    from the PP chain, resulting in hydroperoxide,
    processes which take seconds to 10s minutes.

Iowa State University Optical and Discharge
Physics
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PP SURFACE REACTION MECHANISM TERMINATION
  • TERMINATION Alkoxy radicals react with the PP
    backbone to produce alcohols and carbonyls.
    Further reactions with O eventually erodes the
    film.

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Physics
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BASE CASE ne, Te
  • Ionization is dominantly of N2 and O2,
  • e N2 ? N2 e e,
  • e O2 ? O2 e e.
  • After a few ns current pulse, electrons decay by
    attachment (primarily to O2).
  • Dynamics plasma-dielectric interaction enable
    more efficient ionization on later pulses.
  • N2/O2/H2O 79/20/1, 300 K
  • 15 kV, 9.6 kHz, 0.8 J-cm-2
  • Web speed 250 cm/s (460 pulses)

Iowa State University Optical and Discharge
Physics
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GAS-PHASE RADICALS O, OH
  • Electron impact dissociation of O2 and H2O
    produces O and OH. O is consumed primarily to
    form O3 OH is consumed by both bulk and surface
    processes.
  • After 100s of pulses, radicals attain a periodic
    steady state.
  • O
  • OH
  • N

Iowa State University Optical and Discharge
Physics
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PP SURFACE GROUPS vs ENERGY DEPOSITION
  • Surface concentrations of alcohols, peroxy
    radicals are near steady state with a few J-cm-2.
  • Alcohol densities decrease at higher J-cm-2
    energy due to decomposition by O and OH to
    regenerate alkoxy radicals.
  • Air, 300 K, 1 atm, 30 RH
  • Ref L-A. Ohare et al.,
  • Surf. Interface Anal. 33, 335 (2002).

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Physics
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HUMIDITY PP FUNCTIONALIZATION BY OH
  • Increasing RH produces OH which react with PP to
    form alkyl radicals, which are rapidly converted
    to peroxy radicals by O2.
  • PP-H OH(g) ? PP? H2O(g) PP? O2(g) ?
    PP-O2?
  • Alcohol and carbonyl densities decrease due to
    increased consumption by OH to form alkoxy
    radicals and acids.

PP-OH OH(g)?PP-O? H2O(g) , PPO? OH(g)
? (OH)PPO
Iowa State University Optical and Discharge
Physics
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COMMODITY TO HIGH VALUE
  • As the material value increases (cents to dollars
    /cm2?) higher process refinement is justified to
    customize functionalization.
  • Control of O to O3 ratio using He/O2 mixtures can
    be used to customize surface functionalization.
  • 1 atm, He/O2, 15 kV, 3 mm, 9.6 kHz, 920 pulses.

Iowa State University Optical and Discharge
Physics
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COMMODITY TO HIGH VALUE
  • Additional tuning of functionalization can be
    achieved with sub-mTorr control of water content.
  • Small water addition tuning of
    functionalization can be achieved with sub-mTorr
    control of water content.
  • H and OH reduce O3 while promoting acid
    formation.
  • 1 atm, He/O2/ H2O, 15 kV, 3 mm,
  • 9.6 kHz, 920 pulses.

Iowa State University Optical and Discharge
Physics
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HIGH COST, UTILIZATION OF POLYMERS IN
MICROELECTRONICS FABRICATION
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PLASMAS IN MICROELECTRONICS FABRICATION
  • Plasmas play a dual role in microelectronics
    fabrication.
  • First, electron impact on otherwise unreactive
    gases produces neutral radicals and ions.
  • These species then drift or diffuse to surfaces
    where they add, remove or modify materials.

Iowa State University Optical and Discharge
Physics
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PLASMAS IN MICROELECTRONICS FABRICATION
  • Second, ions deliver directed activation energy
    to surfaces fabricating fine having extreme and
    reproducible tolerances.
  • 0.25 ?m Feature
  • (C. Cui, AMAT)

Iowa State University Optical and Discharge
Physics
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APPLIED MATERIALS DECOUPLED PLASMA SOURCES (DPS)
Iowa State University Optical and Discharge
Physics
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rf BIASED INDUCTIVELY COUPLED PLASMAS
  • Inductively Coupled Plasmas (ICPs) with rf
    biasing are used here.
  • lt 10s mTorr, 10s MHz, 100s W kW, electron
    densities of 1011-1012 cm-3.

Iowa State University Optical and Discharge
Physics
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SELECTIVITY IN MICROELECTRONICS FABRICATION
  • Fabricating complex microelectronic structures
    made of different materials requires extreme
    selectivity in, for example, etching Si with
    respect to SiO2.
  • Complex features are fabricated by selectively
    removing one material but not another with near
    monolayer resolution.
  • Ref G. Timp
  • AMD 90 nm Athlon 64

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Physics
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FLUOROCARBON PLASMA ETCHING SELECTIVITY
  • Selectivity in fluorocarbon etching relies on
    polymer deposition from dissociation of feedstock
    gases.
  • Compound dielectrics contain oxidants which
    consume the polymer, producing thinner polymer
    layers.
  • Thicker polymer on non-dielectrics restrict
    delivery of ion energy (lower etching rates).

Iowa State University Optical and Discharge
Physics
  • G. Oerhlein, et al., JVSTA 17, 26 (1999)

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MODELING OF FLUOROCARBON PLASMA ETCHING
  • Our research group has developed an integrated
    reactor and feature scale modeling hierarchy to
    model plasma processing systems.
  • MCFPM (Monte Carlo Feature Profile Model)
  • Feature scale
  • 2- and 3-dimensional
  • Fluxes from HPEM
  • First principles
  • HPEM (Hybrid Plasma Equipment Model)
  • Reactor scale
  • 2- and 3-dimensional
  • ICP, CCP, MERIE, ECR
  • Surface chemistry
  • First principles

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Physics
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ELECTROMAGNETICS AND ELECTRON KINETICS
  • The wave equation is solved in the frequency
    domain using tensor conductivities and sparse
    matrix techniques
  • Electron energy transport Continuum and Kinetics
  • where S(Te) Power deposition from electric
    fields L(Te) Electron power loss due to
    collisions ? Electron flux
  • ?(Te) Electron thermal conductivity tensor
  • SEB Power source source from beam electrons
  • Kinetic MCS is used to derive
    including e-e collisions using electromagnetic
    and electrostatic fields .

Iowa State University Optical and Discharge
Physics
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PLASMA CHEMISTRY, TRANSPORT AND ELECTROSTATICS
  • Continuity, momentum and energy equations are
    solved for each species (with jump conditions at
    boundaries).
  • Implicit solution of Poissons equation

Iowa State University Optical and Discharge
Physics
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ION/NEUTRAL ENERGY/ANGULAR DISTRIBUTIONS
  • MC methods are used to obtain energy and angular
    distributions of particles striking surfaces.
  • Ar/C4F8, 40 mTorr, 10b MHz, MERIE

Iowa State University Optical and Discharge
Physics
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MONTE CARLO FEATURE PROFILE MODEL (MCFPM)
  • The MCFPM predicts profiles using energy and
    angularly resolved neutral and ion fluxes
    obtained from equipment scale models.
  • Arbitrary reaction mechanisms may be implemented
    (thermal and ion assisted, sputtering, deposition
    and surface diffusion).
  • Mesh centered identify of materials allows
    burial, overlayers and transmission of energy
    through materials.

Iowa State University Optical and Discharge
Physics
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GAS PHASE REACTION MECHANISM Ar/c-C4F8/O2/CO
  • To achieve selectivity, gas mixtures are complex
    Ar/c-C4F8/O2/CO.
  • Refs
  • G. I. Font, J. Appl. Phys 91, 3530 (2002).
  • C. Q. Jiao, Chem. Phys. Lett. 297, 121 (1998).

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Physics
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SURFACE KINETICS FLUOROCARBON PLASMA ETCHING
Si/SiO2
  • CxFy passivation regulates delivery of precursors
    and activation energy.
  • Chemisorption of CFx produces a complex at the
    oxide-polymer interface.
  • 2-step ion activated (through polymer layer)
    etching of the complex consumes the polymer.
    Activation scales inversely with polymer
    thickness.
  • Etch precursors and products diffuse through the
    polymer layer.
  • In Si etching, CFx is not consumed, resulting in
    thicker polymer layers.

Iowa State University Optical and Discharge
Physics
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PLASMA PROPERTIES ICPs IN Ar/c-C4F8/CO/O2
  • In mixtures typically used for dielectric etch
    c-C4F8 has a low mole fraction.
  • Ions are dominated by Ar having temperatures
    near 1 eV in presheaths.
  • Te has large gradients due to collisional nature
    of plasma.
  • Ar/c-C4F8/CO/O2 60/5/25/10, 10 mTorr, 600 W,
    13.56 MHz, 20 sccm.

Iowa State University Optical and Discharge
Physics
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PLASMA PROPERTIES ICPs IN Ar/c-C4F8/CO/O2
  • M- are dominated by F- due to charge exchange
    with CFn- .
  • Densities of CmFn are commensurate with CFn.
  • Ratios critically depend on power, wall reactions
    and charge exchange with Ar.
  • Ar/c-C4F8/CO/O2 60/5/25/10, 10 mTorr, 600 W,
    13.56 MHz, 20 sccm.

Iowa State University Optical and Discharge
Physics
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MIXTURES Ar/c-C4F8, O2/c-C4F8
  • Flux of ions to surface can be tuned by choice of
    additives.
  • Addition of Ar to C4F8 produces more ions that
    are on average less chemically reactive.
  • Addition of O2 adds oxidizing ions without
    changing fluorocarbon reactivity.
  • Te decreases with Ar and O2 as ionization is more
    efficient.
  • 10 mTorr, 600 W, 13.56 MHz, 40 sccm.

Iowa State University Optical and Discharge
Physics
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TEL-DRM Ar / C4F8 / O2 IEADs FOR 2000 W
  • Complex gas mixtures produce a large variety of
    ion energy and angular distributions.
  • Ar/C4F8/O2 200/10/5 sccm, 40 mTorr, 2000 W, 100
    G

Iowa State University Optical and Discharge
Physics
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ETCH RATES C2F6, C4F8, CHF3
  • Due to small differences in the composition of
    the flux of radicals and polymer, and ion energy
    distributions, etching characteristics differ
    with feedstock gases.
  • Experiments Schaepkens et al J. Vac. Sci.
    Technol. A 17, 26 (1999) Oehrlein et al private
    communications

Iowa State University Optical and Discharge
Physics
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POLYMERIZATION PRODUCES SELECTIVITY
  • Highly optimized processes produce nearly
    infinite selectivity. The underlying Si does not
    consume the polymer, and so etches slower.
  • 10 mTorr, C2F6.

Iowa State University Optical and Discharge
Physics
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C4F8/Ar and C4F8/O2
  • Larger ionization rates result in larger ion
    fluxes in Ar/C4F8 mixtures which reduces polymer
    thickness.
  • With high Ar, the polymer thins to sub-monolayer
    (less deposition, more sputtering). Etch rates
    decrease.
  • O2 etches polymer and reduces its thickness. Rate
    has a maximum with O2, similar to Ar addition.
  • 40 sccm, 600 W ICP, 20 mTorr, -125 V self-bias

Iowa State University Optical and Discharge
Physics
Li et al, J. Vac. Sci. Technol. A 20, 2052, 2002.
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POROUS Si FOR LOW-K DIELECTRIC
  • As feature sizes decrease and device count
    increases, the diameter of interconnect wires
    shrinks and path length increases.
  • Larger RC-delay limits performance.
  • Low-dielectric constant materials reduce RC.
  • Porous SiO2 (xerogels) have low-k properties due
    to their lower mass density resulting from
    (vacuum) pores.
  • Porosities 30-70
  • Pore sizes 2-20 nm
  • Ref S. Rossnagel, IBM

Iowa State University Optical and Discharge
Physics
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PROCESSING OF NANOSTRUCTURED MATERIALS
  • The opening of pores during etching of porous
    SiO2 results in the filling of the voids with
    polymer, creating thicker layers.
  • Ions which would have otherwise hit at grazing or
    normal angle now intersect with more optimum
    angle.
  • An important parameter is
  • L/a (polymer thickness / pore radius).
  • Adapted Standaert, JVSTA 18, 2742 (2000)

Iowa State University Optical and Discharge
Physics
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PORE FILLING BY POLYMER
  • Polymer deposition is activated by low energy
    ions.
  • Polymer removal is activated by high energy ions.
  • Low energy fluxes penetrate into pores activating
    polymer deposition
  • Pore filling locally increases depth of polymer.
  • Etching proceeds through a series of break
    throughs, pore-filling, and polymer removal.
  • 15 nm, 60 porosity
  • ICP CHF3, 6 mTorr, 1400 W

Iowa State University Optical and Discharge
Physics
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EFFECT OF PORE RADIUS ON HAR TRENCHES
4 nm
16 nm
10 nm
  • With increase in radius, thicker polymer layers
    are produced in the pores causing a decrease in
    etch rates.

Iowa State University Optical and Discharge
Physics
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HAR PROFILES INTERCONNECTED PORES
100
60
0
Interconnectivity
  • Higher porosities, larger pores and higher
    interconnectivity, filling of pores produces
    thicker polymer layers and lower etch rates.

Iowa State University Optical and Discharge
Physics
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EFFECT OF PORE RADIUS ON CLEANING
  • Larger pores have poor view angles to ions and
    thicker polymer layers.
  • Lower rate of cleaning results.

4 nm
16 nm
  • Ar/O299/1, 40 sccm, 600 W, 4 mTorr

Iowa State University Optical and Discharge
Physics
ANIMATION SLIDE
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THE CHALLENGE COMMODITY PROCESSING FOR HIGH
VALUE MATERIALS
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THE ROLE OF PLASMAS IN BIOSCIENCE
  • Plasmas, to date, have played important but
    limited roles in bioscience.
  • Plasma sterilization
  • Plasma source ion implantation for hardening hip
    and knee replacements.
  • Modification of surfaces for biocompatibility (in
    vitro and in vivo)
  • Artificial skin
  • The potential for commodity use of plasmas for
    biocompatibility is untapped.
  • Low pressure rf H2O2 plasma (www.sterrad.com)

Iowa State University Optical and Discharge
Physics
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HIGH VALUE PROCESSING - CELL MICROPATTERNING
  • PEO - polyethyleneoxide
  • pdAA plasma deposited acrylic acid
  • Low pressure microelectronics-like plasmas are
    used to pattern selective substrate regions with
    functional groups for cell adhesion.
  • These processes have costs commensurate with
    microelectronics high value, high cost.

1Andreas Ohl, Summer School, Germany (2004).
Iowa State University Optical and Discharge
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ATMOSPHERIC PRESSURE PLASMAS THE CHALLENGE
  • 10,000 square miles of polymer sheets are
    functionalized annually with atmospheric pressure
    plasmas. Cost lt 0.05 /m2
  • Low pressure plasma processing technologies
    produce biocompatible polymers having similar
    functionalities. Cost up to 100s /cm2.
  • Microelectronic plasma processing produces
    functionality at the nanoscale.
  • Can these knowledge bases be combined?
  • Can commodity, atmospheric pressure processing
    technology be leveraged to produce high value
    biocompatible films at low cost? The impact on
    health care would be large.

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Physics
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DESCRIPTION OF nonPDPSIM CHARGED PARTICLE,
SOURCES
  • Continuity (sources from electron and heavy
    particle collisions, surface chemistry,
    photo-ionization, secondary emission), fluxes by
    modified Sharfetter-Gummel with advective flow
    field.
  • Poissons Equation for Electric Potential
  • Electron energy equation
  • Photoionization, electric field and secondary
    emission

Iowa State University Optical and Discharge
Physics
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DESCRIPTION OF nonPDPSIM NEUTRAL PARTICLE
TRANSPORT
  • Fluid averaged values of mass density, mass
    momentum and thermal energy density obtained in
    using unsteady algorithms.
  • Individual fluid species diffuse in the bulk
    fluid.

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Physics
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CAN COMMODITY PROCESSES PRODUCE HIGH VALUE
MATERIALS?
  • 2 mm gap, 15 kV pulse, N2/O2/H2O 79.5 / 19.5 /
    1, 1 atm
  • Tantec, Inc.
  • van Veldhuizen et al

Iowa State University Optical and Discharge
Physics
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POTENTIAL, ELECTRIC FIELD, CHARGE
Animation Slide
  • Pulse is initiated with electron emission from
    tip of cathode.
  • Development of plasma streamer deforms potential
    producing large electric field. Pulse is
    terminated with dielectric charging.
  • E/N
  • Potential
  • Charge
  • N2/O2/H2O 79.5 / 19.5 / 1, 1 atm,
  • 15 kV, 0-15 ns

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ELECTRON TEMPERATURE, SOURCES
Animation Slide
  • Electric field at head of streamer elevates
    electron temperature, producing a transitory wave
    of ionization. 2-body attachment occurs in high
    Te regions 3-body attachment in low Te.
  • Net Attachment
  • Net Ionization
  • Te
  • N2/O2/H2O 79.5 / 19.5 / 1, 1 atm,
  • 15 kV, 0-15 ns

Iowa State University Optical and Discharge
Physics
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ELECTRON AND ION DENSITIES
Animation Slide
  • Electrons are consumed by 3-body attachment at
    the end of the pulse.
  • e
  • M
  • M-
  • N2/O2/H2O 79.5 / 19.5 / 1, 1 atm,
  • 15 kV, 0-15 ns

Iowa State University Optical and Discharge
Physics
ISU_0105_76
71
POST PULSE RADICAL DENSITIES
  • Radical and ion densities at end of pulse are as
    high as 10s ppm. Temperature rise is nominal due
    to short pulse duration.
  • H, OH
  • O
  • O2(1?)
  • N2(A)
  • N2/O2/H2O 79.5 / 19.5 / 1, 1 atm,
  • 15 kV, 0-15 ns

Iowa State University Optical and Discharge
Physics
ISU_0105_77
72
SURFACE INTERACTIONS ELECTRON DENSITY
2x109- 2x1011
2x1010- 2x1012
? Electrons penetrate surface features on the
polymer to a limited extent due to surface
charging.
? -15 kV, 760 Torr, N2/O2/H2O79.5/19.5/1
e cm-3
MIN (log scale) MAX
1.45 ns
1.5 ns
1.65 ns

2x1011- 2x1013
1x1011- 5x1013
Iowa State University Optical and Discharge
Physics
10 mm
ISU_0105_79
73
SURFACE INTERACTIONS O DENSITY
1x109- 1x1012
5x1010- 5x1013
? Radicals striking the surface penetrate into
the features by diffusion. ? Unlike ions, the
transport of radicals into features is unimpeded
by surface charging
? -15 kV, 760 Torr, N2/O2/H2O79.5/19.5/1
1.5 ns
1.4 ns
4.0 ns
1.65 ns
7.0 ns

O cm-3
MIN (log scale) MAX
10 mm
1x1011- 1x1014
Iowa State University Optical and Discharge
Physics
ISU_0105_80
74
FUNCTIONAL GROUP DENSITIES ON POLYPROPYLENE
  • 1 atm, N2/O2/H2O79.5/19.5/1, 1.5 ms, 10 kHz.

Iowa State University Optical and Discharge
Physics
ISU_0105_81
75
FUNCTIONALIZATION OF SCAFFOLDING
  • ? Functionalization of scaffolding-like surfaces
    for cell adhesion.
  • Can uniformity of functionalization be maintained
    over microscopic and macroscopic scale lengths.
  • Use 1 atm, He/O2/H2O mixtures to optimize.

Iowa State University Optical and Discharge
Physics
ISU_0105_82
76
FUNCTIONALIZING PP SCAFFOLDING HIGH O2
(He/O2/H2O 69/30/1)
  • High O2 produces O3 and rapid alkoxy formation.
  • Reactivity of O3 limits transport and produces
    long- and short-scale nonuniformities.

? 1 atm, He/O2/H2O 69/30/1
Iowa State University Optical and Discharge
Physics
ISU_0105_83
77
FUNCTIONALIZING PP SCAFFOLDING LOW O2
(He/O2/H2O 89/10/1)
  • Lower O2 produces less O3 and limits alkoxy
    formation.
  • Overall uniformity becomes reaction limited,
    producing smoother functionalization.

? 1 atm, He/O2/H2O 89/10/1
Iowa State University Optical and Discharge
Physics
ISU_0105_84
78
CONCLUDING REMARKS
  • Plasmas materials processing spans a vast range
    in value added, from extremely high value
    microelectronics to commodity polymer
    functionalization.
  • Development of nanostructured and bio-compatible
    materials using plasmas and their broad
    implementation are largely limited by cost.
  • The social benefit to reducing cost of these
    plasma processes would be large .
  • The key to creating high value using commodity
    processing is leveraging knowledge bases
    developed in different contexts. That is, working
    at the interfaces between fields.
  • Rapid improvement in these knowledge bases will
    enable high values materials (plastic
    microelectronics?) to be produced using commodity
    processes during this decade.

Iowa State University Optical and Discharge
Physics
ISU_0105_85
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