US20160181067A1 - Dynamic ion radical sieve and ion radical aperture for an inductively coupled plasma (icp) reactor - Google Patents
Dynamic ion radical sieve and ion radical aperture for an inductively coupled plasma (icp) reactor Download PDFInfo
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- US20160181067A1 US20160181067A1 US15/055,032 US201615055032A US2016181067A1 US 20160181067 A1 US20160181067 A1 US 20160181067A1 US 201615055032 A US201615055032 A US 201615055032A US 2016181067 A1 US2016181067 A1 US 2016181067A1
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J37/00—Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
- H01J37/32—Gas-filled discharge tubes
- H01J37/32009—Arrangements for generation of plasma specially adapted for examination or treatment of objects, e.g. plasma sources
- H01J37/32082—Radio frequency generated discharge
- H01J37/321—Radio frequency generated discharge the radio frequency energy being inductively coupled to the plasma
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J37/00—Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
- H01J37/32—Gas-filled discharge tubes
- H01J37/32431—Constructional details of the reactor
- H01J37/32623—Mechanical discharge control means
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J37/00—Discharge tubes with provision for introducing objects or material to be exposed to the discharge, e.g. for the purpose of examination or processing thereof
- H01J37/32—Gas-filled discharge tubes
- H01J37/32431—Constructional details of the reactor
- H01J37/32623—Mechanical discharge control means
- H01J37/32633—Baffles
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- H05H1/00—Generating plasma; Handling plasma
- H05H1/24—Generating plasma
- H05H1/46—Generating plasma using applied electromagnetic fields, e.g. high frequency or microwave energy
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J2237/00—Discharge tubes exposing object to beam, e.g. for analysis treatment, etching, imaging
- H01J2237/32—Processing objects by plasma generation
- H01J2237/33—Processing objects by plasma generation characterised by the type of processing
- H01J2237/334—Etching
Definitions
- Embodiments described herein relate to semiconductor manufacturing methods and apparatus. More specifically, substrate etching methods and apparatus are disclosed.
- Pattern etching is a staple of semiconductor manufacturing.
- a substrate is commonly exposed to a plasma of reactive ions and neutrals to etch a pattern into a surface of the substrate. Such processes are typically used to etch a pattern into a substrate that is subsequently used in photolithographic patterning of semiconductor substrates.
- the substrate is usually glass or quartz, with a layer of chromium and/or molybdenum-doped silicon nitride on one side.
- the layer is covered with an anti-reflective coating and a photosensitive resist, and patterned by exposure to patterned UV light. Exposed portions of the resist are dissolved, and the underlying chromium layer is patterned by plasma etching.
- a plasma is generally formed adjacent the substrate. Reactive ions and radicals from the plasma react with the substrate surface, removing material from the surface.
- the rate of material removal, or etching, at a location on the substrate surface is proportional to the density of reactive species adjacent to that location. Due to microloading, variation in aspect ratio, plasma effects, and chamber effects, uniformity of the density of reactive species across the surface of a substrate often varies, resulting in variation of etch rate across the substrate. In many cases, etch rate is observed to be higher near the center of a substrate and lower near the periphery.
- Prior methods of addressing etch rate uniformity include chemical methods of etch rate control, thermal methods of controlling precursor temperature and thermal profile of the plasma, and electromagnetic methods featuring electrodes placed at different locations within the chamber.
- Embodiments described herein provide apparatus and methods of etching a substrate using an ion etch chamber having a movable aperture.
- the ion etch chamber has a chamber body enclosing a processing region, a substrate support disposed in the processing region and having a substrate receiving surface, a plasma source disposed at a wall of the chamber body facing the substrate receiving surface, an ion-radical shield disposed between the plasma source and the substrate receiving surface, and a movable aperture member between the ion-radical shield and the substrate receiving surface.
- the movable aperture member is actuated by a lift assembly comprising a lift ring and lift supports from the lift ring to the aperture member.
- the ion-radical shield is supported by shield supports disposed through the aperture member.
- the aperture size, shape, and/or central axis location may be changed using inserts.
- the lift ring may be actuated by a linear actuator to move the aperture member closer to or further from a substrate disposed on the substrate support.
- a method described herein of processing a substrate includes disposing an aperture member between an ion-radical shield and a substrate receiving surface of an ion etching chamber and controlling a density profile of reactive species near the substrate receiving surface by moving the aperture member closer to or further from the substrate receiving surface.
- the lift ring may be coupled to the ion-radical shield to move the ion-radical shield closer to or further from the aperture member, while the aperture member is supported from a fixed member.
- FIG. 1 is a schematic sectional side view of a processing chamber according to one embodiment.
- FIG. 2 is a partial perspective view of an aperture assembly according to one embodiment.
- FIGS. 3A-3C are sectional side views showing an aperture assembly in various processing positions.
- FIG. 4A is a top view of an aperture member according to one embodiment.
- FIG. 4B is a sectional side view of an aperture member according to another embodiment.
- FIG. 5 is a sectional side view of a processing chamber according to another embodiment.
- FIG. 1 is a schematic sectional side view of a processing chamber 100 according to one embodiment.
- Suitable processing chambers that may be adapted for use with the teachings disclosed herein include, for example, the Decoupled Plasma Source (DPS®) II reactor, or the TetraTM family of substrate etch systems, all of which are available from Applied Materials, Inc. of Santa Clara, Calif.
- DPS® Decoupled Plasma Source
- TetraTM family of substrate etch systems all of which are available from Applied Materials, Inc. of Santa Clara, Calif.
- the particular embodiment of the processing chamber 100 shown herein is provided for illustrative purposes and should not be used to limit the scope of the invention. It is contemplated that the invention may be utilized in other plasma processing chambers, including those from other manufacturers.
- the processing chamber 100 generally includes a processing volume 106 defined by chamber walls 102 and a chamber lid 104 .
- the processing chamber 100 includes a plasma source 122 for supplying or generating a plasma in the processing volume 106 .
- the plasma source 122 may include an antenna 110 disposed above the chamber lid 104 for generating an inductively coupled plasma in the processing volume 106 .
- the antenna 110 may include one or more co-axial coils 110 a, 110 b.
- the antenna 110 may be coupled to a plasma power source 112 via a matching network 114 .
- a supporting assembly 108 is disposed within the processing volume 106 for supporting the substrate 101 being processed on a raised portion 130 .
- the raised portion 130 may function as a stage for positioning the substrate 101 at a desired location within the processing volume 106 .
- a top surface 182 of the raised portion 130 functions as a substrate receiving surface.
- the supporting assembly 108 may include an electrostatic chuck 116 , which has at least one clamping electrode 118 connected to a chuck power supply 126 by an electrical connection 128 .
- the supporting assembly 108 may include other substrate retention mechanisms such as a susceptor clamp ring, a mechanical chuck, a vacuum chuck, and the like.
- the supporting assembly 108 may include a resistive heater 124 coupled to a heater power supply 120 and a heat sink 129 for temperature control.
- the chuck power supply 126 may be an RF generator in some embodiments, so an impedance match circuit 127 may be interposed between the chuck power supply 126 and the clamping electrode 118 .
- the bias power from the chuck power supply 126 or the source power from the plasma power source 112 , or both, may be pulsed or continuous.
- the chuck power supply 126 and/or the plasma power source 112 may be operable to provide pulsed RF power at a frequency between about 1 kHz and about 10 kHz, a duty cycle between about 10% and about 90%, with a minimum pulse duration of about 10 psec.
- the match circuit 114 and/or the match circuit 127 may be operable to provide a stable plasma at load of about 50 ⁇ .
- the supporting assembly 108 also includes an adaptor 134 for transferring the substrate 101 between the raised portion 130 and an exterior transfer device, such as an exterior robot.
- the adaptor 134 is disposed over the electrostatic chuck 116 and may have an opening 136 allowing the raised portion 130 to extend therethrough.
- the adaptor 134 may be lifted from the electrostatic chuck 116 by a plurality of lift pins 140 coupled to a lift mechanism 138 .
- Exemplary adaptors are described in U.S. Pat. No. 7,128,806, entitled “Mask Etch Processing Apparatus”.
- the processing chamber 100 may also include an ion-radical shield 142 disposed above the supporting assembly 108 .
- the ion-radical shield 142 may be electrically isolated from the chamber walls 102 and the supporting assembly 108 .
- the ion-radical shield 142 includes a substantially flat plate 146 having a plurality of through holes 148 and a plurality of shield supports 150 supporting the flat plate 146 and positioning the flat plate 146 at a certain distance above the supporting assembly 108 .
- the plurality of shield supports 150 may be disposed on the electrostatic chuck 116 , the adaptor 134 or a baffle 156 .
- the plurality of through holes 148 may be confined to an open area 152 of the flat plate 146 .
- the open area 152 controls the amount of ions that pass from a plasma formed in an upper volume 154 of the processing volume 106 to a lower volume 144 located between the ion-radical shield 142 and the supporting assembly 108 .
- the areal extent covered by the through holes 148 may be larger than an areal extent of the top surface 182 .
- Exemplary ion-radical shields may be found in U.S. Pat. No. 7,909,961, entitled “Method and Apparatus for Substrate Plasma Etching”.
- a gas panel 158 is connected to inlets 160 for supplying one or more processing gases towards the processing volume 106 .
- a vacuum pump 164 is coupled to the processing volume 106 via a throttle valve 162 .
- the baffle 156 may be disposed around the supporting assembly 108 upstream to the throttle valve 162 to enable even flow distribution and compensate for conductance asymmetries in the processing volume 106 .
- An aperture assembly 166 includes an aperture member 168 supported between the ion-radical shield 142 and the supporting assembly 108 on a plurality of lift supports 170 , which may be support pins, coupled to a lift ring 172 .
- the aperture member 168 separates the lower volume 144 from a processing zone 145 between the aperture member and the top surface 182 of the raised portion 130 .
- An actuator 176 such as a linear actuator, for example a hydraulic cylinder, pneumatic cylinder or electrically driven screw actuator, coupled to the lift ring 172 through a shaft 174 , moves the aperture member 168 closer to, or further from, the supporting assembly 108 . Moving the aperture member 168 adjusts the distribution of reactive species near a substrate on the supporting assembly 108 .
- An edge shield 188 may be coupled to the aperture member 168 .
- the edge shield 188 is generally an annular member that has an extension toward the supporting assembly 108 beyond the aperture member 168 .
- the extension of the edge shield 188 prevents process gases flowing around the aperture member 168 to the supporting assembly 108 and any substrate disposed thereon.
- the aperture member 168 has an aperture 178 formed in a central region of the aperture member 168 through which process gases flow to contact the substrate 101 .
- the aperture is shown in FIG. 1 as having a dimension larger than a corresponding dimension of the substrate 101 , but the dimension of the aperture may be smaller than, or about the same size as, the corresponding dimension of the substrate 101 in some embodiments.
- the dimension of the aperture and its proximity to the substrate influence the distribution of reactive species across the substrate surface.
- the aperture member 168 may be a focus plate that focuses reactive species to a desired distribution at the top surface 182 of the raised portion 130 .
- the lift ring 172 is disposed in the processing volume 106 radially outwards of the supporting assembly 108 .
- the lift ring 172 is mounted on the shaft 174 in a substantially horizontal orientation.
- the shaft 174 is driven by the actuator 176 to move the lift ring 172 vertically in the processing volume 106 .
- the three or more lift supports 170 are extending upward from the lift ring 172 and positioning the aperture member 168 above the supporting assembly 108 .
- the three or more lift supports 170 fixedly attach the aperture member 168 to the lift ring 172 .
- the aperture member 168 moves vertically with the lift ring 172 in the processing volume 106 so that the aperture member 168 can be positioned at a desired distance above the substrate 101 and/or an exterior substrate handling device can enter the processing volume 106 between the aperture member 168 and the supporting assembly 108 to transfer the substrate 101 .
- the three or more lift supports 170 may be positioned to allow the substrate 101 to be transferred in and out the processing chamber 100 .
- each of the three or more lift supports 170 may be positioned close to one of the plurality of shield supports 150 supporting the ion-radical shield to maximize access to the substrate 101 .
- the aperture member 168 may be a planar plate in a size substantially similar to the inner dimension of the chamber wall 102 so that the aperture member 168 can block the downward flow of the processing gas or plasma in the processing volume 106 .
- the chamber wall 102 is cylindrical and the aperture member 168 may be a disk having an outer diameter slightly smaller than an inner diameter of the chamber wall 102 .
- the aperture 178 is aligned with the raised portion 130 of the electrostatic chuck 116 , and may be positioned substantially parallel to the substrate 101 .
- the aperture 178 provides a restricted path for the processing gas, or active species, to flow downwards toward the raised portion 130 where the substrate 101 is positioned, thus, controlling the plasma-exposure of the substrate 101 .
- the aperture 178 of the aperture member 168 has an edge 179 that may be contoured for supporting a second member, such as an insert, as described in more detail in connection with FIG. 5B .
- the cross-sectional shape of the contour may be one of beveled, curved, or stepped.
- the contour of the edge 179 faces the ion-radical shield 142 , such that a second member may be supported in the aperture 178 in substantially parallel relationship with the aperture member 168 .
- the edge 179 has a bevel
- the bevel may be a straight bevel machined at any angle up to about 75° referenced to the plane of the aperture member 168 .
- the bevel may be curved or faceted, if desired.
- the edge 179 may be partially beveled in some embodiments, with a beveled portion and a straight portion. For example, a first portion of the edge 179 proximate a surface of the aperture member 168 facing the ion-radical shield 142 may be beveled while a second portion of the edge 179 proximate a surface of the aperture member 168 facing the top surface 182 of the raised portion 130 may be straight (i.e. substantially perpendicular to the top surface 182 ). Such a partially beveled edge may improve stability of a sizing insert nested with the aperture member 168 .
- the aperture 178 may be shaped substantially similar to the shape of the substrate 101 being processed.
- the aperture 178 may be slightly larger than a top surface of the substrate 101 to provide a suitable process window for affecting distribution of reactive species across the surface of the substrate 101 .
- the aperture 178 may be larger than about 6 ⁇ 6 inches.
- a distance 180 between the aperture member 168 and the top surface 182 of the raised portion 130 can be adjusted to achieve desired plasma-exposure of the substrate 101 .
- the aperture member 168 may be movably positioned below the ion-radical shield 142 and above the supporting assembly 108 .
- the aperture member 168 may have a plurality of openings 184 to accommodate the plurality of shield supports 150 that support the flat plate 146 of the ion-radical shield 142 .
- the openings 184 may be through holes, cutouts, notches, or other types of openings formed to allow the aperture member 168 to move freely without impacting the shield supports 150 .
- a plasma is usually formed in the processing volume 106 .
- Species in the plasma such as radicals and ions, pass through the flat plate 146 and the aperture 178 of the aperture member 168 to the substrate 101 .
- the aperture member 168 controls a distribution of the radicals and ions proximate the upper surface of the substrate 101 by creating a flow pathway for the radicals and ions from the lower volume 144 to the processing zone 145 .
- the aperture 178 may be shaped and/or positioned so that species passing through the aperture 178 do not reach the edge and/or sides of the substrate 101 .
- the aperture 178 may also be shaped, sized, and/or positioned to control a density of active species across the substrate 101 . In one embodiment, the density of active species near a central region of the substrate 101 may be reduced, and the density near a peripheral region of the substrate increased, by positioning the aperture member 168 closer to the ion-radical shield 142 than to the substrate 101 .
- the aperture member 168 may be formed from materials that are compatible with the processing chemistry.
- the aperture member 168 may be formed from quartz or ceramics, such as alumina, yttria (yttrium oxide), and K140 (a proprietary material available from Kyocera), among others, including combinations and alloys thereof.
- the aperture member 168 may be coated in some embodiments.
- a ceramic coated metal material may be useful, for example anodized aluminum or aluminum coated with a deposited or sprayed ceramic coating, such as alumina (Al 2 O 3 ) or yttria (Y 2 O 3 ).
- the aperture member 168 may be electrically isolated from the chamber, or may be electrically energized to provide a bias voltage, if desired, or to remove buildup of voltage from exposure to plasma processing.
- An electrical connection 181 may be provided with a path to ground, such as the chamber wall 102 , to remove voltage buildup.
- a control element such as a switch, not shown, may be provided.
- a bias voltage may be applied to the aperture member 168 by coupling a power source to the electrical connection 181 .
- An RF source 177 is shown in FIG. 1 , with a filter circuit 183 , which may also be or include an impedance match circuit.
- the electrical connection 181 is generally coupled to a conductive portion of the aperture member 168 , such as a metal portion if the aperture member 168 is a ceramic coated metal member.
- FIG. 2 is a partial perspective view of the aperture assembly 266 according to one embodiment, with the chamber lid 104 , chamber walls 102 and supporting assembly 108 removed.
- the plurality of lift supports 170 penetrate the baffle 156 to position the aperture member 168 between the baffle 156 and the flat plate 146 .
- the plurality of through holes 184 accommodate the shield supports 150 supporting the flat plate 146 on the baffle 156 .
- the staggered arrangement of shield supports 150 and lift supports 170 allows the aperture member 168 to move independently from the baffle 156 and the flat plate 146 .
- the aperture member 168 is moved vertically by the lift ring 172 .
- the lift ring 172 may include a ring shaped body 204 having a side extension 202 .
- the ring shaped body 204 has an inner opening 206 large enough to surround the supporting assembly 108 ( FIG. 1 ).
- the side extension 202 is located radially outwards from the ring shaped body 204 .
- the side extension 202 allows the lift loop 172 to connect with an actuator from the side.
- the side driven arrangement enables the lift ring 172 and the aperture member 168 to have a separate driven mechanism from the baffle 156 and the flat plate 146 of the ion-radical shield 142 , thus, improving the process flexibility of the processing chamber 100 .
- the aperture member 168 may be positioned at different distances above the supporting assembly 108 ( FIG. 1 ) to control distribution of active species across the surface of the substrate 101 and/or enable movements of the substrate 101 and other chamber components.
- FIG. 3A is a sectional side view showing the aperture member 168 in a lower processing position.
- a lower surface 306 is positioned at a distance 302 above the raised portion 130 of the supporting assembly 108 .
- the distance 302 is less than about 1.0 inches, such as between about 0.4 inches and about 0.6 inches, for example about 0.42 inches, placing the aperture member 168 close to the substrate 101 being processed.
- the aperture member 168 constrains radicals and ions flowing through the aperture 178 from spreading laterally, resulting in a relatively uniform density of active species across the substrate 101 .
- FIG. 3B is a sectional side view showing the aperture member 168 in an upper processing position.
- the lower surface 306 is positioned at a distance 304 above the raised portion 130 of the supporting assembly 108 .
- the aperture member 168 allows radicals and ions flowing through the aperture 178 to spread laterally before contacting the substrate 101 .
- density of active species near a peripheral portion of the substrate 101 becomes lower than density of active species near a central portion of the substrate 101 .
- adjusting a distance between the aperture member 168 and the substrate 101 may control the density distribution of active species near the substrate 101 .
- the distance 302 may be at least about 1.5 inches, such as between about 1.6 inches and about 2.2 inches, for example about 2.1 inches.
- FIG. 3C is a sectional side view showing the aperture member 168 in a transferring position so that the substrate 101 can be transferred to and from the supporting assembly 108 .
- the lift ring 172 and the aperture member 168 are raised to create space between the aperture member 168 and the raised portion 130 for substrate transferring.
- the distance between the aperture member 168 and the raised portion 130 may be dynamically adjusted during processing or between processing of successive substrates to achieve optimal reactive species uniformity for each substrate.
- the distance between the aperture member 168 and the raised portion 130 is maximized, the difference between center etch rate and peripheral etch rate will be maximized, and when the distance is minimized, the etch rate difference will be minimized. This feature may be used to compensate for pattern effects on etch rate uniformity.
- FIG. 4A is a top view of the aperture member 168 .
- FIG. 4B is a sectional side view of the aperture member 168 .
- the aperture member 168 has a planar disk shaped body 402 .
- the planar disk shaped body 402 may be circular for using in a processing chamber having cylindrical sidewalls.
- the aperture 178 is formed through a central area of the planar disk shaped body 402 .
- the aperture 178 may be squared for processing a squared substrate 101 .
- the aperture is generally shaped to follow the shape of substrates to be processed in the plasma chamber.
- the aperture 178 is defined by inner walls 404 , which in the embodiments described herein are beveled, but may be substantially vertical in other embodiments.
- the size of the aperture 178 may be slightly larger than the size of the substrate 101 , such that the substrate 101 is visible through the aperture 178 in FIG. 4A .
- the aperture 178 may be slightly greater than 6 ⁇ 6 inches in size.
- the aperture 178 is configured to be coaxially aligned with the substrate 101 to provide uniform processing of the substrate 101 . It should be noted that the aperture 178 may be offset from a central axis of the substrate 101 , if desired, to achieve a density profile that is not symmetric about a center of the substrate 101 .
- three or more through holes 184 are formed along the periphery of the planar disk shaped body 402 .
- the through holes 184 are configured to accommodate shield supports 150 for the ion-radical shield 142 .
- Supporting features, such as lift supports 170 may be attached to the planar disk shaped body 402 at locations 406 .
- the locations 406 may be recesses adapted to receive support members such as the lift supports 170 .
- the locations 406 may be positioned close to the through holes 184 so that the substrate 101 may be transferred through the space between neighboring lift supports 170 .
- aperture member 168 and the aperture 178 may have different shapes depending on the shape of the chamber and the shape of the substrate respectively.
- one or more ring-shaped inserts 408 may be used with the aperture member 168 .
- the insert 408 has an outer dimension slightly larger than the dimension of the aperture 178 and an outer edge contoured to match the contoured wall 179 of the aperture 178 such that the insert 408 cannot pass through the aperture 178 when the insert 408 and the aperture member 168 are in a parallel mating orientation.
- the insert 408 rests on the contoured edge 179 of the aperture 178 , reducing the size of the aperture 178 and potentially changing the shape and/or the central axis location of the aperture 178 .
- Various inserts 408 may have apertures of different size, and multiple inserts 408 may be used, if desired, to vary the aperture size, shape, and/or central axis location.
- a first insert may have a first aperture that is between about 1 ⁇ 8′′ and about 1 ⁇ 4′′ smaller in dimension that the aperture 178 of the aperture member 168 .
- a second insert may have a second aperture that is between about 1 ⁇ 8′′ and about 1 ⁇ 4′′ smaller than the first aperture, and may nest within the first aperture. Up to about five inserts may be nested within the aperture 168 of the aperture member 178 to reduce the aperture size by up to about 3′′, if desired. Varying the open area of the aperture using one or more inserts adds a method of control that may be used to adjust performance of the aperture member 168 for different substrates and chambers without having to take the chamber out of service to change major chamber components.
- FIG. 5 is a schematic sectional side view of a processing chamber 500 according to another embodiment.
- the embodiment of FIG. 5 is generally similar to the embodiment of FIG. 1 , but the aperture member 568 of FIG. 5 has an aperture 578 that is smaller than the substrate 101 , and the lift supports 170 and shield supports 184 of FIG. 1 are swapped in FIG. 5 for lift supports 570 and aperture support 584 .
- the lift supports 570 couple the ion-radical shield 146 to the lift ring 172 , while the aperture supports 584 support the aperture member 568 from the adaptor 134 .
- the ion-radical shield 146 may be moved closer to or further from the substrate 101 , while the aperture member 568 remains stationary with respect to the substrate 101 .
- FIG. 5 incorporates another method of controlling the distribution of reactive species across the surface of the substrate 101 .
- the ion-radical shield 142 is moved with respect to the aperture member 568 , the density profile of reactive species passing through the aperture 578 changes, resulting in a changing density profile at the substrate 101 .
- both the aperture member 568 and the ion-radical shield 146 are actuated.
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Abstract
Description
- This application is a divisional of co-pending U.S. patent application Ser. No. 13/455,342 filed Apr. 25, 2012, which claims benefit of U.S. Provisional Application Ser. No. 61/491,679, filed May 31, 2011, each of which is incorporated herein by reference.
- Embodiments described herein relate to semiconductor manufacturing methods and apparatus. More specifically, substrate etching methods and apparatus are disclosed.
- Pattern etching is a staple of semiconductor manufacturing. A substrate is commonly exposed to a plasma of reactive ions and neutrals to etch a pattern into a surface of the substrate. Such processes are typically used to etch a pattern into a substrate that is subsequently used in photolithographic patterning of semiconductor substrates. The substrate is usually glass or quartz, with a layer of chromium and/or molybdenum-doped silicon nitride on one side. The layer is covered with an anti-reflective coating and a photosensitive resist, and patterned by exposure to patterned UV light. Exposed portions of the resist are dissolved, and the underlying chromium layer is patterned by plasma etching.
- During plasma etching, a plasma is generally formed adjacent the substrate. Reactive ions and radicals from the plasma react with the substrate surface, removing material from the surface. The rate of material removal, or etching, at a location on the substrate surface is proportional to the density of reactive species adjacent to that location. Due to microloading, variation in aspect ratio, plasma effects, and chamber effects, uniformity of the density of reactive species across the surface of a substrate often varies, resulting in variation of etch rate across the substrate. In many cases, etch rate is observed to be higher near the center of a substrate and lower near the periphery.
- Prior methods of addressing etch rate uniformity include chemical methods of etch rate control, thermal methods of controlling precursor temperature and thermal profile of the plasma, and electromagnetic methods featuring electrodes placed at different locations within the chamber. There remains, however, a need for methods and apparatus that influence the density profile of a plasma in a dynamic, adjustable way.
- Embodiments described herein provide apparatus and methods of etching a substrate using an ion etch chamber having a movable aperture. The ion etch chamber has a chamber body enclosing a processing region, a substrate support disposed in the processing region and having a substrate receiving surface, a plasma source disposed at a wall of the chamber body facing the substrate receiving surface, an ion-radical shield disposed between the plasma source and the substrate receiving surface, and a movable aperture member between the ion-radical shield and the substrate receiving surface. The movable aperture member is actuated by a lift assembly comprising a lift ring and lift supports from the lift ring to the aperture member. The ion-radical shield is supported by shield supports disposed through the aperture member. The aperture size, shape, and/or central axis location may be changed using inserts.
- The lift ring may be actuated by a linear actuator to move the aperture member closer to or further from a substrate disposed on the substrate support. A method described herein of processing a substrate includes disposing an aperture member between an ion-radical shield and a substrate receiving surface of an ion etching chamber and controlling a density profile of reactive species near the substrate receiving surface by moving the aperture member closer to or further from the substrate receiving surface.
- In another embodiment, the lift ring may be coupled to the ion-radical shield to move the ion-radical shield closer to or further from the aperture member, while the aperture member is supported from a fixed member.
- So that the manner in which the above-recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
-
FIG. 1 is a schematic sectional side view of a processing chamber according to one embodiment. -
FIG. 2 is a partial perspective view of an aperture assembly according to one embodiment. -
FIGS. 3A-3C are sectional side views showing an aperture assembly in various processing positions. -
FIG. 4A is a top view of an aperture member according to one embodiment. -
FIG. 4B is a sectional side view of an aperture member according to another embodiment. -
FIG. 5 is a sectional side view of a processing chamber according to another embodiment. - To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.
- Embodiments described herein provide a method and apparatus for etching a substrate using a movable aperture member.
FIG. 1 is a schematic sectional side view of aprocessing chamber 100 according to one embodiment. Suitable processing chambers that may be adapted for use with the teachings disclosed herein include, for example, the Decoupled Plasma Source (DPS®) II reactor, or the Tetra™ family of substrate etch systems, all of which are available from Applied Materials, Inc. of Santa Clara, Calif. The particular embodiment of theprocessing chamber 100 shown herein is provided for illustrative purposes and should not be used to limit the scope of the invention. It is contemplated that the invention may be utilized in other plasma processing chambers, including those from other manufacturers. - The
processing chamber 100 generally includes aprocessing volume 106 defined bychamber walls 102 and achamber lid 104. Theprocessing chamber 100 includes a plasma source 122 for supplying or generating a plasma in theprocessing volume 106. The plasma source 122 may include anantenna 110 disposed above thechamber lid 104 for generating an inductively coupled plasma in theprocessing volume 106. Theantenna 110 may include one ormore co-axial coils antenna 110 may be coupled to aplasma power source 112 via amatching network 114. - A supporting
assembly 108 is disposed within theprocessing volume 106 for supporting thesubstrate 101 being processed on a raisedportion 130. The raisedportion 130 may function as a stage for positioning thesubstrate 101 at a desired location within theprocessing volume 106. Atop surface 182 of the raisedportion 130 functions as a substrate receiving surface. The supportingassembly 108 may include anelectrostatic chuck 116, which has at least oneclamping electrode 118 connected to achuck power supply 126 by anelectrical connection 128. The supportingassembly 108 may include other substrate retention mechanisms such as a susceptor clamp ring, a mechanical chuck, a vacuum chuck, and the like. The supportingassembly 108 may include aresistive heater 124 coupled to aheater power supply 120 and aheat sink 129 for temperature control. - The
chuck power supply 126 may be an RF generator in some embodiments, so animpedance match circuit 127 may be interposed between thechuck power supply 126 and theclamping electrode 118. The bias power from thechuck power supply 126 or the source power from theplasma power source 112, or both, may be pulsed or continuous. Thechuck power supply 126 and/or theplasma power source 112 may be operable to provide pulsed RF power at a frequency between about 1 kHz and about 10 kHz, a duty cycle between about 10% and about 90%, with a minimum pulse duration of about 10 psec. Thematch circuit 114 and/or thematch circuit 127 may be operable to provide a stable plasma at load of about 50 Ω. - The supporting
assembly 108 also includes anadaptor 134 for transferring thesubstrate 101 between the raisedportion 130 and an exterior transfer device, such as an exterior robot. Theadaptor 134 is disposed over theelectrostatic chuck 116 and may have anopening 136 allowing the raisedportion 130 to extend therethrough. Theadaptor 134 may be lifted from theelectrostatic chuck 116 by a plurality of lift pins 140 coupled to alift mechanism 138. Exemplary adaptors are described in U.S. Pat. No. 7,128,806, entitled “Mask Etch Processing Apparatus”. - The
processing chamber 100 may also include an ion-radical shield 142 disposed above the supportingassembly 108. The ion-radical shield 142 may be electrically isolated from thechamber walls 102 and the supportingassembly 108. The ion-radical shield 142 includes a substantiallyflat plate 146 having a plurality of throughholes 148 and a plurality of shield supports 150 supporting theflat plate 146 and positioning theflat plate 146 at a certain distance above the supportingassembly 108. The plurality of shield supports 150 may be disposed on theelectrostatic chuck 116, theadaptor 134 or abaffle 156. The plurality of throughholes 148 may be confined to anopen area 152 of theflat plate 146. Theopen area 152 controls the amount of ions that pass from a plasma formed in anupper volume 154 of theprocessing volume 106 to alower volume 144 located between the ion-radical shield 142 and the supportingassembly 108. The areal extent covered by the throughholes 148 may be larger than an areal extent of thetop surface 182. Exemplary ion-radical shields may be found in U.S. Pat. No. 7,909,961, entitled “Method and Apparatus for Substrate Plasma Etching”. - A
gas panel 158 is connected toinlets 160 for supplying one or more processing gases towards theprocessing volume 106. Avacuum pump 164 is coupled to theprocessing volume 106 via athrottle valve 162. Thebaffle 156 may be disposed around the supportingassembly 108 upstream to thethrottle valve 162 to enable even flow distribution and compensate for conductance asymmetries in theprocessing volume 106. - An
aperture assembly 166 includes anaperture member 168 supported between the ion-radical shield 142 and the supportingassembly 108 on a plurality of lift supports 170, which may be support pins, coupled to alift ring 172. Theaperture member 168 separates thelower volume 144 from aprocessing zone 145 between the aperture member and thetop surface 182 of the raisedportion 130. Anactuator 176, such as a linear actuator, for example a hydraulic cylinder, pneumatic cylinder or electrically driven screw actuator, coupled to thelift ring 172 through ashaft 174, moves theaperture member 168 closer to, or further from, the supportingassembly 108. Moving theaperture member 168 adjusts the distribution of reactive species near a substrate on the supportingassembly 108. - An
edge shield 188 may be coupled to theaperture member 168. Theedge shield 188 is generally an annular member that has an extension toward the supportingassembly 108 beyond theaperture member 168. The extension of theedge shield 188 prevents process gases flowing around theaperture member 168 to the supportingassembly 108 and any substrate disposed thereon. - The
aperture member 168 has anaperture 178 formed in a central region of theaperture member 168 through which process gases flow to contact thesubstrate 101. The aperture is shown inFIG. 1 as having a dimension larger than a corresponding dimension of thesubstrate 101, but the dimension of the aperture may be smaller than, or about the same size as, the corresponding dimension of thesubstrate 101 in some embodiments. The dimension of the aperture and its proximity to the substrate influence the distribution of reactive species across the substrate surface. In some embodiments, theaperture member 168 may be a focus plate that focuses reactive species to a desired distribution at thetop surface 182 of the raisedportion 130. - The
lift ring 172 is disposed in theprocessing volume 106 radially outwards of the supportingassembly 108. Thelift ring 172 is mounted on theshaft 174 in a substantially horizontal orientation. Theshaft 174 is driven by theactuator 176 to move thelift ring 172 vertically in theprocessing volume 106. The three or more lift supports 170 are extending upward from thelift ring 172 and positioning theaperture member 168 above the supportingassembly 108. The three or more lift supports 170 fixedly attach theaperture member 168 to thelift ring 172. Theaperture member 168 moves vertically with thelift ring 172 in theprocessing volume 106 so that theaperture member 168 can be positioned at a desired distance above thesubstrate 101 and/or an exterior substrate handling device can enter theprocessing volume 106 between theaperture member 168 and the supportingassembly 108 to transfer thesubstrate 101. - The three or more lift supports 170 may be positioned to allow the
substrate 101 to be transferred in and out theprocessing chamber 100. In one embodiment, each of the three or more lift supports 170 may be positioned close to one of the plurality of shield supports 150 supporting the ion-radical shield to maximize access to thesubstrate 101. - The
aperture member 168 may be a planar plate in a size substantially similar to the inner dimension of thechamber wall 102 so that theaperture member 168 can block the downward flow of the processing gas or plasma in theprocessing volume 106. In one embodiment, thechamber wall 102 is cylindrical and theaperture member 168 may be a disk having an outer diameter slightly smaller than an inner diameter of thechamber wall 102. Theaperture 178 is aligned with the raisedportion 130 of theelectrostatic chuck 116, and may be positioned substantially parallel to thesubstrate 101. Theaperture 178 provides a restricted path for the processing gas, or active species, to flow downwards toward the raisedportion 130 where thesubstrate 101 is positioned, thus, controlling the plasma-exposure of thesubstrate 101. - The
aperture 178 of theaperture member 168 has anedge 179 that may be contoured for supporting a second member, such as an insert, as described in more detail in connection withFIG. 5B . The cross-sectional shape of the contour may be one of beveled, curved, or stepped. The contour of theedge 179 faces the ion-radical shield 142, such that a second member may be supported in theaperture 178 in substantially parallel relationship with theaperture member 168. In an embodiment wherein theedge 179 has a bevel, the bevel may be a straight bevel machined at any angle up to about 75° referenced to the plane of theaperture member 168. In other embodiments, the bevel may be curved or faceted, if desired. Theedge 179 may be partially beveled in some embodiments, with a beveled portion and a straight portion. For example, a first portion of theedge 179 proximate a surface of theaperture member 168 facing the ion-radical shield 142 may be beveled while a second portion of theedge 179 proximate a surface of theaperture member 168 facing thetop surface 182 of the raisedportion 130 may be straight (i.e. substantially perpendicular to the top surface 182). Such a partially beveled edge may improve stability of a sizing insert nested with theaperture member 168. - The
aperture 178 may be shaped substantially similar to the shape of thesubstrate 101 being processed. Theaperture 178 may be slightly larger than a top surface of thesubstrate 101 to provide a suitable process window for affecting distribution of reactive species across the surface of thesubstrate 101. For example, theaperture 178 may be larger than about 6×6 inches. Adistance 180 between theaperture member 168 and thetop surface 182 of the raisedportion 130 can be adjusted to achieve desired plasma-exposure of thesubstrate 101. - By operating the
lift ring 172, theaperture member 168 may be movably positioned below the ion-radical shield 142 and above the supportingassembly 108. Theaperture member 168 may have a plurality ofopenings 184 to accommodate the plurality of shield supports 150 that support theflat plate 146 of the ion-radical shield 142. Theopenings 184 may be through holes, cutouts, notches, or other types of openings formed to allow theaperture member 168 to move freely without impacting the shield supports 150. - During processing, a plasma is usually formed in the
processing volume 106. Species in the plasma, such as radicals and ions, pass through theflat plate 146 and theaperture 178 of theaperture member 168 to thesubstrate 101. Theaperture member 168 controls a distribution of the radicals and ions proximate the upper surface of thesubstrate 101 by creating a flow pathway for the radicals and ions from thelower volume 144 to theprocessing zone 145. Theaperture 178 may be shaped and/or positioned so that species passing through theaperture 178 do not reach the edge and/or sides of thesubstrate 101. Theaperture 178 may also be shaped, sized, and/or positioned to control a density of active species across thesubstrate 101. In one embodiment, the density of active species near a central region of thesubstrate 101 may be reduced, and the density near a peripheral region of the substrate increased, by positioning theaperture member 168 closer to the ion-radical shield 142 than to thesubstrate 101. - The
aperture member 168 may be formed from materials that are compatible with the processing chemistry. In one embodiment, theaperture member 168 may be formed from quartz or ceramics, such as alumina, yttria (yttrium oxide), and K140 (a proprietary material available from Kyocera), among others, including combinations and alloys thereof. Theaperture member 168 may be coated in some embodiments. A ceramic coated metal material may be useful, for example anodized aluminum or aluminum coated with a deposited or sprayed ceramic coating, such as alumina (Al2O3) or yttria (Y2O3). - The
aperture member 168 may be electrically isolated from the chamber, or may be electrically energized to provide a bias voltage, if desired, or to remove buildup of voltage from exposure to plasma processing. Anelectrical connection 181 may be provided with a path to ground, such as thechamber wall 102, to remove voltage buildup. A control element such as a switch, not shown, may be provided. A bias voltage may be applied to theaperture member 168 by coupling a power source to theelectrical connection 181. AnRF source 177 is shown inFIG. 1 , with afilter circuit 183, which may also be or include an impedance match circuit. For biasing theaperture member 168, theelectrical connection 181 is generally coupled to a conductive portion of theaperture member 168, such as a metal portion if theaperture member 168 is a ceramic coated metal member. -
FIG. 2 is a partial perspective view of the aperture assembly 266 according to one embodiment, with thechamber lid 104,chamber walls 102 and supportingassembly 108 removed. - The plurality of lift supports 170 penetrate the
baffle 156 to position theaperture member 168 between thebaffle 156 and theflat plate 146. The plurality of throughholes 184 accommodate the shield supports 150 supporting theflat plate 146 on thebaffle 156. The staggered arrangement of shield supports 150 and lift supports 170 allows theaperture member 168 to move independently from thebaffle 156 and theflat plate 146. - The
aperture member 168 is moved vertically by thelift ring 172. Thelift ring 172 may include a ring shapedbody 204 having aside extension 202. The ring shapedbody 204 has aninner opening 206 large enough to surround the supporting assembly 108 (FIG. 1 ). Theside extension 202 is located radially outwards from the ring shapedbody 204. Theside extension 202 allows thelift loop 172 to connect with an actuator from the side. The side driven arrangement enables thelift ring 172 and theaperture member 168 to have a separate driven mechanism from thebaffle 156 and theflat plate 146 of the ion-radical shield 142, thus, improving the process flexibility of theprocessing chamber 100. - The
aperture member 168 may be positioned at different distances above the supporting assembly 108 (FIG. 1 ) to control distribution of active species across the surface of thesubstrate 101 and/or enable movements of thesubstrate 101 and other chamber components. -
FIG. 3A is a sectional side view showing theaperture member 168 in a lower processing position. Alower surface 306 is positioned at adistance 302 above the raisedportion 130 of the supportingassembly 108. At the lower processing position, thedistance 302 is less than about 1.0 inches, such as between about 0.4 inches and about 0.6 inches, for example about 0.42 inches, placing theaperture member 168 close to thesubstrate 101 being processed. At the lower processing position, theaperture member 168 constrains radicals and ions flowing through theaperture 178 from spreading laterally, resulting in a relatively uniform density of active species across thesubstrate 101. -
FIG. 3B is a sectional side view showing theaperture member 168 in an upper processing position. Thelower surface 306 is positioned at adistance 304 above the raisedportion 130 of the supportingassembly 108. At the upper processing position, theaperture member 168 allows radicals and ions flowing through theaperture 178 to spread laterally before contacting thesubstrate 101. As the radicals and ions spread laterally, density of active species near a peripheral portion of thesubstrate 101 becomes lower than density of active species near a central portion of thesubstrate 101. Thus, adjusting a distance between theaperture member 168 and thesubstrate 101 may control the density distribution of active species near thesubstrate 101. At the upper processing position, thedistance 302 may be at least about 1.5 inches, such as between about 1.6 inches and about 2.2 inches, for example about 2.1 inches. -
FIG. 3C is a sectional side view showing theaperture member 168 in a transferring position so that thesubstrate 101 can be transferred to and from the supportingassembly 108. Thelift ring 172 and theaperture member 168 are raised to create space between theaperture member 168 and the raisedportion 130 for substrate transferring. - Additionally, the distance between the
aperture member 168 and the raisedportion 130 may be dynamically adjusted during processing or between processing of successive substrates to achieve optimal reactive species uniformity for each substrate. When the distance between theaperture member 168 and the raisedportion 130 is maximized, the difference between center etch rate and peripheral etch rate will be maximized, and when the distance is minimized, the etch rate difference will be minimized. This feature may be used to compensate for pattern effects on etch rate uniformity. -
FIG. 4A is a top view of theaperture member 168.FIG. 4B is a sectional side view of theaperture member 168. Theaperture member 168 has a planar disk shapedbody 402. The planar disk shapedbody 402 may be circular for using in a processing chamber having cylindrical sidewalls. Theaperture 178 is formed through a central area of the planar disk shapedbody 402. Theaperture 178 may be squared for processing asquared substrate 101. The aperture is generally shaped to follow the shape of substrates to be processed in the plasma chamber. Theaperture 178 is defined byinner walls 404, which in the embodiments described herein are beveled, but may be substantially vertical in other embodiments. In one embodiment, the size of theaperture 178 may be slightly larger than the size of thesubstrate 101, such that thesubstrate 101 is visible through theaperture 178 inFIG. 4A . For example, theaperture 178 may be slightly greater than 6×6 inches in size. During processing, theaperture 178 is configured to be coaxially aligned with thesubstrate 101 to provide uniform processing of thesubstrate 101. It should be noted that theaperture 178 may be offset from a central axis of thesubstrate 101, if desired, to achieve a density profile that is not symmetric about a center of thesubstrate 101. - In one embodiment, three or more through
holes 184 are formed along the periphery of the planar disk shapedbody 402. The throughholes 184 are configured to accommodate shield supports 150 for the ion-radical shield 142. Supporting features, such as lift supports 170, may be attached to the planar disk shapedbody 402 atlocations 406. Alternately, thelocations 406 may be recesses adapted to receive support members such as the lift supports 170. Thelocations 406 may be positioned close to the throughholes 184 so that thesubstrate 101 may be transferred through the space between neighboring lift supports 170. - It should be noted that the
aperture member 168 and theaperture 178 may have different shapes depending on the shape of the chamber and the shape of the substrate respectively. - Referring to
FIG. 4B , one or more ring-shapedinserts 408 may be used with theaperture member 168. Theinsert 408 has an outer dimension slightly larger than the dimension of theaperture 178 and an outer edge contoured to match thecontoured wall 179 of theaperture 178 such that theinsert 408 cannot pass through theaperture 178 when theinsert 408 and theaperture member 168 are in a parallel mating orientation. Theinsert 408 rests on thecontoured edge 179 of theaperture 178, reducing the size of theaperture 178 and potentially changing the shape and/or the central axis location of theaperture 178. -
Various inserts 408 may have apertures of different size, andmultiple inserts 408 may be used, if desired, to vary the aperture size, shape, and/or central axis location. For example, a first insert may have a first aperture that is between about ⅛″ and about ¼″ smaller in dimension that theaperture 178 of theaperture member 168. A second insert may have a second aperture that is between about ⅛″ and about ¼″ smaller than the first aperture, and may nest within the first aperture. Up to about five inserts may be nested within theaperture 168 of theaperture member 178 to reduce the aperture size by up to about 3″, if desired. Varying the open area of the aperture using one or more inserts adds a method of control that may be used to adjust performance of theaperture member 168 for different substrates and chambers without having to take the chamber out of service to change major chamber components. -
FIG. 5 is a schematic sectional side view of aprocessing chamber 500 according to another embodiment. The embodiment ofFIG. 5 is generally similar to the embodiment ofFIG. 1 , but theaperture member 568 ofFIG. 5 has anaperture 578 that is smaller than thesubstrate 101, and the lift supports 170 and shield supports 184 ofFIG. 1 are swapped inFIG. 5 for lift supports 570 andaperture support 584. The lift supports 570 couple the ion-radical shield 146 to thelift ring 172, while the aperture supports 584 support theaperture member 568 from theadaptor 134. In the embodiment ofFIG. 5 , the ion-radical shield 146 may be moved closer to or further from thesubstrate 101, while theaperture member 568 remains stationary with respect to thesubstrate 101. - The embodiment of
FIG. 5 incorporates another method of controlling the distribution of reactive species across the surface of thesubstrate 101. As the ion-radical shield 142 is moved with respect to theaperture member 568, the density profile of reactive species passing through theaperture 578 changes, resulting in a changing density profile at thesubstrate 101. It should be noted that embodiments are contemplated in which both theaperture member 568 and the ion-radical shield 146 are actuated. - While the foregoing is directed to embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof.
Claims (20)
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US20120305184A1 (en) | 2012-12-06 |
CN103650118A (en) | 2014-03-19 |
KR20160079932A (en) | 2016-07-06 |
JP2014522573A (en) | 2014-09-04 |
JP6046128B2 (en) | 2016-12-14 |
JP2017063212A (en) | 2017-03-30 |
WO2012166264A2 (en) | 2012-12-06 |
KR20140036231A (en) | 2014-03-25 |
CN105977126B (en) | 2018-12-07 |
TW201701352A (en) | 2017-01-01 |
WO2012166264A3 (en) | 2013-01-24 |
US9287093B2 (en) | 2016-03-15 |
TW201248721A (en) | 2012-12-01 |
KR101744668B1 (en) | 2017-06-08 |
JP6329614B2 (en) | 2018-05-23 |
CN103650118B (en) | 2016-08-24 |
TWI616948B (en) | 2018-03-01 |
CN105977126A (en) | 2016-09-28 |
TWI550710B (en) | 2016-09-21 |
KR101926571B1 (en) | 2018-12-10 |
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