Scaling of Si and GaAs trench etch rates with aspect ratio, feature width, and substrate temperature

Abstract

The scaling of etch rates with feature dimensions is an important issue in the fabrication of microelectronic and photonic devices. Because etch rates depend on circuit layouts and design rules, considerable effort is spent to modify processes each time changes in design are made. Knowing how etch rates scale with design parameters should accelerate the introduction of new designs into manufacturing while minimizing the cost of doing so. Recently it has been shown that etch rates for a variety of conditions scale with the depth/width or aspect ratio and not on width or depth alone. While various mechanisms might be responsible for such scaling, isolating one mechanism from another is not straight forward. Nonetheless, it is important to understand the underlying mechanisms so that differences in etch chemistry and etch reactor design can be accounted for when scaling plasma processes from one design or reactor to another. To assess the effects of etch chemistry alone, the trench etch rates of Si and GaAs are compared under constant plasma conditions. Substrate temperature is varied to further assess the relative importance of surface vs transport phenomena during the etching process. At higher temperatures, both Si and GaAs trench etch rates scale only with aspect ratio in an Ar/Cl2 electron cyclotron resonance plasma. The results are consistent with an ion-neutral synergy model based on Langmuir adsorption kinetics where the scaling can be explained by the aspect ratio dependence of the neutral reactant transport into the trench: charging effects, ion shadowing, and Knudsen transport are not consistent with the data. At −45 °C, the etch rate no longer scales with aspect ratio alone, but now also depends on trench width. The data at this lower temperature are well described by a model incorporating the deposition of an etch inhibiting layer. While the trench etch rates for GaAs and Si scale in similar ways with aspect ratio and trench width, the dependence on feature dimensions of the Si etch rate is much stronger than that for GaAs at all substrate temperatures because the steady-state surface coverage of Cl is smaller for Si. This results in a greater sensitivity to the incoming, aspect ratio dependent, neutral fluxes. The implications of the models on the goal of aspect ratio independent etching are also discussed.