US 12,104,246 B2
Atomic layer deposition of protective coatings for semiconductor process chamber components
David Fenwick, Los Altos, CA (US); and Jennifer Y. Sun, Fremont, CA (US)
Assigned to Applied Materials, Inc., Santa Clara, CA (US)
Filed by Applied Materials, Inc., Santa Clara, CA (US)
Filed on Apr. 11, 2022, as Appl. No. 17/718,205.
Application 17/718,205 is a continuation of application No. 15/495,624, filed on Apr. 24, 2017, granted, now 11,326,253.
Claims priority of provisional application 62/328,588, filed on Apr. 27, 2016.
Prior Publication US 2022/0235458 A1, Jul. 28, 2022
Int. Cl. C23C 16/44 (2006.01); C23C 16/40 (2006.01); C23C 16/455 (2006.01); C23C 28/04 (2006.01)
CPC C23C 16/4404 (2013.01) [C23C 16/40 (2013.01); C23C 16/403 (2013.01); C23C 16/405 (2013.01); C23C 16/4408 (2013.01); C23C 16/45529 (2013.01); C23C 16/45531 (2013.01); C23C 28/042 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method comprising:
depositing a first layer of yttrium oxide onto a surface of a chamber component for a processing chamber using a first number of repetitions of an atomic layer deposition process, wherein the first layer has a thickness ranging from two monolayers to about 1 micrometer, wherein the surface of the chamber component comprise aluminum oxide;
depositing a second layer of yttrium fluoride onto the surface of the chamber component using a second number of repetitions of the atomic layer deposition process, wherein the second layer has a thickness ranging from two monolayers to about 1 micrometer; and
annealing the chamber component comprising the first layer and the second layer to cause the first layer and the second layer to interdiffuse to form a homogenous corrosion and erosion resistant coating comprising a YOxFy solid state phase of the first layer and the second layer, wherein x and y have values that are based on the first number of repetitions of the atomic layer deposition process that are used to deposit the first layer and the second number of repetitions of the atomic layer deposition process that are used to deposit the second layer;
wherein the chamber component comprises one or more high aspect ratio features, and wherein an interior of the one or more high aspect ratio features are coated with the homogenous corrosion and erosion resistant coating, the high aspect ratio features having an aspect ratio of greater than 50:1.