Deposition rate measurements

An
example of thin film deposition rate measurements is presented in
the above figure. The plasma conditions are typical of
microcrystalline silicon thin film growth i.e high pressure, high
power high dilution of silane in hydrogen. The reflected intensity
of the light wave is recorded as a function of the deposition time
by applying the configuration that has been presented in the setup
section. According to the interference concept that has been
presented to the principles section the appearance of two
successively maxima or minima will take place in specific thin film
thickness and when the relative phase difference have a value
β1i-β1(i+1)=π.
When this condition is satisfied the variation of the film thickness
will be equal to:

As a
matter of fact, the record in time of the appearance of two
successive maxima or minima corresponds to a specific thin film
thickness and lead to the calculation of the deposition rate,
according to the relation:

where ΔΤ is the time that required for the appearance of two
successive maxima or minima.
Concerning the shape of the
recorded intensity and according to the discussion in the principle
section, one can say that the initial film growth (first two
fringes) is better described from the three interface configuration
and the continuous increase of the thin film refractive index and
the absorption coefficient. On the other hand, as the film thickness
increases the simpler scheme of the two interfaces and the constant
refractive index describes better the recorded intensity. Thus, for
the accuracy of the deposition rate measurement the first two
fringes have to be ignored as the refractive index in this stage is
also unknown.

The usefulness of the method
can be understood from the above figure. In cases where the
synergetic effect of different combinations of plasma parameters on
the deposition rate is searched, a quite large number of depositions
are required. For example, the investigation of the combined effect
of the total gas pressure and the interelectrode space on the
microcrystalline silicon deposition rate and the determination of
the optimal deposition rate conditions in terms of these two
parameters requires about 100 measurements. If for the measurement
of the film thickness an ex-situ method was applied this
investigation would take about 200 working days (including dead
times for reactor pumping to the base vacuum). On the other hand,
the application of an in - situ method as Laser Reflectance
Interferometry significantly reduces the investigation time to less
than 50 working days as 3 to 5 conditions can be checked at each
deposition.