Chemical dry etching of Si was performed
using the reaction of
F2 + NO → F + FNO at an elevated temperature. The
etched profile, surface morphology, and surface chemical bonding structures,
measured by a scanning electron microscope, X-ray photoelectron spectroscopy
(XPS), and a Fourier transform infrared spectrometer (FT-IR), were
significantly changed when the substrate was heated at 27 and 300
°C. Differences in total energies of Si before and after the
chemical reaction with gas molecules in the etching apparatus were
theoretically calculated by the density functional theory (DFT) using
CAM-B3LYP/6-311G+(d,p) in Gaussian 09. The possible change in chemical
bonding structures during and after the Si etching was considered
by correlating the measured XPS and FT-IR spectra and the DFT calculation
results. When the Si sample was heated at 27∼60 °C, the
nanoporous features were observed since molecules present in the gas
phase remained in the condensed layer near the Si surface and they
reacted with the Si surface at different rates. The chemisorbed F2, F, and FNO promoted Si etching by cleaving different bonds
to form dangling bonds, whereas NO and OH, produced from the reaction
between H2O and F, inhibited the etching by encapsulating
dangling bonds. The etch rate was significantly reduced, and the evolution
of the flat surface was observed at 60∼230 °C due to the
reduction of chemisorbed F2, F, and FNO on the Si surface.
When the Si sample was heated at above 230 °C, the etch rate
increased with the temperature due to the amplification of the reaction
rate constants of F2, F, and FNO with the Si surface. Unique
orientation-dependent etching was observed at these temperatures due
to the termination of dangling bonds by F without cleaving the Si–Si
lattice bonds. The contribution of NO and OH at above 230 °C
was ignored since they desorbed from the Si surface.