Apparatus and method for conditioning a fixed abrasive polishing pad in a chemical mechanical planarization process

Abstract

A method and apparatus for conditioning a fixed abrasive polishing pad used in chemical mechanical planarization of semiconductor wafers is described. The apparatus includes a conditioning member formed from glass, at least one collimated hole structure located within the conditioning member, wherein the collimated hole structure forms a channel, and wherein each channel is arranged in a generally parallel orientation with respect to any other channel. The method includes providing at least one conditioning member formed with at least one capillary tube array, wherein the capillary tube array forms multiple channels within the conditioning member, pressing the conditioning member against the fixed abrasive polishing pad, and moving the fixed abrasive polishing pad. In one embodiment, the method further comprises rotating the conditioning member to simulate the polishing of at least one semiconductor wafer.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

Related subject matter is disclosed in a commonly-owned, co-pending patent application entitled “APPARATUS AND METHOD FOR QUALIFYING A POLISHING PAD IN A CHEMICAL MECHANICAL PLANARIZATION SYSTEM” Attorney Docket No. 7103/181, filed on even date herewith.

FIELD OF THE INVENTION

The present invention relates to an apparatus and method for conditioning a chemical mechanical planarization process. More particularly, the present invention relates to an apparatus and method for conditioning a fixed abrasive polishing pad used in the chemical mechanical planarization of semiconductor wafers.

BACKGROUND

Semiconductor wafers are typically fabricated with multiple copies of a desired integrated circuit design that will later be separated and made into individual chips. A common technique for forming the circuitry on a semiconductor is photolithography. Part of the photolithography process requires that a special camera focus on the wafer to project an image of the circuit on the wafer. The ability of the camera to focus on the surface of the wafer is often adversely affected by unevenness in the wafer surface. This sensitivity is accentuated with the current drive toward smaller, more highly integrated circuit designs. Semiconductor devices are also commonly constructed in layers, where a portion of a circuit is created on a first level and conductive vias are made to connect up to the next level of the circuit. After each layer of the circuit is etched on a semiconductor wafer, an oxide layer is put down allowing the vias to pass through but covering the rest of the previous circuit level. Each layer of the circuit can create or add unevenness to the wafer that is preferably smoothed out before generating the next circuit layer.

Chemical mechanical planarization (CMP) techniques are used to planarize the raw wafer and each layer of material added thereafter. Available CMP systems, commonly called wafer polishers, often use a rotating wafer holder that brings the wafer into contact with a polishing pad moving in the plane of the wafer surface to be planarized. In some CMP systems, a fixed abrasive polishing pad is used to polish the wafer. The wafer holder then presses the wafer against the rotating fixed abrasive polishing pad and is rotated to polish and planarize the wafer.

CMP systems using a fixed abrasive pads require the presence of features on the semiconductor wafer to function. Fixed abrasive pads include abrasive particles embedded within a polymer matrix. To operate a CMP system having a fixed abrasive pad, the fixed abrasive pad must first be conditioned. Traditionally, fixed abrasive pads are conditioned by polishing a patterned semiconductor wafer. The patterned semiconductor wafer conditions the fixed abrasive pad by using the topography features created by the etching and deposition processes on the semiconductor wafer to remove a portion of the polymer matrix, thus exposing the abrasive particles embedded within. By exposing abrasive particles within the polymer matrix, the fixed abrasive pad can begin to polish the semiconductor wafer. In order to continuously condition a fixed abrasive pad, patterned wafers with sufficient topography have to be continuously polished. The fresh, unconditioned fixed abrasive pad exhibits an unpredictable removal rate and needs to be conditioned prior to running product wafers. Typically, dummy patterned wafers are used to prepare the pad for product wafer polishing. These dummy wafers cost a considerable amount of money to manufacture, and the loading of these dummy wafers onto a CMP system takes up a considerable amount of time. Accordingly, further development of an apparatus and method for conditioning a chemical mechanical planarization process, and more specifically, for conditioning a fixed abrasive pad used in the chemical mechanical planarization of semiconductor wafers, is necessary in order to decrease the cost and time for conditioning a fixed abrasive pad.

SUMMARY

According to a first aspect of the present invention, an apparatus for conditioning a fixed abrasive polishing pad used in chemical mechanical planarization of semiconductor wafers is provided. The apparatus includes a conditioning member formed from glass, at least one collimated hole structure located within the conditioning member, wherein the collimated hole structure forms a channel, and wherein each channel is arranged in a generally parallel orientation with respect to any other channel. In one embodiment, the conditioning member includes a material selected from the group consisting of borosilicate glass, soda lime glass, high-lead glass, silicon oxide, and quartz. In another embodiment, each channel within each collimated hole structure has a width of between about 3 microns and about 100 microns.

According to another aspect of the present invention, a method for conditioning a fixed abrasive polishing pad used in chemical mechanical planarization of semiconductor wafers is provided. The method includes providing at least one conditioning member formed with at least one capillary tube array, wherein the capillary tube array forms multiple channels within the conditioning member, pressing the conditioning member against the fixed abrasive polishing pad, and rotating or otherwise moving the fixed abrasive polishing pad. In one embodiment, the method further comprises rotating the conditioning member to simulate the polishing of at least one semiconductor wafer. In one embodiment, the fixed abrasive polishing pad comprises abrasive particles embedded within a polymer matrix.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a preferred embodiment of a pad conditioning apparatus;

FIG. 2 is an enlarged side view of the pad conditioning apparatus in FIG. 1 ;

FIG. 3 is a bottom view of the pad conditioning apparatus in FIG. 2 ;

FIG. 4 is an enlarged perspective view of a conditioning member for a pad conditioning apparatus;

FIG. 5 is an enlarged cross-sectional view of a conditioning member conditioning a fixed abrasive polishing pad;

FIG. 6 . is a side view of a linear wafer polisher; and

FIG. 7 is a perspective view of a rotary wafer polisher.

It should be appreciated that for simplicity and clarity of illustration, elements shown in the Figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements are exaggerated relative to each other for clarity. Further, where considered appropriate, reference numerals have been repeated among the Figures to indicate corresponding elements.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

FIG. 1 illustrates a presently preferred embodiment of conditioning apparatus 20 according to the present invention. Conditioning apparatus 20 is used to condition a fixed abrasive polishing pad 28 , preferably for use in chemical mechanical planarization of semiconductor wafers 22 . Fixed abrasive polishing pad 28 includes abrasive particles 27 embedded within a polymer matrix 25 , as illustrated in FIG. 5 . Abrasive particle 27 include any particles which can be used to wear down or reduce a surface known by those skilled in the art, such as particles of sand, silica, alumina (Al2O3), zirconia, and diamond. Polymer matrix 25 is used to hold abrasive particles 27 , and may include different kinds of polymers that can be used to suspend or hold abrasive particles 27 known to those skilled in the art. Conditioning apparatus 20 includes at least one collimated hole structure 41 , as illustrated in FIGS. 4-5 . Collimated hole structure 41 includes at least one or more channels 46 formed through a conditioning member 40 , as illustrated in FIGS. 4-5 . Channels 46 are formed in a manner so that each channel 46 is generally parallel to each adjacent channel 46 . Preferable, the channels 46 are generally cylindrical in shape. However, channels 46 may form any one of a number of shapes, such as parallelepiped, or have any one of a number of cross sections, such as triangular, or have any irregular shape or cross section. Preferably, channels 46 are continuous and have a generally consistent width W and length L between channels. The width W of each channel 46 and the length L between each channel 46 is designed so as to simulate the features found on a semiconductor wafer. Preferably, channels 46 within each collimated hole structure 41 have a width W of between about 3 microns and about 100 microns. The length L between each channel 46 within each collimated hole structure 41 is preferably between about 3 microns and about 100 microns. Preferably, the height H of the collimated hole structures 41 is greater than the height of a semiconductor wafer, and more preferably, the collimated hole structures 41 have a height H, that is between about 2 millimeters to about 6 millimeters. In one preferred embodiment, conditioning member 40 has a height of between about 0.1 centimeters and about 10 centimeters. Conditioning member 40 includes a material with a similar density and structure as a commonly used deposited SiO2, such as, for example, borosilicate glass, soda lime glass, high-lead glass, and silicon oxide. Collimated hole structures 41 are also known as capillary arrays and may be obtained from Collimated Holes, Inc. of 460 Division Street, Campbell, Calif. 95008. Typically, collimated hole structures 41 come in either the shape of a bar or the shape of a disc.

Collimated hole structures 41 may be produced in any one of a number of methods. In one method, long, hollow tubes of glass are bundled together inside of a larger glass tube, the entire assembly is then reduced to the desired width through a drawing, or stretching, process. Drawn capillaries exhibit pristine, fire-polished inner walls. In another method, collimated hole structures 41 are produced using an etching process. In this method, a block of material is produced in which soluble glass fibers are surrounded by insoluble claddings, forming a regular matrix. After the block has been fused, plates are sliced, polished, and placed in an acid bath. The core glass is etched away, leaving a structure of very precise holes in the residual matrix. Etched plate arrays contain holes throughout the entire matrix, all the way to the edges of the plate.

Conditioning apparatus 20 includes at least one conditioning member 40 , as illustrated in FIG. 3 . Conditioning member 40 can be formed in any one of a variety of shapes. In one preferred embodiment, conditioning member 40 is formed in the shape of a bar 56 , as illustrated in FIG. 3 . In one preferred embodiment, conditioning member 40 is formed in the shape of a disc 58 , as illustrated in FIG. 3 . In one preferred embodiment, conditioning apparatus 20 includes a series of conditioning members 40 in the shape of bars 56 and/or discs 58 that are combined together and placed adjacent to each other in order to approximate the shape and size of a semiconductor wafer, as illustrated in FIG. 3 . In one preferred embodiment, conditioning apparatus 20 includes a single conditioning member 40 in the shape of a bar 56 or a disc 58 in order to approximate the shape and size of a semiconductor wafer.

Conditioning apparatus 20 is mounted or attached onto a retaining fixture 50 , as illustrated in FIGS. 2-3 . Preferably, conditioning apparatus 20 is attached to retaining fixture 50 using any attachment means know to those of skill in the art, such as a retaining ring, a hook and loop type fastener (such as VELCRO™), a screw, a belt, a cable, a snap-fit member, an adhesive, a captivating spring, or any other type of means for attaching one member to a second member. Preferably, conditioning apparatus 20 is removably attached to retaining fixture 50 , however, conditioning apparatus 20 may be fixedly attached to retaining fixture 50 . Retaining fixture 50 forms a cavity 51 within which conditioning apparatus 20 rests. Retaining fixture 50 is connected to a gimbal 54 which is used to retain retaining fixture 50 in a level position when retaining fixture is connected with gimbal shaft 60 . Preferably, gimbal 54 is connected with gimbal shaft 60 through a series of bolts 52 . Bolts 52 secure gimbal 54 to gimbal shaft 60 . Gimbal shaft 60 rotates gimbal 54 , which in turn causes retaining fixture 50 and conditioning apparatus 20 to rotate. Gimbal shaft 60 and fixed abrasive polishing pad 28 are used in and connected with a typical CMP system, or wafer polisher 23 , as illustrated in FIG. 1 .

Preferably, conditioning apparatus 20 is in direct contact with the surface of fixed abrasive polishing pad 28 , as illustrated in FIGS. 1 and 5 . Conditioning apparatus 20 has a width or diameter D defined as the distance from one end of conditioning apparatus 20 to a second end of conditioning apparatus 20 , as illustrated in FIG. 2 . Preferably, conditioning apparatus 20 has a width or diameter D that is equal to a substantial amount of or greater than the diameter of a semiconductor wafer in order to allow conditioning apparatus 20 to simulate the polishing of a semiconductor wafer. In one preferred embodiment, conditioning apparatus 20 has a width or diameter D that is between about 5 centimeters to about 30 centimeters. By mounting conditioning apparatus 20 in retaining fixture 50 , by connecting retaining fixture 50 to gimbal shaft 60 , and by giving conditioning apparatus 20 a width or diameter D that is equal to a substantial amount of or greater than the diameter of a semiconductor wafer, conditioning apparatus 20 is able to simulate the size and movement of a semiconductor wafer within a CMP system, or wafer polisher 23 . In one preferred embodiment, conditioning apparatus 20 has a width or diameter D that is less than the diameter of a semiconductor wafer.

Preferably, conditioning apparatus 20 forms a generally circular footprint over fixed abrasive polishing pad 28 , as illustrated in FIGS. 1 and 4 , in order to simulate the footprint of a semiconductor wafer. However, as known by one of ordinary skill in the art, conditioning apparatus 20 can form footprints with a variety of shapes such as a rectangular shape, a square shape, a v-shape, a w-shape, a u-shape, and any other regular or irregularly shaped footprint over fixed abrasive polishing pad 28 .

In one preferred embodiment, wafer polisher 23 is a linear belt polisher having fixed abrasive polishing pad 28 mounted on linear belt 30 that travels in a forward direction 24 , as illustrated in FIG. 1 . In this embodiment, linear belt 30 is mounted on a series of rollers 32 . Rollers 32 preferably include coaxially disposed drive shafts 33 extending through the length of rollers 32 . Alternatively, each drive shaft 33 may be two separate coaxial segments extending partway in from each of the ends 35 , 36 of rollers 32 . In yet another embodiment, each drive shaft 33 may extend only partly into one of the ends 35 , 36 of rollers 32 . Connectors (not shown) on either end 35 , 36 of rollers 32 hold each drive shaft 33 . A motor 70 connects with at least one drive shaft 33 and causes rollers 32 to rotate, thus moving linear belt 30 and fixed abrasive polishing pad 28 . In one preferred embodiment, polishing pad 28 is stretched and tensed to a tension of approximately 300 lbs. FIG. 6 illustrates one environment in which a preferred embodiment of conditioning apparatus 20 may operate. In FIG. 6 , conditioning apparatus 20 is positioned on retaining fixture 50 attached to a gimbal 54 and gimbal shaft 60 within wafer polisher 23 . The wafer polisher 23 may be a linear belt polisher such as the TERES™ polisher available from Lam Research Corporation of Fremont, Calif. The alignment of the conditioning apparatus 20 with respect to the fixed abrasive polishing pad 28 is best shown in FIGS. 1 and 6 .

In one preferred embodiment, wafer polisher 23 is a rotary wafer polisher having fixed abrasive polishing pad 28 mounted on circular disc 90 that rotates in one direction, as illustrated in FIG. 7 . Circular disc 90 rotates about shaft 92 while conditioning apparatus 20 and retaining fixture 50 rotate about gimbal shaft 60 located a distance away from shaft 92 . Preferably, shaft 92 is positioned coaxially with gimbal shaft 60 . In this embodiment, wafer polisher 23 may be a rotary wafer polisher such as the Mirra polisher available from Applied Materials of Santa Clara, Calif. The alignment of the conditioning apparatus 20 with respect to the fixed abrasive polishing pad 28 is best shown in FIG. 7 .

When wafer polisher 23 is activated, belt 30 begins to move in a forward direction 24 , as illustrated in FIGS. 1 and 7 . Conditioning apparatus 20 is then pressed against and moved across fixed abrasive polishing pad 28 along a trajectory to simulate the polishing of a semiconductor wafer. Preferably, conditioning apparatus 20 is pressed against fixed abrasive polishing pad 28 with a force of between about 0.5 psi and about 4 psi. In one preferred embodiment, conditioning apparatus 20 is applied to the fixed abrasive polishing pad 28 for about 10 seconds to about 80 seconds. In one preferred embodiment, fixed abrasive polishing pad 28 is moved across conditioning apparatus 20 at a speed of about 25 centimeters/second to about 200 centimeters/second. Upon moving conditioning apparatus 20 across fixed abrasive polishing pad 28 , the polymer matrix 25 of fixed abrasive polishing pad 28 becomes worn down, as illustrated in FIG. 5 , exposing abrasive particles 27 . By wearing down polymer matrix 25 of fixed abrasive polishing pad 28 in a manner similar to that of a semiconductor wafer, thus exposing abrasive particles 27 , conditioning apparatus 20 prepares the fixed abrasive polishing pad 28 for polishing semiconductor wafers. An advantage of the presently preferred conditioning apparatus 20 is that by using conditioning apparatus 20 to prepare the fixed abrasive polishing pad 28 for polishing semiconductor wafers, one is able to replace tens or even hundreds of patterned semiconductor wafers costing much more than one single conditioning apparatus 20 . Thus, conditioning apparatus 20 can reduce the costs of preparing the fixed abrasive polishing pad 28 for polishing semiconductor wafers, which in turn reduces the costs of bringing new CMP processes into production and reduces the cost of CMP process development.

In one preferred embodiment, to prepare the fixed abrasive polishing pad 28 for polishing semiconductor wafers, conditioning apparatus 20 is mounted onto a retaining fixture 50 and the retaining fixture is connected with a CMP system. Preferably the height H of the collimated hole structures 41 , and thus the height H of the conditioning member 40 , is approximately between about 2 millimeters and about 10 millimeters in order to allow the conditioning of at least one fixed abrasive polishing pad 28 . In one preferred embodiment, more than one conditioning apparatus 20 is used in order to allow the conditioning of at least one fixed abrasive polishing pad 28 . In one preferred embodiment, a single conditioning apparatus 20 is used to allow the conditioning of more than one fixed abrasive polishing pad 28 . In order to simulate the wear on fixed abrasive polishing pad 28 , conditioning apparatus 20 is pressed against fixed abrasive polishing pad 28 , and fixed abrasive polishing pad 28 is moved across conditioning apparatus 20 at the same rate and for the same time as at least one or more semiconductor wafers would be to allow the conditioning of at least one fixed abrasive polishing pad 28 .

Thus, there has been disclosed in accordance with the invention, an apparatus and method for conditioning a chemical mechanical planarization process that fully provides the advantages set forth above. Although the invention has been described and illustrated with reference to specific illustrative embodiments thereof, it is not intended that the invention be limited to those illustrative embodiments. Those skilled in the art will recognize that variations and modifications can be made without departing from the spirit of the invention. It is therefore intended to include within the invention all such variations and modifications that fall within the scope of the appended claims and equivalents thereof.

Claims

1. An apparatus for conditioning a fixed abrasive polishing pad used in chemical mechanical planarization of semiconductor wafers, the apparatus comprising:a fixed abrasive polishing pad; a conditioning member formed from glass positioned adjacent the fixed abrasive polishing pad and adapted to engage a surface of the fixed abrasive polishing pad; and at least one collimated hole structure located within the conditioning member, the collimated hole structure forming a channels, wherein each channel is arranged in a generally parallel orientation with respect to any other channel.

2. The apparatus of claim 1, wherein the conditioning member comprises a material selected from the group consisting of borosilicate glass, soda lime glass, high-lead glass, silicon oxide, and quartz.

3. The apparatus of claim 1, wherein each channel within each collimated hole structure has a width of between about 3 microns and about 100 microns.

4. The apparatus of claim 1, wherein the conditioning member has a diameter of between about 5 centimeters and about 30 centimeters.

5. The apparatus of claim 1, wherein the conditioning member is formed in the shape of a bar.

6. The apparatus of claim 1, wherein the conditioning member is formed in the shape of a disc.

7. The apparatus of claim 1, wherein the conditioning member has a height of between about 2 millimeters and about 10 millimeters.

8. A method for conditioning a fixed abrasive polishing pad used in chemical mechanical planarization of semiconductor wafers, the method comprising:providing at least one conditioning member formed with at least one capillary tube array, wherein the capillary tube array forms multiple channels within the conditioning member; pressing the conditioning member against the fixed abrasive polishing pad; and moving the fixed abrasive polishing pad.

9. The method of claim 8, wherein the fixed abrasive polishing pad comprises abrasive particles embedded within a polymer matrix.

10. The method of claim 8, wherein the conditioning member is applied to the fixed abrasive polishing pad for about 10 seconds to about 80 seconds.

11. The method of claim 8, further comprising rotating the conditioning member to simulate the polishing of at least one semiconductor wafer.

12. The method of claim 8, wherein the pressing of the conditioning member is conducted with a force of between about 0.5 psi and about 4.0 psi.

13. The method of claim 8, wherein the conditioning member comprises a material selected from the group consisting of borosilicate glass, soda lime glass, high-lead glass, and silicon oxide.

14. The method of claim 8, wherein the conditioning member is removably attached to a retaining fixture.

15. The method of claim 8, wherein the conditioning member has a height of between about 0.1 centimeters and about 10 centimeters.

16. The method of claim 8, wherein the fixed abrasive polishing pad is moved across the conditioning member at a speed of about 25 centimeters/second to about 200 centimeters/second.

17. An apparatus for conditioning a fixed abrasive polishing pad used in chemical mechanical planarization of semiconductor wafers, the apparatus comprising:at least one conditioning member comprising a material selected from the group consisting of borosilicate glass, soda lime glass, high-lead glass, and silicon oxide; and at least one capillary tube array located within the conditioning member, the capillary tube array forming a channels, wherein each channel is arranged in a generally parallel orientation with respect to any other channel, wherein each channel within each capillary tube array has a width of between about 3 microns and about 100 microns, and wherein the distance between each channel within each capillary tube array is between about 3 microns and about 100 microns.

18. The apparatus of claim 17, wherein the conditioning member is formed in the shape of a bar.

19. The apparatus of claim 17, wherein the conditioning member is formed in the shape of a disc.

20. The apparatus of claim 17, further comprising a retaining fixture removably attached to at least one conditioning member, the retaining fixture for securing the conditioning member to a chemical mechanical planarization machine.