Embodiments of the present disclosure generally relate to bake apparatuses for handling and uniform baking of substrates and methods for the handling and uniform baking of substrates.
In the manufacture of optical devices, substrates may be heated to a temperature greater than 50 degrees Celsius (° C.), such as about 50° C. to about 300° C. Substrates, such as glass substrates, may include one or more materials that cause the substrates to bow at temperatures greater than 50° C. The one or more materials may be materials having a refractive index greater than 1.5. A substrate having a refractive index greater than 1.5 when heated to a temperature greater than 50° C. may have bowing of about 1 millimeter (mm) to about 2 mm from the edge of the substrate to the center of the substrate. Therefore, when disposed on a heated substrate support (such as a vacuum chuck, electrostatic chuck, or other substrate support operable to retain the substrate and heat the substrate via heating elements disposed therein) the edge of the substrate may not be retained on the heated substrate support resulting in non-uniform temperature across the surface of the substrate.
During, for example, post-apply baking (PAB) the non-uniform temperature across the surface of the substrate may cause non-uniform removal of solvents from a resist material disposed on the surface of the substrate resulting in a non-uniform resist layer. During, for example, post-exposure baking (PEB) the non-uniform temperature across the surface of the substrate may result in a non-uniform development (e.g., patterning) of the resist layer. Accordingly, what is needed in the art are bake apparatuses for handling and uniform baking of substrates and methods for the handling and the uniform baking of substrates.
In one embodiment, an apparatus is provided. The apparatus includes a substrate holding assembly disposed on a base. The substrate holding assembly includes two or more shafts. Each shaft of the two or more shafts has extensions disposed thereon. The extensions of each shaft of the two or more shafts are operable to support one or more substrates disposed between the one or more shafts. The apparatus further includes a lid. The lid includes one or more heating elements disposed therein. The apparatus further includes a process volume formed between the lid and the base.
In another embodiment, an apparatus is provided. The apparatus includes a substrate support disposed on a base. The substrate support includes one or more heating elements and lift pins operable to support a substrate. The apparatus further includes a lid. The lid includes an edge brace coupled thereon. The edge brace includes a ring. The apparatus further includes a process volume formed between the lid and the base.
In yet another embodiment, a method is provided. The method includes disposing one or more substrates on a substrate holding assembly of a bake apparatus. The method further includes lowering a lid of the bake apparatus to form a process volume in the bake apparatus. The method further includes heating the process volume with one or more heating elements of the bake apparatus. The heating elements heat the one or more substrates uniformly or substantially uniformly.
So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, and may admit to other equally effective embodiments.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.
Embodiments of the present disclosure generally relate to bake apparatuses for handling and uniform baking of substrates and methods for the handling and the uniform baking of substrates. The bake apparatuses allow the substrates to be heated to a temperature greater than 50° C. without bowing of about 1 mm to about 2 mm from the edge of the substrates to the center of the substrates. The bake apparatuses heat the substrates uniformly or substantially uniformly to improve substrate quality.
The one or more extensions 116 of each of the shafts 114 are coupled opposite to each other such that one or more substrates 101 are supported by the extensions 116. The extension 116 is in contact with portions of the edge of each of the substrates 101. Although only three pairs of extensions 116 are shown in
In one embodiment, which can be combined with other embodiments described herein, the one or more substrates 101 include one or more materials that are subject to bowing at a temperature greater than 50° C., such as such as about 50° C. to about 300° C. In another embodiment, which can be combined with other embodiments described herein, the one or more substrates 101 include, but are not limited to, at least one of amorphous dielectrics, non-amorphous dielectrics, crystalline dielectrics, silicon oxide, polymers, and combinations thereof. For example, the one or more substrates 101 include at least one of glass, plastic, and polycarbonate materials that are subject to bowing at a temperature greater than 50° C. In yet another embodiment, which can be combined with other embodiments described herein, the one or more substrates 101 include, but are not limited to, at least one of an oxide, sulfide, phosphide, telluride, and combinations thereof. In one example, the substrates 101 include at least one of silicon (Si), silicon dioxide (SiO2), sapphire, and high-index transparent materials containing materials. In yet another embodiment, which can be combined with other embodiments described herein, the substrates 101 have a refractive index greater than 1.5. In yet another embodiment, which can be combined with other embodiments described herein, the substrates 101 include a glass material having a refractive index greater than 1.5.
In one embodiment, which can be combined with other embodiments described herein, the substrates 101 have a thickness less than about 1 mm. In one embodiment, which can be combined with other embodiments described herein, the substrates 101 have a diameter of about 200 mm. In another embodiment, which can be combined with other embodiments described herein, the substrates 101 have a diameter of about 300 mm. In another embodiment, which can be combined with other embodiments described herein, the substrates 101 have a diameter of about 4 inch to about 12 inch.
The lid 104 includes an actuator 108 operable to raise and lower the lid 104 from a raised position (shown in
Exposing each portion of the substrates 101 to the same temperature allows the one or more substrates 101 to be heated to the temperature greater than 50° C. without bowing. The bowing of the one or more substrates 101 is generally about 1 mm to about 2 mm from the edge of the substrates 101 to the center of the substrates 101. During post-apply baking (PAB), for example, the uniform or substantially uniform or substantially uniform temperature across the surface of the one or more substrates 101 provides for a uniform or substantially uniform resist layer over the one or more substrates 101. During post-exposure baking (PEB), for example, the uniform or substantially uniform temperature across the surface of the one or more substrates 101 provides for a uniform or substantially uniform development (e.g., patterning) of the resist layer over the one or more substrates 101.
In one embodiment, which can be combined with other embodiments described herein, the temperature the one or more substrates 101 are exposed to in the process volume 103 is increased from about 40° C. to about 800° C. The rapid temperature increase bakes the one or more substrates 101. In another embodiment, which can be combined with other embodiments described herein, the temperature the one or more substrates 101 are exposed to in the process volume 103 is decreased from about 800° C. to about 40° C. The rapid cooling of the one or more substrates is in preparation of transfer of the one or more substrates out of the process volume 103. In another embodiment, which can be combined with other embodiments described herein, the temperature the one or more substrates 101 are exposed to in the process volume 103 is maintained during a PEB process at about 80° C. to about 150° C. In yet another embodiment, which can be combined with other embodiments described herein, the temperature the substrates 101 are exposed to in the process volume 103 is maintained during a PAB process at about 80° C. to about 300° C. The embodiments of the bake apparatus 100 of
In one embodiment, which can be combined with other embodiments described herein, the temperature the one or more substrates 101 are exposed to in the process volume 103 is increased from about 40° C. to about 800° C. In another embodiment, which can be combined with other embodiments described herein, the temperature the one or more substrates 101 are exposed to in the process volume 103 is decreased from about 800° C. to about 40° C. In another embodiment, which can be combined with other embodiments described herein, the temperature the one or more substrates 101 are exposed to in the process volume 103 is maintained during a PEB process at about 80° C. to about 150° C. In yet another embodiment, which can be combined with other embodiments described herein, the temperature the substrates 101 are exposed to in the process volume 103 is maintained during a PAB process at about 80° C. to about 300° C. The embodiments of the bake apparatus 200 of
At operation 303, the process volume 103 is heated. The process volume 103 is heated by the one or more heating elements 106. The one or more heating elements 106 are disposed in the lid 104 or the lid 204. Each substrate 101 of the one or more substrates 101 is heated equally in the process volume 103 to the desired temperature. The equal heating of the one or more substrates 101 prevents bowing of the one or more substrates 101. At operation 304, the bake apparatus 100 or the bake apparatus 200 moves form the closed position to the open position. In one embodiment, which can be combined with other embodiments described herein, the lid 104 is raised by the actuator 108 to the open positon (shown in
In one embodiment, which can be combined with other embodiments described herein, the temperature the substrate 101 is exposed to by the substrate support 416 is increased from about 40° C. to about 800° C. In another embodiment, which can be combined with other embodiments described herein, the temperature the substrate 101 is exposed to by the substrate support 416 is decreased from about 800° C. to about 40° C. In another embodiment, which can be combined with other embodiments described herein, the temperature the substrate 101 is exposed to by the substrate support 416 is maintained during the PEB process at about 80° C. to about 150° C. In yet another embodiment, which can be combined with other embodiments described herein, the temperature the substrate 101 is exposed to by the substrate support 416 is maintained during the PAB process at about 80° C. to about 300° C.
The lid 404 includes actuator 408 operable to raise and lower the lid 404 from a raised position (shown in
In the closed position, a ring 426 of the edge brace 424 contacts edge portions of the substrate 101. The edge brace 424 is coupled to the lid 404. The ring 426 of the edge brace 424 contacting the edge portions of the substrate 101 forces the edge portions of the substrate 101 against the surface of the substrate support 416. The substrate 101 is subjected to a uniform or substantially uniform temperature distribution when the substrate 101 is heated by the substrate support 416. In one embodiment, which can be combined with other embodiment described herein, the lift pins 422 are recessed into the substrate support 416 when in the closed position. The lift pins 422 are recessed such that the substrate 101 is in direct contact with the substrate support 416.
The ring 426 of the edge brace 424 has a ring width 427. The ring width 427 corresponds to the diameter of the substrate 101. For example, the ring width 427 is between about 200 mm and about 300 mm. The ring 426 may have different surface profiles 428 that contact the edge portions of the substrate 101 to force the edge portions of the substrate 101 against the surface of the substrate support 416 uniformly or substantially uniformly. The surface profiles 428 include but are not limited to a rectangular, triangular, or trapezoidal shape. The embodiments of the bake apparatus 400 of
Heating each portion across the surface of the substrate 101 to the same temperature allows the substrate 101 to be heated to a temperature greater than 50° C. The heating elements 106 heat the process volume 103 between about 50° C. to about 600° C. During PAB, for example, the uniform or substantially uniform temperature across the surface of the substrate 101 provides for the uniform or substantially uniform resist layer over the substrate 101. During PEB, for example, the uniform or substantially uniform temperature across the surface of the substrate 101 provides for the uniform or substantially uniform development (e.g., patterning) of the resist layer over the substrates.
The retention plate 604 is one of a vacuum chuck, electrostatic chuck, or any other substrate support operable to retain substrates 101 described herein. In one embodiment, as shown in
As discussed, heating each portion across the surface of the substrate 101 to the same temperature allows the substrate 101 to be heated to the temperature greater than 50° C. without bowing of about 1 mm to about 2 mm from the edge of the substrate 101 to the center of the substrate 101. In one embodiment, which can be combined with other embodiments described herein, the device 600 can be utilized in the bake apparatus 400. For example, the retention plate 604 and the heating plate 602 may replace the substrate support 416 of the bake apparatus 400.
In one embodiment, which can be combined with other embodiments described herein, the temperature the one or more substrates 101 are exposed to in the process volume 103 is increased from about 40° C. to about 800° C. In another embodiment, which can be combined with other embodiments described herein, the temperature the one or more substrates 101 are exposed to in the process volume 103 is decreased from about 800° C. to about 40° C. In another embodiment, which can be combined with other embodiments described herein, the temperature the one or more substrates 101 are exposed to in the process volume 103 is maintained during a PEB process at about 80° C. to about 150° C. In yet another embodiment, which can be combined with other embodiments described herein, the temperature the substrates 101 are exposed to in the process volume 103 is maintained during a PAB process at about 80° C. to about 300° C. The embodiments of the device 600 of
In summation, bake apparatuses for handling and uniform or substantially uniform baking of substrates and methods for the handling and the uniform or substantially uniform baking of substrates are described herein. The bake apparatuses allow the substrates to be heated to a temperature greater than 50° C. without bowing of about 1 mm to about 2 mm from the edge of the substrates to the center of the substrates. The bake apparatuses heat the substrates uniformly or substantially uniformly to improve substrate quality.
While the foregoing is directed to examples of the present disclosure, other and further examples of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
This application claims benefit of U.S. Provisional Patent Application Ser. No. 62/951,909, filed Dec. 20, 2019, which is herein incorporated by reference.
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62951909 | Dec 2019 | US |