1. Field of the Invention
The invention relates generally to an apparatus for treating surfaces of wafer-shaped articles, such as semiconductor wafers, wherein one or more treatment fluids may be recovered from within a closed process chamber.
2. Description of Related Art
Semiconductor wafers are subjected to various surface treatment processes such as etching, cleaning, polishing and material deposition. To accommodate such processes, a single wafer may be supported in relation to one or more treatment fluid nozzles by a chuck associated with a rotatable carrier, as is described for example in U.S. Pat. Nos. 4,903,717 and 5,513,668.
Alternatively, a chuck in the form of a ring chuck adapted to support a wafer may be located within a closed process chamber and driven without physical contact through an active magnetic bearing, as is described for example in International Publication No. WO 2007/101764 and U.S. Pat. No. 6,485,531. Treatment fluids which are driven outwardly from the edge of a rotating wafer due to centrifugal action are delivered to a common drain for disposal.
Commonly-owned U.S. patent application Ser. Nos. 12/787,196 (filed May 25, 2010) and 12/842,836 (filed Jul. 23, 2010) and WO2010/113089 disclose improved constructions for ring chucks, in which the wafer is suspended from the underside of the ring chuck by downwardly projecting gripping pins.
The present inventors have discovered that, in chucks of the type described above, treatment liquids expelled from a wafer surface are not routed entirely as intended. In particular, despite the ring chuck being shaped to direct treatment fluid downwardly and outwardly of the wafer and ring chuck, the present inventors have discovered that there is a tendency for a part of the treatment liquid to migrate upwardly into the relatively narrow gap between the ring chuck and a surrounding cylindrical wall.
The present invention therefore provides a device for liquid treatment of a wafer-shaped article, comprising a closed process chamber, a ring chuck located within the closed process chamber, the ring chuck being adapted to be driven without physical contact through a magnetic bearing, a magnetic stator surrounding the closed process chamber, the closed process chamber comprising a cylindrical wall positioned between the ring chuck and the magnetic stator during liquid treatment of a wafer-shaped article, and the ring chuck has a form for preventing upward ingress of processing liquid into a gap defined between the ring chuck and the cylindrical wall.
In preferred embodiments of the present invention, the ring chuck comprises a downwardly-depending spoiler extending from a downwardly-facing surface of the ring chuck.
In preferred embodiments of the present invention, the spoiler extends from the ring chuck in a more vertical orientation than the downwardly-facing surface of the ring chuck from which it extends.
In preferred embodiments of the present invention, the ring chuck comprises a downwardly-facing fluid-directing surface that extends at an oblique angle to an axis of rotation of the ring chuck, and the ring chuck further comprises at least one downwardly-facing annular concave surface formed in a radially outer region of the downwardly-facing fluid-directing surface of the ring chuck.
In preferred embodiments of the present invention, the ring chuck comprises two downwardly-facing annular concave surfaces formed in a radially outer region of the downwardly-facing fluid-directing surface of the ring chuck, wherein the two downwardly-facing annular concave surfaces are adjacent to one another and separated from one another by a discontinuity in the downwardly-facing fluid-directing surface of the ring chuck.
In preferred embodiments of the present invention, the ring chuck comprises a downwardly- and inwardly-facing fluid-directing surface that extends at an oblique angle to an axis of rotation of the ring chuck, and the ring chuck further comprises an annular slit formed in the downwardly- and inwardly-facing fluid-directing surface of the ring chuck, the slit being dimensioned so as to disrupt a liquid flow across the downwardly- and inwardly-facing fluid-directing surface of the ring chuck.
In preferred embodiments of the present invention, the ring chuck comprises a downwardly-facing fluid-directing surface that extends at an oblique angle to an axis of rotation of the ring chuck, and the ring chuck further comprises a series of openings formed in a radially outer region of the downwardly-facing fluid-directing surface of the ring chuck.
In preferred embodiments of the present invention, the ring chuck comprises a downwardly-facing fluid-directing surface that extends at an oblique angle to an axis of rotation of the ring chuck, and the ring chuck further an annular concave fluid trap formed in a radially outwardly facing surface of the ring chuck that is positioned radially outwardly of and axially above the downwardly-facing fluid-directing surface of the ring chuck.
In preferred embodiments of the present invention, the device is a spin chuck in a process module for single wafer wet processing.
In preferred embodiments of the present invention, the ring chuck comprises a series of contact elements projecting downwardly from the ring chuck and adapted to hold a wafer-shaped article suspended from an underside of the ring chuck.
In preferred embodiments of the present invention, the contact elements are a series of pins that are conjointly movable between a radially inner position in which they contact a wafer-shaped article to a radially outer position in which they release the wafer-shaped article.
In preferred embodiments of the present invention, the pins are arranged in a circular series, and each pin projects from a respective pivotal base along an axis parallel to and offset from a pivot axis of said pivotal base.
In preferred embodiments of the present invention, the device further comprises a vertical movement actuator operatively associated with the stator.
In preferred embodiments of the present invention, the vertical movement actuator is operatively associated with the stator through a magnetic couple.
In preferred embodiments of the present invention, the magnetic bearing is an active magnetic bearing.
Other objects, features and advantages of the invention will become more apparent after reading the following detailed description of preferred embodiments of the invention, given with reference to the accompanying drawings, in which:
a is a cross-sectional perspective view of the detail II in
b is a cross-sectional perspective view of the detail II in
c is a cross-sectional perspective view of the detail II in
d is a cross-sectional perspective view of the detail II in
e is a cross-sectional perspective view of the detail II in
f is a cross-sectional perspective view of the detail II in
Referring to
An inner cover plate (131) is seated upon the upper end of the cylindrical chamber wall (105) so as to provide a closed top surface of the upper chamber, extending within the interior of the cylindrical chamber wall (105). The inner cylindrical plate (131) also extends radially outwardly from the upper end of the cylindrical chamber wall (105). Thus, the upper chamber of the closed process chamber comprises an interior region formed below the inner cover plate (131) and within the cylindrical chamber wall (105).
The lower chamber of the closed process chamber, which is larger than the upper chamber, is formed from below by a bottom plate (136). A frame (138) comprises vertical walls which are joined about the periphery of the bottom plate (136) so as to form vertically extending sidewalls of the lower chamber. A wafer loading and unloading access door (134) is provided within one wall of the frame (138) and a maintenance access door is provided within another wall of the frame (138).
Opposite the bottom plate (136), the frame (138) is joined to an inwardly extending annular cover plate (132), so as to form an annular top surface of the lower chamber. Thus, the lower chamber of the closed process chamber comprises an interior region formed above the bottom plate (136), within the frame (138) and below the annular cover plate (132).
The annular cover plate (132) is seated at its inner peripheral edge against the horizontally extending flange of the lower end of the cylindrical chamber wall (105), so as join the upper and lower chambers to form the closed process chamber.
A ring chuck (102) is located within the upper chamber. Ring chuck (102) is adapted to rotatably support a wafer (W). Preferably, ring chuck (102) comprises a rotatable drive ring having a plurality of eccentrically movable gripping members for selectively contacting and releasing the peripheral edge of a wafer.
In the embodiment shown in
Alternatively the ring chuck may be held by a passive bearing where the magnets of the ring chuck are held by corresponding high-temperature-superconducting magnets (HTS-magnets) that are circumferentially arranged on an outer ring chuck outside the chamber. With this alternative embodiment each magnet of the ring chuck is pinned to its corresponding HTS-magnets of the outer rotor. Therefore the inner rotor makes the same movement as the outer rotor without being physically connected.
The inner cover plate (131) is perforated by a medium inlet (110). Similarly, the bottom plate (136) is perforated by a medium inlet (109). During processing of a wafer, processing fluids may be directed through medium inlet (109) and/or (110) to a rotating wafer in order to perform various processes, such as etching, cleaning, rinsing, and any other desired surface treatment of the wafer undergoing processing.
Within the lower chamber of the closed process chamber, one or more vertically movable splash guards (111, 115) are provided. In
Drain (117) extends through the base plate (136) and opens to the inner fluid collector defined by splash guard (115), while drain (108) extends through the base plate (136) and opens to the outer fluid collector defined by splash guard (111). Preferably, base plate (136) is slanted relative to a horizontal plane toward each of the drains (108) and (117), such that fluid that is collected by the inner or outer fluid collector is caused to flow along the base plate (136) toward the drains (117) and (118).
An exhaust opening (106) leading to the closed process chamber also is provided to facilitate the flow of air and/or other gases and fumes.
Each splash guard is independently movable in the vertical direction. Accordingly, each splash guard can selectively be raised and/or lowered relative to the ring chuck (102), and relative to any other splash guard, such that excess process fluid emanating from the trailing edge of the ring chuck (122) is directed toward a selected fluid collector.
One or more actuators are provided outside of the closed process chamber in order to facilitate the selective and independent movement of each splash guard. For example, an actuator (113) is operatively associated with the outer splash guard (111) and another actuator (116) is operatively associated with the inner splash guard (115). Preferably three actuators are provided for each splash guard, although the number of actuators used will depend in part upon the geometric shape of the associated splash guard.
Actuators (113, 116) are provided with permanent magnets which correspond with permanent magnets carried by the splash guards (111, 115). Thus, selective vertical movement of each splash guard can be provided by the actuators through magnetic couples formed by the opposing sets of permanent magnets.
Referring now to
The ring chuck (102) further includes a trailing edge (122) which is oriented at a downward angle directed radially outward from the rotational axis of the ring chuck (102), as shown in
However, the present inventors have discovered that a construction such as that depicted in
Accumulation of the treatment liquid in the gap G between the rotating chuck (102) and the surrounding chamber wall (105) adversely influences the motor performance and can alter the on-wafer performance (process results) as well.
Thus, as illustrated in
As shown in
Reference numeral (126) in
Referring now to
In the embodiment of
Openings (129), like the structures of the other disclosed embodiments of the present invention, serve also to disrupt the flow of used process liquid that is expelled radially outwardly off of the wafer surfaces, promoting the formation of droplets and disrupting any laminar flow. The disclosed embodiments thus not only deflect the used process liquids but also decrease their velocity and flow energy. The droplets of used process liquid formed by the present devices have a lower tendency to travel around the outermost chuck edge and can be more readily spun off.
Referring now to
As shown in
Referring now to
Those skilled in the art will recognize that the structures disclosed in connection with
Stator (80) is mounted to a stator base plate (5) and is concentric with the cylindrical wall (60). The stator base plate (5) can be moved axially along the axis of the cylindrical wall (60), e.g. with pneumatic lifting devices. The stator base plate (5) and the stator (80) mounted thereto have central openings, whose diameter is greater than the outer diameter of the cylindrical wall (60). The top plate (25) can also be moved axially to open the chamber. In its closed position the top plate is sealed against the cylindrical wall (60).
As shown in
This embodiment has six downwardly oriented pin shafts (27), each of which has a small gear, which is driven by the gear ring (30). The pin shafts (27) are mounted so that they can turn about an axis A, which is parallel to the rotation axis of the annular chuck.
A pin (28) is mounted to or formed integrally with each pin shaft (27), at a position that is eccentric with respect to the axis of rotation A of the pin shaft (27).
Consequently, the pins (28) are displaced radially of the chuck when the pin shafts (27) are turned by the gear ring (30). As the pins and the gear ring (30) are both carried by the chuck base body (21), the pins shafts (27) are rotated by the gear ring (30) only when the gear ring (30) rotates relative to the chuck base body.
Pins (28) are positioned so as to contact a wafer W on its peripheral edge. As the pins (28) also support the weight of the wafer W, the pins (28) may either be cylindrical in shape or have recessed portions on their radially inwardly facing sides contacting the wafer edge, to prevent axial displacement of the wafer W relative to the pins (28) when the wafer is being gripped.
In order to mount the gear ring (30) into the annular groove of the chuck base body (21) the gear ring (30) consists of two separate segments, which are fixed together when inserted into the annular groove.
Two permanent magnets (33) (see
The plurality of rotor magnets (85) and the gear ring (30) carrying the permanent magnets (33) are encapsulated in a hollow annular space provided by the chuck base body (21), outer lower chuck cover (22), and the rotor magnet cover (29). Such rotor magnet cover (29) can be a stainless steal jacket.
The covers (22) and (29) are annular and concentric with the chuck base body (21).
When assembling the chuck (20) the pin shafts (27) are inserted from above into their respective seats so that the pin shafts tightly seal against the chuck base body 21 as shown in
Attached to the stator base plate 5 is the stator and active positioning unit (80) which is concentrically arranged with respect to the cylindrical wall (60). The positioning unit (80) corresponds with the rotor magnets (85) therefore levitating, positioning and rotating the chuck (20).
Below the active positioning unit (80) there are two pneumatic cylinders (50) mounted to the stator base plate (5). On the distal ends of the rods of the pneumatic cylinders (50) locking magnets (55) (permanent magnets) are arranged. The locking magnets correspond to the permanent magnets (33) of the gear ring (30). The pneumatic cylinders (50) are arranged so that the locking magnets (55) can be radially moved with respect to the axis of the cylindrical wall (60).
When the pins are to be opened e.g. to release a wafer the following procedure is conducted: the stator base plate (5) is lifted and therewith the levitating chuck (20) so that the cylindrical wall (60) is no longer in the gap between the locking magnets (55) and the chuck (20) (see
Thereafter the pneumatic cylinders (50) move the locking magnets (55) in close proximity to the chuck (20) and the chuck is turned so that the permanent magnets (33) and therewith the gear ring (30) is locked by the locking magnets. Now the chuck is turned while the gear ring stands still and thus the pins (28) open. Alternatively the chuck base body might stand still while the pneumatic cylinders are moved so that the locking magnets tangentially turn (along the circumference of the chuck), whereby the gear ring is turned.
As shown in
Similarly, the chuck as described in connection with present
While the present invention has been described in connection with various illustrative embodiments thereof, it is to be understood that those embodiments should not be used as a pretext to limit the scope of protection conferred by the true scope and spirit of the appended claims.