The following is directed to a temperature sensor. In particular, the description is directed to a fiber optic temperature sensor.
In semiconductor processing tools, there is a need for temperature control and monitoring to understand and maintain process control. A limited selection of materials can be used within chambers to avoid contamination of the chamber and degradation of the sensor materials exposed to the process environment. In addition, specific applications reach high temperatures and require materials to survive over, e.g., 300° C. Fiber optic temperature sensors used in such applications require careful material selection and unique design considerations. There is also a need for similar temperature sensing, monitoring, and control in other applications beyond semiconductor processing, such as, power, oil and gas, medical to name a few.
Fiber optic temperature sensors, such as temperature probes, normally include an optical fiber which can deliver light to a sensing material (e.g., phosphor). The light illuminates the phosphor which, in turn, luminesces visibly. The temperature of the phosphor can be determined by observing the changes in certain characteristics of the emitted light.
Like temperature sensors, thermographic phosphor sensors do not directly measure temperature but instead measure a physical property that exhibits strong temperature dependence, e.g., phosphorescence time decay. When this property is measured relative to a stable and accurate temperature source, the resulting relationship, or calibration curve can then be used to convert between the measured physical property, e.g., time decay, and temperature, enabling sensor functionality.
Phosphor material used inside temperature sensor probes are often exposed to harsh environments with high temperatures and corrosive chemicals. For example, such probes are often used in systems that use active heating and are exposed to radio frequency (RF) through, e.g., plasma generation, such as plasma deposition processes in a chamber. This results in a change or loss of measurement over time as the phosphor is attacked and degrades. The phosphor should be protected from the environment to ensure long term reliability of the temperature sensor measurement systems. The mechanical design of the probe considers protection of the phosphor from the environment containing at least plasma and fluorine at temperatures up to or above, e.g., 300° C.
Minimizing the difference in temperature between the phosphor and target surface enables more accurate measurement. For contact temperature sensors, this can be achieved by minimizing the heat loss from the contact tip to the body of the probe and maximizing the contact between the tip and the measurement surface.
A unique solution is required to achieve accurate contact temperature measurement at high temperatures in semiconductor process environments. To achieve this, the objective of the design often includes protecting the sensing material from the process environment, reducing the heat loss from the tip to improve contact measurement accuracy, and maximizing the material selection in the high temperature and semiconductor process environment.
Another challenge with temperature measurement is in implementing calibration of an electrostatic chuck (ESC) used to support a wafer to be etched or otherwise interacted with in the chamber. Solutions exist that use temperature sensors on the chuck, e.g., resistance temperature detectors (RTDs) glued to a wafer that is placed on the chuck. However, since RTDs need to be physically wired to the wafer, a feedthrough system is required, increasing the complexity of the chamber. Moreover, should one of the RTDs fail, the entire temperature sensing system would need to be changed. Furthermore, by increasing the number of RTDs used, the number of wires also increases, thus increasing the complexity further. All of these issues make the setup of the temperature sensing system fragile, complex, and difficult to scale. While wireless options exist, these are found to be failure prone due to the electronics required. Another option that has been implemented uses radiometry or pyrometry, however, the readings in such a solution can be heavily influenced by the material it is measuring, which can introduce large offsets and limit accuracy.
The following pertains to an optical temperature sensor which provides a separation between the optical fiber used as the light source and the sensing element that is used to measure the temperature of a measured object. The separation can include a gap between the tip and shaft of a temperature probe, or a transparent boundary between the optical fibre and the sensing element, e.g., to remotely measure temperature externally to a chamber or other environment in which the measured object is located.
In one example, the optical temperature sensor is implemented using a probe having a shaft and a tip. The shaft houses the optical fibers while the tip is made of a thermally conductive material and includes a sensing material therein. The sensing material is in optical communication with the optical fibers of the shaft, and the shaft is spaced from the tip to reduce heat transfer from the tip to the shaft. Furthermore, the sensing material is sealed in such a way that it is isolated from the surrounding atmosphere. In a preferred embodiment, a window is hermetically sealed to the tip to isolate the sensing material from the environment surrounding the probe.
In another example, the optical temperature sensor is implemented using an optical fiber positioned externally to a processing environment such as a chamber with a sensing element positioned within the processing environment. The optical fiber is aligned with the sensing element to remotely deliver light to the sensing element and observe changes in certain characteristics of the emitted light, e.g., phosphorescence time decay, and can include a collimating or focusing mechanism to direct the light to the measured object.
In one aspect, there is provided a temperature sensor comprising: an optical fiber; and a sensing element spaced from the optical fiber; wherein the optical fiber is aligned with the sensing element to deliver a source beam to interact with the sensing element and detect a return beam, the return beam exhibiting a temperature dependent property that is measured to determine a temperature of a measured object thermally coupled to the sensing element.
In another aspect, there is provided a temperature sensing system comprising a plurality of temperatures sensors, each sensor comprising: an optical fiber; and a sensing element spaced from the optical fiber; wherein the optical fiber is aligned with the sensing element to deliver a source beam to interact with the sensing element and detect a return beam, the return beam exhibiting a temperature dependent property that is measured to determine a temperature of a measured object thermally coupled to the sensing element.
The features of certain embodiments will become more apparent in the following detailed description in which reference is made to the appended figures wherein:
Turning now to the figures,
In
Turning now to
Yet another configuration is shown in
The configuration shown in
The optical fiber 111 is held in place by the base 107 and shaft 104, however the illumination device 110, photodetector 112 and means for processing the light and wavelength returning to the temperature sensor converter 108 can be located external to probe 102, as shown in
Returning to
The tip 109, shown in
Within the tip 109 is a layer of sensing material 14. This sensing material 14 can be phosphorescent such as phosphor, although other materials would be known to a person skilled in the art.
The sensing material 14 is applied onto the thermally conductive tip 109. In order to do this, the sensing material 14 can be mixed with a suitable adhesive. Application of the sensing material 14 and adhesive combination can be done by any suitable method known to a person skilled in the art including, but not limited to deposition, sputtering, bonding, panting, and spin on. The sensing material 14 is excited by light transmitted through the optical fiber 111. As stated above, the body material 126 is thermally conductive to increase the heat flow from the measurement surface 130 of the measured object 16, to the sensing material 14 for more accurate measurement.
The sensing material 14 can be protected from the environment using a window 48 positioned between the sensing material 14 and the gap 116. The window 48 is sealed to the body 126 of the tip 109 using any suitable sealing process that will hermetically seal the window 48 between the body material 126 and the gap 116. An adhesive having high temperature resistance and resistance to radicals can be used. The window 48 is transparent to allow for light to be transmitted from the optical fiber 111 to the sensing material 14. Although a variety of materials could be used for the window 48, a suitable example material is sapphire as it is highly transparent, compatible with the preferred hermetic sealing technique (described below), capable of surviving high temperature environments and resistant to the harsh chemical environment of a semiconductor chamber. Furthermore, sapphire and alumina have similar coefficients of thermal expansion and thus a seal can be maintained between the two even as the temperature changes. In this respect, similar coefficients of thermal expansion can be defined as coefficients of thermal expansion which are sufficiently similar such that when window material and body material expand and contract, the rates and amount of expansion and contraction are not so different as to cause separation between the two. Typically, materials wherein the difference in coefficients of thermal expansion is in the range of 6-10×10−6° C. or less will be suitable. It can be appreciated by a person skilled in the art that other window and tip materials with similar coefficients of thermal expansion could be used.
As can be seen in
In order to create the hermetic seal, the adhesive, for example zinc borosilicate glass, is heated. For zinc borosilicate glass, it is heated to approximately 400° C. to 700° C. A film of the adhesive can be applied to the sapphire, or alumina, or both the sapphire and alumina, using any suitable method, including, but not limited to, chemical vapor deposition, sputtering, evaporating and spin on.
In an embodiment, the application of the glass seal can be screen printed or painted onto the surface. A stencil is made with a geometry adapted to fill the volume of space between the sensing material and the sealing surface. The glass seal is applied, and the stencil is removed. The window is then placed atop the adhesive using a fixture to ensure concentricity between the window to the tip. The entire assembly is then placed in a furnace and baked at atmospheric pressure.
A layer of gas 134, such as air, can be left between the sensing material 14 and the window 48. This layer of gas 134 ensures that the sensing material 14 does not touch the window 48. In this way, the sensing material 14 is inhibited from losing heat to the window 48 which aids in more accurate temperature measurements.
The window 48 can be directly sealed onto the probe tip 109 in which the sensing material 14 is applied. By sealing the window 48 in the probe tip 109, the tip assembly is self contained and can be used for various tip geometries to maximize contact and heat transfer from the measured surface 130.
In an alternative embodiment a transparent coating of sapphire or other suitable material, such as aluminum oxide, is applied on to the upper surface of the body of the tip 126 to completely cover the sensing material 14, isolating the sensing material 14 from the surrounding environment. This could be done with a variety of different methods such as, but not limited to, deposition, screen printing or with a thermal spray coating process.
When in use, the tip 109 can be placed in contact with the measured object 16 for which the temperature reading is required. Since the body 126 of the tip 109 is made of conductive material, the heat flows from the measurement surface 130 through the body 126 of the tip 109 and to the sensing material 14. A source beam 18 from the illumination device (shown in
By separating the tip 109 from the shaft 104, heat loss from the tip 109 to the shaft 104 is reduced compared to traditional optical temperature sensors. This improves the accuracy of the measurement by reducing the difference in the temperature of the sensing material 14 and the measurement surface 130. Furthermore, since the optical fiber 111 is spaced from the tip 109, heat transfer from the tip 109 to the optical fiber 111 is reduced. This allows materials which have a lower temperature tolerance to be used to make the optical fiber 111, reducing cost. Furthermore, the number of parts required for assembly can also be reduced. By isolating the sensing material 14 from the surrounding harsh environment, durability of the probe can be increased, and should the tip eventually degrade, it would be possible to replace just the tip 109 as opposed to the entire probe 102.
Although the above description includes reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art. Any examples provided herein are included solely for the purpose of illustration and are not intended to be limiting in any way.
Any drawings provided herein are solely for the purpose of illustrating various aspects of the description and are not intended to be drawn to scale or to be limiting in any way. The scope of the claims appended hereto should not be limited by the preferred embodiments set forth in the above description, but should be given the broadest interpretation consistent with the present specification as a whole. The disclosures of all prior art recited herein are incorporated herein by reference in their entirety.
This application is a continuation-in-part of U.S. patent application Ser. No. 16/442,420 filed on Jun. 14, 2019, the contents of which are incorporated herein by reference.
Number | Date | Country | |
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Parent | 16442420 | Jun 2019 | US |
Child | 16901951 | US |