1. Field of the Invention
The present invention relates generally to chemical mechanical planarization (CMP) methods and systems, and more particularly, to a method for pulsing or oscillating a polishing head to reduce or prevent de-lamination of a semiconductor wafer film layers during a CMP process.
2. Description of the Related Art
In the fabrication of semiconductor devices, planarization operations of silicon wafers, which can include polishing, buffing, and cleaning, are often performed. Typically, integrated circuit devices are in the form of multi-level structures on silicon substrate wafers. At the substrate level, transistor devices with diffusion regions are formed. In subsequent levels, interconnect metallization lines are patterned and electrically connected to the transistor devices to define the desired functional device. Patterned conductive layers are insulated from other conductive layers by dielectric materials. As more metallization levels and associated dielectric layers are formed, the need to planarize the dielectric material increases. Without planarization, fabrication of additional metallization layers becomes substantially more difficult due to the higher variations in the surface topography. In other applications, metallization line patterns are formed into the dielectric material, and then metal planarization operations are performed to remove excess metallization.
Planarizing metallization layers, specifically copper metallization layers is becoming more important as copper has begun to replace aluminum as the metal of choice for metallization processes. One method for achieving semiconductor wafer planarization is the Chemical Mechanical Planarization (CMP) technique. Further applications include planarization of dielectric films deposited prior to the metallization process, such as dielectrics used for shallow trench isolation or for poly-metal insulation. In general, the CMP process involves holding and rubbing a typically rotating wafer against a moving polishing pad under a controlled pressure and relative speed. CMP systems typically implement an orbital table or a linear belt in which a preparation surface of a polishing pad is used to polish one side of a wafer. Slurry is used to facilitate and enhance the CMP process. Slurry is most usually introduced onto a moving preparation surface and distributed over the preparation surface as well as the surface of the semiconductor wafer being buffed, polished, or otherwise prepared by the CMP process. The distribution of the slurry is generally accomplished by a combination of the movement of the preparation surface, the movement of the semiconductor wafer and the friction created between the semiconductor wafer and the preparation surface.
A nozzle 120 having a number of discrete dispense points dispenses a slurry 122 onto the top surface of the belt pad 102. Movement of the belt pad 102 in the direction 106 transports slurry 122 underneath the wafer 104. The belt pad 102 is typically configured with longitudinal grooves 103, to enhance the spread of slurry 122. The position of the nozzle 120 can be adjusted across the width of the top surface of the belt pad 102. The nozzle 120 is typically aligned in a position relative to the wafer 104 such as center on the wafer 104. However, the position of the nozzle 120 can be adjusted to somewhat optimize the uniformity of the removal of material from the surface of the wafer 104.
The slurry 122 is a fluid medium that transports reactants to the wafer 104 surface and carries reactions products away from the wafer 104 surface. The slurry 122 also plays an important role in lubricating the interface between the belt pad 102 and wafer 104 surface, ensuring an equal distribution of hydrodynamic pressure across the wafer 104 surface. Heat generated during the CMP process through friction and chemical reaction is also removed by the slurry 122 flow, helping to keep the wafer 104 temperature stable and uniform. The stability and uniformity of CMP process results across the wafer 104 surface are dependent on the slurry 122 distribution characteristics across the wafer 104 surface. The slurry 122 present in the dry wake region 128 differs from the slurry 122 that wraps around the polishing head 108 in many respects such as volume, chemistry, composition, and thermal load. As the belt pad 102 rotates around the drums 112 a fresh amount of slurry 122 from the nozzle 120 will be deposited across the belt pad 102. However, a combination of dry wake region 128 slurry 122 with fresh slurry 122 will continue to differentiate the dry wake region 128 from the remainder of the belt pad 102. As the CMP process continues, the characteristics differentiating the dry wake region 128 from the remainder of the belt pad 102 will become more pronounced.
Semiconductor technology is currently implementing the dual advances of using copper for metal-interconnects and “low-K” materials for the insulation between adjacent metal-interconnects and layers in a semiconductor wafer.
In view of the foregoing, there is a need for an apparatus and method that can be implemented in a CMP process to prevent de-lamination of wafer 104 film layers having weak adhesion characteristics.
Broadly speaking, the present invention fills these needs by providing apparatuses and methods for implementing a pulsed polishing head rotation in a linear belt-type chemical mechanical planarization (CMP) system to maintain a slurry distribution across the width of a belt pad in a manner that prevents de-lamination of a wafer film having weak adhesion characteristics. It should be appreciated that the present invention can be implemented in numerous ways, including as a process, an apparatus, a system, a device, or a method. Several embodiments of the present invention are described below.
In one embodiment, a linear belt-type chemical mechanical planarization (CMP) system is disclosed. The CMP system includes a first drum and a second drum around which a belt pad having a preparation surface and an undersurface is configured. The belt pad can have longitudinal grooves, cross-grooves, or a combination of both longitudinal grooves and cross-grooves. The belt pad is further configured to move in a linear motion as the first drum and second drum are rotated. Between the first drum and second drum, the belt pad traverses over a wafer preparation location supported underneath by a platen. A nozzle having a plurality of locations for dispensing a slurry is positioned to deliver the slurry to the wafer preparation location. The longitudinal grooves and cross-grooves of the belt pad are configured to disperse the slurry across the belt pad. A polishing head capable of receiving a wafer and rotating in a pulsed configuration is further configured to apply the wafer to the wafer preparation location. The pulsed configuration of the polishing head is adjustable in frequency. At a sufficiently high frequency, the pulsed configuration of the polishing head transitions to an oscillated configuration.
In another embodiment, a method for operating a CMP system using a pulsed polishing head rotation is disclosed. The method includes a first operation of moving a belt pad having a coverage of slurry. In a second operation, a polishing head is rotated in a first direction. In a third operation, the polishing head is applied to the belt pad for a first duration while the polishing head is rotating in the first direction. Upon completion of the first duration, a fourth operation is performed wherein the polishing head is removed from the belt pad. In a fifth operation, the polishing head is rotated in a second direction. In a sixth operation, the polishing head is applied to the belt pad for a second duration while the polishing head is rotating in the second direction. Upon completion of the second duration, the method continues by looping back to the second operation.
In another embodiment, a method for operating a CMP system using a pulsed polishing head rotation is disclosed. The method includes a first operation of moving a belt pad having a coverage of slurry. In a second operation, a polishing head is rotated in a first direction. In a third operation, the polishing head is applied to the belt pad for a first duration while the polishing head is rotating in the first direction. Upon completion of the first duration, a fourth operation is performed wherein the polishing head remains applied to the belt pad while being rotated in a second direction. The fourth operation continues for a second duration. Upon completion of the second duration, the method continues by looping back to the third operation.
In another embodiment, a method for operating a CMP system using an oscillated polishing head rotation is disclosed. The method includes a first operation of moving a belt pad having a coverage of slurry. In a second operation, a polishing head is rotated in a first direction. In a third operation, the polishing head is applied to the belt pad for a first period of time while the polishing head is rotating in the first direction. Alternative to the first period of time, the polishing head may be rotated in the first direction through a first finite angular distance. Upon completion of either the first duration or the first finite angular distance, a fourth operation is performed wherein the polishing head remains applied to the belt pad while being rotated in a second direction. The fourth operation continues either for a second duration or until the polishing head has been rotated through a second finite angular distance. Upon completion of the second duration, the method continues by looping back to the third operation.
The advantages of the present invention are numerous. Most notably, the use of the pulsed polishing head rotation as disclosed in the present invention avoids the problems of the prior art by maintaining the slurry distribution across the width of the belt pad. The slurry distribution is maintained in a manner that prevents de-lamination of wafer film layers having weak or potentially weaker adhesion characteristics.
Other aspects and advantages of the invention will become more apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the present invention.
The invention, together with further advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
An invention is disclosed for an apparatus and method for pulsing and oscillating a polishing head in a linear belt-type chemical mechanical planarization (CMP) system to prevent de-lamination of semiconductor wafer film layers having weak adhesion characteristics. Broadly speaking, the present invention implements either a pulsed or oscillated polishing head rotation during a CMP process to maintain a slurry distribution across the width of a belt pad in a manner that prevents de-lamination of a wafer film having weak adhesion characteristics. Thus, the pulsed and oscillated polishing head rotation of the present invention eliminates the problems of the prior art by preventing de-lamination of low-K material film layers during a CMP process.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail in order not to unnecessarily obscure the present invention.
During the pulsed polishing head 108 rotation, the duration over which the polishing head 108 rotates in the first direction 202 and the second direction 206 is monitored and controlled. By controlling the duration of rotation in the first direction 202 and the second direction 206, the first dry wake region 204 and the second dry wake region 208 are controlled. Controlling the duration of the first dry wake region 204 and the second dry wake region 208 serves to maintain a more uniform time-averaged slurry 122 characteristic distribution across the belt pad 102.
Both the pulsed and the oscillated polishing head 108 rotation methods result in maintaining a uniform slurry 122 characteristic distribution across the belt pad 102. Some important slurry 122 characteristics maintained in a uniform manner across the belt pad 102 by implementing either the pulsed or the oscillated rotation methods include volume, chemistry, composition, and thermal load. By maintaining a uniform distribution of slurry 122 characteristics across the belt pad 102, de-lamination of wafer 104 film layers having weak adhesion characteristics is prevented.
In an alternate embodiment, the pulsed polishing head 108 rotation method may be performed without removing the wafer 104 from the belt pad 102. In this alternate embodiment, steps 312 and 322 are eliminated from the method as illustrated in
In an alternate embodiment, the first angular rotation distance and the second angular rotation distance are replaced with a first rotation time and a second rotation time, respectively. This alternate embodiment of the oscillated polishing head 108 rotation method is similar to the pulsed polishing head 108 rotation method wherein the wafer 104 is not removed from the belt pad 102 and a high frequency of rotation direction change is implemented.
Wafer 104 film layers having weak adhesion properties (e.g., low-K material film layers) are subject to de-lamination initiated by mechanical stresses present on the wafer 104 surface. Normal mechanical stresses present on the wafer 104 surface during the CMP process are increased in the presence of non-uniform slurry 122 conditions across the wafer 104 surface. Hence, non-uniform slurry 122 volume, chemistry, composition, and thermal load will serve to increase the mechanical stresses across the wafer 104 surface. Since a dry wake region represents a non-uniform slurry condition, it is important to minimize the differentiating characteristics of the dry wake region with respect to the remainder of the belt pad 102. Both the pulsed polishing head 108 rotation method and the oscillated polishing head 108 rotation method of the present invention serve to minimize slurry 122 non-uniformity across the belt pad. Therefore, the present invention implemented in either its preferred or alternate embodiments will reduce de-lamination of wafer film layers having weak adhesion properties, such as a low-K material film layer.
While this invention has been described in terms of several embodiments, it will be appreciated that those skilled in the art upon reading the preceding specifications and studying the drawings will realize various alterations, additions, permutations and equivalents thereof. It is therefore intended that the present invention includes all such alterations, additions, permutations, and equivalents as fall within the true spirit and scope of the invention.
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