1. Field of the Invention
The present invention generally relates to the field of semiconductor fabrication. More particularly, the invention relates to wafer trimming in semiconductor fabrication.
2. Background Art
Because of their high performance, small size, and low cost, bulk acoustic wave (BAW) filters are increasingly utilized to provide radio frequency (RF) filtering in mobile communications devices, such as cellular phones, as well as other types of electronic devices. A BAW filter includes a multi-layer stack of films that determine, among other things, the operating frequency of the filter. During BAW filter fabrication, there can be a wide distribution of resultant operating frequencies after initial wafer processing due to non-uniformity of film deposition, which can undesirably affect device yield. As a result, a wafer trimming process is typically utilized, wherein a determined amount of material is removed from the top layer of the multi-layer film stack to achieve a target BAW filter operating frequency across the wafer.
In a conventional method of wafer trimming, the amount of material to be removed can be determined by utilizing a single pre-trimming measurement and a model to determine an average trim rate, which can be applied across the wafer to move a desired parameter from the pre-trim measured value to a desire final value. To reduce errors caused by fluctuations in film deposition and material parameters across the wafer and from lot-to-lot, the convention wafer trimming method can be improved by utilizing the errors found in trimming a pilot wafer in a concurrently fabricated lot as feedback so as to trim the remaining wafers in the lot more precisely. However, even with the improvement in the conventional wafer trimming method provided by the pilot wafer, non-uniform layer variations across the wafer can cause an undesirably high distribution in target operating frequencies across the wafer, which can undesirably reduce device yield. Also, the sacrifice of a pilot wafer in the conventional wafer trimming method is undesirable.
A method for wafer trimming for increased device yield, substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims.
The present invention is directed to a method for wafer trimming for increased device yield. The following description contains specific information pertaining to the implementation of the present invention. One skilled in the art will recognize that the present invention may be implemented in a manner different from that specifically discussed in the present application. Moreover, some of the specific details of the invention are not discussed in order not to obscure the invention. The specific details not described in the present application are within the knowledge of a person of ordinary skill in the art.
The drawings in the present application and their accompanying detailed description are directed to merely exemplary embodiments of the invention. To maintain brevity, other embodiments of the invention which use the principles of the present invention are not specifically described in the present application and are not specifically illustrated by the present drawings.
As will be discussed in detail below, the present invention provides an innovative method for site-specific trimming of a wafer to achieve a more accurate target parameter value, such as a BAW (bulk acoustic wave) filter frequency, of devices, such as BAW filters, across the wafer. Although a characteristic frequency of a BAW filter is utilized as a target parameter value to illustrate the present invention, the present invention's method for site-specific wafer trimming can also be utilized for trimming films for on-wafer resistors and capacitors to advantageously provide tighter respective resistance and capacitance distributions across the wafer. In general, the invention's innovative method for site-specific wafer trimming can be utilized to provide a reduced distribution of target parameter values of devices or components fabricated on the wafer, where the devices or components have a target parameter value that is affected by film thickness over the wafer.
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During fabrication, a number of BAW devices, such as BAW filters, can be fabricated on a substrate of a wafer, which can be separated into individual semiconductor dies in a singulation process. Each BAW filter can be situated on a semiconductor die and can include a BAW structure, such as BAW structure 102. During fabrication, it is highly desirable that each BAW filter on the wafer have substantially the same target parameter value, such as a target characteristic frequency, so as to increase device yield and, thereby, reduce manufacturing cost.
The characteristic frequency of a BAW device, such as a BAW filter, can be a center frequency, a frequency that is a number of decibels (dB) on the right or left side of the filter frequency response curve relative to a peak insertion loss, or other specified operating frequency of the filter. For example, the characteristic frequency of the BAW filter that is used as a target frequency can be a frequency that is 10.0 dB less than and located to the high frequency side of the filter frequency response curve relative to the peak insertion loss. Non-uniformity of film deposition during wafer fabrication can result in an undesirably wide distribution of characteristic frequencies of respective BAW filters on the wafer, which can undesirably reduce device yield. Since the thickness of the top layer, such as top layer 114, on the wafer affects the characteristic frequency of the BAW filter, the top layer is typically deposited at a greater thickness than required and trimmed (reduced in thickness) in a trimming process to reduce the distribution of characteristic frequencies across the wafer and, thereby, improve the device yield.
In a conventional wafer trimming method, a top layer, such as a passivation layer, can be deposited over a wafer including a number of BAW devices, such as BAW filters, at a thickness greater than required to achieve a target characteristic frequency across the wafer. After the top layer has been deposited on the wafer, the characteristic frequency can then measured at a number of test sites across the wafer and an average “sensitivity” can be determined. For example, the test sites can be a subset of the number of devices on the wafer, where each test site can be, for example, a BAW device. The “sensitivity” refers to a rate of change of top layer thickness with respect to a parameter, such as characteristic frequency of a BAW filter, and can be expressed in Angstroms per MHz (or in nanometers (nm) per MHz, where 0.10 nm equals 1.0 Angstrom). Thus, a sensitivity value can represent a top layer thickness in Angstroms (or an equivalent thickness in nanometers) that can cause a characteristic frequency of a BAW device, such as a BAW filter, to shift or change by 1.0 MHz. For example, a sensitivity of 10 Angstroms/MHz (1.0 nm/MHz) indicates that a thickness of 10.0 Angstroms (1.0 nm) of a top layer can cause a 1.0 MHz change in the characteristic frequency of a BAW filter. The sensitivity can also be referred to as the reciprocal of the rate of change of a characteristic frequency with respect to top layer thickness.
In the conventional trimming method with a single measurement taken just before trimming, the average sensitivity can only be determined from previously trimmed wafers of a similar type or from a model. The amount of top layer material to be removed at each test site to achieve a target characteristic frequency can then be determined from the average sensitivity and the characteristic frequency measurement that was performed at each test site. In the conventional trimming process, a pilot wafer can then be trimmed in a site-specific etching tool by utilizing the previously determined amount of top layer material to be removed at each site. As a result of trimming the pilot wafer, a correction factor can be determined and utilized to provide a corrected average sensitivity, which can be utilized to trim subsequent wafers.
The conventional wafer trimming method is based on the assumption that sensitivity is uniform across the wafer and from wafer to wafer. In other words, the conventional wafer trimming method assumes that the removal of a selected thickness of top layer material anywhere on any wafer will cause the same change in a target parameter, such as a characteristic frequency of a BAW filter. However, sensitivity is a function of all of the layers of a BAW filter. Thus, the sensitivity can be different at each location of the wafer as a result of non-uniformity in film deposition across the wafer. For example, variations in thickness of a metal layer utilized to form upper electrodes, such as upper electrode 112, can cause corresponding variations in sensitivity across the wafer. As a result, the use of the average sensitivity in the conventional wafer trimming method can undesirably affect the characteristic frequency distribution of BAW filters across the wafer and, thereby, reduce device yield.
In contrast to the conventional wafer trimming method, one embodiment of the invention provides a site-specific wafer trimming method that utilizes two parameter measurements that are performed at each of a number of test sites on the wafer to determine a specific sensitivity for each test site, i.e., a site-specific sensitivity. In one embodiment, the test sites can be a subset of the number of devices on the wafer, where each test site can correspond to a device, such as BAW filter. In another embodiment, the test sites can be correspond to a number of test structures that are formed in the singulation streets between semiconductor dies on the wafer. In one embodiment, the site-specific sensitivity, i.e. a site-specific rate of change of top layer thickness per parameter, can be utilized to determine a thickness of top layer material to remove at each test site to provide a more precise target parameter value, such as a BAW filter target characteristic frequency, across the wafer, thereby increasing device yield. Also, one embodiment of the present site-specific method for wafer trimming does not require the sacrificing of a pilot wafer, as in the conventional method of wafer trimming. An embodiment of the invention's site-specific method for wafer trimming is further discussed below in relation to
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In wafer 200, each BAW filter (not shown in
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At step 302 of flowchart 300, a first parameter measurement, such as a first characteristic frequency measurement, is performed at a number of test sites on wafer 200, such as test sites 202a through 202f. In one embodiment, the first parameter measurement can be performed at a subset of the number of devices on the wafer, where each test site can correspond to a device, such as a BAW filter. The first characteristic frequency measurement can provide a first set of data and can be performed using a standard wafer probe station. The first set of data can be utilized to generate a contour map of wafer 200 corresponding to the first characteristic frequency measurement. At step 304, a top layer, such as top layer 114 in
At step 306, a second parameter measurement, such as a second characteristic frequency measurement, is performed at each of the test sites, such as test sites 202a through 202f, at which the first parameter measurement was performed and a thickness of the top layer is determined. The second characteristic frequency measurement can provide a second set of data and can be performed in a similar manner as the first characteristic frequency measurement. The second set of data can be utilized to generate a contour map of wafer 200 corresponding to the second characteristic frequency measurement. In one embodiment, prior to performing the second parameter measurement, a window can be opened in the top layer over each test site to expose it (i.e. the test site). In the present embodiment, the thickness of the top layer can be determined at each test site by measuring the top layer thickness by utilizing an optical measurement process or other suitable measurement. A set of data provided from the measurement of the top layer thickness at each test site can be utilized to generate a contour map of top layer thickness across the wafer. In one embodiment, the top layer thickness can be determined from a thickness map generated from a test wafer.
At step 308, a site-specific rate of change (i.e. a site-specific sensitivity) of top layer thickness per parameter (e.g. top layer thickness per characteristic frequency) is determined at each test site by using the respective sets of data from the first and second parameter measurements, such as the first and second characteristic frequency measurements, and the measured thickness of the top layer at each test site. For example, the site-specific sensitivity can be determined for each test site by dividing the top layer thickness at the test site by the difference between the first and second characteristic frequency measurements performed at that test site. A set of data corresponding to the site-specific rate of change of top layer thickness per parameter (e.g. top layer thickness per characteristic frequency) can be utilized to generate a contour map of site-specific sensitivity across the wafer. In one embodiment, an average top layer thickness can be used to determine the site-specific sensitivity in place of a top layer thickness that was determined for each test site. However, using an average top layer thickness can reduce the accuracy of the site-specific sensitivity. Thus, a site-specific sensitivity, i.e. a specific top layer thickness in Angstroms (or an equivalent thickness in nanometers) that is required to cause a 1.0 MHz shift in characteristic frequency is determined for each location on the wafer.
At step 310, an amount of top layer material to remove at each test site on wafer 200 is determined to achieve a target parameter value, such as a target characteristic frequency, at the test site. A set of data corresponding to the amount of top layer material, i.e., the thickness of top layer material, to remove at each test site can be utilized to generate a contour map of the thickness of top layer material to remove across the wafer to achieve a target characteristic frequency for all BAW filters on the wafer. At step 312, wafer 200 is trimmed to achieve a target parameter value across the wafer for all BAW filters on the wafer. Wafer 200 can be trimmed in trimming process by utilizing a site-specific etching tool, wherein the top layer of the wafer is etched according to the contour map of top layer material removal previously determined to provide the target characteristic frequency across the wafer. The site-specific etching tool can be, for example, a trim tool manufactured by TEL Epion Inc., located in Billerica, Mass., U.S.A (with one location presently at 37 Manning Road, Billerica, Mass. 01821, USA). In subsequent process step, wafer 200 can be separated into individual dies in a singulation process.
By utilizing two characteristic frequency measurements at each of a number of test sites on a wafer to determine a site-specific sensitivity, an embodiment of the present invention provides a method for site-specific trimming of a wafer to achieve a target characteristic frequency having increased accuracy and a reduced frequency spread across the wafer. In one embodiment of the invention, more than two characteristic frequency measurements can be performed at each test site to account for non-linearity in the rate of change of top layer material with a parameter, such as characteristic frequency of a BAW filter. By utilizing more that two characteristic frequency measurements to determine a site-specific sensitivity, a more precise target parameter, such as a target characteristic frequency, may be provided.
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Thus, as discussed above, by utilizing at least two parameter measurements at each of a number of test sites across the wafer to determine a site-specific rate of change of top layer thickness with respective to a parameter, such as a characteristic frequency of a BAW filter, the present invention's site-specific method of wafer trimming provides a reduced distribution of target parameter values, such as target characteristic frequency values, across the wafer. As a result, the present invention provides a site-specific method of wafer trimming that increases device yield compared to a conventional method of wafer trimming that utilizes an average rate of change of top layer thickness with respective to a parameter, such as a characteristic frequency of a BAW filter.
From the above description of embodiments of the present invention it is manifest that various techniques can be used for implementing the concepts of the present invention without departing from its scope. Moreover, while the present embodiments of the invention have been described with specific reference to certain embodiments, a person of ordinary skill in the art would appreciate that changes can be made in form and detail without departing from the spirit and the scope of the invention. Thus, the described embodiments are to be considered in all respects as illustrative and not restrictive. It should also be understood that the invention is not limited to the particular embodiments described herein but is capable of many rearrangements, modifications, and substitutions without departing from the scope of the invention.