Patent Grant
6910954
1. Field of the Invention
The present invention relates to generally to supplying slurry in manufacturing processes and, more particularly, to a method of supplying slurry and a slurry supply apparatus for supplying slurry to a chemical mechanical polishing (CMP) machine used in planarizing surfaces of semiconductor devices during semiconductor fabrication.
2. Description of Related Art
As semiconductor devices become more highly integrated, a planarization technique using a chemical mechanical polishing (CMP) machine is typically employed. The CMP machine typically uses a slurry comprised of an abrasive material and a diluting agent and possibly a curing agent to create a solution that has a polishing selectivity with respect to an underlying layer that acts as a CMP stopping layer. Selection of a particular slurry depends on the semiconductor layers to be palanarized. For example, a silica-based (SiO2) slurry is typically used for planarizing a silicon oxide layer with a silicon nitride layer being used as the CMP stopping layer, while an alumina-based (Al2O3) slurry is widely used for planarizing a copper layer or a tungsten layer. Similarly, a ceria-based (CeO2) slurry may be used for applications where a higher polishing selectivity than that of the silica-based slurry is required.
A conventional slurry supply apparatus for supplying the slurry to the CMP machine comprises a mixing tank wherein undiluted slurry is diluted with de-ionized water. The mixing tank may include one or more sensors for measuring and controlling the composition of the resulting slurry. The conventional slurry supply apparatus may further include a supply tank that stores the diluted slurry created in the mixing tank until it is delivered to a polishing pad of the CMP machine via delivery conduits.
Disadvantageously, unless the slurries are kept in an agitated or suspension state, abrasive particles will precipitate out of the solution and solidify in interconnecting conduits of the delivery system. Further, such precipitated particles flow out of the slurry supply apparatus in an irregular manner, thereby degrading the uniformity of the chemical mechanical polishing process. As a result, it is difficult to supply slurry having a uniform concentration and uniform mixing ratio to the polishing pad and thus difficult to perform a uniform, reliable and stable CMP process.
Conventional approaches to resolving the problems associated with precipitation and coagulation of particulates have been to either: 1) add a re-circulation loop to the conduit delivery system; or 2) combine the separate slurry component solutions as close to a point of use (POU) as possible (i.e. at the polishing pad of the CMP system.) In the re-circulation loop approach, additional conduits are arranged to form a re-circulation loop, wherein the pre-mixed diluted slurry solution is continuously pumped through the system conduits to keep the solution in an agitated or non-precipitating state. As a quantity of solution is required at the polishing pad, it is ported via a dispensing branch or conduit to a dispensing nozzle, and thence to the polishing pad. Alternatively, with the POU system, the separate chemicals are not mixed until a final stage of the supply conduit system, thus requiring no continuous agitation mechanism.
Both of these approaches have significant disadvantages that effect overall CMP system performance and quality. In the pre-mixed re-circulation system, slurry composition cannot be easily modified as system requirements change (i.e. to deliver a polishing abrasive having a different ratio of un-diluted slurry to diluting agent.) In the POU system, delivery of a properly mixed solution at the polishing pad cannot be guaranteed, resulting in a portion of a device being planarized using a very coarse and predominately un-diluted slurry while another portion of the device is planarized solely with the non-abrasive diluting solution. Further, when a curing agent is used, the pre-mixed slurry solution must be delivered and used within a predetermined period of time, before the slurry cures.
To overcome the pre-mixed slurry problem of the re-circulated approach and particularly the time limitations due to the curing additive, the CMP operation would necessarily be halted while the solution either was changed entirely or was re-mixed and re-circulated to attain a new solution mix ratio. In either event, any “old” solution that may remain in the conduits beyond the re-circulation loop toward the polishing pad would have to be removed to avoid contamination at the polishing pad before a new solution has traversed the dispensing conduit and nozzle.
To overcome the non-uniform mixing problem at the dispensing nozzle of the POU approach, the individual slurry component solutions may be combined at a conduit location a further distance back from the dispensing nozzle. This allows more turbulence mixing to occur before the slurry is dispensed. While such a displacement allows for an engineering tradeoff between a POU mix-change flexibility with more uniform mixing prior to the dispensing nozzle, the further away from the dispensing nozzle, the greater the chance of occurrence of the aforementioned changed-solution contamination and precipitation of the particulates in the un-agitated diluted slurry.
In the embodiments of the present invention, a slurry mixing and dispensing system preferably comprises one or more elements for the storage, mixing, pumping, filtering, and routing of a mixture of polishing slurry for applications in a chemical mechanical polishing (CMP) apparatus. Primary features include 1) re-circulation loops for keeping a slurry solution in an agitated and suspended state, and 2) providing efficient mixing of chemical additives, such as time-sensitive curing chemicals only at or near the point of use. By maintaining separate re-circulating loops for each chemical to be supplied as a component part of a CMP polishing compound, mixture uniformity can be attained. This allows for delayed mixing, which insures that unused pre-mixed polishing compound is not lost upon operational changes in a slurry composition or mixture. Each re-circulation loop may include pumps, valves, filters, and conduits for the porting and transfer of slurry and additive solution.
In a first embodiment according to the present invention, a system preferably comprises a source of an un-diluted slurry solution, a source of a diluting solution, and a source of a chemical additive solution, with necessary interconnecting conduits, valves, filters, and pumps for selectively delivering the solutions to an in-line mixing and dispensing unit. In the first embodiment, an un-diluted slurry storage tank is preferably connected directly to the in-line mixing and dispensing unit. The diluting solution source and the chemical additive source is also connected directly to the in-line mixing and dispensing unit. A computer preferably controls the process for transferring and mixing the various chemicals in a desired ratio as required by a particular CMP operation.
A first embodiment of a method for circulating and dispensing a polishing solution onto a surface of a semiconductor wafer according to the present invention comprises: 1) introducing an undiluted slurry solution to a storage tank, 2) pumping the undiluted slurry solution from the storage tank to an in-line mixing unit and then back to the storage tank, and 3) in response to a first signal from the controller, dispensing a controlled amount of the undiluted slurry solution onto the surface of the semiconductor wafer through the dispensing conduit via a first solution flow control valve in the in-line mixing unit.
Additionally, in response to a second signal from the controller, a second solution flow control valve in the in-line mixing unit may be used to introduce an additive solution for mixing with the undiluted slurry solution to form a first mixed solution, which is dispensed onto the surface of the semiconductor wafer through the dispensing conduit. The additive may be selected from polymeric solutions and oxidizing solutions.
Moreover, in response to a third signal from the controller, a third solution flow control valve may be used to introduce a third solution to the in-line mixing unit to be mixed with the first and second solution to form a second mixed solution, which is dispensed onto the surface of the semiconductor wafer through the dispensing conduit. The third solution may be, e.g., de-ionized water.
A slurry re-circulating and dispensing system according to an alternate embodiment of the present invention comprises: 1) a storage tank, having a re-circulation loop, for receiving and locally re-circulating an un-diluted slurry solution, 2) a mixing tank for mixing the un-diluted slurry with a diluting solution, such as de-ionized water, to create a diluted slurry solution, and 3) an in-line mixing unit for receiving the diluted slurry solution and optionally mixing it with a chemical additive to form the second mixed solution, which is dispensed onto the surface of the semiconductor wafer via a minimized length dispensing conduit.
An alternate method for circulating and dispensing a solution onto a surface of a semiconductor wafer according to the present invention comprises: 1) introducing an undiluted slurry solution to a storage tank, 2) in response to a first mixing control signal from the controller, pumping the undiluted slurry solution from the storage tank to a mixing tank to create a mixed solution, i.e., a diluted slurry solution, by adding a diluting solution, such as de-ionized water, 3) pumping the mixed solution from the mixing tank to an in-line mixing unit and back to the mixing tank to keep the particulates in suspension, and 4) in response to a slurry dispensing control signal from the controller, opening a slurry flow control valve in the in-line mixing unit to controllably dispense a quantity of the mixed solution through a dispensing conduit and onto a surface of a semiconductor wafer. For certain applications, the un-diluted slurry solution from the storage tank may be provided through the mixing tank to the in-line mixing unit without adding the diluting solution. The alternate method may also include an additional step of activating an additive flow control valve for introducing a quantity of chemical additive to the mixed solution, wherein the chemical additive may be one or more solutions selected from polymeric solutions and oxidizing solutions.
A slurry re-circulating and dispensing system according to a preferred embodiment of the present invention comprises: 1) a storage tank for receiving and locally re-circulating an un-diluted slurry solution, 2) a mixing tank for mixing the un-diluted slurry with a diluting solution, such as de-ionized water, to create a diluted slurry solution, 3) a supply tank for receiving the diluted slurry solution from the mixing tank, and 4) an in-line mixing unit for receiving and mixing the diluted slurry solution with a chemical additive, to form a second mixed solution, which is dispensed onto the surface of the semiconductor wafer via a dispensing conduit. It is also preferred that the dispensing conduit has a minimized length.
A preferred method for circulating and dispensing a polishing solution onto a surface of a semiconductor wafer according to the present invention, comprises: 1) introducing an un-diluted slurry solution to a storage tank having a local re-circulation loop for circulating the un-diluted slurry solution, 2) pumping the un-diluted slurry solution from the storage tank to a mixing tank in order to create a first mixed solution, 3) pumping the first mixed solution from the mixing tank to a supply tank, and 4) pumping the first mixed solution from the supply tank to an in-line mixing unit and back to the supply tank in order to re-circulate and maintain in suspension abrasive particulates contained in the first mixed solution, and 5) in response to a slurry dispensing control signal from the controller, opening a slurry flow control valve in the in-line mixing unit to controllably dispense a quantity of the first mixed solution through a dispensing conduit and onto the surface of the semiconductor wafer. The preferred method may also include an additional step of activating an additive flow control valve for introducing and mixing a quantity of chemical additive to the first mixed solution before being dispensed through the dispensing conduit and onto the surface of the semiconductor wafer.
In the above embodiments of the present invention, separate reservoirs are preferably provided for each of the slurry material and chemical additives. Each of these reservoirs are preferably provided with a re-circulating loop that keeps the respective solution uniform and in an agitated state until needed at the CMP point of use (POU). To dispense the required slurry and/or additives, an in-line mixing unit controllably opens an associated valve or valves to allow flow from the particular re-circulation loop to be dispensed. Solution mixtures (ratio of included compounds and solutions) may be measured using a sonic measuring means or by weighting means.
These and other features of the present invention will be readily apparent to those of ordinary skill in the art upon review of the detailed description that follows.
Korean Patent Application No. 2001-74547, filed on Nov. 28, 2001, and entitled “Slurry Supply Apparatus having a Mixing Unit at a Point of Use and a Slurry Storage Unit,” is incorporated by reference herein in its entirety.
Referring to
Undiluted slurry, such as silica-based, ceria-based, or alumina-based slurry, may be stored in the slurry bottle 1, which is typically purchased from a supplier. The undiluted slurry contains abrasive particles, which aggregate or accumulate on the bottom of the slurry bottle 1 as time elapses. Accordingly, in order to uniformly disperse the abrasive particles in the undiluted slurry, slurry bottle 1 is preferably shaken either manually or using a shaker (not shown) before slurry bottle 1 is connected to slurry conduit 61.
A first slurry valve 21 is preferably installed at a predetermined region of the slurry conduit 61 to control the flow of the undiluted slurry in response to control signals from main control unit 19a. Also, a second slurry valve 47 is preferably installed in slurry circulation loop line 63 between the outlet of the slurry storage unit 3 and the connection point for slurry conduit 61. Second slurry valve 47 and first pump 23 are also preferably controlled by signals from main control unit 19a.
In the event that first slurry valve 21 is opened and second slurry valve 47 is closed while first pump 23 is operating, the undiluted slurry in the slurry bottle 1 is transferred into slurry storage unit 3 through slurry conduit 61 and slurry circulation loop line 63. It is preferable that the total amount of the undiluted slurry in the slurry bottle 1 is transferred into slurry storage unit 3 for only a relatively short period of time to avoid settling of the abrasive particles. The amount of the undiluted slurry in slurry storage unit 3 is preferably continuously measured and converted into an associated electrical signal, which is transmitted to main control 19a.
Subsequently, the undiluted slurry stored in slurry storage unit 3 is preferably self-circulated through slurry circulation loop line 63. By closing first slurry valve 21 and opening second slurry valve 47 while first pump 23 is operating, the undiluted slurry may be continuously circulated through slurry circulation loop line 63. Slurry conduit 61, slurry storage unit 3, slurry circulation loop line 63, first pump 23, first slurry valve 21 and second slurry valve 47 constitute a slurry storage portion 91 of slurry supply apparatus 10. Slurry storage portion 91 may further comprise a filter unit 25, which is installed in slurry circulation loop line 63 between the first pump 23 and the outlet of slurry circulation loop line 63 and/or a slurry circulation valve 39, which is installed between the filter unit 25 and the outlet of slurry circulation loop line 63. Slurry circulation valve 39 is preferably opened or closed by a signal from the main control unit 19a in order to allow a portion of the undiluted slurry to be re-routed on demand to a mixing unit 5 through a slurry supply conduit 65.
It is preferable that slurry supply conduit 65 be branched from a predetermined region of the slurry circulation loop line 63 between the first pump 23 and the outlet of slurry circulation loop line 63. More preferably, the slurry supply conduit 65 is branched from a predetermined region of the slurry circulation loop line 63 between the filter unit 25 and the slurry circulation valve 39.
A slurry supply valve 41 is preferably installed at a predetermined region of the slurry supply conduit 65 and is opened or closed by signals from the main control unit 19a. Upon closing of the slurry circulation valve 39 and opening of the slurry supply valve 41, a portion of the undiluted slurry, which is circulated through the slurry circulation loop line 63, is directed into the mixing unit 5.
In mixing unit 5, the undiluted slurry may be mixed with a diluting solution, such as de-ionized water, which is supplied into the mixing unit 5 through a diluting solution supply conduit 71. The diluting solution is preferably supplied from a main system fabrication line under high pressure. To control this supply of diluting solution, a diluting solution valve 49 is preferably installed at a predetermined region of the diluting solution supply conduit 71. Opening and closing of the diluting solution valve 49 is preferably controlled by the main control unit 19a, which in conjunction with complementary opening and closing of the slurry supply valve 41 allows a predetermined mixing ratio of undiluted slurry and diluting solution to be obtained.
The amount of diluted slurry in the mixing unit 5 is preferably sensed and converted into an electrical signal, which is transmitted to the main control unit 19a. The diluted slurry in mixing unit 5 may be self-circulated through a diluted slurry circulation loop line 67. A second pump 27 is preferably installed at a predetermined region of the diluted slurry circulation loop line 67 in order to circulate the diluted slurry, preferably under control of the main control unit 19a. Slurry supply conduit 65, slurry supply valve 41, mixing unit 5, diluted slurry circulation loop line 67, second pump 27, diluting solution supply conduit 71 and diluting solution valve 49 constitute a mixing portion 93 of slurry supply apparatus 10.
Mixing portion 93 may further comprise a diluted slurry circulation valve 43, which is installed between the second pump 27 and an outlet of the diluted slurry circulation loop line 67, as well as a filter unit 29, which is installed between the second pump 27 and the diluted slurry circulation valve 43. Also, it is preferable that the main control unit 19a controls the diluted slurry circulation valve 43 and the filter unit 29.
A portion of the diluted slurry, which is circulated through the diluted slurry circulation loop line 67, may be flowed into a supply unit 7 through a diluted slurry supply conduit 69. The diluted slurry supply conduit 69 is preferably branched from the diluted slurry circulation loop line 67 between the second pump 27 and the outlet of diluted slurry circulation loop line 67. More preferably, the diluted slurry supply conduit 69 is branched from the diluted slurry circulation loop line 67 between the filter unit 29 and the diluted slurry supply valve 43.
A diluted slurry supply valve 45 is preferably installed at a predetermined region of the diluted slurry supply conduit 69. Preferably, the main control unit 19a controls the opening and closing of the diluted slurry supply valve 45, which in conjunction with complementary opening and closing of the diluted slurry supply valve 43, supplies diluted slurry to the supply unit 7. The amount of diluted slurry contained in the supply unit 7 is preferably sensed and converted into an electrical signal, which is transmitted to the main control unit 19a.
The diluted slurry that is stored in the supply unit 7 is preferably circulated through a first circulation loop line 55 and a third pump 31, which is installed at a predetermined region of the first circulation loop line 55. Also, it is preferable that the main control unit 19a controls the operation of the third pump 31. The diluted slurry supply conduit 69, the diluted slurry supply valve 45, the supply unit 7, the first circulation loop line 55 and the third pump 31 constitute a supply portion 95 of slurry supply apparatus 10.
The supply portion 95 may further comprise a filter unit 33, which is installed in the first circulation loop line 55 between the third pump 31 and an inlet of supply unit 7, and a conductivity measurer 32, which is installed in the first circulation loop line 55 between the third pump 31 and the filter unit 33. The conductivity measurer 32 measures the conductivity of the diluted slurry, which is circulated through the first circulation loop line 55, and transmits the measurement result to the main control unit 19a. In the event that the measured mixing ratio is out of a range of the desired values, the main control unit 19a causes slurry supply valve 41 and/or the diluting solution valve 49 to be opened, thereby adjusting the mixing ratio of the diluted slurry in the mixing unit 5 to move within the range of the desired value.
Simultaneously with the mixing and storage of the slurry, an additive is preferably being supplied into an additive storage unit 9 through an additive supply conduit 73. Such an additive is used to adjust polishing selectivity and/or the curing properties of the diluted slurry and may comprise a polymeric solution, such as polycarboxylate, polyammonium, polysulfonate, or polysulfate, etc., and/or an oxidizing solution, such as hydrogen peroxide (H2O2) or potassium ferricyanide, etc. An additive pump 51 is preferably installed at a predetermined region of the additive supply conduit 73, and, preferably, the main control unit 19a controls operation of additive pump 51. Also, the additive storage unit 9 senses the amount of the additive in additive storage unit 9 and generates a corresponding electrical signal which is transmitted to main control unit 19a, thereby controlling the amount of additive supplied to the additive storage unit 9.
The additive in the additive storage unit 9 is preferably circulated through a second circulation loop line 57 and a fourth pump 35, which is installed at the second circulation loop line 57. Also, it is preferable that the main control unit 19a controls the operation of the fourth pump 35. The additive supply conduit 73, the additive pump 51, the additive storage unit 9, the second circulation loop line 57, and the fourth pump 35 constitute an additive storage portion 97 of the slurry supply apparatus 10. The additive storage portion 97 may further comprise a filter unit 37, which is preferably installed at the second circulation loop line 57 between the fourth pump 35 and the outlet of the second circulation loop line 57, and an additive supply valve 53, which is preferably installed at the additive supply conduit 73 between the additive pump 51 and the additive storage unit 9.
The diluted slurry and the additive, which are circulated through first and second circulation loop lines 55 and 57, respectively, are mixed together by at least one in-line point-of-use (P.O.U.) mixing unit to a desired ratio. Although this embodiment discloses two P.O.U. mixing units 11 and 13 as shown in
First and second P.O.U. mixing units 11 and 13 may be controlled by a sub control unit 19b. Sub control unit 19b monitors a state of first and second P.O.U. mixing units 11 and 13, and transmits control signals to first and second CMP machines 15 and 17, respectively.
In an operation of the slurry supply apparatus 10 according to the preferred embodiment of the present invention, an operator determines a first mixing ratio and a second mixing ratio, for a first and second polishing process, respectively. The operator then inputs the predetermined mixing ratios into the sub control unit 19b. When the first CMP machine 15 transmits a first CMP slurry supply signal φ414 to the sub control unit 19b, the sub control unit 19b sends a first CMP slurry valve control signal φ16 to a first CMP slurry valve (not shown) and a first CMP additive valve control signal φ17 to a first CMP additive valve (not shown) as well as a first CMP slurry flow rate control/monitor signal φ11 and a first CMP additive flow rate control/monitor signal φ12 to the first P.O.U. mixing unit 11. Signals φ16, φ17, φ11, and φ12 cause first P.O.U. mixing unit 11 to create a first mixed slurry having a first mixing ratio. Here, the first CMP slurry flow rate control/monitor signal φ11 controls and monitors the flow rate of the first diluted CMP slurry that flows through the first P.O.U. mixing unit 11. The flow rate data for the diluted slurry is preferably continuously transmitted to the sub control unit 19b. Similarly, the first additive flow rate control/monitor signal φ12 controls and monitors the flow rate of the additive that flows through the first P.O.U. mixing unit 11. The flow rate data for the additive is also preferably continuously transmitted to the sub control unit 19b.
The mixing ratio of the mixed slurry that flows out of the first P.O.U. mixing unit 11 may be measured using a first conductivity measurer 81. The first conductivity measurer 81 is preferably installed at a nozzle of the first P.O.U. mixing unit 11 and transmits a measured mixing ratio to the sub control unit 19b. In the event that the measured flow rate of the diluted slurry and the measured flow rate of the additive are outside of an allowable range or the measured mixing ratio of the mixed slurry is out of an allowable range, the sub control unit 19b transmits a first CMP process stop signal φ13 to first CMP machine 15 to halt operation of the first CMP machine 15.
Similarly, when the second CMP machine 17 transmits a second slurry CMP supply signal φ24 to the sub control unit 19b, the sub control unit 19b sends a second CMP slurry valve control signal φ26 to a second CMP slurry valve (not shown) and a second CMP additive valve control signal φ27 to a second CMP additive valve (not shown), as well as a second CMP slurry flow rate control/monitor signal φ21 and a second CMP additive flow rate control/monitor signal 422 to a second P.O.U. mixing unit 13. Signals φ26, φ27, φ21 and φ22 cause the second P.O.U. mixing unit 13 to create a second mixed slurry having a second mixing ratio. Here, the second CMP slurry flow rate control/monitor signal φ21 controls and monitors the flow rate of the second diluted CMP slurry, which is flowed through the second P.O.U. mixing unit 13. The flow rate data for the diluted slurry is preferably continuously transmitted to the sub control unit 19b. The second additive flow rate control/monitor signal φ22 controls and monitors the flow rate of the additive that flows through the second P.O.U. mixing unit 13. Flow rate data for the additive is also preferably continuously transmitted to the sub control unit 19b.
Moreover, the mixing ratio of the mixed slurry, which flows out of the second P.O.U. mixing unit 13 may be measured using a second conductivity measurer 83. The second conductivity measurer 83 is preferably installed at a nozzle of the second P.O.U. mixing unit 13 and transmits a measured mixing ratio to the sub control unit 19b. In the event that the measured flow rate of the diluted slurry and the measured flow rate of the additive are outside of an allowable range or the measured mixing ratio of the mixed slurry is outside of an allowable range, the sub control unit 19b transmits a second CMP process stop signal φ23 to the second CMP machine 17 to halt the operation of the second CMP machine 17.
When the slurry storage portion 91, the mixing portion 93, the supply portion 95, or the additive storage portion 97 are not in a normal condition (i.e., slurry, diluted slurry, and/or additive is low, etc), the main control unit 19a controls the first and second P.O.U. mixing units 11 and 13, respectively, as well as the first and second CMP machines 15 and 17, respectively, through the sub control unit 19b. For example, in the event that the measured mixing ratio of the diluted slurry that flows through the first circulation loop line 55 is outside of a desired range, the main control unit 19a halts the operations of the first and second P.O.U. mixing units 11 and 13, respectively, and the first and second CMP machines 15 and 17, respectively, through the sub control unit 19b. Alternatively, in the event that an exemplary measured mixing ratio of the mixed slurry, which flows out from the first P.O.U. mixing unit 11, is out of an allowed range, the sub control unit 19b may control the slurry storage portion 91, the mixing portion 93, the supply portion 95 or the additive storage portion 97 through the main control unit 19a.
Each of first and second P.O.U. mixing units 11 and 13, respectively, may include a purging means for removing remnants of an unwanted slurry mixture at a time of a mixture change, in order to prevent contamination of a newly introduced slurry mixture. Such purging may be necessary due to application requirements that necessitate significantly changing a mixing ratio or for changing the type of abrasive used in the slurry.
Referring to
An outlet of the slurry supply conduit 107a and an outlet of the diluted slurry circulation loop line 107b are preferably extended to be close to an edge of the bottom of the mixing tank 101. It is also preferable that the outlet of the slurry supply conduit 107a and the outlet of the diluted slurry circulation loop line 107b are bent towards the central portion of the bottom of the mixing tank 101 as shown in FIG. 2. Such an arrangement produces a turbulence/stirring effect on the solutions entering at the bottom of the mixing tank 101.
The mixing unit 5 may further include an ultrasonic sensor 109 or a load cell 105 that measures the amount of the solution in the mixing tank 101. Such measurement devices are preferable to traditional sensor trees mounted on a sidewall of the mixing unit, which can act as a catalyst for precipitating and solidifying the abrasives in the slurry solution, thereby causing measurement inaccuracies. The ultrasonic sensor 109 may be installed at a lid of the mixing tank 101. The measured amount of the solution in the mixing tank 101 is converted into an electrical signal by the ultrasonic sensor 109, with the electrical signal being transmitted to the main control unit 19a.
Alternatively, the load cell 105 is preferably located under the mixing tank 101. In other words, the mixing tank 101 is mounted on the load cell 105. The load cell 105 measures the weight of the mixing tank 101 and the weight of the solution in the mixing tank 101, thereby allowing the net weight of the solution in the mixing tank 101 to be calculated. The measured weight of the solution is converted to an electrical signal, and the electrical signal is transmitted to the main control unit 19a.
An exemplary method for mixing the undiluted slurry and the diluting solution to a desired mixing ratio using the load cell 105 may include the following steps. For the purpose of ease and convenience in explanation, It is assumed that the mixing ratio corresponds to a weight ratio.
In a first step, the undiluted slurry is supplied into the mixing tank 101 through the slurry supply conduit 107a. The load cell 105 continuously measures the weight of the undiluted slurry while the undiluted slurry is supplied. When the weight of the undiluted slurry in the mixing tank 101 reaches a first desired value, the main control unit 19a closes the slurry supply valve 41 and opens the diluting solution valve 49 in a second step.
During a third step, the diluting solution is supplied into the mixing tank 101 via the diluting solution supply conduit 107c with the load cell 105 continuously measuring the weight of the mixing tank 101 and its contents. When the net weight of mixing tank 101 and its contents reach a second desired value, e.g., three times that of the first desired value for an exemplary 3:1 ratio, the main control unit 19a closes the diluting solution valve 49. Thus, using this method, it is possible to accurately attain a desired mixing ratio of the undiluted slurry and the diluting solution.
It is preferable that the mixing unit 5 further includes a stirring device, which is installed at a central portion of mixing tank 101. The stirring device preferably includes a motor 111 installed at a lid of mixing tank 101, a rotation shaft 113 connected to motor 111 and extended to be close to the central portion of the bottom of mixing tank 101, and a propeller 115 fixed at the lower end of rotation shaft 113. When motor 111 is operated, the diluted slurry in the mixing tank 101 is continuously stirred, thereby preventing the diluted slurry in the mixing tank 101 from settling, precipitating or solidifying.
A configuration similar to that used in the mixing unit 5 may be used in the slurry storage unit 3, the supply unit 7, and the additive storage unit 9. In the preferred embodiment of the present invention as described, the additive storage unit 9 does not include the stirring device, even though it may be included depending on the particular preference.
Referring to
Similarly, a second outlet of the first three-way valve 127a is connected to one end of a second conduit 125b, and a second inlet of the second three-way valve 127b is connected to the other end of the second conduit 125b. A second filter 121b may be installed at a predetermined region of the second conduit 12b to filter contaminants that may be contained in a solution that flows through the second conduit 125b. The first and second three-way valves 127a and 127b, respectively, may be manual valves or electronically controlled valves.
In order to allow a solution to flow from through the filter unit, the first outlet of the first three-way valve 127a and the first inlet of second three-way valve 127b are opened and the second outlet of first three-way valve 127a and the second inlet of second three-way valve 127b are closed. More particularly, the solution is introduced into the inlet of the first three-way valve 127a and flows through the first conduit 125a, the first filter 121a and the outlet of the second three-way valve 127b. The first filter 121a is preferably installed such that a normally “lower portion” or loop portion 123a of the first filter 121a is oriented to be higher than an inlet port of the first filter 121a, as shown in FIG. 3. Such an orientation prevents contaminants in the solution from settling or precipitating inside the loop portion 123a of the first filter 121a while the solution passes through the first filter 121a. Similarly, the second filter 121b is preferably installed so that a loop portion 123b of the second filter 121b has a same upward orientation, as shown in FIG. 3.
When the first filter 121a needs to be replaced with a new filter, the second outlet of the first three-way valve 127a and the second inlet of the second three-way valve 127b are opened, and the first outlet of the first three-way valve 127a and the first inlet of the second three-way valve 127b are closed. Accordingly, the solution is introduced through the inlet of the first three-way valve 127a and flows through the second conduit 125b, the second filter 121b, and the outlet of the second three-way valve 127b. In the event that the second filter 121b is not installed, the solution flows through only the second conduit 125b. After completing the replacement of the first filter 121a, the valves may be returned to their former state (i.e., the first outlet of the first three-way valve 127a and the first inlet of the second three-way valve 127b are opened, and the second outlet of the first three-way valve 127a and the second inlet of the second three-way valve 127b are closed). By using a “dual-path” configuration, as just described, it is possible to continuously circulate the solution through the filter unit during the maintenance of the filter unit. Accordingly, since the re-circulation flow of a slurry solution is not allowed to stop, settling, precipitation and/or solidification of the abrasive particles in the undiluted slurry or the diluted slurry is prevented. Also, it is possible to minimize the precipitation of the abrasive particles inside the filter unit by installing the lower, or loop, portion of the filters in an upward orientation.
Referring to
A first flow rate controller 153a is preferably installed at a region of the first conduit 161a between the first valve 151a and the outlet of the first conduit 161a, and a second flow rate controller 153b is installed at a region of the second conduit 161b between the second valve 151b and the outlet of the second conduit 161b. The first flow rate controller 153a is preferably controlled by a first slurry flow rate control/monitor signal φ11, which is outputted from the sub control unit 19b of FIG. 1. Similarly, the second flow rate controller 153b is preferably controlled by the first additive flow rate control/monitor signal φ12, which is also outputted from the sub control unit 19b. Thus, the amount of diluted slurry that flows through the first flow rate controller 153a and the amount of the additive that flows through the second flow rate controller 153b can be appropriately controlled according to a desired mixing ratio. Accordingly, the mixing ratio of the diluted slurry and the additive may be changed in real time according to requirements and needs of a particular polishing process.
A first automated valve 152a is preferably installed at a region of the first conduit 161a between the first valve 151a and the first flow rate controller 153a. Similarly, a second automated valve 152b is preferably installed at a region of the second conduit 161b between the second valve 151b and the second flow rate controller 153b. The first automated valve 152a may be opened or closed by the first slurry valve control signal φ16, which is outputted from the sub control unit 19b. The second automated valve 152b may be opened or closed by the first additive valve control signal φ17, which is also outputted from sub control unit 19b of FIG. 1. In addition, a first conductivity measurer 81 is preferably installed at or near the nozzle 155 in order to measure a mixing ratio of the mixed slurry that flows through the nozzle 155 and transmit the measured result to the sub control unit 19b.
In order to change slurry mixtures, purge lines are preferably installed to remove old mixtures and rinse the delivery conduits before introducing the new slurry mixtures. Accordingly, a first purge line having a first purge valve 157a is preferably branched from the first conduit 161a between the first automated valve 152a and the first flow rate controller 153a. Similarly, a second purge line having a second purge valve 157b is preferably branched from a second conduit 161b between the second automated valve 152b and the second flow rate controller 153b.
By way of example, in order to effect a clean change of a mixing ratio of the mixed slurry for a new polishing process, a previous slurry mixture is first purged and removed from the first conduit 161a, the second conduit 161b and the nozzle 155. The purging process may be accomplished by closing the first and second valves 151a and 151b, respectively, opening the first and second purge valves 157a and 157b, respectively, and introducing de-ionized water and an inert gas, such as nitrogen, into the first and second purge lines. In this manner, the purging process may be conducted while the diluted slurry in the supply portion 95 and the additive in the additive storage portion 97 are concurrently and continuously circulated through the first and second circulation loop lines 55 and 57, respectively, to prevent the abrasive particles in the diluted slurry from settling, precipitated or solidified.
In the meantime, properties of the mixture of the diluted slurry and the additive, such as a polishing selectivity of the mixed slurry, may be changed over time. In the graph shown in
According to the representative graph shown in
It is therefore preferable to maintain the length of the first and second conduits 161a and 161b, respectively, as shown in
According to the present invention, it is preferable that the P.O.U. mixing units 11 and 13 are located close to the CMP machines in order to minimize the lengths of the first and second conduits 161a and 161b, respectively, as well as the length of the nozzle. If the P.O.U. mixing units 11 and 13 are located close to the CMP machines, it will take a second time (t2) for the mixed slurry to reach the outlet of the nozzle. Accordingly, as the second time (t2) is decreased, the less the variation in second time (t2) for a given change in polishing selectivity. As a result, as the distance between the P.O.U. mixing units and the CMP machines becomes closer, greater uniformity of the mixed slurry is achieved.
As stated above, it is preferable that the branch points of the first and second conduits 151a and 151b as well as the first and second valves 151a and 151b be located inside the P.O.U. mixing units 11 and 13 in order to minimize the fluctuation in the physical properties of the mixed slurry as shown in FIG. 5.
A preferred method for supplying a slurry mixture to the first and/or second CMP machines will now be explained with reference to
In a first step, slurry particles in the undiluted slurry are uniformly dispersed by shaking slurry bottle 1, which contains the undiluted slurry. In a second step, the first slurry valve 21 is opened, the second slurry valve 47 is closed, and the first pump 23 is operated to transfer a predetermined amount of the undiluted slurry from the slurry bottle 1 into the slurry storage tank of the slurry storage unit 3 via the slurry conduit 61 and the slurry circulation loop line 63. Simultaneously, a stirring device of the slurry storage tank is operated to continuously agitate the slurry stored in the slurry storage tank, thereby preventing the slurry in the slurry storage tank from settling, precipitating or solidifying.
In a third step, the slurry circulation valve 39 is opened, and the first pump 23 is continuously operated to self-circulate the slurry in the slurry storage tank via the slurry circulation loop line 63. In a fourth step, the slurry supply valve 41 is opened, thereby supplying the undiluted slurry from the slurry storage tank into the mixing tank of the mixing unit 5. When a desired amount of the slurry is transferred to the mixing tank, the slurry supply valve 41 is automatically closed by the main control unit 19a, and in a fifth step, the diluting solution valve 49 is opened to supply the diluting solution into the mixing tank of the mixing unit 5.
In a sixth step, when a desired amount of the diluting solution has been added to the mixing tank, the diluting solution valve 49 is automatically closed by the main control unit 19a, thereby completing a mixing of the undiluted slurry and the diluting solution, e.g., the diluted slurry is formed in the mixing tank. Here, the mixing ratio of the diluted slurry may be controlled using methods other than the above-mentioned method and still be within the scope of the invention. A stirring device installed at the mixing tank is preferably operated to continuously agitate the diluted slurry in the mixing tank.
In a seventh step, the diluted slurry circulation valve 43 is opened, and the second pump 27 is operated to self-circulate the diluted slurry in the mixing tank via the diluted slurry circulation loop line 67, thereby preventing the diluted slurry in the mixing tank from settling, precipitating or solidifying.
In an eighth step, the diluted slurry supply valve 45 is opened, and a portion of the diluted slurry is supplied into the supply tank of the supply unit 7 of the supply portion 95. In a ninth step, when the amount of the diluted slurry in the supply tank reaches an upper limit value, the diluted slurry supply valve 45 is automatically closed by the main control unit 19a.
The diluted slurry stored in the supply tank is stirred by operating a stirring device installed at the supply tank. In addition, a third pump 31 is operated to continuously circulate the diluted slurry in the supply tank through the first circulation loop line 55, thereby preventing the diluted slurry in supply portion 95 from settling, precipitating or solidifying. In a tenth step, the mixing ratio of the diluted slurry in the first circulation loop line 55 is preferably continuously measured using conductivity measurer 32, which transmits a corresponding signal to the main control unit 19a.
In an eleventh step, main control unit 19a compares the measured mixing ratio with a reference mixing ratio, which is set by the operator. In the event that the difference between the measured mixing ratio and the reference mixing ratio is outside of an allowable range, the slurry supply valve 41 and the diluting solution valve 49 of the mixing portion 93 are controlled by the main control unit 19a to provide a diluted slurry having a desired mixing ratio.
In a twelfth step, the additive pump 51 is operated to control the supply of additive in the additive storage tank of the additive storage unit 9. In the event that the amount of the additive in the additive storage tank reaches an upper limit value, the operation of the additive pump 51 is halted. Alternatively, in the event that the amount of the additive in the additive storage tank reaches a lower limit value, the additive pump 51 is operated to supply the additive into the additive storage tank. In a thirteenth step, the fourth pump 35 is operated to circulate the additive in the additive storage tank through the second circulation loop line 57.
In a fourteenth step, at least one of the first and second P.O.U. mixing units 11 and 13, respectively, mixes to a predetermined mixing ratio the diluted slurry which is circulated through the first circulation loop line 55 with the additive solution which is circulated through the second circulation loop line 57. The resulting mixed slurry is supplied to one or more associated CMP machines 15 and 17 through an associated nozzle 155. Here, each of the first and second P.O.U. mixing units 11 and 13, respectively, is controlled by the sub control unit 19b.
In a fifteenth step, at the completion of a polishing process using the associated CMP machine 15, first and second manual valves 151a and 151b, respectively, are closed, first and second purge valves 157a and 157b, respectively, are opened, and the de-ionized water and the nitrogen gas are sequentially introduced into the first and second purge lines. Accordingly, the diluted slurry and the additive that exist in first and second conduits 161a and 161b, respectively, as well as the mixed slurry that exists in the nozzle 155 are completely removed.
In the foregoing discussion, a preferred embodiment of a slurry delivery system is disclosed. One or more of the specific elements included in the preferred embodiment may be omitted in alternate embodiments, and still remain within the scope of the invention. Further, according to the preferred embodiment of the present invention, 1) the slurry is pre-mixed and continuously re-circulated to prevent settling, precipitation and/or solidification of the abrasives in the mixed slurry, and 2) chemical additives are only supplied and mixed at the P.O.U. mixing units at or near the CMP machine and the polishing application, thereby avoiding time limitations associated with adding a curing-type material to a slurry solution. In the re-circulation of the mixed slurry, it can be appreciated that the return conduit may be directed either to the supply tank 7 or to the mixing tank 5 and still maintain the agitation of the mixed slurry, since the two tanks contain the same solution.
It can be appreciated by one having ordinary skill in the art that the relative sizes of the various mixing and storage tanks determine the amount of “old” slurry mix that must be purged before a “new” slurry mix can be introduced into the system without polishing selectivity degradation. It is obviously desirable to be able to re-use as much of an “old” solution as possible. For ratio changes using a same abrasive, ratio adjustments are relatively easy to make. The inherent flexibility of the present invention allows such changes with minimum impact, cost and down time.
However, for changes of abrasive, such as from a silica-based slurry to a ceria-based slurry, either the entire system must be purged and cleaned or a parallel system must be created that may be “switched in” as desired. The engineering trade-off revolves on how often such a change must be made during manufacturing versus the expense and manufacturing space required for maintaining parallel systems.
As long as ratio-changes are small, they can be relatively easily accommodated by weighted calculations using existing slurry vs. an amount of new slurry that must be provided to implement a desired change in the entire amount of slurry retained in the system, with an attendant time delay associated with the mixing and re-circulatory mixing effects to obtain a satisfactory “new” equilibrium solution.
In a simplified example, assume that a specific amount of pre-mixed silica-based slurry, having an exemplary weighted mixing ratio of 3:1, i.e., three parts undiluted slurry to one part diluting agent, exists in all of the “un-purged” elements of mixing portion 93, supply portion 95, and P.O.U mixing units 11 and 13. Assume also that the ratio is to be changed to 2.5:1. If the amount of available weighted space for new material in mixing portion 93 comprises 10% of the total weight of existing slurry, then a weight calculation may be made to arrive at an optimum amount of additional diluting solution that needs to be added to bring the entire amount of slurry to the desired 2.5:1 ratio.
For purposes of explanation, without limitation, for an exemplary 100 pound (lbs) of “old” slurry existing in the elements of the system, with the above 10 lbs of available space for adding new material, the existing quantity of undiluted slurry is 75 lbs and the existing quantity of diluting solution is 25 lbs (a 3:1 ratio.) The quantity of additional diluting solution required to achieve the overall 2.5:1 ratio is 5 lbs to give an overall weight of undiluted slurry of 75 lbs and an overall weight of diluting solution of 30 lbs (2.5:1 ratio.) It can be appreciated that ordinarily adding pure diluting agent would not be particularly desirable, given the amount of mixing time required to uniformly mix the “new solution,” but rather a more graduated approach using incrementally changing proportions of the two solutions would allow faster attainment of acceptable uniformity conditions. Occasionally, such measures may be required, and may include having to purge solution from supply unit 7 of supply portion 95 of slurry supply apparatus 10 to create available space for new materials.
A preferred embodiment of the present invention has been disclosed herein and, although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. Accordingly, it will be understood by those of ordinary skill in the art that various changes in form and details may be made without departing from the spirit and scope of the invention as set forth in the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2001-74547 | Nov 2001 | KR | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 5478435 | Murphy et al. | Dec 1995 | A |
| 5957759 | Cardenas et al. | Sep 1999 | A |
| 6059920 | Nojo et al. | May 2000 | A |
| 6338671 | Kawashima et al. | Jan 2002 | B1 |
| 6406364 | Kimura et al. | Jun 2002 | B1 |
| 6457852 | Hiraoka et al. | Oct 2002 | B1 |
| Number | Date | Country |
|---|---|---|
| 2000-202774 | Jul 2000 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20030100247 A1 | May 2003 | US |
