Remarkable progress made in microelectronic devices over the past several years has led to more useful yet less expensive electronic products of all types. It has also led to entirely new types of products. A major factor in the development of microelectronic devices has been the machines and methods used to manufacture them. Manufacturing of microelectronic devices requires extreme precision, extremely pure materials, and an extremely clean manufacturing environment. Even microscopic particles can cause defects and failures in devices.
Microelectronic devices are typically manufactured by selectively applying and removing various layers or films of material onto a substrate, such as a silicon wafer. Manufacturing by-products, such as polymer, post etch plasma residue, and other contaminants on the wafer after certain process steps, must be removed before the wafer is further processed. These types of contaminants can be difficult to completely remove. Some contaminants are only minimally soluble with preferred aqueous cleaning solutions. Other contaminants become tightly bonded to an underlying layer on the wafer and are difficult to remove. Some contaminants also tend to re-adhere to the wafer surface after they are initially removed during the cleaning process. Developing effective ways to remove contaminants remains as a technological challenge in semiconductor device and other micro-scale device manufacturing.
New cleaning apparatus and methods provide significantly better results with difficult to remove contaminants. The contaminants can now be more quickly and easily removed using lower cost and more environmentally friendly cleaning solutions. In one aspect, the cleaning liquid is sprayed or jetted in a direction generally tangent to the circular edge of a spinning workpiece, enhancing removal of contaminants from areas near the edge. In another aspect, the contaminant is removed via the pressure of the cleaning liquid, the temperature of the cleaning liquid, the chemical composition of the cleaning liquid, or a combination of them.
In the drawings, the same reference number indicates the same element in each of the views.
The invention is directed to apparatus and methods for processing or cleaning a workpiece, such as a semiconductor wafer. The term workpiece or wafer here means any flat article, including semiconductor wafers and other substrates such as glass, mask, and optical or memory media, MEMS substrates, or any other workpiece having, or on which, microelectronic, micromechanical, microelectro-mechanical or micro-optical devices can be formed. The term contaminant here means any unwanted particles, film or other material on a wafer.
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The specific angles described above may vary with different applications. In many applications, only the trailing side nozzles 62 and 70 may be used, with or without the central nozzles 66 and 74, or alternatively, the leading side nozzles 64 and 72 may be used with the central nozzles 66 and 74. In fewer circumstances, both trailing nozzles such as 62 and 70, and the leading side nozzles such as 64 and 72, may be used in the same process.
The angles described above can vary depending upon the diameter of the rotor and wafer, as well as the dimensions between the nozzles and the wafer position in the rotor. Various types of nozzles may be used, such as cone pattern spray nozzles, fan pattern spray nozzles or needle jet nozzles. A jet is a substantially continuous column of moving liquid, in contrast to a spray which is formed from discrete droplets. While the drawings show six nozzles 62, 64, 66, 70, 72, and 74, of course, different numbers of each type of nozzle (declined, inclined, leading, trailing, or central) may be used. The location of the nozzles may also be varied to the extent that the sprays or jets from the nozzles do not excessively interfere with each other.
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Additional fixed nozzles may also be provided in the base 24 to spray the bottom or down facing side of the wafer 25. As shown in
Additional nozzles or outlets may also optionally be provided in the base 24. For example, one or more high pressure edge-on nozzles 96 may be generally vertically aligned with the edge of the wafer 25 (when the wafer 25 and head 22 are in the processing position). If used, the edge-on nozzles 96 may be directed radially inwardly towards the center of the rotor 26. The jet or spray from the edge-on nozzle 96 impacts at the edge of the wafer, where it may more easily penetrate under certain contaminant layers.
A jet or spray from a leading or trailing nozzle tends to carry removed contaminant particles off of the wafer. In contrast, a jet or spray from an edge-on nozzle tends to carry removed contaminant particles inwardly towards the center of the wafer. This is often acceptable with contaminants that do not re-adhere to the wafer. For removing re-adhering contaminants, edge-on nozzles may be successfully used, with other nozzles providing sufficient liquid onto the wafer to maintain an outward flow across the wafer, to prevent re-adhesion.
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In use, a wafer 25 is loaded into the head 22 and secured by the fingers 28 or other equivalent wafer holding devices. The head 22 may be inverted, i.e., in an upside down orientation, during wafer loading/unloading. If the processor 20 is used in a system 140, the handling of the wafer 25 may be computer controlled via the controller 144 and robot 150.
The head 22 is lowered into engagement with the base 24. The head rim 36 may engage the base rim 52, to align the head and base, provide a precise position for the wafer during processing, and/or to seal the bowl 50, to prevent escape of liquids, vapors, or gases.
The motor 30 is switched on and spins the rotor 26. If used, the swing arm assembly 100 is activated, with the motor 108 driving the swing arm 104 back and forth. Fluid is sprayed or jetted onto the spinning wafer 25 from the nozzles 102 on the swing arm 104, and from one or more of the nozzles 62, 64, 66, 70, 72 and 74. In addition, fluid may be sprayed or jetted from the fixed lower nozzles 120, if used. In certain processing steps, the edge-on nozzles may also be used.
In a typical application, the wafer 25 is a silicon wafer with partially completed semi-conductor devices fabricated on one device side, and no devices on the back side. In this example, contamination is targeted for removal from the backside near and at the edge EE of the wafer 25 (including the bevel), from the flat outer edge of the wafer (if present) and from the bevel area on the device side of the wafer.
The nozzles 102 on the swing arm 104 spray a process liquid at high pressure, e.g., 300 psi to 2500 psi or higher, or 1000-2000 or 1200-1800 psi, onto the backside of the wafer 25. The swing arm 104 swings back and forth across the area of the wafer 25 having the contamination to be removed. The nozzles 102 on the swing arm 104 may be oriented perpendicular to the wafer 25. However, they may also be angled outwardly towards the edge of the wafer. In this case, especially where bulk contamination is not dissolved in the process liquid, the process liquid tends to more readily undercut the contamination, while also reducing or eliminating re-adhesion of the contamination on the wafer surface.
Before, with, or after application of the process liquid from the swing arm 104, process liquid may also be sprayed or jetted from one or more of nozzles 62, 64, 70, or 72 in a direction generally tangent to the edge of the wafer, to remove contamination from the edge and bevel and surrounding wafer surfaces. A relatively high pressure jet or spray, e.g., about 300-800, 400-700, or 500 psi, from the nozzles 62, 64, 70 or 72, can tend to cause contaminant films at the edge of the wafer 25 to loosen and lift off the wafer, with the process liquid penetrating beneath the film. This tangential spray or jet of process liquid reduces or eliminates re-adhesion of loosened contamination particles, because the direction of the process liquid tends to carry the contaminant particles off of the surface of the wafer 25. Process liquids may also simultaneously be sprayed towards the center of the top or device side of the spinning wafer 25 from the nozzles 66 and 74, to help to reduce or avoid re-adhesion of contaminate particles up by creating a net movement of process liquid across the wafer surface, towards the edge of the wafer.
The process liquid delivered onto the wafer from any of the nozzles may include a heated mixture of deionized water. Additives may be used including surfactants, detergents, alcohols or co-solvents, chelating agents, or combinations of them, for removing contamination from the backside of the wafer. The tangential nozzles 62, 64, 70, or 72 may also operate at high pressures, up to 1500 or 2000 psi, but more generally operate at pressures of about 300-700 or 400-600 psi, providing a spray or a jet.
On the backside of the wafer, the film of contamination tends to be penetrated by the spray of process liquid at several locations. Penetration of the contamination film is enhanced by heating the liquid, and the pressure or impact of the liquid on the film. The contaminant film on the backside of the wafer is typically also undercut, via the physical effects of the heat and pressure of the liquid, and the chemical effects of the additive. The process liquid, such as deionized water and a surfactant or detergent additive, may be heated to 25 or 30° C.-99° C., and typically to about 85-99° C. To avoid adverse heat related affects with some types of wafers, the process may also be performed at room temperature.
Since a process liquid made up of de-ionized water and a detergent or surfactant is relatively low cost, it may be applied in a single use system, where the process liquid is used and then not reclaimed or recirculated. Where the contaminants are largely insoluble, single use avoids the collection of the contaminant material in the process liquid system. As a result, maintenance of the system to remove the contamination is avoided, and the potential for recontamination via use of reused process liquid is avoided.
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The processor 20 is especially useful for removing insoluable contaminant films, such as post-etch residues. These films may have carbon HF bonds which do not dissolve. Accordingly, the processor 20 removes the contaminant film via the use of impact of the process liquid against the contaminant layer, penetration of the layer, and optionally via use of heat and chemical additives, such as surfactants or detergents. These additives, if used, help to keep the surface of the wafer wet, which aids in preventing redeposition of the contaminant particles.
The methods and apparatus described above may be used in removing metallic contamination from a workpiece. For example, during electro less nickel/lead (Ni/Pb) wafer plating processes, some nickel tends to plate out on the edge and bevel of the wafer. This nickel is not plated onto the device area of the wafer. Accordingly, it is generally only loosely attached to the surface of the wafer and tends to flake off the edge and bevel, in the form of whiskers or stringers. These whiskers can contaminate the wafer and the wafer handling and processing equipment. The whiskers may be removed by delivering a high pressure jet or spray of liquid to the bottom or back side edge of the spinning wafer, preferably at an acute angle to the wafer.
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The whisker removal process may also be performed using a fixed high pressure nozzle, such as a nozzle 120 on the manifold 118, or another nozzle fixed in position elsewhere in the process chamber, below the wafer. Whether the whisker removal nozzle(s) are fixed or moveable, orienting the nozzle to apply liquid an acute angle to the edge allows the whiskers to be removed, and also tends to carry the removed whiskers off of and away from the wafer. Experimental results have demonstrated however that the whiskers may also be removed with nozzles spraying at the edge of the wafer, at substantially a right angle to the plane of the including de-ionized water, with or without any additional process chemicals. The liquid may be heated or used at room temperature.
While the processor 20 is shown as a single wafer processor, the techniques described here may also be used in batch processors. As used here, edge area means the annular area extending inwardly about 20, 10, 8, 5, 4, 3, 2 or 1 mm from the edge of the workpiece.
Thus, novel apparatus and methods have been shown and described. Various changes and substitutions of equivalents may of course be made, without departing from the spirit and scope of the invention. The invention, therefore, should not be limited, except by the following claims and their equivalents.
This Application is a continuation-in-part of U.S. patent application Ser. No. 11/359,969, filed Feb. 21, 2006 and now pending and incorporated herein by reference.
Number | Date | Country | |
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Parent | 11359969 | Feb 2006 | US |
Child | 11739201 | Apr 2007 | US |