The present invention relates generally to substrate processing, and more particularly to methods and apparatus for cleaning an edge of a substrate.
Substrates are used in semi-conductor device manufacturing. During processing, the edge of the substrate may become dirty, which may negatively affect the semi-conductor devices. Conventional systems, which contact a substrate edge with an abrasive film to clean the edge, may not thoroughly clean the edge. For example, the abrasive tape or film may not sufficiently contact both bevels of the edge during cleaning. Additionally, the abrasive tape may run-off during the polishing process, especially when the tape is minimally tensioned. The inability to sufficiently clean the substrate may affect semiconductor device manufacturing throughput. Accordingly improved methods and apparatus for cleaning an edge of a substrate are desired.
In aspects of the invention, an apparatus is provided for polishing an edge of a substrate. The apparatus comprises a polishing head, adapted to contact an edge of a substrate, wherein the polishing head includes one pair of front guide rollers and two pairs of back clamping rollers.
In other aspects of the invention, a system is provided for polishing an edge of a substrate. The system comprises a substrate support adapted to rotate a substrate; a polishing head adapted to contact an edge of a substrate, wherein the polishing head includes one pair of front rollers and two pairs of back rollers; a controller adapted to operate the polishing of the edge of the substrate.
In yet other aspects of the invention, a method is provided for polishing an edge of a substrate. The method comprises rotating a substrate; contacting an edge of the substrate with a polishing head, wherein the polishing head includes one pair of front rollers and two pairs of back rollers; routing a polishing tape between the first pair of back rollers, around the first and second front rollers, and then between the second pair of back rollers, such that the length of polishing tape between the first and second front rollers contacts and polishes the edge of the substrate.
Other features and aspects of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings.
The present invention provides improved methods, systems and apparatus for cleaning and/or polishing the edge of a substrate. The edge of a substrate may be polished by application of an abrasive polishing tape contacting the substrate edge (via a backing pad, in some embodiments) as the substrate is rotated or otherwise moved (e.g., oscillated). However, the polishing tape may run-off the polishing head, even when the apparatus is being operated with minimal tape tension values. According to the present invention, in some embodiments a polishing head is provided that may include a top plate, located in a plane opposite and parallel to a bottom plate. A pair of front guide rollers may be positioned between the top plate and the bottom plate. A first and second pair of back rollers may also be positioned between the top and bottom plates, and opposite each front roller. The back rollers may function to clamp the polishing tape that is routed between the rollers so that the polishing tape maintains alignment on the rollers without requiring tension along the length of the polishing tape. The front and back rollers may be arranged to route the polishing tape around or over the backing pad. In some embodiments, the space between the two back rollers in each pair of back rollers may be limited such that the polishing tape may be constrained in the lateral direction by the walls of the rollers. This may help to ensure that the tape does not run-off the polishing head, even when the apparatus is being operated with minimal tape tension values.
The present invention provides improved methods and apparatus for cleaning and/or polishing the edge of a substrate. With reference to
The exclusion regions 108, 108′ may serve as buffers between the device regions 106, 106′ and the edge 104. The edge 104 of a substrate 100 may include an outer edge 110 and bevels 112, 114. The bevels 112, 114 may be located between the outer edge 110 and the exclusion regions 108, 108′ of the two major surfaces 102, 102′. The present invention is adapted to clean and/or polish the outer edge 110 and at least one bevel 112, 114 of a substrate 100 without affecting the device regions 106, 106′. In some embodiments, all or part of the exclusion regions 108, 108′ may be cleaned or polished as well.
As shown in
The polishing tape 201 may be supplied to the head 204 by a set of spools including a supply spool 209 and a take-up spool 211. The spools 209, 211 may be driven by one or more drivers 213, 215 (e.g., servo motors) which may provide an indexing capability to allow a specific amount of unused polishing tape 201 to be advanced or continuously fed to the substrate edge 104, and/or a tensioning capability to allow the polishing tape 201 to be stretched taught and to apply pressure to the substrate edge 104.
The front and back rollers 210, 212 may be adapted to apply a variable amount of tension to the polishing tape 201, and thereby the substrate edge 104, so as to attain precise control over an edge polishing process which may be used to compensate for different edge geometries and changes in the substrate 100 as material is removed from the substrate edge 104.
The substrate 100 may contact the abrasive tape 201 for about 15 to about 150 seconds depending on the type of tape used, the grit of the tape, the rate of rotation, the amount of polishing required, etc. More or less time may be used. The contact between the backing pad 203, and hence polishing tape 201, and the substrate edge 104 combined with the particular rotation speed of the substrate 100, may provide relative movement between the polishing tape 201 and the substrate edge 104, resulting in the substrate edge 104 being polished. Depending on the amount of force applied by the actuator, the resiliency of the pad selected, the amount of inflation of an inflatable pad, and/or the amount of tension on the polishing tape, a controlled amount of pressure may be applied to polish the substrate edge 104. Thus, the present invention may provide precise control of an edge polish process, which may be used to compensate for different edge geometries and changes in the substrate 100 as material is removed from the substrate edge 104.
The substrate 100 may be rotated in a horizontal plane. The edge 104 of the substrate 100 may be aligned with, or normal to, the polishing tape 201, pad 203 and/or polishing head 204. In additional or alternative embodiments, the substrate 100 may be rotated in a vertical plane, other non-horizontal plane, and/or be moved between different planes of rotation.
In addition, in such multi-head embodiments, each head 304 may use a differently configured or type of polishing tape 201 (e.g., different grits, materials, tensions, pressures, etc.). Any number of heads 304 may be used concurrently, individually, and/or in any sequence. The heads 304 may be disposed in different positions and in different orientations (e.g., aligned with the substrate edge 104, normal to the substrate edge 104, angled relative to the substrate edge 104, etc.) to allow the tape 201 to polish different portions of the edge 104 of the substrate 100.
In some embodiments, one or more of the heads 304 may be adapted to be oscillated or moved (e.g., angularly translated about a tangential axis of the substrate 100 and/or circumferentially relative to the substrate 100) around or along the substrate edge 104 by the frame 202 so as to polish different portions of the substrate edge 104. Different heads 304 may be used for different substrates 100 or different types of substrates.
As further described below, the system 300 may further include a controller 306, (e.g., a programmed computer, a programmed processor, a microcontroller, a gate array, a logic circuit, an embedded real time processor, etc.), which may control the driver(s) used to rotate the substrate 100 and/or the actuator(s) used to push the polishing pad(s) 203 against the substrate edge 104. Note that the controller 306 may be coupled (e.g., electrically, mechanically, pneumatically, hydraulically, etc.) to each of a plurality of actuators. Likewise, the controller 306 may be adapted to receive feedback signals from one or more drivers and/or actuators, that indicate the amount of energy being exerted to rotate the substrate 100 (e.g., rotate a vacuum chuck holding the substrate 100) and/or actuate the actuator(s) to push the polishing pad(s) 203 against the substrate 100. These feedback signals may be employed to determine when a particular layer of film has been removed and/or whether a sufficient amount of polishing has occurred.
Turning to
The polishing head 400 may include a top plate 402, located in a plane opposite and parallel to a bottom plate 404. A pair of front rollers 406a,406b may be positioned between the top plate 402 and the bottom plate 404, such that the front rollers 406a,406b are able to rotate in a plane perpendicular, or alternatively, substantially perpendicular to the top and bottom plates 402,404. In other words, the axis of rotation may be perpendicular (or substantially so) to the horizontal plane of the top and bottom plates 402, 404, and therefore the plane of rotation may be parallel to the top and bottom plates 402, 404. A first and second pair of back rollers 408a and 408b may be positioned between the top and bottom plates 402, 404 and opposite each front roller 406a and 406b, respectively, and may rotate in the same rotational orientation as the front rollers 406.
The rollers may be designed for maximum diameter to reduce friction. The rollers may be made of a plastic bearing material including but not limited to PTFE and PEEK.
Turning to
In some embodiments, the back rollers 408a,408b may be disposed so close together that the back rollers 408a,408b effectively clamp the polishing tape 201 and prevent the polishing tape 201 from moving along the longitudinal dimension of the back rollers 408a,408b and consequently prevent the polishing tape 201 from moving along the longitudinal dimension of the front rollers 406a,406b as well as prevent the polishing tape 201 from slipping off the backing pad 203. In other words, without having to rely on high tension applied to the polishing tape 201 along the length of the polishing tape 201 (i.e., in the longitudinal dimension of the polishing tape 201) to keep the polishing tape 201 aligned on the front rollers 406a,406b and the backing pad 203, the present invention facilitates maintaining the alignment of the polishing tape 201 on the front rollers 406a,406b and the backing pad 203 by using two pairs of back rollers 408a,408b which each clamp the polishing tape 201 on either side of the front rollers 406a,406b which allows the polishing tape 201 to move through the polishing head 400 but not move laterally off the rollers towards the top plate 402 or bottom plate 404.
In some embodiments, the front rollers 406a,b may be placed close to the backing pad 203 (e.g., disposed so as to guide the polishing tape 201 out to a plane that is almost co-planar with the backing pad 203) to reduce the amount of displacement of the polishing tape 201 by the backing pad 203 needed to make the polishing tape 201 contact the edge 104 of the substrate 100. Other front roller orientations may be used. The front and back roller 406a,406b,408a,408b arrangement may reduce the effect of the polishing tape 201 tension on the backing pad 203. In some embodiments (e.g., embodiments that use a roller backing pad 203), the front rollers 406a,406b may be removed, and the polishing tape 201 may be routed just over the backing pad 203.
In some embodiments, the spool of polishing tape 201 mounted to the head 400, may be driven by one or more drivers 213, 215, e.g., servo motors (
Further, the polishing tape 201 may be mounted on the head 400 in a continuous loop and/or the polishing tape 201 may be continuously (or intermittently) advanced to polish and/or increase the polishing effect on the substrate edge 104. For example, the advancement of the tape 201 may be used to create and/or enhance the polishing motion. In some embodiments the tape 201 may be oscillated back and forth to polish and/or enhance the polishing effect on a stationary or rotating substrate 100. In some embodiments, the tape 201 may be held stationary during polishing. Further, the tape 201 tension and/or force may be varied based on various factors including, for example, the angle and/or position of the polishing tape 201, the polishing time, the materials used in the substrate, the layer being polished, the amount of material removed, the speed at which the substrate is being rotated, the amount of current being drawn by the driver rotating the substrate, etc. Any combination of the above described polishing motions and/or methods that are practicable may be employed. These methods provide additional control over the edge polish process which can be used to compensate for geometry and changes in the material being removed as the tape 201 is rotated/moved about, or relative to, the substrate edge 104.
It should be understood that the inventive edge polishing apparatus described herein may be employed in apparatuses other than those adapted for bevel and edge polishing and/or removal of films on substrates. Further, as will be apparent to those of ordinary skill in the art, the apparatus describe herein may be employed to polish and/or remove films on an edge of a substrate supported in any orientation (e.g., horizontal, vertical, diagonal, etc).
Further, it should be understood that although only examples of cleaning a round substrate are disclosed, the present invention could be modified to clean substrates having other shapes (e.g., a glass or polymer plate for flat panel displays). Further, although processing of a single substrate by the apparatus is shown above, in some embodiments, the apparatus may process a plurality of substrates concurrently.
The foregoing description discloses only exemplary embodiments of the invention. Modifications of the above disclosed apparatus and methods which fall within the scope of the invention will be readily apparent to those of ordinary skill in the art. Accordingly, while the present invention has been disclosed in connection with exemplary embodiments thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention, as defined by the following claims.
The present application claims priority from U.S. Provisional Patent Application Ser. No. 60/939,350 filed May 21, 2007, entitled “METHODS AND APPARATUS FOR USING A BEVEL POLISHING HEAD WITH AN EFFICIENT TAPE ROUTING ARRANGEMENT” (Attorney Docket No. 11565/L) which is hereby incorporated herein by reference in its entirety for all purposes. The present application is related to the following commonly-assigned, co-pending U.S. patent applications, each of which is hereby incorporated herein by reference in its entirety for all purposes: U.S. patent application Ser. No. 11/299,295, filed on Dec. 9, 2005, and entitled “METHODS AND APPARATUS FOR PROCESSING A SUBSTRATE” (Attorney Docket No. 10121); U.S. patent application Ser. No. 11/298,555, filed on Dec. 9, 2005, and entitled “METHODS AND APPARATUS FOR PROCESSING A SUBSTRATE” (Attorney Docket No. 10414); U.S. patent application Ser. No. 11/693,695, filed on Mar. 29, 2007, and entitled “METHODS AND APPARATUS FOR POLISHING AN EDGE OF A SUBSTRAET” (Attorney Docket No. 10560); U.S. Patent Application Ser. No. 60/939,351, filed May 21, 2007, entitled “METHODS AND APPARATUS FOR POLISHING A NOTCH OF A SUBSTRATE USING AN INFLATABLE POLISHING WHEEL” (Attorney Docket No. 10674/L); U.S. Patent Application Ser. No. 60/939,353, filed May 21, 2007, entitled “METHODS AND APPARATUS FOR FINDING A SUBSTRATE NOTCH CENTER” (Attorney Docket No. 11244/L); U.S. Patent Application Ser. No. 60/939,343, filed May 21, 2007, entitled “METHODS AND APPARATUS TO CONTROL SUBSTRATE BEVEL AND EDGE POLISHING PROFILES OF EPITAXIAL FILMS” (Attorney Docket No. 11417/L); U.S. Patent Application Ser. No. 60/939,219, filed May 21, 2007, entitled “METHODS AND APPARATUS FOR POLISHING A NOTCH OF A SUBSTRATE USING A SHAPED BACKING PAD” (Attorney Docket No. 11483/L); U.S. Patent Application Ser. No. 60/939,342, filed May 21, 2007, entitled “METHODS AND APPARATUS FOR REMOVAL OF FILMS AND FLAKES FROM THE EDGE OF BOTH SIDES OF A SUBSTRATE USING BACKING PADS” (Attorney Docket No. 11564/L); U.S. Patent Application Ser. No. 60/939,344, filed May 21, 2007, entitled “METHODS AND APPARATUS FOR USING A ROLLING BACKING PAD FOR SUBSTRATE POLISHING” (Attorney Docket No. 11566/L); U.S. Patent Application Ser. No. 60/939,333, filed May 21, 2007, entitled “METHODS AND APPARATUS FOR SUBSTRATE EDGE POLISHING USING A POLISHING ARM” (Attorney Docket No. 11567/L); U.S. Patent Application Ser. No. 60/939,212, filed May 21, 2007, entitled “METHODS AND APPARATUS FOR IDENTIFYING A SUBSTRATE EDGE PROFILE AND ADJUSTING THE PROCESSING OF THE SUBSTRATE ACCORDING TO THE IDENTIFIED EDGE PROFILE” (Attorney Docket No. 11695/L); U.S. Patent Application Ser. No. 60/939,337, filed May 21, 2007, entitled “METHODS AND APPARATUS FOR HIGH PERFORMANCE SUBSTRATE BEVEL AND EDGE POLISHING IN SEMICONDUCTOR MANUFACTURE” (Attorney Docket No. 11809/L); U.S. Patent Application Ser. No. 60/939,228, filed May 21, 2007, entitled “METHODS AND APPARATUS FOR POLISHING A NOTCH OF A SUBSTRATE BY SUBSTRATE VIBRATION” (Attorney Docket No. 11952/L); and U.S. Patent Application Ser. No. 60/939,209, filed May 21, 2007, entitled “METHODS AND APPARATUS FOR CONTROLLING THE SIZE OF AN EDGE EXCLUSION ZONE OF A SUBSTRATE” (Attorney Docket No. 11987/L).
Number | Date | Country | |
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60939350 | May 2007 | US |