Impurities present on the surface of a substrate, such as a semiconductor wafer, may negatively affect the material properties of the substrate. Some impurities may be deposited on the surface of the substrate by water used to rinse the substrate. Accordingly, it is desirable to reduce or eliminate the amount of impurities contained in the water in which the wafers are rinsed. Water used to rinse the substrate is often analyzed to determine the amount and type of impurities present therein so that the proper filters or other remediation systems may be selected and used to reduce or eliminate the impurities contained in the water.
In known systems, the amount and type of impurities deposited on the surface of the substrate is determined by various analytical methods. The analytical methods are capable of determining the presence and amount of impurities above a set threshold level. However, impurities deposited on the surface of the substrate below the threshold level may negatively affect the properties of the substrate or components formed from the substrate. Prior systems are thus incapable of detecting impurities deposited on the surface of substrates that may negatively affect the properties of the substrate.
A first aspect is directed to a method for determining metal content in a container of water. The method comprises contacting a substrate with the water for a predetermined period of time. The substrate is then dried and analyzed to determine the metal content of the substrate surface. A determination is then made of the metal content in the water from the metal content on the substrate surface.
Various refinements exist of the features noted in relation to the above-mentioned aspects. Further features may also be incorporated in the above-mentioned aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to any of the illustrated embodiments may be incorporated into any of the above-described aspects, alone or in any combination.
Referring initially to
Referring now to
The bottom member 112 and side members 114 form a water-tight enclosure that is open at its top 116. The members 112, 114 are joined together with any suitable joining mechanism, such as welding or adhesive bonding. Moreover, in one embodiment, the members 112, 114 are integrally formed from the same blank of material such that joining mechanisms are unnecessary. In other embodiments, the tank 110 includes an additional top member (not shown) coupled to side members 114 such that the tank is an enclosed, multi-sided structure.
A liquid 130 is disposed within the tank 110. The amount of liquid 130 in the tank 110 is great enough such that the wafers W are completely submerged in the liquid 130. However, in one embodiment the wafers W are not completely submerged in the liquid 130. The liquid 130 in this embodiment is water. In other embodiments, the liquid 130 is any suitable liquid (e.g., a solvent) that has sufficient viscosity to flow through the tank 110.
The tank 110 of this embodiment has an inlet 118 and an outlet 120 (or drain) to permit the flow therethrough of the fluid 130. The inlet 118 is coupled to the supply source 50 and the outlet 120 is coupled to reservoir 150. In the embodiment of
The cross-sectional areas of the inlet 118 and outlet 120 are sufficiently sized to achieve a desired flow rate through the tank 110. In the exemplary embodiment, the cross-sectional areas of the inlet 118 and outlet 120 are sized such that the flow rate is between 0 liters per minute and 50 liters per minute. The positions of the inlet 118 and outlet 120 shown in
In
Referring now to
Referring now to
The inlet 118 of the tank 110 has an extension 125 attached thereto and configured to direct the flow of liquid onto approximately a geometric center of the surface of the wafer W. The extension 125 thus directs the flow of liquid 130 to contact the surface of the wafer W. After contacting the surface of the wafer W, the liquid 130 flows off of the surface of the wafer W and is collected in the tank 110 before being directed therefrom through the outlet 120. Moreover, reduced liquid flow rates may be used in the system 200 compared to those used in the system 100. For example, after the surface of the wafer W is sufficiently wetted with liquid 130, the flow rate may be between 0 liters per minute and 2 liters per minute.
As described herein, the method 300 permits the detection of relatively small amounts of contamination present in the liquid 130 that are not otherwise detectable with known systems. For example, known systems are generally only able to detect concentrations of contaminants on the surface of the wafer W that are greater than about 2e8 atoms/cm2. The method 300 described below is capable of detecting concentrations of contaminants that are substantially below 2e8 atoms/cm2. For example, the method 300 is capable of detecting concentrations of contaminants in the range of 1e5 atoms/cm2.
The method 300 of this embodiment begins at block 310 with the placing of wafers W in the tank 110. The tank 110 may be cleaned prior to the placement of the wafers W therein to ensure that the tank is free from contamination. In some embodiments, the tank 110 may be washed with acid. The wafers W are placed in the tank 110 and positioned therein by the wafer support. While reference is made herein to a plurality of wafers W being placed in the tank 110, a single wafer may instead be placed in the tank. The placement of multiple wafers W in the tank 110 results in a correspondingly larger sample of data collected in accordance with the method 300.
In block 320, the flow of liquid 130 through the tank 110 begins. The liquid 130 in this embodiment is water. In other embodiments the liquid 130 may be any suitable liquid, such as a solvent. The liquid 130 first flows into the tank 110 through the inlet 118. The liquid 130 may first be filtered before entering the tank 110 through the inlet 118. In one embodiment, the liquid 130 (e.g., water) may be filtered such that it has a low enough level of contaminants and is referred to as ultra pure water (i.e., water containing less 1 part-per-trillion (ppt) of any metal contaminant). As the liquid 130 flows into the tank 110, the level of the liquid rises and eventually reaches the level of the outlet 120 of the tank. The liquid 130 then flows out of the tank 110 through the outlet 120. The liquid 130 may then be disposed of or recycled after flowing out of the tank 110. As described above, the wafers W may instead be placed within the tank 110 after it is filled with liquid 130.
At block 330, the flow of liquid 130 through the tank 110 continues for a predetermined period of time. In some embodiments, the predetermined period of time is referred to as a soak time. The predetermined period of time may be selected according to numerous factors. For example, if a threshold for the detection of a contaminant on the surface of the wafer W is 2e8 atoms/cm2, the predetermined period of time may be selected such that the amount of contamination deposited on the surface of the wafer W is likely to exceed the threshold detection level. According to some embodiments, the predetermined period of time is approximately 100 to 150 times greater than the normal rinse time. With a rinse time of five minutes, the predetermined period of time is thus in the range of 500 to 1000 minutes. In one embodiment, the predetermined period of time is 750 minutes.
The flow of liquid 130 through the tank 110 ceases at block 340. After cessation of the flow of liquid 130, the liquid may be drained or otherwise removed from the tank. The wafers W may then be dried such that any residual liquid 130 present on the surface is removed. In another embodiment, the wafers W may be removed from the tank 110 while liquid is still present therein such that the wafers are at least partially immersed in the liquid prior to their removal. The wafers W may be removed from the tank 110 in this embodiment with the same type of robotic mechanism described above.
In block 350 the amount of contaminants deposited on the surface of the wafer W are determined. Various methods may be used to determine the amount and/or concentration of the contaminants deposited on the surface of the wafer W. For example, inductively coupled plasma mass spectrometry (ICP-MS) may be used to analyze the surface of the wafer W to determine the amount and/or concentration of the contaminants deposited thereon during the method 300. Concentration of contaminants may be expressed as the number of atoms of contaminants deposited on a given area of the surface of the wafer (e.g., atoms per cm2. In other embodiments, different methods may be used to determine the amount and/or concentration of the contaminants deposited on the surface of the wafer W, such as total reflectance X-ray fluorescence (TXRF).
At block 360, a prediction is made as to the amount of contaminants deposited on the surface of the wafer W for a period of time less than the predetermined period of time in block 330. The period of time less than the predetermined period of time in one embodiment is the typical rinse time for the wafer W (e.g., 1 to 10 minutes). In one embodiment, the typical rinse time is 5 minutes and the predetermined period of time is 750 minutes.
In some embodiments, the steps performed in blocks 310-350 may only be performed either to establish a base line level of contamination or to verify the expected contamination levels. Once the determination is made in block 350, the prediction made in block 360 may be performed independently each time a wafer is rinsed in the liquid. Thus, the determination made in block 350 is not required to be performed every time the prediction in block 360 is performed. Instead, the steps performed in block 310-350 may be performed to calibrate the rinsing system, and the prediction performed in block 360 is performed on each wafer rinsed in the rinsing system.
The rate of deposition of contamination on the surface of the wafer W is assumed to be generally linear, and as such a linear interpolation is used to predict or determine the amount and/or concentration of contaminants that are deposited on the surface of the wafer during the typical wafer rinse time. For example, in one embodiment 2e10 atoms/cm2 were deposited on the surface of the wafer in 750 minutes and a rinse time of the wafers W is 5 minutes. The concentration of contamination deposited on the surface of the wafer W is thus determined by multiplying the concentration of contaminants determined in block 350 by the ratio of the typical rinse time (e.g., 5 minutes) to the predetermined period of time (e.g., 750 minutes). In this embodiment, the concentration of the contaminants deposited on the surface of the wafer during a typical rinse is thus determined to be 1.33e8 atoms/cm2. Accordingly, the linear interpolation is thus represented by the equation:
where c equals the concentration of contaminants deposited on the surface of the wafer during a typical rinse of the wafer W, Tr equals the length of time of a typical wafer rinse, Tp equals the predetermined period of time, and Ec equals the concentration of contaminants determined in block 350.
In other embodiments, the rate of deposition of contamination on the surface W is not generally linear. In these embodiments, the method 300 may be repeated several times and each time the predetermined period of time may be varied. Accordingly, multiple pairs of values for contaminant concentration levels and corresponding predetermined periods of time are determined. The pairs of values may then be used in any number of numerical interpolation methods to determine the rate of deposition of contaminants on the surface of the wafer W. The determined rate of deposition may then be multiplied by the rinse time of the wafer to arrive at the amount and/or concentration of contaminants deposited on the surface of the wafer.
The method 300 described above thus permits the detection of amounts of contaminants in the liquid 130 well below those detectable by known systems. In known systems, the lower limit of detection of the most sensitive ICP-MS methods is about 0.1 ppt. Accordingly, the presence of contaminants in the liquid 130 and on the surface of the wafer W are detectable by the method 300 even though the amount of contaminants is well below those detectable by known systems.
In block 420, the flow of liquid 130 onto the surface of the wafer W begins. The liquid 130 in this embodiment is water. In other embodiments, the liquid 130 may be any suitable liquid, such as a solvent. The liquid 130 first flows into the tank 110 through the inlet 118. The liquid 130 may first be filtered before entering the tank 110 through the inlet 118. In one embodiment, the liquid 130 (e.g., water) may be filtered such that it has a low enough level of contaminants and is referred to as ultra pure water. The liquid 130 may be directed to flow onto the surface of the wafer W by the extension 125 coupled to the inlet 118. After flowing across the surface of the wafer W, the liquid 130 then flows into the tank 110. The liquid 130 then flows out from the tank 110 through the outlet 120. The liquid 130 may then be disposed of or recycled after flowing out of the tank 110. In another embodiment, the wafer W may be rotated by the support member 127 as liquid flows onto the surface of the wafer W,
At block 430, the flow of liquid 130 onto the surface of the wafer W continues for a predetermined period of time. For example, if a threshold for the detection of a contaminant on the surface of the wafer W is 2e8 atoms/cm2, the predetermined period of time may be selected such that the amount of contamination deposited on the surface of the wafer W is likely to exceed the threshold detection level. According to some embodiments, the predetermined period of time is approximately 100 to 150 times greater than the normal rinse time. With a rinse time of five minutes, the predetermined period of time is thus in the range of 500 to 1000 minutes. In one embodiment, the predetermined period of time is 750 minutes.
The flow of liquid 130 onto the surface of the wafer W ceases at block 440. After cessation of the flow of liquid 130, the liquid may be drained or otherwise removed from the tank. The wafer W may then be dried such that any residual liquid 130 present on the surface is removed.
In block 450 the amount of contaminants deposited on the surface of the wafer W are determined in a manner similar to or the same as that described above in block 350. At block 460, a prediction is made as to the amount of contaminants deposited on the surface of the wafer W for a period of time less than the predetermined period of time in block 430. The period of time less than the predetermined period of time in one embodiment is the typical rinse time for the wafer W (e.g., 1 to 10 minutes). In one embodiment, the typical rinse time is 5 minutes and the predetermined period of time is 750 minutes. The prediction made in block 460 is done in a substantially similar or the same method as that described above in block 360.
The method 400 described above thus permits the detection of amounts of contaminants in the liquid 130 well below those detectable by known systems. Accordingly, the presence of contaminants in the liquid 130 and on the surface of the wafer W is detectable even though the amount of contaminants is well below those detectable by known systems.
Although the method 500 is described herein for use with the system 100, the method may be used in conjunction with either the system 100 or system 200 described above and thus the wafer W may either be submerged in the liquid 130 or its surface may instead be contacted by a flow of liquid 130.
The method 500 of this embodiment begins at block 510 with the placing of the wafer W in the tank 110. The wafer W may be placed in the tank by a suitable vacuum wand as described above. The tank 110 may be cleaned prior to the placement of the wafer W therein to ensure that the tank is free from contamination. In some embodiments, the tank 110 may be washed with acid. The wafer W is placed in the support member 140 in the tank 110.
In block 520, the flow of liquid 130 onto the surface of the wafer W begins. The liquid 130 in this embodiment is water. In other embodiments the liquid 130 may be any suitable liquid, such as a solvent. The liquid 130 first flows into the tank 110 through the inlet 118. The liquid 130 may first be filtered before entering the tank 110 through the inlet 118. In one embodiment, the liquid 130 (e.g., water) may be filtered such that it has a low enough level of contaminants and is referred to as ultra pure water. The liquid 130 then flows out from the tank 110 through the outlet 120. The liquid 130 may then be disposed of or recycled after flowing out of the tank 110.
At block 530, the flow of liquid 130 into the tank 110 continues for a predetermined period of time. For example, if a threshold for the detection of a contaminant on the surface of the wafer W is 2e8 atoms/cm2, the predetermined period of time may be selected such that the amount of contamination deposited on the surface of the wafer W is likely to exceed the threshold detection level. According to some embodiments, the predetermined period of time is approximately 100 to 150 times greater than the normal rinse time. With a rinse time of five minutes, the predetermined period of time is thus in the range of 500 to 1000 minutes. In one embodiment, the predetermined period of time is 750 minutes.
The flow of liquid 130 into the tank 110 ceases at block 540. After cessation of the flow of liquid 130, the liquid may be drained or otherwise removed from the tank 110. The wafer W may then be dried such that any residual liquid 130 present on the surface is removed.
In block 550 the amount of contaminants deposited on the surface of the wafer W are determined in a manner similar to or the same as that described above in block 350 or block 450. At block 560, a prediction is made as to the amount of contaminants deposited on the surface of a substrate for a period of time less than the predetermined period of time in block 530. The period of time less than the predetermined period of time in one embodiment is the typical rinse time for the substrate (e.g., 1 to 10 minutes). In one embodiment, the typical rinse time is 5 minutes and the predetermined period of time is 750 minutes. The prediction made in block 560 is done in a substantially similar or the same method as that described above in block 360.
In
Some of the data shown in graphs 700, 800 of
The graph 700 of
When introducing elements of the present invention or the embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawing[s] shall be interpreted as illustrative and not in a limiting sense.
This application is a divisional of U.S. patent application Ser. No. 12/967,382 filed Dec. 14, 2010, which claims the benefit of U.S. Provisional Patent Application No. 61/289,864 filed Dec. 23, 2009, the entire disclosures of which are hereby incorporated by reference.
Number | Date | Country | |
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61289864 | Dec 2009 | US |
Number | Date | Country | |
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Parent | 12967382 | Dec 2010 | US |
Child | 13750371 | US |