Claims
- 1. A method of polishing, comprising:
- placing a polishing fluid having 0-2 weight percent particulate matter into an interface between a polishing pad and a substrate, the substrate containing at least one of silicon, gallium arsenide, silicon dioxide, tungsten, aluminum, and copper, the polishing pad having a surface layer, the surface layer comprising:
- a self-dressing matrix containing a plurality of particles, the matrix having a modulus in the range of 1 to 200 MegaPascals, a critical surface tension greater than or equal to 34 milliNewtons per meter, and an elongation to break in the range of 25% to 1000%, the matrix having a planar polishing surface with a surface area that is engagable with the substrate during polishing, and a three dimensional surface texture defining at least one flow channel in the polishing surface, whereby as the matrix wears during polishing, the surface area of the polishing surface changes by less than 25%, and the particles having an average aggregate diameter of less than 0.5 microns, the matrix being free of any particles greater than or equal to 1 micron in diameter, whereby as the particles separate from the matrix during polishing of the substrate, the matrix diminishes in increments of less than 1 micron.
- 2. A method in accordance with claim 1, whereby the substrate comprises a surface and a plurality of protrusions chemically bonded to the surface and as the polishing fluid and the pad move over the protrusions, a plurality of chemical bonds between the protrusions and the substrate surface are stressed by the polishing particles and the chemical bonds are then broken due to interaction with the polishing fluid, thereby removing the protrusions from the surface without fracturing or scratching the surface.
- 3. A method in accordance with claim 1 further comprising:
- collecting at least a portion of the polishing fluid from the polishing interface, filtering the collected polishing fluid and returning the collected polishing fluid back into the polishing interface.
- 4. A method in accordance with claim 1 further comprising: modifying the pH of the collected polishing fluid prior to returning the collected polishing fluid back into the polishing interface.
- 5. A method of polishing in accordance with claim 1, wherein the particles have a size and a shape which render them incapable of defining a Mohs' hardness.
- 6. A polishing system comprising:
- a polishing pad having a surface layer, the surface layer comprising a self-dressing matrix containing a plurality of particles, the matrix having a modulus in the range of 1 to 200 MegaPascals, a critical surface tension greater than or equal to 34 milliNewtons per meter, and an elongation to break in the range of 25% to 1000%, the matrix having a planar polishing surface with a surface area that is engagable with a substrate during polishing, and a three dimensional surface texture defining a plurality of flow channels each extending to a respective depth below the polishing surface, whereby as the matrix wears to one half the depth of a largest said flow channel, the surface area of the polishing surface changes by less than 25%, and the particles having an average aggregate diameter of less than 0.5 micron, the matrix being free of any particles greater than or equal to 1 micron in diameter, whereby as the particles separate from the matrix during polishing of the substrate, the matrix diminishes in increments of less than 1 micron.
- 7. A polishing system in accordance with claim 6 wherein as the matrix wears during polishing, the surface area of the polishing surface changes by less than 15%.
- 8. A polishing system in accordance with claim 6 wherein the average aggregate diameter of the particles is in the range of 0.1 to 0.4 microns, at least 50 weight percent of the particles are at least one of alumina, silica, ceria, and iron oxide particles, and a weight ratio of the particles to matrix material is in the range of 5:1 to 0.1:1.
- 9. A polishing system in accordance with claim 6 wherein the matrix comprises at least one of urethane, carbonate, amide, sulfone, vinyl chloride, acrylate, methacrylate, vinyl alcohol, ester and acrylamide moieties.
- 10. A polishing system in accordance with claim 6 wherein the matrix material comprises a polyol.
- 11. A polishing system in accordance with claim 6 further comprising a polishing fluid, the polishing fluid comprising less than 15 weight percent particulate matter.
- 12. A polishing system in accordance with claim 11 wherein the polishing fluid comprises 0-2 weight percent particulate matter.
- 13. A polishing system in accordance with claim 12, wherein the polishing fluid comprises at least one of an amine, polycarboxylic acid, halogen ion, and an oxidizing agent.
- 14. A polishing system in accordance with claim 6, wherein the particles have a size and a shape which render them incapable of defining a Mohs' hardness.
- 15. A polishing pad comprising a surface layer, the surface layer comprising a self-dressing matrix which diminishes into a plurality of particles during polishing, the particles having an average aggregate diameter of less than 1 micron, the matrix being free of any particles greater than or equal to 1 micron in diameter, the matrix having a polishing surface with a surface area that is engagable with a substrate during polishing, and a three dimensional surface texture, whereby as the matrix wears during polishing, the surface area of the polishing surface changes by less than 25%, the matrix comprising at least one of urethane, carbonate, amide, sulfone, vinyl chloride, acrylate, methacrylate, vinyl alcohol, ether, ester and acrylamide moieties.
- 16. A polishing pad in accordance with claim 15, wherein the matrix is non-porous and whereby as the matrix wears during polishing, the surface area of the polishing surface changes by less than 15%.
- 17. A polishing pad in accordance with claim 16, wherein the matrix is free of fiber reinforcement.
- 18. A polishing pad in accordance with claim 15, wherein the particles have a size and a shape which render them incapable of defining a Mohs' hardness.
Parent Case Info
This application claims the benefit of U.S. Provisional Application No. 60/037,582 filed Feb. 10, 1997.
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