The present invention relates to the field of chemical-mechanical polishing (CMP). More specifically, the present invention relates to a system for adjusting an end effector used to condition a polishing pad of a CMP apparatus.
Semiconductor wafers, sometimes called silicon wafers, are commonly used as a base on which multilevel integrated circuits are fabricated. A series of deposition and etch steps are required to form such a multilevel pattern on a semiconductor wafer. The deposition and etch steps are typically performed utilizing photolithographic optics-based processes. These processes require accurate focusing in order to produce a precise image on the semiconductor wafer. To achieve accurate focusing, wafers for the semiconductor industry must possess a high degree of surface perfection. Indeed, a non-planar semiconductor wafer surface can result in lower yield and decreased performance of the semiconductor devices, due to inaccurate focusing adversely affecting the photolithographic processes. Accordingly, surface planarity of the wafer is a critical issue in the semiconductor industry.
Chemical-mechanical polishing (CMP) is commonly used for polishing or “planarizing” the front face of a semiconductor wafer. A CMP process may be used to remove rough spots and irregularities from the wafer and to produce a planar surface and substantially uniform thickness of the wafer.
The process steps (using lithography, deposition, and etching) performed to create each layer of the multilevel integrated circuit can result in a multiplicity of irregularities on the wafer surface. It is crucial that these irregularities be removed so that processing can continue to develop new layers or circuitry without loss of focus in the lithography and so that accurate interconnections can be formed between the layers. Accordingly, in addition to polishing the wafer surface, CMP may be employed to planarize the topography of the interconnect layers of the electrical circuitry above the wafer surface.
One problem with CMP processing is that the slurry and abraded materials tend to glaze the surface of polishing pad 26. This accumulation of debris reduces the surface roughness and adversely affects polishing rate and uniformity. To counter this problem, CMP apparatus 20 includes a conditioning apparatus 28 for “conditioning” polishing pad 26. In particular, conditioning apparatus 28 is utilized to roughen the surface of the polishing pad 26.
Conditioning apparatus 28 includes a conditioning arm 30 with an end effector 32 that includes an abrasive disk (not visible). A drive mechanism 34 is coupled at an opposite end of conditioning arm 30 from end effector 32. Drive mechanism 34 is in communication with end effector 32 to cause rotational movement 36 of end effector 32. In addition, conditioning apparatus 28 includes means for vertical movement 38 of end effector 32 to bring end effector 32 into contact with polishing pad 26. Conditioning arm 30 may also include means for rotational movement 40 about axis B, so that end effector 32 is allowed to sweep in a radial direction across a predetermined portion of polishing pad 26. System control may be via a controller 42 which receives conditioning parameters to control rotational movement 36, vertical movement 38, and rotational movement 40 about axis B.
Recent improvements in conditioning apparatuses entail the inclusion of a gimbal mechanism interfaced with end effector 32 so that the abrasive disk of end effector 32 remains level, thus parallel to polishing pad 26. The object of such a mechanism is to yield more uniform, thus efficacious, conditioning of polishing pad 26.
There are a number of problems associated with conventional conditioning apparatuses, such as conditioning apparatus 28. For example, the conditioning pressure of end effector 32 against polishing pad 26 may differ from that which is desired leading to undesirably slow and inefficient conditioning, or conversely, leading to excessive or non-uniform, conditioning that ultimately damages polishing pad 26.
The introduction of vertical movement 38 in some prior art devices can yield undesirably high internal friction. Accordingly, the force developed by the mechanism producing vertical movement 38 and applied to the surface area of end effector 32 may be “absorbed” by the high internal friction of the mechanism, and is thus not transmitted to end effector 32. This friction can contribute to significant error, in terms of an effective reduction in the actual conditioning pressure applied by end effector against polishing pad 26. Consequently, high friction contributes to imprecision in controlling the amount of conditioning pressure applied by end effector 32 against polishing pad 26. If the conditioning pressure is too low, the rate of conditioning of polishing pad 26 may be undesirably slow and inefficient.
In addition, the conditioning pressure of end effector 32 against polishing pad 26 is not currently measured in prior art systems. Thus, it is difficult to compensate or account for the absorption of force due to internal friction. Even if the absorption of force by friction is somehow compensated for, the conditioning pressure can change over time due to mechanical wear of internal components within end effector 32. Mechanical wear can cause a change to internal friction in the mechanism producing vertical movement 38, further introducing an error component to the conditioning pressure.
Typical conditioning apparatuses do not include position feedback of end effector 32 relative to the polishing pad 26. Accordingly, if there is a mechanical failure of components within end effector 32 that causes the distance between end effector 32 and polishing pad 26 to differ from what is expected, this difference may go undetected. Such a situation is undesirable because the polishing pad 26 may become damaged during the conditioning process, the rate of conditioning may be undesirably slow, or conditioning may not occur at all. Unfortunately, such a scenario cannot be detected without interfering with the conditioning process and/or incurring excessive and costly down time.
Yet another problem with prior conditioning apparatuses is that the force range of the mechanism producing vertical movement 38 is limited by the amount of pressure that can be exerted on the internal mechanisms of end effector 32. An undesirable limitation of the force further leads to undesirably slow and inefficient conditioning.
Accordingly, it is an advantage of the present invention that a system for adjusting an end effector of an apparatus relative to a workpiece is provided.
It is another advantage of the present invention that a system is provided in which the conditioning pressure of the end effector can be precisely controlled while maintaining parallel orientation between the end effector and the plane of the workpiece
Another advantage of the present invention is that a system is provided for adjusting the end effector that includes capability for measurement of the applied force of the end effector.
Another advantage of the present invention is that a system is provided for adjusting the end effector that includes capability for detecting the position of the end effector.
Yet another advantage of the present invention is that a system is provided for adjusting the end effector while minimizing vertical height of the system.
The above and other advantages of the present invention are carried out in one form by a system for adjusting an end effector of an apparatus relative to a workpiece. The system includes a linear actuator configured for fixed attachment with an arm of the apparatus. A first link member includes a first segment and a second segment adjoined with the first segment, the first segment being operatively coupled with the linear actuator. A second link member is maintained in parallel alignment with the second segment. The second segment and the second link member are configured for pivotal attachment with the end effector, wherein movement of the first segment powered by the linear actuator causes the first and second link members to pivot producing movement of the end effector relative to the workpiece.
A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, wherein like reference numbers refer to similar items throughout the Figures, and:
The present invention is a system for precisely adjusting an end effector of an apparatus relative to a workpiece. More specifically, the present invention is configured for interconnection with a conditioning apparatus for conditioning polishing pads such as those used in Chemical Mechanical Polishing or Planarization (CMP) Systems. The system is advantageously utilized to precisely adjust an end effector of the conditioning apparatus relative to the polishing pad. The specific details of the preferred embodiment provide a thorough understanding of the invention. However, some CMP system and conditioning apparatus elements which operate in conjunction with the present invention have not been described in detail in order to avoid unnecessarily obscuring the present invention.
Conditioning apparatus 44 generally includes a conditioning arm 52 having end effector 48 positioned at one end of arm 52. End effector 48 includes an abrasive disk 54. Abrasive disk 54 may include diamond abrasive conditioners, cutting teeth, brushes, and the like known to those skilled in the art. A drive mechanism 56 is coupled at an opposite end of conditioning arm 52. Drive mechanism 56 is in communication with end effector 48 to cause rotational movement of end effector 48 and/or to allow end effector 48 to sweep in a radial direction across a predetermined portion of polishing pad 26.
Conditioning apparatus 44 may include a gimbal mechanism interfaced with end effector 48 so that abrasive disk 54 remains level, thus parallel to the plane of polishing pad 26. Adjustment system 46 is adapted to enable precise vertical movement 50 of end effector 48 in the presence or absence of this feature.
Adjustment system 46 includes a linear actuator 58 configured for fixed attachment with conditioning arm 52. More specifically, a body 60 of linear actuator 58 is coupled to an underside of conditioning arm 52 (best seen in
In an exemplary embodiment, drive element 62 is an elongated rod having a generally circular cross-sectional configuration. However, it should be understood that drive element 62 may alternatively be an elongated member extensible from body 60 having any of a number of cross-sectional configurations. Moreover, although a double-acting pneumatic air cylinder is described herein for use as linear actuator 58, it should be understood that a variety of types of linear motion devices may alternatively be utilized. Such linear motion devices include, for example, those powered by hydraulics, pneumatics, or electric motors, and configured to be rod or rodless.
Adjustment system 46 further includes a first link member 64 and a second link member 66. First link member 64 includes a first segment 68 and a second segment 70. First segment 68 includes a first end 72 and a second end 74, and first segment 68 is operatively coupled with drive element 62 via a force transducer 76. In particular, first end 72 of first segment 68 includes an actuator pivot point 77 that enables pivotal movement of first segment 68 relative to force transducer 76 and linear actuator 58. Second segment 70 includes a third end 78 and a fourth end 80, with third end 78 being adjoined with second end 74 of first segment 68. In a preferred embodiment, second segment 70 is fixedly arranged approximately perpendicular to first segment 68. As such, first link member 64 is a generally L-shaped element.
First link member 64 includes a first pivot point 82, positioned at the junction of first and second segments 68 and 70, respectively, and configured for pivotal attachment to conditioning arm 52. In addition, fourth end 80 of first link member 64 at second segment 70 is pivotally attached to end effector 48 at a first effector pivot point 84. Likewise, second link member 66 includes a second pivot point 86, positioned at a first end 88, and pivotally attached to conditioning arm 52. A second end 90 of second link member 66 is pivotally attached to end effector 48 at a second effector pivot point 92.
A distance between first and second pivot points 82 and 86, respectively, is equivalent to a distance between first and second effector pivot points 84 and 92, respectively. In addition, a distance between first pivot point 82 and first effector pivot point 84 is equivalent to a distance between second pivot point 86 and second effector pivot point 92. Furthermore, second pivot point 86 is vertically aligned with first pivot point 82 on conditioning arm 52, and second effector pivot point 92 is vertically aligned with first effector pivot point 84 on end effector 48. Consequently, through the various pivotal attachment points and locations described above, second link member 66 is maintained in parallel alignment with second segment 70 of first link member 64.
The components of second linkage assembly 96 correspond to those of first linkage assembly 94. That is, second linkage assembly 96 includes a third link member 102 having a third segment 104 and a fourth segment 106 (portions of which are shown in ghost form). Second linkage assembly 96 further includes a fourth link member 108 (shown in ghost form) maintained in parallel alignment with fourth segment 106. Third and fourth link members 102 and 108, respectively, pivotally couple to each of conditioning arm 52 and end effector 48 in a similar manner to first and second link members 64 and 66, respectively. Accordingly, the discussion need not be repeated.
In addition, third link member 102 pivotally couples to force transducer 76 (
Referring to
As mentioned previously, adjustment system 46 enables precise movement of end effector 48 relative to polishing pad 26 in the presence or absence of a gimbal mechanism. In addition, adjustment system 46 maintains abrasive disk 54 parallel with polishing pad 26 through vertical movement 50 of end effector 48.
As shown in
As further shown in
Force signal 120 is advantageously utilized to control the conditioning pressure of abrasive disk 54.
Pressure is a function of the force applied to a unit area of surface. In this instance, conditioning pressure is thus a function of the applied force of abrasive disk 54 relative to the surface area of abrasive disk 54 as follows:
Conditioning pressure=applied force/surface area
If a desired conditioning pressure is 1 psi (pounds per square inch), and the surface area of abrasive disk is 12.6 in2, then the applied force is as follows:
Applied force=1 psi×12.6 in2=12.6 lbs
In continuing the above example, the weight of abrasive disk 54 and end effector 48 may be approximately 2 pounds. Thus, horizontal force 116 generated by linear actuator 58 is as follows:
Horizontal force=applied force−weight=12.6−2=10.6 lbs
Assuming negligible friction, when the desired conditioning pressure is applied, force signal 120 should be equivalent to 10.6 lbs. As known to those skilled in the art, force transducer 76 provides force signal 120 as a voltage. If the force signal output of force transducer 76 is 100 lbs, 5 V full scale, then the force transducer scale factor is 20 pounds per volt. Hence, force signal 120 for a generated force is as follows:
Force signal=generated force/scale factor=10.6/20=0.53V
Consequently, to obtain the desired conditioning pressure of 1 psi, actuation signal 122 is adjusted by controller 148 to maintain force signal 120 at 0.53 V, thereby maintaining horizontal force 116 at 10.6 lbs.
As mentioned above, controller 118 is in electrical communication with position sensor 63 to receive a position signal 126 indicating a position of end effector 48. In an exemplary scenario, position sensor 63 may include a first reed switch 128 and a second reed switch 130. A magnet 132 is mounted on piston 124. Each of first and second reed switches 128 and 130, respectively, can sense magnet 132 when piston 124 moves in proximity to either of switches 128 and 130. In an exemplary embodiment, first reed switch 128 is positioned to detect an extension of drive element 62 (shown in
First and second reed switches 128 and 130 are useful to verify the actual position of end effector 48, and consequently abrasive pad 54, which is important for controlling machine timing and for detecting errors due to component failure or other causes. Although only two reed switches are shown, it should be understood that other switches could be added to sense other desired intermediate positions. Reed switches are preferred because they are immune to dust and moisture. In addition, reed switches are passive devices that have the advantage of using no power, and having no leakage current across the contacts. However, position sensing of the present invention is not limited to the use of reed switches. Rather, other position sensors, such as continuous position feedback switches, magnetostrictive position sensors, Hall effect sensors, or any of a variety of sensors for providing information concerning the position of end effector 48 may alternatively be utilized.
Referring first to
Referring to
Horizontal force 116 imparted at first segment 68 is translated through first and second link members 64 and 66, respectively, to produce vertical movement 50. However, in either condition, end effector 48 follows an arc of travel, as represented by an arrow 134 in each of
Referring to
End effector 48 (
To counter this problem, adjustment system 46 further includes means for maintaining tension in belt 144 as end effector 48 is adjusted. In a preferred embodiment, means for maintaining tension in belt 144 includes idler pulleys 146. Idler pulleys 146 are spring-loaded pulleys mounted on shafts and designed to press against belt 144 to maintain the tension of belt 144 as end effector 48 follows arc of travel 134. Those skilled in the art will recognize that other techniques may alternatively be employed for maintaining the tension in belt 144 as end effector 48 follows arc of travel 134.
In summary, the present invention teaches of an adjustment system for adjusting an end effector of a conditioning apparatus relative to a polishing pad. The adjustment system includes a parallel linkage assembly that is actuated by a linear actuator to move the end effector vertically. The linear actuator is arranged approximately horizontally to minimize vertical height of the system. The horizontal linear force provided by the linear actuator is translated through the parallel linkage assembly to yield vertical movement of the end effector. A force transducer is interposed between the linear actuator and the linkage assembly and measures applied force so that the conditioning pressure can be precisely controlled. In addition, a position sensor is provided for detecting the position of the end effector relative to the polishing pad.
Although the preferred embodiments of the invention have been illustrated and described in detail, it will be readily apparent to those skilled in the art that various modifications may be made therein without departing from the spirit of the invention or from the scope of the appended claims.
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