1. Field of the Invention
The present invention relates to the field of reclamation and reuse of semiconductor material substrates. More particularly this invention relates to a method for reclaiming wafers at a reclaim factory based on wafer type.
2. Discussion of Related Art
The increasing process complexity and introduction of new materials to the field of integrated circuit (IC) fabrication has given rise to a greater number of processing steps; each of which must be tested for quality.
Test wafers including “dummy” or “control monitor” wafers are used to check the reliability of IC fabrication equipment. Dummy wafers are used to test new IC fabrication equipment prior to its implementation into the large-scale production process of ICs. For example, a dummy wafer is cycled through new film deposition or etch equipment, and the films disposed on the dummy wafer are then examined to determine if they meet certain specified criteria indicating that the fabrication process was properly performed. Only then is the equipment implemented into the production process. Thereafter, the dummy wafer may be discarded, or “reclaimed” by removing the deposited films and re-using the dummy wafer.
Once fabrication equipment is implemented into the production process, it must be periodically inspected by examining the fabricated ICs to ensure that it is functioning properly. Such quality assurance testing is typically performed on a daily basis, such as at the beginning of every working shift. During such testing, control monitor wafers are used in a trial process, such as film deposition, performed on the wafer. The control wafer is then examined to determine if it meets certain specified criteria indicating that the fabrication process was properly performed. Thereafter, the control wafer may be discarded (to protect intellectual property, for example), or “reclaimed” by removing the deposited films and re-using the control wafer.
All of this quality assurance testing requires the use of a large number of wafers and increases the total cost of IC fabrication. Customers will typically reclaim their wafers using their own equipment. However, each reclamation cycle roughens the wafer surface and after a few such cycles the wafers must be re-polished to meet fab specifications for such wafers to be used in their tools. These wafers are typically sent to a wafer reclaim vendor who provides the essential expertise and service for stripping and re-polishing the wafers to the customer's specifications and returning them to the customer for a service charge.
A typical wafer reclamation process includes multiple preliminary steps of incoming wafer inspection, ID detection, and sorting of the wafers into groups. The initial sorting of the wafers into groups is generally performed by a visual inspection. The grouped wafers are then subjected to removal steps such as grinding and/or etching particular materials, followed by polishing and cleaning. The process is finalized with a final multi-step outgoing wafer inspection to ensure that the proper amount of material was removed, and that customer specifications such as those for surface particles and wafer flatness are met.
The presence of copper films in the back-end processes has posed new problems to the wafer reclaim industry. Copper rapidly diffuses in silicon at relatively low temperatures and can cause the metal to form deep level traps for carriers. Reclaim vendors typically separate wafers that may have copper containing films during the initial visual inspection. However, residual copper containing wafers are inevitably mixed with non-copper containing wafer lots due to human error associated with the subjectivity of a visual inspection. As a result, copper bulk cross-contamination occurs during the reclaim process when a copper containing wafer is erroneously included in a non-copper containing wafer reclaim lot. The integrity of an entire reclaim wafer lot can be compromised by one misidentified copper containing wafer. Therefore, what is needed is a reasonable and cost-effective method for reclaiming wafers in which the risk of copper bulk cross-contamination is minimized.
A method for reclaiming a wafer is disclosed. A wafer to be reclaimed is provided having a surface film disposed over a surface of the wafer. The wafer surface is then measured to determine the film composition. The wafer is sorted into a wafer type based on the results of the surface measurement. The surface film is then stripped form the wafer with a stripping solution specifically tailed to the wafer type.
Embodiments of the present invention disclose a method for reclaiming a wafer. In various embodiments, an apparatus for measurement of surface films and method of reclaiming a wafer are described with reference to figures. However, certain embodiments may be practiced without one or more of these specific details, or in combination with other known methods and materials. In the following description, numerous specific details are set forth, such as specific materials and processes, etc., in order to provide a thorough understanding of the present invention. In other instances, well-known semiconductor process manufacturing techniques have not been described in particular detail in order to not unnecessarily obscure the present invention. Reference throughout this specification to “one embodiment” means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrase “in one embodiment” in various places throughout this specification are not necessarily referring to the same embodiment of the invention. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.
Embodiments of the invention describe a method for reclaiming a wafer in which the surface of the wafer is analytically measured to determine the composition of films formed thereon. As used herein, the term “analytical” and variations thereof, is understood to mean identification of the component parts or constituent elements of a material. In a specific embodiment X-ray fluorescence (XRF) of the wafer surface is analytically measured to determine film composition. The results of the analytical surface measurement are correlated with a wafer type. In one embodiment, the wafer is then sorted into a group of wafers with a similar wafer type and the group of wafers is stripped with a stripping solution determined by the wafer type. In an alternative embodiment, the wafer is processed individually after correlating the results of the analytical surface measurement with a wafer type and sorting the wafer. In an embodiment, wafers are sorted and processed as either a copper film containing wafer type or a non-copper film containing wafer type.
In one aspect, utilizing embodiments of the invention, a reclaim vendor can identify and sort out copper film containing wafers at an initial stage through analytical identification, thereby eliminating the subjectivity and inherent human error associated with sorting of wafers based upon a visual inspection. Utilizing embodiments of the invention, a reclaim vendor can not only eliminate the inherent human error in identifying copper surface films, a reclaim vendor can also reliably identify wafers which contain copper films buried beneath an additional surface film. Such sub-surface copper films are also called stealth copper films because they may not be visible from a visual inspection. As a result the risk of copper bulk cross-contamination is significantly reduced when utilizing embodiments of the present invention.
In another aspect, embodiments of the invention improve the efficiency of the wafer reclaim process by improving the incoming and/or in-process inspection by analytically measuring wafer surface film composition. By doing so the wafers may be sorted according to chemical composition of the films deposited thereon prior to the stripping process, and the stripping process may be specially tailored to wafer composition, thus minimizing the need for re-working wafers which do not strip well in the first instance.
In an embodiment the refractive index of a surface film is measured. An analytical measurement of the refractive index allows the operator to correlate the measured refractive index with that of a known film composition, something that a reclaim vendor may not be able to do accurately and consistently with a visual inspection only. For example, the reclaim vendor may sort the wafers into separate groups for films such as oxide, nitride, low-k, and even bare wafers, all of which may not be accurately and consistently distinguishable based on a visual inspection only.
In an embodiment, the incoming wafer ID (such as T7 code) is read and the wafer thickness is measured during the initial inspection and sorting operation 110. Wafers not possessing a wafer ID or a minimum thickness are sorted out at this point. In an embodiment, wafers possessing a thickness less than approximately 650 μm are considered too thin to reclaim.
After an initial inspection and sorting, the wafers are subjected to a specifically tailored stripping process for the specific materials films present or not present, as shown in block 120. During the stripping process all films present on the wafer surface are removed to expose the bare wafer. Over stripping the wafers in acid baths roughens the wafer surface and requires additional polishing time at step 130. Accordingly, utilizing embodiments of the present invention, a reclaim vendor may avoid problems such as unnecessarily over stripping the wafers because the chemistry of the surface films is known and the stripping solutions and processes are tailored for the specific film chemistries present. In addition, knowledge of the film type enables the reclaim vendor to ensure that appropriate stripping processes are applied to the appropriate wafers, thus reducing the likelihood of having to re-work (re-strip) wafers. Thus, determining the chemistry of the deposited layers at an early stage through methods such as refractive index or x-ray fluorescence can shorten the overall reclaim cycle time.
The wafers are then polished as shown in block 130. Polishing may be single-side polishing (SSP), back-side polishing (BSP), or double-side polishing (DSP) depending on wafer type and/or customer specifications. The polished wafers are then thoroughly cleaned in an SC1/SC2 cleaning process and dried at block 140. The wafers are then visually inspected for microscratches at block 150. Additionally, the wafers can be tested for flatness, thickness, bow/warp to verify the processed wafers are within customer specification. Wafers passing the inspection are then given a final clean in a single wafer cleaning apparatus at block 160. The final cleaned wafers are given a final particle inspection at block 170, and then dried, sorted, and packaged as final reclaim product at block 180.
In one embodiment, the measurement face of XRF analyzer 194 is positioned as close as possible to the bottom surface of wafer 220 without touching wafer 220. In one embodiment, the bottom surface of wafer 220 is the device-side surface, or the surface containing surface films to be removed. In one embodiment, the distance separating the measurement face of XRF analyzer 202 and the wafer 220 is less than approximately 0.1 mm. However, it is to be appreciated that XRF analyzer 194 can also be operated independently, and need not be attached to apparatus 200.
In one embodiment, the operator may simultaneously measure the wafer surface XRF, refractive index, wafer ID, and wafer thickness. As shown in
Then at block 314 non-conforming wafers are rejected from the reclamation process. For example, chipped or broken wafers, or wafers with no wafer ID are sorted out of the process. Additionally, wafers which are too thin for reclaiming may be sorted out at this point. In an embodiment, wafers possessing a thickness less than approximately 650 μm are considered too thin to reclaim and are sorted out.
Wafers which are not sorted out of the reclamation process at block 314 are then sorted based on wafer type at block 316. It is to be appreciated that analytical measurement of the wafer surface allows a reclaim vendor to determine the composition of films formed on the wafer without the subjectivity and guess work associated with making such a determination by visual inspection alone. In addition, the compositions of any films lying beneath the top surface film are also determined.
In an embodiment the wafers are sorted as either a copper film containing wafer type or non-copper film containing wafer type. The copper film containing wafer type may include, for example, wafers having a copper surface film (see
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Additional wafer types that are back-end or copper area wafer types include patterned wafer types (see
Patterned wafer types and stealth copper film wafer types are stripped using a bead blasting technique in which all films disposed on the wafer surface are physically removed in a solid state. Because the removal is in a solid state, this alleviates the concern of bulk copper cross contamination between wafers. Low-k carbon containing film wafer types are stripped using a dry plasma etching technique.
Although the present invention has been described in language specific to structural features and/or methodological acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. The specific features and acts disclosed are instead to be understood as particularly graceful implementations of the claimed invention useful for illustrating the present invention.
This application is a continuation-in-part of and claims priority to application Ser. No. 11/823,061 filed on Jun. 25, 2007.
Number | Date | Country | |
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Parent | 11823061 | Jun 2007 | US |
Child | 11901884 | US |