METHODS AND APPARATUS FOR POLISHING AN EDGE AND/OR NOTCH OF A SUBSTRATE
Apparatus and methods are provided to polish a substrate. In some aspects, the invention includes a polishing head adapted to apply a polishing tape against at least one of a substrate edge and a notch in the substrate edge. The polishing head includes a polisher coupled to the polishing head, wherein the polisher has a hollow portion and is adapted to conform to a shape of at least one of the substrate edge and the notch. Numerous other aspects are provided.
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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. 12/124,137, filed May 20, 2008, entitled “METHODS AND APPARATUS FOR POLISHING A NOTCH OF A SUBSTRATE USING A POLISHING PAD” (Attorney Docket No. 10674);
U.S. patent application Ser. No. ______, filed Oct. 24, 2008, entitled “METHODS AND APPARATUS FOR POLISHING A NOTCH OF A SUBSTRATE” (Attorney Docket No. 10670/L);
U.S. patent application Ser. No. ______, filed Oct. 24, 2008, entitled “METHODS AND APPARATUS FOR POLISHING A NOTCH OF A SUBSTRATE WITH A MANDREL” (Attorney Docket No. 10672/L); and
U.S. patent application Ser. No. ______, filed Oct. 24, 2008, entitled “METHODS AND APPARATUS FOR POLISHING A NOTCH OF A SUBSTRATE WITH AN ABRASIVE CORD” (Attorney Docket No. 10673/L).
FIELD OF THE INVENTIONThe present invention relates generally to substrate processing, and more particularly to methods and apparatus for cleaning an edge of a substrate, and/or a notch in an edge of the substrate.
BACKGROUND OF THE INVENTIONDuring processing of substrates for electronic device manufacturing, a film and/or flakes (‘contaminants’) may be deposited on the surface of the substrate. However, the presence of the contaminants on portions of the substrate, including an edge and/or a notch in the edge of the substrate, may be undesirable as it may negatively affect device fabrication on the substrate. Conventional systems, which contact a substrate edge and/or notch with an abrasive film or tape to clean the substrate edge and/or notch, may not be able to contact all parts of the substrate edge and/or notch and therefore may not be able to thoroughly clean the substrate edge and/or notch to remove the contaminants. The inability to sufficiently clean the substrate may affect electronic device manufacturing throughput. Accordingly improved methods and apparatus for cleaning an edge and notch of a substrate are desired.
SUMMARY OF THE INVENTIONIn some aspects of the invention, an apparatus for polishing a substrate is provided. The apparatus includes a polishing head adapted to apply a polishing tape against at least one of a substrate edge and a notch in the substrate edge. The polishing head includes a polisher coupled to the polishing head, wherein the polisher has a hollow portion and is adapted to conform to a shape of at least one of the substrate edge and the notch.
In other aspects of the invention, a system for polishing a substrate is provided. The system includes a substrate support adapted to rotate a substrate; a polishing head adapted to apply a polishing tape against at least one of a substrate edge and a notch in the substrate edge. The polishing head includes a polishing pad coupled to the polishing head, wherein the polishing pad has a hollow portion and is adapted to conform to a shape of at least one of the substrate edge and the notch. The system also includes a controller adapted to operate the rotation of the substrate and the polishing head.
In yet other aspects of the invention, a method for polishing a substrate is provided. The method includes (1) securing a substrate on a support; (2) pressing a polishing tape against at least one of a substrate edge and a notch with a hollow polishing pad; (3) advancing the polishing tape as the polishing tape is pressed against the notch; and (4) monitoring the polishing process.
Other features and aspects of the present invention will become more fully apparent from the following detailed description, the appended claim and the accompanying drawings.
Substrates used in semiconductor processing often have films and/or surface defects which it is helpful to remove prior to subsequent processing steps. These films and defects may occur on the edge of a substrate, including notches formed thereon.
In some embodiments, the present invention provides apparatus and methods that effectively adapt to various shapes and profiles of different substrate edges and notches, ensuring good contact of a polishing or abrasive film or tape with all sections of a substrate edge and/or notch region. In one or more embodiments, a hollow polisher is provided. The polisher may be adapted to press a moving polishing tape against the substrate edge and/or notch. The hollow portion or the polisher may be selectively filled or inflated with a fluid, which may allow the polisher to substantially conform to a desired shape, such as the shape of the edge and/or notch of the substrate, such that the polishing tape may contact and polish substantially all portions of the edge and/or notch of the substrate.
Turning to
In some embodiments, one or more of the heads 204 may be adapted to be oscillated or moved (e.g., pivoted or angularly translated about a tangential axis of the substrate 102 and/or circumferentially relative to the substrate 102) around or along the substrate edge 104 and/or notch 116 so as to polish different portions of the substrate edge 104 and/or notch 116. In some embodiments, one or more of the heads 204 may be adapted to continuously or intermittently oscillate between the various positions. Alternatively, one or more of the heads 204 may be fixed and/or only adjusted while the substrate 102 is not being rotated. In yet other embodiments, the substrate 102 may be held fixed while one or more of the heads 204 oscillate (as described above) as well as rotate circumferentially around the substrate 102. This movement may be under the direction of a programmed or user operated controller 206, described below. Different heads 204 may be used for different substrates 102 or different types of substrates 102.
As described above, the system 200 may further include the controller 206, (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 102 and/or the actuator(s) used to push a polisher (
As mentioned above, substrate polishing may be performed using one or more polishing apparatuses 202. In one or more embodiments, a plurality of polishing apparatuses 202 may be employed, in which each polishing apparatus 202 may have similar or different characteristics and/or mechanisms. In the latter case, particular polishing apparatuses 202 may be employed for specific operations. For example, one or more polishing apparatuses 202 may be adapted to perform relatively rough polishing and/or adjustments while another one or more polishing apparatus 202 may be adapted to perform relatively fine polishing and/or adjustments. Polishing apparatuses 202 may be used in sequence so that, for example, a rough polishing procedure may be performed initially and a fine polishing procedure may be employed subsequently as needed or according to a polishing recipe. The plurality of polishing apparatuses 202 may be located in a single chamber or module, as shown herein, or alternatively, one or more polishing apparatuses 202 may be located in separate chambers or modules. Where multiple chambers are employed, a robot or another type of transfer mechanism may be employed to move substrates between the chambers so that polishing apparatuses 202 in the separate chambers may be used in series or otherwise.
Substrate [edge/notch] polishing may be performed using one or more polishing apparatuses 202. In one or more embodiments, a plurality of polishing apparatuses 202 may be employed, in which each polishing apparatus 202 may have similar or different characteristics and/or mechanisms. In the latter case, particular polishing apparatuses 202 may be employed for specific operations. For example, one or more of a plurality of polishing apparatuses 202 may be adapted to perform relatively rough polishing and/or adjustments while another one or more of the plurality of polishing apparatus 202 may be adapted to perform relatively fine polishing and/or adjustments. Polishing apparatuses 202 may be used in sequence so that, for example, a rough polishing procedure may be performed initially and a fine polishing procedure may be employed subsequently to make adjustments to a relatively rough polish as needed or according to a polishing recipe. The plurality of polishing apparatuses 202 may be located in a single chamber or module, as shown herein, or alternatively, one or more polishing apparatuses 202 may be located in separate chambers or modules. Where multiple chambers are employed, a robot or another type of transfer mechanism may be employed to move substrates 100 between the chambers so that polishing apparatuses 202 in the separate chambers may be used in series or otherwise.
In one or more embodiments, the polishing tape 318 may be made from many different materials, such as aluminum oxide, silicon oxide, silicon carbide, etc. Other materials may also be used. In some embodiments, abrasives used may range, for example, from about 0.1 micron up to about 10 microns in size or, for example, 0.5 microns to 3 microns in size, although other sizes may be used. Different widths of polishing tape 318 ranging from about 0.55 inch to about 1.5 inches may be used, although other polishing tape widths may be used. In one or more embodiments, the polishing tape 318 may be about 0.002 to about 0.02 inches thick and withstand about 1 to 5 lbs. in tension. Other polishing tapes having different thicknesses and tensile strengths may be used. The supply and take-up spools 324, 326 may have a diameter of approximately 3 inches and be capable of holding about 30,000 inches of polishing tape 318, or may have a diameter of approximately 1 inch and be capable of holding about 500 inches of polishing tape 318. Other spool dimensions may be used. The supply and take-up spools 324, 326 may be constructed from materials such as nylon, polyurethane, polyvinyl difluoride (PVDF), etc. Other materials may also be used.
With reference to
Turning to
In some embodiments, a fluid monitor or sensor 512 may be coupled to the valve 508. The fluid sensor 512 may sense pressure applied by the polisher 500 caused by the force of the pressure of the fluid in the hollow portion 502 of the polisher 500. The fluid sensor 512 may be coupled to the controller 206, for example, such that the controller 206 may receive feedback from the fluid sensor 512 indicative of the amount of pressure exerted by the fluid in the hollow portion 502. The controller 206 may then change or adjust the flow of fluid into/out of the polisher 500 during the polishing process to adjust the pressure applied by the polisher 500, based on a desired polishing effect. This selectively adjustable pressure may be useful because as the polishing head 314 pivots about the substrate edge 104 and/or notch 116, the amount of film on the substrate edge 104 and/or notch 116 may change, due, for example, to different locations and different film profiles. As such, it may be desirable to adjust the amount of pressure applied during the polishing process.
Additionally, filling the polisher pad 500 may have the advantage of allowing precise control of the pressure applied to the film deposited on the substrate edge 104 and/or notch 116. The pressure measurement may also be helpful in tracking the film removed from the substrate edge 104 and/or notch 116. For example, if the applied pressure is set to a particular amount, as the film is removed from the substrate edge 104 and/or notch 116, the applied pressure may increase to maintain the pre-set level. The change in pressure may be indicative that a pre-set amount of film has been removed from the substrate edge 104 and/or notch 116.
In alternate embodiments, a wheel-shaped polisher 700 (
Turning to
Further with respect to the method 800 for cleaning and polishing the substrate edge 104 and/or notch 116, the substrate polishing process may be monitored in step S810. For example, the pressure with which the polishing tape 318 is pressed into contact with, and against, the substrate edge 104 and/or notch 116 may be determined by the force or pressure applied by the fluid in the inflatable polisher 500, the pressure applied by the actuator, and/or the resilience of the polisher 500 and the polishing tape 318. In some embodiments, the fluid sensor 512 may send a signal to the controller 206 indicative of the amount of pressure applied by the fluid in the inflatable polisher 500. As the polishing tape 318 is advanced over the substrate edge 104 and/or notch 116, films and imperfections on the substrate edge 104 and/or notch 116 may be removed and eliminated by abrasion. The force or pressure applied by the polisher 500 due to the pressure of the fluid in the polisher 500, may be adjusted by controller 206, as needed. As described above, the adjustments to the pressure may account for changes in the amount of film removed from the substrate, and the portion of the substrate 100 being polished (i.e. notch, top bevel, bottom bevel, outer edge), for example. Any other suitable parameters may result in changes to the applied pressure. For example, as a layer of film is removed from the substrate edge 104 and/or notch 116, the pressure applied by the polisher 500 may decrease, and therefore, to maintain a pre-set applied pressure, the polisher 500 may be further inflated such that the polisher 500 applies the pre-set pressure to the substrate edge 104 and/or notch 116. In another example the amount and/or type of film deposited in the notch 116 may be different than the amount/type of film deposited on the substrate edge 104. Additionally, the geometries of the substrate edge 104 and notch 116 may be different. As such, the amount of pressure applied by the polisher 500 to polish the notch 116 may be different than the amount of pressure applied by the polisher 500 to polish the substrate edge 104.
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 claim.
Claims
1. An apparatus for polishing a substrate comprising:
- a polishing head adapted to apply a polishing tape against at least one of a substrate edge and a notch in the substrate edge, including:
- a polisher coupled to the polishing head, wherein the polisher has a hollow portion and is adapted to conform to a shape of at least one of the substrate edge and the notch.
2. The apparatus of claim of claim 1 wherein the polisher is selectively inflatable.
3. The apparatus of claim 1 wherein the hollow portion is adapted to retain a fluid.
4. The apparatus of claim 3 wherein the polisher further comprises a port adapted to receive the fluid.
5. The apparatus of claim 4 wherein the fluid is compressed air.
6. The apparatus of claim 1 wherein the polishing head is adapted to pivot about at least one of the substrate edge and the notch.
7. The apparatus of claim 1 wherein the polishing tape is adapted to advance over the polisher during application of the polishing tape to at least one of the substrate edge and the notch.
8. The apparatus of claim 1 wherein the polisher includes a notch portion.
9. A system for polishing a substrate comprising:
- a substrate support adapted to rotate a substrate;
- a polishing head adapted to apply a polishing tape against at least one of a substrate edge and a notch in the substrate edge, including: a polisher coupled to the polishing head, wherein the polisher has a hollow portion and is adapted to conform to a shape of at least one of the substrate edge and the notch; and
- a controller adapted to operate the rotation of the substrate and the polishing head.
10. The system of claim 9 wherein the controller is adapted to incrementally advance the polishing tape to the polishing head.
11. The system of claim 9 wherein the hollow portion is adapted to retain a fluid.
12. The system of claim 11 wherein the polisher further comprises a port adapted to receive the fluid.
13. The system of claim 12 further comprising a sensor adapted to sense a pressure applied by the fluid.
14. The system of claim 13 wherein the sensor is coupled to the controller, and the controller is adapted to receive a signal from the sensor indicative of the applied pressure.
15. The system of claim 11 wherein the controller is adapted to adjust a pressure applied to at least one of the substrate edge and notch by the fluid.
16. The system of claim 15 further comprising a valve, wherein the valve is coupled to the polisher, and wherein the controller is adapted to manipulate the valve to adjust the applied pressure.
17. The system of claim 15 wherein the controller is adapted to increase the applied pressure by increasing the fluid retained in the hollow portion.
18. The system of claim 9 wherein the polisher includes a notch portion.
19. The system of claim 9 wherein the polishing head is adapted to pivot about at least one of the substrate edge and the notch.
20. A method for polishing a substrate comprising:
- securing a substrate on a support;
- pressing a polishing tape against at least one of a substrate edge and a notch with a hollow polisher;
- advancing the polishing tape as the polishing tape is pressed against the notch; and
- monitoring the polishing process.
21. The method of claim 20 further comprising:
- inflating the hollow polisher.
22. The method of claim 21 wherein monitoring the polishing process further comprises:
- receiving a signal indicative of the pressure applied by the inflated polisher.
23. The method of claim 22 further comprising:
- adjusting the pressure based on the received signal.
24. The method of claim 23 wherein adjusting the pressure further comprises one of:
- inflating the hollow polisher and deflating the hollow polisher.
25. The method of claim 24 wherein inflating the hollow polishing pad further comprises:
- flowing a fluid into the hollow polisher.
Type: Application
Filed: Oct 24, 2008
Publication Date: Apr 29, 2010
Applicant: Applied Materials, Inc. (Santa Clara, CA)
Inventors: Gary C. Ettinger (Cupertino, CA), Paul D. Butterfield (San Jose, CA), Antoine P. Manens (Sunnyvale, CA), Sen-Hou Ko (Sunnyvale, CA)
Application Number: 12/258,242
International Classification: B24B 21/00 (20060101);