U.S. patent application number 10/883301 was filed with the patent office on 2005-10-06 for concentric proximity processing head.
This patent application is currently assigned to Lam Research Corp.. Invention is credited to O'Donnell, Robert J., Ravkin, Michael, Smith, Michael G.R..
Application Number | 20050217137 10/883301 |
Document ID | / |
Family ID | 34978713 |
Filed Date | 2005-10-06 |
United States Patent
Application |
20050217137 |
Kind Code |
A1 |
Smith, Michael G.R. ; et
al. |
October 6, 2005 |
CONCENTRIC PROXIMITY PROCESSING HEAD
Abstract
In one of the many embodiments, a method for processing a
substrate is disclosed which includes generating a first fluid
meniscus and a second fluid meniscus at least partially surrounding
the first fluid meniscus wherein the first fluid meniscus and the
second fluid meniscus are generated on a surface of the
substrate.
Inventors: |
Smith, Michael G.R.;
(Dublin, CA) ; Ravkin, Michael; (Sunnyvale,
CA) ; O'Donnell, Robert J.; (Fremont, CA) |
Correspondence
Address: |
MARTINE PENILLA & GENCARELLA, LLP
710 LAKEWAY DRIVE
SUITE 200
SUNNYVALE
CA
94085
US
|
Assignee: |
Lam Research Corp.
Fremont
CA
94538
|
Family ID: |
34978713 |
Appl. No.: |
10/883301 |
Filed: |
June 30, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10883301 |
Jun 30, 2004 |
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10404692 |
Mar 31, 2003 |
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10404692 |
Mar 31, 2003 |
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10330843 |
Dec 24, 2002 |
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10330843 |
Dec 24, 2002 |
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10261839 |
Sep 30, 2002 |
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Current U.S.
Class: |
34/407 ;
34/92 |
Current CPC
Class: |
H01L 21/67028 20130101;
H01L 21/67034 20130101; H01L 21/67063 20130101; H01L 21/67023
20130101; H01L 21/67075 20130101; H01L 21/67017 20130101; H01L
21/6708 20130101; H01L 21/6704 20130101; H01L 21/67051
20130101 |
Class at
Publication: |
034/407 ;
034/092 |
International
Class: |
F26B 013/30; F26B
007/00 |
Claims
What is claimed is:
1. A method for processing a substrate using a proximity head,
comprising: generating a first fluid meniscus on a surface of the
substrate the first fluid meniscus being generated by applying a
first fluid to a surface of the substrate and by removing the first
fluid from the surface of the substrate just as the first fluid is
applied; and generating a second fluid meniscus in contact with and
at least partially surrounding the first fluid meniscus on the
surface of the substrate, the second fluid meniscus being generated
by applying a second fluid to a portion of the surface of the
substrate at least partially surrounding the surface of the
substrate in contact with the first fluid meniscus and by removing
the second fluid from the portion of the surface of the substrate
just as the second fluid is applied; wherein during a substrate
processing operation the first fluid meniscus and the second fluid
meniscus being defined between a processing surface of the
proximity head and the surface of the substrate.
2. A method for processing a substrate as recited in claim 1,
further comprising: processing the surface of the substrate with
the first fluid meniscus, and processing the surface of substrate
with the second fluid meniscus.
3. A method for processing a substrate as recited in claim 2,
wherein processing the surface of the substrate with the first
fluid meniscus includes one of an etching operation, a cleaning
operation, a rinsing operation, a plating operation, ad or a
lithography operation.
4. A method for processing a substrate as recited in claim 2,
wherein processing the surface of the substrate with the second
fluid meniscus includes one of an etching operation, a cleaning
operation, a rinsing operation, a plating operation, a drying
operation, or a lithography operation.
5. A method for processing a substrate as recited in claim 1,
wherein generating the first fluid meniscus includes applying the
first fluid to the surface of the substrate through a first fluid
inlet and removing the first fluid from the surface of the
substrate through a first fluid outlet.
6. A method for processing a substrate as recited in claim 5,
wherein generating the second fluid meniscus includes applying the
second fluid to the surface of the substrate through a second fluid
inlet and removing the second fluid from the surface of the
substrate through the first fluid outlet and a second fluid outlet
and applying a third fluid through a third inlet.
7. A method for processing a substrate as recited in claim 5,
wherein the first fluid is one of a lithographic fluid, an etching
fluid, a plating fluid, a cleaning fluid, or a rinsing fluid.
8. A method for processing a substrate as recited in claim 6,
wherein the second fluid is one of a lithographic fluid, an etching
fluid, a plating fluid, a cleaning fluid, a drying fluid, or a
rinsing fluid.
9. A method for processing a substrate as recited in claim 6,
wherein the third fluid decreases a surface tension of the second
fluid.
10. A method for processing a substrate as recited in claim 6,
wherein the third fluid is an isopropyl alcohol vapor in nitrogen
gas.
11. An apparatus for processing a substrate, comprising: a
proximity head capable of generating a first fluid meniscus on a
substrate surface and capable of generating a second fluid meniscus
on the substrate surface at least partially surrounding the first
fluid meniscus, the proximity head capable of substantially
maintaining an integrity of the second fluid meniscus when in
contact with the first fluid meniscus, the first fluid meniscus and
the second fluid meniscus being defined between a processing
surface of a proximity head and the substrate surface during a
substrate processing operation.
12. An apparatus for processing a substrate as recited in claim 11,
wherein the proximity head includes, a first set of conduits
defined within the proximity head capable of generating the first
fluid meniscus, and a second set of conduits defined within the
proximity head capable of generating the second fluid meniscus, the
second set of conduits at least partially surrounding the first set
of conduits.
13. An apparatus for processing a substrate as recited in claim 12,
wherein the first set of conduits include, at least one inlet for
applying a first fluid to the surface of the wafer, and at least
one outlet for removing at least the first fluid from the surface
of the wafer.
14. An apparatus for processing a substrate as recited in claim 13,
wherein the second set of conduits include, at least one inlet for
applying a second fluid to the surface of the wafer, and at least
one outlet for removing the second fluid from the surface of the
wafer, wherein the at least one outlet for removing the first fluid
from the surface of the wafer also removes at least a portion of
the second fluid.
15. An apparatus for processing a substrate as recited in claim 15,
wherein the second set of conduits further includes, at least one
inlet for applying a third fluid to the surface of the wafer.
16. An apparatus for processing a substrate as recited in claim 11,
wherein the first fluid meniscus is capable of executing one of an
etching operation, a cleaning operation, a rinsing operation, a
plating operation, or a lithography operation.
17. An apparatus for processing a substrate as recited in claim 11,
wherein the second fluid meniscus is capable of executing one of an
etching operation, a cleaning operation, a rinsing operation, a
plating operation, a drying operation, or a lithography
operation.
18. A method for processing a substrate as recited in claim 15,
wherein the third fluid decreases a surface tension of the second
fluid.
19. An apparatus for processing a substrate, comprising: a
proximity head capable of generating a first fluid meniscus on a
surface of the substrate and capable of generating a second fluid
meniscus on the surface of the substrate at least partially
surrounding the first fluid meniscus, the proximity head including,
at least one first inlet defined in a processing surface of the
proximity head configured to apply a first fluid to the surface of
the wafer through the proximity head; at least one first outlet
defined in the processing surface of the proximity head configured
to remove the first fluid and at least a portion of a second fluid
from the surface of the wafer through the proximity head; at least
one second inlet defined in the processing surface of the proximity
head configured to apply the second fluid to the surface of the
wafer though the proximity head; and at least one second outlet
defined in the processing surface of the proximity head configured
to remove at least a portion of the second fluid from the surface
of the wafer through the proximity head; and wherein the at least
one second inlet and the at least one second outlet at least
partially surrounds the at least one first outlet and the at least
one first inlet on the processing surface of the proximity head,
the first fluid meniscus and the second fluid meniscus being
defined between the processing surface and the surface of the
substrate during a substrate processing operation.
20. An apparatus for processing a substrate as recited in claim 19,
wherein the proximity head further includes, at least one third
inlet defined in the processing surface of the proximity head
configured to apply a third fluid to the surface of the wafer.
21. An apparatus for processing a substrate as recited in claim 19,
wherein the first fluid meniscus is capable of executing one of an
etching operation, a cleaning operation, a rinsing operation, a
plating operation, a or a lithography operation.
22. An apparatus for processing a substrate as recited in claim 19,
wherein the second fluid meniscus is capable of executing one of an
etching operation, a cleaning operation, a rinsing operation, a
plating operation, a drying operation, and or a lithography
operation.
23. A method for processing a substrate as recited in claim 20,
wherein the third fluid decreases a surface tension of the second
fluid.
Description
CROSS REFERENCE To RELATED APPLICATION
[0001] This is a continuation-in-part of a co-pending U.S. patent
application Ser. No. 10/404,692, filed on Mar. 31, 2003, from which
priority under 35 U.S.C. .sctn. 120 is claimed, entitled "Methods
and Systems for Processing a Substrate Using a Dynamic Liquid
Meniscus" which is a continuation-in-part of U.S. patent
application Ser. No. 10/330,843 filed on Dec. 24, 2002 and entitled
"Meniscus, Vacuum, IPA Vapor, Drying Manifold," which is a
continuation-in-part of U.S. patent application Ser. No. 10/261,839
filed on Sep. 30, 2002 and entitled "Method and Apparatus for
Drying Semiconductor Wafer Surfaces Using a Plurality of Inlets and
Outlets Held in Close Proximity to the Wafer Surfaces." The
aforementioned patent applications are hereby incorporated by
reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to semiconductor wafer
processing and, more particularly, to apparatuses and techniques
for more efficiently applying and removing fluids from wafer
surfaces while reducing contamination and decreasing wafer
processing costs.
[0004] 2. Description of the Related Art
[0005] In the semiconductor chip fabrication process, it is
well-known that there is a need to process a wafer using operations
such as cleaning and drying. In each of these types of operations,
there is a need to effectively apply and remove fluids for the
wafer operation process.
[0006] For example, wafer cleaning may have to be conducted where a
fabrication operation has been performed that leaves unwanted
residues on the surfaces of wafers. Examples of such a fabrication
operation include plasma etching (e.g., tungsten etch back (WEB))
and chemical mechanical polishing (CMP). In CMP, a wafer is placed
in a holder which pushes a wafer surface against a rolling conveyor
belt. This conveyor belt uses a slurry which consists of chemicals
and abrasive materials to cause the polishing. Unfortunately, this
process tends to leave an accumulation of slurry particles and
residues at the wafer surface. If left on the wafer, the unwanted
residual material and particles may cause, among other things,
defects such as scratches on the wafer surface and inappropriate
interactions between metallization features. In some cases, such
defects may cause devices on the wafer to become inoperable. In
order to avoid the undue costs of discarding wafers having
inoperable devices, it is therefore necessary to clean the wafer
adequately yet efficiently after fabrication operations that leave
unwanted residues.
[0007] After a wafer has been wet cleaned, the wafer must be dried
effectively to prevent water or cleaning fluid remnants from
leaving residues on the wafer. If the cleaning fluid on the wafer
surface is allowed to evaporate, as usually happens when droplets
form, residues or contaminants previously dissolved in the cleaning
fluid will remain on the wafer surface after evaporation (e.g., and
form water spots). To prevent evaporation from taking place, the
cleaning fluid must be removed as quickly as possible without the
formation of droplets on the wafer surface. In an attempt to
accomplish this, one of several different drying techniques are
employed such as spin drying, IPA, or Marangoni drying. All of
these drying techniques utilize some form of a moving liquid/gas
interface on a wafer surface which, if properly maintained, results
in drying of a wafer surface without the formation of droplets.
Unfortunately, if the moving liquid/gas interface breaks down, as
often happens with all of the aforementioned drying methods,
droplets form and evaporation occurs resulting in contaminants
being left on the wafer surface. The most prevalent drying
technique used today is spin rinse drying (SRD).
[0008] FIG. 1A illustrates movement of fluids on a wafer 10 during
an SRD process. In this drying process, a wet wafer is rotated at a
high rate by rotation 14. In SRD, by use of centrifugal force, the
fluid used to rinse the wafer is pulled from the center of the
wafer to the outside of the wafer and finally off of the wafer as
shown by fluid directional arrows 16. As the fluid is being pulled
off of the wafer, a moving liquid/gas interface 12 is created at
the center of the wafer and moves to the outside of the wafer
(i.e., the circle produced by the moving liquid/gas interface 12
gets larger) as the drying process progresses. In the example of
FIG. 1, the inside area of the circle formed by the moving
liquid/gas interface 12 is free from the fluid and the outside area
of the circle formed by the moving liquid/gas interface 12 is the
fluid. Therefore, as the drying process continues, the section
inside (the dry area) of the moving liquid/gas interface 12
increases while the area (the wet area) outside of the moving
liquid/gas interface 12 decreases. As stated previously, if the
moving liquid/gas interface 12 breaks down, droplets of the fluid
form on the wafer and contamination may occur due to evaporation of
the droplets. As such, it is imperative that droplet formation and
the subsequent evaporation be limited to keep contaminants off of
the wafer surface. Unfortunately, the present drying methods are
only partially successful at the prevention of moving liquid
interface breakdown.
[0009] In addition, the SRD process has difficulties with drying
wafer surfaces that are hydrophobic. Hydrophobic wafer surfaces can
be difficult to dry because such surfaces repel water and water
based (aqueous) cleaning solutions. Therefore, as the drying
process continues and the cleaning fluid is pulled away from the
wafer surface, the remaining cleaning fluid (if aqueous based) will
be repelled by the wafer surface. As a result, the aqueous cleaning
fluid will want the least amount of area to be in contact with the
hydrophobic wafer surface. Additionally, the aqueous cleaning
solution tends cling to itself as a result of surface tension (Le.,
as a result of molecular hydrogen bonding). Therefore, because of
the hydrophobic interactions and the surface tension, balls (or
droplets) of aqueous cleaning fluid forms in an uncontrolled manner
on the hydrophobic wafer surface. This formation of droplets
results in the harmful evaporation and the contamination discussed
previously. The limitations of the SRD are particularly severe at
the center of the wafer, where centrifugal force acting on the
droplets is the smallest. Consequently, although the SRD process is
presently the most common way of wafer drying, this method can have
difficulties reducing formation of cleaning fluid droplets on the
wafer surface especially when used on hydrophobic wafer surfaces.
Certain portion of the wafer may have different hydrophobic
properties.
[0010] FIG. 1B illustrates an exemplary wafer drying process 18. In
this example a portion 20 of the wafer 10 has a hydrophilic area
and a portion 22 has a hydrophobic area. The portion 20 attracts
water so a fluid 26 pools in that area. The portion 22 is
hydrophobic so that area repels water and therefore there can be a
thinner film of water on that portion of the wafer 10. Therefore,
the hydrophobic portions of the wafer 10 often dries more quickly
than the hydrophilic portions. This may lead to inconsistent wafer
drying that can increase contamination levels and therefore
decrease wafer production yields.
[0011] Therefore, there is a need for a method and an apparatus
that avoids the prior art by enabling optimized fluid management
and application to a wafer that reduces contaminating deposits on
the wafer surface. Such deposits as often occurs today reduce the
yield of acceptable wafers and increase the cost of manufacturing
semiconductor wafers.
SUMMARY OF THE INVENTION
[0012] Broadly speaking, the present invention fills these needs by
providing a substrate processing apparatus that is capable of
processing wafer surfaces with multiple menisci while significantly
reducing wafer contamination. It should be appreciated that the
present invention can be implemented in numerous ways, including as
a process, an apparatus, a system, a device or a method. Several
inventive embodiments of the present invention are described
below.
[0013] In one embodiment, a method for processing a substrate is
disclosed which includes generating a first fluid meniscus and a
second fluid meniscus at least partially surrounding the first
fluid meniscus wherein the first fluid meniscus and the second
fluid meniscus are generated on a surface of the substrate.
[0014] In another embodiment, an apparatus for processing a
substrate is provided which includes a proximity head capable of
generating a first fluid meniscus on a substrate surface and
capable of generating a second fluid meniscus on the substrate
surface at least partially surrounding the first fluid meniscus.
The proximity head capable of substantially maintaining the
integrity of the second fluid meniscus when in contact with the
first fluid meniscus.
[0015] In yet another embodiment, an apparatus for processing a
substrate is disclosed which includes a proximity head capable of
generating a first fluid meniscus and capable of generating a
second fluid meniscus at least partially surrounding the first
fluid meniscus. The proximity head includes at least one first
inlet defined in a processing surface of the proximity head
configured to apply a first fluid to the surface of the wafer and
at least one first outlet defined in the processing surface of the
proximity head configured to remove the first fluid and at least a
portion of a second fluid from the surface of the wafer. The
proximity head also includes at least one second inlet defined in
the processing surface of the proximity head configured to apply
the second fluid to the surface of the wafer and at least one
second outlet defined in the processing surface of the proximity
head configured to remove at least a portion of the second fluid
from the surface of the wafer. At least one second inlet and the at
least one second outlet at least partially surrounds the at least
one first outlet and the at least one first inlet.
[0016] The advantages of the present invention are numerous. Most
notably, the apparatuses and methods described herein utilize
multi-menisci to efficiently process (e.g., clean, dry, etc.)
substrates by operations which involve optimal management of fluid
application and removal from the substrate while reducing unwanted
fluids and contaminants remaining on a wafer surface. Consequently,
wafer processing and production may be increased and higher wafer
yields may be achieved due to efficient wafer processing.
[0017] The present invention enables optimal wafer processing
through the generation and use of multiple fluid menisci with one
meniscus at least partially surrounding another fluid meniscus. In
one embodiment, concentric fluid inlets and outlets may be utilized
which can generate a first fluid meniscus and a second fluid
meniscus that is concentric to and surrounds the first fluid
meniscus. In additional embodiments, any suitable number of menisci
may be concentric to and/or surround each other.
[0018] Other aspects and advantages of the present invention will
become apparent from the following detailed description, taken in
conjunction with the accompanying drawings, illustrating by way of
example the principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The present invention will be readily understood by the
following detailed description in conjunction with the accompanying
drawings. To facilitate this description, like reference numerals
designate like structural elements.
[0020] FIG. 1A illustrates movement of cleaning fluids on a wafer
during an SRD drying process.
[0021] FIG. 1B illustrates an exemplary wafer drying process.
[0022] FIG. 2 shows a wafer processing system in accordance with
one embodiment of the present invention.
[0023] FIG. 3 illustrates a proximity head performing a wafer
processing operation in accordance with one embodiment of the
present invention.
[0024] FIG. 4A illustrates a wafer processing operation that may be
conducted by a proximity head in accordance with one embodiment of
the present invention.
[0025] FIG. 4B illustrates a side view of exemplary proximity heads
for use in a dual wafer surface processing system in accordance
with one embodiment of the present invention.
[0026] FIG. 5A shows a multi-menisci proximity head in accordance
with on embodiment of the present invention.
[0027] FIG. 5B shows a cross section view of the multi-menisci
proximity head in accordance with one embodiment of the present
invention.
[0028] FIG. 6A illustrates a multi-menisci proximity head in
accordance with one embodiment of the present invention.
[0029] FIG. 6B illustrates the processing surface of the proximity
head in accordance with one embodiment of the present
invention.
[0030] FIG. 6C shows a closer view of the processing surface of the
multi-meniscus proximity head in accordance with one embodiment of
the present invention.
[0031] FIG. 6D shows the facilities plate attaching to the body to
form the multi-menisci proximity head in accordance with one
embodiment of the present invention.
[0032] FIG. 6E illustrates a cross section view of the proximity
head in accordance with one embodiment of the present
invention.
[0033] FIG. 7 illustrates a cross-sectional view of the
multi-menisci proximity head in exemplary wafer processing
operations in accordance with one embodiment of the present
invention.
[0034] FIG. 8A illustrates a cross-sectional view of the
multi-menisci proximity head which is utilized to process a
hydrophobic barrier in accordance with one embodiment of the
present invention.
[0035] FIG. 8B illustrates a close up view of the multi-menisci
proximity head operating on a hydrophilic wafer surface in
accordance with one embodiment of the present invention.
[0036] FIG. 8C shows a close-up view of the multi-menisci proximity
head operating on a hydrophilic wafer surface in accordance with
one embodiment of the present invention.
[0037] FIG. 9 illustrates a multi-menisci proximity head that
includes rectangular shaped menisci in accordance with one
embodiment of the present invention.
[0038] FIG. 10 shows a multi-menisci proximity head with oblong
fluid menisci in accordance with one embodiment of the present
invention.
DETAILED DESCRIPTION
[0039] An invention for methods and apparatuses for processing a
substrate is disclosed. In the following description, numerous
specific details are set forth in order to provide a thorough
understanding of the present invention. It will be understood,
however, by one of ordinary skill in the art, that the present
invention may be practiced without some or all of these specific
details. In other instances, well known process operations have not
been described in detail in order not to unnecessarily obscure the
present invention.
[0040] While this invention has been described in terms of several
preferable embodiments, it will be appreciated that those skilled
in the art upon reading the preceding specifications and studying
the drawings will realize various alterations, additions,
permutations and equivalents thereof. It is therefore intended that
the present invention includes all such alterations, additions,
permutations, and equivalents as fall within the true spirit and
scope of the invention.
[0041] The figures below illustrate embodiments of an exemplary
wafer processing system using multi-menisci proximity heads to
generate one or more of a specific shape, size, and location fluid
menisci. In one embodiment, the multiple menisci that are
concentric and contact each other are utilized to process a wafer.
This technology may be utilized to perform any suitable type of
combination of types of wafer operation(s) such as, for example
drying, etching, plating, etc. It should be appreciated that the
systems and proximity heads as described herein are exemplary in
nature, and that any other suitable types of configurations that
would enable the generation and movement of two or more menisci
that are in contact as described herein may be utilized. In the
embodiments shown, the proximity head(s) may move in a linear
fashion from a center portion of the wafer to the edge of the
wafer. It should be appreciated that other embodiments may be
utilized where the proximity head(s) move in a linear fashion from
one edge of the wafer to another diametrically opposite edge of the
wafer, or other non-linear movements may be utilized such as, for
example, in a radial motion, in a circular motion, in a spiral
motion, in a zig-zag motion, in a random motion, etc. In addition,
the motion may also be any suitable specified motion profile as
desired by a user. In addition, in one embodiment, the wafer may be
rotated and the proximity head moved in a linear fashion so the
proximity head may process all portions of the wafer. It should
also be understood that other embodiments may be utilized where the
wafer is not rotated but the proximity head is configured to move
over the wafer in a fashion that enables processing of all portions
of the wafer. In addition, the proximity head and the wafer
processing system as described herein may be utilized to process
any shape and size of substrates such as for example, 200 mm
wafers, 300 mm wafers, flat panels, etc. Moreover, the size of the
proximity head and in turn the sizes of the menisci may vary. In
one embodiment, the size of the proximity head and the sizes of the
menisci may be larger than a wafer being processed, and in another
embodiment, the proximity head and the sizes of the menisci may be
smaller than the wafer being processed. Furthermore, the menisci as
discussed herein may be utilized with other forms of wafer
processing technologies such as, for example, brushing,
lithography, megasonics, etc.
[0042] A fluid meniscus can be supported and moved (e.g., onto, off
of and across a wafer) with a proximity head. Various proximity
heads and methods of using the proximity heads are described in
co-owned U.S. patent application Ser. No. 10/834,548 filed on Apr.
28, 2004 and entitled "Apparatus and Method for Providing a
Confined Liquid for Immersion Lithography," which is a continuation
in part of U.S. patent application Ser. No. 10/606,022, filed on
Jun. 24, 2003 and entitled "System And Method For Integrating
In-Situ Metrology Within A Wafer Process" which is a
continuation-in-part of U.S. patent application Ser. No. 10/330,843
filed on Dec. 24, 2002 and entitled "Meniscus, Vacuum, IPA Vapor,
Drying Manifold," which is a continuation-in-part of U.S. patent
application Ser. No. 10/261,839 filed on Sep. 30, 2002 and entitled
"Method and Apparatus for Drying Semiconductor Wafer Surfaces Using
a Plurality of Inlets and Outlets Held in Close Proximity to the
Wafer Surfaces," both of which are incorporated herein by reference
in its entirety. Additional embodiments and uses of the proximity
head are also disclosed in U.S. patent application Ser. No.
10/330,897, filed on Dec. 24, 2002, entitled "System for Substrate
Processing with Meniscus, Vacuum, IPA vapor, Drying Manifold" and
U.S. patent application Ser. No. 10/404,692, filed on Mar. 31,
2003, entitled "Methods and Systems for Processing a Substrate
Using a Dynamic Liquid Meniscus."Still additional embodiments of
the proximity head are described in U.S. patent Application Ser.
No. 10/404,270, filed on Mar. 31, 2003, entitled "Vertical
Proximity Processor," U.S. patent application Ser. No. 10/603,427,
filed on Jun. 24, 2003, and entitled "Methods and Systems for
Processing a Bevel Edge of a Substrate Using a Dynamic Liquid
Meniscus," U.S. patent application Ser. No. 10/606,022, filed on
Jun. 24, 2003, and entitled "System and Method for Integrating
In-Situ Metrology within a Wafer Process," U.S. patent application
Ser. No. 10/607,611 filed on Jun. 27, 2003 entitled "Apparatus and
Method for Depositing and Planarizing Thin Films of Semiconductor
Wafers," U.S. patent application Ser. No. 10/611,140 filed on Jun.
30, 2003 entitled "Method and Apparatus for Cleaning a Substrate
Using Megasonic Power," U.S. patent application Ser. No. 10/817,398
filed on Apr. 1, 2004 entitled "Controls of Ambient Environment
During Wafer Drying Using Proximity Head," U.S. patent application
Ser. No. 10/817,355 filed on Apr. 1, 2004 entitled "Substrate
Proximity Processing Structures and Methods for Using and Making
the Same," U.S. patent application Ser. No. 10/817,620 filed on
Apr. 1, 2004 entitled "Substrate Meniscus Interface and Methods for
Operation," U.S. patent application Ser. No. 10/817,133 filed on
Apr. 1, 2004 entitled "Proximity Meniscus Manifold," U.S. Pat. No.
6,488,040, issued on Dec. 3, 2002, entitled "Capillary Proximity
Heads For Single Wafer Cleaning And Drying," U.S. Pat. No.
6,616,772, issued on Sep. 9, 2003, entitled "Methods For Wafer
Proximity Cleaning And Drying," and U.S. patent application Ser.
No. 10/742,303 entitled "Proximity Brush Unit Apparatus and
Method." The aforementioned patent applications are hereby
incorporated by reference in their entirety.
[0043] It should be appreciated that the system described herein is
just exemplary in nature, and the multi-menisci proximity head may
be used in any suitable system such as, for example, those
described in the United States Patent Applications referenced
above. It should also be appreciated that FIGS. 2 through 4B
describe formation of a single meniscus and therefore process
variables (e.g. flow rates, dimensions, etc.) described therein may
be different than the process variables described for a
multi-menisci proximity head as described in FIG. 5A through
8C.
[0044] FIG. 2 shows a wafer processing system 100 in accordance
with one embodiment of the present invention. The system 100
includes rollers 102a and 102b which may hold and/or rotate a wafer
to enable wafer surfaces to be processed. The system 100 also
includes proximity heads 106a and 106b that, in one embodiment, are
attached to an upper arm 104a and to a lower arm 104b respectively.
In one embodiment, the proximity heads 106a and/or 106b may be
multi-menisci proximity heads as described in further detail in
reference to FIGS. 5A through 10. As described herein the term
"multi-menisci proximity head" is a proximity head capable of
generating one or more fluid menisci. In a one embodiment, a first
fluid meniscus is substantially surrounded by a second fluid
meniscus. In a preferable embodiment, the first fluid meniscus and
the second fluid meniscus are concentric with the second fluid
meniscus surrounding the first fluid meniscus. The proximity head
may be any suitable apparatus that may generate a fluid meniscus as
described herein and described in the patent application
incorporated by reference above. The upper arm 104a and the lower
arm 104b can be part of an assembly which enables substantially
linear movement (or in another embodiment a slight arc-like
movement) of the proximity heads 106a and 106b along a radius of
the wafer. In yet another embodiment, the assembly may move the
proximity heads 106a and 106b in any suitable user defined
movement.
[0045] In one embodiment the arms 104 are configured to hold the
proximity head 106a above the wafer and the proximity head 106b
below the wafer in close proximity to the wafer. For example, in
one exemplary embodiment this may be accomplished by having the
upper arm 104a and the lower arm 104b be movable in a vertical
manner so once the proximity heads are moved horizontally into a
location to start wafer processing, the proximity heads 106a and
106b can be moved vertically to a position in close proximity to
the wafer. In another embodiment, the upper arm 104a and the lower
arm 104b may be configured to start the proximity heads 106a and
106b in a position where the menisci are generated before
processing and the menisci that has already been generated between
the proximity heads 106a and 106 may be moved onto the wafer
surface to be processed from an edge area of a wafer 108.
Therefore, the upper arm 104a and the lower arm 104b may be
configured in any suitable way so the proximity heads 106a and 106b
can be moved to enable wafer processing as described herein. It
should also be appreciated that the system 100 may be configured in
any suitable manner as long as the proximity head(s) may be moved
in close proximity to the wafer to generate and control multiple
meniscus that, in one embodiment, are concentric with each other.
It should also be understood that close proximity may be any
suitable distance from the wafer as long as a menisci may be
maintained. In one embodiment, the proximity heads 106a and 106b
(as well as any other proximity head described herein) may each be
located between about 0.1 mm to about 10 mm from the wafer to
generate the fluid menisci on the wafer surface. In a preferable
embodiment, the proximity heads 106a and 106b (as well as any other
proximity head described herein) may each be located bout 0.5 mm to
about 2.0 mm from the wafer to generate the fluid menisci on the
wafer surface, and in more preferable embodiment, the proximity
heads 106a and 106b (as well as any other proximity head described
herein) may be located about 1.5 mm from the wafer to generate the
fluid menisci on the wafer surface.
[0046] In one embodiment, the system 100, the arms 104 are
configured to enable the proximity heads 106a and 106b to be moved
from processed to unprocessed portions of the wafer. It should be
appreciated that the arms 104 may be movable in any suitable manner
that would enable movement of the proximity heads 106a and 106b to
process the wafer as desired. In one embodiment, the arms 104 may
be motivated by a motor to move the proximity head 106a and 106b
along the surface of the wafer. It should be understood that
although the wafer processing system 100 is shown with the
proximity heads 106a and 106b, that any suitable number of
proximity heads may be utilized such as, for example, 1, 2, 3, 4,
5, 6, etc. The proximity heads 106a and/or 106b of the wafer
processing system 100 may also be any suitable size or shape as
shown by, for example, any of the proximity heads as described
herein. The different configurations described herein generate the
fluid menisci between the proximity head and the wafer. The fluid
menisci may be moved across the wafer to process the wafer by
applying fluid to the wafer surface and removing fluids from the
surface. In such a way, depending on the fluids applied to the
wafer, cleaning, drying, etching, and/or plating may be
accomplished. In addition, the first fluid meniscus may conduct one
type of operation and the second fluid meniscus that at least
partially surrounds the first fluid meniscus may conduct the same
operation or a different wafer processing operation as the first
fluid meniscus. Therefore, the proximity heads 106a and 106b can
have any numerous types of configurations as shown herein or other
configurations that enable the processes described herein. It
should also be appreciated that the system 100 may process one
surface of the wafer or both the top surface and the bottom surface
of the wafer.
[0047] In addition, besides processing the top and/or bottom
surfaces of the wafer, the system 100 may also be configured to
process one side of the wafer with one type of process (e.g.,
etching, cleaning, drying, plating, etc.) and process the other
side of the wafer using the same process or a different type of
process by inputting and outputting different types of fluids or by
using a different configuration menisci. The proximity heads can
also be configured to process the bevel edge of the wafer in
addition to processing the top and/or bottom of the wafer. This can
be accomplished by moving the menisci off (or onto) the edge the
wafer which processes the bevel edge. It should also be understood
that the proximity heads 106a and 106b may be the same type of
apparatus or different types of proximity heads.
[0048] The wafer 108 may be held and rotated by the rollers 102a
and 102b in any suitable orientation as long as the orientation
enables a desired proximity head to be in close proximity to a
portion of the wafer 108 that is to be processed. In one
embodiment, the rollers 102a and 102b can rotate in a clockwise
direction to rotate the wafer 108 in a counterclockwise direction.
It should be understood that the rollers may be rotated in either a
clockwise or a counterclockwise direction depending on the wafer
rotation desired. In one embodiment, the rotation imparted on the
wafer 108 by the rollers 102a and 102b serves to move a wafer area
that has not been processed into close proximity to the proximity
heads 106a and 106b. However, the rotation itself does not dry the
wafer or move fluid on the wafer surfaces towards the edge of the
wafer. Therefore, in an exemplary wafer processing operation, the
unprocessed areas of the wafer would be presented to the proximity
heads 106a and 106b through both the linear motion of the proximity
heads 106a and 106b and through the rotation of the wafer 108. The
wafer processing operation itself may be conducted by at least one
of the proximity heads. Consequently, in one embodiment, processed
portions of the wafer 108 would expand from a center region to the
edge region of the wafer 108 in a spiral movement as the processing
operation progresses. In another embodiment, when the proximity
heads 106a and 106b are moved from the periphery of the wafer 108
to the center of the wafer 108, the processed portions of the wafer
108 would expand from the edge region of the wafer 108 to the
center region of the wafer 108 in a spiral movement.
[0049] In an exemplary processing operation, it should be
understood that the proximity heads 106a and 106b may be configured
to dry, clean, etch, and/or plate the wafer 108. In an exemplary
drying embodiment, the at least one of first inlet may be
configured to input deionized water (DIW) (also known as a DIW
inlet), the at least one of a second inlet may be configured to
input N.sub.2 carrier gas containing isopropyl alcohol (IPA) in
vapor form (also known as IPA inlet), and the at least one outlet
may be configured to remove fluids from a region between the wafer
and a particular proximity head by applying vacuum (also known as
vacuum outlet). It should be appreciated that although IPA vapor is
used in some of the exemplary embodiments, any other type of vapor
may be utilized such as for example, nitrogen, any suitable alcohol
vapor, organic compounds, volatile chemicals, etc. that may be
miscible with water.
[0050] In an exemplary cleaning embodiment, a cleaning solution may
be substituted for the DIW. An exemplary etching embodiment may be
conducted where an etchant may be substituted for the DIW. In an
additional embodiment, plating may be accomplished as described in
further detail in reference to U.S. patent application Ser. No.
10/607,611 filed on Jun. 27, 2003 entitled "Apparatus and Method
for Depositing and Planarizing Thin Films of Semiconductor Wafers"
which was incorporated by reference above. In addition, other types
of solutions may be inputted into the first inlet and the second
inlet depending on the processing operation desired.
[0051] It should be appreciated that the inlets and outlets located
on a face of the proximity head may be in any suitable
configuration as long as stable menisci as described herein may be
utilized. In one embodiment, the at least one N.sub.2/IPA vapor
inlet may be adjacent to the at least one vacuum outlet which is in
turn adjacent to the at least one processing fluid inlet to form an
IPA-vacuum-processing fluid orientation. Such a configuration can
generate an outside meniscus that at least partially surrounds the
inside meniscus. In addition, the inside meniscus may be generated
through a configuration with a processing fluid-vacuum orientation.
Therefore, one exemplary embodiment where a second fluid meniscus
at least partially surrounds a first fluid meniscus may be
generated by an IPA-vacuum-second processing fluid-vacuum-first
processing fluid-vacuum-second processing fluid-vacuum-IPA
orientation as described in further detail in reference to FIGS. 6
and 7A. It should be appreciated that other types of orientation
combinations such as IPA-processing fluid-vacuum, processing
fluid-vacuum-IPA, vacuum-IPA-processing fluid, etc. may be utilized
depending on the wafer processes desired and what type of wafer
processing mechanism is sought to be enhanced. In a preferable
embodiment, the IPA-vacuum-processing fluid orientation in the form
described in reference to FIGS. 6 and 7A may be utilized to
intelligently and powerfully generate, control, and move the
menisci located between a proximity head and a wafer to process
wafers. The processing fluid inlets, the N.sub.2/IPA vapor inlets,
and the vacuum outlets may be arranged in any suitable manner if
the above orientation is maintained. For example, in addition to
the N.sub.2/IPA vapor inlet, the vacuum outlet, and the processing
fluid inlet, in an additional embodiment, there may be additional
sets of IPA vapor outlets, processing fluid inlets and/or vacuum
outlets depending on the configuration of the proximity head
desired. It should be appreciated that the exact configuration of
the inlet and outlet orientation may be varied depending on the
application. For example, the distance between the IPA input,
vacuum, and processing fluid inlet locations may be varied so the
distances are consistent or so the distances are inconsistent. In
addition, the distances between the IPA input, vacuum, and
processing fluid outlet may differ in magnitude depending on the
size, shape, and configuration of the proximity head 106a and the
desired size of a process menisci (i.e., menisci shape and size).
In addition, exemplary IPA-vacuum-processing fluid orientation may
be found as described in the U.S. patent applications referenced
above.
[0052] In one embodiment, the proximity heads 106a and 106b may be
positioned in close proximity to a top surface and a bottom surface
respectively of the wafer 108 and may utilize the IPA and DIW
inlets and a vacuum outlets as described in further detail in
reference to FIGS. 5A through 10 to generate wafer processing
menisci in contact with the wafer 108 which are capable of
processing the top surface and the bottom surface of the wafer 108.
The wafer processing menisci may be generated in a manner
consistent with the descriptions in reference to Applications
referenced and incorporated by reference above. At substantially
the same time the IPA and the processing fluid is inputted, a
vacuum may be applied in close proximity to the wafer surface to
remove the IPA vapor, the processing fluid, and/or the fluids that
may be on the wafer surface. It should be appreciated that although
IPA is utilized in the exemplary embodiment, any other suitable
type of vapor may be utilized such as for example, nitrogen, any
suitable alcohol vapor, organic compounds, hexanol, ethyl glycol,
acetone, etc. that may be miscible with water. These fluids may
also be known as surface tension reducing fluids. The portion of
the processing fluid that is in the region between the proximity
head and the wafer is the menisci. It should be appreciated that as
used herein, the term "output" can refer to the removal of fluid
from a region between the wafer 108 and a particular proximity
head, and the term "input" can be the introduction of fluid to the
region between the wafer 108 and the particular proximity head. In
another embodiment, the proximity heads 106a and 106b may be
scanned over the wafer 108 while being moved at the end of an arm
that is being moved in a slight arc.
[0053] FIG. 3 illustrates a proximity head 106 performing a wafer
processing operation in accordance with one embodiment of the
present invention. FIGS. 3 through 4B show a method of generating a
basic fluid meniscus while FIGS. 5A through 10 discuss apparatuses
and methods for generating a more complex menisci configuration
where a first fluid meniscus at least partially surrounded by a
second fluid meniscus. The proximity head 106, in one embodiment,
moves while in close proximity to a top surface 108a of the wafer
108 to conduct a wafer processing operation. It should be
appreciated that the proximity head 106 may also be utilized to
process (e.g., clean, dry, plate, etch, etc.) a bottom surface 108b
of the wafer 108. In one embodiment, the wafer 108 is rotating so
the proximity head 106 may be moved in a linear fashion along the
head motion while the top surface 108a is being processed. By
applying the IPA 310 through the inlet 302, the vacuum 312 through
outlet 304, and the processing fluid 314 through the inlet 306, the
meniscus 116 may be generated. It should be appreciated that the
orientation of the inlets/outlets as shown in FIG. 3 is only
exemplary in nature, and that any suitable inlets/outlets
orientation that may produce a stable fluid meniscus may be
utilized such as those configurations as described in the U.S.
patent applications incorporated by reference previously.
[0054] FIG. 4A illustrates a wafer processing operation that may be
conducted by a proximity head 106a in accordance with one
embodiment of the present invention. Although FIG. 4A shows a top
surface 108a being processed, it should be appreciated that the
wafer processing may be accomplished in substantially the same way
for the bottom surface 108b of the wafer 108. In one embodiment,
the inlet 302 may be utilized to apply isopropyl alcohol (IPA)
vapor toward a top surface 108a of the wafer 108, and the inlet 306
may be utilized to apply a processing fluid toward the top surface
108a of the wafer 108. In addition, the outlet 304 may be utilized
to apply vacuum to a region in close proximity to the wafer surface
to remove fluid or vapor that may located on or near the top
surface 108a. As described above, it should be appreciated that any
suitable combination of inlets and outlets may be utilized as long
as the meniscus 116 may be formed. The IPA may be in any suitable
form such as, for example, IPA vapor where IPA in vapor form is
inputted through use of a N.sub.2 gas. Moreover, any suitable fluid
used for processing the wafer (e.g., cleaning fluid, drying fluid,
etching fluid, plating fluid, etc.) may be utilized that may enable
or enhance the wafer processing. In one embodiment, an IPA inflow
310 is provided through the inlet 302, a vacuum 312 may be applied
through the outlet 304 and processing fluid inflow 314 may be
provided through the inlet 306. Consequently, if a fluid film
resides on the wafer 108, a first fluid pressure may be applied to
the wafer surface by the IPA inflow 310, a second fluid pressure
may be applied to the wafer surface by the processing fluid inflow
314, and a third fluid pressure may be applied by the vacuum 312 to
remove the processing fluid, IPA and the fluid film on the wafer
surface.
[0055] Therefore, in one embodiment of a wafer processing, as the
processing fluid inflow 314 and the IPA inflow 310 is applied
toward a wafer surface, fluid (if any) on the wafer surface is
intermixed with the processing inflow 314. At this time, the
processing fluid inflow 314 that is applied toward the wafer
surface encounters the IPA inflow 310. The IPA forms an interface
118 (also known as an IPA/processing fluid interface 118) with the
processing fluid inflow 314 and along with the vacuum 312 assists
in the removal of the processing fluid inflow 314 along with any
other fluid from the surface of the wafer 108. In one embodiment,
the IPA/processing fluid interface 118 reduces the surface of
tension of the processing fluid. In operation, the processing fluid
is applied toward the wafer surface and almost immediately removed
along with fluid on the wafer surface by the vacuum applied by the
outlet 304. The processing that is applied toward the wafer surface
and for a moment resides in the region between a proximity head and
the wafer surface along with any fluid on the wafer surface forms a
meniscus 116 where the borders of the meniscus 116 are the
IPA/processing fluid interfaces 118. Therefore, the meniscus 116 is
a constant flow of fluid being applied toward the surface and being
removed at substantially the same time with any fluid on the wafer
surface. The nearly immediate removal of the processing fluid from
the wafer surface prevents the formation of fluid droplets on the
region of the wafer surface being dried thereby reducing the
possibility of contamination on the wafer 108 after the processing
fluid has accomplished its purpose depending on the operation
(e.g., etching, cleaning, drying, plating, etc.). The pressure
(which is caused by the flow rate of the IPA) of the downward
injection of IPA also helps contain the meniscus 116.
[0056] The flow rate of the N2 carrier gas containing the IPA may
assist in causing a shift or a push of processing fluid flow out of
the region between the proximity head and the wafer surface and
into the outlets 304 (vacuum outlets) through which the fluids may
be outputted from the proximity head. It is noted that the push of
processing fluid flow is not a process requirement but can be used
to optimize meniscus boundary control. Therefore, as the IPA and
the processing fluid is pulled into the outlets 304, the boundary
making up the IPA/processing fluid interface 118 is not a
continuous boundary because gas (e.g., air) is being pulled into
the outlets 304 along with the fluids. In one embodiment, as the
vacuum from the outlets 304 pulls the processing fluid, IPA, and
the fluid on the wafer surface, the flow into the outlets 304 is
discontinuous. This flow discontinuity is analogous to fluid and
gas being pulled up through a straw when a vacuum is exerted on
combination of fluid and gas. Consequently, as the proximity head
106a moves, the meniscus moves along with the proximity head, and
the region previously occupied by the meniscus has been dried due
to the movement of the IPA/processing fluid interface 118. It
should also be understood that the any suitable number of inlets
302, outlets 304 and inlets 306 may be utilized depending on the
configuration of the apparatus and the meniscus size and shape
desired. In another embodiment, the liquid flow rates and the
vacuum flow rates are such that the total liquid flow into the
vacuum outlet is continuous, so no gas flows into the vacuum
outlet.
[0057] It should be appreciated any suitable flow rate may be
utilized for the N.sub.2/IPA, processing fluid, and vacuum as long
as the meniscus 116 can be maintained. In one embodiment, the flow
rate of the processing fluid through a set of the inlets 306 is
between about 25 ml per minute to about 3,000 ml per minute. In a
preferable embodiment, the flow rate of the processing fluid
through the set of the inlets 306 is about 800 ml per minute. It
should be understood that the flow rate of fluids may vary
depending on the size of the proximity head. In one embodiment a
larger head may have a greater rate of fluid flow than smaller
proximity heads. This may occur because larger proximity heads, in
one embodiment, have more inlets 302 and 306 and outlets 304.
[0058] In one embodiment, the flow rate of the N.sub.2/IPA vapor
through a set of the inlets 302 is between about 1 liters per
minute (SLPM) to about 100 SLPM. In a preferable embodiment, the
IPA flow rate is between about 6 and 20 SLPM.
[0059] In one embodiment, the flow rate for the vacuum through a
set of the outlets 304 is between about 10 standard cubic feet per
hour (SCFH) to about 1250 SCFH. In a preferable embodiment, the
flow rate for a vacuum though the set of the outlets 304 is about
350 SCFH. In an exemplary embodiment, a flow meter may be utilized
to measure the flow rate of the N.sub.2/IPA, processing fluid, and
the vacuum.
[0060] It should be appreciated that any suitable type of wafer
processing operation may be conducted using the meniscus depending
on the processing fluid utilized. For example, a cleaning fluid
such as, for example, SC-1, SC-2, etc., may be used for the
processing fluid to generate wafer cleaning operation. In a similar
fashion, different fluids may be utilized and similar inlet and
outlet configurations may be utilized so the wafer processing
meniscus may also etch and/or plate the wafer. In one embodiment,
etching fluids such as, for example, HF, EKC proprietary solution,
KOH etc., may be utilized to etch the wafer. In another embodiment,
plating fluids such as, for example, Cu Sulfate, Au Chloride, Ag
Sulfate, etc. in conjunction with electrical input may be
conducted.
[0061] FIG. 4B illustrates a side view of exemplary proximity heads
106 and 106b for use in a dual wafer surface processing system in
accordance with one embodiment of the present invention. In this
embodiment, by usage of inlets 302 and 306 to input N.sub.2/IPA and
processing respectively along with the outlet 304 to provide a
vacuum, the meniscus 116 may be generated. In addition, on the side
of the inlet 306 opposite that of the inlet 302, there may be a
outlet 304 to remove processing fluid and to keep the meniscus 116
intact. As discussed above, in one embodiment, the inlets 302 and
306 may be utilized for IPA inflow 310 and processing fluid inflow
314 respectively while the outlet 304 may be utilized to apply
vacuum 312. In addition, in yet more embodiments, the proximity
heads 106 and 106b may be of a configuration as shown in the U.S.
patent applications referenced above. Any suitable surface coming
into contact with the meniscus 116 such as, for example, wafer
surfaces 108a and 108b of the wafer 108 may be processed by the
movement of the meniscus 116 into and away from the surface.
[0062] FIGS. 5A through 10 show embodiments of the present
invention where a first fluid meniscus is at least partially
surrounded by at least a second fluid meniscus. It should be
appreciated that the first fluid meniscus and/or the second fluid
meniscus may be generated to conduct any suitable type of
substrate/wafer processing operation such as, for example,
lithography, etching, plating, cleaning, and drying. The first
fluid meniscus and the second fluid meniscus may be any suitable
shape or size depending on the substrate processing operation
desired. In certain embodiments described herein, the first fluid
meniscus and the second fluid meniscus are concentric where the
second fluid meniscus surrounds the first fluid meniscus and the
first fluid meniscus and the second fluid meniscus provide a
continuous fluid connection. Therefore, after the first fluid
meniscus processes the substrate, the portion of the wafer
processed by the first fluid meniscus is immediately processed by
the second fluid meniscus without a substantial amount of the
contact with the atmosphere. It should be appreciated that
depending on the operation desired, in one embodiment, the first
fluid meniscus may contact the second meniscus and in another
embodiment, the first fluid meniscus does not directly contact the
second meniscus.
[0063] FIG. 5A shows a multi-menisci proximity head 106-1 in
accordance with on embodiment of the present invention. The
multi-menisci proximity head 106-1 includes a plurality of source
inlets 306a that can apply a first fluid to the wafer surface. The
first fluid can then be removed from the wafer surface by
application of vacuum through a plurality of source outlets 304a.
Therefore, the first fluid meniscus may be generated by the
conduits located within a first fluid meniscus region 402 of the
processing surface on the multi-menisci proximity head 106-1.
[0064] The multi-menisci proximity head 106-1 may also include a
plurality of source inlets 306b that can apply a second fluid to
the wafer surface. The second fluid can then be removed from the
wafer surface by application of vacuum through a plurality of
source outlets 304b. In one embodiment, a portion of the second
fluid is also removed by the plurality of source outlets 304a in
conjunction with the removal of the first fluid. In one embodiment,
the plurality of source outlets 304a may be called a one phase
fluid removal conduit because the outlets 304a remove liquids
applied to the wafer through the source inlets 306a and 306b. In
addition, the plurality of source outlets 306b may be called a two
phase removal conduit because the outlets 306b removes the second
fluid from the source inlets 306b and the atmosphere outside of the
fluid meniscus. Therefore, in one embodiment, the outlets 306b
removes both liquid and gas while the outlets 306a remove only
liquids. As a result, the second fluid meniscus may be created by
the conduits located within a second fluid meniscus region 404 of
the processing surface on the multi-meniscus proximity head
106-1.
[0065] Optionally, the multi-menisci proximity head 106-1 may
include a plurality of source inlets 302 which can apply a third
fluid to the wafer surface. In one embodiment, the third fluid may
be a surface tension reducing fluid that can reduce the surface
tension of a liquid/atmosphere border of the second meniscus formed
by that application of the second fluid to the wafer surface.
[0066] In addition, the processing surface (e.g., the surface area
of the multi-menisci proximity head where the conduits exist) of
the multi-menisci proximity head 106-1 (or any other proximity head
discussed herein) may be of any suitable topography such as, for
example, flat, raised, lowered. In one embodiment, the processing
surface of the multi-menisci 106-1 may have a substantially flat
surface.
[0067] FIG. 5B shows a cross section view of the multi-menisci
proximity head 106-1 in accordance with one embodiment of the
present invention. The multi-menisci proximity head 106-1 can apply
the first fluid through the plurality of source inlets 306a and
remove the first fluid through the plurality of source outlets
304a. The first fluid meniscus 116a is located underneath a region
substantially surrounded by the plurality of source outlets 304a.
The multi-menisci proximity head 106-a can also apply the second
fluid through the plurality of source inlets 306b and remove the
second fluid through the plurality of source outlets 304a on one
side of the second fluid meniscus and 304b on the other side. In
one embodiment, the plurality of source inlets 302 may apply the
third fluid to decrease the surface tension of the fluid making up
the second fluid meniscus 116b. The plurality of source inlets 302
may be optionally angled to better confine the second fluid
meniscus 116b.
[0068] FIG. 6A illustrates a multi-menisci proximity head 106-2 in
accordance with one embodiment of the present invention. The
proximity head 106-2 includes, in one embodiment, a facilities
plate 454 and a body 458. It should be appreciated the proximity
head 106-2 may include any suitable numbers and/or types of pieces
as long as the first fluid meniscus and the second fluid meniscus
as described herein may be generated. In one embodiment, the
facilities plate 454 and the body 458 may be bolted together or in
another embodiment, the plate 454 and the body 458 may be attached
by an adhesive. The facilities plate 454 and the body 458 may be
made from the same material or different materials depending on the
applications and operations desired by a user.
[0069] The proximity head 106-2 may include a processing surface
458 which includes conduits where fluid(s) may be applied to
surface of the wafer and the fluid(s) maybe removed from a surface
of the wafer. The processing surface 458 may, in one embodiment, be
elevated above a surface 453 as shown by an elevated region 452. It
should be appreciated that the processing surface 458 does not have
to be elevated and that the surface 458 may be substantially planar
with the surface 453 of the proximity head 106-2 that faces the
surface of the wafer being processed.
[0070] FIG. 6B illustrates the processing surface 458 of the
proximity head 106-2 in accordance with one embodiment of the
present invention. In one embodiment, the processing surface 458 is
a region of the proximity head 106-2 which generates the fluid
menisci. The processing surface 458 may include any suitable number
and type of conduits so the first fluid meniscus and the second
fluid meniscus may be generated. In one embodiment, the processing
surface 458 includes fluid inlets 306a, fluid outlets 304a, fluid
inlets 306b, fluid outlets 304b, and fluid inlets 302.
[0071] The fluid inlets 306a may apply a first fluid to the surface
of the wafer, and the fluid inlets 306b may apply a second fluid to
the surface of the wafer. In addition, the fluid outlets 304a may
remove the first fluid and a portion of a second fluid from the
surface of the wafer by the application of vacuum, and the fluid
outlets 304b may remove a portion of the second fluid from the
surface of the wafer by the application of vacuum, and the fluid
inlets 302 may apply a fluid that can decrease the surface tension
of the second fluid. The first fluid and/or the second fluid may be
any suitable fluid that can facilitate any one of a lithography
operation, an etching operation, a plating operation, a cleaning
operation, a rinsing operation, and a drying operation.
[0072] FIG. 6C shows a closer view of the processing surface 458 of
the multi-meniscus proximity head 106-2 in accordance with one
embodiment of the present invention. In one embodiment, the
processing surface 458 includes a first fluid meniscus region 402
which includes the fluid inlets 306a and fluid outlets 304a. The
processing surface 458 also includes a second fluid meniscus region
404 includes the fluid inlets 306b and the fluid outlets 304b and
the fluid inlets 302. Therefore, the first fluid meniscus region
402 can generate the first fluid meniscus and the second fluid
meniscus region 404 can generate the second fluid meniscus.
[0073] FIG. 6D shows the facilities plate 454 attaching to the body
456 to form the multi-menisci proximity head 106-2 in accordance
with one embodiment of the present invention. Channels
corresponding to the fluid inlets 306a, 304a, and 302 supply fluid
from the facilities plate 454 into the body 456 of the
multi-menisci proximity head 106-2, and channels corresponding to
the fluid outlets 306b and 304b remove fluid from the body 456 to
the facilities 454. In one embodiment channels 506a, 504a, 506b,
504b, and 502 correspond to the fluid inlets 306a, fluid outlets
306b, fluid inlets 304a, fluid outlets 304b, and fluid inlets
302.
[0074] FIG. 6E illustrates a cross section view of the proximity
head 106-2 in accordance with one embodiment of the present
invention. As described in reference to FIG. 6D, channels 506a,
506b, and 502 may supply a first fluid, a second fluid, and a third
fluid to fluid inlets 306a, 306b, and 302 respectively. In
addition, a channel 504a may remove a combination of the first
fluid and the second fluid from the fluid outlets 304a, and channel
504b may remove combination of the second fluid and the third fluid
from the outlets 304b. In one embodiment, the first fluid is a
first processing fluid that can conduct any suitable operation on a
wafer surface such as, for example, etching, lithography, cleaning,
rinsing, and drying. The second fluid is a second processing fluid
that may or may not be the same as the first fluid. As with the
first fluid, the second fluid may be any suitable type of
processing fluid such as, for example, a fluid that can facilitate
etching, lithography, cleaning, rinsing, and drying.
[0075] FIG. 7 illustrates a cross-sectional view of the
multi-menisci proximity head in exemplary wafer processing
operations in accordance with one embodiment of the present
invention. Although FIG. 7 (and also FIG. 8A) shows a top surface
of the wafer 108 being processed, it should be appreciated by those
skilled in the art that both a top surface and a bottom surface of
the wafer 108 may be concurrently processed by, any of the
proximity heads described herein on the top surface of the wafer
108 and by any of the proximity heads described herein on the
bottom surface of the wafer 108. In one embodiment, a first wafer
processing chemistry is applied to the wafer 108 through fluid
inlet 306a. After the first wafer processing chemistry has
processed the wafer surface, the first wafer processing chemistry
is removed from the wafer surface through the fluid outlet 304a.
The first wafer processing fluid may form a first fluid meniscus
116a between the multi-menisci proximity head 106-2 and the wafer
108. In one embodiment, a second processing fluid such as, for
example, deionized water (DIW) is applied to the wafer surface
through the fluid inlets 306b.
[0076] As discussed above, the second processing fluid may be any
suitable fluid that can accomplish the desired operation on the
wafer surface. After the DIW has processed the wafer surface, the
DIW is removed from the wafer surface through both the source
outlets 304a and 304b. The DIW between the multi-menisci proximity
head 106-2 and the wafer surface may form a second fluid meniscus
116b.
[0077] In one embodiment, a surface tension reducing fluid such as,
for example, isopropyl alcohol vapor in nitrogen gas may optionally
be applied from the source inlet 302 to the wafer surface to keep
the liquid/gas border of the second fluid meniscus 116b stable. In
one embodiment, the second fluid meniscus 116b can substantially
surround the first fluid meniscus 116a. In this way, after the
first fluid meniscus 116a has processed the wafer surface, the
second fluid meniscus 116b can nearly immediately begin operating
on a portion of the wafer surface already processed by the first
fluid meniscus 116a. Therefore, in one embodiment, the second fluid
meniscus 116b forms a concentric ring around the first fluid
meniscus 116a. It should be appreciated that the first fluid
meniscus 116a may be any suitable geometric shape such as, a
circle, ellipse, square, rectangle, triangular, quadrilateral, etc.
The second fluid meniscus 116b can be configured to at least
partially surround whatever shape the first fluid meniscus 116a may
be. It should be appreciated that, as discussed above, the first
fluid meniscus 116a and/or the second fluid meniscus 116b may
utilize any suitable fluid(s) depending on the wafer processing
operation desired.
[0078] It should be appreciated that to generate a stable fluid
meniscus, an amount of the first fluid inputted into the first
fluid meniscus through the source inlets 306a should be
substantially equal to the amount of the first fluid removed
through the source outlets 304a. The amount of the second fluid
inputted into the second fluid meniscus through the source inlets
306b should be substantially equal to the amount of the second
fluid removed through the source outlets 304a and 304b. In one
embodiment, the flow rate of the fluids are determined by a
distance 480 the proximity head 106-2 is off of the wafer 108. It
should be appreciated that the distance 480 may be any suitable
distance as long as the menisci can be maintained and moved in a
stable manner. In one embodiment, the distance 480 may be between
50 microns and 5 mm, and in another embodiment 0.5 mm to 2.5 mm.
Preferably, the distance 480 is between about 1 mm and 1.5 mm. In
one embodiment, the distance 480 is about 1.3.
[0079] The flow rates of the fluids as shown in FIG. 7 may be any
suitable flow rate that can generate the first fluid meniscus and
the second fluid meniscus that substantially surrounds the first
meniscus. Depending on the distinction desired between the first
fluid meniscus and the second fluid meniscus, the flow rates may
differ. In one embodiment, source inlets 306a may apply the first
fluid at a flow rate of about 600 cc/min, source inlets 306b may
apply the second fluid at a flow rate of about 900 cc/min, a source
outlets 304a may remove the first fluid and the second fluid at a
flow rate of about 1200 cc/min, and the source outlets 304b may
remove the second fluid and atmosphere (which may include some IPA
vapor in N.sub.2 if such a surface tension reducing fluid is being
applied to the wafer surface) at a flow rate of about 300 cc/min.
In one embodiment, the flow rate of fluids through the source
outlets 304 may equal 2 times the flow rate of fluid through the
source inlets 306a. The flow rate of fluid through the source
inlets 306b may be equal to the flow rate through the source inlets
306a plus 300. It should be appreciated by those skilled in the art
that specific flow rate relationships of the source inlets 306a,
306b and source inlets 304a, 304b may change depending on the
configuration of the process area and/or the configuration of the
proximity heads described herein.
[0080] FIG. 8A illustrates a cross-sectional view of the
multi-menisci proximity head 106-3 which is utilized to process a
hydrophobic barrier 602 in accordance with one embodiment of the
present invention. In one embodiment, the multi-menisci proximity
head 106-3 includes fluid inlets 306a, 306b and fluid outlets 304a,
304b, and optionally fluid inlet 302. As discussed in reference to
FIG. 6, the fluid inlets 306a can apply a first processing fluid to
the wafer surface. It should be appreciated that the first fluid
may be any suitable fluid that can process the wafer surface in the
wafer processing operation desired. Therefore, in one embodiment,
the first fluid may be any one of a lithography enhancing fluid, an
etching fluid, a cleaning fluid, a rinsing fluid, and a drying
fluid. In addition, in an optional embodiment, the fluid inlets 302
can apply a third fluid to the wafer surface. After the processing
fluid has operated on the wafer surface, the processing fluid is
removed, in one example, by vacuum through the fluid outlets 304a.
After the wafer processing chemistry has processed the wafer
surface, the wafer processing chemistry is removed from the wafer
surface through the fluid outlets 304a.
[0081] The multi-menisci proximity head 106-3 may also apply a
second wafer processing fluid to the surface through the fluid
inlets 306b and remove the second wafer processing fluid from the
surface by, in one embodiment, a vacuum applied through the fluid
outlets 304a and 304b. In this way, the second fluid meniscus 116b
may be generated. It should be appreciated that the second fluid
may be any suitable fluid that can process the wafer surface in the
wafer processing operation desired. Therefore, in one embodiment,
the second fluid may be any one of a lithography enhancing fluid,
an etching fluid, a cleaning fluid, a rinsing fluid, and a drying
fluid. In addition, in an optional embodiment, the fluid inlets 302
can apply a third fluid to the wafer surface. It should be
appreciated that the third fluid may be any suitable fluid that can
reduce the surface tension of the second fluid. In one embodiment,
the third fluid is isopropyl alcohol vapor in nitrogen gas
(IPA/N.sub.2).
[0082] In one embodiment of the multi-menisci proximity head 106-3,
a phobic barrier 602 is located between the fluid inlets 304a and
the fluid inlet 306b. The wafer processing fluid forms a first
fluid meniscus 116a between the multi-menisci proximity head 106-2.
In one embodiment, deionized water (DIW) is applied to the wafer
surface through the fluid inlets 306b. After the DIW has processed
the wafer surface, the DIW is removed from the wafer surface
through the source outlet 304b. The DIW between the multi-menisci
proximity head 106-2 and the wafer surface forms a second fluid
meniscus 116b. Isopropyl alcohol vapor in nitrogen gas may
optionally be applied to the wafer surface to keep the liquid/gas
border of the second fluid meniscus 116b stable. In one embodiment,
the second fluid meniscus 116b substantially surrounds the first
fluid meniscus 116a. In this way, after the first fluid meniscus
116a has processed the wafer surface, the second fluid meniscus
116b can nearly immediately begin operating on a portion of the
wafer surface already processed by the first fluid meniscus
116a.
[0083] The embodiment as shown in FIG. 8A includes the phobic
barriers 602 which can separate the first fluid meniscus 116a and
the second fluid meniscus 116b. In such an embodiment, the first
fluid meniscus 116a may not directly contact the second fluid
meniscus 116b. As discussed in further reference to FIG. 8B below,
depleted fluid from the first fluid meniscus 116a that has
processed the wafer surface may be remain on the wafer surface for
removal by the second fluid meniscus 116b.
[0084] FIG. 8B illustrates a close up view of the multi-menisci
proximity head 106-3 operating on a hydrophilic wafer surface in
accordance with one embodiment of the present invention. In one
embodiment, the multi-menisci proximity head 106-3 includes the
first fluid meniscus 116a that can process the wafer surface in
whatever type of wafer processing operation desired as discussed
above. The depleted chemistry from the first fluid meniscus 116a
remaining on the wafer surface can then be processed by the second
fluid meniscus 116b (which in one embodiment as shown is a rinsing
fluid meniscus to remove the depleted chemistry). The embodiment
shown is related to processing of hydrophilic wafers that can hold
onto the depleted chemistry when the first fluid meniscus 116a
moves off of the processing area of the wafer surface.
[0085] FIG. 8C shows a close-up view of the multi-menisci proximity
head 106-3 operating on a hydrophilic wafer surface in accordance
with one embodiment of the present invention. In this embodiment,
the wafer processing chemistry (which in one embodiment is an
aqueous fluid) of the first fluid meniscus 116a does not stay on
the wafer surface after processing because the wafer surface is
hydrophobic. Therefore, the phobic barrier 602 can keep the first
fluid meniscus 116a and the second fluid meniscus 116b totally
separated so there is no intermixing of the fluid of the first
fluid meniscus 116a with the fluid of the second fluid meniscus
116b. In addition the source outlets 304 in such an embodiment only
removes the first fluid from the first fluid meniscus 116a.
[0086] It should be appreciated that although only two menisci
(inside meniscus and outside surrounding meniscus) are shown in the
exemplary embodiments that any suitable number of concentric
menisci can be generated. In such a case each of the inner menisci
may be generated by a set of at least one source inlet 306a and the
source outlet 304a while the last surrounding meniscus (the last
outside meniscus that would surround the menisci) may have a set of
at least one source inlet 306b and 304b. Any inner menisci may be
generated by a set of source inlets 306a and the source outlets
304a that can apply and remove a particular processing fluid.
[0087] FIG. 9 illustrates a multi-menisci proximity head 106-4 that
includes rectangular shaped menisci in accordance with one
embodiment of the present invention. In this embodiment, the
multi-menisci proximity head 106-4 includes a square shaped
meniscus 116a' surrounded by a meniscus 116c which in turn is
surrounded by the outside fluid meniscus 116b'. It should be
appreciated by those skilled in the art that the menisci 116a',
116c, and 116b' may be generated by changing the inlet/outlet
configurations as described herein. In one embodiment, the source
inlets 306a, 306c, and 306b may be configured to apply a first
fluid, a second fluid and a third fluid to the wafer. In addition,
the source outlets 304a, 304c, and 304b may be configured to remove
(by vacuum) the first fluid and the second fluid, the second fluid
and the third fluid, and the third fluid and atmosphere
respectively. In addition, source inlets 302 may optionally be
utilized to apply a surface tension reducing fluid to an outside
portion of the third fluid meniscus.
[0088] It should be appreciated by those skilled in the art that
each of the fluid menisci 116a', 116b', and 116c as described in
reference to FIG. 9 may conduct any suitable operation on the wafer
surface such as, for example, etching, cleaning, lithography,
rinsing, drying etc.
[0089] FIG. 10 shows a multi-menisci proximity head 106-5 with
oblong fluid menisci in accordance with one embodiment of the
present invention. In one embodiment, the fluid meniscus 116a is
surrounded on both sides (length wise in one embodiment) by fluid
menisci 116c-1, 116c-2 which are in turn surrounded by fluid
menisci 116b-1 and 116b-2. It should be appreciated that each of
the fluid menisci shown in FIG. 10 may conduct any suitable
operation on the wafer surface such as, for example, etching,
cleaning, lithography, rinsing, drying etc. It should also be
appreciated that the menisci shown may be generated in any suitable
method consistent with the methodology and apparatuses described
herein.
[0090] While this invention has been described in terms of several
preferred embodiments, it will be appreciated that those skilled in
the art upon reading the preceding specifications and studying the
drawings will realize various alterations, additions, permutations
and equivalents thereof. It is therefore intended that the present
invention includes all such alterations, additions, permutations,
and equivalents as fall within the true spirit and scope of the
invention.
* * * * *