U.S. patent application number 10/869394 was filed with the patent office on 2005-12-22 for polishing pad having grooves configured to promote mixing wakes during polishing.
Invention is credited to Muldowney, Gregory P..
Application Number | 20050282479 10/869394 |
Document ID | / |
Family ID | 35452479 |
Filed Date | 2005-12-22 |
United States Patent
Application |
20050282479 |
Kind Code |
A1 |
Muldowney, Gregory P. |
December 22, 2005 |
POLISHING PAD HAVING GROOVES CONFIGURED TO PROMOTE MIXING WAKES
DURING POLISHING
Abstract
A polishing pad (104, 300, 400, 500) for polishing a wafer (112,
516), or other article. The polishing pad includes a polishing
layer (108) containing a plurality of grooves ((148, 152, 156)(304,
308, 324)(404, 408, 424)(520, 524, 528)) having orientations
largely parallel to one or more corresponding respective velocity
vectors (V1-V4)(V1'-V4')(V1"-V4") (V1'"-V4'") of the wafer. These
parallel orientations promote the formation of mixing wakes in a
polishing medium (120) within these grooves during polishing.
Inventors: |
Muldowney, Gregory P.;
(Earleville, MD) |
Correspondence
Address: |
Rohm and Haas Electronic Materials
CMP Holdings, Inc.
Suite 1300
1105 North Market Street
Wilmington
DE
19899
US
|
Family ID: |
35452479 |
Appl. No.: |
10/869394 |
Filed: |
June 16, 2004 |
Current U.S.
Class: |
451/527 |
Current CPC
Class: |
Y10S 451/921 20130101;
B24B 37/26 20130101 |
Class at
Publication: |
451/527 |
International
Class: |
B24B 001/00 |
Claims
1. A polishing pad suitable for polishing at least one of magnetic,
optical and semiconductor substrates, comprising: (a) a polishing
layer having a polishing region defined by a first boundary
corresponding to a trajectory of a first point on the polishing pad
and a second boundary defined by a trajectory of a second point on
the polishing pad, the second boundary being spaced from the first
boundary, a first zone proximate the second boundary, a second zone
between the second boundary and the first boundary, and a third
zone proximate the first boundary; (b) at least one first
small-angle groove at least partially contained within the
polishing region proximate the first boundary and forming an angle
of -40.degree. to 40.degree. relative to the first boundary at a
point proximate the first boundary and in the third zone; (c) at
least one second small-angle groove at least partially contained
within the polishing region proximate the second boundary and
forming an angle of -40.degree. to 40.degree. relative to the
second boundary at a point proximate the second boundary and in the
first zone, and (d) a plurality of large-angle grooves, each
contained within the polishing region and located between the at
least one first small-angle groove and the at least one second
small angle groove and each of the plurality of large-angle grooves
forming an angle of 45.degree. to 135.degree. relative to each of
the first boundary and the second boundary, and in the second
zone.
2. The polishing pad according to claim 1, wherein the polishing
pad is a rotary polishing pad rotatable about a rotational
axis.
3. The polishing pad according to claim 2, wherein each of the at
least one first small-angle groove and the at least one second
small-angle groove is a spiral groove.
4. The polishing pad according to claim 2, wherein each of the
plurality of large-angle grooves is radial relative to the
rotational axis of the rotary polishing pad.
5. The polishing pad according to claim 1, further comprising a
plurality of first small-angle grooves, wherein each of the
plurality of first small-angle grooves connects to a corresponding
respective one of the plurality of large-angle grooves.
6. The polishing pad according to claim 5, further comprising a
plurality of second small-angle grooves, wherein each one of the
plurality of large angle grooves connects at a first end to a
corresponding respective one of the plurality of first small-angle
grooves and connects at a second end to a corresponding respective
one of the plurality of second small-angle grooves.
7. The polishing pad according to claim 1, wherein the polishing
pad is a linear belt.
8. The polishing pad of claim 1, wherein the plurality of
large-angle grooves form an angle of 60.degree. to 120.degree.
relative to each of the first boundary and the second boundary, and
in the second zone.
9. A method of polishing a magnetic, optical or semiconductor
substrate, comprising the step of polishing the substrate with a
polishing medium and the polishing pad of claim 1.
10. The method according to claim 9, wherein the polishing pad
polishes a semiconductor wafer and the at least one first
small-angle groove, the at least one second small-angle groove and
the plurality of large-angle grooves are adjacent the semiconductor
wafer simultaneously for at least a portion of the polishing.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to the field of
polishing. In particular, the present invention is directed to a
polishing pad having grooves configured to enhance or promote
mixing wakes during polishing.
[0002] In the fabrication of integrated circuits and other
electronic devices, multiple layers of conducting, semiconducting
and dielectric materials are deposited onto and etched from a
surface of a semiconductor wafer. Thin layers of these materials
may be deposited using any of a number of deposition techniques.
Deposition techniques common in modern wafer processing include
physical vapor deposition (PVD), also known as sputtering, chemical
vapor deposition (CVD), plasma-enhanced chemical vapor deposition
(PECVD) and electrochemical plating. Common etching techniques
include wet and dry isotropic and anisotropic etching, among
others.
[0003] As layers of materials are sequentially deposited and
etched, the uppermost surface of the wafer becomes non-planar.
Because subsequent semiconductor processing (e.g.,
photolithography) requires the wafer to have a flat surface, the
wafer needs to be planarized. Planarization is useful for removing
undesired surface topography as well as surface defects, such as
rough surfaces, agglomerated materials, crystal lattice damage,
scratches and contaminated layers or materials.
[0004] Chemical mechanical planarization, or chemical mechanical
polishing (CMP), is a common technique used to planarize
workpieces, such as semiconductor wafers. In conventional CMP using
a dual-axis rotary polisher, a wafer carrier, or polishing head, is
mounted on a carrier assembly. The polishing head holds the wafer
and positions it in contact with a polishing layer of a polishing
pad within the polisher. The polishing pad has a diameter greater
than twice the diameter of the wafer being planarized. During
polishing, each of the polishing pad and wafer is rotated about its
respective center while the wafer is engaged with the polishing
layer. The rotational axis of the wafer is offset relative to the
rotational axis of the polishing pad by a distance greater than the
radius of the wafer such that the rotation of the pad sweeps out a
ring-shaped "wafer track" on the polishing layer of the pad. When
the only movement of the wafer is rotational, the width of the
wafer track is equal to the diameter of the wafer. However, in some
dual-axis polishers, the wafer is oscillated in a plane
perpendicular to its axis of rotation. In this case, the width of
the wafer track is wider than the diameter of the wafer by an
amount that accounts for the displacement due to the oscillation.
The carrier assembly provides a controllable pressure between the
wafer and polishing pad. During polishing, a slurry, or other
polishing medium, is flowed onto the polishing pad and into the gap
between the wafer and polishing layer. The wafer surface is
polished and made planar by chemical and mechanical action of the
polishing layer and slurry on the surface.
[0005] The interaction among polishing layers, polishing media and
wafer surfaces during CMP is being increasingly studied in an
effort to optimize polishing pad designs. Most of the polishing pad
developments over the years have been empirical in nature. Much of
the design of polishing surfaces, or layers, of polishing pads has
focused on providing these layers with various patterns of voids
and/or networks of grooves that are claimed to enhance slurry
utilization and polishing uniformity. Over the years, quite a few
different groove and void patterns and configurations have been
implemented. Prior art groove patterns include radial, concentric
circular, Cartesian grid and spiral, among others. Prior art groove
configurations include configurations wherein the width and depth
of all the grooves are uniform among all grooves and configurations
wherein the width or depth of the grooves varies from one groove to
another.
[0006] Some designers of rotational CMP pads have designed pads
having groove configurations that include two or more groove
configurations that change from one configuration to another based
on one or more radial distances from the center of the pad. These
pads are touted as providing superior performance in terms of
polishing uniformity and slurry utilization, among other things.
For example, in U.S. Pat. No. 6,520,847 to Osterheld et al.,
Osterheld et al. disclose several pads having three concentric
ring-shaped regions, each containing a configuration of grooves
that is different from the configurations of the other two regions.
The configurations vary in different ways in different embodiments.
Ways in which the configurations vary include variations in number,
cross-sectional area, spacing and type of grooves.
[0007] Although pad designers have heretofore designed CMP pads
that include two or more groove configurations that are different
from one another in different zones of the polishing layer, these
designs do not directly consider the effect of the groove
configuration on mixing wakes that occur in the grooves. FIG. 1
shows a plot 10 of the ratio of new slurry to old slurry during
polishing at an instant in time within the gap (represented by
circular region 14) between a wafer (not shown) and a conventional
rotary polishing pad 18 having circular grooves 22. For the
purposes of this specification, "new slurry" may be considered
slurry that is moving in the rotational direction of polishing pad
18, and "old slurry" may be considered slurry that has already
participated in polishing and is being held within the gap by the
rotation of the wafer.
[0008] In plot 10, new slurry region 26 essentially contains only
new slurry and old slurry region 30 essentially contains only old
slurry at an instant in time when polishing pad 18 is rotated in
direction 34 and the wafer is rotated in direction 38. A mixing
region 42 is formed in which new slurry and old slurry become mixed
with one another so as to cause a concentration gradient
(represented by region 42) between new slurry region 26 and old
slurry region 30. Computational fluid dynamics simulations show
that due to the rotation of the wafer, slurry immediately adjacent
to the wafer may be driven in a direction other than the rotational
direction 34 of the pad, whereas slurry somewhat removed from the
wafer is held among "asperities" or roughness elements on the
surface of polishing pad 18 and more strongly resists being driven
in a direction other than direction 34. The effect of wafer
rotation is most pronounced at circular grooves 22 at locations
where the grooves are parallel, or nearly so, to rotational
direction 38 of the wafer because the slurry in the grooves is not
held among any asperities and is easily driven by wafer rotation
along the length of circular grooves 22. The effect of wafer
rotation is less pronounced in circular grooves 22 at locations
where the grooves are transverse to rotational direction 38 of the
wafer because the slurry can be driven only along the width of the
groove within which it is otherwise confined.
[0009] Mixing wakes similar to mixing wakes 46 shown occur in
groove patterns other than circular patterns, such as the groove
patterns mentioned above. Like circular-grooved pad 18 of FIG. 1,
in each of these alternative groove patterns, the mixing wakes are
most pronounced in regions where the rotational direction of the
wafer is most aligned with the grooves, or groove segments, as the
case may be, of the pad. Mixing wakes are undesirable in many CMP
applications because renewal of active chemical species and removal
of heat are slower in the wake region than in the ungrooved areas
of the pad immediately adjacent each groove. However, in other
applications, mixing wakes can be beneficial precisely because they
provide more gradual transitions from spent to fresh chemistry and
from warmer to cooler zones of reaction. Without mixing wakes,
these transitions can be unfavorably sharp and bring about
significant variations in polish conditions point to point under
the wafer. Consequently, there is a need for CMP polishing pad
designs that are optimized, at least in part, based on the
consideration of the occurrence of mixing wakes and the effects
that such wakes have on polishing.
STATEMENT OF THE INVENTION
[0010] In one aspect of the invention, a polishing pad suitable for
polishing at least one of magnetic, optical and semiconductor
substrates, comprising: (a) a polishing layer having a polishing
region defined by a first boundary corresponding to a trajectory of
a first point on a polishing pad and a second boundary defined by a
trajectory of a second point on the polishing pad, the second
boundary being spaced from the first boundary; (b) at least one
first small-angle groove at least partially contained within the
polishing region proximate the first boundary and forming an angle
of -40.degree. to 40.degree. relative to the first boundary at a
point proximate the first boundary; (c) at least one second
small-angle groove at least partially contained within the
polishing region proximate the second boundary and forming an angle
of -40.degree. to 40.degree. relative to the second boundary at a
point proximate the second boundary; and (d) a plurality of
large-angle grooves, each contained within the polishing region and
located between the at least one first small-angle groove and the
at least one second small angle groove and each of the plurality of
large-angle grooves forming an angle of 45.degree. to 135.degree.
relative to each of the first boundary and the second boundary.
[0011] In another aspect of the invention, a method of polishing a
magnetic, optical or semiconductor substrate, comprising the step
of polishing the substrate with a polishing medium and the
polishing pad described immediately above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a partial plan view/partial plot illustrating the
formation of mixing wakes in the gap between a wafer and a prior
art polishing pad having a circular groove pattern;
[0013] FIG. 2 is a perspective view of a portion of a dual-axis
polisher suitable for use with the present invention;
[0014] FIG. 3A is a plan view of a rotary polishing pad of the
present invention; FIG. 3B is a plan view of an alternative rotary
polishing pad of the present invention; FIG. 3C is a plan view of
another alternative rotary polishing pad of the present invention;
and
[0015] FIG. 4 is a partial plan view of a belt-type polishing pad
of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring again to the drawings, FIG. 2 generally
illustrates the primary features of a dual-axis chemical mechanical
polishing (CMP) polisher 100 suitable for use with the present
invention. Polisher 100 generally includes a polishing pad 104
having a polishing layer 108 for engaging an article, such as
semiconductor wafer 112 (processed or unprocessed) or other
workpiece, e.g., glass, flat panel display or magnetic information
storage disk, among others, so as to effect polishing of a surface
116 (hereinafter referred to as "polished surface") of the
workpiece in the presence of a slurry 120 or other polishing
medium. For the sake of convenience, the terms "wafer" and "slurry"
are used below without the loss of generality. In addition, as used
in this specification, including the claims, the terms "polishing
medium" and "slurry" include particle-containing polishing
solutions and non-particle-containing solutions, such as
abrasive-free and reactive-liquid polishing solutions.
[0017] As discussed below in detail, the present invention includes
providing polishing pad 104 with a groove arrangement (see, e.g.,
groove arrangement 144 of FIG. 3A) that enhances the formation of
mixing wakes or increases the size of mixing wakes that occur in
the gap between wafer 112 and polishing pad 104 during polishing.
As discussed in the background section above, mixing wakes occur in
the gap where new slurry replaces old slurry and are most
pronounced in regions where the rotational direction of wafer 112
is most aligned with the grooves, or groove segments, as the case
may be, of polishing pad 104.
[0018] Polisher 100 may include a platen 124 on which polishing pad
104 is mounted. Platen 124 is rotatable about a rotational axis 128
by a platen driver (not shown). Wafer 112 may be supported by a
wafer carrier 132 that is rotatable about a rotational axis 136
parallel to, and spaced from, rotational axis 128 of platen 124.
Wafer carrier 132 may feature a gimbaled linkage (not shown) that
allows wafer 112 to assume an aspect very slightly non-parallel to
polishing layer 108, in which case rotational axes 128, 136 may be
very slightly askew. Wafer 112 includes polished surface 116 that
faces polishing layer 108 and is planarized during polishing. Wafer
carrier 132 may be supported by a carrier support assembly (not
shown) adapted to rotate wafer 112 and provide a downward force F
to press polished surface 116 against polishing layer 108 so that a
desired pressure exists between the polished surface and the
polishing layer during polishing. Polisher 100 may also include a
slurry inlet 140 for supplying slurry 120 to polishing layer
108.
[0019] As those skilled in the art will appreciate, polisher 100
may include other components (not shown) such as a system
controller, slurry storage and dispensing system, heating system,
rinsing system and various controls for controlling various aspects
of the polishing process, such as: (1) speed controllers and
selectors for one or both of the rotational rates of wafer 112 and
polishing pad 104; (2) controllers and selectors for varying the
rate and location of delivery of slurry 120 to the pad; (3)
controllers and selectors for controlling the magnitude of force F
applied between the wafer and pad, and (4) controllers, actuators
and selectors for controlling the location of rotational axis 136
of the wafer relative to rotational axis 128 of the pad, among
others. Those skilled in the art will understand how these
components are constructed and implemented such that a detailed
explanation of them is not necessary for those skilled in the art
to understand and practice the present invention.
[0020] During polishing, polishing pad 104 and wafer 112 are
rotated about their respective rotational axes 128, 136 and slurry
120 is dispensed from slurry inlet 140 onto the rotating polishing
pad. Slurry 120 spreads out over polishing layer 108, including the
gap beneath wafer 112 and polishing pad 104. Polishing pad 104 and
wafer 112 are typically, but not necessarily, rotated at selected
speeds between 0.1 rpm and 150 rpm. Force F is typically, but not
necessarily, of a magnitude selected to induce a desired pressure
of 0.1 psi to 15 psi (6.9 kPa to 103 kPa) between wafer 112 and
polishing pad 104.
[0021] FIG. 3A illustrates in connection with polishing pad 104 of
FIG. 2, a groove arrangement 144 that, as mentioned above, enhances
the formation of mixing wakes (elements 46 of FIG. 1) or increases
the size of mixing wakes within grooves 148, 152, 156 present in
polishing layer 108 of the pad. Generally, the concept underlying
the present invention is to provide grooves 148, 152, 156 that are
parallel, or nearly so, to the tangential velocity vectors of wafer
112 at all locations on polishing layer 108, or at as many
locations as possible or practicable. If rotational axis 136 of
wafer 112 were coincident with rotational axis 128 of the polishing
pad 104, the ideal groove pattern according to the present
invention would be one in which the grooves were concentric with
the rotational axis of the pad. However, in dual-axis polishers,
such as polisher 100 illustrated in FIG. 2, the situation is
complicated by the offset 160 between rotational axes 128, 136 of
polishing pad 104 and wafer 112.
[0022] Nevertheless, it is possible to design a polishing pad,
e.g., pad 104, for use with a dual-axis polisher that approximates
the ideal groove pattern possible when polishing is performed when
rotational axes 136, 128 of wafer 112 and the pad are coincident.
As a result of offset 160 (FIG. 1) between rotational axes 128,
136, the act of polishing causes polishing pad 104 to sweep out
polishing region 164 (commonly referred to as the "wafer track" in
the context of semiconductor wafer planarization) defined by an
inner boundary 168 and an outer boundary 172. Generally, polishing
region 164 is that portion of polishing layer 108 that confronts
the polished surface (not shown) of wafer 112 during polishing as
polishing pad 104 is rotated relative to the wafer. In the
embodiment shown, polishing pad 104 is designed for use with
polisher 100 of FIG. 2, wherein wafer 112 is rotated in a fixed
position relative to the pad. Consequently, polishing region 164 is
annular in shape and has a width W between inner and outer
boundaries 168, 172 that is equal to the diameter of the polished
surface of wafer 112. In an embodiment wherein wafer 112 is not
only rotated, but also oscillated in a direction parallel to
polishing layer 108, polishing region 164 would typically likewise
be annular, but width W between inner and outer boundaries 168, 172
would be greater than the diameter of the polished surface of wafer
112 to account for the oscillation envelope. Each of inner and
outer boundaries 168, 172 may, in general, be considered as being
defined by the trajectory of a corresponding point on polishing pad
104 as the pad is rotated about rotational axis 128. That is, inner
boundary 168 may, in general, be considered to be defined by the
circular trajectory of a point on polishing layer 108 of polishing
pad 104 proximate rotational axis 128, whereas outer boundary 172
may, in general, be considered to be defined by the circular
trajectory of a point on the polishing layer distal from rotational
axis 128.
[0023] Inner boundary 168 of polishing region 164 defines a central
region 176 where a slurry (not shown), or other polishing medium,
may be provided to polishing pad 104 during polishing. In an
embodiment wherein wafer 112 is not only rotated but also
oscillated in a direction parallel to polishing layer 108, central
region 176 may be exceedingly small if the oscillation envelope
extends to, or nearly to, the center of polishing pad 104, in which
case the slurry or other polishing medium may be provided to the
pad at an off-center location. Outer boundary 172 of polishing
region 164 will typically be located radially inward of the outer
peripheral edge 180 of polishing pad 104, but may alternatively be
coextensive with this edge.
[0024] In designing groove pattern 144 in a manner that maximizes
the number of locations where rotational direction 184 of wafer 1
12 is aligned with grooves 148, 152, 156 or segments thereof, it is
useful to consider the velocity of the wafer at four locations L1,
L2, L3, L4, two along a line 188 extending through rotational axes
128, 136 of polishing pad 104 and the wafer, and two along a
circular arc 190 concentric with the rotational axis of the pad and
extending through the rotational axis of the wafer. This is so
because these locations represent four velocity vector extremes of
wafer 112 relative to the rotational direction 192 of polishing pad
104. That is, location L1 represents the location where a velocity
vector V1 of wafer 112 is essentially directly opposite rotational
direction 192 of polishing pad 104 and has the greatest magnitude
in this direction, location L2 represents the location where a
velocity vector V2 of the wafer is essentially in the same
direction as the rotational direction of the pad and has the
greatest magnitude in this direction, and locations L3 and L4
represent the locations where respective velocity vectors V3 and V4
of the wafer are essentially perpendicular to the rotational
direction of the pad and have the greatest magnitude in such
directions. It is at locations L1-L4 that principles underlying the
present invention may be applied so as to approximate the ideal
groove pattern discussed above.
[0025] As can be easily appreciated, consideration of velocity
vectors V1-V4 of wafer 112 at these four locations L1-L4 generally
leads to the partitioning of polishing region 164 into three zones,
zone Z1 corresponding to location L2, zone Z2 corresponding to both
locations L3 and L4 and zone Z3 corresponding to location L1. Width
W of polishing region 164 may be apportioned among zones Z1-Z3
generally in any manner desired. For example, zones Z1 and Z3 may
each be allotted one-quarter of width W and zone Z2 may be allotted
one-half of width W. Other apportionment, such as one-third W may
be allotted to each of zones Z1, Z2 and Z3, respectively, among
others.
[0026] Applying the underlying principles of the present invention,
i.e., providing grooves 148, 152, 156 that are parallel, or nearly
parallel, to velocity vectors V1-V4, to zone Z1 based upon the
velocity vector at location L2, shows that grooves 148 are
desirably circumferential, or nearly so, in zone Z1. This is so
because velocity vector V2 would be parallel to grooves 148 when
they have a circumferential, i.e. circular, configuration It is
noted that grooves 148 need not be truly circular. Rather, each
groove 148 may form an angle .beta. with outer boundary 172 or a
line concentric therewith. Generally, angle .beta. is preferably in
the range of -40.degree. to +40.degree. and, more preferably within
the range of -30.degree. to +30.degree., and even more preferably
within the range of -15.degree. to +15.degree.. In addition, it is
noted that each groove 148 need not have a smooth, continuous
curvature within zone Z1, but rather may be straight, zigzag, wavy
or sawtooth-shaped, among others. Generally, for each groove 148
that is zigzag, wavy, sawtooth-shaped and the like, angle .beta.
can be measured from a line that generally represents the
transverse center of gravity of that groove.
[0027] The requirements for zone Z3 relative to grooves 156 are
essentially the same as the requirements for zone Z1, the primary
difference being that velocity vector V1 at location L1 is opposite
velocity vector V2 at location L2. Accordingly, grooves 156 may be
circumferential like grooves 148 of zone Z1 so as to be parallel to
inner boundary 168. Also like grooves 148, grooves 156 need not be
truly circumferential, but rather may form a non-zero angle .alpha.
with inner boundary 168 or a line concentric therewith. Generally,
angle .alpha. is preferably in the range of -40.degree. to
+40.degree. and, more preferably within the range of -30.degree. to
+30.degree., and even more preferably within the range of
-15.degree. to +15.degree.. Each groove 156 may, if desired, extend
from polishing region 164 to a point coincident with rotational
axis 128 or a point adjacent thereto, e.g., to aid in the
distribution of a polishing medium when the polishing medium is
applied to polishing pad 104 proximate its center. In addition,
like grooves 148, each groove 156 need not form a smooth and
continuous curve, but rather may be straight, zigzag, wavy or
sawtooth-shaped, among others. Also like grooves 148, for each
groove 156 having a zigzag, wavy, sawtooth-shape or like shape,
angle .alpha. can be measured from a line that generally represents
the transverse center of gravity of that groove.
[0028] Velocity vectors V3 and V4 of wafer 112 in zone Z2 are
perpendicular to velocity vectors V1 and V2 in zones Z3 and Z1,
respectively. In order to make grooves 152 in zone Z2 parallel, or
nearly so, to velocity vectors V3 and V4, these grooves may be
perpendicular, or substantially perpendicular, to inner and outer
boundaries 168, 172 of polishing region 164, i.e., radial or nearly
radial relative to rotational axis of polishing pad 104. In this
connection, each groove 152 preferably forms an angle .gamma. with
either inner boundary 168 or outer boundary 172 of preferably
45.degree. to 135.degree., more preferably 60.degree. to
120.degree. and even more preferably 75.degree. to 105.degree..
[0029] Corresponding respective ones of grooves 148, grooves 152
and grooves 156 may, but need not, be connected with one another as
shown so as to form continuous channels (one of which is
highlighted in FIG. 3A and identified by element numeral 196)
extending from a location proximate rotational axis 128 and through
and beyond polishing region 164. Providing continuous channels 196
as shown can be beneficial to slurry utilization and aid in the
flushing of polish debris and removal of heat. Each groove 148 may
be connected to a corresponding respective one of grooves 152 at a
first transition 200 and, likewise, each groove 152 may be
connected to a corresponding respective one of grooves 156 at a
second transition 204. Each of first and second transitions 200,
204 may be gradual, e.g., the curved transitions shown, or abrupt,
e.g., where the connected ones of grooves 148, 152, 156 form a
sharp angle with one another, as desired to suit a particular
design.
[0030] Although polishing region 164 has been described as being
partitioned into three zones Z1-Z3, those skilled in the art will
readily appreciate that the polishing region may be portioned into
a greater number of zones if desired. However, regardless of the
number of zones provided, the process of laying out the grooves,
e.g., grooves 148, 152, 156, in each zone may be essentially the
same as the process described above relative to zones Z1-Z3. That
is, in each of the zones at issue the orientation(s) of the grooves
therein may be selected to be parallel, or nearly so, to a wafer
velocity vector (similar to velocity vectors V1-V4) at a
corresponding location (similar to locations L1-L4).
[0031] For example, two additional zones (not shown), one between
zones Z1 and Z2 and one between zones Z2 and Z3, may be added as
follows. Four additional locations corresponding to four additional
velocity vectors may first be determined using two additional
circular arcs (each similar to circular arc 190) that are each
concentric with rotational axis 128 of polishing pad 104. One of
the additional arcs may be located so as to intersect line 188
midway between location L1 and rotational axis 136 of wafer 112 and
the other may be located so as to intersect line 188 midway between
the rotational axis of the wafer and location L2. The additional
locations for the velocity vectors could then be selected to be the
four points where the two new circular arcs intersect outer
peripheral edge 208 of wafer 112. The two additional zones would
then correspond to the two additional circular arcs in a manner
similar to the correspondence of zone Z2 to circular arc 190 and
corresponding locations L3 and L4. The additional velocity vectors
of wafer 112 could then be determined for the four additional
locations and new grooves oriented relative to the additional
velocity vectors as discussed above relative to grooves 148, 152,
156.
[0032] FIGS. 3B and 3C each show a polishing pad 300, 400 each
having a groove pattern 302, 402 that is generally a variation on
groove pattern 144 of FIG. 3A that captures the underlying concepts
of the present invention. FIG. 3B shows zones Z1' and Z3' as each
partially containing a single groove 304, 308, respectively, that
is generally spiral and substantially parallel to the corresponding
one of inner and outer boundaries 312, 316 of polishing region 320.
Of course, grooves 304, 308 may have other shapes and orientations,
such as the shapes and orientations discussed above in connection
with FIG. 3A. FIG. 3B also shows zone Z2' as containing a plurality
of generally radial, curved grooves 324, wherein at any point
therealong, each groove is largely perpendicular to inner and outer
boundaries 312, 316 (and also largely perpendicular to grooves 304,
308). It can be readily seen that groove pattern 302 provides, in
accordance with the present invention, groove 304 that is
substantially parallel to velocity vector V1', groove 308 that is
substantially parallel to velocity vector V2' and grooves 324 that
are substantially parallel to velocity vectors V3' and V4', so as
to enhance the formation and extent of mixing wakes that form in
zones Z1'-Z3' during polishing. Width W' may be apportioned among
zones Z1'-Z3' in any suitable manner, such as one-quarter
W'/one-half W'/one-quarter W' or one-third W' to each, among
others.
[0033] It is noted that, depending upon the configuration of
grooves 304, 308 in zone Z1' and zone Z3', respectively, one or
more additional grooves may be added to these zones so as to cross
corresponding respective grooves 304, 308. This can be readily
envisioned in the context of spiral grooves 304, 308 of FIG. 3B.
For example, in addition to counterclockwise spiral grooves 304,
308 shown, each of zones Z1' and Z3' may also contain a similar
clockwise spiral groove (not shown), that must necessarily cross
the counterclockwise spiral groove at many locations.
[0034] FIG. 3C shows zone Z1" as containing a plurality of grooves
404 that are substantially spiral in shape relative to polishing
pad 400. This configuration of grooves 404 enhances the
establishment and extent of mixing wakes within zone Z1" in a
manner similar to grooves 148 of FIG. 3A. Also, FIG. 3C shows zone
Z3" as containing grooves 408 that are ring-shaped and concentric
relative to polishing pad 400. Like the spiral configuration of
grooves 404 enhances the ability of mixing wakes to form therein in
zone Z1", the circular configuration of grooves 408 enhances the
ability of mixing wakes to form therein in zone Z3". Of course,
grooves 404, 408 may have other shapes and orientations, such as
the shapes and orientations discussed above in connection with FIG.
3A.
[0035] FIG. 3C further shows zone Z2" as containing a plurality of
radial grooves 424 that are each largely perpendicular to inner and
outer boundaries 412, 416. As in FIGS. 3A and 3B, it can be readily
seen that groove pattern 402 provides, in accordance with the
present invention, grooves 408 that are substantially parallel to
velocity vector V1", grooves 404 that are substantially parallel to
velocity vector V2" and grooves 424 that are substantially parallel
to velocity vectors V3" and V4", so as to enhance the formation and
extent of mixing wakes that form in these grooves during polishing.
Width W" may be apportioned among zones Z1"-Z3" in any suitable
manner, such as one-quarter W"/one-half W"/one-quarter W" or
one-third W" to each, among others.
[0036] FIG. 4 illustrates the present invention in the context of a
continuous belt-type polishing pad 500. Like rotary polishing pads
104, 300, 400 discussed above in connection with FIGS. 3A-3C,
polishing pad 500 of FIG. 4 includes a polishing region 504 defined
by a first boundary 508 and a second boundary 512 spaced from one
another by a distance W'" equal to or greater than the diameter of
the polished surface (not shown) of wafer 516, depending upon
whether or not the wafer is oscillated in addition to rotated
during polishing. Also similar to rotary polishing pads 104, 300,
400, polishing region 504 may be partitioned into three zones Z1'",
Z2'" and Z3'" containing corresponding grooves 520, 524, 528 having
orientations or orientations and shapes selected based on the
direction of certain ones of the velocity vectors of wafer 516,
such as velocity vectors V1'", V2'", V3'" and V4'" located,
respectively, at locations L1'", L2'", L3'" and L4'". Width W'" of
polishing region 504 may be apportioned to zones Z1'", Z2'" and
Z3'" in the manner discussed above relative to FIG. 3A.
[0037] Other than the shape of polishing region 504 being different
from the shape of polishing region 164 of FIG. 3A (linear as
opposed to circular) and the locations L3'" and L4'" of FIG. 4
being different from locations L3 and L4 of FIG. 3A in a similar
manner, the principles underlying the selection of the orientations
of grooves 520, 524, 528 is essentially the same as discussed above
relative to FIG. 3A. That is, it is desirable that grooves 520 in
zone Z1'" be parallel, or nearly so, to velocity vector V1'",
grooves 524 in zone Z2'" be parallel, or nearly so, to velocity
vectors V3'" and V4'" and grooves 528 in zone Z3'" be parallel, or
nearly so, to velocity vector V2'". These desires may be satisfied
in the same manner as discussed above relative to rotary polishing
pads 104, 300, 400, i.e., by making grooves 520 parallel, or
substantially parallel to first boundary 508 of polishing region
504, making grooves 524 perpendicular, or substantially
perpendicular to, first and second boundaries 508, 512 and making
grooves 528 parallel, or substantially parallel, to second boundary
512.
[0038] Generally, these goals may be satisfied by making grooves
520 form an angle .alpha.' with first boundary 508 of about
-40.degree. to +40.degree., more preferably within the range of
-30.degree. to +30.degree., and even more preferably within the
range of -15.degree. to +15.degree., making grooves 524 form an
angle .gamma.' with first or second boundary 508, 512 of about
45.degree. to 135.degree., more preferably 60.degree. to
120.degree. and even more preferably 75.degree. to 105.degree., and
making grooves 528 form an angle .beta.' with second boundary 512
of about -40.degree. to +40.degree., more preferably within the
range of -30.degree. to +30.degree., and even more preferably
within the range of -15.degree. to +15.degree.. It is noted that
although grooves 520, 524, 528 are connected to one another so as
to form continuous channels, this need not be so. Rather grooves
520, 524, 528 may be discontinuous relative to one another, e.g.,
in the manner of grooves 424 of FIG. 3C. Translating radial grooves
424 of FIG. 3C to belt-type polishing pad 500 of FIG. 4, grooves
524 in zone Z2'" would be linear and perpendicular to first and
second boundaries 508, 512. However, if grooves 520, 524, 528 are
connected to one another, transitions may be abrupt (as shown) or
more gradual, e.g., similar to first and second transitions 200,
204 of FIG. 3A.
* * * * *