U.S. patent application number 14/397542 was filed with the patent office on 2015-05-14 for polishing pad and method for manufacturing same.
The applicant listed for this patent is KPX CHEMICAL CO., LTD., SAMSUNG ELECTRONICS CO., LTD.. Invention is credited to Bong-Su Ahn, Jeong-Seon Choo, Young-Jun Jang, Jin-Su Jeong, Hak-Su Kang, Seung-Geun Kim, Gyoung-Pyo Kong, Sang-Mok Lee, Jang-Won Seo, Kee-Cheon Song.
Application Number | 20150133039 14/397542 |
Document ID | / |
Family ID | 49624027 |
Filed Date | 2015-05-14 |
United States Patent
Application |
20150133039 |
Kind Code |
A1 |
Ahn; Bong-Su ; et
al. |
May 14, 2015 |
POLISHING PAD AND METHOD FOR MANUFACTURING SAME
Abstract
Polishing pad and method of manufacturing the same, the method,
whereby materials for forming a polishing layer are mixed and
solidified by a chemical reaction so as to manufacture the
polishing pad, the method including: grinding organic materials by
using a physical method so as to form micro-organic particles;
mixing the micro-organic particles formed in the operation with the
materials for forming the polishing layer; mixing at least one
selected from the group consisting of inert gas, a capsule type
foaming agent, and a chemical foaming agent that are capable of
controlling sizes of pores, with the mixture in the operation so as
to form gaseous pores; performing gelling and hardening of the
mixture generated in the operation so as to form a polishing layer;
and processing the polishing layer so as to distribute open pores
defined by opening gaseous pores on a surface of the polishing
layer.
Inventors: |
Ahn; Bong-Su; (Seoul,
KR) ; Jang; Young-Jun; (Suwon-si, KR) ; Jeong;
Jin-Su; (Seoul, KR) ; Lee; Sang-Mok; (Seoul,
KR) ; Song; Kee-Cheon; (Ulsan, KR) ; Kim;
Seung-Geun; (Ulsan, KR) ; Seo; Jang-Won;
(Busan, KR) ; Choo; Jeong-Seon; (Busan, KR)
; Kang; Hak-Su; (Changwon-si, KR) ; Kong;
Gyoung-Pyo; (Ulsan, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KPX CHEMICAL CO., LTD.
SAMSUNG ELECTRONICS CO., LTD. |
Seoul
Suwon-si |
|
KR
KR |
|
|
Family ID: |
49624027 |
Appl. No.: |
14/397542 |
Filed: |
February 12, 2013 |
PCT Filed: |
February 12, 2013 |
PCT NO: |
PCT/KR2013/001085 |
371 Date: |
October 28, 2014 |
Current U.S.
Class: |
451/526 ;
51/296 |
Current CPC
Class: |
B24D 18/00 20130101;
B24D 11/001 20130101; B24D 11/003 20130101; B24B 37/24 20130101;
B24B 37/26 20130101 |
Class at
Publication: |
451/526 ;
51/296 |
International
Class: |
B24B 37/24 20060101
B24B037/24; B24D 11/00 20060101 B24D011/00 |
Foreign Application Data
Date |
Code |
Application Number |
May 23, 2012 |
KR |
10-2012-0054523 |
Claims
1. A method of manufacturing a polishing pad, whereby materials for
forming a polishing layer are mixed and solidified by a chemical
reaction so as to manufacture the polishing pad, the method
comprising: (a) grinding organic materials by using a physical
method so as to form micro-organic particles; (b) mixing the
micro-organic particles formed in (a) with the materials for
forming the polishing layer; (c) mixing at least one selected from
the group consisting of inert gas, a capsule type foaming agent,
and a chemical foaming agent that are capable of controlling sizes
of pores, with the mixture in (b) so as to form gaseous pores; (d)
performing gelling and hardening of the mixture generated in (c) so
as to form a polishing layer; and (e) processing the polishing
layer so as to distribute open pores defined by opening gaseous
pores on a surface of the polishing layer.
2. A method of manufacturing a polishing pad, whereby materials for
forming a polishing layer are mixed and solidified by a chemical
reaction so as to manufacture the polishing pad, the method
comprising: (a) including monomers for forming micro-organic
particles in the materials for forming a polishing layer and
forming and dispersing the micro-organic particles by
polymerization of the monomers after stirring is performed; (b)
mixing at least one selected from the group consisting of inert
gas, a capsule type foaming agent, and a chemical foaming agent
that are capable of controlling sizes of pores, with the mixture in
(a) so as to form gaseous pores; (c) performing gelling and
hardening of the mixture generated in (b) so as to form a polishing
layer; and (d) processing the polishing layer so as to distribute
open pores defined by opening gaseous pores on a surface of the
polishing layer.
3. The method of claim 1, wherein the micro-organic particles
comprise at least one selected from the group consisting of
polyethylene resin, polypropylene resin, polystyrene resin,
polyvinylchloride resin, polyamide resin, acryl resin, polyurethane
resin, polycarbonate resin, phenyol resin, amino resin, epoxy
resin, urea resin, polyester resin, rubber acrylonitrile butadiene
styrene copolymer (ABS), and styrene acrylonitrile copolymer
(SAN).
4. The method of claim 1, wherein the inert gas is selected from
the group consisting of 8 group elements of a periodic table and
gas that does not react with the materials for forming the
polishing layer.
5. The method of claim 1, further comprising including liquid
materials that constitute liquid microelements in the polishing
layer in the materials for forming the polishing layer.
6. A polishing pad that performs a polishing process by moving in
contact with a surface of an object to be polished, the polishing
pad comprising a polishing layer, wherein the polishing layer
comprises at least one of micro-organic particles formed by
physically grinding organic materials and micro-organic particles
formed by chemical polymerization of monomers and gaseous pores
formed by at least one selected from the group consisting of inert
gas, a capsule type foaming agent, and a chemical agent, and open
pores that are defined by opening the gaseous pores are distributed
on a surface of the polishing layer.
7. The polishing pad of claim 6, wherein the micro-organic
particles comprise at least one selected from the group consisting
of polyethylene resin, polypropylene resin, polystyrene resin,
polyvinylchloride resin, polyamide resin, acryl resin, polyurethane
resin, polycarbonate resin, phenyol resin, amino resin, epoxy
resin, urea resin, polyester resin, rubber acrylonitrile butadiene
styrene copolymer (ABS), and styrene acrylonitrile copolymer
(SAN).
8. The polishing pad of claim 6, wherein the inert gas is selected
from the group consisting of 8 group elements of a periodic table
and gas that does not react with the materials for forming the
polishing layer.
9. The polishing pad of claim 6, wherein the polishing layer
comprises liquid micro elements that are formed in a predetermined
region of the polishing layer.
10. The method of claim 2, wherein the micro-organic particles
comprise at least one selected from the group consisting of
polyethylene resin, polypropylene resin, polystyrene resin,
polyvinylchloride resin, polyamide resin, acryl resin, polyurethane
resin, polycarbonate resin, phenyol resin, amino resin, epoxy
resin, urea resin, polyester resin, rubber acrylonitrile butadiene
styrene copolymer (ABS), and styrene acrylonitrile copolymer
(SAN).
11. The method of claim 2, wherein the inert gas is selected from
the group consisting of 8 group elements of a periodic table and
gas that does not react with the materials for forming the
polishing layer.
12. The method of claim 2, further comprising including liquid
materials that constitute liquid microelements in the polishing
layer in the materials for forming the polishing layer.
13. The polishing pad of claim 7, wherein the inert gas is selected
from the group consisting of 8 group elements of a periodic table
and gas that does not react with the materials for forming the
polishing layer.
14. The polishing pad of claim 7, wherein the polishing layer
comprises liquid microelements that are formed in a predetermined
region of the polishing layer.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a polishing pad and a
method of manufacturing the same, and more particularly, to a
polishing pad including gaseous pores that allows a polishing
slurry to be effectively collected and supplied and a method of
manufacturing the same.
[0003] 2. Description of the Related Art
[0004] A chemical mechanical planarization/polishing (CMP) process
has been used for global planarization of semiconductor devices and
has become important with tendencies to an increase in the diameter
of a wafer, a high integration density, a micro line width, and a
multilayer wiring structure.
[0005] In a CMP process, a polishing speed and the flatness of a
wafer are important, and the performance of such a CMP process
depends on conditions of CMP equipment and performances of a
polishing slurry and a polishing pad that are consumable members.
In particular, the polishing pad allows the polishing slurry
supplied in a state where the polishing pad is in contact with the
surface of the wafer, to be uniformly dispersed onto the wafer so
that physical abrasion is provoked by abrasive particles contained
in the polishing slurry and protrusions of the polishing pad.
[0006] In this case, a polishing pad's surface directly contacting
the wafer needs to be saturated with the polishing slurry so that
the polishing slurry flows smoothly. To this end, techniques for
forming micro holes (for example, pores) in the polishing pad's
surface are disclosed in U.S. Pat. No. 5,578,362 and the like.
[0007] In this way, it is very important to maintain the polishing
pad's surface to be saturated with the polishing slurry so as to
increase the role and performance of the polishing pad in the CMP
process. Thus, grooves in various shapes are formed in the
polishing pad so as to form a large slurry flow, and micro holes
are formed in the polishing pad's surface by opening a microporous
material, as described above.
[0008] However, when pores are formed by introducing liquid
microelements, there are advantages that the pores can be stably
formed and a temperature of the CMP process is lowered. However,
there are disadvantages that the liquid microelements are in a
liquid state and thus a small amount of liquid microelements leaks
during the CMP process.
[0009] Attempts for controlling many matters by introducing fine
additives into a slurry due to the development of the CMP process
are recently increasing. Thus, additive materials that may affect
the CMP process are required not to be put into a pad. Introduction
of gaseous pores has been spotlighted as a method of forming only
pure pores without putting additive materials into a polyurethane
matrix.
[0010] There is an advantage that a gaseous pore pad has no
discharge materials that may affect the CMP process. Thus, in the
gaseous pore pad, it is not easy to control gaseous pores and thus,
a manufacturing process should be optimized. However, the following
problems occur.
[0011] Firstly, when pores are formed by directly injecting gas
into the polyurethane matrix that forms a pad or by introducing a
foaming agent, it is difficult to precisely control sizes and
densities of the pores. In particular, it is not easy to
manufacture pores having uniform sizes of less than 50 .mu.m
compared to other methods.
[0012] Secondly, it is very difficult to change sizes of pores and
densities without changing the composition of the polyurethane
matrix.
[0013] Thirdly, in a pure polyurethane matrix, since abrasion is
not smoothly performed when conditioning is performed using a
diamond disk, a phenomenon such as pore glazing that pores may be
clogged, occurs.
SUMMARY OF THE INVENTION
[0014] The present invention provides a polishing pad that may
maintain an advantage of a chemical mechanical
planarization/polishing (CMP) pad that introduces gaseous pores so
as to form porosity and may solve or improve the above-described
conventional problems and a method of manufacturing the same.
[0015] According to an aspect of the present invention, there is
provided a method of manufacturing a polishing pad, whereby
materials for forming a polishing layer are mixed and solidified by
a chemical reaction so as to manufacture the polishing pad, the
method including: (a) grinding organic materials by using a
physical method so as to form micro-organic particles; (b) mixing
the micro-organic particles formed in (a) with the materials for
forming the polishing layer; (c) mixing at least one selected from
the group consisting of inert gas, a capsule type foaming agent,
and a chemical foaming agent that are capable of controlling sizes
of pores, with the mixture in (b) so as to form gaseous pores; (d)
performing gelling and hardening of the mixture generated in (c) so
as to form a polishing layer; and (e) processing the polishing
layer so as to distribute open pores defined by opening gaseous
pores on a surface of the polishing layer.
[0016] According to another aspect of the present invention, there
is provided a method of manufacturing a polishing pad, whereby
materials for forming a polishing layer are mixed and solidified by
a chemical reaction so as to manufacture the polishing pad, the
method including: (a) including monomers for forming micro-organic
particles in the materials for forming a polishing layer and
forming and dispersing the micro-organic particles by
polymerization of the monomers after stirring is performed; (b)
mixing at least one selected from the group consisting of inert
gas, a capsule type foaming agent, and a chemical foaming agent
that are capable of controlling sizes of pores, with the mixture in
(a) so as to form gaseous pores; (c) performing gelling and
hardening of the mixture generated in (b) so as to form a polishing
layer; and (d) processing the polishing layer so as to distribute
open pores defined by opening gaseous pores on a surface of the
polishing layer.
[0017] According to another aspect of the present invention, there
is provided a polishing pad that performs a polishing process by
moving in contact with a surface of an object to be polished, the
polishing pad including a polishing layer, wherein the polishing
layer includes at least one of micro-organic particles formed by
physically grinding organic materials and micro-organic particles
formed by chemical polymerization of monomers and gaseous pores
formed by at least one selected from the group consisting of inert
gas, a capsule type foaming agent, and a chemical agent, and open
pores that are defined by opening the gaseous pores are distributed
on a surface of the polishing layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and other features and advantages of the present
invention will become more apparent by describing in detail
exemplary embodiments thereof with reference to the attached
drawings in which:
[0019] FIG. 1 is a cross-sectional view of a polishing pad
according to an embodiment of the present invention;
[0020] FIG. 2 is a schematic view of a polishing apparatus on which
the polishing pad illustrated in FIG. 1 is mounted;
[0021] FIGS. 3A and 3B are views of micro-organic particles
included in a polishing layer illustrated in FIG. 1;
[0022] FIGS. 4A and 4B are images obtained by comparing a surface
of the polishing layer depending on whether the micro-organic
particles are included in the polished layer of FIG. 1;
[0023] FIGS. 5 and 6 are flowcharts illustrating a method of
manufacturing the polishing layer of the polishing pad according to
embodiments of the present invention;
[0024] FIG. 7 is a graph showing surface roughness after the
surface of the polishing pad of FIG. 1 is polished using a diamond
disk for 10 minutes, and
[0025] FIG. 8 is an image obtained by comparing surface roughness
when the micro-organic particles are introduced with surface
roughness when the micro-organic particles are not introduced,
after marathon polishing evaluation is performed for 5 hours so as
to check abrasion performance.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present invention will now be described more fully with
reference to the accompanying drawings, in which exemplary
embodiments of the invention are shown.
[0027] FIG. 1 is a cross-sectional view of a polishing pad 100
according to an embodiment of the present invention.
[0028] As illustrated in FIG. 1, the polishing pad 100 according to
an embodiment of the present invention includes a support layer 110
and a polishing layer 120. The support layer 110 is used to fix the
polishing pad 100 to a platen 3, as shown in FIG. 3. The support
layer 110 is made of a material having stability in order to
correspond to a force pressing a silicon wafer 7, i.e., an object
to be polished, which is loaded at a head 5 facing the platen 3 so
that the support layer 110 supports the polishing layer 120 formed
on the support layer 110 with uniform elasticity with respect to
the silicon wafer 7. Accordingly, the support layer 110 is made of
a nonporous, solid, and uniform elastic material mainly and has
lower hardness than the polishing layer 120 formed on the support
layer 110.
[0029] In addition, at least a part of the support layer 110 is
transparent or semitransparent so that a light beam 170 used to
detect the flatness of a surface of the object to be polished can
be transmitted through the support layer 110. In FIG. 3, the object
to be polished is the silicon wafer 7 having a metal or insulation
layer as a layer to be polished. However, various types of
substrates such as a substrate, on which a thin film
transistor-liquid crystal display (TFT-LCD) is to be formed, a
glass substrate, a ceramic substrate, and a polymer plastic
substrate may be objects to be polished. In addition, the polishing
pad 100 can be manufactured without including the support layer
110.
[0030] Also, although the polishing pad 100 has a circular shape so
as to be suitable for the rotation type polishing apparatus 1, as
shown in FIG. 2, the polishing pad 100 can be modified in various
shapes, such as a rectangular shape, a square shape, and the like,
according to the shape of the polishing apparatus 1.
[0031] As shown in FIG. 2, the polishing layer 120 directly
contacts the silicon wafer 7 as the object to be polished. The
polishing layer 120 can be formed by mixing or chemically combining
predetermined materials for forming a polishing layer.
[0032] Here, a material of a polymeric matrix 130 formed by
materials for forming the polishing layer 120, i.e., materials for
forming the polymeric matrix 130 may include at least one selected
from the group consisting of polyurethane, polyether, polyester,
polysulfone, polyacryl, polycarbonate, polyethylene,
polymethylmethacrylate, polyvinylacetate, polyvinylchloride,
polyethyleneimine, polyethersulfone, polyetherimide, polyketone,
melamine, nylon, fluorinated hydrocarbon, or a combination
thereof.
[0033] As a specific example of the polymeric matrix 130,
polyurethane may be obtained from two liquid type low viscosity
liquid urethane including isocyanate prepolymer and a hardener. The
prepolymer that is a precursor for final polymer covers olygomer or
monomer. The isocyanate prepolymer has an average 2 or more
isocyanate functional groups and the content of reactive isocyanate
is 4 to 16 parts by weight and may be obtained by reaction between
polyol, such as polyether, polyesther, or polytetramethyleneglycol
and toluene diisocyanate or methylene diphenyl diisocyanate, and
the isocyanate prepolymer may react with the hardener having an
isocyanate reactive group and may form polyurethane finally. Here,
various polyol based on amine or polyether and polyesther, such as
4,4-methylene-bis(2-chloroaniline) (hereinafter, MOCA), may be used
as the hardener. A material property of polyurethane may be
adjusted by various combinations components.
[0034] In this way, the polymeric matrix 130 that constitutes the
polishing layer 120 is composed of various well-known components,
and a further description of well-known materials and forming
materials will be omitted.
[0035] An operation of forming the polishing layer 120 may include
a casting process in which polyurethane prepolymer and the hardener
are mixed with each other, are injected into a mold and liquid raw
materials are chemically solidified, a splitting process in which
the solidified materials are cut according to a usage purpose, and
a grooving process in which a slurry flow channel is formed in the
cut pad. In the present invention, main features are present in
types of materials to be injected in the casting process among
these processes such that particular materials are included in the
polishing layer 120.
[0036] In detail, micro-organic particles are included in the
polishing layer 120 according to the present invention, and
furthermore, pores 141 and 142 may be included in the polishing
layer 120.
[0037] Here, the micro-organic particles may be particles formed of
copolymer that may be made by mixing monomers used to fabricate
thermoplastic resin particles, thermosetting resin particles, and
polymer or particles formed of mixed materials thereof.
[0038] That is, the micro-organic particles may include at least
one selected from the group consisting of polyethylene resin,
polypropylene resin, polystyrene resin, polyvinylchloride resin,
polyamide resin, acryl resin, polyurethane resin, polycarbonate
resin, phenyol resin, amino resin, epoxy resin, urea resin,
polyester resin, rubber acrylonitrile butadiene styrene copolymer
(ABS), and styrene acrylonitrile copolymer (SAN).
[0039] Two methods (physical method and chemical method) may be
largely used in such a way that the micro-organic particles are
included in the polishing layer 120.
[0040] According to the physical method, organic materials may be
ground using a mechanical method so as to form micro-organic
particles and then, the micro-organic particles may be mixed with
materials for forming the polishing layer 120.
[0041] According to the chemical method, monomer for forming
micro-organic particles may be included in the materials for
forming the polishing layer 120, and the micro-organic particles
may be formed and uniformly dispersed by polymerization of
corresponding monomers after a stirring process is performed.
[0042] A state in which the micro-organic particles are included in
the materials for forming the polishing layer 120, is shown in FIG.
3.
[0043] FIG. 3A is a low magnification image of the micro-organic
particles, and FIG. 3B is a high magnification image of the
micro-organic particles.
[0044] The pores 141 and 142 included in the polishing pad 100 may
be pores of which sizes are capable of being controlled by at least
one selected from the group consisting of inert gas, a capsule type
foaming agent, a chemical foaming agent, and liquid
microelements.
[0045] Here, the liquid microelements are formed of a liquid
material that is not compatible with the polymeric matrix 130 that
constitutes the polishing layer 120, i.e., a material selected from
the group consisting of aliphatic mineral oil, aromatic mineral
oil, silicon oil which does not have a hydroxyl group at the end of
molecules, soybean oil, coconut oil, palm oil, cottonseed oil,
camellia oil, hardened oil, or a combination thereof.
[0046] The liquid microelements may be dispersed into the polymeric
matrix 130 in a micro spherical shape. The average diameter of
spheres may be between 1 to 50 .mu.m, for example, between 10 to 40
.mu.m. The diameter of spheres in the above range is most optimal
to the collection and supply of a polishing slurry 13. However, the
diameter of spheres can be changed depending on a type of the
polishing slurry 13, and the size of the liquid microelements can
be also changed.
[0047] Types of the pores 141 and 142 may be distinguished from
each other by a method of forming the pores 141 and 142. For
example, the pores 141 and 142 are formed by injecting inert gas, a
capsule type foaming agent, or a chemical foaming agent.
[0048] Here, the inert gas may be gas having a valence of 0 that is
chemically stable, i.e., helium (He), neon (Ne), argon (Ar),
krypton (Kr), xenon (Xe), or radon (Rn). Furthermore, the inert gas
may be any gas that does not react with the polymeric matrix 130,
i.e., that does not participate in a urethane reaction, such as
N.sub.2, apart from 8 group elements of the periodic table.
[0049] The foaming agent that is mixed with a predetermined
material and generates a large amount of bubbles by evaporation or
reaction by heat, can be largely classified into a chemical foaming
agent and a physical foaming agent.
[0050] In the chemical foaming agent, foaming occurs in carbon
dioxide that is generated by a reaction with water by using
vitality of an isocyanate group, and thus water is used for a
foaming agent. In the physical foaming agent, bubbles are formed by
generating reaction heat by injecting gas or using a decomposable
or evaporative foaming agent, and thus, the physical foaming agent
does not participate in polymerization. Types and features of these
foaming agents are already well-known and thus, detailed
descriptions thereof will be omitted.
[0051] The pores 141 and 142 are formed on the polishing layer 120
by mixing the inert gas or various foaming agents (capsule type
foaming agent or chemical foaming agent). Different pores 141 and
142 that are controlled by a plurality of methods may be included
in the polishing pad 100, and FIG. 1 is a cross-sectional view of
the polishing pad 100 in which the plurality of pores 141 and 142
are included.
[0052] FIGS. 4A and 4B are images obtained by comparing a
cross-section of the polishing pad 100 including the pores 141 and
142, as described above, depending on whether the micro-organic
particles are included in the polished layer 120 of FIG. 1.
[0053] That is, FIG. 4A shows a pore distribution state of the
surface of the polishing pad 100 when the micro-organic particles
are not introduced (included) in the polishing layer 120, and FIG.
4B shows a pore distribution state of the surface of the polishing
pad 100 when the micro-organic particles are introduced (included)
in the polishing layer 120. In FIGS. 4A and 4B, other conditions
(conditions such as temperature of forming combination materials of
the polishing pad 100 and time) for forming the polishing pad 100
than the micro-organic particles are the same.
[0054] As illustrated in the comparison images of FIGS. 4 and 4B,
when the polishing pad 100 is formed by including the micro-organic
particles, the distribution of pores are more compact.
[0055] In the casting process, appropriate viscosity of a
polyurethane undiluted solution that may collect pores on the gas
and a sufficient stirring ability of a casting machine are required
so that small and uniform pores can be stably formed when gas or
foaming agents are injected into the polyurethane matrix. Since
viscosity of most polyurethane raw solutions used in the related
art is lower than a level at which the gas can be stably collected,
the amount of the gas discharged in the air is larger than the
amount of the gas that remains in polyurethane such that entire
porosity is lowered and it is difficult to form pores having small
sizes.
[0056] However, like in the current embodiment, the micro-organic
particles are introduced (included) in a polyurethane prepolymer
undiluted solution so that the viscosity of the undiluted solution
is increased by interaction between the micro-organic particles and
polyurethane and this contributes to formation of small and uniform
pores together with acquisition of sufficient porosity.
[0057] Furthermore, even when the composition of the polyurethane
matrix is not changed due to adjustment of the content of the
micro-organic particles, the sizes of pores and porosity may be
adjusted.
[0058] Hereinafter, a method of manufacturing the polishing layer
120 of the polishing pad 100 according to an embodiment of the
present invention will be described with reference to FIG. 5.
[0059] First, organic materials are ground using a physical method
and are formed as micro-organic particles (S100), and the
micro-organic particles are mixed with materials for forming the
polishing layer 120 (S110). In detail, the above-described material
for forming the polymeric matrix 130 may be mixed with the ground
micro-organic particles (S110).
[0060] In the mixing process, inert gas (or a predetermined foaming
agent that replaces the inert gas), such as Ar, is together mixed
with the material for forming the polymeric matrix 130 (S120).
[0061] Amounts of the mixed insert gas may be adjusted according to
the sizes of pores to be formed depending on types.
[0062] Subsequently, gelling and hardening are performed (S130).
That is, the mixture is injected into a cast having a predetermined
shape and then solidified through gelling and hardening. Gelling is
performed for 5 to 30 minutes at 80 to 90.degree. C., and hardening
is performed for 20 to 24 hours at 80 to 120.degree. C. However,
processing temperature and time can be variously changed to provide
optimal conditions.
[0063] Last, the resultant structure of the hardening, having the
predetermined shape, is processed (S140). The resultant structure
is processed through taking off the cast, cutting, surface
treatment, and cleaning. First, the hardened resultant structure is
taken out of the cast and cut to have a predetermined thickness and
shape. It is apparent that the polishing layer 120 can be formed in
the shape of sheet using any method, such as casting or extrusion,
known in the field of polymer sheet manufacturing in order to
increase the productivity. Grooves in various shapes may be formed
in a surface of the polishing layer 120 so that the polishing
slurry 13 can be uniformly supplied across the working surface of
the polishing layer 120.
[0064] After a cleaning process is performed, the polishing layer
120 is completed. During the cleaning process, pores 141 exposed at
the surface of the polishing layer 120 flow out, and thus open
pores 141' and 142' are distributed on the polishing layer surface
160.
[0065] The polishing pad 100 can be constituted only by the
polishing layer 120. However, when necessary, the support layer 110
can be made using a method widely known in the field of
manufacturing the polishing pad 100 and is combined with the
polishing layer 120 to complete the polishing pad 100.
[0066] FIG. 6 illustrates a method of manufacturing the polishing
layer 120 of the polishing pad 100 according to another embodiment
of the present invention.
[0067] The method of FIG. 6 is different from the method of FIG. 5
in that micro-organic particles are included in the polishing pad
100 by using a chemical method.
[0068] That is, monomers for forming the micro-organic particles
are included in materials for forming the polishing layer 120, and
the micro-organic particles are formed and dispersed into a
corresponding mixture solution by polymerization of corresponding
monomers after a stirring process is performed (S200).
[0069] Subsequently, at least one selected from the group
consisting of inert gas, a capsule type foaming agent, and a
chemical foaming agent that are capable of controlling sizes of
pores, is mixed in the mixture solution so as to form gaseous pores
(S210).
[0070] Subsequent processes, i.e., processes of gelling and
hardening the mixture so as to form the polishing layer 120 (S220)
and processing (S230) are the same as the above descriptions and
thus, redundant descriptions thereof will be omitted. More details
of the present invention will be described by explaining specific
experimental examples. Details not described below are omitted
because they can be technically inferred by those skilled in the
art. It will be apparent that the scope of the present invention is
not limited to the following experimental examples.
EXPERIMENTAL EXAMPLE 1
[0071] 1600 g of polytetramethylene glycol (having a molecular
weight of 1000) was put into 5 l of a flask, and 400 g of styrene
monomer and a very small amount of an initiator AlBN were slowly
put at 100 to 130.degree. C. so that a chemical reaction
(polymerization) was induced and uniform microparticles could be
generated and dispersed into polytetramethylene glycol. The
viscosity of polytetramethylene glycol in which the uniform
micro-organic particles were dispersed, was 1,700 cPs (25.degree.
C.).
EXPERIMENTAL EXAMPLE 2
[0072] 120 g of the polytetramethylene glycol in which the uniform
micro-organic particles were dispersed, manufactured in
Experimental Example 1, and 52 g of toluene diisocyanate were put,
were reacted at the temperature of 70 to 80.degree. C. for 4 to 5
hours so that the content of NCO of a final product was 9.0%.
[0073] The viscosity of the manufactured isocynate prepolymer was
10,900 cPs (25.degree. C.).
EXPERIMENTAL EXAMPLE 3
[0074] A reaction between the isocynate prepolymer manufactured in
Experimental Example 2 and MOCA (a kind of a urethane hardener) (a
mixture ratio of 10:3) was induced using a casting machine, and
simultaneously, injection of gas was performed in the mixture. The
mixture in which the gas was injected, was put into a rectangular
cast of 80.degree. C. Then, gelling was performed for about 30
minutes, and thereafter, hardening was performed in an oven for 20
hours at 100.degree. C.s. The hardened mixture was taken out of the
cast, and the surface of the hardened mixture was cut to form the
polishing layer 120 of the polishing pad 100.
[0075] An image of pores formed on a surface of the polishing layer
120 according to this result is shown in FIG. 4B, and an average
pore diameter was 32 .mu.m.
[0076] After the manufactured pad was polished using a diamond disk
for 10 minutes, surface roughness of the pad was Ra 5.82, Rp 15.05,
and Rv 24.07, as shown in FIG. 7.
[0077] In FIG. 7, the horizontal axis represents to a distance from
a central axis of the polishing layer 120, and the vertical axis
represents a height of the polishing layer surface 160.
[0078] Marathon polishing evaluation was performed for 5 hours so
as to check abrasion performance of the manufactured pad, and a
result thereof is shown in FIG. 8.
[0079] As shown in FIG. 8, surface roughness was improved when the
micro-organic particles are introduced, compared to a case where
the micro-organic particles are not introduced.
[0080] That is, the micro-organic particles are dispersed between
polyurethane matrices and thus constitute interfaces that contact
between the particles and the polyurethane matrix. This means that
polyurethane is configured to have a weak adhesion force at the
interfaces compared to a case where polyurethane is in a pure
state, so that, when conditioning is performed using a diamond disk
during a CMP process, characteristics in which the polishing pad is
better abraded, are shown.
[0081] In this way, the micro-organic particles contribute to
improvements in abrasion performance, and positive effects are
shown in improvements in a phenomenon of pore glazing.
[0082] While the present invention has been particularly shown and
described with reference to exemplary embodiments thereof, it will
be understood by those of ordinary skill in the art that various
changes in form and details may be made therein without departing
from the spirit and scope of the present invention as defined by
the following claims.
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