Methods and apparatus for correcting substrate deformity

Embodiments of methods and apparatus for correcting substrate deformity are provided herein. In some embodiments, a substrate support includes a base having an interior volume formed by walls extending upward from the base; a plurality of infrared lamps disposed within the interior volume; a support plate disposed above the plurality of infrared lamps, wherein the support plate includes a support surface to support a substrate; and a cover plate disposed atop the support plate and having a central opening corresponding to the support surface and an exhaust portion at a periphery of a top surface of the cover plate, wherein the exhaust portion includes a plurality of perforations fluidly coupling a space above the cover plate with an exhaust conduit formed in the cover plate. Embodiments of a showerhead assembly and processing equipment incorporating the inventive substrate support and showerhead assembly are additionally provided herein.

FIELD

Embodiments of the present disclosure generally relate to correcting deformities in a substrate.

BACKGROUND

Epoxy mold compounds are used to encapsulate dies in substrate packaging. These compounds bow and warp after thermal processes due to inhomogeneous heating and cooling, causing non-uniform expansion/contraction rates in current process equipment. Conventional thermal processes utilize directional heat transfer via radiative, convective or conductive thermal processes. The directionality results in anisotropic expansion and contraction rates. When operated near the thermoplastic regime, non-uniform cooling and, subsequently, contraction rates give rise to a warped substrate. Such warp and bow effects are frequently observed and imply that the substrate is being processed close to the thermoplastic regime of the substrate, giving rise to warpage beyond acceptable levels.

Therefore, the inventors have provided embodiments of methods and apparatus for correcting substrate deformity.

SUMMARY

Methods and apparatus for correcting substrate deformities are provided herein. In some embodiments, a substrate support includes a base having an interior volume formed by walls extending upward from the base, wherein the walls are disposed within a periphery of the base; a plurality of infrared lamps disposed within the interior volume; a support plate disposed above the plurality of infrared lamps, wherein the support plate includes a support surface to support a substrate; and a cover plate disposed atop the support plate and having a central opening corresponding to the support surface and an exhaust portion at a periphery of a top surface of the cover plate, wherein the exhaust portion includes a plurality of perforations fluidly coupling a space above the cover plate with an exhaust conduit formed in the cover plate.

In some embodiments, a showerhead assembly includes an upper plate having a gas inlet and an interior volume formed by walls extending downward from the upper plate, wherein the walls are disposed within a periphery of the upper plate; a plurality of infrared lamps disposed within the interior volume; a holding plate disposed below the plurality of infrared lamps to support the plurality of infrared lamps within the interior volume; a blocker plate having a plurality of apertures and disposed below the holding plate, wherein the blocker plate includes a recessed section which, together with the holding plate, forms a plenum, and wherein the plurality of apertures are disposed in the recessed section; a gas conduit extending from the gas inlet and through the holding plate to supply gas to the plenum; and a cover plate disposed below the blocker plate and having a central opening corresponding to the recessed section, wherein the cover plate is coupled to a top of the walls of the upper plate to couple the holding plate and the blocker plate to the upper plate.

In some embodiments, a processing chamber includes a chamber body having a processing volume; a substrate support disposed in a lower portion of the processing volume; and a showerhead assembly disposed in an upper portion of the processing volume opposite the substrate support. The substrate support includes a base having a first interior volume formed by first walls extending upward from the base, wherein the first walls are disposed within a periphery of the base; a first plurality of infrared lamps disposed within the first interior volume; a support plate disposed above the first plurality of infrared lamps, wherein the support plate includes a support surface to support a substrate; and a first cover plate disposed atop the support plate and having a first central opening corresponding to the support surface and an exhaust portion at a periphery of a top surface of the first cover plate, wherein the exhaust portion includes a plurality of perforations fluidly coupling the processing volume with an exhaust conduit formed in the first cover plate. The showerhead assembly includes an upper plate having a gas inlet and a second interior volume formed by second walls extending downward from the upper plate, wherein the second walls are disposed within a periphery of the upper plate; a second plurality of infrared lamps disposed within the second interior volume; a holding plate disposed below the second plurality of infrared lamps to support the second plurality of infrared lamps within the second interior volume; a blocker plate having a plurality of apertures and disposed below the holding plate, wherein the blocker plate includes a recessed section which, together with the holding plate, forms a plenum, and wherein the plurality of apertures are disposed in the recessed section; a gas conduit extending from the gas inlet and through the holding plate to supply gas to the plenum; and a second cover plate disposed below the blocker plate and having a second central opening corresponding to the recessed section, wherein the second cover plate is coupled to a top of the second walls of the upper plate to couple the holding plate and the blocker plate to the upper plate.

DETAILED DESCRIPTION

Embodiments of a method and apparatus for correcting substrate deformity are provided herein. The method and apparatus may advantageously planarize a substrate that has bowed or warped due to heating and/or cooling of a substrate during previous processing, in particular substrates having epoxy coatings.

FIG. 1depicts a block diagram of a substrate processing system100suitable for performing the inventive method in accordance with some embodiments of the present disclosure in accordance with embodiments of the present disclosure. As depicted inFIG. 1, the substrate processing system100comprises a chamber102enclosing a processing volume103, a support104for supporting a substrate106, a lift pin assembly107, a vacuum source110, a heat transfer supply113, a radiative heat source (lamp array112), lamp driver114, controller116, and an AC power source118. One or more temperature sensors and associated hardware (not shown) may be provided and coupled to the controller for controlling the temperature within the processing volume103. The substrate106is, for example, a semiconductor wafer. The substrate106may comprise an epoxy coating disposed thereon.

The lift pin assembly107includes a plurality of lift pins109that extend through a corresponding plurality of lift pin channels105formed in the support104. The lift pin assembly107may be raised and lowered by a driving mechanism108(such as a motor or actuator) to raise and lower the substrate106onto or off of a support surface117of the support104. The chamber102may further include an opening119through which a robotic arm (not shown) extends to insert/remove the substrate106onto/from the plurality of lift pins109. The lift pin assembly107is moveable between a first position, in which the substrate is proximate the lamp array112, and a second position, in which the substrate106rests on the support surface117. In some embodiments, the substrate106is heated to first predetermined temperature in the first position and cooled to second predetermined temperature in the second position.

In some embodiments, the support104is a vacuum chuck to which the vacuum source110is coupled to chuck the substrate106onto the support surface117. In some embodiments, the support104may alternatively be an electrostatic chuck. The support104includes a plurality of heat transfer channels111fluidly coupled to a heat transfer supply113. In some embodiments, for example, the heat transfer supply113may provide a coolant to the heat transfer channels111to cool the substrate106placed atop the support surface117of the support104.

The AC power source118delivers AC power to the lamp driver114, the operation of which is controlled by the controller116. The lamp driver114distributes power to the lamp array112. In turn, the lamp array112produces heat to thermally treat the substrate106within the chamber102.

In some embodiments, the lamp array112comprises one or more lamps, each of which may be individually controlled by the controller116through the lamp driver114. As illustrated inFIG. 1, three lamps (120,122,124) are shown, although a lesser number or a greater number of lamps may be used. Each lamp120,122,124may be individually controlled by the controller116to provide heat to corresponding heating zones. Because the lamps may be individually controlled, the temperature in the heating zones may also be controlled.

FIG. 2is a flowchart illustrating a method200for correcting substrate deformity in accordance with some embodiments of the present disclosure. At205, the substrate106that is deformed (i.e., warped, bowed, etc.) is raised to a first position proximate the lamp array112by the lift pin assembly107. At210, the substrate106is heated to a predetermined temperature for a first predetermined period of time. The predetermined temperature may be at or above a glass transition temperature of an epoxy disposed on the substrate (for substrates having an epoxy coating). For example, the substrate106may be heated to a temperature of about 180° C. to about 220° C. for a duration of about 30 seconds to 60 seconds. At215, the substrate106is lowered to a second position onto the support surface117. At220, the substrate106is chucked to the support surface117to planarize the deformed substrate. At225, a coolant is flowed through the heat transfer channels111for a second predetermined period of time to cool the substrate106and retain the planarized shape of the substrate106. The substrate106is cooled to a temperature at least below the glass transition temperature for an epoxy coating on the substrate, such as at or below about 130° C. In some embodiments, the second predetermined period of time is between about 30 seconds to about 60 seconds.

FIG. 3depicts a block diagram of a substrate processing system300suitable for performing the inventive method in accordance with some embodiments of the present disclosure in accordance with embodiments of the present disclosure. For example, a substrate processing system300includes a first process chamber302a(i.e., a heating chamber) having a first processing volume304aand a first substrate support306adisposed in a lower portion of the first processing volume304afor supporting a substrate305a,b. The first process chamber302amay be an atmospheric chamber (i.e., not a vacuum chamber) or a vacuum chamber. Providing the first process chamber302aas an atmospheric chamber advantageously reduces the cost of the system since non-vacuum chambers are less expensive to fabricate and maintain than vacuum chambers.

The first substrate support306amay include a first body307ahaving a first support surface308aand a first shaft310ato support the first body307a. Although illustrated inFIG. 1as a pedestal-type design, the substrate support may be any suitable substrate support having a support surface and a member, such as the first shaft310aor any other suitable member for supporting the support surface. In some embodiments, the first substrate support306amay comprise a ceramic material, such as, for example, aluminum oxide (Al2O3) or aluminum nitride (AlN), or a metallic material, such as, for example, aluminum (Al). The first substrate support306adoes not include a chucking mechanism such as, for example, a vacuum chuck, an electrostatic chuck, clamps, or the like. The first substrate support306amay also include a lift pin mechanism (similar to driving mechanism108of lift pin assembly107shown inFIG. 1) having a plurality of lift pins to facilitate placement and removal of the substrate on/from the first support surface308a.

The first substrate support306aincludes a first heater322adisposed in the first substrate support306aproximate the first support surface308ato provide heat to the substrate305a,bwhen disposed on the first support surface308a. The first heater322amay be any suitable heater used in a substrate support, such as a resistive heater or the like. The first heater322amay include one or more conductive lines324athat extend from the first heater322athrough the first shaft310ato provide power to the first heater322a. For example, as illustrated inFIG. 3, the one or more conductive lines324amay couple the first heater322ato a first power supply326adisposed external of the first process chamber302a. For example, the one or more conductive lines324amay include a first line for providing power from the first power supply326ato the first heater322aand a second line for returning power to the first power supply326a. The first power supply326amay include an alternating current (AC) power source, a direct current (DC) power source or the like. Alternatively (not shown), the one or more conductive lines324amay be a single conductive line, which provides power from the first power supply326ato the first heater322a.

The first substrate support306amay include a thermocouple328adisposed in the first substrate support306ato measure a desired temperature, such as the temperature of the first substrate support306a, the first support surface308a, or the temperature of the substrate305a,bwhen disposed on the first support surface308a. For example, the thermocouple328amay be any suitable thermocouple design, such as a thermocouple probe or the like. The thermocouple328amay be removable. As illustrated inFIG. 3, the thermocouple328amay extend along the first shaft310aof the first substrate support306ato proximate the first support surface308a. The thermocouple328aas illustrated inFIG. 3is merely exemplary, and the tip of the thermocouple may extend to proximate the first heater322a(as illustrated inFIG. 3) or to above the first heater322aand proximate the first support surface308a(not shown). The location of the tip of the thermocouple328amay be adjusted relative to the first support surface308ato provide the most accurate measurement of temperature of the substrate305a,bor of some other component such as the first support surface308a. The thermocouple328amay be operatively coupled to a first temperature controller330a. For example, the first temperature controller330amay control the first power supply326abased on the temperature measured by the thermocouple328a. Alternatively, the first temperature controller330amay be part of, or coupled to, a system controller, such as the first controller344athat may control the operations of the first process chamber302a.

In some embodiments, the first substrate support may alternatively be a vacuum chuck such as the substrate support depicted inFIGS. 5 and 6.FIGS. 5 and 6respectively depict exploded isometric and cross-sectional views of a substrate support500in accordance with some embodiments of the present disclosure. In some embodiments, the substrate support500includes a base502having an interior volume504(first interior volume) formed by walls506(first walls) extending upward from the base502. In some embodiments, the base502includes a coolant channel602(FIG. 6) formed in the base502. In some embodiments, the coolant channel602may be disposed outward of the walls506.

A plurality of infrared lamps507are disposed within the interior volume504to heat a substrate to be flattened. In some embodiments, the plurality of infrared lamps507includes a plurality of heating zones that may be controlled independently or in groups. In some embodiments, the plurality of heating zones includes 1-4 heating zones. Each of the plurality of infrared lamps507is configured to reach a temperature between about 170° C. and about 200° C. In some embodiments, each of the plurality of infrared lamps507has a voltage of about 110 volts and a power rating of about 350 watts. However, the plurality of infrared lamps may include lamps of other voltages and power ratings to achieve a desired result (i.e., a desired flatness control of a warped substrate). In some embodiments, the plurality of infrared lamps507are configured to maintain a warped substrate at a temperature between about 180° C. and about 200° C. The inventors have discovered that by using infrared lamps instead of resistive heating elements, the temperature of the substrate support500may advantageously be more rapidly changed as compared to resistive heating elements.

The substrate support500further includes a support plate508disposed above the plurality of infrared lamps507and a cover plate510disposed atop the support plate508. The support plate508includes a support surface512to support a substrate atop the support plate508. The cover plate510includes a central opening514corresponding to and exposing the support surface512. In some embodiments, the support plate508includes a through hole526disposed proximate a center of the support plate508and a plurality of channels528extending outward from the through hole526. The through hole526and the plurality of channels528are configured to distribute a vacuum chucking force over a bottom surface of the substrate being flattened. In some embodiments, the support plate508is formed of quartz.

The cover plate510further includes an exhaust portion516at a periphery518of a top surface520of the cover plate510. The exhaust portion516includes a plurality of perforations522fluidly coupling a space above the cover plate (i.e., first processing volume304a) with an exhaust conduit524formed in the cover plate510beneath the plurality of perforations522. In some embodiments, the cover plate510is formed of a thermally conductive material such as, for example, aluminum, stainless steel, or the like. In some embodiments, the cover plate510includes a first plurality of holes540through which a corresponding plurality of fixation elements (such as bolts, screws, clamps, or the like, not shown) may extend to be inserted into a corresponding second plurality of fixation holes542in a top surface of the walls506to couple the cover plate510to the base502.

In some embodiments, the substrate support500further includes a plurality of support posts530to support the substrate support500within a chamber (e.g., first process chamber302a). The exhaust conduit524is fluidly coupled to an exhaust line532, which is coupled to a pump604configured to pump down the process chamber and exhaust the gases supplied through the showerhead into the processing volume. The through hole526is fluidly coupled to a vacuum chucking supply534. The coolant channel602is fluidly coupled to a coolant supply606to flow a coolant through the coolant channel602and maintain the base502at a desired temperature.

In some embodiments, the substrate support500further includes a lift pin assembly608having a plurality of lift pins610. The base502includes a first plurality of holes536corresponding to the plurality of lift pins610. The support plate508similarly includes a second plurality of holes538corresponding to first plurality of holes536and aligned with the first plurality of holes536so that the plurality of lift pins610extend through the first and second plurality of holes536,538when the lift pin assembly608is in a raised position. The lift pin assembly608includes a lift mechanism612, such as a motor or actuator, configured to raise and lower the lift pin assembly608.

Returning toFIG. 3, the first process chamber302afurther includes a first showerhead319adisposed in an upper portion of the first processing volume304athat is coupled to a first gas panel321aas illustrated inFIG. 3to provide one or more process gases to the first processing volume304a. The one or more process gases may include one or more non-toxic inert gases such as, for example, nitrogen or argon. The first showerhead319ais merely one exemplary chamber component for delivering one or more process gases to the first processing volume304a. Alternatively or in combination, the one or more process gases may be delivered to the first processing volume304avia side injection ports (not shown) disposed about the walls of the first process chamber302a, or gas inlets disposed in other regions of the process chamber. In some embodiments, the first showerhead319amay include a second heater316adisposed in the first showerhead319aproximate a substrate-facing surface of the showerhead to heat the one or more process gases flowing through the showerhead. The second heater316amay be any suitable heater used in a showerhead, such as a resistive heater or the like. The second heater316ais coupled to a second power supply356adisposed external of the first process chamber302a. The second power supply356amay include an alternating current (AC) power source, a direct current (DC) power source or the like. The second power supply356amay be coupled to a second temperature controller360ato control the second power supply356abased on the temperature measured by a thermocouple328a, which is operatively coupled to the second power supply356a. In some embodiments, the one or more process gases may alternatively be heated prior to entering the first showerhead319a.

In some embodiments, the first showerhead may alternatively include a plurality of infrared lamps such as the showerhead assembly depicted inFIGS. 7 and 8.FIGS. 7 and 8respectively depict exploded isometric and cross-sectional views of a showerhead assembly700in accordance with some embodiments of the present disclosure. In some embodiments, the showerhead assembly700includes an upper plate702having a gas inlet704and an interior volume706(second interior volume) formed by walls708(second walls) extending downward from the upper plate702. In some embodiments, the upper plate702includes a coolant channel808formed in the upper plate702to prevent heat from being transmitted to a chamber body in which the showerhead assembly700is installed. In some embodiments, the coolant channel808may be outward of the walls708. In some embodiments, the coolant channel808may alternatively be proximate the walls708. The coolant channel808is coupled to a coolant supply810to flow a coolant through the coolant channel808.

A plurality of infrared lamps710are disposed within the interior volume706. A holding plate712is disposed below the plurality of infrared lamps710to support the plurality of infrared lamps710within the interior volume706. In some embodiments, the plurality of infrared lamps710includes a plurality of heating zones that may be controlled independently or in groups. In some embodiments, the plurality of heating zones includes 1-4 heating zones. Each of the plurality of infrared lamps710is configured to reach a temperature between about 170° C. and about 200° C. In some embodiments, each of the plurality of infrared lamps710has a voltage of about 110 volts and a power rating of about 700 watts. However, the plurality of infrared lamps710may include lamps of other voltages and power ratings to achieve a desired result (i.e., a desired flatness control of a warped substrate). In some embodiments, the plurality of infrared lamps710are configured to maintain a warped substrate at a temperature between about 180° C. and about 200° C. The inventors have discovered that by using infrared lamps instead of resistive heating elements, the temperature of the showerhead assembly700may advantageously be more rapidly changed when compared with resistive heating elements.

The showerhead assembly700further includes a blocker plate714is disposed below the holding plate712. The blocker plate includes a recessed section716which, together with the holding plate712, forms a plenum802(FIG. 8). A plurality of apertures718are formed through the blocker plate714in the recessed section716. In some embodiments, the blocker plate is formed of a transparent material such as, for example, quartz. A gas conduit720extends from the gas inlet704through the holding plate712to supply gas to the plenum802.

The showerhead assembly700further includes a cover plate722disposed below the blocker plate714. The cover plate722includes a central opening724corresponding to the recessed section716to expose the recessed section716and allow gas to flow from the plenum802, through the plurality of apertures718, and into a processing volume (e.g., first processing volume304a) beneath the showerhead assembly. The cover plate722is coupled to a bottom of the walls708of the upper plate702to retain the holding plate and the blocker plate within the interior volume706. In some embodiments, the cover plate722may include a plurality of alignment pins728which are inserted into the bottom of the walls708to properly align the cover plate722with respect to the upper plate702during installation. In some embodiments, the cover plate722may be formed of a thermally conductive material such, as for example, aluminum, stainless steel, or the like.

In some embodiments, the showerhead assembly700further includes a gas supply line726coupled to the gas inlet704of the upper plate702. In some embodiments, the gas supply line726is coupled to a gas supply804to supply an inert gas such as, for example, nitrogen, to the processing volume (e.g., first processing volume304a. In some embodiments. In some embodiments, the gas supply line726includes a heater806disposed within the gas supply line726to heat gas passing through the gas supply line726and maintain the gas at a predetermined temperature.

Returning toFIG. 3, a deformed substrate305a(shown in phantom) may enter the first process chamber302avia a first opening309ain a wall of the first process chamber302a. The first opening309amay be selectively sealed via a first slit valve311a, or other mechanism for selectively providing access to the interior of the chamber through the opening. The first substrate support306amay be coupled to a first lift mechanism338a(such as a motor or actuator) that may control the position of the first substrate support306abetween a lower position (as shown) suitable for transferring substrates into and out of the chamber via the first opening309aand a selectable upper position suitable for processing. The process position may be selected to maximize temperature uniformity across the substrate. The first lift mechanism338amay be coupled to the first process chamber302avia a first bellows340aor other flexible vacuum hose to maintain a predetermined pressure range in the first processing volume304awhen the first substrate support306ais moved.

The first process chamber302amay further include a first exhaust system342afor removing excess process gases from the first processing volume304aof the first process chamber302a. For example, the first exhaust system342amay include a vacuum pump coupled to a pumping plenum via a pumping port for pumping out the exhaust gases from the first process chamber302a, or any suitable exhaust system. For example, the vacuum pump may be fluidly coupled to an exhaust outlet for routing the exhaust to appropriate exhaust handling equipment. A valve (such as a gate valve, z-motion valve, or the like) may be disposed in the pumping plenum to facilitate control of the flow rate of the exhaust gases in combination with the operation of the vacuum pump.

To facilitate control of the first process chamber302aas described above, a first controller344acomprises a first central processing unit (CPU)346a, a first memory348a, and first support circuits350afor the first CPU346aand facilitates control of the components of the first process chamber302a. The first controller344amay any form of general-purpose computer processor that can be used in an industrial setting for controlling various chambers and sub-processors. The first memory348a, or computer-readable medium, of the first CPU346amay be one or more of readily available memory such as random access memory (RAM), read only memory (ROM), floppy disk, hard disk, or any other form of digital storage, local or remote. The first support circuits350aare coupled to the first CPU346afor supporting the processor in a conventional manner. These circuits include cache, power supplies, clock circuits, input/output circuitry and subsystems, and the like. The methods performed in the first process chamber302a, or at least portions thereof, may be stored in the first memory348aas a software routine. The software routine may also be stored and/or executed by another CPU (not shown) that is remotely located from the hardware being controlled by the first CPU346a.

The substrate processing system300further includes a second process chamber302b(i.e., a cooling chamber) having a second processing volume304band a second substrate support306bdisposed in the second processing volume304bfor supporting a planarized substrate305b. The second process chamber302bis also an atmospheric chamber (i.e., is not a vacuum chamber). A description of components of the second process chamber302bthat are substantially identical to corresponding components of the first process chamber302awill be omitted for brevity. Only components of the second process chamber302bwill be described.

In some embodiments, the second process chamber302bmay optionally include a second showerhead319bthat is coupled to a second gas panel321bas to provide one or more process gases to the second processing volume304b. The one or more process gases may include one or more non-toxic inert gases such as, for example, nitrogen or argon. Alternatively or in combination, the one or more process gases may be delivered to the second processing volume304bvia side injection ports (not shown) disposed about the walls of the second process chamber302b, or gas inlets disposed in other regions of the process chamber. The second showerhead319bmay include a first plurality of coolant channels316bto flow a coolant from a first coolant supply356bto cool the one or more process gases passing through the second showerhead319b. The first coolant supply356bmay be coupled to a third temperature controller360bto control the first coolant supply356b.

The second substrate support306bincludes a second plurality of coolant channels322bdisposed in the second substrate support306bproximate the second support surface308bto provide cool the planarized substrate305bwhen disposed on the second support surface308b. The second plurality of coolant channels322bsupply and return lines324bthat extend from the second plurality of coolant channels322bthrough the second shaft310bto provide coolant to the second plurality of coolant channels322b. The supply and return lines324bcouple the second plurality of coolant channels322bto a second coolant supply326bdisposed external of the second process chamber302b. A fourth temperature controller330bmay control the second coolant supply326bto selectively supply coolant to the second plurality of coolant channels322b. Alternatively, the fourth temperature controller330bmay be part of, or coupled to, a system controller, such as the controller344bthat may control the operations of the second process chamber302b. In some embodiments, the second substrate support306bmay include a chucking mechanism (not shown) such as, for example, a vacuum or electrostatic chuck.

A planarized substrate305bmay enter the second process chamber302bvia a second opening309bin a wall of the second process chamber302b. The second opening309bmay be selectively sealed via a second slit valve311b, or other mechanism for selectively providing access to the interior of the chamber through the opening. The second substrate support306bmay also include a lift pin mechanism (not shown) having a plurality of lift pins to facilitate placement and removal of the substrate on/from the second support surface308b.

To prepare the first process chamber302ato planarize a warped substrate305a, a process gas (e.g., one or more inert gases, such as nitrogen or argon) is flowed into the first processing volume304athrough the first showerhead319a. Subsequently, the first heater322ais activated to heat the first substrate support306ato a first predetermined temperature and the second heater316ais activated to heat the process gas to a second predetermined temperature. The predetermined temperature may be at or above a glass transition temperature of an epoxy disposed on the substrate (for substrates having an epoxy coating). For example, in some embodiments, the first predetermined temperature and the second predetermined temperature are both between about 150° C. to about 220° C. In some embodiments, the first and second predetermined temperatures are both between about 160° C. to about 220° C. Alternatively, the predetermined temperature may be at or slightly above the glass transition temperature of an epoxy disposed on the substrate (for substrates having an epoxy coating). For example, in some embodiments, the first and second predetermined temperatures are both between about 150° C. to about 160° C. In some embodiments, the first and second predetermined temperatures are both about 160° C.

After the first process chamber302ais at a predetermined operating temperature, a warped substrate305a(such as a warped substrate having an epoxy coating) is placed on the first support surface308aof the first substrate support306a. In some embodiments, the warped substrate305ais initially at room temperature (e.g., about 21° C.). The warped substrate305ais rapidly heated to the first predetermined temperature during a first time period. In the embodiment in which the first predetermined temperature is about 150° C. to about 160° C., or about 160° C., the first time period is between about 5 second and about 10 seconds. The warped substrate305ais then maintained at the first predetermined temperature for a second time period to deform and planarize the warped substrate305ainto the planarized substrate305b. In the embodiment in which the first predetermined temperature is about 150° C. to about 160° C., or about 160° C., the second time period is between about 10 seconds and about 2 minutes. Subsequently, the second temperature controller360achanges the power supplied to the second heater316aby the second power supply356ato decrease the temperature of the process gas to a third predetermined temperature. In some embodiments, the third predetermined temperature may be between about 25° C. and about 130° C. As a result, the temperature of planarized substrate305bis gradually decreased at a first cooling rate to a fourth predetermined temperature during a third time period. In some embodiments, the fourth predetermined temperature is below the glass transition temperature for an epoxy coating disposed on the substrate. In some embodiments, the fourth predetermined temperature is about 130° C. and the third time period is between about 30 seconds to about 2 minutes.

After the planarized substrate305bhas reached the fourth predetermined temperature, the planarized substrate305bis removed from the first process chamber302aand placed on the second support surface308bof the second substrate support306bto rapidly (i.e., between about 5 seconds to about 10 seconds) cool the planarized substrate at a second cooling rate greater than the first cooling rate. The second processing volume304bis kept at a fifth predetermined temperature so that the planarized substrate305bis rapidly cooled when placed in the second process chamber302b. In some embodiments, the fifth predetermined temperature is between about 5° C. and about 21° C. In some embodiments, a first coolant may be flowed through the second plurality of coolant channels322bto more quickly cool the planarized substrate305b. In some embodiments, cooled process gas may optionally also be provided to the second processing volume304bthrough the second showerhead319b, which is cooled by a second coolant flowing through the first plurality of coolant channels316b. After a fourth time period, the planarized substrate305breaches the fifth predetermined temperature. In the embodiment in which the fifth predetermined temperature is about 21° C., the fourth time period is between about 5 second and 10 seconds. Subsequently, the planarized substrate305bis held at the fifth predetermined temperature for a fifth time period to ensure that the substrate will not deform back to a warped shape. In some embodiments, the fifth time period is about 1 minute.

FIG. 4is a flowchart illustrating a method400for correcting substrate deformity (i.e., flattening a substrate) in accordance with some embodiments of the present disclosure. At402, a warped substrate305ais placed on the first substrate support. At404, the warped substrate305ais rapidly (i.e., within about 5 second to about 10 seconds) heated to a first predetermined temperature. In some embodiments, the first predetermined temperature is between about 150° C. and about 220° C. In some embodiments, the first predetermined temperature is between about 160° C. and about 220° C. In some embodiments, the first predetermined temperature is between about 150° C. and about 160° C. In some embodiments, the first predetermined temperature is about 160° C. At406, the warped substrate305ais held at the first predetermined temperature for a first time period, during which the substrate deforms and becomes planarized. In the embodiment in which the first predetermined temperature is about 150° C. to about 160° C., or about 160° C., the first time period is about 10 seconds to about 2 minutes, or about 2 minutes.

At408, a temperature of the processing gas entering the first process chamber302ais decreased to a second predetermined temperature. In some embodiments, the second predetermined temperature is between about 25° C. and about 130° C. At410, the planarized substrate305bis cooled to a third predetermined temperature less than the first predetermined temperature at a first cooling rate due to the decrease in the temperature of the process gas. In some embodiments, the third predetermined temperature is about 130° C. At412, the planarized substrate305bis placed on a second substrate support306bof a second process chamber302b. At414, the planarized substrate305bis cooled to a fourth predetermined temperature less than the third predetermined temperature at a second cooling rate greater than the first cooling rate. In some embodiments, the fourth predetermined temperature is about 21° C.