Detector, detection device and method of using the same

A detector includes a substrate including a first surface and a second surface opposite to the first surface, a funnel-shaped recess extending from the second surface of the substrate to the first surface of the substrate, a conductive layer disposed below the first surface of the substrate, an insulating layer disposed between the substrate and the conductive layer, and a first through via extending through the conductive layer and the insulating layer, and coupled to the funnel-shaped recess.

BACKGROUND

In the fabrication of semiconductor integrated circuit (IC) devices, various device features such as insulating layers, conductive layers, semiconductive layers, etc., are formed on a semiconductor substrate. It is well known that the processes in which these features are formed are factors in quality of a fabricated IC device. In addition, the quality of the fabricated device and the cleanliness of the manufacturing environment in which the IC device is processed are, in turn, factors in the yield of an IC fabrication process.

The ever-increasing trend of miniaturization of semiconductor IC devices in recent years requires more stringent control of the cleanliness in the fabrication process and in the processing chamber where the process is conducted. This includes more stringent control of the maximum amount of impurities and contaminants that are allowed in a process chamber. When the dimension of a miniaturized device approaches the sub-half-micron level, even a minutest amount of contaminants can significantly reduce the yield of the IC manufacturing process. For instance, the number of particles in a chemical liquid used in the process may raise a yield issue. Further, without on-line particle detection, it is difficult to identify whether the particles come from raw material or from transportation before production processes.

DETAILED DESCRIPTION

This description of illustrative embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present disclosure. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “attached,” “affixed,” “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the disclosure are illustrated by reference to the embodiments. Accordingly, the disclosure expressly should not be limited to such embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the disclosure being defined by the claims appended hereto.

The term “nanoparticles” refers to atomic, molecular or macromolecular particles typically in the length scale of approximately 1 to 100 nanometer range. Typically, the novel and differentiating properties and functions of nanoparticles are observed or developed at a critical length scale of matter typically under 100 nm.

Particles, such as nanoparticles distributed in a chemical liquid may alter characteristics of such chemical liquid. Sometimes, the characteristics of such chemical liquid can be adjusted by introducing conductive or insulating nanoparticles. However, the particles or the nanoparticles may be unwanted and such nanoparticle contamination can result in electrical, yield and device performance degradation. A detector for obtaining the characteristics of chemical liquid or for detecting the nanoparticles distributed in a chemical liquid is therefore needed.

Nanoparticle detectors are therefore developed. In some comparative approaches, the nanoparticle detector is used mainly for conductive liquid. The term “conductive liquid” is referred to as a chemical liquid having a resistivity less than approximately milliohm centimeters (MΩkm). It is found that such nanoparticle detectors do not perform accurate detection for chemical liquids having resistivity greater than milliohm centimeters. In some comparative approaches, the nanoparticle detectors can be used to detect for high-density nanoparticles. In some instances, the term “high-density” refers to an amount greater than approximately 1000 per cubic centimeter. However, it has been found that such nanoparticle detector suffers from failure when the nanoparticle density is less than 1000 per cubic centimeter. In some comparative approaches, the detector can be a laser photo detector (UDI). However, UDI suffered from low efficiency when detecting particles having a size equal to or less than 20 nm.

The present disclosure provides a detection device and method for using the same. In some embodiments, the detection device is able to detect nanoparticles in a chemical liquid having a resistivity greater than milliohm centimeters. In some embodiments, the detection device includes a nano-capacitor. When the chemical liquid flows through the nano-capacitor, a capacitance may be changed. According to the change in the capacitance of the nano-capacitor, a presence of the nanoparticles can be determined. Further, a characteristic of the chemical liquid can be obtained. The detecting approach is dependent on different material own its different dielectric constant.

FIG.1Ais a cross-sectional view illustrating a detector according to aspects of the present disclosure,FIG.1Bis a top view of the detector inFIG.1AandFIG.1Cis a bottom view of the detector inFIG.1A. In some embodiments, a detector100ais provided. The detection device100includes a substrate110, a conductive layer120below the substrate110and an insulating layer130between the conductive layer120and the substrate110. The substrate110includes a first surface112aand a second surface112bopposite to the first surface112a. The conductive layer120is disposed below the first surface112aof the substrate110, and the insulating layer130is disposed between the conductive layer120and the first surface112aof the substrate110.

The substrate110can be a semiconductor substrate that is commonly used in semiconductor manufacturing processes, but the disclosure is not limited thereto. In some embodiment, the semiconductor substrate can be an intrinsic semiconductor substrate, but the disclosure is not limited thereto. In some embodiments, the conductive layer120can include a metal layer. In other embodiments, the conductive layer120can include a doped semiconductor layer such as a doped polysilicon layer, but the disclosure is not limited thereto. In some embodiments, a thickness T of the conductive layer120can be between approximately 1 μm and approximately 10 μm. In other embodiments, the thickness T of the conductive layer120can be between approximately 100 nm and approximately 1 μm. The conductive layer120having different thickness ranges can be used in different detections, as will be described in the following description. In some embodiments, the insulating layer130includes a silicon nitride layer, but the disclosure is not limited thereto. The insulating layer130provides sufficient chemical resistance, mechanical strength and pressure resistance such that the insulating layer130can serve as a supporting layer for the conductive layer120. In some embodiments, a thickness of the insulating layer130is between approximately 10 nm and approximately 500 nm in order to provide sufficient support, but the disclosure is not limited thereto. Further, the conductive layer120has a pattern, and the insulating layer130is exposed through the pattern of the conductive layer120, as shown inFIG.1C. In some embodiment, the pattern of the conductive layer120includes a first portion122aand a second portion122b. In some embodiments, the first portion122aand the second portion122bmay be aligned with each other. In other embodiments, the first portion122aand the second portion122bmay be arranged symmetrically, but the disclosure is not limited thereto. As shown inFIG.1C, the first portion122aand the second portion122bare separated from each other.

As shown inFIGS.1A and1B, the detector100ahas a funnel-shaped recess140extending from the second surface112bof the substrate110to the first surface112aof the substrate110, such that the insulating layer130may be exposed through the bottom of the funnel-shaped recess140. As shown inFIG.1B, the funnel-shaped recess140can have a rectangular configuration as viewed from above, but the disclosure is not limited thereto. In other embodiments, the funnel-shaped recess140can have a circular configuration or other suitable configurations as viewed from above. The funnel-shaped recess140has an upper opening142aat the second surface112band a lower opening142bat the first surface112a. Further, a width, a length or a diameter of the upper opening142ais greater than a width, a length or a diameter of the lower opening142b, as shown inFIG.1A. As shown inFIGS.1A to1C, the detector100afurther has a through via150extending through the conductive layer120and the insulating layer130. The through via150is coupled to the funnel-shaped recess140. The through via150can have a rectangular configuration as viewed from above or as viewed from below, but the disclosure is not limited thereto. Further, the through via150separates the first portion122aand the second portion122bof the conductive layer120, as shown inFIG.1C. The through via150may have a width W and a length L. In some embodiments, both of the width W and the length L are less than a width, a length or a diameter of the lower opening142b. In some embodiments, the length L of the through via150is greater than a width of the pattern of the conductive layer120such that the first portion122aand the second portion122bare entirely separated from each other by the through via150. In some embodiments, the width W of the through via150is less than or equal to approximately 100 nm, but the disclosure is not limited thereto. In some embodiments, the length L of the through via150is between approximately 100 μm and approximately 1000 μm. In other embodiments, the length L of the through via150is between approximately 1 μm and approximately 10 μm. It should be noted that the larger through via150is paired with the thicker conductive layer120. For example, when the length L of the through via150is between approximately 100 μm and approximately 1000 μm, the thickness T of the conductive layer120is between approximately 1 μm and approximately 10 μm. When the length L of the through via150is between approximately 1 μm and approximately 10 μm, the thickness of the conductive layer120can be between approximately 100 nm and approximately 1 μm. The through vias150with different lengths L can be used in different detections, as will be described in the following description.

FIG.2Ais a cross-sectional view illustrating a detector according to aspects of the present disclosure, andFIG.2Bis a bottom view of the detector inFIG.2A. It should be noted that same elements inFIGS.1A to1C and2A to2Bare indicated by the same numerals, and details of the same elements shown inFIGS.1A to1C and2A to2Bare omitted in the description ofFIGS.2A and2Bfor brevity. In some embodiments, a detector100bis provided. The detector100bincludes a substrate110, a conductive layer120and an insulating layer130between the substrate110and the conductive layer120. The substrate110has a first surface112aand a second surface112bopposite to the first surface112a, and the insulating layer130is in contact with the first surface112a. As mentioned above, the conductive layer120has a pattern, and the insulating layer130is exposed through the pattern of the conductive layer120. The detector100bfurther includes a funnel-shaped recess140extending from the second surface112bto the first surface112a. As mentioned above, the funnel-shaped recess140has an upper opening142aat the second surface112band a lower opening142bat the first surface112a, and a width of the upper opening142ais greater than a width of the lower opening142b.

The detector100bfurther includes a plurality of through vias150-1and150-2to150nextending through the conductive layer120and the insulating layer130. For example, there can be two through vias150-1and150-2, as shown inFIGS.2A and2B. The through vias150-1and150-2are both coupled to the funnel-shaped recess140but separated from each other. It should be noted that the above-mentioned pattern of the conductive layer120is formed corresponding to the through vias. For example, when there are two through vias150-1and150-2, the pattern of the conductive layer120may have a first portion122a-1and a second portion122b-1formed corresponding to the through via150-1, and the pattern of the conductive layer120may further have a first portion122a-2and a second portion122b-2formed corresponding to the through via150-2. Further, the first portion122a-1and the second portion122b-1are separated from each other by the through via150-1, and the first portion122a-2and the second portion122b-2are separated from each other by the through via150-2, as shown inFIG.2B.

Still referring toFIGS.2A and2B, the funnel-shaped recess140can have a rectangular configuration as viewed from above, but the disclosure is not limited thereto. In other embodiments, the funnel-shaped recess140can have a circular configuration or other suitable configurations as viewed from above. The through vias150-1and150-2respectively can have a rectangular configuration as viewed from above or as viewed from below, but the disclosure is not limited thereto. Each of the through vias150-1and150-2may have a width W and a length L. In some embodiments, both of the width W and the length L are less than a width, a length or a diameter of the lower opening142bof the funnel-shaped recess140. In some embodiments, the length L of the through vias150-1and150-2is greater than a width of the pattern of the conductive layer120, such that the first portion122a-1and the second portion122b-1are entirely separated from each other by the through via150-1and the first portion122a-2and the second portion122b-2are entirely separated from each other by the through via150-2. In some embodiments, the width W of the through via150is less than or equal to approximately 100 nm, but the disclosure is not limited thereto. In other embodiments, the length L of the through via150is between approximately 1 μm and approximately 10 μm. It should be noted that the smaller through via150is paired with the thinner conductive layer120, and the larger through via is paired with the thicker conductive layer120. For example, when the length L of each through vias150-1and150-2is between approximately 1 μm and approximately 10 μm, the thickness T of the conductive layer120can be between approximately 100 nm and approximately 1 μm. The different thickness ranges can be used in different detections, as will be described in the following description.

FIG.3is a bottom view illustrating a detection device according to aspects of the present disclosure. It should be noted that same elements inFIGS.2A,2B and3are indicated by the same numerals, and details of the same elements shown inFIGS.2A,2B and3are omitted in the description ofFIG.3for brevity. As shown inFIG.3, a detector100cis provided. The detection device110cmay include elements similar to those described above, and thus only the differences are detailed. In some embodiments, the first portions and the second portions of the pattern are not aligned with each other. As shown inFIG.3, in some embodiments, the first portion122a-1and the second portion122b-1are perpendicular to each other, and are separated from each other by the through via150-1. The first portion122a-2and the second portion122b-2are perpendicular to each other, and are separated from each other by the through via150-2. It should be noted that in some embodiments, the first portions122a-1and122a-2can be parallel to each other, and the second portions122b-1and122b-2can be parallel to each other, but the disclosure is not limited thereto. It should be understood that the first portions122a-1,122a-2and the second portions122b-1,122b-2of the pattern can be arranged depending on different product designs, and such details are omitted in the interest of brevity. In some embodiments, the through via150-1and the length of the through via150-2are parallel with each other, as shown inFIG.3.

FIG.4is a bottom view illustrating a detection device according to aspects of the present disclosure. It should be noted that same elements inFIGS.2A,2B and4are indicated by the same numerals, and details of the same elements shown inFIGS.2A,2B and4are omitted in the description ofFIG.4for brevity. As shown inFIG.4, a detector100dis provided. The detection device110dmay include elements similar to those described above, and thus only the differences are detailed. As mentioned above, the detector100dcan include a plurality of through vias150-1and150-2to150-nextending through the conductive layer120an the insulating layer130. For example, there are four through vias150-1,150-2,150-3and150-4in some embodiments. The through vias150-1,150-2,150-3and150-4are all coupled to the funnel-shaped recess140, but are separated from each other as shown inFIG.4. Additionally, the through vias150-1,150-2,150-3and150-4can be aligned with each other to form a straight line, but the disclosure is not limited thereto.

Still referring toFIG.4, as mentioned above, the pattern of the conductive layer120is formed corresponding to the through vias150-1,150-2,150-3and150-4. For example, when there are four through vias150-1,150-2,150-3and150-4, the pattern of the conductive layer120may have a first portion122a-1and a second portion122b-1formed corresponding to the through via150-1, a first portion122a-2and a second portion122b-2formed corresponding to the through via150-2, a first portion122a-3and a second portion122b-3formed corresponding to the through via150-3, and a first portion122a-4and a second portion122b-4formed corresponding to the through via150-4. Further, the first portion122a-1and the second portion122b-1are separated from each other by the via150-1, the first portion122a-2and the second portion122b-2are separated from each other by the through via150-2, the first portion122a-3and the second portion122b-3are separated from each other by the through via150-3, and the first portion122a-4and the second portion122b-4are separated from each other by the through via150-4, as shown inFIG.4. In some embodiments, all of the first portions122a-1to122a-4and the second portions122b-1to122b-4are separated from each other. In some embodiments, the first portion122a-1is aligned with the second portion122b-1, the first portion122a-2is aligned with the second portion122b-2, the first portion122a-3is aligned with the second portion122b-3, and the first portion122a-4is aligned with the second portion122b-4, but the disclosure is not limited thereto. In some embodiments, the first portions (i.e.,122a-1to122a-4) and the second portions (i.e.,122b-1to122b-4) are arranged symmetrically, but the disclosure is not limited thereto. It should be understood that the first portions (i.e.,122a-1to122a-4) and the second portions (i.e.,122b-1to122b-4) of the pattern can be arranged depending on different product designs, and those details are omitted for brevity.

FIG.5is a bottom view illustrating a detection device according to aspects of the present disclosure. It should be noted that same elements inFIGS.2A,2B and5are indicated by the same numerals, and details of the same elements shown inFIGS.2A,2B and5are omitted in the description ofFIG.5for brevity. As shown inFIG.5, a detector100eis provided. The detection device110emay include elements similar to those described above, and thus only the differences are detailed. As mentioned above, the detector100ecan include a plurality of through vias150-1and150-2to150-nextending through the conductive layer120and the insulating layer130. For example, there are five through vias150-1,150-2,150-3,150-4and150-5in some embodiments. The through vias150-1,150-2,150-3,150-4and150-5are all coupled to the funnel-shaped recess140, but are separated from each other as shown inFIG.5. In some embodiments, the through vias150-1,150-2,150-3,150-4and150-5can be aligned with each other to form a straight line, but the disclosure is not limited thereto. In other embodiments, the through vias150-1,150-2,150-3,150-4and150-5can be arranged dependent on different product designs. For example, the through vias150-1,150-2,150-3150-4and150-5can be arranged to form a quincunx, as shown inFIG.5, but the disclosure is not limited thereto.

Still referring toFIG.5, as mentioned above, the pattern of the conductive layer120is formed corresponding to the through vias150-1,150-2,150-3,150-4and150-5. For example, when there are five through vias150-1,150-2,150-3,150-4and150-5, the pattern of the conductive layer120may have a first portion122a-1and a second portion122b-1formed corresponding to the through via150-1, a first portion122a-2and a second portion122b-2formed corresponding to the through via150-2, a first portion122a-3and a second portion122b-3formed corresponding to the through via150-3, a first portion122a-4and a second portion122b-4formed corresponding to the through via150-4, and a first portion122a-5and a second portion122b-5formed corresponding to the through via150-5. Further, the first portion122a-1and the second portion122b-1are separated from each other by the through via150-1, the first portion122a-2and the second portion122b-2are separated from each other by the through via150-2, the first portion122a-3and the second portion122b-3are separated from each other by the through via150-3, the first portion122a-4and the second portion122b-4are separated from each other by the through via150-4, and the first portion122a-5and the second portion122b-5are separated from each other by the through via150-5as shown inFIG.5. In some embodiments, the first portions122a-1to122a-5and the second portions122b-1to122b-5are separated from each other. Further, the arrangement of the first portions122a-1to122a-5and the second portions122b-1to122b-5can be modified depending on different product designs.

FIG.6Ais a cross-sectional view of a detector illustrating a stage of a method for forming the detector according to aspects of the present disclosure, andFIG.6Bis a bottom view of the detector inFIG.6A. The detector100a,100b,100c,100dor100ecan be formed by suitable operations, therefore the following described details are provided as an example, but the disclosure is not limited thereto. Further, same elements in the aforementioned drawings andFIGS.6A and6Bcan include similar materials and be indicated by the same numerals, and therefore such details are omitted. In some embodiments, a substrate110can be provided. As shown inFIG.6A, the substrate110can include a first surface112aand a second surface112bopposite to the first surface112a. An insulating layer130is formed on the first surface112aof the substrate110. A conductive layer120can be formed on the insulating layer130. Accordingly, the insulating layer130is disposed between the substrate110and the conductive layer120. A thickness T of the conductive layer120is determined according to the length L of the through via to be formed. The relationship between the thickness T of the conductive layer120and the length L of the through via to be formed has been described above; therefore, such details are omitted for brevity. The conductive layer120is patterned to form a first portion122aand a second portion122bcoupled to each other, as shown inFIG.6B. The first portion122aand the second portion122bform a pattern, and the insulating layer130is exposed through the pattern. In some embodiments, the pattern is formed according to a quantity of through vias to be subsequently formed. For example, when there is one through via to be formed, the pattern is formed to have one first portion122aand one second portion122b. In other embodiments, when there are a plurality of through vias to be formed, a quantity of the first portions122a-1and122a-2to122a-nand a quantity of the second portions122b-1and122b-2to122b-nare respectively equal to the quantity of the through vias to be formed. In some embodiments, after forming the pattern, the substrate110, the insulating layer130and the conductive layer120are flipped over. In some embodiments, the second surface112bis therefore referred to as a top surface or an exposed surface, but the disclosure is not limited thereto.

FIG.7Ais a cross-sectional view of a detector illustrating a stage of a method for forming the detector according to aspects of the present disclosure, andFIG.7Bis a top view of the detector inFIG.7A. A funnel-shaped recess140is formed in the substrate110. In some embodiments, the funnel-shaped recess140is formed by a suitable wet etching operation, but the disclosure is not limited thereto. As described above, the funnel-shaped recess140extends through the second surface112bto the first surface112a. As shown inFIGS.7A and7B, the funnel-shaped recess140has an upper opening142aat the second surface112band a lower opening142bat the first surface112a. A width of the upper opening142ais greater than a width of the lower opening142b. Additionally, the insulating layer130is exposed through the lower opening142bof the funnel-shaped recess140.

FIG.8Ais a cross-sectional view of a detector illustrating a stage of a method for forming the detector according to aspects of the present disclosure, andFIG.8Bis a bottom view of the detector inFIG.8A. In some embodiments, a through via150is formed in the insulating layer130and the conductive layer120. As shown inFIG.8A, the through via150extends through the conductive layer120and the insulating layer130. The through via150can be formed by suitable dry etching operation, but the disclosure is not limited thereto. Further, the quantity of the through via150can be determined depending on different product requirements. Therefore, in other embodiments, a plurality of through vias150-1and150-2to150-ncan be formed in the insulating layer130and the conductive layer120. The through via150is coupled to the funnel-shaped recess140. Further, the first portion122aand the second portion122bof the conductive layer120are separated from each other by the through via150. In some embodiments, the through via150has a width W and a length L. The length L of the through via150is great enough to separate the first portion122aand the second portion122b, as shown inFIG.8B. The width W of the through via150is less than the width of the lower opening142bof the funnel-shaped recess140. It should be noted that the length L of the through via150can be modified according to different detection purposes. For example, when the detector is to detect whether a chemical liquid is contaminated or not, the length L of the through via150is between approximately 100 μm and approximately 1000 μm, but the disclosure is not limited thereto. In other embodiments, when the detector is to detect particles in the chemical liquid, the length L of the through via150is between approximately 1 μm and approximately 10 μm, but the disclosure is not limited thereto.

It should be noted that the quantity of the through vias150can be modified depending on different product designs, the length L of each of the through vias150can be modified according to different detection purposes, and the thickness T of the conductive layer120is modified corresponding to the length L of the through via150.

FIG.9is a cross-sectional view of a detection device according to aspects of the present disclosure. It should be noted that same elements in the aforementioned drawings andFIG.9are indicated by the same numerals, and details of the same elements shown in aforementioned drawings andFIG.9are omitted in the description ofFIG.9for brevity. In some embodiments, a detection device200ais provided. The detection device200acan include any combination of the aforementioned detector100a,100b,100c,100dand100e, but is not limited thereto. In some embodiments, the detection device200aincludes a first detector202aand a second detector202b. In some embodiments, the first detector202aand the second detector202bare electrically connected in parallel, but the disclosure is not limited thereto. In some embodiments, the first detector202aand the second detector202bare physically separated from each other, as shown inFIG.9, but the disclosure is not limited thereto.

The first detector202acan include a substrate210a, a conductive layer220aand an insulating layer230abetween the substrate210aand the conductive layer220a, a recess240aextending through the substrate210aand a through via250aextending through the conductive layer220aand the insulating layer230a. The conductive layer220acan have a pattern including a first portion serving as a first electrode and a second portion serving as a second electrode. Though not shown, the first portion and the second portion of the pattern can have configurations similar to those described above, and therefore repeated description of such details is omitted. As mentioned above, the first portion and the second portion of the pattern are separated from each other by the through via250a. The recess240acan be a funnel-shaped recess as mentioned above, and includes an upper opening and a lower opening as mentioned above. The insulating layer230ais exposed through the lower opening of the recess240a. In some embodiments, the insulating layer230ais exposed through a bottom of the recess240a. The through via250ais coupled to the recess240a, and a width W1of the through via250ais less than a width of the recess240a.

The second detector202bcan include a substrate210b, a conductive layer220band an insulating layer230bbetween the substrate210band the conductive layer220b, a recess240bextending through the substrate210band a plurality of through vias250b-1,250b-2extending through the conductive layer220band the insulating layer230b. The conductive layer220bcan have a pattern including first portions serving as first electrodes and second portions serving as second electrodes. Though not shown, the first portions and the second portions of the pattern can have configurations similar to those shown above, and therefore repeated description of such details is omitted. As mentioned above, the first portions and the second portions of the pattern are separated from each other by the through vias250b-1,250b-2. The recess240bcan be a funnel-shaped recess as mentioned above, and includes an upper opening and a lower opening as mentioned above. The insulating layer230bis exposed through the lower opening of the recess240b. In some embodiments, the insulating layer230bis exposed through a bottom of the recess240b. The through via250ais coupled to the recess240a, and a width W2of each of the through vias250b-1,250b-2is less than a width of the recess240b. Further, the width W2of each through via250b-1,250b-2is less than the width W1of the through via250a, as shown inFIG.9.

Still referring toFIG.9, a sum of the widths W2of the through vias250b-1,250b-2is equal to or greater than the width W1of the through via250a. It should be noted that in some embodiments, the recess240aserves as a liquid inlet and the through vias250b-1and250b-2serve as a liquid outlet. The liquid enters the detection device200afrom the recess240aand passes through the through via250aand the recess240b, and the liquid drained out through the through vias250b-1and250b-2. If the sum of the widths W2of the through vias250b-1,250b-2is less than the width W1of the through via250a, the liquid may not drain out sufficiently quickly. Consequently, stagnation may be caused in the recess240b, the through via250aand the recess240a. The detection device200atherefore suffers failure.

Referring back toFIG.9, in some embodiments, the substrates210aand210bcan include the same material, but the disclosure is not limited thereto. In some embodiments, the insulating layer230aand the insulating layer230bcan include the same insulating material, but the disclosure is not limited thereto. As mentioned above, the thicknesses of the insulating layers230aand230bare correlated to the length L of the through vias250aand250b-1,250b-2. Consequently, the thickness of the insulating layer230a, though which the bigger through via250aextends, is greater than the thickness of the insulating layer230b, though which the smaller through vias250b-1and250b-2extend. In some embodiments, the conductive layer220aand the conductive layer220bcan include the same conductive material, but the disclosure is not limited thereto. In other embodiments, the conductive layer220aand the conductive layer220bcan include different materials. For example, the conductive layer220acan include a doped semiconductor material such as doped polysilicon while the conductive layer220bincludes metal.

FIG.10is a cross-sectional view of a detection device according to aspects of the present disclosure. It should be noted that same elements inFIGS.9and10are indicated by the same numerals, and details of the same elements shown inFIGS.9and10are omitted in the description ofFIG.10for brevity. In some embodiments, a detection device200bis provided. As mentioned above, the detection device200bcan include any combination of the aforementioned detector100a,100b,100c,100dand100e, but is not limited thereto. In some embodiments, the detection device200bincludes a first detector202aand a second detector202b. In contrast to the first and second detectors202aand202bof the detection device200ashown inFIG.9, the first detector202aand the second detector202bof the detection device200bare in contact with each other. In some embodiments, the conductive layer220aof the first detector202ais in contact with the substrate210bof the second detector202b, but the disclosure is not limited thereto.

FIG.11is a cross-sectional view of a detection device according to aspects of the present disclosure. It should be noted that same elements inFIGS.9and11are indicated by the same numerals, and details of the same elements shown inFIGS.9and11are omitted in the description ofFIG.11for brevity. In some embodiments, a detection device200cis provided. As mentioned above, the detection device200ccan include any combination of the aforementioned detectors100a,100b,100c,100dand100e, but is not limited thereto. In some embodiments, the detection device200cincludes a first detector202aand a second detector202b. In contrast to the first and second detectors202aand202bof the detection device200ashown inFIG.9, the first detector202aand the second detector202bof the detection device200care in contact with each other. In some embodiments, the substrate210aof the first detector202ais in contact with the conductive layer220bof the second detector202b, but the disclosure is not limited thereto. In such embodiments, the through via250aof the first detector202aserves as a liquid inlet while the recess240bof the second detector202bserves as liquid outlet. It should be noted that because a sum of the widths W2of the through vias250b-1,250b-2is equal to or greater than the width W1of the through via250a, when the liquid enters the detection device200cfrom the through via250aand passes through the recess240aand the through vias250b-1,250b-2, the liquid can drain out through the through vias250b-1and250b-2. In some comparative approaches, if the sum of the widths W2of the through vias250b-1,250b-2is less than the width W1of the through via250a, the liquid may not drain out sufficiently quickly. Consequently, stagnation may be caused in the recess240aand the through via250a. The detection device200ctherefore suffers failure.

FIG.12is a cross-sectional view of a detection device according to aspects of the present disclosure. It should be noted that same elements inFIGS.11and12are indicated by the same numerals, and details of the same elements shown inFIGS.11and12are omitted in the description ofFIG.12for brevity. In some embodiments, a detection device200dis provided. As mentioned above, the detection device200dcan include any combination of the aforementioned detector100a,100b,100c,100dand100e, but is not limited thereto. In some embodiments, the detection device200dincludes a first detector202aand a second detector202b. In contrast to the detection device200cshown inFIG.11, the detection device200dfurther includes a layer260. The layer260serves as a sealing layer or a packaging material for supporting and integrating the detectors202aand202b. In some embodiments, the layer260can include a print circuit board (PCB). In other embodiments, the layer260can include plastic materials such as perfluoroalkoxy alkanes (PFA) or Polytetrafluoroethene (PTFE). In some embodiments, the substrate210bis disposed between the insulating layer230band the dielectric layer260. In some embodiments, the dielectric layer260includes a plurality of holes262-1and262-2to262-n. It should be noted that a quantity of the holes262-1and262-2to262-nis equal to the quantity of the through vias250b-1and250b-2to250b-nof the second detector202b. For example, when there are two through vias250b-1and250b-2in the second detector202b, there are two holes262-1and262-2in the dielectric layer260. The holes262-1and262-2are all coupled to the recess240b. In some embodiments, each of the holes262-1and262-2is aligned with one of the through vias250b-1and250b-2, but the disclosure is not limited thereto. In some embodiments, the holes262-1and262-2respectively include a length, a diameter or a width W3, and the width W3of the holes262-1and262-2is equal to or greater than the width W2of the through vias250b-1and250b-2.

Still referring toFIG.12, in such embodiments, the holes262-1and262-2serves as a liquid outlet. It should be noted that because the width W3of the holes262-1and262-2is equal to or greater than the width W2of the through vias250b-1and250b-2, a sum of the widths W3of the holes262-1and262-2is equal to or greater than the width W1of the through via250a. Therefore, when the liquid enters the detection device200dfrom the through via250aand passes through the recess240a, the through vias250b-1,250b-2and the recess240b, the liquid can drain out through the holes262-1and262-2. Accordingly, liquid stagnation in the recess240b, the through vias250b-1,250b-2, the recess240aand the through via250acan be mitigated.

FIG.13is a cross-sectional view of a detection device according to aspects of the present disclosure. It should be noted that same elements inFIGS.9and13are indicated by the same numerals, and details of the same elements shown inFIGS.9and13are omitted in the description ofFIG.13for brevity. In some embodiments, a detection device200eis provided. As mentioned above, the detection device200ecan include any combination of the aforementioned detectors100a,100b,100c,100dand100e, but not limited thereto. In some embodiments, the detection device200eincludes a first detector202aand a second detector202b. The first detector202aincludes a substrate, a conductive layer and an insulating layer between the substrate and the conductive layer, while the second detector202bincludes a substrate, a conductive layer and an insulating layer between the conductive layer and the substrate. In such embodiments, the substrate of the first detector202ais in contact with the substrate of the second detector202bto form a substrate210, the conductive layer of the first detector202ais in contact with the conductive layer of the second detector202bto form a conductive layer220, and the insulating layer of the first detector202ais in contact with the insulating layer of the second detector202bto form an insulating layer230, as shown inFIG.13. The first detector202aincludes a recess240aextending through the substrate210and the second detector202bincludes a recess240bextending through the substrate210. The recess240aand the recess240bare separated from each other. The first detector202aincludes a through via250aextending through the conductive layer220and the insulating layers230, and the second detector202bincludes a plurality of through vias250bextending through the conductive layer220and the insulating layers230. The through vias250a,250b-1and250b-sare all separated from each other. The through via250ais coupled to the recess240a, and the through vias250bare coupled to the recess240b. Further, a width W2of the through vias250b-1,250b-2is less than a width W1of the through via250afor different detection purposes. In such embodiments, both of the recess240aof the first detector202aand the recess240bof the second detector202bserve as liquid inlets, and all of the through vias250a,250b-1,250b-2of the first detector202aand second detector202bserve as liquid outlets.

FIG.14is a flowchart representing a method for detecting particles in a chemical liquid10according to aspects of the present disclosure. In some embodiments, the method10can be used to detect purity or characteristic of the chemical liquid. The method10includes a number of operations (11,12,13,14,15aand15b). The method10will be further described according to one or more embodiments. It should be noted that the operations of the method10may be rearranged or otherwise modified within the scope of the various aspects. It should be further noted that additional processes may be provided before, during, and after the method10, and that some other processes may be only briefly described herein. Thus, other implementations are possible within the scope of the various aspects described herein.

The method for detecting particles in a chemical liquid10can be performed with the above-mentioned detection device200a,200b,200c,200dor200e, but is not limited thereto. Further, the method for detecting particles in a chemical liquid10can be performed by the first detector202ain any combination in the detection device200a,200b,200c,200dor200e.

FIG.15is a schematic drawing illustrating a portion of the detection device in some embodiments of the method for detecting particles in a chemical liquid according to aspects of the present disclosure, andFIGS.16A and16Bare diagrams illustrating detection results according to aspects of the present disclosure. At operation11, a detection device is provided. In some embodiments, the detection device include a detector such as the first detector202a, wherein the first detector202ahas a through via250awith a length L between approximately 100 μm and approximately 1000 μm.

At operation12, a chemical liquid300is provided to flow through the detection device, i.e., the first detector202a. As shown inFIG.15, the chemical liquid300flows through the through via250a.

At operation13, a capacitance of the detection device is measured during the flowing of the chemical liquid. It should be noted that in the first detector202a, the conductive layer220has the pattern having a first portion and a second portion separated from each other by the through via250a. With the chemical liquid300passing through the through via250a, the conductive layer220having the pattern works as a capacitor with the first portion as a first electrode, the second portion as a second electrode, and the chemical liquid300as a dielectric material therebetween. A capacitance can be obtained during the flowing of the chemical liquid300through the through via250a. In some embodiments, the capacitor formed by the first electrode, the second electrode and the chemical liquid300has a capacitance equal to or greater than approximately 1 nanofarad (nF). In some embodiments, such capacitor is referred to as an nano-capacitor.

At operation14, a dielectric constant of the chemical liquid300is calculated according to the capacitances of the detection device. It is understood that a capacitance of a capacitor is correlated to a dielectric constant of the dielectric material and the distance between the two electrodes. In some embodiments, because the distance between the two electrodes is fixed, the dielectric constant of the dielectric material serves as a main parameter of the capacitance. Accordingly, the dielectric constant of the chemical liquid300can be obtained during the flowing of the chemical liquid300through the detection device, i.e., the first detector202a.

Referring toFIGS.16A and16B, in some embodiments, a diagram illustrating the detection result can be obtained. The abscissa of the diagram can be the time during which the chemical liquid passes through the through via250a, and the ordinate can be the dielectric constant calculated according to the capacitance of the detection device. At operation15a, when the dielectric constant of the chemical liquid is between an upper limit and a lower limit, as shown inFIG.16A, the chemical liquid300is determined to be normal. In some embodiments, when the dielectric constant of the chemical liquid300is greater than the upper limit or less than the lower limit, as shown inFIG.16B, the chemical liquid is determined to be abnormal.

It should be noted that, by observing the dielectric constant of the chemical liquid300, it is easy to determine a characteristic of the chemical liquid300. For example, when the dielectric constant of the chemical liquid300is between the upper limit and the lower limit, as shown inFIG.16A, it can be concluded that the chemical liquid has been produced, stored or transported without contamination or with low contamination, and the characteristic of the chemical liquid remains unaffected. When the dielectric constant of the chemical liquid300is greater than the upper limit or less than the lower limit, as shown inFIG.16B, it can be concluded that particles or contamination are in the chemical liquid300, and such particles or contamination has altered the characteristic of the chemical liquid300and thus the dielectric constant of the chemical liquid300is changed.

FIG.17is a flowchart representing a method for detecting particles in a chemical liquid20according to aspects of the present disclosure. In some embodiments, the method20can be used to detect purity or characteristic of the chemical liquid. The method20includes a number of operations (21,22,23,24,25,26aand26b). The method20will be further described according to one or more embodiments. It should be noted that the operations of the method20may be rearranged or otherwise modified within the scope of the various aspects. It should be further noted that additional processes may be provided before, during, and after the method20, and that some other processes may be only briefly described herein. Thus, other implementations are possible within the scope of the various aspects described herein.

The method for detecting particles in a chemical liquid20can be performed with the above-mentioned detection device200a,200b,200c,200dor200e, but is not limited thereto. Further, the method for detecting particles in a chemical liquid20can be performed by the second detector202bin any combination in the detection device200a,200b,200c,200dor200e.

FIG.18is a schematic drawing illustrating a portion of the detection device in some embodiments of the method for detecting particles in a chemical liquid according to aspects of the present disclosure, andFIGS.19A and19Bare diagrams illustrating detection results according to aspects of the present disclosure. At operation21, a detection device is provided. In some embodiment, the detection device includes a detector such as the second detector202b, wherein the second detector202bhas a through via250bwith a length L between approximately 1 μm and approximately 10 μm.

At operation22, a chemical liquid300is provided to flow through the detection device. As shown inFIG.18, the chemical liquid300flows through the through via250b.

At operation23, a capacitance of the detection device is measured during the flowing of the chemical liquid. It should be noted that in the second detector202b, the conductive layer220has a pattern having a first portion and a second portion separated from each other by the through via250b. With the chemical liquid300passing through the through via250b, the conductive layer220having the pattern works as a capacitor with the first portion as a first electrode, the second portion as a second electrode, and the chemical liquid300as a dielectric material therebetween. A capacitance can be obtained during the flowing of the chemical liquid through the through via250b-1. In some embodiments, the capacitor formed by the first electrode, the second electrode and the chemical liquid300has a capacitance less than or equal to approximately 0.01 picofarad (pF). In some embodiments, such capacitor is referred to as an nano-capacitor.

At operation24, a dielectric constant of the chemical liquid300is calculated according to the capacitance of the detection device. As mentioned above, a capacitance of a capacitor is correlated to a dielectric constant of the dielectric material and the distance between the two electrodes. In some embodiments, because the distance between the two electrodes is fixed, the dielectric constant of the dielectric material serves as a main parameter of the capacitance. Accordingly, the dielectric constant of the chemical liquid300can be obtained during the flowing of the chemical liquid300through the detection device, i.e., the second detector202b.

At operation25, in some embodiments, the dielectric constant of the chemical liquid300may change during the flowing of the chemical liquid300through the detection device. In such embodiments, such dielectric constant changes are calculated and recorded.

Referring toFIGS.19A and19B, in some embodiments, a diagram illustrating the detection result can be obtained. The abscissa of the diagram can be the time during which the chemical liquid passes through the through via250band the ordinate can be the dielectric constants calculated according to the capacitances of the detection device. At operation26a, when the dielectric constant of the chemical liquid is between an upper limit and a lower limit, as shown inFIG.18A, the chemical liquid300is determined to be normal. Further, at operation26a, when a quantity of the dielectric constant changes is less than a value, the chemical liquid300is determined to be normal. In some embodiments, when the quantity of the dielectric constant changes is greater than the value, as shown inFIG.19B, the chemical liquid300is determined to be abnormal.

Because the particles may alter the characteristic of the chemical liquid300and change the dielectric constant of the chemical liquid300, it is easy to determine whether there are particles in the chemical liquid300by observing the dielectric constant of the chemical liquid300. In some embodiments, when the dielectric constant of the chemical liquid300is between the upper limit and the lower limit, as shown inFIG.19A, it can be concluded that the chemical liquid300has been produced, stored or transported without particles or with few particles. In other embodiments, when the dielectric constant of the chemical liquid300is greater than the upper limit or less than the lower limit, it can be concluded that particles or contamination are in the chemical liquid300, and such particles have altered the characteristic of the chemical liquid300and thus the dielectric constant of the chemical liquid300is changed.

In some embodiments, when the particles are nano-particles, such particles may not be sufficient to alter the dielectric constant of the chemical liquid300beyond the upper or lower limits, but does cause dielectric constant to change. In such embodiments, the dielectric constant changes are recorded, as shown inFIG.19B. In some embodiments, when the quantity of the dielectric constant changes is less than a value, it is concluded that an quantity of the nano-particles in the chemical liquid300is not sufficient to cause an unstable dielectric constant, and the chemical liquid300can be determined to be normal. In some embodiments, when the quantity of the dielectric constant changes is greater than a value, it is concluded that an amount of the nano-particles in the chemical liquid300is sufficient to cause the unstable dielectric constant, and the chemical liquid300can be determined to be abnormal.

It will be appreciated that in the foregoing methods10and20, the chemical liquid to be tested can be a liquid having a dielectric constant less than 100, but the disclosure is not limited thereto. In some embodiments, the chemical liquid to be tested can be a liquid having a dielectric constant less than 80, but the disclosure is not limited thereto.

It will be appreciated that in the forgoing methods, the detection device can include the first detector202aand the second detector202bsuch that when the chemical liquid300flows into the detection device, the chemical liquid300passes through the bigger through via250aand the smaller through vias250b. Accordingly, characteristics and potential dielectric constant changes are both obtained. Accordingly, the contamination caused by particles or nano-particles can be easily detected at early stage.

According to one embodiment of the present disclosure, a detector is provided. The detector includes a substrate including a first surface and a second surface opposite to the first surface, a funnel-shaped recess extending from the second surface of the substrate to the first surface of the substrate, a conductive layer disposed below the first surface of the substrate, an insulating layer disposed between the substrate and the conductive layer, and a first through via extending through the conductive layer and the insulating layer, and coupled to the funnel-shaped recess.

According to one embodiment of the present disclosure, a detection device is provided. The detection device includes a first detector and a second detector. The first detector includes a first substrate having a first recess, a first conductive layer, a first insulating layer disposed between the first substrate and the first conductive layer, and a first through via extending through the first conductive layer and the first insulating layer. In some embodiments, a portion of the first insulating layer is exposed through a bottom of the first recess. In some embodiments, the first through via is coupled to the first recess. The second detector includes a second substrate having a second recess, a second conductive layer, a second insulating layer disposed between the second substrate and the second conductive layer, and a plurality of second through vias extending through the second conductive layer and the second insulating layer. In some embodiments, a portion of the second insulating layer is exposed through a bottom of the second recess. In some embodiments, the second through vias are coupled to the second recess. In some embodiments, the first through via has a first width, each of the second through vias has a second width, and the second width is less than the first width.

According to one embodiment of the present disclosure, a method for detecting particles in a liquid is provided. The method includes following operations. A detection device is provided. A chemical liquid is provided to flow through the detection device. A capacitance of the detection device is measured during the flowing of the chemical liquid. A dielectric constant of the chemical liquid is calculated according to the capacitance of the detection device. When the dielectric constant of the chemical liquid is between an upper limit and a lower limit, the chemical liquid is determined to be normal.