POLISHING APPARATUS

A polishing apparatus is provided. The polishing apparatus includes a platen. The polishing apparatus includes a polishing pad coupled to the platen and configured to be rotated by the platen. The polishing apparatus includes a first pad conditioner in contact with a polishing surface of the polishing pad. The polishing apparatus includes a second pad conditioner in contact with the polishing surface.

BACKGROUND

Semiconductor devices are formed on, in, and/or from semiconductor wafers, and are used in a multitude of electronic devices, such as mobile phones, laptops, desktops, tablets, watches, gaming systems, and various other industrial, commercial, and consumer electronics. One or more semiconductor fabrication processes are performed to form semiconductor devices on, in, and/or from a semiconductor wafer.

DETAILED DESCRIPTION

The term “overlying” and/or the like may be used to describe one element or feature being vertically coincident with and at a higher elevation than another element or feature. For example, a first element overlies a second element if the first element is at a higher elevation than the second element and at least a portion of the first element is vertically coincident with at least a portion of the second element.

In some embodiments, a polishing apparatus includes a platen and a polishing pad coupled to the platen and configured to be rotated by the platen for polishing a semiconductor wafer. The polishing apparatus includes a first pad conditioner and a set of supplementary pad conditioners for conditioning the polishing pad. The set of supplementary pad conditioners include one or more supplementary pad conditioners to provide for improved control and/or customizability of a thickness profile of the polishing pad. In some embodiments, the set of supplementary pad conditioners are used to condition an edge portion of the polishing surface for improved edge thickness profile customizability of the polishing pad over a tool life of the polishing pad. In some embodiments, the set of supplementary pad conditioners provide for quicker pad conditioning of the polishing pad as compared to merely using the first pad conditioner to condition the polishing pad, thereby providing for at least one of reduced conditioning time required to prepare the polishing pad for use in polishing a semiconductor wafer, increased production capacity and/or throughput of the polishing apparatus, etc.

FIG. 1 illustrates a polishing apparatus 100 according to some embodiments. In some embodiments, the polishing apparatus 100 is configured to perform a polishing process to polish a first semiconductor wafer 132. In some embodiments, the polishing process comprises a chemical mechanical planarization (CMP) process. In some embodiments, the polishing process is performed to homogenize and/or planarize a first surface of the first semiconductor wafer 132 using a combination of chemical and mechanical forces. Embodiments are contemplated in which items different than a semiconductor wafer are polished using the polishing apparatus 100.

In some embodiments, the polishing apparatus 100 comprises at least one of a platen 110 configured to support a polishing pad 120, the polishing pad 120 configured to be rotated by the platen 110, a wafer holder 130 configured to support the first semiconductor wafer 132 in a polishing position relative to a polishing surface 121 of the polishing pad 120 for polishing of the first semiconductor wafer 132, a first pad conditioner 102 configured to condition the polishing pad 120, a second pad conditioner 112 configured to condition the polishing pad 120, or a slurry provider 122 configured to provide a slurry 134 to the polishing surface 121 of the polishing pad 120. FIG. 1 depicts the first semiconductor wafer 132 in the polishing position in accordance with some embodiments.

In some embodiments, the first semiconductor wafer 132 comprises at least one of a substrate, a photomask, a semiconductor device, a dielectric layer, an epitaxial layer, a silicon-on-insulator (SOI) structure, a semiconductor layer, a conductive material layer, a die, etc. The first semiconductor wafer 132 comprises at least one of silicon, germanium, carbide, arsenide, gallium, arsenic, phosphide, indium, antimonide, SiGe, SiC, GaAs, GaN, GaP, InGaP, InP, InAs, InSb, GaAsP, AllnAs, AlGaAs, GalnAs, GalnP, GalnAsP, or other suitable material. The first semiconductor wafer 132 comprises at least one of monocrystalline silicon, crystalline silicon with a <100> crystallographic orientation, crystalline silicon with a <110> crystallographic orientation, crystalline silicon with a <111> crystallographic orientation or other suitable material. Other structures and/or configurations of the first semiconductor wafer 132 are within the scope of the present disclosure. In some embodiments, the polishing process performed using the polishing apparatus 100 polishes the first surface of the first semiconductor wafer 132 comprising at least one of a surface of the substrate, a surface of the photomask, a surface of the semiconductor device, a surface of the dielectric layer, a surface of the epitaxial layer, a surface of the SOI structure, a surface of the semiconductor layer, a surface of the conductive material layer, etc.

In some embodiments, the polishing pad 120 is configured to be driven by the platen 110 to rotate in a first rotational direction 154 about an axis 150. In some embodiments, the polishing pad 120 and the platen 110 rotate synchronously in the first rotational direction 154 about the axis 150. In some embodiments, the platen 110 is rotated using a first driving mechanism (not shown), such as a motor configured to drive a cylinder 140 coupled to the platen 110, to rotate the polishing pad 120 about the axis 150.

In some embodiments, the slurry provider 122 comprises at least one of a slurry provider arm 125 or a slurry outlet 123. In some embodiments, the slurry outlet 123 comprises a nozzle. In some embodiments, the slurry provider arm 125 controls a position of the slurry outlet 123 relative to the polishing surface 121 while providing the slurry 134 to the polishing surface 121 of the polishing pad 120. In some embodiments, the slurry provider 122 is connected to a reservoir (not shown) containing the slurry 134, which is conducted from the reservoir to the slurry outlet 123 for application to the polishing pad 120. In some embodiments, the slurry 134 comprises a liquid comprising at least one of one or more polishing particles or one or more reactive chemicals.

The polishing pad 120 comprises a porous material, such as porous polyurethane foam. Other materials of the polishing pad 120 are within the scope of the present disclosure. In some embodiments, a hardness of the polishing pad 120 is at least one of (i) harder than a first threshold hardness to allow at least one of the polishing pad 120 or the slurry 134 to polish, such as mechanically and/or chemically polish, the first surface of the first semiconductor wafer 132, or (ii) softer than a second threshold hardness to mitigate scratching the first surface of the first semiconductor wafer 132. In some embodiments, the polishing pad 120 is removably coupled to the platen 110. In some embodiments, the polishing pad 120 is coupled to the platen 110 using an adhesive.

In some embodiments, the wafer holder 130 comprises at least one of a wafer holder head 128, a wafer holder cylinder 124, or a wafer holder union 126 between the wafer holder head 128 and the wafer holder cylinder 124. In some embodiments, the wafer holder 130 exerts a wafer polishing force onto the first semiconductor wafer 132 in a direction 152 towards the polishing pad 120. In some embodiments, the direction 152 of the wafer polishing force is about parallel to the axis 150. In some embodiments, when the first semiconductor wafer 132 is in the polishing position relative to the polishing surface 121, the first semiconductor wafer 132 is in contact with the polishing surface 121. In some embodiments, the wafer holder 130 is configured to rotate at least one of the wafer holder head 128 or the first semiconductor wafer 132 in a second rotational direction 156. In some embodiments, the first rotational direction 154 and the second rotational direction 156 are the same rotational direction (e.g., clockwise or counterclockwise). Embodiments are contemplated in which the first rotational direction 154 and the second rotational direction 156 are different rotational directions (e.g., one is clockwise and the other is counterclockwise). In some embodiments, the first semiconductor wafer 132 is rotated by the wafer holder 130 using a second driving mechanism (not shown), such as a motor configured to drive the wafer holder cylinder 124.

In some embodiments, during the polishing process, at least one of (i) the slurry provider 122 provides the slurry 134 to the polishing surface 121, (ii) the first semiconductor wafer 132 and the polishing pad 120 are rotated, or (iii) the slurry 134 flows between the first semiconductor wafer 132 and the polishing pad 120 as the first semiconductor wafer 132 and the polishing pad 120 are rotated. In some embodiments, the polishing process polishes the first surface of the first semiconductor wafer 132 by at least one of (i) mechanical force between polishing particles of the slurry 134 and the first surface of the first semiconductor wafer 132, (ii) mechanical force between the polishing pad 120 and the first surface of the first semiconductor wafer 132, or (iii) chemical reaction between reactive chemicals of the slurry 134 and the first surface of the first semiconductor wafer 132.

In some embodiments, the first pad conditioner 102 comprises at least one of a first pad conditioner arm 104, a first pad conditioner head 107, a first head carrier 106 configured to hold the first pad conditioner head 107, or a first pad conditioner cylinder 108. In some embodiments, at least one of the first pad conditioner arm 104, the first pad conditioner head 107, or the first head carrier 106 overlie the polishing pad 120. In some embodiments, the first pad conditioner head 107 is in contact with the polishing surface 121 of the polishing pad 120. In some embodiments, the first pad conditioner 102 is configured to rotate at least one of the first head carrier 106 or the first pad conditioner head 107 in a third rotational direction 160. In some embodiments, the first rotational direction 154 and the third rotational direction 160 are the same rotational direction (e.g., clockwise or counterclockwise). Embodiments are contemplated in which the first rotational direction 154 and the third rotational direction 160 are different rotational directions (e.g., one is clockwise and the other is counterclockwise). In some embodiments, the first pad conditioner head 107 is rotated using a third driving mechanism (not shown) of the first pad conditioner 102, such as a motor configured to rotate the first head carrier 106. A first rotation speed with which the first pad conditioner head 107 is rotated in the third rotational direction 160 is between about zero rotations per minute to about 150 rotations per minute. Other values of the first rotation speed are within the scope of the present disclosure.

In some embodiments, the first pad conditioner head 107 is configured to exert a first pad conditioning force onto the polishing pad 120. In some embodiments, the first pad conditioning force is exerted onto the polishing pad 120 in the direction 152 towards the polishing pad 120. In some embodiments, the first pad conditioning force is exerted onto the polishing pad 120 using a fourth driving mechanism (not shown) of the first pad conditioner 102, such as a motor configured to move the first pad conditioner head 107 in the (downwards) direction 152 and/or a (upwards) direction opposite to the direction 152. The first pad conditioning force is at least one of (i) between about 0 newtons to about 150 newtons, (ii) between about 2 newtons to about 110 newtons, or (iii) between about 1 newton to about 100 newtons. In some embodiments, the first pad conditioning force corresponds to a down force of the first pad conditioner 102. Other values of the first pad conditioning force are within the scope of the present disclosure.

In some embodiments, the first pad conditioner arm 104 is configured to oscillate the first head carrier 106 and the first pad conditioner head 107. In some embodiments, the first pad conditioner arm 104 oscillates the first head carrier 106 and the first pad conditioner head 107 using a fifth driving mechanism (not shown) of the first pad conditioner 102, such as a motor coupled to the first pad conditioner cylinder 108.

FIGS. 2A-2D illustrate top views of the polishing pad 120, in accordance with some embodiments. FIG. 2A illustrates a top view of the first pad conditioner 102 relative to the polishing pad 120 when the first pad conditioner arm 104 is used to oscillate the first head carrier 106 and the first pad conditioner head 107 along a first oscillation path 206 between a first position 204 relative to the polishing surface 121 and a second position 216 relative to the polishing surface 121. In some embodiments, the first pad conditioner cylinder 108 swings the first pad conditioner arm 104 to oscillate the first head carrier 106 and the first pad conditioner head 107 along the first oscillation path 206. A first oscillation angle 208 associated with the first oscillation path 206 is between about 0 degrees to about 100 degrees. Other values of the first oscillation angle 208 are within the scope of the present disclosure. In some embodiments, the first oscillation angle 208 corresponds to an angle between (i) the first pad conditioner arm 104 when the first head carrier 106 and the first pad conditioner head 107 have the first position 204 relative to the polishing surface 121, and (ii) the first pad conditioner arm 104 when the first head carrier 106 and the first pad conditioner head 107 have the second position 216 relative to the polishing surface 121. A first distance 210 between an edge 119 of the polishing surface 121 and a closest position, along the first oscillation path 206, of the first pad conditioner head 107 is at least one of (i) at most about 200 millimeters, (ii) at most about 100 millimeters, (iii) at most about 50 millimeters, or (iv) at most about 30 millimeters. In some embodiments, the closest position of the first pad conditioner head 107 to the edge 119 is at least one of the first position 204, the second position 216, or other position of the first pad conditioner head 107 along the first oscillation path 206. Other values of the first distance 210 are within the scope of the present disclosure. In some embodiments, along at least some of the first oscillation path 206, the first pad conditioner head 107 overlies the edge 119 of the polishing surface 121 such that the first distance 210 is zero millimeters.

In some embodiments, the first pad conditioner head 107 performs a first conditioning process to condition at least a first portion of the polishing surface 121 of the polishing pad 120 in which at least one of (i) the first pad conditioner head 107 is in contact with the polishing surface 121 of the polishing pad 120, (ii) the first pad conditioner head 107 is rotated in the third rotational direction 160, or (iii) the first pad conditioner head 107 is oscillated along the first oscillation path 206. In some embodiments, the first conditioning process at least one of (i) planarizes at least some of the first portion of the polishing surface 121 using the first pad conditioner head 107, (ii) removes contaminants from the first portion of the polishing surface 121 using the first pad conditioner head 107, wherein the contaminants comprise at least one of byproducts and/or residue from a semiconductor wafer polished using the polishing pad 120, or byproducts and/or residue from the slurry 134 provided by the slurry provider 122, (iii) removes defects from the first portion of the polishing surface 121 using the first pad conditioner head 107, or (iv) removes a portion of the polishing pad 120 to adjust and/or reduce a thickness of at least a portion of the polishing pad 120.

FIG. 2B illustrates the first portion (shown as a patterned region with reference number 224) of the polishing surface 121 in accordance with some embodiments in which the first portion 224 conditioned by the first pad conditioner head 107 is separated from the edge 119 of the polishing surface 121 by a second distance 222. The second distance 222 is at least one of (i) at most about 200 millimeters, (ii) at most about 100 millimeters, (iii) at most about 50 millimeters, or (iv) at most about 30 millimeters. Other values of the second distance 222 are within the scope of the present disclosure. In some embodiments, the first portion 224 of the polishing surface 121 comprises the edge 119 of the polishing surface 121. FIG. 2C illustrates the first portion (shown with reference number 224) of the polishing surface 121 in accordance with some embodiments in which the first portion 224 of the polishing surface 121 comprises the edge 119 of the polishing surface 121.

In some embodiments, the second pad conditioner 112 comprises at least one of a second pad conditioner arm 114, a second pad conditioner head 117, a second head carrier 116 configured to hold the second pad conditioner head 117, or a second pad conditioner cylinder 118. In some embodiments, at least one of the second pad conditioner arm 114, the second pad conditioner head 117 or the second head carrier 116 overlie the polishing pad 120. In some embodiments, the second pad conditioner head 117 is in contact with the polishing surface 121 of the polishing pad 120. In some embodiments, the second pad conditioner 112 is configured to rotate at least one of the second head carrier 116 or the second pad conditioner head 117 in a fourth rotational direction 158. In some embodiments, the third rotational direction 160 and the fourth rotational direction 158 are the same rotational direction (e.g., clockwise or counterclockwise). Embodiments are contemplated in which the third rotational direction 160 and the fourth rotational direction 158 are different rotational directions (e.g., one is clockwise and the other is counterclockwise). In some embodiments, the second pad conditioner head 117 is rotated using a sixth driving mechanism (not shown) of the second pad conditioner 112, such as a motor configured to rotate the second head carrier 116. A second rotation speed with which the second pad conditioner head 117 is rotated in the fourth rotational direction 158 is between about zero rotations per minute to about 150 rotations per minute. Other values of the second rotation speed are within the scope of the present disclosure.

In some embodiments, the second pad conditioner head 117 is configured to exert a second pad conditioning force onto the polishing pad 120. In some embodiments, the second pad conditioning force is exerted onto the polishing pad 120 in the direction 152 towards the polishing pad 120. In some embodiments, the second pad conditioning force is exerted onto the polishing pad 120 using a seventh driving mechanism (not shown) of the second pad conditioner 112, such as a motor configured to move the second pad conditioner head 117 in the (downwards) direction 152 and/or a (upwards) direction opposite to the direction 152. The second pad conditioning force is at least one of (i) between about 0 newtons to about 150 newtons, (ii) between about 2 newtons to about 110 newtons, or (iii) between about 1 newton to about 100 newtons. Other values of the second pad conditioning force are within the scope of the present disclosure. In some embodiments, the second pad conditioning force corresponds to a down force of the second pad conditioner 112.

In some embodiments, the second pad conditioner arm 114 is configured to oscillate the second head carrier 116 and the second pad conditioner head 117. In some embodiments, the second pad conditioner arm 114 oscillates the second head carrier 116 and the second pad conditioner head 117 using an eighth driving mechanism (not shown) of the second pad conditioner 112, such as a motor coupled to the second pad conditioner cylinder 118. In some embodiments, the second pad conditioner arm 114 oscillates the second head carrier 116 and the second pad conditioner head 117 along a second oscillation path (not shown) between a third position (not shown) relative to the polishing surface 121 and a fourth position (not shown) relative to the polishing surface 121. In some embodiments, the second pad conditioner cylinder 118 swings the second pad conditioner arm 114 to oscillate the second head carrier 116 and the second pad conditioner head 117 along the second oscillation path. A second oscillation angle (not shown) associated with the second oscillation path is between about 0 degrees to about 100 degrees. Other values of the second oscillation angle are within the scope of the present disclosure. In some embodiments, the second oscillation angle corresponds to an angle between (i) the second pad conditioner arm 114 when the second head carrier 116 and the second pad conditioner head 117 have the third position relative to the polishing surface 121, and (ii) the second pad conditioner arm 114 when the second head carrier 116 and the second pad conditioner head 117 have the fourth position relative to the polishing surface 121.

In some embodiments, the second pad conditioner head 117 performs a second conditioning process to condition at least a second portion of the polishing surface 121 of the polishing pad 120 in which at least one of (i) the second pad conditioner head 117 is in contact with the polishing surface 121 of the polishing pad 120, (ii) the second pad conditioner head 117 is rotated in the fourth rotational direction 158, or (iii) the second pad conditioner head 117 is oscillated along the second oscillation path. In some embodiments, the second conditioning process at least one of (i) planarizes at least some of the second portion of the polishing surface 121 using the second pad conditioner head 117, (ii) removes contaminants from the second portion of the polishing surface 121 using the second pad conditioner head 117, wherein the contaminants comprise at least one of byproducts and/or residue from a semiconductor wafer polished using the polishing pad 120, or byproducts and/or residue from the slurry 134 provided by the slurry provider 122, (iii) removes defects from the second portion of the polishing surface 121 using the first pad conditioner head 107, or (iv) removes a portion of the polishing pad 120 to adjust and/or reduce a thickness of at least a portion of the polishing pad 120.

In some embodiments, at least some of the first conditioning process performed using the first pad conditioner 102 and at least some of the second conditioning process performed using the second pad conditioner 112 are performed concurrently. In some embodiments, at least some of the first conditioning process performed using the first pad conditioner 102 and at least some of the second conditioning process performed using the second pad conditioner 112 are performed separately, such as during separate time periods.

In some embodiments, the second portion of the polishing surface 121 conditioned using the second pad conditioner 112 is different than first portion 224 conditioned using the first pad conditioner 102. In some embodiments, the second portion and the first portion 224 at least partially overlap. In some embodiments, the second portion is larger than the first portion 224 at least partially overlap. In some embodiments, the second oscillation path of the second pad conditioner 112 is different than the first oscillation path 206 such that at least one of (i) the second pad conditioner 112 and the first pad conditioner 102 do not collide, or (ii) the second pad conditioner 112 conditions a different, such as larger, portion of the polishing surface 121. FIG. 2D illustrates the second portion (shown as a patterned region with reference number 234) of the polishing surface 121 relative to an inner boundary 225 of the first portion 224 shown as a dashed circle, in accordance with some embodiments. In some embodiments, the first portion 224 is a sub-portion, of the second portion 234, that is proximal the edge 119 (e.g., the second portion spans an entirety of the first portion 224).

FIGS. 3A-3D illustrate side views of the first pad conditioner 102 in accordance with some embodiments. The first pad conditioner head 107 comprises at least one of a diamond disk, a brush, a first pad, a sponge or other type of pad conditioner head. FIG. 3A illustrates the first pad conditioner 102 according to some embodiments in which the first pad conditioner head 107 comprises the diamond disk. In some embodiments, the diamond disk comprises a substrate, such as a metal disk, and one or more diamond abrasives embedded and/or encapsulated on the substrate. A length 306 of the diamond disk is between about 30 millimeters to about 200 millimeters. Other values of the length 306 are within the scope of the present disclosure. In some embodiments, the diamond disk contacts the polishing surface 121 of the polishing pad 120 when the first pad conditioner 102 is used to condition the polishing surface 121. A length 302 of the first pad conditioner 102 is between about 500 millimeters to about 750 millimeters. A height 304 of the first pad conditioner 102 is between about 200 millimeters to about 600 millimeters. Other values of the length 302 and the height 304 are within the scope of the present disclosure.

FIG. 3B illustrates the first pad conditioner 102 according to some embodiments in which the first pad conditioner head 107 comprises a brush, such as a brush disk. In some embodiments, the brush comprises at least one of bristles, wire, filaments, etc. A length 316 of the brush is between about 30 millimeters to about 200 millimeters. Other values of the length 306 are within the scope of the present disclosure. In some embodiments, the brush contacts the polishing surface 121 of the polishing pad 120 when the first pad conditioner 102 is used to condition the polishing surface 121.

FIG. 3C illustrates the first pad conditioner 102 according to some embodiments in which the first pad conditioner head 107 comprises the first pad. In some embodiments, the first pad comprises a hydrophilic pad, such as a hydrophilic soft pad having a hardness less than a third threshold hardness. In some embodiments, the hydrophilic soft pad comprises at least one of carbon such as a carbon additive, silicon such as a silicon additive, oxygen such as an oxide additive, or other suitable material. In some embodiments, a shore A hardness level of the hydrophilic soft pad is less than a first threshold shore A hardness level. In some embodiments, the first pad comprises a hydrophobic pad, such as a hydrophobic soft pad having a hardness less than a fourth threshold hardness. In some embodiments, the hydrophobic soft pad comprises at least one of polyurethane or other suitable material. In some embodiments, a shore A hardness level of the hydrophobic soft pad is less than a second threshold shore A hardness level. In some embodiments, the first pad comprises a hard pad having a hardness greater than a fifth threshold hardness. In some embodiments, a shore D hardness level of the hard pad is greater than a threshold shore D hardness level. A length 326 of the first pad is between about 30 millimeters to about 200 millimeters. Other values of the length 326 are within the scope of the present disclosure. In some embodiments, the first pad contacts the polishing surface 121 of the polishing pad 120 when the first pad conditioner 102 is used to condition the polishing surface 121.

FIG. 3D illustrates the first pad conditioner 102 according to some embodiments in which the first pad conditioner head 107 comprises the sponge. In some embodiments, the sponge comprises a porous structure. In some embodiments, the sponge comprises at least one of a polyvinyl alcohol (PVA) sponge or other type of sponge. In some embodiments, the PVA sponge is negatively charged. A length 336 of the sponge is between about 30 millimeters to about 200 millimeters. Other values of the length 336 are within the scope of the present disclosure. In some embodiments, the sponge contacts the polishing surface 121 of the polishing pad 120 when the first pad conditioner 102 is used to condition the polishing surface 121.

In some embodiments, the first pad conditioner head 107 is replaced with a third pad conditioner head via a head replacement process. In some embodiments, the first pad conditioner head 107 is of a first conditioner head type and the third pad conditioner head is of a third conditioner head type. In some embodiments, the first conditioner head type is different than the third conditioner head type, such as where (i) the first pad conditioner head 107 comprises the diamond disk, and the third pad conditioner head comprises at least one of the brush, the hydrophilic pad, the hydrophobic pad, the hard pad, or the sponge, (ii) the first pad conditioner head 107 comprises the brush, and the third pad conditioner head comprises at least one of the diamond disk, the hydrophilic pad, the hydrophobic pad, the hard pad, or the sponge, (iii) the first pad conditioner head 107 comprises the hydrophilic pad, and the third pad conditioner head comprises at least one of the diamond disk, the brush, the hydrophobic pad, the hard pad, or the sponge, (iv) the first pad conditioner head 107 comprises the hydrophobic pad, and the third pad conditioner head comprises at least one of the diamond disk, the brush, the hydrophilic pad, the hard pad, or the sponge, (v) the first pad conditioner head 107 comprises the hard pad, and the third pad conditioner head comprises at least one of the diamond disk, the brush, the hydrophilic pad, the hydrophobic pad, or the sponge, or (vi) the first pad conditioner head 107 comprises the sponge, and the third pad conditioner head comprises at least one of the diamond disk, the brush, the hydrophilic pad, the hydrophobic pad, or the hard pad. Embodiments are contemplated in which the first pad conditioner head 107 is of the same conditioner head type as the third pad conditioner head, such as where at least one of (i) the first pad conditioner head 107 comprises a used and/or worn pad conditioner head and the third pad conditioner head comprises a new and/or replacement pad conditioner head, or (ii) the first pad conditioner head 107 comprises a pad conditioner head having a first size and the third pad conditioner head comprises a pad conditioner head having a second size.

In some embodiments, the first conditioning process comprises the head replacement process. In some embodiments, the first conditioning process comprises using two or more pad conditioner heads of two or more pad conditioner head types to condition the first portion 224 of the polishing surface 121. In some embodiments, the first conditioning process comprises (i) conditioning at least the first portion 224 of the polishing surface 121 of the polishing pad 120 using the first pad conditioner head 107 of the first conditioner head type, (ii) performing the head replacement process to replace the first pad conditioner head 107 with the third pad conditioner head, and (iii) conditioning at least the first portion 224 of the polishing surface 121 of the polishing pad 120 using the third pad conditioner head of the third conditioner head type.

FIGS. 4A-4B illustrate side views of the first pad conditioner 102 during the head replacement process in accordance with some embodiments. FIG. 4A illustrates separation 402 of the first pad conditioner head 107 from the first head carrier 106. In some embodiments, prior to separating 402 the first pad conditioner head 107 from the first head carrier 106, the first pad conditioner head 107 is coupled to the first head carrier 106 via at least one of a magnetic force between the first head carrier 106 and the first pad conditioner head 107, an adhesive between the first head carrier 106 and the first pad conditioner head 107, or an attachment mechanism of the first head carrier 106. In some embodiments, the first head carrier 106 comprises at least one of magnetic material, polyetheretherketone material, stainless steel, or other material. In some embodiments, the first pad conditioner head 107 is separated 402 from the first head carrier 106 via at least one of pulling (by a person, a robotic arm, etc.) the first pad conditioner head 107 from the first head carrier 106 or decoupling (by a person, a robotic arm, etc.) the attachment mechanism to release the first pad conditioner head 107 from the first head carrier 106. FIG. 4B illustrates attaching 404 the third pad conditioner head (shown with reference number 406) to the first head carrier 106. Although FIG. 4B illustrates the third pad conditioner head 406 to comprise the brush, other conditioner head types of the third pad conditioner head 406 are within the scope of the present disclosure.

In some embodiments, different conditioner head types used by the first pad conditioner 102 are used to achieve various impacts. In some embodiments, one or more conditioner head types are selected for use in the first conditioning process based upon one or more desired conditioning functions. In some embodiments, relative to one or more other conditioner head types, the diamond disk at least one of (i) has greater roughness and/or abrasiveness, or (ii) removes portions of the polishing surface 121 of the polishing pad 120 with greater speed. In some embodiments, relative to one or more other conditioner head types, the brush reaches more deeply into the polishing pad 120 for cleaning the polishing pad 120, such as cleaning recesses of the polishing pad 120. In some embodiments, relative to one or more other conditioner head types, the hydrophobic pad removes hydrophobic byproducts from the polishing pad 120 with greater speed. In some embodiments, relative to one or more other conditioner head types, the hydrophilic pad removes hydrophilic byproducts from the polishing pad 120 with greater speed. In some embodiments, the hard pad cleans the polishing pad 120 while removing portions of the polishing surface 121 at a lower rate than the diamond disk. In some embodiments, relative to one or more other conditioner head types, the sponge removes one or more types of byproducts from the polishing pad 120 with greater speed.

In some embodiments, the second pad conditioner head 117 of the second pad conditioner 112 is of a second conditioner head type. In some embodiments, the first conditioner head type of the first pad conditioner head 107 is different than the second conditioner head type, such as where (i) the first pad conditioner head 107 comprises the diamond disk, and the second pad conditioner head 117 comprises at least one of the brush, the hydrophilic pad, the hydrophobic pad, the hard pad, or the sponge, (ii) the first pad conditioner head 107 comprises the brush, and the second pad conditioner head 117 comprises at least one of the diamond disk, the hydrophilic pad, the hydrophobic pad, the hard pad, or the sponge, (iii) the first pad conditioner head 107 comprises the hydrophilic pad, and the second pad conditioner head 117 comprises at least one of the diamond disk, the brush, the hydrophobic pad, the hard pad, or the sponge, (iv) the first pad conditioner head 107 comprises the hydrophobic pad, and the second pad conditioner head 117 comprises at least one of the diamond disk, the brush, the hydrophilic pad, the hard pad, or the sponge, (v) the first pad conditioner head 107 comprises the hard pad, and the second pad conditioner head 117 comprises at least one of the diamond disk, the brush, the hydrophilic pad, the hydrophobic pad, or the sponge, or (vi) the first pad conditioner head 107 comprises the sponge, and the second pad conditioner head 117 comprises at least one of the diamond disk, the brush, the hydrophilic pad, the hydrophobic pad, or the hard pad. Embodiments are contemplated in which the first pad conditioner head 107 is of the same conditioner head type as the second pad conditioner head 117, such as where (i) the first pad conditioner head 107 comprises the diamond disk, and the second pad conditioner head 117 comprises a second diamond disk, (ii) the first pad conditioner head 107 comprises the brush, and the second pad conditioner head 117 comprises a second brush, (iii) the first pad conditioner head 107 comprises the hydrophilic pad, and the second pad conditioner head 117 comprises a second hydrophilic pad, (iv) the first pad conditioner head 107 comprises the hydrophobic pad, and the second pad conditioner head 117 comprises a second hydrophobic pad, (v) the first pad conditioner head 107 comprises the hard pad, and the second pad conditioner head 117 comprises a second hard pad, or (vi) the first pad conditioner head 107 comprises the sponge, and the second pad conditioner head 117 comprises a second sponge.

FIG. 5 illustrates the polishing apparatus 100 comprising a controller 502 and a set of sensors (e.g., a set of one or more sensors) in accordance with some embodiments. In some embodiments, the controller 502 is connected to and/or configured to control one or more components of the polishing apparatus 100, such as at least one of the first pad conditioner 102, the second pad conditioner 112, the first driving mechanism, the second driving mechanism, the third driving mechanism, the fourth driving mechanism, the fifth driving mechanism, the sixth driving mechanism, the seventh driving mechanism, the eighth driving mechanism, the wafer holder 130, the slurry provider 122, or other component of the polishing apparatus 100. In some embodiments, the controller 502 controls the first pad conditioner 102 via transmitting a first control signal CS1 to the first pad conditioner 102 using at least one of a wired connection, a wireless connection, etc. In some embodiments, the controller 502 controls the second pad conditioner 112 via transmitting a second control signal CS2 to the second pad conditioner 112 using at least one of a wired connection, a wireless connection, etc.

In some embodiments, the controller 502 controls a first set of parameters (e.g., a first set of one or more parameters) associated with the first pad conditioner 102 and/or the first conditioning process. In some embodiments, the first set of parameters comprises at least one of (i) the length 302 of the first pad conditioner 102 and/or a length of the first pad conditioner arm 104, (ii) the height 304 of the first pad conditioner 102 and/or a length of the first pad conditioner cylinder 108, (iii) a hardness and/or roughness of the first pad conditioner head 107, (iv) a size of the first pad conditioner head 107, (v) a conditioner head type, (vi) the first oscillation path 206, (vii) an oscillation speed by which the first pad conditioner arm 104 oscillates the first head carrier 106 and the first pad conditioner head 107 along the first oscillation path 206, (viii) the first rotation speed with which the first pad conditioner head 107 is rotated, (ix) the third rotational direction 160 by which the first pad conditioner head 107 is rotated, (x) the first pad conditioning force exerted by the first pad conditioner head 107 onto the polishing pad 120, or (xi) one or more other parameters.

In some embodiments, the controller 502 performs and/or facilitates a first set of adjustments (e.g., a first set of one or more adjustments) of the first pad conditioner 102 and/or the first conditioning process. In some embodiments, the first set of adjustments comprise at least one of (i) adjusting the length 302 of the first pad conditioner 102, such as by extending or retracting the first pad conditioner arm 104 using at least one of hydraulic means, pneumatic means, or other means of controlling a length of the first pad conditioner arm 104, (ii) adjusting the height 304 of the first pad conditioner 102, such as by extending or retracting the first pad conditioner cylinder 108 using at least one of hydraulic means, pneumatic means, or other means of controlling a length of the first pad conditioner cylinder 108, (iii) adjusting a hardness and/or roughness of the first pad conditioner head 107, (iv) adjusting a size of the first pad conditioner head 107, (v) replacing the first pad conditioner head 107 with a pad conditioner head (e.g., the third pad conditioner head 406) of a different conditioner head type, (vi) adjusting the first oscillation path 206 to span a different oscillation path, such as a larger oscillation path or a smaller oscillation path, (vii) adjusting an oscillation speed by which the first pad conditioner arm 104 oscillates the first head carrier 106 and the first pad conditioner head 107 along the first oscillation path 206, (viii) adjusting the first rotation speed with which the first pad conditioner head 107 is rotated, (ix) changing a direction of the third rotational direction 160 by which the first pad conditioner head 107 is rotated, (x) adjusting the first pad conditioning force exerted by the first pad conditioner head 107 onto the polishing pad 120, or (xi) one or more other adjustments.

In some embodiments, the controller 502 controls the first set of parameters and/or performs and/or facilitates the first set of adjustments based upon a set of measurements 504 received from the set of sensors. In some embodiments, the set of sensors collect measurements in at least one of a continuous manner, a periodic manner, or an aperiodic manner. In some embodiments, the set of sensors comprise at least one of one or more proximity sensors, one or more spectrometry sensors, one or more image sensors, or one or more other types of sensor. In some embodiments, a sensor of the set of sensors is positioned proximal a component of the polishing apparatus 100. In some embodiments, the set of sensors comprise one or more sensors positioned proximal the polishing pad 120 to collect one measurements associated with the polishing pad 120 and provide the one or more measurements to the controller 502. In some embodiments, the set of sensors comprise at least one of a first sensor S1 (comprising at least one of a first proximity sensor, a first spectrometry sensor, a first image sensor, or other type of sensor), a second sensor S2 (comprising at least one of a second proximity sensor, a second spectrometry sensor, a second image sensor, or other type of sensor), a third sensor S3 (comprising at least one of a third proximity sensor, a third spectrometry sensor, a third image sensor, or other type of sensor), or one or more other sensors (not shown).

In some embodiments, the first conditioning process is performed (in-situ) concurrently with the polishing process performed by the polishing apparatus 100 to polish the first semiconductor wafer 132. In some embodiments, the polishing apparatus 100 provides for in-situ control capability of one or more parameters of the first set of parameters of the first conditioning process performed using the first pad conditioner 102. In some embodiments, one or more adjustments of the first set of adjustments are performed during the polishing process.

In some embodiments, the controller 502 controls one or more parameters of the first set of parameters based upon a target thickness profile associated with the polishing pad 120. In some embodiments, the target thickness profile is indicative of one or more target thicknesses of one or more portions of the polishing pad 120. In some embodiments, the controller 502 performs and/or facilitates one or more adjustments of the first set of adjustments to achieve the one or more target thicknesses at the one or more portions of the polishing pad 120. In some embodiments, the controller 502 determines a measured thickness of a portion of the polishing pad 120 based upon the set of measurements 504. In some embodiments, the controller 502 compares the measured thickness with a target thickness (indicated by the target thickness profile) of the portion of the polishing pad 120 to determine a thickness difference. In some embodiments, the controller 502 controls one or more parameters of the first set of parameters based upon the thickness difference. In some embodiments, based upon the measured thickness being greater than the target thickness, the controller 502 performs and/or facilitates one or more adjustments comprising at least one of (i) increasing the first pad conditioning force exerted by the first pad conditioner head 107 onto the polishing pad 120, or (ii) increasing a hardness and/or roughness of the first pad conditioner head 107. In some embodiments, the controller 502 performs the one or more adjustments (i) in real time in response to the set of measurements 504, (ii) during the first conditioning process, (iii) during the polishing process (e.g., in-situ adjustments), and/or (iv) outside the polishing process (e.g., ex-situ adjustments).

In some embodiments, the controller 502 controls a second set of parameters (e.g., a second set of one or more parameters) associated with the second pad conditioner 112 and/or the second conditioning process. In some embodiments, the second set of parameters comprise one, some or all parameters provided herein with respect to the first set of parameters. In some embodiments, the controller 502 performs and/or facilitates a second set of adjustments (e.g., a second set of one or more adjustments) associated with the second pad conditioner 112 and/or the second conditioning process. In some embodiments, the second set of adjustments comprise one, some or all adjustments provided herein with respect to the first set of adjustments.

In some embodiments, the polishing apparatus 100 comprises the second pad conditioner 112 (e.g., a standard pad conditioner) and a set of supplementary pad conditioners (e.g., a set of one or more pad conditioners). In some embodiments, the polishing apparatus 100 is manufactured to include the second pad conditioner 112, and subsequently the set of supplementary pad conditioners are retrofitted to the polishing apparatus 100. In some embodiments, the polishing apparatus 100 is manufactured to include the second pad conditioner 112 and the set of supplementary pad conditioners. In some embodiments, the set of supplementary pad conditioners comprise at least one of the first pad conditioner 102, a third pad conditioner, a fourth pad conditioner, a fifth pad conditioner, or one or more other pad conditioners. In some embodiments, each pad conditioner of the set of supplementary pad conditioners has one, some, or all of the features provided herein with respect to the first pad conditioner 102. In some embodiments, each pad conditioner of the set of supplementary pad conditioners performs one, some or all of the actions provided herein with respect to the first pad conditioner 102.

In some embodiments, pad conditioners of the set of supplementary pad conditioners comprise pad conditioner heads of different head types. In some embodiments, all pad conditioners of the set of supplementary pad conditioners comprise pad conditioner heads of the same head type, such as at least one of the diamond disk, the brush, the hydrophilic pad, the hydrophobic pad, or the hard pad. In some embodiments, one or more pad conditioners of the set of supplementary pad conditioners comprise one or more pad conditioner heads that are of different head types than the second conditioner head type of the second pad conditioner head 117. In some embodiments, one or more pad conditioners of the set of supplementary pad conditioners comprise one or more pad conditioner heads that are of the same head type as the second conditioner head type of the second pad conditioner head 117.

FIGS. 6A-6D illustrate various arrangements of the set of supplementary pad conditioners relative to the polishing pad 120, in accordance with some embodiments. For simplicity, components other than the set of supplementary pad conditioners and the polishing pad 120, such as the second pad conditioner 112, the wafer holder 130, etc., are not depicted in FIGS. 6A-6D.

In some embodiments, each pad conditioner of one, some, or all of the set of supplementary pad conditioners is positioned such that a pad conditioner head of the pad conditioner is in contact with and/or conditions at least some of a first edge portion 630 of the polishing surface 121 of the polishing pad 120. In some embodiments, the first edge portion 630 comprises the edge 119 of the polishing surface 121. In some embodiments, the first edge portion 630 spans a portion of the polishing surface 121 from the edge 119 to a point 634 of the polishing surface 121 separated from the edge 119 by a third distance 632. In some embodiments, the third distance 632 is at least one of (i) at most about 300 millimeters, (ii) at most about 200 millimeters, (iii) between about 30 millimeters to about 300 millimeters, or (iv) between about 30 millimeters to about 200 millimeters. Other values of the third distance 632 are within the scope of the present disclosure. In some embodiments, the third distance 632 is configured based upon a diameter corresponding to a platen diameter of the platen 110 and/or a pad diameter of the polishing pad 120. The third distance 632 is at least one of (i) between about 0.02×d to about 0.5×d, or (ii) between about 0.04×d to about 0.25×d, wherein d corresponds to the diameter. Other values of the third distance 632 are within the scope of the present disclosure. Embodiments are contemplated in which the first edge portion 630 is separated from the edge 119 (not shown) of the polishing surface 121 by a fourth distance (not shown). The fourth distance is at least one of (i) at most about 200 millimeters, (ii) at most about 100 millimeters, (iii) at most about 50 millimeters, or (iv) at most about 30 millimeters. Other values of the fourth distance are within the scope of the present disclosure.

In some embodiments, a size (e.g., a diameter) of the first pad conditioner head 107 is based upon the third distance 632. In some embodiments, a greater size of the first pad conditioner head 107 corresponds to a greater value of the third distance 632. In some embodiments, the size of the first pad conditioner head 107 is about equal to the third distance 632 and/or a position of the first pad conditioner head 107 does not change during a time period such that during the time period, the first edge portion 630 of the polishing surface 121 is conditioned by the polishing pad 120 rotating in the first rotational direction 154 while the first pad conditioner head 107 is in contact with the first edge portion 630. In some embodiments, the size (e.g., the diameter) of the first pad conditioner head 107 is greater than or less than the third distance 632.

FIG. 6A illustrates a top view of a first arrangement 600 of the set of supplementary pad conditioners comprising a single pad conditioner corresponding to the first pad conditioner 102. FIG. 6B illustrates a top view of a second arrangement 650 of the set of supplementary pad conditioners comprising two pad conditioners comprising the first pad conditioner 102 and the third pad conditioner (shown with reference number 602). FIG. 6C illustrates a top view of a third arrangement 660 of the set of supplementary pad conditioners comprising two pad conditioners comprising the first pad conditioner 102 and the third pad conditioner 602. In some embodiments, the first pad conditioner 102 and the third pad conditioner 602 are positioned in symmetrical and/or opposite positions relative to the polishing surface 121.

In some embodiments, the third pad conditioner 602 comprises one, some or all of the features provided herein with respect to the first pad conditioner 102. In some embodiments, the third pad conditioner 602 comprises at least one of a third pad conditioner arm 604, a third pad conditioner head (not shown), a third head carrier 606 configured to hold the third pad conditioner head, or a third pad conditioner cylinder 608. In some embodiments, the third pad conditioner 602 performs a third conditioning process to condition a third portion of the polishing pad 120. In some embodiments, during at least some of the third conditioning process, the third pad conditioner 602 is in contact with the third portion. In some embodiments, the third portion corresponds to the first edge portion 630. In some embodiments, the controller 502 controls a third set of parameters (e.g., a third set of one or more parameters) of the third pad conditioner 602. In some embodiments, the third set of parameters comprises one, some or all parameters provided herein with respect to the first set of parameters. In some embodiments, the controller 502 performs a third set of adjustments (e.g., a third set of one or more adjustments) using one or more of the techniques provided herein with respect to performing the first set of adjustments. In some embodiments, the third set of adjustments comprises one, some or all adjustments provided herein with respect to the first set of adjustments.

FIG. 6D illustrates a top view of a fourth arrangement 670 of the set of supplementary pad conditioners comprising three pad conditioners comprising the first pad conditioner 102, the third pad conditioner 602 and the fourth pad conditioner (shown with reference number 612). In some embodiments, the three pad conditioners are arranged along a triangle (e.g., an equilateral triangle) with sides having lengths about equal to a. In some embodiments, a center of gravity of the triangle is about equal to a center 617 of the polishing pad 120 and/or the platen 110. In some embodiments, the three pad conditioners are arranged such that respective pad conditioner heads of the three pad conditioners overlap with vertices of the triangle. A radius of the platen 110 and/or the polishing pad 120 is at least one of (i) between about

to about

or (ii) about equal to

A circumference of the platen 110 and/or the polishing pad 120 is at least one of (i) between about

to about

or (ii) about equal to

Other values of the radius and the circumference are within the scope of the present disclosure.

In some embodiments, the fourth pad conditioner 612 comprises one, some or all of the features provided herein with respect to the first pad conditioner 102. In some embodiments, the fourth pad conditioner 612 comprises at least one of a fourth pad conditioner arm 614, a fourth pad conditioner head (not shown), a fourth head carrier 616 configured to hold the fourth pad conditioner head, or a fourth pad conditioner cylinder 618. In some embodiments, the fourth pad conditioner 612 performs a fourth conditioning process to condition a fourth portion of the polishing pad 120. In some embodiments, during at least some of the fourth conditioning process, the fourth pad conditioner 612 is in contact with the fourth portion. In some embodiments, the fourth portion corresponds to the first edge portion 630. In some embodiments, the controller 502 controls a fourth set of parameters (e.g., a fourth set of one or more parameters) of the fourth pad conditioner 612. In some embodiments, the fourth set of parameters comprises one, some or all parameters provided herein with respect to the first set of parameters. In some embodiments, the controller 502 performs a fourth set of adjustments (e.g., a fourth set of one or more adjustments) using one or more of the techniques provided herein with respect to performing the first set of adjustments. In some embodiments, the fourth set of adjustments comprises one, some or all adjustments provided herein with respect to the first set of adjustments.

FIGS. 7A-7B illustrates scenarios associated with operation of the polishing apparatus 100, in accordance with some embodiments. In some embodiments, a scenario of FIGS. 7A-7B comprises at least one of (i) a pre-dressing stage prior to processing of the first semiconductor wafer 132 using the polishing apparatus 100, (ii) a ramp-up stage in which the first semiconductor wafer 132 is loaded into the wafer holder 130 of the polishing apparatus 100, (iii) a main polish stage in which the polishing process is performed to polish the first surface of the first semiconductor wafer 132, (iv) a wafer de-chuck stage in which at least one of the wafer holder 130 releases the first semiconductor wafer 132 and/or the first semiconductor wafer 132 is transported from the wafer holder 130 to a different location, such as a wafer storage device (not shown) or other location, (v) a post-dressing stage subsequent to the wafer de-chuck stage, or (vi) one or more other stages. In some embodiments, the wafer storage device (not shown) comprises at least one of a front opening unified pod (FOUP), a cassette pod, a reticle pod, or other type of wafer storage device.

FIG. 7A illustrates ex-situ scenarios in which the set of supplementary pad conditioners (labeled “Suppl. PC” in FIGS. 7A-7B) are not used to condition the polishing pad 120 in a corresponding main polish stage. In ex-situ scenario 702, (i) during the pre-dressing stage, the second pad conditioner 112 (labeled “PC 1” in FIGS. 7A-7B) performs a conditioning process (e.g., the second conditioning process) and the set of supplementary pad conditioners perform one or more respective conditioning processes (e.g., the first conditioning process) to condition the polishing pad 120, and (ii) during the post-dressing stage, the second pad conditioner 112 performs a conditioning process (e.g., the second conditioning process) and the set of supplementary pad conditioners perform one or more respective conditioning processes (e.g., the first conditioning process) to condition the polishing pad 120. In ex-situ scenario 704, (i) during the pre-dressing stage, the second pad conditioner 112 performs a conditioning process (e.g., the second conditioning process) and the set of supplementary pad conditioners perform one or more respective conditioning processes (e.g., the first conditioning process) to condition the polishing pad 120, and (ii) during the post-dressing stage, the second pad conditioner 112 performs a conditioning process (e.g., the second conditioning process) to condition the polishing pad 120. In ex-situ scenario 706, (i) during the pre-dressing stage, the second pad conditioner 112 performs a conditioning process (e.g., the second conditioning process) to condition the polishing pad 120, and (ii) during the post-dressing stage, the second pad conditioner 112 performs a conditioning process (e.g., the second conditioning process) and the set of supplementary pad conditioners perform one or more respective conditioning processes (e.g., the first conditioning process) to condition the polishing pad 120.

FIG. 8 illustrates a data structure 800 representative of a first thickness profile of the polishing pad 120, in accordance with some embodiments. A vertical axis of the data structure 800 corresponds to a pad thickness of the polishing pad 120. A horizontal axis of the data structure 800 spans from a point 802 on a first side “Edge (−)” of the edge 119 to a point 804 on a second side “Edge (+)” of the edge 119. Thickness values across the polishing pad 120 are shown with white-filled circles 804. Contaminants (e.g., byproducts and/or residue) are shown with black-filled shapes 802. Some polishing systems that use a single pad conditioner and/or do not employ the set of supplementary pad conditioners wear out polishing pads such that the polishing pads have (relatively deep) valleys in which contaminants gather, wherein the single pad conditioner is not able to (efficiently) remove the contaminants since the contaminants are trapped and/or wedged in the valleys. In some embodiments, the first thickness profile achieved using the set of supplementary pad conditioners to condition the polishing pad 120 provides for reduced contaminants and/or improved efficiency and/or speed with which contaminants are removed, such as due, at least in part, to the contaminants being removed in directions 806 and/or 808 with increased ease without becoming trapped in valleys. Further, using the set of supplementary pad conditioners at least one of (i) mitigates defects (e.g., valleys) in the polishing pad 120, (ii) increases a tool life of the polishing pad 120, (iii) improves polishing performance of the polishing apparatus 100, (iv) provides for customized edge break-in control for customizing a thickness profile of at least a portion of the polishing pad 120, or (v) improves within wafer (WiW) thickness range uniformity of semiconductor wafers produced using the polishing apparatus 100, such as due, at least in part, to the polishing pad 120 having a reduced amount of defects and/or having a more uniform thickness profile.

FIG. 9 illustrates a data structure 900 comprising a thickness curve 910 representative of a second thickness profile of at least a portion of the polishing pad 120, in accordance with some embodiments. A vertical axis of the data structure 900 corresponds to a pad thickness of the polishing pad 120 across at least a portion of the polishing pad 120. A horizontal axis of the data structure 900 corresponds to a distance from the center 617 of the polishing pad 120. In some embodiments, a second edge portion 906 (e.g., the same as or different than the first edge portion 630) of the polishing pad 120 has a decreasing pad thickness. In some embodiments, the second edge portion 906 comprises a portion, of the polishing pad 120, spanning from a first point at a first distance 902 from the center 617 to a second point at a second distance 904 from the center 617. The first point corresponds to 60 millimeters (or other distance) from the edge 119 of the polishing surface 121. In some embodiments, the second point corresponds to the edge 119 of the polishing surface 121 and the second distance 904 corresponds to a distance from the center 617 to the edge 119. In some embodiments, the controller 502 controls the set of supplementary pad conditioners to condition the second edge portion 906 of the polishing pad 120 into having the decreasing pad thickness based upon the target thickness profile being indicative of the second edge portion 906 of the polishing pad 120 having the decreasing pad thickness to provide a tapered pad edge of the polishing pad 120. In some embodiments, the tapered pad edge provides for improved polishing of semiconductor wafers (e.g., the first semiconductor wafer 132) using the polishing apparatus 100, such as due, at least in part, to reduced contaminants remaining on the polishing pad 120 as compared to the polishing pad 120 not having the tapered pad edge. In some embodiments, the reduced contaminants is a result of the contaminants falling and/or flowing off of the polishing pad 120 (and/or being pushed off of the polishing pad 120 using a pad conditioner) with more ease due to the tapered pad edge.

FIG. 10 illustrates a first data structure 1002 associated with the second pad conditioner 112 and a second data structure 1004 associated with one, some or all of the set of supplementary pad conditioners, in accordance with some embodiments. A relative time indicated by the first data structure 1002 is an approximate percentage corresponding to a duration of time that the second pad conditioner 112 conditions a corresponding zone area of the polishing surface 121 of the polishing pad 120 relative to a total duration of time that the second pad conditioner 112 conditions the polishing surface 121. A zone area corresponds to a portion of the polishing surface 121 of the polishing pad 120 spanning from a first distance to the center 617 of the polishing pad 120 to a second distance to the center 617. For example, a zone area 330˜310 corresponds to a portion of the polishing surface 121 of the polishing pad 120 spanning from 330 millimeters from the center 617 of the polishing pad 120 to 310 millimeters from the center 617. In some embodiments, the edge 119 is about 330 millimeters from the center 617 and the zone area 330˜310 comprises the edge 119. A relative time indicated by the second data structure 1004 is an approximate percentage corresponding to a duration of time that a supplementary pad conditioner (e.g., at least one of the first pad conditioner 102, the third pad conditioner 602, the fourth pad conditioner 612, etc.) conditions a corresponding zone area of the polishing pad 120 relative to a total duration of time that the supplementary pad conditioner conditions the polishing pad 120. In some embodiments, an increased relative time of a zone area is associated with more pad wear at the zone area of the polishing pad 120. In accordance with some embodiments, as shown in FIG. 10, one, some or all of the set of supplementary pad conditioners spends more time conditioning a portion (e.g., the first edge portion 630 and/or the second edge portion 906) of the polishing pad 120 proximal the edge 119 (e.g., the portion may comprise zone area 330˜310, zone area 310˜290 and/or zone area 290˜270) than the second pad conditioner 112 to achieve an improved thickness profile of the polishing pad 120, such as a thickness profile associated with the tapered pad edge. Thus, the second pad conditioner 112 requires relatively less time conditioning the zone area 330˜310 as compared with systems that do not include the set of supplementary pad conditioners, which provides for a reduced duration of conditioning time required to condition the polishing pad 120 to have a desired thickness profile, which leads to improved production capacity and/or throughput (e.g., improved wafer per hour (WPH)) of the polishing apparatus 100.

In some embodiments, the polishing apparatus 100 comprising the set of supplementary pad conditioners provides for at least one of (i) increased stability and/or uniformity of processing temperatures of polishing processes performed using the polishing pad 120 over the tool life of the polishing pad 120 as compared to a polishing apparatus that does not include the set of supplementary pad conditioners, such as due, at least in part, to an improved thickness profile (and/or increased uniformity of a thickness profile) of the polishing pad 120 achieved using the set of supplementary pad conditioners, whereas a polishing system that does not use the set of supplementary pad conditioners may have decreasing processing temperatures over the tool life of the polishing pad 120, (ii) increased stability and/or uniformity of low down force (LDF) end-point detection times of polishing processes performed using the polishing pad 120 over the tool life of the polishing pad 120 as compared to a polishing apparatus that does not include the set of supplementary pad conditioners, such as due, at least in part, to the improved thickness profile (and/or increased uniformity of the thickness profile) of the polishing pad 120 achieved using the set of supplementary pad conditioners, whereas a polishing system that does not use the set of supplementary pad conditioners may have increasing LDF end-point detection times over the tool life of the polishing pad 120, or (iii) increased stability and/or uniformity of high down force (HDF) end-point detection times of polishing processes performed using the polishing pad 120 over the tool life of the polishing pad 120 as compared to a polishing apparatus that does not include the set of supplementary pad conditioners, such as due, at least in part, to the improved thickness profile (and/or increased uniformity of the thickness profile) of the polishing pad 120 achieved using the set of supplementary pad conditioners, whereas a polishing system that does not use the set of supplementary pad conditioners may have increasing HDF end-point detection times over the tool life of the polishing pad 120. In some embodiments, increased stability and/or uniformity of the processing temperatures, the LDF end-point detection times and/or the HDF end-point detection times extends the tool life of the polishing pad 120, provides for more stable processing conditions and/or provides for increased conditioning speed of the polishing pad 120.

A method 1100 of operating a polishing apparatus, such as the polishing apparatus 100, is illustrated in FIG. 11 in accordance with some embodiments. In some embodiments, the polishing apparatus comprises a platen (e.g., the platen 110) and a polishing pad (e.g., the polishing pad 120) coupled to the platen. At 1102, a first pad conditioner of the polishing apparatus is used to condition a first portion of a polishing surface of the polishing pad. At 1104, a second pad conditioner of the polishing apparatus is used to condition a second portion of the polishing surface, wherein the second portion is different than the first portion.

One or more embodiments involve a computer-readable medium comprising processor-executable instructions configured to implement one or more of the techniques presented herein. An exemplary computer-readable medium is illustrated in FIG. 12, wherein the embodiment 1200 comprises a computer-readable medium 1208 (e.g., a CD-R, DVD-R, flash drive, a platter of a hard disk drive, etc.), on which is encoded computer-readable data 1206. This computer-readable data 1206 in turn comprises a set of processor-executable computer instructions 1204 configured to implement one or more of the principles set forth herein when executed by a processor. In some embodiments 1200, the processor-executable computer instructions 1204 are configured to implement a method 1202, such as at least some of the aforementioned method(s) when executed by a processor. In some embodiments, the processor-executable computer instructions 1204 are configured to implement a system, such as at least some of the one or more aforementioned system(s) when executed by a processor. Many such computer-readable media may be devised by those of ordinary skill in the art that are configured to operate in accordance with the techniques presented herein.

In some embodiments, a polishing apparatus is provided. The polishing apparatus includes a platen. The polishing apparatus includes a polishing pad coupled to the platen and configured to be rotated by the platen. The polishing apparatus includes a first pad conditioner in contact with a polishing surface of the polishing pad. The polishing apparatus includes a second pad conditioner in contact with the polishing surface.

In some embodiments, a method of operating a polishing apparatus is provided. The polishing apparatus includes a platen and a polishing pad coupled to the platen. The method includes conditioning, using a first pad conditioner of the polishing apparatus, a first portion of a polishing surface of the polishing pad. The method includes conditioning, using a second pad conditioner of the polishing apparatus, a second portion of a polishing surface, wherein the second portion is different than the first portion.

In some embodiments, a polishing apparatus is provided. The polishing apparatus includes a platen. The polishing apparatus includes a polishing pad coupled to the platen and configured to be rotated by the platen. The polishing apparatus includes a wafer holder configured to support a semiconductor wafer in a polishing position relative to the polishing pad for polishing of the semiconductor wafer. The polishing apparatus includes a slurry provider configured to provide a slurry to a polishing surface of the polishing pad for polishing of the semiconductor wafer. The polishing apparatus includes a first pad conditioner configured to condition a first portion of the polishing surface. The polishing apparatus includes a second pad conditioner configured to condition a second portion of the polishing surface, wherein the second portion is different than the first portion.

It will be appreciated that layers, features, elements, etc. depicted herein are illustrated with particular dimensions relative to one another, such as structural dimensions or orientations, for example, for purposes of simplicity and ease of understanding and that actual dimensions of the same differ substantially from that illustrated herein, in some embodiments. Additionally, a variety of techniques exist for forming layers, regions, features, elements, etc. mentioned herein, such as at least one of etching techniques, planarization techniques, implanting techniques, doping techniques, spin-on techniques, sputtering techniques, growth techniques, or deposition techniques such as chemical vapor deposition (CVD), for example.