Brush drive assembly in a substrate processing brush box

A modular brush drive assembly used in a brush box for processing a substrate is provided. The modular brush drive assembly includes a pair of brush drives. Each of the pair of brush drives has a mandrel capable of receiving a brush for processing a substrate, a mandrel support arm, and a brush drive housing configured to receive the mandrel and the mandrel support arm. The brush drive housing is configured to pivot. A brush drive position control assembly is further provided and includes a pair of interlocking brush angle gears which interconnect with brush drive shafts. A positioning control is coupled to one of the interlocking brush angle gears to cause pivoting of each brush drive housing. Component parts are designed to be configurable to a plurality of orientations and implementations.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to substrate and semiconductor wafer preparation systems and methods, and more particularly, the present invention relates to the cleaning of substrates and semiconductor wafers using an inventive brush box and employing space, process, and manufacturing efficient systems.

2. Description of the Related Art

In the fabrication of semiconductor devices, there is a need to perform wet cleaning of substrates at various stages of the fabrication process. Typically, integrated circuit devices are in the form of multi-level structures. At the substrate level, transistor devices having diffusion regions are formed over and into silicon substrates. In subsequent levels, interconnect metallization lines are patterned and electrically connected to the transistor devices to define the desired functional device. As is well known, patterned conductive layers are insulated from other conductive layers by dielectric materials, such as silicon dioxide. At each metallization level there is a need to planarize metal or associated dielectric material. Without planarization, fabrication of additional metallization layers becomes substantially more difficult due to the higher variations in the surface topography. In some applications, metallization line patterns are formed in the dielectric material, and then metal CMP operations are performed to remove excess metallization.

Following each CMP operation, a wet clean of the substrate is performed. The wet clean is designed to wash away any by-products of the fabrication process, remove contaminants, and to achieve and maintain the necessary degree of cleanliness essential to proceed to a subsequent fabrication operation. As transistor device structures become smaller and more complex, the precision required to achieve and maintain structure definition demands exacting standards of cleanliness be maintained in all process operations. If a wet clean is incomplete or ineffective, or if a post-wet clean drying is incomplete or ineffective, then unacceptable residue or contaminants are introduced into the processing environment.

Similarly, in the fabrication of hard disk drives, planarization and cleaning operations are needed to maintain a clean and smooth disk substrate. Residue or contaminants remaining on substrates in the fabrication of hard disks and other devices utilizing similar substrates is likewise unacceptable.

Substrate cleaning and scrubbing techniques, methods, and apparatus are plentiful and known in the art, and incorporate such operations as rinsing and scrubbing, immersion, and the application of thermal, mechanical, chemical, electrical, and/or sonic energy and the like to remove or displace water to dry the substrate. One known cleaning and scrubbing technique implements brush stations in which polyvinyl alcohol (PVA) brushes are used to scrub both sides of a substrate. In a typical brush station process, a substrate is rotated in a vertical orientation by substrate drive rollers, also called substrate edge wheels. As the substrate is rotated, a pair of cylindrical brushes or pads is brought into contact with the opposing surfaces of the wafer. The brushes or pads are mounted on counter-rotating mandrels disposed on opposite sides of the wafer being processed. The mandrels span the diameter of the substrate across the substrate center. The rotation of the mandrels rotates the cylindrical brushes or pads which are then applied against the opposing surfaces of the rotating substrate. During the scrubbing operation in some systems, nozzles direct sprays of liquid, e.g., an abrasive slurry, a chemical solution, or a rinse solution, on the opposing surfaces of the wafer. In some applications, liquid for polishing, scrubbing, or cleaning is supplied through the brush or pad, and some systems employ a combination of nozzles and fluid delivery through the brush or pad.

Substrate fabrication equipment is typically configured in integrated systems to maximize efficiency of processing by combining a plurality of fabrication processes to minimize substrate transfer and handling, to maximize the economical utilization of clean room floor space, and to maximize production throughput. Since a substrate wet cleaning is performed after many of the substrate fabrication steps, brush stations are often integrated into a plurality of fabrication and processing systems. By way of example, brush stations may be configured in pairs, side by side, with a pair of spin, rinse, and dry (SRD) tools configured vertically above the brush stations. Two brush stations are used, each with a pair of brushes, to enable the application of chemicals in one brush station and deionized (DI) water in the other. This dual brush station approach has been shown to improve the cleaning performance as well as increase throughput. In another typical configuration, each of the pair of brush stations performs the same scrubbing, cleaning, or other process operation, and the tandem implementation increases efficiency and throughput.

In typical prior art processing systems implementing one or more brush stations, the brush stations are specifically designed and configured for the particular system in which it is to be used, and often designed and configured for a specific location within an integrated system. Although many brush station parts, e.g., the brushes, are interchangeable between the various brush stations, each station is often unique to a particular implementation, and a specific location within the system, and typically requires manufacture of individual and specific components or parts for specific locations or implementations.

In view of the foregoing, there is a need for substrate brush station preparation systems and methods that provide modular and interchangeable brush stations with ease of access for service, ease of configuration for a plurality of system implementations, case of configuration for a plurality of substrates and substrate sizes, and that maximize the cleaning and processing of wafers and other substrates in order to meet and exceed the ever more stringent cleanliness requirements for fabrication processes.

SUMMARY OF THE INVENTION

Broadly speaking, the present invention fills these needs by providing a substrate processing brush box that is modular and symmetrical in design and implementation enabling ease of configuration and incorporation into a plurality of substrate processing applications. In particular, the brush drive assembly of the substrate processing brush box provides a modular component of the brush box that is easily configurable to a plurality of applications.

In one embodiment, a pair of brush cores is disclosed. Each of the brush cores is adapted to receive a brush. The pair of brush cores is configured to reside within a brush box, and the pair of brush cores are controlled by a position control assembly. The position control assembly includes a first brush drive shaft and a second brush drive shaft. Each of the first and second brush drive shafts are respectively configured to receive one of the pair of brush cores. The position control assembly further includes a first angle gear and a second angle gear. The first angle gear is coupled to the first brush drive shaft, and the second angle gear is coupled to the second brush drive shaft. The first angle gear has a first set of teeth that are aligned and interlocked with the second angle gear that has a second set of teeth. The position control assembly also includes a gear coupled to the first brush drive shaft. The gear is capable of positive control to cause the first angle gear to pivot. The pivoting of the first angle gear is transferred to the second angle gear through the aligned and interlocked teeth. The transferred pivoting causes an equal and opposite pivoting of the second angle gear resulting in an associated pivoting of the pair of brush cores within the brush box.

In another embodiment, a position control assembly for adjusting a pair of brush cores of a wafer processing brush box is disclosed. The brush cores are capable of being adjusted to apply a desired hold and a desired pressure to a substrate. The substrate is capable of being prepared in the brush box between the pair of brush cores, and the pair of brush cores are capable of receiving scrub brushes. The position control assembly includes a pair of interlocking angle gears. Each of the interlocking angle gears is capable of interconnecting to a respective one of the pair of brush cores. The position control assembly further includes a gear coupled to one of the interlocking angle gears. The gear is capable of pivoting one of the pair of interlocking angle gears and causing an equal and opposite pivoting to the other of the pair of interlocking angle gears. The pivoting of the pair of interlocking angle gears causes an equal pivoting of the pair of brush cores of the processing brush box.

In yet another embodiment, a modular brush drive in a brush box for processing a substrate is disclosed. The modular brush drive includes a pair of brush drives. Each of the pair of brush drives includes a mandrel capable of receiving a brush for processing a substrate, a mandrel support arm configured to provide structural support for and a structural housing in which the mandrel is configured to rotate, and a brush drive housing configured to receive the mandrel and the mandrel support arm. The brush drive housing is configured to pivot. The modular brush drive further includes a brush drive position control assembly which includes a pair of interlocking brush angle gears. Each of the interlocking brush angle gears interconnects with a brush drive shaft. The brush drive position control assembly further includes a positioning control coupled to one of the interlocking brush angle gears. The positioning control is capable of pivoting the one interlocking brush angle gear and causing an equal and opposite pivoting of the other interlocking brush angle gear. The pivoting of the pair of interlocking brush angle gears causes a corresponding pivoting of each brush drive housing.

The advantages of the present invention are numerous. One notable benefit and advantage of the invention is the modular design. Assembly and component parts of the present invention are designed for configuration to a plurality of implementations of the present invention. Assembly and component parts can be configured for right-hand or left-hand access using the same parts, and thus significantly reducing the cost of manufacture. Instead of typical prior art specially designed and manufactured parts for specific implementations, the present invention incorporates symmetrical design providing for modular parts that can be turned, reversed, or otherwise simply configured for a particular location or implementation. In addition to significantly reducing the cost of manufacture, training costs are reduced, and serviceability is greatly increased.

Another benefit is the ease with which the present invention is configured for a plurality of substrate sizes. In some substrate processing implementations, it is preferable to utilize brushes or pads that are specifically matched to a substrate size. In one embodiment of the present invention, brushes or pads are easily changed on brush assembly mandrels, or entire brush assemblies can be easily configured for specific substrate sizes, and the brush assemblies implemented in embodiments of the present invention as desired.

An additional benefit is the ability to integrate the system into existing process equipment resulting in increased quality and quantity of product with fewer defects or scrap due to contamination. One embodiment of the invention is of essentially identical dimension as existing brush boxes, and the present invention can be implemented to replace existing tools with embodiments of the present invention with a resulting increase in serviceability and performance.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An invention for substrate preparation is disclosed. In preferred embodiments, apparatus and methods include a substrate processing brush box of symmetrical and modular design for implementation in a plurality of substrate processing tools and applications. The substrate processing brush box incorporates a modular brush drive assembly and a modular edge wheel assembly.

FIG. 1shows a brush box100in accordance with one embodiment of the present invention. InFIG. 1, brush box100is shown in an open configuration revealing a number of structural features in the interior of the brush box100. In one embodiment, brush box100is operated with the interior of the brush box100at less than atmospheric pressure, and therefore must be sealed. Brush box door110provides access to the interior structural components of brush box100, and provides a surface through which a substrate124is inserted into and removed from the interior of the brush box100. Inner door panel112provides an interior structure on the brush box door110, and a slot door panel (not visible inFIG. 1) is configured in between the brush box door110and the inner door panel112. Slot door panel142(seeFIG. 5A) provides a seal to contain the interior region of the brush box100, and in an open position, provides access for inserting or removing a substrate124.

In one embodiment, an edge wheel assembly114is configured to a side of the brush box100. The modular edge wheel assembly114is attached to the illustrated brush box100through a side panel and provides support, positioning, cooling, movement, and the like for edge wheels116as is described in greater detail below in reference toFIGS. 14A-14Eand15A-15C. InFIG. 1, front edge wheel116ais shown providing support for a substrate124positioned in brush box100. Rear edge wheel116bis not visible in the illustrated brush box100. Front edge wheel116aand rear edge wheel116bare configured to support a substrate124in a vertical orientation within brush box100, and to rotate, which rotates the substrate supported thereon.

A substrate stabilizer is configured to support a top edge of substrate124when the substrate124is positioned on edge wheels116, and brushes118are in a retracted position away from the substrate124. The substrate stabilizer assembly134is configured to a side panel of brush box100and includes an actuator133and a substrate stabilizer arm122. In one embodiment, the actuator133positions connecting rods in the substrate stabilizer assembly134which position the substrate stabilizer arm122in brush box100. In one embodiment, the substrate stabilizer assembly134is controlled in conjunction with a substrate sensing system and a brush positioning system to ensure the substrate stabilizer arm122is positioned to support the substrate124in a vertical orientation only when a substrate is present and the brushes118are in a retracted position away from substrate124surfaces, or are to be moved into the retracted position. Brush box100and substrate stabilizer assembly134are configured so that substrate stabilizer assembly134can be configured to either side panel of brush box100to maximize access for serviceability in a plurality of brush box100configurations and implementations.

InFIG. 1, substrate124is positioned between brushes attached to brush cores118which are mounted on counter-rotating mandrels (not visible inFIG. 1) and configured to a brush drive assembly120. The brush drive assembly120is configured through the rear of brush box100, and is described in greater detail below in reference toFIGS. 6A-13C. In one embodiment of the invention, the brush drive assembly120is generally configured to counter-rotate mandrels (not visible) with brushes and brush cores118attached thereto. The counter-rotating brushes are applied to opposing surfaces of substrate124, which is rotated by front edge wheel116aand rear edge wheel116b(not visible). The brush drive assembly120is configured to supply fluid for cleaning, polishing, buffing, and the like through the counter-rotating brushes. In one embodiment, fluid is supplied to the fluid delivery system through brushes and brush cores118at fluid delivery fitting136.

Also shown inFIG. 1is wafer sensing apparatus132. Wafer sensing apparatus132is configured to each side panel of brush box100and senses the presence of a substrate124in processing position within brush box100. In one embodiment, wafer sensing apparatus132is a fiberoptic system that senses the presence of substrate124in processing position between brushes on brush cores118and on the edge rollers116. In one embodiment, the wafer sensing apparatus132transmits the state of substrate presence to a system controller (not shown) to enable or disable a plurality of functions of and within brush box100. By way of example, position of substrate stabilizer arm might be enabled by presence of a substrate, opening of door110might be disabled by presence of a substrate, delivery of fluids through the fluid delivery system might be enabled by the presence of a substrate, and the like.

In accordance with one embodiment of the present invention, brush box100is of a symmetrical and modular configuration about a vertical axis or center line through brush box100to enable integration into a plurality of fabrication and processing tools. In one embodiment of the invention, brush box100is typically implemented as a right-hand or a left-hand brush box100within a system. In fabricating brush box100as essentially symmetrical about a vertical center line, components of the brush box100that are typically mirrored as right and left components, or right and left brush box100assemblies, are generally fabricated as essentially identical parts that are mounted, configured, attached, and the like as mirror images, as will be illustrated and described in several examples below. Additionally, symmetrical configuration minimizes fabrication of specialized component parts of brush box100. By way of example inFIG. 1, door110is shown with hinges126on the left side of door110, and securing screws130along the right edge of door110. Door110is easily configured to be hinged on the right side with hinges126attached to hinge cut outs127on door110and affixed in holes128in the front panel of brush box100. Similarly, securing screws130can be attached along left edge of door110. In this manner, door110is easily configured for either right hand or left hand opening, using the same parts for either configuration.

InFIG. 1, edge wheel assembly114is shown attached to brush box100through the right panel. In one embodiment of the invention, brush box100might be configured to a fabrication or processing tool, or integrated processing system, so that access and serviceability of brush box100is maximized. As will be described in greater detail below in reference toFIGS. 14A-15C, edge wheel assembly114is configurable through either the right or the left panel of brush box100. Additionally, edge wheel assembly114is configurable through either the right or left panel of brush box100using substantially the same assembly and support/mounting parts in either position. As can be seen inFIG. 1, an edge wheel assembly mounting position131is visible in the left panel of brush box100. The position of the edge wheel assembly114is then easily configured depending on the specific application or location of brush box100within a tool or integrated processing system.

The modular design of brush box100is implemented in both the general structure of the brush box100and in the individual assemblies incorporated into brush box100. By way of example, one embodiment of the present invention can be implemented in a wafer fabrication cleaning and drying tool which includes two brush boxes100side-by-side, and two SRD tools mounted vertically over the brush boxes, one SRD over each brush box100(see FIGS.16A and16B). The tool might be configured in a stand or rack to supply power, gas or liquid chemistry, water, exhaust, drainage, and the like. In such a tool, each of the integrated brush boxes100might be configured to provide maximum serviceability and access with exterior configuration of the edge wheel insert assemblies114, doors110configured to open toward the center of the tool, and the like. Each brush box100might be configured for a particular application and location, but using substantially the same brush box100and support/mounting structures in each configuration.

FIGS. 2-4show additional views of brush box100with various features as described above identified from a plurality of angles in accordance with an embodiment of the invention.FIG. 2shows another view of brush box100in accordance with an embodiment of the invention. InFIG. 2, brush box100is once again shown in an open configuration. Brush box door110provides access into an interior region of brush box100, and is attached to brush box100at hinges126. Brush box door can be secured to the brush box100body with securing screws130along an edge opposite hinges126. Hinge cut outs127on brush box door110, and corresponding holes128on brush box100illustrate the ability to configure brush box door110to open from either edge utilizing the same component parts. On the interior of brush box door110is inner door panel112. Brush box door is described in greater detail below in reference toFIGS. 5A and 5B.

Wafer sensing apparatus132senses the presence of a substrate in processing position within brush box100, between brushes on brush rollers118and supported on edge wheels116. Wafer sensing interior flange132ais visible on an interior wall of brush box100. Also visible in an interior of brush box100are brush cores118, fluid delivery fittings136, and fluid delivery plugs137which are described in detail below in reference toFIGS. 6A-13Cwhich illustrate embodiments of the brush drive assembly120.

Edge wheel assembly114includes the various components associated with the edge wheels116(front edge wheel116ais shown in FIG.2), including edge wheel assembly block fitting206which provides a connection for fluid supply to the components of the edge wheel assembly114. As described in greater detail in reference toFIGS. 14A-15C, the symmetrical design of the edge wheel assembly114provides for the ability to position the edge wheel assembly114in either of a right panel or a left panel of brush box100. InFIG. 2, an edge wheel assembly mounting position131is visible in a panel of brush box100opposite edge wheel assembly114.

Above edge wheel assembly114inFIG. 2is the substrate stabilizer assembly134and actuator133as described above in reference to FIG.1. Substrate stabilizer arm122(seeFIG. 1) is not visible in FIG.2.

FIG. 3shows another perspective of brush box100in accordance with an embodiment of the invention. InFIG. 3, door110is in an open position, but the interior of brush box100is not visible. As described above, door110can be configured to brush box100to open from either edge, and is attached to brush box100with hinges126and securing screws130. Holes128and hinge cut-outs127accept hinges126when attaching brush box door110to brush box100.

FIG. 3also shows another perspective of wafer sensing apparatus132, and an exterior view of edge wheel assembly mounting position131. That portion of the brush drive assembly120exterior to the brush box100is shown in a rear section of brush box100.

FIG. 4shows a perspective from the rear of brush box100in accordance with an embodiment of the invention. As inFIG. 3, that portion of the brush drive assembly120that remains exterior to brush box100is visible in FIG.4. Also shown is edge wheel assembly114, including edge wheel drive motor202which remains in an external location to brush box100. The wafer sensing apparatus132, substrate stabilizer assembly134and actuator133, and a view of holes128that accept hinges126(not shown) are all identified in FIG.4.

FIGS. 5A and 5Bshow additional detail of door110in accordance with an embodiment of the present invention.FIG. 5Ais an exploded view of door110in accordance with an embodiment of the invention. InFIG. 5A, door110is shown with hinges126attached to the right side of door110, and securing screws130configured along the left edge of door110. Consistent with the overall design of brush box100in one embodiment, door110is substantially symmetrical and configurable to be attached to brush box100with hinges126on either the right side of door110or on the left side of door110. Hinge cut outs127are shown opposite hinges126, and attachment points are provided for securing screws130along both the right and left edges of door110to be configured with securing screws130along whichever edge is opposite the hinges126. A single door110is thus provided to be configured for a plurality of brush box100applications and configurations, and can be manufactured as a single component part rather than a specialized part for a particular application, location or configuration.

Slot140is provided in substantially the center of door110. Slot140is generally configured to provide access to brush box100for the insertion or extraction of a substrate124(not shown). Slot door142is positioned between door110and door inner panel112and provides for sealing the interior of brush box100. In one embodiment, slot door142is configured to slide into either one of an open position or a closed position between door110and door inner panel112. Door inner panel112is therefore larger on one side of slot140than on the other. In order to maintain the symmetrical design of brush box100, inner door panel112is configured to be reversible to accommodate the sliding of slot door142to an open position on either the right or left side of slot140.

FIG. 5Bshows another perspective with a plan view of door110in accordance with an embodiment of the invention. Identified features of door110inFIG. 5Binclude hinges126, hinge cut outs127, securing screws130, and door inner panel112.

FIGS. 6A and 6Bshow a detail view of the brush drive assembly120in accordance with one embodiment of the present invention. Referring toFIG. 6A, brush drive assembly120includes a right brush drive150aand a left brush drive150bwhich are assembled from substantially identical parts configured to face each other and to be pivoted into a desired position as will be described below. In one embodiment, right brush drive150aand left brush drive150bare configured with brushes attached to brush cores118mounted on counter rotating mandrels (not visible). Mandrel support arms152are provided for support of the mandrel, brush, and brush core118structures. Each mandrel support arm152and mandrel (not visible) is connected on one end to a brush drive housing153. Brush drive housing153is configured to house gears to impart rotation of brush drive shaft154to mandrel and, in one embodiment, the side-by-side right brush drive150aand left brush drive150bare configured with counter-rotating mandrels. A mandrel support connector151is provided at a distal end of the right brush drive150aand the left brush drive150bto connect the mandrel and the mandrel support arm152. A bearing (not visible) is provided to allow the mandrel to rotate freely in the mandrel support connector151. In one embodiment, the mandrel support arm152is configured to be substantially rigid and fixed in place.

In one embodiment of the invention, fluids used for cleaning, polishing, buffing, rinsing, and the like are delivered through brushes attached to brush cores118and applied to substrate surfaces by the brushes. Fluids are supplied to the interior of mandrels (not visible) at fluid delivery fittings136. In one embodiment, the structure of the right brush drive150ais substantially identical to the structure of left brush drive150b. Fluid delivery plugs137are provided to allow the fluid delivery fittings136to be configured to a top surface of each brush drive150, and allow the substantially identical brush drives150to be configured to either a right or a left position in brush drive assembly120. Configuration is accomplished by turning, rotating, flipping, reversing, or otherwise re-positioning essentially identical component parts into a right or left, top or bottom, position.

In one embodiment, fluid delivery through the brush is supplemented with fluid delivery through a manifold (not shown) configured in or to mandrel support arms152. Fluid is sprayed, dripped, or otherwise dispensed through manifolds (not shown) that span the length of mandrel support arms152. In one embodiment, fluid delivery is configured to include at least two separate systems such that one fluid delivery system supplies fluid through mandrels and brushes through fluid delivery fittings136, and another fluid delivery system supplies fluid through manifolds through what is shown inFIG. 6Aas fluid delivery plugs137. In this manner, by way of example, chemistries can be mixed on the surface of a substrate and used for cleaning, polishing, buffing, and the like, or a rinse operation can immediately follow a process utilizing a processing chemistry, or any other desired combination of same or different fluid or chemistry delivery. In one embodiment, the fluid delivery system includes a common delivery through both the mandrels and brushes118, and through manifolds along mandrel support arms152.

Brush drive housings153are attached to brush drive front mounting plate156, and configured to provide for the positional pivoting of right brush drive150aand left brush drive150b, and, in one embodiment, to seal the gears, bearings, bushings, and such structures configured to impart rotational force to the mandrels. Brush drive shafts154extend through brush drive front mounting plate156and are configured to rotate. One end of the brush drive shafts154terminates in brush drive housing153where the rotation of brush drive shafts154is imparted through gears, in one embodiment, to mandrels (not shown) of the right brush drive150aand the left brush drive150b. In one embodiment, brush drive front mounting plate156defines a barrier between the structures that will be within brush box100(seeFIGS. 1-4) including brush drive housings153and right and left brush drives150a,150b, and those structures that will be external to the brush box100.

In one embodiment, the rotation of the mandrels is caused by a motor176configured to a brush drive rear mounting plate178. Motor176turns brush rotating drive pulley172. Belt174connects brush rotating drive pulley172to right brush rotating pulley170aand left brush rotating pulley170b, and is configured to turn right brush rotating pulley170aand left brush rotating pulley170bin opposite directions. Right brush rotating pulley170aand left brush rotating pulley170bdrive brush drive shafts154, resulting in the counter-rotation of the mandrels.

In addition to counter-rotating mandrels, one embodiment of the invention provides for pivoting right brush drive150aand left brush drive150bto bring brushes on brush cores118together, and to separate brushes on brush cores118to create an opening between brushes of the right brush drive150aand the left brush drive150b. Referring toFIG. 1, brushes on brush cores118are separated in order to enable substrate124to be inserted in between the brushes. Once substrate124is in place in between brushes, supported on edge rollers116, and stabilized by substrate stabilizer arm122, brushes on brush cores118are positioned together to contact opposing surfaces of substrate124. In one embodiment, the cleaning, polishing, buffing, and the like of a substrate124is enhanced and/or manipulated by the application of varying degrees of force against the opposing surfaces of substrate124by brushes attached to brush cores118.

Returning toFIG. 6A, brush angle gears158are configured to position brush drive shafts154to coordinately move right brush drive150aand left brush drive150bto move the brushes on brush cores118together and to separate the brushes attached to brush cores118. In one embodiment, the positioning of brush drive shafts154by brush angle gears158pivots the right brush drive150aand the left brush drive150b. Brush drive housings153are configured to allow the coordinate movement of the right brush drive150aand the left brush drive150bin equal and opposite directions. As right brush drive150apivots in a direction to position right brush on brush core118towards a center axis between the right brush drive150aand the left brush drive150b, the left brush drive150bpivots in the opposite direction positioning the left brush on brush core118towards the same center axis between the right brush drive150aand the left brush drive150b. Brush angle gears158are configured to position brush drive shafts154in equal and opposite directions of movement. Brush drive housings153are configured to allow a maximum range of motion for right brush drive150aand left brush drive150bto pivot brushes attached to brush cores118towards a center axis where a substrate would be positioned in a vertical orientation, and as well to pivot brushes away from the center axis providing for the insertion or removal of a substrate.

In one embodiment, movement of the brush angle gears158is driven by worm gear162. Worm shaft164is rotated to spin worm drive166which drives worm gear162. Movement of worm gear162, therefore, results in torque being applied to brush drive shaft154. In one embodiment, worm shaft164, worm drive166, and worm gear162provide for positive, precise positioning of brush drives150a,150b. Interlocked brush angle gears158ensure movement of right brush drive150ais equal and opposite to that of left brush drive150b.

Until brushes attached to brush cores118contact opposite sides of a substrate (not shown), resistance to pivotal positioning of right brush drive150aand left bush drive150bis generally limited to friction between gears, bearings, and the like. Once the brushes, however, contact opposite surfaces of a substrate (not shown), measurable force can be applied in order to position brushes attached to brush cores118, resulting in measurable force applied against the surfaces of the substrate. In one embodiment, frictional resistance is calibrated and accommodated, and the force applied to position the brushes attached to brush cores118is measured, and is approximately equal to the force applied the wafer surface, with reasonable calculation. In one embodiment, a load cell160is provided to measure the force applied to position brushes, enabling the measurement of force applied to substrate surfaces. The ability to measure and control the force applied to substrate surfaces by brushes enables more precise and controlled substrate processing. In one embodiment, a load cell (not shown) is configured to the edge wheels (seeFIGS. 14A-15C) to measure the force of the substrate downward on the edge wheels as a component of the force applied to the substrate surfaces.

FIG. 6Bshows a detailed view of brush angle gears158, load cell160, and worm gear162. The component parts precisely control the pivoting of right and left brush drives150a,150b(see FIG.6A), and in one embodiment, worm gear162and associated structures enable controlled, incremental positioning of brush drives in order to apply desired and measurable force against substrate surfaces for processing. The illustrated component parts, all on the same side of brush drive front mounting plate156, are external to the brush box100(seeFIG. 1) when brush drive assembly120is configured to brush box100.

Referring once again toFIG. 6A, in one embodiment, each of the component parts of brush drive assembly120that is implemented in pairs (e.g., brush positioning pulleys170aand170b, brush angle gears158, brush drive shafts154, brush drive housings153, brush drives150aand150b, brush cores118, and the like) are manufactured as identical component pieces, and then configured for a particular (e.g., right or left) implementation in brush drive assembly120. Cost of manufacture is significantly decreased by reduction in specialized part manufacture, and serviceability is significantly increased. In one embodiment, most assemblies that include a right and left (or top and bottom) component part use identically manufactured parts that are reversed, turned, or otherwise configured to be implemented in a desired location.

In one embodiment of the invention, right brush drive150aand left brush drive150bare configured to process a plurality of substrate sizes. By way of example, each of a 300 mm and a 200 mm semiconductor wafer, or any other desired size semiconductor wafer, can be processed by the same configuration of brush drives150aand150b. In another embodiment, brush drives150aand150bare configurable for a specific substrate size. By way of example, one size of brushes and brush cores118implemented on brush drives150aand150bare designed and configured for a 200 mm semiconductor wafer, and a different set of brushes and brush cores118are implemented on brush drives150aand150bthat are designed and configured for a 300 mm semiconductor wafer. The modular design of brush drive assembly120enables substrate processing with a brush drive assembly120designed for processing a plurality of substrate sizes, or the brush drive assembly120can be removed and replaced to customize a particular brush drive assembly120for processing a particular substrate size.

FIGS. 7A-13Cshow additional views of brush drive assembly120with various features as described above identified from a plurality of angles in accordance with an embodiment of the invention.FIG. 7Ashows a view of the brush drive assembly120in accordance with an embodiment of the invention. Identified features include fluid delivery fittings136, mandrel support connector151, mandrel support arm152, brush core118, and brush drive housing153. Also shown are brush rotating drive pulley172, right brush rotating pulley170a, left brush rotating pulley170b, belt174, and motor176, at brush drive rear mounting plate178, and behind brush drive front mounting plate156.

FIG. 7Bshows another perspective of brush drive assembly120in accordance with an embodiment of the invention. Identified features inFIG. 7Binclude right and left brush drives150a,150b, having fluid delivery fittings136, mandrel support arms152, brush cores118, and brush drive housings153. The brush drive front mounting plate156and the brush drive rear mounting plate178are also identified. Brush rotating drive pulley172, right brush rotating pulley170a, left brush rotating pulley170bare shown at the brush drive rear mounting plate178.

FIG. 7Cshows another perspective of a brush drive assembly120in accordance with an embodiment of the invention. InFIG. 7C, identified features include a right brush drive150aand a left brush drive150bhaving brush drive housings153, brush cores118, and mandrel support arms152. Opposite the brush drive housings153are mandrel support connectors151having fluid delivery plugs137. Brush drive front mounting plate156separates those structures that will be inserted into, and those structures that will remain external to the brush box100(see FIG.4). Additional identified features include brush angle gears158, brush drive shafts154, worm gear162, motor176, brush rotating drive pulley172, right brush rotating pulley170a, left brush rotating pulley170b, and belt174.

FIG. 8Ashows a view of a brush drive assembly120in accordance with an embodiment of the present invention. Identified features inFIG. 8Ainclude brush drive rear mounting plate178, and brush drive front mounting plate156. Brush drive housings153, are shown with mandrel support arms152, brush cores118, and mandrel support connectors151having fluid delivery fittings136and fluid delivery plugs137.

FIG. 8Bshows another view of a brush drive assembly120in accordance with an embodiment of the invention. Features identified inFIG. 8Binclude brush drive rear mounting plate178, and brush drive front mounting plate156. Brush drive housings153, are shown with mandrel support arms152, brush cores118, and mandrel support connectors151having fluid delivery fittings136and fluid delivery plugs137.

FIG. 8Cshows another view of a brush drive assembly120in accordance with an embodiment of the invention. Features identified inFIG. 8Cinclude brush drive rear mounting plate178, brush drive shafts154, and brush drive front mounting plate156. Brush drive housings153, are shown with mandrel support arms152, brush cores118, and mandrel support connectors151having fluid delivery fittings136and fluid delivery plugs137.

FIG. 8Dshows another view of a brush drive assembly120in accordance with an embodiment of the invention. InFIG. 8D, identified features include brush drive rear mounting plate178, motor176, brush rotating drive pulley172, right brush rotating pulley170a, left brush rotating pulley170b, and belt174. Also identified are brush drive front mounting plate156, brush drive housings153with mandrel support arms152, mandrel support connectors151, fluid delivery fittings136and fluid delivery plugs137.

FIG. 9Ais an exploded view of a brush drive assembly120in accordance with another embodiment of the present invention. Features identified inFIG. 9Ainclude motor176attached to brush drive rear mounting plate178. Right brush rotating pulley170a, left brush rotating pulley170b, and brush rotating drive pulley172are interconnected with belt174. Worm gear162, worm shaft164, worm drive166, and brush drive shafts154are shown aft of brush front mounting plate156. Right and left brush drives150a,150binclude brush drive housings153with mandrel support arms152, brush cores118, mandrel support connectors151, fluid delivery fittings136and fluid delivery plugs137.

FIG. 9Bis another exploded view of a brush drive assembly120in accordance with an embodiment of the invention. Features identified inFIG. 9Binclude brush drive rear mounting plate178and brush front mounting plate156. Right and left brush drives150a,150binclude brush drive housings153with mandrel support arms152, brush cores118, mandrel support connectors151, fluid delivery fittings136and fluid delivery plugs137. Brush drive shafts154translate the rotary drive force generated by motor176(seeFIG. 9A) to counter-rotate mandrels and brushes on brush cores118through, in one embodiment, interconnecting gears within brush drive housings153.

In one embodiment, right and left brush drives150a,150bare within an interior region of brush box100(see FIG.1), and associated drive components as described herein and located on an opposite side of brush front mounting plate156are outside of or exterior to the processing area of brush box100. Chemistries and other processing fluids used to process substrates within brush box100are contained within the brush box100processing region by seals156a, and additional seals (not shown) within brush drive housings153, which also protect brush drive component parts from the corrosive effects of moisture, corrosive chemistries, and the like. Seals156a, however, create a component of friction in rotating components which is calibrated, compensated, or otherwise compensated in force measurement calculations, and the like. In another embodiment, a labyrinth configuration is used in place of seals156a.

FIG. 10Ais a side plan view of a brush drive assembly120in accordance with an embodiment of the present invention. Illustrated features include belt174, and brush front mounting plate156. Brush drive housing153is also identified having a mandrel support arm152, brush core118, mandrel support connector151, and fluid delivery fitting136.

FIG. 10Bis a bottom plan view of a brush drive assembly120in accordance with an embodiment of the invention. InFIG. 10B, illustrated features include right brush rotating pulley170a, left brush rotating pulley170b, motor176, and brush rotating drive pulley172. Brush drive shafts154, connected to right brush rotating pulley170aand left brush rotating pulley170btravel through brush front mounting plate156into brush drive housings153. From each brush drive housing153, mandrel support arms152, and brush cores118are shown. Each mandrel support arm152is connected to a respective brush core118with a mandrel support connector151, having a fluid delivery plug137.

FIG. 11Ashows an exploded view of a single brush drive150a,150b, in accordance with an embodiment of the invention. Illustrated features include brush drive shaft154, and brush drive housing153. Also shown are mandrel support arm152, brush core118, mandrel support connector151, and fluid delivery fitting136.

FIG. 11Bshows another perspective of exploded brush drive150a,150b, in accordance with one embodiment of the present invention. Illustrated features inFIG. 11Binclude brush drive shaft154, brush drive housing153, brush core118, mandrel support arm152, mandrel support connector151, fluid delivery fitting136and fluid delivery plug137.FIG. 11Cshows a detail view of the brush drive housing153shown in FIG.11B.

FIG. 12Ais a cross-section view of a brush drive150a,150b, in accordance with an embodiment of the invention.FIG. 12Ashows mandrel190within brush drive150a,150b. In one embodiment, mandrel190is generally a hollow cylinder having a plurality of perforations therein, and a fitting191configured to receive fluid plumbing connections. Chemistries, rinses, or any other desired fluids used in substrate processing are dispensed through fitting191, through the hollow mandrel190, out of the perforations, and through the brushes on brush cores118on to the surfaces of a substrate. Also shown inFIG. 12Aare mandrel support arm152, between mandrel support connector151and brush drive housing153. A brush core118is fitted over mandrel190.

FIG. 12Bshows a detail view of the mandrel support connector151shown in FIG.12A. Mandrel support arm152connects to mandrel support connector151on one side of mandrel support connector151, and the mandrel190, having a brush core attached thereto, connects to the mandrel support connector151adjacent to the mandrel support arm152. Fitting191is within the mandrel support connector151, configured to connect to fluid delivery fitting136(not shown).

FIG. 12Cshows a detail view of the brush drive housing153shown in FIG.12A. Mandrel support arm152connects to brush drive housing153on one side of brush drive housing153, and the mandrel190, having a brush core attached thereto, connects to the brush drive housing153adjacent to the mandrel support arm152. Bearings, seals, and the like are not specifically identified inFIG. 12C, but visible to illustrate an exemplary configuration.

FIG. 13Ashows another side plan view of a brush drive assembly120in accordance with an embodiment of the present invention. Illustrated features include belt174, brush drive rear mounting plate178, and brush front mounting plate156. Brush drive housing153is also identified having a mandrel support arm152, brush core118, mandrel support connector151, and fluid delivery fitting136.

FIG. 13Bis another bottom plan view of a brush drive assembly120in accordance with an embodiment of the invention. InFIG. 13B, illustrated features include brush drive housings153, mandrel support arms152, and brush cores118. Each mandrel support arm152is connected to a respective brush core118with a mandrel support connector151, having a fluid delivery plug137.

FIG. 13Cshows a detail view of the brush drive components fromFIG. 13Bthat are exterior to the brush box100(see FIG.4). Illustrated features include right brush rotating pulley170a, left brush rotating pulley170b, motor176, and brush rotating drive pulley172. Brush drive shafts154, connected to right brush rotating pulley170aand left brush rotating pulley170btravel through brush front mounting plate156into brush drive housings153(not identified in FIG.13C). Worm shaft164and brush angle gears158are also identified in FIG.13C.

FIG. 14Ashows a detailed view of modular edge wheel assembly114in accordance with an embodiment of the invention. The illustrated edge wheel assembly114includes an edge wheel assembly block200configured to support and contain the primary features of the edge wheel assembly114. In one embodiment, the edge wheel assembly block200is a solid structure constructed of a corrosive-resistant material such as PET, or other light weight, durable, and easily fabricated material, and is manufactured as a single component part for a plurality of implementations as is discussed below.

Edge wheels116aand116bare attached to edge wheel shafts204which are configured through edge wheel assembly block200in shaft bores230or232(seeFIGS. 14D,14E,14F). In one embodiment, two pairs of shaft bores230and232are configured into edge wheel assembly block200to enable configuration of edge wheel assembly insert114for a plurality of substrate sizes. By way of example, edge wheel shafts204mounted through shaft bores230might position a 200 mm substrate on edge wheels116aand116bfor optimal processing, and edge wheel shafts204mounted through shaft bores232might position a 300 mm substrate on edge wheels116aand116bfor optimal processing. Shaft bores230or232not used in a desired implementation are plugged with bore plugs234(seeFIGS. 14B,14E). As will be described in greater detail, shaft bores230and232are configured with passages in the interior of edge wheel assembly block200, and bore plugs234seal the passages and bores. In one embodiment of the invention, shaft bores230and232provide for the easy configuration of the modular edge wheel assembly114for optimal processing of both 200 mm substrates and 300 mm substrates. In one embodiment, edge wheels116a,116b, are provided of a particular size to be used with a specific size of substrate.

Edge wheels116aand116bare rotated by edge wheel shafts204. Edge wheel shafts204are rotated by driven pulleys212connected to an edge wheel motor202. Edge wheel motor202is attached to edge wheel motor plate208and drives drive pulley210. Drive pulley210is connected to driven pulleys212by belt216in order to rotate driven pulleys212connected to drive shafts204, thereby rotating edge wheels116aand116b. Belt216is configured to rotate driven pulleys212in the same direction so that edge wheels116aand116brotate a substrate (not shown) positioned thereon. Belt tensioner214is provided to maintain constant and appropriate contact between belt216, drive pulley210, and driven pulleys212. In one embodiment, configuration of drive shafts204in shaft bores230utilizes a larger belt216than configuration of edge wheel shafts204configured in shaft bores232. In another embodiment, the process of rotating edge wheel shafts204is accomplished by gears.

In one embodiment of the invention, edge wheel assembly block200includes a plurality of passages through the interior of the edge wheel assembly block200for fluid delivery to a plurality of locations in and on or around edge wheel assembly114. Edge wheel assembly block fitting206is provided to connect fluid supply to the edge wheel assembly114. In one embodiment, supplied fluid includes DI water, and is provided for rinsing, lubrication, cooling, and the like of the edge of a substrate positioned on edge wheels116aand116b. In addition, edge wheels116aand116bare rinsed, cooled, lubricated, and the like, as well as edge wheel shafts204, shaft bores230and232, and interior seals, fittings, bushings, and the like of edge wheel assembly block200. Sprayers220are provided on the edge wheel assembly block200in a plurality of locations for desired dispensing of fluids on a substrate edge, edge wheels116aand116b, and edge wheel shafts204. In one embodiment, edge wheel assembly block200is configured to accept sprayers220in a plurality of locations adjacent to both shaft bores230and232for sprayer220implementation in a plurality of substrate size configurations of edge wheel assembly114.

In one embodiment, shaft bore sprayer236(seeFIG. 14E) is provided to dispense fluid to the interior of shaft bores230and232for cooling and lubrication. Shaft bore sprayers236are connected to the interior fluid passages within edge wheel assembly block200such that when fluid is supplied to the edge wheel assembly114, edge wheel shafts204are cooled and lubricated with the same fluid used for rinsing, cooling, lubricating, and the like of edge wheels116aand116b, and the substrate edge. Shaft bore230or232that does not have a edge wheel shaft204configured in a desired configuration is sealed with bore plug fittings234(seeFIGS. 14B,14E).

Interior fluid passages within edge wheel assembly block200are configured for a plurality of applications of the edge wheel assembly114. The interior fluid passages provide for the configuration of sprayers220in desired locations, and for the implementation of both shaft bores230and232to contain shaft bore sprayers236. In one embodiment, edge wheel assembly block200is thereby fabricated as a single component piece to be implemented in a plurality of configurations of edge wheel assembly114. In one embodiment, edge wheel assembly block200is fabricated as a symmetrical component about a mid-point vertical axis. The same assembly block200is therefore capable of attaching to a brush box100(seeFIG. 1) on either a right or left side of brush box100, and the configured sprayers, fittings, and the like can be configured for either orientation to perform required functions as necessary. The interior fluid passages are configured to provide the desired fluid supply in the plurality of desired applications without requiring specifically and specially manufactured piece parts. In one embodiment, openings224in edge wheel assembly block200are created during the manufacture of edge wheel assembly block200, and are fitted with plugs224ato seal the interior fluid passages.

FIG. 14Bshows another view of edge wheel assembly114in accordance with an embodiment of the invention. Illustrated features inFIG. 14Binclude edge wheel assembly block200with openings224in edge wheel assembly block200created during manufacture which can be fitted with plugs224a. Edge wheel assembly block fitting206is provided to connect fluid supply to the edge wheel assembly114, and sprayers220are shown adjacent to edge wheels116a,116b. An unused bore is shown sealed by bore plug234. Edge wheel motor plate208is configured to attach edge wheel drive motor202to edge wheel assembly block200. In one embodiment, edge wheel motor plate208is reversible, and thereby configurable to attach edge wheel drive motor202to edge wheel assembly block200in a plurality of implementations of the edge wheel assembly114.

FIG. 14Cshows another view of edge wheel assembly114in accordance with an embodiment of the invention. Identified features inFIG. 14Cinclude edge wheel assembly block200, sprayer220, and edge wheels116a,116b. Edge wheel motor plate208is shown attaching edge wheel drive motor202to edge wheel assembly block200.

FIG. 14Dshows a cross-sectional view of edge wheel assembly114in accordance with an embodiment of the invention. Features identified inFIG. 14Dinclude edge wheels116a,116b, sprayer220, and edge wheel assembly block fitting206. Shaft bores230and232are identified, and described in greater detail below.

FIG. 14Eshows a detail cross-sectional view of shaft bores230,232from FIG.14D. InFIG. 14E, side-by-side shaft bores230and232are shown with an edge wheel shaft204and edge wheel116configured in shaft bore230, and a bore plug234configured in unused shaft bore230. Shaft bore sprayer236is shown adjacent to edge wheel shaft204in shaft bore230. In one embodiment, shaft bore sprayer236provides cooling, lubrication, and the like to edge wheel shaft204and shaft bore230, and additionally keeps shaft seals, bearings, bushings, (not identified inFIG. 14E, but visible) and the like lubricated, pliable, and properly functioning.

FIG. 14Fis a side plan view of edge wheel assembly114in accordance with an embodiment of the present invention. Identified features inFIG. 14Finclude edge wheel assembly block200having shaft bores230and232. Driven pulleys212, and drive pulley210are interconnected by belt216, with belt tensioner214provided to maintain constant and appropriate contact between belt216, drive pulley210, and driven pulleys212. In an embodiment with drive shafts204(not shown) in shaft bores232, a different size of belt216may be provided than that in the illustrated embodiment. Edge wheel motor plate208is configured to attach edge wheel drive motor202(not visible inFIG. 14F) to edge wheel assembly block200.

FIG. 15Ashows another perspective view of edge wheel assembly114in accordance with an embodiment of the invention. InFIG. 15A, identified features include edge wheel assembly block200with openings224and plugs224a, and sprayers220. Edge wheels116a,116bare configured in one set of shaft bores, and unused shaft bores232are visible. Edge wheel drive motor202is attached to edge wheel assembly block200with edge wheel motor plate208. Fluids, chemistries, and the like are provided to edge wheel assembly block200through edge wheel assembly block fitting206.

FIG. 15Bshows another perspective view of edge wheel assembly114in accordance with another embodiment of the present invention. Identified features inFIG. 15Binclude edge wheel assembly block200with openings224and plugs224a, and sprayers220. Edge wheels116a,116bare configured in shaft bores230, and unused shaft bores232are visible. Edge wheel drive motor202is attached to edge wheel assembly block200with edge wheel motor plate208.

FIG. 15Cshows another perspective view of edge wheel assembly114in accordance with another embodiment of the invention. Identified features inFIG. 15Cdriven pulleys212, and drive pulley210interconnected by belt216, with belt tensioner214provided to maintain constant and appropriate contact between belt216, drive pulley210, and driven pulleys212. Edge wheels116a,116bare configured in shaft bores230(not identified in FIG.15C), and unused shaft bores232are visible. Edge wheel drive motor202is attached to edge wheel assembly block200with edge wheel motor plate208. Fluids, chemistries, and the like are provided to edge wheel assembly block200through edge wheel assembly block fitting206.

In one embodiment of the present invention, substantially all pieces, components, and assembly parts of the brush box100that may be exposed to processing fluids are constructed of durable, light weight, and easily manufactured, molded, and configured material that is resistant to corrosion or other deterioration that might result from exposure to a plurality of processing fluids. Materials for such wet exposure include plastic, PET, or other similar materials. Supporting, structural, and other such component parts of the brush box100that are generally not exposed to processing fluids are manufactured of strong, light weight, and low particle generating materials such as hastelloy and stainless steel.

As described, one embodiment of the brush box100is easily configurable for a plurality of applications. Primary components are generally modular and symmetrical to provide for more efficient manufacture of components that are implemented in a plurality of configurations. In a typical implementation, brush box100is implemented as a pair of side-by-side brush boxes100, with a left and right brush box100. Left and right brush boxes100are typically of a symmetrical configuration with maximum access for use and serviceability. In one embodiment, such a configuration includes the edge wheel insert assemblies114configured to the exterior panels of brush box100, and doors110hinged to open towards the center of the configuration. The present invention provides for the configuration of a plurality of desired implementations without requiring specialized or specific manufacture of the various component parts. In this manner, cost of manufacture is significantly reduced, and serviceability is significantly increased.

FIGS. 16A and 16Bshow an integrated processing tool incorporating a pair of brush boxes100in accordance with an embodiment of the invention. InFIG. 16A, a pair of brush boxes100is configured side-by-side, and a pair of drying tools is configured above the brush boxes100. Implementing a pair of brush boxes100with a pair of drying tools provides an efficient and economical method of substrate processing at a plurality of substrate process steps. By way of example, batches of semiconductor wafers can be processed through a post-CMP wet clean with minimal transfer and handling of the wafers when the integrated processing tool is positioned proximate to the CMP tool.

FIG. 16Bshows the same integrated processing tool as inFIG. 16Afrom a different angle. As can be seen, one embodiment of the invention implementing a side-by-side configuration maximizes serviceability and space efficiency. Brush boxes100are configured with such assemblies as the wafer sensing apparatus, the substrate stabilizer assembly, and the edge wheel assembly on the exterior or outboard panel300of each brush box100. Doors10are configured to open toward the interior or inboard region of the tool with securing screws130shown on the exterior or outboard edge of doors110. A system controller is shown and is used to integrate the plurality of functions of the present invention, as well as the present invention with the additional processing tools.