Abstract:
The cleaning of particles from an electrostatic chuck. In one embodiment, a method of cleaning an electrostatic chuck in a processing chamber is disclosed. The method comprises directing a flow of gas across the electrostatic chuck to dislodge particles from the electrostatic chuck and removing the flow of gas and particles through an exhaust port in the processing chamber. In this embodiment, the vacuum integrity of the chamber is not compromised during the cleaning of the electrostatic chuck.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is related to and claims the benefit under 35 USC 119(e) of Provisional Application Ser. No. 60/503,701 (the &#39; 701  Application), filed on Sep. 17, 2003. The &#39; 701  Application is incorporated by reference 
     
    
     TECHNICAL FIELD  
       [0002]     The present invention relates generally to electrostatic chuck and in particular the present invention relates to the cleaning of particles from an electrostatic chuck.  
       BACKGROUND OF THE INVENTION  
       [0003]     Electrostatic chucks (e-chucks) are used in processing semiconductor devices. In particular, e-chucks are used to hold a semiconductor wafer in place during processing. Processing of the wafer typically takes place in a vacuum processing chamber. As stated above, the e-chucks hold the wafer in place while it is being processed in the processing chamber. An e-chuck is generally a capacitor element having a conductor/insulator structure that is adapted to selectively generate an electrostatic filed between the wafer and an e-chuck to selectively hold the wafer in place during processing. During processing, particles as the result of the processing can accumulate on the e-chuck. For example, processes such as depositions and etching can create particles that can accumulate on the e-chucks. These particles can compromise the surface of the e-chuck causing the e-chuck to no longer effectively hold a wafer in place during processing. If a wafer is dislodged as a result of an accumulation of particles, the wafer is either scrapped or reprocessed. If the problem persists, the general practice in the art is venting the chamber and manually cleaning the e-chuck. This, however, creates a significant loss in manufacturing time.  
         [0004]     For the reasons stated above and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for a method effectively removing particles from the surface of the e-chuck without venting the chamber  
       SUMMARY OF THE INVENTION  
       [0005]     The above-mentioned problems and limitations existing in the prior art are addressed by embodiments of the present invention and will be understood by reading and studying the following specification.  
         [0006]     In one embodiment, a method of cleaning an electrostatic chuck in a processing chamber is disclosed. The method comprises directing a flow of gas across the electrostatic chuck to dislodge particles from the electrostatic chuck and removing the flow of gas and particles through an exhaust port in the processing chamber. In this embodiment, the vacuum integrity of the chamber is not compromised during the cleaning of the electrostatic chuck.  
         [0007]     In yet another embodiment, a semiconductor processing chamber system is disclosed. The chamber system includes a vacuum chamber, an electrostatic chuck, one or more gas inlets and one or more exhaust ports. The vacuum chamber is used to provide a pressure regulated environment. The electrostatic chuck received in the vacuum chamber adapted to selectively hold a wafer to be processed. The one or more gas inlets are adapted to direct a flow of gas on a surface of the electrostatic chuck to remove particles accumulated on the electrostatic chuck surface. Moreover, the one or more exhaust ports are adapted to remove the flow of gas and particles from the chamber without breaking the vacuum integrity of the vacuum chamber.  
         [0008]     In still another embodiment, a wafer blade for placing and removing wafers on and from an electrostatic chuck in a semiconductor processing chamber is disclosed. The wafer blade comprises a first surface and a second surface. The first surface is adapted to face the electrostatic chuck, the first surface has one or more gas inlets adapted to direct one or more flows of gas to a surface of the electrostatic chuck to remove particles form the surface of the electrostatic chuck. The second surface adapted to engage a wafer. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]     The present invention can be more easily understood and further advantages and uses thereof more readily apparent, when considered in view of the description of the preferred embodiments and the following figures in which:  
         [0010]      FIG. 1  is a cross-sectional side view of a processing vacuum chamber of one embodiment of the present invention;  
         [0011]      FIG. 2A  is a bottom view of a wafer blade of one embodiment of the present invention;  
         [0012]      FIG. 2B , is a side view of wafer blade of one embodiment of the present invention;  
         [0013]      FIG. 3  is a bottom view of a wafer blade of another embodiment of the present invention;  
         [0014]      FIG. 4 , is a close up view of a slit opening of a gas inlet of one embodiment of the present invention;  
         [0015]      FIG. 5 , is a close up view of an oval opening of a gas inlet of one embodiment of the present invention; and  
         [0016]      FIG. 6 , is a side view of an embodiment of a rotatable nozzle of a gas inlet of one embodiment of the present invention. 
     
    
       [0017]     In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Reference characters denote like elements throughout Figures and text.  
       DETAILED DESCRIPTION  
       [0018]     In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the claims and equivalents thereof.  
         [0019]     The present invention allows for a situ cleaning of the surface of the e-chuck without the need to break the vacuum integrity of the chamber and without the loss in production time related to venting and manually cleaning the e-chuck. Embodiments of the present invention accomplish this by directing a gas flow across the e-chuck. As a result the particles are removed with the flow of gas. The gas is then vented through an exhaust port common to vacuum chambers without breaking the vacuum integrity of the chamber.  
         [0020]     One embodiment of a processing chamber of the present invention is illustrated in the cross-sectional side view of  FIG. 1 .  FIG. 1  includes an e-chuck  102  in a chamber  110 . The chamber  110  includes gas inlets  104  that provide a flow of gas to remove accumulated particles on the e-chuck  102 . The gas flow and particles are removed through the exhaust outlet  106 . This is accomplished without breaking the vacuum of the chamber  110 . Although, this embodiment only illustrates one exhaust output  106 , other embodiments include more than one exhaust outputs  106 . Also illustrated in  FIG. 1 , is a wafer blade  108 . The wafer blade  108  is used to remove and place wafers on the e-chuck. The blade  108  is adapted to move into and out of the chamber  110 . The wafer blade  108  works in concert with wafer pins  112  to remove and place wafers on the e-chuck. In particular, the pins  112  are adapted to move up and out of the e-chuck  102  to receive wafers from the blade  108 . The pins  112  are further adapted to move down into the e-chuck  102  to place the wafer on the e-chuck  102 . The pins  112  are further adapted to remove a wafer by moving up and out of the e-chuck  102  and engaging the wafer. The blade  108  is then adapted to remove the wafer from the pins  112 .  
         [0021]     In one embodiment of the present invention, the wafer blade  108  is adapted to provide the stream of gas that removes the particles from the e-chuck  112 . An example of a wafer blade  200  of this embodiment is illustrated in  FIG. 2 . As the bottom view of the embodiment of  FIG. 2  illustrates, a bottom (first surface)  201  has a plurality of gas inlets  202  that provide the stream of gas that removes the accumulated particles from the e-chuck. The advantage to this embodiment is that as the wafer blade  200  is moved across the e-chuck  112  (please refer to  FIG. 1 ) when placing and removing wafers  204  from the e-chuck  112 , the flow of gas provided by the wafer blade  200  is provided in close proximity to the e-chuck  112 . In one embodiment, the gas is adapted to flow each time a wafer  204  is placed on the e-chuck  112 . In another embodiment, the gas is adapted to flow each time a wafer  204  is removed from the e-chuck  112 . In still another embodiment, the gas is adapted to flow each time a wafer  204  is place and removed from the e-chuck  112 . Still further in other embodiments, the wafer blade  200  is passed over its associated e-chuck one or more times without a wafer on the e-chuck to remove the accumulated particles. Referring to  FIG. 2B  a side view of the wafer blade  200  of  FIG. 2A  is illustrated. As  FIG. 2B  illustrates, the gas inlets  202  extend from a bottom (first surface)  201  of the wafer blade  200 . A top (second surface)  203  of the wafer blade  200  is adapted to engage a wafer  204 . The bottom surface  201  of the wafer blade is adapted to face an associated e-chuck.  
         [0022]     Referring to  FIG. 3 , another embodiment of a wafer blade  300  is illustrated.  FIG. 3 , is a bottom view of the wafer blade  300  of this embodiment. As illustrated, the wafer blade  300  includes gas inlets  302  on the bottom surface (first surface)  311  of the wafer blade  300 . A top surface (second surface) (not shown) of the wafer blade  300  is adapted to engage a wafer  306 . In this embodiment, arms  308  and  310  are pivotally coupled to the bottom surface  311  of the wafer chuck  300  by respective pivot connections  109  and  311 . As illustrated, arms  308  and  310  have gas inlets  304 . In this embodiment, the arms are adapted to pivot out away from the wafer blade during an e-chuck cleaning. When the arms  308  and  310  are pivoted away from the wafer blade  300  more of the surface area of the e-chuck is subjected to the gas flow at a closer proximity to the gas inlets  302  and  304 .  
         [0023]     The embodiments openings of the gas inlets  104 ,  202 ,  302  and  304  and of  FIGS. 1, 2A ,  3 B and  3  are illustrated as generally being round in shape, in other embodiments this is not the case. For example, in the embodiment of  FIG. 4 , the gas inlets  400  openings  402  are generally a rectangular slot and in the embodiment of  FIG. 5 , the gas inlets  500  openings  502  are generally oval in shape. In yet another example, the gas inlets are adapted to rotate to disburse the gas flow in different directions. This embodiment is illustrated in the side view of a wafer blade  600  of  FIG. 6 . As illustrated, the gas inlets  602  are coupled to a bottom surface (first surface)  601  of wafer blade  600 . A top surface (second surface) is adapted to selectively engage a wafer  604 . The gas inlets  602  of this embodiment are adapted to rotate as the flow of gas is being expelled from their respective openings  606 . With this embodiment, one or more gas inlets  602  rotate to expel the gas flow across generally the entire surface of an associated e-chuck to remove accumulated particles.  
         [0024]     Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.