Abstract:
A method and device for processing wafer-shaped articles includes a spin chuck for holding and rotating a wafer-shaped article about a rotation axis, and at least one dispenser for dispensing a fluid onto at least one surface of a wafer-shaped article. A collector surrounds the spin chuck for collecting process fluids, with at least two collector levels for separately collecting fluids in different collector levels. Each collector level comprises an exhaust gas collecting chamber leading to a respective exhaust gas conduit. At least one of the exhaust gas conduits comprises a valve mechanism that reciprocally restricts exhaust gas flow from its associated exhaust gas conduit while opening the exhaust gas conduit to an ambient environment outside the collector, and vice-versa.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The invention relates to a device and a method for processing wafer-shaped articles, such as semiconductor wafers, flat panel displays or optical discs. 
         [0003]    2. Description of Related Art 
         [0004]    Semiconductor wafers are subjected to various surface treatment processes such as etching, cleaning, polishing and material deposition. To accommodate such processes, a single wafer may be supported in relation to one or more treatment fluid nozzles by a chuck associated with a rotatable carrier, as is described for example in U.S. Pat. Nos. 4,903,717 and 5,513,668. 
         [0005]    U.S. Pat. No. 4,903,717 discloses that its spin-chuck may be raised and lowered relative to a surrounding liquid collector that has plural liquid collecting levels and a common exhaust for collecting gas from the interior of the liquid collector. 
         [0006]    U.S. Pat. No. 7,837,803 discloses an improved liquid and gas collector in which the exhaust at each of the levels may be individually controlled via valves provided at each of the levels. However, depending upon the particular process being performed upon the wafer-shaped article, the valves of that patent will come in contact with chemically aggressive fumes. It can be difficult to maintain such valves in good working order under such conditions. 
         [0007]    There is therefore a need for a collector structure that can better prevent fumes from various media (e.g., acid, base, organic) from intermingling in a common process chamber, so as to prevent vapor cross-contamination. Such cross-contamination could result in the deposition of crystalline solids on delicate processing equipment, as well as various safety issues. 
       SUMMARY OF THE INVENTION 
       [0008]    The invention in one aspect thus pertains to a device for processing wafer-shaped articles, comprising a spin chuck for holding and rotating a wafer-shaped article about a rotation axis, and at least one dispenser for dispensing a fluid onto at least one surface of a wafer-shaped article. A collector surrounds the spin chuck for collecting process fluids, with at least two collector levels for separately collecting fluids in different collector levels. Each of the at least two collector levels comprises an exhaust gas collecting chamber leading to a respective exhaust gas conduit. At least one of the exhaust gas conduits comprises a valve mechanism that reciprocally restricts exhaust gas flow from its associated exhaust gas conduit while opening the exhaust gas conduit to an ambient environment outside the collector, and vice-versa. The term “fluid” as used herein is intended to connote a liquid, however such liquid may contain gas bubbles (for example as a two-phase mixture in the nature of a foam), or may be a mixture of two or more miscible or immiscible liquids, or a liquid including suspended solids, or any mixtures of the foregoing. 
         [0009]    In preferred embodiments of the device according to the present invention, one of the exhaust conduits comprises a bypass valve operable to route exhaust gas from the one of the exhaust conduits to another of the exhaust conduits. 
         [0010]    In preferred embodiments of the device according to the present invention, the valve mechanism comprises a flap valve movable between a chamber position in which exhaust gas from its associated exhaust conduit is permitted to pass while the exhaust conduit is sealed to the exterior ambient, and an ambient position in which ambient atmosphere outside the collector is permitted to pass while the exhaust conduit is sealed to chamber exhaust gases upstream of the valve mechanism. 
         [0011]    In preferred embodiments of the device according to the present invention, the collector comprises at least three of the collector levels, and wherein exhaust conduits of at least two of the collector levels each comprise a corresponding valve mechanism. 
         [0012]    In preferred embodiments of the device according to the present invention, one of the exhaust conduits comprises a first bypass valve operable to route exhaust gas from one of the exhaust conduits to a second of the exhaust conduits, and a second bypass valve operable to route exhaust gas from one of the exhaust conduits to a third of the exhaust conduits. 
         [0013]    In preferred embodiments of the device according to the present invention, a controller is provided for actuating the valve mechanism, and the valve mechanism is actuated in response to the spin chuck being moved relative to the collector from one collector level to another collector level. 
         [0014]    In preferred embodiments of the device according to the present invention, the collector levels are vertically superposed along an axis of rotation of the spin chuck. 
         [0015]    In preferred embodiments of the device according to the present invention, the collector comprises three collector levels, and an exhaust conduit of an uppermost one of the three collector levels comprises a first bypass valve that is operable to divert exhaust gas from the exhaust conduit to an exhaust conduit of a lowermost one of the three collector levels, a second bypass valve that is operable to divert exhaust gas from the exhaust conduit to an exhaust conduit of a middle one of the three collector levels, and a valve mechanism disposed in the exhaust conduit of the uppermost collector level downstream of the first and second bypass valves. 
         [0016]    In preferred embodiments of the device according to the present invention, the collector comprises three collector levels, and each corresponding exhaust conduit comprises a respective valve mechanism. 
         [0017]    In preferred embodiments of the device according to the present invention, the valve mechanism is operable such that actuation of the valve mechanism in its associated exhaust conduit causes a pressure variation of less than 20 Pa in any others of the at least two collector levels. 
         [0018]    In preferred embodiments of the device according to the present invention, the collector comprises three collector levels, and each corresponding exhaust conduit comprises a respective valve mechanism. 
         [0019]    In preferred embodiments of the device according to the present invention, at least one of the exhaust gas conduits further comprises a bypass valve disposed upstream of the valve mechanism, the bypass valve being operable to route exhaust gas from that exhaust conduit to another of the exhaust conduits. 
         [0020]    In preferred embodiments of the device according to the present invention, the valve mechanism and the bypass valve are operated by a controller such that the bypass valve is actuated to divert exhaust gas from the at least one conduit to another conduit simultaneously with actuation of the valve mechanism to seal the at least one exhaust conduit against passage of chamber exhaust while opening the at least one gas conduit to an exterior ambient at a location downstream of the bypass valve. 
         [0021]    In another aspect, the present invention relates to a method for processing wafer-shaped articles, comprising holding and rotating a wafer-shaped article about a rotation axis on a spin chuck, and dispensing a first fluid onto at least one surface of the wafer-shaped article. Process fluids are separately collected in at least two process levels of a collector that surrounds the spin chuck. Each of the at least two collector levels comprises an exhaust gas collecting chamber leading to a respective exhaust gas conduit. A valve mechanism associated with at least one of the exhaust gas conduits is operated so as reciprocally to restrict exhaust gas flow from its associated exhaust gas conduit while opening that exhaust gas conduit to an ambient environment outside the collector, and vice-versa. 
         [0022]    In preferred embodiments of the method according to the present invention, a bypass valve mounted in one of the exhaust conduits is operated so as to route exhaust gas from that exhaust conduit to another exhaust conduit. 
         [0023]    In preferred embodiments of the method according to the present invention, the valve mechanism is operated so as to move a flap valve between a chamber position in which exhaust gas from its associated exhaust conduit is permitted to pass while the exhaust conduit is sealed to the exterior ambient, and an ambient position in which ambient atmosphere outside the collector is permitted to pass while the exhaust conduit is sealed to chamber exhaust gases upstream of the valve mechanism. 
         [0024]    In preferred embodiments of the method according to the present invention, the valve mechanism is operated such that actuation of the valve mechanism in its associated exhaust conduit causes a pressure variation of less than 20 Pa in any others of the at least two collector levels. 
         [0025]    In preferred embodiments of the method according to the present invention, process gases having respectively different compositions are exhausted each through a respective exhaust conduit. 
         [0026]    In preferred embodiments of the method according to the present invention, a second fluid is dispensed onto the wafer, wherein the chemical composition of the second fluid differs from that of the first fluid, and collecting gas generated from the second process fluid through a different exhaust conduit than that through which gas generated by the first process fluid is collected. 
         [0027]    In preferred embodiments of the method according to the present invention, exhaust gases are collected simultaneously from at least two separate collectors, by a common exhaust unit. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]    Other objects, features and advantages of the invention will become more apparent after reading the following detailed description of preferred embodiments of the invention, given with reference to the accompanying drawings, in which: 
           [0029]      FIG. 1  shows a schematic side view of a device according to a first embodiment of the present invention; 
           [0030]      FIG. 2  shows a preferred structural configuration for one of the flap valves  52  shown in  FIG. 1 ; 
           [0031]      FIG. 3  shows a combination of valve states for a first wafer process; 
           [0032]      FIG. 4  shows a combination of valve states for a second wafer process; 
           [0033]      FIG. 5  shows a combination of valve states for a third wafer process; 
           [0034]      FIG. 6  shows a combination of valve states for a fourth wafer process; 
           [0035]      FIG. 7  shows a combination of valve states for a fifth wafer process; 
           [0036]      FIG. 8  shows a combination of valve states for a sixth wafer process; 
           [0037]      FIG. 9  shows in greater detail the valve states of  FIGS. 3 ,  4  and  8 ; 
           [0038]      FIG. 10  shows in greater detail the valve states of  FIG. 5 ; 
           [0039]      FIG. 11  shows in greater detail the valve states of  FIG. 6 ; 
           [0040]      FIG. 12  shows in greater detail the valve states of  FIG. 7 ; 
           [0041]      FIG. 13  shows a variation of the valve states of  FIGS. 6 and 11 ; 
           [0042]      FIG. 14  shows a variation of the valve states of  FIGS. 7 and 12 ; and 
           [0043]      FIG. 15  is a schematic plan view of a process module that includes multiple devices according to the present invention, with exhaust units each of which is common to a given exhaust level of the multiple devices. 
       
    
    
     DETAILED DESCRIPTION 
       [0044]    In the embodiments described hereinafter, the exhaust gas flow is controlled so that minimum influence occurs when specific exhausts corresponding to specific process levels are switched on or off. If an exhaust of a process level is closed this would create a reduced pressure in that specific exhaust. For avoiding this (pressure drop) the exhaust is closed to the process level and simultaneously opened to the ambient air. Consequently the same amount of air is exhausted and there will not occur any sudden pressure reduction. This technique thus also prevents cross contamination in the chamber if the pressure were to suddenly increase. 
         [0045]      FIG. 1  shows a device  1  comprising a spin chuck  2  for holding and rotating a wafer W. The spin chuck  2  is connected to a gear motor unit  5  to be rotated about its axis A. A dispensing device  3  is used for dispensing fluid onto the upper surface of the substrate W. Wafer W may for example be a 300 mm or 450 mm silicon wafer undergoing any of various front-end-of-line (FEOL), middle-of-line, (MOL), or back-end-of-line (BEOL) processes, including associated cleaning and drying processes. 
         [0046]    A cup-like fluid collector  4  circumferentially surrounds the spin chuck  2 . The fluid collector is preferably mounted on a frame (not shown). Lifting devices H, such as hydraulic jacks or pneumatic cylinders, are provided to alter the spin chuck position relative to the fluid collector, in this case by raising the fluid collector  4 . The spin chuck  2  can thus be positioned at each of the three collector levels L 1 , L 2  and L 3 . 
         [0047]    Each collector level L 1 , L 2 , L 3  comprises an annular duct  41 ,  42 ,  43  that collects spun-off process fluid. An additional splash guard (not shown) can be used for each collector level to allow spun-off fluid to hit it at an acute angle and thereafter to be directed to the annular duct. Each annular duct  41 ,  42 ,  43  is connected to a respective pipe (not shown) through which the collected fluid is drained. Drained fluid can be reused to be dispensed to the substrate, or collected as waste fluid. 
         [0048]    The dashed lines in  FIG. 1  indicate the relative positions where the substrate is to be placed for spinning off the fluids into the different collector levels. 
         [0049]    Above each collector level L 1 , L 2 , L 3  an interiorly open annular exhaust duct  21 ,  22 ,  23  is arranged. Each duct  21 ,  22 ,  23  leads to a respective annular gas-collecting chamber  11 ,  12 ,  13 . 
         [0050]    Each gas-collecting chamber  11 ,  12 ,  13  is connected by a respective exhaust pipe  31 ,  32 ,  33  to an exhaust unit  60 , which comprises a fan or the like to draw exhaust gases from the collector and discharge those gases as depicted by the arrow E. Only one exhaust unit  60  is shown in Each exhaust pipe  31 ,  32 ,  33  in this embodiment is equipped with a respective valve  51 ,  52 ,  53  that can be controlled so as to pass the exhaust gas from its associated collector level, or, alternatively, to close off the exhaust from its associated collector level while opening the valve  51 ,  52 ,  53  to the ambient atmosphere outside the collector  4 . 
         [0051]    Also in this embodiment, a bypass valve  54  is positioned in communication with exhaust pipes  31  and  33 , so that the exhaust from level L 3  of the collector may if desired be re-routed from the exhaust pipe  33  to the exhaust pipe  31 , or vice-versa, via a bypass conduit  56 . Similarly, in this embodiment, a bypass valve  55  is positioned in communication with exhaust pipes  32  and  33 , so that the exhaust from level L 3  of the collector may if desired be re-routed from the exhaust pipe  33  to the exhaust pipe  32 , or vice versa, via a bypass conduit  57 . 
         [0052]    In  FIG. 1 , the chuck  2  is positioned at level L 1 , where a given process is performed on the wafer W, for example an SC- 1  cleaning process that utilizes an aqueous mixture of ammonium hydroxide and hydrogen peroxide. The gases generated during such a process, which are basic in character, are withdrawn from the chamber  11  via exhaust pipe  31 , because bypass valve  54  is in the level  1  position and valve  51  is in the chamber position. 
         [0053]    On the other hand, valve  52  is in the ambient position, so that the gas drawn through exhaust pipe  32  is not from the chamber  12  but rather is ambient air, as indicated by the arrow A in  FIG. 1 . Bypass valve  55  is in the level  2  position, so that the ambient air passes through exhaust pipe  32  and into the exhaust unit  60 . As to the level  3  exhaust, this passes through exhaust pipe  33  into the exhaust unit  60 , because valve  53  is in the chamber position and bypass valves  54  and  55  are both closed, so that there is no transfer of exhaust among the pipes  31 ,  32 ,  33 . 
         [0054]    As shown in  FIG. 2 , the valve  52  in this embodiment is configured as a flap that moves between the solid line position, in which ambient air is admitted into exhaust pipe  32  through holes  58  (the “ambient position”) and the broken line position in which the holes  58  are blocked and exhaust gas E 2  from the L 2  level of collector  4  is free to enter the exhaust pipe  32  (the “chamber position”). Significantly, a valve  52  as thus described can also be positioned at any desired intermediate position, such that a controlled mixture of ambient and chamber gas is fed to the exhaust pipe. 
         [0055]    Although valve  52  is illustrated in  FIG. 2 , it will be appreciated that valves  51  and  53  are similarly constructed and operate on the same principle. 
         [0056]    In the following table, a series of processing operations are set forth in terms of the corresponding positions of valves  51 - 55 , and these will be described in connection with  FIGS. 3-14 . 
         [0000]    
       
         
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                   
                   
                   
                 Level 3 
                 Level 3 
                 Level 3 
               
               
                 Exhaust 
                   
                 Level 1 
                 Level 2 
                 processing  
                 processing 
                 (processing 
               
               
                 valve 
                 Load/Unload 
                 processing 
                 processing 
                 (exhaust to Level 1) 
                 (exhaust to Level 2) 
                 exhaust to Level 3) 
               
               
                   
               
             
             
               
                 Valve 51 
                 Chamber 
                 Chamber 
                 Ambient 
                 Chamber 
                 Chamber 
                 Chamber 
               
               
                 Valve 52 
                 Ambient 
                 Ambient 
                 Chamber 
                 Chamber 
                 Ambient 
                 Ambient 
               
               
                 Valve 53 
                 Chamber 
                 Chamber 
                 Chamber 
                 Ambient 
                 Chamber 
                 Chamber 
               
               
                 Valve 54 
                 Level 3 
                 Level 3 
                 Level 3 
                 Level 1 
                 Level 3 
                 Level 3 
               
               
                 Valve 55 
                 Level 3 
                 Level 3 
                 Level 3 
                 Level 3 
                 Level 2 
                 Level 3 
               
               
                   
               
             
          
         
       
     
         [0057]    In  FIG. 3 , the chuck  2  is in an uppermost position relative to collector  4 , which is a load/unload position at which a wafer W may be loaded onto or unloaded from the chuck  2 . At this position, the state of valves  51 - 55  is the same as in  FIG. 1 .  FIG. 9  is a corresponding view that more fully illustrates a possible configuration of exhaust pipes  31 ,  32 ,  33  and valves  51 - 54 . It will be appreciated from  FIG. 9  that the exhaust pipes  31 ,  32 ,  33  can be laid out and the bypass valves  54 ,  55  positioned such that there is no need of additional bypass pipes  56 ,  57  such as those indicated schematically in  FIG. 1 . 
         [0058]    In  FIG. 4 , the chuck  2  has been lowered relative to the collector  4  such that the wafer W is at the process level L 1 . The state of valves  51 - 55  is unchanged from  FIG. 3 , and thus remains as shown also in  FIGS. 1 and 9 . 
         [0059]    In  FIG. 5 , the chuck  2  has been raised relative to the collector  4  such that the wafer W is at the process level L 2 . The level  2  processing in this embodiment involves etching the wafer with a dilute solution of hydrofluoric acid (DHF). As to the state of valves  51 - 55 , it will be appreciated that, in moving from the level  1  processing of  FIG. 4  to the level  2  processing of  FIG. 5 , valve  51  has been switched from its chamber position to its ambient position, whereas valve  52  has been switched from its ambient position to its chamber position.  FIG. 10  is a corresponding view that shows the valves and exhaust pipes more fully, and without additional bypass pipes. 
         [0060]    In particular, electromechanical actuators under the control of the microprocessor that controls the overall operation of the apparatus, cause the valves  51 ,  52  to change their respective positions simultaneously and at substantially the same speed. Consequently, any pressure fluctuation within the collector  4  is greatly suppressed. Gases generated by the level  2  processing, which tend to be acidic in character, are exhausted through the pipe  32 . 
         [0061]    In  FIG. 6 , the chuck  2  has again been raised relative to the collector  4  such that the wafer W is at the process level L 3 . The level  3  processing in  FIG. 6  of this embodiment involves reduction of airborne molecular contamination (AMC), in which it is desirable to direct the exhaust to the exhaust pipe  31  that is designated for handling exhaust gases of a basic character. 
         [0062]    As to the state of valves  51 - 55 , it will be appreciated that, in moving from the level  2  processing of  FIG. 5  to the level  3  processing of  FIG. 6 , valve  51  has been switched from its ambient position to its chamber position, whereas valve  53  has been switched from its chamber position to its ambient position. Additionally, bypass valve  54  has been switched to its level  1  position, such that exhaust gas withdrawn from the chamber  13  of collector  4  will be diverted from exhaust pipe  33  to the exhaust pipe  31 .  FIG. 11  is a corresponding view that shows the valves and exhaust pipes more fully, and without additional bypass pipes. 
         [0063]    In moving from the level  2  processing of  FIGS. 5 and 10  to the level  3  processing of  FIGS. 6 and 11 , the valves  51 ,  53 ,  55  are again actuated simultaneously and in synchronization so as to minimize any pressure fluctuation within the collector  4 . Moreover, in  FIGS. 6 and 11 , although valve  51  is shown in its chamber position, it may help to equalize the pressure within the collector  4  to position valve  51  at an intermediate position in which it admits into the pipe  31  downstream of valve  51  a predetermined ratio of ambient atmosphere and exhaust gas from the chamber  11 , as illustrated in  FIG. 13 . 
         [0064]    In  FIG. 7 , the chuck  2  remains at the same position relative to the collector  4  such that the wafer W remains at the process level L 3 . However, a different process is performed in  FIG. 7 , which in this embodiment involves the use of carbon dioxide dissolved in deionized water (DI/CO 2 ). For such processing it is desirable to direct the exhaust to the exhaust pipe  32  that is designated for handling exhaust gases of an acidic character. 
         [0065]    As to the state of valves  51 - 55 , it will be appreciated that, in changing from the level  3  processing of  FIG. 6  to the level  3  processing of  FIG. 7 , the positions of bypass valves  54 ,  55  have been reversed, so that exhaust gas withdrawn from chamber  13  of collector  4  is now transferred from pipe  33  to pipe  32 .  FIG. 12  is a corresponding view that shows the valves and exhaust pipes more fully, and without additional bypass pipes. 
         [0066]    In changing from the level  3  processing of  FIGS. 6 and 11  to the level  3  processing of  FIGS. 7 and 12 , the valves  54 ,  55  are again actuated simultaneously and in synchronization so as to minimize any pressure fluctuation within the collector  4 . Moreover, in  FIGS. 7 and 12 , although valve  52  is shown in its chamber position, it may help to equalize the pressure within the collector  4  to position valve  52  at an intermediate position in which it admits into the pipe  32  downstream of valve  52  a predetermined ratio of ambient atmosphere and exhaust gas from the chamber  12 , as illustrated in  FIG. 14 . 
         [0067]    In  FIG. 8 , the chuck  2  still remains at the same position relative to the collector  4  such that the wafer W remains at the process level L 3 . However, yet another different process is performed in  FIG. 8 , which in this embodiment involves the use of isopropyl alcohol (IPA) to rinse and dry the wafer W. For such processing it is desirable to direct the exhaust to the exhaust pipe  33  that is designated for handling exhaust gases of an organic character. 
         [0068]    As to the state of valves  51 - 55 , it will be appreciated that, in changing from the level  3  processing of  FIG. 7  to the level  3  processing of  FIG. 8 , valves  51 - 55  are returned to the state shown in  FIGS. 3 ,  4  and  9 . 
         [0069]    The exhaust system as thus described allows switching between chamber levels while keeping the pressure fluctuation as low as possible (+/−20 Pa). Furthermore, with the possibility to activate in the chamber two levels to the exhaust, it is possible to keep cross-contamination at less than 25 ppm even when using high temperature concentrated chemistries (for example: 60° C. 1:5 NH 4 OH). 
         [0070]    In the foregoing description a single exhaust unit  60  is shown, for ease of explanation. In practice, however, there is more preferably a separate exhaust provided for each type of chemical to be exhausted. Such different types of gases may be for example organics (e.g. organic solvents like IPA), oxidizing substances (e.g. ozone, hydrogen peroxide), acidic substances (e.g. HF or HCl) and basic substances (e.g. NH 3 ). 
         [0071]    However, the device and method according to the present invention allow to selectively switch on/off specific process level exhausts without resulting in a significant change of exhaust volume flow. Consequently this allows a plurality of up to eight or more chambers to be simultaneously exhausted without any negative interaction due to unintended pressure drops. 
         [0072]    Thus, with reference to  FIG. 15 , a plurality of chucks  2 - 1  through  2 - 8 , each with a corresponding collector  4 - 1  through  4 - 8 , may be positioned within a same process module  6  for single wafer wet processing of semiconductor wafers. Each collector comprises an exhaust system with flap valves and bypass valves as described previously, in association with its associated exhaust conduits  31 - 1 ,  32 - 1 ,  33 - 1  through  31 - 8 ,  32 - 8 ,  33 - 8 . 
         [0073]    Gases exhausted through the conduits  31 - 1  through  31 - 8  may all be handled in a same exhaust unit  60 - 1 , whereas gases exhausted through the conduits  32 - 1  through  32 - 8  may all be handled in a same exhaust unit  60 - 2 , and gases exhausted through the conduits  33 - 1  through  33 - 8  may all be handled in a same exhaust unit  60 - 3 . This more efficient design is made possible by the novel arrangement and operation of valves as described in detail above. 
         [0074]    Although the invention has been described in connection with several preferred embodiments in the foregoing description, it will be appreciated by those skilled in the art that various modifications are possible without departing from the true scope and spirit of the invention as disclosed herein and as set forth in the appended claims.