Abstract:
The present invention relates to a containment chamber that is used for carrying out multiple processing steps such as depositing on, polishing, etching, modifying, rinsing, cleaning, and drying a surface on the workpiece. In one example of the present invention, the chamber is used to electro chemically mechanically deposit a conductive material on a semiconductor wafer. The same containment chamber can then be used to rinse and clean the same wafer. As a result, the present invention eliminates the need for separate processing stations for depositing the conductive material and cleaning the wafer. Thus, with the present invention, costs and physical space are reduced while providing an efficient apparatus and method for carrying out multiple processes on the wafer surface using a containment chamber.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to methods and apparatus for carrying out multiple processes such as depositing, plating, polishing, etching a conductive material and rinsing, cleaning, and modifying the surface of a substrate using a vertically configured containment chamber. More particularly, the present invention is directed to a vertically configured containment chamber that can be used for carrying out a first set of processes using one section of the chamber and another set of processes using a different section of the chamber.  
         BACKGROUND OF THE INVENTION  
         [0002]    A conventional process step in the manufacturing of integrated circuits and devices involves plating a conductive material on a semiconductor wafer or a workpiece surface. For example, an “electro chemical mechanical deposition” (ECMD) method can be used to achieve such a result. One goal of ECMD is to uniformly fill the holes and trenches on the wafer/workpiece surface with the conductive material while maintaining the planarity of the surface. The ECMD process is generally performed in a chamber specifically designed for such deposition. A more detailed description of the ECMD method and apparatus can be found in the co-pending U.S. application Ser. No. 09/201,929, entitled “Method and Apparatus For Electro Chemical Mechanical Deposition”, commonly owned by the assignee of the present invention.  
           [0003]    If a conventional plating process is performed to deposit the conductive material, after performing such step in a deposition chamber, the workpiece may be transferred to another chamber for polishing (e.g., chemical mechanical polishing). In other instances, for example, ECMD, the deposition and polishing process can be performed using a dual depositing/polishing tool in a combined deposition/polishing chamber.  
           [0004]    Regardless of which process used, the workpiece is next transferred to a rinsing/cleaning chamber after the deposition and/or polishing steps. A robotic arm/machine that lifts the workpiece by its edges from, for example, the deposition/polishing chamber to another horizontally configured cleaning chamber can perform this transfer process. Additionally, a workpiece cassette may be used to store the workpiece as it is being transferred from the deposition/polishing chamber to the cleaning chamber. The workpiece surface can then be cleaned using, for example, a spin, rinse, and dry process, as known in the art.  
           [0005]    During such transfer of the workpiece from one chamber to another, contaminants such as particles may attach themselves on the workpiece surface because the workpiece is exposed to the external environment. The source of these contaminants may be the surrounding air, the processing facility, personnel, process chemicals, or the like. In some cases, exposing the workpiece to light between processing steps may not be desirable. The workpiece surface must be free of such contaminants; otherwise, the contaminants may affect device performance characteristics and may cause device failure to occur at faster rates than usual. Thus, such contaminants can result in defective chips, which results in lost revenues and low overall process yield for the manufacturer.  
           [0006]    In the conventional method and apparatus described above, the rinsing/cleaning and deposition/polishing chambers are at least two separate horizontally configured chambers that are located apart from each other. Thus, workpieces are exposed to potential contaminants as they are transferred from one chamber to another. In addition, more physical space in a clean room is occupied when multiple chambers are required. This increases the costs for manufactures as they must use larger facilities in order to use such chambers.  
           [0007]    Although, example here is given for carrying out the depositing/polishing and rinsing/cleaning processes, there are other types of processes that are being carried out in other horizontally configured chambers. These processes include etching or otherwise modifying the workpiece surface, depositing different materials on the workpiece surface, etc. Regardless of the specific processes that are being carried out in these conventional chambers, the costs associated to operate such chambers are nevertheless very high for the reasons mentioned above.  
           [0008]    Therefore, there is a need for methods and apparatus for carrying out multiple processes on a workpiece using a vertically configured chamber without exposing the workpiece to the external environment. There is also a particular need for methods and apparatus for depositing/polishing the conductive material on the workpiece surface and then rinsing/cleaning such surface without exposing the workpiece to contaminants. Accordingly, the present invention provides a vertically configured containment chamber that can be used for carrying out different processes on the workpiece surface. The containment chamber of the present invention can be specifically used for both depositing/polishing the conductive material and rinsing/cleaning the workpiece surface. The present invention further provides a more cost effective, efficient, contaminant free methods and apparatus than those currently available.  
         SUMMARY OF THE INVENTION  
         [0009]    It is an object of the present invention to provide methods and apparatus for carrying out multiple processes in multiple sections of a vertically configured containment chamber.  
           [0010]    It is another object of the present invention to provide methods and apparatus for carrying out multiple processes such as depositing, plating, polishing, etching, rinsing, cleaning, and modifying a conductive material and/or a substrate surface using a vertically configured containment chamber.  
           [0011]    It is yet another object of the present invention to provide methods and apparatus that deposits a conductive material on a workpiece surface and then cleans the same surface in a vertically configured containment chamber.  
           [0012]    It is another object of the present invention to provide methods and apparatus that deposits a conductive material on a workpiece surface using electro chemical mechanical deposition and cleans the same surface using a spin, rinse, and dry process in a vertically configured containment chamber.  
           [0013]    It is a further object of the present invention to provide methods and apparatus that reduces/eliminates contaminants from being formed on the workpiece surface during multiple processing steps.  
           [0014]    It is yet another object of the present invention to provide methods and apparatus for decreasing the physical space occupied by multiple chambers by providing a vertically configured containment chamber for multiple process.  
           [0015]    It is yet another object of the present invention to provide methods and apparatus that efficiently deposits and cleans a workpiece surface in a vertically configured containment chamber.  
           [0016]    These and other objects of the present invention are obtained by providing a vertically configured containment chamber that can be used for multiple processes such as depositing a conductive material on the workpiece surface and cleaning the same surface. In one specific embodiment of the present invention, an electo chemical mechanical deposition can be performed in the lower half of the containment chamber while a spin, rinse, and dry process can be performed in the upper half of the containment chamber. A movable process/rinse guard is positioned in between the lower and upper halves of the containment chamber such that the two halves of the chamber are physically separated from each other during processing in the upper half of the containment chamber. The movable process/rinse guard further prevents a cleaning solution from entering the lower half of the containment chamber.  
           [0017]    In a second embodiment of the present invention, multiple flaps are used to separate the upper and lowers halves of the containment chamber. For example, when the flaps are in their vertical position, a depositing/polishing process can be performed in the lower half, and when the flaps are in their horizontal position, a rinsing/cleaning process can be performed in the upper half. In addition, when the flaps are in their horizontal position, loss of electrolyte solution from the containment chamber due to vaporization is minimized.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]    These and other objects and advantages of the present invention will become apparent and more readily appreciated from the following detailed description of the presently preferred exemplary embodiments of the invention taken in conjunction with the accompanying drawings, of which:  
         [0019]    [0019]FIG. 1 illustrates a cross sectional view of a first preferred embodiment of the present invention for use during a depositing/polishing process;  
         [0020]    [0020]FIG. 2 illustrates a cross sectional view of a first preferred embodiment of the present invention for use during a rinsing/cleaning process;  
         [0021]    [0021]FIG. 3 illustrates a perspective view of a process guard support mechanism in accordance with the first preferred embodiment of the present invention;  
         [0022]    [0022]FIG. 4 illustrates a cross sectional view of a second preferred embodiment of the present invention for use during a depositing/polishing process;  
         [0023]    [0023]FIG. 5 illustrates a cross sectional view of a second preferred embodiment of the present invention during the transition from a depositing/polishing process to a rinsing/cleaning process;  
         [0024]    [0024]FIG. 6 illustrates a cross sectional view of a second preferred embodiment of the present invention for use during a rinsing/cleaning process;  
         [0025]    [0025]FIG. 7 illustrates a perspective view of the upper chamber in accordance with the second preferred embodiment of the present invention; and  
         [0026]    [0026]FIG. 8 illustrates a cross sectional view of yet another preferred embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0027]    The preferred embodiments of the present invention will now be described with greater detail with reference to FIGS.  1 - 8 . As described elsewhere herein, various refinements and substitutions of the various embodiments are possible based on the principles and teachings herein.  
         [0028]    As noted above, conventional processing uses different processing chambers, at different times, to obtain a conductive material on the wafer surface and to rinse/clean/etch/modify/dry the same surface. Accordingly, the equipment cost needed for depositing, polishing, etching, rinsing, modifying the surface, drying, and cleaning can be high. The present invention contemplates using one vertically configured containment chamber that plates/deposits and/or polishes the conductive material on the workpiece/wafer, as well as rinses/cleans/etches/modifies/dries the workpiece/wafer surface. In other words, the present invention provides a vertically configured containment chamber used for carrying out multiple processes.  
         [0029]    Furthermore, although a semiconductor wafer will now be used to describe the preferred embodiments of the present invention, other semiconductor workpieces such as flat panels or magnetic films may also be used in accordance with the present invention.  
         [0030]    [0030]FIG. 1 illustrates a cross sectional view of a first preferred embodiment of the present invention during the deposition process. A containment chamber  2  includes two sections, an ECMD lower section  4  and a rinsing/cleaning top section  6 . The ECMD section  4  occupies the lower half of the containment chamber  2 , and the cleaning section  6  occupies the upper half of the containment chamber  2 . In the first mode of operation, an ECMD process is performed in the ECMD section  4 , and in the second mode of operation, a rinsing/cleaning process is performed in the cleaning section  6 .  
         [0031]    [0031]FIG. 1 illustrates the first mode of operation in accordance with the first preferred embodiment of the present invention. A wafer holder  10  supports a wafer  12  as ECMD is performed in the ECMD section  4 . The wafer holder  10  may include a nonconductive, preferably circular, chuck  14  with a cavity (not shown) that is preferably a few millimeters deep at its center and which cavity may contain a resting pad (not shown). The wafer  12  is loaded into the cavity, backside first, against the resting pad using a conventional type of transport or vacuum mechanism to ensure that the wafer  12  is stationary and secure with respect to the wafer holder  10  while in use. A shaft  16  is used to raise and lower the wafer holder  10  within the containment chamber  2 . The shaft  16  is further adapted to move side to side and to rotate about axis  18 , thus allowing the wafer holder  10  and the wafer  12  to move side to side and rotate about the same axis  18 . Other conventional wafer holders can be used in accordance with the present invention.  
         [0032]    During the ECMD process, a conductive material is applied in holes, trenches, and/or other desired areas on the wafer  12  using an electrolyte solution held in an ECMD apparatus  20 . In the example provided herein, the ECMD apparatus  20  includes a pad assembly  23  having a pad  24  placed on an anode  26  for depositing and/or polishing the conductive material on the wafer  12 . The electrolyte solution (not shown) may be held in the ECMD apparatus  20  or flowed through the pad  24 . In one embodiment, the pad  24  may include pores  25  so that the electrolyte solution can be held and/or flowed through the pad  24 . The term “pores” herein is broadly defined as any type of perforation in the pad  24  that allows the electrolyte to flow from the bottom surface to the upper surface of the pad  24 . Also, in the preferred embodiment, the pad  24  should be an abrasive pad or at a minimum, the pad surface facing the wafer  12  should be abrasive.  
         [0033]    In another embodiment, the ECMD apparatus  20  may include a pad assembly having a circular or square pad mounted on a cylindrical anode that rotates around another axis. Such apparatus is described in the co-pending U.S. application Ser. No. 09/201,929, entitled “Method and Apparatus For Electro Chemical Mechanical Deposition”, commonly owned by the assignee of the present invention. Although two embodiments of the ECMD apparatus  20  are described herein, other ECMD apparatus and methods may be used in accordance with the present invention. What is important to note from the previous examples is that the ECMD process is performed in the lower section of the containment chamber  2 .  
         [0034]    In the ECMD process, chemical/electrochemical etching of the workpiece surface can also be carried out by controlling the potential difference between the wafer surface and the anode  26 . For example, when applying a potential difference where the anode is more positive than the wafer surface, deposition may be performed. On the other hand, when applying a potential difference where the anode is more negative than the wafer surface, electrochemical etching may be performed. Furthermore, when a potential difference between the anode and the wafer surface is zero, chemical etching of the wafer surface may be performed.  
         [0035]    Additionally, in the ECMD section  4 , splashguards  22 A may be used and extend out from the inner walls of the containment chamber  2 . The splashguards  22 A prevent the electrolyte solution from exiting from the ECMD section  4  to the top section of the chamber  2 . Further, as described in more detail below, the splashguards  22 A also prevent a cleaning solution from the top section of the chamber  2  from entering the ECMD apparatus  20 .  
         [0036]    [0036]FIG. 2 illustrates a cross sectional view of a second mode of operation in accordance with the first preferred embodiment of the present invention. The rinsing/cleaning section  6  includes the upper half of the containment chamber  2 . The border/barrier between the cleaning section  6  and the ECMD section  4  is determined by a process guard  30  that is attached to a process guard support  31 . The process guard support  31  may be in the form of a pair of tensioned cords that are looped around idle rollers  32   b ,  32   c ,  32   d , and the motor driven roller  32   a . The motor driven roller  32   a  allows the process guard support  31  and the process guard  30  to move in and out of the chamber  2 . As shown, the process guard  30  and the support  31  are positioned at an angle Z from the horizontal plane  50 . In the preferred embodiment, the angle Z from a horizontal plane  50  to the plane of the process guard  30  is between 5-60 degrees (or any other angle Z such that the cleaning solution can be flowed out of the chamber  2 ). Such incline of the process guard  30  is required such that the cleaning solution can be flowed out of the containment chamber  2  after cleaning/rinsing the wafer  12 .  
         [0037]    One end of the process guard  30  fits into slit  34  and the other end into a housing  38  along the two side walls of the containment chamber  2  such that a physical border is formed between the ECMD section  4  and the cleaning section  6 . Other methods of supporting the process guard  30  and the process guard support  31  in the containment chamber  2  may be used in the present invention. The process guard  30  is moved in and out of the housing  38  via the set of rollers  32   a ,  32   b ,  32   c , and  32   d , which move the process guard support  31 . The roller  32   a  is preferably attached to a mechanical device capable of rotating the roller  32   a  in both clockwise and counterclockwise directions so that one end of the process guard  30  can be moved from one wall to the opposite wall so as to form a temporary border between the two sections  4 ,  6 . In other embodiments, other devices and methods may be used to move and position the process guard  30  from the housing  38  to the containment chamber  2  to the position as shown in FIG. 2.  
         [0038]    [0038]FIG. 3 illustrates a perspective view of the process guard support mechanism in accordance with the first preferred embodiment of the present invention. This figure illustrates the process guard  30  and process guard support  31  positioned in the second mode of operation where the rinsing/cleaning step is performed. An adhesive, screw and nut, or the like can be used to attach the bottom side of the process guard  30  to the process guard support  31 .  
         [0039]    The process guard  30  is made from a material that is rigid enough to support the cleaning solution as it is flowed out of the cleaning section  6 , while being flexible enough to bend as it is being stored in the housing  38 . Preferably, the process guard  30  and the support  31  are made from materials such as plastic, metals, or coated metals that are compatible with the chemical used in the chamber. The process guard  30  is shaped in a configuration that fits inside the containment chamber  2  such that the cleaning solution is prevented from entering the ECMD section  4 .  
         [0040]    Referring back to FIG. 2, the cleaning section  6  further includes multiple nozzles  40  for spraying the rinsing/cleaning solution  42  onto the wafer  12 . An inlet tube  44  is used to flow the cleaning solution through the nozzles  40 . The cleaning solution  42  may be water, acidic or basic solutions or organic solvents. A second set of splashguards  22 B may be positioned in the cleaning section  6  so as to prevent the cleaning solution  42  from exiting from the top section of the containment chamber  2 .  
         [0041]    In operation according to the first preferred embodiment of the present invention, after performing the ECMD process as described earlier, the wafer holder  10  supporting the wafer  12  is vertically raised from the deposition section  4  such that it is positioned in the cleaning section chamber  6  for the rinse, spin, and dry process. The wafer holder  10  is vertically raised in between the process guard support  331  (i.e., two sets of cords) (FIG. 3). The process guard  30  is then guided by the process guard support  31  using rollers  32   a ,  32   b ,  32   c ,  32   d  into the containment chamber  2  from the housing  38  so as to form a physical border between the two sections  4 ,  6 . The process guard  30  should be flexible enough to bend during the guiding process from the housing  38  to the containment chamber  2 , but should also be rigid enough to be guided into the slit  34 . Any known apparatus and method may be used to guide the process guard  30  in and out of the housing  38 . The rinsing/cleaning solution  42  is then applied to the wafer  12  through the nozzles  40 . During this process, the rinsing/cleaning solution  42  that drips onto the process guard  30  is flowed to the housing  38  or an outside reservoir (not shown) for storage and/or disposal. The incline of the process guard  30  allows the used rinsing/cleaning solution  42  to flow out of the containment chamber  2 .  
         [0042]    The cleaning process of the present invention is a spin, rinse, and dry process, as known in the art. The wafer holder  10  rotates the wafer  12  at a very high speed. The rinsing/cleaning solution  42  is applied/sprayed onto the wafer surface using nozzles  40 . Once the spraying is completed, the wafer is dried by the rotation of the wafer holder  10 . The wafer is then transferred to the next processing station.  
         [0043]    The present invention contemplates adding another processing step such that the wafer  12  is cleaned before and after performing the ECMD. For example, the wafer  12  can be cleaned first in the cleaning section  6  before performing the ECMD process in ECMD section  4 . Then, the wafer  12  can be cleaned for the second time in the cleaning section  6 . The solution used in the cleaning section  6  may contain chemicals that can modify the surface of the wafer  12 . For example, a mild etching solution can be used for this purpose.  
         [0044]    FIGS.  4 - 7  illustrate cross sectional views of the second preferred embodiment of the present invention. In this second embodiment, multiple flaps are used to separate the lower processing section from the upper processing section. For example, when flaps  150  are in the vertical position as shown in FIG. 4, a first process can be performed in the lower section. On the other hand, when the flaps  150  are in the substantially horizontal position as shown in FIG. 6, a second process can be performed in the upper section.  
         [0045]    Described hereinafter in greater detail is one possible application of the present invention where the first process that is carried out in the lower section is a depositing/polishing process and the second process that is carried out in the upper section is a rinsing/cleaning process.  
         [0046]    Referring back to FIG. 4, a containment chamber  100  includes two sections similar to that described above, a depositing/polishing lower section  104  and a rinsing/cleaning top section  106 . In the first mode of operation, a depositing/polishing is performed in the section  104 , and in the second mode of operation, a rinsing/cleaning step is performed in the section  106 .  
         [0047]    In the first mode of operation in accordance with the second preferred embodiment of the present invention, a wafer holder  10 , as described above, supports a wafer  12  as deposition and polishing process is performed in the lower section  104 . The flaps  150  via linkage shafts/rollers  152  are positioned vertically such that the wafer holder  10  using shaft  16  can be lowered into the lower section  104 .  
         [0048]    During the deposition and polishing process, a conductive material is applied in holes, trenches, and/or other desired areas in the wafer  12  using an electrolyte solution while the conductive material is polished from undesired areas on the wafer. The deposition/polishing apparatus  120  is similar to that described earlier herein. In the example provided herein, the apparatus  120  includes a pad assembly  123  having a pad  124  placed on an anode  126  for depositing/polishing the conductive material on the wafer  12 . The chamber  100  also includes sealing and anti-splash portion  134  and O-ring  132  to prevent any solution from exiting the chamber  100 .  
         [0049]    [0049]FIG. 5 illustrates a cross sectional view of a second preferred embodiment of the present invention during the transition from a depositing/polishing process to a rinsing/cleaning process. After the deposition and polishing process in the lower section  104 , the wafer holder  10  is raised using shaft  16  to approximately its uppermost position. The flaps  150  are then moved from their vertical position to their horizontal position using the linkage shaft/rollers  152 . Once the flaps  150  are in their final horizontal position, the second mode of operation (rinsing/cleaning) can be carried out.  
         [0050]    [0050]FIG. 6 illustrates a cross sectional view of a second preferred embodiment of the present invention for use during a rinsing/cleaning process. From its uppermost position of the wafer holder  10  in FIG. 5, the wafer holder  10  is lowered slightly to a position that is suitable for rinsing/cleaning the wafer  12 . The rinsing/cleaning process of the wafer  12  is similar to that described earlier herein, where the rinsing cleaning solution is provided via nozzles  140  and other inlet tubes that are commonly used in this field. In other embodiments, the wafer  12  may be brush cleaned using a brush as known in the art. It should be noted that the used rinsing/cleaning solution that drips down from the wafer  12  is guided by the flaps  150  into outlet channels  151  along the side walls of the upper section  106 . In this manner, the used solution is drained out of the chamber  100  using outlet channels  151 , which is described in more detail below.  
         [0051]    The flaps  150  are made from a material that is rigid enough to support the cleaning solution as it is flowed out of the rinsing/cleaning section  106 . Preferably, the flaps  150  are made from materials such as plastic or teflon, or any other material that is compatible with the chemical used in the chamber.  
         [0052]    An additional advantage of using the second embodiment of the present invention is that when the chamber  100  is not being used, the flaps  150  can be positioned in a horizontal position to enclose the lower section  104  of the chamber  100 . When the lower section  104  is enclosed using flaps  150 , this reduces/minimizes electrolyte solution evaporation from the chamber  100 , thereby saving money and resources for the manufacturer.  
         [0053]    During the rinsing/cleaning process according to either the first or second preferred embodiments, the wafer  12  can be rotated using the wafer holder  10  at 5 to 200 rpm, but preferably between 10 to 150 rpm. The rinsing/cleaning solution can be applied to the wafer  12  at 2 to 2000 ml/minute, but preferably between 5 to 800 ml/minute for a period ranging from 5 to 15 seconds. Thereafter, the wafer  12  may be spun dried by rotating the wafer  12  at 500 to 2500 rpm, but preferably between 800 to 2000 rpm for a period of about 10 seconds. After such rinsing/cleaning process, the wafer  12  can be transferred from the either chamber  2 ,  100  using the wafer holder  10  to another processing device.  
         [0054]    [0054]FIG. 7 illustrates a perspective view of the upper chamber in accordance with the second preferred embodiment of the present invention. Flaps  150  can be moved up and down around the axis of the linkage shaft/rollers  152  using motors  153 . Further, the flaps  150  are designed such that when they are in the closed position, the used solution falling on the flaps  150  is flowed into the outlet channels  151  along the walls of the upper section  106 . The used solution is then drained from the outlet channels  151  into a reservoir (not shown) for recycling and/or disposal.  
         [0055]    [0055]FIG. 8 illustrates a cross sectional view of yet another preferred embodiment of the present invention. In this embodiment, the wafer  12  is rinsed through sprayers  141  that are mounted on the flaps  150 . The rinsing/cleaning solution can be fed to the sprayers  141  through various tubes/pipes that are located either inside/outside the flaps  150 . Although FIG. 8 illustrates one sprayer  141  mounted per each flap  150 , more or less than one sprayer can be mounted on either flap  150 .  
         [0056]    Sprayers  141  can also be used to blow air/gases such that the wafer  12  can be dried quickly. It is also possible to use different sprayers that are used for different purposes (i.e., one for liquid and one for gas). In other embodiments, both the sprayers mounted on the flaps  150  (FIG. 8) and side mounted nozzles (FIG. 6) can be used to simultaneously rinse/clean the wafer  12 .  
         [0057]    Although a specific application of the present invention involving deposition in the lower section and rinsing/cleaning in the upper section has been described in detail, the present invention contemplates performing other types of processes in the upper and lower sections, which sections are separated by the movable process guard or flaps. In this case, the nozzles and/or sprayers can be used to provide various “process solutions” or “process gases” to the wafer surface. For example, as described above, if the upper section is used for cleaning, the process solution can be a cleaning solution. If, on the other hand, the process in the upper section is an etching or surface modification process, then the process solution may be a mild etching solution. Furthermore, process gases such as O 2 , CF 4 , CL 2 , NH 2 , etc., can be introduced onto the wafer surface in the upper section. The wafer may also be heated (using lamp, etc.) when the gas is introduced such that surface modifications can result. For example, O 2  gas may be used to oxidize the wafer surface prior to performing the next processing step in the lower section.  
         [0058]    In other instances, the upper section may be used for deposition, which in this case, the process solution may contain chemicals that cause film growth on the wafer surface as a result of the applied solution. Electroless material deposition solutions such as electroless nickel, palladium, gold, copper, platinum, and the like are examples of process solutions that can be used in the upper section to deposit a film on the wafer surface.  
         [0059]    The processing sequence as described above in the upper and lower sections may be changed, thus allowing for multiple processes to be carried out in each section. For example, the wafer surface may first be cleaned, etched, modified, etc., using a cleaning/etching solution in the upper section with the flaps/process guard in their/its appropriate position(s). After cleaning/etching the wafer surface, the wafer can further be rinsed/dried again in the upper section. Thereafter, after repositioning the flaps/process guard, the wafer can be lowered into the lower section where metal deposition and polishing can be carried out. The deposited metal may be Cu, Au, Pt, Ni, Co, Ni—Co alloy, and the like. After deposition, the wafer can again be raised to the upper section such that the wafer surface can be cleaned. After this cleaning process, a deposition step can be carried out in the upper section, as described above. For example, after Ni deposition in the lower section, Au may be deposited over the Ni film in the upper section using an electroless Au solution applied (using nozzles/sprayers) over the Ni coated wafer surface. The Au solution and the wafer may further be heated at this stage. After deposition in the upper chamber, another rinsing and cleaning process can be carried out in upper section.  
         [0060]    From the previous discussion, an important aspect of this invention is that it provides a vertically configured chamber such that multiple processes can be carried out in the different sections of the chamber. Sections are separated from each other using a removable process guard or flaps such that one chemistry used in one section does not effect a different chemistry used in another section. Although the examples shown above discloses two sections, three or more sections can be used so long as the physical height of each section and the overall height of the chamber is kept within a reasonable limit.  
         [0061]    For example, the vertically configured chamber can be sectioned off into three or more distinct sections having top, middle, and bottom sections. The top section can be used for first depositing the conductive material on the wafer surface using a first set of nozzles/sprayers and process guard/flaps, which process guard/flaps prevent(s) the depositing solution from entering the middle section, as described earlier herein. The wafer can then be lowered into the middle section after positioning the first process guard in its housing or the flaps in their vertical positions. The wafer surface can then be cleaned, rinsed, etc. using a second set of nozzles/sprayer and process guard/flaps, which process guard/flaps prevent(s) the cleaning, rinsing, etc., solutions from entering the bottom section of the chamber. The wafer can be further lowered into the bottom section of the chamber for additional deposition after positioning the second process guard in its housing or the flaps in their vertical positions. Thereafter, the wafer can be raised to the middle section for a second cleaning/rinsing. As can be appreciated, this process can continue allowing for multiple cleaning/rinsing and depositing steps.  
         [0062]    Although specific embodiments, including specific apparatus, process steps, process parameters, materials, solutions, etc., have been described, various modifications to the disclosed embodiments will be apparent to one of ordinary skill in the art upon reading this disclosure. Therefore, it is to be understood that such embodiments are merely illustrative of and not restrictive of the broad invention and that this invention is not limited to the specific embodiments shown and described. Those skilled in the art will readily appreciate that many modifications of the exemplary embodiment are possible without materially departing from the novel teachings and advantages of this invention.