Patent Publication Number: US-2018036752-A1

Title: High Velocity Spray (HVS) Dispense Arm Assemblies including a Gas Shield Nozzle

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     The present application claims priority k and the benefit of U.S. patent application Ser. No. 62/372,130, filed Aug. 8, 2016, which is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention is directed to liquid process equipment for treatment of a substrate (wafer) and more specifically, to a high velocity spray (HVS) dispense arm assembly that provides a gas shield nozzle that is arranged to dispense (blow) compressed gas out circumferentially around the HVS dispense arm to reduce or eliminate mist from contacting surfaces above the substrate being treated within process equipment. 
     BACKGROUND 
     An HVS dispense arm is used to dispense liquid process chemistry at high velocity out of a nozzle towards a wafer or other substrate. This high speed is achieved through the addition of compressed gas (typically nitrogen gas) to the chemistry at the point of dispense within the nozzle. The high speed thus achieved aids certain processes, but causes the chemistry to splash off of the wafer and form a mist within the process equipment. For reasons of cleanliness, it is desirable to keep the mist from contacting surfaces above the wafer within the process equipment. There is therefore a desire to provide a dispense arm that reduces or eliminates mist from contacting surfaces above the wafer within the process equipment. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         FIG. 1  is a perspective view of an HVS dispense arm assembly according to a first embodiment; 
         FIG. 2  is a cross-sectional view of the HVS dispense arm assembly of  FIG. 1 ; 
         FIG. 3  is a perspective view of an HVS dispense arm assembly according to a second embodiment; 
         FIG. 4  is a cross-sectional view of the HVS dispense arm assembly of  FIG. 3 ; 
         FIG. 5  is a perspective view of an HVS dispense arm assembly according to a third embodiment; 
         FIG. 6  is a cross-sectional view of an HVS dispense arm assembly of  FIG. 5 ; 
         FIG. 7  is a perspective view of an HVS dispense arm assembly according to a fourth embodiment; 
         FIG. 8  is a cross-sectional view of an HVS dispense arm assembly of  FIG. 7 ; 
         FIG. 9  is a perspective view of an HVS dispense arm assembly according to a fifth embodiment; 
         FIG. 10  is a cross-sectional view of an HVS dispense arm assembly of  FIG. 9 ; 
         FIG. 11  is a perspective view of an HVS dispense arm according to a sixth embodiment; 
         FIG. 12  is a cross-sectional view of an HVS dispense arm of  FIG. 11 ; 
         FIG. 13  is a perspective view of an HVS dispense arm according to a seventh embodiment; and 
         FIG. 14  is a cross-sectional view of the HVS dispense arm of  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS 
     The following description is directed to an HVS dispense arm construction. The referenced device is now described more fully with reference to the accompanying drawings, in which one or more illustrated embodiments and/or arrangements of the apparatuses and methods are shown. The apparatuses and methods are not limited in any way to the illustrated embodiments and/or arrangements as the illustrated embodiments and/or arrangements described below are merely exemplary of the present apparatuses and methods, which can be embodied in various forms as appreciated by one skilled in the art. Therefore, it is to be understood that any structural and functional details disclosed herein are not to be interpreted as limiting the present application, but rather are provided as a representative embodiment and/or arrangement for teaching one skilled in the art one or more ways to implement the present apparatuses and/or methods. Moreover, just because a certain feature is depicted in combination with a particular set of other features, no intent to so limit the invention can be inferred and each feature can be combined with any other set of other features. Accordingly, certain aspects of the present apparatuses and methods can take the form of an entirely hardware embodiment or an embodiment combining software and hardware. 
     In accordance with the present invention, an HVS dispense arm construction is provided and is configured such that a compressed gas, such as nitrogen, is pumped or otherwise flows through a nozzle to prevent the mist created by the HVS dispense arm from spreading above the process equipment (assembly). This mist can be referred to as being an HVS dispense that is generated from the liquid chemistry that inputted into the dispense arm. The present invention thus provides a gas shield nozzle (e.g., nitrogen shield nozzle) that is arranged to dispense (blow) compressed gas (e.g., nitrogen gas) out circumferentially around the HVS dispense arm. 
     First HVS Dispense Arm Assembly Construction 
       FIGS. 1 and 2  show an HVS dispense arm assembly  100  according to a first embodiment. The HVS dispense arm assembly  100  includes an HVS nozzle body  110  and an HVS nozzle  120  that is disposed at a distal end of the HVS nozzle body  110 . The HVS nozzle body  110  and HVS nozzle  120  include a channel architecture to allow gas to flow therethrough. In particular, the HVS nozzle body  110  includes a first channel  112  through which HVS nozzle liquid chemistry flows and a second channel  114  through which compressed gas (e.g., nitrogen gas) flows. Conventional techniques are used to deliver the liquid chemistry to the first channel  112  and the compressed gas to the second channel  114 . For example, a pump or other similar piece of equipment can be used to deliver the liquid chemistry and the compressed gas from respective sources. In other words, the conduits (lines) that deliver the liquid chemistry and the compressed gas can be connected to pumps the deliver the respective fluids to the dispense arm assembly. 
     The first and second channels  112 ,  114  are in fluid communication with a third channel  116  that is formed in the HVS nozzle  120 . As shown in  FIG. 2 , an HVS dispense (liquid spray)  130  is discharged from the HVS nozzle  120  in a direction toward a substrate  10 , such as a wafer. 
     The assembly  100  includes a shield gas nozzle  200  that surrounds the HVS nozzle body  110  and the HVS nozzle  120 . For example, in the illustrated embodiment, the HVS nozzle body  110 , the HVS nozzle  120  and the shield gas nozzle  200  are concentric with respect to one another due to the HVS nozzle body  110  and the HVS nozzle  120  having a cylindrical shape and the shield gas nozzle  200  having an annular shape (sharing a common axis). 
     The shield gas nozzle  200  has a body  210  with a distal end  212 . The shield gas nozzle  200  has an inlet  215  for receiving compressed gas (e.g., nitrogen gas) and formed within the body  210  is a channel architecture. More specifically, the inlet  215  communicates with a first channel portion  220  that has an annular (ring) shape and at a distal end of the first channel portion  220  is a second channel portion  230  that is in fluid communication thereof. The first and second channel portions  220 ,  230  are continuous with respect to one another. As illustrated, the second channel portion  230  is formed at an angle and extends in a radially directed manner to an opening (exit port) that is formed along a surface of the body  210 . As shown, the opening (exit port) can be formed at an interface between a bottom wall and side wall of the body  210 . Based on the constructions of the shield gas nozzle  200 , the flow out of the shield gas nozzle  200  is both down (i.e., the second channel portion  230  is angled down) and radially outward to form a circumferential gas flow pattern. Fluid flowing into and through this narrow portion increases fluid pressure and results in a high velocity spray being generated. As also shown, the second channel portion  230  extends radially outward. 
     The discharge port the second channel portion  230  lies proximate to but preferably above the discharge port of the nozzle  120 . 
     As discussed above, the shield gas nozzle  200  is arranged to blow compressed gas (e.g., nitrogen) out circumferentially around the HVS dispense (body  110 ) thus generating a generally (roughly) horizontal flow regime, thereby forcing the mist out to the edges of the wafer  10  rather than allowing the mist to move upwards within the process environment. 
     As shown, the relative dimensions of the first and second channel portions  220 ,  230  can be different. For example, the dimensions of the second channel portion  230  can be less than the dimensions of the first channel portion  220  as shown. In other words, the diameter of the second channel portion  230  is less than the diameter of the first channel portion  220 . However, it is within the scope of the present invention that the dimensions of the first and second channel portions  220 ,  230  be at least substantially the same. 
     In this embodiment, the shield gas nozzle  200  is a separate part from the HVS nozzle  110  which can be a commercially available air atomizing nozzle. The shield gas and the HVS gas are plumbed and controlled independently. For example, flow control equipment, such as valves and pumps, are used to control the flow of the shield gas and the HVS gas. 
     Second HVS Dispense Arm Assembly Construction 
       FIGS. 3 and 4  show an HVS dispense arm assembly  101  according to a second embodiment. The HVS dispense arm assembly  101  is very similar to assembly  100  and therefore, like elements are numbered alike. 
     In the second embodiment, the shield gas and the HVS gas are plumbed together and adjusted with a valve  150 . In particular, there is a compressed gas (nitrogen gas) source  151  and a split conduit in that the compressed flows from the source  151  in a conduit that splits into a first conduit section  152  and a second conduit section  153 . The first conduit section  152  is connected to the inlet  114 , while the second conduit section  153  is connected to the inlet  215 . Along the first conduit section  152 , the valve  150  is provided to reduce the pressure or flow of the compressed gas (nitrogen) flowing into the nozzle body  110 . Any number of suitable valves  150  can be used. The valve  150  is located downstream of the split of conduit sections  152 ,  153  but is located within the conduit section  152 . 
     Third HVS Dispense Arm Assembly Construction 
       FIGS. 5 and 6  show an HVS dispense arm assembly  103  according to a third embodiment. The HVS dispense arm assembly  103  is very similar to assembly  100 ,  101  and therefore, like elements are numbered alike. 
     In the third embodiment, the location of the valve  150  is moved and repositioned along the second conduit section  153  (shield gas nozzle inlet side). Along the second conduit section  153 , the valve  150  is provided to reduce the pressure or flow of the compressed gas (nitrogen) flowing into the shield gas nozzle body  210 . Any number of suitable valves  150  can be used. 
     The valve  150  is located downstream of the split of conduit sections  152 ,  153  but is located within the conduit section  153 . 
     Fourth HVS Dispense Arm Assembly Construction 
       FIGS. 7 and 8  show an HVS dispense arm assembly  105  according to a fourth embodiment. The HVS dispense arm assembly  105  is very similar to assembly  100 ,  101  and therefore, like elements are numbered alike. 
     In the fourth embodiment, the second channel portion  230  is a horizontal channel. The illustrated shield gas nozzle is thus constructed such that flow out of the shield nozzle  200  (i.e., discharge from second channel portion  230 ) is both horizontal and radially outward. 
     As illustrated, there is a right angle interface between the first channel portion  220  and the second channel portion  230 . 
     It will also be appreciated that the assembly  105  can include the split conduit and valve arrangement shown in  FIGS. 3-4  or the one shown in  FIGS. 5-6  to control flow of the compressed gas to the respective inlets. 
     Fifth HVS Dispense Arm Assembly Construction 
       FIGS. 9 and 10  show an HVS dispense arm assembly  107  according to a fifth embodiment. The HVS dispense arm assembly  107  is very similar to assembly  100 ,  101  and therefore, like elements are numbered alike. 
     In the fifth embodiment, the second channel portion  230  is angled slightly upward relative to a bottom of the shield gas nozzle. The illustrated shield gas nozzle is thus constructed such that flow out of the shield nozzle  200  (i.e., discharge from the second channel portion  230 ) is both slightly up (relative to a bottom plane containing the bottom of the shield nozzle body) and radially outward. 
     It will also be appreciated that the assembly  107  can include the split conduit and valve arrangement shown in  FIGS. 3-4  or the one shown in  FIGS. 5-6  to control flow of the compressed gas to the respective inlets. 
     Sixth HVS Dispense Arm Assembly Construction 
       FIGS. 11 and 12  show an HVS dispense arm assembly  300  according to a sixth embodiment. The sixth embodiment shows a more integrated implementation. 
     The HVS dispense arm assembly  300  includes an HVS nozzle body  310  that includes a HVS nozzle  320  that is disposed at a distal end of the HVS nozzle body  310 . The HVS nozzle body  310  and HVS nozzle  320  incudes a channel architecture to allow gas to flow therethrough. In particular, the HVS nozzle body  310  includes a first channel  312  through which HVS nozzle liquid chemistry flows and a second channel  314  through which compressed gas (e.g., nitrogen gas) flows. Conventional techniques are used to deliver the liquid chemistry to the first channel  312  and the compressed gas to the second channel  314 . For example, a pump or other similar piece of equipment can be used to deliver the liquid chemistry and the compressed gas. 
     The first and second channel  312 ,  314  are in fluid communication with a third channel  316  that is formed in the HVS nozzle  320 . As shown in  FIG. 12 , an HVS dispense  130  is discharged from the HVS nozzle  320  in a direction toward a substrate  10 , such as a wafer. 
     In the assembly  300 , a shield gas nozzle  350  is formed between the body  310  and an outer ring part  330 . The shield gas nozzle  350  surrounds the HVS nozzle body  310 . For example, in the illustrated embodiment, the HVS nozzle body  310  and the outer ring part  330  are concentric with respect to one another. 
     An inlet  315  for receiving compressed gas (e.g., nitrogen gas) is provided to direct the compressed gas into the shield gas nozzle  350 . Similar to the first embodiment, the shield gas nozzle  350  is formed of a channel structure including a first channel portion  220  that has an annular (ring) shape and at a distal end of the first channel portion  220  (in fluid communication with inlet  315 ) and a second channel portion  230  that is in fluid communication thereof. The first and second channel portions  220 ,  230  are continuous with respect to one another. As illustrated, the second channel portion  230  is formed at an angle (downward) and extends in a radially directed manner to an opening (exit port). Based on the construction of the shield gas nozzle  350 , the flow out of the shield gas nozzle  350  is both down (i.e., the second channel portion  230  is angled down) and radially outward. 
     As discussed above, the shield gas nozzle  350  is arranged to blow compressed gas (e.g., nitrogen) out circumferentially around the nozzle  320  thus generating a generally (roughly) horizontal flow regime, thereby forcing the mist out to the edges of the wafer  10  rather than allowing the mist to move upwards within the process environment. 
     As shown in  FIG. 12 , the distal end of the HVS nozzle body  310  has an outwardly flared end (beveled flange). Similarly, the distal end of the outer ring part  330  has a beveled edge that is complementary to the outwardly flared end of the body  310  so as to define the second channel portion  230 —angled down and radially outward. 
     It will also be appreciated that the assembly  300  can include the split conduit and valve arrangement shown in  FIGS. 3-4  or the one shown in  FIGS. 5-6  to control flow of the compressed gas to the respective inlets. 
     Seventh HVS Dispense Arm Construction 
       FIGS. 13 and 14  show an HVS dispense arm  400  according to a seventh embodiment. The seventh embodiment shows a more integrated implementation and more specifically, a single body includes both the shield gas nozzle and the HVS nozzle. 
     The HVS dispense arm  400  includes a body  410  that has an inlet  420  for the liquid chemistry (HVS nozzle liquid in) and a first channel  430  that is in fluid communication with the inlet  420 . The first channel  430  terminates at a distal end in a nozzle portion  440  to discharge the HVS dispense  130 . 
     The shield gas nozzle construction is in the form of a compressed gas inlet  440  that is in fluid communication with a shield gas channel  450 . The shield gas channel  450  includes a first channel portion  452  and a second channel portion  454 . The first channel portion  452  has at least a section that has an annular (ring) shape and at a distal end of the first channel portion  452 , the second channel portion  454  is formed. The first and second channel portions  452 ,  454  are continuous with respect to one another. As illustrated, the second channel portion  454  is formed at an angle (downward angle) and extends in a radially directed manner to an opening (exit port or gas outlet). Based on the construction of the shield gas nozzle channel  450 , the flow out of the shield gas nozzle  450  is both down (i.e., the second channel portion  454  is angled down) and radially outward. It will be understood that the second channel portion  454  can be formed horizontal ( FIG. 8 ) or formed upwardly ( FIG. 10 ). 
     As shown in the figure and according to one embodiment, the shield gas channel  450  has an upper portion that is in fluid communication with the inlet  440  and a lower portion that terminates in the gas outlet. As shown, the upper portion of the shield gas channel  450  can have a linear shape, while the lower portion has an annular shape. The first channel  430  is located internally within the annular shaped lower portion of the shield gas channel  450 . 
     As also shown, the nozzle  440  is disposed below the bottom surface of the outer peripheral portion of the body  410 . The outer peripheral portion has an annular shape. The second channel  450  is open along the bottom surface. The gas outlet is thus located above the HVS dispense (the shield is thus discharged above the discharge location of the HVS dispense). 
     The body  410  includes an internal bleed off feature  460  that fluidly connects the shield gas nozzle channel  450  and the first channel  430 . The bleed off feature  460  is in the form of a channel that connects to the channels  450 ,  430 . Thus, shield gas and HVS gas enter the nozzle together (through inlet  440 ) and the internal bleed off  460  allows some of this gas to feed the HVS dispense. In other words, gas flowing into the inlet  440  flows through the channel  450  and some gas flows through the bleed off channel  460  to the channel  430  in which it flows to the nozzle  440  and is discharged therefrom. 
     As discussed above, the shield gas nozzle  450  is arranged to blow compressed gas (e.g., nitrogen) out circumferentially around the nozzle  440  thus generating a generally (roughly) horizontal flow regime, thereby forcing the mist out to the edges of the wafer  10  rather than allowing the mist to move upwards within the process environment. 
     It will also be appreciated that the dispense arm assembly of the present invention is typically a part of a piece of an automated (motorized) equipment that moves the dispense arm in a controlled motion over the wafer for dispensing chemical at select locations. 
     Notably, the figures and examples above are not meant to limit the scope of the present invention to a single embodiment, as other embodiments are possible by way of interchange of some or all of the described or illustrated elements. Moreover, where certain elements of the present invention can be partially or fully implemented using known components, only those portions of such known components that are necessary for an understanding of the present invention are described, and detailed descriptions of other portions of such known components are omitted so as not to obscure the invention. In the present specification, an embodiment showing a singular component should not necessarily be limited to other embodiments including a plurality of the same component, and vice-versa, unless explicitly stated otherwise herein. Moreover, applicants do not intend for any term in the specification or claims to be ascribed an uncommon or special meaning unless explicitly set forth as such. Further, the present invention encompasses present and future known equivalents to the known components referred to herein by way of illustration. 
     The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the relevant art(s) (including the contents of the documents cited and incorporated by reference herein), readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Such adaptations and modifications are therefore intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance presented herein, in combination with the knowledge of one skilled in the relevant art(s). 
     While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example, and not limitation. It would be apparent to one skilled in the relevant art(s) that various changes in form and detail could be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.