Patent Abstract:
A plating assembly for use in plating metallic materials onto a surface of a substrate is provided. The plating assembly comprising a delivery unit having a fluid chamber, a metallic source, and a porous insert. The plating assembly also comprising a receiving unit having a fluid chamber and a metallic receiver. The receiving unit also has a porous insert. The porous insert of the delivery unit being substantially aligned with, and spaced apart from, the porous insert of the receiving unit. The metallic receiver being substantially aligned with the porous insert of the delivery unit and a path being defined between the delivery unit and the receiving unit. Wherein a plating meniscus is capable of being defined in the path between the porous inserts of the delivery unit and the receiving unit and a substrate is capable of being moved through the plating meniscus to enable the plating of metallic materials onto the surface of the substrate. Examples for de-plating are also provided.

Full Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to the processing of semiconductor substrates, and more particularly, the plating of semiconductor substrates. 
     2. Description of the Related Art 
     Semiconductor substrate processing may include multiple operations where each operation can be dependent on the previous operation or operations. During processing, a substrate may be subjected to operations such as etching, chemical mechanical polishing, cleaning, and plating. With each operation, it is the possible to create defects or to introduce contaminants that can render the final product inoperable. To maximize output, many precautions may be taken in order to minimize process variables. For example, processing semiconductors in clean room environments is a standard practice intended to minimize processing variables including reducing sources of potential contamination. However, even with the use of clean room environments it may still be desirable to minimize exposure and handling of the semiconductor substrate. 
     In conjunction with the desire to minimize exposure and handling of the semiconductor substrate is the desire to minimize the use of processing chemicals while processing the semiconductor substrate. Reducing the amount of chemicals used during processing may reduce operating costs. Furthermore, due to the potentially hazardous nature of some of the chemical used, reducing the amount of chemicals used can also result in a safer and healthier environment. 
     In view of the forgoing, there is a need for improved processing techniques that can minimize both substrate handling and consumption of process chemicals. 
     SUMMARY 
     In one embodiment, a substrate plating assembly is disclosed. The substrate plating assembly is comprised of a delivery unit having an exterior surface and an interior chamber capable of housing a consumable plating metal. The interior chamber of the delivery unit is capable of containing a plating fluid and has an opening interfaced by a first porous insert. The opening of the interior chamber allows the plating fluid to move in and out of the interior chamber of the delivery unit. The substrate plating assembly also has a receiving unit having an exterior surface and an interior volume. The receiving unit is capable of housing a metal that facilitates distribution of an electrical field. The interior volume of the receiving unit is configured to hold at least part of the plating fluid. The interior volume of the receiving unit also has an opening interfaced by a second porous insert that allows the plating fluid to move in and out of the interior chamber of the receiving unit. The second porous insert is substantially aligned with the first porous insert, thereby defining a plating meniscus from the plating fluid between the first and second porous inserts. A substrate path is defined by a distance separating the delivery unit and the receiving unit while the meniscus is formed between the first porous insert and the second porous insert in the substrate path. Wherein the substrate path is configured to provide passage for a substrate. A surface of the substrate capable of being metallically plated when exposed to the plating fluid of the plating meniscus as the substrate is moves through the substrate path between the delivery unit and the receiving unit. 
     In another embodiment a plating assembly for use in plating metallic materials onto a surface of a substrate is disclosed. The plating assembly comprising a delivery unit having a fluid chamber, a metallic source, and a porous insert. The plating assembly also comprising a receiving unit having a fluid chamber and a metallic receiver. The receiving unit also has a porous insert. The porous insert of the delivery unit being substantially aligned with, and spaced apart from, the porous insert of the receiving unit. The metallic receiver being substantially aligned with the porous insert of the delivery unit and a path being defined between the delivery unit and the receiving unit. Wherein a plating meniscus is capable of being defined in the path between the porous inserts of the delivery unit and the receiving unit and a substrate is capable of being moved through the plating meniscus to enable the plating of metallic materials onto the surface of the substrate. 
     In yet another embodiment, a method for plating a substrate is disclosed. The method comprising forming a meniscus from a electrolytic fluid, the meniscus being formed between a plating source and a plating facilitator. The method also includes moving a substrate through a path that intersects the meniscus and the substrate being charged so that plating material in the plating fluid are attracted to a surface of the substrate when the meniscus is present on the surface of the substrate. Further included in the method is moving the substrate through the meniscus enabling plating across the surface of the substrate. Additionally, the method includes inducing a charge through the meniscus, such that a charge from the plating source is substantially uniformly directed toward the plating facilitator. 
     In another embodiment, a method for de-plating a substrate is disclosed. The method comprising forming a meniscus from an electrolytic fluid, the meniscus being formed between a first metallic material and a second metallic material. The method further includes placing the substrate at a location that intersects the meniscus and the substrate being charged so that metallic material from a surface of the substrate is attracted away from the surface of the substrate toward one of either the first metallic material or the second metallic material. 
     Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention, together with further advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings. 
         FIG. 1  is a high level schematic of substrate processing apparatus in accordance with one embodiment of the present invention. 
         FIG. 2  is a high level schematic of a process module in accordance with one embodiment of the present invention. 
         FIG. 3A  is a cross-section of a plating assembly in accordance with one embodiment of the present invention. 
         FIG. 3B  is a schematic showing the different areas of the substrate path in accordance with one embodiment of the present invention. 
         FIGS. 4A and 4B  are schematics illustrating the how the bottom cathode promotes an even plating of the substrate in accordance with one embodiment of the present invention. 
         FIGS. 5A-5D  illustrate how to control the batch volume of plating fluid  128  within the plating meniscus  142  in accordance with one embodiment of the present invention. 
         FIG. 6A  shows a schematic of a perspective view of the plating assembly in accordance with one embodiment of the present invention. 
         FIG. 6B  shows a schematic of an exploded view of the top section in accordance with one embodiment of the present invention. 
         FIG. 7  shows a schematic of the gripper  121  in accordance with one embodiment of the present invention. 
         FIG. 8  shows a schematic of the gripper, the plating assembly, and the substrate in accordance with one embodiment of the present invention. 
         FIG. 9  shows a schematic of a process module that includes the plating module in accordance with one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     An invention is disclosed for devices and methods for performing a plating operation on a surface of a substrate. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order not to unnecessarily obscure the present invention. The various embodiments will thus be described in accordance with the order of the drawings, but without limitation to any particular structure or configuration, as they are provided to illustrate the many permutations, combinations and/or alternatives, within the spirit and broad scope of the enumerated claims. 
       FIG. 1  is a high level schematic of substrate processing apparatus  100  in accordance with one embodiment of the present invention. The substrate processing apparatus  100  can contain a single or multiple process modules  102 . The process modules  102  can perform a variety of processing including, but not limited to, etching, cleaning, plating, and other substrate preparation operations. The process modules  102  are connected to a control system  104 . The control system  104  can be physically separated from the process module  102  as shown, or an integrated component within the process module  102 . The control system  104  can be used to ensure the required processing conditions and operations are achieved within the processing module  102 . The control system  104  can also monitor and control movement of substrate material between process modules  102 . The control system  104  is connected to a computer  106 . The computer  106  can be used to adjust and monitor the performance of the processing apparatus  100  through the control system  104 . In one embodiment, the control system  104  can be connected to a network, such as the Internet, to enable remote setup, operation, and control. 
       FIG. 2  is a high level schematic of a process module  102  in accordance with one embodiment of the present invention. In this embodiment, the process module  102  is connected to computer  106  and the control system  104  of  FIG. 1 . The process module  102  may be located in a clean room  108 . The clean room  108  can include facilities  109  that can provide fluids and gases used by the process module  102 . The process module  102  includes gas controls  110  and fluid controls  112 . The gas controls  110  can include air filters, gas valves, and devices to control the temperature and humidity of gases used in the process module. The fluid controls  112  can include fluid handlers  114 , flow controllers  116 , and valves  118 . In one embodiment the fluid handlers  114  can be used to store process chemicals and de-ionized water. The flow controllers  116  and valves  118  can be used to control the mixing and dispensing of fluids. 
     The process module  102  can have a single process station or multiple process stations. It should be clear that a process module could contain fewer or more process stations than shown in  FIG. 2 . The individual process station can perform one, or a combination of processes including, but not limited to, plating, etching, cleaning or other operations typically used in the semiconductor processing environment. For simplicity, process station A and process station C are shown as blocks. In one embodiment Process station B includes a plating assembly  120 , grippers  121  and substrate handlers  123 . When a gripper  121  is not manipulating a substrate  150 , the substrate handlers  123  can control the movement of the substrate  150  within the process station. The gripper  121  is used to move the substrate  150  from a substrate handler  123  through the plating assembly  120 . In one embodiment there is a gripper  121  on each side of the plating assembly and the substrate  150  is handled by both of the grippers  121  as the substrate  150  emerges from the plating assembly  120 . In one embodiment, the grippers  121  also provide an electrical connection to facilitate plating, as will be described below. After passing through the plating assembly the substrate  150  is placed on a substrate handler  123 . 
       FIG. 3A  is a cross-section of a plating assembly  120  in accordance with one embodiment of the present invention. The plating assembly  120  includes a delivery unit  200 A and a receiving unit  200 B. A distance separating the delivery unit  200 A from the receiving unit  200  defines a substrate path  190  through which the substrate  150  can pass. In one embodiment, the substrate path  190  is defined by a separation gap that will enable passage of a substrate, and the separation gap may vary depending on the thickness of the substrate. In an embodiment where the substrate is a semiconductor wafer, the separation gap will range from between about 5 mm and about 0.5 mm, and more particularly between about 4 mm and about 1.5 mm, and in a specific embodiment about 3 mm. 
     In one embodiment, the delivery unit  200 A includes a top section  120   a , a mid-section  120   b  and the receiving unit  200 B includes a bottom section  120   c . The top section  120   a  may include an anode chamber  122   a  and an anode chamber  122   b  attached to a plating fluid chamber  122   c . The anode chambers  122   a  and  122   b  contain anodes  124   a  and  124   b , respectively. The anode, or first charge source, may be composed of a metal that is consumed during an electroplating reaction. In one embodiment the anode, or plating source, is made from a copper containing material, substantially pure copper, or copper alloy. In other embodiments the anodes  124   a  and  124   b  are made from different electroplating materials. The plating fluid chamber  122   c  along with anode chamber  122   a  and anode chamber  122   b  may be filled with a plating fluid  128 . In one embodiment the plating fluid  128  is an electrolytic solution selected because of the ability to promote electroplating. 
     The anodes  124   a  and  124   b  may need to be replaced after being consumed during the electroplating process. The electroplating process (and the consumption of the anodes) may extend to the plating of one substrate to many substrates, depending on the thickness being plated and other factors. Membranes  126   a  and  126   b  are placed between the plating fluid chamber  122   c  and the respective anode chambers  122   a  and  122   b . In this embodiment, the membranes  126   a  and  126   b  retain most of the plating fluid  128  within the plating fluid chamber  122   c  but allow the passage of copper ions from the anode chambers  122   a  and  122   b  to the plating fluid chamber  122   c . In one embodiment, mechanically, the membranes  126   a  and  126   b  enable the removal of the respective anode chambers  122   a  and  122   b , without requiring draining of the plating fluid  128 . Because the anodes  124   a  and  124   b  can be replaced without draining the plating fluid  128 , downtime for the plating assembly  120  is minimized. It should be noted that the use of two anodes in the orientation shown in  FIG. 3A  is merely one embodiment of the top section  120 . Other embodiments of the top section  120   a  may have more or fewer anodes in different orientations. 
     The top section  120   a  is attached to the mid-section  120   b . In one embodiment, the mid-section  120   b  includes a pre-wet top head  130   a , a pre-wet porous insert  132   a , curtain gas inlet  134   a , a curtain gas inlet  134   b , a rinse/dry top head  136   a  and a porous plating insert  140   a . The pre-wet top head  130   a  may contain a pre-wet fluid and an opening to the substrate path  190  that is interfaced by the pre-wet porous insert  132   a . The pre-wet porous insert  132   a  is saturated with the pre-wet fluid. The curtain gas inlets  134   a  and  134   b  direct a flow of pressurized gas toward the bottom section  120   c . The curtain gas may be selected from a multitude of inert gases include mixtures of gases. In one embodiment the curtain gas can be composed of pure nitrogen. In other embodiment the curtain gas can be argon or a mixture of nitrogen and argon, IPA, or CO 2 . A rinse/dry top head  136   a  includes multiple areas capable of providing vacuum suction and rinsing fluid. 
     As a component of the delivery unit  200 A, the mid-section  120   b  is configured to accommodate the plating fluid chamber  122   c  and allow the plating fluid  128  to saturate the porous plating insert  140   a , but still allow the plating ions to pass through. In one embodiment the plating fluid chamber  122   c  extends into the mid-section  120   b  from the top section  120   a . In another embodiment the plating fluid chamber  122   c  is formed when a cavity of the top section  120   a  is joined with a cavity in the mid-section  120   b . In yet another embodiment the plating fluid chamber  122   c  is a cavity that extends into the top section  120   a  from the bottom section  120   b . A surface of the porous plating insert  140   a  is exposed to the substrate path  190 . In one embodiment, the choice of material for the porous plating insert  140   a  is chosen based on the porosity of the material and the viscosity of the plating fluid  128 . Materials that can be used for the porous plating insert  140   a  can include, but are not limited to, porous plastics such as many varieties of nylon and a variety of porous ceramics. 
     In one embodiment the receiving unit  200 B is located below the delivery unit  200 A. In the embodiment shown in  FIG. 3A  the receiving unit  200 B is the bottom section  120   c . In another embodiment the receiving unit  200 B may me made up of multiple assemblies including a bottom section. The receiving unit can be connected to the plating assembly  120   b . The bottom section  120   c  may include a pre-wet bottom head  130   b , a pre-wet porous insert  132   b , a rinse/dry bottom head  136   b , a porous plating insert  140   b , and a bottom cathode  144  within a chamber containing plating fluid  128 . The pre-wet bottom head  130   b  can contain the same pre-wet fluid used in the pre-wet top head  130   a . An opening from the pre-wet bottom head  130   b  to the substrate path  190  is interfaced by the pre-wet porous insert  132   b . The locations of the porous insert  132   a  and porous insert  132   b  allow a pre-wet meniscus  137  of pre-wet fluid to form in the substrate path  190 . 
     The porous plating insert  140   b  interfaces an opening to a chamber within the bottom section  120   c  that contains the bottom cathode  144 , or second charge source. To facilitate electroplating, plating fluid  128  surrounds the bottom cathode  144 , or plating facilitator, and saturates the porous plating insert  140   b . Similar to the pre-wet meniscus, the orientation and alignment of the porous plating inserts  140   a  and  140   b  allow the formation of a plating meniscus  142  across the substrate path  190 . The rinse/dry bottom head  136   b  is similar to the rise/dry top head  136   a . The rinse/dry bottom head  136   b  includes multiple areas capable of providing vacuum suction and rinsing fluid. 
     In one embodiment the plating assembly  120  performs a plating operation when a substrate  150  passes through the various menisci and dry/rinse areas intersecting the substrate path  190 . During the plating operation the substrate  150  may be held with a first gripper  121  and passed/pushed into the substrate path  190 . In one embodiment, an electrical charge with the same polarity as the bottom cathode  144  is applied to the substrate  150  using a cathode  146 . In one embodiment the cathode  146  may be incorporated into the first gripper  121 . As the substrate  150  enters the substrate path  190  the leading edge of the substrate  150  passes through the curtain gas from curtain gas inlet  134   a  followed by the pre-wet meniscus  137 . As the substrate  150  enters the pre-wet meniscus  137  the curtain gas may help prevent pre-wet fluid from running across the surface of the substrate  150  to the exterior of the plating assembly  120 . As previously mentioned, the curtain gas can be an inert gas such as nitrogen, IPA, CO 2 , argon or a mixture thereof. Because the pre-wet fluid can be used to prepare the substrate  150  for plating, the choice of a pre-wet fluid can vary depending on the particular plating fluid  128  and the type of metal being plated. For example, if a copper sulfate plating solution is being used the pre-wash fluid can include a philic agent to promote copper plating on the substrate  150 . 
     As the substrate  150  enters the plating meniscus  142  the electrical charge applied to the substrate in conjunction with the electrical charge from the bottom cathode  144  attract metal ions in the plating solution  128  to the surface of the substrate  150 . After passing through the plating meniscus  142 , the substrate  150  passes under the curtain gas inlet  134   b . Curtain gas inlet  134   b  helps to contain the plating fluid  128  and prevent the plating fluid  128  from escaping to the exterior of the plating assembly  120 . Note that in this embodiment it is possible for fluid from the pre-wet meniscus  137  to mix with the plating fluid  128 . However, curtain gas from both curtain gas inlets  134   a  and  134   b  are meant to contain both the pre-wet fluid and the plating fluid  128  within the plating assembly  120 . In another embodiment, additional curtain gas inlets between the pre-wet meniscus  137  and the plating meniscus  142  could prevent the mixing of pre-wet fluid and plating fluid  128 . 
     After passing through the curtain gas inlet  134   b  the substrate  150  encounters a vacuum area surrounding the rinse/dry top head  136   a  and the rinse/dry bottom head  136   b . In one embodiment the rinse/dry top head  136   a  and the rinse/dry bottom head  136   b  can define a cleaning area positioned at an exit of the plating assembly. The first vacuum area encountered by the substrate  150  can remove residual plating fluid moisture from the surface of the substrate. After the first vacuum area the substrate  150  passes through the fluid meniscus  138  between the rinse/dry top head  136   a  and the rinse/dry bottom head  136   b . The fluid meniscus  138  is where the now plated surface of the substrate  150  is exposed to rinsing fluids. The rinsing fluids can include de-ionized water, chemicals or a mixture thereof. Other fluids may be used to rinse the substrate and those listed should not be considered inclusive of potential rinsing fluids. After passing through the fluid meniscus  138 , the substrate  150  passes through a second vacuum area. The second vacuum area can remove any residual fluid and ensure the substrate  150  is in a substantially dry state. Thus, the substrate  150  can enter the plating assembly  120  dry and exit dry. This is a substantial benefit over other plating systems that require additional assemblies to rinse and dry a substrate after a plating operation. 
     A second gripper may be waiting to clamp onto the portion of the substrate  150  that exits the plating assembly  120 . Because the first gripper would prevent the entire substrate from being plated, the second gripper can pull the substrate  150  through the plating assembly  120 . Similar to the first gripper, the second gripper may also be able to apply an electrical charge to the substrate  150  using a cathode  146 . At a certain point the first and second grippers may be moving simultaneously, each clamped to the substrate  150 . The first gripper may release the substrate  150  while the second gripper continues to move the substrate  150  through the plating assembly  120  while continuing to apply an electrical charge to the substrate. 
       FIG. 3B  is a schematic showing the different areas of the substrate path  190  in accordance with one embodiment of the present invention. The curtain gas inlet  134   a  are shown as a row of circles that are followed by the pre-wet meniscus  137 . The plating meniscus  142  can be seen along with the curtain gas inlets  134   b . In another embodiment the curtain gas inlet  134   a/b  could be a slot that allows the curtain gas to escape into the path  140 . The fluid meniscus  138  is visible after the curtain gas inlet  134   b . Not shown are the first and second vacuum areas. In one embodiment the vacuum could be drawn through small holes. In another embodiment, the vacuum could be drawn through a slot. Note that the curtain gas inlets  134   a/b , pre-wet meniscus  137 , plating meniscus  142 , and fluid meniscus  138  can be positioned so they extended beyond the edges of the substrate  150 . This helps to ensure that the entire surface of the substrate  150  is processed. 
       FIGS. 4A and 4B  are schematics illustrating the how the bottom cathode  144  promotes an even plating of the substrate  150  in accordance with one embodiment of the present invention. Grippers  122  hold the substrate  150 , and as previously discussed, the grippers  122  can apply an electrical charge to the substrate  150  using the cathodes  146 . The substrate  150  is guided into the plating meniscus  142  made from plating fluid  128 . The anodes  124   a/b  are consumed during the electrolysis process by release metallic ions (e.g., copper ions Cu+) into the plating fluid  128 . The metallic ions are drawn toward the oppositely charged cathode  144  and the substrate  150 . 
     Though the substrate  150  is electrically charged as a cathode, the use of the cathode  144  can help assist in the uniform application of a plating layer  152  on the substrate  150 . Using only the substrate  150  as the cathode, or second charge source, it is possible for an uneven deposition of plating material at the edge of the substrate. This uneven plating may be caused of the concentration of the electric field at the edge of the substrate as the substrate moves in or out of the system. As shown in  FIG. 4B , the cathode  144  extends beyond the edges of the substrate  150 . Thus, the cathode  144  can prevent excessive build up of plating material at the edge of the substrate  150  by providing an even electrical field across the substrate  150 , including the edge. Thus, the electric field will be substantially even when the substrate is present, when the substrate is not present, and when the substrate is in transition through the path  190  (e.g., at any stage of progression through the path  190  of the plating assembly  120 ). This is a particular benefit, as reliance on the substrate  150  as the only cathode can produce the above-mentioned non-uniformities in plating. 
       FIGS. 5A-5D  illustrate how to control the batch volume of plating fluid  128  within the plating meniscus  142  in accordance with one embodiment of the present invention. For clarity,  FIGS. 5A-5D  only show the plating meniscus. Note that the techniques used to control the plating meniscus  142  could also be applied to other menisci used in other processes including those in the plating assembly  120 .  FIG. 5A  shows the substrate is seen approaching the plating assembly  120 . Before the substrate  150  enters the plating meniscus  142 , the plating meniscus is stable. In this case, a stable meniscus means that the plating fluid  128  is contained between the porous plating inserts  140   a/b . In one embodiment the volume of the plating meniscus is about 70 mL and the volume of the pre-wet meniscus is about 8 mL. Note that the volume of the plating meniscus and the pre-wet meniscus can be dependent on the size of the substrate being processed. The volume of the menisci can also vary based on the material being plated to the substrate and the speed of the substrate through the processing assembly. 
     As the substrate  150  moves into the plating meniscus  142 , as shown in  FIG. 5B , plating fluid  128  is removed from the plating meniscus  142  using fluid control out valves  160   a  and  160   b . The removal rate the plating fluid  128  corresponds with the displacement of plating fluid  128  from the plating meniscus  142  by the intrusion of the substrate  150 . By removing plating fluid  128  from the plating meniscus  142  at the same rate the substrate  150  displaces the plating fluid  128 , the plating meniscus  142  remains stable. One of the many benefits of maintaining a plating meniscus  142  is the minimization of the plating fluid  128  that is wasted. Another benefit of maintaining a stable plating meniscus  142  is that it is possible to calculate precise volumes of fluids required for a plating process. Another benefit is that the plating meniscus  142  remains contained to the location of process, without dripping or spillage. 
     In the embodiment shown in  FIGS. 5A-5D  the substrate  150  is shown as circular. Therefore, after half of the substrate  150  has been plated plating fluid  128  needs to be added to maintain a stable meniscus. As shown in  FIG. 5C , the fluid control valves  160   a  and  160   b  can allow the reintroduction of plating fluid  128  at the same rate the displaced volume of plating fluid is decreasing to maintain the stability of the plating meniscus  142 . It should be noted that the fluid control valves  160   a/b  may be used to add and remove fluid from the plating meniscus based on a substrate of any shape and rate of movement.  FIG. 5D  illustrates the substrate  150  as it exits the plating meniscus  142 . The fluid control valves  160   a/b  continue to add plating fluid  128  in order to compensate for the decreasing displacement of fluid from the substrate  150  and maintain a stable plating meniscus. 
       FIG. 6A  shows a schematic of a perspective view of the plating assembly  120  in accordance with one embodiment of the present invention. Visible in  FIG. 6A  is the top section  120   a , mid-section  120   b  and bottom section  120   c . In the embodiment shown in  FIG. 6A  the anode chamber  122   a  and  122   b  are shown connected to the plating fluid chamber  122   c . The substrate  150  can be seen partially inserted into the substrate path  190 . Also shown on the embodiment of mid-section  120   b  are multiple ports to the interior chambers of the plating assembly  120 . Note that the ports shown in  FIG. 6A  are exemplary and should not inclusive of the possible ports on the plating assembly  120 . The ports can be used to supply the curtain gas or processing fluids such as de-ionized water, isopropyl alcohol, carbon dioxide, inert gases, or plating fluid. The ports can also be used to draw a vacuum for the rinse/dry head. The plating assembly  120 , although shown in isolation, is in one embodiment, connected to a module. The module can either be a self-contained module or can be a multiple station module. A plating module, in a broad sense, is a unit that will hold the plating assembly  120 , and can accept substrates to be plated in a dry state and output substrates in a dry state. The plating module can therefore be integrated with other modules, such as etching modules, chemical mechanical polishing modules, etc. Within the plating module, the ambient environment can also be controlled, so that a desired level of controlled plating can be achieved. In one embodiment, the controlled ambient can be a reduced oxygen ambient, that will assist in reducing oxidation after the plating operation is complete. Of course, other uses implementations of the plating module can also take place. 
       FIG. 6B  shows a schematic of an exploded view of the top section  120   a  in accordance with one embodiment of the present invention. The plating fluid chamber  122   c  is shown along with frames  154   a/b  and membranes  126   a/b . The frames  154   a/b  can be used to hold the membranes  126   a/b . In one embodiment the plating fluid chamber  122   c  includes recessed areas to accommodate the frames  154   a/b  and the membranes  126   a/b . The frames  154   a/b  and corresponding membranes  126   a/b  may be attached to the plating fluid chamber  122   c  using a variety of fastening techniques including mechanical fasteners, adhesives, etc. 
     As previously discussed, the membranes  126   a/b  retain most of the plating fluid within the plating fluid chamber while allowing the passage of electroplating ions from the anodes  124   a/b . As shown in  FIG. 6B , the anodes  124   a/b  and the anode chambers  122   a/b  can be attached to the plating fluid chamber  122   c  using mechanical fasteners such as screws. In other embodiments different fastening techniques may be used such as adhesives. The anodes  124   a/b  may include features that facilitate attaching the anodes  124   a/b  to the anode chamber  122   a/b.    
     Because substrate processing can be highly sensitive to contamination the choice of material for the plating fluid chamber  122   c  and anode chambers  122   a/b  can include, but are not limited to, plastics and other materials that do not create contaminants when exposed to an electroplating environment. One example of a plastic that can be used for the plating fluid chamber  122   c  and the anode chamber  122   a/b  is polycarbonate. Because the anodes are consumed during the electroplating process, the use of a clear or substantially clear polycarbonate for the anode chambers  122   a/b  enables visual inspection of the anodes to determine if an anode requires replacement. The frames  154   a/b  can also be made from a plastic such as polycarbonate. However, because the frames  154   a/b  are internal components the toughness and transparent qualities of polycarbonate are not necessary. Thus, the frames  154   a/b  can also be made from plastics such as nylon. 
       FIG. 7  shows a schematic of the gripper  121  in accordance with one embodiment of the present invention. In one embodiment the gripper  121  can include electrodes  180 . The electrodes can move from a first position not in contact with the substrate  150  to a second position contacting the substrate  150 . When contacting the substrate  150  the electrodes  180  may impart an electrical charge that enables the substrate  150  to act as a cathode. Note that in some embodiments an electrical charge is applied to the substrate  150  when the electrodes contact the substrate. In other embodiments the electrical charge can be controlled so the electrodes  180  may be in contact with the substrate  150  without passing a charge. 
       FIG. 8  shows a schematic of the gripper  121 , the plating assembly  120 , and the substrate  150  in accordance with one embodiment of the present invention. A substrate  150  is shown partially inserted into the plating assembly  120 . For clarity, a gripper is not shown holding the substrate  150 . The gripper  121  is shown on the output side of the plating assembly  120 . In this example, the substrate  150  has not emerged from the plating assembly. 
       FIG. 9  shows a schematic of a process module  102  that includes the plating module  120  in accordance with one embodiment of the present invention. The plating assembly is shown connected to the computer  106 . Also connected to the computer  106  are grippers  121 . Ports on the plating assembly are attached to facilities. 
     The ability for the plating assembly  120  to accept a dry substrate  150  and output a plated, clean and dry is enabled by the integration of the rinse/dry head, also known as a proximity head, with the plating assembly  120 . One of the many benefits of integrating the proximity head is that the substrate does not need to be moved to a separate clean/dry station either within the process station or within a separate process module. Because the substrate does not need to travel to another station or module handling of the substrate is reduced and that can reduce the possibility of introducing contaminants to the substrate. Another benefit of integrating the proximity head with the plating assembly may be the reduction in the physical footprint of the process station and process module. Since a separate process station or process module is no longer required to rinse/dry the substrates the process stations and the process modules may be constructed to by physically smaller. Alternatively, the space saved by integrating the proximity head can be used to add different process stations allowing more operations to be performed within a process module. 
     In another embodiment, the plating apparatus  120  can be used as a de-plating apparatus. With minor modifications, the plating apparatus  120  may be used to remove a metallic material from the surface of a substrate material. The modifications may include, but not are limited to, reversing the polarity of the electrodes. Thus, the cathode in the plating operation becomes an anode for a de-plating operation. Similarly, the polarity of the charge applied to the substrate may also be reversed, thereby making the substrate an anode. Furthermore, the polarity of the plating anode may be reversed resulting in the plating anode becoming a de-plating cathode. Additional modification of the plating apparatus may be necessary to enable de-plating including modifications to remove gaseous byproducts of the de-plating process. 
     Further, during de-plating, the substrate can be placed within the meniscus in many ways. For instance, the substrate can first be placed in a de-plating position and then the de-plating meniscus can be activated and allowed to be placed over the surface of the substrate. The de-plating meniscus can also be formed first, and then the substrate is placed into the meniscus. 
     In another embodiment, the substrate, once in the de-plating position, can be moved or traversed in a direction, and the direction can either be linear or rotation. The handling of the substrate can therefore take on many forms and the connections to the substrate can be made such that the electric connection is moved or shifted to enable full de-plating of the material, even when the substrate is handled by a charged handler. The handler can take on many forms, and such forms may include rollers, grippers, plurality of pins or rollers with metallic connections at contact regions, such that the substrate can be supported, transported, rotated and otherwise handled. 
     For additional information with respect to the proximity head noted above, reference can be made to an exemplary proximity head, as described in the U.S. Pat. No. 6,616,772, issued on Sep. 9, 2003 and entitled “M ETHODS FOR WAFER PROXIMITY CLEANING AND DRYING .” This U.S. Patent Application, which is assigned to Lam Research Corporation, the assignee of the subject application, is incorporated herein by reference. 
     For additional information about top and bottom menisci, reference can be made to the exemplary meniscus, as disclosed in U.S. patent application Ser. No. 10/330,843, filed on Dec. 24, 2002 and entitled “M ENISCUS , V ACUUM , IPA V APOR , D RYING  M ANIFOLD .” This U.S. Patent Application, which is assigned to Lam Research Corporation, the assignee of the subject application, is incorporated herein by reference. 
     For additional information with respect to fluids, reference can be made to the exemplary processes and systems, as disclosed in U.S. patent application Ser. No. 11/513,634, filed on Aug. 30, 2006 and entitled “P ROCESSES AND SYSTEMS FOR ENGINEEING A COPPER SURFACE FOR SELECTIVE METAL DEPOSITION ”. This U.S. Patent Application, which is assigned to Lam Research Corporation, the assignee of the subject application, is incorporated herein by reference. 
     For additional information about fluids, reference can be made to the exemplary processes and systems, as disclosed in U.S. patent application Ser. No. 11/514,038, filed on Aug. 30, 2006 and entitled “P ROCESSES AND SYSTEMS FOR ENGINEERING A BARRIER SURFACE FOR COPPER DEPOSITION ”. This U.S. Patent Application, which is assigned to Lam Research Corporation, the assignee of the subject application, is incorporated herein by reference. 
     For additional information about fluids, reference can be made to the exemplary processes and systems, as disclosed in U.S. patent application Ser. No. 11/513,446, filed on Aug. 30, 2006 and entitled “P ROCESSES AND SYSTEMS FOR ENGINEERING A SILICON - TYPE SURFACE FOR SELECTIVE METAL DEPOSITION TO FORM A METAL SILICIDE ”. This U.S. Patent Application, which is assigned to Lam Research Corporation, the assignee of the subject application, is incorporated herein by reference. 
     For additional information regarding plating fluids, plating materials or plating solutions, reference can be made to the exemplary solutions as disclosed in U.S. patent application Ser. No. 11/382,906, filed on May 11, 2006 and entitled “ PLATING SOLUTION FOR ELECTROLESS DEPOSITION OF COPPER ”. This U.S. Patent Application, which is assigned to Lam Research Corporation, the assignee of the subject application, is incorporated herein by reference. 
     Additional information regarding plating fluids and plating solutions can be found by referencing the exemplary solutions as disclosed in U.S. patent application Ser. No. 11/472,266, filed on Jun. 28, 2006 and entitled “ PLATING SOLUTIONS FOR ELECTROLESS DEPOSITION OF COPPER ”. This U.S. Patent Application, which is assigned to Lam Research Corporation, the assignee of the subject application, is incorporated herein by reference. 
     Aspects of the control, programming or interfacing may be practiced with other computer system configurations including hand-held devices, microprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframe computers and the like. The invention may also be practiced in distributing computing environments where tasks are performed by remote processing devices that are linked through a network. 
     With the above embodiments in mind, it should be understood that the invention may employ various computer-implemented operations involving data stored in computer systems. These operations are those requiring physical manipulation of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. Further, the manipulations performed are often referred to in terms, such as producing, identifying, determining, or comparing. 
     Any of the operations described herein that form part of the invention are useful machine operations. The invention also relates to a device or an apparatus for performing these operations. The apparatus may be specially constructed for the required purposes, such as the carrier network discussed above, or it may be a general purpose computer selectively activated or configured by a computer program stored in the computer. In particular, various general-purpose machines may be used with computer programs written in accordance with the teachings herein, or it may be more convenient to construct a more specialized apparatus to perform the required operations. 
     The invention can also be embodied as computer readable code on a computer readable medium. The computer readable medium is any data storage device that can store data, which can thereafter be read by a computer system. The computer readable medium can also be distributed over a network coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     Although the foregoing invention has been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. For instance, in another embodiment, a meniscus can be formed to the size or larger than the substrate, and the substrate can be exposed to the meniscus in a clam shell operating-like process (to either one or both sides of the substrate). The clam shell operating-like process can also be used to de-plate the entire surface of the substrate, if the substrate is first place in position and then a fluid is allowed to contact the substrate surface. In such embodiments, the substrate is provided with electrical contact and the plating assembly is modified for size, handling, and/or support. Accordingly, it should be understood that many modification, permutations, adjustments and configuration are possible, so long as the basic elements of the claims that are appended hereto are understood in their broadest terms and application. 
     Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.

Technology Classification (CPC): 2