Source: https://patents.google.com/patent/US9931728B2/en
Timestamp: 2018-11-20 16:58:51
Document Index: 309602212

Matched Legal Cases: ['Application No. 14198969', 'Application No. 201280024792', 'Application No. 11201402224', 'Application No. 2014', 'Application No. 2014', 'Application No. 2016', 'Application No. 2014', 'Application No. 1020167021338', 'Application No. 10', 'Application No. 10', 'Application No. 2014', 'Application No. 104119891', 'Application No. 101118246', 'Application No. 101118247']

US9931728B2 - Polishing pad with foundation layer and polishing surface layer - Google Patents
Polishing pad with foundation layer and polishing surface layer Download PDF
US9931728B2
US9931728B2 US14732497 US201514732497A US9931728B2 US 9931728 B2 US9931728 B2 US 9931728B2 US 14732497 US14732497 US 14732497 US 201514732497 A US201514732497 A US 201514732497A US 9931728 B2 US9931728 B2 US 9931728B2
US14732497
US20150273655A1 (en )
Polishing pads with foundation layers and polishing surface layers are described. In an example, a polishing pad for polishing a substrate includes a foundation layer. A polishing surface layer is bonded to the foundation layer. Methods of fabricating polishing pads with a polishing surface layer bonded to a foundation layer are also described.
This application is a divisional of U.S. patent application Ser. No. 13/306,845, filed on Nov. 29, 2011, the entire contents of which are hereby incorporated by reference herein.
Embodiments of the present invention are in the field of chemical mechanical polishing (CMP) and, in particular, polishing pads with foundation layers and polishing surface layers.
Embodiments of the present invention include polishing pads with foundation layers and polishing surface layers.
In an embodiment, a polishing pad for polishing a substrate includes a foundation layer having a first hardness. A polishing surface layer is bonded directly to the foundation layer. The polishing surface layer has a second hardness less than the first hardness.
In another embodiment, a polishing pad for polishing a substrate includes a foundation layer having a first hardness. A polishing surface layer is bonded directly to the foundation layer. The polishing surface layer has a second hardness equal to or greater than the first hardness.
In another embodiment, a polishing pad for polishing a substrate includes a foundation layer having an energy loss factor of less than approximately 100 KEL at 1/Pa at 40° C. A polishing surface layer is attached to the foundation layer. The polishing surface layer has an energy loss factor of greater than approximately 1000 KEL at 1/Pa at 40° C. The foundation layer and the polishing surface layer together have an energy loss factor of less than approximately 100 KEL at 1/Pa at 40° C.
In another embodiment, a polishing pad for polishing a substrate includes a foundation layer having a first hardness. A polishing surface layer is attached to the foundation layer. The polishing surface layer has a second hardness less than the first hardness and is composed of a thermoset material.
In another embodiment, a polishing pad for polishing a substrate includes a nonporous foundation layer. A polishing surface layer is bonded directly to the foundation layer. The polishing surface layer has a pore density of closed cell pores.
In another embodiment, a method of fabricating a polishing pad for polishing a substrate includes providing, in a formation mold, a foundation layer and a mixture formed from mixing a set of polymerizable materials. A pattern of protrusions of the formation mold is coupled with the mixture. With the pattern of protrusions coupled with the mixture, the mixture is at least partially cured to form a molded homogeneous polishing surface layer directly on the foundation layer. The molded homogeneous polishing surface layer includes a pattern of grooves corresponding to the pattern of protrusions of the formation mold.
In another embodiment, a method of fabricating a polishing pad for polishing a substrate includes providing, in a formation mold, a foundation layer and a mixture formed from mixing a set of polymerizable materials. A pattern of protrusions of the formation mold is coupled with the mixture. With the pattern of protrusions coupled with the mixture, the mixture is at least partially cured to form a molded homogeneous polishing surface layer attached to the foundation layer. The molded homogeneous polishing surface layer includes a pattern of grooves corresponding to the pattern of protrusions of the formation mold. The foundation layer having the molded homogeneous polishing surface layer attached thereto is removed from the base of the formation mold when the extent of curing is sufficient to maintain geometry of the molded homogeneous polishing surface layer but insufficient for the molded homogeneous polishing surface layer to withstand mechanical stress.
Polishing pads with foundation layers and polishing surface layers are described herein. In the following description, numerous specific details are set forth, such as specific polishing pad compositions and designs, in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without these specific details. In other instances, well-known processing techniques, such as details concerning the combination of a slurry with a polishing pad to perform CMP of a semiconductor substrate, are not described in detail in order to not unnecessarily obscure embodiments of the present invention. Furthermore, it is to be understood that the various embodiments shown in the figures are illustrative representations and are not necessarily drawn to scale.
In another example, the materials of polishing surface layer 108 or 208 and corresponding foundation layer 102 or 202 may each have defined hardness suitable to provide desired polishing characteristics, either as individual components or collectively for the polishing pad as an entirety. In an embodiment, the foundation layer 102 or 202 has a hardness greater than approximately 75 Shore D, e.g., approximately 84-85 Shore D for a polycarbonate foundation layer. In an embodiment, the polishing surface layer 108 or 208 has a hardness less than approximately 70 Shore D and, preferably, less than approximately 60 Shore D. In an embodiment, the foundation layer 102 or 202 has a hardness approximately in the range of 70-90 Shore D, and the corresponding polishing surface layer 108 or 208 has a hardness approximately in the range of 50-60 Shore D, e.g., for a hard polyurethane polishing surface layer. In another embodiment, the foundation layer 102 or 202 has a hardness approximately in the range of 7-90 Shore D, and the corresponding polishing surface layer 108 or 208 has a hardness approximately in the range of 20-50 Shore D, e.g., for a soft polyurethane polishing surface layer.
Referring to FIG. 8, a polishing apparatus 800 includes a platen 804. The top surface 802 of platen 804 may be used to support a polishing pad with a foundation layer and a polishing surface layer. Platen 804 may be configured to provide spindle rotation 806 and slider oscillation 808. A sample carrier 810 is used to hold, e.g., a semiconductor wafer 811 in place during polishing of the semiconductor wafer with a polishing pad. Sample carrier 810 is further supported by a suspension mechanism 812. A slurry feed 814 is included for providing slurry to a surface of a polishing pad prior to and during polishing of the semiconductor wafer. A conditioning unit 890 may also be included and, in one embodiment, includes a diamond tip for conditioning a polishing pad.
Thus, polishing pads with foundation layers and polishing surface layers have been disclosed. In accordance with an embodiment of the present invention, a polishing pad for polishing a substrate includes a foundation layer having a first hardness. A polishing surface layer is bonded directly to the foundation layer. The polishing surface layer has a second hardness less than the first hardness. In one embodiment, the polishing surface layer includes a continuous layer portion with a plurality of polishing features protruding there from, the continuous layer portion bonded directly to the foundation layer. In one embodiment, the polishing surface layer includes a plurality of discrete polishing protrusions bonded directly to the foundation layer.
1. A method of fabricating a polishing pad for polishing a substrate, the method comprising:
roughening a surface of a foundation layer
providing, in a formation mold, the foundation layer and a mixture formed from mixing a set of polymerizable materials;
coupling a pattern of protrusions of the formation mold with the mixture; and, with the pattern of protrusions coupled with the mixture,
at least partially curing the mixture to form a molded homogeneous polishing surface layer directly on the foundation layer, the molded homogeneous polishing surface layer comprising a pattern of grooves corresponding to the pattern of protrusions of the formation mold, further comprising:
removing the foundation layer having the molded homogeneous polishing surface layer formed thereon from the base of the formation mold when the extent of curing is sufficient to maintain geometry of the molded homogeneous polishing surface layer but insufficient for the molded homogeneous polishing surface layer to withstand mechanical stress.
2. The method of claim 1, wherein providing the foundation layer comprises placing the foundation layer in a base of the formation mold, wherein providing the mixture comprises providing the mixture in the base of the formation mold, on the foundation layer, wherein coupling the pattern of protrusions of the formation mold comprises coupling a lid of the formation mold with the mixture, the lid having disposed thereon the pattern of protrusions, and wherein at least partially curing the mixture comprises heating the base of the formation mold.
3. The method of claim 1, wherein the foundation layer extends beyond the molded homogeneous polishing surface layer, and wherein removing the foundation layer having the molded homogeneous polishing surface layer formed thereon from the base of the formation mold comprises taking hold of the foundation layer but not the molded homogeneous polishing surface layer.
4. The method of claim 1, wherein at least partially curing the mixture comprises heating both the mixture and the foundation layer.
removing the molded homogeneous polishing surface layer from the foundation layer; and
forming a second homogeneous polishing surface layer on the foundation layer.
6. The method of claim 1, wherein providing the foundation layer in the formation mold comprises first removing a previously formed polishing surface layer from the foundation layer.
7. The method of claim 1, wherein forming the molded homogeneous polishing surface layer comprises forming a thermoset polyurethane material.
8. The method of claim 1, wherein mixing the set of polymerizable materials further comprises adding a plurality of porogens to the set of polymerizable materials to form a plurality of closed cell pores in the molded homogeneous polishing surface layer, each closed cell pore having a physical shell.
9. The method of claim 1, wherein mixing the set of polymerizable materials further comprises injecting a gas into the set of polymerizable materials, or into a product formed there from, to form a plurality of closed cell pores in the molded homogeneous polishing surface layer, each closed cell pore having no physical shell.
10. The method of claim 1, wherein mixing the set of polymerizable materials comprises mixing an isocyanate and an aromatic diamine compound.
11. The method of claim 1, wherein mixing the set of polymerizable materials further comprises adding an opacifying particle filler to the set of polymerizable materials to form an opaque molded homogeneous polishing surface layer.
further curing the molded homogeneous polishing surface layer by heating the foundation layer having the molded homogeneous polishing surface layer formed thereon in an oven.
13. The method of claim 1, wherein a polishing pad comprising the foundation layer having the molded homogeneous polishing surface layer formed thereon is suitable for performing a polishing process without performing a backside cut of the foundation layer.
14. The method of claim 1, wherein at least partially curing the mixture forms the molded homogeneous polishing surface layer covalently bonded with the foundation layer.
15. A method of fabricating a polishing pad for polishing a substrate, the method comprising:
at least partially curing the mixture to form a molded homogeneous polishing surface layer attached to the foundation layer, the molded homogeneous polishing surface layer comprising a pattern of grooves corresponding to the pattern of protrusions of the formation mold; and
removing the foundation layer having the molded homogeneous polishing surface layer attached thereto from the base of the formation mold when the extent of curing is sufficient to maintain geometry of the molded homogeneous polishing surface layer but insufficient for the molded homogeneous polishing surface layer to withstand mechanical stress.
16. The method of claim 15, wherein the foundation layer having the molded homogeneous polishing surface layer attached thereto is removed from the base of the formation mold less than approximately 4 minutes after coupling the pattern of protrusions of the formation mold with the mixture.
17. The method of claim 15, wherein removing the foundation layer having the molded homogeneous polishing surface layer attached thereto from the formation mold is performed immediately after the material of the molded homogeneous polishing surface layer gels.
18. The method of claim 15, wherein the foundation layer extends beyond the molded homogeneous polishing surface layer, and wherein removing the foundation layer having the molded homogeneous polishing surface layer attached thereto from the base of the formation mold comprises taking hold of the foundation layer but not the molded homogeneous polishing surface layer.
19. The method of claim 15, wherein at least partially curing the mixture comprises heating both the mixture and the foundation layer.
forming a second homogeneous polishing surface layer attached to the foundation layer.
21. The method of claim 15, wherein providing the foundation layer in the formation mold comprises first removing a previously formed polishing surface layer from the foundation layer.
further curing the molded homogeneous polishing surface layer by heating the foundation layer having the molded homogeneous polishing surface layer attached thereto in an oven.
23. The method of claim 15, wherein a polishing pad comprising the foundation layer having the molded homogeneous polishing surface layer attached thereto is suitable for performing a polishing process without performing a backside cut of the foundation layer.
US14732497 2011-11-29 2015-06-05 Polishing pad with foundation layer and polishing surface layer Active 2032-01-19 US9931728B2 (en)
US13306845 US9067297B2 (en) 2011-11-29 2011-11-29 Polishing pad with foundation layer and polishing surface layer
US14732497 US9931728B2 (en) 2011-11-29 2015-06-05 Polishing pad with foundation layer and polishing surface layer
US13306845 Division US9067297B2 (en) 2011-11-29 2011-11-29 Polishing pad with foundation layer and polishing surface layer
US20150273655A1 true US20150273655A1 (en) 2015-10-01
US9931728B2 true US9931728B2 (en) 2018-04-03
ID=48467319
US13306845 Active 2033-10-31 US9067297B2 (en) 2011-11-29 2011-11-29 Polishing pad with foundation layer and polishing surface layer
US14732497 Active 2032-01-19 US9931728B2 (en) 2011-11-29 2015-06-05 Polishing pad with foundation layer and polishing surface layer
US14736568 Abandoned US20150273656A1 (en) 2011-11-29 2015-06-11 Polishing pad with foundation layer and polishing surface layer
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Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ALLISON, WILLIAM C.;SCOTT, DIANE;LEFEVRE, PAUL ANDRE;AND OTHERS;REEL/FRAME:044813/0594