Source: http://www.google.com/patents/US6478937?dq=5,884,271
Timestamp: 2017-07-21 06:11:47
Document Index: 500292013

Matched Legal Cases: ['application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09']

Patent US6478937 - Substrate holder system with substrate extension apparatus and associated method - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsAn apparatus and associated method that removes electrolyte solution from a substrate, the apparatus comprises a thrust plate and a substrate extension unit. The thrust plate at least partially defines a spin recess. The substrate extension unit can be displaced between a retracted position and an extended...http://www.google.com/patents/US6478937?utm_source=gb-gplus-sharePatent US6478937 - Substrate holder system with substrate extension apparatus and associated methodAdvanced Patent SearchTry the new Google Patents, with machine-classified Google Scholar results, and Japanese and South Korean patents.Publication numberUS6478937 B2Publication typeGrantApplication numberUS 09/765,855Publication dateNov 12, 2002Filing dateJan 19, 2001Priority dateJan 19, 2001Fee statusLapsedAlso published asUS20020096436, WO2002064861A2, WO2002064861A3Publication number09765855, 765855, US 6478937 B2, US 6478937B2, US-B2-6478937, US6478937 B2, US6478937B2InventorsDonald J. K. Olgado, Jayant LakshmikanthanOriginal AssigneeApplied Material, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (73), Non-Patent Citations (20), Referenced by (27), Classifications (16), Legal Events (6) External Links: USPTO, USPTO Assignment, EspacenetSubstrate holder system with substrate extension apparatus and associated method
US 6478937 B2Abstract
What is claimed is: 1. A thrust plate for retaining a substrate comprising:
a main thrust plate portion at least partially defining a spin recess; and a substrate extension unit displaceable between a retracted position and an extended position, wherein the substrate extension unit when in its retracted position is disposed substantially within the spin recess, and wherein the substrate extension unit, when in its extended position, at least partially extends from within the spin recess. 2. The thrust plate of claim 1, further comprising a substrate holder assembly, wherein when the substrate extension unit is in its extended position, the substrate extension unit can hold a substrate at a position remote from the main thrust plate portion.
positioning a substrate extension unit into an extended position wherein the substrate extension unit at least partially extends from within the spin recess, wherein the substrate is secured by the substrate extension unit in a position remote from the main thrust plate portion. 15. The method of claim 14, further comprising rotating the substrate extension unit to cause spinning of the substrate.
a seal that biases a substrate against an electric contact while permitting a substrate holder assembly to rotate the substrate while the substrate holder assembly is in a first rotational configuration during plating, and the seal secures the substrate to the substrate holder assembly to spin the wafer when the substrate holder assembly is in a second rotational configuration in which the substrate is remote from the electric contact. 18. The apparatus of claim 17, further comprising
a main thrust plate portion having a spin recess formed therein; and a substrate extension unit that can be located within the spin recess. 19. The apparatus of claim 18, wherein the substrate extension unit is substantially retracted into the spin recess when the substrate holder assembly is in its first rotational configuration.
21. The apparatus of claim 18, wherein the seal is an inflatable seal.
22. The apparatus of claim 18, wherein the seal comprises an O-ring.
23. The apparatus of claim 18, wherein the seal comprises a lip seal.
providing a main thrust plate portion at least partially defining a spin recess; and providing a substrate extension unit that can be displaced between a retracted position and an extended position, wherein the substrate extension unit is disposed within the spin recess when positioned in the retracted position, the substrate extension unit at least partially extends from within the spin recess when positioned in the extended position; processing the substrate by immersing at least a portion of the substrate in a wet solution; removing the substrate from the wet solution; extending the substrate extension unit into its extended position, and securing the substrate to the substrate extension unit; and spinning the substrate. 26. The method of claim 25, wherein the extending the substrate extension unit into its extended position limits the formation of fluid traps within the substrate holder assembly or between the substrate and the substrate holder assembly.
27. The method of claim 25, wherein the substrate extension unit comprises one from the list of lip seal and O-ring that is configured to form a seal with the substrate to support the substrate.
28. The method of claim 25, further comprising a contact element, wherein the main thrust plate portion can bias a substrate into electric contact with the contact element.
FIG. 1A is a perspective view of one embodiment of an electro-chemical plating (ECP) system;
FIG. 1B is a top view of the ECP system of FIG. 1A;
FIG. 2 is a side cross sectional view of one embodiment of process cell to be used in the electrochemical plating (ECP) system of FIG. 1A;
FIG. 3A is a cross sectional view of one embodiment of the substrate holder system to be used with the process cell of FIG. 2;
FIG. 3B is a cross sectional view of one embodiment of a rotatable head assembly of the substrate holder assembly of FIG. 3A;
FIG. 4 is an enlarged cross sectional view of one embodiment of substrate holder assembly of the rotatable head assembly shown in FIG. 3B, with the main thrust plate portion raised and the substrate extension unit retracted;
FIG. 5 is the substrate holder assembly of FIG. 4 with the main thrust plate portion lowered and the substrate extension unit retracted;
FIG. 6 is the substrate holder assembly of FIG. 4, with the main thrust plate portion raised and the substrate extension unit extended;
FIG. 7 including FIGS. 7A to 7F, is a progression illustrating side views of the substrate holder system of FIG. 3B during insertion of a substrate into, and removal of the substrate from, electrolyte solution contained in an electrolyte cell;
FIG. 8 is a side cross sectional view of a portion of one embodiment of the substrate extension unit including associated pumps and piping associated with the substrate extension unit;
FIG. 9 is an expanded side cross sectional view of one embodiment of the bladder arrangement of the substrate extension unit of FIG. 8;
FIG. 10 is a perspective view of the bladder included in the bladder arrangement of FIG. 9; and
FIG. 11 is a flow chart of an embodiment of the method performed by the controller of FIG. 2 during the progression shown in FIGS. 7A to 7F.
This disclosure is directed generally to processing systems in which substrates are immersed in wet process cells that are utilized wet processes such as electro chemical plating (ECP). One example of a wet process cell is an electrolyte cell that is used in ECP.
FIG. 1A is a side partial cross-sectional view of one embodiment of an ECP system 1200. FIG. 1B is a top plan view of the ECP system 1200. Referring to both FIGS. 1A and 1B in combination, the ECP system 1200 generally comprises a loading station 1210, at least one rapid thermal anneal (RTA) chamber 1211, a spin-rinse-dry (SRD) station 1212, a mainframe 1214, and an electrolyte solution system 1220. Preferably, the ECP system 1200 is enclosed in a clean environment that is partially defined using panels such as PLEXIGLAS® (a trademark of the Rohm and Haas Company of West Philadelphia, Pa.). The mainframe 1214 generally comprises a mainframe transfer station 1216 and a plurality of processing stations 1218. Each processing station 1218 includes one or more wet process cells 1240. The electrolyte solution system 1220 is positioned adjacent the ECP system 1200 and is fluidly connected to the individual wet process cells 1240 to circulate electrolyte solution used for the electroplating process to each wet process cell. The ECP system 1200 also includes a controller 222 that typically comprises a programmable microprocessor.
Preferably, the embodiment of mainframe transfer station 1216 shown in FIG. 1B includes one or more flipper robots 1248 that are designed to facilitate “flipping” of a substrate from a face-up position on the robot blade 1246 of the mainframe transfer robot 1242 to the face down position normally required for processing in a wet process cell 1240. The flipper robot 1248 includes a main body 1250 and a flipper robot arm 1252. The main body 1250 provides both vertical and rotational movements to transfer a substrate within a horizontal plane. The flipper robot arm 1252 provides rotational movement along the axis of the flipper robot arm 1252 that can “flip” the substrate to invert a substrates upper and lower surface. Flipper robots are generally known in the art and can be attached as end effectors for substrate handling robots, such as model RR701, available from Rorze Automation, Inc. of Milpitas, Calif. Preferably, a vacuum suction gripper 1254, disposed on the flipper robot arm 1252, holds the substrate as the substrate is flipped and transferred by the flipper robot 1248. The flipper robot 1248 positions a substrate 221 into the wet process cell 1240 for face-down processing.
FIG. 2 shows a side cross-sectional view of one embodiment of a wet process cell or electrolyte cell 1240 used in an ECP system 1200, shown schematically in FIGS. 1A and 1B. In this disclosure, a wet process cell is considered any process cell that contains a liquid during processing. The wet process cell 1240 comprises an electrolyte cell 2212. The electrolyte cell 2212 used during ECP processing contains electrolyte solution during processing, and the electrolyte cell has an upper opening 2213. A substrate holder system 14 securely holds a substrate 221 so the substrate can be immersed into, or removed from, the electrolyte solution through an upper opening 2213 of the electrolyte cell. An anode 16 is mounted within the electrolyte cell 2212.
FIG. 3B shows a cross sectional view of one embodiment of rotatable head assembly 2410 of the substrate holder system 14 shown in FIG. 3A. The rotatable head assembly 2410 provides for such actions as rotation of the substrate, and vertical displacement of the thrust plate 66 relative to the electric contact elements 67 to position a substrate, when the substrate is positioned between the thrust plate and the electric contact elements, in contact with the electric contact element 67. The thrust plate 66 can be raised to provide a space between the thrust plate 66 and the electric contact element 67 to permit removal of the substrate from, or insertion of the substrate into, a substrate holder assembly 2450. The rotatable head assembly 2410 comprises the substrate holder assembly 2450, the rotating actuator 2464, a shaft shield 2763 (not shown in FIG. 3A), a shaft 2470, an electric feed through 2767, an electric conductor 2771, and a plurality of vacuum sources 2773 a, 2773 b, and 2773 c. The rotating actuator 2464 comprises a head rotation housing 2760 and a head rotation motor 2706. The head rotation motor 2706 comprises a coil segment 2775 and a magnet rotary element 2776. The hollow coil segment 2775 is configured to generate a magnetic field that acts to rotate the magnetic rotary element 2776 about a vertical axis to provide the rotational displacement of the head rotation motor to the shaft 2470. The substrate holder assembly 2450 comprises a fluid shield 2720, a contact housing 2765, the thrust plate 66, the electric contact element 67, and a spring assembly 2732.
The first vacuum source 2773 a controllably supplies a vacuum to portions of the rotatable head assembly 2410 to control the position of the thrust plate relative to the electric contact element 67. The first vacuum source 2773 a supplies the vacuum to the pressure reservoir 2740 partially defined by an upper spring surface 2728, and comprises a controllable vacuum supply 2790 a, a sleeve member 2792, a fluid conduit 2794 a, a circumferential groove 2795 a, a fluid aperture 2796 a, and a fluid passage 2798 a. The pressure reservoir 2740 may be configured to maintain either positive air pressure or vacuum, depending upon the relative biasing and operation of the spring assembly 2732 and the head assembly 2410. For example, the spring assembly 2732 can be biased upward by a vacuum applied to the pressure reservoir 2740. Alternatively, the spring assembly 2732 can be biased downward by pressure applied to the pressure reservoir 2740. The sleeve member 2792 may be a distinct member or a portion of the shaft as shown in FIG. 3B. The circumferential groove 2795 a extends within the sleeve member 2792 about the circumference of the shaft 2470. The fluid aperture 2796 a is in fluid communication with the circumferential groove. The fluid aperture 2796 a extends axially through the shaft 2470 from the circumferential groove 2795 a to the bottom of the shaft 2470. The fluid passage 2798 a extends through the rotary mount 2799 within the contact housing 2765 and is in fluid communication with the pressure reservoir 2740. The fluid aperture 2796 a is also in fluid communication with the fluid passage 2798 a. In the first vacuum source 2773 a, a vacuum is applied from the vacuum supply 2790 a via the fluid conduit 2794 a to the inner surface of the sleeve member 2792 and the circumferential groove 2795 a. The vacuum is applied from the fluid aperture 2796 a to the fluid passage 2798 a and the pressure reservoir 2740. The inner surface of the sleeve member 2792 has a small clearance, e.g., about 0.0002 inch, with the outer surface of the shaft 2470 to allow relative rotation between these two members. Due to the tight clearance between the sleeve member 2792 and the shaft 2470, a vacuum applied to the inner surface of the sleeve member 2792 extends via the circumferential groove 2795 a to the fluid aperture 2796 a. The tight clearance limits air entering, and the vacuum escaping, between the sleeve member 2792 and the outer surface of the shaft 2470. Therefore, the vacuum applied from the controllable vacuum supply 2790 a passes through the fluid passage 2798 a and the rotary mount 2799 to the pressure reservoir 2740 formed between the spring assembly 2732 and the contact housing 2765. The vacuum applied by the controllable vacuum supply 2790 a thereby controls the vacuum in the pressure reservoir 2740.
FIGS. 3 and 4 both show the thrust plate in its extended position with the main thrust plate portion 266 raised and the substrate extension unit 390 retracted within spin recess 389 formed in the main thrust plate portion 266. The thrust plate and the substrate extension unit is in this position as the substrate is inserted into, or retracted from the substrate holder assembly. In this position, the first vacuum source 2773 a is actuated, the second vacuum source 2773 b is actuated, and the third vacuum source 2773 c is actuated. FIG. 5 shows thrust plate in its position during normal plating where the main thrust plate portion is lowered and the substrate extension unit 390 is extended from within the spin recess 389 formed in the thrust plate 66. To move the substrate extension unit 390 downwardly relative to plunger rod 330 into its extended position, or upwardly into its retracted position, the second vacuum source 2773 b is respectively deactuated/actuated. In the FIG. 5 position, the first vacuum source 2773 a is deactuated, the second vacuum source 2773 b can be either deactuated or actuated since the substrate is supported on the electric contact element and securing the substrate to the substrate extension unit 390 is optional, and the third vacuum source 2773 c is actuated. FIG. 6 shows the thrust plate in a position that it is in to spin a substrate to dry the substrate, where the main thrust plate portion is raised, and the substrate extension unit 390 is extended from within the spin recess 389. In this position, the first vacuum source 2773 a is actuated, the second vacuum source 2773 b is actuated, and the third vacuum source is deactuated.
Processing can occur on the substrate when the substrate holder assembly 2450 s lowered into the process position as shown in FIG. 5. During processing the spring bellow connector 2729, the thrust plate 66, and the electric contact element 67 are rotated at an angular velocity of between about 20 RPM and about 500 RPM, preferably between about 10 RPM and about 40 RPM. The rotation of the substrate 221 during processing enhances the uniformity of the deposition of the metal film on the seed layer but is not sufficient to create turbulence between the substrate (or the electric contact elements supporting the substrate) and the electrolyte solution. In the process position, the thrust plate 66, the substrate 221, the substrate extension unit 390, the electric contact element 67, and the spring assembly 2732 can all rotate as a unit.
Following processing, the thrust plate 66 including the substrate extension unit 390 and the main thrust plate portion 266 are both raised to the exchange position shown in FIG. 4. The raising of the thrust plate 66 is accomplished by the first vacuum source 2773 a establishing a vacuum. Following the raising of the entire thrust plate 66, the third vacuum source 2773 c applies a slight pressure to vertically displace the substrate extension portion 390 relative to the main thrust plate portion 266. This relative vertical displacement disengages metal deposits that may have formed between the O-ring 385 and the backside of the substrate 221 during processing. The disengaging of the metal deposits thereby dislodges the substrate 221 from the main thrust plate portion 266. After the substrate is disengaged from the main thrust plate portion, the substrate is still attached to the substrate extension unit 390 by the vacuum supplied by the second vacuum source 2773 b. After the substrate is dislodged from the thrust plate 66 and the O-ring 385, the substrate extension unit 390 continues downward travel relative to the main thrust plate portion 266 into the spin-dry position shown in FIG. 6 by deactuation of the third vacuum source 2773 c. At this time, the rotatable head assembly 2410 can rotate the substrate extension unit 390, and the main thrust plate portion 266 that is connected thereto by key 403, about a vertical access with the substrate 221 attached thereto. The main thrust plate portion 266, the substrate extension unit 390, the spring assembly 2732, the electric contact element 67, and the substrate can all be spun as a unit using the head rotation motor 2706 of the rotatable head assembly shown in FIG. 3B.
In FIG. 7B, the thrust plate 66 including the combined main thrust plate portion 66 and substrate extension unit 390, shown in FIG. 3B, is lowered to exert a physical force against the backside of the substrate (the backside of the substrate faces up since the substrate is inverted) to secure the substrate 221 against the electric contact elements 67. The force establishes and maintains an electric contact between the substrate seed layer and the electric contact element 67 as shown in block 1106. The thrust plate 66 is not lowered with sufficient force, however, to damage the substrate 221. The lowering of the thrust plate is accomplished by decreasing the vacuum within the pressure reservoir 2740 by the deactuation of the first vacuum source 2773 a, shown in FIGS. 3-6, to allow the spring bellow connector 2729 to force the thrust plate 66 downward. The thrust plate remains in the lowered biased position until the thrust plate is moved to the exchange position as indicated by FIG. 7F.
FIG. 7C shows the lowering of the substrate holder assembly 2450 to effect insertion of the substrate 221, contained in the substrate holder assembly 2450, into the electrolyte solution. To effect this lowering of the substrate holder assembly 2450, the lift guide 2466 is moved downwardly along the mounting slide 2460 (see FIG. 3A) to displace the shaft 2468 downward. In one embodiment, the substrate holder assembly 2450 can be tilted from horizontal by, e.g., pivoting the head assembly 2410 in FIG. 3A about pivot joint 2459 in a direction as indicated by arrow A3, during immersion of the substrate into the electrolyte solution. This tilting enhances the removal of air that may be trapped within the electrolyte solution under the substrate and/or substrate holder assembly during the immersion. FIG. 7D shows the substrate holder assembly 2450 positioned in its process position as indicated by block 1108. To displace the substrate holder assembly to the process position, the substrate 221 is either rotated to a substantially horizontal process position within the electrolyte solution by actuation of the cantilever arm actuator 2457 shown in FIG. 3A and/or the lift guide 2466 is displaced along the mounting slide to vertically lower the substrate holder assembly.
FIG. 7E and block 1110 in FIG. 11 in method 1100 shows the substrate holder assembly 2450 being raised to remove the substrate from the electrolyte solution in the electrolyte cell. As the substrate is removed from the electrolyte solution, the metal film deposition on the seed layer ceases and no further processing occurs on the substrate. The raising of the substrate holder assembly 2450 is accomplished by the head lift actuator 2458 vertically displacing the lift guide 2466 along the mounting slide 2460.
The present invention has particular application where contacts 226 of varying geometries are used. It is well known that a constriction resistance, RCR, results at the interface of two conductive surfaces, such as between the contacts 226 and the substrate seed layer 15, due to asperities between the two surfaces. Generally, as the applied force is increased the apparent contact area is also increased. The apparent area is in turn inversely related to RCR so that an increase in the apparent area results in a decreased RCR, Thus, to minimize overall resistance it is preferable to maximize force. The maximum force applied in operation is limited by the yield strength of a substrate that may be damaged under excessive force and resulting pressure. However, because pressure is related to both force and area, the maximum sustainable force is also dependent on the geometry of the contacts 226. Thus, while the contacts 226 may have a flat upper surface as in FIG. 2, other shapes may be used to advantage. The pressure supplied by the inflatable bladder 136 may then be adjusted for a particular contact geometry to minimize the constriction resistance without damaging the substrate. A more complete discussion of the relation between contact geometry, force, and resistance is given in Ney Contact Manual, by Kenneth E. Pitney, The J. M. Ney Company, 1973, which is hereby incorporated by reference in its entirety.
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K.;LAKSHMIKANTHAN, JAYANT;REEL/FRAME:011504/0608;SIGNING DATES FROM 20010104 TO 20010119Apr 26, 2006FPAYFee paymentYear of fee payment: 4Apr 22, 2010FPAYFee paymentYear of fee payment: 8Jun 20, 2014REMIMaintenance fee reminder mailedNov 12, 2014LAPSLapse for failure to pay maintenance feesDec 30, 2014FPExpired due to failure to pay maintenance feeEffective date: 20141112RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services