Abstract:
A system and method for remote monitoring one or more liquid chemical delivery systems and/or tools associated with the fabrication and/or manufacturing of electronic/semiconductor components. Such a system and method allows the operator to quickly and accurately verify the status of each delivery system and tool with respect to liquid condition, alarms, problem situations, and other indications from one convenient location.

Description:
RELATED APPLICATION  
       [0001]    This application claims priority to U.S. Provisional Application Serial No. 60/372,330, filed on Apr. 12, 2002. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention relates to a system and method for remote monitoring one or more liquid chemical delivery systems. The system allows an operator to quickly and accurately verify the status of each system with respect to liquid condition, alarms, problem situations, and other indications from one convenient location. The system and method may be utilized for monitoring and controlling high purity liquid delivery systems in the electronics/semiconductor industry from remote locations.  
           [0004]    2. Description of the Prior Art  
           [0005]    During the fabrication of components for the electronic and semiconductor industry there are normally multiple delivery systems containing and dispensing a variety of chemicals to tools used in the fabrication and/or manufacturing process. The chemicals supplied to the tools range from low k dielectrics to barrier materials, all designed to serve and address the low k/copper process generation during manufacturing of the components. As consumers continuously strive for lower priced electronics, the component manufacturing fabs or laboratories are driven to higher and higher levels of efficiency to successfully compete in today&#39;s market place. The most obvious sign of increasing efficiency is the shift to 300 mm wafer technology, which allows the fabs to produce more chips per unit time, thus increasing efficiency. Another aspect of the increased efficiency is maximization of tool utilization in a fab. The fab with the highest tool utilization will typically be the more cost efficient facility, as the return on investment for their assets will be maximized. Therefore, in order to keep a tool functioning at maximum efficiency, the tool must be supplied constantly with the necessary liquid chemicals and facility services.  
           [0006]    Although there has been much activity in ensuring that the facility services such as air, exhaust, nitrogen, etc., are well supplied and monitored at all times, there has been little to no effort spent on ensuring that the liquid chemistry is constantly being supplied to the fabrication and manufacturing tools. Failure to supply the proper liquid chemistry to the tools results in the stopping of the fabrication and/or manufacturing process, therein decreasing efficiency. Therefore, the assurance that the supply of these chemistries to the tools are constant is critical for any fab to achieve the efficiency demanded in today&#39;s market.  
           [0007]    The present invention provides a system and method that addresses the problem of properly supplying tools used during the fabrication and/or manufacturing of components for the semiconductor/electronics industry. For example, the present invention provides the operator of liquid chemical vapor deposition (CVD) tools a system and method by which they can quickly and efficiently monitor the tool status, including the tool-critical low k, high k, barrier, and other copper chemistries from one easily accessible location. The operator may therefore monitor the tools without leaving the clean room environment and can quickly determine the status of each critical chemical and delivery system.  
           [0008]    Utilization of the system and/or method of the present invention will allow for the increased efficiency of the entire fab in a variety of ways. For example, first, a computerized system may constantly monitor all the critical liquids being delivered to the tool and alert the operators or support personnel that attention should be given to any particular system that may adversely affect the efficiency or utilization of the tool set. Second, the operator may focus on core process technology and more rapidly develop new processes for the fab without being distracted by inspecting the various systems in multiple locations. Third, additional facility staff required to monitor all the delivery system locations may be reduced as the operator can call down to a staff member and direct them quickly and efficiently to the source of the tool problem.  
           [0009]    In addition to being able to quickly determine the level of chemistry available to the tool, the operator will be able to monitor the entire status of each system ranging from, but not limited to loss of air, loss of nitrogen, loss of exhaust, unauthorized entry, a liquid spill or leak, or temperature. A variety of independent sensors may also be installed in each tool that constantly monitor tool parameters (e.g., loss of air, loss of nitrogen, loss of exhaust, unauthorized entry, or a liquid spill or leak, temperature, etc.) and other parameters to ensure a constant and steady supply of chemistry to the tools allowing the tools to achieve its maximum efficiency.  
           [0010]    Without the level of diagnosis provided by the present invention an operator must troubleshoot the chemical delivery system and tool by physically moving to the delivery system and the tool. Since the delivery system and tool are normally in different locations, a large time commitment is required. The troubleshooting duration is lengthened because chemical delivery systems are normally located in the sub-fab area where the price per square foot is much lower than that in the clean room. The clean room is where the operators of the tool systems typically reside and work. In order for an operator to inspect the delivery system, the operator may normally travel not only a long distance, but through several floors and through several clean room boundaries. Entry and exit from a clean room requires the operator to remove their clean room suit. The operator must then investigate the delivery systems in the sub-fab, and then upon returning to the clean room, re-apply their clean room suit. Clearly, this costs valuable time and money, not only in moving between areas, but in clothes and garments that need to be re-issued. Again, the system of the present invention allows rapid and accurate diagnosis of the situation, which will allow the situation to be fixed quickly. Historically, without this level of diagnosis, the operator may spend countless hours investigating all other areas and eliminating them one by one until the operator discovers the problem.  
         SUMMARY OF THE INVENTION  
         [0011]    The present invention provides a system and method for monitoring support and chemical delivery systems associated with tools used in the fabrication and/or manufacture of electronic/semiconductor components. This system and method are capable of monitoring parameters associated with tools used in the fabrication and/or manufacturing of components in the electronics/semiconductor industry.  
           [0012]    A system for monitoring chemical delivery to at least one tool, according to an embodiment of the present invention, includes an interface; at least one chemical delivery system in communication with the interface; and at least one tool connected to the chemical delivery system.  
           [0013]    A method for monitoring the chemical delivery to a tool, according to an embodiment of the present invention includes the steps of sensing the status of at least one parameter of a chemical delivery system and/or at least one parameter of the tool; communicating the status to a computer; and analyzing the status to determine whether the parameters of the chemical delivery system and or the tool are within a predetermined range.  
           [0014]    The present invention also provides a system and method, which is capable of utilizing a monitoring system that enables an operator to monitor tool parameters and troubleshoot error conditions from a remote location. This can be accomplished via a screen that will allow an operator to monitor the parameters of a number of fabrication tools from a single location. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    [0015]FIG. 1 is a perspective view of a system in accordance with a preferred embodiment of the present invention;  
         [0016]    [0016]FIG. 2 shows an example of a computer screen display identifying the tool parameters and chemical delivery system parameters for a tool of the present invention;  
         [0017]    [0017]FIG. 3 shows another example of a computer screen display identifying the status of chemical delivery system parameters for four tools of the present invention;  
         [0018]    [0018]FIG. 4 shows another example of a computer screen display identifying four chemical delivery systems of the present invention;  
         [0019]    [0019]FIG. 5 shows a pictorial overview of the another embodiment of the present invention; and  
         [0020]    [0020]FIG. 6 is a block diagram showing a method for remote monitoring of a process according to the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]    Referring to FIG. 1, one embodiment of the remote monitoring system  10  of the present invention may include a computer interface  12  connected to a chemical delivery system  14  for a tool  16 . The computer interface  12  may be routed via cable  34  or wireless technology (not shown) back to a central processing station  18 . The central processing station  18  may include a computer  20 .  
         [0022]    The system  10  may include delivery sensors  22  that monitor parameters associated with the chemical delivery system  14 . Signals from the delivery sensors  22  may be sent via the cables  34  and computer interface  12  to the computer  20  for display on a computer screen  26 . The delivery sensors  22  may monitor any suitable parameters associated with the chemical delivery system  14  including liquid container volume, container pressure status, exhaust status, door status, spill, leak, etc. The chemical delivery systems  14  may include a number of liquid containers depending on the tool  12  serviced by the delivery system  14 .  
         [0023]    The system  10  may also include tool sensors  24  that monitor any suitable parameters associated with the tool  12  including air pressure, nitrogen pressure, temperature, liquid spill, or leak, etc. The tools sensors  24  may be connected to the central processing station  18  via the computer interface  12  and routed via cable  34  or wireless technology (not shown) back to the central processing station  18 . The tool sensors  24  allow for the tool to be constantly monitored and may help ensure a steady supply of chemistry to the tool, therein allowing the tool to achieve maximum efficiency.  
         [0024]    The signals from both sensors  22 ,  24  may be displayed on a computer screen  26  of the computer  20 . The screen  26  may display the parameters of the tool  16  and delivery system  14  monitored by the monitoring system  10 . The central processing station  18  may be located in a clean room  28  whereas the tool cabinets  30  associated with the delivery systems  14  may be located in an area away from the clean room  28 . The remote monitoring system  10  may be configured to monitor any number of tools  16  and delivery systems  14  by configuration of any necessary interfaces  12  or cables  34  to the monitoring system  10 .  
         [0025]    The monitored parameters may be displayed on a single computer display screen  26  to therein allow the operator to monitor all tool parameters and delivery system parameters from one screen  26 . The remote monitoring system  10  therefore allows the operator to quickly scan each tool  16  and the parameters of delivery systems  14  by looking at the screen  26  and to detect any problems associated therewith since the central processing station  18  constantly monitors the delivery systems  14 .  
         [0026]    Should a condition occur in any one of the tools  16  or delivery systems  14 , the computer system  20  will quickly detect the problem and alert the operator by displaying a visual indication on the screen  26  or the system may include an alarm  32  for signaling an audio alarm. The operator may then identify the indicated parameter for the specific tool or delivery system to a support person in order for the support person to diagnose the problem.  
         [0027]    For example, any one of the following occurrences could precipitate a visual indication or alarm signal including low liquid level, low exhaust level, loss of air, loss of nitrogen, high temperature, liquid spill, or leak. When the indication or alarm is triggered, the signal may then be quickly identified by the operator on the screen  26 . The operator may then select the delivery systems  14  showing the problem from the computer  20  and review all the parameters of delivery systems  14  pertaining to those delivery systems  14  which caused the signal such as liquid level, exhaust level, temperature, entry status, etc. A support person may then be contacted by the operator and notified of delivery systems  14  experiencing the problem. The situation may then be solved immediately ensuring and protecting the chemical supply to the tool, thus, maximizing the tool utilization and creating a more efficient fab. The same troubleshooting procedures may be followed if the indication is caused by a signal sent from a tool sensor  24 .  
         [0028]    With reference to FIG. 2, an example  40  of a computer screen display identifying the tool parameters and chemical delivery system parameters for a tool of the present invention is shown. The display identifies the chemical delivery system and also the status display indicators for the chemical delivery system. The status indicators for the chemical delivery systems may include indications for Left Cabinet Empty (L.C. empty), Left Door (L. Door), Left Spill (L. Spill), etc. The display may be configured based on the type of tool and the type of chemical delivery system being utilized. FIG. 3 shows another example  50  of a computer screen display identifying the status of chemical delivery system parameters for four tools of the present invention. The four tool cabinet symbols may be used to identify the chemical delivery system of the tool. FIG. 4 shows another example  60  of a computer screen display identifying four chemical delivery systems of the present invention. The displays may be configured by the operator to maximize efficiency.  
         [0029]    Referring to FIG. 5, another embodiment of the remote monitoring system  70 , or GeMS™ System, may include, but is not limited to, the following equipment. Computer system  72 , with user interface for input and visual and audio outputs, has communication connections  74  to the various GenStream™ systems  76 . The communication connections may be either wired or wireless. Associated hardware is installed in the GenStream™ systems to allow for communication back to the GeMS™ system  76 .  
         [0030]    Referring to FIG. 6, a logic and block diagram shows another embodiment of the system and method of the present invention. The monitoring system of the present invention may include a computer that monitors the status of the tool and chemical delivery system. The program includes the following steps, which will monitor the tool system (TS) and chemical delivery system (CDS). Logic block  100  checks the TS status. If the TS is not working, then block  102  generates an error signal to the computer. If the TS is working, then block  104  checks the CDS status. If the CDS is not working, then block  106  generates an error signal to the computer and generates a signal to turn off the TS.  
         [0031]    The next step is to begin the monitoring of the TS and CDS as shown in block  108 . Block  1   10  shows the start of the TS monitoring. If the TS monitoring does not function, then an error signal identifying the problem is sent to the computer as shown in block  112 . If the TS monitoring begins, then the next step is to check the parameters to be monitored on the TS. For example, block  114  shows the monitoring of the TS parameters by the tool sensors including for example, air pressure, nitrogen pressure, exhaust status, temperature, etc. The parameter readings are sent to the computer as seen in block  116 . The computer monitors the signals as shown in block  118  and then analyzes each signal. Block  120  shows that the readings are then analyzed.  
         [0032]    All of the TS parameters may be analyzed in order to determine whether the parameters are within an acceptable range or status. For example, blocks  122  through  126  show the analyzing of the air pressure. Block  122  shows the air pressure compared to the normal TS air pressure range. Block  124  shows that if the TS air pressure is too high or too low a signal is sent to send an alarm to flash an alarm on the computer screen. Block  126  shows that if the reading is within an acceptable range, the next reading is analyzed by returning to block  118 . These same types of analysis steps may be repeated for any other TS parameters (e.g., nitrogen pressure, exhaust pressure, etc.). In some instances an alarm signal and a shut down signal will be sent to the TS and the CDS if a parameter is out of a particular range, as shown in block  128 .  
         [0033]    Block  130  shows the start of the CDS monitoring. If the CDS monitoring does not function, then an error signal identifying the problem is sent to the computer, as shown in block  132 . If the CDS monitoring begins, then the next step is to check the parameters to be monitored on the CDS. For example, block  134  shows the monitoring of the CDS parameters by the delivery sensors including, for example, Left Cabinet Empty, Left Door status, Left Can status, etc. The parameter readings are sent to the computer as seen in block  136 . The computer monitors the signals as shown in block  138  and then analyzes each signal. Block  140  shows that the readings are then analyzed.  
         [0034]    All of the CDS parameters may be analyzed to determine whether the parameters are within an acceptable range or status. For example, blocks  142  through  148  show the analyzing of the liquid level of a chemical that is sent to the tool. Block  142  shows the liquid level compared to the normal CDS liquid level range. Block  144  shows that if the CDS liquid level is too low, then an alarm signal is sent to the computer screen. Block  146  shows that if the liquid level is critically low, then a different alarm signal is sent to the screen and a shut down signal is sent to the tool. Block  148  shows that if the reading shows that the liquid level is above normal, then the next reading is analyzed by repeating block  138  for new readings. Similar analysis steps may be repeated for the other CDS parameters (e.g., left cabinet status, left door entry status, spill status, etc.). In some instances, an alarm signal and a shut down signal will be sent to the TS and the CDS if a specific parameter is out of a normal range and a critical failure could occur with the TS and or the CDS.  
         [0035]    [0035]FIG. 6 is one example of a block and logic diagram for the present invention. The parameters are continuously read by the TS and CDS sensors and analyzed by the computer during the system operation.  
         [0036]    The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit of the present invention.