Patent Description:
A method of surface processing by dry chemo-mechanical grinding (CMG) may be used (e.g., refer to <CIT>). In the CMG process, a synthetic grindstone in which abrasive (abrasive grains) is fixed with resin binder such as a thermoplastic resin is used. Then, the synthetic grindstone is pressed against a wafer while rotating the wafer and the synthetic grindstone (e.g., refer to <CIT>). Convex portions on the wafer surface are heated and oxidized by friction with the synthetic grindstone, become brittle, and fall off. In this way, only the convex portions of the wafer are ground and planarized.

Synthetic grindstones are known known from e.g. <CIT> and <CIT>.

As the CMG process progresses, the abrasive grains (abrasive) gradually fall off from a surface (polishing action surface) of the binder of the synthetic grindstone with respect to a workpiece, and the polishing action surface of the synthetic grindstone becomes smooth. Thus, for example, a chance of contact between the binder with the thermoplastic resin and the workpiece increases on the polishing action surface. As a result, there is a problem wherein a contact pressure between the abrasive grains and the workpiece is reduced and a processing efficiency decreases, while, in particular, when dry processing is performed for the purpose of improving a processing rate, frictional heat between the polishing action surface and the workpiece becomes excessive and burning or scratching due to entrainment of polishing sludge may occur on the workpiece.

The present invention has been made to solve the above-described problem, and an object of the present invention is to provide a synthetic grindstone capable of suppressing frictional heat from becoming excessive, for example, when performing dry polishing processing, a synthetic grindstone assembly, and a manufacturing method of the synthetic grindstone.

In an aspect of the present invention, a synthetic grindstone for performing surface processing, includes: abrasive grains; binder made of a thermosetting resin material and holding the abrasive grains in a dispersed state; and filler including first filler, second filler, and third filler. The first filler has a larger average particle diameter than the abrasive grains. The second filler has electrical conductivity. The third filler is harder than a workpiece. The filler is disposed in a state of being dispersed in the binder. An abrasive grain rate (Vg) of the abrasive grains is more than <NUM> vol% and <NUM> vol% or less. A binder rate (Vb) of the binder is <NUM> vol% or more and <NUM> vol% or less. The first filler is <NUM> vol% or more and <NUM> vol% or less. The second filler is <NUM> vol% or more and <NUM> vol% or less. The third filler is <NUM> vol% or more and <NUM> vol% or less. A porosity is set according to values of the abrasive grain rate, the binder rate, and the filler such that a total sums up to <NUM> vol%.

As shown in <FIG>, a synthetic grindstone <NUM> is formed of abrasive grains (abrasive) <NUM> and binder <NUM>. The synthetic grindstone <NUM> may further have pores <NUM>. In the present embodiment, the synthetic grindstone <NUM> holds the abrasive grains <NUM> in a dispersed state in the binder <NUM>, and has the pores <NUM> arranged by being dispersed in the binder <NUM>.

The abrasive grains <NUM> are not limited to the following, but when the workpiece is silicon, it is preferable to apply, for example, silica, cerium oxide, or a mixture thereof. Similarly, in a case where the workpiece is sapphire, it is preferable to apply chrome oxide, ferric oxide, or a mixture thereof. In addition, alumina, silicon carbide, or a mixture thereof can also be used as an applicable abrasive depending on the kind of workpiece.

In the present embodiment, an example will be described in which the workpiece is silicon, and, for example, cerium oxide having an average particle diameter of approximately <NUM> is used as the abrasive grains <NUM>. The particle diameter of the abrasive grains <NUM> can be set as appropriate, but is preferably less than <NUM>, for example.

As the binder <NUM>, a thermosetting resin is used in the present embodiment. As an example of the thermosetting resin, phenol resin can be used.

The synthetic grindstone (molded body) <NUM> is formed based on a flow (manufacturing method) shown in <FIG>.

First, the abrasive grains <NUM> in a volume ratio to be described later and liquid phenol as the binder <NUM> are mixed to obtain a mixed material (step ST1).

Next, a mold for forming the mixed material into a shape that will become a final shape of the synthetic grindstone <NUM> is filled with the mixed material (step ST2). For example, liquid phenol is thermally cured by pressure molding (hot press) at <NUM> degrees for thirty minutes to mold the synthetic grindstone <NUM> as a molded body (step ST3). Then, the molded body in the mold is demolded (step ST4).

<FIG> shows a table of a composition of the synthetic grindstone <NUM> when manufacturing the synthetic grindstone <NUM> using a thermosetting resin as the binder <NUM> as described above.

As shown in <FIG>, an abrasive grain rate (Vg) of the abrasive grains <NUM> is more than <NUM> vol% and <NUM> vol% or less. A binder rate (Vb) of the binder <NUM> is <NUM> vol% or more and <NUM> vol% or less.

In the present embodiment, the synthetic grindstone <NUM> is formed in an annular shape, and used for dry chemo-mechanical grinding (CMG) processing for processing through a combined action by a mechanical action and a chemical component. That is, the synthetic grindstone <NUM> exerts a dry chemo-mechanical grinding action on the surface of the wafer W, which is the workpiece, to perform the surface processing of the wafer W as the workpiece. Then, the synthetic grindstone <NUM> is fixed to a grindstone holding member (base body) <NUM> with a double-faced tape, an adhesive, etc. to be formed as a synthetic grindstone assembly <NUM>, and is attached to the CMG device <NUM> shown in <FIG> to be used for the surface processing of the wafer W as the workpiece. It suffices that the grindstone holding member <NUM> has appropriate rigidity to withstand CMG processing, is heat resistant at temperatures that may increase with use of the synthetic grindstone <NUM>, and does not heat soften, such as an aluminum alloy material.

The synthetic grindstone assembly <NUM> having the grindstone holding member <NUM> and the synthetic grindstone <NUM> and the wafer W as the workpiece are each rotated in an arrow direction in <FIG> while the wafer W is pressed against the synthetic grindstone <NUM>. At this time, the synthetic grindstone <NUM> is rotated at a peripheral speed of, for example, <NUM>/min, and the wafer W is pressed with a processing pressure of <NUM>/cm<NUM>. Thus, the synthetic grindstone <NUM> and the surface of the wafer W slide against each other. Upon starting of the processing, the synthetic grindstone <NUM> and the surface of the wafer W slide against each other, and an external force acts on the binder <NUM>. As the CMG process progresses, by the continuous action of the external force, the abrasive grains (abrasive) <NUM> gradually fall off from a surface (polishing action surface) of the binder <NUM> of the synthetic grindstone <NUM> with respect to the surface of the wafer W as the workpiece. Then, the surface of the wafer W is polished by the chemo-mechanical action by the fixed abrasive grains <NUM> held in the thermosetting resin as the binder <NUM> or by the abrasive grains <NUM> fallen off from the surface of the binder <NUM>. Convex portions on the surface of the wafer W are heated and oxidized by friction with the synthetic grindstone <NUM>, become brittle, and fall off. In this way, only the convex portions on the surface of the wafer W are ground, and the surface of the wafer W is planarized.

In the present embodiment, the thermosetting resin is used as the binder <NUM> instead of using a thermoplastic resin material (e.g., ethyl cellulose) as binder. This allows for a higher melting temperature as compared to a case of using a thermoplastic resin material as binder, and stabilizes the rigidity and mechanical strength of the synthetic grindstone <NUM> at appropriately high temperatures. Thus, the synthetic grindstone <NUM> according to the present embodiment has greater dimensional stability at appropriate high temperatures, for example, as compared to the case of using a thermoplastic resin material as binder. Therefore, the synthetic grindstone <NUM> according to the present embodiment can suppress deformation at the appropriate high temperatures during machining of the workpiece and improve shape accuracy.

In the case where a thermoplastic resin material is used as binder, heat accumulates between the synthetic grindstone and the wafer W, and softens the thermoplastic resin material as binder, resulting in planarization of the synthetic grindstone surface. Upon melting of the thermoplastic resin material as the binder and welding to the surface of the wafer W, known as sticking, grinding resistance of the synthetic grindstone suddenly increases and the frictional heat becomes excessive, which can cause surface roughness and scratching of the wafer W.

In contrast, in the case where thermosetting resin is used as the binder <NUM>, as in the synthetic grindstone <NUM> according to the present embodiment, even if heat accumulates in the binder <NUM>, the melting point temperature of the binder <NUM> can be made high enough to suppress planarization of the synthetic grindstone <NUM> under appropriate temperatures. Thus, even if heat accumulates between the synthetic grindstone <NUM> and the wafer W, the resin can be prevented from melting. Accordingly, the synthetic grindstone <NUM> according to the present embodiment can maintain a stable processing property for a longer period of time. Therefore, it is possible to suppress the occurrence of unintentional scratches on the surface of the wafer W as the workpiece.

This is due to the fact that the inventor of the present invention, in his diligent efforts to improve the excessive frictional heat in dry polishing processing, found that by forming the synthetic grindstone <NUM> to meet the volume ratio described above, it is possible to achieve excellent workability for the workpiece. That is, the synthetic grindstone <NUM> suitable for dry surface processing, for example, includes the abrasive grains <NUM> with an abrasive grain rate (Vg) greater than <NUM> vol% and <NUM> vol% or less, and the binder <NUM> made of a thermosetting resin material with a binder rate (Vb) of <NUM> vol% or more and <NUM> vol% or less. A porosity (Vp) is set according to the values of the abrasive grain rate (Vg) and the binder rate (Vb) so as to be <NUM> vol% together.

According to the present embodiment, it is possible to provide a synthetic grindstone <NUM>, a synthetic grindstone assembly <NUM>, and a manufacturing method of the synthetic grindstone <NUM>, that can suppress excessive frictional heat, for example, when performing dry polishing processing.

In the present embodiment, an example has been described in which the synthetic grindstone <NUM> is provided in a discoidal shape. The synthetic grindstone <NUM> can be formed in various kinds of shapes, such as a pellet shape and an elongated rectangular-parallelepiped shape. The synthetic grindstone assembly <NUM> is formed in an appropriate shape to hold the synthetic grindstone <NUM>.

By using a thermosetting resin material as the binder <NUM>, the synthetic grindstone <NUM> described in the present embodiment is generally more rigid than synthetic grindstones that use a thermoplastic resin material as binder, and less rigid than synthetic grindstones that use a vitrified bond as binder. This allows an optimal synthetic grindstone to be chosen from the synthetic grindstone <NUM> that uses a thermosetting resin material as the binder <NUM>, a synthetic grindstone that uses a conventional thermoplastic resin material as binder, and a synthetic grindstone that uses a conventional vitrified bond as binder, to suit the material of the workpiece. That is, the synthetic grindstone <NUM> according to the present embodiment allows for a wider range of options for the workpiece. For example, there has been a need for users to use synthetic grindstones that have greater rigidity than synthetic grindstones that use a thermoplastic resin material as binder and less rigidity than synthetic grindstones that use vitrified bond as binder. Such needs can be served by using the synthetic grindstone <NUM> according to the present embodiment.

The synthetic grindstone <NUM> according to the present embodiment has been described in the example of using dry machining, but it can also be used in, for example, wet machining using grinding water (e.g., pure water).

In the present embodiment, the example of using phenol resin as the thermosetting resin material used for the binder <NUM> has been described. For example, epoxy resin, melamine resin, rigid urethane resin, urea resin, unsaturated polyester resin, alkyd resin, polyimide resin, polyvinyl acetal resin, etc. can be used as thermosetting resin materials for the binder <NUM>. These resin materials may be used in combination as appropriate. These cured thermosetting resin materials have excellent water resistance, chemical resistance, and heat resistance, as well as moderate hardness and excellent shape and dimensional stability during use.

The synthetic grindstone <NUM> according to the present modification will be described for a case where coarse particles of an appropriate size are included as the first filler.

Each of shapes of the first filler is preferably, but not necessarily limited to, a spherical shape, and may include some unevenness and deformation as long as it is an aggregate. The first filler is silica, for example, and is dispersed and fixed by the binder <NUM> made of a thermosetting resin material. It is preferable for the first filler to include silica with a particle diameter larger than the particle diameter of the abrasive grains <NUM> and smaller particle diameter silica that is fixed around the larger particle diameter silica. The smaller particle diameter silica is preferably smaller in particle diameter than the abrasive grains <NUM>. A volume ratio of the first filler in the synthetic grindstone <NUM> is set according to a correlation with the abrasive grain rate (Vg) of the abrasive grains <NUM>, for example, based on the binder rate (Vb) of the binder <NUM>. The first filler is preferably more than <NUM> vol% and <NUM> vol% or less.

With respect to the wafer W as a silicon workpiece, the abrasive grains <NUM> made of cerium oxide is as hard as or softer than the wafer W or its oxide. With respect to the abrasive grains <NUM>, the first filler made of silica is as hard as or softer than the wafer W or its oxide.

The synthetic grindstone <NUM> containing the abrasive grains <NUM>, the binder <NUM> made of a thermosetting resin material, and the first filler is manufactured as described in the above embodiment.

Since an average particle diameter of the first filler is larger than that of the abrasive grains <NUM>, the synthetic grindstone <NUM> and the wafer W during processing almost come into contact with each other via an apex of the first filler. That is, since the first filler is present between the base material (the abrasive grains <NUM> and the binder <NUM> made of a thermosetting resin material) of the synthetic grindstone <NUM> and the wafer W, the base material and the wafer W are not in direct contact with each other, and a constant space is formed therebetween.

Upon starting of processing in a state in which the first filler is in contact with the wafer W, an external force acts on the base material. By this external force continuously acting, the abrasive grains <NUM> falls off from the base material. The released abrasive grains <NUM> is present at a processing interface in a state of being adhered to the first filler in the space between the synthetic grindstone <NUM> and the wafer W. Thus, the abrasive grains <NUM> and the wafer W during processing almost come into contact with each other via the apex of the first filler. As a result, an actual contact area between the abrasive grains <NUM> and the wafer W is greatly reduced, and a working pressure at a processing point is increased. Therefore, the grinding process proceeds with a high processing efficiency.

Circulation of the air near the surface of the wafer W with the outside air is promoted by the space, and the processing surface is cooled. In addition, sludge generated by the abrasive grains <NUM> is discharged from the wafer W to the outside through the space, so that the surface of the wafer W can be prevented from being damaged. As a result, burning and scratching on the surface of the wafer W due to frictional heat can be prevented.

In this way, the surface of the wafer W is ground flat and to a predetermined surface roughness by the synthetic grindstone <NUM>.

According to the synthetic grindstone <NUM> of the present modification, even if the processing proceeds, the contact pressure between the abrasive grains <NUM> and the wafer W is sufficiently maintained to maintain the processing efficiency, and the direct contact between the binder <NUM> and the wafer W is suppressed, so that quality deterioration and scratching of the wafer W can be prevented. In the present modification, it is possible to suppress excessive frictional heat due to the heat generated between the synthetic grindstone <NUM> and the workpiece, as described in the above embodiment.

As the first filler, silica, carbon, silica gel which is a porous body thereof, activated carbon, spherical resin, etc. are applicable. Hollow balloons used as pore-forming agents are not suitable because they break during processing and cause scratches.

A case will be described in which the synthetic grindstone <NUM> according to the present modification contains, as second filler, a conductive material that is smaller than the first filler described in the first modification and that has an appropriate size. The grindstone holding member <NUM> of the CMG device <NUM> described above is described in the present modification as a material having electrical conductivity and appropriate thermal conductivity, for example, an aluminum alloy material.

Examples of the conductive material include carbon nanotubes, etc. These materials are smaller in particle diameter than the average particle diameter of the abrasive grains <NUM>. A volume ratio of the second filler in the synthetic grindstone <NUM> is set, for example, based on the binder rate (Vb) of the binder <NUM>, in correlation with the abrasive grain rate (Vg) of the abrasive grains <NUM>. It is preferable for the second filler to be added at more than <NUM> vol% and not more than <NUM> vol%.

Further, the second filler can improve the strength of the synthetic grindstone <NUM> as a structure by, for example, using carbon nanotubes, etc..

Upon start of the processing of the wafer W at the CMG device <NUM>, the synthetic grindstone <NUM> and the wafer W slide against each other, and an external force acts on the binder <NUM>. By a continuous action of the external force, the abrasive grains <NUM> falls off onto the wafer W. The released abrasive grains <NUM> slides in a space between the synthetic grindstone <NUM> and the wafer W. By the chemo-mechanical action of the abrasive grains <NUM>, the surface of the wafer W is polished.

Upon polishing of the surface of wafer W and an occurrence of friction, static electricity can be generated on the surface of the wafer W. At this time, the conductive second filler conducts static electricity from the surface of the wafer W to the grindstone holding member <NUM> (refer to <FIG>). Accordingly, by using the synthetic grindstone <NUM> according to the present modification, the static electricity generated on the surface of the wafer W can be removed while polishing the surface of the wafer W. As a result, dust, etc. can be prevented from adhering to the surface of the wafer W.

Further, in the present modification, the thermal conductivity of the grindstone holding member <NUM> is higher than that of the synthetic grindstone <NUM>. Upon polishing of the surface of the wafer W and an occurrence of friction, frictional heat is generated on the surface of the wafer W. At this time, the second filler absorbs the frictional heat, and the heat absorbed by the second filler is heat-conducted to the grindstone holding member <NUM>. Accordingly, by using the synthetic grindstone <NUM> according to the present modification, the frictional heat generated on the surface of the wafer W can be removed while polishing the surface of the wafer W. As a result, burning and scratching on the surface of the wafer W due to the frictional heat between the surface of the synthetic grindstone <NUM> and the surface of the wafer W can be prevented. Therefore, the synthetic grindstone <NUM> according to the present modification can not only process the surface of the wafer W well, but also extend the service life of the synthetic grindstone <NUM>.

It is also preferable to provide a heat dissipation portion such as a heat dissipation fin in the grindstone holding member <NUM> that rotates together with the synthetic grindstone <NUM>, i.e., it is also preferable that the synthetic grindstone assembly <NUM> have a heat dissipation portion (heat transmission portion). In this case, rotation brings the heat dissipation portion into contact with the air, effectively dissipating heat from the synthetic grindstone <NUM>.

It is also possible to cool the grindstone holding member <NUM> and the synthetic grindstone <NUM> by installing water pipes for cooling water or the like inside the grindstone holding member <NUM>.

In the present modification, the example of the grindstone holding member <NUM> having electrical conductivity and higher thermal conductivity than that of the synthetic grindstone <NUM> has been described, but it may be formed of a material having at least one of electrical conductivity or higher thermal conductivity than that of the synthetic grindstone <NUM>. In the case of having the electrical conductivity, static electricity between the workpiece and the synthetic grindstone <NUM> can be removed, and in the case of having the higher thermal conductivity than that of the synthetic grindstone <NUM>, heat that can be generated in the synthetic grindstone <NUM> can be effectively dissipated.

The first modification describes the example in which the first filler is used, and the second modification describes the example in which the second filler is used. The synthetic grindstone <NUM> preferably includes both of the first filler and the second filler. In this case, the abrasive rate of the abrasive grains <NUM> is, for example, <NUM> vol%, the binder rate of the binder <NUM> is, for example, <NUM> vol%, the porosity of the pores <NUM> is, for example, <NUM>%, the first filler is <NUM> vol%, and the second filler is <NUM> vol%. In this case as well, the synthetic grindstone <NUM> also determines the binder rate (Vb) of the binder <NUM> first, and then the abrasive grain rate (Vb) of the abrasive grains <NUM> and the volume ratios of the first filler and the second filler are set according to the correlation of the abrasive grains <NUM>, first filler, and second filler.

A case will be described in which the synthetic grindstone <NUM> according to the present modification contains, as a third filler, particles that are smaller than the first filler described in the first modification and that have an appropriate size.

Examples of the particles of the third filler include green carborundum (GC), etc. These particles are harder than the wafer W as the workpiece. The particles of the third filler, such as GC, may be larger or smaller than the average particle diameter of the abrasive grains <NUM>. As a matter of course, the particles of GC, etc. may be as large as the average particle diameter of the abrasive grains <NUM>.

For example, the average particle diameter of the metal oxide-based abrasive grains <NUM>, such as aluminum oxide (alumina), zirconium oxide (zirconia), cerium oxide (ceria), and silicon oxide (silica), can be larger, smaller, or of similar size than GC. For example, the average particle diameter of the alumina, zirconia, and ceria-based abrasive grains <NUM> is almost always larger than GC. For example, the average particle diameter of the alumina-based abrasive grains <NUM> can be as large as GC (~<NUM>). For example, if a particle of GC, etc. is <NUM>, the average particle diameter of the abrasive grains <NUM> such as silica may be <NUM>.

A volume ratio of the third filler in the synthetic grindstone <NUM> is set according to a correlation with the abrasive grain rate (Vg) of the abrasive grains <NUM>, for example, based on the binder rate (Vb) of the binder <NUM>. The third filler is preferably added at more than <NUM> vol% and <NUM> vol% or less.

There is a technique (gettering effect) in which a gettering site such as a fine scratch is formed on the back surface of the wafer W opposite to the front surface, and impurities are captured by the gettering site. GC is harder than the back surface of the wafer W and is used to intentionally scratch the back surface of the wafer W.

In the present modification, as described in the above embodiment, it is possible to suppress frictional heat from becoming excessive due to heat generated between the synthetic grindstone <NUM> and the workpiece. If the GC is conductive, it can also suppress static electricity that can be generated between the synthetic grindstone <NUM> and the workpiece.

The first modification has described an example in which the first filler is used, and the second modification has described an example in which the second filler is used. It is also preferable for the synthetic grindstone <NUM> to contain two or three of the first filler, the second filler, and the third filler. In the case where three are included, it is preferable that the abrasive rate of the abrasive grains <NUM> is, for example, more than <NUM> vol% and <NUM> vol% or less, the binder rate is <NUM> vol% or more and <NUM> vol% or less, the first filler is more than <NUM> vol% and <NUM> vol% or less, the second filler is more than <NUM> vol% and <NUM> vol% or less, and the third filler is more than <NUM> vol% and <NUM> vol% or less. The second filler and the third filler together are preferably more than <NUM> vol% and <NUM> vol% or less. If the synthetic grindstone <NUM> contains the second filler and the third filler, the second filler is preferably <NUM> vol% or less.

Claim 1:
A synthetic grindstone (<NUM>) for performing surface processing, the synthetic grindstone (<NUM>) comprising:
abrasive grains (<NUM>);
binder (<NUM>) made of a thermosetting resin material and holding the abrasive grains (<NUM>) in a dispersed state; and
filler including
first filler having a larger average particle diameter than the abrasive grains (<NUM>), and
second filler having electrical conductivity, and
third filler harder than a workpiece,
the filler being disposed in a state of being dispersed in the binder (<NUM>);
wherein:
an abrasive grain rate (Vg) of the abrasive grains (<NUM>) is more than <NUM> vol% and <NUM> vol% or less,
a binder rate (Vb) of the binder (<NUM>) is <NUM> vol% or more and <NUM> vol% or less,
the first filler is <NUM> vol% or more and <NUM> vol% or less,
the second filler is <NUM> vol% or more and <NUM> vol% or less,
the third filler is <NUM> vol% or more and <NUM> vol% or less, and
a porosity (Vp) is set according to values of the abrasive grain rate (Vg), the binder rate (Vb), and the filler such that a total sums up to <NUM> vol%.