Patent ID: 12202094

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

Numerical values in the specification and claims of this application should be understood to include numerical values which are the same when reduced to the same number of significant figures and numerical values which differ from the stated value by less than the experimental error of conventional measurement technique of the type described in the present application to determine the value. All ranges disclosed herein are inclusive of the recited endpoint.

The term “about” can be used to include any numerical value that can vary without changing the basic function of that value. When used with a range, “about” also discloses the range defined by the absolute values of the two endpoints, e.g., “about 2 to about 4” also discloses the range “from 2 to 4.” The term “about” may refer to plus or minus 10% of the indicated number.

According to some chemical mechanical polishing (CMP) platforms, a platen is covered with a polishing pad and is configured to rotate the polishing pad. CMP polishing pads may be made of a plurality of different materials. In some implementations, the pads are manufactured from hard and porous polyurethane foam, and may be patterned with narrow high-aspect ratio grooves (i.e. to collect debris from wafers being polished). These pads may include a single layer or a composite layer of materials such as felts, polymer impregnated felts, microporous polymers films, microporous synthetic leathers, filled polymer films, unfilled textured polymer films, combinations of same, or the like. Representative polymers may include polyurethane, polyolefins, or the like.

A rotating polishing head, such as a wafer carrier, is arranged over the polishing pad, and is configured to support and rotate a workpiece, e.g., silicon wafer. The polishing head comprises concentric pressure zones configured to press corresponding concentric regions on a to-be-polished surface of the workpiece into the polishing pad with varying force. A slurry distribution system comprises one or more nozzles arranged over the polishing pad, and is configured to provide a slurry to the polishing pad through the nozzle(s). In some instances, the ultra-fine chemical polishing slurry is sprayed onto and channeled around the pad surface, via the grooves. The slurry comprises chemical and abrasive components. Due to the pressing force and the slurry, the to-be-polished surface undergoes chemical and mechanical polishing. A conditioner is arranged over the polishing pad, and is configured to remove polishing debris from the polishing pad.

As pads wear out, they must be replaced to prevent damage to wafers being polished, as well as to remain effective in performing the CMP processing. This determination may be the result of a set number of operations or period of time, as well as actually damage to the pad. To replace such pads, a technician must manually peel/scrape the used pad from the top of a platen followed by cleaning of the platen surface. In some instances, this requires the technician to remove the platen from the CMP tool to effectively remove and replace a pad. A new pad is then readied for placement on the cleaned platen by removal of backing from the pad (self-adhering pads) or by preparation of the platen surface with an adhesive. For the new pad to be effective, the technician must carefully align the new pad on the platen. After alignment, the technician must manually check the pad for flatness, i.e., the presence of any bubbles under the pad (e.g., debris or air pockets between the platen and the pad). This preventative maintenance/emergency maintenance is exceedingly time consuming and labor intensive. Any CMP tool having a pad replaced may be inaccessible for semiconductor manufacturing operations for extended periods of time, thereby slowing down fabrication within a given facility. Further, when a technician performs this type of maintenance, the 6S Safety (i.e., sort, set in order, shine, standardize, sustain, security) is impacted.

In embodiments disclosed herein, an automated pad replacement system is provided that reduces downtime of the CMP tool for pad replacement, and also reduces the amount of manual labor entailed in performing pad replacement. The automated pad replacement system provides automated hardware for removing the used pad, pressing down the new pad onto the platen, and checking for bubbles. Additionally, embodiments disclosed herein provide multiple platens in the CMP tool with a mechanism for switching between the platens. This facilitates the automated pad replacement, and also extends the time intervals between pad replacement downtime sessions by enabling all pads of the multiple platens to be replaced in one pad replacement downtime session.

Turning now toFIG.1, there is shown a CMP pad tape replacement module100for automated CMP pad replacement in accordance with one embodiment. According to varying embodiments contemplated herein, the CMP pad tape replacement module100is configured for removable attachment to a CMP tool300(shown inFIG.3). As shown inFIG.1, the CMP pad tape replacement module100includes a pad tape supply roller102configured to store a pad tape supply104, i.e., a roll of pad tape106.

Although not illustrated inFIG.1, the pad tape replacement module100may be affixed to a movable assembly configured to align over the CMP tool300to allow replacement of pads108on platens126A in accordance with the methods described in greater detail below. In other embodiments, the pad tape module100may be configured to align along a side of the CMP tool300, thereby allowing replacement of pads108on a side of the CMP tool300, as opposed to the top surface of the tool300. In such embodiments, the individual components of the pad tape replacement module100described herein may each be mounted to the referenced assembly, or may be individually placed in proximity to the CMP tool300to effectuate the pad replacement processes disclosed herein. The skilled artisan will appreciate that such assembly may be maneuvered into position via automated or manual means. For example and without limitation, the assembly holding the CMP pad tape replacement module100may be positioned on rails (not shown) or other guides to enable proper positioning of the pad tape replacement module100over the CMP tool300. Such positioning may be accomplished via mechanized means, e.g., motors, pulleys, etc., alone or in combination with manual actions by a technician.

FIGS.2A,2B, and2Cprovide images of the pad tape106before and after extraction of pads108onto a platen126A of a CMP tool300, as discussed in greater detail below. As shown inFIG.2A, a section of pad tape106is illustrated having a plurality of pads108disposed therein. In some embodiments, the pad tape106is precut into the shape of a pad108that fits on a platen126A of the CMP tool300. In such embodiments, the pad tape106(shown more fully inFIG.2B) includes a backing tape/layer112disposed over an adhesive layer120and a pad layer122comprising the precut pads108. It will be appreciated by those skilled in the art that the backing layer112may comprise any suitable material capable of preventing the adhesive layer120from adhering to other materials, e.g. the pad layer122when presented in a roll (i.e., the pad tape supply104). In some embodiments, the pad tape106may have a width greater than the diameter of the platen126A, with the precut pads108on the tape106having the same diameter as that of the platen126A. As a non-limiting example, when the platen has a diameter of about 520 mm, the precut pads have a diameter of about 520 mm and the width of tape is about 540 mm. Other diameters and widths are also capable of being used, and the diameter of the platen may dictate the diameter and width of the tape. It will be appreciated that such examples may utilize ranges of +/−50 mm to allow for a range of different sized platens. In some embodiments, the platen platform may rotate from 0 to 360 degrees for taping and pad removing.

Returning toFIG.1, the pad tape106is initially fed through backing removal rollers110A and110B, wherein the backing tape/layer112is separated from the pad layer122and adhesive layer120. The backing tape/layer112is then wound into a backing tape recycle roll118around the backing tape recycle roller116through backing tape recycle guide rollers114A and114B. In some embodiments, the backing removal rollers110A-B, and/or the backing tape recycle roller116are suitably configured to turn the backing tape recycle roll118to collect the backing tape/layer112while maintaining suitable tension in the backing tape/layer112coming from the removal rollers110A-B. The skilled artisan will appreciate that such tension assists in separating the backing tape/layer112from the adhesive layer120and prevents the backing tape/layer112from bundling or otherwise interfering with operations of the CMP pad tape replacement module100.

According to one embodiment, the pad tape106, after having been stripped of the backing tape/layer112(i.e., the adhesive layer120and the pad layer122) is directed from the backing removal rollers110A-B over a platen126A through pad tape recycle guide rollers128A and128B to the pad tape recycle roller130, forming a pad tape recycle roll132of the pad layer122. It will be appreciated by those skilled in the art that the pad tape recycle roller130may be suitably configured to turn the pad tape recycle roll132to collect the pad tape layer/adhesive layer120after application of a pad108to a platen126A. In accordance with one embodiment, as the adhesive layer120and pad layer122are passed over the aforementioned platen126A, a pressure roller124applies pressure to cause the pad108to adhere to the platen126A. According to one embodiment, the pressure roller124is configured to transit across the platen126A, applying equal pressure to the pad108on the platen126A. It will be appreciated by those skilled in the art that the pressure roller124may be suitably configured to move the pressure roller124in multiple axes of motion (e.g. raise and lower to allow movement of pad tape106), apply even pressure, rotate, and the like. The skilled artisan will appreciate that such pressure enables the adhesive120on the pad108to adhere to the platen126A. The pressure roller124may then return to its previous position and the pad tape roller102, the pad tape recycle roller130, and the backing recycle roller118increments (i.e. rotates) one pad length so as to position a fresh pad108in the pad tape106in position above the CMP tool300for affixing to the next platen126A of a platen carrier, as discussed below. The various rollers may be driven by a motor (not shown), pulley/belt assembly (not shown), geared coupling, or the like,

Referring now toFIGS.3A,3B, and3C, there is shown a CMP tool300with which the pad tape replacement module100may be utilized to replace a CMP pad108on a platen126A in accordance with one embodiment of the subject application. As shown inFIGS.3A-C, the platen126A is configured to support a CMP pad108. The platen126A comprises a substantially planar upper surface configured to interface with an adhesive of the bottom surface of the pad108that is opposite the top surface of the pad108that facilitates polishing of an associated wafer.

The CMP tool300includes a platen cleaning process module302, a pad waste bin module304, a pad bubble detection module306, a pad conditioner module308, a polish head module310, a pad wear detection module312, a slurry flow module314, and a CMP tool controller316. The platen cleaning process module302is illustrated and described in greater detail with respect toFIGS.4-6B.

According to one embodiment, the pad bubble detection module306comprises a support arm318laterally spaced on a top surface320of the platen cleaning process module302. The support arm318may extend laterally over the platen126A, from adjacent to the platen126A and may be implemented as telescoping. The support arm318of the pad bubble detection module306may be coupled at one end to a support arm motor322, which is operable to rotate the support arm318across the platen126A and/or telescope the arm318as it sweeps across the platen126A. A pad bubble detection head324may be positioned at a distal end of the support arm318, opposite the end coupled to the support arm motor322. In varying embodiments, the bubble detection head324is configured to detect a presence of a bubble or other disturbance/imperfection under the pad108during replacement thereof. The bubble detection head324may comprise, for example and without limitation, an optical sensor, a contact sensor, an ultrasonic sensor, or other suitable sensor capable of detecting issues on the surface of the pad108. The support arm motor322and receipt/operation of the bubble detection head324may be controlled and operated via the CMP tool controller316, as discussed in greater detail below.FIG.3Billustrates the movement of the support arm318of the pad bubble detection module306across the surface of the pad108on the platen126A, thereby enabling the bubble detection head324with associated sensors to detect the presence of any bubbles or other imperfections on the pad108.

As indicated above, the CMP tool300further includes a pad conditioner module308comprising a pad conditioner support arm326on the top surface320of the platen cleaning process module302. The support arm326may extend laterally over the platen126A, from adjacent to the platen126A and may be implemented as telescoping. The support arm326of the pad conditioner module308may be coupled at one end to a support arm motor328, which is operable to rotate the support arm326across the platen126A and/or telescope the arm318as it sweeps across the CMP pad108positioned on the platen126A. A pad conditioner head330may be positioned at a distal end of the support arm326, opposite the end coupled to the support arm motor328. In some embodiments, the pad conditioner head330is configured to rotate a pad conditioner332attached thereto over the CMP pad108.

According to varying embodiments, the pad conditioner332may be coupled to the conditioner head330via mechanical or other suitable fastening means, e.g., adhesive, hook and loop fasteners, or the like. As will be appreciated by the skilled artisan, the pad conditioner332may comprise a substrate over which an array of abrasive particles are adhered. In varying embodiments, the pad conditioner332may remove wafer debris and excess slurry from the CMP pad108during CMP processing. In other embodiments, the pad conditioner332may facilitate the creation of grooves or other textures on the pad108against which a wafer may be polished. Rotation of the pad conditioner head330may be accomplished via a suitable motor (not shown), as will be understood by the skilled artisan.FIG.3Cillustrates the movement of the support arm326of the pad conditioner module308across the surface of the pad108on the platen126A, thereby enabling the pad conditioner332to condition the CMP pad108during CMP processes.FIG.7provides a cross-sectional view of the CMP tool300during a CMP process in accordance with one embodiment, including the pad conditioner support arm326, the pad conditioner head330, and the pad conditioner332.

The CMP tool300depicted inFIGS.3A-Calso includes a polishing head module310comprising a polishing head support arm334on the top surface320of the platen cleaning process module302. The support arm334may extend laterally over the platen126A, from adjacent to the platen126A and may be implemented as telescoping. The support arm334of the polishing head module310may be coupled at one end to a support arm motor336, which is operable to rotate the support arm334across the platen126A and/or telescope the arm318as it sweeps across the CMP pad108positioned on the platen126A. A polishing head338may be positioned at a distal end of the support arm334, opposite the end coupled to the support arm motor336. The polishing head338may be configured to hold a wafer340to be polished. In some embodiments, the polishing head338is configured to rotate the wafer340over the CMP pad108during planarization/polishing.

As indicated above, the polishing head338is configured to hold a semiconductor wafer340(see, e.g.,FIG.7) via any suitable means. For example, and without limitation, the polishing head338may utilize a carrier and retainer ring that is mounted to the carrier via mechanical fasteners or other suitable attachment mechanisms. During operations of the CMP process, the wafer340is held in place within the polishing head340, with the surface to be polished facing down onto the pad108. The polishing head338is configured to apply a downward force or pressure urging the workpiece into contact with polishing pad108.

Located in relative proximity to the pad108on the platen126A is the pad wear detection sensor module312. The pad wear detection sensor module312includes one or more sensors configured to detect wear (i.e., the state) of the pad108, e.g., loss of abrasive characteristics, damage (e.g., rips, tears, etc.) to the pad108, or the like. Suitable sensors may include, for example and without limitation, optical sensors, infrared sensors, or the like.

In accordance with one embodiment, the CMP tool300further includes a slurry flow module314configured to dispense a slurry342onto the pad108during CMP processing. During the aforementioned CMP processing, the platen126A rotates, which causes the slurry342to be distributed on the pad108. It will be appreciated that the type of slurry342may depend upon the types of material to be polished or removed. For example, slurry342may comprise a reactant, an abrasive, a surfactant, and a solvent. The reactant may be a chemical, such as an oxidizer or a hydrolyzer, which will chemically react with a material of the wafer340to assist the CMP pad108in abrading/removing material.

In accordance with other embodiments, the reactant may be, e.g., hydrogen peroxide; although any other suitable reactant, such as hydroxylamine, periodic acid, ammonium persulfate, other periodates, iodates, peroxomonosulfates, peroxymonosulfuric acid, perborates, malonamide, combinations of these, or the like, configured to aid in removal of material may be alternatively, conjunctively, or sequentially employed. Other reactants may be used to remove other types of materials. For example, in some embodiments in which a material to be removed includes an oxide, the reactant may comprise HNO3, KOH, NH4OH, combinations of same, or the like. The abrasive may include any suitable particulate that, in conjunction with the CMP pad108, is configured to polish/planarize the workpiece. In some embodiments, the abrasive may include silica, aluminum oxide, cerium oxide, polycrystalline diamond, polymer particles (e.g., polymethacrylate, or the like), combinations of these, or the like.

It will be appreciated by those skilled in the art that the control of the pad tape replacement module100, the platen cleaning process module302, the pad bubble detection module306, the pad conditioner module308, the polishing head module310, the pad wear detection module312, and the slurry flow module314may be accomplished via the CMP controller316, as discussed in greater detail below with respect toFIG.8.

Referring now toFIG.4, there is shown an interior chamber400of the platen cleaning process module302in accordance with one exemplary embodiment. The interior chamber400houses a platen carrier402upon which a plurality of platens126A,126B are mounted. The platen carrier402may be configured to carry two, four, or more platens, each of which may be utilized in CMP processing. According to one embodiment, the platen carrier402is rotatable and suitably configured to rotate within the chamber400to alter the platen that is being used for CMP processing.FIG.5Adepicts a four-sided platen carrier500having four platens126A,126B,126C and126D affixed thereto.FIG.5Bdepicts a two-sided platen carrier502having two platens126A and126B affixed thereto.

The interior chamber400of the platen cleaning process module302shown inFIG.4includes a plurality of components configured to facilitate the CMP process as well as the replacement of pads108in accordance with varying embodiments contemplated herein. As shown inFIG.4, the platen carrier402(either the carrier500or502inFIGS.5A-5B) is mounted to a rotation motor404operable to rotate the platen carrier402such that one of the platens126A-D (four-sided) or126A-B (two-sided) is positioned for CMP operations of the CMP tool300.

The platen carrier402inFIG.4depicts two platens126A and126B to allow for illustration of the various internal drive components of the platen cleaning process module302. It will be appreciated that a four-sided platen carrier500may also be utilized in the chamber400ofFIG.4, such as the four-sided platen carrier500that is illustrated inFIGS.5A,6A and6B. Each platen126A-126B is rotatably coupled to a central shaft406that extends between the platens126A-126B. The rotation motor404is coupled to a drive shaft408connected to the central shaft406. Positioned on the central shaft406are a plurality of couplings410, configured to allow the platens126A-126B to be spun independent from the rotation of the central shaft406, as well as from each other. That is, each platen126A-B (FIG.4, and platens126A-D inFIGS.6A-6B) are independently rotatable via the couplings410. A pulley or gear (sprocket) or other drive coupling mechanism412is positioned around the central shaft406adjacent each platen126A,126B and is configured to engage a corresponding drive coupling mechanism414of a platen rotation motor416. During the CMP process, the platen rotation motor416operates to spin the platen126A via the drive coupling mechanisms414and412.

According to one embodiment, the platen rotation motor416is mounted to a support structure418that extends towards and retracts from the central shaft406. That is, the support structure418moves the platen rotation motor416and drive coupling mechanism414to engage with or disengage from the drive coupling mechanism412associated with the platen126A or126B. In accordance with one embodiment, the support structure418is driven by a sweep motor420via a screw drive422. That is, rotation of the screw drive422by the sweep motor420moves the support structure418toward or away from the central shaft406. It will be appreciated by those skilled in the art that the location of the sweep motor420and screw drive422is dependent upon the location of the support structure418. Further, the skilled artisan will appreciate that the platen drive motor418and associated components are positioned perpendicularly to the rotation of the platen carrier402, as illustrated inFIG.4. An exhaust424is arranged on an outside portion of the interior chamber400of the platen cleaning process module302enabling removal of moisture and/or providing access to the pad waste bin module304. Located on a bottom portion of the interior chamber400of the platen cleaning process module302is a fan426, proximate to the platen126B and operable to dry out the pad located on the platen126B of any residual moisture, e.g., water, slurry, or the like.

In accordance with one embodiment, the interior chamber400of the platen cleaning process module302further includes a pad tearer tool504, illustrated inFIGS.5A and5B, that is configured to remove used pads108from a platen126A-D during CMP pad replacement operations. In varying embodiments contemplated herein, the pad tearer tool504is movable along one or more axes, allowing the tool504to move into position to remove a used pad108from a platen126A-D. According to one embodiment, the pad tearer tool504may utilize a 30-60 degree angle to remove the pad108from a platen126A-D. The platen carrier402may rotate, causing the pad tearer tool504to peel the used pad108from the platen126A-D. In some embodiments, the pad tearer tool504may move along one or more axes as the platen carrier402rotates to ensure proper removal of the pad108and to prevent damage to the platen126A-D. The pad tearer tool504may then return to its original position after removal of the pad108. In some embodiments, the pad tearer tool504is in communication with a receptacle, e.g., the pad waste bin module304, to recover the pad108that is removed. Operations of the various components described above will be better understood in conjunction with the methodologies discussed with respect toFIG.9.

Turning now toFIG.8, there is shown a block diagram of a CMP tool controller316in accordance with one embodiment. The various components of the CMP tool controller316may be connected by a data/control bus808. The processor802of the CMP tool controller316is in communication with an associated database820via a link814. A suitable communications link814may include, for example, the public switched telephone network, a proprietary communications network, infrared, optical, or other suitable wired or wireless data communications. The database820is capable of implementation on components of the CMP tool controller316, e.g., stored in local memory804, i.e., on hard drives, virtual drives, or the like, or on remote memory accessible to the CMP tool controller316.

The associated database820is representative of any organized collections of data used for one or more purposes. The skilled artisan will appreciate that such information may be updated via machine learning during operations of the subject CMP tool system300and/or the pad tape replacement module100. Implementation of the associated database820is capable of occurring on any mass storage device(s), for example, magnetic storage drives, a hard disk drive, optical storage devices, flash memory devices, or a suitable combination thereof. The associated database820may be implemented as a component of the CMP tool controller316, e.g., resident in memory804, or the like. In one embodiment, the associated database820may include data corresponding to production scheduling, pad wear information, slurry information, lot information, platen orientation information, and the like.

The CMP tool controller316may include one or more input/output (I/O) interface devices822and824for communicating with external devices. The I/O interface824may communicate, via communications link812, with one or more of a display device816, for displaying information, such estimated destinations, and a user input device818, such as a keyboard or touch or writable screen, for inputting text, and/or a cursor control device, such as mouse, trackball, or the like, for communicating user input information and command selections to the processor802. The I/O interface822may communicate with external devices such as the CMP tool300, the pad tape replacement module100, the platen cleaning process module302, the pad bubble detection module306, the pad conditioner module308, polish head module310, pad wear detection module312, the slurry flow module314, and the various components associated therewith via the communications links826.

It will be appreciated that the CMP tool controller316illustrated inFIG.8is capable of implementation using a distributed computing environment, such as a computer network, which is representative of any distributed communications system capable of enabling the exchange of data between two or more electronic devices. It will be further appreciated that such a computer network includes, for example and without limitation, a virtual local area network, a wide area network, a personal area network, a local area network, the Internet, an intranet, or any suitable combination thereof. Accordingly, such a computer network comprises physical layers and transport layers, as illustrated by various conventional data transport mechanisms, such as, for example and without limitation, Token-Ring, Ethernet, or other wireless or wire-based data communication mechanisms. Furthermore, while depicted inFIG.8as a networked set of components, the CMP tool controller316is capable of implementation on a stand-alone device adapted to interact with the CMP tool300and/or the pad tape replacement module100described herein.

The CMP tool controller316may include one or more of a computer server, workstation, personal computer, cellular telephone, tablet computer, pager, combination thereof, or other computing device capable of executing instructions for performing the exemplary method.

According to one example embodiment, the CMP controller316includes hardware, software, and/or any suitable combination thereof, configured to interact with an associated user, a networked device, networked storage, remote devices, or the like.

The memory804illustrated inFIG.8as a component of the CMP tool controller316may represent any type of non-transitory computer readable medium such as random access memory (RAM), read only memory (ROM), magnetic disk or tape, optical disk, flash memory, or holographic memory. In one embodiment, the memory804comprises a combination of random access memory and read only memory. In some embodiments, the processor802and memory804may be combined in a single chip. The network interface(s)822,824allow the computer to communicate with other devices via a computer network, and may comprise a modulator/demodulator (MODEM). Memory804may store data processed in the method as well as the instructions for performing the exemplary method.

The digital processor802can be variously embodied, such as by a single core processor, a dual core processor (or more generally by a multiple core processor), a digital processor and cooperating math coprocessor, a digital controller, or the like. The digital processor802, in addition to controlling the operation of the CMP tool controller316, executes instructions806stored in memory804for performing the method set forth hereinafter.

As shown inFIG.8, the instructions806stored in memory804may include a sensor component828configured to receive an output from one or more sensors, e.g. the bubble detection head324and/or pad wear detection sensor module312. In some embodiments, the sensor component828is configured to determine from the received output whether the pad108is flat (i.e. no bubbles, deformities, etc.), the wear of the pad108, and the like. When the output from the bubble detection head324indicates that one or more sensors indicate the presence of a bubble or other deformity on a pad108, the sensor component828may generate feedback to the processor802to alert a technician that pad replacement is needed. Such an alert may include, for example and without limitation, an audible alert, a visual alert, a text message, an electronic mail message, an automated call, or the like. The sensor component828may further be configured to receive an output from the pad wear detection sensor module312, indicative of a tear, worn portion, number of operations, passage of a predetermined period of time, or the like. In the event that such an output is received via the sensor component828, the component828may generate the aforementioned feedback to the processor802as discussed above.

The instructions806stored in the memory804of the CMP tool controller316may further include a pad tape module control component830configured to determine a current position of the pad tape replacement module100, the status of the pad tape supply104, and the like. In some embodiments, the pad tape module control component830, in conjunction with the processor802, may direct movement of the pad tape replacement module100toward or away from the CMP tool300, orientation and position of the platen carrier402, orientation and position of the pad tearer tool504, position and operation of rollers (e.g., operations of the pressure roller124) and the like. According to other embodiments, the pad tape module control component830may be configured to operate the various motors associated with the platen cleaning process module302, including rotation of the platen carrier402via the rotation motor404, positioning of the sweep motor420and screw drive422, and the like.

The memory804of the CMP tool controller316may further store a CMP processing component832in the instructions806configured to control a CMP process to be performed by the CMP tool300. In some embodiments, the CMP processing component directs operations of the pad conditioner module308, the polish head module310, and the slurry flow module314in accordance with a given CMP polishing operation. It will be appreciated that the CMP processing component832, via the processor802, may direct movement of the sweep motor420to engage and rotate the platen126A via the drive coupling mechanisms412,414. The skilled artisan will appreciate that the CMP processing component832may further be configured to control rotation of the various motors discussed above with respect toFIG.4to facilitate a polishing process on an associated wafer340.

The term “software” as used herein is intended to encompass such instructions stored in storage medium such as RAM, a hard disk, optical disk, or so forth, and is also intended to encompass so-called “firmware” that is software stored on a ROM or so forth. Such software may be organized in various ways, and may include software components organized as libraries, Internet-based programs stored on a remote server or so forth, source code, interpretive code, object code, directly executable code, and so forth. It is contemplated that the software may invoke system-level code or calls to other software residing on a server or other location to perform certain functions. Operations of the CMP tool controller316will be better understood in conjunction with the exemplary methods set forth inFIG.9.

Turning now toFIG.9, there is shown a flowchart illustrating a method900for in-situ CMP pad replacement in accordance with one embodiment. The method900begins at902, whereupon the CMP tool controller316via the sensor component828receives output from the pad wear detection module306regarding a pad108currently being used in CMP polishing operations of the CMP tool300. A determination is then made at904whether replacement of the pad108is required. In varying embodiments, the determination may be made based upon the usage of the pad, i.e., number of wafers340polished, number of polishing operations, and the like. In accordance with other embodiments, the determination may be made based upon detected wear of the pad108, i.e., holes, lack of abrasive qualities, thinness/thickness of the pad108, or the like. Upon a negative determination at904, operations return to902for continued monitoring of the output from the pad wear detection module312.

When it is determined at904that replacement of the pad108is needed, operations proceed to906, whereupon a technician is alerted. After such an alert, a determination is made at908whether another platen126A,126B,126C, or126D is available for use. That is, a determination is made whether one of the platens126A,126B,126C, or126D remains available with an unused pad108. It will be appreciated that the availability of an unused pad108may be dependent upon the number of platens on the carrier402, i.e. two, four, or more. Upon a positive determination at908, operations proceed to910, whereupon the platen carrier402is rotated to allow the unused pad108/platen126A,126B,126C, or126D to be positioned on the top320of the CMP tool300. Operations then proceed to938, whereupon CMP processing is performed by the CMP tool300using the unused pad108.

Upon a determination at908that no unused pads108remain available, the CMP tool controller316directs movement of the pad tape replacement module100into position over the CMP tool300at912, as well as rotation of the various modules306,308,314away from the platen126A,126B,126C, or126D. The CMP tool controller316directs rotation of the platen carrier402toward the pad tearer tool504(as illustrated inFIGS.5A-5B) at914. Concurrently or sequentially therewith, at916, the pad tearer tool504is engaged to tear/remove the used pad108from the platen126A,126B,126C, or126D. A determination is then made at918whether all platens126A,126B,126C, and126D have been cleared of used pads108. When a platen126A,126B,126C, or126D has not yet been cleared of a used pad108, operations proceed to920, whereupon the pad tearer tool504is retracted so as to prevent damage to the tool504and/or the platens126A,126B,126C, or126D. Operations then return to914, whereupon the platen carrier402is rotated and the pad tearer tool504is engaged at916to remove the used pad108from the platen126A,126B,126C, or126D. It will be appreciated by those skilled in the art that during the aforementioned cleaning operations, the fan426is activated to dry/remove excess fluids on the platen126A,126B,126C, or126D positioned on the bottom of the interior chamber400as the carrier402rotates.

Upon a determination at918that all used pads have been removed, operations proceed to922, whereupon the pad tape106is rolled over the current platen126A,126B,126C, or126D positioned at the top of the CMP tool300. That is, the backing tape112is removed via backing rollers110A-B, leaving the pad108in the pad layer122with the adhesive layer120exposed, and the pad tape supply roller102, the backing recycle roller116, and the pad tape recycle roller130are activated to increment/advance the pad tape106such that a fresh pad108disposed in the pad tape106is in the correct position above the platen126A,126B,126C, or126D for application thereto. At924, the pressure roller124is engaged to apply downward force to the pad tape106above the platen126A,126B,126C, or126D and to roll across the platen126A,126B,126C, or126D providing constant, even pressure on the pad108to enable the adhesive122to adhere or otherwise engage with the platen126A,126B,126C, or126D.

A determination is then made at926whether any bubbles (or other deformities) are detected via output of the bubble detection module306. In accordance with another embodiment contemplated herein, the pad tape replacement module100may be positioned on a side of the CMP tool300, i.e., on a side of the platen cleaning process module302, as opposed to the top of the platen cleaning process module302. In such an embodiment, the skilled artisan will appreciate that the pad bubble detection module306may be positioned on the same side as that of the pad tape replacement module100for performance of bubble detection as discussed above.

Upon a determination that a bubble or other deformity is detected, operations proceed to928, whereupon the platen carrier402is rotated and the tearer tool504is engage at930. Operations then return to922and the pad tape106is rolled over the next platen126A,126B,126C, or126D. Upon a determination at926that no bubbles or other deformities are detected, operations proceed to932. At932, a determination is made whether another platen126A,126B,126C, or126D remains for pad replacement. Upon a positive determination, operations proceed to934, whereupon the platen carrier402is rotated and flow returns to922for continued operation.

When it is determined that no other platens126A,126B,126C, or126D remain for pad replacement, operations progress to936, whereupon the pad tape replacement module100is retracted/moved from above the CMP process tool300. CMP processing by the CMP process tool300then resumes at938.

In accordance with a first embodiment, there is provided a method for in-situ chemical mechanical polishing (CMP) pad replacement in an associated CMP tool. The method includes receiving, at a controller including a processor in communication with memory, an output from a pad wear detection module corresponding to a state of a CMP pad on a first platen of a plurality of platens of a platen carrier. The method further comprises positioning a pad tape replacement module proximate to the first platen responsive to an output of the pad wear detection module, the pad tape replacement module including a pad tape supply containing a plurality of pads. The method further includes rotating the platen carrier toward a pad tearer tool movably positioned adjacent to the platen carrier, and engaging the pad tearer tool to remove the CMP pad on the first platen. Furthermore, the method includes the step of rolling, via a pressure roller of the pad tape replacement module, a pad disposed in the pad tape supply onto a second platen of the plurality of platens of the platen carrier.

In accordance with a second embodiment, there is provided chemical mechanical polishing (CMP) pad replacement system. The system includes a pad tape replacement module configured to removably engage a platen of an associated CMP processing tool, and a CMP tool controller in communication with the pad tape replacement module and the associated CMP processing tool. The pad tape replacement module includes a pad tape supply roller that stores pad tape, at least one backing removal roller, a backing recycle roller, a pressure roller, and a pad tape recycle roller. The CMP tool controller includes a processor in communication with memory, with the memory storing instructions that are executed by the processor and cause the processor to receive an output from a pad wear detection module corresponding to a state of a CMP pad on a first platen of a plurality of platens of a platen carrier, as well as to position the pad tape replacement module proximate to the first platen responsive to an output of the pad wear detection module. Furthermore, the instructions cause the processor to rotate the platen carrier toward a pad tearer tool movably positioned adjacent to the platen carrier, and to engage the pad tearer tool to remove the CMP pad on the first platen; and roll, via the pressure roller, a pad disposed in the pad tape onto a second platen of the plurality of platens of the platen carrier.

In accordance with a third embodiment, there is provided chemical mechanical polishing (CMP) device. The CMP device includes a platen carrier positioned within an interior chamber of the CMP device and comprising a plurality of independently rotatable platens. The device further includes a plurality of polishing pads correspondingly affixed to each of the independently rotatable platens, and a rotation motor coupled to a central shaft of the platen carrier and configured to rotate the platen carrier. In addition, the device includes a platen rotation motor removably coupled to at least one platen, the platen rotation motor configured to rotate the at least one platen during chemical mechanical polishing operation.

Some portions of the detailed description herein are presented in terms of algorithms and symbolic representations of operations on data bits performed by conventional computer components, including a central processing unit (CPU), memory storage devices for the CPU, and connected display devices. These algorithmic descriptions and representations are the means used by those skilled in the data processing arts to effectively convey the substance of their work to others skilled in the art. An algorithm is generally perceived as a self-consistent sequence of steps leading to a desired result. The steps are those requiring physical manipulations 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. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.

It should be understood, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise, as apparent from the discussion herein, it is appreciated that throughout the description, discussions utilizing terms such as “processing” or “computing” or “calculating” or “determining” or “displaying” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.

The exemplary embodiment also relates to an apparatus for performing the operations discussed herein. This apparatus may be specially constructed for the required purposes, or it may comprise a general-purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readable storage medium, such as, but is not limited to, any type of disk including floppy disks, optical disks, CD-ROMs, and magnetic-optical disks, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards, or any type of media suitable for storing electronic instructions, and each coupled to a computer system bus.

The algorithms and displays presented herein are not inherently related to any particular computer or other apparatus. Various general-purpose systems may be used with programs in accordance with the teachings herein, or it may prove convenient to construct more specialized apparatus to perform the methods described herein. The structure for a variety of these systems is apparent from the description above. In addition, the exemplary embodiment is not described with reference to any particular programming language. It will be appreciated that a variety of programming languages may be used to implement the teachings of the exemplary embodiment as described herein.

A machine-readable medium includes any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer). For instance, a machine-readable medium includes read only memory (“ROM”); random access memory (“RAM”); magnetic disk storage media; optical storage media; flash memory devices; and electrical, optical, acoustical or other form of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.), just to mention a few examples.

The methods illustrated throughout the specification, may be implemented in a computer program product that may be executed on a computer. The computer program product may comprise a non-transitory computer-readable recording medium on which a control program is recorded, such as a disk, hard drive, or the like. Common forms of non-transitory computer-readable media include, for example, floppy disks, flexible disks, hard disks, magnetic tape, or any other magnetic storage medium, CD-ROM, DVD, or any other optical medium, a RAM, a PROM, an EPROM, a FLASH-EPROM, or other memory chip or cartridge, or any other tangible medium from which a computer can read and use.

Alternatively, the method may be implemented in transitory media, such as a transmittable carrier wave in which the control program is embodied as a data signal using transmission media, such as acoustic or light waves, such as those generated during radio wave and infrared data communications, and the like.

The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.