Patent ID: 12195866

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.

In some cases, a plating tool (e.g., a tool that is used to plate semiconductor wafers) may include a plating membrane. The plating membrane may be used to reduce and/or prevent additives in a plating solution from reaching an anode. While additives may be used to improve the plating process, additives that reach the anode may react with the anode and cause the formation of undesirable byproducts in the plating solution. The plating membrane may include a filter that permits the passage of plating material but prevents passage of additives. Accordingly, the filter of the plating membrane may be used to reduce and/or prevent additives from reaching the anode while still permitting plating material from the anode to pass through the plating membrane and plate the wafer.

However, the plating membrane may cause disruptions in the flow of the plating solution from a nozzle that directs the flow of the plating solution toward the wafer. For example, the plating membrane may cause turbulence in the flow, which can decrease the ability of the nozzle to direct the flow of the plating solution toward the wafer. As a result, the plating solution may be unable to penetrate into structures (particularly, deep and/or high aspect-ratio structures) in and/or on the wafer, which can cause voids in these structures. These voids can cause decreased conductivity, decreased reliability, and/or decreases in other electrical performance characteristics.

Some implementations described herein provide a plating membrane that includes a frame having an inner wall that is angled outward from a plating tool nozzle. The outward angle of the inner wall relative to the nozzle directs a flow of plating solution from the nozzle in a manner that increases uniformity of the flow of the plating solution toward a wafer, reduces the amount of plating solution that is redirected inward toward the center of the plating membrane, reduces plating material voids in trenches, vias, interconnects, and/or other structures in and/or on the wafer.

FIGS.1A and1Bare diagrams of an example plating membrane100described herein.FIG.1Aillustrates a perspective view of plating membrane100.FIG.1Billustrates a cross-sectional view along line AA shown inFIG.1A. In some implementations, plating membrane100is for use in a plating tool, such as a plating tool for plating wafers (e.g., semiconductor wafers, insulating wafers, and/or the like). The plating tool may include various types of plating tools, such as a copper electroplating tool, an aluminum electroplating tool, a nickel electroplating tool, a tin electroplating tool, a compound material or alloy (e.g., tin-silver, tin-lead, and/or the like) electroplating tool, and/or an electroplating tool for one or more other types of conductive materials, metals, and/or the like. Plating membrane100may be used to permit passage of plating material from an anode of the plating tool such that the plating material may reach and plate a wafer, while reducing and/or preventing passage of plating solution additives that would otherwise reach the anode and cause the formation of byproducts and/or contaminants.

As shown inFIG.1A, plating membrane100may include a support structure102to hold or otherwise support a filter104and a frame106. In some implementations, support structure102includes a plurality of support members102aand one or more support rings102b. However, the configuration of support structure102as illustrated inFIG.1Ais an example, and support structure102may constructed in other various configurations to support filter104and/or frame106.

As further shown inFIG.1A, in some implementations, plating membrane100may be circular (or substantially circular) shaped, and a nozzle108of the plating tool may be located at the center (or substantially at the center) of plating membrane100to evenly direct and/or guide a flow of plating solution from nozzle108about the circumference of plating membrane100. In these cases, support members102amay extend radially outward from a center of plating membrane100and/or from nozzle108. Support members102amay attach or connect to nozzle108at a first end to secure plating membrane100in place. Support members102amay also attach or connect to, or may be integrated with, frame106at a second opposing end to hold and/or provide support to frame106. Support members102amay be located at various locations about the circumference of plating membrane100. Support members102amay be evenly and/or unevenly spaced about the circumference of plating membrane100. Support ring(s)102bmay be attached to or integrated with support members102ato provide support and/or rigidity to support members102aagainst rotational forces applied to plating membrane100and to reduce bending of support members102a.

In some implementations, plating membrane100may be other various shapes, such as oval shaped, square shaped, rectangular shaped, non-uniform shaped, non-standard shaped, and/or the like, and support structure102may be configured accordingly to support filter104and frame106. In some implementations, support structure may be integrated with nozzle108such that plating membrane100and nozzle108are a single part or component. In some implementations, support structure102may be referred to as a skeleton, a web, or another type of structure that is capable of supporting filter104and/or frame106.

Filter104includes a semi-permeable membrane or another type of filter that is capable of permitting the flow of the plating material through filter104while filtering, reducing, and/or preventing the flow of plating solution additives through filter104. Filter104may be positioned such that filter104is capable of filtering plating solution that flows through the area between nozzle108and frame106. In some implementations, filter104is attached to a bottom side or underside of support structure102. In some implementations, filter104is attached to a top side or upper side of support structure102. In some implementations, filter104includes a plurality of filter elements positioned in open areas of support structure102formed between support members102aand/or support ring(s)102b. In some implementations, filter104is attached to a bottom side or underside of support structure102. In some implementations, filter104is integrated with support structure102such that filter104and support structure102are a single and/or unified part.

Frame106may be circular or substantially circular (or ring) shaped so as to provide an even flow path of plating material dispensed from nozzle108. Frame106may further provide support and/or rigidity to plating membrane100, which may increase the strength of plating membrane100. Further, frame106may provide an attachment point for plating membrane100to be attached or connected to a wall of the plating tool to prevent movement of plating membrane100.

Plating membrane100, and/or support structure102, filter104, and frame106included therein, may be formed of various materials. The material(s) of plating membrane100, and/or support structure102, filter104, and frame106included therein, may be selected so as to provide strength and and/or rigidity to plating membrane100, to meet and/or increase reliability and longevity requirements, to reduce and/or minimize negative or undesirable reactions with intended use plating materials and/or additives, and/or the like.

As shown in the cross-sectional view inFIG.1B, frame106may include an inner wall112. If frame106is circular or substantially circular, inner wall112may extend along the circumference (e.g., the inner circumference) of frame106. As further shown inFIG.1B, inner wall112may be angled. In particular, inner wall112may be angled outward and away from the center of plating membrane100and/or nozzle108. The outward angle away from the center of plating membrane100and/or nozzle108may direct the flow of plating solution from nozzle108radially outward from the center of plating membrane100and/or nozzle108and toward a wafer that is to be plated. Inner wall112may be angled outward and away from the center of plating membrane100and/or nozzle108along the circumference (e.g., the inner circumference) of frame106in a uniform manner (e.g., at a substantially uniform angle) to increase the uniformity of flow of plating solution radially outward from the center of plating membrane100and/or nozzle108, and to increase the uniformity of flow of plating solution toward a wafer that is to be plated. Moreover, inner wall112may be angled outward and away from the center of plating membrane100and/or nozzle108to reduce the amount of plating solution that is redirected by inner wall112inward toward the center of plating membrane100and/or nozzle108. In some implementations, inner wall112is angled outward and away from the center of plating membrane100and/or nozzle108to eliminate the redirection of plating solution by inner wall112inward toward the center of plating membrane100and/or nozzle108.

In some implementations, the outward angle of inner wall112may be defined or identified from various reference points of plating membrane100. For example, the angle of inner wall112may be defined relative to the center of plating membrane100. In these cases, the outward angle of inner wall112may be greater than 0° and less than 90°. As another example, and as illustrated in a closeup view110inFIG.1B, the outward angle of inner wall112may be defined based on an angle114between an upper (or top) surface116of frame106. In these cases, angle114may be greater than 90° and less than 180°. As another example, and as illustrated in closeup view110, the outward angle of inner wall112may be defined based on an angle118between a lower (or bottom) surface120of frame106. In these cases, angle118may be greater than 0° and less than 90°.

In this way, plating membrane100includes frame106having inner wall112that is angled outward and away from a nozzle108and/or a center of plating membrane100. The outward angle of inner wall112relative to nozzle108directs a flow of plating solution from nozzle108in a manner that increases uniformity of the flow of the plating solution toward a wafer, reduces the amount of plating solution that is redirected inward toward the center of plating membrane100, and/or reduces plating material voids in trenches, vias, interconnects, and/or other structures in and/or on the wafer.

As indicated above,FIGS.1A and1Bare provided as one or more examples. Other examples may differ from what is described with regard toFIGS.1A and1B.

FIG.2illustrates an example flow pattern200of a plating solution using the example plating membrane100illustrated and described above in connection withFIGS.1A and1B. In some implementations, a similar uniformity of flow may be achieved using other example plating membranes having a frame with inner wall angled outward and/or away from the centers of the other example plating membranes.

Example flow pattern200illustrates an example flow of plating solution from a nozzle of a plating tool toward a wafer that is to be plated. As shown inFIG.2, the flow of plating solution may include an inner portion202and an outer portion204. Inner portion202may be directed toward the wafer without interacting with inner wall112of frame106of plating membrane100. Conversely, outer portion204may be directed toward the wafer by inner wall112.

As further shown inFIG.2, the outward angle of inner wall112away from the center of plating membrane100increases the uniformity of flow of outer portion204radially outward from the center of plating membrane100. Moreover, as further shown inFIG.2, the outward angle of inner wall112away from the center of plating membrane100increases the uniformity of flow of inner portion202and outer portion204toward a wafer that is to be plated. In particular, the outward angle of inner wall112away from the center of plating membrane100increases the uniformity of flow of inner portion202by reducing and/or eliminating the amount of plating solution that is redirected by inner wall112inward toward the center of plating membrane100.

As indicated above,FIG.2is provided as an example. Other examples may differ from what is described with regard toFIG.2.

FIG.3illustrates an example portion300a wafer including a plurality of plated structures302that were plated using the example plating membrane100illustrated and described above in connection withFIGS.1A and1B. In some implementations, a similar uniformity of plating may be achieved using other example plating membranes having a frame with inner wall angled outward and/or away from the centers of the other example plating membranes.

As shown inFIG.3, plated structures302are evenly colored and have a uniform contrast in portion300. This indicates that plated structures302are substantially absent of voids. In some implementations, the outward angle of inner wall112away from the center of plating membrane100permits plating solution to travel deep into plated structures302to deposit plating material within plated structures302such that voids (e.g., pockets devoid of plating material) in plated structures302do not occur. In some implementations, plated structures302include trenches, vias, interconnects, and/or other structures formed on and/or in portion300of the wafer. In some implementations, plated structures302includes high aspect ratio trenches, which may include trenches having an aspect ratio greater than 5 (e.g., trenches having a depth or height greater than 5 times the width of the trenches).

As indicated above,FIG.3is provided as an example. Other examples may differ from what is described with regard toFIG.3.

FIGS.4A and4Bare diagrams of an example environment400in which systems and/or methods described herein may be implemented. As shown inFIGS.4A and4B, environment400may include a plating tool402, a plating system430, and/or the like. Devices and/or systems of environment400may interconnect via wired connections, wireless connections, or a combination of wired and wireless connections.

A plating tool402may include a tool that plates a wafer404(e.g., a semiconductor wafer, an insulating wafer, and/or another type of wafer). As shown inFIG.4A, a plating tool402includes a wafer holder406, a plating bath408, a power supply416, an anode418, a plating membrane420, a nozzle422, one or more return lines424, a pump426, and a controller428. Wafer holder406is capable of holding wafer404during a plating process. In some implementations, wafer holder406may lower wafer404into plating bath408, which may be a chamber that is filled with a plating solution410. Plating solution410may be a liquid containing plating material412and one or more additives414. Power supply416may be a direct current (DC) power supply that is connected to anode418and wafer404via leads and may apply a voltage across anode418and wafer404to cause anode418to be oxidized and to release plating material412into plating solution410.

Plating material412and anode418include various types of conductive materials, metals, and/or the like. For example, plating material412and anode418may include copper, aluminum, nickel, tin, tin-lead, tin-silver, and/or another type of material. Additives414include various types of levelers, brighteners or accelerators, inhibitors, suppressors, enhancers, and/or other types of organic and/or inorganic additives that may be used to increase or decrease deposition rates of plating material412on wafer404, reduce surface roughness of plating material412deposited onto wafer404, and/or the like.

Plating membrane420may include plating membrane100illustrated and described above in connection withFIGS.1A and1Band/or another plating membrane including a frame with an inner wall angled away from a center of the plating membrane. Plating membrane420may reduce and/or prevent additives414from traveling through plating solution410and reaching anode418while still permitting plating material412released from anode418to travel toward wafer404.

Nozzle422includes an elongated cylindrical structure or another type of elongated structure to direct the flow of plating solution410toward wafer404. In some implementations, nozzle422may dispense plating solution410provided via return line(s)424. In this way, plating solution410may be circulated through plating bath408and reused. Pump426includes any one of various types of pumps that are capable of pumping a liquid from return line(s)424and through nozzle422.

Controller428may include a processor, a computer (e.g., a desktop computer, a laptop computer, a tablet computer, a server, and/or the like), and/or another device capable of controlling various devices and/or components of plating tool402. For example, controller428may be connected to power supply416, and is capable of causing power supply416to apply a voltage across anode418and wafer404, is capable of causing power supply416to stop applying a voltage across anode418and wafer404, is capable of changing the voltage applied by power supply416, and/or the like.

As another example, controller428may be connected to pump426and may cause pump426to pump plating solution410from return line(s)424to nozzle422, may cause pump426to stop pumping plating solution410, may adjust the speed or rate at which plating solution410is pumped through nozzle422, and/or the like. As another example, controller428may be connected to wafer holder406and may cause wafer holder406to lower wafer404into plating bath408, may case wafer holder406to rotate wafer404while wafer404is at least partially submerged in plating bath408(e.g., to increase the coverage and uniformity of plating material412on wafer404), may cause wafer holder406to raise wafer404out of plating bath408, and/or the like.

As shown inFIG.4B, plating system430includes a plurality of plating tools402. Each plating tool402may be configured to plate wafer404with a particular plating material412. In some implementations, each plating tool402is configured to plate wafer404with a different plating material412. For example, a first plating tool402may be configured to plate wafer404with copper, a second plating tool402may be configured to plate wafer404with nickel, and so on. In some implementations, one or more plating tools402may be configured to plate wafers with the same plating material412to increase the throughput of plating system430.

In some implementations, each plating tool402may include devices and/or components illustrated inFIG.4A. In some implementations, the plating tools402included in plating system430may share one or more of the devices and/or components illustrated inFIG.4A. For example, plating system430may include a power supply416that applies voltages to a plurality of plating tools402included in plating system430. As another example, plating system430includes a controller428that controls a plurality of plating tools402and/or wafer handler432.

As further shown inFIG.4B, plating system430includes a wafer handler432. Wafer handler432may include a robotic arm or another type of device that is capable of handling wafer404, capable of transporting wafer404between a wafer lot holder to a plating tool402, capable of transporting wafer404from one plating tool402to another plating tool402, and/or the like.

The number and arrangement of devices and networks shown inFIGS.4A and4Bare provided as one or more examples. In practice, there may be additional devices and/or systems, fewer devices and/or systems, different devices and/or systems, or differently arranged devices and/or systems than those shown inFIGS.4A and/or4B. Furthermore, two or more devices and/or systems shown inFIGS.4A and/or4Bmay be implemented within a single device and/or system, or a single device and/or system shown inFIGS.4A and/or4Bmay be implemented as multiple, distributed devices and/or systems. Additionally, or alternatively, a set of devices and/or systems (e.g., one or more devices, one or more systems, and/or the like) of environment400may perform one or more functions described as being performed by another set of devices and/or systems of environment400.

FIG.5is a diagram of example components of a device500. Device500may correspond to plating tool402, controller428, wafer handler432, one or more devices included in plating system430, and/or the like. In some implementations, plating tool402, controller428, wafer handler432, one or more devices included in plating system430, and/or the like may include one or more devices500and/or one or more components of device500. As shown inFIG.5, device500may include a bus510, a processor520, a memory530, a storage component540, an input component550, an output component560, and a communication interface570.

Bus510includes a component that permits communication among multiple components of device500. Processor520is implemented in hardware, firmware, and/or a combination of hardware and software. Processor520is a central processing unit (CPU), a graphics processing unit (GPU), an accelerated processing unit (APU), a microprocessor, a microcontroller, a digital signal processor (DSP), a field-programmable gate array (FPGA), an application-specific integrated circuit (ASIC), or another type of processing component. In some implementations, processor520includes one or more processors capable of being programmed to perform a function. Memory530includes a random access memory (RAM), a read only memory (ROM), and/or another type of dynamic or static storage device (e.g., a flash memory, a magnetic memory, and/or an optical memory) that stores information and/or instructions for use by processor520.

Storage component540stores information and/or software related to the operation and use of device500. For example, storage component540may include a hard disk (e.g., a magnetic disk, an optical disk, and/or a magneto-optic disk), a solid state drive (SSD), a compact disc (CD), a digital versatile disc (DVD), a floppy disk, a cartridge, a magnetic tape, and/or another type of non-transitory computer-readable medium, along with a corresponding drive.

Input component550includes a component that permits device500to receive information, such as via user input (e.g., a touch screen display, a keyboard, a keypad, a mouse, a button, a switch, and/or a microphone). Additionally, or alternatively, input component HW50 may include a component for determining location (e.g., a global positioning system (GPS) component) and/or a sensor (e.g., an accelerometer, a gyroscope, an actuator, another type of positional or environmental sensor, and/or the like). Output component560includes a component that provides output information from device500(via, e.g., a display, a speaker, a haptic feedback component, an audio or visual indicator, and/or the like).

Communication interface570includes a transceiver-like component (e.g., a transceiver, a separate receiver, a separate transmitter, and/or the like) that enables device500to communicate with other devices, such as via a wired connection, a wireless connection, or a combination of wired and wireless connections. Communication interface570may permit device500to receive information from another device and/or provide information to another device. For example, communication interface570may include an Ethernet interface, an optical interface, a coaxial interface, an infrared interface, a radio frequency (RF) interface, a universal serial bus (USB) interface, a Wi-Fi interface, a cellular network interface, and/or the like.

Device500may perform one or more processes described herein. Device500may perform these processes based on processor520executing software instructions stored by a non-transitory computer-readable medium, such as memory530and/or storage component540. As used herein, the term “computer-readable medium” refers to a non-transitory memory device. A memory device includes memory space within a single physical storage device or memory space spread across multiple physical storage devices.

Software instructions may be read into memory530and/or storage component540from another computer-readable medium or from another device via communication interface570. When executed, software instructions stored in memory530and/or storage component540may cause processor520to perform one or more processes described herein. Additionally, or alternatively, hardware circuitry may be used in place of or in combination with software instructions to perform one or more processes described herein. Thus, implementations described herein are not limited to any specific combination of hardware circuitry and software.

The number and arrangement of components shown inFIG.5are provided as an example. In practice, device500may include additional components, fewer components, different components, or differently arranged components than those shown inFIG.5. Additionally, or alternatively, a set of components (e.g., one or more components) of device500may perform one or more functions described as being performed by another set of components of device500.

FIG.6is a flowchart of an example process600for plating a wafer. In some implementations, one or more process blocks ofFIG.6may be performed by a controller of a plating tool (e.g., controller428, device500, and/or the like). In some implementations, one or more process blocks ofFIG.6may be performed by another device or a group of devices separate from or including the controller, such as a power supply (e.g., power supply416), a pump (e.g., pump426), a wafer handler (e.g., wafer handler432), and/or the like.

As shown inFIG.6, process600may include causing a power supply to apply a voltage to an anode formed of a plating material (block610). For example, the controller (e.g., using processor520, memory530, storage component540, input component550, output component560, communication interface570, and/or the like) may cause a power supply (e.g., power supply416) to apply a voltage to an anode (e.g., anode418) formed of a plating material (e.g., plating material412), as described above.

As further shown inFIG.6, process600may include causing, using a plating membrane, a plating solution including the plating material to be directed toward a wafer, wherein the plating membrane includes a frame having an inner wall that is angled outward from a nozzle (block620). For example, the controller (e.g., using processor520, memory530, storage component540, input component550, output component560, communication interface570, and/or the like) may cause, using a plating membrane (e.g., plating membrane100, plating membrane420, and/or the like), a plating solution (e.g., plating solution410) including the plating material to be directed toward a wafer (e.g., wafer404), as described above. In some implementations, the plating membrane includes a frame (e.g., frame106) having an inner wall (e.g., inner wall112) that is angled outward from a nozzle (e.g., nozzle108, nozzle422, and/or the like).

Process600may include additional implementations, such as any single implementation or any combination of implementations described below and/or in connection with one or more other processes described elsewhere herein.

In a first implementation, the voltage applied to the anode causes oxidation of the anode, which causes plating material ions to be released from the anode. In a second implementation, alone or in combination with the first implementation, causing the plating solution to be directed toward the wafer includes causing a pump (e.g., pump426) to cause the plating solution to flow through the nozzle and toward the wafer. In a third implementation, alone or in combination with one or more if the first or second implementations, the outward angle of the inner wall of the plating membrane directs the flow of plating solution from the nozzle in a manner that increases uniformity of the flow of the plating solution toward the wafer.

In a fourth implementation, alone or in combination with one or more if the first through third implementations, the outward angle of the inner wall of the plating membrane reduces the amount of plating solution that is redirected inward toward the center of the plating membrane. In a fifth implementation, alone or in combination with one or more if the first through fourth implementations, the outward angle of the inner wall of the plating membrane reduces plating material voids in structures (e.g., plated structures302) of the wafer (e.g., high aspect ratio trenches). In a sixth implementation, alone or in combination with one or more if the first through fifth implementations, process600includes causing a wafer holder (e.g., wafer holder406) to rotate the wafer while the wafer is at least partially submerged in the plating solution.

AlthoughFIG.6shows example blocks of process600, in some implementations, process600may include additional blocks, fewer blocks, different blocks, or differently arranged blocks than those depicted inFIG.6. Additionally, or alternatively, two or more of the blocks of process600may be performed in parallel.

In this way, a plating membrane (e.g., plating membrane100, plating membrane420, and/or the like) includes a frame (e.g., frame106) having an inner wall (e.g., inner wall112, and/or the like) that is angled outward from a plating tool nozzle (e.g., nozzle108, nozzle422, and/or the like). The outward angle of the inner wall relative to the nozzle directs a flow of plating solution (e.g., plating solution410and/or the like) from the nozzle in a manner that increases uniformity of the flow of the plating solution toward a wafer (e.g., wafer404and/or the like), reduces the amount of plating solution that is redirected inward toward the center of the plating membrane, reduces plating material voids in various types of structures (e.g., plated structures302) in and/or on the wafer, such as trenches, vias, interconnects, and/or the like.

As described in greater detail above, some implementations described herein provide a plating membrane. The plating membrane includes a support structure extending radially outward from a nozzle that is to direct a flow of a plating solution toward a wafer. The plating membrane includes a frame, supported by the support structure, having an inner wall that is angled outward from the nozzle.

As described in greater detail above, some implementations described herein provide a plating membrane. The plating membrane includes plating solution toward a wafer. The plating membrane includes a frame, supported by the support structure, having an inner wall that is angled radially outward from the nozzle to direct the flow of the plating solution radially outward from the nozzle and to reduce an amount of the plating solution that is redirected inward toward a center of the plating membrane.

As described in greater detail above, some implementations described herein provide a plating tool. The plating tool includes a nozzle and a plating membrane. The nozzle is positioned substantially at the center of the plating membrane and is to direct a flow of a plating solution in a plating bath toward a wafer. The plating membrane includes a support structure extending radially outward from the nozzle. The plating membrane includes a frame, attached to and supported by the support structure, having an inner wall that is angled away from a center of the plating membrane.

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.