Patent ID: 12257612

DETAILED DESCRIPTION

It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of the disclosure. Specific embodiments or 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, dimensions of elements are not limited to the disclosed range or values, but may depend upon process conditions and/or desired properties of the device. Moreover, 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 interposing the first and second features, such that the first and second features may not be in direct contact. Various features may be arbitrarily drawn in different scales for simplicity and clarity.

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 device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly. In addition, the term “made of” may mean either “comprising” or “consisting of.”

The present disclosure relates to a contaminant particle removing assembly that is designed to remove contaminants from a cup or shroud used in a wet process apparatus to improve cleanliness of a semiconductor wafer manufacturing process. In some embodiments, the wet process apparatus includes a photo resist coater, a photo resist developer, a wet etching apparatus, and a wet cleaning apparatus, in which a solution is applied to the surface of rotating wafer.

FIGS.1A and1Bschematically illustrate methods of cleaning a cup of a wet process apparatus used for a semiconductor wafer manufacturing process, which includes a cup960and a particle removing assembly1000, according to embodiments of the disclosure. A dispensing nozzle900may be used to eject a processing solution onto the wafer800, while the wafer chuck930rotates the wafer800. In some embodiments, the wafer chuck930holds a peripheral edge of the wafer800as shown inFIGS.1A and1B. In some embodiments, the processing solution is photo resist, developer, wet etchant or wet cleaning solution. During a resist coating process, a resist developing process, a wet etching process and/or a wet cleaning process, most of the contaminant material849(e.g., a photo resist, etching by-products, particles, etc.), as shown inFIG.1A, which was on or adhered to the surface of the wafer800, is removed from the wafer800, and is directed to a drain of the apparatus. However, some contaminant material850may be deposited on an unreachable dead zone999of the cup960and adhere to the inner surface on the curved portion964of the cup960. The unreachable dead zone999of the cup960is an area or a zone not reachable by conventional cup cleaning devices.

In some embodiments, the contaminant material850is a photo resist, an organic bottom antireflective coating material, a top coat material, a developer such as tetramethylammonium hydroxide (TMAH) or an organic solvent. In other embodiments, the contaminant material includes process chemicals, such as an acid (e.g., HF, BHF, HCl, H2SO4, HNO3, H3PO4, etc); an alkaline (e.g., KOH, etc.); any solutions used in the semiconductor manufacturing process; or mixtures thereof.

As shown inFIG.1B, in some embodiments, various types of manual cleaning devices995may be used to clean the inner surface of the curved portion of the cup. However, due to various sizes and configurations of the manual cleaning devices995, it may be insufficient to completely remove the contaminant materials850adhered to the curved portion964of the cup960. In some embodiments, due to an inclined/curved shape, the contaminant material850adhered to the curved portion964may be more likely to fall back on the wafer800. According to an embodiment of the disclosure, a particle removing assembly1000as shown inFIGS.2A and2Bis provided for cleaning the cup. The particle removing assembly1000is configured to remove contaminant particles from locations where it is difficult or near impossible to reach by the manual cleaning devices995, such as the unreachable dead zone999of the cup.

As shown inFIGS.2A and2B, in an embodiment according to this disclosure, the particle removing assembly1000includes a flexible ejecting member1100from which pressurized cleaning material1080is introduced onto the unreachable dead zone999in the curved portion964of the cup960to remove the contaminant material850from the unreachable dead zone999of the cup960. The flexible ejecting member1100, as shown inFIG.2B, includes an elongated tube unit1131and an elongated tube assembly1130. The elongated tube assembly1130includes two or more elongated tube units1131. The elongated tube unit1131includes a front tip1134, and a cleaning tip adapter1136configured to attach the front tip to an elongated tube body1132. The flexible ejecting member1100, according to embodiments of the disclosure, is made of PE (polyethylene) or PTFE (polytetrafluoroethylene). In some embodiments, the flexible ejecting member1100is made of an elastic material to reach and clean the unreachable dead zone999of the cup960. Examples of the elastic material forming the elongated tube assembly1130include crosslinked rubber materials such as silicone rubber, chloroprene rubber, EPDM, NBR, natural rubber, and fluororubber. In some embodiments, some examples of the silicone rubber include (meth) acryloyloxy group-containing polysiloxane, vinyl polysiloxane, mercaptoalkyl group-containing polysiloxane, and the like.

In some embodiments, the front tip1134is detachable from the elongated tube body1132. The cleaning tip adapter1136connects the front tip1134and the elongated tube body1132together. In some embodiments, the elongated tube unit1131is monolithic unit including the front tip1134fixedly attached or integrated with the elongated tube body1132. In some embodiments, the front tip1134of the elongated tube units1131has a diameter in a range of about 2.9 mm to about 5.0 mm. In some embodiments, the elongated tube assembly1130include about 3 to about 9 elongated tube units1131depending on the design of the elongated tube assembly1130and the cleaning needs associated with the unreachable dead zone999in various embodiments. In some embodiments, the number of elongated tubes is greater than 9 or less than 3.

As shown inFIG.2B, the flexible ejecting member1100includes the front tip1134, which includes front openings1135and/or lateral openings1137that are configured to eject the pressurized cleaning material. In some embodiments, the lateral openings1137have a diameter in a range of between about 0.1 mm and about 2 mm. In some embodiments, no front opening is provided (closed) in the front tip1134, and in other embodiments, no lateral opening is provided (closed) in the front tip1134. In some embodiments, the flexible ejecting member1100includes an L-shaped front tip1139. In some embodiments, the flexible ejecting member1100includes both the straight shape front tip and the L-shape front tip, which are, for example, alternately arranged.

In some embodiments, the front tip1134and the cleaning tip adapter1136may be fixedly attached or integrated with the elongated tube body1132. In alternative embodiments, the front tip1134and the cleaning tip adapter1136may be detachable from the elongated tube body1132.

FIG.3schematically shows a flexible ejecting member1100including various front tips1134according to embodiments of the disclosure. The cross-section of the front tip1134is not particularly limited. For example, in an embodiment, the shape of cross-section of the front tip1134is a circle, an ellipse, a triangle, and a regular or irregular convex polygon. In some embodiments, as shown in (a) ofFIG.3, the front tip1134includes a frustoconical shape. In other words, the front tip1134has a longitudinally tapering shape to provide a pressurized ejection of the fluid. The length of the one or more elongated tubes is not particularly limited. In some embodiments, a sleeve1138is slideably attached with the lateral openings1137of the flexible ejecting member1100. In some embodiments, the sleeve1138is slideably disposed within the front tip1134. In some embodiments, the flexible ejecting member1100has an adjustable orifice having a variable diameter of the front openings or the lateral openings1137.

Referring back toFIGS.2A and2B, a user selects the front tip for the cleaning need and attaches the front tip to the elongated tube using the cleaning tip adapter. Then, the pressurized cleaning material1080is fluidly connected with and introduced into the flexible ejecting member1100. The flexible ejecting member1100can then be introduced, by the user, into the unreachable dead zone999of the cup960. The user moves the front openings or the lateral openings1137(shown inFIG.2B) of the flexible ejecting member1100towards the contaminant material850located at the unreachable dead zone999in the curved portion964of the cup960. Finally, the user may open a valve connecting the pressurized cleaning material1080to the flexible ejecting member1100, and removes the contaminant material850from the unreachable dead zone999in the curved portion964of the cup960.

In some embodiments, as shown inFIG.4, an automatic cup-cleaning operation1500includes a cleaning operation1520, a rinse operation1540(as shown inFIG.7A), and a drying operation1560(as shown inFIG.7B). The automatic cup-cleaning operation1500can be started automatically or manually by an operator's instruction. In some embodiments, the automatic cup-cleaning operation1500can be triggered by a pre-determined fixed time interval, such as 1 minute, 2 minutes, 5 minutes, 10 minutes, or the combination thereof, or after every N-wafers processed where N is 25, 50, 100 or any suitable number.

In some embodiments of the present disclosure, instead of or in addition to the manual cleaning as explained above, an automatic cleaning operation is employed.FIG.4shows a schematic illustration of an automatic cup-cleaning operation in accordance with some embodiments of the disclosure. Referring toFIG.4, during the cleaning operation1520, the particle removing assembly1000includes a dispensing nozzle1210for cup cleaning. In some embodiments, the dispensing nozzle1210is coupled to a moving and supporting mechanism and is connected to supporting devices such as a pump, a compressor, and connecting lines from the pump or the compressor to the dispensing nozzle1210. In some embodiments, the dispensing nozzle1210is configured to eject the pressurized cleaning material1080with an incident angle1299between the pressurized cleaning material1080and an upper surface of a dummy disk1230to remove the contaminant material850from the unreachable dead zone999in the curved portion964of the cup960. The particle removing assembly1000is configured to adjust the incident angle1299of the pressurized cleaning material1080such that the pressurized cleaning material1080is directed towards the unreachable dead zone999of the cup960by centrifugal force due to the rotation of the dummy disk1230. When the pressurized cleaning material1080spun out by the dummy disk1230reaches the unreachable dead zone999of the cup960, the pressurized cleaning material1080removes the contaminant material850at the unreachable dead zone999of the cup960.

In some embodiments, as also shown inFIGS.5A and5B, the particle removing assembly1000is configured to adjust an incident point1295, along a radius line on the surface of the dummy disk. In some embodiments, the incident point is the center of the dummy disk, and in other embodiments, the incident point is offset from the center of the disk by, for example 1-15 cm. In some embodiments, the particle removing assembly1000is configured to adjust a first reflective angle1298corresponding to the incident angle1299of the pressurized cleaning material1080. In some embodiments, the dummy disk1230is a dummy wafer. In some embodiments, one or more dispensing nozzles1211may be provided to eject the pressurized cleaning material1080. The dummy disk1230is disposed on the wafer chuck, and washes the cup960without detaching the cup from the semiconductor apparatus.

When a cup cleaning process is started, the dummy disk1230is placed on the wafer chuck930located within the cup960. As shown inFIG.4, the dispensing nozzle1210ejects the pressurized cleaning material1080onto the dummy disk1230, while the wafer chuck930rotates the dummy disk1230. The pressurized cleaning material1080on the dummy disk1230is reflected with the first reflective angle1298, as shown inFIGS.5A and5B, of the pressurized cleaning material1080to the unreachable dead zone999of the cup960by a centrifugal force due to the rotation of the dummy disk1230. Then, the pressurized cleaning material1080reflected by the dummy disk1230removes the contaminant material850at the unreachable dead zone999of the cup960.

In some embodiments, the automatic cup-cleaning operation1500replaces the manual cleaning process. In such embodiments, the automatic cup-cleaning operation1500includes configurable parameters that include one or more of a type of fluids, spin speed, flow rate or pressure, a liquid temperature, a cup height with respect to the surface of the dummy disk, and/or the incidence angle1299. The configurable parameters of the cup-cleaning operation1500, according to some embodiments, further include control parameters to control the supporting devices.

In some embodiments, the particle removing assembly1000performs the cup-cleaning operation1500with a spin speed of the wafer chuck930, holding the dummy disk1230, from about 200 rpm to about 2500 rpm to remove the contaminant material850located in different portions of the curved portion964of the cup960. The particle removing assembly1000is configured to perform the automatic cup-cleaning operation1500with an incidence angle1299of the pressurized cleaning material1080between the dispensing nozzle1210and the upper surface dummy disk1230in a range of between about 20 degrees to about 60 degrees. In some embodiments, the angle is fixed during the cleaning operation, and in other embodiments, the angle is changed within this range during the cleaning operation.

During the automatic cup-cleaning operation1500, the dispensing nozzle1210ejects the pressurized cleaning material1080at a flow rate between about 1000 cc/min and about 2000 cc/min. In some embodiments, the flow rate is linearly adjusted by the controller between about 1000 cc/min to about 2000 cc/min. In alternative embodiments, the flow rate may be non-linearly adjusted by the controller between about 1000 cc/min to about 2000 cc/min. In some embodiments, the pressurized cleaning material1080includes at least one of pure water, CO2water, an alkaline solution (e.g., aqueous NH4OH), an acid solution, and an organic solvent, or another suitable cleaning material.

In some embodiments, the cleaning and/or coating processes of the production is provided with the pressurized cleaning material1081that is heated and ejected from the backside nozzle925of the wafer stage as shown inFIG.4. In some embodiments, the wafer chuck930includes a through hole932. In the through hole932, the backside nozzle925is located and connected to a heater927. In such an embodiment, the heater927heats the pressurized cleaning material1080to a temperature in a range between about 20° C. to about 90° C. In some embodiments, the pressurized cleaning material1080also includes a flow rate in a range of between about 100 cc/min to about 2000 cc/min.

As shown inFIGS.5A and5B, during the automatic cup-cleaning operation1500, the particle removing assembly1000adjust a height of the cup960to remove the contaminant material850from the unreachable dead zone999in the curved portion964of the cup960. In some embodiments, as shown inFIG.5A, various types of the cup960may be used and the curved portion964of the cup960may include different types of inclined/curved shapes966for the cleaning and/or coating processes of the wafer processing.

Due to the various sizes and configurations of the inclined/curved shape966, complete removal of the contaminant material850that are adhered to the curved portion964of the cup960may be insufficient. Due to inclined/curved shape966, the contaminant material850adhering to the unreachable dead zone999may be difficult to remove by adjusting the incident point1295and the first reflective angle1298corresponding to the incident angle1299of the pressurized cleaning material1080on the dummy disk1230. According to an embodiment of the disclosure, the particle removing assembly1000adjusts the height of the cup960for cleaning the cup. For example, as shown inFIG.5B, the particle removing assembly1000increases the height of the cup960such that the pressurized cleaning material1080is reflected again with a second reflective angle1297. The pressurized cleaning material1080reflected by second reflective angle1297can reach the unreachable dead zone999and remove contaminant particles850from the unreachable dead zone999where it is difficult or near impossible to otherwise reach by adjusting the height of the cup960. In some embodiments, during the automatic cup-cleaning operation1500, the particle removing assembly1000includes a height adjustment of the cup960in a range between about 10 mm and about 50 mm.

In some embodiments, during the automatic cup-cleaning operation1500, the pressurized cleaning material1080includes de-ionized water (DIW) or an organic solvent. In some embodiments, a temperature of the de-ionized water (DIW) is in a range between about 20° C. and about 90° C.

In some embodiments, the dispensing nozzle1210rotates around the cup to provide uniform cleaning to the cup.

In other embodiments, the dispensing nozzle structure2210includes a plurality of dispensing nozzles2200, as shown inFIG.6A. In some embodiments, a plurality of dispensing nozzles2200are positioned within the dispensing nozzle structure2210. During the automatic cup-cleaning operation1500, the dispensing nozzle structure2210is positioned over the dummy disk1230and at or adjacent to a center of the dummy disk1230. The dispensing nozzle structure2210includes the structure portions2232,2234,2236to provide a weight balancing mechanism between three dispensing nozzles2211,2212,2213such that the dispensing nozzle structure2210can rotate concentrically. The structure portions2232,2234,2236have a fan shape having central angles θ1, θ2, θ3. In some embodiments, the central angles θ1, θ2, θ3 are in a range from about 115 degrees to about 125 degrees. In some embodiments, central angles θ1, θ2, θ3 are the same. In some embodiments, the three dispensing nozzles2211,2212,2213of the dispensing nozzle structure2210are equally divided into three fan areas and at least one area extends angle θ=120 degrees. In some embodiments, angles θ1, θ2, θ3 may be different.

In some embodiments shown inFIG.6B, the dispensing nozzle structure2210includes the structure portions2232,2234,2236with the three dispensing nozzles such that cleaning material is dispensed towards the center of the dummy disk1230.

In some embodiments shown inFIG.6C, the dispensing nozzle structure2210includes the structure portions2232′,2234′,2236′,2238′. The structure portions2232′,2234′,2236′,2238′ have a fan shape having central angles θ1′, θ2′, θ3′, θ4′. In some embodiments, the central angles θ1′, θ2′, θ3′, θ4′ are in a range from about 85 degrees to about 95 degrees. In some embodiments, central angles θ1′, θ2′, θ3′, θ4′ are the same. In some embodiments, four dispensing nozzles2211′,2212′,2213′,2214′ of the plurality of dispensing nozzles2200are equally divided into four fan areas and at least one area extends angle θ=90 degrees. In some embodiments, angles θ1′, θ2′, θ3′, θ4′ may be different.

In other embodiments, as shown inFIG.6D, the plurality of dispensing nozzles2200are stacked around an axis A1perpendicular to the dummy disk1230. In such embodiments, the three dispensing nozzles2211,2212,2213forming a first layer and the four dispensing nozzles2211′,2212′,2213′,2214′ forming a second layer are arranged such that the first layer and the second layer are stacked around the axis A1. In alternative embodiments, the four dispensing nozzles2211′,2212′,2213′,2214′ forming a first layer and the three dispensing nozzles2211,2212,2213forming a second layer are arranged such that the first layer and the second layer are stacked around the axis A1.

FIGS.7A and7Bare schematic views of the rinse operation1540and the drying operation1560for rinsing and drying the unreachable dead zone999in the curved portion964of the cup960, respectively. After an application of the cleaning material on the unreachable dead zone999is completed, the unreachable dead zone999is subjected to a rinsing operation to clean the unreachable dead zone999. The rinse operation1540is carried out using the particle removing assembly1000.

As shown inFIG.7A, in some embodiments during the rinse operation1540, rinsing fluid124is ejected from the dispensing nozzle1210and onto the upper surface of the dummy disk1230during the rinsing operation. The rinsing fluid124transforms a dry or partially wetted surface of the cleaning surface to a uniformly wetted cleaning surface. Simultaneously, the wafer chuck930holds and rotates the dummy disk1230at a predetermined rotational speed. The rinsing fluid124strikes the dummy disk1230and is drawn outward by centrifugal force toward the edge of the dummy disk1230, rinsing the unreachable dead zone999. In some embodiments, one or more additional nozzles, for example, the plurality of dispensing nozzles2200(shown inFIGS.6A-6D) are used to dispense other cleaning agents on the unreachable dead zone999in the curved portion964of the cup960.

Referring toFIG.7B, in some embodiments, the drying operation1560uses an adjustable pattern (AP) nozzle1310. The adjustable pattern (AP) nozzle1310rotates at a spin speed between about 900 rpm and about 2500 rpm, while the dummy disk1230stands still. In alternative embodiments, the adjustable pattern (AP) nozzle1310rotates at a non-linearly increasing spin speed between about 900 rpm and about 2500 rpm. In some embodiments, the adjustable pattern (AP) nozzle1310stands still, while the dummy disk1230rotates. The adjustable pattern (AP) nozzle1310is configured to provide a pressurized air stream1384from a center1312and/or two lateral sides1314,1316of the AP nozzle. The AP nozzle1310includes a flow rate between about 10 liter/min and about 100 liter/min to dry the unreachable dead zone999in the curved portion964of the cup960. During the drying operation1560, the AP nozzle1310, according to embodiments of the disclosure, is configured to provide a pressurized air stream1384such that the wafer maintains a relative humidity below about 25% across the surface of the wafer. In some embodiments, the AP nozzle1310is positioned at a height between about 1 mm and 3 mm above a center of the wafer. In some embodiments, the AP nozzle1310is positioned at a height of about 2 mm above the wafer center.

In some embodiments as shown inFIG.7C, the AP nozzle1310further includes a pulsation insert1360and a directional insert1370to generate various patterns of the pressurized air stream1384. The pulsation insert1360is configured to generate a pulsation/oscillation of the pressurized air stream1384by inserting a mechanical device into the AP nozzle1310. The directional insert1370is configured to change a two-dimensional direction and/or three-dimensional rotation of the pressurized air stream1384by inserting a mechanical device into the AP nozzle1310. In some embodiments, the AP nozzle1310further includes an extendable nozzle1380. The extendable nozzle1380“pops-up” from the AP nozzle1310when needed and is substantially concealed within the AP nozzle1310when not in use. A controller70selectively enables a telescopingly extendable portion of the extendable nozzle1380in some embodiments. The telescopingly extendable portion includes a cylindrical body that is coaxially slideably received within the AP nozzle1310and has an inwardly projecting annular flange, which bears against any appropriate type of sealing. In some embodiments, the extendable nozzle1380is a 3-axis rotational device.

In some embodiments, the automatic cup-cleaning operation1500is triggered based on monitored and sensed contaminant particles.

As shown inFIG.8, in some embodiments, a controller70is configured to monitor the contaminant material850at the unreachable dead zone999in the curved portion964of the cup960. By using a monitoring device1420, the controller70adjusts a configurable parameter when an amount of contaminant material850at the unreachable dead zone999is more than a threshold amount or greater than a threshold size, and regulates ejecting parameters of the pressurized cleaning material1080by operating the compressor and the pump when the pressurized cleaning material1080is ejected from the adjustable nozzle. In such embodiments, the automatic cup-cleaning operation1500includes configurable parameters that include one or more of a type of fluids, spin speed, flow rate, temperature and a cup distance, an incidence angle, etc. The configurable parameters of the cup-cleaning operation1500, according to some embodiments, further include control parameters to control the supporting devices, such as a pump and a compressor. In some embodiments, the monitoring device1420is a camera. In some embodiments, the monitoring device1420includes an image process unit/algorithm using the camera. In some embodiments, the ejection of the pressurized cleaning material1080from the adjustable nozzle is stopped when the monitoring device detects the amount of the contaminant material850on the unreachable dead zone999in the curved portion964of the cup960is below the threshold amount. Any appropriate controlling configuration regarding automatic and/or manual operation is contemplated and is not limited in this regard.

The cleaning position of the particle removing assembly1000with respect to portions at the unreachable dead zone999of the cup960is programmed by the controller70according to different cleaning recipes. For example, the cleaning position may be programmed with an incident angle of the pressurized cleaning material1080of about 45 degrees. After positioning the dispensing nozzle1210to the cleaning position (the 45 degree configuration of the processing apparatus10), the nozzle positioner stops moving. The pressurized cleaning material1080then cleans the unreachable dead zone999in the curved portion964of the cup960until the end of the cleaning operation1520.

FIG.9shows show an automatic cup cleaning recipe scheme for cleaning the unreachable dead zone in the curved portion wall of the cup for a wet process apparatus according to an embodiment of the disclosure. An exemplary cleaning recipe according to embodiments of the disclosure is as follows: in operation S1001, the wafer handler1420holds the dummy disk1230where a notch is oriented in an entry direction. In operation S1002, the dummy disk is transferred from an indexer robot IR to a substrate platform PASS while rotating the dummy disk opposite from the entry direction. In operation S1003, the dummy disk is transferred from the substrate platform PASS into a central robot CR. In operation S1004, the dummy disk moves into one of the chambers MPC and is rotated by a predetermined angle. The particle removing assembly brings up the pressurized cleaning material and cleans the unreachable dead zone in the curved portion wall of the cup. In operation51005, the particle removing assembly changes the pressurized cleaning material and cleans the unreachable dead zone in the curved portion wall of the cup ranging from about 20° C. to about 90° C. In operation S1006, the particle removing assembly1000switches the cup position. In operation S1006, the particle removing assembly dries the cup and the chamber. After the cleaning of a chamber MPC is completed, the dummy disk is transferred to another chamber MPC for a cleaning operation.

During this automatic cup-cleaning operation1500, the cleaning recipe scheme repeats steps i) providing different fluids to clean the cup at a temperature of from 25˜90° C., (ii) adjusting the cup position, and (iii) using the AP nozzle1310to dry the cup and chamber.

FIGS.10A and10Billustrate a configuration of the controller70in accordance with some embodiments of the disclosure. In some embodiments, a computer system2000is used as the controller70. In some embodiments, the computer system2000performs the functions of the controller as set forth above.

FIG.10Ais a schematic view of a computer system. All of or a part of the processes, method and/or operations of the foregoing embodiments can be realized using computer hardware and computer programs executed thereon. InFIG.10A, a computer system2000is provided with a computer2001including an optical disk read only memory (e.g., CD-ROM or DVD-ROM) drive2005and a magnetic disk drive2006, a keyboard2002, a mouse2003, and a monitor2004.

FIG.10Bis a diagram showing an internal configuration of the computer system2000. InFIG.10B, the computer2001is provided with, in addition to the optical disk drive2005and the magnetic disk drive2006, one or more processors, such as a micro processing unit (MPU)2011, a ROM2012in which a program such as a boot up program is stored, a random access memory (RAM)2013that is connected to the MPU2011and in which a command of an application program is temporarily stored and a temporary storage area is provided, a hard disk2014in which an application program, a system program, and data are stored, and a bus2015that connects the MPU2011, the ROM2012, and the like. Note that the computer2001may include a network card (not shown) for providing a connection to a LAN.

The program for causing the computer system2000to execute the functions of an apparatus for controlling the apparatus in the foregoing embodiments may be stored in an optical disk2021or a magnetic disk2022, which are inserted into the optical disk drive2005or the magnetic disk drive2006, and transmitted to the hard disk2014. Alternatively, the program may be transmitted via a network (not shown) to the computer2001and stored in the hard disk2014. At the time of execution, the program is loaded into the RAM2013. The program may be loaded from the optical disk2021or the magnetic disk2022, or directly from a network. The program does not necessarily have to include, for example, an operating system (OS) or a third party program to cause the computer2001to execute the functions of the controller70in the foregoing embodiments. The program may only include a command portion to call an appropriate function (module) in a controlled mode and obtain desired results.

Embodiments of the present disclosure provide a cleaner cup with reduced contamination. Embodiments of the present disclosure further provide the benefit of reducing downtime during maintenance and servicing photolithographic tools and masks. The design of the cleaning system and particle removing assembly allows for faster maintenance with reduced servicing time. The adaptation of the cleaning system allows an improved process resulting in reduced manpower required to perform the maintenance, and an increased output of conforming servicing items of the photolithographic tools—both of which ultimately result in a cost-savings. As such, the photolithographic tools and masks are more efficiently used. However, it will be understood that not all advantages have been necessarily discussed herein, no particular advantage is required for all embodiments or examples, and other embodiments or examples may offer different advantages.

An embodiment of the disclosure is a method of cleaning a cup used in a wet process apparatus. The method includes providing a cup adjacent to a wafer chuck within a chamber, the cup configured to guard contaminant material against spreading into the chamber. Then, a particle removing assembly configured to remove contaminant material from the cup having an unreachable area from a linear fluidic access caused by a curvature of the cup. The particle removing assembly comprises a flexible ejecting member including one or more elongated tubes and a front tip. The front tip includes at least one of a front opening or a lateral opening, from which pressurized cleaning material is ejected. The cleaning tip adapter is configured to attach the front tip to each of the one or more elongated tubes. Then, the flexible ejecting member is positioned to face the unreachable area of the cup. Subsequently, the pressurized cleaning material is ejected through the front opening with a first diameter or the lateral opening with a second diameter to remove the contaminant material from the unreachable area of the cup. Finally, the by the flexible ejecting member rinses unreachable area of the cup.

In some embodiments, the front tip detachable from the one or more elongated tubes is replaced with an L-shaped front tip. In some embodiments, the front tip that includes the front opening with a third diameter is replaced. In some embodiments, the particle removing assembly further includes a cleaning tip adapter that is configured to attach the front tip to each of the one or more elongated tubes. In some embodiments, the one or more elongated tubes is monolithic unit including the front tip fixedly attached or integrated with an elongated tube body. In some embodiments, the flexible ejecting member is made of polyethylene (PE) or polytetrafluoroethylene (PTFE).

Another embodiment of the disclosure is an apparatus for cleaning a cup. The apparatus includes a cup adjacent to a wafer chuck to guard contaminant material against spreading into a chamber, a particle removing assembly, and a controller communicating with the particle removing assembly. The particle removing assembly is configured to remove contaminant material from the cup. The particle removing assembly includes a dispensing nozzle and a drying nozzle. The particle removing assembly includes a dispensing nozzle and a drying nozzle. The dispensing nozzle is configured to eject pressurized cleaning material towards an incident point along with an incident angle between the pressurized cleaning material and a dummy wafer, so that the pressurized cleaning material is reflected off the dummy wafer to an unreachable area from a linear fluidic access introduced by a curvature of the cup by rotating force. The controller is configured to determine whether a variation in an amount of contaminant material in the unreachable area of the cup is within an acceptable range, and control the particle removing assembly such that the variation in an amount of contaminant material in the unreachable area of the cup is within the acceptable range during a cup cleaning operation.

In some embodiments, in response to a determination that a detected variation in the amount of contaminant material is not within an acceptable range, the controller automatically adjusts a configurable parameter of the particle removing assembly. In some embodiments, the controller controls the wafer chuck to rotate at a spin speed between 200 rpm and 2500 rpm during the cup cleaning operation. In some embodiments, the dispensing nozzle ejects the pressurized cleaning material with an angle of incidence between a dispensing nozzle and an upper surface of the dummy wafer in a range of between 20 degrees to 60 degrees. In some embodiments, the cup cleaning operation is triggered automatically by a pre-determined fixed time interval. In some embodiments, the dispensing nozzle ejects the pressurized cleaning material in a flow rate between 1000 cc/min and 2000 cc/min. In some embodiments, the apparatus further includes a heater to heat the pressurized cleaning material. In some embodiments, the heater is configured to eject the heated cleaning material from a center of the wafer stage. In some embodiments, during the cup-cleaning operation, the controller is configured to set a flow rate of the pressurized cleaning material in a range of between 100 cc/min and 2000 cc/min. In some embodiments, the monitoring device is a camera. In some embodiments, the controller is configured to set a height adjustment of the cup in a range between about 10 mm and about 50 mm.

According to another aspect of the present disclosure is a method of cleaning a cup in a wet process apparatus. The wet process apparatus includes a cup adjacent to a wafer chuck within a chamber and a particle removing assembly configured to remove contaminant material from the cup. The particle removing assembly includes a nozzle and a drying nozzle. The nozzle is configured to eject pressurized cleaning material onto a dummy wafer, so that the pressurized cleaning material is reflected off the dummy wafer to an unreachable area introduced by a curvature of the cup by rotating force. The method includes ejecting the pressurized cleaning material through a dispensing nozzle. Then, the unreachable area of the cup is rinsed. Subsequently, the unreachable area of the cup is dried by the drying nozzle.

In some embodiments, the contaminant material at the unreachable area of the cup is monitored by a monitoring device. In some embodiments, a configurable parameter of the particle removing assembly is adjusted. In some embodiments, the pressurized cleaning material is at least one of de-ionized water (DIW) and an organic solvent. The foregoing outlines features of several embodiments or examples 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 or examples 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.