Method of manufacturing a high definition heater system
10049903 ยท 2018-08-14
Assignee
Inventors
- Kevin Ptasienski (O'Fallon, MO, US)
- Allen Norman Boldt (Kirkwood, MO, US)
- Janet Lea Smith (Columbia, MO, US)
- Cal Thomas Swanson (St. Louis, MO, US)
- Mohammad Nosrati (Fenton, MO, US)
- Kevin Robert Smith (Columbia, MO, US)
Cpc classification
H05B3/20
ELECTRICITY
H05B2203/005
ELECTRICITY
H05B1/02
ELECTRICITY
H05B2213/03
ELECTRICITY
H05B3/06
ELECTRICITY
Y10T156/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
H01B13/00
ELECTRICITY
H05B3/20
ELECTRICITY
H05B1/02
ELECTRICITY
B44C1/22
PERFORMING OPERATIONS; TRANSPORTING
C03C15/00
CHEMISTRY; METALLURGY
H05B3/06
ELECTRICITY
H01L21/67
ELECTRICITY
Abstract
Methods of manufacturing a heater are provided that generally include forming a laminate having a dielectric layer, a first double-sided adhesive dielectric layer, and a conductive layer. Next, a circuit pattern is created into the conductive layer, and then the circuit pattern is covered with a second double-sided adhesive dielectric layer. The second double-sided adhesive dielectric layer is covered with a sacrificial layer, and then the heater is formed, the heater comprising the dielectric layer, the first double-sided adhesive dielectric layer, the conductive layer, and the second double-sided adhesive dielectric layer. Subsequently, the sacrificial layer is removed.
Claims
1. A method of manufacturing a heater comprising: forming a first laminate having a dielectric layer, a first double-sided adhesive dielectric layer, and a conductive layer; creating a circuit pattern into the conductive layer; covering the circuit pattern with a second double-sided adhesive dielectric layer; covering the second double-sided adhesive dielectric layer with a sacrificial layer to form a second laminate comprising the dielectric layer, the first double-sided adhesive dielectric layer, the circuit pattern, the second double-sided adhesive dielectric layer, and the sacrificial layer, wherein the circuit pattern and the sacrificial layer are disposed on opposing surfaces of the second double-sided adhesive dielectric layer, the sacrificial layer overlapping the circuit pattern; pressing the second laminate that comprises the dielectric layer, the first double-sided adhesive dielectric layer, the circuit pattern, the second double-sided adhesive layer, and the sacrificial layer; and subsequently removing the sacrificial layer after the pressing to form a heater comprising the dielectric layer, the first double-sided adhesive dielectric layer, the circuit pattern, and the second double-sided adhesive dielectric layer.
2. The method according to claim 1, wherein the sacrificial layer is a copper material.
3. The method according to claim 1, wherein the conductive layer is formed of a Nickel alloy material.
4. The method according to claim 1, wherein the double-sided adhesive dielectric layers are formed of a polyimide material.
5. The method according to claim 1, wherein each of the conductive layer and the dielectric layers each define a thickness between about 0.025 mm and about 0.050 mm.
6. The method according to claim 1, wherein the circuit pattern is created by an etching process.
7. A method of manufacturing a heater, the method comprising: forming a first laminate having a first double-sided adhesive dielectric layer, a first sacrificial layer on one side of the first double-sided adhesive dielectric layer, and a conductive layer on an opposite side of the first double-sided adhesive dielectric layer; creating a circuit pattern into the conductive layer; covering the circuit pattern with a second double-sided adhesive dielectric layer; covering the second double-sided adhesive dielectric layer with a second sacrificial layer to form a second laminate comprising the first double-sided adhesive dielectric layer, the first sacrificial layer, the circuit pattern, the second double-sided adhesive dielectric layer, and the second sacrificial layer, wherein the circuit pattern and the second sacrificial layer are disposed on opposing surfaces of the second double-sided adhesive dielectric layer, the second sacrificial layer overlapping the circuit pattern; pressing the second laminate that comprises the first double-sided adhesive dielectric layer, the first sacrificial layer, the circuit pattern, the second double-sided adhesive dielectric layer, and the second sacrificial layer; and subsequently removing at least one of the first and second sacrificial layers after the pressing to form a heater comprising the first double-sided adhesive dielectric layer, the circuit pattern, the second double-sided adhesive dielectric layer, and at most one of the first and the second sacrificial layers.
8. The method according to claim 7, wherein the sacrificial layers are a copper material.
9. The method according to claim 7, wherein the double-sided adhesive dielectric layers are formed of a polyimide material.
10. The method according to claim 7, wherein the conductive layer is formed of a Nickel alloy material.
11. The method according to claim 7, wherein each of the conductive layer and the double-sided adhesive dielectric layers each define a thickness between about 0.025 mm and about 0.050 mm.
12. The method according to claim 7, wherein the circuit pattern is created by an etching process.
Description
DRAWINGS
(1) In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
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(18) The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
(19) The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. For example, the following forms of the present disclosure are directed to chucks for use in semiconductor processing, and in some instances, electrostatic chucks. However, it should be understood that the heaters and systems provided herein may be employed in a variety of applications and are not limited to semiconductor processing applications.
(20) Referring to
(21) In another form, rather than providing fine tuning of a heat distribution, the tuning layer 60 may alternately be used to measure temperature in the chuck 12. This form provides for a plurality of area-specific or discreet locations, of temperature dependent resistance circuits. Each of these temperature sensors can be individually read via a multiplexing switching arrangement, exemplary forms of which are set forth in greater detail below, that allows substantially more sensors to be used relative to the number of signal wires required to measure each individual sensor. The temperature sensing feedback can provide necessary information for control decisions, for instance, to control a specific zone of backside cooling gas pressure to regulate heat flux from the substrate 26 to the chuck 12. This same feedback can also be used to replace or augment temperature sensors installed near the base heater 50 for temperature control of base heating zones 54 or balancing plate cooling fluid temperature (not shown) via ancillary cool fluid heat exchangers.
(22) In one form, the base heater layer 50 and the tuning heater layer 60 are formed from enclosing heater circuit 54 and tuning layer heating elements 62 in a polyimide material for medium temperature applications, which are generally below 250 C. Further, the polyimide material may be doped with materials in order to increase thermal conductivity.
(23) In other forms, the base heater layer 50 and/or the tuning heater layer 60 are formed by a layered process, wherein the layer is formed through application or accumulation of a material to a substrate or another layer using processes associated with thick film, thin film, thermal spraying, or sol-gel, among others.
(24) In one form, the base heating circuit 54 is formed from Inconel and the tuning layer heating elements 62 are a Nickel material. In still another form, the tuning layer heating elements 62 are formed of a material having sufficient temperature coefficient of resistance such that the elements function as both heaters and temperature sensors, commonly referred to as two-wire control. Such heaters and their materials are disclosed in U.S. Pat. No. 7,196,295 and pending U.S. patent application Ser. No. 11/475,534, which are commonly assigned with the present application and the disclosures of which are incorporated herein by reference in their entirety.
(25) With the two-wire control, various forms of the present disclosure include temperature, power, and/or thermal impedance based control over the layer heating elements 62 through knowledge or measurement of voltage and/or current applied to each of the individual elements in the thermal impedance tuning layer 60, converted to electrical power and resistance through multiplication and division, corresponding in the first instance, identically to the heat flux output from each of these elements and in the second, a known relationship to the element temperature. Together these can be used to calculate and monitor the thermal impedance load on each element to allow an operator or control system to detect and compensate for area-specific thermal changes that may result from, but are not limited to, physical changes in the chamber or chuck due to use or maintenance, processing errors, and equipment degradation. Alternatively, each of the individually controlled heating elements in the thermal impedance tuning layer 60 can be assigned a setpoint resistance corresponding to the same or different specific temperatures which then modify or gate the heat flux originating from corresponding areas on a substrate through to the base heater layer 52 to control the substrate temperature during semiconductor processing.
(26) In one form, the base heater 50 is bonded to a chuck 51, for example, by using a silicone adhesive or even a pressure sensitive adhesive. Therefore, the heater layer 52 provides primary heating, and the tuning layer 60 fine tunes, or adjusts, the heating profile such that a uniform or desired temperature profile is provided to the chuck 51, and thus the substrate (not shown).
(27) In another form of the present disclosure, the coefficient of thermal expansion (CTE) of the tuning layer heating elements 62 is matched to the CTE of the tuning heating layer substrate 60 in order to improve thermal sensitivity of the tuning layer heating elements 62 when exposed to strain loads. Many suitable materials for two-wire control exhibit similar characteristics to Resistor Temperature Devices (RTDs), including resistance sensitivity to both temperature and strain. Matching the CTE of the tuning layer heating elements 62 to the tuning heater layer substrate 60 reduces strain on the actual heating element. And as the operating temperatures increase, strain levels tend to increase, and thus CTE matching becomes more of a factor. In one form, the tuning layer heating elements 62 are a high purity Nickel-Iron alloy having a CTE of approximately 15 ppm/ C., and the polyimide material that encloses it has a CTE of approximately 16 ppm/ C. In this form, materials that bond the tuning heater layer 60 to the other layers exhibit elastic characteristics that physically decouple the tuning heater layer 60 from other members of the chuck 12. It should be understood that other materials with comparable CTEs may also be employed while remaining within the scope of the present disclosure.
(28) Referring now to
(29) A tuning heater 90 is disposed on top of the substrate 88 and is secured to a chuck 92 using an elastomeric bond layer 94, as set forth above. The chuck 92 in one form is an Aluminum Oxide material having a thickness of approximately 2.5 mm. It should be understood that the materials and dimensions as set forth herein are merely exemplary and thus the present disclosure is not limited to the specific forms as set forth herein. Additionally, the tuning heater 90 has lower power than the base heater 84, and as set forth above, the substrate 88 functions to dissipate power from the base heater 84 such that witness marks do not form on the tuning heater 90.
(30) The base heater 84 and the tuning heater 90 are shown in greater detail in
(31) The present disclosure also contemplates that the base heater 84 and the tuning heater 90 not be limited to a heating function. It should be understood that one or more of these members, referred to as a base functional layer and a tuning layer, respectively, may alternately be a temperature sensor layer or other functional member while remaining within the scope of the present disclosure. Other functions may include, by way of example, a cooling layer or a diagnostic layer that would collect sensor input such as various electrical characteristics, among others.
(32) As shown in
(33) In another form, the base functional layer may include a plurality of thermoelectric elements rather than the base heater 84 construction as set forth above. These thermoelectric elements may also be arranged in zones and are generally disposed on top of, or proximate, the base plate or cooling plate 82.
(34) In still another form, the multiple tuning layers may be employed in a stacked configuration, or configured vertically such that individual resistive traces are offset from adjacent resistive traces on opposed layers to compensate for the gaps that exist between traces. For example, as shown in
(35) Referring to
(36) In one form, the tuning layer 330 is a heater, and yet in another form, the tuning layer 330 is a temperature sensor, as set forth in detail above. This tuning layer 330, and also the base member 310, may be designed with a material having sufficient TCR characteristics such that they function as both a heater and as a temperature sensor. Additionally, a secondary tuning layer (shown in
(37) The apparatus 300 may also employ the routing layer 66 as shown in
(38) Referring to
(39) By way of background, and with reference to
(40) The methods according to the present disclosure are illustrated in
(41) The heater is then formed, for example by a press operation, wherein the heater itself comprises the first double-sided adhesive dielectric layer 506, the conductive layer 508, and the second double-sided adhesive dielectric layer 510. After the heater is formed, at least one of the sacrificial layers 507 and 512 is removed. Accordingly, by using the sacrificial layers 507 and 512, the need for the previous dielectric layers is eliminated and the heater can transfer heat more efficiently.
(42) Another variation of this method is illustrated in
(43) Yet another variation of the methods above is shown in
(44) Still another variation of the methods according to the present disclosure is shown in
(45) The conductive layer 508 is an Inconel material in one form of the present disclosure and may generally be one of a variety of Nickel alloys. The double-sided adhesive dielectric layers 506 and 510 are a polyimide material in one form of the present disclosure. In one form, each of the conductive layer 508 and the dielectric layers 506 and 510 define a thickness between about 0.025 mm and about 0.050 mm, and the sacrificial layer 502 defines a thickness of about 0.017 mm. Additionally, a cleaning operation, such as a light pumice scrub, may be employed after removing the sacrificial layers 507 and/or 512.
(46) The sacrificial layers are Copper in one form of the present disclosure and are generally removed by an etching process. In another form, the sacrificial layers may be Aluminum and partially ground down to create a flat surface for wafer processing. Accordingly, some of the layer would remain with the heater or laminate stack and not be entirely removed. It should also be understood that the various sacrificial and carrier layers may be entirely removed or remain with the heater during subsequent operations while remaining within the scope of the present disclosure.
(47) Referring now to
(48) As shown in
(49) Each of the tuning layers/heaters set forth herein are controlled by a control system, various forms of which are set forth in greater detail in co-pending applications titled System and Method for Controlling a Thermal Array, and applications titled Thermal Array System, concurrently filed herewith and commonly assigned with the present application. Generally, the control systems have a plurality of sets of power lines in communication with the tuning layer and a plurality of addressable control elements in electrical communication with the power lines and with the tuning layer, the control elements providing selective control of the tuning layer zones. The control elements may be, by way of example, threshold voltage switching circuits, which may be semiconductor switches. The threshold voltage switching circuits may be packaged, for example in an ASIC (Application Specific Integrated Circuit). Furthermore, the control elements may be embedded within the component, such as the chuck, as set forth above. These control systems and their related algorithms are described and illustrated in greater detail in the co-pending applications set forth above and thus are not included herein for purposes of clarity.
(50) It should be noted that the disclosure is not limited to the embodiments described and illustrated as examples. A large variety of modifications have been described and more are part of the knowledge of the person skilled in the art. These and further modifications as well as any replacement by technical equivalents may be added to the description and figures, without leaving the scope of the protection of the disclosure and of the present patent.