Jet spray nozzle and method for cleaning photo masks and semiconductor wafers
09656278 ยท 2017-05-23
Assignee
Inventors
Cpc classification
Y10S134/902
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
B05B1/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A jet spray nozzle for cleaning a photolithographic mask or semiconductor wafer and method for cleaning the same. The jet spray nozzle in one embodiment includes a water supply inlet, a gas supply inlet, a first row of gas injection nozzles communicating with the gas supply inlet, a mixing cavity defining a jet spray nozzle outlet, and a flow mixing baffle disposed in the cavity. The mixing baffle preferably is configured and arranged to combine gas and water in the jet spray nozzle for delivering a concentrated stream of gas with a cluster of micro water droplets entrained in the gas for removing contaminant particles from the mask. The jet spray nozzle is capable of cleaning photo masks or wafers without the use of chemicals. In one embodiment, the water may be deionized water and the gas may be nitrogen. In another embodiment, the jet spray nozzle further includes a second row of gas injection nozzles spaced above or below the first row of gas injection nozzles that communicate with the gas supply inlet.
Claims
1. A jet spray nozzle for cleaning a photolithographic mask or semiconductor wafer comprising: a liquid supply inlet configured to introduce a liquid; a gas supply inlet configured to introduce a gas; a first plurality of gas injection nozzles communicating with the gas supply inlet; the first plurality of gas injection nozzles arranged in a circular ring of spaced apart nozzles around an axial centerline of the jet spray nozzle; a second plurality of gas injection nozzles communicating with the gas supply inlet, the second plurality of gas injection nozzles arranged in an additional circular ring of spaced apart nozzles around the axial centerline of the jet spray nozzle, wherein the first and the second plurality of gas injection nozzles are concentrically arranged around the axial centerline of the jet spray nozzle; and a jet spray nozzle outlet; wherein the jet spray nozzle is configured to combine the gas and the liquid to deliver a gas-liquid jet spray stream from the nozzle outlet.
2. The jet spray nozzle of claim 1, wherein the second plurality of gas injection nozzles are spaced above or below the first plurality of gas injection nozzles.
3. The jet spray nozzle of claim 1, wherein the second plurality of gas injection nozzles are offset from the first plurality of gas injection nozzles by an angle such that the first and the second plurality of gas nozzles are not radially aligned.
4. The jet spray nozzle of claim 1, wherein the first plurality of gas injection nozzles are disposed at an angle with respect to a horizontal axis extending through the jet spray nozzle that is different than a corresponding angle of the second plurality of gas nozzles with respect to the horizontal axis.
5. The jet spray nozzle of claim 1, wherein the liquid supply inlet is aligned with the axial centerline of the jet spray nozzle.
6. The jet spray nozzle of claim 1, wherein the jet spray nozzle outlet is defined by an enlarged mixing cavity, the cavity being radially larger than the liquid supply inlet.
7. The jet spray nozzle of claim 6, further comprising a baffle disposed in the cavity for mixing flows, the baffle being configured to combine the gas and the liquid for delivering the gas-liquid jet spray stream from the nozzle outlet; wherein the first plurality of injection nozzles are configured to discharge the gas into the cavity toward the baffle.
8. The jet spray nozzle of claim 1, wherein the liquid comprises deionized water, and the gas is pressurized.
9. The jet spray nozzle of claim 1, wherein the jet spray nozzle is configured to deliver a gas-liquid jet spray stream comprising liquid droplets having a size distribution of 85% less than about 30 microns.
10. A jet spray nozzle for cleaning a photolithographic mask or semiconductor wafer comprising: a liquid supply inlet configured to introduce a liquid; a gas supply inlet configured to introduce a pressured gas; a first plurality of gas injection nozzles communicating with the gas supply inlet; the first plurality of gas injection nozzles arranged in a circular ring of spaced apart nozzles around an axial centerline of the jet spray nozzle; a second plurality of gas injection nozzles spaced above or below the first plurality of gas injection nozzles and communicating with the gas supply inlet, the second plurality of gas injection nozzles arranged in an additional circular ring of spaced apart nozzles around the axial centerline of the jet spray nozzle; and a jet spray nozzle outlet; wherein the jet spray nozzle is configured to combine the gas and the liquid to deliver a gas-liquid jet spray stream from the jet spray nozzle outlet onto the photolithographic mask or wafer, the gas-liquid jet spray stream comprising a cluster of micro water droplets having a predetermined size entrained in the gas.
11. The jet spray nozzle of claim 1, wherein the liquid supply inlet is aligned with the axial centerline of the jet spray nozzle; and the jet spray nozzle outlet is defined by an enlarged mixing cavity, the cavity being radially larger than the liquid supply inlet.
12. The jet spray nozzle of claim 11, further comprising a conically shaped baffle disposed in the cavity, the baffle configured to combine the gas and the liquid for delivering the gas-liquid jet spray stream from the nozzle outlet.
13. The jet spray nozzle of claim 1, wherein the first plurality of gas nozzles inject the gas at a downward angle with respect to the axial centerline of the jet spray nozzle.
14. A jet spray nozzle for cleaning a photolithographic mask or semiconductor wafer comprising: a liquid supply inlet configured to introduce a liquid; a gas supply inlet configured to introduce a gas from a pressurized gas source; a first plurality of gas injection nozzles communicating with the gas supply inlet; the first plurality of gas injection nozzles arranged in a circular ring of spaced apart nozzles around an axial centerline of the jet spray nozzle; a second plurality of gas injection nozzles communicating with the gas supply inlet, the second plurality of gas injection nozzles in an additional circular ring of spaced apart nozzles around the axial centerline of the jet spray nozzle; and a jet spray nozzle outlet; wherein the jet spray nozzle is configured to combine the gas and the liquid to deliver a gas-liquid jet spray stream from the nozzle outlet.
15. The jet spray nozzle of claim 14, wherein the second plurality of gas injection nozzles are spaced above or below the first plurality of gas injection nozzles.
16. The jet spray nozzle of claim 14, wherein the second plurality of gas injection nozzles are offset from the first plurality of gas injection nozzles by an angle such that the first and the second plurality of gas nozzles are not radially aligned.
17. The jet spray nozzle of claim 14, wherein the liquid supply inlet is aligned with the axial centerline of the jet spray nozzle; and the jet spray nozzle outlet is defined by an enlarged mixing cavity, the cavity being radially larger than the liquid supply inlet.
18. The jet spray nozzle of claim 17, further comprising a conically shaped baffle disposed in the cavity, the baffle being configured to combine the gas and the liquid for delivering the gas-liquid jet spray stream from the nozzle outlet; wherein the first and the second plurality of gas injection nozzles are configured to discharge the gas toward the baffle at a downward angle with respect to the axial centerline of the jet spray nozzle.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The features of the preferred embodiments will be described with reference to the following drawings where like elements are labeled similarly, and in which:
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(10) All drawings are schematic and are not drawn to scale.
DETAILED DESCRIPTION
(11) This description of illustrative embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as lower, upper, horizontal, vertical,, above, below, up, down, top and bottom as well as derivative thereof (e.g., horizontally, downwardly, upwardly, etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as attached, affixed, connected and interconnected, refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the preferred embodiments. Accordingly, the invention expressly should not be limited to such preferred embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.
(12) Through testing, the inventors have determined that combining deionized water with a pressurized gas in a specially-configured jet spray nozzle described herein produces a high energy focused stream comprising a cluster of micro water droplets entrained in the gas that have a predetermined size capable of producing sufficient force to dislodge inorganic contaminant particles adhered to the surface of the photo mask. The operating principle behind the jet spray nozzle for cleaning the photo mask is illustrated in
(13) An ideal or target water droplet 48 size of 10 microns has been determined to be most effective. However, this droplet size alone is difficult to produce consistently in actual practice. It was further determined through testing that a jet spray stream having a deionized water droplet 48 size distribution of 85% less than about 30 microns effectively removes contaminant particles 21 from the surface 27 of photo mask 26 without seriously damaging the patterned mask surface features. As shown in
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(15) Jet spray nozzle 20 further preferably includes at least one gas supply inlet 28 for supplying a pure or inert gas 23 to the jet spray nozzle, and more preferably may include a plurality of gas supply inlets for evenly feeding the gas to the jet spray nozzle. Gas 23 may be any suitable pure or inert gas such as without limitation N2 (nitrogen), XCDA (Extreme Clean Dry Air) reticle purge gas available from Entegris Incorporated, etc. As shown in
(16) With continuing reference to
(17) In one preferred embodiment, jet spray nozzle 20 is symmetrical in configuration about the centerline CL as shown in
(18) Cavity 29 further includes an internal flow mixing baffle 30 disposed in the cavity for combining the water 22 with gas 23. In one possible embodiment, as best shown in
(19) With reference to
(20) As shown in
(21) It will be appreciated that uniform injection and distribution of gas 23 into jet spray nozzle 20 is necessary for producing the desired water droplet 48 size distribution described herein.
(22) Jet spray nozzle 20 may be made of any suitable material, such as for example without limitation polymers, and preferably Teflon (e.g. Teflon-PFA, Teflon-PTFA, etc.) in some embodiments.
(23) The operation of jet spray nozzle 20 will now be described. Tests were conducted to optimize the flow and pressure of the deionized water 22 and gas 23 for achieving the desired water droplet 48 size distribution, which in one embodiment is preferably 97% droplet 48 size less than 100 microns, and more preferably 85% droplets 48 less than 30 microns. The water droplet 48 size is proportional to the diameter of the water supply inlet 50, and the water supply pressure and flow rate. The droplet 48 speed or velocity (v) is proportional to the pressure of the gas supply 23 and inversely proportional to the diameter 38 of the gas injection nozzle outlets 35.
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(25) The operational arrangement of jet spray nozzle and photo mask 26 for the jet spray cleaning process will now be described. Referring again to
(26) The particle removal efficiency (PRE) of jet spray nozzle 20 was determined using the foregoing operational setup, jet spray nozzle having the two-level gas injection nozzles 34, 39 arrangement, and deionized water and gas flow rates/pressures described herein according to the present invention. A standardized testing procedure used to measure photo mask cleaning PRE was followed. This standard test included using 100 nm size SiN4 particles as the contaminant which were disposed on the surface of a photo mask. A minimum target PRE of 90% was established which is considered good PRE performance when measuring the effectiveness for photo mask cleaning processes. At a PRE of 90% or above, a sufficient number of contaminant particles are removed from the surface of the photo mask so that any remaining particles do not generally interfere with the photolithography process and proper patterning of the photoresist on the wafer. A maximum of 10 minutes spray time was used during which time the photo mask with 100 nm test contaminant particles were exposed to the concentrated cleaning jet spray of clustered deionized water. Exceeding the 10 minute threshold increases the probability of damaging the pattern on the photo mask.
(27) The results of the foregoing standardized PRE tests are graphically shown in
(28) Although the jet spray nozzle and method according to the present invention has been described herein for use in photo mask cleaning, the jet spray nozzle 20 may be used to clean other components involved in semiconductor fabrication. In one embodiment, for example, the jet spray nozzle 20 and method may be used to clean a semiconductor wafer. The wafer cleaning application may use only one of the upper row or ring 40 of gas nozzles 39 or lower row or ring 41 of gas nozzles 34 in some applications because the main purpose of jet spray cleaning on wafer application is for the final rinse process. A single row of nozzles in the jet spray nozzle head is powerful enough on chemical residue and contamination removal where the water droplet 48 uniformity is not as much of a concern as in photomask cleaning.
(29) While the foregoing description and drawings represent preferred or exemplary embodiments of the present invention, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. One skilled in the art will further appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. In addition, numerous variations in the preferred or exemplary methods and processes described herein may be made without departing from the spirit of the invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims and equivalents thereof, and not limited to the foregoing description or embodiments. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.