METAL LIFTOFF TOOLS AND METHODS
20170110346 ยท 2017-04-20
Assignee
Inventors
Cpc classification
H01L21/67086
ELECTRICITY
B08B3/045
PERFORMING OPERATIONS; TRANSPORTING
B08B3/024
PERFORMING OPERATIONS; TRANSPORTING
H01L21/67023
ELECTRICITY
B08B3/04
PERFORMING OPERATIONS; TRANSPORTING
H01L21/67057
ELECTRICITY
H01L21/68742
ELECTRICITY
B08B3/08
PERFORMING OPERATIONS; TRANSPORTING
B08B3/02
PERFORMING OPERATIONS; TRANSPORTING
B08B3/048
PERFORMING OPERATIONS; TRANSPORTING
International classification
H01L21/67
ELECTRICITY
B08B3/02
PERFORMING OPERATIONS; TRANSPORTING
H01L21/027
ELECTRICITY
B08B3/08
PERFORMING OPERATIONS; TRANSPORTING
Abstract
In certain embodiments the metal liftoff tool comprises an immersion tank for receiving a wafer cassette with wafers therein, the immersion tank including an inner weir, a lifting and lowering mechanism capable of raising and lowering the wafer cassette while submerged in fluid in the immersion tank, low pressure high velocity primary spray jets for stripping the metal, the primary spray jets positioned at opposing sides of the immersion tank parallel to the wafer surfaces planes, and secondary spray jets for pressure equalization force, positioned at the bottom of the immersion tank. A wafer lift insert is positioned at the bottom of the immersion tank to receive and periodically lift the wafers within the cassette.
Claims
1. A metal liftoff apparatus comprising: a. an immersion tank having a first and second opposing sidewalls and a bottom, the immersion tank dimensioned to receive a cassette of wafers and a working fluid; b. primary spray jets positioned on the first and second opposing side walls of the immersion tank; c. secondary spray jets positioned on the bottom of the immersion tank; and d. a lifting and lowering mechanism connectable to a cassette of wafers configured to raise and lower the cassette of wafers while in the cassette of wafers remains submerged in the immersion tank.
2. The metal liftoff apparatus of claim 1 further comprising an inner weir in the immersion tank over which the secondary spray jets are configured to spray working fluid stream to force stripped metal pieces from the immersion tank inner weir.
3. The metal liftoff apparatus of claim 1 further comprising a recessed area formed in the bottom of the immersion tank in which recessed area stripped metal pieces not forced over the inner weir are collected.
4. The metal liftoff apparatus of claim 3 further comprising a lifting assembly configured to lift the wafers a distance from a bottom portion of the cassette such that all portions of the wafer surfaces are exposed to spray jets while submerged in the immersion tank.
5. The apparatus of claim 1 further comprising an outer weir configured to collect working fluid and stripped metal pieces that flow over the inner weir of the immersion tank.
6. The apparatus of claim 2 further comprising a screen configured to capture stripped metal pieces from the working fluid flowed from the outer weir.
7. The apparatus of claim 2 further comprising a filtration loop configured to remove stripped metal particles from the working fluid stream.
8. The apparatus of claim 1 further comprising a heater configured to heat the fluid stream and/or working fluid in the immersion tank and/or prior to entering the immersion tank.
9. The apparatus of claim 5 further comprising a pump configured to pressurize the fluid stream.
10. The apparatus of claim 5 further comprising a valve configured to independently control the fluid jets.
11. The apparatus of claim 5 further comprising a removable filter-trap.
12. The apparatus of claim 5 further comprising a computer controller and computer software configured to operate the pumps, valves, jets and/or heater.
13. A metal liftoff apparatus comprising: a. an immersion tank configured to receive a cassette of wafers and a working fluid; b. primary spray jets positioned on opposing side walls of the immersion tank, the primary jets configured to flow streams of working fluid in a direction parallel with planes defined by wafer surfaces in the cassette, while the wafers are immersed in the working fluid; c. secondary spray jets positioned on the bottom of the immersion tank configured to direct working fluid flow directly in an upward direction relative to the bottom of the immersion tank; and d. a lifting assembly configured to lift the wafers a distance from a bottom portion of the cassette such that no portion of the cassette covers a wafer surface but the wafers remain submerged in the immersion tank when in a lifted position.
14. A method comprising: removing metal from a wafer surface by a. immersing a cassette of wafers in a working fluid in an immersion tank; b. directing working fluid streams from primary fluid spray jets positioned along at least one sidewall of the immersion tank directly toward the surfaces of the wafers, such that the working fluid stream flows over surfaces of the wafers in the cassette while immersed in the working fluid; c. simultaneously to directing working fluid streams from the primary fluid spray jets, raising and lowering the cassette of wafers within the immersion tank through the primary fluid spray jets; and d. directing working fluid streams from secondary fluid spray jets positioned at the bottom of the immersion tank such that working fluid streams flow directly upward relative to the bottom of the immersion tank.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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[0019] (Robot Arm with End Effector) that holds the wafer cassette, plumbing, and the reservoir.
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DETAILED DESCRIPTION
[0035] With reference to
[0036] As used herein wafer means a slice of semiconductor material, such as a silicon, silicon carbide, sapphire, germanium or GaAs, used in the fabrication of integrated circuits and other microdevices. As used herein, wafer includes wafers having thicknesses of, for example, 200-300 m, 160 m, 375 m, 525 m, 625 m, 675 m, 725 m, 775 m, 925 m or other currently available thicknesses or possible thicknesses as known to those skilled in the art. As used herein, wafer includes wafers having diameters of 25.4-450 mm or 100-300 mm in diameter or other currently available diameters or possible diameters as known to those skilled in the art.
[0037] The immersion tank 10, also called the process tank, can be of any configuration and dimension suitable for receiving the wafer cassette and accommodating the primary and secondary spray bars or jets 38 positioned as described herein. The immersion tank may comprise a square or rectangular container made of materials compatible with the solvents and/or acids required to strip the wafers. Because the immersion tank does not include moving parts, the tank may be formed of stainless steel or a plastic, or like material(s). Certain embodiments of the immersion tank include four side walls and a bottom sized to include a stationary wafer lifting assembly 28 contacting the wafers on edge to minimize contact surface of each wafer to lift the wafers in the wafer cassette to ensure all portions of the wafer surface are exposed to the primary spray jets 34 and undesired metal is stripped from the wafer surfaces in a standard wafer cassette which wafers have surface areas that may contact the cassette. Certain embodiments include a single central or dual side mounted wafer lift inserts or lifting assembly.
[0038] In certain embodiments, as shown in
[0039] In certain embodiments the immersion tank 10 further comprises an outer weir 26 (
[0040] In certain embodiments the immersion tank further comprises a recessed area (dead zone) 46 at the bottom of the inner weir 22 under the location where the wafer cassette 14 is placed, for capturing liftoff metal that is not forced over the inner weir 22 (
[0041] Embodiments of the disclosed metal liftoff tool further comprise a lifting and lowering mechanism 30 that attaches to the wafer cassette 14 to raise and lower the wafers 18 in the wafer cassette in the immersion tank 10 (
[0042] Embodiments of the metal liftoff tool further comprise primary and secondary spray jets 34, 38 (
[0043] In certain embodiments the primary spray jets 34 positioned at opposing side walls of the immersion tank 10 are offset vertically from one another such that the jets provide maximum stripping force across the entirety wafers' surfaces (
[0044] One or more secondary spray jets 38 (
[0045] The presently disclosed metal liftoff tools including such immersion tanks utilizing screens 66 and filters to trap metal prevent metal pieces 40 from reaching drain valves, filters or pumps. Screens may be included in the inner weir 22 over the drain port and in the outer weir 26 to trap metal from reaching the pumps (
[0046] In general, embodiments of the metal liftoff methods comprise submerging a wafer cassette 14 with wafers 18 therein to be processed into a fluid in an immersion tank 10, the fluid being a liquid solvent for undermining the sacrificial layer under the metal layer to be removed. Edges of the wafers proximal to the bottom of the immersion tank 10 are periodically lifted by the wafer lifting assembly 28 as the lifting mechanism 30 lowers the wafer cassette into the immersion tank. Streams of low pressure, high velocity fluid are sprayed from the primary spray jets 34 positioned at side walls of the immersion tank 10 in a direction parallel with the or at a slight angle, e.g. 0-20% or 0-15% or 15% relative to surfaces of the wafers 18 when in the immersion tank, thereby undercutting the resist layer (or other sacrificial material) and providing maximum metal stripping force across the entire surface of the wafers. The wafer cassette 14 and wafers 18 are raised and lowered in the immersion tank 10 through the streams of fluid from the primary spray jets 34 to provide a complete or substantially complete metal liftoff. Fluid is simultaneously and/or intermittently sprayed from one or more of the secondary spray jets 38 positioned on the bottom of the immersion tank 10 to provide pressure equalization forces that causes the majority of the stripped metal pieces to move to the top of the immersion tank and flow from the inner weir 22 to the outer weir 26.
[0047] In certain embodiments of the disclosed methods, wafers with deposited metal layers are placed inside a standard Teflon wafer process cassette. The process cassette 14 is connected to a lifting and lowering mechanism 30, such as an MEI Robot End Effector (MEI, LLC, Albany, Oreg.). The lifting and lowering mechanism 30 lowers the wafers 18 in the cassette 14 into the immersion tank 10. The immersion tank 10 is filled with a solvent for removing the sacrificial layer, such as a liquid in the form of either acid chemicals (performed using a chemically compatible plastic tank) or organic solvents (performed using a suitable tank material such as stainless steel) using low pressure high velocity primary spray jets 34 of fluid. The primary spray jets 34 positioned on opposing sides of the cassette 14 within the inner weir 22 of the immersion tank 10 spray the solvent or other liquid being used across the entire surface of the wafer 18 at a flow rate at the spray jet outlets of greater than 10 liters/minute, such as 10-20 liters/minute or 17-20 liters/minute. In certain embodiments, during the strip cycle the secondary spray jets 38 are on and the left and right sidewall primary spray jets 34 are alternatingly on to strip the metal from the surfaces of the wafers. The secondary spray jets 38 provide lift to the primary spray jets 34 lateral movement and the two forces combine to sweep the surfaces of the wafers 18. Other on/off sequences for the spray jets may be used in certain embodiments.
[0048] In certain embodiments, periodically a short cycle of all pumps being on is used to flush off any small metal pieces that may have redeposited during a wait time where all pumps are off an liftoff metal pieces are allowed to settle. The drain is then opened to allow the metal pieces 40 settled in the dead zone 46 to evacuate the immersion tank 10 to the reservoir where the fluid is screened and filtered before returning the working fluid to the immersion tank. After that point, in certain embodiments one or more of the pumps may be on with repetitive wait and drain times until the wafers are completely or substantially completely stripped.
[0049] The lifting and lowering mechanism 30 moves the wafer cassette 14 with wafers 18 therein in a vertical direction (up and down) through the primary stripping jet 34 streams of fluid to provide a complete or substantially complete metal liftoff process. In certain embodiments, the wafer cassette 14 is cyclically, intermittently or periodically raised and lowered for a total distance movement of from 1-5 inches, from 1-3 inches, or from 1-2 inches.
[0050] The secondary spray jets 38 within the immersion tank 10 positioned at the bottom of the tank under the wafer cassette 14 and wafers 18 therein to spray a low pressure high velocity solvent or other liquid being used streams in an upward direction, such as directly perpendicular relative to planes defined by surfaces of the immersion tank sidewalls, to provide pressure equalization forces in the immersion tank, moving the liftoff metal pieces toward the top of the immersion tank and over the inner weir 22. The secondary spray jet 38 flow rates at the spray jet outlets is a rate greater than 1 liter/minute, or greater than 5 liters/minute, or greater than 10 liters/minute, such as 10-20 liters/minute or 17-20 liters/minute. Once the liftoff metal pieces 40 are carried by the high velocity flow to the outer weir 26, the metal pieces are caught by the primary recapture screen 66 in the outer weir 26 (
[0051] In certain embodiments during the stripping process the wafers 18 in the wafer cassettes 14 are resting on the wafer lifting assembly 28 as the secondary spray jets 38 force fluid in an upward direction. In certain embodiments the wafers are raised off of and lowered back onto the lifting assembly 28 to lift the wafers out of the cassette cradle. This action, in certain embodiments, is repeated throughout the stripping process cycle and may be performed during just a portion of the stripping process. Wafers 18 are lifted up a distance within the wafer cassette 14 by contact with the wafer lifting assembly 28 while the primary and/or secondary spray jets 34, 38 are streaming fluid to ensure the wafer surface is completely stripped by the fluid jets. Wafers in the wafer carriers/cassettes mask metal in lower corners of the wafer surface at positions of 4 and 8 o'clock inhibiting metal removal if the wafers are not lifted within the cassette as part of the process.
[0052] In certain embodiments, the stripped metal pieces 40 that are not lifted over the inner weir 22 fall into the reservoir or dead zone 46 at the bottom of the inner weir immersion tank 10. In certain embodiments, this recessed area 46 of the tank is below the level of the process flow and pressures created by the primary and secondary jets. In certain embodiments, the sides of the dead zone 46 are sloped to assist the metal pieces 40 to move to the center of the zone. In certain embodiments of the disclosed methods a piston valve under the dead zone 46 is opened between stripping process cycles to allow the metal pieces trapped in the dead zone to flow freely down to a secondary fluid reservoir. As the fluid flows into the reservoir the reservoir trap captures the metal pieces while still allowing the fluid to flow into a lower chamber of the reservoir. In certain of the disclosed methods the screen 66 is removed between cycles to allow it to be cleaned and the metal pieces reclaimed.
[0053] In certain embodiments of the metal liftoff methods the fluid in the reservoir is cycled back to the immersion tank by the use of a pump in combination with level sensors. The pump may also serve as a circulation pump for the secondary spray jets.
[0054] Certain embodiments of the disclosed metal liftoff tools and methods provide advantages over existing single wafer spin tools or immersion tools using roller technology. In certain embodiments of the disclosed metal liftoff tools and processes multiple wafer sizes can be processed in a single tank. In certain embodiments using the stationary wafer lifting assembly, wafers with flats can be substantially stripped or stripped completely. Because the present embodiments of the tools and processes disclosed do not include roller assemblies, the presently disclosed tools and methods can lift the wafers within the cassette to allow edge metal to be flushed up and out of the immersion tank even where the wafers include flats.
[0055] Embodiments of the disclosed metal liftoff tools and processes include immersion tanks configured to optimize fluid flow out of an inner weir 22 to remove the maximum amount of liftoff metal pieces from the inner weir where wafers are processed. This minimizes damage to the wafer from metal debris. The embodiments having one or more screens and filters trap metal pieces from reaching drain valves, filters or pumps to protect the spray jets and manifold assemblies from blockages and to allow for metal recovery.
[0056] In certain embodiments the disclosed metal liftoff tools and processes include immersion tanks 10 that are self-cleaning, which minimizes down time and maximizing throughput. By use of the immersion tank inner weir 22 dead zone 46 and large dump valve 50 to the fluid reservoir, metal pieces 40 are captured by the screen 66 and the fluid is recirculated to the immersion tank. The fluid reservoir 74 shown in
[0057] Certain embodiments may further comprise software to accelerate the metal removal process by allowing maximum flexibility in solvent strip jet cycles. Because, as known to those of ordinary skill in the art, different metal layers are stripped effectively using different cycle sequences to remove. The software allows maximum flexibility to the user to tune a process sequence that works best for the particular metal being stripped.
[0058] In certain embodiments ultrasonic energy is used in the fluid process tank. The ultrasonic energy may be used, e.g., to remove thin layers of negative resist and/or to assist with the metal removal. Varying frequencies of the ultrasonics (between 170K Hz and 40 KHz) aids in the stripping of metal without damaging the IC structures on the wafers.
[0059] In certain embodiments, the tools and methods may further comprise a separate wafer rinse tank 78 such as shown in
[0060] The present tools and methods can be applied to remove resist or other such materials rather than metal layers.
[0061] As used herein, comprising means including and the singular forms a or an or the include plural references unless the context clearly dictates otherwise. The term or refers to a single element of stated alternative elements or a combination of two or more elements, unless the context clearly indicates otherwise.
[0062] Unless explained otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, suitable methods and materials are described herein. The materials, methods, and examples are not intended to be limiting unless indicated otherwise.
[0063] Unless otherwise indicated, all numbers expressing quantities such as pressure and velocity, properties, percentages, and so forth, as used in the specification or claims are to be understood as being modified by the term about. Unless otherwise indicated, non-numerical properties, such as fluid flow directions, as used in the specification or claims are to be understood as being modified by the term substantially, meaning to a great extent or degree. In certain uses, substantially means within 5%, 3%, 2%, or 1%. Accordingly, unless otherwise indicated, implicitly or explicitly, the numerical parameters and/or non-numerical properties set forth are approximations that may depend on the desired properties sought, limits of detection under standard test conditions/methods, limitations of the processing methods, and/or the nature of the parameter or property. When directly and explicitly distinguishing embodiments from discussed prior art, the embodiment numbers are not approximates unless the word about is recited.
[0064] In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims.