JP2010274362A - Method for manufacturing polyurethane foam and method for manufacturing polishing pad - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing polyurethane foam and a polishing pad having uniform pores and suppressing shear droop at the end face. <P>SOLUTION: The method for manufacturing polyurethane foam includes the steps of mixing and stirring an isocyanate-group containing compound with 3,000 mPa s or below viscosity at 40°C, unfoamed heat-expandable minute spherical bodies, and an active hydrogen containing compound to be hardened, and foaming the heat-expandable minute spherical bodies by heat of reaction. The pot life of a urethane resin composite which is a mixture of the isocyanate-group containing compound and the active hydrogen containing compound is 200 s or longer. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for producing foamed polyurethane and a method for producing a polishing pad using the same.

  A chemical mechanical polishing (CMP) technique is used for planarization processing of a semiconductor wafer or the like, and various CMP apparatuses using the CMP technique have been proposed.

  FIG. 11 is a schematic configuration diagram of a conventional CMP apparatus. A polishing slurry 3 is supplied from a slurry supply device 4 to a polishing pad 2 attached to the surface of the surface plate 1. For example, a semiconductor wafer 5 as an object to be polished is held by a polishing head 6 via a backing film 7. When a load is applied to the polishing head 6, the semiconductor wafer 5 is pressed against the polishing pad 2.

  The slurry 3 supplied onto the polishing pad 2 spreads on the polishing pad 2 and reaches the semiconductor wafer 5. The surface plate 1 and the polishing head 6 rotate in the same direction and move relatively as indicated by an arrow A, and the slurry 3 enters between the polishing pad 2 and the semiconductor wafer 5 to perform polishing. . Reference numeral 8 denotes a dresser for conspicuous the surface of the polishing pad 2.

  As such a polishing pad 2, one using foamed polyurethane having excellent wear resistance or the like is known (for example, see Patent Document 1).

  In foamed polyurethane, it is necessary to generate fine pores (bubbles). For example, a main agent containing an isocyanate group-containing compound and a curing agent containing an active hydrogen group-containing compound such as an aromatic amine are mixed and stirred. There is a manufacturing method using so-called two-component curable polyurethane which is cast and cured in a predetermined mold.

In such a conventional example, for example, water is mixed as a foaming agent into the main agent, and CO ₂ is generated by the reaction between an isocyanate group and water to be foamed.

  As another conventional example, in addition to water, unexpanded heat-expandable microspheres are mixed, and the heat-expandable microspheres are foamed by heat of reaction between the main agent and the curing agent and external heating. There is also a method (see Patent Document 2).

JP-A-2005-236200 JP 2000-344850 A

As described above, in the production method in which the main agent containing an isocyanate group-containing compound, the curing agent containing an active hydrogen group-containing compound such as an aromatic amine, and water as a blowing agent are mixed, stirred, and cast, the casting is performed. Since CO ₂ generated by the subsequent foaming reaction rises upward and grows, a small pore is formed at the bottom of the polyurethane cake, which is a molded body, while a large pore is formed at the top, The pore diameter at becomes uneven.

  In addition, the two-component curable polyurethane has a short pot life, which is a time from the start of curing to the loss of fluidity. Therefore, it is necessary to perform the above stirring at a high speed. Since the curing speed is high and the viscosity rapidly increases, the entrained air cannot be discharged, resulting in extremely large pores compared to the pores formed by the foaming reaction, and the pores in the polyurethane cake The diameter becomes more uneven.

  When the pore diameter of the polyurethane cake becomes uneven, the pore diameter of the polishing pad obtained by cutting the polyurethane cake into a sheet having a predetermined thickness and punching it is also uneven.

  In such a polishing pad having non-uniform pores, the polishing pressure tends to be non-uniform, and the amount of slurry retained varies within the surface, resulting in unstable polishing. Further, end face dripping (roll-off) occurs in which the outer peripheral edge of the object to be polished is excessively polished.

  In Patent Document 2, it is essential to form two types of pores having different sizes of foaming by heat-expandable microspheres and foaming by water. However, as long as water foaming is used, foaming is possible. As described above, the pores that have become larger in the process gather at the upper portion of the polyurethane cake due to buoyancy, and the pore diameter becomes uneven. As described in Patent Document 2, the polishing pad obtained by Patent Document 2 has a pore having a relatively large diameter of 100 to 800 μm caused by water foaming. In ultra-precision polishing such as CMP, a large-diameter pore has a high frequency of collision with the end of the object to be polished, and is related to the end of the object to be polished at the time of the collision in proportion to the size of the pore diameter. The stress increases, and as a result, the end face droop becomes remarkable.

  The present invention has been made in view of the above points, and an object of the present invention is to provide a method for producing a foamed polyurethane and a polishing pad that have uniform pores and can suppress end-face sagging.

  The process for producing a foamed polyurethane according to the present invention comprises curing by mixing and stirring an isocyanate group-containing compound having a viscosity at 40 ° C. of 3000 mPa · s or less, an unfoamed heat-expandable microsphere, and an active hydrogen-containing compound. And a foamed polyurethane manufacturing method in which the heat-expandable microspheres are foamed by reaction heat, the pot life of the urethane resin composition obtained by mixing the isocyanate group-containing compound and the active hydrogen-containing compound is 200. More than a second.

  In one embodiment, the isocyanate group-containing compound is an isocyanate-terminated prepolymer having an isocyanate group, and the isocyanate-terminated prepolymer may use an aromatic isocyanate as an isocyanate component.

  In another embodiment, the unexpanded heat-expandable microspheres have a particle size of 20 μm to 40 μm.

  The method for producing a polishing pad of the present invention uses the method for producing foamed polyurethane according to the present invention.

  According to the method for producing a polyurethane foam of the present invention, the viscosity of the isocyanate group-containing compound such as an isocyanate-terminated prepolymer is lower than that of the conventional example, and the pot life of the urethane resin composition is longer than that of the conventional example. When mixing and stirring the group-containing compound, the unexpanded heat-expandable microspheres, and the active hydrogen-containing compound, it is possible to suppress air entrainment and to smoothly discharge the entrained air. It is possible to prevent the generation of extremely large pores due to the entrainment of. In addition, since the heat-expandable microspheres having a small particle size are used, the floating of the heat-expandable microspheres is suppressed and uniformly dispersed during mixing and stirring. Can be obtained.

  Further, since the heat-expandable microspheres are foamed by the reaction heat due to the curing reaction, they can be mixed and stirred in an unfoamed state, and the viscosity is increased compared to the case of mixing and stirring the foamed spherical bodies. It can be added in a small amount and in a large amount, whereby a low-density foamed polyurethane can be obtained.

  According to the polishing pad manufacturing method of the present invention, it is possible to prevent the formation of extremely large pores due to air entrainment, and it is possible to obtain a polishing pad having a uniform pore due to foaming of heat-expandable microspheres. As a result, the polishing pressure and the slurry holding amount do not vary, and the polishing is stabilized. Further, it is possible to improve end face droop (roll-off) in which the outer peripheral edge of the object to be polished is excessively polished.

  According to the present invention, a polyurethane foam is produced using a urethane resin composition having a low viscosity and a long pot life and an unexpanded heat-expandable microsphere, so that generation of extremely large pores due to air entrainment is prevented and uniform. Therefore, it is possible to obtain a foamed polyurethane and a polishing pad having a small pore, thereby enabling stable polishing and improving the end face of the object to be polished.

It is a scanning electron microscope (SEM) photograph of a section of conventional examples 1 and 2 and an example. It is a figure which shows the relationship between the pad position and scraping amount of the prior art examples 1 and 2 and an Example. It is a figure which shows the pore distribution of an Example. It is a figure which shows the pore distribution of the prior art example 1. It is a figure which shows the pore distribution of the prior art example 2. It is a figure which shows the pore distribution of patent document 2. FIG. It is a figure which shows the change of the storage elastic modulus (E ') by temperature. It is a figure which shows the change of the loss elastic modulus (E '') with temperature. It is a figure which shows the change of the loss tangent (tan-delta) by temperature. It is a figure which shows the polishing rate of the prior art examples 1 and 2 and an Example. It is a schematic block diagram of CMP apparatus.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  In this embodiment, description will be made by applying to a method for producing a polishing pad made of polyurethane foam.

  In this embodiment, the polishing pad made of foamed polyurethane is prepared by mixing and stirring an isocyanate-terminated prepolymer as an isocyanate group-containing compound, an unfoamed heat-expandable microsphere, and an aromatic amine as an active hydrogen-containing compound. Then, it is poured into a predetermined mold, reacted and cured, and the heat-expandable microspheres are foamed by the reaction heat to obtain a foamed polyurethane molded body.

  Further, the foamed polyurethane molding is cut into a sheet having a predetermined thickness, and punched out to obtain a polishing pad.

  In this embodiment, an isocyanate-terminated prepolymer, which is an isocyanate group-containing compound, is used in order to prevent the formation of extremely large pores in the foamed polyurethane molded body due to the air entrained during the mixing and stirring. A low-viscosity material is used, and the viscosity at 40 ° C. is 3000 mPa · s or less, more preferably 2000 mPa · s or less.

  Furthermore, in this embodiment, the pot life of the urethane resin composition in which the isocyanate group-containing compound and the active hydrogen-containing compound are mixed is made longer than before, and the pot life is 200 seconds or more, more preferably , 250 seconds or more.

  The pot life of this urethane resin composition is preferably 8 minutes or less, for example, at 60 ° C.

  Since the urethane resin composition having a low viscosity and a long pot life is used in this way, the viscosity increase due to curing has not started when mixing and stirring, and the low viscosity state is maintained, and the stirring efficiency is improved. In addition, the entrainment of air can be suppressed and the entrained air can be discharged.

  The isocyanate-terminated prepolymer is obtained by reacting a polyisocyanate and a polyol under commonly used conditions. This isocyanate-terminated prepolymer may be a commercially available one, or may be synthesized from a polyol and a polyisocyanate.

  Examples of the polyisocyanate include 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, 4,4′-diphenylmethane diisocyanate, naphthalene-1,5-diisocyanate, and the like.

  Examples of the polyol include polyether polyols such as poly (oxytetramethylene) glycol and poly (oxypropylene) glycol, polycarbonate polyols, and polyester polyols.

  For polishing, an ether-based polyol that does not cause hydrolysis is preferable. As an ether-based polyol, -O- bonds such as PPG (polypropylene glycol), PTMG (polytetramethylene ether glycol), and PEG (polyethylene glycol) are used. Among them, a PTMG system having good physical properties (tensile properties) is preferable. In particular, PTMG having a molecular weight MW = 500 to 2000 is preferable.

  As an aromatic amine which is an active hydrogen-containing compound, for example, as a diamine compound, 3,3′-dichloro-4,4′-diaminodiphenylmethane (MOCA), chloroaniline-modified dichlorodiaminodiphenylmethane, 3,5-bis ( And methylthio) -2,4-toluenediamine and 3,5-bis (methylthio) -2,6-toluenediamine.

  Unexpanded heat-expandable microspheres are those in which low-boiling hydrocarbons are encapsulated in the hollow portion and the shell portion is made of a thermoplastic resin. For example, heat-expandable microcapsules manufactured by Matsumoto Yushi Seiyaku Co., Ltd. And so on.

  The unexpanded heat-expandable microspheres preferably have a softening temperature of the thermoplastic resin forming the shell higher than the boiling point of the encapsulated low-boiling hydrocarbon. Therefore, when heat equal to or higher than the softening temperature of the thermoplastic resin of the shell is applied, the thermoplastic resin softens and the volume of the low-boiling hydrocarbons expands simultaneously, and the microspheres expand.

  The particle size of the unexpanded heat-expandable microsphere is, for example, about 20 μm to 30 μm. Thus, since the particle size at the time of unfoaming is small, the viscosity of the compound at the time of mixing with the isocyanate-terminated prepolymer can be kept low, and the entrainment of air at the time of mixing and stirring with the active hydrogen compound can be suppressed, Compared to the foamed spherical body, it can be added in a large amount, and a low density foamed polyurethane can be obtained.

  This unfoamed heat-expandable microsphere is foamed during the two-component reaction curing and exists as a micropore.

  The thermoplastic resin constituting the shell of the unexpanded heat-expandable microsphere is composed of, for example, an acrylonitrile-vinylidene chloride copolymer or an acrylonitrile-methyl methacrylate copolymer.

  Moreover, as a low boiling point hydrocarbon which exists in the inside of a microsphere, Preferably, for example, isobutane, pentane, isopentane, petroleum ether, etc. are mentioned. The unexpanded heat-expandable microspheres are mainly foamed by the heat of reaction released when the isocyanate-terminated prepolymer and the active hydrogen-containing compound are mixed and stirred and cured by reaction.

  Hereinafter, the present invention will be described in more detail based on examples and conventional examples.

  As an example, a polishing pad made of foamed polyurethane was produced by the above-described method using an isocyanate-terminated prepolymer having physical properties shown in Table 1 below and a urethane resin composition having a pot life.

  Further, as a conventional example, a conventional polishing pad made of the above-mentioned water-foamed polyurethane without containing heat-expandable microspheres was produced. The physical property values of the isocyanate-terminated prepolymer of this conventional example and the pot life of the urethane resin composition are shown together in Table 1.

  As shown in Table 1, the isocyanate-terminated prepolymers of the examples have a viscosity at 40 ° C. of 1500 mPa · s and a low viscosity of about 1/3 of the viscosity of the conventional example of 4620 mPa · s. The pot life of the urethane resin composition of the example is 450 seconds, which is approximately three times as long as the pot life of the conventional example of 150 seconds. Moreover, the Shore A hardness of the isocyanate terminal prepolymer of an Example is 75 degree | times, and is higher than the hardness of 72 degree | times of a prior art example.

  The tensile strength of the isocyanate-terminated prepolymer of the example is 56 Mpa, which is slightly lower than the tensile strength of 60 Mpa of the conventional example. Further, the elongation of the isocyanate-terminated prepolymer of the example is 50% and the tear strength is 99 N / m, which is lower than the elongation of 238% and the tear strength of 190 N / m of the conventional example.

  Thus, the elongation and tear strength are lower than those of the conventional example, and the resulting polishing pad is hard and brittle. As will be described later, the hardness is high and the cut rate is high. This makes it difficult to polish.

  The composition of the polishing pads of the examples and the conventional examples is shown in Table 2 below.

  As for the conventional example, two types of polishing pads of Conventional Examples 1 and 2 were manufactured by changing the amount of water as a foaming agent.

  The polishing pad of the example was prepared by mixing a mixture of an isocyanate-terminated prepolymer and an unexpanded heat-expandable microsphere in advance according to the formulation shown in Table 2, and 3,3-dichloro-4,4-diaminophenylmethane (MOCA). Are mixed and stirred, cast into a predetermined mold, and cured in an oven at 100 ° C. for 4 hours to obtain a foamed polyurethane molded body. Further, the foamed polyurethane molded body is formed into a sheet having a predetermined thickness. Cut and punched out to obtain a polishing pad.

  Conventional examples 1 and 2 were prepared by mixing and stirring an isocyanate-terminated prepolymer, water as a blowing agent, and 3,3-dichloro-4,4-diaminophenylmethane (MOCA) according to the formulation in Table 2, respectively. And then cured in an oven at 100 ° C. for 4 hours to obtain a foamed polyurethane molded body. Further, the foamed polyurethane molded body is cut into a sheet having a predetermined thickness, and then punched and polished. Each pad was obtained.

  The physical properties of the polishing pads obtained in Examples and Conventional Examples 1 and 2 are shown in Table 3 below, and cross-sectional scanning electron microscope (SEM) photographs are shown in FIGS. 1 (a) to 1 (c), respectively.

  As shown in Table 3, the density of the polishing pad of the example is 0.37, which is lower than the density of 0.52 and 0.40 of the conventional examples 1 and 2, although the density is low. The Shore A hardness of this polishing pad is 85 degrees, which is equivalent to the hardness of 85 degrees and 83 degrees of the conventional examples 1 and 2.

  As described above, the polishing pad of the example is high in hardness as in the conventional example, but has a low density and a larger proportion of pores than the conventional example, thereby increasing the amount of slurry retained and increasing the polishing rate. Can be increased.

The cut rate (μm / min) in Table 3 is dressed under the conditions of a dressing time of 4 minutes, a pressure of 100 g / cm ² , a dresser having a diameter of 150 μm and a protruding amount of 70 μm diamond pellets, a head rotation speed of 100 rpm, and a platen rotation speed of 100 rpm. The amount of wear per unit time was calculated.

  That is, the cut rate refers to the amount of polishing pad that is scraped off by a dresser per unit time.

  FIG. 2 shows the relationship between the pad position due to this dress and the thickness displacement (scrap amount). The cut amount, which is the displacement difference between the center portion of the pad that is not dressed and the dressed portion around it, was divided by the dress time to obtain the cut rate. In FIG. 2, a line L indicates an embodiment, and lines L1 and L2 indicate conventional examples 1 and 2, respectively.

  The cut rate of Conventional Example 1 is 9 μm / min (= 35/4) and the cut rate of Conventional Example 2 is 13 μm / min (= 50/4), whereas the cut rate of Example is 24 μm / min (= It is found that the polishing pad has a high cut rate, is easy to cut, and therefore is not easily clogged.

  Further, the pores of the polishing pads of the example and the conventional examples 1 and 2 were measured under the following conditions.

  Using a VE-8800 manufactured by Keyence as a scanning electron microscope (SEM), the image was observed at an acceleration voltage of 1 kV and a magnification of 50 times, and the obtained image was image analysis software WinRoof Ver 5.6.2 (Mitani Corporation). The distribution of pores was measured using 1600 × 2000 μm as a measurement range.

  As shown in Table 3, the range of pore diameters of Conventional Examples 1 and 2 is as wide as 10 μm to 2.5 mm, whereas the range of pore diameters of Examples is as narrow as 10 μm to 250 μm. From the scanning electron micrographs of FIG. 1, the conventional examples 1 and 2 in FIGS. 1A and 1B have large and small pores and uneven pore diameters, whereas FIG. ), The pore diameter is found to be uniform.

  3 to 5 show the pore distributions of Example and Conventional Examples 1 and 2, respectively. The horizontal axis indicates the pore diameter, and the vertical axis indicates the frequency. In these figures, the pore diameter distribution up to 1500 μm is shown.

  The embodiment of FIG. 3 has a very high frequency and a sharp distribution around 150 μm in which the pore diameter is smaller than the conventional examples 1 and 2 of FIGS. 4 and 5.

  FIG. 6 shows the result of measuring the pore distribution after manufacturing an unfoamed heat-expandable microsphere and a foamed polishing pad by adding water, as in the above-mentioned Patent Document 2. Yes. Since Patent Document 2 includes pores formed by heat-expandable microspheres and pores formed by water foaming, as shown in FIG. 6, the appearance frequency of a pore diameter of about 200 μm and a pore diameter of about 450 μm is high, and a plurality of peaks are observed. It can be seen that the appearance frequency of pore diameters of 800 μm or more is high.

  FIGS. 7 to 9 show changes in storage elastic modulus (E ′), loss elastic modulus (E ″), and loss tangent (tan δ) of Example and Conventional Examples 1 and 2 with temperature.

  As shown in FIG. 8, it can be seen that the loss elastic modulus (E ″) hardly changes in the range of 20 ° C. to 80 ° C. in the example.

Next, using the polishing pads of Examples and Conventional Examples 1 and 2, the wafer was polished under the following polishing conditions, and the polishing rate was measured.
Polishing conditions / dress pressure 100g / cm2, rotation speed 100rpm, time 600sec
・ Rate pressure 300g / cm2, rotation speed 100rpm, slurry flow rate 100ml / min, time 30min
Slurry Nanopure NP6220 manufactured by Nitta Haas, 20-fold diluted The measurement results are shown in FIG.

  Since the example has a lower density and is softer than Conventional Example 1, the polishing rate is lower than that of Conventional Example 1, but the polishing rate is higher than that of Conventional Example 2 that has the same density.

  The manufacturing method of the polyurethane foam of the present invention is not limited to the polishing pad, and may be used for manufacturing a cushion material, a sealing material, a vibration isolating material, and the like.

  The present invention is useful for manufacturing a polishing pad used for polishing a silicon wafer or a glass substrate.

2 Polishing pad 3 Slurry 5 Semiconductor wafer

Claims (5)

An isocyanate group-containing compound having a viscosity at 40 ° C. of 3000 mPa · s or less, a non-foamed heat-expandable microsphere, and an active hydrogen-containing compound are mixed and stirred to be cured, and the heat-expandable by reaction heat. A method of producing a polyurethane foam for foaming microspheres,
A polyurethane resin composition in which the isocyanate group-containing compound and the active hydrogen-containing compound are mixed has a pot life of 200 seconds or longer.   The method for producing a polyurethane foam according to claim 1, wherein the isocyanate group-containing compound is an isocyanate-terminated prepolymer having an isocyanate group.   The method for producing a polyurethane foam according to claim 2, wherein the isocyanate-terminated prepolymer uses an aromatic isocyanate as an isocyanate component.   The method for producing a polyurethane foam according to any one of claims 1 to 3, wherein a particle size of the unfoamed heat-expandable microsphere is 20 µm to 30 µm.   The manufacturing method of the polishing pad using the manufacturing method of the polyurethane foam as described in any one of the said Claims 1 thru | or 4.