TWI671162B - 拋光物和用於製造化學機械拋光物的整合系統 - Google Patents

拋光物和用於製造化學機械拋光物的整合系統 Download PDF

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TWI671162B
TWI671162B TW104133737A TW104133737A TWI671162B TW I671162 B TWI671162 B TW I671162B TW 104133737 A TW104133737 A TW 104133737A TW 104133737 A TW104133737 A TW 104133737A TW I671162 B TWI671162 B TW I671162B
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polishing
polymer material
features
micro
polymer
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TW201622894A (zh
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帕逖邦德拉納格B
克利許南卡錫拉曼
瑞特法德丹尼爾
巴札拉吉菲
派瑞羅素艾德華
敏克葛利格瑞E
瑞德可佛瑞德C
奧利拉馬韓卓C
馮傑森G
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美商應用材料股份有限公司
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10Processes of additive manufacturing
    • B29C64/106Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/112Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24BMACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B37/00Lapping machines or devices; Accessories
    • B24B37/11Lapping tools
    • B24B37/20Lapping pads for working plane surfaces
    • B24B37/22Lapping pads for working plane surfaces characterised by a multi-layered structure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24BMACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B37/00Lapping machines or devices; Accessories
    • B24B37/11Lapping tools
    • B24B37/20Lapping pads for working plane surfaces
    • B24B37/24Lapping pads for working plane surfaces characterised by the composition or properties of the pad materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24BMACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B37/00Lapping machines or devices; Accessories
    • B24B37/11Lapping tools
    • B24B37/20Lapping pads for working plane surfaces
    • B24B37/26Lapping pads for working plane surfaces characterised by the shape of the lapping pad surface, e.g. grooved
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D11/00Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
    • B24D11/001Manufacture of flexible abrasive materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00Apparatus for additive manufacturing; Details thereof or accessories therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00Materials specially adapted for additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00Products made by additive manufacturing
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
    • H01L21/18Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
    • H01L21/30Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
    • H01L21/302Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to change their surface-physical characteristics or shape, e.g. etching, polishing, cutting
    • H01L21/304Mechanical treatment, e.g. grinding, polishing, cutting
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
    • H01L21/18Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer the devices having semiconductor bodies comprising elements of Group IV of the Periodic Table or AIIIBV compounds with or without impurities, e.g. doping materials
    • H01L21/30Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26
    • H01L21/302Treatment of semiconductor bodies using processes or apparatus not provided for in groups H01L21/20 - H01L21/26 to change their surface-physical characteristics or shape, e.g. etching, polishing, cutting
    • H01L21/306Chemical or electrical treatment, e.g. electrolytic etching
    • H01L21/30625With simultaneous mechanical treatment, e.g. mechanico-chemical polishing
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/67005Apparatus not specifically provided for elsewhere
    • H01L21/67011Apparatus for manufacture or treatment
    • H01L21/67092Apparatus for mechanical treatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16Fillers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037Other properties
    • B29K2995/007Hardness
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
  • Mechanical Treatment Of Semiconductor (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

拋光物製造系統包含進料段以及捲取段以及列印段與固化段,捲取段包含供應輥而用於化學機械拋光處理,拋光物設置於供應輥上,列印段包含複數個列印頭,該等列印頭設置於進料段與捲取段之間,且固化段設置於進料段與捲取段之間,固化段包含熱固化元件以及電磁固化元件之一者或兩者。

Description

拋光物和用於製造化學機械拋光物的整合系統
所揭露的內容之實施例一般而言係關於用於基板或晶圓的化學機械拋光之裝置與方法,更具體地,係關於拋光物製造系統以及關於用於化學機械拋光的拋光物或拋光墊之製造方法。
在基板上之積體電路以及其他電子元件的製造中,導體、半導體,以及介電材料的多層被沉積於基板上或從基板的特徵側移除。將這些材料連續沉積在基板上與從基板移除可能使特徵側成為非平面而需要平坦化處理(一般稱之為拋光),其中先前所沉積之材料會從基板的特徵側移除以形成一般地均勻、平坦或水平的表面。這種處理對移除不期望的表面形貌與表面缺陷(例如粗糙表面、附聚材料、晶格損壞和劃傷)是有用的。拋光處理對藉由移除用以填平特徵的過量的沉積材料而在基板上形成特徵亦是有用的,且藉以提供用於後續沉積與處理的均勻或水平表面。
一種拋光處理被稱之為化學機械拋光(CMP),其中基板被置於在基板支架組件中且可控地推 壓安裝於移動式壓盤組件的拋光介質。拋光介質通常為拋光物或拋光墊。支架組件提供相對於移動式壓盤的旋轉運動且材料的移除係藉由基板的特徵側與拋光介質之間的化學活性、機械研磨或化學活性與機械研磨之組合而完成。
然而,拋光處理導致拋光介質的拋光表面會被「打光」或平滑化,其將減少薄膜移除速率。拋光介質的表面接著被「粗糙化」或經調節成恢復拋光表面,其強化局部流體輸送且改良移除率。傳統上在將兩個晶圓拋光之間或在將晶圓拋光的同時,會以塗覆有磨料(例如微米級的工業用鑽石)的調節圓盤來執行調節作用。調節圓盤旋轉並按壓介質表面且機械地切割拋光介質的表面。然而,當施加於調節圓盤的旋轉與/或向下力受控制時,該切割的動作相對地沒有章法,且磨料可能未均勻地切割拋光表面,這會產生橫跨於拋光介質的拋光表面的表面粗糙度的梯度。當調節圓盤的切割動作未適當地控制時,介質的壽命可能縮短。再者,調節圓盤的切割動作有時會在拋光表面產生大的凹凸,以及墊碎片。縱使這些凹凸有益於拋光處理(在拋光期間凹凸會脫離),其卻會產生會在基板上產生缺陷的(伴隨來自於切割動作的)碎片。
執行於拋光物的拋光表面上的許多其他的方法與系統已被執行以試圖提供拋光表面的均勻的調節。然而,元件與系統的控制(例如切割、向下力或其他指標)仍不盡如人意且可能因拋光介質本身的性質而受挫。舉例 而言,例如墊介質的硬度與/或密度等性質可能為非均勻的,其將導致對拋光表面的一些部分相對於其他部分的更積極的調節。
因此,需要具有促進均勻拋光與調節的性質的拋光物。
所揭露的內容之實施例一般而言係關於用於基板或晶圓的化學機械拋光之裝置與方法,更具體地,係關於拋光物製造系統以及關於用於化學機械拋光的拋光物或拋光墊之製造方法。
在一個實施例中,拋光物製造系統包括:一進料段與一捲取段,該捲取段包含一供應輥,該供應輥具有一拋光物而用於化學機械拋光處理,該拋光物設置於該供應輥上;一列印段;該列印段包含複數個列印頭,該等列印頭設置於該進料段與該捲取段之間;及一固化段,該固化段設置於該進料段與該捲取段之間,該固化段包含一熱固化元件和一電磁固化元件的一者或兩者。
在另一個實施例中,提供一種拋光物且該拋光物包括:一複合墊體,該複合墊體包含:複數個拋光特徵,該等拋光特徵形成一拋光表面以及一或更多個基特徵,其中該等複數個拋光特徵由一第一材料形成;該等基特徵由一第二材料形成,其中該等一或更多個基特徵包圍該等複數個拋光特徵以形成一單一主體且該第一材料具有一硬度,該硬度大於該第二材料的一硬度。
在另一個實施例中,提供一種用於化學機械拋光處理的替換的供應輥,該供應輥包括:一桿件,該桿件具有一拋光物,該拋光物纏繞於該桿件上。該拋光物包含:一複合墊體,該複合墊體包含:複數個拋光特徵,該等特徵形成一拋光表面,其中該等複數個拋光特徵由一第一材料形成;以及一或更多個基特徵,該等基特徵由一第二材料形成,其中該等一或更多個基特徵包圍該等複數個拋光特徵以形成一單一主體且該第一材料具有一硬度,該硬度大於該第二材料的一硬度。
102‧‧‧工廠接口
104‧‧‧裝載機器人
106‧‧‧拋光模組
108‧‧‧控制器
110‧‧‧中央處理單元(CPU)
112‧‧‧記憶體
114‧‧‧基板/支援電路
121‧‧‧基板
122‧‧‧基板
123‧‧‧拋光物
132‧‧‧壓盤組件
134‧‧‧旋轉料架
136‧‧‧轉移站
140‧‧‧基座
142‧‧‧輸入緩衝器
144‧‧‧輸出緩衝器
146‧‧‧轉移機器人/支援電路
148‧‧‧裝載杯組件
150‧‧‧手臂
152‧‧‧承載頭
154‧‧‧流體噴嘴
204‧‧‧上部引導部件
205‧‧‧下部引導部件
206‧‧‧供應組件
208‧‧‧捲取組件
212‧‧‧能量源
214‧‧‧上部引導部件
215‧‧‧電磁能量
216‧‧‧下部引導部件
218‧‧‧側壁
220‧‧‧光學感測元件
221‧‧‧上部表面
222‧‧‧馬達
224‧‧‧馬達
226‧‧‧背襯襯墊組件
228‧‧‧致動器
230‧‧‧壓盤
232‧‧‧真空系統
234‧‧‧通道
236‧‧‧盤件
238‧‧‧子襯墊
240‧‧‧子板件
242‧‧‧開孔
244‧‧‧真空源
251‧‧‧圖案化表面
252‧‧‧捲取輥
254‧‧‧供應輥
255‧‧‧桿件
260‧‧‧頂表面
300A‧‧‧墊製造系統
300B‧‧‧墊製造系統
302‧‧‧進料段
304‧‧‧列印段
306‧‧‧固化段
308‧‧‧墊捲繞段
310‧‧‧輸送帶
311‧‧‧控制器
312‧‧‧網件
314‧‧‧輥件
315‧‧‧驅動馬達
316‧‧‧供應輥
317‧‧‧背襯材料
318‧‧‧進料輥
319‧‧‧黏著劑
320‧‧‧控制元件
322‧‧‧預處理元件
324‧‧‧列印站
325‧‧‧材料源
326‧‧‧噴嘴
327‧‧‧列印頭
328‧‧‧圖案化表面
330‧‧‧可移動平台
332‧‧‧運動控制元件
333‧‧‧固化元件
334‧‧‧外殼
336‧‧‧雷射源
338‧‧‧電子束發射器
340‧‧‧捲取輥
342‧‧‧運動控制元件
344‧‧‧預處理段
346‧‧‧插槽/晶粒塗佈機
348‧‧‧固化站
350‧‧‧固化站
352‧‧‧熱固化元件
400‧‧‧支撐座
405‧‧‧拋光層
410‧‧‧滴液
415‧‧‧滴液噴射列印器
420A‧‧‧膜層
420B‧‧‧膜層
422‧‧‧膜層
425‧‧‧固化材料
430A‧‧‧列印頭
430B‧‧‧列印頭
430‧‧‧子層
432‧‧‧磚片
435‧‧‧噴嘴
445‧‧‧磨料顆粒/顆粒
450‧‧‧結構
455‧‧‧溝槽
500‧‧‧拋光物
505‧‧‧拋光表面
515‧‧‧第一材料
519‧‧‧黏著劑
520‧‧‧第二材料
522‧‧‧背襯材料
530‧‧‧溝槽
532‧‧‧磚片
536‧‧‧透明部分
570‧‧‧拋光材料
600‧‧‧拋光物
602‧‧‧複合墊主體
604‧‧‧硬質特徵
605‧‧‧拋光表面
606‧‧‧彈性特徵
630‧‧‧溝槽
632‧‧‧磚片
635‧‧‧橫向溝槽/溝槽
636‧‧‧透明部分
670‧‧‧拋光材料
700‧‧‧拋光物
705‧‧‧拋光表面
710‧‧‧第一材料
712‧‧‧第二材料
732‧‧‧孔隙
736‧‧‧側部
800‧‧‧拋光物
802‧‧‧複合墊主體/基材層
804‧‧‧硬質特徵
805‧‧‧軟材料
806‧‧‧凸起特徵
808‧‧‧上表面/外表面
818‧‧‧溝槽
900‧‧‧拋光墊
902‧‧‧複合墊主體
904‧‧‧硬質特徵
906‧‧‧彈性特徵
910‧‧‧觀察窗
1000‧‧‧拋光墊
1002‧‧‧表面特徵
1004‧‧‧基底材料層
1006‧‧‧背襯層
1100‧‧‧拋光物
1102‧‧‧複合墊體
1104‧‧‧背襯層
1106‧‧‧外緣區/邊緣區域
1108‧‧‧內緣區/邊緣區域
1110‧‧‧中央區域
1202‧‧‧表面特徵
1204‧‧‧表面特徵
1206‧‧‧基底材料層
1208‧‧‧基底材料層
1210‧‧‧鎖定層
藉由參照所附圖式中繪示之本發明的一些例示實施例,可瞭解簡短總結於上文且在下文更詳細論述之本發明的實施例。但是,應注意到,所附圖式只例示本發明之一般實施例且因此不視為限制本發明之範圍,因為本發明可容許其他等效實施例。
第1圖是範例性化學機械拋光模組的平面視圖。
第2圖是第1圖的模組的範例性處理站的剖面視圖。
第3A圖是卷對卷墊製造系統的一個實施例的示意性等角視圖。
第3B圖是卷對卷墊製造系統的其他的實施例的示意性側視圖。
第4A圖是被用於第3A圖的墊製造系統或第3B圖的墊製造系統的3D列印站的一個實施例的示意性剖面視圖。
第4B圖是被用於第3A圖的墊製造系統或第3B圖的墊製造系統的3D列印站的一個實施例的示意性剖面視圖。
第5A圖是拋光物組件的一個實施例的俯視圖。
第5B圖是第5A圖所示之拋光物組件之一部分的放大等角視圖。
第6A圖是拋光物組件的其他的實施例的俯視圖。
第6B圖是第6A圖所示之拋光物組件之一部分的放大等角視圖。
第7A圖是拋光物組件的其他的實施例的俯視圖。
第7B圖是第6A圖所示之拋光物組件之一部分的放大等角視圖。
第8圖是根據本揭露內容的其他的實施例的拋光物的示意性透視剖面視圖。
第9圖是具有觀察窗的拋光物的其他的實施例的示意性透視剖面視圖。
第10圖是包含背襯層的拋光物的其他的實施例的示意性剖面視圖。
第11圖是具有多個區域的拋光物的其他的實施例的示意性剖面視圖。
第12圖是第11圖的拋光物的局部的放大剖面視圖。
為了促進瞭解,已經在任何可能的地方使用相同的參考數字來表示圖式中共用的相同元件。可瞭解到,一實施例的元件與特徵可有利地併入在其他實施例中,而不用另外詳述。
第1圖繪示出拋光模組106的平面視圖,拋光模組106是位於美國加州聖克拉拉市的應用材料公司所製造的化學機械拋光機-REFLEXION®-之一部分。在此所述的實施例可用於這個拋光系統。然而,所屬技術領域之技術人員可有利地適當修改在此所教示與所述的實施例以將其應用於由其他製造者所製之使用拋光材料(且特別是使用卷形式的拋光材料)的其他化學機械拋光機。
拋光模組106一般包含裝載機器人104、控制器108、轉移站136、複數個處理或拋光站(例如支撐複數個拋光或承載頭152(僅一個示於第1圖中)的壓盤組件132、基座140以及旋轉料架134)。一般而言,裝載機器人104設置成鄰近於拋光模組106與工廠接口102(未示)以促進基板122在其間之轉移。
轉移站136一般包含轉移機器人146、輸入緩衝器142、輸出緩衝器144以及裝載杯組件148。輸入緩 衝器站142從裝載機器人104接收基板122。轉移機器人146將基板122從輸入緩衝器站142移動且移動至裝載杯組件148,在裝載杯組件148中基板122被轉移至承載頭152。
如上所述為促進拋光模組106的控制,控制器108包含中央處理單元(CPU)110、支援電路114與記憶體112。CPU 110可被用於工業設定,工業設定係用來控制不同拋光器、驅動器、機器人以及子處理器的任何型式的電腦處理器之一者。記憶體112耦接於CPU 110。記憶體112(或電腦可讀媒體)可為容易取得的記憶體(諸如隨機存取記憶體(RAM)、唯讀記憶體(ROM)、軟碟、硬碟,或任何其他形式的(區域性或遠程性)數位儲存)之一或更多者。支援電路114耦接於CPU 110以用於以習知方式支援處理器。這些電路包含快取、電源、時序電路、輸入/輸出電路、子系統等。
一般而言,旋轉料架134具有複數個手臂150,該等手臂150每一者支撐承載頭152之一者。手臂150之兩者繪示於第1圖中且以虛線示出,使得設置於壓盤組件132一者上的轉移站與平坦化或拋光物123可被看見。旋轉料架134可轉位使得承載頭152在壓盤組件132與轉移站136之間移動。
典型地,藉由將保留在承載頭152的基板122相對於受支撐在壓盤組件132上的拋光物123移動,化學機械拋光處理會在每一個壓盤組件132處執行。拋光物 123可具有平緩表面、織紋表面、含磨料的表面,或它們的組合。再者,拋光物123可前進而橫跨或相對地固定至拋光表面。典型地,拋光物123藉由真空、機械夾具或藉由其他固定方法而被可釋放地固定至壓盤組件132。
拋光物123的實施例可包含根據在此所述的實施例而由三維(3D)列印處理所產生的聚合材料。拋光物123可包含奈米尺寸的特徵(例如具有約10奈米至約200奈米大小的聚合物基質內的粒子與/或離散區或域)。拋光處理可利用包含磨料顆粒且被流體噴嘴154傳送至墊表面的漿料來輔助拋光基板122。流體噴嘴154可在所示的方向上旋轉而如所示旋轉至不與壓盤組件132接觸的位置,或至壓盤組件132之每一者上方的位置。
在此所述的3D列印包含(但不限於)PolyJet的沉積、噴墨印刷、熔融沉積建模、粘結劑噴射、粉末床融合、選擇性雷射燒結、立體微影術、光聚合固化技術數位光處理、片材層疊、定向能量沉積,以及上述外其他的3D沉積或印刷處理。
第2圖繪示出壓盤組件132與範例性供應組件206與捲取組件208的側視圖,其繪示出橫跨壓盤230的拋光物123的位置。一般地,供應組件206包含設置於壓盤組件132的側壁218之間的供應輥254、上部引導部件204與下部引導部件205。拋光物123可繞著桿件255纏繞,其中桿件255可為管狀構件或銷釘。一般地,捲取組件208包含設置於側壁218之間的捲取輥252、上部引導 部件214以及下部引導部件216之所有者。捲取輥252一般包含拋光物123的經使用的部分且被配置以便一旦捲取輥252由經使用的拋光物123所填滿,其可容易地以空的捲取輥加以替換。上部引導部件214經定位用以將拋光物123從壓盤230引導至下部引導部件216。下部引導部件216將拋光物123引導至捲取輥252上。壓盤組件132亦可包含光學感測元件220(例如雷射),光學感測元件220適於接收與傳送光學信號以在基板上的平坦化或拋光處理中以端點偵測。
供應輥254一般包含拋光物123的未使用部分且被配置以便一旦設置於供應輥254上的拋光物123已由拋光或平坦化處理消耗,供應輥254可容易地以其他包含新拋光物123的供應輥254加以替換。在一些實施例中,能量源212可經定位以將電磁能量215朝向設置於供應輥254與捲取輥252之間的拋光物123的上部表面221供應。電磁能量215可為光束或能量流的形式且可被用以與拋光物123的上部表面221的離散區域選擇性地交互作用(即消融和/或熱)。電磁能量215可為電子束或一些電子束、雷射光束或一些雷射光束,以及其組合。電磁能量215可被用以在拋光處理之前、過程中或之後調節拋光物123的上部表面221。在一些實施例中,電磁能量215被用以在拋光期間調節拋光物123的上部表面221以調整拋光處理。
拋光物123的上部表面221一般被配置成可控地促進拋光物123以X方向橫跨背襯襯墊組件226。拋光物123一般藉由平衡馬達222(耦接至供應組件206)及馬達224(耦接至捲取組件208)之間的力而相對於壓盤230移動。棘輪機制和/或煞車系統(未示)可耦接至供應組件206與捲取組件208的之一者或兩者以將拋光物123相對於背襯襯墊組件226而固定。壓盤230可被可操作地耦接至旋轉致動器228,旋轉致動器228將壓盤組件132繞一旋轉軸旋轉,該旋轉軸一般垂直於X與/或Y方向。真空系統232可耦接於致動器228與背襯襯墊組件226之間。真空系統232可被用以將拋光物123之位置固定至壓盤230上。真空系統232可包含形成在盤件236內的通道234,盤件236設置於背襯襯墊組件226下方。背襯襯墊組件226可包含子襯墊238與子板件240,其中之每一者具有開孔242,開孔242被形成通過子襯墊238與子板件240且與通道234與真空源244流體相通。子襯墊238一般為塑膠(例如聚碳酸酯或發泡聚氨酯)。一般而言,子襯墊238的硬度或硬度計可被選擇以產生特別的拋光結果。子襯墊238一般將拋光物123的上部表面221保持在與基板平面(未示)平行的平面以提升基板的全區域的平坦化程度。子板件240位於子襯墊238上且位於壓盤230的上方使得子襯墊238的上部表面一般而言被保持與壓盤230的頂表面260平行。
第3A圖為用於準備可用於第2圖之壓盤組件132的拋光物123的墊製造系統300A的一個實施例的示意性等角視圖。在一個實施例中,墊製造系統300A一般包含進料段302、列印段304、固化段306以及墊捲繞段308。墊製造系統300A亦包含輸送帶310,輸送帶310包含設置於至少兩個輥件314之間的網件312。輥件314之一者或兩者可耦接至驅動馬達315,驅動馬達315將輥件314與/或網件312以指示為A的箭頭所繪示的方向旋轉。進料段302、列印段304、固化段306以及墊捲繞段308可被可操作地耦接至控制器311。輸送帶310可被可操作地由控制器311連續地移動或間歇性地移動。
進料段302可包含供應輥316,供應輥316可操作地耦接至輸送帶310。供應輥316可為背襯材料317(例如聚合物材料,例如,雙軸取向的聚對苯二甲酸乙酯(BOPET)材料)。供應輥316可被設置於進料輥318上,進料輥318受馬達控制元件320所驅動或控制。馬達控制元件320可為馬達與/或包含煞車系統,煞車系統將預定的張力提供於供應輥316上,使得供應輥316的退繞速度由驅動馬達315與/或網件312所驅動。進料段302亦可包含預處理元件322。於列印段304進行列印之前,預處理元件322可配置成將塗層噴灑於或另提供於背襯材料317上。在一些實施例中,於列印段304進行列印之前,預處理元件322可被利用以將背襯材料317加熱。
列印段304包含設置於進料段302下游的3D列印站324。列印段304利用一或更多個列印頭327以將圖案化表面328提供於背襯材料317上。列印段304可包含耦接至運動控制元件332的可移動平台330,運動控制元件332可被利用以將列印頭327相對於背襯材料317與網件312而移動。
列印頭327可耦接至具有列印材料的材料源325,列印材料可被用以形成圖案化表面328。列印材料可包含聚合物材料如聚氨酯、聚碳酸酯、含氟聚合物、聚四氟乙烯(PTFE)、PTFA、聚苯硫醚(PPS),或它們的組合。範例還包括聚乙烯醇、果膠、聚乙烯吡咯烷酮、羥乙基纖維素、甲基纖維素、羥丙甲纖維素(hydropropylmethylcellulose)、羧甲基纖維素、羥丙基纖維素、聚丙烯酸、聚丙烯酰胺、聚乙二醇、聚羥基醚丙烯酸酯(polyhydroxyetheracrylites)、澱粉、馬來酸共聚物、聚環氧乙烷、聚氨酯以及它們的組合。
在一個實施例中,聚合材料可被當作基材料而沉積在背襯材料317上。所形成的聚合材料可包含一個開細孔或閉合細孔的聚氨酯材料,並且可以包括散佈於其中的奈米級的顆粒。粒子可包含有機奈米粒子。在一個實施例中,奈米粒子可包含分子或元素環和/或奈米結構。範例包含碳(C)同素異形體,如碳奈米管和其它結構,分子碳環具有五鍵(五邊形)、六鍵(六邊形),或超過六鍵。其它實例包括富勒烯狀超分子。在另一個實施方案 中,奈米尺度顆粒可以是一種陶瓷材料、氧化鋁、玻璃(例如,二氧化矽(SiO2)),以及它們的組合或衍生物。在另一個實施方案中,奈米尺度顆粒可以包括金屬氧化物(如鈦(IV)氧化物或二氧化鈦(TiO2)、氧化鋯(IV)、氧化或二氧化鋯(ZrO2),它們的組合及它們的衍生物在內的其它氧化物)。
由列印頭327所形成的圖案化表面328可包含複合基材,例如聚合物基質,其可以從氨基甲酸乙酯、蜜胺、聚酯、聚碸、聚醋酸乙烯酯、氟代烴,和類似物,以及它們的混合物、共聚物和它們的移植物形成。在一個實施例中,聚合物基質包含聚氨酯聚合物,聚氨酯聚合物可從一個聚醚基液體聚氨酯形成。液體聚氨酯可以與多官能胺、二胺、三胺或多官能羥基化合物或混合的功能的化合物(如氨基甲酸酯/脲的交聯組合物的羥基/胺,其在固化時形成脲鏈接和一個交聯的聚合物網絡)加以反應。
固化段306包含可設置於外殼334內或上的固化元件333。外殼334設置於網件312上方使得在背襯材料317上的網件312與圖案化表面328可在外殼334下方通過。固化元件333可為熱烤箱、紫外(UV)光發射器,或其組合。在一個實施例中,固化元件333可包含雷射源336與電子束發射器338之一或兩者,雷射源336與電子束發射器338可被用以將由列印頭327所沉積的材料加以固化而形成圖案化表面328。在一些實施例中,當使用電子束發射器時,墊製造系統300A可位於外殼中,其中 在外殼中壓力可被控制。雷射源336與電子束發射器338可單獨或與熱或UV能量結合而被使用。在一些實施例中,雷射源336與電子束發射器338可被用於圓點固化處理中,在圓點固化處理中圖案化表面328之特定部分被瞄準。藉由雷射源336或電子束發射器338之圓點瞄準可將圖案化表面328的離散區域加熱以產生離散區域的表面,其可比周圍部分較硬或可壓縮性較小。雷射源336亦可被用以將圖案化表面328之部分加以燒蝕以在該部分產生細緻的紋理。
墊捲繞段308包含捲取輥340,在捲取輥340中拋光物123可被纏繞。捲取輥340可從墊製造系統300A移除以在第2圖的壓盤組件132中被使用作為供應輥254。在製造期間,捲取輥340可耦接於運動控制元件342。運動控制元件342可為馬達與/或包含控制捲取輥340的纏繞速度的煞車系統。
第3B圖為墊製造系統300B的其他的實施例的示意性側視圖。墊製造系統300B包含具有進料段302的輸送帶310、列印段304、固化段306及墊捲繞段308,墊製造系統300B可相似於第3A圖的墊製造系統300A。然而,墊製造系統300B包含供應輥316,供應輥316可控地鬆綁網件312,網件312將輸送帶310移動至捲取輥340。網件312可為相似於第3A圖所述之背襯材料317的背襯材料。網件312的運動與輸送帶310以及捲取輥340可由運動控制元件與控制器所控制,運動控制 元件與控制器相似於第3A圖所述的墊製造系統300A且為求簡潔第3B圖中省略相關描述。
墊製造系統300B包含可選的預處理段344,預處理段344位於進料段302與列印段304之間。預處理段344可被用以在網件312上形成黏著層或釋放層。可替換地,黏著或釋放層可使用3D列印站324而被形成於列印段304上。當使用預處理段344時,插槽/晶粒塗佈機346可被用以將一層或多層沉積於網件312上。額外地,固化站348(使用UV光或加熱元件)可被用以將由插槽/晶粒塗佈機346所沉積的材料加以固化。
在這個實施例中,3D列印站324包含一陣列的列印頭327。列印頭327可被用以可選地在網件312上形成黏著或釋放層並且用以在網件312上形成圖案化表面328。在一個範例中,列印頭327的多個列與欄可橫跨輸送帶310的寬度以及輸送帶310長度的之一部分。在一些實施例中,一或更多個列印頭327可相對於輸送帶310移動。列印頭327會耦接於第3A圖所述之材料源325。
固化段306可包含可選的電磁能量源350與熱固化元件352之一者或兩者。電磁能量源350可為第3A圖所述的雷射源或電子束發射器之一或其組合。熱固化元件352可為烤箱或UV光陣列。
墊捲繞段308包含捲取輥340,在捲取輥340中拋光物123可被纏繞。捲取輥340可從墊製造系統 300A中移除以在第2圖之壓盤組件132中被用以作為供應輥254。
第4A圖為可被用於第3A圖的墊製造系統300A或第3B圖的墊製造系統300B的3D列印站324的一個實施例的示意性剖面視圖。第4A圖示出使用3D列印處理所製造的拋光物123的一個實施例的一部分。3D列印提供用於產生拋光物的方便且高度可控的處理,其中磨料嵌埋於拋光物的拋光層內的特定區域內。拋光物123可被列印於支撐座400上,支撐座400可為第3A圖之背襯材料317或第3B圖之網件312。
提到第4A圖,至少拋光物123的拋光層405係使用3D列印處理製造。在製造處理中,當支撐座被沿著A所指的箭頭(沿X方向)移動時,材料的薄層逐步沉積且逐步融合於支撐座400上。例如,墊前驅物材料(來自於第3A圖的材料源325)的滴液410可被從滴液噴射列印器415的噴嘴326噴射出以形成複數個膜層420A、420B以及422。膜層可形成固化材料425,固化材料425包含能將其他層連續沉積於其上的墊前驅物材料。滴液噴射列印器415可相似於噴墨列印器,但滴液噴射列印器415使用墊前驅物材料而非墨水。在製造期間,當支撐座400連續地或斷斷續續地在X方向上移動時,噴嘴326可在X或Y方向之一者或兩者中改變。
在一個範例中,第一個膜層420A可藉由將滴液410噴射於支撐座400上而被沉積。在固化之後,隨後 的膜層(例如膜層420B與422(介於其之間的其他層為求簡潔而未示))可被沉積於第一個膜層420A上。在每一層固化後,新的膜層接著被沉積於前一個沉積的膜層上直到製造出全三維拋光層405為止。可藉由聚合作用來完成固化作用。例如,墊前驅物材料的膜層可為單體,且單體可藉由UV固化或藉由加熱來進行原位(in-situ)聚合。墊前驅物材料可被有效地且隨著沉積立即地固化,或墊前驅物材料的整層可被沉積且接著該層可同時被固化。
每一層可由噴嘴326以一圖案方式供應,該圖案存於3D圖式電腦程式中,3D圖式電腦程式被提供於控制器311上。420A、420B與422之每一層的厚度可少於拋光層405的50%或全部。在一個實施例中,420A、420B與422之每一層的厚度可少於拋光層405整體厚度的10%(例如少於5%(例如約少於拋光層405整體厚度的1%))。在一個實施例中,每一層的厚度可包含約30微米至約60微米或更少的厚度(例如為奈米級數(例如1至100奈米)),以及甚至至微微尺寸(picoscale)維度(例如微微(10-12)米)。
支撐座400可為剛性的基座,或者一個可撓性薄膜(例如一層聚四氟乙烯(PTFE))。倘若支撐座400為薄膜,則支撐座400可形成拋光物123之一部分。例如,支撐座400可為背襯材料317或為背襯材料317與拋光層405之間的一層。可替換地,拋光層405可從支撐座400移除且膜層420A與420B可形成背襯層材料。
在一些實施例中,磨料顆粒可分散在墊前驅物材料的滴液410中。在膜層形成期間,磨料顆粒可局部地分散進入拋光層405。磨料顆粒的局部分散有助於將結塊最小化。在一些實施例中,磨料顆粒可與液體熱固性聚合物前驅物預先混合。熱固性聚合物前驅物和磨料顆粒的混合物的連續攪拌可防止顆粒的結塊,類似於用於將在噴墨列印器中使用的墨水顏料均勻化的相似的裝置。此外,混合物的連續攪拌確保了前驅物材料中的磨料顆粒的相當均勻的分佈。這樣可導致通過拋光層的顆粒的更均勻的分佈,如此可改善拋光的均勻性且亦可助於防止結塊。
預先混合的混合物可從單一噴嘴(例如,噴嘴326)根據特定的圖案的方式加以分配。例如,預先混合混合物可以被均勻地分配以產生一種均勻的拋光層405,其中嵌埋於拋光層405中的磨料顆粒均勻地分佈於整個拋光層405的厚度。
第4B圖是可用於第3A圖的墊製造系統300A或第3B圖的墊製造系統300B的一個三維列印站324的一個實施的一個示意性的剖面視圖。在第4B圖中圖示了使用3D列印處理之拋光物123的其他的實施例的一部分的剖面視圖。基於來自CAD程式的指令,拋光物123由滴液噴射列印器415形成而包含由溝槽455分開的複數個結構450。結構450與溝槽455可形成拋光層405。子層430亦可隨拋光物123而由滴液噴射列印器415形成。子層430可為背襯材料317(示於第3A圖中)。例 如,子層430與拋光層405可由滴液噴射列印器415的不中斷的操作所製造。藉由使用不同前驅物與/或不同數量的固化作用(例如不同強度或照射時間的UV輻射)而提供相較於拋光層405具有不同硬度的子層430。在其他實施例中,子層430由習知處理所製造且接著固定於拋光層405。例如,拋光層405可藉由薄黏著層(例如壓力感測黏著劑)固定至子層430。
在第4B圖中,具有噴嘴435的列印頭430A可被用以分配純液體熱固性聚合物的前驅物,而具有噴嘴435的列印頭430B可被用於具有磨料顆粒445包含在其中的液體熱固性聚合物前驅物或熔融熱塑性塑膠。磨料顆粒445可以僅分配在選定的拋光物123上的位置。這些選定的位置共同地形成所需的磨料顆粒的印刷圖案,並且可以被存儲為CAD兼容的文件,CAD兼容的文件接著由電子控制器讀取(如,控制器311),電子控制器會控制滴液噴射列印器415。電子控制信號接著發送給滴液噴射列印器415以在僅當噴嘴435被移動至由CAD兼容文件所指定的位置時,分配預先混合的混合物。顆粒445的例子可以包括成孔劑,例如聚乙二醇(PEG)、聚環氧乙烷(PEO)、中空粒子/微球((在約5奈米至約50微米的尺寸),例如,明膠、脫乙酰殼多醣、氮化矽、聚甲基丙烯酸甲酯);中孔奈米顆粒、羧甲基纖維素(CMC)、大孔的水凝膠和乳液的微球。可替換地,榨取技術可以由作為共致孔劑的鹽微粒(NaCl)和PEG的組合所使用。
可替換地,磨料顆粒445可以與熔融的熱塑性塑膠預混合而非使用液體熱固性聚合物的前驅物。在本實施例中,與磨料顆粒445混合的混合物在被攪拌之前亦連續地被分配。當根據所需的列印圖案而將混合物從液滴噴射列印器415分配出後,該混合物的熔融部分冷卻並凝固,且磨料顆粒445被鎖定在適當位置。混合物的連續攪動確保前驅物材料中的磨料顆粒445能相當均勻的分佈。這可導致顆粒445的更均勻的分佈通過拋光層,這可改善拋光的均勻性,也可以盡量減少結塊。
類似於使用液體熱固性聚合物前驅物的例子,熱塑性混合物可以被均勻地分配以產生橫跨整個拋光層405的磨料顆粒445的均勻分佈。可替換地,含有研磨顆粒的熱塑性混合物可以根據所需的磨料顆粒445的印刷圖案(該圖案存儲為一個CAD兼容的文件且由用於驅動液滴噴射列印器415的電子控制器所讀取)而僅分配於拋光層405的選定的位置。
研磨顆粒可直接以粉末形式從列印頭430B的噴嘴435分配而不是從耦接至列印頭430B的噴嘴435以懸浮液分注磨料顆粒,而列印頭430A的噴嘴435被用來分配墊聚合物前驅物。在一個實施例中,聚合物前驅物是在磨料顆粒445被分配到所沉積的聚合物材料之前分配,且隨後將該混合物固化。
雖然使用研磨顆粒445(例如,氧化鋁、二氧化鈰,以及其他成分)的3D列印來建構拋光物123是特 別有用的(研磨顆粒445當處在以往建構的拋光物時容易集聚),3D列印也可以用於分配和摻入其它拋光顆粒與拋光物123。因此,併入拋光物123中的磨料顆粒可以包括二氧化矽、陶瓷的氧化物、金屬和硬聚合物。
液滴噴射列印器415可以沉積顆粒445,顆粒445是實心或具有中空芯的顆粒445。液滴噴射列印器415也可以分配不同類型的顆粒,其中的一些可以在CMP處理期間就歷經化學反應以在拋光物123的一膜層或多個膜層上產生所需的變化並與正被拋光的基板產生化學反應。使用於CMP處理的化學反應的範例包含的發生於pH值為10~14的鹼性pH範圍內的化學處理,其涉及製造漿料所使用的氫氧化鉀、氫氧化銨和其它專有化學處理之一或更多者。發生於pH值為2~5的酸性pH範圍內的化學處理涉及有機酸(如乙酸),檸檬酸也可用於CMP處理。涉及過氧化氫的氧化反應亦可是使用於CMP處理的化學反應的範例。磨料顆粒445也可以被用來提供機械研磨功能。顆粒445可具有1毫米或更小(例如10微米或更小(例如1微米或更小))的尺寸。顆粒445可具有不同的形態,例如,顆粒445可以是圓形的、細長的或有刻面的。
該3D列印方法使實現於拋光層405的圖案具嚴密的容差且使因逐層列印方法而嵌埋於拋光層405內的磨料顆粒445的分佈具高容差。
拋光物
第5A和5B圖描繪了可使用於第2圖的壓盤組件132上的拋光物500的一個實施例。拋光物500的拋光表面505包括複數個條帶或磚片532,條帶或磚片532形成第3A和3B圖中的圖案化表面328。磚片532由形成在或通過拋光材料570的溝槽530所分開。拋光材料570可被黏著到載體膜(例如背襯材料522)。在一個實施例中,至少拋光表面505可由第3A~4B圖中所述之3D列印處理所製造。拋光表面505可藉由合適的黏著劑319而被結合到背襯材料522,黏著劑319係被選擇為耐CMP處理中使用的化學和物理成分。在一些實施例中,背襯材料522和黏著劑319之一者或兩者可藉由如第3A~4B圖所描述的3D列印處理而被製造。
藉由在拋光材料570中形成深度小於拋光材料570的厚度的溝槽530,複數個磚片532之每一者可連接到另一磚片532。溝槽530的深度為可選的以使拋光材料570具可撓性且同時保持拋光材料570的完整性。在第5A和5B圖所描繪的實施例中,溝槽530和磚片532大致平行於橫跨機器的方向,即橫向於供給和捲取輥的方向。溝槽530形成通道,通道可加強漿料保持且強化漿料輸送到基板表面。溝槽530亦被用來打破拋光材料570的表面張力,可增加拋光材料570的柔韌性以促進拋光物500從供應輥卸下且附上捲取輥。
在第5A圖所示的實施例中,磚片532基本上是矩形並且基本上為背襯材料522的橫跨機器寬度的方 向的長度。其它實施例亦可被理解,例如兩個大致呈矩形的磚片532,其所形成的長度基本上為背襯材料522的橫跨機器的寬度的一半。在一個實施例中,磚片532可被形成為使得拋光物500被製造而具有對光或電磁輻射呈透明的透明部分536。透明部分536可沿著拋光物500(在機器方向上)的長度而被形成。背襯材料522(其亦對光學感測元件220(第2圖所示)所發射的光或電磁輻射呈透明)可被使用以促進端點偵測。磚片532的寬度(即,基本上垂直於長度的維度)可以被形成為任何尺寸。作為一個例子,磚片532可具有約1英寸或者更小的寬度。
在一些實施例中,拋光材料570包括複合材料,諸如設置於第二材料520內的第一材料515。在一個實施例中,第二材料520可以是聚合物基體且第一材料515可以是混合在第二材料520中的微元素。微元素可以是聚合物材料、金屬材料、陶瓷材料,或它們的組合。微元素的至少之一部分的平均直徑為可以是約10奈米(縱使可使用大於或小於10奈米的直徑)。微元素的平均直徑可以基本相同或可以改變(具有不同尺寸或混合不同尺寸),並且可以根據需求而浸漬在聚合物基質中。微元素之每一者可以約0.1微米至約100微米的平均距離間隔開。微元素可基本上在整個聚合物基體材料均勻地分佈。
當與第二材料520相比時,第一材料515可以對電磁能量(如來自能量源212的一或多個能量束(在第2圖所示))具有不同的反應性。不同反應性可以被使 用以在拋光表面505上形成微紋理。第一材料515與第二材料520之間的不同反應性可提供:第一材料515將以比第二材料520更大的速率來燒蝕,或反之亦然。聚合物微元素可以是微米尺寸或奈米尺寸的材料,該材料在拋光物500的拋光表面505內形成微米尺寸或奈米尺寸維度。微元素之每一者可包含少於約150微米至10微米或更少的平均直徑。
圖6A和6B描繪了可使用在第2圖的壓盤組件132的拋光物600的其他的實施例。拋光物600具有拋光表面605,拋光表面605形成第3A和3B圖中的圖案化表面328。拋光表面605包括複數個條帶或磚片632,複數個條帶或磚片632由相鄰的橫向的溝槽630所分離,溝槽630形成於或通過拋光材料670且黏著到背襯材料522。在本實施例中,拋光材料570包含複數個顆粒445(如第4B圖所述)混合在其中。藉由將溝槽630之每一者形成在拋光材料670內而使溝槽630深度為小於拋光材料670的厚度之深度,所述多個條帶或磚片632之每一者可以彼此連接。溝槽630的深度可被選擇以使拋光材料670具可撓性同時保持完整性。可替代地,拋光材料670可以表現出彈性或其它機械屬性的係數,以促進滾動形式的運動,輥形式的運動避免了對背襯材料522的需求。在這個實施例中,複數個磚片432可能由多個溝槽所形成且以無黏著劑319和背襯材料522的輥形式加以使用。作為另一替代方案,可形成拋光材料570使得溝槽630形成分 開的或離散的磚片632,且拋光材料570藉由合適的黏著劑519結合至背襯材料522。在所示的實施例中,拋光物600具有相應的橫向溝槽635,藉增加溝槽635以輔助漿料的保持以及輔助漿料輸送至基板,並提高拋光物600的可撓性。
磚片632可以是任何形狀和尺寸,以促進有效地拋光。在一個實施例中,可形成磚片632使得拋光物600經製造而具有光或電磁輻射透明部分636。透明部分636可以沿著(在機器方向的)長度形成拋光物600。背襯材料522(其亦對光學感測元件220(第2圖所示)所發射的光或電磁輻射呈透明)可被使用以促進端點偵測。
第7A和7B圖描繪了可使用於第2圖的壓盤組件132上的拋光物700的其他的實施例。拋光物700具有拋光表面705,拋光表面705形成第3A和3B圖中的圖案化表面328。拋光表面705包括形成於拋光材料570內的複數個孔隙732。拋光材料570可藉由合適的黏著劑519而被結合到背襯材料522,其中黏著劑519係被選擇為耐CMP處理中使用的化學和物理成分。在拋光物123內的孔隙732是大致圓形或橢圓形的形狀,但可以包括其它的環形幾何形狀(例如圓錐或中空截錐體(即介於基本上平行的平面之間的圓錐體))。正如在其他實施例中,側部736可以是透明的以允許藉由光學感測元件220(第2圖)監測基板。
在一個實施例中,孔隙732可以是中空的(即,空的空間)其經尺寸調整和/或間隔開以增強拋光物700的漿料保留以及輔助拋光物700的滾動。在一個實施例中,孔隙732可以至少部分地被第一材料710填充,第一材料710不同於拋光材料570(第二材料712)。相較於第二材料712,第一材料710可對固化方法有不同的反應性的聚合物材料。例如,第二材料712可以是對UV能量可固化的,而第一材料710並不受UV能量顯著影響。然而,在一個實施例中,第一材料710可以被熱固化。在一個實施例中,所述拋光物700可以使用第一材料710和第二材料712而差異性地固化。在一個差異性固化的範例中,拋光物700的第一材料710和第二材料712可以不固化第一材料710的UV能量進行固化。這可能使第二材料712比第一材料710更硬,這可以增加拋光物700的可壓縮性和/或可撓性因為第一材料710比第二材料712更黏稠。
在一個實施例中,第一材料710經熱固化以使具有第一材料710在其中的孔隙732更硬,但比第二材料712更軟且更有可壓縮性。在另一個實施例中,在第一在孔隙732中的第一材料710由在基板拋光處理期間的摩擦所產生的熱加以熱固化。在這個實施例中,第一材料710可以被固化成比所述第二材料712更硬因此在拋光表面705上形成比周圍的第二材料712更硬的區域。
在其它實施例中,當與第二材料712相比時,第一材料710可以對電磁能量(如來自能量源212的一或多個能量束(在第2圖所示))具有不同的反應性。不同反應性可以被使用以在拋光表面705上形成微紋理。第一材料710與第二材料712之間的不同反應性可提供:第一材料710將以比第二材料712更大的速率來燒蝕,或反之亦然。孔隙732可以是微米尺寸或奈米尺寸的材料,該材料在拋光物700的拋光表面705內形成微米尺寸或奈米尺寸維度。在一個實施例中,孔隙732可包含少於約150微米至10微米或更少的平均直徑。
在拋光物123、500、600或700的上述實施例中,背襯材料317或522是塑料材料(如聚酯薄膜),例如雙軸取向的聚對苯二甲酸乙酯或聚對苯二甲酸乙酯物料,其可由3D列印處理或作為在3D列印處理的基體材料來形成。可以提供厚度約為0.002英寸(50.8微米)到大約0.012英寸(304.8微米)(例如約0.004英寸(101.6微米))的背襯材料317或522。圖案化表面328和拋光材料570、670或770可以是硬度在約20~80(肖氏D標度)的硬度範圍內的聚合物材料。在一個實施方案中,拋光物123的厚度介於約0.019英寸(482.6微米)至約0.060英寸(1524微米)之間。
第8圖是可被當作第2圖的壓盤組件132上的拋光物123來使用的拋光物800的示意性透視剖面視圖。拋光物800包含一種複合墊主體802,複合墊主體 802可以是從與硬質特徵804相互混合的軟材料所形成的基材層。複合墊主體802可由3D列印來形成。複數個凸起特徵806可以包括軟材料805的一或更多層,其至少局部地圍繞硬質特徵804。在一個實施例中,硬質特徵804可具有約40(肖氏D標度)至約90(肖氏D標度)的硬度。軟材料805以及複合墊主體802的其餘部分可具有約26(肖氏A尺度)至約95(肖氏A尺度)之間的硬度量值。
所述的複合墊主體802包含多個層,每一層包含可以由3D列印器所沉積的用於軟材料805的第一材料的區域和用於硬質特徵804的第二材料的區域。所述多個層可接著被固化,例如藉由UV光,由熱源,或電磁能量加以固化並達到期望的硬度。在沉積和固化之後,硬質特徵804和軟材料805被接合在一起以形成一個整體的複合墊主體802。
軟材料805可從具有較低的硬度值和具有較低的楊氏係數的值的第一材料來形成,而硬質特徵804可以從具有較高的硬度值和較高的楊氏係數的值的第二材料來形成。
硬質特徵804可以由聚合物材料來形成,例如,聚氨酯、丙烯酸酯、環氧、丙烯腈-丁二烯-苯乙烯(ABS)、聚醚酰亞胺、聚酰胺、三聚氰胺、聚酯、聚砜、聚醋酸乙烯酯、氟代烴,和類似物及其混合物、共聚物和移植物。在一個實施例中,硬質特徵可以從一個模 擬塑料3D列印材料來形成,例如聚醚酮(PEEK)、聚苯砜(PPS)、聚甲醛(POM),和類似物。硬質特徵也可以由前驅物材料和/或聚氨酯來提供,且可被改造成為多個硬質特徵。在一個實施例中,磨料顆粒可以被嵌埋於硬質特徵604中以提高拋光。磨料顆粒可以是金屬氧化物,如氧化鈰、氧化鋁、二氧化矽,或它們的組合、聚合物、介金屬或陶瓷。
軟材料805可以由彈性體材料形成,例如,彈性體聚氨酯。在一個實施例中,軟材料805可以由橡膠狀3D列印材料形成,例如聚丁二烯、異戊二烯、氯丁二烯、EPDM,和類似物。彈性特徵,也可以由前驅物材料和/或聚氨酯來提供,且可以被改造為橡膠狀以提供彈性的特性。
在一個實施例中,凸起特徵806可以線性圖案、為同心環的矩形圖案,或以線圖案呈現。溝槽818形成於凸起特徵806之間。在拋光期間,凸起特徵806的上表面808形成接觸基板的圖案化表面251,而溝槽818則保有拋光液。
在一個實施例中,凸起特徵806的寬度可以是約250微米至約2毫米。凸起特徵806之間的間距可為約0.5毫米到約5毫米。每個凸起特徵806可具有約250微米至約2毫米的寬度,並且可包括相同的間距,或者寬度和/或可以隨橫跨拋光物800的半徑的方式加以變化以提供不同硬度的區域的一種間距。
與其他拋光物相比,本揭露內容的複合拋光物800具有幾個優勢。傳統拋光物一般而言包括拋光層,拋光層具有具紋理的拋光表面和/或研磨材料,研磨材料由從軟質材料(諸如泡沫)所形成的子墊加以支撐,以獲得所需的拋光基板的硬度或楊氏係數。藉由選擇各種不同楊氏係數的材料、藉由調整特徵的尺寸,或藉由以使用3D列印來改變不同特徵的配置,可在複合墊主體802中實現所希望的硬度或楊氏係數而無需使用子墊。因此,拋光物800藉由消除子墊而減少擁有的子墊的成本。此外,拋光物800的硬度和磨損可藉由混合具有不同硬度和耐磨性的特徵來調整,因而改善拋光性能。
根據本揭露內容,藉由圖案變化和/或特徵尺寸的變化,複合拋光物可具有橫跨整個表面特徵(如硬質特徵604,和基底材料(如軟材料805))的可變的楊氏係數。橫跨整個拋光墊的楊氏係數可以是對稱的或是非對稱的、均勻的或不均勻的,以實現所需的性能。凸起特徵806的圖案根據實現所需性質可以是徑向的、同心的、矩形的,或隨機的。
凸起特徵806的外表面808由聚合物材料所形成,聚合物材料比硬特性804更軟或更具彈性。在一個實施例中,凸起特徵806的外表面808可以由與基材層802相同的材料所形成。在一些實施例中,凸起特徵806包括嵌入其中的硬質特徵804。嵌埋的硬質特徵804提供拋光所需的硬度和剛性。外表面808的軟聚合物層可以減 少正被拋光的基板上的缺陷和提高正被拋光的基板上的平坦化。或者,軟聚合物材料可被列印在本揭露內容的其它拋光墊的表面上以提供同樣的好處。
第9圖是具有一個類似於第5A圖中描述的電磁輻射透明部分536的觀察窗910的拋光墊900的一個示意性透視剖面視圖。所述拋光墊900可被用作第2圖的壓盤組件132上的拋光物1223以及用作此所述的拋光墊的其他實施例。一種複合墊主體902包含一個或多個硬質特徵904和一個或多個彈性特徵906。硬質特徵604和彈性特徵606為在邊界連接在一起的離散特徵,用以形成複合墊主體602且可包含與軟材料805和硬質特徵804相關之上述材料。
將拋光墊900可以包括從彈性特徵906延伸的一個或多個彈性特徵906和複數個硬質特徵904。在一個實施例中,硬質特徵904可以具有約40肖氏D標度至約90肖氏D標度之硬度。彈性功能906可能有在大約26肖氏A標度與約95肖氏A之間的硬度值。根據本揭露內容,硬質特徵904可被佈置在任何合適的圖案。
觀察窗910可以由透明材料形成以對待拋光的基板進行監測。該觀察窗910可透過彈性部件906或硬質特徵904來形成。在一個實施例中,觀察窗910可以由透明3D列印光聚合物來形成。在一個實施例中,觀察窗910可以由紫外線可透過的聚氨酯丙烯酸酯、聚酯丙烯酸 酯、聚醚丙烯酸酯、聚甲基丙烯酸甲酯(PMMA)來形成。
第10圖是包含背襯層1006的拋光物600的一個示意性剖面視圖。拋光墊1000可以被用作第2圖的壓盤組件132上的拋光物1223以及被用作在此所述的其他實施例的拋光墊。所述拋光墊1000包含從基底材料層1004突出的一個基底材料層1004和複數個表面特徵1002。拋光墊1000可以是類似於如上所述之拋光物500、600、700、800或900,除具有附連到基材層1004的背襯層1006。背襯層1006可以提供對拋光物1000的可壓縮性。在一個實施例中背襯層1006可具有小於80肖氏A標度的硬度值。
在一個實施例中,所述背襯層1006可以由開孔泡沫或閉孔泡沫(如聚氨酯或帶有空隙聚矽酮)來形成,從而在壓力下,孔隙會坍塌且背襯層1006會壓縮。在另一個實施方案中,背襯層1006可以由天然橡膠、乙烯丙烯二烯單體(EPDM)橡膠、腈,或者聚氯丁二烯(氯丁橡膠)來形成。
第11圖是具有多個區域的拋光物1100的示意性剖面視圖。在拋光期間,拋光物1100可被設計為在接觸基板121的中心區域的區域中具有(相較於與基板121的周邊部分接觸的區域的屬性)不同的屬性。第11圖示意性示出相對於所述拋光物1100而將基板121加以定位的承載頭152。在一個實施例中,拋光物1100可以 包括設置在背襯層1104上的複合墊體1102。複合墊體1102可由3D列印處理加以製造。如第11圖所示,拋光墊1100可以被劃分成一個外緣區1106,沿其半徑的內緣區1108,和一個中央區域1110。在拋光期間,外緣區1106和內緣區1108接觸基板114的邊緣區域,而在拋光期間,中央區域1110接觸基板114的中央區域。
將拋光墊1100具有在邊緣區域1106、1108的(與中心區域1110相比)不同的係數以提升邊緣拋光品質。在一個實施例中,邊緣區域1106、1108可以具有(相較於中央區域1110)較低的楊氏係數。
第12圖是第11圖的拋光物1100的部放大剖面視圖,示出用於邊緣區域1106和內緣區1108的範例性設計。邊緣區域1106包含一個基底材料層1206和複數個表面特徵1202。表面特徵1204可由比基底材料層1206更硬的材料來形成。內緣區1108包含基底材料層1208和複數個表面特徵1204。所述表面特徵1202可以由比基底材料層1208更硬的材料來形成。在一個實施例中,中心區域1108可以包括基底材料層1208下的鎖定層1210。鎖定層1210可由硬材料來形成。複數個表面特徵1204可以被列印在鎖定層1210上以提高穩定性。如第12圖所示,內緣區1108內的表面特徵1202在尺寸上大於在外緣區1106內的表面特徵1204。在一個實施例中,在邊緣區域1106內的表面特徵1204的間距可以小於內緣區1108內的表面特徵1202的間距。
雖然前述揭露關於本發明之範例性實施例,應理解在不脫離本發明如下述申請專利範圍所定義出之基本範圍的情況下,亦可設計其他及進一步實施例。

Claims (25)

  1. 一種拋光物製造系統,包括:一進料段與一墊捲繞段,該進料段包含一供應輥,該供應輥具有設置於其上的一背襯材料;一列印段;該列印段包含複數個列印頭,該等列印頭設置於該進料段與該墊捲繞段之間;及一固化段,該固化段設置於該列印段下游的該進料段與該墊捲繞段之間,該固化段包含一熱固化元件和一電磁固化元件的一者或兩者,其中該系統在該背襯材料上製造一拋光物,該拋光物包含一複合墊體,該複合墊體包含複數個拋光特徵與一或更多個聚合物基特徵,該等複數個拋光特徵由一溝槽分開且由一第一聚合物材料所形成,且該等一或更多個聚合物基特徵由一第二聚合物材料所形成。
  2. 如請求項1所述之系統,其中該等列印頭之每一者包含一或更多個噴嘴。
  3. 如請求項1所述之系統,其中該第一聚合物材料與該第二聚合物材料相比具有對電磁能量的一不同的反應性。
  4. 如請求項1所述之系統,其中該第二聚合物材料是一聚合物基質且該第一聚合物材料包括複數個微元素,該等微元素分散在該第一聚合物材料中。
  5. 如請求項4所述之系統,其中該等微元素之一部分更包括一金屬材料、一陶瓷材料,或它們的組合。
  6. 如請求項4所述之系統,其中該等微元素之每一者包括一平均直徑,該平均直徑為150微米至10微米,或更小。
  7. 一種拋光物,包括:一複合墊體,包含:複數個拋光特徵,該等拋光特徵形成一拋光表面,其中該等複數個拋光特徵由一第一聚合物材料所形成且該等複數個拋光特徵之每一者由一溝槽分開;以及一或更多個基特徵,該等基特徵由一第二聚合物材料所形成,其中該等一或更多個基特徵包圍該等複數個拋光特徵以形成一單一主體且該第一聚合物材料具有一硬度,該硬度大於該第二聚合物材料的一硬度。
  8. 如請求項7所述之拋光物,其中該第一聚合物材料與該第二聚合物材料相比具有對電磁能量的一不同的反應性。
  9. 如請求項7所述之拋光物,其中該第二聚合物材料是一聚合物基質且該第一聚合物材料包括複數個微元素,該等微元素分散在該第一聚合物材料中。
  10. 如請求項9所述之拋光物,其中該等微元素之一部分更包括一金屬材料、一陶瓷材料,或它們的組合。
  11. 如請求項9所述之拋光物,其中該等微元素之每一者包括一平均直徑,該平均直徑為150微米至10微米,或更小。
  12. 如請求項7所述之拋光物,其中該複合墊體設置在一基薄膜上。
  13. 如請求項12所述之拋光物,其中該基薄膜對電磁能量是呈透明的。
  14. 一種用於一化學機械拋光處理的替換的供應輥,包括:一桿件,該桿件具有一拋光物,該拋光物纏繞於該桿件上,該拋光物包含:一複合墊體,該複合墊體包含:複數個拋光特徵,該等拋光特徵形成一拋光表面,其中該等複數個拋光特徵由一第一聚合物材料所形成且該等複數個拋光特徵之每一者由一溝槽分開;以及一或更多個基特徵,該等基特徵由一第二聚合物材料形成,其中該等一或更多個基特徵包圍該等複數個拋光特徵以形成一單一主體且該第一聚合物材料具有一硬度,該硬度大於該第二聚合物材料的一硬度。
  15. 如請求項14所述之供應輥,其中該第一聚合物材料與該第二聚合物材料相比具有對電磁能量的一不同的反應性。
  16. 如請求項14所述之供應輥,其中該第二聚合物材料是一聚合物基質且該第一聚合物材料包括複數個微元素,該等微元素分散在該第一聚合物材料中。
  17. 如請求項16所述之供應輥,其中該等微元素之一部分更包括一金屬材料、一陶瓷材料,或它們的組合。
  18. 如請求項16所述之供應輥,其中該等微元素之每一者包括一平均直徑,該平均直徑為150微米至10微米,或更小。
  19. 如請求項14所述之供應輥,其中該複合墊體設置在一基薄膜上,該基薄膜對電磁能量是呈透明的。
  20. 一種拋光物,該拋光物包含:一複合墊體,該複合墊體包含:一基底材料層;以及複數個拋光特徵,該等複數個拋光特徵從該基底材料層延伸且形成一拋光表面,其中該等複數個拋光特徵包含一第一聚合物材料,該第一聚合物材料具有一硬度,該硬度大於包含一第二聚合物材料的該基底材料層的一硬度,且該等複數個拋光特徵之每一者由一溝槽分開。
  21. 如請求項20所述之拋光物,其中該第一聚合物材料與該第二聚合物材料相比具有對電磁能量的一不同的反應性。
  22. 如請求項20所述之拋光物,其中該第二聚合物材料是一聚合物基質且該第一聚合物材料包括複數個微元素,該等微元素分散在該第一聚合物材料中。
  23. 如請求項22所述之拋光物,其中該等微元素之一部分更包括一金屬材料、一陶瓷材料,或它們的組合。
  24. 如請求項22所述之拋光物,其中該等微元素之每一者包括一平均直徑,該平均直徑為150微米至10微米,或更小。
  25. 如請求項20所述之拋光物,其中該等拋光特徵的一間距隨橫跨該複合墊體的一半徑的方式加以變化。
TW104133737A 2014-10-17 2015-10-14 拋光物和用於製造化學機械拋光物的整合系統 TWI671162B (zh)

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