A method for forming holes from both sides of a substrate

Abstract

Provided herein are methods and apparatus for forming holes through a substrate. In some embodiments, a method for forming holes in a substrate for use in a processing chamber includes partially drilling a plurality of holes in the substrate using a first drill to form a plurality of rough holes extending through the substrate from a first side of the substrate to an opposite second side of the substrate, positioning the substrate between a second drill and a third drill, using the second drill to finish the plurality of rough holes from the first side of the substrate to a first position at least halfway along the length of each of the plurality of rough holes, and using the third drill to finish the plurality of rough holes from the second side of the substrate to at least the first position along the length of each of the plurality of rough holes.

Description

[Technical Field]

[0001] FIELD Embodiments of the present disclosure generally relate to semiconductor processing equipment. [Background technology]

[0002] Deposition chambers and etch chambers (processing chambers) are typically used during the manufacture of semiconductor devices. Some components located within these processing chambers include holes. For example, a gas distribution plate for use within the processing chamber may include high aspect ratio holes for distributing one or more process fluids within the processing chamber. The holes may be formed using a single drill. However, the inventors have observed that forming high fidelity holes using a single drill may require a more expensive drill, may require more power consumption, and may result in lower throughput.

[0003] In response, the inventors have provided an improved method and apparatus for forming holes through components of a processing chamber. Summary of the Invention

[0004] Provided herein are methods and apparatus for forming holes through a substrate. In some embodiments, a method for forming holes in a substrate for use in a processing chamber includes partially drilling a plurality of holes in the substrate using a first drill to form a plurality of rough holes extending through the substrate from a first side of the substrate to an opposite second side of the substrate, positioning the substrate between a second drill and a third drill, using the second drill to finish the plurality of rough holes from the first side of the substrate to a first position at least halfway along the length of each of the plurality of rough holes, and using the third drill to finish the plurality of rough holes from the second side of the substrate to at least the first position along the length of each of the plurality of rough holes.

[0005] In some embodiments, a method of forming holes in a substrate for use in a processing chamber includes mounting the substrate on a substrate support in a first position, using a first drill to form a plurality of rough holes through the substrate, rotating the substrate from about 45 degrees to about 135 degrees to a second position, and using a second drill to form a first set of rough holes to a second dimension from a first side of the substrate, while using a third drill to form a second set of rough holes to a second dimension different from the first set of rough holes from a second side of the substrate opposite the first side.

[0006] In some embodiments, an apparatus for forming holes in a substrate includes a substrate support having one or more holding surfaces for holding the substrate and a central opening exposing a bottom surface of the substrate, the substrate support being configured to rotate about a central axis of the substrate support and about an extension axis of the substrate support perpendicular to the central axis, a first drill positioned above the substrate support, and a second drill and a third drill positioned on either side of the substrate support.

[0007] Other and further embodiments of the present disclosure are described below.

[0008] Embodiments of the present disclosure, briefly summarized above and described in more detail below, can be understood by reference to exemplary embodiments thereof as illustrated in the accompanying drawings. However, because the present disclosure is susceptible to other equally effective embodiments, the accompanying drawings illustrate only typical embodiments of the present disclosure and therefore should not be considered limiting in scope. [Brief explanation of the drawings]

[0009] [Figure 1] 1 shows a flowchart of a method for forming holes in a substrate for use in a processing chamber according to some embodiments of the present disclosure. [Figure 2A] FIG. 1 is a schematic side view of a hole forming device in a first position, according to some embodiments of the present disclosure. [Figure 2B]FIG. 1 is a schematic top view of a hole forming device in a first position, according to some embodiments of the present disclosure. [Figure 3] 1 is a schematic side view of a hole forming device in a second position, according to at least some embodiments of the present disclosure. [Figure 4] 1 is a schematic partial isometric view of a hole forming device in a second position, according to at least some embodiments of the present disclosure. FIG. [Figure 5] 1 is a schematic side view of a hole forming device in a first position, according to at least some embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0010] To facilitate understanding, the same reference numerals are used, where possible, to designate identical elements that are common to multiple figures. The figures are not drawn to scale and may be simplified for clarity. Elements and features of one embodiment may be beneficially incorporated in other embodiments without further description.

[0011] Provided herein are embodiments of a method and apparatus for forming holes in a substrate for use in a processing chamber. The method includes forming a plurality of holes through the substrate using a plurality of drills. A first drill of the plurality of drills faces a first surface of the substrate to form a plurality of rough holes through the substrate. A second set of drills of the plurality of drills finishes the plurality of rough holes to form a plurality of holes. In some embodiments, the second set of drills includes a second drill and a third drill positioned on opposite sides of the substrate. In some embodiments, the second set of drills includes the first drill and a second drill positioned on the opposite side of the substrate, advantageously forming a plurality of holes from both sides of the substrate.

[0012] Each drill of the second set of drills finishes the plurality of rough holes at least halfway along the length of each of the plurality of holes. Having each drill of the second set of drills finish the plurality of rough holes approximately halfway along the length of each of the plurality of holes advantageously reduces the power requirements from each of the drills in the second set and shortens the time to form the plurality of holes through the substrate.

[0013] FIG. 1 illustrates a flowchart of a method 100 for forming holes in a substrate for use in a processing chamber, according to some embodiments of the present disclosure. In some embodiments, the method 100 can be implemented using the hole forming apparatus 200 of FIGS. 2A-5. The method begins at 102 by partially drilling a plurality of holes in a substrate (e.g., substrate 208) using a first drill (e.g., first drill 220) to form a plurality of rough holes (e.g., rough holes 214) that extend through the substrate from a first side of the substrate to an opposite second side of the substrate. The rough holes have a first diameter dimension. In some embodiments, the substrate is mounted to a substrate support (e.g., substrate support 204) prior to forming the rough holes. In some embodiments, the holes have a diameter or first dimension of about 0.005 inches to about 0.04 inches.

[0014] In some embodiments, a first drill forms a first set of one or more holes of the plurality of rough holes, then forms a next set of one or more holes of the plurality of rough holes, and so on until all of the plurality of rough holes are formed. In some embodiments, the substrate rotates about a central axis of the substrate (e.g., central axis 212) between forming sets of rough holes using the first drill. In some embodiments, the first drill moves between forming sets of rough holes by rotating relative to the substrate (e.g., about central axis 224). In some embodiments, the first drill moves laterally relative to the substrate (e.g., lateral direction 226) between forming sets of rough holes.

[0015] FIG. 2A shows a schematic side view of a hole formation apparatus 200 in a first position for performing 102, according to some embodiments of the present disclosure, and FIG. 2B shows a schematic top view of the hole formation apparatus 200 in a first position for performing 102, according to some embodiments of the present disclosure. The hole formation apparatus 200 includes a substrate 208 mounted on a substrate support 204. The substrate support 204 is rotatable about a central axis 212 to rotate the substrate 208. In some embodiments, the substrate support 204 is configured to rotate about an extension axis 202 perpendicular to the central axis 212 to move the substrate 208 from a first position to a second position, as shown in FIG. 3 and described in more detail below. The substrate support 204 can be supported by one or more legs 206. In some embodiments, the one or more legs 206 include two legs rotatably coupled to the substrate support 204 on either side of the substrate support 204.

[0016] The substrate 208 includes a second side 260 facing the substrate support 204 and a first side 250 opposite the second side 260. The substrate support 204 includes one or more retention surfaces for retaining the substrate 208 and a central opening 228 for exposing the second side 260 or the bottom surface of the substrate 208. In some embodiments, the one or more retention surfaces are annular ledges that extend into the central opening 228. In some embodiments, as shown in FIG. 2B , the one or more retention surfaces include a plurality of mounting tabs 216 that extend into the central opening 228.

[0017] Substrate 208 may be made of a material suitable for use in a processing chamber. In some embodiments, substrate 208 is made of a material including silicon (Si), e.g., silicon carbide (SiC), polycrystalline silicon, or single crystal silicon. In some embodiments, substrate 208 is made of a metal, e.g., aluminum or molybdenum. In some embodiments, substrate 208 has a thickness (i.e., height) of about 2.0 mm to about 20.0 mm. In some embodiments, substrate 208 has a thickness of about 8.0 mm to about 15.0 mm. In some embodiments, substrate 208 is a gas distribution plate for use in a processing chamber. In some embodiments, substrate 208 is a round plate.

[0018] A first drill 220 is disposed on the substrate support 204. In the first position, the first drill 220 faces a first side 250 of the substrate 208. In some embodiments, the first drill 220 is configured to move laterally 226 (e.g., up / down / left / right) relative to the first surface 205. In some embodiments, the first drill 220 is configured to rotate about a central axis 224 of the first drill 220 relative to the substrate 208. In some embodiments, when the substrate is in the first position, the central axis 224 of the first drill 220 is parallel to the central axis 212 of the substrate 208.

[0019] In some embodiments, first drill 220 is a laser drill configured to direct photon energy 222 to remove material from substrate 208 to form multiple rough holes 214. In some embodiments, multiple rough holes 214 include multiple sets, where each set includes multiple holes, and the multiple holes make up the multiple rough holes 214. For example, multiple rough holes 214 include first set 252. In some embodiments, first drill 220 is a laser drill with multiple laser heads for simultaneously forming multiple holes (e.g., first set 252).

[0020] In some embodiments, the first drill 220 is a rotary drill configured to machine the plurality of rough holes 214. In some embodiments, the first drill 220 is a rotary drill having multiple drill bits for simultaneously forming multiple holes of the plurality of rough holes 214. In some embodiments, the first drill 220 is a water drill configured to direct high-pressure water at the substrate 208 to form the plurality of rough holes 214.

[0021] In some embodiments, first drill 220 is a water drill having multiple high-pressure water streams for simultaneously forming multiple holes of plurality of rough holes 214. In some embodiments, first drill 220 is a sonic drill configured to finish multiple rough holes 214. In some embodiments, first drill 220 is a sonic drill having multiple sonic drill bits for simultaneously finishing multiple holes of plurality of rough holes 214.

[0022] In some embodiments, the second drill 230 and the third drill 240 are disposed opposite each other on opposite sides of the substrate support 204. In some embodiments, the second drill 230 is configured to move laterally 236 (e.g., up / down / left / right) relative to the substrate support 204. In some embodiments, the third drill 240 is configured to move laterally 246 (e.g., up / down / left / right) relative to the substrate support 204. In some embodiments, the second drill 230 is configured to rotate relative to the substrate 208 along a central axis 234 of the second drill 230. In some embodiments, the third drill 240 is configured to rotate relative to the substrate 208 along a central axis 244 of the third drill 240.

[0023] In some embodiments, the hole forming apparatus 200 includes an enclosure 210, and the substrate support 204 is disposed within the enclosure 210. In some embodiments, the first drill 220 is coupled to a top wall of the enclosure 210. In some embodiments, the second drill 230 and the third drill 240 are coupled to side walls of the enclosure 210 on either side of the substrate support 204. In some embodiments, as shown in FIGS. 2A-2B and 3, the first drill 220, the second drill 230, and the third drill 240 are disposed outside the enclosure 210. In some embodiments, as shown in FIG. 5, the first drill 220, the second drill 230, and the third drill 240 are disposed within the enclosure 210. In some embodiments, at least one of the first drill 220, the second drill 230, and the third drill 240 is disposed within the enclosure 210, and the remaining ones of the first drill 220, the second drill 230, and the third drill 240 are disposed outside the enclosure 210.

[0024] At 104, a substrate is positioned between a second drill (e.g., second drill 230) and a third drill (e.g., third drill 240). In some embodiments, the substrate is rotated about the extension axis of the substrate support (e.g., extension axis 202). In some embodiments, the substrate is rotated from about 45 degrees to about 135 degrees from the first position to the second position. In some embodiments, the substrate is rotated about 90 degrees from the first position to the second position. FIG. 3 shows a schematic side view of a hole forming apparatus in the second position, according to some embodiments of the present disclosure. In the second position, the second drill 230 faces the first side 250 of the substrate 208, and the third drill 240 faces the second side 260 of the substrate 208. In some embodiments, the second drill 230 faces the second side 260 and the third drill 240 faces the first side 250 .

[0025] At 106, a second drill is used to finish a plurality of rough holes from a first side (e.g., first side 250) of the substrate to a first location. In some embodiments, the first location is at least halfway along the length of each hole of the plurality of holes. In some embodiments, finishing the plurality of rough holes includes at least one of reducing the roughness of the plurality of rough holes, improving the circularity of the plurality of rough holes, increasing the diameter of the plurality of rough holes to a second dimension, or making the diameter of the plurality of rough holes more uniform relative to one another. For example, the plurality of rough holes may be smaller pilot holes, and finishing the plurality of rough holes includes removing additional material around the smaller pilot holes to form finished holes having at least one of improved hole-to-hole uniformity, improved concentricity, or reduced roughness compared to the plurality of rough holes. The sidewalls of the finished plurality of holes may be increased vertically relative to the top surface (e.g., first side 250) or bottom surface (e.g., second side 260) of the substrate more than the plurality of rough holes. In some embodiments, the rough holes are more flared (ie, gradually widen at one end) than the finished holes.

[0026] In some embodiments, the concentricity of the finished holes is up to about 15% greater than the concentricity of the rough holes. In some embodiments, the concentricity of the finished holes is from about 0.002 inches to about 0.125 inches. In some embodiments, the circularity of the rough holes is about 15% greater than the circularity of the finished holes. In some embodiments, the diameter, or second dimension, of the finished holes is up to about 25% greater than the diameter, or first dimension, of the rough holes. In some embodiments, the second dimension is from about 0.005 inches to about 0.04 inches.

[0027] In some embodiments, the plurality of rough holes comprises multiple sets. In some embodiments, a second drill finishes one set of the plurality of sets, then finishes another set of the plurality of sets, and so on until all of the plurality of rough holes have been finished from the first side of the substrate. In some embodiments, after finishing one set of the plurality of sets using the second drill, the substrate is rotated about its central axis (e.g., central axis 212). In some embodiments, the second drill moves between finishing each set of the plurality of sets by rotating relative to the substrate (e.g., about central axis 234). In some embodiments, the second drill moves laterally relative to the substrate (e.g., lateral direction 236) between finishing each set of the plurality of sets.

[0028] At 108, a third drill is used to finish the plurality of rough holes from a second side (e.g., second side 260) of the substrate to the first location or to a location at least halfway along the length of each of the plurality of rough holes. Both the second drill and the third drill finish approximately half of each of the plurality of rough holes, advantageously reducing the work required of each of the second and third drills. In some embodiments, the first drill, the second drill, and the third drill together form and finish the plurality of holes. In some embodiments, the third drill finishes the plurality of rough holes from the second side of the substrate in a manner similar to that described above with respect to the second drill. In some embodiments, the substrate rotates about a central axis (e.g., central axis 212) of the substrate after finishing one of the plurality of sets using the third drill. In some embodiments, the third drill moves between finishing each of the plurality of sets by rotating relative to the substrate (e.g., about central axis 244). In some embodiments, a third drill moves laterally (eg, laterally 246) relative to the substrate between finishing each set of the multiple sets.

[0029] In some embodiments, finishing the plurality of rough holes using the second drill occurs simultaneously with finishing the plurality of rough holes using the third drill. In some embodiments, the second drill and the third drill do not finish the same holes of the plurality of rough holes at the same time. In some embodiments, as shown in FIG. 4, the second drill can simultaneously finish a first set of holes while the third drill finishes a second set of holes. FIG. 4 is a schematic partial isometric view of a hole formation apparatus in a second position, according to at least some embodiments of the present disclosure. For clarity, the substrate support 204 is not shown in FIG. 4.

[0030] In some embodiments, the multiple sets of the plurality of rough holes 214 include a first set 410, a second set 420, and a third set 430. Each of the first set 410, the second set 420, and the third set 430 may include two or more holes of the plurality of rough holes 214 (the two sets of holes shown in FIG. 4 ). In some embodiments, the second drill 230 is configured to simultaneously finish each hole in the first set 410. In some embodiments, the third drill 240 is configured to simultaneously finish each hole in the second set 420. In some embodiments, the second drill 230 is configured to finish each hole in the first set 410 at the same time that the third drill 240 finishes each hole in the second set 420. One or more of the substrate 208, the second drill 230, or the third drill 240 may be moved to finish the third set 430. The second drill 230 and the third drill 240 are configured to finish all of the plurality of rough holes 214 to form the plurality of finished holes 414 .

[0031] 3 , in some embodiments, second drill 230 and third drill 240 are configured to move in lateral directions 236 and 246, respectively, relative to first side 250 and to rotate relative to first side 250. In some embodiments, central axis 234 of second drill 230 is parallel to central axis 212 of substrate 208 when substrate 208 is in the second position. In some embodiments, central axis 244 of third drill 240 is parallel to central axis 212 of substrate 208 when substrate 208 is in the second position.

[0032] In some embodiments, second drill 230 and third drill 240 are laser drills configured to direct photon energy 332 and photon energy 342, respectively, to remove material from substrate 208 to finish plurality of rough holes 214 to form finished holes. In some embodiments, second drill 230 is a laser drill having multiple laser heads for simultaneously finishing multiple holes of plurality of rough holes 214. In some embodiments, third drill 240 is a laser drill having multiple laser heads for simultaneously finishing multiple holes of plurality of rough holes 214. In some embodiments, first drill 220 can be a high-power keyhole laser.

[0033] In some embodiments, second drill 230 and third drill 240 are rotary drills configured to remove material from substrate 208 to finish multiple rough holes 214. In some embodiments, second drill 230 is a rotary drill with multiple drill bits for simultaneously finishing multiple holes of multiple rough holes 214. In some embodiments, third drill 240 is a rotary drill with multiple drill bits for simultaneously finishing multiple holes of multiple rough holes 214.

[0034] In some embodiments, second drill 230 and third drill 240 are water drills configured to direct high-pressure water at substrate 208 to finish multiple rough holes 214. In some embodiments, second drill 230 is a water drill with multiple high-pressure water jets for simultaneously finishing multiple holes of multiple rough holes 214. In some embodiments, third drill 240 is a water drill with multiple high-pressure water jets for simultaneously finishing multiple holes of multiple rough holes 214.

[0035] In some embodiments, second drill 230 and third drill 240 are sonic drills configured to remove material from substrate 208 to finish the plurality of rough holes 214. In some embodiments, second drill 230 is a sonic drill having multiple sonic drill bits for simultaneously finishing multiple holes of the plurality of rough holes 214. In some embodiments, third drill 240 is a sonic drill having multiple sonic drill bits for simultaneously finishing multiple holes of the plurality of rough holes 214.

[0036] In some embodiments, the first drill 220 operates at a higher power than the second drill 230 and the third drill 240. In some embodiments, the second drill 230 and the third drill 240 are configured to form higher fidelity holes than the first drill 220. For example, the higher fidelity holes may include lower roughness, improved roundness, and less hole-to-hole diameter variation.

[0037] While the forgoing is directed to embodiments of the present disclosure, other and further embodiments of the present disclosure may be devised without departing from the basic scope thereof.

Claims

1. 1. A method for forming a plurality of holes in a substrate for use in a processing chamber of a semiconductor manufacturing equipment, comprising: partially drilling the holes in the substrate using a first drill to form a plurality of rough holes extending through the substrate from a first side of the substrate to an opposite second side of the substrate; forming the plurality of rough holes in the substrate using the first drill, and then positioning the substrate between a second drill and a third drill; using the second drill to finish the plurality of rough holes from the first side of the substrate to a first position at least halfway along a length of each of the plurality of rough holes; using the third drill to finish the plurality of rough holes from the opposite second side of the substrate along the length of each hole of the plurality of rough holes to at least the first position; A method comprising:

2. The method of claim 1 , wherein the first drill, the second drill, and the third drill are laser drills.

3. The method of claim 1 , wherein the first drill, the second drill, and the third drill are rotary drills, water drills, or sonic drills.

4. 2. The method of claim 1, wherein finishing the plurality of rough holes comprises at least one of reducing a roughness of the plurality of rough holes, improving the circularity of the plurality of rough holes, increasing a diameter of the plurality of rough holes, or making the diameters of the plurality of rough holes more uniform relative to one another.

5. The method of claim 1 , further comprising rotating the substrate about a central axis of the substrate while forming the plurality of rough holes using the first drill.

6. 5. The method of claim 1, wherein finishing the plurality of rough holes using the second drill is performed simultaneously with finishing the plurality of rough holes using the third drill.

7. 7. The method of claim 6, wherein the plurality of rough holes includes a first set and a second set different from the first set, and using the second drill includes finishing the first set simultaneously with finishing the second set using the third drill.

8. 5. The method of claim 1, wherein forming the plurality of rough holes through the substrate using the first drill comprises forming a first set of the plurality of rough holes and then moving the first drill to form a second set of the plurality of rough holes.

9. The method according to any one of claims 1 to 4, wherein the substrate in which the plurality of holes are formed has a thickness of 2.00 mm to 20.0 mm.

10. 5. The method of claim 1, further comprising mounting the substrate in a first position on a substrate support before partially forming the plurality of holes in the substrate using the first drill, and wherein positioning the substrate between a second drill and a third drill comprises rotating the substrate by between 45 degrees and 135 degrees to a second position.

11. 11. The method of claim 10, wherein using the second drill and using the third drill comprises using the second drill to finish a first set of the plurality of rough holes from the first side of the substrate, while using the third drill to finish a second set of the plurality of rough holes different from the first set of the plurality of rough holes from the second side of the substrate opposite the first side.

12. 12. The method of claim 11, further comprising moving the second drill after forming the first set of the plurality of rough holes to form a third set of the plurality of rough holes different from the first set of the plurality of rough holes.

13. 12. The method of claim 11, wherein finishing the first set of rough holes using the second drill occurs simultaneously with finishing the second set of rough holes using the third drill.

14. 1. An apparatus for forming holes in a substrate for use in a processing chamber of a semiconductor manufacturing apparatus, comprising: a substrate support having one or more holding surfaces for holding a substrate and a central opening exposing a bottom surface of the substrate; a first drill unit having a drill disposed above the substrate support; a second drill unit having a drill and a third drill unit having a drill, the second drill unit and the third drill unit being disposed on opposite sides of the substrate support; Equipped with the substrate support is configured to rotate around a central axis of the substrate placed on the substrate support and around an extension axis of the substrate support that is perpendicular to the central axis, with the central axis of the substrate placed on the substrate support and the central axis of the drill of the first drill unit being parallel to the central axis; the second drill unit is configured to rotate about a rotation axis along a central axis of a drill of the second drill unit to rotationally move a position of a drill of the second drill unit relative to the substrate, and the third drill unit is configured to rotate about a rotation axis along a central axis of a drill of the third drill unit to rotationally move a position of a drill of the third drill unit relative to the substrate; wherein the drills of each of the second drill unit and the third drill unit are configured to produce holes with less roughness or greater roundness than the drills of the first drill unit.

15. 15. The apparatus of claim 14, further comprising an enclosure, wherein the substrate support is disposed within the enclosure, the first drill unit is coupled to a top wall of the enclosure, and the second drill unit and the third drill unit are coupled to side walls of the enclosure.

16. The apparatus of claim 15 , wherein the first drill unit, the second drill unit, and the third drill unit are located outside the enclosure.

17. 15. The apparatus of claim 14, wherein the drills of the first drilling unit, the drills of the second drilling unit, and the drills of the third drilling unit are laser drills.

18. 18. The apparatus of any one of claims 14 to 17, wherein the drills of the first drilling unit, the second drilling unit, and the third drilling unit are rotary drills, water drills, or sonic drills.

19. 18. The apparatus of claim 14, wherein the first drill unit, the second drill unit, and the third drill unit are configured to move laterally relative to the substrate support and to rotate relative to the substrate support.

20. 18. The device of any one of claims 14 to 17, wherein the one or more retention surfaces include a plurality of mounting tabs that extend into the central opening.

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