Color-Changing Indicator for Plasma Treatment Uniformity

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Solution Overview

Problem

Current methods for ensuring uniform treatment of plasma, ozone, ultraviolet rays, and radical-containing gases on semiconductor wafers and other substrates during electronic device manufacturing are time-consuming, require additional equipment, and do not directly observe in-plane distribution, making them inefficient for process optimization and yield improvement.

Innovation Solution

A color-changing indicator with a shape matching the substrate, composed of a color-changing layer formed by an ink composition that reacts to plasma, ozone, or ultraviolet rays, allowing for direct visualization of treatment uniformity without the need for additional measuring instruments, which can be used in various electronic device manufacturing processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional methods (Langmuir probe, emission spectrometry) are used to measure plasma uniformity, then measurement precision is improved, but device complexity increases and measurement time increases

Engineering Contradiction:
Improveplasma uniformity measurement precisionVSAvoidmeasurement device complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses a dummy substrate that replicates the physical and chemical properties of the actual substrate to be treated. This dummy substrate serves as a simplified copy that can be used for measurement purposes without requiring complex measurement equipment. The dummy substrate is placed in the plasma treatment chamber along with the actual substrates, and after treatment, the plasma uniformity is assessed by examining the dummy substrate's surface characteristics, thereby avoiding the need for Langmuir probes or emission spectrometers.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The dummy substrate acts as an intermediary between the plasma treatment process and the evaluation of treatment uniformity. Instead of directly measuring plasma parameters with complex instruments, the dummy substrate mediates the interaction by absorbing the plasma treatment effects, which can then be visually or microscopically examined to infer plasma uniformity without requiring direct plasma measurement.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Measurement precision

If Langmuir probe is installed in the apparatus to measure plasma characteristics, then measurement precision is improved, but ease of operation deteriorates due to vacuum breaking and probe installation/removal requirements

Engineering Contradiction:
Improveplasma characteristics measurement precisionVSAvoidapparatus operation simplicity
Core Design Contradiction:
Measurement precisionVSEase of operation

Solution Approach 1:

The dummy substrate serves as a passive copy that remains in the chamber throughout the plasma treatment process without requiring installation or removal. It naturally records the plasma treatment effects on its surface, eliminating the need to break vacuum for probe installation and removal, thereby maintaining operational simplicity while still enabling plasma uniformity assessment.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The dummy substrate performs the measurement function automatically during the plasma treatment process without requiring separate measurement operations. As plasma treats the substrates, the dummy substrate simultaneously accumulates treatment effects that reflect plasma uniformity, eliminating the need for separate measurement steps and maintaining continuous vacuum conditions.

Inventive Principle:
Principle #25Self-service

3Measurement precision

If emission spectrometry is used to evaluate plasma uniformity, then measurement precision is improved, but productivity decreases due to limited measurement scope from window restrictions

Engineering Contradiction:
Improveplasma uniformity measurement precisionVSAvoidmeasurement efficiency
Core Design Contradiction:
Measurement precisionVSProductivity

Solution Approach 1:

The dummy substrate provides a complete surface record of plasma treatment across the entire substrate area, unlike emission spectrometry which is limited to viewing through windows. The dummy substrate captures plasma uniformity information from all regions simultaneously, enabling comprehensive evaluation without restricting the measurement scope or requiring multiple measurements from different angles.

Inventive Principle:
Principle #26Copying

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables easy detection of uniform treatment distribution, simplifies process management, and improves yield by providing visual feedback on treatment uniformity and optimizing process conditions without the need for additional instrumentation.

Implementation Method 1

the color-changing layer is formed by an ink composition whose color changes or disappears by reaction with at least one member selected from the group consisting of plasma, ozone, ultraviolet rays, and radical-containing gas

Methodology Applied
Scientific EffectPlasma reaction: Plasma

Implementation Method 2

the color-changing layer is formed by an ink composition whose color changes or disappears by reaction with at least one member selected from the group consisting of plasma, ozone, ultraviolet rays, and radical-containing gas

Methodology Applied
Scientific EffectPhoto-oxidation: Photo-oxidation

Data Source

PatentUS10181414B2Indicator used in electronic device manufacturing apparatus and method for designing and/or managing the apparatus
Publication Date: 2019.01.15 SAKURA COLOR PRODUCTS CORPORATION
  • US10181414B2 patent drawing
  • US10181414B2 patent drawing
  • US10181414B2 patent drawing

AI summary

Provided is an indicator that can easily detect whether treatment with at least one member of plasma, ozone, ultraviolet rays, and radical-containing gas is uniformly performed on an entire substrate in an electronic device manufacturing apparatus; also provided is a method for designing and/or managing an electronic device manufacturing apparatus using the indicator. The indicator is used in an electronic device manufacturing apparatus, wherein (1) the indicator detects at least one member selected from the group consisting of plasma, ozone, ultraviolet rays, and radical-containing gas, (2) the indicator has a shape that is the same as that of a substrate used in the electronic device manufacturing apparatus, (3) the indicator contains a color-changing layer, and (4) the color-changing layer is formed by an ink composition whose color changes or disappears by reaction with at least one member selected from the group consisting of plasma, ozone, ultraviolet rays, and radical-containing gas.