Heater with Vacuum Gap for Uniform Wafer Heating

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Solution Overview

Problem

Existing heaters for semiconductor manufacturing and oxygen sensors face challenges in efficiently heating wafers while managing thermal expansion and reducing heat transfer between the resistance heating element and the base body, leading to uneven heating and potential thermal stress.

Innovation Solution

A heater design featuring an insulating base body with a resistance heating element where a vacuum or gas-filled gap is interposed between the side or bottom surface of the resistance heating element and the base body, allowing for efficient heat transfer to the top surface while reducing heat transfer to the sides or bottom, thus promoting uniform heating and accommodating thermal expansion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the resistance heating element is embedded directly in the base body, then the structure is simple, but heat transfer to the base body causes uneven heating and thermal stress

Engineering Contradiction:
Improvestructure simplicityVSAvoidheating uniformity
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The patent introduces a gap (vacuum or gas-filled) as an intermediary layer between the resistance heating element and the base body. This gap acts as a thermal insulator, preventing direct heat transfer to the base body while allowing the heating element to maintain contact with the wafer for efficient heating. The gap material (vacuum or inert gas) specifically blocks heat conduction to the base body, resolving the contradiction between structural simplicity and heating uniformity.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If the resistance heating element is in direct contact with the base body, then thermal stress is generated due to heat transfer, but isolating them completely reduces heating efficiency

Engineering Contradiction:
Improvethermal stress reductionVSAvoidheating efficiency
Core Design Contradiction:
ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent applies local quality by creating a selective thermal isolation system. The heating element maintains local contact with the wafer (high heating efficiency) while being thermally isolated from the base body (thermal stress reduction). The gap is positioned specifically at the interface between the heating element and base body, allowing different thermal conditions in different locations: efficient heat transfer to the wafer where needed, and thermal insulation from the base body where not needed.

Inventive Principle:
Principle #3Local quality

3Stability of the object's composition

If the resistance heating element is constrained tightly in the base body, then the structure is stable, but thermal expansion is restricted causing stress

Engineering Contradiction:
Improvestructural stabilityVSAvoidthermal stress resistance
Core Design Contradiction:
Stability of the object's compositionVSStrength

Solution Approach 1:

The patent extracts the resistance heating element from direct embedding in the base body by introducing a gap between them. This extraction allows the heating element to be positioned stably within the base body structure while being thermally decoupled. The gap provides the necessary clearance for thermal expansion without generating stress, while the overall structure remains stable through the mechanical support of the base body and electrode connections.

Inventive Principle:
Principle #2Taking out (Extraction)

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

The design ensures efficient and uniform heating of wafers, reducing thermal stress and improving processing accuracy by minimizing heat transfer between the heating element and the base body, while allowing for efficient thermal insulation and expansion accommodation.

Implementation Method 1

A vacuum or gas-filled gap is interposed between a side surface of the resistance heating element and the base body

Methodology Applied
Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

a resistance heating element extending in the base body along a top surface of the base body

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Implementation Method 3

accommodate a volume of expansion of the resistance heating element

Methodology Applied
Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12016087B2Heater and method of production of same
Publication Date: 2024.06.18 KYOCERA CORP
  • US12016087B2 patent drawing
  • US12016087B2 patent drawing
  • US12016087B2 patent drawing

AI summary

A heater includes a base body and a resistance heating element. The base body is configured by an insulating material and includes a top surface on which a wafer is placed. The resistance heating element extends in the base body along the top surface. A top surface of the resistance heating element and the base body are in contact with each other. A vacuum or gas-filled gap is interposed between a side surface of the resistance heating element and the base body.