Pulse Gas Delivery Control for Precise Semiconductor Gas Timing
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Solution Overview
Problem
Current pulse gas delivery systems in semiconductor manufacturing face challenges with repeatability and accuracy due to the workload of host controllers and communication jitter, which affect the timing and precision of gas pulses, especially in high-speed processes like the Bosch process for TSV creation.
Innovation Solution
A programmable mass flow controller with a dedicated controller that can operate independently of the host controller, receiving programmed instructions and parameters for pulse gas delivery, allowing for precise control of gas flow and synchronization of pulses, reducing reliance on host controller resources and minimizing communication jitter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a host controller is used to control pulse gas delivery, then the system can coordinate multiple process steps, but communication jitter and workload affect the timing precision and repeatability of gas pulses
Solution Approach 1:
The control system is segmented into two independent parts: a host controller for high-level process coordination and a dedicated pulse gas delivery controller for precise timing execution. This segmentation allows each component to specialize in its function, with the dedicated controller eliminating communication jitter by locally managing pulse timing without relying on continuous host controller communication.
Solution Approach 2:
A dedicated pulse gas delivery controller acts as an intermediary between the host controller and the gas delivery system. It receives high-level commands from the host controller and translates them into precisely timed pulse signals, isolating the timing-critical path from the communication overhead of the host controller.
2Ease of operation
If communication signals are transmitted between host controller and mass flow controller, then control instructions can be sent, but communication jitter degrades the repeatability of pulse delivery
Solution Approach 1:
The dedicated controller pre-loads pulse sequences and timing parameters into its local memory before execution. By preparing the control sequence in advance and storing it locally, the system eliminates real-time communication dependencies during pulse delivery, ensuring repeatable execution without communication jitter.
Solution Approach 2:
The pulse gas delivery controller is self-sufficient, maintaining its own timing clock and control logic independent of the host controller. It autonomously generates precise pulse sequences based on stored parameters, serving itself rather than relying on continuous external control signals.
Data Source
AI summary
A system for delivering pulses of a desired mass of gas to a tool, comprising: a mass flow controller including flow sensor, a control valve and a dedicated controller configured and arranged to receive a recipe of a sequence of steps for opening and closing the control valve so as to deliver as sequence of gas pulses as a function of the recipe. The mass flow controller is configured and arranged so as to operate in either one of at least two modes: as a traditional mass flow controller (MFC) mode or in a pulse gas delivery (PGD) mode. Further, the mass flow controller includes an input configured to receive an input signal; an output configured to provide an output signal; a communication port configured to receive program instructions; memory configured and arranged to receive programming data determining the programmed configuration of the mass flow controller as either a digital or analog configuration; and a processor/controller for operating the mass flow controller in accordance with the programmed configuration.


