Substrate Chuck Thermal Reset for Stable Wafer Processing

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Solution Overview

Problem

In semiconductor processing, maintaining the temperature of a substrate chuck during location-specific processes is challenging due to heat imbalances, leading to device defects and variability, and existing systems with gas and liquid channels for heating/cooling are costly, complex, and unreliable.

Innovation Solution

A substrate chuck with high heat capacity materials and a thermal blocking coating, coupled with a docking station for temperature reset, and a chuck arm for moving the wafer under a stationary process nozzle, reduces temperature fluctuations and eliminates the need for complex heating/cooling systems by using a rechargeable battery and gas plenum integrated into the chuck.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If gas and liquid channels are added to the substrate chuck for heating and cooling, then temperature control capability is improved, but device complexity and cost increase

Engineering Contradiction:
Improvesubstrate chuck temperature controlVSAvoidheating and cooling system complexity
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The patent removes the complex gas and liquid channel systems from the substrate chuck design. Instead of embedding heating and cooling channels within the chuck, the invention uses a simpler chuck structure that relies on radiative heat transfer control through selective surface coatings and periodic docking with a temperature reset station, thereby eliminating the complexity of fluid distribution systems while maintaining temperature control capability

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical fluid-based heating and cooling system with a thermal radiation-based system. By using selective emissivity coatings on the substrate chuck surface and periodic docking with a temperature reset station, the system achieves temperature control through radiative heat transfer rather than through mechanical gas or liquid flow systems, significantly reducing device complexity

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If the substrate chuck processes multiple wafers continuously, then productivity is improved, but temperature stability deteriorates due to heat accumulation

Engineering Contradiction:
Improvewafer processing throughputVSAvoidsubstrate chuck temperature stability
Core Design Contradiction:
ProductivityVSTemperature

Solution Approach 1:

The patent implements periodic docking of the substrate chuck with a temperature reset station during the wafer processing sequence. Between processing batches, the chuck docks briefly to reset its temperature, creating a periodic cycle of processing followed by temperature normalization. This allows continuous high-productivity operation while periodically restoring temperature stability, preventing cumulative heat buildup from affecting subsequent wafers

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent performs temperature reset actions in advance before processing new batches of wafers. By docking the substrate chuck with the temperature reset station prior to loading new wafers, the system ensures temperature stability is reestablished before the next processing sequence begins, preventing temperature drift from affecting productivity while maintaining consistent processing conditions

Inventive Principle:
Principle #10Preliminary action

3Productivity

If the substrate chuck temperature is allowed to change during processing, then processing speed is improved, but manufacturing precision deteriorates due to thermal effects

Engineering Contradiction:
Improveprocessing speedVSAvoidcritical dimension control
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent maintains temperature stability during critical processing operations by implementing periodic docking with a temperature reset station. The chuck remains stationary under the processing beam for the duration of each wafer treatment, eliminating movement-induced temperature variations and ensuring consistent thermal conditions throughout the processing cycle, thereby maintaining manufacturing precision while achieving high throughput through rapid sequential processing

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent changes the thermal parameters of the substrate chuck by applying selective emissivity coatings to control radiative heat transfer. By modifying the surface emissivity characteristics, the system optimizes heat retention during processing while enabling rapid heat dissipation during docking cycles, allowing the chuck to maintain stable temperature during processing (improving precision) while quickly resetting between batches (maintaining productivity)

Inventive Principle:
Principle #35Parameter changes

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

This solution maintains the substrate chuck temperature within a specified range, reducing device defects, improving reliability, and lowering the cost and complexity of location-specific processing systems.

Implementation Method 1

a coating covering a portion of a surface of the substrate chuck, the coating including a thermal blocking material to reduce radiative heat loss

Methodology Applied
Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 2

a docking station in the processing chamber configured to reset a temperature of the substrate chuck when the wafer is docked in a docking position

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250022739A1Process system, method, and substrate chuck
Publication Date: 2025.01.16 TOKYO ELECTRON LTD
  • US20250022739A1 patent drawing
  • US20250022739A1 patent drawing
  • US20250022739A1 patent drawing

AI summary

An embodiment apparatus includes a processing chamber and an equipment housing; a processing tool in the equipment housing with a process nozzle projecting into the processing chamber; a substrate chuck for supporting a wafer disposed in the processing chamber. The apparatus includes a docking station in the processing chamber configured to reset a temperature of the substrate chuck when the wafer is docked in a docking position; and a chuck arm in the processing chamber. The chuck arm is configured to move the wafer under the process nozzle and to move the wafer to the docking position.