Substrate Support Warpage Prevention via Thermal Expansion Control

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Solution Overview

Problem

Substrate supports with materials having different thermal expansion coefficients can warp during temperature changes, affecting the uniform contact of probes with the substrate and compromising test quality in semiconductor manufacturing.

Innovation Solution

A substrate support design featuring a top plate made of silicon carbide and a channel-forming member made of glass, bonded using epoxy resin, with a light irradiation mechanism and a transparent resistance heating heater to adjust the temperature of the channel-forming member, preventing warpage by controlling the thermal expansion mismatch.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If members made of materials having different thermal expansion coefficients are bonded together to form a substrate support, then the substrate support can be constructed with diverse material properties (e.g., light transmission, thermal management), but warpage occurs during temperature changes due to thermal expansion mismatch

Engineering Contradiction:
Improvematerial property diversityVSAvoidstructural stability
Core Design Contradiction:
Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The patent applies parameter changes by actively controlling the temperature of the channel-forming member using a heater. By adjusting the temperature parameter of the glass channel-forming member to match the thermal expansion characteristics of the silicon carbide top plate, the patent compensates for thermal expansion differences and prevents warpage during temperature changes, thus maintaining structural stability while using materials with different inherent thermal expansion coefficients.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent introduces a heater as an intermediary element between the channel-forming member and the external environment. This heater acts as a mediator that actively manages the thermal state of the glass channel-forming member, enabling precise temperature control to match thermal expansion rates with the top plate, thereby preventing warpage while allowing the use of materials with different thermal properties.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Use of energy by moving object

If a light irradiation mechanism is used to heat the substrate, then heating efficiency is improved, but temperature uniformity across the substrate may be compromised

Engineering Contradiction:
Improveheating efficiencyVSAvoidtemperature uniformity
Core Design Contradiction:
Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The patent applies local quality by providing multiple light-emitting elements arranged in an array across the light irradiation mechanism. Each light-emitting element independently irradiates a specific local region of the substrate, allowing for spatially distributed heating. This arrangement enables efficient heating of the entire substrate area while maintaining temperature uniformity through coordinated control of multiple localized light sources.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The light irradiation mechanism is segmented into multiple independent light-emitting elements rather than using a single light source. This segmentation allows each element to target specific regions of the substrate, enabling precise control over the heating pattern. By coordinating the operation of these segmented light sources, the system achieves both high heating efficiency and uniform temperature distribution across the substrate.

Inventive Principle:
Principle #1Segmentation

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 solution effectively prevents warpage of the substrate support, ensuring uniform probe contact and accurate electrical characteristic testing across a wide temperature range, maintaining test quality and device reliability.

Implementation Method 1

a light irradiation mechanism which includes a plurality of light-emitting elements, is disposed to face the substrate placed on the top plate portion, and heats the substrate using light emitted from the light-emitting elements

Methodology Applied
Scientific EffectLight absorption: Absorption (EM radiation)

Implementation Method 2

the temperature adjustment part is a resistance heating heater made of a light-transmitting material and is provided on a surface of the channel-forming member opposite to the top plate portion or inside the channel-forming member

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Implementation Method 3

refrigerant channels are formed between the channel-forming member and the top plate portion, a refrigerant which transmits the light emitted from the light-emitting elements flows through the refrigerant channels

Methodology Applied
Scientific EffectConvection: Convection

Implementation Method 4

the top plate portion and the channel-forming member are made of materials having different thermal expansion coefficients

Methodology Applied
Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP3882644B1Substrate support, test device, and method of adjusting temperature of substrate support
Publication Date: 2024.04.17 TOKYO ELECTRON LTD
  • EP3882644B1 patent drawingFigure 1
  • EP3882644B1 patent drawingFigure 2
  • EP3882644B1 patent drawingFigure 3

AI summary

A substrate support includes a top plate portion having a surface on which a substrate is placed; a light irradiation mechanism including light-emitting elements, disposed to face the substrate and heating the substrate using light from the light-emitting elements; a channel-forming member transmitting the light from the light-emitting elements and is bonded to a rear surface of the top plate portion so as to be interposed between the top plate portion and the light irradiation mechanism, and a temperature adjustment part for adjusting a temperature of the channel-forming member by using light having a wavelength absorbed by a light-transmitting material or the channel-forming member. Refrigerant channels are formed between the channel-forming member and the top plate portion, a refrigerant transmitting the light from the light-emitting elements flows through the refrigerant channels, and the top plate portion and the channel-forming member are made of materials having different thermal expansion coefficients.