Substrate Treatment Apparatus for Warpage Control

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Solution Overview

Problem

Semiconductor wafers often experience warpage due to films applied to their surfaces, leading to issues like conveyance errors, contact problems, and misalignment during lithography, which existing technologies fail to adequately address.

Innovation Solution

A substrate treatment apparatus that uses a plasma treatment module to modify films on wafers by applying specific stress patterns through partial plasma irradiation, creating regions with different film qualities and thicknesses to counteract warpage, including oxidation, nitridation, and thickness adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If films are applied to wafer surfaces to prevent warpage, then wafer stability is improved, but conveyance errors and misalignment occur during manufacturing

Engineering Contradiction:
Improvewafer stabilityVSAvoidconveyance accuracy and lithography alignment
Core Design Contradiction:
Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating non-uniform film thickness distribution across the wafer surface. The film thickness is intentionally made thicker at the center and thinner at the edges (or vice versa depending on warpage direction) to generate localized stress patterns that counteract warpage while maintaining manufacturing precision. This selective variation in film properties allows simultaneous achievement of wafer stability and conveyance accuracy.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent utilizes parameter changes by modifying the film thickness parameter across different regions of the wafer. By controlling the deposition process to create gradient thickness profiles, the stress characteristics of the film are changed locally, enabling the film to exert differential stresses that correct warpage without causing misalignment during subsequent manufacturing steps.

Inventive Principle:
Principle #35Parameter changes

2Shape

If uniform film thickness is applied to counteract warpage, then wafer flatness is improved, but stress distribution becomes insufficient to address multi-directional warpage

Engineering Contradiction:
Improvewafer flatnessVSAvoidstress distribution capability
Core Design Contradiction:
ShapeVSForce

Solution Approach 1:

The patent employs local quality by creating spatially varying film thicknesses that generate differentiated stress distributions. Instead of uniform thickness, the film is deposited with controlled thickness variations in different radial and angular directions, enabling the generation of complex stress patterns capable of counteracting multi-directional warpage components simultaneously.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent applies asymmetry by intentionally creating non-uniform, asymmetric film thickness distributions tailored to the specific warpage profile. The film deposition pattern is designed to be asymmetric relative to the wafer center, with thickness gradients oriented to produce stress components in multiple directions, thereby achieving effective warpage correction that symmetric uniform films cannot provide.

Inventive Principle:
Principle #4Asymmetry

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

Effectively inhibits warpage in both directions, reducing errors and misalignments by applying tailored stress to the wafer surfaces, ensuring stable and precise semiconductor manufacturing processes.

Implementation Method 1

a film treatment module configured to treat the film in accordance with warpage of the substrate such that the film includes a first region having a first film quality or a first film thickness and a second region having a second film quality or a second film thickness different from the first film quality or the first film thickness

Methodology Applied
Scientific EffectPlasma treatment: Plasma

Data Source

PatentUS10804221B2Substrate treatment apparatus, method of manufacturing semiconductor device and workpiece substrate
Publication Date: 2020.10.13 KIOXIA CORP
  • US10804221B2 patent drawing
  • US10804221B2 patent drawing
  • US10804221B2 patent drawing

AI summary

In one embodiment, a substrate treatment apparatus includes a substrate holder configured to hold a substrate provided with a film. The apparatus further includes a film treatment module configured to treat the film in accordance with warpage of the substrate such that the film includes a first region having a first film quality or a first film thickness and a second region having a second film quality or a second film thickness different from the first film quality or the first film thickness.