Supercritical Drying Density Correction for Substrate Processing

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Solution Overview

Problem

Existing substrate processing apparatuses using supercritical drying struggle to accurately determine the termination time of liquid replacement with supercritical fluid, leading to inefficiencies and potential pattern collapse during the drying process.

Innovation Solution

Incorporation of a density detector, temperature detector, and pressure detector in the substrate processing apparatus to calculate a correction value for the reference density, allowing precise determination of the density difference between mixed fluid and supercritical fluid, thereby optimizing the drying process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the termination time of liquid replacement is determined by comparing density profiles obtained by supplying and discharging supercritical fluid, then the drying process can be controlled, but the measurement precision is insufficient leading to inaccurate termination time determination

Engineering Contradiction:
Improvetermination time determination accuracyVSAvoiddrying process control reliability
Core Design Contradiction:
Measurement precisionVSReliability

Solution Approach 1:

The patent applies parameter changes by introducing temperature and pressure as correction parameters to improve density measurement accuracy. The density detector measures density under actual drying conditions (temperature and pressure), and the controller calculates corrected density values by applying temperature and pressure correction coefficients. This resolves the contradiction by transforming the measurement from a simple density comparison to a multi-parameter corrected measurement, achieving both high precision termination time determination and reliable drying process control.

Inventive Principle:
Principle #35Parameter changes

2Manufacturing precision

If density detection is performed without temperature and pressure correction, then the measurement process is simple, but the manufacturing precision deteriorates due to inaccurate density difference calculation

Engineering Contradiction:
Improvedensity difference calculation accuracyVSAvoidmeasurement system complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex physical correction mechanisms with computational processing. Instead of using additional mechanical sensors or complex measurement systems, the invention uses the existing density detector combined with temperature and pressure detection, then applies mathematical correction through the controller. The controller calculates corrected density by applying correction coefficients to the measured density based on detected temperature and pressure values. This substitution of mechanical complexity with computational processing achieves high manufacturing precision while maintaining relatively simple device structure.

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

3Loss of information

If the reference density is not corrected based on temperature and pressure variations, then the processing time is reduced, but the loss of information occurs leading to inaccurate drying termination judgment

Engineering Contradiction:
Improvedensity information accuracyVSAvoiddrying processing efficiency
Core Design Contradiction:
Loss of informationVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-storing temperature and pressure correction coefficient tables in the controller before the actual drying process. These correction coefficients are determined in advance through experiments or calculations and stored for quick retrieval. During the drying process, the controller simply looks up the appropriate correction coefficients based on detected temperature and pressure values and applies them to the measured density. This preliminary preparation eliminates the need for complex real-time calculations, minimizing information loss while maintaining high processing efficiency.

Inventive Principle:
Principle #10Preliminary action

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

Enhances the accuracy of determining the liquid replacement termination time, reducing pattern collapse and improving the efficiency of supercritical drying processes.

Implementation Method 1

a density detector configured to detect a density of the fluid flowing through the discharge line

Methodology Applied
Scientific EffectDensity detection:

Implementation Method 2

a temperature detector configured to detect a temperature of the fluid flowing through the discharge line

Methodology Applied
Scientific EffectTemperature detection:

Implementation Method 3

a pressure detector configured to detect a pressure of the fluid flowing through the discharge line

Methodology Applied
Scientific EffectPressure detection:

Implementation Method 4

a processing chamber configured to perform a drying processing on a substrate by supplying a supercritical fluid into the processing chamber and replacing a drying liquid accumulated on the substrate with the supercritical fluid

Methodology Applied
Scientific EffectSupercritical fluid replacement: Supercritical Fluid

Implementation Method 5

replacing a drying liquid accumulated on the substrate with the supercritical fluid

Methodology Applied
Scientific EffectDiffusion: Diffusion

Data Source

PatentUS20250379070A1Substrate processing apparatus and substrate processing method
Publication Date: 2025.12.11 TOKYO ELECTRON LTD
  • US20250379070A1 patent drawing
  • US20250379070A1 patent drawing
  • US20250379070A1 patent drawing

AI summary

A substrate processing apparatus includes a processing chamber; a discharge line; a density detector; a temperature detector; a pressure detector; and processing circuitry. The density detector, the temperature detector, and the pressure detector are configured to detect a density, a temperature, and a pressure, respectively, of a fluid flowing through the discharge line. The processing circuitry is configured to acquire a mixed fluid density and a reference density, which is a density of the supercritical fluid; calculate a correction value based on detection results from the temperature detector and the pressure detector; correct the reference density based on the correction value; and calculate a density difference between the mixed fluid density and the corrected reference density.