3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 1 of 18 Int. J. Nano Technology (IJNT) 1 A comprehensive review of end point detection in chemical mechanical polishing for deep-submicron integrated circuits manufacturing H. Hocheng and Y. -L. Huang Department of Power Mechanical Engineering, National Tsing-Hua University, Hsinchu, Taiwan, R.O.C. E-mail: [email protected] Abstract: As the number of metal levels and the wafer size increase, the need for global planarity across the wafer becomes more crucial. Chemical mechanical planarization (CMP) is considered the key technique to achieve this goal. Accurate in situ end point detection and monitoring method can reduce the product variance, improve the yield and throughput. During CMP process, the wafer is brought downward against the polishing pad completely. The monitoring of the wafer polishing in such a con®guration becomes a dif®cult task. Many methods have been proposed in the past years, including the optical, electrical, acoustical/vibrational, thermal, frictional, chemical/electrochemical methods and others, which are critically reviewed in this study. The mainstream of the industrial application and the future trend are investigated. Keywords: chemical mechanical planarization, chemical mechanical polishing, CMP, end point detection, monitoring, semiconductor. Reference to this paper should be made as follows: Hocheng, H. and Huang, Y.-L. (2002) `A comprehensive review of end point detection in chemical mechanical polishing for deep-submicron integrated circuits manufacturing', Int. J. Nano Technology, Vol. X, No. Y, pp. 1±18. Biographical notes: Professor H. Hocheng earned his Diplom-Ing. from Technische Hochschule at Aachen and PhD from University of California at Berkeley. He has been faculty at National Tsing Hua University since 1989. He was awarded Outstanding Research from National Science Council. His research interest lies in the area of innovative processing of materials. Mr. Y.L. Huang earned his Bachelor's degree of Engineering from National Chiao-Tung University in 1995. He has been since then working on his doctorate theses at National Tsing-Hua University. His current research interest is the end point detection for CMP process. 1 Introduction With the shrinking device scale and higher performance requirement of integrated circuits (IC), the utilization of the advanced photolithographic and anisotropic etching techniques are essential. The increasing number of interconnection layers requires highly planarized surface on every layer to ensure that the accumulated roughness of the layers are less than the depth of focus of the lithography stepper. Copyright # 2002 Inderscience Enterprises Ltd. M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d 2 H. Hocheng and Y.-L. Huang Figure 1 Schematic diagram of CMP machine. Date: 20/5/02 Time 12:21pm Page 2 of 18 The innovative solution to improve the surface planarity was introduced, known as chemical mechanical planarization (CMP) technique. CMP has become a key process for the Cu interconnects, low-k materials and dual damascene process. During a CMP process, the wafer is held by a rotating carrier that brings the wafer against a rotating circular pad or a linearly moving belt with an applied downward force, as shown in Figure 1. The slurry made of abrasive particles suspended in a chemically etching liquid is dispensed on the pad to achieve the removal of the surface layer. As more wafers are polished, the pad starts to degrade and affects its planarizing ability. In order to ensure the wafers are properly planarized and to control the constant yield of CMP, the on-line monitoring and end point detection techniques are needed. This study presents a review of the existing monitoring and end point detection methods shown in the journals, conference proceedings, patents and industrial reports. 2 De®nition of end point Monitoring for CMP processes can be divided into two categories, in situ quality monitoring and end point detection. The former is to detect the abnormal wafer conditions, such as the surface scratches and wafer slipping, and the abnormal conditions of the applied consumables, namely pad and slurry, during CMP. The end point detection is to determine when to stop a CMP process. For oxide CMP, the end point is reached when the wafer surface is ¯at enough for the following lithography process, and the thickness of the dielectric layer enough to insulate the metal lines, as shown in Figure 2(a). For metal CMP, the fully removal of the extra metal on the wafer surface without overpolishing the metal lines inside the vias or contacts that might cause dishing and erosion de®nes the end point, as shown in Figure 2(b). End point detection is considered a vital step in the volume production of high value-added semiconductor manufacturing. Currently, CMP processes are operated based on empirical open-loop designs, without monitoring and feedback to determine the end point of the process. Since the wafer surface is in full engagement with the polishing pad and rotated by the M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 3 of 18 A comprehensive review of end point detection in chemical mechanical polishing 3 Figure 2 Schematic diagram of CMP end point for (a) Oxide CMP process; (b) Metal CMP process. carrier, in situ detection of the end point of a CMP process is dif®cult to perform. The production line often takes two hours per shift for off-line product evaluation, thus reducing the CMP equipment capacity by 50% [1]. Therefore an accurate, robust and easy-to-use monitoring technique is required. 3 End point detection methods Numerous approaches have been proposed for in situ monitoring and end point detection. In the past three years, T. Bibby and K. Holland [1], D.L. Hetherington and D.J. Stein [2, 3], and H. Hocheng, H.Y. Tsai and Y.-L. Huang [4] have reviewed the proposed approaches. In this study, Tables 1, 2, 3, 4, 5, and 6 summarize the US patents using optical, electrical, acoustical/vibrational, thermal, frictional, and chemical/electrochemical methods, respectively. Table 7 summarizes a variety of miscellaneous patents that cannot ®t into the above categories. 3.1 Optical methods Optical method is one of the most practically used methods in monitoring CMP processes. Many researches have devoted into this area [5±18]. These researches mainly focused on the various arrangement of the optical measuring module and the processing algorithms of the detected signal. The optical measuring module can be installed inside the platen [Table 1, 5,433,651, 5,609,511, 5,838,447, 5,893,796, 5,964,643, 5,985,679, 6,045,439, 6,071,177, 6,074,517, 6,106,662, 6,111,634, 6,146,248, 6,159,073, 6,171,181, M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) 4 J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 4 of 18 H. Hocheng and Y.-L. Huang Table 1 Optical monitoring for CMP. US patent no. Date 5,081,796 5,413,941 5,427,878 5,433,651 5,461,007 5,483,568 5,499,733 5,605,760 5,609,511 5,658,183 5,663,797 5,667,424 5,672,091 5,691,253 5,695,660 5,708,506 5,724,144 5,730,642 5,733,171 5,777,739 5,801,066 5,823,853 5,838,447 5,838,448 5,872,633 5,891,352 5,893,796 5,899,792 5,910,846 5,934,974 5,936,733 5,949,927 5,961,369 5,964,643 5,985,679 5,993,289 6,024,628 6,028,669 6,045,439 6,071,177 Jan. 21, 1992 May 9, 1995 Jun. 27, 1995 Jul. 18, 1995 Oct. 24, 1995 Jan. 9, 1996 Mar. 19, 1996 Feb. 25, 1997 Mar. 11, 1997 Aug. 19, 1997 Sep. 2, 1997 Sep. 16, 1997 Sep. 30, 1997 Nov. 25, 1997 Dec. 9, 1997 Jan. 13, 1998 Mar. 3, 1998 Mar. 24, 1998 Mar. 31, 1998 Jun. 7, 1998 Sep. 1, 1998 Oct. 20, 1998 Nov. 17, 1998 Nov. 17, 1998 Feb. 16, 1999 Apr. 6, 1999 Apr. 13, 1999 May 4, 1999 Jun. 8, 1999 Aug. 10, 1999 Aug. 10, 1999 Sep. 7, 1999 Oct. 5, 1999 Oct. 12, 1999 Nov. 16, 1999 Nov. 30, 1999 Feb. 15, 2000 Feb. 22, 2000 Apr. 4, 2000 Jun. 6, 2000 6,074,517 6,075,606 6,077,452 6,106,662 6,110,752 6,111,634 6,114,706 6,117,780 6,146,242 6,146,248 6,159,073 6,172,756 6,190,234 Jun. 13, 2000 Jun. 13, 2000 Jun. 20, 2000 Aug. 22, 2000 Aug. 29, 2000 Aug. 29, 2000 Sep. 5, 2000 Sep. 12, 2000 Nov. 14, 2000 Nov. 14, 2000 Dec. 12, 2000 Jan. 9, 2001 Feb. 20, 2001 M????? Assignee End point detection Micron Technology Inc. Micron Technology Inc. Digital Equipment Corp. IBM Motorola Kabushiki Kaisha Toshiba Luxtron Rodel Hitachi Micron Technology Micron Technology Chartered Semiconductor Ebara Motorola Luxtron Applied Materials IBM, Toshiba Micron Technology Speedfam Micron Technology Micron Technology Speedfam Ebara Nikon Speedfam Luxtron Applied Materials Nikon Micron Technology Aplex Group Micron Technology Wallace T.Y. Tang Speedfam-IPEC Applied Materials LSI Logic Speedfam-IPEC United Microelectronics Corp. Luxtron Applied Materials Taiwan Semiconductor Manufacturing Co. Ltd. LSI Logic Trung T. Doan Luxtron Speedfam-IPEC Luxtron Lam Research Micron Technology Mosel Vitelle Strasbaugh Lam Research Applied Materials Filmetrics Applied Materials Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset * * * * * * * * * * 3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 5 of 18 A comprehensive review of end point detection in chemical mechanical polishing 5 Table 1 continued. US patent no. 6,214,734 6,271,047 6,280,289 6,285,035 6,287,171 6,301,006 6,309,276 6,309,555 Date Apr. 10, 2001 Aug. 7, 2001 Aug. 28, 2001 Sep. 4, 2001 Sep. 11, 2001 Oct. 9, 2001 Oct. 30, 2001 Oct. 30, 2001 Assignee End point detection VLSI Technology Nikon Applied Materials LSI Logic Speedfam-IPEC Micron Technology Applied Materials United Microelectronics Corp. Note: *also for quality monitoring. Table 2 Electrical monitoring for CMP. US patent no. 4,793,895 5,081,421 5,132,617 5,213,655 5,242,524 5,265,378 5,321,304 5,337,015 5,486,129 5,559,428 5,644,221 5,685,766 5,731,697 5,738,562 5,762,536 5,865,665 5,868,896 6,020,264 6,129,613 6,143,123 6,185,865 6,254,454 Date Assignee End point detection Dec. 27, 1988 Jan. 14, 1992 Jul. 21, 1992 May 25, 1993 Sep. 7, 1993 Nov. 30, 1993 Jun. 14, 1994 Aug. 9, 1994 Jan. 23, 1996 Sep. 24, 1996 Jul. 1, 1997 Nov. 11, 1997 Mar. 24, 1998 Apr. 14, 1998 Jun. 9, 1998 Feb. 2, 1999 Feb. 9, 1999 Feb. 1, 2000 Oct. 10, 2000 Nov. 7, 2000 Feb. 13, 2001 Jul. 3, 2001 IBM AT&T Bell Laboratories IBM IBM IBM LSI Logic LSI Logic IBM Micron Technology IBM IBM Speedfam IBM Micron Technology Lam Research William Yueh Micron Technology IBM Philips Elec. North America Micron Technology Lam Research Agere Systems Table 3 Acoustical/vibration monitoring for CMP. US patent no. 5,222,329 5,240,552 5,245,794 5,399,234 5,439,551 5,876,265 5,904,609 M????? Date Assignee Jun. 29, 1993 Aug. 31, 1993 Sep. 21, 1993 Mar. 21, 1995 Aug. 8, 1995 Mar. 2, 1999 May 18,1999 Micron Technology Micron Technology Advanced Micro Devices Motorola Micron Technology Fujitsu Fujitsu Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) End point detection Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) 6 J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 6 of 18 H. Hocheng and Y.-L. Huang Table 4 Thermal monitoring for CMP. US patent no. Date Assignee End point detection 5,196,353 5,597,442 Mar. 23, 1993 Jan. 28, 1997 5,643,050 Jul. 1, 1997 5,647,952 Jul. 15, 1997 5,722,875 5,834,377 Mar. 3, 1998 Nov. 10, 1998 5,891,352 6,007,408 6,077,452 6,077,783 6,110,752 6,150,271 Apr. 6, 1999 Dec. 28, 1999 Jun. 20, 2000 Jun. 20, 2000 Aug. 29, 2000 Nov. 21, 2000 Micron Technology Taiwan Semiconductor Manufacturing Co. Ltd. Industrial Technology Research Institute Industrial Technology Research Institute Tokyo Electron, IPEC-Planar Industrial Technology Research Institute Luxtron Micron Technology Luxtron LSI Logic Luxtron Lucent Technology Table 5 Frictional monitoring for CMP. US patent no. 5,036,015 5,069,002 5,308,438 5,562,529 5,595,526 5,624,300 5,639,388 5,643,046 5,667,629 5,743,784 5,830,041 5,846,882 6,046,111 6,268,224 6,293,845 Date Assignee End point detection Jul. 30, 1991 Dec. 3, 1991 May 3, 1994 Oct. 8, 1996 Jan. 21, 1997 Apr. 29, 1997 Jun. 17, 1997 Jul. 1, 1997 Sep. 16, 1997 Apr. 28, 1998 Nov. 3, 1998 Dec. 8, 1998 Apr. 4, 2000 Jul. 31, 2001 Sep. 25, 2001 Micron Technology Micron Technology IBM Fujitsu Intel Fujitsu Ebara Kabushiki Kaisha Toshiba Chartered Semiconductor Applied Materials Ebara Applied Materials Micron Technology LSI Logic Mitsubishi Materials * Note: *also for quality monitoring. 6,190,234, 6,280,289, 6,285,035], at the periphery of the platen [Table 1, 5,081,796, 5,413,941, 5,672,091], or inside the carrier [Table 1, 5,695,660, 5,891,352, 5,949,927, 6,028,669, 6,077,452, 6,110,752, 6,172,756, 6,287,171], as shown in Figure 3. In the ®rst case, the measuring light is directed to the wafer surface through windows opened on the pad and in the platen. Hence the measurement is performed every time the window passes beneath the wafer. In the second case, the wafer has to move partly outside the pad for measurement. This gives the opportunities to clean the wafer surfaces with water or compressed air before or during measurement, which also gives a constant interface for the measuring light. In the third case, the measuring module inside the carrier directs the measuring light through the wafer M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 7 of 18 A comprehensive review of end point detection in chemical mechanical polishing 7 Table 6 Chemical/electrochemical monitoring for CMP. US patent no. 5,637,185 5,733,176 5,836,805 5,876,266 5,911,619 6,071,818 6,080,670 6,117,779 6,121,147 6,126,848 6,206,769 6,214,732 6,251,784 6,258,205 6,258,231 6,261,851 6,293,847 6,325,706 Date Assignee End point detection Jun. 10, 1997 Mar. 31, 1998 Nov. 17, 1998 Mar. 2, 1999 Jun. 15, 1999 Jun. 6, 2000 Jun. 27, 2000 Sep. 12, 2000 Sep. 19, 2000 Oct. 3, 2000 Mar. 27, 2001 Apr. 10, 2001 Jun. 26, 2001 Jul. 10, 2001 Jul. 10, 2001 Jul. 17, 2001 Sep. 25, 2001 Dec. 4, 2001 Rensselaer Micron Technology Lucent Technology IBM IBM LSI Logic LSI Logic LSI Logic LSI Logic IBM Micron Technology Lucent Technology IBM LSI Logic Agere Systems IBM Agere Systems Lam Research * Note: *also for quality monitoring. Table 7 Miscellaneous monitoring for CMP. US patent no. Date Assignee End point detection 5,234,868 5,492,594 5,609,718 5,618,447 5,637,031 5,643,048 5,655,951 5,659,492 5,700,180 5,705,435 5,720,845 5,736,427 5,834,375 5,834,645 5,851,135 6,113,466 Aug. 10, 1993 Feb. 20, 1996 Mar. 11, 1997 Apr. 8, 1997 Jun. 10, 1997 Jul. 1, 1997 Aug. 12, 1997 Aug. 19, 1997 Dec. 23, 1997 Jan. 6, 1998 Feb. 24, 1998 Apr. 7, 1998 Nov. 10, 1998 Nov. 10, 1998 Dec. 22, 1998 Sep. 5, 2000 6,113,479 6,117,777 6,120,347 6,150,260 6,159,786 Sep. 5, 2000 Sep. 12, 2000 Sep. 19, 2000 Nov. 21, 2000 Dec. 12, 2000 6,160,314 6,276,987 Dec. 12, 2000 Aug. 21, 2001 IBM IBM Micron Technology Micron Technology Industrial Technology Research Institute Micron Technology Micron Technology IBM Micron Technology Industrial Technology Research Institute Keh-Shium Liu Micron Technology Industrial Technology Research Institute Speedfam Micron Technology Taiwan Semiconductor Manufacturing Co. Ltd. Obsidian Chartered Semiconductor Micron Technology Chartered Semiconductor Taiwan Semiconductor Manufacturing Co. Ltd. United Microelectronics Corp. IBM Note: *also for quality monitoring. M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset * * * 3B2 Version Number 6.05e/W (Mar 29 1999) 8 J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 8 of 18 H. Hocheng and Y.-L. Huang Figure 3 Optical methods to monitor CMP: (a) Inside the platen [US patent 6,280,289]; (b) At the periphery of the platen [US patent 5,081,796] and (c) Inside the carrier [US patent 5,695,660.] substrate to the wafer surface. This technique can eliminate the possible interruption of the slurry or the cleaning water. The applied signal processing algorithms vary with different CMP processes. For the oxide CMP processes, the changing oxide ®lm thickness can be measured by the changes in wavelength of the re¯ected lights. While in metal CMP processes, the removal of a re¯ective surface tells the end point. The comparison of the spectra is also used for the analysis of signal [13]. The optical technique is the most intuitive method to monitor CMP processes. But for a patterned wafer, the scattering and diffraction effects due to the existence of the metal lines often interfere the measurement. Besides, the optical methods measure only one point on wafer surface to represent the condition across the whole wafer, which can lead to wrong judgements. M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 9 of 18 A comprehensive review of end point detection in chemical mechanical polishing 9 Figure 4 An electrical method to monitor CMP [US patent 5,337,015]. 3.2 Electrical methods Methods in this section measure the changes of electrical properties or use the sensors for certain signals to detect the process end point. Most of the references in this area are found in patents. Many of the methods use the embedded electrodes in the pad or on the carrier to measure the variations in the electrical conductivity, capacity, impedance, or resistance during CMP processes, as shown in Figure 4. These methods require a modi®ed carrier and platen to accommodate the electrodes and a complex wiring route, which seriously limit the acceptance in the practical applications. Displacement sensors, such as LVDT (line variable displacement transducer), measure the small position difference of the carrier to estimate the ®lm thickness of the wafer held by the carrier [Table 2, 5,868,896]. Pressure sensors were also used to detect the pressure variance of the carrier [Table 2, 6,143,123, 6,129,613] or in the bearing ¯uid [Table 2, 6,186,865]. The pressure sensor generates a signal in response to the measured pressure that corresponds to a planarizing parameter of the wafer. 3.3 Acoustic/vibrational methods CMP processes are often used to remove the surplus metal layers from wafer surface. Different acoustic waves and vibrations are sent out while polishing different materials. The acoustic signal can be detected either by acoustic sensors attached to the equipment or by a microphone located near the wafer being polished, as shown in Figure 5. Vibrations are detected by commercial accelerometers. The frequency spectrum and the signal magnitude are obtained from the acquired signals for further analysis [19±26]. M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm 10 H. Hocheng and Y.-L. Huang Figure 5 An acoustical method to monitor CMP [US patent 5,222,329]. Page 10 of 18 Using acoustic methods to monitor CMP processes can ®lter low-frequency background noise easily, especially when measuring the acoustic emission (AE) signal to detect the end point and to monitor the abnormal conditions [4, 22±24]. The inherent high frequency feature of AE signal keeps the acquired signal away from low-frequency noise. However, it requires that the sensors be placed as close to the acoustic source, i.e. the polished wafer, as possible, which makes the proper sensor placement a challenge. 3.4 Thermal methods Thermal methods measure the thermal properties of the pad or the wafer during CMP, as shown in Figure 6. Since the temperature does affect chemical reactions, many CMP equipments have already installed a platen temperature controller or a pad temperature-measuring module. Thus many investigators have tried to use the thermal principles to detect the end point of metal CMP [26±38]. Some researches used an infra-red camera to take the full 2-dimensional thermal images instead of the temperature of one point on the pad [26, 27]. The information of the temperature and the thermal emissivity of the pad can be extracted from the acquired thermal images, which can be used to evaluate the polishing end point as well as the pad life [27, 28]. The temperature distribution was also found closely related to the kinematic nonuniformity of the wafer [28]. The advantage of this technique is that it can perform the measurement at a distance from the pad without attaching sensors with the entangled wires. However, the usage of thermal methods is limited for metal CMP. This is due to the low sensitivity of the change of the temperature distribution correlated to the uniformity variation of the oxide layer on the wafer. 3.5 Frictional methods The frictional methods measure the change of the torque, the motor current [32, 33, 34, 38], or the motor voltage applied to the carrier or the platen [13, 36]. This is also a M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 11 of 18 A comprehensive review of end point detection in chemical mechanical polishing Figure 6 A thermal method to monitor CMP [US patent 5,722,875]. Figure 7 A frictional method to monitor CMP [US patent 5,639,388]. M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 11 3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 12 H. Hocheng and Y.-L. Huang Figure 8 A chemical method to monitor CMP [US patent 6,261,851]. Time 12:21pm Page 12 of 18 widely used method to detect the end point of metal CMP processes. The hardness of the oxide layer differs from that of the metal layer, and so is the coef®cient of friction of the two layers engaged with the pad. Thus when the upper metal layer is removed and the pad starts to polish the underlying oxide layer, the electric motor has to change the power to drive the carrier or the platen. The power variation is used to monitor the end point of removal of the metal layer. However, the acquired signal often contains considerable unwanted noise and needs to be ®ltered, or even the change is too weak to judge, that limits its applications. 3.6 Chemical/electrochemical methods Recently, some researches have used chemical and electrochemical methods for monitoring, especially reported in the US patents. The proposed methods mainly measure the particle size [39, 40], the presence of certain vapour [Table 6, 6,293,847, 6,261,851, 6,080,670], the electrochemical potential [Table 6, 6,258,231, 6,214,732], zeta potential, conductivity [Table 6, 5,836,805, 6,251,784], or pH level of the slurry or the wafer to detect the end point. For example, during metal CMP, the conductivity of the waste slurry or the current that passes through the waste slurry rises gradually as a function of time, levels off, and then decreases [Table 6, 5,836,805]. When the current, which will never decrease to zero, reaches approximately zero, the end point is reached. The disadvantage of this method is the electrodes have to contact the rotating wafer or the slurry to measure the data. The response time of the method is also a concern. M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 13 of 18 A comprehensive review of end point detection in chemical mechanical polishing 3.7 13 Miscellaneous methods There are methods cannot be categorized into the previous sections [41±46]. Most of these techniques involve the process parameters operation. For example, the US patent 5, 705, 435 monitors the end point by the ratio of the removal rates of the dielectric layers with and without pattern layer beneath. Others use a spacer of known thickness to stop polishing at the desired polishing depth, or use a self-stop layer [45]. These methods can be achieved without extra equipment or performing data analysis, but they also require inserting a stop layer with lower removal rate and thus increasing the complexity of the whole semiconductor process. A comprehensive database of the removal rates of different materials under different operating parameters is also required. 4 Analysis of monitoring techniques 4.1 Mainstream of industrial applications Based on the survey shown in the previous sections, one can conclude that the major efforts of end point detection were devoted to the application of optical principles. Actually most of the related US patents apply optical methods to monitor CMP processes. Figure 9 shows a comparison of the commercial CMP equipment vendors with their number of ®led patents of different methods. It shows that all vendors have patents in the area of optical methods, and these techniques are used on their own CMP equipments. It is the industrial point of view that the optical methods are the most practical to monitor CMP processes. On the other hand, many vendors have investigated the frictional and thermal methods. While the optical methods provide data of only one point of the wafer, the frictional and thermal methods give information across the whole wafer. Therefore most commercialized CMP machines now apply the optical technique to monitor the end point, whereas at the same time provide the data of pad temperature and motor current for process monitoring. Figure 9 Comparison of patented methods among major CMP vendors. M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) 14 J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 14 of 18 H. Hocheng and Y.-L. Huang Figure 10 Comparison of patented amount among different categories. 4.2 Future trend 4.2.1 Versatile development Recently, researches that investigated the acoustical/vibrational and chemical/ electrochemical techniques are gradually increasing, as shown in Figure 10. The use of acoustical/vibrational methods can prevent the interference of low-frequency noise, while a successful ®ltering and signal processing plus the robust mountings of the sensors are the prerequisites. 4.2.2 Fusion of multiple sensors Since each monitoring method possesses its advantages and disadvantages, a multisensor system compensating the individual drawbacks is desired as a solution. Several CMP equipments now are installed with optical as well as thermal/frictional sensors. A good diagnostic approach to the analysis of the acquired multiple data is required in the future. 4.2.3 Beyond metal CMP Most of the current methods are used for metal CMP. There is no plausible method to detect the end point for oxide CMP due to the limited changes in wafer surface during the process. A practical method to monitor the oxide CMP is desired, which can be also applied to the mass LCD production. 5 Conclusions An extensive review of the existing end point detection techniques for CMP is provided in this paper. Based on the applied sensors, these techniques can be categorized into optical, electrical, acoustical/vibrational, thermal, frictional, chemical/electrochemical methods and others. The mainstream of current industrial practice is the optical applications, while recently the acoustical/vibrational and the M????? Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset 3B2 Version Number 6.05e/W (Mar 29 1999) J:/JOBSIN/M10439/Article12.3d Date: 20/5/02 Time 12:21pm Page 15 of 18 A comprehensive review of end point detection in chemical mechanical polishing 15 chemical/electrochemical methods have been explored widely. Many vendors now provide secondary monitoring setup other than the optical devices on their CMP equipment. In the future, the fusion of multiple sensors with sophisticated diagnostic approach will be pursued. The monitoring technique beyond the metal CMP for broader applications such as LCD production is desired. 6 Acknowledgement The current research is supported by National Science Council under contract NSC90±2212-E007±064. References 1 Bibby, T. and Holland, K. (October 1998), `Endpoint Detection for CMP', Journal of Electronic Materials, Vol. 27, No.10, pp. 1073±1081. 2 Hetherington, D.L. and Stein, D.J. 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Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???) Tradespools Ltd., Frome, Somerset
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