A Comprehensive Review of Endpoint Detection in Chemical

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. (September 1999) `In-Line Monitoring of ChemicalMechanical Polishing Processes', Proceedings of the SPIE, The International Society for
Optical Engineering, In-Line Methods and Monitors for Process and Yield Improvement,
Vol. 3884, pp. 24±35.
3 Stein, D.J. and Hetherington, D.L. (2001), `Recent Advances in Endpoint and In-Line
Monitoring Techniques for Chemical-Mechanical Polishing Processes', Proceedings of the
SPIE, The International Society for Optical Engineering, In-Line Characterization,
Yield, Reliability, and Failure Analysis in Microelectronic Manufacturing II, Vol. 4406,
pp. 157±170.
4 Hocheng, H., Tsai, H.-Y. and Huang, Y.-L. (2001) `Essential Aspects of Chemical
Mechanical Planarization for Oxide Semiconductor,' Key Engineering Materials,
Vol. 196, pp. 1±24.
5 Sun, M., Tseng, H.-M., Litvak, H. and Glenn, D. (February 1996), `In-situ Detection of
Film Thickness Removal During CMP of Oxide and Metal Layers', First International
Chemical-Mechanical Polish (C.M.P.) for VLSI/ULSI Multilevel Interconnection
Conference (CMP-MIC) : 1996 proceedings, The Institute for Microelectronics
InterConnection, pp. 256±262.
6 Fang, S.-J., Barda, A., Janecko, T., Little, W., Outley, D., Hempel, G., Joshi, S.,
Morrison, B., Shinn, G.B. and Birang, M. (April 1998) `Control of Dielectric CMP Using
an Interferometry Based Endpoint Sensor', Proceedings of the IEEE 1998 International
Interconnect Technology Conference, IEEE Electron Devices Society, pp. 76±78.
7 Bakin, D.V., Glen, D.E. and Sun, M.-H. (September 1998) `Application of Backside
Fibre-Optic System for in-situ CMP Endpoint Detection On Shallow Trench Isolation
Wafers', Proceedings of the SPIE, The International Society for Optical Engineering,
Process, Equipment, and Materials Control in Integrated Circuit Manufacturing IV,
Vol. 3507, pp. 201±207.
8 Moriyama, S., Yamaguchi, K., Honma, Y. and Yasui, K. (March 1996) `An End-Point
Detector for Planarization of Semiconductor-devices by Chemical-Mechanical Polishing',
International Journal of the Japan Society for Precision Engineering, Vol. 30, No.1,
pp. 55±58.
9 Chan, D.A., Serdek, B., Wiswesser, A. and Birang, M. (September 1998) `Process Control
and Monitoring with Laser Interferometry Based Endpoint Detection in Chemical
Mechanical Planarization', Proceedings of the 1998 IEEE/SEMI Advanced Semiconductor
Manufacturing Conference and Workshop, IEEE, pp. 377±384.
M?????
Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???)
Tradespools Ltd., Frome, Somerset
3B2 Version Number 6.05e/W (Mar 29 1999)
16
10
11
12
13
14
15
16
17
18
19
20
21
J:/JOBSIN/M10439/Article12.3d
Date: 20/5/02
Time 12:21pm
Page 16 of 18
H. Hocheng and Y.-L. Huang
Ushino, Y., Ueda, T., Nakahira, H., Matsukawa, E. and Koyama, M. (February 1999),
`In-situ Monitoring of CMP Process Utilizing 0-Order Spectrometry', Fourth International Chemical-Mechanical Planarization for ULSI Multilevel Interconnection Conference
(CMP-MIC); 1999 Proceedings, The Institute for Microelectronics InterConnection,
pp. 23±29.
Szarka, F., Givens, J. and Easterday, D. (May 1999) `Characterization, Development,
and Implementation of Multi-Platen In-situ Rate Monitor (ISRM) Control for Chemical
Mechanical Planarization in ASIC Manufacturing', Proceedings of the SPIE, The
International Society for Optical Engineering, Proceedings of the 1999 Process and
Equipment Control in Microelectronic Manufacturing, Vol. 3742, pp. 28±42.
Dunton V. and Szarka, F. `STI-CMP Process Control Improvement with Optical
Endpoint Detection', Chemical Mechanical Planarization in IC device manufacturing III :
Proceedings of the International Symposium, Electronics and Dielectric Science
and Technology Divisions of the Electrochemical Society, Third International Symposium
on Chemical Mechanical Planarization in Integrated Circuit Device Manufacturing,
Vol. 99±37, pp. 30±44.
Yeng, M.-C., Shau, F.-Y., Huang, C.-S., Yi, C. and Tang, R. (February 1998)
`Comparison of End Point Detectors for Tungsten Dual Damascene CMP', Third
International Chemical-Mechanical Planarization for ULSI Multilevel Interconnection
Conference (CMP-MIC); 1998 Proceedings, The Institute for Microelectronics InterConnection, pp. 216±223.
Xie, J., Pallinti, J., Nagahara, R. and Lee, D. (March 2001) `Endpoint Enhancement by
Re¯ective and Anti-re¯ective Coating for Oxide CMP', Sixth International ChemicalMechanical Planarization for ULSI Multilevel Interconnection Conference (CMP-MIC);
2001 Proceedings, The Institute for Microelectronics InterConnection, pp. 503±509.
Shieh, A., Liu, Y., Chen, J., Hwang, Y.L., Chang, J., Liu, T. and Tsai, P. (January 2000)
`Novel Tungsten CMP Process with Soft Pad and Optical Endpoint System Control',
Seventeenth International VLSI Multilevel Interconnection Conference (VMIC); 2000
Proceedings, The Institute for Microelectronics InterConnection, pp. 183±188.
Liu, A.H., Solis, R. and Givens, J.H. (May 1999) `Utilization of Optical Metrology as
an In-Line Characterization Technique for Process Performance Improvement and
Yield Enhancement of Dielectric and Metal CMP in IC Manufacturing', Proceedings
of the SPIE, The International Society for Optical Engineering, Proceedings of the 1999
In-Line Characterization, Yield Reliability, and Failure Analyses in Microelectronic
Manufacturing, Vol. 3743, pp. 102±111.
Noriyuki, K., Takahisa, H., Hitoshi, A., Masahiro, H., Masao, Y., Norio, K., Manabu,
T., Hiroyuki, Y. and Katsuya, O. (2000) `Film Thickness Monitor for CMP Processing',
Materials Research Society Symposium Proceedings, The 1999 MRS Spring Meeting ±
Symposium `Chemical-Mechanical Polishing ± Fundamentals and Challenges', Vol. 566,
pp. 233±243.
Eric, W. (January 1996) `New CMP Architecture Addresses Key Process Issues', Solid
State Technology, Vol. 39, No.1, pp. 61±62.
Fukuroda, A., Nakamura, K. and Arimoto, Y. (December 1995) `In situ CMP
Monitoring Technique for Multi-layer Interconnection', Technical Digest International
Electron Devices Meeting, Proceedings of the 1995 International Electron Devices Meeting,
pp. 469±472.
Hetherington, D.L., Stein, D.J., Lauffer, J.P., Wyckoff, E.E. and Shingledecker, D.M.
(May 1999) `Analysis of In-situ Vibration Monitoring for End-Point Detection of CMP
Planarization Process', Proceedings of the SPIE, The International Society for Optical
Engineering, Proceedings of the 1999 In-Line Characterization, Yield Reliability, and
Failure Analyses in Microelectronic Manufacturing. Vol. 3743, pp. 89±101.
Kojima, T., Miyajima, M., Akaboshi, F., Yogo, T., Ishimoto, S. and Okuda, A. (August
2000) `Application of CMP Process Monitor to Cu Polishing', IEEE Transactions on
Semiconductor Manufacturing, Vol. 13, No.3, pp. 293±299.
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 17 of 18
A comprehensive review of end point detection in chemical mechanical polishing
17
22 Tang, J., Dornfeld, D., Pangrle, S.K. and Dangca, A. (October 1998) `In-process
Detection of Micro-Scratching During CMP Using Acoustic Emission Sensing
Technology', Journal of Electronic Materials, Vol. 27, No.10, pp. 1099±1103.
23 Tang, J., Unger, C., Moon, Y. and Dornfeld, D. (April 1997) `Low-k Dielectric Material
Chemical Mechanical Polishing Process Monitoring Using Acoustic Emission', LowDielectric Constant Materials III Materials Research Society Symposium Proceedings,
Proceedings of the 1997 MRS Spring Meeting, Vol. 476, pp. 155±160.
24 Hocheng, H. and Huang, Y.L. (November 2001) `Preliminary Study of Endpoint
Detection for Chemical Mechanical Planarization Process Using Acoustic Emission',
Eighteenth International VLSI Multilevel Interconnection Conference (VMIC); 2001
Proceedings, The Institute for Microelectronics InterConnection.
25 Colgan, M., Morath, C., Tas, G. and Grief, M. (February 2001) `An Ultrasonic Laser
Sonar Technique for Copper Damascene CMP Metrology', Solid State Technology,
Vol. 44, No. 2, pp. 67, 71±72, 74.
26 Lin, Z.-H., Chiou, H.-W., Shih, S.-Y., Kuo, L.-H., Chen, L.-J. and Hsia, C. (February
1999) `Study of Tungsten CMP Endpoint Window', Fourth International ChemicalMechanical Planarization for ULSI Multilevel Interconnection Conference (CMP-MIC);
1999 Proceedings, The Institute for Microelectronics InterConnection, pp. 65±68.
27 Chen, L.J., Huang, Y.L., Lin, Z.H. and Chiou, H.W. (February 1998) `Pad thermal
Image End-pointing for CMP Process', Third International Chemical-Mechanical
Planarization for ULSI Multilevel Interconnection Conference (CMP-MIC); 1998
Proceedings, The Institute for Microelectronics InterConnection, pp. 28±35.
28 Hocheng, H., Huang, Y.L. and Chen, L.J. (November 1999), `Kinematic Analysis and
Measurement of Temperature Rise on Pad in Chemical Mechanical Planarization',
Journal of the Electrochemical Society, Vol. 146, No. 11, pp. 4236±4239.
29 Sicurani, E., Fayolle, M., Gobil, Y., Morand, Y. and Tardif, F. (October 1996) `W-CMP
Consumables Evaluation ± Electrical Results and End-Point Detection', Proceedings of
the Advanced metallization and interconnect systems for ULSI applications in 1996,
Materials Research Society, Conference on Advanced Metallization and Interconnect
Systems for ULSI Applications, pp. 561±566.
30 Fayolle, M., Sicurani, E. and Morand, Y. (November 1997) `W-CMP Process
Integration: Consumables Evaluation Electrical Results and End-Point Detection',
Microelectronic Engineering, Vol. 37±38, pp. 347±352.
31 Wang, Y.L., Liu, C., Feng, M.S. and Tseng, W.T. (January 1998), `The Exothermic
Reaction and Temperature-Measurement for Tungsten CMP Technology and its
Application and its Application on End-Point Detection', Materials Chemistry and
Physics, Vol. 52, No.1, pp. 17±22.
32 Springer, G. (February 1999), `Dependence of Wafer Carrier Motor Current and Polish
Pad Surface Temperature Signal on CMP Consumable Conditions and Ti/TiN Liner
Deposition Parameters For Tungsten CMP Endpoint Detection', Fourth International
Chemical-Mechanical Planarization for ULSI Multilevel Interconnection Conference
(CMP-MIC); 1999 Proceedings, The Institute for Microelectronics InterConnection, pp. 45±51.
33 Stein, D.J. and Hetherington, D.L. (May 1999) `Prediction of Tungsten CMP Pad Life
Using Blanket Removal Rate Data and Endpoint Data Obtained from Process
Temperature and Carrier Motor Current Measurements', Proceedings of the SPIE,
The International Society for Optical Engineering, In-Line Characterization, Yield
Reliability, and Failure Analyses in Microelectronic Manufacturing, Vol. 3743, pp. 112±119.
34 Sue, L., Lutzen, J., Gonzales, S., Wertsching, F. and Golzarian, R. (April 1999)
`Tungsten Chemical Mechanical Polishing Endpoint Detection', Materials Research
Society Symposium Proceedings, Chemical-Mechanical Polishing ± Fundamentals and
Challenges, Vol. 566, pp. 109±114.
35 Stein, D.J., Hetherington, D.L. and Ceecchi, J.L. (May 1999) `Investigation of the
Kinetics of Tungsten Chemical Mechanical Polishing in Potassium Iodate-Based Slurries.
M?????
Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???)
Tradespools Ltd., Frome, Somerset
3B2 Version Number 6.05e/W (Mar 29 1999)
18
36
37
38
39
40
41
42
43
44
45
46
J:/JOBSIN/M10439/Article12.3d
Date: 20/5/02
Time 12:21pm
Page 18 of 18
H. Hocheng and Y.-L. Huang
I. Role of Alumina and Potassium Iodate', Journal of the Electrochemical Society,
Vol. 146, No. 5, pp. 1934±1938.
Beckage, P.J., Lukner, R., Cho, W., Edwards, K., Jester, M. and Shaw, S. (September
1999) `Improved Metal CMP Endpoint Control by Monitoring Carrier Speed Controller
Output or Pad Temperature', Proceedings of the SPIE, The International Society for
Optical Engineering, Process, Equipment, and Materials Control in Integrated Circuit
Manufacturing V, Vol. 3882, pp. 118±125.
Sugimoto, F., Arimoto, Y. and Ito, T. (December 1995) `Simultaneous Temperature ±
Measurement of Wafers in Chemical Mechanical Polishing of Silicon Dioxide
Layers', Japanese Journal of Applied Physics Part 1 ± Regular Papers, Vol. 34, No. 12A,
pp. 6314±6320.
Litvak, H.E. and Tzeng, H.M. (July 1996) `Implementing Real-Time Endpoint Control in
CMP', Semiconductor International, Vol. 19, No. 8, pp. 259±60, 262, 264.
Tamboli, D.C., Desai, V.H., Dogariu, A., Sundaram, K.B., Maury, A. and Obeng, Y.
(May 1998) `Aggregate Behaviour in Metal CMP Slurries', Proceedings of the Second
International Symposium on Chemical Mechanical Planarization in Integrated Circuit
Device Manufacturing, The Second International Symposium on Chemical Mechanical
Planarization in Integrated Circuit Device Manufacturing, Electrochemical Society,
pp. 206±217.
Nagahara, R., Lee, S.K. and You, H.M. (June 1996) `The Effect of Slurry Particle Size on
Defect Levels for a BPSG CMP Process', Thirteenth International VLSI Multilevel
Interconnection Conference (VMIC); 1996 Proceedings, The Institute for Microelectronics InterConnection, p. 433.
Yueh, W. (February 1998) `CMP Global Endpoint Monitor (GEM)', Third International
Chemical-Mechanical Planarization for ULSI Multilevel Interconnection Conference
(CMP-MIC); 1998 Proceedings, The Institute for Microelectronics InterConnection,
pp. 231±234.
Tai, S.Y., Yang, M.C., Wang, J.F. and Yi, C. (June 2000) `The Improvement on Dual
Damascene Tungsten Planarization via End-Point Signal Triggered Two-step Polishing',
Seventeenth International VLSI Multilevel Interconnection Conference (VMIC); 2000
Proceedings, The Institute for Microelectronics InterConnection, pp. 171±176.
Wang, X.B., Tse, T.Y., Loeng, L.S., Zheng, J.Z., Churm, C. and Lin, C. (September
1999) `Optimization of Endpoint Controlled Dual-Head Tungsten CMP Process',
Sixteenth International VLSI Multilevel Interconnection Conference (VMIC); 1999
Proceedings, The Institute for Microelectronics InterConnection, pp. 513±515.
Sakai, K., Doy, T.K., Touzov, M.M., Satoh, M. and Kasai, T. (October 1999)
`Development of a Novel Air-Back Wafer Carrier with an Integrated Endpoint Detector
for Copper CMP Application', 1999 IEEE International Symposium on Semiconductor
Manufacturing Conference Proceedings, IEEE, 1999 IEEE International Symposium on
Semiconductor Manufacturing Conference, pp. 183±186.
Oliver, M. Hosali, S. Evans, D.R. Hetherington, D.L. Stein, D.J. and Stevens, J.
(February 1999) `Selective Slurry in a Self-Stopping ILD CMP Process', Fourth
International Chemical-Mechanical Planarization for ULSI Multilevel Interconnection
Conference (CMP-MIC); 1999 Proceedings, The Institute for Microelectronics InterConnection, pp. 383±389.
Moriyama, S., Yamaguchi, K., Honma, Y. and Yasui, K. (March 1996) `An End-Point
Detector for Planarization of Semiconductor-Devices by Chemical-Mechanical Polishing,' International Journal of the Japan Society for Precision Engineering, Vol. 30, No. 1,
pp. 55±58.
M?????
Inderscience Enterprises Ltd: International Journal of ?????? ?????? (IJ???)
Tradespools Ltd., Frome, Somerset