TWI878168B - System for real-time measurement of film thickness using acoustic wave elements - Google Patents
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Abstract
一種應用聲波元件即時量測薄膜厚度之系統,包含至少一具薄膜之載體,薄膜具一薄膜厚度;至少一聲波單元,設於載體之周側並實時偵測薄膜厚度的變化而產生一諧振頻率;一計算單元接收及處理聲波元件偵測產生的諧振頻率。計算單元由〔薄膜厚度-諧振頻率〕數值得至少一校正前膜厚頻率二維座標系,還由〔腔體溫度-諧振頻率〕數值得至少一溫度頻率代償二維座標系;計算單元再將校正前膜厚頻率二維座標系和溫度頻率代償二維座標系運算得一膜厚測量三維座標系,供測量時內插搜尋得到薄膜厚度,可實時偵測反饋薄膜厚度,準確率高,提高鍍膜良率。A system for measuring film thickness in real time using an acoustic wave element comprises at least one carrier having a film having a film thickness; at least one acoustic wave unit disposed around the carrier and detecting changes in the film thickness in real time to generate a harmonic frequency; and a computing unit receiving and processing the harmonic frequency generated by the acoustic wave element detection. The calculation unit obtains at least one two-dimensional coordinate system of the film thickness frequency before correction from the value of [film thickness-resonance frequency], and also obtains at least one two-dimensional coordinate system of temperature frequency compensation from the value of [chamber temperature-resonance frequency]; the calculation unit then calculates the two-dimensional coordinate system of the film thickness frequency before correction and the two-dimensional coordinate system of temperature frequency compensation to obtain a three-dimensional coordinate system for film thickness measurement, for interpolation search to obtain the film thickness during measurement, and can detect and feedback the film thickness in real time with high accuracy, thereby improving the coating yield.
Description
本創作與薄膜厚度測量有關,特別是指一種應用聲波元件即時量測薄膜厚度之系統。This invention is related to film thickness measurement, and in particular to a system that uses acoustic wave components to measure film thickness in real time.
按,在例如晶圓載體上進行鍍膜時,需要根據鍍膜的厚度以進行各項作業參數的調整,且鍍膜的厚度還供作其他數據的計算。而目前常用於鍍膜厚度測量的聲波元件有Surface Acoustic Wave(簡稱SAW)、Film Bulk Acoustic Resonator(簡稱FBAR)、Bulk Acoustic Waves-Solidly Mounted Resonator(簡稱BAW-SMR)等,利用偵測諧振頻率以換算得到鍍膜的厚度。然而隨着鍍膜厚度增加,或鍍膜時腔體溫度上升,均影響偵測得到的諧振頻率,導致以該諧振頻率換算得到的鍍膜厚度與實際鍍膜厚度偏差較大。爲避免腔體溫度影響所測得諧振頻率的準確度,業者只有在鍍膜完成待晶圓載體及聲波元件冷卻後才進行膜厚量測及諧振頻率數據收集,然而離線測量必須反覆地在腔體破真空後再抽真空的狀態下進行量測,這樣除了額外耗費時間外,還無法實時得知鍍膜過程中鍍膜厚度的變化,以馬上進行相應的作業調整,且停止鍍膜再啓動後,新舊膜層之間有銜接誤差,存在鍍膜良率降低且報廢重來之問題。When coating a film on a wafer carrier, for example, it is necessary to adjust various operating parameters according to the thickness of the coating, and the thickness of the coating is also used for the calculation of other data. The acoustic wave elements commonly used for measuring coating thickness include Surface Acoustic Wave (SAW), Film Bulk Acoustic Resonator (FBAR), Bulk Acoustic Waves-Solidly Mounted Resonator (BAW-SMR), etc., which use the detected resonant frequency to convert the thickness of the coating. However, as the coating thickness increases or the cavity temperature rises during coating, the detected resonant frequency is affected, resulting in a large deviation between the coating thickness converted by the resonant frequency and the actual coating thickness. To prevent the chamber temperature from affecting the accuracy of the measured resonant frequency, the industry only performs film thickness measurement and resonant frequency data collection after the film coating is completed and the wafer carrier and acoustic wave device have cooled down. However, offline measurement must be repeatedly performed in a state where the chamber is vacuumed after breaking the vacuum and then evacuating the vacuum. In addition to wasting extra time, it is also impossible to know the changes in the film thickness during the coating process in real time to make corresponding operational adjustments immediately. Moreover, after stopping the coating and restarting it, there is a connection error between the new and old film layers, resulting in a reduction in the coating yield and the need to scrap and start over.
另外,某些習用技術是在聲波元件採用溫度補償層(例如SiO 2)以代償鍍膜時聲波元件的溫度變化,但此方式僅能降低溫度對諧振頻率的干擾,仍然不能持續不間斷地偵測鍍膜過程中鍍膜厚度的變化。且此類習用技術僅考量溫度變化對諧振頻率的影響,並未將鍍膜厚度增加所導致的諧振頻率變化共同納入變數比對以計算得到準確之鍍膜厚度。由此可見,習用技術既不具有實時監控鍍膜厚度變化之功能,亦無法提供一精確之諧振頻率以換算得到準確的鍍膜厚度。 In addition, some conventional techniques use a temperature compensation layer (such as SiO 2 ) on the acoustic wave element to compensate for the temperature change of the acoustic wave element during the coating process. However, this method can only reduce the interference of temperature on the resonant frequency, and still cannot continuously detect the change of the coating thickness during the coating process. Moreover, this conventional technique only considers the impact of temperature change on the resonant frequency, and does not include the change of the resonant frequency caused by the increase of the coating thickness into the variable comparison to calculate the accurate coating thickness. It can be seen that the conventional technique neither has the function of real-time monitoring of the coating thickness change, nor can it provide an accurate resonant frequency to convert to obtain the accurate coating thickness.
有鑒於此,故如何解決上述問題,即為本發明所欲解決之首要課題。In view of this, how to solve the above-mentioned problem is the primary subject that the present invention intends to solve.
本發明之主要目的,在於提供一種應用聲波元件即時量測薄膜厚度之系統,藉由薄膜厚度與諧振頻率構成之校正前膜厚頻率二維座標系,及溫度與諧振頻率構成之溫度頻率代償二維座標系,構成一包含腔體溫度、薄膜厚度及諧振頻率對應數值之膜厚測量三維座標系,透過實時測量得到的腔體溫度和諧振頻率於該膜厚測量三維座標系內插搜尋,即可得到一(腔體溫度-諧振頻率-薄膜厚度)之三維座標,從而實時得到薄膜厚度,不僅可實時偵測薄膜厚度變化以調整作業參數,還可快速獲得薄膜厚度相關數值,縮短測量所需時間。The main purpose of the present invention is to provide a system for real-time measurement of film thickness using an acoustic wave element. A pre-corrected film thickness frequency two-dimensional coordinate system consisting of film thickness and resonant frequency, and a temperature-frequency compensation two-dimensional coordinate system consisting of temperature and resonant frequency are used to form a film thickness measurement three-dimensional coordinate system including the corresponding values of cavity temperature, film thickness and resonant frequency. By interpolating and searching the cavity temperature and resonant frequency obtained by real-time measurement in the film thickness measurement three-dimensional coordinate system, a three-dimensional coordinate of (cavity temperature-resonant frequency-film thickness) can be obtained, thereby obtaining the film thickness in real time. Not only can the film thickness change be detected in real time to adjust the operating parameters, but also the film thickness-related values can be quickly obtained, shortening the measurement time.
爲達前述之目的,本發明提供一種應用聲波元件即時量測薄膜厚度之系統,該系統包含:To achieve the above-mentioned purpose, the present invention provides a system for real-time measurement of film thickness using an acoustic wave element, the system comprising:
至少一載體,其表面鍍有一薄膜,該薄膜具有一薄膜厚度;At least one carrier, a surface of which is coated with a thin film having a film thickness;
至少一聲波元件,設於該載體之周側,用以實時偵測該薄膜厚度的變化,並產生一諧振頻率;At least one acoustic wave element is disposed around the carrier to detect the change of the film thickness in real time and generate a harmonic frequency;
一計算單元,用以接收及處理該聲波元件偵測產生的諧振頻率;A computing unit, used for receiving and processing the resonant frequency generated by the acoustic wave element detection;
當持續於該載體之表面鍍薄膜時,該聲波元件的表面也會被鍍上相同的薄膜以實時偵測該薄膜厚度變化,該聲波元件所產生的諧振頻率隨該薄膜厚度的增加而降低,在固定溫度條件下,由該計算單元透過〔薄膜厚度-諧振頻率〕測量數值對應產生至少一校正前膜厚頻率二維座標系;When the film is continuously deposited on the surface of the carrier, the surface of the acoustic wave element is also deposited with the same film to detect the thickness change of the film in real time. The resonant frequency generated by the acoustic wave element decreases as the thickness of the film increases. Under a fixed temperature condition, the calculation unit generates at least one two-dimensional coordinate system of the film thickness frequency before correction through the correspondence of the measured values of [film thickness-resonant frequency];
當腔體溫度持續上升,該聲波元件的溫度隨之上升時,該聲波元件實時偵測該薄膜厚度所產生的諧振頻率隨溫度的升高而降低,在固定薄膜厚度條件下,由該計算單元透過〔腔體溫度-諧振頻率〕測量數值對應產生至少一溫度頻率代償二維座標系;When the cavity temperature continues to rise, the temperature of the acoustic wave element rises accordingly, and the resonance frequency generated by the acoustic wave element detecting the film thickness in real time decreases as the temperature rises. Under the condition of a fixed film thickness, the calculation unit generates at least one temperature-frequency compensation two-dimensional coordinate system through the correspondence of the measured values of [cavity temperature-resonance frequency];
該計算單元進一步將該些校正前膜厚頻率二維座標系和該些溫度頻率代償二維座標系綜合運算產生一膜厚測量三維座標系,可獲得包含腔體溫度、薄膜厚度及諧振頻率對應數值之三維座標,藉以使該聲波元件偵測該薄膜厚度時,可將偵測之諧振頻率值、腔體溫度於該膜厚測量三維座標系進行內插搜尋,獲得一〔腔體溫度-薄膜厚度-諧振頻率〕之三維座標值,即可得到所對應之薄膜厚度,並以間歇式測量鍍膜過程中腔體溫度及諧振頻率而達到即時量測薄膜厚度之作用。The calculation unit further generates a three-dimensional coordinate system for measuring film thickness by comprehensively calculating the two-dimensional coordinate systems of the film thickness frequency before correction and the two-dimensional coordinate systems of the temperature frequency compensation, and obtains three-dimensional coordinates including the corresponding values of the cavity temperature, the film thickness and the resonant frequency. When the acoustic wave element detects the film thickness, the detected resonant frequency value and the cavity temperature can be interpolated and searched in the three-dimensional coordinate system for measuring film thickness, and a three-dimensional coordinate value of [cavity temperature-film thickness-resonant frequency] can be obtained, and the corresponding film thickness can be obtained. The cavity temperature and the resonant frequency can be intermittently measured during the coating process to achieve the effect of measuring the film thickness in real time.
較優地,該聲波元件的諧振頻率介於1GHz〜10GHz。Preferably, the resonant frequency of the acoustic wave element is between 1 GHz and 10 GHz.
較優地,該聲波元件實時偵測該載體之薄膜厚度變化時,薄膜厚度每增加1nm,該聲波元件的諧振頻率變化介於1KHz〜20MHz。Preferably, when the acoustic wave element detects the change in the film thickness of the carrier in real time, the resonant frequency of the acoustic wave element changes between 1 KHz and 20 MHz for every 1 nm increase in the film thickness.
較優地,該系統適用於溫度變化範圍爲0℃〜150℃,所鍍的薄膜厚度範圍爲1nm〜1000nm之載體鍍膜環境。Preferably, the system is suitable for a carrier coating environment with a temperature variation range of 0°C to 150°C and a film thickness range of 1nm to 1000nm.
較優地,該些載體面向一鍍膜來源,該鍍膜來源與該些載體之間設有複數個擋片,該些擋片與該計算單元通訊,根據該計算單元實時偵測得到之薄膜厚度,控制改變該些擋片與該載體之間的相對位置,以調整該鍍膜來源對該載體鍍膜的均勻度。Preferably, the carriers face a coating source, and a plurality of baffles are provided between the coating source and the carriers. The baffles communicate with the computing unit, and the relative positions between the baffles and the carrier are controlled to change according to the film thickness detected in real time by the computing unit to adjust the uniformity of the coating of the carrier by the coating source.
較優地,該些載體的鍍膜過程結束,轉爲進行蝕刻作業時,該些聲波元件亦配合該計算單元實時測得薄膜厚度,以調整薄膜蝕刻深度。Preferably, when the coating process of the carriers is completed and the etching process is started, the acoustic wave elements also cooperate with the calculation unit to measure the film thickness in real time to adjust the film etching depth.
較優地,數個聲波元件陣列排佈於各載體之周側,各聲波元件對應設置一MEMS(Micro Electro Mechanical Systems)開關元件,使該些MEMS開關元件形成陣列排設,並藉由啓閉該些MEMS開關以決定所對應之聲波元件運作或關閉。Preferably, a plurality of acoustic wave elements are arranged in array around each carrier, and a MEMS (Micro Electro Mechanical Systems) switch element is provided corresponding to each acoustic wave element, so that the MEMS switch elements are arranged in an array, and the corresponding acoustic wave element is operated or closed by turning on and off the MEMS switches.
較佳地,各該載體對應地置放於一沉積區域,或將該沉積區域貼近於該載體周側佈設,各該MEMS開關元件對應該聲波元件之一側的表面積大於該聲波元件之諧振有效區域,以完全遮蔽該聲波元件之諧振有效區域繼而控制該聲波元件運作。Preferably, each of the carriers is placed in a deposition area correspondingly, or the deposition area is arranged close to the periphery of the carrier, and the surface area of each MEMS switch element corresponding to one side of the acoustic wave element is larger than the resonant effective area of the acoustic wave element, so as to completely shield the resonant effective area of the acoustic wave element and then control the operation of the acoustic wave element.
較佳地,上述即時量測薄膜厚度之系統在載體鍍膜時包含以下運作步驟:Preferably, the system for measuring film thickness in real time comprises the following operating steps when the carrier is coated:
步驟一,各聲波元件還分別設在與一鍍膜來源不同距離處,以收集不同環境條件的諧振頻率;Step 1: each acoustic wave element is also disposed at different distances from a film source to collect resonant frequencies of different environmental conditions;
步驟二,該計算單元接收上述諧振頻率並透過運作該即時量測薄膜厚度之系統計算獲得一膜厚沉積率,並將該膜厚沉積率之數據回傳至一控制系統;Step 2, the calculation unit receives the resonant frequency and calculates a film thickness deposition rate by operating the real-time film thickness measurement system, and transmits the film thickness deposition rate data back to a control system;
步驟三,該控制系統調整各擋片對該鍍膜來源的遮擋面積、遮擋角度及遮擋距離;Step 3, the control system adjusts the shielding area, shielding angle and shielding distance of each shielding plate to the coating source;
步驟四,重複步驟二並判斷是否達到目標膜厚沉積率,若未達到則重複步驟三,若達到則執行步驟五;Step 4: repeat step 2 and determine whether the target film thickness deposition rate is reached. If not, repeat step 3; if reached, proceed to step 5.
步驟五,固定擋片的參數。Step 5: Fix the parameters of the baffle.
較佳地,步驟一中,鍍膜前該腔體內升溫並測試該聲波元件所產生的諧振頻率,判斷該諧振頻率在一校正範圍內後再進行鍍膜測量,而在鍍膜測量過程中偵測該諧振頻率的變化並比對是否超出經校正後的諧振頻率範圍,判斷該聲波元件能否正常運作。Preferably, in step 1, the temperature in the cavity is increased before coating and the resonant frequency generated by the acoustic wave element is tested. Coating measurement is performed after the resonant frequency is determined to be within a calibration range. During the coating measurement process, the change of the resonant frequency is detected and compared to see whether it exceeds the calibrated resonant frequency range to determine whether the acoustic wave element can operate normally.
而本發明之上述目的與優點,不難從下述所選用實施例之詳細說明與附圖中獲得深入了解。The above-mentioned objects and advantages of the present invention can be more clearly understood from the following detailed description of the selected embodiments and the accompanying drawings.
如第1圖至第11圖所示,爲本發明實施例所提供的一種應用聲波元件即時量測薄膜厚度之系統,該系統包含至少一載體、至少一聲波元件、一計算單元。As shown in FIG. 1 to FIG. 11 , a system for real-time measurement of film thickness using an acoustic wave element is provided in an embodiment of the present invention. The system includes at least one carrier, at least one acoustic wave element, and a calculation unit.
請參閱第9圖所示,本實施例中設置有三個載體,各載體之周側均設有一聲波元件,用以實時偵測鍍膜時形成於該載體表面之薄膜厚度的變化,並產生一諧振頻率,該聲波元件的諧振頻率介於1GHz〜10GHz。該聲波元件爲Surface Acoustic Wave(簡稱SAW)、Film Bulk Acoustic Resonator(簡稱FBAR)、Bulk Acoustic Waves-Solidly Mounted Resonator(簡稱BAW-SMR中其中一種,上述聲波元件均隨溫度改變而發生頻率變化。本實施例之聲波元件爲FBAR。Please refer to FIG. 9. In this embodiment, three carriers are provided. An acoustic wave element is provided around each carrier to detect the change of the thickness of the film formed on the surface of the carrier during coating in real time and generate a resonant frequency. The resonant frequency of the acoustic wave element is between 1 GHz and 10 GHz. The acoustic wave element is one of Surface Acoustic Wave (SAW for short), Film Bulk Acoustic Resonator (FBAR for short), and Bulk Acoustic Waves-Solidly Mounted Resonator (BAW-SMR for short). The above acoustic wave elements all change in frequency with temperature changes. The acoustic wave element in this embodiment is FBAR.
承上,當持續於該載體之表面鍍薄膜時,該聲波元件的表面也會被鍍上相同的薄膜以實時偵測該薄膜厚度變化,該聲波元件所產生的諧振頻率隨該薄膜厚度的增加而降低。需特別說明,該薄膜厚度每增加1nm時,該聲波元件的諧振頻率變化介於1KHz〜20MHz。在固定溫度條件下,由該計算單元透過〔薄膜厚度-諧振頻率〕測量數值對應產生一如第1圖所示之校正前膜厚頻率二維座標系。本發明在腔體溫度分別穩定爲25℃、40℃、50℃和100℃的條件下,分別測量隨薄膜厚度增加,諧振頻率的變化,由該計算單元透過偵測在4個不同溫度條件下,得到不同薄膜厚度產生的〔薄膜厚度-諧振頻率〕測量數值,進而獲得所對應之校正前膜厚頻率二維座標系。As mentioned above, when the film is continuously deposited on the surface of the carrier, the surface of the acoustic wave element will also be deposited with the same film to detect the change of the film thickness in real time. The resonant frequency generated by the acoustic wave element decreases as the film thickness increases. It should be noted that the resonant frequency of the acoustic wave element changes between 1KHz and 20MHz for every 1nm increase in the film thickness. Under fixed temperature conditions, the calculation unit generates a two-dimensional coordinate system of the film thickness frequency before correction as shown in Figure 1 through the corresponding measurement value of [film thickness-resonant frequency]. The present invention measures the change of the resonant frequency as the film thickness increases under the conditions that the chamber temperature is stabilized at 25°C, 40°C, 50°C and 100°C respectively. The calculation unit obtains the measured values of [film thickness-resonant frequency] generated by different film thicknesses under 4 different temperature conditions by detecting, and then obtains the corresponding two-dimensional coordinate system of the film thickness frequency before correction.
請參見第2圖所示曲線爲不同諧振面積之聲波元件在腔體溫度25℃條件下,薄膜厚度與諧振頻率之間的關係圖。其中聲波元件之諧振面積分別爲6400um 2、10000 um 2、14400 um 2及25600 um 2,以及薄膜厚度分別爲0nm(即未鍍膜)、5nm、10nm、15nm、20nm、25nm、30nm、35nm、40nm、45nm及50nm的條件下,聲波元件偵測得到的諧振頻率隨鍍膜厚度增加而逐漸降低。從上述校正前膜厚頻率二維座標系可見,在腔體溫度不變的條件下,載體的薄膜厚度增加,而聲波單元所偵測獲得的諧振頻率逐漸降低。 Please refer to the curve shown in Figure 2, which is the relationship between the film thickness and the resonant frequency of the acoustic wave element with different resonant areas under the condition of cavity temperature of 25℃. The resonant areas of the acoustic wave element are 6400um2 , 10000um2 , 14400um2 and 25600um2 , and the film thickness is 0nm (i.e., uncoated), 5nm, 10nm, 15nm, 20nm, 25nm, 30nm, 35nm, 40nm, 45nm and 50nm. The resonant frequency detected by the acoustic wave element gradually decreases as the coating thickness increases. From the two-dimensional coordinate system of film thickness frequency before correction, it can be seen that when the cavity temperature remains unchanged, the film thickness of the carrier increases, while the resonant frequency detected by the acoustic wave unit gradually decreases.
當腔體溫度持續上升,該聲波元件的溫度隨之上升時,該聲波元件實時偵測該薄膜厚度所產生的諧振頻率隨溫度的升高而降低。在固定薄膜厚度條件下,由該計算單元透過偵測得到的〔腔體溫度-諧振頻率〕測量數值對應產生一如第3圖所示之溫度頻率代償二維座標系。進一步地,當聲波元件的有效諧振面積為6400 um 2,本發明在載體與聲波元件具有0nm(即未鍍膜)、5nm、10nm、15nm、30nm和50nm不同薄膜厚度時,腔體溫度分別爲25℃、40℃、50℃、100℃的條件下,測量並記錄隨溫度升高其諧振頻率的變化,由該計算單元透過偵測得到不同薄膜厚度對應4個不同溫度條件產生的〔腔體溫度-諧振頻率〕測量數值,進而獲得所對應之溫度頻率代償二維座標系,並將上述校正前溫度頻率代償二維座標系彙整如第4圖所示,從上述溫度頻率代償二維座標系可見,在載體薄膜厚度不變的條件下,腔體溫度逐漸增高,而聲波單元所偵測獲得的諧振頻率逐漸降低。 As the cavity temperature continues to rise, the temperature of the acoustic wave element rises accordingly. The resonance frequency generated by the acoustic wave element detecting the film thickness in real time decreases as the temperature rises. Under the condition of a fixed film thickness, the measurement value of [cavity temperature-resonance frequency] obtained by the calculation unit through detection corresponds to a temperature-frequency compensation two-dimensional coordinate system as shown in Figure 3. Furthermore, when the effective resonance area of the acoustic wave element is 6400 um 2 In the present invention, when the carrier and the acoustic wave element have different film thicknesses of 0nm (i.e., uncoated), 5nm, 10nm, 15nm, 30nm, and 50nm, and the cavity temperature is respectively 25°C, 40°C, 50°C, and 100°C, the change of the resonant frequency as the temperature increases is measured and recorded. The calculation unit detects the four different temperatures corresponding to different film thicknesses. The measured values of [cavity temperature-resonance frequency] generated by the conditions are used to obtain the corresponding temperature-frequency compensation two-dimensional coordinate system, and the temperature-frequency compensation two-dimensional coordinate system before correction is summarized as shown in Figure 4. It can be seen from the temperature-frequency compensation two-dimensional coordinate system that under the condition that the thickness of the carrier film remains unchanged, the cavity temperature gradually increases, while the resonant frequency detected by the acoustic wave unit gradually decreases.
接着,該計算單元進一步將該些校正前膜厚頻率二維座標系和該些溫度頻率代償座標系綜合運算產生一如第5圖所示之膜厚測量三維座標系,可獲得包含腔體溫度、薄膜厚度及諧振頻率對應數值之三維座標,藉以使該聲波元件偵測該薄膜厚度時,可將偵測之諧振頻率、腔體溫度於該膜厚測量三維座標系進行內插搜尋,獲得一〔腔體溫度-薄膜厚度-諧振頻率〕之三維座標值,即可得到所對應之薄膜厚度,並以間歇式測量鍍膜過程中腔體溫度及諧振頻率而達到即時量測薄膜厚度之作用,該系統適用於溫度變化範圍爲0℃〜150℃,所鍍的薄膜厚度範圍爲1nm〜1000nm之載體鍍膜環境。Next, the calculation unit further calculates the pre-corrected film thickness frequency two-dimensional coordinate system and the temperature frequency compensation coordinate system to generate a film thickness measurement three-dimensional coordinate system as shown in FIG. 5, and obtains a three-dimensional coordinate system including the corresponding values of the cavity temperature, film thickness and resonant frequency, so that when the acoustic wave element detects the film thickness, the detected resonant frequency and cavity temperature can be used in the film thickness measurement three-dimensional coordinate system. The system performs interpolation search to obtain a three-dimensional coordinate value of [chamber temperature-film thickness-resonance frequency], and the corresponding film thickness can be obtained. The chamber temperature and resonance frequency are measured intermittently during the coating process to achieve real-time measurement of film thickness. The system is suitable for carrier coating environments with a temperature variation range of 0℃~150℃ and a film thickness range of 1nm~1000nm.
其中,如第9圖和第10圖所示,該些載體2面向一鍍膜來源4,該鍍膜來源4以濺射方式令鍍膜材料於載體2表面形成一薄膜,鍍膜方法可以爲蒸鍍、濺鍍或化學氣相沉積鍍膜。該鍍膜來源4與該些載體2之間設有複數個擋片5。在本實施例中設置三個載體2面對一鍍膜來源4,並於該鍍膜來源4與該些載體2之間設有至少2片可左右擺動之擋片5。該些擋片5與該計算單元通訊,計算單元依據實時偵測之腔體溫度及諧振頻率於該膜厚量測三維座標系得到實時薄膜厚度,根據實時薄膜厚度控制改變該些擋片5與該載體2之間的相對位置,以調整該鍍膜來源對該載體鍍膜的均勻度。詳言之,擋片5用以調整鍍膜來源之鍍膜速率,其對鍍膜來源4或載體2的遮擋面積與膜厚成反比關係,當薄膜厚度鍍得越厚標示越接近目標設定厚度,此時要放慢鍍膜速率,因此計算單元控制擋片5移動增加遮擋面積、調整遮擋角度以及遮擋距離,從而降低鍍膜速率,保證載體鍍膜的均勻度。As shown in FIG. 9 and FIG. 10 , the carriers 2 face a coating source 4, and the coating source 4 forms a thin film on the surface of the carrier 2 by sputtering the coating material. The coating method can be evaporation, sputtering or chemical vapor deposition. A plurality of baffles 5 are provided between the coating source 4 and the carriers 2. In this embodiment, three carriers 2 are arranged to face a coating source 4, and at least two baffles 5 that can swing left and right are provided between the coating source 4 and the carriers 2. The baffles 5 communicate with the calculation unit, and the calculation unit obtains the real-time film thickness in the film thickness measurement three-dimensional coordinate system according to the real-time detected cavity temperature and resonant frequency, and controls the change of the relative position between the baffles 5 and the carrier 2 according to the real-time film thickness to adjust the uniformity of the coating source on the carrier. In detail, the baffle 5 is used to adjust the plating rate of the plating source, and its blocking area for the plating source 4 or the carrier 2 is inversely proportional to the film thickness. When the film thickness is thicker and the mark is closer to the target set thickness, the plating rate should be slowed down. Therefore, the calculation unit controls the movement of the baffle 5 to increase the blocking area, adjust the blocking angle and the blocking distance, thereby reducing the plating rate and ensuring the uniformity of the carrier plating.
如第8圖所示進一步說明,本發明數個聲波元件1陣列排佈於各載體2周側,各聲波元件1對應設置一MEMS(Micro Electro Mechanical Systems)開關元件3,使該些MEMS開關元件3形成陣列排設。進一步說明,各該載體對應地置放於一沉積區域,於其他可實施之態樣中亦可將該沉積區域貼近該載體佈設。各該MEMS開關元件對應該聲波元件之一側的表面積大於該聲波元件的諧振有效區域,以完全遮蔽該聲波元件1,而藉由啓閉該些MEMS開關3以決定所對應之聲波元件1運作或關閉,即該MEMS開關3打開,其對應之聲波元件1運作並產生諧振頻率;若MEMS開關3閉合,則所對應之聲波元件1關閉停止運作,實現根據所需測量的載體數量靈活調整相應運作的聲波元件。在薄膜厚度測量過程中,開啓至少一聲波元件作爲測量組監測載體的薄膜厚度變化,並可於不同鍍膜時間及溫度開啓另外一聲波元件作爲對比組,以對照組偵測之諧振頻率與測量組之數據比對用以判斷測量組偵測之諧振頻率是否有問題。抑或使用一段時間後,例如1000小時後開啓對比組來驗證聲波元件的準確性。As further illustrated in FIG. 8 , the present invention has a plurality of acoustic wave elements 1 arranged in an array around each carrier 2, and each acoustic wave element 1 is provided with a corresponding MEMS (Micro Electro Mechanical Systems) switch element 3, so that the MEMS switch elements 3 are arranged in an array. Further, each of the carriers is placed in a deposition area correspondingly, and in other practicable embodiments, the deposition area can also be arranged close to the carrier. The surface area of one side of the acoustic wave element corresponding to each MEMS switch element is larger than the resonant effective area of the acoustic wave element so as to completely shield the acoustic wave element 1. The operation or shutdown of the corresponding acoustic wave element 1 is determined by turning on and off the MEMS switches 3. That is, when the MEMS switch 3 is turned on, the corresponding acoustic wave element 1 operates and generates a resonant frequency; if the MEMS switch 3 is closed, the corresponding acoustic wave element 1 is closed and stops operating, thereby realizing flexible adjustment of the corresponding operating acoustic wave element according to the number of carriers to be measured. During the film thickness measurement process, at least one acoustic wave element is turned on as a measurement group to monitor the change of the film thickness of the carrier, and another acoustic wave element can be turned on at different coating times and temperatures as a comparison group, and the harmonic frequency detected by the comparison group is compared with the data of the measurement group to determine whether there is a problem with the harmonic frequency detected by the measurement group. Alternatively, the accuracy of the acoustic wave element can be verified by turning on the comparison group after a period of time, such as 1000 hours.
另外,第2圖、第6圖和第7圖所示曲線爲聲波元件之諧振面積、SiO 2膜層厚度與諧振頻率之間的關係圖,在腔體溫度分別爲25℃、40℃,以及薄膜厚度分別爲0nm(即未鍍膜)、5nm、10nm、15nm、20nm、25nm、30nm、35nm、40nm、45nm、50nm以及聲波元件之有效諧振面積爲6400um 2、10000um 2、14400um 2、25600um 2的條件下,聲波元件偵測得到的諧振頻率隨聲波元件之有效諧振面積的增加而上升,但隨膜層厚度的增加而降低。據此可透過MEMS開關半開或部分開啓微調即時薄膜厚度測量系統,亦可用於校正溫度升高引起的諧振頻率飄移。 In addition, the curves shown in Figures 2, 6 and 7 are the relationship diagrams between the resonant area of the acoustic wave element, the thickness of the SiO2 film layer and the resonant frequency. When the cavity temperature is 25°C and 40°C respectively, and the film thickness is 0nm (i.e., uncoated), 5nm, 10nm, 15nm, 20nm, 25nm, 30nm, 35nm, 40nm, 45nm, 50nm respectively, and the effective resonant area of the acoustic wave element is 6400um2 , 10000um2 , 14400um2 , 25600um2 , the resonant frequency detected by the acoustic wave element increases with the increase of the effective resonant area of the acoustic wave element, but decreases with the increase of the film thickness. The real-time film thickness measurement system can be fine-tuned by half-opening or partially opening the MEMS switch, and can also be used to correct the resonant frequency drift caused by temperature rise.
如第11圖所示,本發明之應用聲波元件即時測量薄膜厚度之系統在載體鍍膜時包含以下運作步驟:As shown in FIG. 11 , the system for real-time measurement of film thickness using an acoustic wave element of the present invention comprises the following operating steps when the carrier is coated:
步驟一,各聲波元件還分別設在與一鍍膜來源的不同距離處,以收集不同環境條件(如腔體溫度)的諧振頻率;鍍膜前該腔體內升溫並測試該聲波元件所產生的諧振頻率,判斷該諧振頻率在一校正範圍內後再進行鍍膜測量,而在鍍膜測量過程中偵測該諧振頻率的變化並比對是否超出經校正後的諧振頻率範圍,判斷該聲波元件是否正常運作,判斷正常運作後再執行步驟二;In step 1, each acoustic wave element is also arranged at different distances from a coating source to collect the resonant frequency of different environmental conditions (such as cavity temperature); before coating, the temperature in the cavity is increased and the resonant frequency generated by the acoustic wave element is tested, and coating measurement is performed after the resonant frequency is judged to be within a calibration range, and during the coating measurement process, the change of the resonant frequency is detected and compared to see whether it exceeds the calibrated resonant frequency range, and it is judged whether the acoustic wave element is operating normally, and step 2 is performed after it is judged to be operating normally;
步驟二,該計算單元接收上述諧振頻率並透過運作該即時量測薄膜厚度之系統計算獲得一膜厚沉積率,並將該膜厚沉積率之數據回傳至一控制系統;Step 2, the calculation unit receives the resonant frequency and calculates a film thickness deposition rate by operating the real-time film thickness measurement system, and transmits the film thickness deposition rate data back to a control system;
步驟三,該控制系統調整各擋片對該鍍膜來源的遮擋面積、遮擋角度及遮擋距離;Step 3, the control system adjusts the shielding area, shielding angle and shielding distance of each shielding plate to the coating source;
步驟四,重複步驟二並判斷是否達到目標膜厚沉積率,若未達到則重複步驟三,若達到則執行步驟五;Step 4: repeat step 2 and determine whether the target film thickness deposition rate is reached. If not, repeat step 3; if reached, proceed to step 5.
步驟五,固定擋片的參數。Step 5: Fix the parameters of the baffle.
本發明還可應用於鍍膜完成後的蝕刻作業,利用鍍膜時薄膜厚度增加則諧振頻率變低,蝕刻薄膜時薄膜厚度減少則諧振頻率增加且腔體溫度升高則頻率降低的原理。在該些載體的鍍膜過程結束後,轉爲進行蝕刻作業時,該些聲波元件亦配合該計算單元實時測得薄膜厚度,計算單元根據諧振頻率的增加得到薄膜蝕刻深度,繼而根據工藝需求調整薄膜蝕刻深度。The present invention can also be applied to etching operations after film coating is completed, using the principle that when the film thickness increases during film coating, the resonant frequency becomes lower, and when the film thickness decreases during film etching, the resonant frequency increases, and when the cavity temperature increases, the frequency decreases. After the film coating process of the carriers is completed, when the etching operation is performed, the acoustic wave elements also cooperate with the calculation unit to measure the film thickness in real time. The calculation unit obtains the film etching depth according to the increase in the resonant frequency, and then adjusts the film etching depth according to the process requirements.
從上述實施例可見,本創作所提供的應用聲波元件即時測量薄膜厚度之系統可達下列改善效果:From the above embodiments, it can be seen that the system for real-time measurement of film thickness using an acoustic wave element provided by the present invention can achieve the following improvement effects:
第一,實時偵測反饋薄膜厚度,提高鍍膜良率;本發明透過構建一包含腔體溫度、薄膜厚度和諧振頻率之膜厚計算三維座標系,實際使用時僅需偵測腔體溫度及諧振頻率,並將上述二數據於該膜厚計算三維座標系內插搜尋,即可得到準確之薄膜厚度,計算效率高,且實時回饋製程中關鍵參數薄膜厚度,有利於操作人員及時調整作業參數,保證鍍膜的均勻度,提高鍍膜良率。First, real-time detection and feedback of film thickness can improve the yield of film coating. The present invention constructs a three-dimensional coordinate system for film thickness calculation that includes chamber temperature, film thickness and resonant frequency. In actual use, it is only necessary to detect the chamber temperature and resonant frequency, and interpolate and search the above two data in the three-dimensional coordinate system for film thickness calculation to obtain accurate film thickness. The calculation efficiency is high, and the key parameter film thickness in the process is fed back in real time, which is beneficial for operators to adjust the operating parameters in time, ensure the uniformity of film coating, and improve the yield of film coating.
第二,自動代償腔體溫度導致的諧振頻率變化,結果準確度高;習用技術採用溫度補償層以代償鍍膜時腔體的溫度變化,但因溫度補償層無法根據生產實際情況靈活調整,導致其代償的溫度變化並不準確。而本發明透過大量的實驗數據而建立的膜厚計算三維座標系,囊括了不同腔體溫度條件下對應的諧振頻率,在膜厚計算三維座標系中以該諧振頻率代償實際測得之諧振頻率,從而得到準確的薄膜厚度。Second, it automatically compensates for the resonant frequency changes caused by the cavity temperature, and the results are highly accurate. Conventional technology uses a temperature compensation layer to compensate for the temperature changes of the cavity during film coating, but because the temperature compensation layer cannot be flexibly adjusted according to the actual production situation, the temperature changes it compensates for are not accurate. The three-dimensional coordinate system for film thickness calculation established by the present invention through a large amount of experimental data includes the corresponding resonant frequencies under different cavity temperature conditions. In the three-dimensional coordinate system for film thickness calculation, the resonant frequency is used to compensate for the actually measured resonant frequency, thereby obtaining an accurate film thickness.
第三,可以靈活選擇聲波元件;相較習用技術,本發明無需在聲波元件加入溫度補償層後方可對載體鍍膜進行膜厚偵測,因此大部分的聲波元件適用於本發明。Third, the acoustic wave element can be flexibly selected; compared with the conventional technology, the present invention does not need to add a temperature compensation layer to the acoustic wave element before the film thickness detection of the carrier coating can be performed, so most of the acoustic wave elements are suitable for the present invention.
第四,可應用於不同工序之膜厚偵測;本發明可應用於鍍膜及蝕刻時的實時膜厚偵測,當鍍膜過程結束後即可立刻轉爲蝕刻作業,本發明之聲波元件亦配合計算單元實時偵測薄膜厚度,利用鍍膜時薄膜厚度增加則諧振頻率變低,蝕刻薄膜時薄膜厚度減少則諧振頻率增加且腔體溫度升高則頻率降低的原理,計算單元根據諧振頻率的增加得到薄膜蝕刻深度,繼而根據工藝需求調整薄膜蝕刻深度。Fourth, it can be applied to film thickness detection in different processes; the present invention can be applied to real-time film thickness detection during coating and etching. When the coating process is completed, it can immediately switch to etching operation. The acoustic wave element of the present invention also cooperates with the calculation unit to detect the film thickness in real time. It uses the principle that the resonant frequency becomes lower when the film thickness increases during coating, and the resonant frequency increases when the film thickness decreases during etching, and the frequency decreases when the cavity temperature increases. The calculation unit obtains the film etching depth according to the increase in the resonant frequency, and then adjusts the film etching depth according to the process requirements.
惟,以上所述者,僅爲本發明之一較佳實施例而已,當不能以之限定本發明之範圍,即大凡依申請專利範圍所作之均等變化與修飾,皆應仍屬本發明專利涵蓋之範圍內。However, what is described above is only a preferred embodiment of the present invention and should not be used to limit the scope of the present invention. In other words, all equivalent changes and modifications made within the scope of the patent application should still fall within the scope of the present invention.
綜上所述,當可使熟知本項技藝者明瞭本發明確可達成前述目的,實已符合專利法之規定,故依法提出申請。In summary, those familiar with the art will be able to understand that the present invention can achieve the aforementioned purpose and is in compliance with the provisions of the Patent Law, and therefore can file an application in accordance with the law.
聲波元件1 載體2 MEMS開關元件3 鍍膜來源4 擋片5 Acoustic wave element 1 Carrier 2 MEMS switch element 3 Coating source 4 Baffle 5
第1圖為本發明之校正前膜厚頻率二維座標系圖。 第2圖爲本發明之25℃條件下不同諧振面積的聲波元件之薄膜厚度-諧振頻率二維座標曲線圖。 第3圖爲本發明之溫度頻率代償二維座標系圖。 第4圖爲本發明之具不同鍍膜厚度的聲波元件之溫度頻率代償二維座標系圖。 第5圖爲本發明之膜厚測量三維座標系圖。 第6圖爲本發明之25℃條件下不同膜厚的聲波元件之諧振面積-諧振頻率二維座標曲線圖。 第7圖爲本發明之40℃條件下不同膜厚的聲波元件之諧振面積-諧振頻率二維座標曲線圖。 第8圖爲本發明之聲波元件與MEMS開關元件之位置結構示意圖。 第9圖為本發明之鍍膜來源與載體之位置結構示意圖。 第10圖爲本發明之各部件連接關係之方塊示意圖。 第11圖爲本發明之膜厚監控及修正之流程示意圖。 Figure 1 is a two-dimensional coordinate system diagram of the film thickness frequency before correction of the present invention. Figure 2 is a two-dimensional coordinate curve diagram of the film thickness-resonance frequency of the acoustic wave element with different resonant areas under 25°C conditions of the present invention. Figure 3 is a two-dimensional coordinate system diagram of temperature-frequency compensation of the present invention. Figure 4 is a two-dimensional coordinate system diagram of temperature-frequency compensation of the acoustic wave element with different film thicknesses of the present invention. Figure 5 is a three-dimensional coordinate system diagram of film thickness measurement of the present invention. Figure 6 is a two-dimensional coordinate curve diagram of the resonant area-resonance frequency of the acoustic wave element with different film thicknesses under 25°C conditions of the present invention. Figure 7 is a two-dimensional coordinate curve of the resonant area-resonant frequency of the acoustic wave element of the present invention at 40°C with different film thicknesses. Figure 8 is a schematic diagram of the position structure of the acoustic wave element and the MEMS switch element of the present invention. Figure 9 is a schematic diagram of the position structure of the coating source and the carrier of the present invention. Figure 10 is a block diagram of the connection relationship of each component of the present invention. Figure 11 is a schematic diagram of the process of film thickness monitoring and correction of the present invention.
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| WO2013062203A1 (en) * | 2011-10-25 | 2013-05-02 | 삼성전자주식회사 | Thin film bulk acoustic resonator and method for manufacturing same |
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| CN117879523A (en) * | 2024-03-12 | 2024-04-12 | 华南理工大学 | A preparation system for tunable thin film bulk acoustic wave resonator |
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| WO2013062203A1 (en) * | 2011-10-25 | 2013-05-02 | 삼성전자주식회사 | Thin film bulk acoustic resonator and method for manufacturing same |
| US20210184200A1 (en) * | 2019-12-11 | 2021-06-17 | GM Global Technology Operations LLC | Homogenous film coating of a particle |
| CN116054773A (en) * | 2022-12-09 | 2023-05-02 | 中国科学技术大学 | Bulk acoustic wave resonator and its preparation method |
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