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1 SAMI UR REHMAN
Particle Counters are used to determine the air quality by counting and sizing the number of particles in the air. This information is useful in determining the amount of particles inside a building or in the ambient air It also is useful in understanding the cleanliness level in a controlled environment.
Cost Analysis
Quotations have been sent SANCO Rough estimates of the equipment have been obtained from:
CLEAN ROOM
PARTICLE COUNTERS
Manufacturer Model Price Year of Manufacture Dimensions Capovani Brothers Inc PARTICLE MEASURMENT SYSTEMS LPS A-310 $ 7,350.00 (each) 2001 Width8.750 in (22.2 cm) Depth18.000 in (45.7 cm) H eight7.000 in (17.8 cm) 30 lb (14 kg) Maximum Number of Channels =4 Channel Sizes= 0.3, 0.5, 1.0, 5.0 m Light Source=HeNe Multimode, Passive Cavity
SAMI UR REHMAN (samirehman.blogspot.com)
7 $7,350
CLEAN ROOM
PARTICLE COUNTERS
Manufacturer Model Price Year of Manufacture Dimensions Pacific Scientific MET ONE $ 4,250.00 2001
SAMI UR REHMAN (samirehman.blogspot.com)
Width13.000 in (33.0 cm) Depth12.000 in (30.5 cm) Heig ht7.000 in (17.8 cm) 30 lb (14 kg) Part no.: 331-3-1-AL Particle size: 0.3 to 10 Micron
8 $4,250
CLEAN ROOM
5,459 lb (2,476 kg) Unit contains a 9W X 10H array of stainless steel cubicles (6.25"W x 4"H x 11"D) Blower: (2) EBM's STD Prefilter #: (2) 16 x 20 x 1 Hepa Filter #: (1) 18 x 48 x 3
$3,250
CLEAN ROOM
Weight (lbs): AirPod I: 312, AirPod II: 394, AirPod III: 455
Nominal Air flow: 2500 CFM (3/4 HP), 5000 CFM (3HP), 4000 CFM (3HP with AD after-filter). Blower Pkg (HP): AirPod I: 2-speed forward curve, direct drive; AirPod II & III: Dynamically balanced, nonsparking, motor/blowers. (Optional 2-speed motor/blower available for AirPod II.) Electrical: AirPod I, standard: 115/1/60, 11.4 amps, 3/4 HP; AirPod II & III, standard: 208-230/460/3/60, 7.87.2/4 amps, 3 HP; optional: 230/1/60 11.7 amps, 3 HP.
$3,000
Width: AirPod I: 62.50, AirPod II: 80.50, AirPod III: 104.50 Height: 31.00 Depth: 31.00
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IC FABRICATION PHILOSOPHY!
Adding layer onto wafer! Adding impurities in wafer!
Implantation Photolithography
Etching
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Photomask Creation
The photomask is a copy of the circuit pattern, drawn on a glass plate coated with a metallic film. The glass plate lets light pass, but the metallic film does not. Due to increasingly high integration and miniaturization of the pattern, the size of the photomask is usually magnified four to ten times the actual size.
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PHOTOLITHOGRAPHY
Wafer processing consists of a sequence of additive and subtractive steps with patterning!!!!!
oxidation deposition ion implantation etching lithography
SAMI UR REHMAN (samirehman.blogspot.com)
Lithography refers to the process of transferring a circuit pattern, embedded on a mask, to the surface of the wafer Equipment, materials, and processes needed:
A mask (for each layer to be patterned) with the desired pattern A light-sensitive material (called photoresist) covering the wafer so as to receive the pattern A light source and method of projecting the image of the mask onto the photoresist (printer or projection stepper or projection scanner) A method of developing the photoresist, that is selectively removing it from the regions where it was exposed
Photolithography is a process analogous to developing film in a darkroom
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PHOTOLITHOGRAPHY STEPS
1 # PRE BAKE THE WAFER Wafer is preheated to about 200 - 250 degrees C in a bake oven. The purpose of this step is to ensure that the wafer is completely dry. Any moisture on the wafer surface would interfere with the photolithography process, causing it to yield poor results.
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PHOTOLITHOGRAPHY STEPS
2 # PHOTORESIST APPLICATION AND SPINNING The wafer is placed on the wafer chuck in the center of the Photoresist Spinner. After properly adjusting the wafer on the spinner, photo resist material is applied onto the surface of the wafer and is spun so that photo resist evenly distributes on the wafer Using the Nitrogen Gun, now the wafer surface is Blown to remove any dust particles.
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PHOTOLITHOGRAPHY STEPS
Photoresist Raw Materials
http://www.mitsuichemicals.com/photoresist.htm
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PR
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Photoresist Applying
PR dispenser nozzle Wafer
SAMI UR REHMAN (samirehman.blogspot.com)
Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Wafer
Chuck Spindle
To vacuum pump
Solvent
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Wafer
Chuck Spindle
To vacuum pump
Solvent
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Exposed Photoresist
Chuck Spindle
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PHOTOLITHOGRAPHY STEPS
3 # SOFT BAKE The wafer is placed into the Soft-Bake Oven for 30 minutes. The purpose of the soft bake is to semi-harden the photoresist
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Baking Systems
Wafer Heater
MW Source
Heated N 2
Chuck
Photoresist
Hot Plates
Widely used in the industry Back side heating, no surface crust In-line track system
Heater
Wafer
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PHOTOLITHOGRAPHY STEPS
4 # EXPOSE TO UV LIGHT carefully place the wafer on the wafer chuck of the Aligner When the wafer has been properly aligned to the mask, expose it to UV light the exposure time should be set according to the particular type of photo resist and wattage of the bulb being used.
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Alignment
Gate Mask
Photoresist
Polysilicon n+ P-Well n+
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Exposure
Gate Mask
Photoresist
Polysilicon n+ P-Well n+
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Photoresist
Polysilicon n+ P-Well n+
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PHOTOLITHOGRAPHY STEPS
5 # DEVELOPMENT The type of developer solution used is determined by the type of photoresist chosen. Then we check the developer for the recommended development time. Typically, this will be around 30 seconds Then the wafer is immersed in the developer and agitate mildly until the time has expired. Finally the wafer is rinsed with ionized water
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Water sleeve
Chuck Drain Vacuum
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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Chuck Spindle
To vacuum pump
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DI Water Rinse
DI water dispenser nozzle Wafer
SAMI UR REHMAN (samirehman.blogspot.com)
Chuck Spindle
To vacuum pump
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Spin Dry
Wafer
Chuck Spindle
To vacuum pump
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Development Profiles
PR Substrate PR
SAMI UR REHMAN (samirehman.blogspot.com)
Substrate
Normal Development
Incomplete Development
PR
PR
Substrate
Under Development
Substrate
Over Development 50
Developer Solution
+PR normally uses weak base solution The most commonly used one is the tetramethyl ammonium hydride, or TMAH ((CH3)4NOH).
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Developer Solutions
Positive PR
Developer TMAH
Negative PR
SAMI UR REHMAN (samirehman.blogspot.com)
Xylene
Rinse
DI Water
n-Butylacetate
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PHOTOLITHOGRAPHY STEPS
6 # HARD BAKE THE WAFER The wafer is placed into the Hard Bake oven now which should be preheated to between 120-130 degrees C. The wafers should remain in the hard bake oven for 30 minutes. This prepares the wafer for the next processing step.
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Types of Photoresist
Negative Photoresist Becomes insoluble after exposure Positive Photoresist
SAMI UR REHMAN (samirehman.blogspot.com)
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Photoresist
Positive Photoresist
Substrate
After Development 55
Comparison of Photoresists
- PR
Film Substrate
+ PR
Film Substrate
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Wafer In
Hot Plate Spin Station
Stepper
SAMI UR REHMAN (samirehman.blogspot.com)
Track Robot
Developer dispenser
Hot Plate
Track
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Track Robot
Developer dispenser
Hot Plate
Track
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Track Robot
Developer dispenser
Hot Plate
Track
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Soft Bake
Hot Plate Spin Station Stepper
SAMI UR REHMAN (samirehman.blogspot.com)
Track Robot
Developer dispenser
Hot Plate
Track
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Track Robot
Developer dispenser
Hot Plate
Track
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Track Robot
Developer dispenser
Hot Plate
Track
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Development
Hot Plate Spin Station Stepper
SAMI UR REHMAN (samirehman.blogspot.com)
Track Robot
Developer dispenser
Hot Plate
Track
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Hard Bake
Hot Plate Spin Station Stepper
SAMI UR REHMAN (samirehman.blogspot.com)
Track Robot
Developer dispenser
Hot Plate
Track
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Wafer out
Hot Plate Spin Station Stepper
SAMI UR REHMAN (samirehman.blogspot.com)
Track Robot
Developer dispenser
Hot Plate
Track
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Resolution
The achievable, repeatable minimum feature size Determined by the wavelength of the light and the numerical aperture of the system. The resolution can be expressed as
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Resolution
K1 R NA
K1 is the system constant is the wavelength of the light NA = 2 ro/D, is the numerical aperture
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Numerical Aperture
NA is the ability of a lens to collect diffracted light NA = 2 r0 / D
r0 : radius of the lens D = the distance of the object from the lens
Lens with larger NA can capture higher order of diffracted light and generate sharper image.
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To Improve Resolution
Increase NA Larger lens, could be too expensive and unpractical Reduce DOF and cause fabrication difficulties Reduce wavelength Need develop light source, PR and equipment Limitation for reducing wavelength UV to DUV, to EUV, and to X-Ray
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Depth of focus
The range that light is in focus and can achieve good resolution of projected image Depth of focus can be expressed as:
SAMI UR REHMAN (samirehman.blogspot.com)
K 2 DOF 2 2( NA)
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Depth of Focus
Smaller numerical aperture, larger DOF
Disposable cameras with very small lenses Almost everything is in focus Bad resolution
Prefer reduce wavelength than increase NA to improve resolution High resolution, small DOF Focus at the middle of PR layer
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Photolithography
MASK ALLIGNER
Karl Suss MA-6 Mask Aligner
$69,000
Description Can handle Si and Compound semiconductor wafers Up to 6"in size 240 nm to 365 nm wavelength. 1:1 exposure system Maximum wafer thickness: 4.3mm Alignment accuracy of +-0.5um
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Photolithography
MASK ALLIGNER
Mask-aligner EV-420
Description Contact mask-aligner for optical lithography Double side exposure Lamp power: 350 W Illumination spectrum: no filters
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Photolithography
MASK ALLIGNER
Manufacturer Model Weight
Accessories/ Other Specifications 400 V 16 A 50 Hz System features Programmable controller
PC with windows NT4SP6 and applications program Respect 1.0b0087/1.1b0002 Touch screen RS 232 Interface Vacuum monitoring External cabinet exhaust connection Automatic exhaust control Media control panel Silicon and compound semiconductor wafers
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Photolithography
SPINNERS
Solitec 5100 LVT
$30,000 Provides spin processing of single wafers/substrates of up to 225mm diagonal Tools for loading and centering for: 4 inch (100 mm) substrate 2 inch (50 mm) substrate Solitic is the main manufacturer of this equipment, Various models from the same Company shown below
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Photolithography
BAKE OVENS
Yes 450pb oven
Description: The 450PB is a high temperature vacuum oven using a programmable temperature controller and programmed vacuum and nitrogen flow cycles for curing of polyimide films. The unit features filtered heated nitrogen purging from the entire surface of the roof through the floor of the chamber. This flow acts to clean the wafers during the process. $22,500
Specs
Capacity: Up to two boats of 6 inch wafers Ramp: 8C/min Cool-down: 1-2C/min Max Temperature: 400C Idle Temperature: 50C
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WAFER PROCESSING
Deposition Etching
Ion implantation
DIFFUSION ANNEALING
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Chemical Vapor Deposition is the formation of a non-volatile solid film on a substrate by the reaction of vapor phase chemicals (reactants) that contain the required constituents.
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PECVD
PECVD uses two electrodes one of which contains the wafer A strong electric field b/w the electrodes ignites the plasma which decomposes the reactant gases into the material to be deposited on the wafer substrate.
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SPUTTERING
High energy plasma knocks metal atoms out of its crystalline structure and are deposited on the wafer substrate! Mainly used for creating metal contacts (Aluminum, Titanium etc)
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SPUTTERING
PVD75 RF Sputterer
$60,000 82
Description The RF sputterer can be used to deposit many dielectrics. Sputter two or more dissimilar materials simultaneously for complete control of film stoichiometry (co-deposition) Integrated touch screen control Single substrate up to 12" diameter Multiple substrate up to 4" diameter Substrate fixture rotation up to 20rpm
SPUTTERING
ARC-12M sputtering system
Gases available: Ar, O2 & N2 - DC sputtering power source: 2 x 250W - RF sputtering power source: 600W at 13.56MHz - Chamber pressure: 5x10-6 torr - Substrate size: 2, 4 wafer or square glass, or specimen - Targets available: Ag, Al, Al/Si (1%), Au, Cu, Cr, Hf, Mo, Pt, SnO2, SiN, Ti, TiW
83 http://www.mff.ust.hk/Eq_Sputter.htm
$55,000
SAMI UR REHMAN (samirehman.blogspot.com)
SPUTTERING
CVC DC Sputterer
Capabilities Deposition - Metal Deposition - Aluminum Chromium - Copper Gold Iron Nickel $55,000 to Palladium 110,000 Platinum Ruthenium
Description The DC sputterer is used to coat samples with metals. Metal coatings are usually performed with this sputterer or with the CVC E-Beam evaporator. -Process wafers/substrates up to 6" -Computer-controlled planetary system for uniform deposition -Two 3" and two 8" sputter guns
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EVAPORATION
Metal atom to be deposited are held in a tungsten coil which carries huge currents The metal evaporates under intense heat and finally deposits on a relatively cooler wafer.
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$30,000
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http://department.fzu.cz/surfaces/mbe/soubory/mbe/mbe_method.htm
The MBE process during the epilayer growth on GaAs substrate. Typical working temperatures of the effusion cells : Ga ~1000oC, Al ~1100oC, As ~300oC, Be ~900oC, Si ~1100oC.
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WET ETCHING
Various mixtures of wet-chemical acid solutions are used for wet etching. The primary acids used are sulphuric , hydrofluoric (HF), hydrochloric (HCl) and phosphoric . As in silicon processing, hydrogen peroxide is used with sulphuric acid, and ammonium hydroxide provides a caustic etch. A cyanide solution (sodium or potassium) is also used for etching aluminium. As an alternative to wet etching, a plasma etching and process is used. The reactor configurations and reactant gases are very similar to those utilized in silicon device processing.
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PLASMA ETCHING
In this form of etching, plasma is used to produce chemically reactive gases which are then made to react with the material to be etched on the wafer substrate!
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PLASMA ETCHING
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PLASMA ETCHING
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$120,000
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PLASMA ETCHING
SAMCO RIE200iP
Manufacturer: SAMCO International Classification: Dry Etch Equipment: Inductively coupled plasma etching Uses: Etching of InP, GaAs, and other III-V compounds, SiNx, SiO2, and photoresist Etch gases Cl2, SiCl4, BCl3, Ar, CF4, CHF3, and O2
http://www.princeton.edu/mnfl/the-toollist/samco-rie200ip/
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SURFACE PROFILER
Tencor Sono Gauge 300
For single point measurement of Wafer thickness, Aluminum film thickness and Sheet resistance of metal film. Wafer Diameter : 3, 4, 5 and 6 Substrate Thickness : 250-700 m Sheet Resistance : 1 to 1999 /sq. Minimum Metal Film Thickness : 100
$6,800
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PARAMETER ANALYSER
HP 4145B Semiconductor Parameter Analyzer
Specs
$4,500
In/Out Ports : 8 Source/Monitor Unit : 4 Voltage Source : 2 Voltage Monitor : 2 Voltage Resolution : 1 mV Current Resolution : 1 pA Maximum Voltage : 100 V Measurement Function : DC current through voltage-biased or current-biased devices
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PROBE STATION
Signatone S-1160 Manual probe station
Specs Microscope of 10x to 70x magnification 4 Micropositioners in S-926 series X-Y-Z motion : 254 microns per knob revolution Tip diameter : 4 microns Vacuum chuck Max. accept a 6wafer Temperature from room temp. to 300
$5,500
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$3,500
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Measure the change of curvature induced in a sample due to the deposited film on a reflected substrate. Measure 1-D stress and produce 3-D topographical profile Specs Wafer size : 2 to 8 Thickness Limit : less than 11 mm Statistical process control and spreadsheet compatibility Automatic segmentation calculation
WET BENCH
Amerimade 8ft Polypro Wet Bench
Construction: Polypro wet bench - Length: 8ft
$10,000
- Teflon Static Bath Tank (Qty 1): a. can handle up to 6" wafers b. Dims: 7"x10"x10" (WxDxH) c. Immersion heater at bottom of tank d. Temperature controllers for each tank
- Teflon Rinse Sinks (Qty 2): a. Dims: 5.5"x9"x5" (WxDxH) DI Spray Gun - 1 Amerimade Bath Timer - 2 Photohelic Exhaust Monitors - 5 Tank Fill Buttons - 4 Alarm Buttons
- Teflon Heated Bath Tanks (Qty 3): a. can handle up to 6" wafers b. Dims: 7"x10"x10" (WxDxH) c. Immersion heater at bottom of tank d. Temperature controllers for each tank
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WET BENCH
JST 4ft Stainless Steel Wet Bench
Model: JST STA00115 - Overall Length: 4ft - Dimensions: 48"x50"x82" (LxWxH) - All tanks sized for single 4"/100mm cassette - All tanks programmed via PLC controller - Automatic wafer handling (cassette) via robot
SAMI UR REHMAN (samirehman.blogspot.com)
- Heated Recirculating Stainless Steel Tank: a. Tank is heated and recirculating b. White Knight Pneumatic Pump c. Tank Lid d. Tank dimensions: 7.5"x7.25"x15" (LxWxH) e. Condenser - Quick Dump Rinse (QDR) Tank: a. Dimensions: 7.5"x7.5"x5" (LxWxH) b. Controlled via PLC controller c. Tank Lid - Static Stainless Steel Tank: a. Tank dimensions: 7.5" x 7.5" x 7" (LxWxH) b. On/Off Drain
$10,000 100
MICROSCOPES
AMERICAN OPTICAL STEREO ZOOM MICROSCOPE 7X - 42X
Unit Price Number of Units Manufacturer Model Binocular Angle Eyepieces Magnification Magnification Range Zoom Range Illumination Type Stand Type Condition
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Cost Model
US $ 350,750
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