Correlation between conductivity and pH measurements for KOH texturing solutions and additives

1. A method of etching material from at least one substrate, the method comprising:

a) immersing the at least one silicon substrate in an etchant solution comprising KOH in a concentration ranging from 0.5 wt. % to 20 wt. % within a process chamber, the process chamber operably coupled to a recirculation line to form a closed-loop circulation system;

b) circulating a circulation volume of the etchant solution through the closed-loop circulation system;

c) repetitively measuring conductivity of the circulation volume of the etchant solution that is circulating through the closed-loop circulation system with a conductivity sensor; and

d) upon detecting that the circulation volume of the etchant solution has an average measured conductivity over a predetermined period of time that is at or below a lower threshold of conductivity, automatically performing a feed-and-bleed event that comprises: (i) bleeding a volume of contaminated etchant solution from the circulation volume of the etchant solution; and (ii) adding fresh etchant solution to the circulation volume of the etchant solution to increase the conductivity of the circulation volume of the etchant solution to a value that is greater than the lower threshold of conductivity but less than or equal to an upper threshold of conductivity.

2. The method of claim 1 wherein during the predetermined period of time, the conductivity of the circulation volume of the etchant solution is measured a plurality of times by the conductivity sensor, and wherein said plurality of conductivity measurements are utilized to determine the average measured conductivity.

3. The method of claim 1 wherein step d) is performed during the processing of the at least one substrate.

4. The method of claim 1 further comprising:

e) repetitively performing steps b) through d); and

wherein subsequent to the performance of step d), the conductivity of the circulation volume of the etchant solution is not considered for determining whether a subsequent feed-and-bleed event should be initiated for a mixing period of time.

5. The method of claim 1 wherein steps d-i) and d-ii) are performed contemporaneously.

6. The method of claim 1 wherein during step d-ii) a volume of the fresh etchant that is added to the circulation volume of the etchant solution that is substantially equal to the volume of the contaminated etchant solution bled from the circulation volume of the etchant solution.

7. The method of claim 1 wherein the circulation volume of the etchant solution has a target concentration of an etchant, and wherein the fresh etchant solution added during step d-ii) has a concentration of the etchant that is greater than the target concentration of the etchant in the circulation volume of the etchant solution.

8. The method of claim 1 , wherein the lower threshold of conductivity is indicative of a lower threshold of etchant concentration in the circulation volume of the etchant solution and the upper threshold of conductivity is indicative of an upper threshold of etchant concentration in the circulation volume of the etchant solution, and wherein each of the upper and lower thresholds of concentration are within a predetermined range of a target concentration of etchant in the circulation volume of the etchant solution.

9. The method of claim 1 wherein step c) further comprises repetitively measuring temperature of the circulation volume of the etchant solution that is circulating through the closed-loop circulation system with a temperature sensor; and wherein the upper and lower thresholds of conductivity are established during step d) based on the measured temperature of the circulation volume of the etchant solution.

10. The method of claim 1 wherein the circulation volume of the etchant solution that is circulating through the closed-loop circulation system is maintained at a substantially constant temperature; and wherein the upper and lower thresholds of conductivity are based, at least in part, on the substantially constant temperature.

11. The method of claim 1 wherein the circulation volume in step c) is held at a temperature ranging from 25° C. to 90° C.

12. A method of generating a control process for maintaining concentration of an etchant solution based on conductivity of the etch solution, the method comprising:

a) circulating a circulation volume of an etchant solution through a closed-loop circulation system and in contact with at least one substrate to etch material from the at least one substrate, the circulation volume of the etchant solution being at a known temperature;

b) measuring conductivity and temperature of the circulation volume of the etchant solution circulating through the closed-loop circulation system;

c) measuring pH of the circulation volume of the etchant solution circulating through the closed-loop circulation system; and

d) assign an etchant concentration value to the measured conductivity of step b) based on the combination of the measured pH of step c) and the measured temperature of step b) whereby the etchant concentration value of step d) is dependent on both the measured pH of step c) as well as the measured temperature of step b).

13. The method of claim 12 wherein the circulation volume in step b) is held at a temperature ranging from 25° C. to 90° C.

14. The method of claim 12 wherein the etchant solution comprises an etchant selected from the group consisting of KOH, NaOH, TMAH, HF, and combinations thereof.

15. The method of claim 12 wherein the etchant solution comprises KOH.

16. The method of claim 12 , wherein the material is selected from the group consisting of silicon, silicon dioxide, and silicon nitride.

17. The method of claim 1 , wherein the concentration of KOH in the etchant solution of step a) ranges from 1.0 wt. % to 10.0 wt. % within the process chamber.