Coating method and coating apparatus
10279368 ยท 2019-05-07
Assignee
Inventors
Cpc classification
B05B1/044
PERFORMING OPERATIONS; TRANSPORTING
B05B13/0442
PERFORMING OPERATIONS; TRANSPORTING
B05C5/0254
PERFORMING OPERATIONS; TRANSPORTING
B05B13/0228
PERFORMING OPERATIONS; TRANSPORTING
G03F7/162
PHYSICS
H01L21/6715
ELECTRICITY
International classification
B05D1/00
PERFORMING OPERATIONS; TRANSPORTING
B05B1/04
PERFORMING OPERATIONS; TRANSPORTING
B05B13/02
PERFORMING OPERATIONS; TRANSPORTING
B05B13/04
PERFORMING OPERATIONS; TRANSPORTING
H01L21/67
ELECTRICITY
B05C5/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A slit opening of a slit nozzle extends unidirectionally in a longitudinal direction from near the center of a circular substrate to near an outer edge of the substrate, and has a length in the longitudinal direction equal to or smaller than a radius of the substrate. When the slit nozzle discharges chemical onto the substrate, a rotary holder rotates the substrate and the slit nozzle relatively to each other about the center of the substrate. Accordingly, the chemical from the slit nozzle all adheres to a surface of the substrate to form an excellent liquid column and a chemical film on an almost entire surface of the substrate along the outer edge of the circular substrate. This yields satisfactory coating of the substrate with the chemical while waste chemical is suppressed.
Claims
1. A coating method of coating chemical, comprising: a discharging step of discharging chemical onto a circular substrate with a slit nozzle having a slit opening; a rotating step of rotating the substrate and the slit nozzle relatively to each other about the center of the substrate with a chemical discharging rotator during the discharging step of discharging the chemical with the slit nozzle, the slit opening extending unidirectionally in a longitudinal direction from near the center of the substrate to near an outer edge of the substrate, and having a length in the longitudinal direction being equal to or smaller than a radius of the substrate; a first moving step of moving a gas nozzle by a gas nozzle moving unit above an overlap or a clearance of a chemical film generated between a start point and an end point of chemical discharge or an extension of the overlap or the clearance; a gas blowing step of blowing gas from the gas nozzle above the substrate directly onto the chemical film formed on the substrate after the discharging step of discharging the chemical; a second moving step of moving the gas nozzle in a radial direction of the substrate by the gas nozzle moving unit during the gas blowing step of blowing the gas directly from the gas nozzle; and rotating the substrate and the slit nozzle relatively to each other by one time and performing planarization by blowing the gas to at least the overlap or the clearance of the chemical film.
2. The coating method according to claim 1, wherein the gas contains solvent vapor.
3. The coating method according to claim 1, wherein a first end face of the slit opening adjacent to the outer edge of the substrate is disposed inside the outer edge of the substrate.
4. The coating method according to claim 1, wherein a second end face of the slit opening adjacent to the center of the substrate is disposed outside the center of the substrate.
5. The coating method according to claim 3, wherein a second end face of the slit opening adjacent to the center of the substrate is disposed outside the center of the substrate.
6. The coating method according to claim 1, wherein the slit opening is wider from near the center of the substrate to near the outer edge of the substrate.
7. The coating method according to claim 1, wherein the slit nozzle has a discharge amount of chemical gradually increasing from near the center of the substrate to near the outer edge of the substrate.
8. The coating method according to claim 7, wherein the slit nozzle has a gap between the slit opening thereof and a surface of the substrate gradually increasing from near the center of the substrate to near the outer edge of the substrate.
9. The coating method according to claim 1, wherein the chemical discharging rotator is rotated by less than 360 degrees.
10. The coating method according to claim 1, wherein the chemical has viscosity of 300 cP or more and 10000 cP or less.
11. The coating method according to claim 1, comprising performing said planarization by blowing the gas to at least said clearance of the chemical film generated between the start point and the end point of chemical discharge.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1) For the purpose of illustrating the invention, there are shown in the drawings several forms which are presently preferred, it being understood, however, that the invention is not limited to the precise arrangement and instrumentalities shown.
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EMBODIMENT 1
(13) The following describes Embodiment 1 of the present invention with reference to drawings.
(14) Reference is made to
(15) The rotary holder 2 includes a spin chuck 4 holding the substrate W rotatably about a rotary shaft AX1, and a rotary drive unit 5 rotating the spin chuck 4 about the rotary shaft AX1. The spin chuck 4 suction-holds a rear face of the substrate W, thereby holding the substrate W in a substantially horizontal attitude. The rotary drive unit 5 is formed by a motor and the like. Here, the rotary holder 2 corresponds to the chemical discharging rotator in the present invention. The rotary shaft AX1 substantially conforms to the center CT of the substrate W.
(16) A cup 7 is provided lateral to the rotary holder 2 for surrounding the rotary holder 2. The cup 7 is moved vertically by a drive unit, not shown.
(17) The slit nozzle 3 is supported by an arm 9. The slit nozzle 3 supported by the arm 9 reciprocates between a standby pot (not shown) outside the cup 7 and a given position above the substrate W with a slit nozzle moving unit 11. The slit nozzle moving unit 11 moves the slit nozzle 3 in at least any of an X-direction (first horizontal direction), a Y-direction (second horizontal direction), and a Z-direction (vertical direction). Here, the slit nozzle moving unit 11 may rotate the slit nozzle 3 around a rotary shaft AX2. The slit nozzle moving unit 11 is formed by a motor, a guide rail, and the like.
(18) The chemical is supplied from a chemical supplying source 13 to the slit nozzle 3. The chemical is supplied from the chemical supplying source 13 through a chemical pipe 15 to the slit nozzle 3. The chemical pipe 15 has an open/close valve V1 for supplying the chemical and stopping supply of the chemical, a pump P, and the like, each interposingly arranged on the chemical pipe 15.
(19) The coating apparatus 1 includes a controller 17 controlling elements of the coating apparatus 1, a memory unit (not shown) formed by a hard disk and the like and storing operating conditions of the coating apparatus 1, and an operating unit 19 with a display unit and an input unit. The controller 17 is formed by a central processing unit (CPU). The display unit of the operating unit 19 is formed by a liquid crystal monitor and the like. The input unit is formed by a joystick, a mouse, a keyboard, a button, and the like.
(20) The following describes the slit nozzle 3 in detail. As illustrated in
(21) The slit nozzle 3 with the above slit opening 21 discharges chemical onto the substrate W. During this, the rotary holder 2 rotates the substrate W about the center CT (rotary shaft AX1). See
(22)
(23) As illustrated in
(24) In
(25) Moreover, as illustrated in
(26) Moreover, as illustrated in
(27) The following describes operation of the coating apparatus 1.
(28) Reference is made to
(29) After the substrate W is transported, the slit nozzle moving unit 11 moves the slit nozzle 3 from the standby pot (not shown) to a give position above the substrate W. When the slit nozzle 3 is moved to the given position, the slit opening 21 of the slit nozzle 3 is disposed so as to extend unidirectionally from near the center CT of the circular substrate W to near the outer edge E of the substrate W along the radius direction RD, as illustrated in
(30) While the slit nozzle 3 discharges the chemical, i.e., from start to end of the chemical discharge, the rotary holder 2 holds and rotates the substrate W about the center CT (rotary shaft AX1) approximately once. Consequently, the slit nozzle 3 and the substrate W rotate relatively to each other about the center CT of the substrate W approximately once. Moreover, the substrate W may be rotated before the discharge of the chemical starts. Moreover, the substrate W may be rotated continuously after the chemical discharge.
(31) The chemical discharged from the slit nozzle 3 all adheres to the surface of the substrate W, whereby an excellent liquid column is formed. In addition, the chemical film F is formed on almost the entire surface of the substrate W so as to draw a circle along the outer edge E of the circular substrate W. Accordingly, no chemical is discharged out of the circular substrate W, which differs from
(32) Moreover, the rotary holder 2 rotates the substrate W while the chemical is discharged at a number of rotations (rotation speed) at which the chemical adhering to the substrate W does not run out of the substrate W by a centrifugal force. In other words, the substrate W is rotated slowly at low speeds. Consequently, no chemical is discharged outside the substrate W, leading to further suppression of the waste chemical. In addition, the substrate W is not rotated at high speeds as in the spin coating system, leading to no mist caused by the chemical and the like. Then the cup 7 containing a less amount of exhaust gas than that in the spin coating system is obtainable. This achieves suppressed operation energy for the apparatus.
(33) After the chemical film F is formed, the slit nozzle moving unit 11 moves the slit nozzle 3 from the given position above the substrate W to the standby pot (not shown). If the substrate W is being rotated, the rotary holder 2 stops the rotation of the substrate W, and releases holding of the substrate W. Thereafter, the cup 7 is moved downward. The substrate transport mechanism (not shown) transports the substrate W on the spin chuck 4.
(34) In the aspect of the present embodiment, the slit opening 21 of the slit nozzle 3 extends unidirectionally in the longitudinal direction from near the center CT of the circular substrate W to near the outer edge E of the substrate W. The slit opening 21 has a length in the longitudinal direction smaller than the radius of the substrate W. When such a slit nozzle 3 discharges the chemical onto the substrate W, the rotary holder 2 rotates the slit nozzle 3 and the substrate W relatively to each other about the center CT of the substrate W. Accordingly, the chemical from the slit nozzle 3 all adheres to the surface of the substrate W to form an excellent liquid column and the chemical film F on almost the entire surface of the substrate along the outer edge E of the circular substrate W. This yields satisfactory coating of the substrate W with the chemical while waste chemical is suppressed.
(35) In addition, the film F of the chemical discharged from the slit nozzle 3 according to the aspect of the present invention allows integrated one connection (see an overlap portion OL in
(36) In addition, if the chemical film F is formed to the outer edge E of the substrate W, the arm (also referred to as a hand) of the substrate transport mechanism may be contaminated. Such a problem arises. However, the first end face 21a of the slit opening 21 adjacent to the outer edge E of the substrate W is actually disposed inside the outer edge E of the substrate W by the gap G1 in
(37) Moreover, the second end face 21b of the slit opening 21 adjacent to the center CT of the substrate W is disposed outside the center CT of the substrate W by the gap G2 in
(38) The viscosity of the chemical is, for example, equal to or more than 300 cP (centipoise), and is equal to or less than 10000 cP. This achieves satisfactory coating of the circular substrate W with the chemical with high viscosity while waste chemical is suppressed.
EMBODIMENT 2
(39) The following describes Embodiment 2 of the present invention with reference to drawings. Here, the description common to that of Embodiment 1 is to be omitted.
(40) In Embodiment 1, the chemical is discharged, and thereafter the substrate transport mechanism transports the substrate W. However, in the present embodiment of the present embodiment, the chemical is discharged, and thereafter the film F of the chemical discharged onto the substrate W is subjected to planarization.
(41) Reference is made to
(42) The gas nozzle 31 is supported by the arm 33. The gas nozzle 31 supported by the arm 33 is moved by a gas nozzle moving unit 35 between a standby position outside the cup 7 and a pre-set given position above the substrate W. The gas nozzle moving unit 35 moves the gas nozzle 31 in at least any of the X-direction (first horizontal direction), the Y-direction (second horizontal direction), and the Z-direction (vertical direction). The gas nozzle moving unit 35 may also rotate the gas nozzle 31 about a rotary shaft AX3. The gas nozzle moving unit 35 is formed by a motor, a guide rail, and the like.
(43) A gas supplying source 39 supplies gas to the gas nozzle 31 via a gas pipe 37. The gas pipe 37 has an open/close valve V2 interposingly arranged thereon for blowing gas and stopping blowing gas. A controller 17 controls the gas nozzle moving unit 35 and the open/close valve V2.
(44) Examples of the gas blown to the chemical film F include inactive gas such as nitrogen, air, and other types of gas. Moreover, the gas may contain solvent vapor (evaporated solvent). The solvent is, for example, made from the same solvent contained in the chemical. If only nitrogen, for example, containing no solvent vapor is blown to the chemical film F, the solvent in the chemical at a portion of the substrate to which the nitrogen is blown may possibly evaporate to dry the chemical. However, the gas contains the solvent vapor. Consequently, even when the gas is blown to the chemical film F, it is avoidable for the solvent in the chemical to evaporate and be dried.
(45) The following describes operation of the coating apparatus 1 according to the aspect of the present embodiment.
(46) As illustrated in
(47) As illustrated in
(48) Moreover, the gas may be blown while the gas nozzle 31 is moved in the radius direction RD when the rotary holder 2 rotates the substrate W. This achieves blow of the gas to the chemical film F while the gas nozzle 31 and the substrate W rotate relatively to each other about the center CT of the substrate W. In addition, combination to the move of the gas nozzle 31 in the radius direction RD achieves movement of the gas nozzle 31 to any positions within the substrate W. Moreover, as illustrated in
(49) The following describes one example of blowing the gas. The gas nozzle 31 blows the gas obliquely downward to the outside in the radius direction RD. The gas nozzle 31 is moved from near the center CT to near the outer edge E in a gas blowing direction by the gas nozzle 31 while the substrate W is rotated at low speeds. This causes the chemical to flow to planarize the film. Here, the substrate W is rotated at a number of rotations (rotation speed) at which the chemical adhering to the substrate W does not run out of the substrate W by a centrifugal force.
(50) After the chemical film F is planarized, the gas nozzle moving unit 35 moves the gas nozzle 31 to the standby position outside the cup 7. If the substrate W is rotated, the rotary holder 2 stops the rotation of the substrate W, and releases holding of the substrate W. Thereafter, the cup 7 is moved downward. The substrate transport mechanism transports the substrate W on the spin chuck 4.
(51) With the aspect of the present embodiment, the gas nozzle 31 blows gas from above the substrate W to the chemical film F formed by discharging the chemical to the substrate W. This yields planarization of the chemical film F.
(52) Here in the present embodiment, the gas nozzle 31 includes a single gas blow port 31a in
(53) In the present embodiment, the gas nozzle 31 is moved to the radius direction RD. However, the gas nozzle 31 may be fixed in the radius direction RD as necessary when blowing the gas. For instance, movement of the gas nozzle 31 to the radius direction RD may be omitted as long as the gas can be blown in the longitudinal direction along the radius direction RD, for example, with the slit-like port.
(54) The present invention is not limited to the foregoing examples, but may be modified as follows.
(55) (1) In the above Embodiment 2, the chemical is discharged, and thereafter, planarization is performed to the chemical film F on the substrate W by blowing the gas to the chemical film F. However, the planarization may be performed by rotating the substrate W about the center CT (rotary shaft AX1) with the rotary holder 2. In this case, the substrate W is rotated at a number of rotations (rotation speed) at which the chemical adhering to the substrate W does not run out of the substrate W by a centrifugal force. Accordingly, this requires no element for blowing gas, such as the gas nozzle 31, leading to a simplified configuration. Here, a number of rotations upon the planarization may be different from that when the chemical is discharged.
(56) (2) In the above embodiments and modification (1), the gap G3 between the slit opening 21 of the slit nozzle 3 and the surface of the substrate W is constant from near the center CT to near the outer edge E of the substrate W as illustrated in
(57) (3) In the above embodiments and the modifications, the slit opening 21 has a width WD gradually increasing from near the center CT to near the outer edge of the substrate W as illustrated in
(58) As illustrated in
(59) Alternatively, instead of the configuration in
(60) (4) In the above embodiments and modifications, the substrate W is rotated approximately once, and then, upon completion of chemical discharge to the substrate W (i.e., stop of chemical supply), the slit nozzle moving unit 11 moves the slit nozzle 3 slightly upward. Such may be adopted. This avoids contamination of the slit nozzle 3.
(61) (5) In the above embodiments and modifications, the rotary holder 2 rotates the substrate W relatively to the slit nozzle 3 about the center CT while the slit nozzle 3 discharges the chemical. However, the slit nozzle moving unit 11 may rotate the slit nozzle 3 relatively to the substrate W about the center CT (rotary shaft AX1). In this case, the slit nozzle 3 is rotated similarly at a number of rotations (rotation speed) at which the chemical adhering to the substrate W does not run out of the substrate W by a centrifugal force.
(62) (6) In the above embodiments and modifications, the rotary holder 2 rotates the substrate W relatively to the gas nozzle 31 about the center CT (rotary shaft AX1) while the gas nozzle 31 blows the gas. However, the gas nozzle moving unit 35 may rotate the gas nozzle 31 relatively to the substrate W about the center CT (rotary shaft AX1).
(63) (7) In the above embodiments and modifications, the slit nozzle 3 and the substrate W are rotated about the center CT approximately once when the chemical is discharged onto the substrate W. Here, the rotation by the substrate holder 2 may be less than 360 degrees. This yields a clearance between the start point and the end point of chemical discharge from the slit nozzle 3. This avoids an increased chemical film thickness due to overlapped chemical film F as the overlap OL in
(64) (8) In the above embodiments and modifications, the single slit nozzle 3 is provided. However, as illustrated in
(65) Moreover, the two slit nozzles 3 in
(66) (9) In the above embodiments and modifications, the substrate W is rotated approximately once while the slit nozzle 3 discharges the chemical onto the substrate W. However, the rotation may be two or more times. In this case, the level of the slit nozzle 3 is controlled so as not to contaminate the slit nozzle 3.
(67) (10) In the above embodiments and modifications, the slit opening 21 has a longitudinal length smaller than the radius of the substrate W. However, the length may be equal to the radius. For instance, for the substrate W whose diameter is 300 mm, the slit opening 21 has a longitudinal length of 150 mm.
(68) (11) In the above embodiments and modifications mentioned above, an extension of the end face of the slit opening 21 adjacent to the center CT passes above the center CT when seen the substrate W from above. However, the slit opening 21 may be inclined such that the extension of the end face of the slit opening 21 adjacent to the center CT does not pass above the center CT.
(69) The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.