Abstract:
An in-line apparatus includes a loader chamber loading and unloading a substrate, a plurality of process chambers coupled in series to the loader chamber, and respectively and sequentially performing predetermined processes for the substrate, and at least one buffer chamber disposed in parallel to the process chambers, wherein the buffer chamber replaces at least one process chamber to transfer the substrate therethrough.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to Korean Patent Application No. 10-2008-0031200 filed on Apr. 3, 2008, the entire contents of which are incorporated herein by reference. 
       BACKGROUND OF THE INVENTION 
       [0002]    (a) Technical Field 
         [0003]    The present disclosure relates to an in-line apparatus, and more particularly, to an in-line apparatus for manufacturing electrical wiring or an electrode used for a micro-electronic device. 
         [0004]    (b) Discussion of the Related Art 
         [0005]    A micro-electronic device such as a display device or a semiconductor device includes electrical wiring or electrodes. For example, flat panel displays such as a liquid crystal display, an organic light emitting device, and a plasma display device include electrodes made of indium tin oxide (ITO), indium zinc oxide (IZO), or a metal, and a plurality of signal lines. 
         [0006]    The signal lines or the electrodes may have a single-layered structure or a multi-layered structure, and can be formed by a sputtering method. In the sputtering method, gas ions having high energy of plasma formed in a vacuum chamber collide with a target, and then atoms ejected from the target due to the collision are deposited as a thin film on a substrate. 
         [0007]    Devices for forming the signal lines and the electrodes can be divided into a cluster type and an in-line type according to, for example, configuration and/or a transfer method. In the in-line type, process chambers are disposed in series such that continuous transfer of substrates is possible. Accordingly, if the in-line type is used when forming signal lines and electrodes, process speed may be increased. However, in the in-line apparatus, when the target is exhausted and exchanged in one chamber, or when defects are generated and preventive maintenance is performed, the entire operation of the in-line apparatus stops. 
       SUMMARY OF THE INVENTION 
       [0008]    Accordingly, exemplary embodiments of the present invention provide an in-line apparatus that can be operated during preventive maintenance of a portion of the chambers thereof. 
         [0009]    According to an exemplary embodiment of the present invention, an in-line apparatus comprises a loader chamber loading and unloading a substrate, a plurality of process chambers coupled in series to the loader chamber, and respectively and sequentially performing predetermined processes for the substrate, and at least one buffer chamber disposed in parallel to the process chambers, wherein the buffer chamber replaces at least one process chamber to transfer the substrate therethrough. 
         [0010]    The in-line apparatus may further include at least one rail, and the buffer chamber and the process chambers can be disposed on the rail and move along the rail. 
         [0011]    The process chambers ma include a first process chamber and a second process chamber connected thereto, and the first process chamber and the second process chamber can disposed on different rails. 
         [0012]    The buffer chamber can be positioned on a rail where the second process chamber is disposed. 
         [0013]    When the second process chamber is separated from the first process chamber and moves away from the first process chamber, the buffer chamber may moves to be coupled in series to the first process chamber. 
         [0014]    The in-line apparatus may further comprise a transfer chamber connected to one of the process chambers, wherein the transfer chamber includes a direction-converting apparatus to transfer the substrate back to the loader chamber. 
         [0015]    The in-line apparatus may further comprise a heater chamber disposed in series between the loader chamber and one of the process chambers. 
         [0016]    The process chambers may execute a sputtering process. 
         [0017]    The process chambers may include first and fourth process chambers having a molybdenum target, and second and third process chambers disposed between the first process chamber and the fourth process chamber and, respectively having an aluminum target, and the first to fourth process chambers can be disposed on different rails, and the at least one buffer chamber may include a first buffer chamber positioned on a rail where the second process chamber is disposed, and a second buffer chamber positioned on a rail where the third process chamber is disposed. 
         [0018]    The process chambers and the at least one buffer chamber can be in a vacuum state. 
         [0019]    When the second process chamber is separated from the first and third process chambers and moves away from the first and third process chambers, the first buffer chamber can move between the first and third process chambers to be coupled in series to the first and third process chambers and provide a transfer space in a vacuum state. 
         [0020]    When the third process chamber is separated from the second and fourth process chambers and moves away from the second and fourth process chambers, the second buffer chamber can move between the second and fourth process chambers to be coupled in series to the second and fourth process chambers and provide a transfer space in the vacuum state. 
         [0021]    The process chambers ma include first and second process chambers having an ITO or IZO target, and the first process chamber and the second process chamber can be disposed on different rails, and the buffer chamber can be disposed on a rail where the first process chamber is disposed. 
         [0022]    When the first process chamber is separated from the second process chamber and moves away from the second process chamber, the buffer chamber can move to be connected to the second process chamber and provide a transfer space in the vacuum state. 
         [0023]    According to an exemplary embodiment of the present invention, an apparatus for manufacturing electrical wiring or an electrode used for a micro-electronic device, the apparatus comprises a loader chamber loading a substrate, a first process chamber receiving the substrate from the loader chamber, a second process chamber connected to the first process chamber, a third process chamber connected to the second process chamber, a fourth process chamber connected to the third process chamber, and a first buffer chamber connected to the second process chamber, wherein the first buffer chamber replaces the second process chamber to transfer the substrate from the first process chamber to the third process chamber. 
         [0024]    The apparatus may further comprise a second buffer chamber connected to the third process chamber, wherein the second buffer chamber can replace the third process chamber to transfer the substrate from the second process chamber to the fourth process chamber therethrough. 
         [0025]    A loadlock chamber and a heater chamber can be formed between the loader chamber and the first process chamber. 
         [0026]    The fourth process chamber may include elements for changing a transfer direction of the substrate. 
         [0027]    According to an exemplary embodiment of the present invention, a method of transferring a substrate between chambers comprises loading a substrate in a loader chamber, transferring the substrate from the loader chamber to a first process chamber connected to the loader chamber, transferring the substrate from the first process chamber to a second process chamber connected to the first process chamber, transferring the substrate from the second process chamber to a third process chamber connected to the second process chamber, and replacing the second process chamber with a first buffer chamber to transfer the substrate from the first process chamber to the third process chamber through the buffer chamber in a vacuum state when the second process chamber is separated from the first and third process chambers. According to an exemplary embodiment of the present invention, the apparatus operation is not stopped during the preventive maintenance of a portion of the chambers. Accordingly, productivity of the products may be increased. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]    Exemplary embodiments of the present invention can be understood in more detail from the following descriptions taken in conjunction with the accompanying drawings in which: 
           [0029]      FIG. 1  is a top plan view of an in-line apparatus according to an exemplary embodiment of the present invention; 
           [0030]      FIG. 2  is a cross-sectional view of a process chamber according to an exemplary embodiment of the present invention; and 
           [0031]      FIG. 3  is a top plan view showing an operation of an in-line apparatus according to an exemplary embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0032]    The invention is described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. It will be understood that when an element such as a layer, film, region, or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. 
         [0033]    An in-line apparatus according to an exemplary embodiment of the present invention is described with reference to  FIG. 1  and  FIG. 2 . 
         [0034]      FIG. 1  is a top plan view of an in-line apparatus according to an exemplary embodiment of the present invention.  FIG. 2  is a cross-sectional view of a process chamber according to an exemplary embodiment of the present invention. 
         [0035]    Referring to  FIG. 1  and  FIG. 2 , the in-line apparatus includes a loader chamber  100 , a loadlock chamber  200 , a heater chamber  300 , and first to fourth process chambers  400 ,  500 ,  600 , and  700 . The chambers  100 ,  200 ,  300 ,  400 ,  500 ,  600 , and  700  are coupled in series through valves  90  interposed therebetween, and execute a series of processes for a substrate  10 . 
         [0036]    The loader chamber  100  executes pre-aligning of the substrate  10  and loading of the substrate  10 . In the loader chamber  100 , the substrate  10  is unloaded after predetermined processes are completed. 
         [0037]    The loadlock chamber  200  can be connected to the loader chamber  100  through the valve  90  interposed therebetween, and receives the substrate  10  from the loader chamber  100  under an atmospheric pressure state. The substrate  10  can be transferred in a vertically standing state. Next, the loadlock chamber  200  is changed from the atmospheric pressure state to a vacuum state. 
         [0038]    The heater chamber  300  can be connected to the loadlock chamber  200  through the valve  90  interposed therebetween, and receives the substrate  10  from the loadlock chamber  200  under the vacuum state. The transmitted substrate  10  is heated by a heater  50  to an appropriate temperature. 
         [0039]    In the first to fourth process chambers  400 ,  500 ,  600 , and  700 , signal lines or electrodes are formed on the substrate  10  that is transmitted from the heater chamber  300  through, for example, a sputtering method. The process chambers  400 ,  500 ,  600 , and  700  are coupled in series to each other, and respectively include material supply units  430 ,  530 ,  630 , and  730  and a heater  50  to maintain the temperature of the substrate  10 . Each of the first to fourth process chambers  400 ,  500 ,  600 , and  700  may include a substrate supporter  450 , a gas supply unit  40 , a vacuum pump  30 , and a radio frequency induction file (not shown). The signal lines and the electrodes may be formed by different methods other than the sputtering method. 
         [0040]    The material supply units  430 ,  530 ,  630 , and  730  are, respectively, connected to a surface of the process chambers  400 ,  500 ,  600 , and  700 . Each of the material supply units  430 ,  530 ,  630 , and  730  includes a target  437  that is a material to be attached to the substrate  10  and a cathode  435  connected to the target  437 . The target  437  may be separated from the process chamber  400  for exchange of the target  437 . 
         [0041]    The target  437  may comprise, for example, an aluminum-based metal such as aluminum (Al) or an aluminum alloy, a silver-based metal such as silver (Ag) or a silver alloy, a copper-based metal such as copper (Cu) or a copper alloy, a molybdenum-based metal such as molybdenum (Mo) or a molybdenum alloy, nitrides, chromium (Cr), tantalum (Ta), or titanium (Ti). In an exemplary embodiment, the first and fourth material supply units  430  and  730  include a molybdenum target, and the second and third material supply units  530  and  630  include an aluminum target. 
         [0042]    The process chambers  400 ,  500 ,  600 , and  700  with the material supply units  430 ,  530 ,  630 , and  730  are disposed on rails  70 , and may move along the rails  70 . 
         [0043]    Buffer chambers  550  and  650  are disposed on the rails  70  on which the second and third process chambers  500  and  600  are disposed. The buffer chambers  550  and  650  are apart from the second and third process chambers  500  and  600 . The buffer chambers  550  and  650  provide a space, for example, a vacuum state space, where the substrate  10  may be transferred during a preventive maintenance process of the second process chamber  500  or the third process chamber  600 . The buffer chambers  550  and  650  may be moved along the rails  70 . 
         [0044]    The fourth process chamber  700  includes a direction-converting apparatus for changing the transfer direction of the substrate  10  back to the loader chamber  100  after having completed a predetermined process. The fourth process chamber  700  may be a transfer chamber having the direction-converting apparatus. In the transfer chamber, a process of forming a thin film may or may not be performed. 
         [0045]    The operation of the process chambers  400 ,  500 ,  600 , and  700  is described with reference to  FIG. 2 . In  FIG. 2 , the first process chamber  400  is shown. The second to fourth process chambers  500 ,  600 , and  700  have substantially the same structure and operation as the first process chamber  400 . In an exemplary embodiment, the fourth process chamber  700  further includes elements for converting the transfer direction of the substrate  10  and elements for the sputtering process. 
         [0046]    The first process chamber  400  includes the material supply unit  430  having the cathode  435  and the target  437 , the supporter  450  supporting the substrate  10 , the heater  50 , the vacuum pump  30 , and the gas supply unit  40 . The substrate supporter  450  may function as an anode. 
         [0047]    For forming a layer on the substrate  10 , the substrate  10  is loaded in the process chamber  400  while maintaining the vacuum state through the vacuum pump  30 . Next, an inert gas such as argon gas is injected into the process chamber  400  through the gas supply unit  40 . Then, the cathode  435  and the substrate supporter  450  are supplied with a radio frequency (RF) or a direct current (DC) to generate plasma. Thus, argon ions (Ar + ) generated in the plasma collide with the target  437 , and atoms of the target  437  exit the target  437  and are attached to the substrate  10  to form a thin film. 
         [0048]    An operation of the in-line apparatus according to an exemplary embodiment of the present invention is described with reference to  FIG. 2  and  FIG. 3 . 
         [0049]      FIG. 3  is a top plan view showing an operation of an in-line apparatus according to an exemplary embodiment of the present invention. 
         [0050]    Referring to  FIG. 2  and  FIG. 3 , the substrate  10  is loaded in the loader chamber  100  under atmospheric pressure, and is transferred to the loadlock chamber  200 . Next, the loadlock chamber  200  is changed to the vacuum state, and the substrate  10  is transferred to the heater chamber  300 . The substrate  10  is heated to an appropriate temperature by the heater  50  disposed in the heater chamber  300 . The heated substrate  10  is then transferred to the process chambers  400 ,  500 ,  600 , and  700 . The process chambers  400 ,  500 ,  600 , and  700  are maintained in the vacuum state. 
         [0051]    In the process chambers  400 ,  500 ,  600 , and  700 , a pixel electrode, a common electrode, a signal line, and/or a drain electrode can be formed by, for example, the sputtering method. The signal line can be a gate line having a gate electrode or a data line having a source electrode. 
         [0052]    The gate line may comprise, for example, an aluminum-based metal such as aluminum (Al) or an aluminum alloy, a silver-based metal such as silver (Ag) or a silver alloy, a copper-based metal such as copper (Cu) or a copper alloy, a molybdenum-based metal such as molybdenum (Mo) or a molybdenum alloy, chromium (Cr), tantalum (Ta), or titanium (Ti). However, the signal line may have a multi-layered structure including two conductive layers having different physical properties. One of the conductive layers may be formed using a metal having low resistivity, such as an aluminum-based metal or a copper-based metal, to reduce signal delay or voltage drop. In an exemplary embodiment, other conductive layers may be formed using a material having good physical, chemical, and electrical contact characteristics with indium tin oxide (ITO) and indium zinc oxide (IZO). Examples of the other conductive layers can be a molybdenum-based metal, chromium, tantalum, or titanium. Examples of the combination for the two layer structure may include a lower chromium film and an upper aluminum (alloy) film, or a lower aluminum (alloy) film and an upper molybdenum (alloy) film. 
         [0053]    The data line and the drain electrode may be formed using a refractory metal such as, for example, molybdenum, chromium, tantalum, titanium, or an alloy thereof, and may have a multi-film structure including a refractory metal film and a low resistance conductive layer. Examples of the multi-film structure may include a dual film of a lower chromium or molybdenum film and an upper aluminum (alloy) film, or a triple film of a lower molybdenum (alloy) film, an intermediate aluminum (alloy) film, and an upper molybdenum (alloy) film. In an exemplary embodiment, the data line and the drain electrode may be formed using various metals or conductors other than the above-mentioned materials. 
         [0054]    The pixel electrode or the common electrode may comprise, for example, a transparent conductive material such as ITO or IZO, or a reflective metal such as aluminum, silver, chromium, or alloys thereof. 
         [0055]    In an exemplary embodiment, the process chambers  400 ,  500 ,  600 , and  700  are used for forming a triple film of a lower molybdenum film, an intermediate aluminum film, and an upper molybdenum film. 
         [0056]    The lower molybdenum layer is formed in the first process chamber  400 , the intermediate aluminum layer is formed in the second and third process chambers  500  and  600 , and the upper molybdenum layer is formed in the fourth process chamber  700 . If the target material to be attached to the substrate  10  is exhausted, the process of forming a layer is stopped. The material supply unit  430  with an exhausted target is separated from the process chamber  400  to exchange the target. The exhaustion degree is different according to the kind of target during the same time frame. For example, the exhausted amount of the molybdenum target is less than that of the aluminum target for a certain period. Accordingly, in an exemplary embodiment, there are two process chambers  500  and  600  having the aluminum target with the faster exhaustion speed. When a target is exhausted, the material supply units  530 ,  630  or  730  are separated from the process chambers  500 ,  600  or  700 , respectively, to replace the targets in the material supply units  530 ,  630  or  730 . 
         [0057]    In the first process chamber  400 , the molybdenum lower layer is formed on the substrate  10  that is transferred from the heater chamber  300 . The substrate  10  on which the molybdenum lower layer is formed is transferred to the second process chamber  500 . In the second process chamber  500 , the intermediate aluminum layer is formed on the substrate  10 . The substrate  10  having the intermediate aluminum layer is then transferred to the fourth process chamber  700  through the third process chamber  600 . The third process chamber  600  provides a transfer space in the vacuum state for the substrate  10  transferring from the second process chamber  500  to the fourth process chamber  700 . A sputtering process is not executed in the third process chamber  600 . In the fourth process chamber  700 , the upper molybdenum layer is formed on the substrate  10 , and the substrate  10  of which the process is completed is transferred back to the loader chamber  100  through the path that the substrate  100  has passed. In the in-line apparatus according to an exemplary embodiment of the present invention, the substrate  10  moves in a first direction, and then moves in a second direction which is opposite to the first direction. A system in which the loading and unloading are both executed in the loader chamber  100  without an additional unloader chamber is referred to as an interback system. 
         [0058]    The aluminum target is exhausted faster than the molybdenum target such that the aluminum target used in the second process chamber  500  is exchanged more often than the molybdenum target in different process chambers. Accordingly, if the aluminum target of the second material supply unit  530  is exhausted, a process of forming a layer is temporary stopped, and the second process chamber  500  is separated from the first and third process chamber  400  and  600  and moved downwardly along the rail  70 . In an exemplary embodiment, the valves  90  disposed between the second process chamber  500  and the first process chamber  400 , and between the second process chamber  500  and the third process chamber  600 , are locked such that the first and third process chambers  400  and  600  may be maintained in the vacuum state. When the second process chamber  500  is moved, the buffer chamber  550  is moved downwardly. Next, the buffer chamber  550  is coupled in series with the first and third process chambers  400  and  600  through the valves  90 , and provides a space through which the substrate  10  may be transferred in the vacuum state. This period is referred to as a mode change period, and takes about 1 hour in an exemplary embodiment of the present invention. 
         [0059]    When changing the target of the second material supply unit  530 , the buffer chamber  550  provides the transfer space in the vacuum state instead of the second process chamber  500  such that the process is not stopped except for the mode change period. The target of the second material supply unit  530  is exchanged in a state in which the second material supply unit  530  is separated from the second process chamber  500 . However, the target may be exchanged in a state where the second material supply unit  530  is not separated from the second process chamber  500 . In an exemplary embodiment, the target exchange is executed under atmospheric pressure and the exchange time is about 12 hours. 
         [0060]    When the buffer chamber  550  is coupled in series between the first and third process chambers  400  and  600 , the process that was stopped during the mode change period begins. The substrate  10  from the first process chamber  400  passes through the buffer chamber  550  and is transferred to the third process chamber  600 , and the intermediate layer is formed on the substrate  10 . Next, the substrate  10  is transferred to the fourth process chamber  700 , and the upper molybdenum layer is formed on the substrate  10 . 
         [0061]    If the aluminum target of the third material supply unit  630  is exhausted, the mode is converted. That is, the sputtering process is temporary stopped, the third process chamber  600  and the buffer chamber  650  move downwardly along the rail  70 , and the second process chamber  500  and the buffer chamber  550  move upwardly. Thus, the first process chamber  400  and the second process chamber  500  are connected to each other through the valve  90 , and the buffer chamber  650  is connected between the second process chamber  500  and the fourth process chamber  700 . In an exemplary embodiment, the process for forming the intermediate aluminum layer is executed in the second process chamber  500 , and the buffer chamber  650  provides the transfer space of the vacuum state. 
         [0062]    Accordingly, in exemplary embodiments of the present invention, the process is stopped only during the mode change period. Furthermore, maintenance of the second and third process chambers  500  and  600  can be performed during the exchange of the target  437 . 
         [0063]    Although exemplary embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the present invention should not be limited thereto and that various other changes and modifications may be affected therein by one of ordinary skill in the related art without departing from the scope or spirit of the invention. All such changes and modifications are intended to be included within the scope of the invention.