Substrate processing apparatus

Provided is a substrate processing apparatus wherein, even if a trouble occurs, it is bound to continue a process for the substrate without stopping the substrate processing apparatus entirely. The substrate processing apparatus according to the present disclosure includes first and second substrate conveying devices configured to convey wafers, and first and second processing blocks provided on the right and left sides of the substrate conveying device and having processing unit arrays each configured to perform the same process. Processing unit arrays on one side and processing unit arrays on the other side are respectively connected to a processing liquid supply system commonly provided with them. And, when any one of substrate conveying devices, processing liquid supply systems has a problem, the process for the wafer can be performed in the processing unit array to which the substrate conveying device and the processing liquid supply system under normal operation belong.

This application is based on and claims priority from Japanese Patent Application No. 2009-232056 filed on Oct. 6, 2009 with the Japanese Patent Office, the disclosure of which is incorporated herein in its entirety by reference.

TECHNICAL FIELD

The present disclosure relates to a technology in which a substrate transferring device is used for transferring substrates such as semiconductor wafers, for example, to a plurality of processing units performing a fluid processing such as a liquid processing or a surface processing for the substrates and then the substrates are processed.

BACKGROUND

In a process for manufacturing a semiconductor device etc., a liquid processing has been known that supplies the surface of a substrate such as a semiconductor wafer (hereinafter, referred to as “wafer”) with a processing liquid such as a chemical liquid or deionized water (DIW) to remove particles or contaminants adhered on the substrate.

As an example of a liquid processing apparatus configured to perform this liquid processing, a liquid processing apparatus has been known that places substrates on a spin-chuck one by one, supplies a processing liquid to the surface of the substrate while rotating the substrate, thereby performing the liquid processing. For example, there is a liquid processing apparatus of this type in which the substrates are transferred to a plurality of liquid processing units capable of performing the same kind of liquid processing by using a common substrate transfer device, and the substrates are continuously replaced while performing the liquid processing by the plurality of liquid processing units thereby improving the number of substrates (throughputs) processed per unit time. See, for example, Japanese Patent Laid-open Publication No. 2008-34490, paragraph [0020] andFIG. 1.

The present inventors have considered a method that significantly increases the throughput of the liquid processing apparatus having such a structure, and increases the number of substrates capable of being processed in parallel by providing a plurality of processing blocks each configured to transfer substrates to the plurality of liquid processing units by using a common substrate transferring device, in one liquid processing apparatus.

However, as the number of substrates capable of being processed in one liquid processing apparatus is increased, losses are increased by stopping the liquid processing apparatus when either one of liquid processing unit, a substrate transfer device, or a processing liquid supply system for liquid processing unit and the like has a trouble. In particular, in a case when a plurality of processing blocks are provided within the liquid processing apparatus as described above, although it would be possible to continue the operation of the processing blocks except a trouble point, an opportunity loss will occur upon stopping the entire apparatus, thereby disturbing the effective operation of the liquid processing apparatus.

Here, Japanese Patent Application Laid-open Publication No. 2004-87675 (paragraph [0040], [0108],FIGS. 1 to 3) discloses a coating and developing apparatus that performs a series of process, such as a coating process of an applying liquid to a semiconductor wafer, a heating process, and a developing process after the exposure. In particular, the coating and developing apparatus is provided with a plurality of processing lines configured to perform a series of processes, and it is possible to continue operating the residual processing lines even when a device included in one processing line is out of order.

In the coating and developing apparatus described in Japanese Patent Application Laid-open Publication No. 2004-87675, when any device belonging to each processing line is broken, the processing line containing the broken device needs to be stopped entirely, regardless of the broken point. In contrast, as described above, in a case where there are provided a plurality of liquid processing blocks each configured to transfer substrates to a plurality of liquid processing units by means of one substrate transfer device, even when a trouble occurs in the device needed to operate a certain liquid processing block, it is sometimes possible to continue the liquid processing by other liquid processing units included in the liquid processing block. As a result, it is often the case that the liquid processing apparatus cannot be operated efficiently despite of applying the technique described in Japanese Patent Application Laid-open Publication No. 2004-87675.

SUMMARY

According to an exemplary embodiment, there is provided a substrate processing apparatus including (a) a substrate introduction block having a container placement portion configured to place a substrate storage container having substrates stored therein, and a transfer device configured to transfer the substrates with the substrate storage container placed on the container placement portion; (b) a first processing block placed adjacent to the substrate introduction block, configured to process the substrates received from the substrate introduction block, and having a first substrate conveying device configured to convey the substrates along a straight conveying path, and a first processing unit array comprised of a plurality of processing units each configured to perform the same process with a processing liquid, where the first processing unit array is provided at both sides of the first substrate conveying device, and the substrates are conveyed to the plurality of processing units of the first processing unit array by the first substrate conveying device; (c) a second processing block placed adjacent to the first processing block, configured to process the substrates received from the substrate introduction block, and having a second substrate conveying device configured to convey substrates along a straight conveying path, and a second processing unit array comprised of a plurality of processing units each configured to perform the same process as the plurality of processing units of the first processing unit, where the second processing unit array is provided at both sides of the second substrate conveying device, and the substrates are conveyed to the plurality of processing units of the second processing unit array by the second substrate conveying device; (d) a first processing fluid supply system commonly provided with respect to the first processing unit array of one side at the first processing block and the second processing unit array of one side at the second processing block; (e) a second processing fluid supply system commonly provided with respect to the first processing unit array of the other side at the first processing block and the second processing unit array of the other side at the second processing; and (f) a control unit configured to process the substrates using the other processing block when one of the first and second substrate conveying devices has a trouble, and to process the substrates using the processing unit array that belongs to a processing fluid supply system having no trouble when one of the first and second processing fluid supply systems has a trouble.

DETAILED DESCRIPTION

The present disclosure is accomplished in view of such circumstances, and aims to provide a substrate processing apparatus in which even when a trouble occurs, it is possible to continue performing a substrate processing without stopping the substrate processing apparatus entirely.

According to an aspect of the present disclosure, there is provided a substrate processing apparatus including (a) a substrate introduction block having a container placement portion configured to place a substrate storage container having substrates stored therein, and a transfer device configured to transfer the substrates with the substrate storage container placed on the container placement portion; (b) a first processing block placed adjacent to the substrate introduction block, configured to process the substrates received from the substrate introduction block, and having a first substrate conveying device configured to convey the substrates along a straight conveying path, and a first processing unit array comprised of a plurality of processing units each configured to perform the same process with a processing liquid, where the first processing unit array is provided at both sides of the first substrate conveying device, and the substrates are conveyed to the plurality of processing units of the first processing unit array by the first substrate conveying device; (c) a second processing block placed adjacent to the first processing block, configured to process the substrates received from the substrate introduction block, and having a second substrate conveying device configured to convey substrates along a straight conveying path, and a second processing unit array comprised of a plurality of processing units each configured to perform the same process as the plurality of processing units of the first processing unit, where the second processing unit array is provided at both sides of the second substrate conveying device, and the substrates are conveyed to the plurality of processing units of the second processing unit array by the second substrate conveying device; (d) a first processing fluid supply system commonly provided with respect to the first processing unit array of one side at the first processing block and the second processing unit array of one side at the second processing block; (e) a second processing fluid supply system commonly provided with respect to the first processing unit array of the other side at the first processing block and the second processing unit array of the other side at the second processing; and (f) a control unit configured to process the substrates using the other processing block when one of the first and second substrate conveying devices has a trouble, and to process the substrates using the processing unit array that belongs to a processing fluid supply system having no trouble when one of the first and second processing fluid supply systems has a trouble.

The substrate processing apparatus may include the following features.

When a trouble occurs at a processing unit, the control unit may control to stop using the processing unit array containing the processing unit and process the substrates by another processing unit array.

The first processing block and the second processing block may be stacked on each other.

The second processing block may be provided on the opposite side of the substrate introduction block with respect to the first processing block.

The substrate processing apparatus further includes, a substrate placement portion configured to transfer substrates between the first processing block and the second processing block; a first interblock conveying device provided independently of the first conveying device, and configured to convey the substrates received from the substrate introduction block to the first processing block or the substrate placement portion; and a second interblock conveying device provided independently of the second conveying device, and configured to convey the substrates placed on the substrate placement portion to the second processing block.

According the present disclosure, the combination of processing unit array in which the substrates are transferred by each substrate conveying device differs from the combination of processing unit array that is connected to each processing fluid supply system commonly provided. Therefore, even when a trouble occurs at one substrate conveying device, for example, it is possible to continue processing substrates using the other substrate transfer device, and in this state, even though a further trouble occurs at one processing fluid supply system, there is at least a processing unit array left being able to continue processing the substrates using the other substrate transfer device and the other processing fluid supply system with no trouble. As a result, it is possible to increase the possibility to continuously process the substrates without stopping the substrate processing apparatus entirely for an occurred trouble.

Hereinafter, an exemplary embodiment as a non-limiting example of the present disclosure will be described with reference to appended drawings. In all of the appended drawings, the same or corresponding members (or components) are designated with the same or corresponding reference numerals to omit repeated descriptions.

As a liquid processing apparatus according to the present disclosure, a liquid processing apparatus1will be described with reference toFIGS. 1 to 7. Liquid processing apparatus1is configured to supply a chemical liquid as a processing liquid to a wafer W as a substrate to perform a liquid processing for removing particles or contaminants adhered on the substrate.FIG. 1is a cross-sectional plan view showing the entire configuration of liquid processing apparatus1,FIG. 2is a longitudinal sectional side view of the same. Assuming that the left side in these figures is the front side, liquid processing apparatus1has a placement block11configured to place FOUP (Front-opening Unified Pod)7as a substrate storage container having a plurality of wafers W stored therein, a transfer block12configured to take wafer W out of FOUP7and to carry the wafer into liquid processing apparatus1, a transfer block13configured to transfer wafer W taken out by conveying block12into a liquid processing block14a,14bat the rear stage, and liquid processing block14a,14bconfigured to carry wafer W transferred from transfer block13into liquid processing unit2and to perform a liquid processing. It is noted that the components are connected in this order from the front side. Herein, in view of the throughput enhancement, liquid processing apparatus1according to the present embodiment includes two liquid processing blocks14a,14bstacked on each other (disposed adjacent to each other) in a vertical direction. For example, in the present embodiment, liquid processing block14ain the upper stage side corresponds to the first processing block, and liquid processing block14bin the lower stage side corresponds to the second processing block.

Placement block11is constructed as a placement table capable of placing, for example, four FOUPs7, and serves as a container placement portion that fixes each FOUP7placed on the placement table and connects it to transfer block12. Transfer block12is configured to provide an opening/closing device (not shown) configured to open/close an open/close door provided in a connection surface with each FOUP7and a carry-in/carry-out arm121configured to transfer wafer W between FOUP7and transfer block13within a common casing.

For example, carry-in/carry-out arm121has a transfer arm configured to advance/retreat in the front/rear directions, to move in the right/left directions, to rotate and to elevate and a driving unit thereof. Carry-in/carry-out arm121serves to transfer wafer W between transfer block13through a first opening123provided in a partition wall for defining transfer block12from transfer block13.

Transfer block13is a space within the casing provided at the position interposed between transfer block12and liquid processing blocks14a,14bin the front/rear direction. For example, transfer block13is provided with a first transfer shelf133connected to first opening123at transfer block12side, and second transfer shelves131a,131beach located above and below first transfer shelf133and configured to transfer wafer W before and after a liquid processing between first transfer shelf133and second openings132a,132bprovided in the partition wall at each liquid processing block14a,14bside. For example, eight wafers W can be placed on each second transfer shelf131a,131b, and each second transfer shelf131a,131bis provided at the upper position and the lower position in the space of transfer block13. Each second transfer shelf131a,131bplays a role to temporarily place wafer W introduced from transfer block12side and wafer W delivered out of liquid processing blocks14a,14bsides.

Further, as shown inFIG. 1, transfer block13is provided at its inner space with an elevate-transfer device134configured to move in the vertical directions and to advance/retreat in the front/rear directions. Elevate-transfer device134plays a role to transfer wafer W between first transfer shelf133and second transfer shelves131a,131b.

Placement block11, transfer block12, and transfer block13described above constitute a substrate introduction block of the present embodiment.

In the rear end of transfer block13and adjacent to transfer block13, two liquid processing blocks14a,14bare stacked vertically. Each configuration of liquid processing blocks14a,14bis substantially equivalent to each other, and a plurality of, for example, twelve liquid processing units2configured to perform a liquid processing for wafer W are disposed within the casing. Each liquid processing block14a,14bis provided with transfer paths142a,142bas straight conveying paths of wafer W extending in the front/rear direction, and six liquid processing units2are arranged in a row on opposite sides of conveying paths142a,142b, respectively.

As shown inFIGS. 1 and 3, each transfer path142a,142bis provided with process arms141a,142bwhich are allowed to move along conveying paths142a,142bto advance towards and retreat from each liquid processing unit2provided at left and right sides of conveying paths142a,142b, allowed to rotate about a vertical axis, and allow to elevate up/down. Each process arm141a,142bcorresponds to the first and second substrate transfer devices of the present embodiment, and can transfer wafer W between the second transfer shelf131a,131bcorresponding to each liquid processing block14a,14bat transfer block13side and each liquid processing unit2. Herein, inFIGS. 1 to 3, each liquid processing block14a,14bis provided with one process arm141a,141b, but may be provided with two or more process arms141a,141bdepending on the number of liquid processing unit2.

In summary for the above description, in liquid processing apparatus1of the present embodiment, twelve liquid processing units2are provided in liquid processing block14aof the upper stage side and twelve liquid processing units2are provided in liquid processing block14bof the lower stage side, so the total number of liquid processing unit2is 24, as shown inFIGS. 1 to 3. Also, in liquid processing block14aof the upper stage side, the common process arm141acarries-in/carries-out wafer W with respect to liquid processing unit2included in a first liquid processing unit array U1having six liquid processing units2that are arranged in a row on the right side of conveying path142aand a second liquid processing unit array U2having six liquid processing units2that are arranged in a row on the left side of conveying path142a, as seen from the front. Also, in liquid processing block14bof the lower stage side, the common process arm142acarries-in/carries-out wafer W with respect to liquid processing unit2included in a third liquid processing unit array U3having six liquid processing units2that are arranged in a row on the right side of conveying path142band a fourth liquid processing unit array U4having six liquid processing units2that are arranged in a row on the left side of conveying path142b, as seen from the front.

Next, the configuration of liquid processing unit2provided in each liquid processing block14a,14b, the supply system for supplying a chemical liquid to each liquid processing unit2and the collecting system for collecting the chemical liquid will be described with reference toFIGS. 4 and 5. Liquid processing unit2is provided with an outer chamber21configured to form an enclosed processing space where each of a liquid processing, a rinse cleaning and a spin drying for wafer W is done, a wafer holding device23provided in outer chamber21and configured to rotate wafer W while holding it substantially horizontally, a nozzle arm24configured to supply a chemical liquid to the upper surface of wafer W held by wafer holding device23, and an inner cup22provided within outer chamber21to surround wafer holding device23and configured to receive the chemical liquid scattered from the rotating wafer W to the surrounding area.

Outer chamber21is provided within a casing separated from another liquid processing unit2placed adjacent to each other, as shown inFIGS. 1 to 3. Wafer W is carried-in/carried-out by process arm141a,141bthrough a wafer introduction opening which is not shown. Reference numeral26denotes a drain line configured to discharge a drained water, such as DIW (deionized water), gathered in the bottom surface of outer chamber21and reference numeral27denotes an exhaust line configured to discharge an atmosphere within outer chamber21, which are provided in the bottom surface of outer chamber21. Also, wafer holding device23is formed at its interior with a chemical liquid supply path231through which a chemical liquid can be supplied to the lower surface of the rotating wafer W.

A nozzle for supplying a chemical liquid is provided at the front end of nozzle arm24and is movable by a driving device (not shown) between an upper position located at the center side of wafer W held by wafer holding device23and a standby position located outside of outer chamber21, for example. Inner cup22elevates up/down direction between a processing position surrounding wafer W held by wafer holding device23and a retreat position retreated downwards from the processing position, and plays a role to receive various chemical liquids supplied to the surface of rotating wafer W and thus to discharge the chemical liquids to the outside of liquid processing unit2through a drain line25provided in the bottom surface of inner cup22.

Next, a mechanism for supplying a chemical liquid to each liquid processing unit2will be described. The nozzle provided in nozzle arm24is connected with an upper-side supply line47, and upper-side supply line47branches into an IPA supply line411and a chemical liquid supply intermediate line44. IPA supply line411is connected with an IPA supplying portion31, and IPA supplying portion31plays a role to supply IPA for drying wafer W with its high volatility to the upper surface side of wafer W. A mass flow controller42is provided in IPA supply line411, and thereby a predetermined amount of IPA can be supplied to nozzle arm24a.

Other chemical liquid supplying intermediate line44that is branched from upper-side supply line47is connected with chemical liquid supply lines412,413,414of three way systems via a switching valve43. A DIW supplying portion32configured to supply DIW (DeIonized Water) as a rinse solution for removing DHF solution or SC1 solution remained in wafer W after the chemical liquid processing is provided in the upstream side of a DIW supply line412. A SC1 supplying portion33configured to supply SC1 solution (a mixing solution of ammonia and oxygenated water) as a chemical liquid for removing particles and organic contaminants adhered on the surface of wafer W is provided the upstream side of a SC1 supply line413. And, a DHF supplying portion34configured to supply a diluted hydrofluoric acid aqueous solution (hereinafter referred to as “DHF solution”) as an acidic solution for removing a natural oxide film on the surface of wafer W is provided in the upstream side of a DHF supply line414.

Further, chemical liquid supplying intermediate line44connected with DIW supplying portion32, SC1 supplying portion33and DHF supplying portion34is also connected with chemical liquid supplying path231configured to supply the chemical liquid to the lower surface of wafer W, via a lower-side supply line48. InFIG. 4, a mass flow controller configured to control the supply amount of the chemical liquid to nozzle arm24side is designated by a reference numeral45, and a mass flow controller configured to control the supply amount of the chemical liquid to wafer holding device23side is designated by a reference numeral45.

For example, IPA supplying portion31, DIW supplying portion32, SC1 supplying portion33and DHF supplying portion34described above are disposed together within a common chemical liquid supplying unit3a,3b, and these supplying portions31,32,33,34as a whole are illustrated together inFIG. 5, for example. Herein, in liquid processing apparatus1according to the present embodiment, first liquid processing unit array U1and third liquid processing unit array U3stacked vertically on the right side of conveying paths142a,142b, as seen from the front, are connected with common chemical liquid supplying unit3a, and second liquid processing unit array U2and fourth liquid processing unit array U4stacked vertically on the left side of conveying path142a,142bas seen from the front, are connected with common chemical liquid supplying unit3b, as shown inFIGS. 3 and 5. These common chemical liquid supplying units3a,3bcorrespond to a supply system of a processing fluid in the present embodiment, and each supply system is commonly provided with respect to liquid processing unit arrays U1, U3and U2, U4.

As described above, chemical liquid supplying units3aand3bare connected respectively with liquid processing unit arrays U1, U3and U2, U4on opposite sides of conveying paths142a,142b. So, for example, each supply line411-414and the like can be disposed without interfering with process arm141a,141b, the power supply system thereof and the like. Consequently, there are advantages that the piping design can be simplified and the piping length can be shortened. Furthermore, for the convenience of illustration,FIG. 5shows representatively the state that chemical liquid supplying unit3ais connected with liquid processing unit arrays U1, U3, but chemical liquid supplying unit3band liquid processing unit arrays U2, U4are connected to each other in the same way.

As generally illustrated inFIG. 5, supplying portions31,32,33,34of each chemical liquid have a configuration that a supply pump302, a filter303and a heater304are provided in a chemical liquid supply line401connected with a circulation tank301accommodating various chemical liquids. And, at the downstream side thereof, chemical liquid supply line401branches into branch lines402connected with each liquid processing unit2of liquid processing block14a,14b. Chemical liquid supply lines401and branch lines402correspond to each supply line412˜413shown inFIG. 4. For example, the branch lines402of each chemical liquid supply line401join together at switching valve43provided at the lower side of each liquid processing unit2.

Meanwhile, drain line25provided in the bottom portion of inner cup22of each liquid processing unit2is connected, for example, via a switching valve (not shown), with a chemical liquid collecting line403configured to collect a chemical liquid to circulation tank301of each supplying portion31,33,34. Therefore, a used chemical liquid can be collected. Further, drain line26of outer chamber21is connected with, for example, a drained water processing equipment of a factory, and does not collect a drained water, instead of collecting a drained water through chemical liquid collecting line403to circulation tank301of DIW supplying portion32, unlike the chemical liquid collection line403of each chemical liquid supplying portions31,33,34shown inFIG. 5.

Chemical liquid supplying units3a,3bof the above configuration can be disposed, for example, below a floor of a factory at which liquid processing apparatus1is located.FIG. 3shows schematically the arrangement of chemical liquid supplying unit3a,3bconnected with liquid processing unit arrays U1, U3and U2, U4. InFIG. 3, chemical liquid supply line401connected with supplying portion31,32,33,34of each chemical liquid is shown briefly as one pipe. Further, chemical liquid collecting line403is not shown inFIG. 3.

As shown inFIG. 1, a control unit6is connected to liquid processing apparatus1. For example, control unit6includes a computer including a CPU and a memory device which stores a program including a group of control steps (commands) related to the operation of liquid processing apparatus1, and to the movements from the time of carrying wafer W into liquid processing unit2of each liquid processing block14a,14band performing a liquid processing to the time of accommodating wafer W after the liquid processing within FOUP7. This program is stored at a storage medium such as hard disk, compact disk, magneto optical disk, and memory card, and is installed into computer via the storage medium.

Liquid processing apparatus1having the configuration described above is configured to, when process arms141a,141bor chemical liquid supplying units3a,3b, etc., for example, has a trouble, stop the operation of only liquid processing unit2affected by this trouble, and continue operating the other liquid processing unit2. Hereinafter, an explanation of the detailed configuration thereof will be given.

FIG. 6is a block diagram illustrating the electrical configuration of liquid processing apparatus1. Each liquid processing unit2, chemical liquid supplying unit3a,3b, process arm141a,141b, and carry-in/carry-out arm121is connected with control unit6(which includes, for example, a CPU61and a memory device62) described above, and thereby the trouble occurred in these components2,3a,3b,141a,141b,121can be detected.

Also, liquid processing units2in liquid processing apparatus1that belong to each liquid processing unit array U1˜U4, are connected to a separate power supply unit5, and each power supply unit5assigned to each liquid processing unit array U1˜U4is configured to supply/shutout the electric power to each liquid processing unit2on the basis of the instructions from control unit6.

For example, a stop/operate control program621is stored in memory device62of control unit6. For example, depending on the component2,3a,3b,141a,141b,121where a trouble occurs, stop/operate control program621is configured to change liquid processing unit array U1˜U4in which electric power is to be shutout, with reference to, for example, a group classification table622stored in memory device62, and continue liquid processing wafer W by means of liquid processing unit2that belongs to liquid processing unit array U1˜U4in which the electric power is to be supplied.

FIG. 7shows an example of group classification table622according to the present embodiment. In this table622, each row denotes a component where a trouble occurs, and each column denotes a liquid processing unit arrays U1˜U4to be stopped depending on the component where a trouble has occurred. In this Figure, “O” denotes that liquid processing unit2continues operating, and “X” denotes that liquid processing unit2stops.

According to group classification table622ofFIG. 7, when liquid processing unit2that belongs to each liquid processing unit array U1˜U4has a trouble, each liquid processing unit array U1˜U4including liquid processing unit2with a trouble is only to be stopped, and liquid processing units2of the other liquid processing unit array U1˜U4continue operating. The fact that liquid processing unit array U1˜U4other than the stopped liquid processing unit array U1˜U4continues operating, can be also applied to the other components described below.

For process arm141a,141b, liquid processing unit arrays U1, U2are to be stopped in a case that process arm141ain the upper stage (denoted as “PA1” inFIG. 7) has a trouble, and liquid processing unit arrays U3, U4are to be stopped in a case that process arm141bin the lower stage (denoted as “PA2” inFIG. 7) has a trouble. For chemical liquid supplying unit3a,3b, liquid processing unit arrays U1, U3are to be stopped in a case that chemical liquid supplying unit3a(denoted as “CU1” inFIG. 7) on the right side, as seen from the front, has a trouble, and liquid processing unit arrays U2, U4are to be stopped in a case that chemical liquid supplying unit3b(similarly denoted as “CU2” inFIG. 7) on the left side, as seen from the front, has a trouble.

Further, in a case that carry-in/carry-out arm121has a trouble, the operation to carry wafer W into any liquid processing block14a,14bat the rear stage and the operation to carry wafer W out from the same cannot be performed, so all liquid processing unit arrays U1˜U4are to be stopped.

Hereinafter, the operation of liquid processing apparatus1having the configuration as described above will be described. When liquid processing apparatus1begins a process, carry-in/carry-out arm121takes out wafer W from FOUP7placed on placement block11, and disposes wafer W within first transfer shelf133. Elevate-transfer device134takes out wafer W from first transfer shelf133, and disposes sequentially wafer W in second transfer shelf131a,131bcorresponding to each liquid processing block14a,14b.

Process arms141a,141bin each liquid processing block14a,14breceives wafer W from second transfer shelf131a,131b, enters into one of liquid processing units2, and delivers wafer W to wafer holding device23. When wafer W is held, nozzle arm24is moved to the upper position located at the center side of wafer W, and inner cup22is elevated to the processing position. At this time, a SC1 solution is supplied from the nozzle on wafer holding device23side and chemical liquid supplying path231within wafer holding device23side to both the upper and lower surfaces of wafer W, while wafer holding device23rotates wafer W. As a result, a liquid film of the chemical liquid is formed on wafer W, and thereby a cleaning is performed by an alkaline chemical liquid.

When the cleaning with the alkaline chemical liquid is completed, inner cup22is moved towards the retreat position, a rinse cleaning for removing the SC1 solution on the surface of wafer W is performed by supplying DIW to inner cup22and chemical liquid supplying path231of wafer holding device23.

When the rinse cleaning is completed, a spin drying is performed, and then inner cup22is elevated to the processing position again. At this time, a DHF solution is supplied from nozzle arm24and chemical liquid supplying path231in wafer holding device23to the upper and lower surfaces of wafer W, while wafer holding device23rotates wafer W. As a result, a liquid film of the DHF solution is formed on the upper and lower surfaces of wafer W, and thereby a cleaning is performed by an acidic chemical liquid. After a predetermined time is elapsed, inner cup22is moved down towards the retreat position, the supply system for supplying the chemical liquid is switched to a DIW supplying mode, and then the rinse cleaning is performed again.

After the rinse cleaning is performed, inner cup22is elevated to the processing position, an IPA is supplied to the upper surface of wafer W, while rotating wafer W, and thereby an IPA dry is performed using a volatility of the IPA. And thus, a residual DIW on the surface of wafer W after the rinse cleaning is removed entirely from wafer W. And then, inner cup22retreats to the retreat position, a carry-in/carry-out port which is not shown is opened, process arm141a,141benters into liquid processing unit2, and then processed wafer W is taken out.

Processed wafer W after the liquid processing is transferred to second transfer shelf131a,131b, vertical conveying device134, first transfer shelf133and carry-in/carry-out arm121according to the opposite route as compared when wafer W is carried in, and then is accommodated in FOUP7on placement block11. By performing these operations successively, liquid processing apparatus1operates concurrently total 24 liquid processing units2in liquid processing block14aof the upper stage and liquid processing block14bof the lower stage. For example, in the present liquid processing apparatus1, the number of wafer W to be cleaned/dried in a unit time can be increased, in comparison with the conventional liquid processing apparatus that is provided with one set of liquid processing block14a(e.g. twelve liquid processing units2).

On the basis of the operations described above, the operation of liquid processing apparatus1performing a liquid processing for wafer W, in a case that a predetermined component of liquid processing apparatus1has a trouble, will be described with reference to the flow diagram ofFIG. 8andFIGS. 9,10.

First, liquid processing apparatus1starts an operation (start), and then monitors whether or not each component2,3a,3b,141a,141b,121shown in block diagram ofFIG. 6, for example, has a trouble. And, when there is no trouble (Step S101; NO), liquid processing apparatus1continues the operation as it is.

When a trouble occurs (Step S101: YES), it is checked whether the trouble has occurred in liquid processing unit2. In a case that the trouble is related to liquid processing unit2, for example as in a case of malfunction of a rotation driving unit of wafer holding device23, a wafer W transfer device and the like (Step S102; YES), only liquid processing unit array U1˜U4including liquid processing unit2with a trouble (Step S105) is to be stopped, and then a responding operation for the trouble is finished (End).

For example,FIG. 9(a) shows the operating state of each liquid processing unit array U1˜U4when liquid processing unit2belonging to liquid processing unit array U1has a trouble. In this Figure, liquid processing unit array U1painted gray denotes that it has been stopped. At this time, in liquid processing unit array U1which has been stopped, an access door provided in the surface of a casing of liquid processing blocks14a,14b, for example constituting a sheathing body of liquid processing unit array U1, can be opened and maintenance of liquid processing unit2having a trouble can be performed, while the other three liquid processing unit arrays U2˜U4continues operating. By stopping the entire liquid processing unit array U1˜U4including liquid processing unit2with a trouble, a maintenance staff can be protected from an exposure to an atmosphere where a chemical liquid is supplied when the access door is opened.

Referring back to the description of the flow diagram inFIG. 8, if it is determined that the trouble is not related to liquid processing unit2(Step S102; NO), then it is checked whether the trouble occurs in process arms141a,141b. When the trouble occurs in process arms141a,141b, for example, in a case of a driving device malfunction (Step S103; YES), process arm141a,142bhaving a trouble is to be stopped based on group classification table622, along with the corresponding liquid processing unit arrays U1, U2(or liquid processing unit arrays U3, U4) (Step S106), and then a responding action for the trouble is completed (End).FIG. 9(b) shows the operating state of each liquid processing unit array U1˜U4, when process arm141ain the upper stage side has a trouble.

If it is determined that the trouble is not related to process arm141a,141b(Step S103; NO), then it is checked whether the trouble occurs in chemical liquid supplying unit3a,3b. When the trouble occurs in chemical liquid supplying unit3a,3b, for example, in a case of a liquid level down in circulation tank301, a stop of supply pump302, increase of pressure loss of filter303(Step S104; YES), and the like, chemical liquid supplying unit3a,3bhaving a trouble is to be stopped based on group classification table622, along with the corresponding liquid processing unit arrays U1, U3(or liquid processing unit arrays U2, U4) (Step S108), and then a responding action for the trouble is finished (End).FIG. 10(a) shows the operating state of each liquid processing unit array U1˜U4, when chemical liquid supplying unit3aon the right side as seen from the front has a trouble. Herein, in the configuration of liquid processing unit2according to the present embodiment, the trouble of liquid processing unit2(Step S105) includes the trouble of switching valve43or mass flow controller45,46and the like, as shown inFIG. 5.

If it is determined that the trouble is not related to any one of liquid processing unit2, process arm141a,141band chemical liquid supplying unit3a,3b(Step S104; NO), then the trouble is related to a driving device of carry-in/carry-out arm121, etc., for example. For this reason, all of liquid processing unit arrays U1˜U4are to be stopped (i.e., the processing apparatus1is to be stopped entirely) (Step S107), and then a responding action for the trouble is finished (End).FIG. 10(b) shows the operating state of each liquid processing unit array U1˜U4, when carry-in/carry-out arm121has a trouble.

As such, depending on the component2,3a,3b,141a,141b,121where a trouble occurs, only liquid processing unit2affected by the trouble is to be stopped. As a result, for example, if a maintenance staff settles the trouble of the corresponding component and the operation start state can be achieved, then a restoring signal is inputted to control unit6, for example, and the operation of the stopped liquid processing unit array U1˜U4is resumed (start). And then, while one of process arms141a,141bis stopped, for example, even when one of chemical liquid supplying units3a,3bis further stopped, there is at least one liquid processing unit array U1, U2left being able to continue operating with the other process arm141b,141aand the other chemical liquid supplying unit3b,3a, and thereby a liquid processing can be performed continuously in liquid processing unit2of liquid processing unit array U1, U2having no trouble.

Liquid processing apparatus1according to the present embodiment has the following effects. The combination of liquid processing unit array to which the substrate is transferred by each substrate conveying device differs from the combination of liquid processing unit array that is connected to each processing fluid supply system commonly provided. On this account, for example, even when a trouble occurs in one of process arms141a,141b, it is possible to perform a liquid processing of wafer W continuously using the other process arm141b,141a, and in this state, even though a further trouble occurs in one of chemical liquid supplying units3a,3b, there is at least liquid processing unit array U1˜U4left capable of performing the liquid processing of wafer W continuously using the other process arm141b,141aand the other chemical liquid supplying unit3b,3ahaving no trouble. As a result, it is possible to increase the possibility to perform the liquid processing of wafer W continuously without stopping liquid processing apparatus1entirely for an occurred trouble.

FIGS. 11 to 13show a configuration of a liquid processing apparatus1aaccording to a second embodiment. Liquid processing apparatus1aaccording to the second embodiment is different from liquid processing apparatus1described above having two liquid processing blocks14a,14bstacked vertically, in that two liquid processing blocks14a,14bin the rear stage of transfer block13are disposed in the front/rear direction. In other words, liquid processing block14b(the second processing block) is provided on the opposite side to transfer block13(the substrate introduction block) with respect to liquid processing block14a(the first processing block). In liquid processing apparatus1ashown inFIGS. 11 to 13, the same components as those in liquid processing apparatus1shown inFIGS. 1 to 3are designated with the same reference numerals.

Each liquid processing block14a,14bis provided with liquid processing unit arrays U1˜U4on the right and left sides of a central conveying path142a,142bwhen viewed from the front, and six liquid processing units2are arranged in each liquid processing unit array U1˜U4in two rows in the front/rear directions and three stages in the vertical direction. Accordingly, in liquid processing apparatus1aof the present embodiment, twelve liquid processing units2are arranged in liquid processing block14aof the front stage side and twelve liquid processing units2are arranged in liquid processing block14bof the rear stage side, so the total number of liquid processing unit2is 24.

Also, in liquid processing block14aof the front stage side, common process arm141acarries-in/carries-out wafer W with respect to liquid processing unit2included in a first liquid processing unit array U1consisted of six liquid processing units2that are stacked in two rows in the front/back direction and three stages in the vertical direction on the right side of conveying path142awhen viewed from the front and liquid processing unit2included in a second liquid processing unit array U2having six liquid processing units2that are stacked on the left side of conveying path142ain the same manner as first liquid processing unit array U1. Also, in liquid processing block14bof the rear stage side, the common process arm141bcarries-in/carries-out wafer W with respect to liquid processing unit2included in a third liquid processing unit array U3having six liquid processing units2that are stacked on the right side of conveying path142bwhen viewed from the front and liquid processing unit2included in a fourth liquid processing unit array U2having six liquid processing units2that are stacked on the left side of conveying path142b.

In this regard, referring to the chemical liquid supplying units3a,3b, as shown inFIG. 13, first liquid processing unit array U1provided on the right side of conveying path142a(process arm141a) in liquid processing block14aof the front stage, when viewed from the front, and third liquid processing unit array U3provided on the right side of conveying path142b(or process arm141b) when viewed from the front in liquid processing block14bof the rear stage, are connected with common chemical liquid supplying unit3a. Meanwhile, second liquid processing unit array U2provided on the left side of conveying path142ain liquid processing block14aof the front stage and the fourth liquid processing unit array U4provided on the left side of conveying path142bin liquid processing block14bof the rear stage, are connected with common chemical liquid supplying unit3b.

In liquid processing apparatus1a, transfer block13has one transfer shelf131, and all of wafers W conveyed between conveying block12and liquid processing block14a,14bare placed on transfer shelf131. Also, a transfer block15is provided between liquid processing block14aof the front stage and liquid processing block14bof the rear stage, and wafer W is transferred between the front stage and the rear stage through a transfer shelf151as a substrate placement portion provided in transfer block15. Also, transfer block15is not shown inFIGS. 13 to 16.

In liquid processing block14aof the front stage, a shuttle arm143aas a first interblock conveying device is provided between liquid processing unit2in the first stage and liquid processing unit2in the second stage of liquid processing unit array U1on the right side, for example, when viewed from the front. And the first interblock conveying device is configured to convey wafer W within a space provided between the first stage and the second stage, and to transfer wafer W among transfer shelf131, process arm141aprovided in liquid processing block14aof the front stage, and transfer shelf151.

Meanwhile, in liquid processing block14bof the rear stage, a shuttle arm143bas a second interblock conveying device is provided between liquid processing unit2in the first stage and liquid processing unit2in the second stage of liquid processing unit array U3on the right side, for example, when viewed from the front. And the first interblock conveying device is configured to convey wafer W within a space provided between the first stage and the second stage, and to transfer wafer W between transfer shelf151and process arm141bprovided in liquid processing block14bof the rear stage.

By incorporating the above configuration, wafer W placed on transfer shelf131in order to perform a liquid processing in liquid processing unit2within liquid processing block14aof the front stage, is transferred from shuttle arm143a→process arm141ain this order, and then is carried into each liquid processing unit2. Meanwhile, wafer W placed on transfer shelf131in order to perform a liquid processing in liquid processing unit2within liquid processing block14bof the rear stage, is transferred from shuttle arm143a→transfer arm151→shuttle arm143b→process arm141bin this order, and then is carried into each liquid processing unit2.

Now, the operating state according to the trouble occurred at each component2,3a,3b,141a,141b,143a,143b,121of liquid processing apparatus1awith the above configuration will be described.FIG. 14(a) shows the operating state, for example, when liquid processing unit2provided in the uppermost stage of liquid processing unit array U1has a trouble. In a case that an access door for maintenance is provided in every stage of liquid processing block14a,14bas described above, it is not necessary to stop liquid processing unit array U1entirely. In this example, in liquid processing unit array U1including liquid processing unit2having a trouble, only liquid processing unit2of the stage sharing the access door is to be stopped.

When a trouble occurs in process arm141a,141b, this process arm141a,142bis to be stopped along with liquid processing unit arrays U1, U2(or U3, U4) provided on the right and left sides thereof.FIG. 14(b) shows the operating state, when process arm141aof the front stage side has a trouble.

When a trouble occurs in chemical liquid supplying unit3a,3b, this chemical liquid supplying unit3a,3bis to be stopped along with liquid processing unit arrays U1, U3(or U2, U4) connected thereto.FIG. 15(a) shows the operating state, when chemical liquid supplying unit3aon the right side as seen from the front has a trouble.

Next, when a trouble occurs at shuttle arm143aprovided in liquid processing block14aof the front stage, wafer W cannot be transferred between process arm141aof liquid processing block14aand transfer shelf151of the rear stage. For this reason, all of liquid processing unit arrays U1˜U4are to be stopped as shown inFIG. 15(b). Although not shown in the present embodiment, when carry-in/carry-out arm121is stopped, then all of liquid processing unit arrays U1˜U4are to be stopped.

Meanwhile, when a trouble occurs at shuttle arm143bprovided in liquid processing block14bof the rear stage, wafer W simply cannot be transferred only between shuttle arm143band transfer shelf151, but shuttle arm143aof the front stage side can transfer wafer W to process arm141aof liquid processing block14a. Accordingly, only liquid processing unit arrays U3, U4of liquid processing block14bare to be stopped (FIG. 16).

Herein, the number of the stages of liquid processing blocks14a,14bstacked vertically as in liquid processing apparatus1according to the first embodiment, or the number of liquid processing blocks14a,14barranged in a row in the front/rear directions as in liquid processing apparatus1aaccording to the second embodiment, is not limited to the number indicated in these embodiments. For example, liquid processing blocks14a,14bmay be provided in three or more stages, or in three or more rows, and liquid processing blocks14a,14balso may be provided by combination of arranging them in a row in the front/rear directions and stacking them in a vertical direction, such as 3 rows×3 stages.

Also, liquid processing blocks14a,14bincluding process arms141a,141bconfigured to convey wafer W in a transverse direction may be connected to each other in the front/rear directions, for example, via transfer block15, as shown in liquid processing apparatus1of the first embodiment. Alternatively, liquid processing blocks14a,14bincluding process arms141a,141bconfigured to convey wafer W in the vertical direction may be stacked on the top of each other in the vertical direction, as shown in liquid processing apparatus1aof the second embodiment. Further, if the layout of a factory allows, for example, liquid processing blocks14a,14bmay be connected to transfer block13side by side in the left/right directions as seen from the front, and chemical liquid supplying units3a,3bmay be shared among liquid processing unit arrays U1˜U2adjacent to each other.

Also, in each embodiment described above, when it is checked that a trouble occurs in each component2,3a,3b,141a,141b,143a,143b,121to be monitored, liquid processing unit arrays U1˜U4chosen on the basis of the setup of group classification table622is to be stopped immediately. However, the stop timing is not limited to the above. For example, when a trouble occurs in single liquid processing unit2, process arms141a,14ab, or carry-in/carry-out arm121, then liquid processing unit2being able to continue processing is included in liquid processing unit array U1˜U4to be stopped. In this case, after the current running processing for wafer W is completed, if the condition that wafer W can be taken out is established, then liquid processing unit arrays U1˜U4chosen can be stopped.

Further, by incorporating a configuration accessible to first transfer shelf133and also through process arms141a,141b, for example, when a trouble occurs at carry-in/carry-out arm121, liquid processing unit arrays U1˜U4may be stopped after the processing for wafer W in all of liquid processing unit arrays U1˜U4is completed, and then wafer W is taken out from each liquid processing unit2and accommodated in first transfer shelf133.

In addition, it is not limited to the case that chemical liquid supplying units3a,3bare shared in liquid processing unit arrays U1and U3, U2and U4located at the same side with respect to conveying paths142a,142b. For example, chemical liquid supplying units3a,3bmay be shared in liquid processing unit arrays U1and U4, U3and U2located at the opposite side across conveying paths142a,142b.

Also, in each embodiment described above, control unit6checks actively whether a trouble occurs in each component2,3a,3b,141a,141b,143a,143b,121, and then the supplying of electric power to liquid processing unit arrays U1˜U4chosen on the basis of group classification table622is to be shutout. However, it is not limited to the case that each of liquid processing unit arrays U1˜U4is to be stopped by actively shutting out the supplying of electric power as described above. For example, when either one of process arms141a,141bor carry-in/carry-out arm121has a trouble, each liquid processing unit2performs the processing for wafer W on the basis of a recipe, and at the time that a sequence cannot proceed further due to the stop of process arms141a,141bor carry-in/carry-out arm121, liquid processing unit arrays U1˜U4indicated in group classification table622inFIG. 7can be stopped consequently. When either one of chemical liquid supplying units3a,3bhas a trouble, because the chemical liquid cannot be supplied, even when the electric power is not shutout, liquid processing unit arrays U1˜U4connected to chemical liquid supplying units3a,3bare to be stopped at the moment of trouble occurrence.

Also, the processing using a fluid is not limited to the above liquid processing, but can be applied to, for example, a processing apparatus for hydrophobic modification of the surface of wafer W by supplying wafer W with HMDS (Hexa-Methyl-Di-Silazane) vapor and the like.