Substrate alignment apparatus, substrate processing apparatus, substrate arrangement apparatus, substrate alignment method, substrate processing method, and substrate arrangement method

In a substrate alignment apparatus, a motor sequentially rotates a plurality of substrates in a circumferential direction, the substrates being to be held in a vertical posture at a lower edge portion by a substrate holder. A controller controls the motor on the basis of warpage-and-notch-position information and input information that is input about a warped state of the substrates, to determine circumferential positions of the notches of the substrates. This reduces a distance in a thickness direction between a lower edge portion and an upper edge of each substrate that is held by the substrate holder. As a result, it is possible to facilitate handling of a plurality of substrates held by the substrate holder.

TECHNICAL FIELD

The present invention relates to a technique for aligning a plurality of substrates each having a notch in a peripheral portion.

BACKGROUND ART

Substrate processing apparatuses that perform various types of processing on substrates have conventionally been used in the process of manufacturing semiconductor substrates (hereinafter, simply referred to as “substrates”). For example, Japanese Patent Application Laid-Open No. 2010-93230 (Document 1) discloses a batch-type substrate processing apparatus that processes a plurality of substrates by one operation. With the substrate processing apparatus in Document 1, a plurality of substrates held in a horizontal posture and arranged along the thickness (hereinafter, referred to as a “thickness direction”) of the substrates are carried into the apparatus by a batch hand. Then, a posture changing mechanism changes the posture of the plurality of substrates to a vertical posture at once and then collectively transfers the substrates to a pusher. This substrate processing apparatus includes a substrate-direction alignment mechanism for aligning the directions of a plurality of substrates that are held in a vertical posture by a chuck. The substrate-direction alignment mechanism aligns a plurality of substrates so that the orientations (i.e., circumferential positions) of notches provided in peripheral portions of the substrates match one another.

Japanese Patent Application Laid-Open No. 2008-78544 (Document 2) discloses an example of the structure of a substrate alignment apparatus. This substrate alignment apparatus aligns a plurality of substrates by rotating the substrates held in a vertical posture via a driving roller and stopping the rotation when a notch of each substrate has engaged with an engagement shaft that extends in the direction of arrangement of the substrates.

By the way, substrates to be processed by a substrate processing apparatus may be warped under the influence of processing performed before transport to the substrate processing apparatus. The sizes in the thickness direction of warped substrates are larger than those of flat substrates. Thus, the substrates held in a vertical posture by, for example, the pusher of Document 1 may excessively approach or come into contact with adjacent substrates. While the aforementioned batch hand supports two side portions of the substrates in a horizontal posture from the underside, it is difficult for the batch hand to stably support and transport warped substrates.

SUMMARY OF INVENTION

The present invention is intended for a substrate alignment apparatus, and it is an object of the present invention to facilitate handling of a plurality of substrates held by a substrate holder. The present invention is also intended for a substrate alignment method.

A substrate alignment apparatus according to the present invention aligns a plurality of substrates, each substrate having a notch in a peripheral portion. This substrate alignment apparatus includes a rotor for rotating a plurality of substrates either sequentially or simultaneously in a circumferential direction, the plurality of substrates being to be held in a vertical posture at a lower edge portion by a substrate holder, a storage for storing warpage-and-notch-position information that includes a plurality of combinations of a warped state of the plurality of substrates and a notch position at which a substrate in the warped state is held in a proper posture by the substrate holder, and a controller for controlling the rotor. The controller controls the rotor on the basis of the warpage-and-notch-position information and input information that is input about the warped state of the plurality of substrates, to rotate the plurality of substrates either sequentially or simultaneously in the circumferential direction and determine positions in the circumferential direction of the notches of the plurality of substrates and thereby to reduce a distance in a thickness direction between a lower edge portion and an upper edge of each substrate that is held by the substrate holder. With this substrate alignment apparatus, it is possible to facilitate handling of a plurality of substrates held by the substrate holder.

The present invention is also intended for a substrate processing apparatus. The substrate processing apparatus includes the aforementioned substrate alignment apparatus, the substrate holder for holding the plurality of substrates aligned by the substrate alignment apparatus, and a liquid processing part for retaining a processing liquid in which the plurality of substrates held by the substrate holder are to be immersed. The present invention is also intended for a substrate processing method.

The present invention is also intended for a substrate arrangement apparatus. The substrate arrangement apparatus includes the aforementioned substrate alignment apparatus, the substrate holder for holding the plurality of substrates aligned by the substrate alignment apparatus, and a substrate arrangement mechanism for disposing each of the plurality of substrates held by the substrate holder between each pair of another plurality of substrates that are held by another substrate holder. The present invention is also intended for a substrate arrangement method.

Another substrate alignment apparatus according to the present invention aligns a plurality of substrates, each having a notch in a peripheral portion. The substrate alignment apparatus includes a rotor for rotating a plurality of substrates either sequentially or simultaneously in a circumferential direction, the plurality of substrates being to be supported in a horizontal posture at a lower surface by a substrate holder, a storage for storing warpage-and-notch-position information that includes a plurality of combinations of a warped state of the plurality of substrates and a notch position at which a substrate in the warped state is held in a proper posture by the substrate holder, and a controller for controlling the rotor. The controller controls the rotor on the basis of the warpage-and-notch-position information and input information that is input about the warped state of the plurality of substrates, to rotate the plurality of substrates either sequentially or simultaneously in the circumferential direction and determine positions in the circumferential direction of the notches of the plurality of substrates and thereby to reduce a distance in a thickness direction between a top of each substrate that is held by the substrate holder and an area of contact of the peripheral portion of the substrate with the substrate holder. With this substrate alignment apparatus, it is possible to facilitate handling of a plurality of substrates held by the substrate holder.

In the aforementioned substrate alignment apparatus, for example, each substrate is curved in a first radial direction to one side in the thickness direction with a first curvature, and is curved in a second radial direction orthogonal to the first radial direction to the one side in the thickness direction with a second curvature greater than the first curvature.

In the aforementioned substrate alignment apparatus, for example, each substrate is curved in a first radial direction to one side in the thickness direction, and is curved in a second radial direction orthogonal to the first radial direction to the other side in the thickness direction.

DESCRIPTION OF EMBODIMENTS

FIG. 1is a plan view of a substrate processing apparatus10according to an embodiment of the present invention. The substrate processing apparatus10has an approximately rectangular shape in plan view. The substrate processing apparatus10is a batch-type substrate processing apparatus that processes a plurality of semiconductor substrates9(hereinafter, simply referred to as “substrates9”) by one operation. The substrates9are approximately disc-like substrates. Each substrate9has a notch93(seeFIGS. 4 and 5) indicating a crystal orientation in a peripheral portion. The notch93has a depth of approximately 1 mm from the outer periphery of the substrate9.

The substrate processing apparatus10includes a FOUP holder1, a substrate processing part2, a main transport mechanism3, a carry-in-and-out mechanism4, a posture changing mechanism5, a pusher6, a delivery mechanism7, a substrate alignment mechanism8, a controller100, and a storage101. The controller100controls operations or other activities of each constituent element of the substrate processing apparatus10. The controller100is a general computer system that includes, for example, a CPU that performs various types of computations, a ROM that stores basic programs, and a RAM that stores various types of information. The FOUP holder1is disposed at one corner of the substrate processing apparatus10. The FOUP holder1holds a FOUP95. The FOUP95is a container that houses a plurality of (e.g., 25) substrates9in a horizontal posture, with the substrates9being stacked in the Z direction.

The Z direction inFIG. 1is a direction parallel to the direction of gravity, and is also referred to as an “up-down direction.” The X direction inFIG. 1is a direction perpendicular to the Z direction. The Y direction is a direction perpendicular to the X and Y directions. A horizontal posture of the substrates9refers to a posture in which the direction of the normal to the main surfaces of the substrates9points approximately in the Z direction. A vertical posture of the substrates9, which will be described later, refers to a posture in which the direction of the normal to the main surfaces of the substrates9points in a direction approximately perpendicular to the Z direction. In the substrate processing apparatus10, a plurality of substrates9are stacked in either a horizontal or vertical posture in a direction approximately perpendicular to the main surfaces of the substrates9. In other words, a plurality of substrates9in a horizontal or vertical posture are aligned in the thickness direction of the substrates9.

FIG. 2is an enlarged plan view of a portion on the −Y side of the substrate processing apparatus10.FIG. 3is a side view of the portion on the −Y side of the substrate processing apparatus10. In the substrate processing apparatus10, the carry-in-and-out mechanism4is disposed on the +Y side of the FOUP holder1and opposes the FOUP holder1in the Y direction as illustrated inFIG. 2. The substrate alignment mechanism8is disposed on the +Y side of the carry-in-and-out mechanism4. The FOUP holder1and the substrate alignment mechanism8are not shown inFIG. 3.

As illustrated inFIGS. 2 and 3, the posture changing mechanism5is disposed on the +X side of the carry-in-and-out mechanism4. The pusher6is disposed on the +X side of the posture changing mechanism5. The delivery mechanism7and the main transport mechanism3are disposed on the +X side of the pusher6. In the state illustrated inFIG. 3, the main transport mechanism3is located on the +Z side of (i.e., above) the delivery mechanism7. The substrate processing part2is disposed on the +Y side of the main transport mechanism3as illustrated inFIG. 1.

The substrate processing part2includes a first liquid chemical tank21, a first rinsing liquid tank22, a second liquid chemical tank23, a second rinsing liquid tank24, a dry processing part25, a first lifter27, and a second lifter28. The first liquid chemical tank21, the first rinsing liquid tank22, the second liquid chemical tank23, the second rinsing liquid tank24, and the dry processing part25are aligned in the Y direction from the +Y side to the −Y side in the specified order. The first liquid chemical tank21and the second liquid chemical tank23retain liquid chemicals of the same type or different types. The first rinsing liquid tank22and the second rinsing liquid tank24each retain a rinsing liquid (e.g., deionized water).

When the substrate processing apparatus10processes substrates9, a FOUP95that houses a plurality of (e.g., 25) substrates9in a horizontal posture is first prepared. Then, one of the plurality of (e.g., 25) substrates housed in the FOUP95is held by a single-substrate hand42of the carry-in-and-out mechanism4illustrated inFIGS. 2 and 3and carried out of the FOUP95. The single-substrate hand42holds a single substrate9in a horizontal posture. The carry-in-and-out mechanism4also includes a batch hand41that collectively holds a plurality of substrates9that are arranged in the Z direction in a horizontal posture.

Then, the single-substrate hand42rotates horizontally and moves ahead toward the substrate alignment mechanism8so that the single substrate9is transferred from the carry-in-and-out mechanism4to the substrate alignment mechanism8. The substrate alignment mechanism8rotates the substrate9in the circumferential direction to change the circumferential orientation of the substrate9and determine the circumferential position of the substrate9.

The substrate alignment mechanism8includes a substrate supporter80, a motor81, and a sensor82. The substrate supporter80rotatably supports a substrate9in a horizontal posture. The motor81is a rotor that rotates a substrate9along with the substrate supporter80. The sensor82acquires the angular position of a rotating substrate9(i.e., circumferential orientation of the substrate9) by optically detecting the notch93of the substrate9supported by the substrate supporter80. In the substrate alignment mechanism8, the motor81rotates the substrate9supported by the substrate supporter80in the circumferential direction to change the circumferential orientation of the substrate9. Then, the sensor82detects the notch93of the rotating substrate9, and the motor81is stopped with predetermined timing after the detection (i.e., after the elapse of a predetermined period of time since the detection of the notch93). Note that the predetermined period of time may be zero. In this way, the rotation of the substrate9is stopped when the notch93of the substrate9is located at a predetermined position. That is, the notch93of the substrate9is aligned in the circumferential direction. The substrate alignment mechanism8is a notch-position changing mechanism for changing the circumferential position of the notch93of the substrate9.

When the substrate alignment mechanism8has determined the circumferential position of the substrate9, the substrate9is carried out of the substrate alignment mechanism8by the single-substrate hand42and returned to the FOUP95on the FOUP holder1. Subsequently, in the same manner, the next substrate9is taken out of the FOUP95, and then returned to the FOUP95after the substrate alignment mechanism8has determined the circumferential position of the substrate9(i.e., the notch93is aligned in the circumferential direction). By repeating this operation for all of the substrates9in the FOUP95, the circumferential orientations of the substrates9in the FOUP95are changed, and the circumferential positions of the substrates9are determined. In other words, these substrates9are aligned in the circumferential direction.

In the operation of determining the circumferential positions of the substrates9, the notches93of all of the substrates9housed in the FOUP95may be located at the same circumferential position, or may be located at different circumferential positions. For example, the circumferential position of the notch93of each odd-numbered substrate9in the arrangement direction of the substrates9may be set to a first predetermined position, and the circumferential position of the notch93of each even-numbered substrate9in the arrangement direction may be set to a second predetermined position different from the first predetermined position.

When the substrate alignment mechanism8has completed the alignment of the substrates9(i.e., alignment in the circumferential direction of the notches93), the substrates9are transported out of the FOUP95by the batch hand41of the carry-in-and-out mechanism4. The batch hand41then rotates horizontally and moves ahead toward the posture changing mechanism5so that the substrates9are transferred from the carry-in-and-out mechanism4to the posture changing mechanism5. The posture changing mechanism5collectively holds the plurality of substrates9, which are stacked in the Z direction in a horizontal posture, with a horizontal holder51. The posture changing mechanism5causes a holder rotation mechanism54to rotate the plurality of substrates9by 90 degrees in the counterclockwise direction inFIG. 3about a rotational shaft541pointing in the Y direction, along with the horizontal holder51, a vertical holder52, and a mounting block53. This rotation changes the posture of the substrates9at once from horizontal to vertical. The substrates9in a vertical posture are collectively held by the vertical holder52.

Then, an up-and-down holder61is moved upward by driving a holder elevating mechanism62of the pusher6, and receives and holds the substrates9from the vertical holder52indicated by the dashed double-dotted line inFIG. 3. That is, the substrates9held in a vertical posture are transferred between the vertical holder52and the pusher6. The up-and-down holder61collectively holds the substrates9that are arranged (i.e., stacked) approximately in the X direction in a vertical posture. When the horizontal holder51and the vertical holder52of the posture changing mechanism5are rotated by 90 degrees in the clockwise direction inFIG. 3and retracted from above the holder elevating mechanism62, the up-and-down holder61is rotated horizontally by 180 degrees about a rotational shaft63pointing in the Z direction and then moved down by the holder elevating mechanism62. Accordingly, the positions in the stacking direction of the substrates9are shifted by a half of the pitch of the substrates9(i.e., a half of the distance in the stacking direction between two adjacent substrates9, which is hereinafter referred to as a “half pitch”) from the positions before the rotation.

Thereafter, in the same procedure as described above, a new plurality of (e.g.,25) substrates9housed in the FOUP95are sequentially aligned in the circumferential direction by the substrate alignment mechanism8and then transferred from the carry-in-and-out mechanism4to the posture changing mechanism5. The posture changing mechanism5collectively changes the posture of the new substrates9from horizontal to vertical. Then, the up-and-down holder61of the pusher6is again moved upward and receives and holds the new substrates9from the posture changing mechanism5. At this time, the substrates9already held by the up-and-down holder61(hereinafter, referred to as a “first substrate group”) are inserted among the new substrates9(hereinafter, referred to as a “second substrate group”) from the underside. In this way, the posture changing mechanism5and the pusher6carry out batch assembly in which the first and second substrate groups are combined into a batch.

As described above, the substrates9(hereinafter, also referred to as “first substrates9”) in the first substrate group are rotated by 180 degrees (i.e., turned around) before their insertion into the second substrate group. Thus, each of the first substrates9in the first substrate group is disposed between each pair of the substrates9(hereinafter, also referred to as “second substrates9”) in the second substrate group, with the first substrates9and second substrates9alternately arranged front-to-front and back-to-back. In other words, each pair of adjacent substrates9among the plurality of (e.g.,50) substrates9held by the up-and-down holder61are disposed such that their front surfaces or their rear surfaces face each other (i.e., they are in a face-to-face situation). The front surfaces of the substrates9may be main surfaces where circuit patterns are formed, and the rear surfaces of the substrates9may be main surfaces on the side opposite to the front surfaces.

Alternatively, when the up-and-down holder61that holds the first substrate group is only moved horizontally by the half pitch in the direction of arrangement of the substrates9without being rotated by 180 degrees before receipt of the second substrate group, the pusher6may carry out batch assembly in a state in which each pair of adjacent substrates9is disposed such that their front and rear surfaces face each other (i.e., they are in a face-to-back situation).

The substrates9assembled into a batch on the up-and-down holder61are transferred from the up-and-down holder61to a carry-in chuck71of the delivery mechanism7. The carry-in chuck71moves in the +X direction from above the holder elevating mechanism62while holding the received substrates9in a vertical posture. Subsequently, an intermediate chuck72of the delivery mechanism7moves downward to receive the substrates9from the carry-in chuck71, and then moves upward. Then, a substrate chuck31of the main transport mechanism3receives the substrates9from the intermediate chuck72. The substrate chuck31holds the substrates9that are arranged in the X direction in a vertical posture.

The main transport mechanism3transports the unprocessed substrates9held by the substrate chuck31in the +Y direction and positions the substrates9above the first lifter27of the substrate processing part2illustrated inFIG. 1. The first lifter27collectively receives the substrates9, which are arranged in the X direction in a vertical posture, from the substrate chuck31. The first lifter27moves the substrates9down into the first liquid chemical tank21and collectively immerses the substrates9in the liquid chemical retained in the first liquid chemical tank21. Immersing the substrates9in the liquid chemical for a predetermined period of time completes liquid chemical processing performed on the substrates9.

The first lifter27then pulls the substrates9up out of the first liquid chemical tank21and moves in the −Y direction. The first lifter27moves the substrates9down into the first rinsing liquid tank22and collectively immerses the substrates9in the rinsing liquid retained in the first rinsing liquid tank22. Immersing the substrates9in the rinsing liquid for a predetermined period of time completes rinsing processing performed on the substrates9. After the rinsing processing has completed, the first lifter27pulls the substrates9up out of the first rinsing liquid tank22. The substrate chuck31of the main transport mechanism3collectively receives the substrates9from the first lifter27and moves to above the second lifter28.

Like the first lifter27, the second lifter28collectively receives the substrates9from the substrate chuck31and collectively immerses the substrates9in the liquid chemical retained in the second liquid chemical tank23. After the liquid chemical processing performed on the substrates9has completed, the second lifter28pulls the substrates9up out of the second liquid chemical tank23and collectively immerses the substrates9in the rinsing liquid retained in the second rinsing liquid tank24. After the rinsing processing performed on the substrates9has completed, the second lifter28pulls the substrates9up out of the second rinsing liquid tank24. The substrate chuck31of the main transport mechanism3collectively receives the substrates9from the second lifter28and moves to above the dry processing part25.

The dry processing part25collectively receives the substrates9from the substrate chuck31and performs dry processing on the substrates9at once. The dry processing involves, for example, supplying an organic solvent (i.e., isopropyl alcohol) to the substrates9in a reduced-pressure atmosphere and rotating the substrates9to remove the liquids on the substrates9by centrifugal force. After the dry processing performed on the substrates9has completed, the substrate chuck31of the main transport mechanism3collectively receives the processed substrates9from the dry processing part25and moves in the −Y direction.

Then, a delivery chuck73of the delivery mechanism7illustrated inFIGS. 2 and 3collectively receives the substrates9from the substrate chuck31of the main transport mechanism3and moves in the −X direction to position the substrates9above the up-and-down holder61of the pusher6. The up-and-down holder61of the pusher6moves upward and receives the substrates9from the delivery chuck73. The up-and-down holder61holds the plurality of (e.g.,50) substrates9arranged in the X direction in a vertical posture.

Next, the up-and-down holder61moves downward to transfer the substrates9in a vertical posture between the pusher6and the vertical holder52. More specifically, among the substrates9, the plurality of (e.g., 25) substrates9in the second substrate group are transferred to the vertical holder52indicated by the dashed double-dotted line inFIG. 3. In other words, the batch of the first substrate group and the second substrate group is disassembled, and the first substrate group and the second substrate group are separated from each other. The horizontal holder51and the vertical holder52of the posture changing mechanism5are rotated by 90 degrees in the clockwise direction inFIG. 3. This rotation changes the posture of the substrates9in the second substrate group at once from vertical to horizontal. These substrates9are collectively held by the horizontal holder51while being stacked in the Z direction in a horizontal posture. Then, the batch hand41of the carry-in-and-out mechanism4receives the substrates9from the horizontal holder51and carries the substrates9into the FOUP95. The FOUP95into which the processed substrates9have been carried is replaced with a new FOUP95.

When the posture changing mechanism5has changed the posture of the substrates9in the second substrate group from vertical to horizontal as described above, the up-and-down holder61that holds the plurality of (e.g., 25) substrates9in the first substrate group is moved upward. The horizontal holder51and the vertical holder52that have transferred the substrates9in the second substrate group to the carry-in-and-out mechanism4are rotated by 90 degrees in the counterclockwise direction inFIG. 3.

Then, the up-and-down holder61is again moved downward to transfer the substrates9in a vertical posture between the pusher6and the vertical holder52. More specifically, the substrates9in the first substrate group are transferred to the vertical holder52indicated by the dashed double-dotted line inFIG. 3. The horizontal holder51and the vertical holder52are again rotated by 90 degrees in the clockwise direction inFIG. 3. This rotation changes the posture of the substrates9in the first substrate group at once from vertical to horizontal. These substrates9are collectively held by the horizontal holder51while being stacked in the Z direction in a horizontal posture. Then, the batch hand41of the carry-in-and-out mechanism4receives the substrates9from the horizontal holder51and carries the substrates9into the FOUP95. Note that the posture changing mechanism5may first receive the first substrate group and then receive the second substrate group in the operation of moving the substrates9from the pusher6to the posture changing mechanism5.

The posture changing mechanism5and the pusher6change the posture of the substrates9from horizontal to vertical or from vertical to horizontal as described above under the control of the controller100. In other words, the posture changing mechanism5, the pusher6, and the controller100constitute a posture changing device that changes the posture of the substrates9from one of horizontal and vertical postures to the other posture.

While the substrate processing apparatus10illustrated inFIGS. 1 to 3performs processing on the substrates9having an approximately disc-like shape as described above, these substrates9may be warped under the influence of processing (i.e., pre-processing) performed before transport of the substrates to the substrate processing apparatus10. Although various types of warpage may occur in the substrates9, a plurality of substrates9housed in a single FOUP95are generally warped in the same way. More specifically, when the positions of the notches93are used as a reference, the substrates9are in the same warped state. The warped state of the substrates9indicates information including the orientation of the warp in the substrates9(e.g., orientation in which each substrate is convex to the front surface side) and the magnitude of the warp in the substrates9.

FIGS. 4 and 5are perspective views illustrating examples of substrates9in different warped states. The substrate9inFIG. 4is curved in a first radial direction K1to one side in the thickness direction (i.e., direction in which the substrate is convex upward inFIG. 4) with a first curvature. The substrate9inFIG. 4is also curved in a second radial direction K2orthogonal to the first radial direction K1to the one side in the thickness direction (i.e., the same direction as the direction of the curve in the first radial direction K1) with a second curvature greater than the first curvature.

The substrate9inFIG. 5is curved in a first radial direction K3to one side in the thickness direction (i.e., direction in which the substrate is convex upward inFIG. 5). The first radial direction K3may be different from the first radial direction K1illustrated inFIG. 4. The substrate9inFIG. 5is also curved in a second radial direction K4orthogonal to the first radial direction K3to the other side in the thickness direction (i.e., direction opposite to the direction of the curve in the first radial direction K3).

In the following description, the warped states of the substrates9illustrated inFIGS. 4 and 5are also respectively referred to as a “first warped state” and a “second warped state.” The distance in the thickness direction between lowest and highest points in the thickness direction of each warped substrate9in a horizontal posture is referred to as the “size in the thickness direction” of the substrate9. When this substrate9is held in a vertical posture, the size in the thickness direction of the substrate9is equal to the distance in the thickness direction between a point of the substrate9that is closest to the one side in the thickness direction and a point of the substrate9that is closest to the other side in the thickness direction. When the substrate9is flat and not warped, the size in the thickness direction of the substrate9is the same as the thickness of the substrate9. The size in the thickness direction of a warped substrate9may be greater by approximately 0.5 mm than that of a flat substrate9.

Next, the procedure for aligning the substrates9by the substrate alignment mechanism8will be described with reference to the flowchart inFIG. 6. In the substrate processing apparatus10illustrated inFIG. 1, first, “warpage-and-notch-position information” is input to and stored in the storage101in advance before a plurality of substrates9are sequentially carried into the substrate alignment mechanism8(step S11). The warpage-and-notch-position information includes a plurality of combinations of a warped state, which is common to a plurality of substrates9, and a notch position at which the substrates9in the above warped state are held in a proper posture. The notch position refers to the position in the circumferential direction of the notch93of the substrate9. For example, when each substrate9is held in a vertical posture, a reference notch position (i.e., 0° notch position) indicates a state in which the notch93is located at the topmost position. When the notch93is away in the circumferential direction from the reference position, the angle in the clockwise direction between the reference position and the notch93when the substrate9is viewed from the front surface side is referred to as the “notch position.”

One exemplary combination of the warped state and the notch position included in the warpage-and-notch-position information is a combination of a code (e.g., numeric or symbol) that indicates the warped state of the substrate9illustrated inFIG. 4 or 5and the angle that indicates the notch position. The notch position may be the position of the notch93at which, in a state in which the substrate9in the warped state illustrated inFIG. 4 or 5is held in a vertical posture at a lower edge portion by the up-and-down holder61, the distance in the thickness direction between the lower edge portion and an upper edge of the substrate9becomes a minimum (i.e., the inclination of the substrate9with respect to the up-down direction becomes a minimum). Alternatively, the notch position in the above combination included in the warpage-and-notch-position information may be the position of the notch93at which, in a state in which the substrate9in the warped state illustrated inFIG. 4 or 5is held in a vertical posture at a lower edge portion by the first lifter27or the second lifter28, the distance in the thickness direction between the lower edge portion and the upper edge of the substrate9becomes a minimum.

FIG. 7is a side view illustrating a state in which the lower edge portions of substrates9in the warped state illustrated inFIG. 4are held in a vertical posture by the up-and-down holder61. In the case of the substrate9illustrated inFIG. 4, the notch93is located along the second radial direction K2.FIG. 7illustrates an assumed case in which three substrates9with different notch positions are simultaneously held by the up-and-down holder61. The leftmost substrate9inFIG. 7shows a state in which the notch93is located at the reference position (i.e., 0° notch position). The substrate9in the center inFIG. 7shows a state in which the notch is located at a 45° notch position. The rightmost substrate9inFIG. 7shows a state in which the notch is located at a 90° notch position.

In the example illustrated inFIG. 7, when the notch is located at the 45° notch position, the substrate9in a vertical posture is held approximately parallel to the up-down direction (i.e., Z direction), and a distance D1in the thickness direction between the lower edge portion and upper edge of the held substrate9is the smallest. When the notch is located at the 90° notch position, the distance D1is the next smallest after that in the case where the notch is located at the 45° notch position. When the notch is located at the 0° notch position, the distance D1is the largest. The warpage-and-notch-position information includes, for example, a combination of the 45° notch position and a code that indicates the warped state of the substrate9illustrated inFIG. 4. Note that the notch position in the combination that is included in the warpage-and-notch-position information does not necessarily have to be the position of the notch93at which the distance D1becomes the smallest, and may be any position at which the distance D1becomes smaller than when the notch93is located at any other position. Thus, the warpage-and-notch-position information may include a combination of the 90° notch position and the code indicating the warped state of the substrate9illustrated inFIG. 4.

In the substrate processing apparatus10illustrated inFIG. 1, after step S11, the warped state that is common to a plurality of substrates9carried into the substrate processing apparatus10is input to and stored in the storage101as input information about the warped state. This input information may be a code that indicates the warped state of a plurality of substrates9.

Next, the controller100(seeFIG. 1) controls the single-substrate hand42of the carry-in-and-out mechanism4as described above, so that a first substrate9housed in the FOUP95on the FOUP holder1is carried into the substrate alignment mechanism8, and the substrate alignment mechanism8starts rotating the substrate9(step S12). Then, the controller100controls the motor81on the basis of the position of the notch93detected by the sensor82, the above input information, and the warpage-and-notch-position information. Thus, the circumferential position of the notch93of the substrate9is changed and set to a desired position.

More specifically, the controller100extracts a notch position that corresponds to the warped state of the substrate9indicated by the input information, from the aforementioned plurality of combinations included in the warpage-and-notch-position information. Then, the substrate9is rotated until the position of the notch93of the substrate9matches the extracted notch position. When the position of the notch93has matched the extracted notch position, the rotation of the substrate9is stopped, and the circumferential position of the notch93of the substrate9is determined (step S13). The substrate9for which the position of the notch93has been determined is returned to the FOUP95on the FOUP holder1by the single-substrate hand42. By repeating the aforementioned processing in steps S12and S13for all of the substrates9housed in the FOUP95on the FOUP holder1, all of the substrates9housed in the FOUP95are sequentially aligned, with the position of the notch93of each substrate9having matched the notch position extracted by the controller100. In the substrate processing apparatus10, the substrate alignment mechanism8, the storage101, and the controller100serve as a substrate alignment apparatus for aligning a plurality of substrates9, each having a notch93in the peripheral portion. Note that the FOUP95and the carry-in-and-out mechanism4may also be regarded as part of the substrate alignment apparatus.

The plurality of substrates9aligned by the substrate alignment apparatus are transferred in a horizontal posture to the carry-in-and-out mechanism4illustrated inFIG. 1. The substrates9are transferred from the carry-in-and-out mechanism4to the posture changing mechanism5. The posture changing mechanism5changes the posture of the substrates9at once from horizontal to vertical as described above. Then, the substrates9in a vertical posture are transferred from the posture changing mechanism5to the pusher6and held by the up-and-down holder61of the pusher6. The posture changing mechanism5and the pusher6carry out batch assembly as described above, in which the up-and-down holder61that holds the first substrate group receives the second substrate group held by the posture changing mechanism5.

FIGS. 8 and 9are side views illustrating the movement of the posture changing mechanism5and the pusher6during batch assembly. In order to facilitate understanding of the drawings, the number of substrates9illustrated inFIGS. 8 and 9is smaller than the actual number. In the state illustrated inFIG. 8, the plurality of substrates9(i.e., the first substrates9in the first substrate group) that have already been transferred from the posture changing mechanism5to the pusher6are held in a vertical posture by the up-and-down holder61that is a substrate holder. Moreover, another plurality of substrates9(i.e., the second substrates9in the second substrate group) are held in a vertical posture by the vertical holder52that is another substrate holder. The first substrates9and the second substrates9are already aligned by the aforementioned substrate alignment apparatus before being held by the posture changing mechanism5and the pusher6.

In the substrate processing apparatus10, the controller100(seeFIG. 1) controls the holder elevating mechanism62(seeFIG. 3) so as to move the up-and-down holder61upward. The up-and-down holder61receives the substrates9in a vertical posture from the vertical holder52and holds the substrates9as illustrated inFIG. 9while moving upward through the space between the pair of vertical support members521of the vertical holder52and between the pair of horizontal support members511of the horizontal holder51. This completes the aforementioned batch assembly, and the first and second substrate groups are held by the up-and-down holder61of the pusher6. During batch assembly, the first substrate group is inserted from the underside among the second substrate group, and each of the first substrates9in the first substrate group is disposed between each pair of the second substrates9in the second substrate group. In the substrate processing apparatus10, the holder elevating mechanism62that moves the up-and-down holder61upward serves as a substrate arrangement mechanism for arranging each of the first substrates9among the second substrates9. The substrate alignment apparatus, the up-and-down holder61, and the holder elevating mechanism62described above serve as a substrate arrangement apparatus for arranging a plurality of substrates9.

As described previously, the first substrates9held by the up-and-down holder61are aligned in advance by the aforementioned substrate alignment apparatus so as to reduce the distance D1(seeFIG. 7) in the thickness direction between the lower edge portion and upper edge of each substrate9. This alignment prevents or suppresses the contact of the first substrates9with the second substrates9held by the vertical holder52during batch assembly. This alignment also prevents or suppresses the contact of the first substrates9with the vertical holder52and the horizontal holder51.

The second substrates9held by the vertical holder52are also aligned in advance by the substrate alignment apparatus so as to reduce the distance D1in the thickness direction between the lower edge portion and upper edge of each substrate9. This alignment more suitably prevents or further suppresses the contact between the first substrates9and the second substrates9during batch assembly. Note that, if it is possible to prevent or suppress the contact between the first substrates9and the second substrates9, the second substrates9may be held by the posture changing mechanism5without being aligned by the substrate alignment apparatus.

The plurality of substrates9(i.e., the first and second substrate group) assembled into a batch by the above-described substrate arrangement apparatus are transported via the delivery mechanism7and the main transport mechanism3illustrated inFIG. 1to the substrate processing part2. In the substrate processing part2, as described above, the substrates9held in a vertical posture by the first lifter27are immersed in the liquid chemical that is a processing liquid retained in the first liquid chemical tank21, and are also immersed in a rinsing liquid that is a processing liquid retained in the first rinsing-liquid tank22. Also, the substrates9held in a vertical posture by the second lifter28are immersed in the liquid chemical that is a processing liquid retained in the second liquid chemical tank23, and are also immersed in the rinsing liquid that is a processing liquid retained in the second rinsing-liquid tank24.

In the substrate processing apparatus10, the first lifter27and the second lifter28serve as substrate holders that hold a plurality of substrates9aligned by the aforementioned substrate alignment apparatus in a vertical posture. The first liquid chemical tank21, the first rinsing-liquid tank22, the second liquid chemical tank23, and the second rinsing-liquid tank24serve as liquid processing parts that retain processing liquids in which the substrates9held by the substrate holder (i.e., the first lifter27or the second lifter28) are to be immersed.

As described above, the substrates9held by the first lifter27are aligned in advance by the substrate alignment apparatus so as to reduce the distance D1(seeFIG. 7) in the thickness direction between the lower edge portion and upper edge of each substrate9. Thus, it is possible to make the conditions in the first liquid chemical tank21and the first rinsing-liquid tank22, such as the amounts of processing liquids between adjacent substrates9and the flows of processing liquids between adjacent substrates9, close to the conditions in the case where each substrate9is not warped. In other words, it is possible to make the conditions of processing in the first liquid chemical tank21and the first rinsing-liquid tank22close to the design conditions of processing. As a result, the substrates9are suitably processed with the processing liquids in the first liquid chemical tank21and the first rinsing-liquid tank22.

The substrates9held by the second lifter28are also aligned in advance by the aforementioned substrate alignment apparatus. Thus, it is possible to make the conditions in the second liquid chemical tank23and the second rinsing-liquid tank24, such as the amounts of processing liquids between adjacent substrates and the flows of processing liquids between adjacent substrates9, close to the conditions in the case where each substrate9is not warped. In other words, it is possible to make the conditions of processing in the second liquid chemical tank23and the second rinsing-liquid tank24close to the design conditions of processing. As a result, the substrates9are suitably processed with the processing liquids in the second liquid chemical tank23and the second rinsing-liquid tank24.

As described above, the aforementioned substrate alignment apparatus includes the motor81, the storage101, and the controller100. The motor81is a rotor that sequentially rotates a plurality of substrates9in a circumferential direction, the substrates9being to be held in a vertical posture at their lower edge portions by the substrate holder (e.g., the up-and-down holder61, the first lifter27, or the second lifter28). The storage101stores the warpage-and-notch-position information that includes a plurality of combinations of the warped state of a plurality of substrates9and the notch position at which each substrate9in this warped state is held in a proper posture by the above substrate holder. The controller100controls the motor81.

The controller100controls the motor81on the basis of the warpage-and-notch-position information and input information that is input about the ward state of a plurality of substrates9, so as to sequentially rotate the substrates9in the circumferential direction to determine the circumferential positions of the notches93of the substrates9. This reduces the distance D1in the thickness direction between the lower edge portion and upper edge of each substrate9that is held by the above substrate holder. In other words, the inclination of each substrate9held by the substrate holder is reduced. As a result, it is possible to facilitate handling of a plurality of substrates9held by the substrate holder (e.g., holding, transport, and delivery of the substrates9or processing of the substrates9using processing liquids).

As described above, the substrate processing apparatus10includes the above-described substrate alignment apparatus, the substrate holder (e.g., the first lifter27or the second lifter28), and the liquid processing part (e.g., the first liquid chemical tank21, the first rinsing-liquid tank22, the second liquid chemical tank23, or the second rinsing-liquid tank24). The substrate holder holds a plurality of substrates9that are aligned by the substrate alignment apparatus. The liquid processing part retains a processing liquid in which a plurality of substrates9held by the substrate holder are to be immersed. With the substrate processing apparatus10, since the above-described distance D1of each substrate9held by the substrate holder can be reduced (i.e., the inclination of each substrate9can be reduced), it is possible to make the conditions, such as the amounts of processing liquids between adjacent substrates9and the flows of processing liquids between adjacent substrates9, close to the conditions in the case where each substrate9is not warped. As a result, the substrates9can be suitably processed with the processing liquids.

Focusing on the immersion of the substrates9in the processing liquids in the procedure of processing performed on the substrates9, steps S21and S22illustrated inFIG. 10are performed after the substrates9are aligned by the substrate alignment method in steps S11to S13illustrated inFIG. 6. More specifically, the substrate holder (e.g., the first lifter27or the second lifter28) holds a plurality of substrates9aligned by the substrate alignment method (step S21). Then, the substrates9held by the substrate holder are immersed in the processing liquids (step S22). This allows the substrates9to be suitably processed with the processing liquids as described above.

The aforementioned substrate arrangement apparatus includes the above-described substrate alignment apparatus, the up-and-down holder61that is the substrate holder, and the holder elevating mechanism62that is the substrate arrangement mechanism. The up-and-down holder61holds a plurality of substrates9aligned by the substrate alignment apparatus. The holder elevating mechanism62disposes each of the substrates9held by the up-and-down holder61between each pair of another plurality of substrates9held by the vertical holder52that is another substrate holder.

With the substrate arrangement apparatus, since the above-described distance D1of each substrate9held by the up-and-down holder61can be reduced (i.e., the inclination of each substrate9can be reduced) as described above, it is possible to prevent or suppress the contact of the substrates9held by the up-and-down holder61with the other substrates9held by the vertical holder52during batch assembly. It is also possible to prevent or suppress the contact of the substrates9held by the up-and-down holder61with the substrate holder such as the vertical holder52or the horizontal holder51during batch assembly. As a result, a plurality of substrates9can be suitably assembled into a batch. The substrate arrangement apparatus that is capable of preventing or suppressing the contact between substrates9is in particular suitable for the case where the substrate holder holds a plurality of substrates9in a face-to-face situation in which adjacent substrates9are inclined in opposite directions.

Focusing on the operation of arranging the substrates9in the procedure of processing performed on the substrates9, steps S31and S32illustrated inFIG. 11are performed after a plurality of substrates9are aligned by the substrate alignment method in steps S11to S13illustrated inFIG. 6. More specifically, the up-and-down holder61that is the substrate holder holds a plurality of substrates9aligned by the substrate alignment method (step S31). Then, each of the substrates9held by the up-and-down holder61is disposed between each pair of another plurality of substrates9held by the vertical holder52that is another substrate holder (step S32). This allows the substrates9to be suitably assembled into a batch.

In the substrate processing apparatus10, the aforementioned warpage-and-notch-position information stored in the storage101includes various combinations of the warped state and the notch position other than those described above. For example, the notch position in the above combination included in the warpage-and-notch-position information may be the position of the notch93at which, in a state in which the substrates9in the warped state illustrated inFIG. 4 or 5are held in a horizontal posture by the batch hand41(seeFIG. 1) that is the substrate holder, a distance in the thickness direction between the top of each substrate9and an area of contact of the peripheral portion of the substrate9with the batch hand41becomes the smallest.

FIG. 12is a plan view of a substrate9held in a horizontal posture by the batch hand41.FIG. 12illustrates a single substrate9in a horizontal posture and two hand elements43of the batch hand41that support the lower surface of the substrate9from the underside. Each hand element43is a member that extends approximately in the X direction. More specifically, each hand element43is a plate-like member having a generally strip shape in plan view. The two hand elements43are arranged side by side in the Y direction.

When each substrate9is held in a horizontal posture, for example, a reference notch position (i.e., 0° notch position) indicates a state in which the notch93is located at a position that is furthest to the +Y side away from the two hand elements43as illustrated inFIG. 12. When the notch93is away in the circumferential direction from the reference position, the angle in the counterclockwise direction between the reference position and the notch93when the substrate9is viewed from above (i.e., the +Z side) is referred to as the “notch position.”

FIGS. 13 and 14are cross-sectional views illustrating a state in which substrates9in the warped state illustrated inFIG. 4are supported in a horizontal posture from the underside by the batch hand41.FIG. 13illustrates a cross-section taken at a position along line XIII-XIII inFIG. 12, andFIG. 14illustrates a cross-section taken at a position along line XIV-XIV inFIG. 12.FIGS. 13 and 14illustrate an assumed case in which three substrates9whose notches are located at different notch positions are simultaneously held by the batch hand41. The uppermost substrate9inFIGS. 13 and 14shows a state in which the notch93is located at the reference position (i.e., 0° notch position). The substrate9in the center inFIGS. 13 and 14shows a state in which the notch is located at a 45° notch position. The lowermost substrate9inFIGS. 13 and 14shows a state in which the notch is located at a 90° notch position.

In the example illustrated inFIGS. 13 and 14, when the notch is located at the 90° notch position, a distance D2in the thickness direction between the top of the substrate9in a horizontal posture and the area of contact of the peripheral portion of the substrate9with the batch hand41is the smallest. When the notch is located at the 0° notch position, the distance D2is the next smallest after that in the case where the notch is located at the 90° notch position. When the notch is located at the 45° notch position, the distance D2is the largest. When the notch is located at the 45° notch position, the number of areas of contact between the substrate9and the hand elements43becomes smaller than that in the case where the notch is located at the other notch positions. Thus, the substrates9cannot easily be held stably during, for example, transport by the carry-in-and-out mechanism4.

The warpage-and-notch-position information includes, for example, a combination of the 90° notch position and a code that indicates the warped state of the substrate9illustrated inFIG. 4. Note that the notch position in the combination included in the warpage-and-notch-position information does not necessarily have to be the position of the notch93at which the distance D2becomes the smallest, and may be any position at which the distance D2becomes smaller than in the case where the notch93is located at the other positions. Thus, the warpage-and-notch-position information may include a combination of the 0° notch position and a code that indicates the warped state of the substrate9illustrated inFIG. 4.

As described above, in the aforementioned substrate alignment apparatus, the motor81sequentially rotates a plurality of substrates9in the circumferential direction, the substrates9being to be supported in a horizontal posture from the underside by the substrate holder (e.g., batch hand41). Then, the controller100controls the motor81on the basis of the warpage-and-notch-position information and the input information that is input about the warped state of the substrates9, so as to determine the circumferential positions of the notches93of the substrates9and thereby to reduce the distance D2in the thickness direction between the top of each substrate9that is held by the substrate holder and the area of contact of the peripheral portion of the substrate9with the substrate holder. As a result, it is possible to facilitate handling of the substrates9held by the substrate holder (i.e., holding, conveyance, or transfer of the substrates9). Besides, in the case where the number of substrates9held by the substrate holder is counted by a counter, the decrease in the distance D2of each substrate9allows the number of substrates9to be acquired with high precision.

The substrate alignment apparatus, the substrate arrangement apparatus, and the substrate processing apparatus10described above may be modified in various ways.

The substrate alignment mechanism8may be an apparatus having any of various types of structures as long as it is possible to align a plurality of substrates9, each having a notch93in the peripheral portion. For example, the substrate alignment mechanism8may be a mechanism for rotating a plurality of substrates9simultaneously in the circumferential direction to determine the circumferential position of each of the notches93of the substrates9. That is, the motor81of the substrate alignment mechanism8may be a rotor that rotates a plurality of substrates9either sequentially or simultaneously in the circumferential direction. In either case, it is possible to facilitate handling of a plurality of substrates9held by the substrate holder as described above. The substrate alignment mechanism8may also be a mechanism for rotating substrates9in a vertical posture either sequentially or simultaneously in the circumferential direction to change the circumferential orientations of the substrates9. Moreover, the substrate alignment mechanism8may stop the rotation of the substrates9when the notches93of the substrates9have engaged with a predetermined engagement shaft.

The substrate holder that holds a plurality of substrates9aligned by the aforementioned substrate alignment apparatus is not limited to the up-and-down holder61of the pusher6, the first and second lifters27and28of the substrate processing part2, and the batch hand41of the carry-in-and-out mechanism4, and may be any other portion of the substrate processing apparatus10.

The aforementioned substrate alignment apparatus does not necessarily have to be included in the substrate processing apparatus10, and may be provided outside and independently of the substrate processing apparatus10. In this case, the controller100and the storage101in the substrate alignment apparatus may be provided independently of a controller and a storage in the substrate processing apparatus10. A plurality of substrates9aligned by the substrate alignment apparatus may, for example, be housed in a FOUP95and carried into and processed by the substrate processing apparatus10. Like the substrate alignment apparatus, the aforementioned substrate arrangement apparatus may also be provided outside the substrate processing apparatus10. In this case, the controller100and the storage101in the substrate arrangement apparatus may be provided independently of a controller and a storage in the substrate processing apparatus10. The substrate alignment apparatus and the substrate arrangement apparatus may be incorporated into and used by various apparatuses other than the aforementioned substrate processing apparatus10.

The substrate processing apparatus10may be used to process glass substrates used in display devices such as liquid crystal displays, plasma displays, and field emission displays (FEDs), instead of semiconductor substrates. The substrate processing apparatus10may also be used to process other substrates such as optical disk substrates, magnetic disk substrates, magneto-optical disk substrates, photomask substrates, ceramic substrates, and solar-cell substrates.

The configurations of the above-described preferred embodiments and variations may be appropriately combined as long as there are no mutual inconsistencies.

While the invention has been shown and described in detail, the foregoing description is in all aspects illustrative and not restrictive. It is therefore to be understood that numerous modifications and variations can be devised without departing from the scope of the invention. This application claims priority benefit under 35 U.S.C. Section 119 of Japanese Patent Application No. 2016-190860 filed in the Japan Patent Office on Sep. 29, 2016, the entire disclosure of which is incorporated herein by reference.

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