SUBSTRATE PROCESSING APPARATUS

This invention includes a substrate holder provided rotatably about an axis of rotation extending in a vertical direction while sucking and holding a central part of a lower surface of a substrate, a rotating mechanism for outputting a rotational driving force for rotating the substrate holder, a processing mechanism for processing the substrate by supplying a processing liquid to the substrate held by the substrate holder, and a rotating cup provided rotatably about the axis of rotation while surrounding an outer periphery of the rotating substrate and configured to collect liquid droplets of the processing liquid scattered from the substrate. The rotating mechanism includes a power transmitter for transmitting a part of the rotational driving force as a cup driving force to the rotating cup, and simultaneously rotates the substrate holder and the rotating cup by the rotational driving force.

CROSS REFERENCE TO RELATED APPLICATION

The disclosure of Japanese Patent Application No. 2022-46649 filed on Mar. 23, 2022 including specification, drawings and claims is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a substrate processing technique for processing a substrate by supplying a processing liquid to a peripheral edge part of the substrate.

2. Description of the Related Art

A substrate processing apparatus is known which applies a chemical processing or cleaning processing by supplying a processing liquid to a substrate such as a semiconductor wafer while rotating the substrate. For example, in an apparatus described in JP 2017-11015A, a scattering preventing part is provided to collect and recover a processing liquid or the like scattered from a rotating substrate. The scattering preventing part includes a splash guard (may also be called a “cup”) fixedly arranged to surround the outer periphery of the rotating substrate. The inner peripheral surface of the splash guard is facing the outer periphery of the substrate and collects liquid droplets of the processing liquid shaken off from the rotating substrate.

SUMMARY OF INVENTION

Incidentally, when the liquid droplets are collected by the splash guard, the liquid droplets collide with the inner peripheral surface of the splash guard. By this collision, bouncing liquid droplets may be generated. If the bouncing liquid droplets adhere onto the substrate again, watermarks are produced. Further, the scattering of the bouncing liquid droplets to the outside of the splash guard becomes one of main causes for the contamination of a surrounding atmosphere. Therefore, it is important to suppress the scattering of the bouncing liquid droplets to satisfactorily process the substrate in the above substrate processing apparatus. Accordingly, to achieve this, it is considered to rotate the splash guard together with the rotation of the substrate.

However, if a dedicated rotating mechanism for rotating the splash guard is added to the conventional apparatus, it not only increases apparatus cost, but also requires a control for simultaneously controlling the rotation of the splash guard and the substrate. It may become difficult to stably perform substrate processing.

This invention was developed in view of the above problem and aims to process a substrate at low cost and stably by suppressing bouncing liquid droplets in a substrate processing apparatus for processing the substrate by supplying a processing liquid to the rotating substrate.

The invention is a substrate processing apparatus. The substrate processing apparatus comprises: a substrate holder configured to suck and hold a central part of a lower surface of a substrate and provided rotatably about an axis of rotation extending in a vertical direction; a rotating mechanism configured to output a rotational driving force for rotating the substrate holder; a processing mechanism configured to process the substrate by supplying a processing liquid to the substrate held by the substrate holder; and a rotating cup configured to collect liquid droplets of the processing liquid scattered from the substrate and provided rotatably about the axis of rotation while surrounding an outer periphery of the rotating substrate, wherein the rotating mechanism includes a power transmitter configured to transmit a part of the rotational driving force as a cup driving force to the rotating cup, the rotating mechanism configured to simultaneously rotate the substrate holder and the rotating cup by the rotational driving force.

In the invention thus configured, the rotational driving force for rotating the substrate holder holding the substrate is output from the rotating mechanism. A part of this rotational driving force is transmitted as the cup driving force to the rotating cup by the power transmitter. Therefore, the substrate holder and the rotating cup are simultaneously rotated by the rotation driver.

According to this invention, the substrate can be processed at low cost and stably by suppressing bouncing liquid droplets.

All of a plurality of constituent elements of each aspect of the invention described above are not essential and some of the plurality of constituent elements can be appropriately changed, deleted, replaced by other new constituent elements or have limited contents partially deleted in order to solve some or all of the aforementioned problems or to achieve some or all of effects described in this specification. Further, some or all of technical features included in one aspect of the invention described above can be combined with some or all of technical features included in another aspect of the invention described above to obtain one independent form of the invention in order to solve some or all of the aforementioned problems or to achieve some or all of the effects described in this specification.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG.1is a plan view showing a schematic configuration of a first embodiment of a substrate processing apparatus according to the invention. This figure is a diagram not showing the external appearance of the apparatus, but showing an internal structure of a substrate processing system100by excluding an outer wall panel and other partial configurations. This substrate processing system100is, for example, a single-wafer type apparatus installed in a clean room and configured to process substrates W each having a circuit pattern (hereinafter, referred to as a “pattern”) only on one principal surface one by one. An embodiment of a substrate processing method according to the invention is carried out in a processing unit1equipped in the substrate processing system100. In this specification, a pattern formation surface (one principal surface) formed with the pattern is referred to as a “front surface” and the other principal surface not formed with the pattern on an opposite side is referred to as a “back surface”. Further, a surface facing down is referred to as a “lower surface” and a surface facing up is referred to as an “upper surface”. Further, in this specification, the “pattern formation surface” means a surface of the substrate where an uneven pattern is formed in an arbitrary region regardless of whether the surface is flat, curved or uneven.

Here, various substrates such as semiconductor wafers, glass substrates for photomask, glass substrates for liquid crystal display, glass substrates for plasma display, substrates for FPD (Flat Panel Display), optical disk substrates, magnetic disk substrates and magneto-optical disk substrates can be applied as the “substrate” in this embodiment. Although the substrate processing apparatus used in processing semiconductor wafers is mainly described as an example with reference to the drawings below, application to the processing of various substrates illustrated above is also possible.

As shown inFIG.1, the substrate processing system100includes a substrate processing station110for processing the substrate W and an indexer station120coupled to this substrate processing station110. The indexer station120includes a container holder121capable of holding a plurality of containers C for housing the substrates W (FOUPs (Front Opening Unified Pods), SMIF (Standard Mechanical Interface) pods, OCs (Open Cassettes) for housing a plurality of the substrates W in a sealed state), and an indexer robot122for taking out an unprocessed substrate W from the container C by accessing the container C held by the container holder121and housing a processed substrate W in the container C. A plurality of the substrates W are housed substantially in a horizontal posture in each container C.

The indexer robot122includes a base122afixed to an apparatus housing, an articulated arm122bprovided rotatably about a vertical axis with respect to the base122a, and a hand122cmounted on the tip of the articulated arm122b.The hand122cis structured such that the substrate W can be placed and held on the upper surface thereof. Such an indexer robot including the articulated arm and the hand for holding the substrate is not described in detail since being known.

The substrate processing station110includes a mounting table112on which the indexer robot122places the substrate W, a substrate conveyor robot111arranged substantially in a center in a plan view and a plurality of processing units1arranged to surround this substrate conveyor robot11. Specifically, the plurality of processing units1are arranged to face a space where the substrate conveyor robot111is arranged. The substrate conveyor robot111randomly accesses the mounting table112for these processing units1and transfers the substrate W to and from the mounting table112. On the other hand, each processing unit1performs a predetermined processing to the substrate W, and corresponds to the substrate processing apparatus according to the present invention. In this embodiment, these processing units (substrate processing apparatus)1have the same function. Thus, a plurality of the substrates W can be processed in parallel. If the substrate conveyor robot111can directly transfer the substrate W from the indexer robot122, the mounting table112is not necessarily required.

FIG.2is a diagram showing the configuration of the first embodiment of the substrate processing apparatus according to the invention.FIG.3is a plan view in section along line A-A ofFIG.2. InFIGS.2and3and each figure to be referred to below, the dimensions and numbers of respective components may be shown in an exaggerated or simplified manner to facilitate understanding. The substrate processing apparatus (processing unit1) is provided with a rotating mechanism2, a scattering preventing mechanism3, an upper surface protecting/heating mechanism4, a processing mechanism5, an atmosphere separating mechanism6, an elevating mechanism7, a centering mechanism8and a substrate observing mechanism9. Each of these components is electrically connected to a control unit10for controlling the entire apparatus while being stored in an internal space12of a chamber11. Each component2to9operates in response to an instruction from the control unit10.

A unit similar to a general computer can be, for example, adopted as the control unit10. That is, in the control unit10, each component of the substrate processing apparatus1is controlled by a CPU serving as a main controller performing an arithmetic processing in accordance with a procedure described in a program. Note that detailed configuration and operation of the control unit10are described in detail later. Further, although the control unit10is provided in each substrate processing apparatus1in this embodiment, the plurality of substrate processing apparatuses1may be configured to be controlled by one control unit. Further, the substrate processing apparatuses1may be configured to be controlled by a control unit (not shown) for controlling the entire substrate processing system100.

As shown inFIG.2, a fan filter unit (FFU)13is attached to a ceiling wall11aof the chamber11. This fan filter unit13further cleans air in a clean room in which the substrate processing apparatus1is installed, and supplies the cleaned air into a processing space in the chamber11. The fan filter unit13includes a fan and a filter (e.g. a HEPA (High Efficiency Particulate Air) filter) for taking in the air in the clean room and feeding the air into the chamber11, and feeds the cleaned air via an opening11bprovided in the ceiling wall11a. In this way, a downflow of the cleaned air is formed in the processing space in the chamber11. Further, a punching plate14perforated with a multitude of air outlets is provided right below the ceiling wall11ato uniformly disperse the cleaned air supplied from the fan filter unit13.

As shown inFIGS.1and3, a shutter15is provided in a side surface of the chamber11in the substrate processing apparatus1. A shutter opening/closing mechanism (not shown) is connected to the shutter15, and opens or closes the shutter15in response to an opening/closing command from the control unit10. More specifically, in the substrate processing apparatus1, the shutter opening/closing mechanism opens the shutter15in carrying an unprocessed substrate W into the chamber11, and the unprocessed substrate W is carried in a face-up posture to a spin chuck (substrate holder)21of the rotating mechanism2by a hand (denoted by RH inFIG.16A) of a substrate conveyor robot111. That is, the substrate W is placed on the spin chuck21with an upper surface Wf facing up. If the hand of the substrate conveyor robot111is retracted from the chamber11after the substrate W is carried into, the shutter opening/closing mechanism closes the shutter15. Then, a bevel processing is performed on the peripheral edge part Ws of the substrate W in the processing space (equivalent to a sealed space SPs to be described in detail later) of the chamber11. Further, after the bevel processing is finished, the shutter opening/closing mechanism opens the shutter15again and the hand of the substrate conveyor robot111carries out the processed substrate W from the spin chuck21. As just described, in this embodiment, the internal space12of the chamber11is kept in a normal temperature atmosphere. Note that the “normal temperature” means a temperature in a range of 5° C. to 35° C. in this specification.

The rotating mechanism2has a function of rotating the substrate W while holding the substrate W substantially in a horizontal posture with the upper surface of the substrate W facing up, and synchronously rotating a part of the scattering preventing mechanism3in the same direction as the substrate W. The rotating mechanism2rotates the substrate W and a rotating cup31of the scattering preventing mechanism3about a vertical axis of rotation AX passing through a center of a principal surface. Note that parts to be rotated are dotted inFIG.2to clearly show members, parts and the like to be integrally rotated by the rotating mechanism2.

The rotating mechanism2includes the spin chuck21, which is a disk-like member smaller than the substrate W. The spin chuck21is so provided that the upper surface thereof is substantially horizontal and a center axis thereof coincides with the axis of rotation AX. A hollow cylindrical rotary shaft22is coupled to the lower surface of the spin chuck21. The rotary shaft22extends in a vertical direction with an axis thereof coinciding with the axis of rotation AX. Further, a rotation driver (e.g. motor)23is connected to the rotary shaft22. The rotation driver23rotationally drives the rotary shaft22about the axis of the rotary shaft22in response to a rotation command from the control unit10. Therefore, the spin chuck21is rotatable about the axis of rotation AX together with the rotary shaft22. The rotation driver23and the rotary shaft22provide a function of rotating the spin chuck21with the axis of rotation AX as a center and a lower end part of the rotary shaft22and the rotation driver23are stored in a tubular casing24.

An unillustrated through hole is provided in a central part of the spin chuck21and communicates with an internal space of the rotary shaft22. A pump26is connected to the internal space via a pipe25having a valve (not shown) disposed therein. This pump26and the valve are electrically connected to the control unit10and operate in response to a command from the control unit10. In this way, a negative pressure and a positive pressure are selectively applied to the spin chuck21. If the pump26applies a negative pressure to the spin chuck21, for example, with the substrate W placed substantially in a horizontal posture on the upper surface of the spin chuck21, the spin chuck21sucks and holds the substrate W from below. On the other hand, if the pump26applies a positive pressure to the spin chuck21, the substrate W can be taken out from the upper surface of the spin chuck21. Further, if the suction of the pump26is stopped, the substrate W is horizontally movable on the upper surface of the spin chuck21.

A nitrogen gas supplier29is connected to the spin chuck21via a pipe28provided in a central part of the rotary shaft22. The nitrogen gas supplier29supplies a nitrogen gas at a normal temperature supplied from a utility of a factory, in which the substrate processing system100is installed, to the spin chuck21at a flow rate and a timing corresponding to a nitrogen gas supply command from the control unit10, and causes the nitrogen gas to flow from the central part to a radially outer side on the side of a lower surface Wb of the substrate W. Note that although the nitrogen gas is used in this embodiment, another inert gas may be used. This point also applies to a heating gas discharged from a central nozzle to be described later. Further, the “flow rate” means a moving amount of a fluid such as the nitrogen gas per unit time.

The rotating mechanism2includes a power transmitter27for not only rotating the spin chuck21integrally with the substrate W, but also rotating the rotating cup31in synchronization with the former rotation.FIG.4is a plan view showing the configuration of the power transmitter, andFIG.5is a section along line B-B ofFIG.4. The power transmitter27includes an annular member27amade of a non-magnetic material or resin, magnets27bbuilt-in the annular member27a,and magnets27cbuilt-in a lower cup32, which is one component of the rotating cup31. The annular member27ais attached to the rotary shaft22and rotatable about the axis of rotation AX together with the rotary shaft22. More particularly, the rotary shaft22includes a flange part22aprotruding radially outward at a position right below the spin chuck21as shown inFIG.5. The annular member27ais arranged concentrically with respect to the flange part22a,and coupled and fixed by an unillustrated bolt or the like.

As shown inFIGS.4and5, a plurality of (36 in this embodiment) the magnets27bare arranged radially and at equal angular intervals (10° in this embodiment) with the axis of rotation AX as a center on an outer peripheral edge part of the annular member27a.In this embodiment, as shown in an enlarged view ofFIG.4, an N-pole and an S-pole are respectively arranged on an outer side and an inner side of one of the two magnets27badjacent to each other, and an S-pole and an N-pole are respectively arranged on an outer side and an inner side of the other magnet.

Similarly to these magnets27b,a plurality of (36 in this embodiment) the magnets27care arranged radially and at equal angular intervals (10° in this embodiment) with the axis of rotation AX as a center. These magnets27care built in the lower cup32. The lower cup32is a constituent component of the scattering preventing mechanism3to be described next and, as shown inFIGS.4and5, has an annular shape. That is, the lower cup32has an inner peripheral surface capable of facing the outer peripheral surface of the annular member27a.An inner diameter of this inner peripheral surface is larger than an outer diameter of the annular member27a.The lower cup32is arranged concentrically with the rotary shaft22and the annular member27awhile this inner peripheral surface is separated from the outer peripheral surface of the annular member27aby a predetermined distance (=(the inner diameter-the outer diameter)/2) and facing the outer peripheral surface of the annular member27a.Engaging pins35and coupling magnets36are provided on the upper surface of the outer peripheral edge of the lower cup32, the upper cup33is coupled to the lower cup32by these, and this coupled body functions as the rotating cup31. This point is described in detail later.

The lower cup32is supported rotatably about the axis of rotation AX while being kept in the above arranged state by a bearing not shown in figures. As shown inFIGS.4and5, the plurality of (36in this embodiment) magnets27care arranged radially and at equal angular intervals (10° in this embodiment) with the axis of rotation AX as a center on an inner peripheral edge part of this lower cup32. Further, two magnets27cadjacent to each other are arranged similarly to the magnets27b.That is, an N-pole and an S-pole are respectively arranged on an outer side and an inner side of one magnet, and an S-pole and an N-pole are respectively arranged on an outer side and an inner side of the other magnet.

In the power transmitter27thus configured, if the annular member27ais rotated together with the rotary shaft22by the rotation driver23, the lower cup32rotates in the same direction as the annular member27awhile maintaining an air gap GPa (gap between the annular member27aand the lower cup32) by the action of magnetic forces between the magnets27band27c.In this way, the rotating cup31rotates about the axis of rotation AX. That is, the rotating cup31rotates in the same direction as and in synchronization with the substrate W.

The scattering preventing mechanism3includes the rotating cup31rotatable about the axis of rotation AX while surrounding the outer periphery of the substrate W held on the spin chuck21and a fixed cup34fixedly provided to surround the rotating cup31. The rotating cup31is provided rotatably about the axis of rotation AX while surrounding the outer periphery of the rotating substrate W by the upper cup33being coupled to the lower cup32.

FIG.6is an exploded assembly perspective view showing the structure of the rotating cup.FIG.7is a diagram showing a dimensional relationship of the substrate held on the spin chuck and the rotating cup.FIG.8is a diagram showing parts of the rotating cup and the fixed cup. The lower cup32has an annular shape. The lower cup32has an outer diameter larger than that of the substrate W and is arranged rotatably about the axis of rotation AX while radially protruding from the substrate W held on the spin chuck21in a plan view vertically from above. In this protruding region, i.e. an upper surface peripheral edge part321of the lower cup32, the engaging pins35standing vertically upward and the flat plate-like lower magnets36are alternately mounted along a circumferential direction. A total of three engaging pins35are mounted, and a total of three lower magnets36are mounted. These engaging pins35and lower magnets36are arranged radially and at equal angular intervals (60° in this embodiment) with the axis of rotation AX as a center.

On the other hand, as shown inFIGS.2,3,6and7, the upper cup33includes a lower annular part331, an upper annular part332and an inclined part333coupling these. An outer diameter D331of the lower annular part331is equal to an outer diameter D32of the lower cup32and, as shown inFIG.6, the lower annular part331is located vertically above the peripheral edge part321of the lower cup32. Recesses335open downward are provided to be fittable to tip parts of the engaging pins35in regions vertically above the engaging pins35on the lower surface of the lower annular part331. Further, upper magnets37are mounted in regions vertically above the lower magnets36. Thus, the upper cup33is engageable with and disengageable from the lower cup32with the recesses335and the upper magnets37respectively facing the engaging pins35and the lower magnets36as shown inFIG.6. Note that a relationship of the recesses and the engaging pins may be reversed. Further, magnets may be provided on one side and ferromagnets may be provided on the other side, besides a combination of the lower magnets36and the upper magnets37.

The upper cup33is movable up and down along the vertical direction by the elevating mechanism7. If the upper cup33is moved up by the elevating mechanism7, a conveyance space (SPt inFIG.16A) for carrying in and out the substrate W is formed between the upper cup33and the lower cup32in the vertical direction. On the other hand, if the upper cup33is moved down by the elevating mechanism7, the recesses335are fit to cover the tip parts of the engaging pins35and the upper cup33is positioned in a horizontal direction with respect to the lower cup32. Further, the upper magnets37approach the lower magnets36, and the positioned upper and lower cups33,32are bonded to each other by attraction forces generated between the both magnets. In this way, as shown in a partial enlarged view ofFIG.3andFIG.8, the upper and lower cups33,32are integrated in the vertical direction with a gap GPc extending in the horizontal direction formed. The rotating cup31is rotatable about the axis of rotation AX while forming the gap GPc.

In the rotating cup31, an outer diameter D332of the upper annular part332is slightly smaller than the outer diameter D331of the lower annular part331as shown inFIG.7. Further, if diameters d331, d332of the inner peripheral surfaces of the lower and upper annular parts331,332are compared, the lower annular part331is larger than the upper annular part332and the inner peripheral surface of the upper annular part332is located inside the inner peripheral surface of the lower annular part331in a plan view vertically from above. The inner peripheral surface of the upper annular part332and that of the lower annular part331are coupled by the inclined part333over the entire circumference of the upper cup33. Thus, the inner peripheral surface of the inclined part333, i.e. a surface surrounding the substrate W, serves as an inclined surface334. That is, as shown inFIG.8, the inclined part333can collect liquid droplets scattered from the substrate W by surrounding the outer periphery of the rotating substrate W, and a space surrounded by the upper and lower cups33,32functions as a collection space SPc.

Moreover, the inclined part333facing the collection space SPc is inclined upwardly of the peripheral edge part of the substrate W from the lower annular part331. Thus, as shown inFIG.8, the liquid droplets collected by the inclined part333can flow to a lower end part of the upper cup33, i.e. the lower annular part331, along the inclined surface334, and can be discharged to the outside of the rotating cup31via the gap GPc.

The fixed cup34is provided to surround the rotating cup31and forms a discharge space SPe. The fixed cup34includes a liquid receiving part341and an exhaust part342provided inside the liquid receiving part341. The liquid receiving part341has a cup structure open to face an opening (left opening ofFIG.8) of the gap GPc on a side opposite to the substrate. That is, an internal space of the liquid receiving part341functions as the discharge space SPe and communicates with the collection space SPc via the gap GPc. Therefore, the liquid droplets collected by the rotating cup31are guided into the discharge space SPe via the gap GPc together with gas components. Then, the liquid droplets are collected in a bottom part of the liquid receiving part341and discharged from the fixed cup34.

On the other hand, the gas components are collected into the exhaust part342. This exhaust part342is partitioned from the liquid receiving part341via a partition wall343. Further, a gas guiding part344is arranged above the partition wall343. The gas guiding part344extends from a position right above the partition wall343into the discharge space SPe and the exhaust part342, thereby forming a flow passage for gas components having a labyrinth structure by covering the partition wall343from above. Accordingly, the gas components, out of a fluid flowing into the liquid receiving part341, are collected in the exhaust part342by way of the flow passage. This exhaust part342is connected to an exhaust mechanism38. Thus, a pressure in the fixed cup34is adjusted by the operation of the exhaust mechanism38in response to a command from the control unit10, and the gas components in the exhaust part342are efficiently exhausted. Further, a pressure and a flow rate in the discharge space SPe are adjusted by a precise control of the exhaust mechanism38. For example, the pressure in the discharge space SPe is reduced to below that in the collection space SPc. As a result, the liquid droplets in the collection space SPc can be efficiently drawn into the discharge space SPe and movements of the liquid droplets from the collection space SPc can be promoted.

FIG.9is an external perspective view showing the configuration of the upper surface protecting/heating mechanism.FIG.10is a sectional view of the upper surface protecting/heating mechanism shown inFIG.9. The upper surface protecting/heating mechanism4includes a shielding plate41arranged above the upper surface Wf of the substrate W held on the spin chuck21. This shielding plate41includes a disk part42held in a horizontal posture. The disk part42has a built-in heater421drive-controlled by a heater driver422. This disk part42has a diameter slightly shorter than that of the substrate W. The disk part42is so supported by a support member43that the lower surface of the disk part42covers a surface region excluding the peripheral edge part Ws, out of the upper surface Wf of the substrate W, from above. Note that reference sign44inFIG.9denotes a cut provided in a peripheral edge part of the disk part42, and this cut is provided to prevent interference with processing liquid discharge nozzles included in the processing mechanism5. The cut44is open radially outward.

A lower end part of the support member43is mounted in a central part of the disk part42. The cylindrical through hole is formed to vertically penetrate through the support member43and the disk part42. Further, a center nozzle45is vertically inserted into this through hole. As shown inFIG.2, the nitrogen gas supplier47is connected to this center nozzle45via a pipe46. The nitrogen gas supplier47supplies a nitrogen gas at a normal temperature supplied from utilities of the factory in which the substrate processing system100is installed, to the center nozzle45at a flow rate and a timing corresponding to a nitrogen gas supply command from the control unit10. Further, in this embodiment, a ribbon heater48is mounted in a part of the pipe46. The ribbon heater48generates heat in response to a heating command from the control unit10to heat the nitrogen gas flowing in the pipe46.

The nitrogen gas (hereinafter, referred to as a “heating gas”) heated in this way is fed under pressure toward the center nozzle45and discharged from the center nozzle45. For example, as shown inFIG.10, by supplying the heating gas with the disk part42positioned at a processing position near the substrate W held on the spin chuck21, the heating gas flows toward a peripheral edge part from a central part of the space SPa sandwiched between the upper surface Wf of the substrate W and the disk part42including the built-in heater. In this way, an atmosphere around the substrate W can be suppressed from reaching the upper surface Wf of the substrate W. As a result, the liquid droplets included in the atmosphere can be effectively prevented from getting in the space SPa sandwiched between the substrate W and the disk part42. Further, the upper surface Wf is entirely heated by heating of the heater421and the heating gas, whereby an in-plane temperature of the substrate W can be made uniform. In this way, the warping of the substrate W can be suppressed and a liquid landing position of the processing liquid can be stabilized. Note that the temperature and flow rate of the heating gas supplied to the center nozzle45are desirably controlled to obtain these effects. This point is described in detail based on a simulation result (FIGS.21to24) and the like later.

As shown inFIG.2, an upper end part of the support member43is fixed to a beam member49extending in a horizontal direction orthogonal to a substrate conveying direction (lateral direction ofFIG.3) along which the substrate W is carried in and out. This beam member49is connected to the elevating mechanism7and moved up and down by the elevating mechanism7in response to a command from the control unit10. For example, inFIG.2, the beam member49is positioned below, whereby the disk part42coupled to the beam member49is located at the processing position via the support member43. On the other hand, if the elevating mechanism7moves up the beam member49in response to a move-up command from the control unit10, the beam member49, the support member43and the disk part42integrally move upward and the upper cup33is also linked, separated from the lower cup32and moves up. In this way, the upper cup33and the disk part42are spaced wider apart from the spin chuck21and the substrate W can be carried to and from the spin chuck21(seeFIG.16A).

FIG.11is a perspective view showing the processing liquid discharge nozzle on an upper surface side equipped in the processing mechanism.FIG.12is a diagram showing nozzle positions in a bevel processing mode and a pre-dispense mode.FIG.13is a perspective view showing processing liquid discharge nozzles on a lower surface side equipped in the processing mechanism and a nozzle support for supporting these nozzles. The processing mechanism5includes processing liquid discharge nozzles51F arranged on the upper surface side of the substrate W, processing liquid discharge nozzles51B arranged on the lower surface side of the substrate W and processing liquid suppliers52for supplying the processing liquid to the processing liquid discharge nozzles51F,51B. The lower processing liquid discharge nozzles51F on the upper surface side and the processing liquid discharge nozzles51B on the lower surface side are respectively referred to as “upper surface nozzles51F” and “lower surface nozzles51B” to be distinguished. Further, two processing liquid suppliers52shown inFIG.2are identical.

In this embodiment, three upper surface nozzles51F are provided, and the processing liquid supplier52is connected to those. Further, the processing liquid supplier52is configured to be capable of supplying SC1, DHF and functional water (CO2water or the like) as the processing liquids, and the SC1, DHF and functional water can be respectively independently discharged from the three upper surface nozzles51F.

As shown inFIG.11, each upper surface nozzle51F is provided with a discharge port511for discharging the processing liquid in the lower surface of a tip. As shown in the enlarged view ofFIG.3, lower parts of a plurality of (three in this embodiment) upper surface nozzles51F are arranged in the cut44of the disk part42and upper parts of the upper surface nozzles51F are mounted movably in a radial direction X of the substrate W with respect to a nozzle holder53with the respective discharge ports511facing the peripheral edge part of the upper surface Wf of the substrate W. This nozzle holder53is supported by a support member54, and this support member54is fixed to a lower sealing cup member61of the atmosphere separating mechanism6. That is, the upper surface nozzles51F and the nozzle holder53are integrated with the lower sealing cup member61via the support member54, and moved up and down along the vertical direction Z together with the lower sealing cup member61by the elevating mechanism7. Note that the elevating mechanism7is described in detail later.

As shown inFIGS.3and12, the nozzle holder53includes a built-in nozzle mover55for collectively moving the upper surface nozzles51F in the radial direction X. Accordingly, the nozzle mover55collectively drives the three upper surface nozzles51F in the direction X in response to a position command from the control unit10. In this way, the upper surface nozzles51F reciprocally move between a bevel processing position shown inFIG.12(a)and a pre-dispense position shown inFIG.12(b). The discharge ports511of the nozzle mover55positioned at this bevel processing position are facing the peripheral edge part of the upper surface Wf of the substrate W. If the processing liquid supplier52supplies the processing liquid corresponding to a supply command, out of three kinds of processing liquids, to the upper surface nozzle51F for the processing liquid in response to the supply command from the control unit10, the processing liquid is discharged to the peripheral edge part of the upper surface Wf of the substrate W from the discharge port511of this upper surface nozzle51F.

On the other hand, the discharge ports511of the upper surface nozzles51F positioned at the pre-dispense position are located above the peripheral edge part of the upper surface Wf and facing the inclined surface334of the upper cup33. If the processing liquid supplier52supplies all or part of the processing liquid to the corresponding upper surface nozzle51F in response to a supply command from the control unit10, this processing liquid is discharged to the inclined surface334of the upper cup33from the discharge port511of this upper surface nozzle51F. In this way, the pre-dispense processing is performed. Note that the liquid droplets of the processing liquids used in the bevel processing and the pre-dispense processing are collected by the upper cup33and discharged into the discharge space SPe via the gap GPc as shown inFIG.12. reference sign56inFIG.12denotes a structure composed of the upper surface nozzles51F and the nozzle holder53including the built-in nozzle mover55, and referred to as a “nozzle head56” below. Further, although only the upper surface nozzles51F are mounted in the nozzle head56, a gas discharge nozzle for discharging an inert gas such as a nitrogen gas may be additionally equipped and purge the processing liquid remaining on the peripheral edge part Ws without separating with the inert gas from the gas discharge nozzle, for example, while the substrate W is making one turn.

In this embodiment, the lower surface nozzles51B and a nozzle support57are provided below the substrate W held on the spin chuck21to discharge the processing liquid toward the peripheral edge part of the lower surface Wb of the substrate W. As shown inFIG.13, the nozzle support57includes a thin hollow cylindrical part571extending in the vertical direction and a flange part572having an annular shape and bent to expand radially outward in an upper end part of the hollow cylindrical part571. The hollow cylindrical part571is shaped to be loosely insertable into the air gap GPa formed between the annular member27aand the lower cup32. As shown inFIG.2, the nozzle support57is so fixedly arranged that the hollow cylindrical part571is loosely inserted in the air gap GPa and the flange part572is located between the substrate W supported on the spin chuck21and the lower cup32. Three lower surface nozzles51B are mounted on a peripheral edge part of the upper surface of the flange part572. Each lower surface nozzle51B includes a discharge port511open toward the peripheral edge part of the lower surface Wb of the substrate W and can discharge the processing liquid supplied from the processing liquid supplier52via a pipe58.

The bevel processing for the peripheral edge part of the substrate W is performed by the processing liquids discharged from these upper surface nozzles51F and lower surface nozzles51B. Further, on the lower surface side of the substrate W, the flange part572is extended to the vicinity of the peripheral edge part Ws. Thus, the nitrogen gas supplied to the lower surface side via the pipe28flows into the collection space SPc along the flange part572as shown inFIG.8. As a result, a backflow of the liquid droplets from the collection space SPc to the substrate W is effectively suppressed.

FIG.14is a partial sectional view showing the configuration of the atmosphere separating mechanism. The atmosphere separating mechanism6includes the lower sealing cup member61and an upper sealing cup member62. Both of the upper and lower sealing cup members61,62have a tube shape open in the vertical direction. Inner diameters of those are larger than an outer diameter of the rotating cup31, and the atmosphere separating mechanism6is arranged to completely surround the spin chuck21, the substrate W held on the spin chuck21, the rotating cup31and the upper surface protecting/heating mechanism4from above. More particularly, as shown inFIG.2, the upper sealing cup member62is fixedly arranged at a position right below the punching plate14such that the upper opening thereof covers the opening11bof the ceiling wall11afrom below. Thus, a downflow of clean air introduced into the chamber11is separated into a flow passing through the inside of the upper sealing cup member62and a flow passing outside the upper sealing cup member62.

Further, a lower end part of the upper sealing cup member62includes a flange part621bent inwardly and having an annular shape. An O-ring63is mounted on the upper surface of this flange part611. The lower sealing cup member61is arranged movably in the vertical direction inside the upper sealing cup member62.

An upper end part of the lower sealing cup member61includes a flange part611bent to expand outward and having an annular shape. The flange part611overlaps the flange part621in a plan view vertically from above. Thus, if the lower sealing cup member61moves down, the flange part611of the lower sealing cup member61is locked by the flange part621of the upper sealing cup member62via the O-ring63as shown inFIGS.3and14. In this way, the lower sealing cup member61is positioned at a lower limit position. At this lower limit position, the upper and lower sealing cup members62,61are connected in the vertical direction, and a downflow introducing into the upper sealing cup member62is guided toward the substrate W held on the spin chuck21.

A lower end part of the lower sealing cup member61includes a flange part612bent outwardly and having an annular shape. This flange part612overlaps an upper end part of the fixed cup34(upper end part of the liquid receiving part341) in a plan view vertically from above. Thus, at the lower limit position, the flange part612of the lower sealing cup member61is locked by the fixed cup34via an O-ring64as shown in the enlarged view ofFIG.3andFIG.14. In this way, the lower sealing cup member61and the fixed cup34are connected in the vertical direction, and a sealed space SPs is formed by the upper sealing cup member62, the lower sealing cup member61and the fixed cup34. The bevel processing on the substrate W can be performed in this sealed space SPs. That is, by positioning the lower sealing cup member61at the lower limit position, the sealed space SPs is separated from an outside space SPo of the sealed space SPs (atmosphere separation). Therefore, the bevel processing can be stably performed without being influenced by an outside atmosphere. Further, the processing liquids are used to perform the bevel processing. The processing liquids can be reliably prevented from leaking from the sealed space SPs to the outside space SPo. Thus, a degree of freedom in selecting/designing components to be arranged in the outside space SPo is enhanced.

The lower sealing cup member61is also configured to be movable vertically upward. The nozzle head56(=upper surface nozzles51F+nozzle holder53) is fixed to an intermediate part of the lower sealing cup member61in the vertical direction via the support member54as described above. Besides this, as shown inFIGS.2and3, the upper surface protecting/heating mechanism4is fixed to an intermediate part of the lower sealing cup member61via the beam member49. That is, as shown inFIG.3, the lower sealing cup member61is connected to one end part of the beam member49, the other end part of the beam member49and the support member54at three positions mutually different in the circumferential direction. By moving up and down the one end part of the beam member49, the other end part of the beam member49and the support member54by the elevating mechanism7, the lower sealing cup member61is also moved up and down accordingly.

As shown inFIGS.2,3and4, a plurality of (four) projections613are provided to project inward as engaging parts engageable with the upper cup33on the inner peripheral surface of the lower sealing cup member61. Each projection613extends to a space below the upper annular part332of the upper cup33. Further, each projection613is so mounted to be separated downward from the upper annular part332of the upper cup33with the lower sealing cup member61positioned at the lower limit position. By an upward movement of the lower sealing cup member61, each projection613is engageable with the upper annular part332from below. The lower sealing cup member61moves further upward also after this engagement, whereby the upper cup33can be separated from the lower cup32.

In this embodiment, after the lower sealing cup member61starts to be moved up together with the upper surface protecting/heating mechanism4and the nozzle head56by the elevating mechanism7, the upper cup33also moves up. In this way, the upper cup33, the upper surface protecting/heating mechanism4and the nozzle head56are separated upward from the spin chuck21. By a movement of the lower sealing cup member61to a retracted position (position inFIG.16Ato be described later), the conveyance space (SPt inFIG.16A) for allowing the hand (RH inFIG.16A) of the substrate conveyor robot111to access the spin chuck21is formed. The substrate W can be loaded onto the spin chuck21and unloaded from the spin chuck21via this conveyance space. As just described, in this embodiment, the substrate W can access the spin chuck21by a minimum upward movement of the lower sealing cup member61by the elevating mechanism7.

The elevating mechanism7includes two elevation drivers71,72. In the elevation driver71, a first elevation motor711is provided as shown inFIG.3. The first elevation motor711generates a rotational force by operating in response to a drive command from the control unit10. Two elevators712,713are coupled to this first elevation motor711. The elevators712,713simultaneously receive the rotational force from the first elevation motor711. Then, the elevator712moves up and down a support member491supporting the one end part of the beam member49along the vertical direction Z according to a rotation amount of the first elevation motor711. Further, the elevator713moves up and down the support member54supporting the nozzle head56along the vertical direction Z according to the rotation amount of the first elevation motor711.

The elevation driver72includes a second elevation motor721and an elevator722as shown inFIG.3. The second elevation motor721generates a rotational force by operating in response to a drive command from the control unit10and gives the generated rotational force to the elevator722. The elevator722moves up and down a support member492supporting the other end part of the beam member49along the vertical direction Z according to a rotation amount of the second elevation motor721.

The elevation drivers71,72synchronously and vertically move the support members491,492and54respectively fixed to the side surface of the lower sealing cup member61at three positions mutually different in the circumferential direction. Therefore, the upper surface protecting/heating mechanism4, the nozzle head56and the lower sealing cup member61can be stably moved up and down. Further, the upper cup33can be also stably moved up and down as the lower sealing cup member61is moved up and down.

The centering mechanism8includes contact members81capable of moving toward and away from an end surface of the substrate W loaded on the spin chuck21, and a centering driver82for horizontally moving the contact members81. In this embodiment, three contact members81are arranged radially and at equal angular interval with the axis of rotation AX as a center, and only one of those is shown inFIG.2. In this centering mechanism8, the centering driver82moves the contact members81toward the substrate W in response to a centering command from the control unit10(centering processing) while suction by the pump26is stopped (i.e. while the substrate W is horizontally movable on the upper surface of the spin chuck21). By this centering processing, the eccentricity of the substrate W with respect to the spin chuck21is eliminated and a center of the substrate W and that of the spin chuck21coincide.

The substrate observing mechanism9includes an observation head91for observing the peripheral edge part of the substrate W. This observation head91is configured to approach to and separate from the peripheral edge part of the substrate W. An observation head driver92is connected to the observation head91. In observing the peripheral edge part of the substrate W by the observation head91, the observation head driver92moves the observation head91toward the substrate W in response to an observation command from the control unit10(observation processing). Then, the peripheral edge part of the substrate W is imaged using the observation head91. A captured image is sent to the control unit10. Whether or not the bevel processing has been satisfactorily performed is inspected based on this image by the control unit10.

The control unit10includes an arithmetic processor10A, a storage10B, a reader10C, an image processor10D, a drive controller10E, a communicator10F and an exhaust controller10G. The storage10B is constituted by a hard disk drive or the like, and stores a program for performing the bevel processing by the substrate processing apparatus1. This program is stored, for example, in a computer-readable recording medium RM (e.g. an optical disk, a magnetic disk, a magneto-optical disk, or the like), read from the recording medium RM by the reader10C and saved in the storage10B. Further, the program may be provided, for example, via an electrical communication line without being limited to provision via the recording medium RM. The image processor10D applies various processings to an image captured by the substrate observing mechanism9. The drive controller10E controls each driver of the substrate processing apparatus1. The communicator10F conducts communication with a controller for integrally controlling each component of the substrate processing system100and the like. The exhaust controller10G controls the exhaust mechanism38.

Further, a display unit10H (e.g. a display and the like) for displaying various pieces of information and an input unit10J (e.g. a keyboard, a mouse and the like) for receiving an input from an operator are connected to the control unit10.

The arithmetic processor10A is constituted by a computer including a CPU (=Central Processing Unit), a RAM (=Random Access Memory) and the like, and performs the bevel processing by controlling each component of the substrate processing apparatus1in accordance with the program stored in the storage10B as described below. The bevel processing by the substrate processing apparatus1is described below with reference toFIGS.15and16A to16D.

FIG.15is a flow chart showing the bevel processing performed as an example of a substrate processing operation by the substrate processing apparatus shown inFIG.2.FIGS.16A to16Dare diagrams showing each apparatus component during the bevel processing. Note that a configuration to be integrally moved up is dotted for reference to be clearly shown inFIG.16A, and a configuration to be integrally rotated is dotted for reference to be clearly shown inFIG.16C.

In applying the bevel processing to the substrate W by the substrate processing apparatus1, the arithmetic processor10A causes the elevation drivers71,72to integrally move up the lower sealing cup member61, the nozzle head56, the beam member49, the support member43and the disk part42. While the lower sealing cup member61is moving up, the projections613are engaged with the upper annular part332of the upper cup33and, thereafter, the upper cup33is moved up together with the lower sealing cup member61, the nozzle head56, the beam member49, the support member43and the disk part42and positioned at the retracted position. In this way, the conveyance space SPt sufficient to allow the entrance of the hand RH of the substrate conveyor robot111is formed above the spin chuck21. If it is confirmed that the formation of the conveyance space SPt is completed, the arithmetic processor10A gives a loading request of the substrate W to the substrate conveyor robot111via the communicator10F and it is waited until an unprocessed substrate W is carried into the substrate processing apparatus1and placed on the upper surface of the spin chuck21as shown inFIG.16A. Then, the substrate W is placed on the spin chuck21(Step S1). Note that, at this point of time, the pump26is stopped and the substrate W is horizontally movable on the upper surface of the spin chuck21.

If the loading of the substrate W is completed, the substrate conveyor robot111is retracted from the substrate processing apparatus1. Following that, the arithmetic processor10A controls the centering driver82such that the three contact members81(only two are shown inFIG.16B) approach the substrate W. In this way, the eccentricity of the substrate W with respect to the spin chuck21is eliminated and the center of the substrate W coincides with that of the spin chuck21(Step S2). If the centering processing is completed in this way, the arithmetic processor10A controls the centering driver82to separate the three contact members81from the substrate W and operates the pump26to apply a negative pressure to the spin chuck21. In this way, the spin chuck21sucks and holds the substrate W from below.

Subsequently, the arithmetic processor10A gives a move-down command to the elevation drivers71,72. In response to this, the elevation drivers71,72integrally move down the lower sealing cup member61, the nozzle head56, the beam member49, the support member43and the disk part42. During these downward movements, the upper cup33supported from below by the projections613of the lower sealing cup member61is coupled to the lower cup32. That is, the recesses335are fit to cover the tip parts of the engaging pins35as shown inFIG.6, the upper cup33is positioned in the horizontal direction with respect to the lower cup32and the upper and lower cups33,32are bonded to each other to form the rotating cup31by attraction forces generated between the upper and lower magnets37,36.

After the rotating cup31is formed, the lower sealing cup member61, the nozzle head56, the beam member49, the support member43and the disk part42are further integrally moved down, and the flange parts611,612of the lower sealing cup member61are respectively locked by the flange part621of the upper sealing cup member62and the fixed cup34. In this way, the lower sealing cup member61is positioned at the lower limit position (position inFIGS.2and16C) (Step S3). After the above locking, the flange part621of the upper sealing cup member62and the flange part611of the lower sealing cup member61are held in close contact via the O-ring63, and the flange part612of the lower sealing cup member61and the fixed cup34are held in close contact via the O-ring63. As a result, as shown inFIG.2, the lower sealing cup member61and the fixed cup34are connected in the vertical direction, and the sealed space SPs is formed by the upper sealing cup member62, the lower sealing cup member61and the fixed cup34, and the sealed space SPs is separated from the outside atmosphere (outside space SPo) (atmosphere separation).

In this atmosphere separated state, the lower surface of the disk part42covers the surface region excluding the peripheral edge part Ws, out of the upper surface Wf of the substrate W, from above. Further, the upper surface nozzles51F are positioned in such a posture that the discharge ports511are facing the peripheral edge part of the upper surface Wf of the substrate W in the cut44of the disk part42. If preparation for the supply of the processing liquids to the substrate W is completed in this way, the arithmetic processor10A gives a rotation command to the rotation driver23to start the rotation of the spin chuck21holding the substrate W and the rotating cup31(Step S4). Rotating speeds of the substrate W and the rotating cup31are set, for example, at 1800 rpm. Further, the arithmetic processor10A controls the drive of the heater driver422to heat the heater421to a desired temperature, e.g. 185° C.

Subsequently, the arithmetic processor10A gives a nitrogen gas supply command to the nitrogen gas supplier47. In this way, as shown by an arrow F1ofFIG.16C, the supply of the nitrogen gas from the nitrogen gas supplier47to the center nozzle45is started (Step S5). This nitrogen gas is discharged from the center nozzle45toward the space SPa (FIG.10) sandwiched between the substrate W and the disk part42after being heated to a desired temperature (e.g. 100° C.) by the ribbon heater48while passing in the pipe46. In this way, the entire upper surface Wf of the substrate W is heated. Further, the substrate W is also heated by the heater421. Thus, the temperature of the peripheral edge part Ws of the substrate W rises with the passage of time and reaches a temperature suitable for the bevel processing, e.g. 90° C. Further, the temperature of the substrate W other than the peripheral edge part Ws is also increased to a substantially equal temperature. That is, in this embodiment, the in-plane temperature of the upper surface Wf of the substrate W is substantially uniform. Therefore, the warping of the substrate W can be effectively suppressed.

Following this, the arithmetic processor10A supplies the processing liquids to the upper surface nozzles51F and the lower surface nozzles51B by controlling the processing liquid suppliers52(arrows F2, F3inFIG.16C). That is, flows of the processing liquids are discharged from the upper surface nozzles51F to contact the peripheral edge part of the upper surface of the substrate W, and flows of the processing liquids are discharged from the lower surface nozzles51B to contact the peripheral edge part of the lower surface of the substrate W. In this way, the bevel processing is performed on the peripheral edge part Ws of the substrate W (Step S6). Upon detecting the passage of a processing time required for the bevel processing of the substrate W, the arithmetic processor10A gives a supply stop command to the processing liquid suppliers52to stop the discharge of the processing liquids.

Following that, the arithmetic processor10A gives a supply stop command to the nitrogen gas supplier47to stop the supply of the nitrogen gas from the nitrogen gas supplier47to the center nozzle45(Step S7). Further, the arithmetic processor10A gives a rotation stop command to the rotation driver23to stop the rotation of the spin chuck21and the rotating cup31(Step S8).

In next Step S9, the arithmetic processor10A observes the peripheral edge part Ws of the substrate W to inspect a result of the bevel processing. More specifically, the arithmetic processor10A positions the upper cup33at the retracted position to form the conveyance space SPt in a manner similar to that during the loading of the substrate W. Then, the arithmetic processor10A controls the observation head driver92to bring the observation head91closer to the substrate W. If the peripheral edge part Ws is imaged by the observation head91, the arithmetic processor10A controls the observation head driver92to retract the observation head91from the substrate W. In parallel with this, the arithmetic processor10A inspects based on the captured image of the peripheral edge part Ws whether or not the bevel processing has been satisfactorily performed.

After the inspection, the arithmetic processor10A gives an unloading request of the substrate W to the substrate conveyor robot111via the communicator10F, and the processed substrate W is carried out from the substrate processing apparatus1(Step S10). Note that this series of steps is repeatedly performed.

As described above, in this embodiment, the atmosphere separating mechanism6is provided above the scattering preventing mechanism3to conduct the so-called atmosphere separation of separating the sealed space SPs for performing the bevel processing by the processing liquids and the outside space SPo. In this way, a range to be processed by the processing liquids is limited, turbulence generation positions can be reduced, and the bevel processing can be stably performed. Further, components having no chemical resistance can be adopted in the outside space SPo although being in the chamber11. To obtain such effects, the atmosphere separating mechanism6is composed of the upper sealing cup member62fixed near the ceiling wall11aand the lower sealing cup member61movable up and down between the upper sealing cup member62and the scattering preventing mechanism3. Therefore, the following effects are also obtained.

To conduct the atmosphere separation, a technique has been conventionally proposed which brings a cup member constituting a scattering preventing mechanism into contact with a ceiling of a chamber (e.g. JP 6282904B). In this conventional technique, the entire cup member needs to be moved down in carrying in and out the substrate W. In contrast, in this embodiment, it is sufficient to move up the lower sealing cup member61by a minimum distance necessary for the carry-in and -out processing of the substrate W, and a movement amount of the lower sealing cup member61can be suppressed. This point can be dealt with by moving up the lower sealing cup member61also when the centering processing shown inFIG.16Bis performed and when the observation processing shown inFIG.16Dis performed. From these, a tact time of the substrate processing apparatus1can be made shorter than that of the conventional apparatus (effect A).

Further, in the above embodiment, a load applied to the elevating mechanism can be made smaller than that of the conventional apparatus for moving up and down the entire cup member since only the lower sealing cup member61is moved up and down. Further, as shown inFIG.3, the lower sealing cup member61is moved up and down while being supported at three positions mutually different in the circumferential direction. Therefore, the lower sealing cup member61can be stably moved up and down. Further, the upper cup33, the upper surface protecting/heating mechanism4and the nozzle head56are moved up and down via the lower sealing cup member61, and these can also be stably moved up and down at low cost (effect B).

Further, in this embodiment, as shown inFIG.2, the clean air sent from the fan filter unit13is separated to the clean air to be sent to the sealed space SPs and that to be sent to the outside space SPo by bringing the upper opening of the upper sealing cup member62closer to the punching plate14provided right below the ceiling wall11a. In this way, an air volume of the clean air to be sent to each space is controlled. Therefore, the sealed space SPs can be set to have a desired pressure value and a pressure difference between the sealed space SPs and the outside space SPo can be adjusted with high accuracy. Moreover, a volume of the sealed space SPs functioning as a processing liquid atmosphere area can be reduced, and the use of the utilities of the factory in which the substrate processing apparatus1is installed can be reduced (effect C).

Here, various methods can be adopted for the air volume control of the clean air. For example, as shown inFIG.17A, the air volume into the sealed space SPs may be controlled to be more than that into the outside space SPo by making an inner diameter of air outlets141facing the upper opening of the upper sealing cup member62than those of other air outlets142. To enhance the pressure accuracy of the sealed space SPs and the outside space SPo, a fan filter unit13A for the sealed space SPs and a fan filter unit13B for the outside space SP0 may be individually provided, for example, as shown inFIG.17B. Further, as shown inFIG.17C, the clean air blown from the fan filter unit13may be supplied into the sealed space SPs via a first pipe16aand supplied into the outside space SPo via a second pipe16binstead of the punching plate14. Dampers17a,17bmay be respectively disposed in the first and second pipes16a,16b,and a damper controller18may individually control an opening of each damper17a,17bin response to an opening command from the control unit10, thereby controlling the pressure by adjusting supply amounts into the sealed space SPs and the outside space thereof.

Further, in the above embodiment, the liquid droplets scattered from the substrate W are collected inside the rotating cup31, i.e. in the collection space SPc as shown inFIG.8. At this time, a centrifugal force generated according to cup rotation acts on the liquid droplets adhering to the inclined surface334of the rotating cup31. Further, the liquid droplets are affected by a gas flow formed by the nitrogen gas or the like supplied during the bevel processing and flowing radially outward along the upper and lower surfaces of the substrate W. By these, a load of a downward vector along the inclined surface334acts on the liquid droplets. The liquid droplets having received this stress are moved to the gap GPc between the upper and lower cups33,32along the inclined surface334. The liquid droplets having reached the entrance of the gap GPc are moved to the discharge space SPe of the fixed cup34via the gap GPc together with the gas components such as the nitrogen gas. Thus, the liquid droplets adhering to the rotating cup31are quickly discharged from the rotating cup31by way of the gap GPc. Particularly, since the gap GPc is parallel to a direction of the centrifugal force and the gas flow, the liquid droplets can be smoothly discharged from the collection space SPc into the discharge space SPe. Thus, the collision of the liquid droplets scattered from the substrate W and those adhering to the rotating cup31can be reduced and the generation of the bouncing liquid droplets can be suppressed. As a result, the bevel processing can be satisfactorily performed (effect D). Note that although the inclined surface334of the upper cup33is finished into a truncated conical surface having a constant angle of inclination in a vertical cross-section in this embodiment, the inclined surface334may be finished into a surface bulging radially outward (leftward ofFIG.18), for example, as shown inFIG.18.

Further, in this embodiment, the upper cup33is coupled to the lower cup32by the engagement of the engaging pins35with the recesses335and attraction forces generated between the upper and lower magnets37,36as shown inFIG.6. Accordingly, the upper and lower cups33,32are firmly coupled also during rotation, and the bevel processing can be stably performed (effect E). Of course, the coupling of the upper and lower cups33,32is not limited to this. For example, the upper and lower cups33,32may be coupled only by the engagement.

Further, in this embodiment, a part of a rotational driving force output from the rotation driver23to rotate the substrate W is given as a cup driving force to the lower cup32via the power transmitter27. In this way, both the substrate W and the rotating cup31can be driven by the single rotation driver23, and the apparatus configuration can be simplified. Further, the substrate W and the rotating cup31can be synchronously rotated in the same direction. Thus, if the rotating cup31is viewed from the peripheral edge part of the rotating substrate W, the rotating cup31is relatively stationary. Therefore, the bounce of the liquid droplets caused when the liquid droplets of the processing liquid scattered from the substrate W collide with the rotating cup31can be further satisfactorily suppressed (effect F).

This power transmitter27uses the action of magnetic forces between the magnets27band27c.Thus, as shown inFIGS.4and5, the cup driving force can be transmitted to the lower cup32while the air gap GPa (gap between the annular member27aand the lower cup32) is maintained between the annular member27aand the lower cup32. Then, as shown inFIG.2, the flange part572of the nozzle support57is loosely inserted into this air gap GPa, and the nozzle support57is fixedly arranged. Further, the air gap GPa is also used as a piping route. That is, pipes connected to the lower surface nozzles51B supported on the nozzle support57are connected to the processing liquid supplier52by way of the air gap GPa. Therefore, the pipe lengths are considerably shortened, and a degree of freedom and tolerances of the layout of the respective components of the substrate processing apparatus1can be enhanced (effect G).

Further, in this embodiment, the inclined part333of the upper cup33extends above the peripheral edge part Ws of the substrate W as shown inFIGS.7and8. That is, parts of the upper annular part332and the inclined part333function as an eaves part for covering the peripheral edge part Ws of the substrate W held on the spin chuck21over the entire circumference in a plan view vertically from above. Further, in this embodiment, the upper surface nozzle51F discharges the processing liquid from the discharge port511thereof and causes the processing liquid to land on the peripheral edge part Ws of the substrate W with the discharge port511located at the bevel processing position lower than the eaves part in the vertical direction as shown inFIG.12(a). Therefore, the following effect is obtained.

When being collected by the rotating cup31, the liquid droplets may collide with the inclined surface334of the upper cup33and some of them may fly upward. Further, when the processing liquid is supplied to the peripheral edge part of the substrate W, some of the liquid droplets of the processing liquid may be scattered upward. If the liquid droplets scattered upward adhere to the substrate W again, watermarks are produced. However, in this embodiment, the above eaves part effectively prevents re-adhesion to the substrate W by collecting the liquid droplets scattered upward. Therefore, the substrate W can be more satisfactorily beveled. Further, a similar effect is obtained also in the pre-dispense processing shown inFIG.12(b)(effect H).

This pre-dispense processing can be performed by moving the upper surface nozzles51F by a very short distance in the radial direction X of the substrate W by the nozzle mover55. Accordingly, the upper surface nozzles51F need not be moved to a position distant from the rotating cup31for the pre-dispense processing, and the pre-dispense processing can be performed in the rotating cup31. As a result, a tact time of the substrate processing apparatus1can be made shorter than that of the conventional apparatus (effect I).

Here, a moving direction of the upper surface nozzle51F in performing the pre-dispense processing is not limited to the radial direction X, but arbitrary. For example, as shown inFIG.19, an pivot axis AX51 is provided in one end part513distant from the discharge port511, out of a nozzle body512constituting the upper surface nozzle51F. This pivot axis AX51extends in parallel to the vertical direction Z. Thus, a landing position of the processing liquid discharged from the discharge port511can be changed by the nozzle mover55moving the upper surface nozzle51F about the pivot axis AX51. More specifically, the bevel processing position and the pre-dispense position may be switched by rotating the upper surface nozzle51F about the pivot axis AX51.

Further, in this embodiment, the nozzle mover55can not only switch the bevel processing position and the pre-dispense position, but also change the landing position of the processing liquid by changing the position of the discharge port511in the radial direction X of the substrate W. That is, the processing liquid can be landed on a desired position of the peripheral edge part Ws by the arithmetic processor10A controlling the nozzle mover55. Thus, a width (length from the end surface of the substrate W to the liquid landing position in the radial direction X) of the bevel processing can be changed in the peripheral edge part Ws of the substrate W. Note that such a function is similarly achieved also in the embodiment shown inFIG.19.

Further, in this embodiment, the disk part42is provided to cover the upper surface Wf of the substrate W from above. Accordingly, as shown inFIG.9, the disk part42is provided with the cut44, and the upper surface nozzles51F are movable over a relatively wide range, and the function of switching between the bevel processing position and the pre-dispense position and the mechanism for changing the bevel processing width can be effectively achieved (effect J).

Here, the cut44is one of main causes to generate a turbulence in the sealed space SPs. However, in this embodiment, the lower end parts of the upper surface nozzles51F enter the cut44to partially close the cut44as shown inFIGS.3,9and12. In this way, the generation of a turbulence in the cut44can be suppressed (effect K).

Further, to effectively suppress the generation of a turbulence, attachments514may be attached to the respective upper surface nozzles51F while the positions of the discharge ports511and the postures of the upper surface nozzles51F are maintained as shown inFIG.20A. Further, as shown inFIG.20B, a single attachment515may be attached to all the upper surface nozzles51F while the positions of the discharge ports511and the postures of the upper surface nozzles51F are maintained. By these arrangements, an occupancy ratio of the respective upper surface nozzles51F with attachment(s) in the cut44increases and the cut44can be substantially closed. As a result, the generation of a turbulence in the cut44can be more effectively suppressed.

Further, in this embodiment, the upper surface protecting/heating mechanism4is provided to make the in-plane temperature of the substrate W uniform. More specifically, the flow rate and temperature of the heating gas to be supplied to the center nozzle45are controlled based on a simulation result to be described next.

As shown inFIG.10, an airflow analysis was performed for cases where a nitrogen gas (heating gas) was discharged at various flow rates from the center nozzle45toward the substrate W rotating with the disk part42held in proximity to the substrate W held on the spin chuck21in the vertical direction. Here, the heater421and the ribbon heater48were stopped and specific analysis conditions were set as follows.Separation distance between substrate W and disk part42=2 mmRotating speed of substrate W=1800 rpmDischarge flow rate of nitrogen gas=0, 50, 75, 100, 130 L/minAperture of center nozzle 45=60 mmϕ

A graph plotting air flow velocities at respective positions in the radial direction X of the substrate W under these analysis conditions is shown inFIG.21. As is understood from

FIG.21, the air flow velocity in the radial direction X of the substrate W changes according to the flow rate of the nitrogen gas discharged from the center nozzle45. Particularly, if the air flow velocity at the peripheral edge part Ws (here,147mm from the substrate center) of the substrate W falls below zero, i.e. if an airflow from the periphery (collection space SPc) of the substrate W toward the substrate center is generated, liquid droplets are entrained. Accordingly, the air flow velocity at the peripheral edge part Ws (here, 147 mm from the substrate center) of the substrate W is read for each gas flow rate and a graph plotting the air flow velocities is shown inFIG.22. As is understood fromFIG.22, the nitrogen gas needs to be discharged at about 57 L/min or higher from the center nozzle45to prevent the entrainment of the liquid droplets.

On the other hand, the air flow velocity increases as the flow rate of the nitrogen gas discharged from the center nozzle45increases. Accordingly, if the nitrogen gas is supplied at an excessive flow rate from the center nozzle45, the air flow velocity along the upper surface Wf of the substrate W increases and a pattern formed on the upper surface Wf of the substrate W may be adversely affected. Further, in this embodiment, the liquid droplets and the gas components collected in the collection space SPc are discharged into the discharge space SPe via the gap GPc as shown inFIG.8. Thus, if the flow rate of the nitrogen gas flowing into the collection space SPc from the substrate W becomes excessive beyond an exhaust flow rate from the discharge space SPe by the exhaust mechanism38, a backflow swirl may be generated. If the flow rate of the nitrogen gas is increased, an exhaust air velocity between the substrate W and the rotating cup31decreases. This is found from the airflow analysis. One of main causes of this is that the gap GPc is narrow and, if the flow rate of the nitrogen gas is increased, a pressure loss is caused and an exhaust, which cannot be discharged, may form a backflow to generate a swirl of the backflow also on an end part of the upper surface of the substrate W. Accordingly, it is desirable to set a maximum value of the flow rate of the nitrogen gas discharged from the center nozzle45within such a range that these are not generated, and the maximum value is set at about 0.3-fold of the above exhaust flow rate.

Next, the temperature of the heating gas is described. An airflow analysis was performed for cases where the heating gas was discharged at various temperatures from the center nozzle45toward the substrate W rotating with the disk part42including the built-in heater held in proximity to the substrate W held on the spin chuck21in the vertical direction. Here, specific analysis conditions were set as follows.Temperature of heater421=185° C.Temperature of heating gas=27° C., 80° C., 130° C.Separation distance between substrate W and disk part 42=2 mmRotating speed of substrate W=1800 rpmDischarge flow rate of heating gas=80 L/minAperture of center nozzle 45=60 mmϕ

A graph plotting surface temperatures of the substrate W at respective positions in the radial direction X of the substrate W under these analysis conditions is shown inFIG.23. As is understood fromFIG.23, the uniformity of the in-plane temperature in the substrate W tends to be improved and show a peak as the temperature of the heating gas increases and be slightly reduced by a further temperature increase. Accordingly, graphs plotting surface temperature changes of the substrate W according to a change in the discharge temperature of the heating gas at a center position (r=0 mm) and an edge position (r=150 mm) of the substrate W are shown inFIG.24. As is understood from these graphs, the surface temperature of the substrate W can be made uniform by setting the temperature of the heating gas discharged from the center nozzle45at about 100° C. Further, a surface temperature difference is desirably suppressed within a range of20° C. or less to satisfactorily perform the bevel processing while suppressing the warping of the substrate W. From this point, in this embodiment, an upper limit value of the discharge temperature of the heating gas is set at 130° C. from a chain line1(+20° C.) and a dotted line (r=0 mm) inFIG.24, and a lower limit value of the discharge temperature of the heating gas is set at 65° C. from a chain line2(−20° C.) and the dotted line (r=0 mm). That is, the arithmetic processor10A sets the temperature of the heating gas in a discharge temperature range of 65° C. to 130° C.

In the embodiment described above, the spin chuck21corresponds to an example of a “substrate holder of the invention. The annular member27aand the magnets27b,27crespectively correspond to examples of a “rotating member”, “first magnets” and “second magnets” of the invention. The pipe58corresponds to an example of a “pipe” of the invention.

Note that the invention is not limited to the embodiments described above and various changes other than the aforementioned ones can be made without departing from the gist of the invention. For example, although the bevel processing is applied to the peripheral edge part Ws of the substrate W using three kinds of the processing liquids in the above embodiments, the kinds of the processing liquids are not limited to these.

Further, although the atmosphere separating mechanism6is provided in the above embodiment, the invention can be applied also to a substrate processing apparatus not including the atmosphere separating mechanism6.

Further, in the above embodiments, the invention is applied to the substrate processing apparatuses1in which liquid droplets are collected by the rotating cup31having a so-called divided structure and obtained by coupling the mutually separable upper and lower cups33,32to each other during the processing to integrate the upper and lower cups33,32. However, the application range of the invention is not limited to this and the invention can be also applied to a substrate processing apparatus in which liquid droplets are collected by a rotating cup composed of upper and lower cups integrated in advance.

Although the invention is applied to the substrate processing apparatuses1in which the scattering preventing mechanism3includes the rotating cup31and the fixed cup34in the above embodiments, the application range of the invention is not limited to this. For example, the invention can be also applied to a substrate processing apparatus in which liquid droplets from the substrate W are collected by a cup fixedly arranged to surround the outer periphery of the substrate W held on the spin chuck21.

Further, in the above embodiment, the invention is applied to the substrate processing apparatus1in which the peripheral edge part Ws is beveled by supplying the processing liquids to the peripheral edge part Ws of the substrate W. However, the invention can be applied to substrate processing techniques in general for collecting and discharging liquid droplets scattered from the substrate W by the scattering preventing mechanism3while processing the substrate W by supplying processing liquids to the substrate W.

Although the invention has been described by way of the specific embodiments above, this description is not intended to be interpreted in a limited sense. By referring to the description of the invention, various modifications of the disclosed embodiments will become apparent to a person skilled in this art similarly to other embodiments of the invention. Hence, appended claims are thought to include these modifications and embodiments without departing from the true scope of the invention.

This invention is applicable to substrate processing techniques in general for processing a substrate by supplying a processing liquid to the substrate.