Substrate processing method, substrate processing apparatus, and semiconductor device manufacturing method

A method for a substrate processing apparatus having a substrate holding mechanism and a chemical solution dispensing/sucking mechanism including a chemical solution dispensing port for supplying a first chemical solution and a chemical solution suction port, includes placing the target substrate on the substrate holding mechanism, laying out an auxiliary plate at a periphery of the substrate such that the two main faces are substantially flush with each other, supplying a second chemical solution onto the main faces, dispensing the first solution from the dispensing port and sucking the first and second solutions through the suction port, with the dispensing and suction ports brought into contact with the second solution, and while dispensing the first solution from the dispensing port and sucking the first solution through the suction port, scanning the dispensing/sucking mechanism such that the dispensing and suction ports are opposed to the main face of the substrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from prior Japanese Patent Applications No. 2004-118279, filed Apr. 13, 2004; and No. 2004-189928, filed Jun. 28, 2004, the entire contents of both of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a substrate processing method and a substrate processing apparatus for processing a substrate with a chemical solution, and a semiconductor device manufacturing method using the same.

2. Description of the Related Art

A wet process is extensively used for a substrate processing technique in a process of manufacturing a semiconductor device or a liquid crystal display. In particular, regarding a developing process to be carried out after a photosensitive resin is photosensitized, a puddle technique has been actively studied.

In a conventional puddle technique, a chemical solution is supplied onto a substrate to be processed (target substrate) while the substrate is rotated. The chemical solution is supplied by a chemical solution supply part laid out above the substrate. However, it is very difficult for the chemical solution supply part to make uniform a dispensing pressure of the chemical solution or a chemical supply quantity per unit area at a central part and at a peripheral part of the substrate. Therefore, it has been very difficult to obtain uniform developing precision in the plane of the substrate. A problem associated with such processing precision exists similarly in a substrate processing method other than the developing process.

As developing advances, a dissolved product or a developing solution with a low concentration is generated as a byproduct of such advancement. In general, it is believed that a dissolved product or a developing solution with a low concentration inhibits dissolution of a photosensitive thin film. The dissolved product or the like is generated according to the pattern density in the substrate, and thus, is generated with a certain distribution on the substrate. Then, the dissolved product or the like is subject to a force such as a centrifugal force caused by substrate rotation, and moves on the substrate with non-uniformity. For such a reason as well, in the conventional puddle technique, it has been impossible to obtain uniform processing precision in the plane.

There is proposed a substrate processing method using a suction nozzle in order to generate the flow of a chemical solution in the course of developing. For example, in Jpn. Pat. Appln. KOKAI Publication No. 2002-252167 by the present inventors, there is proposed a nozzle comprising a chemical solution dispensing port and a chemical solution suction port and a substrate processing method using the nozzle.

The above substrate processing method is directed to a method for processing a substrate in the case where a developing solution is used as a chemical solution; namely, while dispensing the developing solution from a developing solution dispensing port, sucking the developing solution from a developing solution suction port, and then, processing the substrate while scanning the nozzle in proximity to the substrate. The above substrate processing method is one method of making a nozzle proximal to a substrate, and increasing the flow rate of a chemical on the substrate, thereby achieving replacement of the chemical between patterns, and then, reducing a pattern dimensional difference caused by a pattern density.

In a state in which the nozzle and the substrate are thus very proximal to each other, bubbles or the like exist between the nozzle and the substrate. Such bubbles cause the impairment of the uniformity of the flow of the chemical on the substrate. Specifically, the flow rate or the like of the chemical becomes different depending on an upstream side and a downstream side with respect to a position at which the bubbles exist. Therefore, there has been a demand for providing a substrate processing method and a substrate processing apparatus capable of preventing the non-uniformity of the flow of the chemical caused by the bubbles.

In addition, a wet process is used for a substrate processing technique in the steps of manufacturing a semiconductor device or a liquid crystal display. In particular, regarding the developing and etching processes after a photosensitive resin has been photosensitized, a paddle method or a spray method are actively discussed. In these methods, in general, the developing solution or etching solution has been supplied and processed on the substrate, and then, the substrate is rotated while pure water is supplied during rinse processing, thereby removing a by-product caused at the time of developing (resist residue) or metallic or organic particles and the like which may exist on the substrate. However, the by-product or particles and the like are not completely reduced, thus causing the impaired yield of photomasks or wafers.

As developing or etching advances, a dissolved product or a resist residue is produced as a by-product thereof. The product and residue float in the solution existing on the substrate, and it is believed that there is a high probability that the dissolved product, resist residue and the like exist on the vicinity of the liquid solution surface. In the latest investigation, it is found that, when the liquid on the substrate becomes thin, and then, disappears, the dissolved product, resist residue and the like existing on the liquid solution surface or in the liquid solution adhere to the substrate surface, causing a defect.

In Jpn. Pat. Appln. KOKAI Publication No. 2002-252167 described previously, there is proposed a nozzle which comprises a chemical solution dispensing port and a chemical solution sucking port and a substrate processing method using the nozzle. The document describes a case of using a developing solution as a chemical solution and relates to a method of sucking the developing solution from a developing solution sucking port while dispensing the developing solution from a developing solution dispensing port, and then, processing the substrate while carrying out scanning with the nozzle being proximal to the substrate. In more detail, by making the nozzle proximal to the substrate, the replacement of the chemical solution between patterns is achieved by increasing the flow rate of the chemical, and one method for reducing the pattern dimensional difference caused by a pattern density is provided.

A sucking part exists at the above reported nozzle. The sucking section carries out processing while sucking and removing particles such as the dissolved product or resist reside contained in the liquid solution existing on the substrate. Thus, there is an advantage that these particles can be almost removed from the top of the substrate. However, the monitoring of particles is not carried out, thus making it possible to deny a possibility that a dissolved product or a floating object such as a resist residue exists on a liquid surface.

Therefore, there is a growing demand for a technique for guaranteeing that the particles hardly exist in the liquid before drying the substrate surface. That is, there has been a demand for achieving a substrate processing method and a substrate processing apparatus capable of restricting the particles from adhering to the substrate surface after drying the substrate surface and improving the yielding.

BRIEF SUMMARY OF THE INVENTION

According to a first aspect of the invention, there is provided a method of substrate processing, which comprises:

preparing a substrate processing apparatus comprising a substrate holding mechanism to hold a target substrate to be processed having a first main face, and a chemical solution dispensing/sucking mechanism which comprises a chemical solution dispensing port to dispense a first chemical solution, and a chemical solution suction port to suck a chemical solution including the first chemical solution;

placing the target substrate on the substrate holding mechanism so as to expose the first main face;

preparing an auxiliary plate having a second main face, followed by laying out the auxiliary plate at a periphery of the target substrate such that the second main face is substantially flush with the first main face;

supplying a second chemical solution onto the first main face and the second main face;

dispensing the first chemical solution from the chemical solution dispensing port and sucking the first chemical solution and the second chemical solution through the chemical solution suction port, in a state in which the chemical solution dispensing port and the chemical solution suction port are brought into contact with the second chemical solution; and

while dispensing the first chemical solution from the chemical solution dispensing port and sucking the first chemical solution through the chemical solution suction port, scanning the chemical solution dispensing/sucking mechanism in a state in which the chemical solution dispensing port and the chemical solution suction port are opposed to the first main face of the target substrate.

According to a second aspect of the invention, there is provided an apparatus for substrate processing, which comprises:

a substrate holding mechanism to hold a target substrate to be processed having a first main face;

a chemical solution dispensing/sucking mechanism including a chemical solution dispensing port to dispense a first chemical solution onto the first main face and a chemical solution suction port to suck a chemical solution including the first chemical solution;

an auxiliary plate having a second main face, the auxiliary plate being laid out at a periphery of the target substrate such that the second main face is substantially flush with the first main face; and

at least one selected from the group consisting of (1) a recess portion provided on the second main face of the auxiliary plate, the recess portion being wider than an area including the chemical solution dispensing port and the chemical solution suction port, (2) a determining mechanism to determine whether a bubble is present or absent in the chemical solution dispensing port; and (3) a vibration mechanism to vibrate the first chemical solution and the second chemical solution.

According to a third aspect of the invention, there is provided a method of manufacturing a semiconductor device, which comprises:

preparing a substrate processing apparatus comprising a semiconductor wafer holding mechanism to hold a target semiconductor wafer to be processed having a first face and a chemical solution dispensing/sucking mechanism including a chemical solution dispensing port to dispense a first chemical solution and a chemical solution suction port to suck a chemical solution including the first chemical solution;

placing the target semiconductor wafer on the semiconductor wafer holding mechanism so as to expose the first main face;

preparing an auxiliary plate having a second main face, followed by laying out the auxiliary plate at the periphery of the target semiconductor wafer such that the second main face is substantially flush with the first main face;

supplying a second chemical solution onto the first main face and the second main face;

dispensing the first chemical solution from the chemical solution dispensing port and sucking the first chemical solution and the second chemical solution through the chemical solution suction port, in a state in which the chemical solution dispensing port and the chemical solution suction port are brought into contact with the second chemical solution, so as to preclude a first chemical solution from coming into contact with the first main face of the target semiconductor wafer; and

while dispensing the first chemical solution from the chemical solution dispensing port and sucking the first chemical solution through the chemical solution suction port, scanning the chemical solution dispensing/sucking mechanism in a state in which the chemical solution dispensing port and the chemical solution suction port are opposed to the first main face of the target semiconductor wafer.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. According to the embodiments presented below, there can be provided a substrate processing method and a substrate processing apparatus capable of preventing the non-uniformity of flow of a chemical solution caused by air bubbles.

First Embodiment

FIG. 1is a view schematically depicting an outline construction of a substrate processing apparatus according to a first embodiment of the present invention.FIG. 2is a view schematically depicting an outline construction of a chemical solution dispensing/sucking mechanism of the substrate processing apparatus according to the present embodiment.

A substrate processing apparatus100comprises: a substrate holding mechanism10for holding a target substrate1substantially horizontally; an auxiliary plate20for surrounding the target substrate1and the substrate holding mechanism10and making vertical movement; a chemical solution dispensing/sucking mechanism30laid out above the substrate holding mechanism10; and a chemical solution supply/suction system for supplying a chemical solution or the like into the chemical solution dispensing/sucking mechanism30and sucking the chemical solution or the like from the inside of the chemical solution dispensing/sucking mechanism3.

The target substrate1comprises, for example, an Si wafer and a photosensitive thin film provided on the Si wafer. The substrate holding mechanism10is provided as a wafer holding device, for example. An upper face of the auxiliary plate20is set to be substantially as high as, or slightly lower than an upper face of the target substrate1(for example, an upper face of the photosensitive thin film).

The chemical solution dispensing/sucking mechanism30, as shown inFIG. 2, comprises a chemical solution dispensing/sucking head (hereinafter, referred to as a scan nozzle)30SN. At the upper side of the scan nozzle30SN, there are provided: a chemical solution inlet31into which a chemical solution50is to be introduced; first and second liquid outlets321,322which are laid out so as to sandwich the chemical solution inlet31, the outlets causing a liquid solution51to be discharged therefrom; and first and second rinse solution inlets331,332which are laid out at the outside of the liquid outlets321,322, the inlets causing a rinse solution52to be introduced therefrom. The chemical50is provided as, for example, a developing solution. The above liquid solution includes, for example, a developing solution; pure water; a developing solution and pure water; a developing solution, pure water, and a rinse solution; or a developing solution and a rinse solution.

On the other hand, at the lower side of the scan nozzle30SN, there are provided: a slit shaped chemical solution dispensing port34for supplying the chemical solution50onto the target substrate1; slit shaped first and second chemical solution suction ports351,352which are laid out at both sides of the chemical solution dispensing port34, the suction ports being adopted to suck in the liquid51on the target substrate1; and first and second rinse solution dispensing port361,362which are laid out at the outside of the chemical solution suction ports351,352, the dispensing ports361,362being adopted to supply the rinse solution52onto the target substrate1.

The chemical solution dispensing port34communicates with the chemical solution inlet31via a pipe37. Similarly, the liquid solution outlets331,332and the rinse solution suction ports351,352communicate with each other via a pipe38; and the rinse solution inlets331,332and the rinse solution dispensing ports361,362communicate with each other via a pipe39. The pipes37,38,39each comprise a liquid solution reservoir.

The chemical supply/suction system40comprises first and second liquid solution suction systems421,422and first and second rinse supply systems431,432. The chemical supply system41, the liquid solution suction systems421,422, and the rinse supply systems431,432each communicate with the chemical solution inlet31, the liquid solution outlets321,322, and the rinse solution inlets331,332via pipes44,45and46. Valves47,48and49are provided in the middle of the pipes44,45and46each other.

By pressurizing a chemical solution canister (not shown), the chemical solution50is supplied into the pipe45via the chemical solution inlet31, and is dispensed from the chemical solution dispensing port34. The liquid solution suction systems421,422are connected to the liquid solution outlets321,322, respectively, via a pump (not shown). The liquid solution is sucked in by a suction force of the pump. The rinse solution is continuously dispensed from the rinse solution dispensing ports361,362. In this case, a liquid solution including the chemical solution and the rinse solution is sucked into the liquid solution suction ports351,352.

A well known gap measuring mechanism and a gap adjusting mechanism, which are although not shown, are provided at the chemical solution dispensing/sucking mechanism30. The substrate processing apparatus100further comprises a well known moving mechanism for relatively moving the chemical solution dispensing/sucking mechanism30and the substrate holding mechanism10.

FIGS. 3A and 3Eare views each adopted to explain a substrate processing method using a substrate processing apparatus according to the present embodiment. Here, a description will be given with respect to a case where the chemical liquid is a developing solution, namely, a case of a developing processing method. In the figures that followsFIG. 13A, the substrate holding mechanism10is omitted for clarity.

First, the target substrate1is prepared. The target substrate1comprises: a semiconductor wafer; an undercoat film provided and processed on the wafer; and a resist pattern provided on the undercoat film. The resist pattern is produced as follows. That is, a photosensitive resin film such as a resist having thickness of 0.4 micron is formed on the undercoat film, and then, with an exposure process using a KrF excimer laser stepper, a 0.10 micron pattern latent image is formed on the photosensitive resin film.

Next, the target substrate1is held horizontally by the substrate holding mechanism. Next, as shown inFIG. 3A, a liquid solution51(pure water at this stage) is filled on the target substrate1and the auxiliary plate20(first and second main faces) laid out so as to surround the target substrate1. The liquid solution51(second chemical solution) is supplied from a liquid solution filling nozzle70. When the liquid solution51is filled, the liquid solution filling nozzle70is moved from a liquid solution filling nozzle standby position (not shown) onto the target substrate1. After the filling of the liquid solution51has completed, the liquid solution filling nozzle70is moved from the top of the target substrate1to the liquid solution filling nozzle standby position.

Next, as shown inFIG. 3B, the scan nozzle30SN is moved from a scan nozzle standby position (not shown) upwardly of the auxiliary plate20. Next, as shown inFIG. 3C, the scan nozzle30SN moved to above the auxiliary plate20is fallen. Then, as shown inFIG. 3D, in a state in which a lower face (nozzle lower face) of the scan nozzle30SN comes into contact with a liquid level of the liquid solution51, the scan nozzle30SN is held.

Here, at a moment at which the nozzle lower face has come into contact with the liquid level of the liquid solution51, air bubbles80enter the inside of the chemical solution dispensing port34situated on the nozzle lower face. Therefore, in the present embodiment, in order to eliminate the air bubbles80from the inside of the chemical solution dispensing port34, operations of developing solution dispensing, liquid solution sucking and rinse solution dispensing are made in a state in which the nozzle lower face has come into contact with the liquid level of the liquid solution51. By these operations, the air bubbles80having entered the inside of the chemical solution dispensing port34are purged out from the chemical solution dispensing port34. The air bubbles80purged out from the chemical solution dispensing port34are sucked into the chemical solution suction ports351,352, and the sucked bubbles are purged out from the liquid solution outlets321,322to the outside of the scan nozzle30SN.

Similarly, at a moment at which the nozzle lower face has come into contact with the liquid level of the liquid solution51, air bubbles80adhered to the nozzle lower face are released from the nozzle lower face due to operations of developing solution dispensing, liquid solution sucking and rinse solution dispensing. The air bubbles80released from the nozzle lower face are sucked into the chemical solution suction ports351,352, and the sucked bubbles are purged out from the liquid solution outlets321,322to the outside of the scan nozzle30SN.

In order to reliably eliminate the air bubbles80having entered the inside of the chemical solution dispensing port34or the air bubbles80adhered to the nozzle lower face, it is preferable to intermittently carry out operations of the above developing solution dispensing, liquid solution sucking, and rinse solution dispensing.

It is desirable that a gap G1between the nozzle lower face and the auxiliary plate20during operations of the developing solution dispensing, liquid solution sucking and rinse solution dispensing is greater than a diameter of each of the air bubbles80having entered the nozzle lower face. This is because, in the case where the gap G1is equal to or greater than the diameter of the air bubbles80, there is no need for a large amount of force to move the air bubbles80. In actuality, it is considered desirable that the gap G1is about 3 mm because the diameter of the air bubble80is about 0.1 mm to 3 mm in general. In addition, during the operations of the above developing solution dispensing, liquid solution sucking, and rinse solution dispensing, it is preferable that the developing solution dispensed from the chemical solution dispensing port34should not come into contact with the top of the target substrate1. Further, it is preferable that the rinse solution dispensed from the rinse solution dispensing ports361,362should not come into contact with the top of the target substrate1.

Next, as shown inFIG. 3E, the scan nozzle30SN is further lowered until a gap G2between the nozzle lower face and the auxiliary plate20is obtained as a desired value, i.e., 100 microns in the present embodiment. Thereafter, while the gap G2is held at the above desired value, the operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing are carried out, and the scan nozzle30SN is scanned above the target substrate1at a speed of 1 mm per second, thereby carrying out a developing process. At this time, the scan nozzle30SN is scanned in a state in which the chemical solution dispensing port34, the chemical solution suction ports351,352and the rinse solution dispensing ports361,362are opposed to an upper face of the target substrate1.

In the present embodiment, tetramethyl ammonium hydroxide (TMAH) (normality 0.27N) is used as a developing solution. Further, a dispensing flow rate of the developing solution, a suction flow rate of liquid solution, and a suction pressure of the liquid solution suction flow rate are adjusted in advance such that the developing solution dispensed from the chemical solution dispensing port34is sucked into the chemical solution suction ports351,352. Next, the target substrate1is rotated, and the liquid solution on the target substrate1is vibrated. Then, the target substrate1is dried, whereby a resist pattern forming process completes.

When the in-plane uniformity of a resist pattern formed in accordance with the method of the embodiment was measured, a result of 2.7 nm (3σ) was obtained. On the other hand, when the in-plane uniformity of the resist pattern formed in accordance with the conventional technique (developing without elimination of air bubbles80) was measured, a result of 7.5 nm (3σ) was obtained. From the above results, it was verified that a resist pattern having significantly improved uniformity can be provided according to the embodiment.

After the scan nozzle30SN had been fabricated of a transparent element material, when the presence of air bubbles or foreign objects (dust and/or particles) in the chemical solution dispensing port34and the presence of air bubbles or foreign objects adhered to the nozzle lower face were monitored, it was successfully verified that the number of air bubbles and foreign objects can be reduced to 0 by using the embodiment.

As has been described above, according to the present embodiment, the dispensing and sucking of the processing liquid solution (chemical solution, rinse solution) are carried out while a gap greater than the diameter of air bubble80is maintained on the auxiliary substrate20laid out at the periphery of the target substrate1. This makes it possible to eliminate (bubble-remove) the air bubbles or foreign objects which exist in the chemical solution dispensing port34and the air bubbles or foreign objects adhered to the nozzle lower face by means of sucking operation.

In the present embodiment, a bubble removing process is carried out while the nozzle lower face comes into contact with a liquid level above the auxiliary plate20. In this manner, the bubble removing process can be carried out while avoiding the outflow of the processing liquid solution onto the target substrate1before substrate processing. After the bubble removing process has completed, the scan nozzle30SN is moved upwardly of the target substrate1in a state in which the nozzle comes into contact with the liquid level, and substrate processing is carried out. Accordingly, there is little possibility of new entry of air bubbles or the like.

Second Embodiment

FIG. 4is a view adopted to explain a substrate processing method using a substrate processing apparatus according to a second embodiment of the invention. Here, a description will be given with respect to a case where a chemical solution is a developing solution, namely, a case of a developing processing method. Like constituent elements inFIGS. 1 to 3Eare designated by like reference numerals, and a detailed description is omitted here. In the following figures, like constituent elements in the existing figures are designated by like reference numerals, and a detailed description is omitted here.

A substrate processing apparatus according to this embodiment is different from that of the first embodiment in that the auxiliary plate20comprises a recess portion21which is greater by one round than an area in which there exist the chemical solution dispensing port34, the liquid solution suction ports351,352and the rinse solution dispensing port361,362. In the embodiment, the depth of the recess portion21is 5 nm. In addition, a substrate processing method according to the present embodiment is different from that of the first embodiment in that air bubbles are eliminated in the recess portion21. Hereinafter, the present embodiment will be described in detail.

First, as in the first embodiment, the target substrate1comprising a wafer, an undercoat film, and a resist pattern is prepared. Then, the target substrate1is held horizontally by the substrate holding mechanism.

Next, as shown inFIG. 4A, as in the first embodiment, the liquid solution51is filled on the target substrate1and the auxiliary plate20laid out so as to surround the target substrate1.

Next, as shown inFIG. 4B, the scan nozzle30SN is moved from a nozzle standby position (not shown) upwardly of the auxiliary plate20. At this time, when seen from the top of the scan nozzle30SN, the position of the scan nozzle30SN is set at a position such that a region in which there exist the chemical solution dispensing port34, the liquid solution suction ports351,352and the rinse solution dispensing ports361,362is included in the recess portion21provided on the surface of the auxiliary plate20.

Next, as shown inFIG. 4C, the scan nozzle30SN moved onto the auxiliary plate20is fallen. Then, as shown inFIG. 4D, the scan nozzle30SN is held in a state in which the nozzle lower face comes into contact with the liquid level of the liquid solution51. At this time, a gap G3between the nozzle lower face and the auxiliary plate20is substantially equal to the gap G2in the first embodiment.

Here, at a moment at which the nozzle lower face has come into contact with the liquid level of the liquid solution51, air bubbles80enters the inside of the chemical solution dispensing port34situated on the nozzle lower face. Then, in the embodiment, in order to eliminate the air bubbles80from the inside of the chemical solution dispensing port34, operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing are carried out in a state in which the nozzle lower face has come into contact with the liquid level of the liquid solution51. By these operations, the air bubbles80having entered the inside of the chemical solution dispensing port34are purged out from the chemical solution dispensing port34. The air bubbles80purged out from the chemical solution dispensing port34are sucked into the chemical solution suction ports351,352, and then, the sucked air bubbles are purged out from the liquid solution outlets321,322to the outside of the scan nozzle30SN.

Similarly, at a moment at which the nozzle lower face has come into contact with the liquid level of the liquid solution51, the air bubbles80adhered to the nozzle lower face are also released from the nozzle lower face by the above operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing. Then, the air bubbles80released from the nozzle lower face are sucked into the chemical solution suction ports351,352, and the sucked air bubbles are purged out from the liquid solution outlets321,322to the outside of the scan nozzle30SN.

In order to reliably eliminate the air bubbles80having entered the inside of the chemical solution dispensing port34or the air bubbles80adhered to the nozzle lower face, it is preferable to intermittently carry out the above operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing.

Next, as shown inFIG. 4E, the operations of developing solution dispensing, liquid solution sucking, and rinse liquid solution dispensing are carried out without changing the gap G3(=G2) between the nozzle lower face and the auxiliary plate20, and the scan nozzle30SN is scanned above the target substrate1at a speed of 1 mm per second, thereby carrying out a developing process.

In this embodiment, TMAH (normality 0.27N) is used as a developing solution. Further, a dispensing flow rate of the developing solution, a suction flow rate of liquid solution, and a suction pressure of the liquid solution suction flow rate are adjusted in advance such that the developing solution dispensed from the chemical solution dispensing port34is sucked into the chemical solution suction ports351,352. Next, the target substrate1is rotated, and the liquid solution on the target substrate1is vibrated. Then, the target substrate1is dried, whereby a resist pattern forming process completes.

When the in-plane uniformity of a resist pattern formed in accordance with the method of the embodiment was measured, a result of 2.7 nm (3σ) was obtained. On the other hand, when the in-plane uniformity of the resist pattern formed in accordance with the conventional technique (developing without elimination of air bubbles80) was measured, a result of 7.5 nm (3σ) was obtained. From the above results, it was verified that a resist pattern having significantly improved uniformity can be provided according to the embodiment.

When the scan nozzle30SN was fabricated of a transparent element material, and the presence of air bubbles or foreign objects (dust and/or particles) in the chemical solution dispensing port34and the presence of air bubbles or foreign objects adhered to the nozzle lower face were monitored, it was successfully verified that the number of air bubbles and foreign objects can be reduced to 0 by using the present embodiment.

Also in this embodiment, advantageous effect similar to that of the first embodiment can be attained. Further, according to the embodiment, in a state in which a region in which there exist the chemical solution dispensing port34, the liquid solution suction ports351,352, and the rinse solution dispensing ports361,362is included in the recess portion21of the auxiliary plate20when seen from the top, the dispensing and sucking of the processing liquid solution (nozzle operation) are carried out, thereby making it possible to carry out a bubble removing process more efficiently. In addition, there is another advantageous effect that the number of recipes for carrying out nozzle operation is reduced, and the bubble removing process can be easily carried out.

In order to improve the advantageous effect of the present embodiment, an auto cleaning machine and/or a liquid solution removing mechanism etc. may be used to prevent a foreign object or the like from being accumulated in the recess portion21.

Third Embodiment

FIGS. 5A and 5Bare views each showing a scan nozzle of a substrate processing apparatus according to a third embodiment of the invention.FIG. 5Ais a view schematically showing an outline construction of the scan nozzle, andFIG. 5Bis a perspective view of the scan nozzle.

The substrate processing apparatus according to the embodiment is different from that of the first embodiment in that the scan nozzle30SN comprises a light source11and a light receiving part12(light receiving element). The light source11comprises, for example, a laser. The light receiving part12comprises, for example, a photo diode.

The light source11is provided at one end of a slit shaped chemical solution dispensing port34, and the light receiving part12is provided at the other end of the chemical solution dispensing port34. An optical axis alignment is obtained such that the light emitted from the light source11transmits the chemical solution dispensing port34and is received by the light receiving part12.

An optical system including the light source11and the light receiving part12may not always be directly mounted on the scan nozzle30SN. The optical system may be mounted on a device other than the scan nozzle30SN as long as the light beams radiated from the light source11propagate so as to transmit the chemical solution dispensing port34and the light receiving part12can measure the transmitted light quantity, a scattered light quantity, a reflection light quantity, or the like.

FIGS. 6A to 6Fare views each adopted to explain a substrate processing method using the substrate processing apparatus of the embodiment. Here, a description will be given with respect to a case in which a chemical solution is a developing solution, namely, a case of a developing processing method.

First, the target substrate1is prepared. The target substrate1comprises: a wafer; an undercoat film provided and processed on the wafer; and a resist pattern provided on the undercoat film. The resist pattern is produced as follows. That is, a photosensitive resin film such as a resist having thickness of 0.3 micron is formed on the undercoat layer. Then, in accordance with an exposure process using an ArF excimer stepper, a 0.07 micron pattern latent image is formed on the photosensitive resin film.

Next, the target substrate1is held horizontally by the substrate holding mechanism10. Next, as shown inFIG. 6A, the liquid solution51(pure water at this stage) is filled on the target substrate1and the auxiliary plate20laid out so as to surround the target substrate1.

Subsequently, as shown inFIG. 6B, the scan nozzle30SN is moved from a scan nozzle standby position (not shown) upwardly of an auxiliary plate20. Next, as shown inFIG. 6C, the scan nozzle moved onto the auxiliary plate20is fallen. Then, as shown inFIG. 6D, the scan nozzle30SN is held in a state in which a lower face (nozzle lower face) of the scan nozzle30SN has come into contact with the liquid level of the liquid solution51. At this time, a gap G1between the nozzle lower face and the auxiliary plate20is set to, for example, 3 mm.

Here, at a moment at which the nozzle lower face has come into contact with the liquid level of the liquid solution51, air bubbles80enter the inside of the chemical solution dispensing port34situated on the nozzle lower face. Therefore, in the embodiment, in order to eliminate the air bubbles80from the inside of the chemical solution dispensing port34, operations of developing solution dispensing, liquid solution sucking and rinse solution dispensing are made in a state in which the nozzle lower face has come into contact with the liquid level of the liquid solution51. By these operations, the air bubbles80having entered the inside of the chemical solution dispensing port34are purged out from the chemical solution dispensing port34. The air bubbles80purged out from the chemical solution dispensing port34are sucked into the chemical solution suction ports351,352, and the sucked bubbles are purged out from the liquid solution outlets321,322to the outside of the scan nozzle30SN.

Similarly, at a moment at which the nozzle lower face has come into contact with the liquid level of the liquid solution51, the air bubbles80adhered to the nozzle lower face are also released by the above operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing. Then, the air bubbles80released from the nozzle lower face are sucked into the chemical solution suction ports351,352, and the sucked air bubbles are purged out from the liquid solution outlets321,322to the outside of the scan nozzle30SN.

Next, the above-described operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing are terminated, and then, light is radiated from the light source11provided at one end of the chemical solution dispensing port34. The light radiated from the light source11propagates the inside of the chemical solution dispensing port34in its longitudinal direction. The propagated light is received by the light receiving part12provided at the other end of the chemical solution dispensing port34. The light receiving part12outputs a current which corresponds to the received light quantity. This current is measured by a measuring instrument (not shown). The measurement result is sent to a scan nozzle control part (not shown).

In the embodiment, the above light quantity was 1200 (arbitrary unit (a.u.)). On the other hand, a light quantity (reference value) which had been measured in advance was 1240 (a.u.), which is the light quantity of the light received by the light receiving part12, the light being radiated from the light source11in a state in which no air bubbles were included in the chemical solution dispensing port34and the inside of the dispensing port was filled with the developing solution. The light quantity (1240 (a.u.)) is stored as a reference value in advance in a scan nozzle control part (not shown).

In the embodiment, after the above-described operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing have been completed, the light quantity of the light received at the light receiving part12and the light quantity defined as a reference value are compared with each other by the scan nozzle control part. As a result of the comparison, in the case where the values of these light quantities are equal to each other, processing goes to the step shown inFIG. 6E. On the other hand, in the case where they are not equal, the above-described operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing are carried out again. That is, the operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing are repeated until it has been determined that no air bubbles exist in the chemical solution dispensing port34.

In the case where it has been determined that no air bubbles exist in the chemical solution dispensing port34, as shown inFIG. 6E, the scan nozzle30SN is further fallen until a gap G2between the nozzle lower face and the auxiliary plate20has been set at a desired value, 50 microns in this embodiment. Then, while the gap G2is held at the above desired value, the operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing are carried out, and the scan nozzle30SN is scanned above the target substrate1at a speed of 1 mm per second, thereby carrying out a developing process.

In the present embodiment, TMAH (normality 0.27N) is used as a developing solution. Further, a dispensing flow rate of the developing solution, a suction flow rate of liquid solution, and a suction pressure of the liquid solution suction flow rate are adjusted in advance such that the developing solution dispensed from the chemical solution dispensing port34is sucked into the chemical solution suction ports351,352.

Next, the target substrate1is rotated, and the liquid solution on the target substrate1is vibrated. Then, the target substrate1is dried, whereby a resist pattern forming process completes.

When the in-plane uniformity of a resist pattern formed in accordance with the method of the embodiment was measured, a result of 2.7 nm (3σ) was obtained On the other hand, when the in-plane uniformity of the resist pattern formed in accordance with the conventional technique (developing without elimination of air bubbles80) was measured, a result of 7.5 nm (3σ) was obtained. From the above results, it was verified that a resist pattern having significantly improved uniformity can be provided according to the embodiment.

According to the present embodiment, advantageous effect similar to that according to the first embodiment can be attained. Further, according to the embodiment, there can be provided advantageous effect that a developing process can be carried out after it has been verified that no air bubbles exist in the chemical solution dispensing port34by using the scan nozzle30SN comprising the light source11and the light receiving part12. That is, according to the present embodiment, the developing process can be carried out in a state in which no air bubbles reliably exist in the chemical solution dispensing port34, thereby making it possible to reliably prevent the non-uniformity of the flow of the chemical solution caused by the air bubbles.

In the embodiment, although the auxiliary plate20according to the first embodiment has been used, the auxiliary plate20according to the second embodiment, namely, the auxiliary plate20comprising the recess portion21may be used. In this case, the bubble removing process is carried out in the same manner as that in the second embodiment except a process for determining the presence or absence of air bubbles in the chemical solution dispensing port34. The sensitivity adjustment of the optical system including the light source11and the light receiving part12is periodically carried out.

Fourth Embodiment

FIGS. 7A to 7Dare views each adopted to explain a substrate processing method according to a fourth embodiment of the invention. In more detail, these figures are views each adopted to explain a method for making operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing in the third embodiment.

First, as in the third embodiment, up to the processes shown inFIG. 6Care carried out. Next, the scan nozzle30SN is held in a state in which a lower face (nozzle lower face) of the scan nozzle30SN has come into contact with the liquid level of the liquid solution51.

Here, at a moment at which the nozzle lower face has come into contact with the liquid level of the liquid solution51, air bubbles80enter the inside of the chemical solution dispensing port34situated on the nozzle lower face. Then, in the embodiment, in order to eliminate the air bubbles80from the inside of the chemical solution dispensing port34, operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing (dispensing/sucking operations) are carried out in a state in which the nozzle lower face has come into contact with the liquid level of the liquid solution51, as shown inFIGS. 7A to 7D. Here, these operations will be described in more detail.

First, as shown inFIG. 7A, dispensing/sucking operation is carried out for5seconds in all the chemical solution dispensing port34, the chemical solution suction ports351,352and the rinse solution dispensing ports361,362.

At this time, in the case where air bubbles have existed immediately beneath the chemical solution dispensing port34, the air bubbles are sucked from the chemical solution suction ports351,352with a substantially equal suction force. Thus, the above air bubbles cannot be sometimes removed while the bubbles are kept at their same position.

Next, as shown inFIG. 7B, dispensing/sucking operation is further carried out for 5 second in all the ports excluding the chemical solution suction port351. At this time, in the case where air bubbles have existed immediately beneath the chemical solution suction port34, the sucking by the chemical solution suction port351stops. Thus, the above air bubbles are sucked by the inside of the chemical solution suction port352, and the sucked bubbles are removed.

Next, as shown inFIG. 7C, dispensing/sucking operation is further carried out for 5 seconds in all the ports excluding the chemical solution suction port352. At this time, in the case where air bubbles have existed immediately beneath the chemical solution suction port34, the sucking by the chemical solution suction port352stops. Thus, the residual air bubbles are sucked into the chemical solution suction port351, and the sucked bubbles are removed.

Next, as in the third embodiment, light is radiated from the light source11provided at one end of the chemical solution dispensing port34. The light is received at the light receiving part12provided at one end of the chemical solution dispensing port34. Further, the light quantity of the received light and the light quantity 1240 (a.u.) defined as a reference value are compared with each other. In this embodiment, the light quantity of the received light was 1150 (a.u.).

Then, as shown inFIG. 7D, dispensing/sucking operation was carried out for 5 seconds in all the ports of the chemical solution dispensing port34, the chemical solution suction ports351,352, and the rinse solution dispensing ports361,362. Then, light was radiated from the light source11, the light was received at the light receiving port12, and then, the light quantity was measured.

As a result, the light quantity was 1240 (a.u.) which is equal to a reference value. That is, it was determined that no air bubbles exist in the chemical solution suction port352. The dispensing/sucking operation shown inFIGS. 7A to 7Cmay be carried out instead of the dispensing/sucking operation shown inFIG. 7D. The dispensing/sucking operation according to the present embodiment is repeated until it has been determined that no air bubbles exist in the chemical solution suction port352.

Then, a process (FIGS. 6E and 6F) which is similar to that according to the third embodiment is carried out, and a developing process terminates.

When the in-plane non-uniformity of the resist pattern formed in accordance with the method of the embodiment was measured, a result of 2.7 nm (3σ) was obtained. On the other hand, when the in-plane uniformity of the resist pattern formed in accordance with the conventional technique (developing without elimination of air bubbles80) was measured, a result of 7.5 nm (3σ) was obtained. From the above results, it was verified that a resist pattern having significantly improved uniformity can be provided according to the embodiment.

According to the embodiment, advantageous effect similar to that according to the third embodiment can be attained. Further, according to the embodiment, dispensing/sucking operation is carried out such that air bubbles hardly remain in the chemical solution dispensing port34, thus making it possible to more effectively prevent the non-uniformity of the flow of the chemical solution caused by the air bubbles.

The dispensing/sucking operation according to the present embodiment can be applied to the first embodiment, the second embodiment, and further, a fifth embodiment described later. Furthermore, this operation can be applied to a substrate processing apparatus and a substrate processing method which do not use an auxiliary plate.

In addition, a combination example of dispensing/sucking operation is not limited to that of the embodiment. Various modifications can occur depending on the number of dispensing ports, the number of suction ports, or their arrangement sequences, of the scan nozzle30N. That is, any construction may be provided as long as it can change the pressure or flow of a liquid solution in the left and right regions which sandwich the suction port in order to remove the air bubbles in the dispensing port.

Fifth Embodiment

FIG. 8is a view schematically depicting an outline construction of a substrate processing apparatus according to a fifth embodiment of the invention. The substrate processing apparatus according to this embodiment is different from that of the third embodiment in that a vibrator13is incorporated in the scan nozzle30SN.

The vibrator13can be vibrated by selecting any arbitrary one of a plurality of vibration frequencies. The above vibration frequency is not limited in particular as long as it does not affect pattern dimensions in the target substrate1.

Now, a description will be given with respect to a substrate processing method using the substrate processing apparatus of the embodiment. Here, a description will be given with respect to a case where the chemical liquid is a developing solution, namely, a case of a developing processing method.

First, as in the third embodiment, the liquid solution51is filled on the target substrate1and the auxiliary plate20laid out so as to surround the target substrate1. Next, the scan nozzle30SN is moved from a scan nozzle standby position (not shown) upwardly of the auxiliary plate20. Then, the scan nozzle30SN is fallen, and the scan nozzle30SN is held in a state in which the nozzle lower face has come into contact with the liquid level of the liquid solution51. At this time, a gap G1between the nozzle lower face and the auxiliary plate20is set to, for example, 4 mm.

Here, at a moment at which the nozzle lower face has come into contact with the liquid level of the liquid solution51, air bubbles80enter the inside of the chemical solution dispensing port34situated on the nozzle lower face. Therefore, in the present embodiment, in order to remove the air bubbles80from the inside of the chemical solution dispensing port34, operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing (dispensing/suction operations) are carried out in a state in which the nozzle lower face has come into contact with the liquid level of the liquid solution51and the vibrator13is operated to vibrate the scan nozzle31. In more detail, the dispensing/sucking operation is carried out for 5 second and five times for all the ports of the chemical solution dispensing port34, the chemical solution suction ports351,352, and the rinse solution dispensing ports361,362.

Next, light is radiated from the light source11provided at one end of the chemical solution dispensing port34. Then, the light is received at the light receiving section12provided at one end of the chemical solution dispensing port34. Further, the light quantity of the received light and the light quantity 1240 (a.u.) defined as a reference value are compared with each other. In the embodiment, the light quantity of the received light was 1240 (a.u). That is, it was determined that no air bubbles exist in the chemical solution dispensing port352.

Next, the scan nozzle30SN is further lowered until a gap between the nozzle lower face and the auxiliary plate20is obtained as a desired value, i.e., 100 microns in the present embodiment. Thereafter, while the gap is held at the above desired value, the operations of developing solution dispensing, liquid solution sucking, and rinse solution dispensing are carried out, and the scan nozzle30SN is scanned above the target substrate1at a speed of 3 mm per second, thereby carrying out a developing process.

Next, the target substrate1is rotated, and the liquid solution on the target substrate is vibrated. Then, the target substrate1is dried, whereby a process for forming a resist pattern completes.

When the in-plane uniformity of a resist pattern formed in accordance with the method of the embodiment was measured, a result of 2.7 nm (3σ) was obtained. On the other hand, when the in-plane uniformity of the resist pattern formed in accordance with the conventional technique (developing without elimination of air bubbles80) was measured, a result of 7.5 nm (3σ) was obtained. From the above results, it was verified that a resist pattern having significantly improved uniformity can be provided according to the embodiment.

According to the embodiment, advantageous effect similar to that according to the third embodiment can be attained. Further, according to the embodiment, the scan nozzle30SN is vibrated by the vibrator13during dispensing/sucking operation. In this manner, the air bubbles in the chemical solution dispensing port34can be effectively moved, thus making it possible to more effectively remove the air bubbles.

In addition, the substrate processing apparatus and the substrate processing method using the vibrator according to the embodiment can be applied to any of the first, second, and fourth embodiments.

FIGS. 9 to 11each show an modified embodiment of the present embodiment.FIG. 9shows an embodiment of using an arm14capable of vertically vibrating the scan nozzle30SN in a state in which the scan nozzle30SN is held instead of the vibrator13.

FIG. 10shows a modified embodiment of using a vibration mechanism15which applies vibration (including pulsation) to the chemical solution introduced into the chemical solution inlet31, thereby making it easy to move the air bubbles in the chemical solution inlet31.

FIG. 11shows a modified embodiment of using the vibration mechanism15which applies vibration (including pulsation) to the liquid discharged from the liquid solution exits321,322instead of the vibrator13, thereby making it easy to move the air bubbles in the chemical solution inlet31.

The above modified examples shown inFIGS. 9 to 11can also be applied to any of the first, second and fourth embodiments.

The present invention is not limited to the above-described embodiments. For example, while the above embodiments have described a case of applying the present invention to developing of a resist on a wafer, the present invention can also be applied to, for example, wet etching of a film (insulation film, electrically conducting film) on a wafer; developing of a photosensitive film on a substrate in a photo mask fabrication process for the manufacture of a semiconductor; wet etching; a stripping process; a cleaning or color filter fabrication process; or developing or cleaning in a process for processing a disk such as DVD.

In addition, a gap produced during bubble removal can be changed in accordance with a diameter of each of the air bubbles or foreign objects existing in the chemical solution dispensing port.

While the first to fifth embodiments have described a method for removing air bubbles in a supplied chemical solution, the sixth embodiment described later describes a method for monitoring particles included in a sucked chemical solution, and terminating a chemical solution process according to the number of particles. According to the fifth embodiment, it becomes possible to remove the particles before drying a substrate surface. Further, the particles contained in the chemical solution are restricted from adhering to the substrate surface, and the yielding is improved. Note that the particles are by-products caused at the time of developing (resist residue) or metallic or organic particles and the like which may exist on the substrate.

Sixth Embodiment

FIG. 12is a view showing an outline construction of a substrate processing section in a substrate developing device according to a sixth embodiment of the present invention. As shown inFIG. 12, the developing device comprises: a substrate110; a substrate holding mechanism for substantially horizontally holding a semiconductor wafer, for example; a developing unit120; a cleaning unit160; and a scan stage201.

The developing unit120comprises: a developing solution dispensing port131; suction ports132,133; a pre-wet liquid solution dispensing port134; and a rinse solution dispensing port135in a developing solution dispensing/sucking head130. A developing solution canister151is connected to the developing solution dispensing port via a pipe141. A pump152is connected to the suction ports132,133via pipes142,143. A pre-wet liquid solution canister153is connected to the pre-wet liquid solution dispensing port134via a pipe144. A rinse solution canister154is connected to the rinse solution dispensing port135via a pipe145. A construction of the developing unit120is similar to that described in Jpn. Pat. Appln. KOKAI Publication No. 2002-252167 described previously, and a duplicate description is omitted here.

A construction of the cleaning unit160will be described with reference toFIGS. 12 to 14.FIG. 13is a view showing a construction of an ozone water dispensing/sucking head, andFIG. 14is a plan view when the ozone water dispensing/sucking head in the developing device is seen from the bottom.

The cleaning unit160comprises an ozone water dispensing/sucking head170which can be scanned on the substrate110by the scan stage201. The ozone water dispensing/sucking head170comprises: an ozone water dispensing port (first dispensing port)171; first and second suction ports172,173; and first and second rinse solution dispensing ports (second and third dispensing ports)174,175.

The ozone water dispensing port171has an ozone water dispensing outlet (first dispensing outlet)171aon a lower face of the ozone water dispensing/sucking head170. The first and second rinse solution dispensing outlet ports174,175have first and second rinse solution dispensing outlets (second and third dispensing outlets)174a,175a, respectively, on a lower face of the ozone water dispensing/sucking head170. The first and second suction ports172,173have first and second sucking inlets172,173aon a lower face of the ozone water dispensing/sucking head170.

In the present embodiment, the ozone water dispensing outlet171a; the first and second rinse solution dispensing outlets174a,175a; and the first and second sucking inlets172a,173ahas long edges in a direction vertical to a scanning direction. These elements are shaped in an elongated port which has short edges in a direction parallel to a moving direction.

An ozone water generator191is connected to he ozone water dispensing port171via a pipe181. Particle counter (measuring mechanism, P.C.)192,193, and a pump194are connected to the suction ports172,173via pipes182,183. The particle counters192,193measure the number of particles by scattering light beams caused by light emission. Rinse solution canisters195,196are connected to the rinse solution dispensing ports174,175via pipes184,185.

On a side face of the ozone water dispensing/sucking head170, a cap measuring mechanism202using laser light is provided in order to measure a gap between a lower face of the ozone water dispensing/sucking head170and an upper face of the semiconductor wafer110placed on a substrate holder111.

A moving mechanism has a scan stage201. A gap adjusting mechanism203is provided both end parts of the ozone water dispensing/sucking head170. The adjusting mechanism is mounted to be integrated with the ozone water dispensing/sucking head170so as to be movable on the scan stage201in a vertical direction.

The gap adjusting mechanism203comprises a piezoelectric element so that a gap between the lower face of the ozone water dispensing/sucking head170and the upper face of the semiconductor wafer110placed on the substrate holder (vacuum chuck)111is adjusted to a predetermined value on the basis of a result of measurement obtained by the gap measuring mechanism202.

The substrate holding mechanism comprises the substrate holder111and an auxiliary plate112. A substrate110is placed on the substrate holder111. The auxiliary plate112is laid out at the periphery of the substrate holder111. The auxiliary plate112can move vertically so that a surface of the substrate110is equal to that of the auxiliary plate112in height during developing. In this manner, when the developing solution is sucked by the ozone water dispensing/sucking head170, a sucking force functions equally in a wafer face.

It is preferable to select the auxiliary plate112made of a material such that the wetting properties between the substrate of the plate and that of the substrate become equal to each other. Specifically, a contact angle of the developing solution on the substrate is set so as to be equal to that of the developing solution on the auxiliary plate112.

Now, developing and cleaning processes using the above described devices will be described here. The developing solution is supplied into the developing solution dispensing port131by pressurizing the developing solution canister151. The developing solution is continuously dispensed from a developing solution dispensing port131aof the developing solution dispensing port131to the substrate110. When the developing solution is dispensed, a pre-wet liquid solution is supplied into the pre-wet liquid solution dispensing port134by pressurizing the pre-wet liquid solution canister153. The pre-wet liquid solution is continuously dispensed from a dispensing outlet of the pre-wet liquid solution dispensing port134to the substrate110. A rinse solution is supplied into the rinse solution dispensing port135by pressurizing the rinse solution canister154. This rinse solution is continuously dispensed from a dispensing outlet of the rinse solution dispensing port135to the substrate110.

The suction ports132,133suck a solution on a substrate by applying a pump sucking force. A mixture liquid solution between the developing solution and the pre-wet liquid solution is sucked through a sucking inlet of the suction port132. A mixture liquid solution between the developing solution and the rinse solution is sucked through a sucking inlet of the suction port133.

As has been described above, while sucking and rinse solution dispensing are carried out at the same time, the port is scanned with a gap of about 100 microns being maintained on a photo mask substrate, and a developing process is carried out. After the developing process has been carried out, the head130is retracted from the top of the substrate, and an entire face on the photo mask is kept in a state in which the rinse solution remains (no dry region).

Now, a cleaning process will be described here. The cleaning process is carried out while the rinse solution is filled on the photo mask substrate after developing of a photo resist film has been carried out.

An ozone water is supplied from the ozone water generator191into the ozone water dispensing port171. The ozone water is dispensed from the ozone water dispensing outlet171aof the ozone water dispensing port171to the substrate. In addition, when the ozone water is dispensed, the rinse solution is supplied into the rinse solution dispensing ports174,175by pressurizing the rinse solution canisters195,196. The solution on the substrate110is sucked through the first and second suction ports172,173by applying the sucking force of the pump194. Both of the ozone water and the rinse solution enter the sucking inlet. As described above, while ozone water dispensing, sucking, and rinse solution dispensing are carried out at the same time, the head170is reciprocally scanned on the surface of the photo mask substrate, and the cleaning process is carried out. During reciprocal scanning, a gap between the substrate surface and the head lower face is set to about 100 microns.

During the cleaning process, the number of particles included in a solution (chemical solution) sucked from the sucking inlet is measured by means of the particle counters192,193. For example, the number of particles is measured by using scattering light beams caused by light emission. A measurement value and measurement position information are transmitted to a controller190. The controller190compares a measurement value in a target region R with a predetermined value. In the case where the measurement values are greater than the predetermined value in all the target regions on the substrate, the controller190causes the cleaning process to be continued. In contrast, in the case where the measurement values in all the target regions on the substrate are equal to or smaller than the predetermined value, the controller190causes the scanning and cleaning processes of the head70to be terminated at a time point at which the ozone water dispensing/sucking head reaches an end part of the substrate. Then, the substrate is dried.

In the case of the present embodiment, the number of particles became 0, which excludes the number of microscopic bubbles, in the target region R at a third reciprocal movement. Thus, the head scanning and cleaning processes are interrupted after three and half reciprocal movements, and then, the substrate was dried. When a defect evaluation was carried out by a mask defect inspecting device with respect to a formed pattern, the number of defects was 0 in a pattern area of about 120 mm×120 mm.

It is preferable to count the number of particles by using the particle counters192,193, after the solution sucked through the first and second sucking ports172a,173ahas been degassed. Particle counting by the particle counters may count air bubbles contained in a solution as a noise. In accordance with the methods of the first to fifth embodiments, the number of particles is counted after the microscopic bubbles have been removed from the inside of the liquid solution, thereby making it possible to precisely count the number of particles.

In the present embodiment, the layouts of the chemical solution dispensing ports and sucking ports are not limited to the above-described layouts. For example, these ports can be laid out in location as shown inFIGS. 15 to 20and can be laid out in any other similar location. InFIGS. 15 to 20, reference numeral221denotes a first chemical solution dispensing port;222denotes a first sucking port;223denotes a second sucking port;224denotes a second chemical solution dispensing port;225denotes a third chemical solution port;226denotes a third sucking port227denotes a fourth sucking port;228denotes a third chemical solution dispensing port;229denotes a fourth chemical solution dispensing port;230denotes a fifth chemical solution dispensing port; and231denotes a sixth chemical solution dispensing port.

In the present embodiment, although the developing solution dispensing/sucking head and the ozone water dispensing/sucking head are relatively scanned on a substrate surface, relative scanning is not always required, depending on the size of the head or the size of the target region R. Although the developing solution dispensing/sucking head and the ozone water dispensing/sucking head has been moved, the substrate may be moved. In addition, the substrate and the developing solution dispensing/sucking head and the ozone water dispensing/sucking head may be moved.

While the present embodiment has shown an application example relating to mask developing, the present invention is not limited thereto. For example, the present invention can be applied to, for example, a wafer developing process or a rinse process; wet etching of an opaque film on a substrate in a photo mask fabrication process for the manufacture of a semiconductor or cleaning of a variety of substrates such as a photo mask; and developing in a color filter fabrication process and a process for processing a disk such as DVD.

FIG. 21is a view showing an outline construction of a developing/cleaning device according to a modified example of the sixth embodiment. Like constituent elements inFIG. 12are designated by like reference numerals, and a detailed description is omitted here.

As shown inFIG. 21, a chemical solution dispensing port241is provided at a developing/cleaning head240. The developing solution canister151and the zone water generator191are connected to the chemical liquid solution port241via a switching device242.

In the case of this apparatus, a chemical solution supplied to the chemical solution dispensing port241is switched by the switching device242, whereby a developing process and a cleaning process can be carried out by one head240.

The following method can also be used to determine the end of the cleaning process according to the number of particles. If the number of particles counted at a sucking port at the frontal side in the scanning direction has become equal to that counted at a sucking port at the rear side in the scanning direction, scanning is terminated at a time point when the nozzle has moved up to the nozzle scanning end position, and the rinse process is terminated.

When the processing termination is thus determined, incorrect sensing of particles due to an effect of the bubbles which exist in the liquid can be restricted.

The present invention is not limited to the above-described embodiments. For example, while the above embodiments have described the cleaning process that follows the developing process, the present invention can be used for a cleaning process that follows an etching process. In addition, an electrolytic ion water or a pure water can be used instead of the ozone water.

The substrate processing method and the substrate processing apparatus according to the sixth embodiment are summarized as follows.

The substrate processing method according to the sixth embodiment is directed to a substrate processing method for supplying a chemical solution to a substrate, and then, processing a target region of the substrate by using the chemical solution, the method including:

laying out on a target region a chemical solution dispensing/sucking part of which a dispensing port for dispensing the chemical solution and a sucking port for sucking a solution on the substrate are laid out on a lower face thereof; dispensing the chemical solution from the dispensing port of the chemical solution dispensing/sucking part against the substrate; sucking the solution on the substrate at the sucking port during the dispensing; counting the number of particles included in the solution sucked through the sucking port during the sucking; and in the case where a count value of the number of particles included in the solution sucked in the target region is equal to or smaller than a predetermined value, stopping dispensing of the chemical solution.

During the dispensing, the chemical solution dispensing/sucking part can be scanned on the substrate surface relatively.

The chemical solution is provided as a developing solution, an ozone water, an electrolytic ion water, or a pure water.

It is preferable that air bubbles are removed from the chemical solution sucked through the sucking port.

The substrate processing apparatus according to the sixth embodiment is directed to a substrate processing apparatus for supplying a chemical solution to a substrate, and then, processing a target region of the substrate by using the chemical solution, the apparatus comprising: a substrate holding mechanism which holds a substrate; a chemical solution dispensing/sucking part which comprises a chemical supply system including a lower face opposed to the substrate and a first chemical solution dispensing nozzle which dispenses a first chemical solution from a first chemical solution dispensing port arranged on the lower face, and a solution sucking system comprising a first sucking nozzle which sucks the solution on the substrate from a first sucking port arranged on the lower face; a counting mechanism which counts the number of particles included in the solution sucked by the solution sucking system; and a determining part, in the case where the number of particles counted by this counting mechanism is equal to or smaller than a predetermined value, which terminates the chemical solution processing.

The counting mechanism counts the number of particles by the scattering light beams caused by light emission.

This apparatus can further comprise a scanning mechanism which relatively scans the chemical solution dispensing/suction part on the substrate.

The chemical solution supply system further comprises second and third chemical solution dispensing nozzles for dispensing second and third chemical solutions from second and third chemical solution dispensing outlets arranged on the lower face, respectively. The solution sucking system further comprises a second sucking nozzle for sucking a solution on the substrate from the second sucking port arranged on the lower face. The first, second, and third chemical solution dispensing ports and the first and second sucking ports are arranged along the scanning direction. The first and second sucking ports are arranged so as to sandwich the first chemical solution dispensing port between the sucking ports. The second and third chemical solution dispensing ports are arranged so as to sandwich the first and second sucking ports between the dispensing outlets.

The solution sucking system further comprises a second sucking nozzle which sucks a solution on the substrate from the second sucking port arranged on the lower face. The first and second sucking ports are laid out so as to sandwich the first chemical solution dispensing port between the sucking ports.

The first sucking port is laid out so as to surround the first chemical solution dispensing port.