Patent Publication Number: US-2023144827-A1

Title: Substrate processing apparatus

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims priority to and benefits of Korean Patent Application No. 10-2021-0155207 under 35 U.S.C. § 119, filed on Nov. 11, 2021, in the Korean Intellectual Property Office (KIPO), the disclosure of which is incorporated by reference herein in its entirety. 
     BACKGROUND 
     1. Technical Field 
     The disclosure relates to a substrate processing apparatus used in a manufacturing process of a display device. 
     2. Description of the Related Art 
     Examples of a display device may include a liquid crystal display device and an organic light emitting display device. 
     In manufacturing a display device, a vacuum chamber for performing manufacturing processes such as etching or deposition in a vacuum state is required. In case that the size of the vacuum chamber increases, pressure applied to the outer wall of the vacuum chamber also increases due to the vacuum pressure formed inside the vacuum chamber, and the vacuum chamber may deform more easily. 
     SUMMARY 
     Embodiments of the disclosure provide a substrate processing apparatus with improved process uniformity. 
     Additional features of the disclosure will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the disclosure. 
     A substrate processing apparatus according to an embodiment may include a chamber having a working space, maintaining a vacuum state, and including an upper wall positioned on the working space, a nozzle assembly positioned in the working space and including nozzles, and a lifting module including a frame positioned outside of the chamber, a lifting part that lifts the frame, and at least one shaft passing through the upper wall, connected to the frame and the nozzle assembly, and extending in a direction of gravity. 
     In an embodiment, a first end portion of the at least one shaft may be connected to the frame on the upper wall, and a second end portion opposite to the first end portion of the at least one shaft may be connected to the nozzle assembly in the working space. 
     In an embodiment, the lifting module may further include a first fastening part positioned between the upper wall and the frame, surrounding the at least one shaft, fixed to the at least one shaft, and having a flat plate shape, and the substrate processing apparatus may further include at least one first elastic member connected to a bottom surface of the first fastening part and an upper surface of the upper wall, and the at least one first elastic member being expandable and contractible in the direction of gravity. 
     In an embodiment, the at least one first elastic member may surround the at least one shaft. 
     In an embodiment, the at least one shaft may be separated from the upper wall. 
     In an embodiment, the nozzle assembly may have an overall rectangular shape in a plan view, the at least one shaft may include a plurality of shafts, and the plurality of the shafts may be positioned at vertices of the rectangular shape of the nozzle assembly. 
     In an embodiment, the at least one first elastic member may include a plurality of first elastic members, and the plurality of the first elastic members may be positioned at vertices of the rectangular shape of the nozzle assembly, and surround the plurality of the shafts. 
     In an embodiment, the substrate processing apparatus may further include a gas supply pipe passing through the upper wall, connected to the nozzle assembly, and supplying gas to the nozzle assembly, a second fastening part positioned on the upper wall, surrounding the gas supply pipe, fixed to the gas supply pipe, and having a flat plate shape and a second elastic member connected to a bottom surface of the second fastening part and an upper surface of the upper wall, and expandable and contractible in the direction of gravity. 
     In an embodiment, the second elastic member may surround the gas supply pipe. 
     In an embodiment, the gas supply pipe may be separated from the upper wall. 
     In an embodiment, the substrate processing apparatus may further include a gas exhaust pipe passing through the upper wall, connected to the nozzle assembly, and exhausting gas from the nozzle assembly to the outside of the chamber, a third fastening part positioned on the upper wall, surrounding the gas exhaust pipe, fixed to the gas exhaust pipe, and having a flat plate shape and a third elastic member connected to a bottom surface of the third fastening part and an upper surface of the upper wall, and expandable and contractible in the direction of gravity. 
     In an embodiment, the third elastic member may surround the gas exhaust pipe. 
     In an embodiment, the gas exhaust pipe may be separated from the upper wall. 
     In an embodiment, the chamber may further include a side wall, and the lifting part may be supported by the side wall. 
     In an embodiment, the substrate processing apparatus may further include a support frame adjacent to the chamber from the outside of the chamber, wherein the lifting part may be supported by the support frame. 
     A substrate processing apparatus according to an embodiment may include a chamber having a working space, maintaining a vacuum state, and including an upper wall positioned on the working space, a nozzle assembly positioned in the working space and including nozzles, a lifting module (including a frame positioned outside of the chamber, a lifting part that lifts the frame, a shaft passing through the upper wall, connected to the frame and the nozzle assembly, and extending in a direction of gravity, and a first fastening part positioned between the upper wall and the frame, surrounding the shaft, fixed to the shaft, and having a flat plate shape), a gas supply pipe passing through the upper wall, connected to the nozzle assembly, and supplying gas to the nozzle assembly, a second fastening part positioned on the upper wall, surrounding the gas supply pipe, fixed to the gas supply pipe, and having a flat plate shape, a first elastic member connected to a bottom surface of the first fastening part and an upper surface of the upper wall, and expandable and contractible in the direction of gravity and a second elastic member connected to a bottom surface of the second fastening part and the upper surface of the upper wall, and expandable and contractible in the direction of gravity. 
     In an embodiment, a first end portion of the shaft may be connected to the frame on the upper wall, and a second end portion opposite to the first end portion of the shaft may be connected to the nozzle assembly in the working space. 
     In an embodiment, the first elastic member may surround the shaft, and the second elastic member may surround the gas supply pipe. 
     In an embodiment, each of the shaft and the gas supply pipe may be separated from the upper wall. 
     In an embodiment, the substrate processing apparatus may further include a gas exhaust pipe passing through the upper wall, connected to the nozzle assembly, and exhausting gas from the nozzle assembly to the outside of the chamber, a third fastening part positioned on the upper wall, surrounding the gas exhaust pipe, fixed to the gas exhaust pipe, and having a flat plate shape and a third elastic member connected to a bottom surface of the third fastening part and the upper surface of the upper wall, and expandable and contractible in the direction of gravity. 
     According the embodiments of the disclosure, even if the upper wall of the vacuum chamber is deformed by vacuum pressure, the nozzle assembly inside of the vacuum chamber may not be deformed. Accordingly, a distance between the nozzles and the substrate may be kept constant throughout a nozzle assembly, and a uniformity of a substrate processing process may be maintained. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the disclosure as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure, and together with the description serve to explain the disclosure. 
         FIG.  1    is a schematic cross-sectional view illustrating a substrate processing apparatus according to an embodiment of the disclosure. 
         FIG.  2    is a plan view illustrating a lifting module included in the substrate processing apparatus of  FIG.  1   . 
         FIG.  3    is a plan view illustrating a shaft included in the lifting module of  FIG.  2   . 
         FIG.  4    is an enlarged view illustrating area ‘A’ of  FIG.  1   . 
         FIG.  5    is a plan view illustrating a first fastening part included in the lifting module of  FIG.  2   . 
       FIS.  6  is a plan view illustrating a second fastening part and a third fastening part included in the substrate processing apparatus of  FIG.  1   . 
         FIG.  7    is a view illustrating a substrate processing apparatus according to an embodiment of the disclosure. 
         FIG.  8    is a plan view illustrating a lifting module included in the substrate processing apparatus of  FIG.  7   . 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Illustrative, non-limiting embodiments will be more clearly understood from the following detailed description in conjunction with the accompanying drawings. 
     The spatially relative terms “under”, “below”, “beneath”, “lower”, “above”, “upper”, or the like, may be used herein for ease of description to describe the relations between one element or component and another element or component as illustrated in the drawings. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation, in addition to the orientation depicted in the drawings. For example, in the case where a device illustrated in the drawing is turned over, the device positioned “below” or “beneath” another device may be placed “above” another device. Accordingly, the illustrative term “below” may include both the lower and upper positions. The device may also be oriented in other directions and thus the spatially relative terms may be interpreted differently depending on the orientations. 
       FIG.  1    is a schematic cross-sectional view illustrating a substrate processing apparatus according to an embodiment of the disclosure. 
     Referring to  FIG.  1   , a substrate processing apparatus  1000  according to an embodiment of the disclosure may include a chamber  100 , a nozzle assembly  200 , a lifting module  300  including a first fastening part  340 , a gas supply pipe  410 , a second fastening part  420 , a gas exhaust pipe  510 , a third fastening part  520 , a first elastic member  610 , a second elastic member  620 , and a third elastic member  630 . 
     The chamber  100  may have a working space  110  capable of maintaining a vacuum state, and may include an upper wall  120  and a side wall  130 . The working space  110  may be a space in which various processing processes for a substrate, such as an etching process or a deposition process, are performed. 
     The nozzle assembly  200  may be positioned in the working space  110 , and may include multiple nozzles  210 . The multiple nozzles  210  may spray gas onto the substrate  1 . 
       FIG.  2    is a plan view illustrating a lifting module included in the substrate processing apparatus of  FIG.  1   . 
     Referring to  FIGS.  1  and  2   , the lifting module  300  may include a frame  310 , lifting part  320 , a shaft  330 , and a first fastening part  340 , and may lift the nozzle assembly  200 . 
     The frame  310  may be positioned outside of the chamber  100 . For example, as illustrated in  FIGS.  1  and  2   , the frame  310  may be positioned on the upper wall  120  of the chamber  100 . 
     In an embodiment, as illustrated in  FIG.  1   , the frame  310  may be positioned on the lifting part  320 . Also, the frame  310  may overlap each of the lifting part  320  , the shaft  330  , and the first fastening part  340 . Also, the frame  310  may have a rectangular shape in a plan view. Accordingly, as illustrated in  FIG.  2   , the lifting module  300  may have a rectangular shape in a plan view. 
     As illustrated in  FIG.  1   , the lifting part  320  may be connected to the frame  310  and may lift the frame  310 . For example, the lifting part  320  may include a jack screw (not illustrated) fixed to the chamber  100  and a motor (not illustrated) for driving the jack screw. Also, the jack screw (not illustrated) may lift the frame  310  by driving of the motor (not illustrated). 
     In an embodiment, as illustrated in  FIG.  1   , the sidewall  130  of the chamber  100  may support the lifting part  320 . 
       FIG.  3    is a plan view illustrating a shaft included in the lifting module of  FIG.  2   . 
     Referring to  FIGS.  1  to  3   , the shaft  330  may pass through the upper wall  120  of the chamber  100  and may extend in a direction of gravity Dg. Also, the shaft  330  may be connected to each of the frame  310  and the nozzle assembly  200 . For example, a first end portion of the shaft  330  may be connected to the frame  310  on the upper wall  120 , and a second end portion of the shaft  330  opposite to the first end portion may be connected to the nozzle assembly  200  in the working space  110 . Accordingly, the shaft  330  may transmit a power generated outside of the chamber  100  to the nozzle assembly  200 . 
     The lifting part  320  may be connected to the frame  310  and may lift the frame  310 . Also, the shaft  330  may transmit the power generated outside of the chamber  100  to the nozzle assembly  200 . Accordingly, the lifting module  300  may lift the nozzle assembly  200 . 
     In an embodiment, a first distance of which the frame  310  moves may be substantially the same as a second distance of which the nozzle assembly  200  moves. 
     In an embodiment, as illustrated in  FIG.  3   , the nozzle assembly  200  may have an overall rectangular shape in a plan view. Also multiple shaft  330  may be provided, and the multiple of shaft  330   a,    330   b,    330   c,  and  330   d  may be respectively positioned at vertices of the rectangular shape. 
       FIG.  4    is an enlarged view illustrating area ‘A’ of  FIG.  1   . 
     Referring to  FIG.  4   , the shaft  330  may be separated from the upper wall  120 . For example, the shaft  330  may be not in contact with the upper wall  120 . Accordingly, the shaft  330  may be not fixed to the upper wall  120 . In other words, The shaft  330  may be not constrained by the upper wall  120 , and may descend in the direction of gravity Dg or rise in a direction opposite to the direction of gravity Dg by lifting of the frame  310 . 
       FIG.  5    is a plan view illustrating a first fastening part included in the lifting module of  FIG.  2   . 
     Referring to  FIGS.  4  and  5   , the first fastening part  340  may be positioned between the upper wall  120  and the frame  310 , may surround the shaft  330 , and may be fixed to the shaft  330 . Also, the first fastening part  340  may have a flat plate shape. The first fastening part  340  and the shaft  330  may be integral with each other or may be fastened after being formed separately. 
     In an embodiment, as illustrated in  FIG.  5   , the first fastening part  340  may have a circular shape in a plan view. However, embodiments are not limited thereto. 
     As illustrated in  FIG.  4   , the first elastic member  610  may be connected to a bottom surface of the first fastening part  340  and an upper surface of the upper wall  120 , respectively, and may expand and contract in the direction of gravity Dg. Also, the first elastic member  610  may surround the shaft  330 . 
     In an embodiment, as illustrated in  FIG.  5   , multiple first elastic member  610  may be provided. The multiple first elastic member  610   a ,  610   b ,  610   c , and  610   d  may be respectively positioned at the vertices of the rectangular shape described with reference to  FIG.  3    and may surround the multiple shaft  330   a ,  330   b ,  330   c , and  330   d , respectively. 
     In an embodiment, the first elastic member  610  may be a bellows. As illustrated in  FIGS.  1  and  5   , the first elastic member  610  may seal the chamber  100  so that the working space  110  of the chamber  100  maintains the vacuum state. 
     In case that the working space  110  maintains a vacuum state, the chamber  100  may be deformed by vacuum pressure. For example, in case that the working space  110  maintains a vacuum state, the upper wall  120  may sag in the direction of gravity Dg. If the nozzle assembly  200  is fixed to the upper wall  120  or a movement is restricted, the nozzle assembly  200  may deflect in the direction of gravity Dg. Also, the amount of deflection of a center of the nozzle assembly  200  may be different from the amount of deflection of a edge of the nozzle assembly  200 . Accordingly, in case that the multiple nozzles  210  inject gas onto the substrate  1 , a characteristic of the center of the substrate  1  and a characteristic of the edge of the substrate  1  may be different. 
     However, according to embodiments of the disclosure, the lifting module  300  for lifting the nozzle assembly  200  may be supported by the sidewall  130  of the chamber  100 . Also, the shaft  330  connected to the nozzle assembly  200  may be separated from the upper wall  120  and may not be constrained by the upper wall  120 . Also, the first elastic member  610  connecting the first fastening part  340  fixed to the shaft  330  and the upper wall  120  may be expandable and contractible in the direction of gravity Dg. Accordingly, even if the upper wall  120  is deformed by the vacuum pressure, the nozzle assembly  200  may not be deformed. Accordingly, a distance between the nozzles  210  and the substrate  1  may be kept constant throughout the nozzle assembly  200 , and a uniformity of a substrate processing process may be maintained. 
     FIS.  6  is a plan view illustrating a second fastening part and a third fastening part included in the substrate processing apparatus of  FIG.  1   . 
     Referring to  FIGS.  1  and  6   , the gas supply pipe  410  may pass through the upper wall  120  and may be connected to the nozzle assembly  200 . The gas supply pipe  410  may supply gas to the nozzle assembly  200 . 
     The second fastening part  420  may be positioned on the upper wall  120  and may surround the gas supply pipe  410 . The second fastening part  420  may have a flat plate shape. 
     In an embodiment, as illustrated in  FIG.  6   , the second fastening part  420  may have a rectangular shape in a plan view. However, embodiments are not limited thereto. 
     The second elastic member  620  may be connected to a bottom surface of the second fastening part  420  and the upper surface of the upper wall  120 , respectively, and may expand and contract in the direction of gravity Dg. Also, the second elastic member  620  may surround the gas supply pipe  410 . 
     In an embodiment, the second elastic member  620  may be a bellows. As illustrated in  FIGS.  1  and  6   , the second elastic member  620  may seal the chamber  100  so that the working space  110  of the chamber  100  maintains the vacuum state. 
     The gas supply pipe  410  may be separated from the upper wall  120 . For example, the gas supply pipe  410  may be not in contact with the upper wall  120  like the shaft  330  described with reference to  FIG.  4   . Accordingly, the gas supply pipe  410  may not be fixed to the upper wall  120 . In other words, the gas supply pipe  410  may be not constrained by the upper wall  120 , and may rise in the direction of gravity Dg or may descend in a direction opposite to the direction of gravity Dg. Accordingly, even if the upper wall  120  is deformed by the vacuum pressure, the nozzle assembly  200  may not be deformed. Accordingly, the distance between the nozzles  210  and the substrate  1  may be kept constant throughout the nozzle assembly  200 , and the uniformity of the substrate processing process may be maintained. 
     The gas exhaust pipe  510  may pass through the upper wall  120  and may be connected to the nozzle assembly  200 . The gas exhaust pipe  510  may exhaust gas from the nozzle assembly  200  to the outside of the chamber  100 . 
     In an embodiment, as illustrated in  FIG.  6   , multiple gas exhaust pipes  510  may be provided. The multiple gas exhaust pipes  510   a  and  510   b  may be symmetrical with respect to the gas supply pipe  410 . However, embodiments are not limited thereto. 
     The third fastening part  520  may be positioned on the upper wall  120  and may surround the gas exhaust pipe  510 . The third fastening part  520  may have a flat plate shape. 
     In an embodiment, as illustrated in  FIG.  6   , multiple third fastening parts  520  may be provided. The multiple third fastening parts  520   a  and  520   b  may surround the multiple gas exhaust pipes  510   a  and  510   b , respectively. 
     In an embodiment, as illustrated in  FIG.  6   , the third fastening part  520  may have a rectangular shape in a plan view. However, embodiments are not limited thereto. 
     The third elastic member  630  may be connected to a bottom surface of the third fastening part  520  and the upper surface of the upper wall  120 , respectively, and may expand and contract in the direction of gravity Dg. Also, the third elastic member  630  may surround the gas exhaust pipe  510 . 
     In an embodiment, the third elastic member  630  may be a bellows. As illustrated in  FIGS.  1  and  6   , the third elastic member  630  may seal the chamber  100  so that the working space  110  of the chamber  100  maintains the vacuum state. 
     The gas exhaust pipe  510  may be separated from the upper wall  120 . For example, the gas exhaust pipe  510  may be not in contact with the upper wall  120  like the shaft  330  described with reference to  FIG.  4   . Accordingly, the gas exhaust pipe  510  may be not fixed to the upper wall  120 . In other words, the gas exhaust pipe  510  may not be constrained by the upper wall  120 , and may rise in the direction of gravity Dg or may descend in the direction opposite to the direction of gravity Dg. Accordingly, even if the upper wall  120  is deformed by the vacuum pressure, the nozzle assembly  200  may not be deformed. Accordingly, the distance between the nozzles  210  and the substrate  1  may be kept constant throughout the nozzle assembly  200 , and the uniformity of the substrate processing process may be maintained. 
       FIG.  7    is a view illustrating a substrate processing apparatus according to an embodiment of the disclosure. 
     Referring to  FIG.  7   , the substrate processing apparatus  2000  according to an embodiment of the disclosure may include a chamber  100 , a nozzle assembly  200 , a support frame  1100 , a lifting module  1300  including a first fastening part  1340 , a gas supply pipe  410 , a second fastening part  420 , a gas exhaust pipe  510 , a third fastening part  520 , a first elastic member  1610 , a second elastic member  1620 , a the third elastic member  1630 . 
     The support frame  1100  included in the substrate processing apparatus  2000  may be positioned adjacent to the chamber  100  outside of the chamber  100 . 
     Hereinafter, a description of the substrate processing apparatus  1000  already described with reference to  FIG.  1    will be omitted or simplified. 
       FIG.  8    is a plan view illustrating a lifting module included in the substrate processing apparatus of  FIG.  7   . 
     Referring to  FIGS.  7  and  8   , the lifting module  1300  may include a frame  1310 , lifting part  1320 , a shaft  1330 , and a first fastening part  1340 , and may lift the nozzle assembly  200 . 
     The frame  1310  may be positioned outside of the chamber  100 . For example, as illustrated in  FIGS.  7  and  8   , the frame  1310  may be positioned on the support frame  1100 . 
     In an embodiment, as illustrated in  FIG.  7   , The frame  1310  may be positioned on the lifting part  1320 , and may overlap each of the lifting part  1320 , the shaft  1330 , and the first fastening part  1340 . Also, the frame  1310  may have a rectangular shape in a plan view. Accordingly, as illustrated in  FIG.  8   , the lifting module  1300  may have the rectangular shape in a plan view. 
     As illustrated in  FIG.  7   , the lifting part  1320  may be connected to the frame  1310  and may lift the frame  1310 . For example, the lifting part  1320  may include a jack screw (not illustrated) fixed to the support frame  1100  and a motor (not illustrated) for driving the jack screw. Also, the jack screw (not illustrated) may lift the frame  1310  by driving of the motor (not illustrated). 
     In an embodiment, as illustrated in  FIG.  7   , the support frame  1100  may support the lifting part  1320 . 
     The shaft  1330  may pass through the upper wall  120  of the chamber  100  and may extend in the direction of gravity Dg. Also, the shaft  1330  may be connected to each of the frame  1310  and the nozzle assembly  200 . For example, a first end portion of the shaft  1330  may be connected to the frame  1310  on the upper wall  120 , and a second end portion opposite to the first end portion of the shaft  1330  may be connected to the nozzle assembly  200  in the working space  110  . Accordingly, the shaft  1330  may transmit a power generated outside of the chamber  100  to the nozzle assembly  200 . 
     The lifting part  1320  may be connected to the frame  1310  and may lift the frame  1310 . Also, the shaft  1330  may transmit the power generated outside of the chamber  100  to the nozzle assembly  200 . Accordingly, the lifting module  1300  may lift the nozzle assembly  200 . 
     The shaft  1330  may be separated from upper wall  120 . For example, shaft  330  may be not in contact with the upper wall  120 . Accordingly, the shaft  1330  may be not fixed to the upper wall  120 . In other words, the shaft  1330  may not be constrained by the upper wall  120 , and may rise in the direction of gravity Dg or may descend in the direction opposite to the direction of gravity Dg. 
     According to embodiments of the disclosure, the lifting module  1300  for lifting the nozzle assembly  200  may be supported by the support frame  1100  positioned outside of the chamber  100 . Also, the shaft  1330  connected to the nozzle assembly  200  may be separated from the upper wall  120  of the chamber  100  and may be not constrained by the upper wall  120 . Also, the first elastic member  1610  connecting the first fastening part  1340  fixed to the shaft  1330  and the upper wall  120  may be expandable and contractible in the direction of gravity Dg. Accordingly, even if the upper wall  120  or the side wall  130  of the chamber  100  is deformed by the vacuum pressure, the nozzle assembly  200  may not be deformed. Accordingly, the distance between the nozzles  210  and the substrate  1  may be kept constant throughout the nozzle assembly  200 , and the uniformity of the substrate processing process may be maintained. 
     Although certain embodiments and implementations have been described herein, other embodiments and modifications will be apparent from this description. Accordingly, the disclosure are not limited to such embodiments, but rather to the broader scope of the appended claims and various obvious modifications and equivalent arrangements as would be apparent to a person of ordinary skill in the art.