Patent Abstract:
A vacuum processing apparatus which includes a cassette mount table for holding a cassette, a conveying structure for transferring a wafer from the held on the cassette mount table, a robot, and a vacuum loader. The vacuum loader is provided with a vacuum conveyor chamber and a conveying structure which further include an additional robot.

Full Description:
This application is a Divisional application Ser. No. 09/766,587, filed Jan. 23, 2001, which is a Divisional application of application Ser. No. 09/461,432, filed Dec. 16, 1999, now U.S. Pat. No. 6,330,755, which is a Continuation application of application Ser. No. 09/177,495, filed Oct. 23, 1998, now U.S. Pat. No. 6,012,235, which is a continuation application of application Ser. No. 09/061,062, filed Apr. 16, 1998, now U.S. Pat. No. 5,950,330 which is a Continuation application of application Ser. No. 08/882,731, filed Jun. 26, 1997, now U.S. Pat. No. 5,784,799, which is a Divisional application of application Ser. No. 08/593,870, filed Jan. 30, 1996, now U.S. Pat. No. 5,661,913, which is a Continuing application of application Ser. No. 08/443,039, filed May 17, 1995, now U.S. Pat. No. 5,553,396, which is a Divisional application of application Ser. No. 08/302,443, filed Sep. 9, 1994, now U.S. Pat. No. 5,457,896, which is a Continuing application of application Ser. No. 08/096,256, filed Jul. 26, 1993, now U.S. Pat. No. 5,349,762, which is a Continuing application of application Ser. No. 07/751,951, filed Aug. 29, 1991 now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a vacuum processing apparatus and operating method therefor. More specifically, the present invention relates to a vacuum processing apparatus having vacuum processing chambers the inside of which must be cleaned, and its operating method. 
     2. Description of the Prior Art 
     In a vacuum processing apparatus such as a dry etching apparatus, a CVD apparatus or a sputtering apparatus, a predetermined number of substrates to be treated are stored as one unit (which is generally referred to as a “lot”) in a substrate cassette and are loaded in the apparatus. The substrates after being processed are likewise stored in the same unit in the substrate cassette and are recovered. This is an ordinary method of operating these apparatuses to improve the productivity. 
     In such a vacuum processing apparatus described above, particularly in an apparatus which utilizes a reaction by an active gas, as typified by a dry etching apparatus and a CVD apparatus, reaction products adhere to and are deposited on a vacuum processing chamber with the progress of processing. For this reason, problems such as degradation of vacuum performance, the increase of dust, the drop of the levels of optical monitoring signals occur. To solve these problems, conventionally the insides of the vacuum processing chambers are cleaned periodically. Cleaning operations include so-called “wet cleaning” which is wiping-off of the adhering matters by use of an organic solvent, etc., and so-called “dry cleaning” in which an active gas or plasma is used for decomposing adhering matters. Dry cleaning is superior from the aspect of the working factor and efficiency. These features of the dry cleaning have become essential with the progress in automation of production lines. 
     An example of vacuum processing apparatuses having such a dry cleaning function is disclosed in Japanese Utility Model Laid-Open No. 127125/1988. This apparatus includes a preliminary vacuum chamber for introducing wafers to be treated into a processing chamber from an atmospheric side to a vacuum side, which is disposed adjacent to the processing chamber through a gate valve, dummy wafers are loaded in the preliminary vacuum chamber and are transferred into the processing chamber by exclusive conveyor means before the processing chamber is subjected to dry cleaning, and the dummy wafer is returned to the vacuum preparatory chamber by the conveyor means after dry cleaning is completed. 
     SUMMARY OF THE INVENTION 
     In the prior art technology described above, the structure of the vacuum processing apparatus is not much considered. The preliminary vacuum chamber for storing the dummy wafers must have a large capacity, the exclusive conveyor means is necessary for transferring the dummy wafers and thus, the apparatus is complicated in structure. 
     Dummy wafers used for plasma cleaning are again returned to the preliminary vacuum chamber and are made to stand by. In this instance, reaction products generated during plasma cleaning and residual gas used for plasma cleaning adhere on the used dummy wafers. Thereafter, normal processing for wafers is resumed. Therefore, the used dummy wafers and unprocessed wafers exist in mixture inside the preliminary vacuum chamber and this state is not desirable from the aspect of contamination of unprocessed wafers. 
     The present invention provides a vacuum processing apparatus which solves the problems described above, is simple in structure, prevents contamination of unprocessed substrates and accomplishes a high production yield. A vacuum processing apparatus having vacuum processing chambers the insides of which are dry-cleaned after substrates to be treated are processed in vacuum is provided with first storage means for storing substrates to be treated, second storage means for storing dummy substrates, the first and second storage means being disposed in the air, conveyor means for transferring the substrates to be processed between the first storage means and the vacuum processing chambers and for transferring the dummy substrates between the second storage means and the vacuum processing chambers, and control means for controlling the conveyor means so as to transfer the dummy substrates between the second storage means and the vacuum processing chambers before and after dry cleaning of the vacuum processing chambers. A method of operating a vacuum processing apparatus having vacuum processing chambers the insides of which are dry-cleaned after substrates to be processed are processed in vacuum comprises the steps of disposing first storage means for storing the substrates to be processed together with second storage means for storing dummy substrates in the air atmosphere, transferring the substrates to be processed between the first storage means and the vacuum processing chambers and vacuum-processing the substrates to be processed, and transferring the dummy substrates between the second storage means and the vacuum processing chambers before and after dry-cleaning of the vacuum processing chambers. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view of a dry etching apparatus as an embodiment of a vacuum processing apparatus in accordance with the present invention; and 
     FIG. 2 is a vertical sectional view taken along line  1 — 1  of FIG.  1   
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As substrates to be processed are processed in a vacuum processing apparatus, reaction products adhere to and are deposited in vacuum processing chambers. The reaction products adhering to and deposited in the vacuum processing chambers are removed by disposing dummy wafers inside the vacuum processing chambers and by conducting dry-cleaning. To carry out dry cleaning, the timings of dry cleaning of the vacuum processing chambers are determined and during or after the processing of a predetermined number of substrates to be processed, dummy substrates are conveyed by substrate conveyor means from dummy substrate storage means disposed in the air atmosphere together with processed substrate storage means, and are then disposed inside the vacuum processing chambers. After the dummy substrates are thus disposed, a plasma is generated inside each of the vacuum processing chambers to execute dry-cleaning inside the vacuum processing chamber. After dry-cleaning inside the vacuum processing chambers is completed, the dummy substrates are returned from the vacuum processing chambers to the dummy substrate storage means by the substrate conveyor means. In this manner, a preliminary vacuum chamber and an exclusive transfer mechanism both necessary in prior art techniques become unnecessary, and the apparatus structure gets simplified. The dummy substrates used for the dry-cleaning and the substrates to be processed do not co-exist inside the same chamber, so that contamination of substrates to be processed due to dust and remaining gas is prevented and a high production yield can be achieved. 
     Hereinafter, an embodiment of the present invention will be explained with reference to FIGS. 1 and 2. 
     FIGS. 1 and 2 show a vacuum processing apparatus of the present invention which is, in this case, a dry-etching apparatus for etching wafers, i.e., substrates to be processed by plasma. 
     Cassette tables  2   a  to  2   c  are disposed in an L-shape in this case in positions such that they can be loaded into and unloaded from the apparatus without changing their positions and postures. In other words, the cassettes  1   a  to  1   c  are fixed always in predetermined positions on a substantially horizontal plane, while the cassette tables  2   a  and  2   b  are disposed adjacent to and in parallel with each other on one of the sides of the L-shape. The cassette table  2   c  is disposed on the other side of the L-shape. The cassettes  1   a  and  1   b  are for storing unprocessed wafers and for recovering the processed wafers. They can store a plurality (usually 25) of wafers  20  as the substrates to be treated. The cassette  1   c  in this case is for storing the dummy wafers for effecting dry-cleaning using plasma (hereinafter referred to as “plasma-cleaning”) and recovering the dummy wafers after plasma-cleaning. It can store a plurality of (usually twenty-five pieces) dummy wafers  30 . 
     A load lock chamber  5  and unload lock chamber  6  are so disposed as to face the cassette tables  2   a  and  2   b , and a conveyor  13  is disposed between the cassette tables  2   a ,  2   b  and the load lock chamber  5  and the unload lock chamber  6 . The load lock chamber  5  is equipped with an evacuating device  3  and a gas introduction device  4 , and can load unprocessed wafers in the vacuum apparatus through a gate valve  12   a . The unload lock chamber  6  is similarly equipped with the evacuating device  3  and the gas introduction device  4 , and can take out processed wafers to the atmosphere through a gate valve  12   d . The conveyor  13  is equipped with a robot having X, Y, Z and θ axes, which operates so as to deliver and receive the wafers  20  between the cassettes  1   a ,  1   b  and the load lock and unload lock chambers  5  and  6  and the dummy wafers  30  between the cassette  1   c  and the load lock and unload lock chambers  5  and  6 . 
     The load lock chamber  5  and the unload lock chamber  6  are connected to a transfer chamber  16  through the gate valves  12   b  and  12   c . The transfer chamber  16  is rectangular, in this case, and etching chambers  11   a ,  11   b  and  11   c  are disposed on the three side walls of the transfer chamber  16  through gate valves  15   a ,  15   b  and  15   c , respectively. A conveyor  14  capable of delivering the wafers  20  or the dummy wafers  30  from the load lock chamber  5  to the etching chambers  11   a ,  11   b ,  11   c  and of delivering them from the chambers  11   a ,  11   b ,  11   c  to the unload lock chamber  6  is disposed inside the transfer chamber  16 . The transfer chamber  16  is equipped with an evacuating device  17  capable of independent evacuation. 
     The etching chambers  11   a ,  11   b ,  11   c  have the same structure and can make the same processing. The explanation will be given on the etching chamber  11   b  by way of example. The etching chamber  11   b  has a sample table  8   b  for placing the wafers  20  thereon, and a discharge chamber is so provided as to define a discharge portion  7   b  above the sample table  8   b . The etching chamber  11   b  includes a gas introduction device  10   b  for introducing a processing gas in the discharge portion  7   b  and an evacuating device  9   b  for decreasing the internal pressure of the etching chamber  11   b  to a predetermined pressure. The etching chamber  11   b  further includes generation means for generating a microwave and a magnetic field for converting processing gas in the discharge portion  7   b  to plasma. 
     A sensor  18  for measuring the intensity of plasma light is disposed at an upper part of the etching chamber. The measured value of the sensor  13  is inputted to a controller  19 . The controller  19  compares the measured value from the sensor  18  with a predetermined one and determines the timing of cleaning inside the etching chamber. The controller  19  controls the conveyors  13  and  14  to control the transfer of the dummy wafers  30  between the cassette  1   c  and the etching chambers  11   a  to  11   c.    
     In a vacuum processing apparatus having the construction described above, the cassettes  1   a ,  1   b  storing unprocessed wafers are first placed onto the cassette tables  2   a ,  2   b  by a line transfer robot which operates on the basis of the data sent from a host control apparatus, or by an operator. On the other hand, the cassette  1   c  storing the dummy wafers is placed on the cassette table  2   c . The vacuum processing apparatus executes the wafer processing or plasma cleaning on the basis of recognition by itself of the production data provided on the cassettes  1   a  to  1   c , of the data sent from the host control apparatus, or of the command inputted by an operator. 
     For instance, the wafers  20  are sequentially loaded in the order from above into the etching chambers  11   a ,  11   b ,  11   c  by the conveyors  13  and  14 , and are etched. The etched wafers are stored in their original positions inside the cassette  1   a  by the conveyors  14  and  13 . In this case, from the start to the end of the operation, without changing the position and posture of the cassettes, the unprocessed wafers are taken out from the cassettes and are returned in their original positions where the wafers have been stored, and are stored there. In this manner, the apparatus can easily cope with automation of the production line, contamination of the wafers due to dust can be reduced and high production efficiency and high production yield can thus be accomplished. 
     As etching is repeated, the reaction products adhere to and are deposited on the inner wall of the etching chambers  11   a  to  11   c . Therefore, the original state must be recovered by removing the adhering matters by plasma cleaning. The controller  19  judges the timing of this plasma cleaning. In this case, a portion through which the plasma light passes is provided in each of the etching chambers  11   a  to  11   c . The sensor  18  measures the intensity of the plasma light passing through this portion and when the measured value reaches a predetermined one, the start timing of plasma cleaning is judged. Alternatively, the timing of plasma cleaning may be judged by counting the number of wafers processed. In each etching chamber by the controller  19  and judging the timing when this value reaches a predetermined value. The actual timing of plasma cleaning that is carried out may be during a processing of a predetermined number of wafers in the cassette  1   a  or  1   b , after the processing of all the wafers  20  in a cassette is completed and before the processing of wafers in the next cassette. 
     Plasma cleaning is carried out in the following sequence. In this case, the explanation will be given about a case where the etching chambers  11   a  to  11   c  are subjected to plasma cleaning by using three dummy wafers  30  among the dummy wafers  30  (twenty-five dummy wafers are stored in this case) stored in the cassette.  1   c.    
     Dummy wafers  30  which are stored in the cassette  1   c  and are not used yet or can be used because the number of times of use for plasma cleaning is below a predetermined one are drawn by the conveyor  13 . At this time, dummy wafers  30  stored in any position in the cassette  1   c  may be used but in this case, the position numbers of the dummy wafers in the cassette and their number of times of use are stored in the controller  19 , and accordingly dummy wafers having smaller numbers of times of use are drawn preferentially. Then, the dummy wafers  30  are loaded in the load lock chamber  5  disposed on the opposite side to the cassette  1   a  by the conveyor  13  through the gate valve  12   a  in the same way as the transfer at the time of etching of wafers  20 . After the gate valve  12   a  is closed, the load lock chamber  5  is evacuated to a predetermined pressure by the vacuum exhaust device  3  and then the gate valves  12   b  and  15   a  are opened. The dummy wafers  30  are transferred by the conveyor  14  from the load lock chamber  5  to the etching chamber  11   a  through the transfer chamber  16  and are placed on the sample table  8   a . After the gate valve  15   a  is closed, plasma cleaning is carried out in the etching chamber  11   a  in which the dummy wafers  30  are disposed, under a predetermined condition. 
     In the interim, the gate valves  12   a ,  12   b  are closed and the pressure of the load lock chamber  5  is returned to the atmospheric pressure by the gas introduction device  4 . Next, the gate valve  12   a  is opened and the second dummy wafer  30  is loaded in the load lock chamber  5  by the conveyor  13  in the same way as the first dummy wafer  30 , and evacuation is effected again by the evacuating device  3  to a predetermined pressure after closing the gate valve  12   a . Thereafter, the gate valves  12   b  and  15   b  are opened and the second dummy wafer  30  is transferred from the load lock chamber  5  to the etching chamber  11   b  through the transfer chamber  16  by the conveyor  14 . Plasma cleaning is started after the gate valve  15   b  is closed. 
     In the interim, the third dummy wafer  30  is transferred into the etching chamber  11   c  in the same way as the second dummy wafer  30  and plasma cleaning is carried out. 
     After plasma cleaning is completed in the etching chamber  11   a  in which the first dummy wafer  20  is placed, the gate valves  15   a  and  12   c  are opened. The used dummy wafer  30  is transferred from the etching chamber  11   a  to the unload lock chamber  6  by the conveyor  14 . Then, the gate valve  12   c  is closed. After the pressure of the unload lock chamber  6  is returned to the atmospheric pressure by the gas introduction device  4 , the gate valve  12   d  is opened. The used dummy wafer  30  transferred to the unload lock chamber  6  is taken out in the air by the conveyor  13  through the gate valve  12   d  and is returned to its original position in the cassette  1   c  in which it is stored at the start. 
     When plasma cleaning of the etching chambers  11   b  and  11   c  is completed, the second and third dummy wafers  20  are returned to their original positions in the cassette  1   c.    
     In this way, the used dummy wafers  30  are returned to their original positions in the cassette  1   c  and the dummy wafers  30  are always stocked in the cassette  1   c . When all the dummy wafers  30  in the cassette  1   c  are used for plasma cleaning or when the numbers of times of use of the wafers  30  reach the predetermined ones after the repetition of use, the dummy wafers  30  are replaced as a whole together with the cassette  1   c . The timing of this replacement of the cassette is managed by the controller  19  and the replacement is instructed to the host control apparatus for controlling the line transfer robot or to the operator. 
     Although the explanation given above deals with the case where the etching chambers  11   a  to  11   c  are continuously plasma-cleaned by the use of three dummy wafers  30  among the dummy wafers  30  in the cassette  1   c , other processing methods may be employed, as well. 
     For example, the etching chambers  11   a  to  11   c  are sequentially plasma-cleaned by the use of one dummy wafer  30 . In the case of such plasma cleaning, unprocessed wafers  20  can be etched in etching chambers other than the one subjected to plasma cleaning, and plasma cleaning can thus be carried out without interrupting etching. 
     If the processing chambers are different, for example, there are an etching chamber, a post-processing chamber and a film-formation chamber, and wafers are sequentially processed while passing through each of these processing chambers, each of the processing chambers can be subjected appropriately to plasma cleaning by sending dummy wafers  30  during the processing of the wafers  20  which are stored in the cassette  1   a  or  2   a  and drawn and sent sequentially, by passing merely the dummy wafers  30  through the processing chambers for which plasma cleaning is not necessary, and by executing plasma cleaning only when the dummy wafers  30  reach the processing chambers which need plasma cleaning. 
     According to the embodiment described above, the cassette storing the dummy wafers and the cassettes storing the wafers to be processed are disposed together in the air, the dummy wafers are loaded from the cassette into the apparatus by the same conveyor as the conveyor for transferring the wafers, at the time of cleaning, and the used dummy wafers are returned to their original positions in the cassette. In this way, a mechanism for conducting exclusively plasma cleaning need not be provided, and the construction of the apparatus can be simplified. It is not necessary to handle plasma cleaning as aparticular processing sequence, but the plasma cleaning can be incorporated in an ordinary etching processing and can be carried out efficiently in a series of operations. 
     The dummy wafers used for plasma cleaning are returned to their original positions in the cassette placed in the air. Accordingly, the used dummy wafers and the wafers before and after processing do not exist mixedly in the vacuum chamber, so that contamination of wafers due to dust and remaining gas does not occur unlike conventional apparatuses. 
     The used dummy wafers are returned to their original positions in the cassette and the numbers of times of their use is managed. Accordingly, it is possible to prevent the confusion of the used dummy wafers with the unused dummy wafers and the confusion of the dummy wafers having small numbers of times of use with the dummy wafers having large numbers of times of use. For these reasons, the dummy wafers can be used effectively without any problem when plasma cleaning is carried out. 
     Furthermore, in accordance with the present invention, the apparatus can have a plurality of processing chambers and can transfer wafers and dummy wafers by the same conveyor. Since plasma cleaning can be carried out by managing the timing of cleaning of each processing chamber by the controller, the cleaning cycle can be set arbitrarily, dry cleaning can be carried out without interrupting the flow of the processing, the processing can be efficiently made and the productivity can be improved. 
     As described above, according to the present invention, there are effects that the construction of the apparatus is simple, the substrates to be processed are free from contamination and the production yield is high.

Technology Classification (CPC): 8