Source: https://patents.justia.com/patent/20130273252
Timestamp: 2020-07-08 05:22:12
Document Index: 215571480

Matched Legal Cases: ['Application No. 61', 'art 31', 'art 32', 'art 33', 'art 34', 'art 35', 'art 37', 'art 25', 'art 33', 'art 45', 'art 45', 'art 37', 'art 37', 'art 37', 'art 37', 'art 37', 'art 55', 'art 58', 'art 59', 'art 53', 'art 58', 'art 58', 'art 58', 'art 58', 'art 58', 'art 58', 'art 58', 'art 58', 'art 58', 'art 59', 'art 59', 'art 59', 'art 59', 'art 59', 'art 59', 'art 59', 'art 59', 'art 59', 'art 53', 'art) 53', 'art 53', 'art 53', 'art 53', 'art 53', 'art 65', 'art 68', 'art 69', 'art 70', 'art 70', 'art 70', 'art 81', 'art 82', 'art 85', 'art 86', 'art 87', 'art 88', 'art 90', 'art 81', 'art 82', 'art 81', 'art 82', 'art 82', 'art 81', 'art 81', 'art 82', 'art 82', 'art 82', 'art 85', 'art 71', 'art 85', 'art 85', 'art 87', 'art 87', 'art 87', 'art 88', 'art 88', 'art 88', 'art 70', 'art 70', 'art 90', 'art 90', 'art 90', 'art 91', 'art 92', 'art 91', 'art 91', 'art 91', 'art 91', 'art 91', 'art 91', 'art 91', 'art 90', 'art 91', 'art 91', 'art 91', 'art 91', 'art 92', 'art 91', 'art 91', 'art 92', 'art 91', 'art 91', 'art 92', 'art 92', 'art 91', 'art 92', 'art 91', 'art 92', 'art 94', 'art 94', 'art 95', 'art 92', 'art 94', 'art 95', 'art 92', 'art 92', 'art 92', 'art 91', 'art 72', 'art 92', 'art 92', 'art 91', 'art 91', 'art 91', 'art 93', 'art 93', 'art 91', 'art 91', 'art 91', 'art 93', 'art 37', 'art 15', 'art 25', 'art 53', 'art 58', 'art 59', 'art 53', 'art 59', 'art 53', 'art 53', 'art 53', 'art 72', 'art 85', 'art 72', 'art 85', 'art 72', 'art 85', 'art 85', 'art 72', 'art 70', 'art 72', 'art 85', 'art 82', 'art 82', 'art 81', 'art 86', 'art 81', 'art 82', 'art 86', 'art 85', 'art 87', 'art 88', 'art 82', 'art 81', 'art 88', 'art 90', 'art 72', 'art 90', 'art 91', 'art 91', 'art 90', 'art 92', 'art 92', 'art 93', 'art 95', 'art 94', 'art 92', 'art 92', 'art 91', 'art 92', 'art 93', 'art 70', 'art 71', 'art 90', 'art 90', 'art 90', 'art 70', 'art 90', 'art 90', 'art 90', 'art 90', 'art 53', 'art 53', 'art 53', 'art 53', 'art 53', 'art 53', 'art 53', 'art 53', 'art 55', 'art 53', 'art 92', 'art 192', 'art 92', 'art 192', 'art 192', 'art 192', 'art 292', 'art 92', 'art 292', 'art 291', 'art 292', 'art 291', 'art 91', 'art 91', 'art 392', 'art 92', 'art 392', 'art 91', 'art 491', 'art 491', 'art 492', 'arts 93', 'art 491', 'art 491', 'art 90', 'art 70', 'art 70', 'art 90']

US Patent Application for COATING APPARATUS AND COATING METHOD Patent Application (Application #20130273252 issued October 17, 2013) - Justia Patents Search
Justia Patents Gas Jet Or Blast Mechanically Treats CoatingUS Patent Application for COATING APPARATUS AND COATING METHOD Patent Application (Application #20130273252)
Apr 15, 2013 - Tokyo Ohka Kogyo Co., Ltd.
This application claims priority to U.S. Provisional Application No. 61/625,477 filed on Apr. 17, 2012, the content of which is incorporated herein by reference.
In contrast, as the method of forming the light absorbing layer, the present inventors propose a method of coating the semiconductor materials in the form of a liquid material on a substrate, followed by heating the substrate to form a coating film. In such a method of forming the light absorbing layer, the following problems arise.
For example, the coating film formed on the substrate is likely to have cracks and the like formed on the peripheral portion thereof, which becomes the cause of generation of foreign matters. Such foreign matters sometimes cause deterioration of the quality of the coating film. Therefore, suppression of the generation of foreign matters has been demanded.
The present invention takes the above circumstances into consideration, with an object of providing a coating apparatus and a coating method capable of suppressing generation of foreign matters.
The coating apparatus according to a first aspect of the present invention includes: a coating part which coats a liquid material containing a metal on a substrate; a coating-film forming part which subjects the liquid material coated on the substrate to a predetermined treatment to form a coating film; and a removing part which removes a peripheral portion of the coating film formed along the outer periphery of the substrate.
According to the present invention, by virtue of including a removing part which removes a peripheral portion of the coating film formed along the outer periphery of the substrate, even in the case where cracks and the like are formed on a peripheral portion of the coating film, the peripheral portion can be removed with the crack by using the removing part. As a result, generation of foreign matters can be suppressed.
In the coating apparatus, the coating-film forming part may include a heating part which heats the liquid material as the predetermined treatment.
In this embodiment, since generated cracks can be removed by heating the liquid material with the heating part, generation of foreign matters can be suppressed.
In the coating apparatus, the coating-film forming part may include a drying part which dries the liquid material as the predetermined treatment.
In this embodiment, since generated cracks can be removed by drying the liquid material with the drying part, generation of foreign matters can be suppressed. Herein, drying includes vacuum drying in which the ambient pressure of the liquid material is reduced, and a rotation drying in which the liquid material is rotated by rotating the entire substrate.
In the coating apparatus, the coating-film forming part may include a baking part which bakes the liquid material as the predetermined treatment.
In this embodiment, since generated cracks can be removed by baking the liquid material with the baking part, generation of foreign matters can be suppressed.
The coating apparatus may further include a suction part which suctions the peripheral portion removed by the removing part.
In this embodiment, by virtue of further including a suction part which suctions the peripheral portion removed by the removing part, the removed peripheral portion can be prevented from being retained around the substrate or inside the apparatus. As a result, the environment for forming a coating material on a substrate can be maintained clean, thereby reliably suppressing generation of foreign matters.
The coating apparatus may further include a moving part which moves the removing part along the outer periphery of the substrate.
In this embodiment, by virtue of further including a moving part which moves the removing part along the outer periphery of the substrate, the peripheral portion of the coating film can be efficiently removed.
In the coating apparatus, the removing part and the suction part may be secured to be integrally movable.
In this embodiment, by virtue of the removing part and the suction part being secured to be integrally movable, the portion of the substrate from which the peripheral portion has been removed can be suctioned along the outer periphery of the substrate. In this manner, the removing operation and the suction operation on the peripheral portion can be performed smoothly or simultaneously, thereby preventing retention or scattering of foreign matters.
In the coating apparatus, the removing part may include a brush part which rubs the peripheral portion.
In this embodiment, by virtue of the removing part including a brush part which rubs the peripheral portion, the peripheral portion of the coating film can be efficiently removed by using the brush part to rub the peripheral portion.
In the coating apparatus, the removing part may further include a rotation part which rotates the brush part.
In this embodiment, by virtue of the removing part including a rotation part which rotates the brush part, the peripheral portion of the coating film can be efficiently removed by rotating the brush part.
In the coating apparatus, the removing part may include a squeegee part which scrapes off the peripheral portion.
In this embodiment, by virtue of the removing part including a squeegee part which scrapes off the peripheral portion, the peripheral portion of the coating film can be efficiently removed by using the squeegee part to scrape off the peripheral portion.
In the coating apparatus, the removing part may include a jetting part which jets a gas or a liquid to the peripheral portion.
In this embodiment, by virtue of the removing part including a jetting part which jets a gas or a liquid to the peripheral portion, the peripheral portion of the coating film can be efficiently removed by using the jetting part to jet a gas or a liquid to the peripheral portion.
In the coating apparatus, the removing part may include an irradiation part which irradiates an energy wave to the peripheral portion.
In this embodiment, by virtue of the removing part including an irradiation part which irradiates an energy wave to the peripheral portion, the peripheral portion of the coating film can be efficiently removed by using the irradiation part to irradiate an energy wave to the peripheral portion.
The coating method according to a second aspect of the present invention includes: a coating step in which a liquid material containing a metal is coated on a substrate; a coating-film forming step in which the liquid material coated on the substrate is subjected to a predetermined treatment to form a coating film; and a removing step in which, after the coating-film forming step, a peripheral portion of the coating material formed along the outer periphery of the substrate is removed by using a removing part which is configured to remove the peripheral portion.
According to the present invention, by virtue of coating a liquid material containing a metal on a substrate, subjecting the liquid material coated on the substrate to a predetermined treatment to form a coating film and then removing a peripheral portion of the coating material formed along the outer periphery of the substrate using a removing part which is configured to remove the peripheral portion, even in the case where cracks and the like are formed on a peripheral portion of the coating film, the peripheral portion can be removed with the crack by using the removing part. As a result, generation of foreign matters can be suppressed.
In the coating method, the coating-film forming step may include a heating step in which the liquid material is heated as the predetermined treatment.
In this embodiment, since generated cracks can be removed by heating the liquid material, generation of foreign matters can be suppressed.
In the coating method, the coating-film forming step may include a drying step in which the liquid material is dried as the predetermined treatment.
In this embodiment, since generated cracks can be removed by drying the liquid material, generation of foreign matters can be suppressed. Herein, drying includes vacuum drying in which the ambient pressure of the liquid material is reduced, and a rotation drying in which the liquid material is rotated by rotating the entire substrate.
In the coating method, the coating-film forming step may include a baking step in which the liquid material is baked as the predetermined treatment.
In this embodiment, since generated cracks can be removed by baking the liquid material, generation of foreign matters can be suppressed.
The coating method may further include a suction step in which the peripheral portion removed by the removing part is suctioned.
In this embodiment, by virtue of further including a suction step in which the peripheral portion removed by the removing part is suctioned, the removed peripheral portion can be prevented from being retained around the substrate or inside the apparatus. As a result, the environment for forming a coating material on a substrate can be maintained clean, thereby reliably suppressing generation of foreign matters.
The coating method may further include a moving step in which the removing part is moved along the outer periphery of the substrate.
In this embodiment, by virtue of moving the removing part along the outer periphery of the substrate, the peripheral portion of the coating film can be efficiently removed.
The coating method may further include a suction step in which the peripheral portion removed by the removing part is suctioned, wherein the suction step includes suctioning the peripheral portion using a suction part, and the moving step includes integrally moving the removing part and the suction part.
In this embodiment, by virtue of integrally moving the removing part and the suction part, the portion of the substrate from which the peripheral portion has been removed can be suctioned along the outer periphery of the substrate. In this manner, the removing operation and the suction operation on the peripheral portion can be performed smoothly or simultaneously, thereby preventing retention or scattering of foreign matters.
In the coating method, the removing step may include rubbing the peripheral portion.
In this embodiment, by virtue of rubbing the peripheral portion in the removing step, the peripheral portion can be efficiently removed.
In the coating method, the removing step may include rotating a brush part to rub the peripheral portion.
In this embodiment, by virtue of rotating a brush part to rub the peripheral portion in the removing step, the peripheral portion can be efficiently removed.
In the coating method, the removing step may include scraping off the peripheral portion.
In this embodiment, by virtue of scraping off the peripheral portion in the removing step, the peripheral portion can be efficiently removed.
In the coating method, the removing step may include jetting a gas or a liquid to the peripheral portion.
In this embodiment, by virtue of jetting a gas or a liquid to the peripheral portion in the removing step, the peripheral portion can be efficiently removed.
In the coating method, the removing step may include irradiating an energy wave to the peripheral portion.
In this embodiment, by virtue of irradiating an energy wave to the peripheral portion in the removing step, the peripheral portion can be efficiently removed.
In the coating method, the heating step may include a drying step in which the liquid material is dried.
In this embodiment, by virtue of the drying step in which the liquid material is dried, even in the case where cracks and the like are formed on a peripheral portion of the coating film, the peripheral portion can be removed with the crack by using the removing part. As a result, generation of foreign matters can be suppressed.
In the coating method, the heating step may include a baking step in which the liquid material is baked.
In this embodiment, by virtue of the baking step in which the liquid material is baked, even in the case where cracks and the like are formed on a peripheral portion of the coating film, the peripheral portion can be removed with the crack by using the removing part. As a result, generation of foreign matters can be suppressed.
According to the present invention, generation of foreign matters can be suppressed.
FIG. 4 is a diagram showing a configuration of a vacuum drying part according to the present embodiment.
FIG. 5 is a diagram showing a configuration of part of a baking part according to the present embodiment.
FIG. 6 is a perspective view showing a configuration of a removing part according to the present embodiment.
FIG. 7 is a cross-sectional view showing a configuration of a removing part according to the present embodiment.
FIG. 13 is a diagram showing a step in a vacuum drying treatment performed by a coating apparatus according to the present embodiment.
FIG. 14 is a diagram showing a step in a vacuum drying treatment performed by a coating apparatus according to the present embodiment.
FIG. 15 is a diagram showing a step in a vacuum drying treatment performed by a coating apparatus according to the present embodiment.
FIG. 16 is a diagram showing a step in a vacuum drying treatment performed by a coating apparatus according to the present embodiment.
FIG. 18 is a diagram showing a step in a baking treatment performed by a coating apparatus according to the present embodiment.
FIG. 19 is a diagram showing a step in a baking treatment performed by a coating apparatus according to the present embodiment.
FIG. 20 is a diagram showing a step in a baking treatment performed by a coating apparatus according to the present embodiment.
FIG. 21 is a diagram showing a step in a baking treatment performed by a coating apparatus according to the present embodiment.
FIG. 22 is a diagram showing a step in a removing treatment performed by a coating apparatus according to the present embodiment.
FIG. 23 is a diagram showing a step in a removing treatment performed by a coating apparatus according to the present embodiment.
FIG. 24 is a diagram showing a configuration of a coating apparatus according to a modified example of the present invention.
FIG. 25 is a diagram showing a configuration of a coating apparatus according to a modified example of the present invention.
FIG. 26 is a diagram showing a configuration of a removing part according to a modified example of the present invention.
FIG. 27 is a diagram showing a configuration of a removing part according to a modified example of the present invention.
FIG. 28 is a diagram showing a configuration of a removing part according to a modified example of the present invention.
FIG. 29 is a diagram showing a configuration of a removing part according to a modified example of the present invention.
As shown in FIG. 1, the coating apparatus CTR is an apparatus which applies a liquid material to a substrate S. The coating apparatus CTR includes a substrate loading/unloading part LU, a first chamber CB1, a second chamber CB2, a connection part CN and a control part CONT. The first chamber CB1 has a coating part CT. The second chamber CB2 has a baking part BK. The connection part CN has a vacuum drying part VD.
In this embodiment, as the liquid material to be applied to the substrate S, for example, a liquid composition is used which includes a solvent such as hydrazine and metals such as a combination of copper (Cu), indium (In), gallium (Ga), and selenium (Se) or a combination of copper (Cu), zinc (Zn), tin (Sn) and selenium (Se). The liquid composition includes a metal material for forming a light absorbing layer (photoelectric conversion layer) of a CIGS solar cell or a CZTS solar cell.
In the present embodiment, the liquid composition contains a substance for obtaining the grain size of a light absorbing layer of a CIGS solar cell or a CZTS solar cell. Needless to say, as the liquid material, a liquid material in which another oxidizable metal (such as metal nano particles) is dispersed in the solution may be used.
The first chamber CB1 is mounted on the base BC placed on the floor FL. The first chamber CB1 is formed in the shape of a rectangular box. Inside the first chamber CB1, an accommodation room 20a is formed. The coating part CT is provided in the treatment room 20a. The coating part CT performs the coating treatment of the liquid material on the substrate S.
The first chamber CB1 has a first opening 21 and a second opening 22. The first opening 21 and the second opening 22 communicate the treatment 20a with the outside of the first chamber CB1. The first opening 21 is formed on a −X-side face of the first chamber CB1. The second opening 22 is formed on a +X-side face of the first chamber CB1. The first opening 21 and the second opening 22 are formed to have a size which allows the substrate S to pass through. The substrate S is placed in or taken out of the first chamber CB1 through the first opening 21 and the second opening 22.
The coating part CT has an ejection part 31, a maintenance part 32, a liquid material supply part 33, a washing liquid supply part 34, a waste liquid storing part 35, a gas supply/exhaust part 37 and a substrate transporting part 25.
FIG. 3(a) is a diagram showing a configuration of the slit nozzle NZ.
As shown in FIG. 3(a), the nozzle NZ is formed to have an elongate shape, and is arranged such that the lengthwise direction thereof is in parallel to the X direction. The nozzle NZ has a main part NZa and a protruding part NZb. The main part NZa is a housing capable of accommodating the liquid material inside thereof. The main part NZa is made of, for example, a material containing titanium or a titanium alloy. The protruding part NZb is formed to protrude from the main part NZa on the +X-side and the −X-side. The protruding part NZb is held by part of the nozzle actuator NA.
FIG. 3(b) shows the configuration when the nozzle NZ is viewed from the −Z direction side thereof.
As shown in FIG. 3(b), the nozzle NZ has an ejection opening OP on the −Z-side end (tip TP) of the main part NZa. The ejection opening OP is an opening for ejecting a liquid material. The ejection opening OP is formed as a slit elonging in the X direction. The ejection opening OP is formed, for example, so that the longitudinal direction thereof is substantially equal to the X-direction dimension of the substrate S.
The nozzle NZ ejects, for example, a liquid material in which four types of metals, namely, Cu, Zn, Sn, and Se are mixed with a predetermined composition ratio. The nozzle NZ is connected to a liquid supply part 33 via a connection pipe or the like (not shown). The nozzle NZ includes a holding part which holds the liquid material therein. A temperature control part which controls the temperature of the liquid material held by the holding part may be provided.
FIG. 3(c) is a diagram showing the cross-sectional shape of the nozzle NZ and the nozzle-tip control part 45. As shown in FIG. 3(c), the wiping part 45a is formed to cover the tip TP of the nozzle NZ and part of the inclined plane on the tip TP-side in the cross-sectional view.
The gas supply/exhaust part 37 has a gas supply part 37a and a gas exhaust part 37b. The gas supply part 37a supplies an inert gas such as a nitrogen gas or an argon gas to the treatment room 20a. The gas exhaust part 37b suctions the treatment room 20a, and discharges the gas in the treatment room 20a outside the first chamber CB1.
The connection part CN connects the first chamber CB1 and the second chamber CB2. The substrate S is moved between the first chamber CB1 and the second chamber CB2 via the connection part CN. The connection part CN has a third chamber CB3. The third chamber CB3 is formed in the shape of a rectangular box. Inside the third chamber CB3, a treatment room 50a is formed. In the present embodiment, the treatment room 50a is provided with a vacuum drying part VD. The vacuum drying part VD dries the liquid material coated on the substrate S. The third chamber CB3 is provided with gate valves V2 and V3.
The third chamber CB3 has a first opening 51 and a second opening 52. The first opening 51 and the second opening 52 communicate the treatment room 50a with the outside of the third chamber CB3. The first opening 51 is formed on a −X-side face of the third chamber CB3. The second opening 52 is formed on a +X-side face of the third chamber CB3. The first opening 51 and the second opening 52 are formed to have a size which allows the substrate S to pass through. The substrate S is placed in or taken out of the third chamber CB3 through the first opening 51 and the second opening 52.
The vacuum drying part VD has a substrate transporting part 55, a gas supply part 58, a gas exhaust part 59 and a heating part 53.
FIG. 4 is a schematic diagram showing a configuration of the vacuum drying part VD.
As shown in FIG. 4, the gas supply part 58 supplies an inert gas such as a nitrogen gas or an argon gas to the treatment room 50a. The gas supply part 58 has a first supply part 58a and a second supply part 58b. The first supply part 58a and the second supply part 58b are connected to a gas supply source 58c such as a gas bomb or a gas pipe. Supplying of a gas to the treatment room 50a is performed mainly by using the first supply part 58a. The second supply part 58b makes a fine control of the amount of gas supplied by the first supply part 58a.
The gas exhaust part 59 suctions the treatment room 50a, and discharges the gas in the treatment room 50a outside the third chamber CB3, thereby reducing the pressure inside the treatment room 50a. By reducing the pressure inside the treatment room 50a, evaporation of the solvent contained in the liquid material on the substrate S can be promoted, thereby drying the liquid material. The gas exhaust part 59 has a first suction part 59a and a second suction part 59b. The first suction part 59a and the second suction part 59b are connected to a suction source 59c and 59d such as a pump. Suction from the treatment room 50a is performed mainly by using the first suction part 59a. The second suction part 59b makes a fine control of the amount of suction by the first suction part 59a.
The heating part 53 is connected to a lifting mechanism (moving part) 53a. The lifting mechanism 53a moves the heating part 53 in the Z-direction. As the lifting mechanism 53a, for example, a motor mechanism or an air-cylinder mechanism is used. By moving the heating part 53 in the Z-direction using the lifting mechanism 53a, the distance between the heating part 53 and the substrate S can be adjusted. With respect to the heating part 53, the distance to be moved and the timing to be moved by the lifting mechanism 53a can be controlled by the control part CONT.
The second chamber CB2 is mounted on the base BB placed on the floor FL. The second chamber CB2 is formed in the shape of a rectangular box. Inside the second chamber CB2, a treatment room 60a is formed. The baking part BK is provided in the treatment room 60a. The baking part BK bakes the coating film coated on the substrate S.
The second chamber CB2 has an opening 61. The opening 61 communicates the treatment room 60a with the outside of the second chamber CB2. The opening 61 is formed on a −X-side face of the second chamber CB2. The opening 61 is formed to have a size which allows the substrate S to pass through. The substrate S is placed in or taken out of the second chamber CB2 through the opening 61.
The baking part BK has a substrate transporting part 65, a gas supply part 68, a gas exhaust part 69 and a heating part 70.
FIG. 5 is a cross-sectional view showing the configuration of the heating part 70.
As shown in FIG. 5, the heating part 70 is disposed on the platform 74, and has a first accommodation part 81, a second accommodation part 82, a first heating plate 83, a second heating plate 84, a lifting part 85, a sealing part 86, a gas supply part 87, an exhaust part 88 and a removing part 90.
The first accommodation part 81 is formed in the shape of a rectangular open box as viewed in the Z-direction, and is mounted on the bottom of the second chamber CB2 such that the opening faces the +Z side. The second accommodation part 82 is formed in the shape of a rectangular open box as viewed in the Z-direction, and is disposed such that the opening faces the first accommodation part 81. The second accommodation part 82 is movable in the Z direction by using a lifting mechanism (not shown). By superimposing the edge portion 82a of the second accommodation part 82 on the edge 81a of the first accommodation part 81, the inside of the first accommodation part 81 and the second accommodation part 82 is closed.
The second heating plate 84 is accommodated in the second accommodation part 82. The second heating plate 84 is formed of, for example, a metal material, and is provided with a heating device such as an infrared device or a hot plate inside thereof. The temperature of the second heating plate 84 is adjustable, for example, from about 200 to 800° C. The second heating plate 84 is provided to be movable independently from the second accommodation part 82 in the Z direction by a lifting mechanism (not shown). By moving the second heating plate 84 in the Z direction, the interval between the second heating plate 84 and the substrate S can be adjusted.
The lifting part 85 moves the substrate S between the arm part 71 and the first heating plate 83. The lifting part 85 has a plurality of support pins 85a and a moving part 85b which is movable in the Z direction while holding the support pins 85a. For easier discrimination of the drawings, in FIG. 5, a configuration is shown in which two support pins 85a are provided. However, in practice, it is possible to provide, for example, sixteen support pins 85a (see FIG. 5). The plurality of through-holes 83a provided on the first heating plate 83 are arranged at positions corresponding to the plurality of support pins 85a as viewed in the Z direction.
The gas supply part 87 supplies a nitrogen gas or the like to the treatment room 60a. The gas supply part 87 is connected to the +Z-side face of the second chamber CB2. The gas supply part 87 has a gas supply source 87a such as a gas bomb or a gas pipe, and a connection pipe 87b which connects the gas supply source 87a with the second chamber CB2.
The exhaust part 88 suctions the treatment room 60a, and discharges the gas in the treatment room 60a outside the second chamber CB2. The exhaust part 88 is connected to the −Z-side face of the second chamber CB2. The exhaust part 88 has a suction source 88a such as a pump, and a connection pipe 88b which connects the suction source 88a with the second chamber CB2.
Further, in the present embodiment, solvent concentration sensors SR3 and SR4 are provided. Like the aforementioned solvent concentration sensors SR1 and SR2, the solvent concentration sensors SR3 and SR4 detects the concentration of the solvent (in the present embodiment, hydrazine) for the liquid material in the ambient atmosphere, and sends the detection results to the control part CONT. The solvent concentration sensor SR3 is provided on the platform 74 on the +Y side of the heating part 70 within the treatment room 60a. The solvent concentration sensor SR3 is provided at a position remote from the heating part 70. The solvent concentration sensor SR4 is provided outside the second chamber CB2. In the present embodiment, for detecting the concentration of hydrazine which has a larger specific gravity than air, like the solvent concentration sensors SR1 and SR2, the solvent concentration sensors SR3 and SR4 are disposed on the lower side of the transport path of the substrate S in the vertical direction. Further, by providing a solvent concentration sensor SR4 outside the second chamber CB2, it becomes possible to detect leakage of hydrazine from the second chamber CB2.
The removing part 90 removes a peripheral portion of the coating film F formed on the substrate S after heating. The peripheral portion refers to a portion of the coating film F formed along the outer periphery of the substrate S. FIG. 6 is a perspective view showing the configuration of the removing part 90. FIG. 7 is a diagram showing a configuration along the cross-section A-A in FIG. 6. As shown in FIG. 6 and FIG. 7, the removing part 90 has a frame part 91 and a brush part 92.
The frame part 91 is formed to have a U-shaped cross-section by a first plate-shaped part 91a and a second plate-shaped part 91b which are disposed in parallel to the XY-plane, and a third plate-shaped part 91c which is disposed perpendicular to the first plate-shaped part 91a and the second plate-shaped part 91b. The frame part 91 is configured to be movable in the X, Y and Z directions and rotatable in the θZ direction. By such a configuration, the removing part 90 is capable of accessing to or withdrawing from the substrate S. The frame part 91 has a space K surrounded by the first plate-shaped part 91a, the second plate-shaped part 91b and the third plate-shaped part 91c.
The brush part 92 is provided between the first plate-shaped part 91a and the second plate-shaped part 91b. The brush part 92 has a plurality of linear members extending from the first plate-shaped part 91a to the second plate-shaped part 91b. The brush part 92 has a first end part 92a on the first plate-shaped part 91a side and a second end part 92b on the second plate-shaped part 91b side.
The first end part 92a of the brush 92 is bound on a base part 94. The base part 94 is configured to be rotatable in the θZ direction by a rotation part 95. Thus, the brush part 92 is configured to be integrally rotatable with the base part 94 in the θZ direction by actuating the rotation part 95.
The second end part 92b of the brush part 92 is disposed to form a gap between the second end part 92b and the second plate-shaped part 91b in the Z direction. The gap is capable of accommodating the substrate S having a coating film formed thereon and the substrate supporting part 72a which holds the substrate S. The second end part 92b is disposed at a position where the second end part 92b comes into contact with a portion of the coating film F.
On the third plate-shaped part 91c of the frame part 91, an opening 91d is formed. The opening 91d is formed to penetrate through the third plate-shaped part 91c in the X direction. The opening 91d has a suction part 93 connected thereto. The suction part 93 has a pipe 93a and a suction pump 93b.
One end of the pipe 93a is connected to the opening 91d. The suction pump 93b is provided on the pipe 93a. The suction pump 93b suctions the space K via the pipe 93a and the opening 91d. The pipe 93a and the suction pump 93b are integrally provided with the frame part 91 by a securing mechanism (not shown). Thus, by moving the frame part 91, the frame part 91 and the suction part 93 are integrally moved.
As shown in FIG. 1, the first chamber CB1 has anti-chambers AL1 to AL3 connected thereto.
The anti-chambers AL1 to AL3 are provided to communicate with the inside and outside of the first chamber CB1. Each of the anti-chambers AL1 to AL3 is a path through which a component of the treatment room 20a is taken out of the first chamber CB1 or the component is placed into the treatment room 20a from outside the first chamber CB1.
The second chamber CB2 has an anti-chamber AL4 connected thereto.
As shown in FIG. 1, the first chamber CB1 has a glove part GX1 connected thereto. Further, the second chamber CB2 has a glove part GX2 connected thereto.
The glove parts GX1 and GX2 are parts where an operator accesses the inside of the first chamber CB1 and the second chamber CB2. By inserting the hands inside the glove parts GX1 and GX2, the operator can conduct maintenance inside the first chamber CB1 and the second chamber CB2. The glove parts GX1 and GX2 are formed to have a bag-like shape. The glove parts GX1 and GX2 are respectively provided at a plurality of portions on the first chamber CB1 and the second chamber CB2. A sensor may be provided inside the first chamber CB1 and the second chamber CB2 which detects whether or not an operator has put his hand in the glove part GX1 or GX2.
Between the second opening 22 of the first chamber CB1 and the first opening 51 of the third chamber CB3, a gate valve V2 is provided. The gate valve V2 is provided to be movable in the Z-direction by an actuator (not shown). By moving the gate valve V2 in the Z-direction, the second opening 22 of the first chamber CB1 and the first opening 51 of the third chamber CB3 are simultaneously opened or closed. When the second opening 22 and the first opening 51 are simultaneously opened, a substrate S can be moved through the second opening 22 and the first opening 51.
Between the second opening 52 of the third chamber CB3 and the opening 61 of the second chamber CB2, a gate valve V3 is provided. The gate valve V3 is provided to be movable in the Z-direction by an actuator (not shown). By moving the gate valve V3 in the Z-direction, the second opening 52 of the third chamber CB3 and the opening 61 of the second chamber CB2 are simultaneously opened or closed. When the second opening 52 and the opening 61 are simultaneously opened, a substrate S can be moved through the second opening 52 and the opening 61.
The control part CONT is a part which has the overall control of the coating apparatus CTR. Specifically, the control part CONT controls the operations of the substrate loading/unloading part LU, the coating part CT, the vacuum drying part VD, the baking part BK and the gate valves V1 to V3. As an example of the adjusting operation, the control part CONT controls the amount of gas to be supplied from the gas supply part 37a, based on the detection results of the solvent concentration sensors SR1 to SR4. The control part CONT has a timer or the like (not shown) for measuring the treatment time.
After the lid portion 14 is closed, the control part CONT opens the gate valve V1, so as to communicate the accommodation room 10a of the chamber 10 with the treatment room 20a of the first chamber CB1 of the coating part CT. After opening the gate valve V1, the control part CONT transports the substrate S in the X-direction using the substrate transporting part 15.
After a portion of the substrate S has been inserted into the treatment room 20a of the first chamber CB1, the control part CONT uses the substrate transporting part 25 to completely load the substrate S into the treatment room 20a. After the substrate S has been loaded, the control part CONT closes the gate valve V1. After closing the gate valve V1, the control part CONT transports the substrate S to the treatment stage 28.
After wiping the tip TP of the nozzle NZ, the control part CONT moves the nozzle NZ to the treatment stage 28. After the ejection opening OP of the nozzle NZ reaches the −Y-side end of the substrate S, as shown in FIG. 11, the control part CONT ejects the liquid material Q from the ejection opening OP to the substrate S while moving the nozzle NZ in the +Y-direction at a predetermined speed. By this operation, a coating film F of the liquid material Q is formed on the substrate S.
When the substrate S reaches the second opening 22 of the first chamber CB1, as shown in FIG. 13, the control part CONT opens the gate valve V2, and transports the substrate S from the first chamber CB1 to the second chamber CB2 (transporting step). In the transporting step, the substrate S passes through the third chamber CB3 disposed at the connection part CN. When the substrate S passes through the third chamber CB3, the control part CONT conducts a drying treatment of the substrate S using the vacuum drying part VD. Specifically, after the substrate S is accommodated in the treatment room 50a of the third chamber CB3, as shown in FIG. 14, the control part CONT closes the gate valve V2.
After closing the gate valve V2, the control part CONT uses the lifting mechanism 53a to adjust the position of the heating part 53 in the Z-direction. Thereafter, as shown in FIG. 15, the control part CONT uses the gas supply part 58 to adjust the atmosphere inside the treatment room 50a and uses the gas exhaust part 59 to reduce the pressure inside the treatment room 50a. When the pressure inside the treatment room 50a is reduced by this operation, evaporation of the solvent contained in the coating film of the liquid material Q formed on the substrate S is promoted, and the coating film is dried. The control part CONT may adjust the position of the heating part 53 in the Z-direction using the lifting mechanism 53a while reducing the pressure inside the treatment room 50a using the gas exhaust part 59.
Further, as shown in FIG. 15, the control part CONT uses the heating part 53 to heat the coating film F on the substrate S. By this operation, evaporation of the solvent contained in the coating film F on the substrate S is promoted, so that the vacuum drying treatment can be conducted in a short time. The control part CONT may adjust the position of the heating part 53 in the Z-direction using the lifting mechanism 53a while conducting the heating operation by the heating part 53.
After the vacuum drying treatment, as shown in FIG. 16, the control part CONT opens the gate valve V3, and transports the substrate S from the connection part CN to the second chamber CB2. After the substrate S is accommodated in the treatment room 60a of the second chamber CB2, the control part CONT closes the gate valve V3.
As shown in FIG. 17, by the movement of the substrate supporting part 72a, the substrate S is disposed above a central portion of the first heating plate 83. Thereafter, as shown in FIG. 18, the control part CONT moves the lifting part 85 in the +Z direction. By this operation, the substrate S leaves the substrate supporting part 72a of the transport arm 72, and is supported by the plurality of support pins 85a of the lifting part 85. In this manner, the substrate S is delivered from the substrate supporting part 72a to the lifting part 85. After the substrate S has been supported by the support pins 85a of the lifting part 85, the control part CONT withdraws the substrate supporting part 72a outside the heating part 70 in the −X direction.
After withdrawing the substrate supporting part 72a, as shown in FIG. 19, the control part CONT moves the lifting part 85 in the −Z direction, and also moves the second accommodation part 82 in the −Z direction. By this operation, the edge portion 82a of the second accommodation part 82 is superimposed on the edge 81a of the first accommodation part 81, so that the sealing part 86 is sandwiched between the edge portion 82a and the edge portion 81a. As a result, a closed baking room 80 is formed by the first accommodation part 81, the second accommodation part 82 and the sealing part 86.
After forming the baking room 80, as shown in FIG. 20, the control part CONT moves the lifting part 85 in the −Z direction and mounts the substrate S on the first heating plate 83. After the substrate S has been mounted on the first heating plate 83, the control part CONT moves the second heating plate 84 in the −Z direction, so that the second heating plate 84 approaches the substrate S. The control part CONT appropriately adjusts the position of the second heating plate 84 in the Z direction.
After adjusting the position of the second heating plate 84 in the Z direction, as shown in FIG. 21, a nitrogen gas or a hydrogen sulfide gas is supplied to the baking room 80 by using the gas supply part 87, and the baking room 80 is suctioned by using the exhaust part 88. By this operation, not only the atmosphere and pressure inside the baking room 80 are adjusted, but also a stream of the nitrogen gas or the hydrogen sulfide gas is formed from the second accommodation part 82 to the first accommodation part 81. In a state where the stream of the nitrogen gas or the hydrogen sulfide gas is formed, the control part CONT actuates the first heating plate 83 and the second heating plate 84, so as to perform the baking operation of the substrate S (heating step). By this operation, the solvent component is evaporated from the coating film F on the substrate S, and bubbles contained in the coating film F are removed. Further, by the stream of the nitrogen gas or the hydrogen sulfide gas, the solvent component evaporated from the coating films F and the bubbles are swept away, and suctioned by the exhaust part 88.
In addition, in the baking operation, at least one of the metal components contained in the coating films F is heated to its melting point or higher, so as to dissolve at least a portion of the coating film F. For example, in the case where the coating film F is used for a CZTS solar cell, among the components that constitute the coating film F, Ti, S and Se are heated to their melting points or higher, so as to liquefy these substances and aggregate the coating film F. Thereafter, the coating film F is cooled to a temperature at which the coating film F is solidified. By solidifying the coating films F, the strength of the coating films F can be enhanced.
After the completion of the baking operation, the coating film F on the substrate S may have cracks or the like generated on a peripheral portion for example. In such a case, a portion of the coating film F may be scattered from the crack, thereby causing generation of foreign matters. Such foreign matters sometimes cause deterioration of the quality of the coating film F. Therefore, in the present embodiment, a step in which the peripheral portion is removed by the removing part 90 is conducted (removing step).
Prior to the removing step, the control part CONT hands the substrate from the supporting pins 85a to the substrate supporting part 72a. Needless to say, the removing step may be conducted in a state where the substrate is supported by the supporting pins 85a. Then, the control part CONT allows the removing part 90 to come close to the substrate S. By this operation, the substrate S is sandwiched between the first plate-shaped part 91a and the second plate-shaped part 91b of the removing part 90, and the second end part 92b of the brush part 92 comes into contact with the peripheral portion of the coating film F.
In this state, as shown in FIG. 22, the control part CONT uses the suction part 93 to suction the space K (suction step), and also operates the rotation part 95 to rotate the base part 94 in the θZ direction (rotating step). By this operation, the peripheral portion of the coating film F is rubbed by the second end part 92b of the brush part 92 in the rotating direction, thereby removing the peripheral portion from the substrate S. The removed peripheral portion (foreign matters Fa) is discharged outside the space K via the opening 91d and the pipe 93a.
Further, the control part CONT moves the frame part 91 in the Y direction in a state where the brush part 92 is rotated in the θZ direction and the suction part 93 is operated (moving step). By this operation, as shown in FIG. 23, the peripheral portion of the coating film F is removed along the outer periphery of the substrate S in the Y direction. In the same manner as described above, the foreign matters resulted from the removed peripheral portion are discharged outside the space K via the opening 91d and the pipe 93a.
After conducting such a removing step, the control part CONT transports the substrate S in the −X direction. Specifically, the substrate S is unloaded from the baking part BK via the heating part 70, the arm part 71 and the substrate guide stage 66, and is returned to the substrate loading/unloading part LU via the coating part CT (second transporting step). After the substrate S has been returned to the substrate loading/unloading part LU, the control part CONT opens the lid portion 14 in a state where the gate valve V1 is closed. Thereafter, an operator collects the substrate S in the chamber 10, and accommodates a new substrate S in the accommodation room 10a of the chamber 10.
In the case where, after the substrate S has been returned to the substrate loading/unloading part LU, another coating film is formed to be superimposed on the coating film F formed on the substrate S, the control part CONT transports the substrate S to the coating part CT again, and repeats the coating treatment, the vacuum drying treatment and the baking treatment. In this manner, coating film F is laminated on the substrate S.
As described above, according to the present embodiment, by virtue of including a removing part 90 which removes a peripheral portion of the coating film F formed along the outer periphery of the substrate S, even in the case where cracks and the like are formed on a peripheral portion of the coating film F, the peripheral portion can be removed with the crack by using the removing part 90. As a result, generation of foreign matters can be suppressed.
In the aforementioned embodiment, explanation was given taking example of a configuration in which the baking operation is conducted by the baking part in the second chamber CB2. However, the present invention is not limited thereto. For example, as shown in FIG. 24, a configuration may be employed in which a fourth chamber CB4 is provided at a position different from the second chamber CB2, and the substrate S is heated by a heating part HT provided on the fourth chamber CB4.
In this case, for example, a coating film F is laminated on the substrate S, and then, a heat treatment can be conducted for baking the laminated coating film F by the heating part HT of the fourth chamber CB4. In the second heating step, the heat treatment for heating the coating film F is conducted at a heating temperature higher than that in the heat treatment by the baking part BK. By this heating treatment, the solid contents (metal components) of the laminated coating film F can be crystallized, thereby further enhancing the film quality of the coating film F.
The heating after laminating the coating film F on the substrate S may be performed by the baking part BK of the second chamber CB2. In such a case, in the baking part BK, the heating temperature for baking the laminated coating film F can be controlled to become higher than the heating temperature for baking each layer of the coating film F.
In the aforementioned embodiment, explanation was given taking example of a configuration in which the removing part 90 is provided on the heating part 70. However, the present invention is not limited thereto. For example, as shown in FIG. 24, a configuration in which the removing part 90 is provided on the vacuum drying part VD may be employed. In such as case, after the vacuum drying treatment of the liquid material Q, cracks generated by the vacuum drying treatment can be removed by the removing part 90. Further, as shown in FIG. 24, the removing part 90 may be provided on the baking part BK. In such as case, after the baking treatment of the coating film F, cracks generated by the baking treatment can be removed by the removing part 90.
In the aforementioned embodiment, explanation was given taking example of a configuration in which a lifting mechanism 53a moves the heating part 53 to adjust the distance between the substrate S and the heating part 53 within the third chamber CB3. However, the present invention is not limited thereto. For example, a configuration may be employed in which the lifting mechanism 53a is capable of moving not only the heating part 53, but also the substrate S in the Z direction. Alternatively, a configuration in which the lifting mechanism 53a is capable of moving only the substrate S in the Z direction may be employed.
In the aforementioned embodiment, explanation was given taking example of a configuration in which the heating part 53 is provided on the −Z side (lower side in the vertical direction) of the substrate S in the vacuum drying part VD. However, the present invention is not limited thereto. For example, a configuration in which the heating part 53 is provided on the +Z side of the substrate S may be employed. Alternatively, a configuration may be employed in which the heating part 53 is movable between a position on the −Z side of the substrate S and a position on the +Z side of the substrate S. In this case, the heating part 53 has a shape which enables the heating part 53 to pass through the plurality of rollers 57 constituting the substrate transporting part 55 (e.g., the heating part 53 is provided with openings).
Furthermore, with respect to the configuration of the coating apparatus CTR, as shown in FIG. 25 for example, a first chamber CB1 having a coating part CT, a connection part CN having a vacuum drying part VD and a second chamber CB2 having a baking part BK may be repeatedly arranged on the +X-side of the substrate loading/unloading part LU.
In FIG. 25, a configuration in which the first chamber CB1, the connection part CN and the second chamber CB2 are repeatedly arranged three times is shown. However, the present invention is not limited to this configuration, and a configuration in which the first chamber CB1, the connection part CN and the second chamber CB2 are repeatedly arranged twice, or a configuration in which the first chamber CB1, the connection part CN and the second chamber CB2 are repeatedly arranged four times may be employed.
According to this configuration, since the first chamber CB1, the connection part CN and the second chamber CB2 are repeatedly arranged in series in the X-direction, the substrate S can be transported in one direction (+X-direction), and there is no need to transport the substrate S back and forth. Therefore, the step of laminating the coating film on the substrate S can be continuously performed. As a result, coating films can be efficiently formed on the substrate S.
In the aforementioned embodiment, explanation was given taking example of a configuration in which the coating film F is removed by the brush part 92. However, the present invention is not limited thereto.
For example, as shown in FIG. 26, a configuration in which a squeegee part 192 is provided instead of the brush part 92 may be employed. In such a case, by scraping off the peripheral portion of the coating film F by using the squeegee part 192, the peripheral portion can be removed. In FIG. 26, a configuration in which the squeegee part 192 is bent in a direction parallel to one edge of the substrate S (i.e., Y direction) is shown, but the present invention is not limited thereto. For example, a configuration in which the squeegee part 192 is bent in a direction intersecting with one edge of the substrate S may be employed.
Alternatively, for example, as shown in FIG. 27, a configuration in which a fluid jetting part 292 is provided instead of the brush part 92 may be employed. In such a case, the fluid jetting part 292 can be used to jet a fluid 293 (such as a gas or a liquid) to the peripheral portion of the coating film F, so as to remove the peripheral portion. In FIG. 27, a fluid supply part 291 which supplies the fluid 293 to the fluid jetting part 292 is provided. The fluid supply part 291 may be integrally attached to the frame part 91, or may be provided independently from the frame part 91.
Alternatively, as shown in FIG. 28, a configuration in which an energy irradiation part 392 is provided instead of the brush part 92 may be employed. In such a case, the energy irradiation part 392 can be used to irradiate an energy wave 393 (such as an ultraviolet ray) to the peripheral portion of the coating film F, so as to remove the peripheral portion.
Further, for example, in the aforementioned embodiment, explanation was given taking example of a configuration in which the frame part 91 is moved (for scanning) in the Y direction, so as to remove the peripheral portion on one edge of the substrate S in the Y direction. However, the present invention is not limited thereto. For example, as shown in FIG. 29, a configuration may be employed in which the frame part 491 is formed to be elonged in one direction (e.g., the Y direction), and one edge of the substrate S can be accommodated in the longitudinal direction of the frame part 491.
In this configuration, for example, as shown in FIG. 29, the base 494 can be configured to move in the Y direction, so that the brush part 492 rubs the peripheral portion of the coating film F. Alternatively, a configuration may be employed in which a fluid (such as a gas or a liquid) is jetted along one edge of the coating film F, or an energy wave is irradiated along one edge of the coating film F.
Further, as shown in FIG. 29, a configuration in which a plurality of suction parts 93 are provided in the longitudinal direction of the frame part 491 may be employed. In this manner, the space K of the frame part 491 can be efficiently suctioned.
In the aforementioned embodiment, explanation was given taking example of a configuration in which the removing part 90 is provided on the heating part 70, and the removing step is conducted after the heating step in the heating part 70. However, the present invention is not limited thereto. For example, an embodiment may be employed in which the removing part 90 is provided on the vacuum drying part VD, and the removing step is conducted after the vacuum drying step.
a coating part which coats a liquid material containing a metal on a substrate;
a coating-film forming part which subjects the liquid material coated on the substrate to a predetermined treatment to form a coating film; and
a removing part which removes a peripheral portion of the coating film formed along the outer periphery of the substrate.
13. A coating method comprising:
a coating step in which a liquid material containing a metal is coated on a substrate;
a coating-film forming step in which the liquid material coated on the substrate is subjected to a predetermined treatment to form a coating film and
a removing step in which, after the coating-film forming step, a peripheral portion of the coating material formed along the outer periphery of the substrate is removed by using a removing part which is configured to remove the peripheral portion.
19. The coating method according to claim 18, further comprising a suction step in which the peripheral portion removed by the removing part is suctioned,
wherein the suction step comprises suctioning the peripheral portion using a suction part, and
the moving step comprises integrally moving the removing part and the suction part.
Applicant: Tokyo Ohka Kogyo Co., Ltd. (Kawawsaki-shi)
Inventor: Hidenori Miyamoto (Kawasaki-shi)
Application Number: 13/863,194
Current U.S. Class: Gas Jet Or Blast Mechanically Treats Coating (427/348); Solid Member Or Material Acting On Coating After Application (118/100); With Treatment Of Coating Material (118/600); Miscellaneous (118/506); To Remove Or Spread Applied Coating By Gas Blast (118/63); With Post-treatment Of Coating Or Coating Material (427/331); Heating Or Drying (e.g., Polymerizing, Vulcanizing, Curing, Etc.) (427/372.2); Vacuum Or Reduced Pressure Utilized (427/350); Solid Treating Member Or Material Contacts Coating (427/355); Brushing (427/368)
International Classification: B05D 3/12 (20060101); B05D 3/04 (20060101); B05D 3/06 (20060101); B05D 3/02 (20060101);