Patent ID: 12211735

DESCRIPTION OF THE EMBODIMENTS

Hereinafter, embodiments will be described in detail with reference to the attached drawings. Note, the following embodiments are not intended to limit the scope of the claimed invention. Multiple features are described in the embodiments, but limitation is not made to an invention that requires all such features, and multiple such features may be combined as appropriate. Furthermore, in the attached drawings, the same reference numerals are given to the same or similar configurations, and redundant description thereof is omitted.

FIG.1schematically shows the configuration of a processing device including a load lock device100according to the first embodiment of the present invention. The load lock device100can include a load lock chamber110arranged between a loader chamber30and a transfer chamber20. The loader chamber30can be maintained in an atmospheric environment. In the loader chamber30, for example, a substrate S can be provided from a carrier. Alternatively, the substrate S can be provided from a pre-processing device to the loader chamber30. The loader chamber30can include a filter32on the ceiling, and a downflow can be supplied to the internal space of the loader chamber30via the filter32. A conveyance robot34is arranged in the loader chamber30, and the substrate S can be conveyed by the conveyance robot34. The conveyance robot34can convey the substrate S from the loader chamber30to the load lock chamber110via a valve50. The pressure in the load lock chamber110to which the substrate S is conveyed is sufficiently reduced. After that, a conveyance robot22arranged in the transfer chamber20can convey the substrate S from the load lock chamber110to the transfer chamber20via a valve40. After that, the conveyance robot22can convey the substrate S from the transfer chamber20to a reduced-pressure processing device10via a valve60. The reduced-pressure processing device10can be one of, for example, a CVD device, a PVD device, an etching device, a plasma processing device, and an electron-beam exposure device.

The load lock chamber110can include a first conveyance port111connected to the transfer chamber20connected to the reduced-pressure processing device10, and a second conveyance port112connected to the loader chamber30. In an example, the height of the first conveyance port111(for example, the height of the lower end of the first conveyance port111) is lower than the height of the second conveyance port112(for example, the height of the lower end of the second conveyance port112). The first conveyance port111can be arranged to communicate with the internal space of the transfer chamber20via the valve40. The second conveyance port112can be arranged to communicate with the internal space of the loader chamber30via the valve50.

The load lock device100can include a gas introducing portion160that introduces a gas (for example, clean dry air or nitrogen gas) into the load lock chamber110. The gas introducing portion160can be arranged above a path between a substrate holding structure120and the transfer chamber20in a state in which, for example, the substrate S is conveyed to the transfer chamber20via the first conveyance port111. In an example, the gas introducing portion160can be arranged above the first conveyance port111. The gas introducing portion160can include a gas dispersing portion162that disperses the gas to the internal space of the load lock chamber110. At least a part of the gas dispersing portion162can be arranged in the load lock chamber110. The gas dispersing portion162can be arranged at a position facing the second conveyance port112. The gas introducing portion160can include a flow adjusting valve164that adjusts the gas introduction. The gas dispersing portion162can have a pillar-shaped portion. The inner side surface of the load lock chamber110can be apart from the pillar-shaped portion, and can include a curved surface along the pillar-shaped portion. The pillar-shaped portion can have a columnar shape, and the curved surface can form a part of a cylindrical surface.

The load lock device100can have the substrate holding structure120that holds the substrate S in the load lock chamber110. The substrate holding structure120can include a facing surface OS facing the substrate S, and can be configured to allow a gas to flow through a space between the substrate S and the facing surface OS. As shown in the enlarged view ofFIG.10, the substrate holding structure120can have a structure in which the distance between the substrate S and a portion PP located inside an outer edge EE of the facing surface OS is larger than the distance between the substrate S and the outer edge EE of the facing surface OS in a state in which the substrate S is held by the substrate holding structure120. It was confirmed by simulations that such a structure can effectively suppress formation of a standing vortex in a gas flow in the internal space of the load lock chamber110, as schematically indicated by dotted arrows inFIG.10. Here, the gas flow can be formed by introducing the gas to the internal space of the load lock chamber110by the gas introducing portion160and/or discharging the gas from the internal space by the pump150or the like as will be described later. Hence, the gas flow can necessarily be formed in the load lock chamber110in which the pressure changes in a wide range from the atmospheric pressure to a high vacuum.

On the other hand, as schematically indicated by dotted arrows inFIG.11, if a substrate holding structure SH configured to hold the substrate S includes a wall that impedes the gas flow, a standing vortex A may be formed in the gas flow. Such a standing vortex A may blow up particles and adhere the particles to the substrate S. It was also confirmed by simulations that even if a substrate holding structure SH′ configured to hold the substrate S includes a flat facing surface OS' parallel to the lower surface of the substrate S, a standing vortex A is formed in the gas flow, as schematically indicated by a dotted arrow inFIG.12. Such a standing vortex may blow up particles and adhere the particles to the substrate S.

Referring back toFIG.1, the substrate holding structure120can include a first member125with the facing surface OS, and a second member126with an upper surface US facing a lower surface LS of the first member125. The substrate holding structure120can include a plurality of contact portions124that contact the substrate S so as to support the substrate S. The second member126can support the first member125and the plurality of contact portions124. The upper surface US of the second member126can have a shape along the lower surface LS of the first member125. Such a structure enables the smooth flow of the gas. With a structure in which the space defined by the first member125(lower surface LS) and the second member126(upper surface US), which face each other, does not exist as a channel for the gas, that is, with a structure in which the space is filled with a solid, the gas flow is impeded, and a standing vortex may be generated. On the other hand, a structure in which the first member125(lower surface LS) and the second member126(upper surface US) face each other is advantageous in suppressing generation of a standing vortex.

The load lock device100can include a driving mechanism130. The driving mechanism130can be arranged on the lower side of the load lock chamber110to move the substrate holding structure120up and down. The driving mechanism130can be connected to the substrate holding structure120via a connecting member122.

The load lock chamber110can include an extension chamber140extended from the lower portion of the load lock chamber110to a side, and a pump150arranged on the lower side of the extension chamber140and discharge a gas in the load lock chamber110via the extension chamber140. The extension chamber140can include a bottom surface144with an opening142at a position deviated from the vertically lower position of the substrate holding structure120. The pump150can be connected to the opening142. Although not illustrated, a valve can be arranged between the pump150and the opening142.

The pump150can include, for example, a rotary pump, and a turbomolecular pump arranged between the rotary pump and the opening142. The turbine of the turbomolecular pump rotates at a high speed during the operation. If particles sucked by the turbomolecular pump collide against the turbine, these may be bounced by the turbine. In addition, the pump150itself may generate particles independently of whether the pump150is a turbomolecular pump or not. Hence, it is preferable that the pump150is connected to the opening142provided in the bottom surface144of the extension chamber140extended from the lower portion of the load lock chamber110to the side. This can reduce the particles from the pump150reaching the space above the substrate S via a gap G between the side surface of the substrate holding structure120and the inner side surface of the load lock chamber and adhering to the substrate S.

A gas discharge line52can be connected to the valve50arranged between the loader chamber30and the second conveyance port112of the load lock chamber110. The gas in the space near the second conveyance port112can be discharged to the external space of the load lock chamber110via the gas discharge line52. A pump (not shown) can be connected to the gas discharge line52.

At least a part of the second conveyance port112can be arranged above (vertically above) the extension chamber140. Alternatively, at least a part of the extension chamber140can be arranged between the second conveyance port112and the pump150. This configuration is advantageous in reducing the foot print of the load lock device100.

At least a part of the loader chamber30can be arranged above (vertically above) the extension chamber140. Alternatively, at least a part of the extension chamber140can be arranged between the loader chamber30and the pump150. This configuration is also advantageous in reducing the foot print of the load lock device100.

FIG.15is a plan view showing the arrangement of the load lock chamber110, the extension chamber140, and the gas dispersing portion162. This plan view can also be understood as an orthogonal projection to the floor on which the load lock device100is arranged. In the plan view or orthogonal projection, the substrate holder120can be located between the gas dispersing portion162and the extension chamber140. Alternatively, in the plan view or orthogonal projection, the opening142can be located between the gas dispersing portion162and the extension chamber140.

The area of the gap G between the side surface of the substrate holding structure120and the inner side surface of the load lock chamber110is preferably smaller than the sectional area of the second conveyance port112. The area of the gap G is more preferably smaller than ½, ⅓, or ¼ of the sectional area of the second conveyance port112. When the substrate S is conveyed from the loader chamber30to the internal space of the load lock chamber110via the second conveyance port112, this configuration is advantageous in increasing the amount of the gas introduced from the gas dispersing portion162to the internal space of the load lock chamber110and discharged via the second conveyance port112and the gas discharge line52as compared to the amount of the gas discharged from the space above the substrate S to the space below the substrate holding structure120via the gap G. This is effective to suppress particles entering from the loader chamber30to the internal space of the load lock chamber110via the second conveyance port112.

The area of the gap G between the side surface of the substrate holding structure120and the inner side surface of the load lock chamber110is preferably smaller than the sectional area of the opening142provided in the bottom surface144of the extension chamber140. This configuration is advantageous in reducing the particles from the pump150reaching the space above the substrate S via the gap G and adhering to the substrate S. The area of the gap G is preferably smaller than the sectional area (the sectional area along a vertical plane) of a connection portion146between the load lock chamber110and the extension chamber140. This configuration is also advantageous in reducing the particles from the pump150reaching the space above the substrate S via the gap G and adhering to the substrate S.

FIGS.2,3,4, and5exemplarily show the operation of the processing device shown inFIG.1. First, while introducing (supplying) the gas from the gas introducing portion160to the internal space of the load lock chamber110, the gas in the internal space can be discharged by the pump150to the external space of the load lock chamber110. At this time, to raise the pressure in the internal space, the introduction amount of the gas from the gas introducing portion160to the internal space can be made larger than the gas discharge amount by the pump150. When the pressure in the internal space becomes equal to or more than the atmospheric pressure, the valve50can be opened, as shown inFIG.2, and the gas discharge via the gas discharge line52can be started. After that, the conveyance robot34can convey the substrate S from the loader chamber30to the substrate holding structure120in the internal space of the load lock chamber110.

After that, as shown inFIG.3, the valve50can be closed, and the substrate holding structure120can be driven upward by the driving mechanism130. Also, in a state in which the gas is introduced from the gas introducing portion160to the internal space of the load lock chamber110, the gas discharge amount from the internal space by the pump150is increased, and the pressure in the internal space is reduced. After that, gas introduction to the internal space by the gas introducing portion160can be stopped, and the gas discharge amount from the internal space by the pump150can further be increased.

When the pressure in the internal space of the load lock chamber110is sufficiently reduced, the substrate holding structure120can be driven downward by the driving mechanism130up to a height to convey the substrate S to the transfer chamber20, as shown inFIG.4. After that, as shown inFIG.5, the valve40can be opened, and the conveyance robot22can convey the substrate S from the internal space of the load lock chamber110to the transfer chamber20and then to the reduced-pressure processing device10. Then, the valve40is closed, and the substrate S is processed in the reduced-pressure processing device10.

After that, the valve40can be opened, and the conveyance robot22can convey the substrate S in the reduced-pressure processing device10to the internal space of the load lock chamber110, as shown inFIG.5. After that, the valve40can be closed.

Then, while introducing the gas from the gas introducing portion160to the internal space of the load lock chamber110, the gas in the internal space can be discharged by the pump150to the external space of the load lock chamber110. At this time, to raise the pressure in the internal space, the introduction amount of the gas from the gas introducing portion160to the internal space can be made larger than the gas discharge amount by the pump150. When the pressure in the internal space becomes equal to or more than the atmospheric pressure, the valve50can be opened, as shown inFIG.2, and the gas discharge via the gas discharge line52can be started. After that, the conveyance robot34can convey the substrate S from the substrate holding structure120in the internal space of the load lock chamber110to the loader chamber30. After that, the valve50can be closed, and the gas discharge via the gas discharge line52can be stopped.

As shown inFIGS.1,3, and4, the substrate holding structure120can hold the substrate S such that at least a part of the side surface (outer peripheral surface) of the substrate S faces the inner surface of the load lock chamber110. Here, the substrate holding structure120can hold the substrate S such that the at least part of the side surface (outer peripheral surface) of the substrate S held by the substrate holding structure120can face the inner surface of the load lock chamber110concerning a direction parallel to the surface of the substrate S.

As shown inFIGS.1to5, the substrate holding structure120can be arranged at a plurality of positions in the internal space of the load lock chamber110. The plurality of positions can include a position where a part of the side surface of the substrate S held by the substrate holding structure120faces the gas dispersing portion162, as shown inFIG.1. Here, the part of the side surface (outer peripheral surface) of the substrate S held by the substrate holding structure120can face the gas dispersing portion162concerning a direction parallel to the surface of the substrate S.

As shown inFIG.13A, the substrate holding structure120may be configured such that a size DH of the facing surface OS of the substrate holding structure120in a surface direction (a direction parallel to the X-Y plane) along the surface of the substrate S is smaller than a size DS of the substrate S in the surface direction. As shown inFIGS.13A and13B, the portion PP of the substrate holding structure120can be located inside the outer edge EE of the facing surface OS concerning a predetermined direction (Y direction) in a horizontal plane (X-Y plane). The cross sections of the facing surface OS cut along a plurality of planes (a plurality of planes parallel to the Y-Z plane) that are perpendicular to the horizontal plane (X-Y plane) and parallel to the predetermined direction (Y direction) can have shapes identical to each other.

As shown inFIG.14A, the substrate S held by the substrate holding structure120can have a rectangular shape. Alternatively, as shown inFIG.14B, the substrate S held by the substrate holding structure120can have a circular shape with a notch portion NT indicating a reference direction. However, the substrate S held by the substrate holding structure120may have another shape.

FIG.6schematically shows the configuration of a processing device including a load lock device100according to the second embodiment of the present invention. Matters that are not mentioned as the second embodiment can comply with the first embodiment. The load lock device100according to the second embodiment includes a portion601where the ceiling portion of a load lock chamber110faces the inside region of the outer edge of a substrate S, and a portion602facing the outer edge of the substrate S, and the distance between the portion601and the substrate S is larger than the distance between the portion602and the substrate S.

FIG.7schematically shows the configuration of a processing device including a load lock device100according to the third embodiment of the present invention. Matters that are not mentioned as the third embodiment can comply with the first embodiment. The load lock device100according to the third embodiment includes a portion601where the ceiling portion of a load lock chamber110faces the inside region of the outer edge of a substrate S, and a portion602facing the outer edge of the substrate S, and the distance between the portion601and the substrate S is larger than the distance between the portion602and the substrate S. In the third embodiment, the portion601is formed by a smooth curved surface.

FIG.8schematically shows the configuration of a processing device including a load lock device100according to the fourth embodiment of the present invention. Matters that are not mentioned as the fourth embodiment can comply with the first embodiment. In the fourth embodiment, a first member125has a corrugated wing shape. The corrugated wing shape is advantageous in, for example, suppressing a large vortex throughout the space between a facing surface OS and a substrate S.

FIG.9schematically shows a plan view of a first member125in a load lock device100according to the fifth embodiment of the present invention.FIG.10schematically shows a side view of the first member125in the load lock device100according to the fifth embodiment of the present invention. Matters that are not mentioned as the fifth embodiment can comply with the first embodiment. In the fifth embodiment, in a state in which a substrate S is held by a substrate holding structure120, a portion PP located inside an outer edge EE of a facing surface OS is located inside the outer edge EE of the facing surface OS concerning a predetermined direction DIR, and the first member125is divided into a plurality of portions125aand125bconcerning a direction orthogonal to the predetermined direction DIR.

The present invention is not limited to the above embodiments and various changes and modifications can be made within the spirit and scope of the present invention. Therefore, to apprise the public of the scope of the present invention, the following claims are made.