1. Field of the Invention
The present invention relates to a processing apparatus and method for processing a workpiece, and more particularly to a processing apparatus and method for processing a workpiece such as a semiconductor substrate, a glass substrate, and a crystal substrate.
2. Description of the Related Art
In a processing apparatus for processing various workpieces, a workpiece to be processed is held in a process chamber and processed under predetermined conditions in the process chamber.
Semiconductor wafers, liquid crystal panels, or the like tend to become larger in size in accordance with the advance of the generation of technology. Therefore, for processing workpieces in these fields, such as semiconductor wafers, glass substrates, and crystal substrates, the process chamber of the processing apparatus becomes larger in size because of larger workpieces, resulting in a larger installation space for the processing apparatus.
The present invention has been made in view of the above drawbacks. It is therefore an object of the present invention to provide a processing apparatus and method for processing a workpiece which can reduce an installation space for the apparatus and an amount of a material required for the process, such as a process gas or a cleaning liquid.
In order to achieve the above object, according to the present invention, there is provided a processing apparatus which has a size smaller than a surface, to be processed, of a workpiece, as shown in FIG. 1. Specifically, according to a first aspect of the present invention, there is provided a processing apparatus for processing a workpiece, comprising: a cover for covering a portion of a surface, to be processed, of the workpiece; a process chamber formed by the cover and the surface, to be processed, of the workpiece; and a sealing portion provided between the cover and the surface of the workpiece for sealing the process chamber.
According to a second aspect of the present invention, there is provided a processing method for processing a workpiece, comprising: disposing on a surface, to be processed, of the workpiece, a processing apparatus comprising a cover for covering a portion of the surface, to be processed, of the workpiece, a process chamber formed by the cover and the surface, to be processed, of the workpiece, and a sealing portion provided between the cover and the surface of the workpiece for sealing the process chamber; and processing the surface of the workpiece in the process chamber.
According to the present invention, even if a workpiece to be processed becomes larger in size, it is not necessary to make a process chamber larger, and hence the processing apparatus has a highly compact structure to reduce an installation space for the apparatus and an amount of a material required for the process.
In this case, the sealing portion may comprise at least one of a contact seal and a non-contact seal. The contact seal may comprise at least one of an O-ring and an oil seal. The non-contact seal may comprise at least one of a magnetic fluid seal and a differential pumping seal (differential exhaust seal).
The processing apparatus may further comprise a chemical vapor deposition device in the process chamber for depositing a thin film on the surface of the workpiece. Alternatively, the processing apparatus may further comprise a chemical liquid cleaning device in the process chamber for cleaning the surface of the workpiece with a chemical liquid.
The processing apparatus may further comprise a sensor for detecting conditions of the surface of the workpiece. With this arrangement, conditions of the surface of the workpiece before or after performing a process can be detected for thereby diagnosing the process. Such diagnosis can be applied to a process for regenerating the surface of the workpiece or removing a defective workpiece.
In this case, the processing apparatus may further comprise an adjustment device for adjusting processing conditions in the process chamber by feedback control based on a signal from the sensor. With this arrangement, the surface of the workpiece can properly be processed based on the actual conditions of the surface of the workpiece before or after the process.
The surface of the workpiece may be processed under a pressure lower than atmospheric pressure, or processed under a wet condition.
Processing conditions in the process chamber may be changed for sequentially performing a plurality of processes. When processing conditions in the processing chamber are changed, a plurality of processes can sequentially be performed in one process chamber.
According to a preferred aspect of the present invention, a plurality of processing apparatuses are disposed on the workpiece, and a plurality of portions of the workpiece are simultaneously processed in the respective process chambers of the plurality of processing apparatuses. As described above, the processing apparatus according to the present invention has a size smaller than the surface, to be processed, of the workpiece, and hence the workpiece can be processed by a plurality of processing apparatuses. Therefore, a plurality of portions of the workpiece can substantially simultaneously be processed by a plurality of processing apparatuses.
In this case, a plurality of processes may be performed under different processing conditions in the respective process chambers of the plurality of processing apparatuses. If periods of time required for the respective processes in the process chambers are different from each other, then processing conditions are properly modified for the respective process chambers to control reaction rates in the respective process chambers. Thus, the periods of time required for the respective processes in the process chambers can properly be adjusted.
According to a preferred aspect of the present invention, the surface of the workpiece is processed while the process chamber is being moved relatively to the surface of the workpiece. With this method, the whole surface of the workpiece or only a desired area of the surface of the workpiece can be processed. In this case, the process chamber may continuously be moved relatively to the surface of the workpiece. Alternatively, the process chamber may intermittently be moved relatively to the surface of the workpiece for processing another portion of the surface of the workpiece.
The above and other objects, features, and advantages of the present invention will be apparent from the following description when taken in conjunction with the accompanying drawings which illustrates preferred embodiments of the present invention by way of example.
A processing apparatus for processing a workpiece according to embodiments of the present invention will be described below with reference to the accompanying drawings.
Generally, it is necessary to maintain desired processing conditions in a process chamber where a workpiece is processed. For example, the pressure in the process chamber is required to be lower than that in an exterior space in some cases, and the pressure in the process chamber is required to be higher than that in the exterior space in other cases. Further, the workpiece is processed with use of a reactive gas or a reactive liquid in some cases. Therefore, in order to maintain desired processing conditions in the process chamber, it is necessary to seal an interior of the process chamber from the outside space. In the processing apparatus according to the present invention, the cover 2 has the sealing portion 4 provided at the lower end thereof to seal the interior of the process chamber 3 from the exterior space. Various sealing mechanisms may be used as the sealing portion 4. For example, the sealing portion 4 may comprise a contact seal such as an O-ring or an oil seal, or a non-contact seal such as a magnetic fluid seal or a differential pumping seal.
At the beginning of processing, the cover 2 is downwardly moved relatively to the workpiece 10 by a lifting/lowering mechanism (not shown) provided on the cover 2, for thereby pressing the sealing portion 4 such as an O-ring against the surface 11 to be processed at a predetermined pressure. Alternatively, the cover 2 may downwardly be moved and positioned so as to produce a predetermined gap G between the sealing portion 4 and the surface 11 to be processed (see FIG. 5).
Various devices for performing respective processes for the workpiece 10 can be incorporated into the process chamber 3 sealed from the exterior space by the sealing portion 4. For example, in semiconductor fabrication processes and electronic component fabrication processes, devices for performing the following processes are provided as needed.
1) Processes under vacuum (for example, dry etching such as reactive ion etching (RIE), and sputtering, chemical vapor deposition (CVD), physical vapor deposition (PVD), baking, and drying)
2) Processes under atmospheric pressure (for example, lithography and drying)
3) Wet processes (for example, chemical liquid coating, wet etching, resist coating, plating, and chemical mechanical polishing (CMP))
4) Cleaning processes (for example, pure water cleaning, chemical liquid cleaning, ultrasonic cleaning, and scrubbing)
5) Inspection processes for inspecting conditions of a surface, to be processed, of a workpiece
As shown in
In this example, the sealing portion 4 comprises a differential pumping seal. The cover 2 has a support portion 20 having two recesses 23, 24 defined in the lower surface thereof. These recesses 23, 24 are connected to a vacuum source (not shown) via exhaust passages 47, 48. A vacuum level of the exhaust passage 47 is higher than the vacuum level of the exhaust passage 48. A gas supply passage 49 is formed in the support portion 20 at a radially outward position of the exhaust passage 48 and is connected to a gas supply source (not shown). A sealing gas (dry inert gas) such as N2 or Ar is supplied through the gas supply passage 49 to the recesses 23, 24. The supplied sealing gas is exhausted via the exhaust passages 47, 48 to seal the interior of the process chamber 3 from the exterior space. Thus, the interior of the process chamber 3 is kept hermetically sealed.
In this example, the processing apparatus 1 may comprise a vacuum gauge for detecting a vacuum level in the process chamber 3, a vacuum gauge for detecting a vacuum level of the reverse side of the workpiece 10, i.e., a vacuum level in the recess 13, and a control device for controlling the pressure in the recess 13 so as to be equal to the pressure in the process chamber 3 during the process, based on the signals from the vacuum gauges. In this case, a differential pressure is not developed between the face side and the reverse side of the workpiece 10 in the process chamber 3, for thereby processing the workpiece 10 without deflection thereof. Since atmospheric pressure is applied to a portion of the workpiece 10 that is not covered by the cover 2, a differential pressure is developed between the face side and the reverse side of the workpiece 10 at the above portion. Therefore, the workpiece 10 can be attracted to the recess 13 of the workpiece holder 12 with this differential pressure. Although the details of the chucking mechanism are not shown in
With the processing apparatus 1 shown in
As shown in
As shown in
Cover 2 has a support portion 20 having an O-ring 41 as a contact seal. A chemical liquid suction passage 64 for sucking the chemical liquid 61 that leaks out of the an interior of the process chamber 3 is formed in the support portion 20 at a radially outward position of the O-ring 41. The chemical liquid suction passage 64 is connected to a vacuum source (not shown) such as a vacuum pump. Accordingly, the chemical liquid 61 that leaks out of the interior of the process chamber 3 near the chemical liquid suction passage 64 is sucked via the chemical liquid suction passage 64, so that the chemical liquid 61 in the process chamber 3 is prevented from leaking out to the exterior space. The chemical liquid suction passage 64 may be connected to the chemical liquid supply passage 63 to circulate and reuse the chemical liquid 61 that has been sucked via the chemical liquid suction passage 64.
With the processing apparatus 1 shown in
In this example shown in
Various processing methods of a workpiece with use of the above processing apparatus will be described below.
When the process chamber 3 is moved relatively to the surface 11, to be processed, of the workpiece 10, the whole surface of the workpiece 10 or only a desired area of the surface of the workpiece 10 can be processed. In this case, the process chamber 3 (processing apparatus 1) may be moved relatively to the surface 11 of the workpiece 10, as shown in
The process chamber 3 and the workpiece 10 may continuously be moved relative to each other, for continuously changing portions to be processed. Alternatively, after a specific portion of the surface 11 of the workpiece 10 is processed, the process chamber 3 and the workpiece 10 may intermittently be moved relatively to each other, for processing respective portions of the workpiece 10 one after another. When the process is completed, or when a portion to be processed is changed, the cover 2 may be moved upwardly by the aforementioned lifting/lowering mechanism.
It is more effective to combine a plurality of processing apparatuses according to the present invention. For example, as shown in
With regard to processes performed in the process chamber 3, a plurality of processes are sequentially performed in one process chamber 3. For example, as shown in
For example, as shown in
In the case where different processes are performed in a plurality of process chambers 3 as described above, if periods of time required for the respective processes in the process chambers 3 are different from each other, then processing conditions are properly modified for respective process chambers 3 to control reaction rates in the respective process chambers 3. Thus, the periods of time required for the respective processes in the process chambers 3 can properly be adjusted.
A cleaning process and a drying process may be performed after performance of the above process (a process under vacuum, a process under atmospheric pressure, or a wet process) to prevent contamination on the workpiece. Therefore, it is easy to arrange a processing apparatus suitable for dry in dry out process in which the workpiece to be processed is introduced into the processing apparatus in a dry state and the processed workpiece is removed from the processing apparatus in a dry state.
As described above, according to the present invention, since a large process chamber is not required even in the case of a larger workpiece, the processing apparatus has a highly compact structure to reduce an installation space for the apparatus and an amount of a material required for the process.
Although certain preferred embodiments of the present invention have been shown and described in detail, it should be understood that various changes and modifications may be made therein without departing from the scope of the appended claims.
Number | Date | Country | Kind |
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2001-001831 | Jan 2001 | JP | national |
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Number | Date | Country | |
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20020088399 A1 | Jul 2002 | US |