A resist coating apparatus according to an embodiment of the present invention will be described with reference to
The cup body 23 is formed at its upper surface with an opening larger than the wafer W so that the spin chuck 20 can rise and lower, and formed with a gap 24 forming a drainage path between its side peripheral surface and the outer periphery of the guide ring 22. The lower portion of the cup body 23 forms a bending path in conjunction with the outer peripheral portion of the guide ring 22 to constitute a gas/liquid separating section. An exhaust port 25 is formed at an inner side area of the bottom portion of the cup body 23, and an exhaust pipe 25a is connected to the exhaust port 25. Further, a drain port 26 is formed at an outer side area of the bottom portion of the cup body 24, and a drain pipe 26a is connected to the drain port 26.
The resist coating apparatus also includes a resist solution nozzle 30 for supplying a resist solution onto the central portion of the front surface of the wafer W and a solvent nozzle 40 for supplying a liquid agent, for example, a solvent (thinner) to the central portion of the front surface of the wafer W. The resist solution nozzle 30 is connected to a resist solution supply source 32 for supplying the resist solution via a resist solution supply pipe 31. Along the resist solution supply pipe 31, a supply equipment group 33 is also provided including a valve, a flow control unit and so on. The solvent nozzle 40 is connected to a solvent supply source 42 for supplying the solvent, for example, the thinner via a solvent supply pipe 41. Along the solvent supply pipe 41, a supply equipment group 43 is also provided including a valve, a flow control unit and so on. In this embodiment, the resist solution supply source 32 and the supply equipment group 33 correspond to a resist solution supply unit, and the solvent supply source 42 and the supply equipment group 43 correspond to a solvent supply unit.
The resist solution nozzle 30 is connected, as shown in
The solvent nozzle 40 is connected, as shown in
The resist coating apparatus includes, as shown in
Next, the operation of the above-described embodiment will be described.
First of all, an external carrier arm holding the wafer W (for example, a carrier arm A2 or A3 in
Subsequently, the solvent nozzle 40 is moved from the position above the central portion of the wafer W, and instead, the resist nozzle 30 is moved to a position above the central portion of the wafer W, and the wafer W is rotated by controlling the rotation drive unit 21 whose rotation speed is increased to 1000 rpm at an acceleration of 10000 rpm/sec. At the point in time when the number of rotations reaches 1000 rpm, the resist nozzle 30 starts to discharge the resist solution onto the central portion of the wafer W, and the number of rotations is increased to 3200 rpm at an acceleration of 1500 rpm/sec.
The states on the front surface of the wafer W so far are shown at (i) and (ii) in
At the time when the number of rotations of the wafer W reaches 3200 rpm, the resist solution has been spread with a high uniformity within the entire surface as shown at (iii) in
Therefore, it is preferable to perform the deceleration as soon as possible, in which the rotation is decelerated to the second number of rotations, for example, to 100 rpm, for example, at an acceleration (a negative acceleration) of 30000 rpm/sec. The time required to reduce the speed from the first number of rotations to the second number of rotations is preferably, for example, within 0.2 seconds. Note that the second number of rotations is not limited to 100 rpm, but is preferably 1000 rpm or less. Besides, the time in which the second number of rotations is maintained is, for example, 1 second, and may be adjusted depending on the viscosity of the resist solution.
The completion time point of resist discharge may be before the first number of rotations is reached, and is desirably the time point as close as possible to that of the first number of rotations in viewpoint of decreasing the amount of the resist. Further, since it is disadvantageous to discharge the resist solution during the deceleration from the first number of rotations to the second number of rotations as a result of a later-described evaluation experiment, it is preferable that the completion time point of resist discharge does not overlap the deceleration step. However, it is conceivable that even if it is unavoidable that the discharge of the resist solution slightly overlaps the deceleration step due to the operation error of hardware parts, it is necessary to stop the supply of the resist solution at a timing when the supply amount of the resist solution while the wafer W is accelerated to the first number of rotations is 80% or more of the total supply amount, in order to achieve the effects of the present invention. Note that, for implementation of the present invention, there is no conceivable advantage of creating a recipe for positive discharge of the resist solution in the deceleration step, but it is also within the technical scope of the present invention that the supply amount of the resist solution while the rotation is accelerated to the first number of rotations is 80% or more of the total supply amount.
After the wafer is rotated at the second number of rotations, the number of rotations of the wafer W is increased, for example, to a third number of rotations lower than the first number of rotations and maintained at the third number of rotations for a while, for example, for 20 seconds. The reason why the wafer W is rotated at the third number of rotations is to dry the resist film by the rotation, in which the remaining resist solution is also shaken off so that the film thickness is adjusted. The third number of rotations and its duration are determined depending on the target film thickness, the viscosity of the resist solution and so on, and the rotation number for the 12-inch size wafer is preferably 2000 rpm or less and is set, for example, to 1000 rpm to 1800 rpm. The wafer W is thereafter subjected to rinse treatment for its rear surface and then transferred to the external carrier arm by the operation reverse to that for the above-described carrying-in.
Here, the method of supplying the resist solution to the wafer W during the first number of rotations as in Japanese Patent Application Laid-open No. H11-260717 and the method of the present invention of supplying the resist solution to the wafer W during the acceleration to the first number of rotations are compared. When the supply amount of the resist solution is set to a certain amount now, the present invention provides a film thickness distribution in which the film thickness at the peripheral portion of the wafer W is larger as shown at A in
Namely, if the film thickness at the peripheral portion is larger than that at the central portion, the film thickness can be uniformed within a plane by reducing the discharge amount of the resist solution, by adjusting the first number of rotations, or by adjusting the time for rotation at the second number of rotations. On the other hand, the fact that the film thickness on the entire surface becomes uniform means impossibility of further adjustment, in other words, indicates the limit in reducing the amount of the resist. If the amount of the resist is further reduced, the film thickness at the peripheral portion will become smaller than that at the central portion as shown by a dotted-line C in
The inventors consider the reason of the above as follows. In the case where the resist solution is discharged to the central portion of the rotating wafer W, when the resist solution on the wafer W is regarded a set of ring-shape portions, aggregations R of the solution in the ring-shape portions (a symbol R for the aforementioned resist solution is given for convenience) as shown in
Besides, the point in time of starting discharge of the resist solution is preferably the time point when the number of rotations of the wafer W is smaller than the third number of rotations. The reason therefor is as follows. The third number of rotations is within the range of the numbers of rotations where the remaining resist solution is shaken off and drying proceeds, and is determined depending on the viscosity of the resist solution in use. Accordingly, if the number of rotations is higher than the third number of rotations, evaporation of the solvent used for pre-wetting proceeds so that the wettability on the entire surface of the wafer W becomes hard to be secured, which degrades the effect of the pre-wetting, thereby causing unevenness in coating of the resist solution to tend to occur.
According to the above-described embodiment, the front surface of the wafer W is wetted with the solvent in advance to make the resist solution to easily diffuse, and subsequently all or most of the resist solution is applied during acceleration of the rotation of the wafer W, so that the resist solution spreads with a high uniformity with the result that unevenness in coating hardly occurs. As is clear also from the later-described evaluation experiment, the resist solution can be efficiently spread to the outer periphery of the wafer W to reduce the consumption of the resist solution as compared to the case where the resist solution is supplied onto the wafer W while the substrate is being rotated at the first number of rotations (as compared to the method in Japanese Patent Application Laid-open No. H11-260717). In other words, the method according to the embodiment can perform coating treatment with a high uniformity of the film thickness within a plane even with a small amount of resist solution, and therefore is a method suitable for manufacturing a semiconductor device for which miniaturization of the pattern, reduction in film thickness, and increase in cost of the resist solution are advanced.
In the present invention, the rotation of the wafer W is not limited to that the rotation is decelerated to the second number of rotations immediately after the number of rotations of the wafer W reaches the first number of rotations, but the first number of rotations may be maintained for a while. However, if the supply to the wafer W is completed concurrently with the time when the first number of rotations is reached as in the above embodiment, it is preferable to decelerate the rotation to the second number of rotations immediately after it reaches the first number of rotations. The example shown in
Furthermore, if the uniformity of the film thickness of the resist solution within a plane is high at the point in time when the discharge of the resist solution is completed, the rotation of the wafer W does not always need to be decelerated to the second number of rotations, but may be decelerated to the third number of rotations as shown in
It should be noted that the first number of rotations is preferably 4000 rpm or less and more preferably 1500 rpm to 3500 rpm for the 12-inch size wafer W. The first number of rotations is preferably 6000 rpm or less and more preferably 3000 rpm to 5000 rpm for the 8-inch size wafer W. Further, the third number of rotations is preferably 4000 rpm or less for the 8-inch size wafer W.
Evaluation experiments for confirming the effects of the present invention will be described next. As recipes for the numbers of rotations and application of the resist solution, three examples, such as Example 1, Comparative Example 1, and Comparative Example 2 were prepared as follows.
Example 1 is as shown in
As shown in
In Example 1, the rotation was decelerated from the first number of rotations to 1000 rpm at an acceleration of 1500 rpm/sec during which the resist solution was supplied to the wafer W, and the rotation was then decelerated to the second number of rotations at an acceleration of 30000 rpm/sec. The recipe other than the above was the same as that for Example 1.
Checking the film thickness distributions of the resist films on the wafer W after the respective recipes were completed shows the results shown in
The above results shows that the film thickness at the peripheral portion of the wafer W was larger than that at the central portion in the present invention, whereas the film thickness was uniform over the entire surface of the wafer W in Comparative Example 1 in which the resist solution was supplied while the wafer W was being rotated at the first number of rotations. Accordingly, there was already no margin in Comparative Example 1 as described above and, as a result, it is found that the resist solution can be further reduced in amount in the present invention. Note that the film thickness at the peripheral portion of the wafer W was smaller than that at the central portion in Comparative Example 2 in which the resist solution was supplied during deceleration, which shows that application of the resist solution with a high uniformity within a plane cannot be achieved with 0.5 ml of resist solution.
Subsequently, the whole configuration of a coating and developing apparatus in which the above-described resist coating apparatus is incorporated and to which an aligner is connected will be briefly described with reference to
To the rear side of the carrier station B1, a processing block B2 is connected which is surrounded by a housing 82, and shelf units U1, U2 and U3 in each of which units of heating and cooling systems are multi-tiered and main arms A2 and A3 forming substrate carrier means for transferring the wafer W between the units in shelf units U1, U2 and U3 and solution treatment units U4 and U5 are provided arranged alternately in sequence from the front side in the processing block B2. Further, each of the main arms A2 and A3 is placed in a space surrounded by a partition wall 83 composed of face portions on the side of the shelf units U1, U2, and U3 which are arranged in a forward and backward direction as viewed from the carrier station B1, one face portion on the side of, for example, the later-described solution treatment unit U4 or U5 on the right side, a rear face portion forming one face on the left side. Numerals 84 and 85 in
The solution treatment units U4 and U5 are configured such that the above-described resist coating apparatuses (COT) 90 for applying the resist solution to the front surface of the wafer W, developing units (DEV) 87 for applying a developing solution to front surface of the wafer W, antireflection film forming units (BARC) and so on are multi-tiered, for example, five-tiered on chemical storage unit 86 for the resist solution, the developing solution and so on, for example, as shown in
To the rear side of the shelf unit U3 in the processing block B2, an aligner B4 is connected via an interface section B3 composed of a first carrier chamber 88a and a second carrier chamber 88b. Inside the interface section B3, an edge exposure unit (WEE) for selectively exposing only an edge portion of the wafer W, a buffer cassette (SBU) for temporarily housing a plurality of, for example, 25 wafers W, a transfer unit (TRS 2) for transferring the wafer W, a high-precision temperature regulating unit (CPL), for example, having a cooling plate and so on are provided in addition to two transfer means A4 and A5 for transferring the wafer W between the processing block B2 and the aligner B4.
Taking an example of the flow of the wafer W in this apparatus, when the carrier 8 housing wafers W is carried in from the outside and mounted on the mounting table 80, the lid body of the carrier 8 is removed together with the opening/closing unit 81, and a wafer W is taken out by the transfer means A1. The wafer W is transferred via a transfer unit (not shown) forming one tier in the shelf unit U1 to the main carrier means A2 and subjected, for example, to hydrophobic treatment and cooling processing as the pre-processing of the coating treatment in one shelf in one of the shelf units U1 to U3. Thereafter, the resist solution is applied to the front surface of the wafer W in the resist coating apparatus (COT) 90, and a water-repellent protection film is then formed on the front surface of the wafer W having the resist film formed thereon in a protection film forming unit (TC) 3 being a protection film forming section. Subsequently, the wafer W is heated (baking processing) in the heating unit (PAB) forming one tier in one of the shelf units U1 to U3, then cooled, and carried via the transfer unit (TRS 1) in the shelf unit U3 into the interface section B3. In the interface section B3, the wafer W is carried by the transfer means A4, for example, to the edge exposure unit (WEE), to the buffer cassette (SBU), and to the high-precision temperature regulating unit (CPL), and the wafer W mounted on the high-precision temperature regulating unit (CPL) is carried by the transfer means A5 to the aligner B4 where the wafer W is subjected to exposure processing. The exposed wafer W is carried by the transfer means A5 to the transfer unit (TRS 2) and then carried by the transfer means A5 from the transfer unit (TRS 2) to the heating unit (PEB) in the shelf unit U3. In the developing unit (DEV) forming one tier in the shelf unit U5, the developing solution is supplied to the front surface of the wafer W to develop the resist, whereby a resist mask in a predetermined pattern is formed on the wafer W. Thereafter, the wafer W is returned by the transfer means A1 to the original carrier 8 on the mounting table 80.
Number | Date | Country | Kind |
---|---|---|---|
2006-126826 | Apr 2006 | JP | national |