SUBSTRATE PROCESSING APPARATUS, METHOD OF MANUFACTURING SEMICONDUCTOR DEVICE AND NON-TRANSITORY COMPUTER-READABLE RECORDING MEDIUM

There is provided a technique for suppressing interference between processes respectively performed in the plurality of reactors. According to one aspect thereof, a substrate processing apparatus includes: a first vessel including a transfer port and a process chamber; a second vessel adjacent to the first vessel and communicating with the first vessel via the transfer port; a lid for closing the transfer port; a seal arranged between the transfer port and the lid; and a controller for controlling the inner pressure of the first vessel to be lower than the inner pressure of the second vessel with the transfer port closed by the lid while the substrate is processed in the process chamber and the inner pressure of the first vessel to be higher than the inner pressure of the second vessel after the substrate is processed and before the first vessel comes into communication with the second vessel.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This non-provisional U.S. Pat. Application claims priority under 35 U.S.C. § 119 of Japanese Patent Application No. 2022-034844, filed on Mar. 7, 2022, in the Japanese Patent Office, the entire contents of which are hereby incorporated by reference.

BACKGROUND

The present disclosure relates to a substrate processing apparatus, a method of manufacturing a semiconductor device and a non-transitory computer-readable recording medium.

2. Related Art

According to some related arts, as an example of a substrate processing apparatus used in a manufacturing process of a semiconductor device, a cluster type apparatus provided around a plurality of reactors and a vacuum transfer chamber may be used. The plurality of reactors may be configured to be capable of performing different processes, respectively. For example, a film-forming process may be performed in a first reactor among the plurality of reactors, and a modification process may be performed in a second reactor among the plurality of reactors. A substrate processed in a reactor such as the first reactor may be transferred to another reactor such as the second reactor via the vacuum transfer chamber, or may be transferred out of the substrate processing apparatus.

As described above, since the plurality of reactors are configured to be capable of performing the different processes, respectively, it is preferable to suppress interference between processes respectively performed in the plurality of reactors.

SUMMARY

According to the present disclosure, there is provided a technique capable of suppressing interference between processes respectively performed in a plurality of reactors when the plurality of reactors are configured to be capable of performing different processes, respectively.

According to one aspect of the technique of the present disclosure, there is provided a substrate processing apparatus including: a first vessel including: a loading/unloading port structure constituting a loading/unloading port through which a substrate is capable of being transferred; and a process chamber in which the substrate is accommodated; a second vessel provided adjacent to the first vessel and configured to be capable of communicating with the first vessel via the loading/unloading port; a lid configured to be capable of closing the loading/unloading port; a seal arranged between the loading/unloading port structure and the lid; and a controller configured to be capable of controlling an inner pressure of the first vessel and an inner pressure of the second vessel such that the inner pressure of the first vessel is set to be lower than the inner pressure of the second vessel with the loading/unloading port closed by the lid while the substrate is processed in the process chamber and such that the inner pressure of the first vessel is set to be higher than the inner pressure of the second vessel after the substrate is processed and before the first vessel comes into communication with the second vessel.

DETAILED DESCRIPTION

Embodiments

Hereinafter, one or more embodiments (also simply referred to as “embodiments”) according to the technique of the present disclosure will be described with reference to the drawings. The drawings used in the following descriptions are all schematic. For example, a relationship between dimensions of each component and a ratio of each component shown in the drawing may not always match the actual ones. Further, even between the drawings, the relationship between the dimensions of each component and the ratio of each component may not always match.

Configuration of Substrate Processing Apparatus

Hereinafter, a substrate processing apparatus 100 according to the present embodiments will be described with reference toFIGS.1and2.FIG.1is a diagram schematically illustrating a horizontal cross-section of an exemplary configuration of the substrate processing apparatus 100 according to the present embodiments.FIG.2is a diagram schematically illustrating a vertical cross-section of the exemplary configuration of the substrate processing apparatus 100 according to the present embodiments, taken along a line α - α shown inFIG.1.

As shown inFIGS.1and2, the substrate processing apparatus100to which the present embodiments are applied is configured to process a substrate S serving as a substrate (wafer). The substrate processing apparatus100is constituted mainly by an I/O stage (input/output stage)110, an atmospheric transfer chamber120, a load lock chamber130, a vacuum transfer chamber140, a reactor200and a reactor300. Hereinafter, components of the substrate processing apparatus100will be described in detail.

The I/O stage (also referred to as a “loading port shelf”)110is provided in front of the substrate processing apparatus100. The I/O stage110is configured such that a plurality of pods including a pod111can be placed on the I/O stage110. In the present specification, the plurality of pods including the pod111may be also be simply referred to as “pods111”. The pod111is used as a carrier for transferring the substrate S such as a silicon (Si) substrate.

The I/O stage110is provided adjacent to the atmospheric transfer chamber120. The load lock chamber130, which will be described later, is connected to a side surface of the atmospheric transfer chamber120other than a side surface at which the I/O stage110is provided. An atmospheric transfer robot122capable of transferring the substrate S is provided in the atmospheric transfer chamber120.

A substrate loading/unloading port128through which the substrate S is transferred (loaded or unloaded) into or out of the atmospheric transfer chamber120and a pod opener121are provided at a front side of a housing127constituting the atmospheric transfer chamber120. A substrate loading/unloading port129through which the substrate S is transferred (loaded or unloaded) into or out of the load lock chamber130is provided at a rear side of the housing127of the atmospheric transfer chamber120. The substrate loading/unloading port129is opened or closed by a gate valve133. When the substrate loading/unloading port129is opened by a gate valve133, the substrate S may be transferred (or loaded) into or transferred (or unloaded) out of the load lock chamber130.

The load lock chamber130is provided adjacent to the atmospheric transfer chamber120. The vacuum transfer chamber140, which will be described later, is provided at a side surface of a housing131constituting the load lock chamber130other than a side surface of the housing131that is adjacent to the atmospheric transfer chamber120. The vacuum transfer chamber140is connected to the load lock chamber130via a gate valve134.

A substrate mounting table136provided with at least two placing surfaces135on which the substrate S is placed is provided in the load lock chamber130. A distance between the two placing surfaces135may be set based on a distance between end effectors of an arm of a transfer robot180described later.

The substrate processing apparatus100includes the vacuum transfer chamber140, that is, a transfer space in which the substrate S is transferred under a negative pressure. For example, a housing141constituting the vacuum transfer chamber140is pentagonal when viewed from above. The load lock chamber130and the reactor200(that is, reactors200a,200band200cdescribed later) where the substrate S is processed and the reactor300where the substrate S is processed are connected to respective sides of the housing141of a pentagonal shape. In the present specification, the reactors200a,200band200cmay be collectively or individually referred to as the “reactor200”. The transfer robot180capable of transferring the substrate S under the negative pressure is provided approximately at a center of the vacuum transfer chamber140with a flange144as a base. The transfer robot180serves as a transfer structure.

The transfer robot180provided in the vacuum transfer chamber140is configured to be elevated or lowered by an elevator145while maintaining the vacuum transfer chamber140airtight by the flange144. The elevator145is configured to elevate and lower two arms including an arm181of the transfer robot180. InFIG.2, for convenience of explanation, the end effectors of the arm181are illustrated, and a configuration such as a robot shaft connected to the flange144is omitted. In the present specification, the arms including the arm181may also be referred to as “arms181”.

The reactor200(that is, the reactors200a,200band200c) and the reactor300are connected to an outer periphery of the vacuum transfer chamber140. The reactors200a,200band200cand the reactor300are arranged radially around the vacuum transfer chamber140.

A substrate loading/unloading port148(seeFIG.3) is provided in each of sidewalls of the housing141facing the reactor200(that is, the reactors200a,200band200c) and the reactor300, respectively. For example, as shown inFIG.2, a substrate loading/unloading port148ais provided in the sidewall of the housing141facing the reactor200a. Further, as shown inFIG.1, a substrate loading/unloading port148b, a substrate loading/unloading port148cand a substrate loading/unloading port148dare provided in a manner corresponding to the reactors200b,200cand the reactor300, respectively. Since configurations of the reactors200band200care the same as that of the reactor200a, the detailed description thereof will be omitted. In the present specification, the substrate loading/unloading ports148athrough148dmay be collectively or individually referred to as the “substrate loading/unloading port148”. In addition, for example, the substrate loading/unloading port148dand a gate valve149dare provided in the sidewall of the housing141facing the reactor300. As shown inFIG.1, a gate valve149a, a gate valve149b, a gate valve149cand the gate valve149dare provided in a manner corresponding to the reactors200a,200b,200cand the reactor300, respectively. In the present specification, the gate valves149athrough149dmay be collectively or individually referred to as a “gate valve149”. Since the reactor200(that is, the reactors200athrough200c) and the reactor300communicate with the vacuum transfer chamber140, the reactor200and the reactor300are also operated at a vacuum level such that it is possible to prevent an inner atmosphere of the vacuum transfer chamber140from flowing into each of the reactor200and the reactor300. When the substrate S is transferred (loaded or unloaded) between the vacuum transfer chamber140and each of the reactor200and the reactor300, a pressure in each of the reactor200and the reactor300may be further adjusted (or controlled).

Subsequently, the transfer robot180provided in the vacuum transfer chamber140will be described. The transfer robot180includes the two arms181. The arm181includes the end effectors on which the substrate S is placed.

The elevator145is capable of controlling an elevating operation and a rotating operation of the arm181. The arm181is capable of being rotated or extended around an arm shaft (not shown). By rotating or extending the arms181, the substrate S may be loaded into or unloaded out of the reactor200(that is, the reactors200a,200band200c) or the reactor300.

Subsequently, the reactors200a,200band200cwill be described with reference toFIG.3. Since the configurations of the reactors200a,200band200care the same, in the following descriptions, the reactors200a,200band200cwill be collectively described as the reactor200. Each reactor200is configured to be capable of performing a plurality of processes. The reactor200will be described in detail below.

A housing201constituting the reactor200includes a reaction tube storage chamber210at an upper portion thereof and a transfer chamber270at a lower portion thereof. In the reaction tube storage chamber210, a heater211and an inner reaction tube222are mainly provided. The transfer chamber270is configured to be capable of communicating with the vacuum transfer chamber140. The substrate loading/unloading port148(that is, the substrate loading/unloading ports148athrough148c) through which the substrate S is transferred into or out of the transfer chamber270is provided at the transfer chamber270. The substrate loading/unloading port148(that is, the substrate loading/unloading ports148athrough148c) is opened or closed by the gate valve149(that is, the gate valves149athrough149c). The heater211is spaced apart from a wall of the inner reaction tube222, and is arranged along the wall (which is a wall of a process chamber222cextending in a vertical direction) of the inner reaction tube222. The heater211may also be referred to as a “first heater” or a “wall heater”.

The transfer chamber270is installed below the inner reaction tube222, and is configured to be capable of communicating with the inner reaction tube222. In the transfer chamber270, the substrate S may be placed (or mounted) on a substrate support structure (hereinafter, also referred to as a “boat”)240described later by the transfer robot180via the substrate loading/unloading port148, or the substrate S may be taken (or unloaded) out of the substrate support structure240by the transfer robot180via the substrate loading/unloading port148.

Subsequently, the reaction tube storage chamber210and the inner reaction tube222provided in the reaction tube storage chamber210will be described. A reaction tube is constituted by the inner reaction tube222and an outer reaction tube221. The inner reaction tube222is accommodated in the outer reaction tube221. According to the present embodiments, the outer reaction tube221and the inner reaction tube222may also be collectively referred to as a “first vessel”.

The outer reaction tube221is provided between the inner reaction tube222and the heater211. InFIG.3, the outer reaction tube221and the inner reaction tube222are configured such that an inner atmosphere of the outer reaction tube221and an inner atmosphere of the inner reaction tube222are separated from each other. A chamber of the outer reaction tube221, where the inner reaction tube222is stored, may also be referred to as an “inner reaction tube storage chamber221b”. However, the present embodiments are not limited thereto. For example, the inner atmosphere of the outer reaction tube221and the inner atmosphere of the inner reaction tube222may communicate with each other.

A flange221ais provided at a lower portion of the outer reaction tube221. The flange221ais fixed to a wall constituting the reaction tube storage chamber210. A hole is provided at a center of the flange221a. A flange222aof the inner reaction tube222is inserted into the hole and fixed. The flange221aand the flange222amay also be collectively referred to as a “furnace opening222b”.

An upper portion of the inner reaction tube222is closed, and the flange222ais provided at a lower portion of the inner reaction tube222. The furnace opening222bthrough which the substrate support structure240is transferred is provided at a center of the flange222a. That is, the flange222ais provided at a lower portion of a wall constituting the inner reaction tube222and extending in the vertical direction. Since the substrate support structure240is transferred through the furnace opening222b, the furnace opening222bmay also be referred to as a “substrate support loading/unloading port” or simply referred to as a “loading/unloading port”. Further, the flange222aand the furnace opening222bmay also be collectively referred to as a “substrate support loading/unloading port structure” or simply referred to as “loading/unloading port structure”. The furnace opening222bmay be included in the flange222a.

The inner reaction tube222is configured to be capable of accommodating the substrate S supported by the substrate support structure240. The inner reaction tube222is provided with a nozzle (or nozzles)223serving as a part of a gas supplier (which is a gas supply structure or a gas supply system) through which a gas is supplied. The nozzle (or nozzles)223may be configured to extend in the vertical direction, which is an arrangement direction of a plurality of substrates including the substrate S. In the present specification, the plurality of substrates including the substrate S may also be referred to as “substrates S”. The gas supplied through the nozzle (or nozzles)223is supplied to each of the substrates S.

For example, the nozzles223are provided for each gas type. The present embodiments will be described by way of an example in which three nozzles223a,223band223care provided as the nozzles223. Each of the nozzles223is arranged so as not to overlap one another in a horizontal direction. While the three nozzles223a,223band223care illustrated as the nozzles223inFIG.3for convenience of explanation, the present embodiments are not limited thereto. For example, four or more nozzles may be provided in accordance with contents of a substrate processing.

Subsequently, the gas supplier capable of supplying the gas to each of the nozzles223will be described with reference toFIGS.4A,4B,4C and4D. According to the present embodiments, for example, a first gas supplier (which is a first gas supply structure or a first gas supply system)224and a second gas supplier (which is a second gas supply structure or a second gas supply system)225, which will be described later, may also be collectively or individually referred to as the gas supplier.

First, the first gas supplier224capable of supplying the gas to the nozzle223awill be described with reference toFIG.4A. A first gas supply source224b, a mass flow controller (MFC)224cserving as a flow rate controller (or a flow rate control structure) and a valve224dserving as an opening/closing valve are sequentially provided in this order at a gas supply pipe224afrom an upstream side toward a downstream side of the gas supply pipe224ain a gas flow direction. The gas supply pipe224ais configured to be capable of communicating with the nozzle223a.

The first gas supply source224bis a source of a first gas (also referred to as a “first element-containing gas”) containing a first element. The first element-containing gas serves as a source gas, which is one of process gases. According to the present embodiments, for example, the first element is silicon (Si). More specifically, a chlorosilane source gas containing a silicon -chlorine bond (Si - Cl bond) such as hexachlorodisilane gas (Si2Cl6, abbreviated as HCDS) gas, monochlorosilane (SiH3Cl, abbreviated as MCS) gas, dichlorosilane (SiH2Cl2, abbreviated as DCS) gas, trichlorosilane (SiHCl3, abbreviated as TCS) gas, tetrachlorosilane (SiCl4, abbreviated as STC) gas and octachlorotrisilane (Si3Cl8, abbreviated as OCTS) gas may be used as the first element-containing gas.

The first gas supplier224is constituted mainly by the gas supply pipe224a, the MFC224cand the valve224d. The first gas supplier224may also be referred to as a “silicon-containing gas supplier” (which is a silicon-containing gas supply structure or a silicon-containing gas supply system).

A gas supply pipe224eis connected to the gas supply pipe224aat a downstream side of the valve224d. An inert gas supply source224f, a mass flow controller (MFC)224gand a valve224hare sequentially provided in this order at the gas supply pipe224efrom an upstream side toward a downstream side of the gas supply pipe224ein the gas flow direction. For example, an inert gas such as nitrogen (N2) gas is supplied from the inert gas supply source224f.

A first inert gas supplier (which is a first inert gas supply structure or a first inert gas supply system) is constituted mainly by the gas supply pipe224e, the MFC224gand the valve224h. The inert gas supplied from the inert gas supply source224fis used as a carrier gas or a dilution gas of the first gas in the substrate processing described later. The first gas supplier224may further include the first inert gas supplier.

Subsequently, the second gas supplier225capable of supplying the gas to the nozzle223bwill be described with reference toFIG.4B. A second gas supply source225b, a mass flow controller (MFC)225cand a valve225dare sequentially provided in this order at a gas supply pipe225afrom an upstream side toward a downstream side of the gas supply pipe225ain the gas flow direction. The gas supply pipe225ais configured to be capable of communicating with the nozzle223b.

The second gas supply source225bis a source of a second gas (also referred to as a “second element-containing gas”) containing a second element. The second element-containing gas serves as one of the process gases. Further, the second element-containing gas may serve as a reactive gas or a modification gas.

According to the present embodiments, for example, the second element-containing gas contains the second element different from the first element. As the second element, for example, one of oxygen (O), nitrogen (N) and carbon (C) may be used. According to the present embodiments, for example, a nitrogen-containing gas is used as the second element-containing gas. More specifically, a hydrogen nitride-based gas containing a nitrogen - hydrogen bond (N - H bond) such as ammonia (NH3), diazene (N2H2) gas, hydrazine (N2H4) gas and N3H8gas may be used as the second element-containing gas.

The second gas supplier225is constituted mainly by the gas supply pipe225a, the MFC225cand the valve225d. The second gas supplier225may also be referred to as a “reactive gas supplier” (which is a reactive gas supply structure or a reactive gas supply system).

A gas supply pipe225eis connected to the gas supply pipe225aat a downstream side of the valve225d. An inert gas supply source225f, a mass flow controller (MFC)225gand a valve225hare sequentially provided in this order at the gas supply pipe225efrom an upstream side toward a downstream side of the gas supply pipe225ein the gas flow direction. For example, the inert gas is supplied from the inert gas supply source225f.

A second inert gas supplier (which is a second inert gas supply structure or a second inert gas supply system) is constituted mainly by the gas supply pipe225e, the MFC225gand the valve225h. The inert gas supplied from the inert gas supply source225fis used as a carrier gas or a dilution gas of the second gas in the substrate processing described later. The second gas supplier225may further include the second inert gas supplier.

Subsequently, an inert gas supplier (which is an inert gas supply structure or an inert gas supply system)226capable of supplying the gas to the nozzle223cwill be described with reference toFIG.4C. An inert gas supply source226b, a mass flow controller (MFC)226cand a valve226dare sequentially provided in this order at a gas supply pipe226afrom an upstream side toward a downstream side of the gas supply pipe226ain the gas flow direction. The inert gas supplied from the inert gas supply source226bmay be used as a purge gas for purging the inner atmosphere of the inner reaction tube222or may be used as a pressure adjusting gas for adjusting an inner pressure of the inner reaction tube222. The gas supply pipe226ais configured to be capable of communicating with the nozzle223c.

An exhauster (which is an exhaust structure or an exhaust system)230configured to exhaust the inner atmosphere of the inner reaction tube222includes an exhaust pipe231configured to be capable of communicating with the inner reaction tube222.

A vacuum pump (not shown) serving as a vacuum exhaust apparatus is connected to the exhaust pipe231via a valve232serving as an opening/closing valve and an APC (Automatic Pressure Controller) valve233serving as a pressure regulator (which is a pressure adjusting structure). Thereby, the inner reaction tube222is vacuum-exhausted such that the inner pressure of the inner reaction tube222reaches and is maintained at a predetermined pressure (vacuum degree). The exhauster230is provided with a pressure detector234. The pressure detector234is configured to be capable of detecting the inner pressure of the inner reaction tube222. The exhauster230may also be referred to as a “process chamber exhauster” (which is a process chamber exhaust structure or a process chamber exhaust system) so as to distinguish the exhauster230from an exhauster (which is an exhaust structure or an exhaust system)280provided in the transfer chamber270, which will be described later.

The inner pressure of the inner reaction tube222is adjusted by cooperation between the gas supplier and the exhauster230described above. When adjusting the inner pressure of the inner reaction tube222, for example, the inner pressure of the inner reaction tube222is adjusted such that a pressure value detected by the pressure detector234is set to be a predetermined value. Since an inner atmosphere of the first vessel can be adjusted by the gas supplier and the exhauster230as described above, according to the present embodiments, the gas supplier and the exhauster230may also be collectively referred to as a “first atmosphere controller”.

A region in the inner reaction tube222, in which the substrate S is accommodated, may also be referred to as a “process region” or a “substrate processing region”, and a configuration constituting the process region may also be referred to as the “process chamber222c”. According to the present embodiments, the process chamber222cis defined by the inner reaction tube222.

A substrate support is constituted by at least the substrate support structure240. The substrate S is transferred into or out of the substrate support structure240through the substrate loading/unloading port148by the transfer robot180in the transfer chamber270. Further, the substrate support structure240transfers the substrate S accommodated therein into the inner reaction tube222. Then, the substrate processing such as a process of forming a film on a surface of the substrate S (also referred to as a “film-forming process”) is performed in the inner reaction tube222.

The substrate support structure240includes an elevator241serving as a first driving structure capable of driving the substrate support structure240in the vertical direction. InFIG.3, the substrate support structure240elevated by the elevator241and accommodated in the inner reaction tube222is illustrated. Further, the substrate support structure240includes a rotation driver242serving as a second driving structure capable of driving the substrate support structure240to rotate.

Each driving structure described above is connected to a shaft243configured to support a support base244. The support base244is provided with a plurality of support columns246capable of supporting the substrate S. The plurality of support columns246are configured to support a top plate249. InFIG.3, for convenience of explanation, one support column among the plurality of support columns246is illustrated. A plurality of substrate support components are provided on each of the plurality of support columns246at a predetermined interval therebetween in the vertical direction, and the plurality of substrates S are supported by the plurality of substrate support components, respectively. Lower portions of the plurality of support columns246are covered with a heat insulating cover245. The heat insulating cover245is configured to be capable of suppressing a transfer of a heat in the substrate processing region to the vicinity of the furnace opening222b. Thereby, it is possible to uniformize an inner temperature of the substrate processing region.

The substrate support structure240supports the substrates S (for example, five substrates) in a multistage manner along the vertical direction by the plurality of support columns246. The top plate249and the plurality of support columns246are made of a material such as quartz and silicon carbide (SiC). The present embodiments will be described by way of an example in which seven substrates are supported by the substrate support structure240as the substrates S. However, the present embodiments are not limited thereto. For example, the substrate support structure240may be configured to support about five substrates to fifty substrates as the substrates S.

The substrate support structure240is moved in the vertical direction between the inner reaction tube222and the transfer chamber270by the elevator241, and is driven by the rotation driver242in a rotation direction around a center of the substrate S supported by the substrate support structure240.

A lid247capable of closing the furnace opening222bis fixed to the shaft243via a fixing structure247a. A diameter of the lid247is set to be greater than a diameter of the furnace opening222b. A heater247bcapable of heating the lid247is provided at the lid247. An O-ring248serving as a seal is provided on the flange222aof the inner reaction tube222. The heater247bserves as an auxiliary configuration for uniformizing the inner temperature of the inner reaction tube222in the vertical direction. By turning on the heater247b, it is possible to maintain a temperature of a substrate (among the substrates S) arranged at a lower portion of the substrate support structure240substantially equal to a temperature of a substrate (among the substrates S) arranged at an upper portion of the substrate support structure240. The heater247bmay also be referred to as a “second heater” or a “lid heater”.

For example, when the substrate S is processed, the lid247closes the furnace opening222b. When the lid247closes the furnace opening222b, as shown inFIG.3, the elevator241elevates the lid247such that an upper surface of the lid247is set at a position where the lid247is pressed against the flange222a. As a result, it is possible to maintain an inner portion of the inner reaction tube222airtight. As will be described later, according to the present embodiments, since an inner pressure of the transfer chamber270is set to be higher than an inner pressure of the process chamber222c, the O-ring248is crushed and deformed. Thereby, the O-ring248is crimped to the flange222a.

The present embodiments are described by way of an example in which the O-ring248is provided on the flange222aof the inner reaction tube222. However, the present embodiments are not limited thereto. For example, the O-ring248may be provided on the flange221aof the outer reaction tube221. In such a case, the diameter of the lid247is set to be greater than a diameter of the O-ring248provided on the flange221aof the outer reaction tube221. Further, the O-ring248may be provided at the lid247. In such a case, when the O-ring248is replaced with a new one, it is possible to replace the O-ring248for each lid247. Thereby, it is possible to easily perform a maintenance operation.

The transfer chamber270will be explained. The transfer chamber270is provided below the reaction tube storage chamber210. In the transfer chamber270, the substrate S may be placed (or mounted) on the substrate support structure240by the transfer robot180via the substrate loading/unloading port148, or the substrate S may be taken (or unloaded) out of the substrate support structure240by the transfer robot180via the substrate loading/unloading port148. The transfer chamber270may also be referred to as a “second vessel”.

A hole through which the shaft243penetrates is provided on a bottom wall of the transfer chamber270. Further, the exhauster280configured to exhaust an inner atmosphere of the transfer chamber270is provided at the transfer chamber270. The exhauster280includes an exhaust pipe281connected to the transfer chamber270and configured to be capable of communicating with an inside of the transfer chamber270.

A vacuum pump (not shown) serving as a vacuum exhaust apparatus is connected to the exhaust pipe281via a valve282serving as an opening/closing valve and an APC (Automatic Pressure Controller) valve283serving as a pressure regulator (which is a pressure adjusting structure). Thereby, the transfer chamber270is vacuum-exhausted such that the inner pressure of the transfer chamber270reaches and is maintained at a predetermined pressure (vacuum degree). The exhauster280may also be referred to as a “transfer chamber exhauster”. The exhauster280is provided with a pressure detector284. The pressure detector284is configured to be capable of detecting the inner pressure of the transfer chamber270. Since the exhauster280is configured to be capable of controlling the inner atmosphere of the transfer chamber270as described above, the exhauster280may also be referred to as a “second atmosphere controller”.

An inert gas supplier (which is an inert gas supply structure or an inert gas supply system)271shown inFIG.4Dmay be connected to the transfer chamber270. As shown inFIG.4D, an inert gas supply source271b, a mass flow controller (MFC)271cand a valve271dare sequentially provided in this order at a gas supply pipe271afrom an upstream side toward a downstream side of the gas supply pipe271ain the gas flow direction. The inert gas supplied from the inert gas supply source271bmay be used as a purge gas for purging the inner atmosphere of the transfer chamber270or may be used as a pressure adjusting gas for adjusting the inner pressure of the transfer chamber270. The inert gas supplier271may also be referred to as a third gas supplier (which is a third gas supply structure or a third gas supply system). Since the inert gas supplier271is capable of controlling the inner atmosphere of the transfer chamber270in cooperation with the exhauster280, the second atmosphere controller may further include the inert gas supplier271.

Subsequently, the reactor300will be described in detail with reference toFIG.5. As shown inFIG.5, the reactor300includes a vessel302. A process chamber301defining a process space305in which the substrate S is processed and a transfer chamber306defining a transfer space through which the substrate S is transferred into or out of the process space305are provided in the vessel302. The vessel302is constituted by an upper vessel302aand a lower vessel302b. A partition plate308is provided between the upper vessel302aand the lower vessel302b. The vessel302may also be referred to as a “third vessel”.

The substrate loading/unloading port148(that is, the substrate loading/unloading port148d) is provided adjacent to the gate valve149(that is, the gate valve149d) at a side surface of the lower vessel302b. The substrate S is transferred between the transfer chamber306and the vacuum transfer chamber140through the substrate loading/unloading port148. A plurality of lift pins307are provided at a bottom of the lower vessel302b.

A substrate support310configured to support the substrate S is provided in the process space305. The substrate support310mainly includes: a substrate mounting table312provided with a substrate placing surface311on which the substrate S is placed; and a heater313which is a heating structure embedded in the substrate mounting table312. A plurality of through-holes314through which the plurality of lift pins307penetrate are provided at positions on the substrate mounting table312corresponding to the plurality of lift pins307.

Wiring322configured to supply the electric power to the heater313is connected to the heater313. The wiring322is connected to a heater controller323. The heater controller323is electrically connected to a controller400. The controller400is configured to control the heater controller323to operate the heater313.

The substrate mounting table312is supported by a shaft317. The shaft317penetrates a bottom of the vessel302, and is connected to an elevator318at an outside of the vessel302.

The substrate S placed on the substrate placing surface311of the substrate mounting table312is capable of being elevated or lowered by operating the elevator318to elevate or lower the shaft317and the substrate mounting table312.

For example, the process chamber301is constituted by a plasma generation chamber330described later and the substrate mounting table312. Further, the process chamber301may be configured by another structure as long as the process space305in which the substrate S is processed can be secured.

When the substrate S is transferred, the substrate mounting table312is lowered until the substrate placing surface311faces the substrate loading/unloading port148, that is, the substrate placing surface311reaches a transfer position P0. When the substrate S is processed, the substrate mounting table312is elevated until the substrate S reaches a processing position (also referred to as a “substrate processing position”) in the process space305as shown inFIG.5.

The plasma generation chamber330capable of converting the gas into a plasma state is provided at an upper portion (or an upstream side) of the process space305. A fourth gas supplier (which is a fourth gas supply structure or a fourth gas supply system)340described later is connected to a lid331so as to communicate with a gas introduction hole331aprovided in the lid331of the plasma generation chamber330. A coil332is arranged around the plasma generation chamber330. An electrode (not shown) is connected to the coil332. By supplying the electric power through the electrode, it is possible to convert the gas supplied into the plasma generation chamber330into the plasma state.

Subsequently, an exhauster (which is an exhaust structure or an exhaust system)391will be described. An exhaust pipe392is configured to be capable of communicating with the process space305. The exhaust pipe392is connected to the upper vessel302aso as to communicate with the process space305. The exhaust pipe392is provided with an APC393serving as a pressure controller capable of controlling an inner pressure of the process space305to a predetermined pressure. The APC393includes a valve body (not shown) whose opening degree is capable of being adjusted. The APC393is configured to adjust a conductance of the exhaust pipe392in response to an instruction from the controller400. A valve394is provided at the exhaust pipe392at a downstream side of the APC393. A dry pump (not shown) is provided at an upstream side of the exhaust pipe392. The dry pump is configured to exhaust an inner atmosphere of the process space305through the exhaust pipe392.

Subsequently, the fourth gas supplier340capable of supplying the gas to the process chamber301will be described with reference toFIG.6. A fourth gas supply source342, a mass flow controller (MFC)343serving as a flow rate controller (or a flow rate control structure) and a valve344serving as an opening/closing valve are sequentially provided in this order at a gas supply pipe341from an upstream side toward a downstream side of the gas supply pipe341in the gas flow direction. Further, a plasma generator349may be provided at the gas supply pipe341as shown inFIG.6. Further, an inert gas supply pipe345is connected to the gas supply pipe341. An inert gas supply source346, a mass flow controller (MFC)347and a valve348serving as an opening/closing valve are sequentially provided in this order at the inert gas supply pipe345from an upstream side toward a downstream side of the inert gas supply pipe345in the gas flow direction.

The fourth gas supply source342is a source of a third gas (also referred to as a “third element-containing gas”) containing a third element. For example, the third element-containing gas may refer to a gas reacting with the film formed on the substrate S. The third element-containing gas may be considered as a modification gas.

According to the present embodiments, as the third element, for example, one of oxygen (O), nitrogen (N), carbon (C) and hydrogen (H) may be used. According to the present embodiments, for example, a hydrogen-containing gas is used as the third element-containing gas. More specifically, hydrogen (H2) gas may be used as the hydrogen-containing gas.

When the third gas is supplied to the process chamber301, the inert gas serving as a dilution gas or a carrier gas of the third gas may be supplied to the process chamber301.

The fourth gas supplier340is constituted mainly by the gas supply pipe341, the MFC343and the valve344. The fourth gas supplier340may further include an inert gas supplier (which is an inert gas supply structure or an inert gas supply system) constituted mainly by the inert gas supply pipe345, the MFC347and the valve348.

Subsequently, the controller400will be described with reference toFIG.7. The substrate processing apparatus100includes the controller400configured to control operations of components constituting the substrate processing apparatus100.

The controller400serving as a control apparatus or a control structure may be embodied by a computer including a CPU (Central Processing Unit)401, a RAM (Random Access Memory)402, a memory403serving as a storage and an I/O port (input/output port)404. The RAM402, the memory403and the I/O port404may exchange data with the CPU401via an internal bus405. Transmission/reception of data in the substrate processing apparatus100may be performed by an instruction from a transmission/reception instruction controller406, which is also one of functions of the CPU401.

The CPU401is configured to read and execute a control program411from the memory403and read a process recipe from the memory403in accordance with an instruction such as an operation command inputted from an input/output device423. In accordance with contents of the read process recipe from the input/output device423, the CPU401is configured to be capable of controlling various operations such as an opening and closing operation of the gate valve149, an ON/OFF control operation of each pump described above, a flow rate adjusting operation of each MFC described above and an opening/closing operation of each valve described above.

The memory403may be embodied by a component such as a flash memory and a HDD (hard disk drive). For example, a recipe410such as the process recipe in which information such as sequences and conditions of the substrate processing described later is stored and the control program411for controlling the operations of the substrate processing apparatus100is stored may be readably stored in the memory403.

The process recipe is obtained by combining the sequences (steps) of the substrate processing described later such that the controller400can execute the steps to acquire a predetermined result, and functions as a program. For example, the process recipe is prepared for each reactor described above, and is read for each reactor described above.

Hereinafter, the process recipe and the control program may be collectively or individually referred to simply as a “program.” Thus, in the present specification, the term “program” may refer to the process recipe alone, may refer to the control program alone, or may refer to both of the process recipe and the control program. The RAM402serves as a memory area (work area) in which the program or the data read by the CPU401can be temporarily stored.

The I/O port404is electrically connected to the components of the substrate processing apparatus100described above such as the gate valve149, each pressure regulator described above, each pump described above and the heater controller323. Further, a network transmitter/receiver421connected to a host apparatus420via a network is provided.

For example, the controller400according to the present embodiments may be embodied by preparing an external memory422storing the program described above therein and by installing the program onto the computer by using the external memory422. For example, the external memory422may include a magnetic disk such as a hard disk, an optical disk such as a DVD, a magneto-optical disk such as an MO or a semiconductor memory such as a USB memory. Further, a method of providing the program to the computer is not limited to the external memory422. For example, the program may be directly provided to the computer by a communication interface such as the Internet and a dedicated line instead of the external memory422. The memory403and the external memory422may be embodied by a non-transitory computer-readable recording medium. Hereinafter, the memory403and the external memory422may be collectively or individually referred to as a recording medium. Thus, in the present specification, the term “recording medium” may refer to the memory403alone, may refer to the external memory422alone, or may refer to both of the memory403and the external memory422.

Substrate Processing

Subsequently, the substrate processing will be described with reference toFIG.8. As a part of a processing performed in the substrate processing apparatus100, the substrate processing of processing the substrate S by using the substrate processing apparatus100described above will be described. In the following description, the controller400controls the operations of the components constituting the substrate processing apparatus100.

A substrate moving step S202will be described. The substrate processing apparatus100receives a FOUP (front opening unified pod) such as the pod111in which the plurality of substrates S are stored by using a robot provided in a factory. The atmospheric transfer robot122picks up the substrate S from the FOUP and transfers the substrate S into the load lock chamber130. An inner atmosphere of the load lock chamber130is replaced such that an inner pressure of the load lock chamber130is adjusted from an atmospheric pressure to a pressure substantially equal to an inner pressure of the vacuum transfer chamber140. Thereafter, the gate valve134is opened, and the transfer robot180picks up the substrate S in the load lock chamber130.

The transfer robot180moves the substrate S from the vacuum transfer chamber140to the reactor200(that is, one of the reactors200a,200band200c). When moving the substrate S, the inner pressure of the transfer chamber270is set to be equal to or lower than the inner pressure of the vacuum transfer chamber140so as to prevent the inner atmosphere of the transfer chamber270from flowing into the vacuum transfer chamber140. In the substrate loading step S204, for example, the exhauster280is controlled to adjust the inner pressure of the transfer chamber270.

Subsequently, with the substrate support structure240lowered into the transfer chamber270, the gate valve149of the reactor200is opened. When opening the gate valve149, for example, a height of the substrate support structure240is adjusted such that an uppermost substrate support component among the plurality of substrate support components and the substrate loading/unloading port148are provided at the same height.

By extending the arm181, the transfer robot180supports the substrate S on the uppermost substrate support component. Thereafter, the arm181is retracted and the gate valve149of the reactor200is closed.

After placing a substrate such as the substrate S on a substrate support component such as the uppermost substrate support component, the height of the substrate support structure240is adjusted such that a substrate support component (which is provided below the substrate support component such as the uppermost substrate support component on which the substrate such as the substrate S is already supported) and the substrate loading/unloading port148are provided at the same height. On the other hand, the transfer robot180picks up a new substrate S among the substrates S transferred into the load lock chamber130and waits until the substrate S (that is, the new substrate S) is capable of being transferred into the reactor200. Thereafter, the gate valve149is opened in the same manner as described above, and the transfer robot180places the substrate S (that is, the new substrate S) on the substrate support structure240.

By repeatedly performing an operation described above a predetermined number of times, a predetermined number of substrates S can be placed on the substrate support structure240. After the predetermined number of substrates S are placed on the substrate support structure240, the gate valve149is closed and the substrate support structure240is further elevated such that the substrate support structure240is transferred (or loaded) into the inner reaction tube222as shown inFIG.3. When elevating the substrate support structure240, the lid247is elevated together with the substrate support structure240, and the O-ring248is pressed against the lid247. As a result, an inside of the inner reaction tube222is sealed. Further, the heater211is in an operating state, and is maintained at a substrate processing temperature serving as a first temperature described later.

Subsequently, the inner pressure of the inner reaction tube222is adjusted (or set) to a predetermined pressure by cooperation between the inert gas supplier226and the exhauster230. Further, in parallel with adjusting the inner pressure of the inner reaction tube222, the inert gas supplier271and the exhauster280are controlled such that the inner pressure of the transfer chamber270is higher than the inner pressure of the inner reaction tube222. Thereby, it is possible to suppress a movement of the inner atmosphere of the inner reaction tube222to the transfer chamber270.

<First Film Processing Step S206>

Subsequently, a first film processing step S206will be described. The first film processing step S206is a step of processing the film formed on the substrate S in the reactor200. When the inner pressure of the process chamber222cdefined by the inner reaction tube222reaches a desired pressure, by controlling the first gas supplier224and the second gas supplier225, the first gas and the second gas are supplied to the substrate S in the inner reaction tube222so as to process the substrate S. In the first film processing step S206, for example, a process performed on the substrate S refers to a process in which the first gas and the second gas are reacted with each other to form a predetermined film on the substrate S. According to the present embodiments, for example, the HCDS gas is supplied as the first gas and the NH3gas is supplied as the second gas to form a silicon nitride film (hereinafter, also referred to as a “SiN film”). When forming the SiN film, with the gate valve149closed, the inert gas supplier271and the exhauster280are controlled such that the inner pressure of the transfer chamber270is maintained higher than the inner pressure of the inner reaction tube222. Thereby, it is possible to suppress a movement of the lid247even while the process of the first film processing step S206is being performed. As a result, it is possible to suppress the movement of the inner atmosphere of the inner reaction tube222to the transfer chamber270.

For example, process conditions of the present step are as follows:The first gas: HCDS gas;A gas supply amount of the first gas: from 5 sccm to 5,000 sccm;The second gas: the NH3gas;A gas supply amount of the second gas: from 10 sccm to 10,000 sccm;The inner pressure of the process chamber222c: from 133 Pa to 13,332 Pa; andA processing temperature: 300° C. to 500° C.

After a predetermined time has elapsed, a supply of the first gas through the first gas supplier224and a supply of the second gas through the second gas supplier225are stopped. Further, the inert gas is supplied through the inert gas supplier226to exhaust an inner atmosphere of the process chamber222c.

A substrate unloading step S208will be described. After a predetermined time has elapsed, the elevator241lowers the substrate support structure240. When lowering the substrate support structure240, the lid247is also lowered. Thereby, the lid247is separated from the furnace opening222b. A lowering method of lowering the substrate support structure240will be described later in detail. When the substrate support structure240is lowered, the substrate S is transferred (or unloaded) out of the substrate support structure240in the order reverse to that of loading the substrate S in the substrate loading step S204. When unloading the substrate S, it is preferable to open the gate valve149with a movement of the substrate support structure240stopped. Thereby, it is possible to suppress a formation of a turbulent flow in the inner atmosphere of the transfer chamber270, which is generated by moving the substrate support structure240. Further, it is preferable to set a pressure relationship in each chamber such that the inner pressure of the inner reaction tube222is higher than the inner pressure of the transfer chamber270, and the inner pressure of the transfer chamber270is lower than the inner pressure of the vacuum transfer chamber140. By setting the pressure relationship as described above, it is possible to prevent (or suppress) the inner atmosphere of the inner reaction tube222from flowing (or moving) into the vacuum transfer chamber140. As a result, it is possible to suppress a contamination in the vacuum transfer chamber140. Therefore, it is possible to prevent (or suppress) the gas used in the inner reaction tube222from entering the reactor300, and it is also possible to prevent (or suppress) an unexpected reaction in the reactor300(for example, a formation of the film on an inner wall of the vessel).

Subsequently, a substrate moving step S210will be described. The transfer robot180on which the substrate S unloaded out of the reactor200is placed moves the substrate S such that the substrate S is capable of being transferred (or loaded) into the reactor300.

A substrate loading step S212will be described. In the substrate loading step S212, the substrate S is transferred (or loaded) into the reactor300. In the substrate loading step S212, the substrate mounting table312is lowered to a position of transferring the substrate S (that is, the transfer position P0) such that the plurality of lift pins307penetrate through the plurality of through-holes314of the substrate mounting table312, respectively. As a result, the lift pins307protrude from a surface of the substrate mounting table312by a predetermined height. In parallel with lowering the substrate mounting table312and protruding the lift pins307from the surface of the substrate mounting table312as described above, by performing a process such as supplying the inert gas through the fourth gas supplier340and exhausting an inner atmosphere of the transfer chamber306, an inner pressure of the transfer chamber306is set to be the same as that of the vacuum transfer chamber140provided adjacently.

Subsequently, the gate valve149is opened so as to communicate the transfer chamber306with the vacuum transfer chamber140provided adjacently. Then, the transfer robot180transfers (or loads) the substrate S from the vacuum transfer chamber140into the transfer chamber306and places the substrate S on the lift pins307. After the substrate S is placed on the lift pins307, the substrate mounting table312is elevated until the substrate S is placed on the substrate placing surface311. Then, the substrate mounting table312is further elevated until the substrate S reaches the substrate processing position as shown inFIG.5. When the substrate S is being placed on the substrate placing surface311, the electric power is supplied to the heater313and the heater313is controlled such that a temperature of the surface of the substrate S is adjusted to a predetermined temperature.

<Second Film Processing Step S214>

A second film processing step S214will be described. In the second film processing step S214, for example, the exhauster391and the fourth gas supplier340are operated. When a desired inner pressure of the process chamber301is reached, by controlling the fourth gas supplier340, the third gas is supplied to the substrate S in the process chamber301so as to process the film on the substrate S. In the second film processing step S214, for example, a process performed on the substrate S refers to a process of modifying the film (which is formed in the first film processing step S206) with the third gas. Further, in the present step, the plasma generator349may be operated in accordance with the recipe. According to the present embodiments, by supplying the hydrogen (H2) gas to the SiN film formed in the first film processing step S206, the SiN film is modified.

For example, process conditions of the present step are as follows:The third gas: H2gas;A gas supply amount of the third gas: from 10 sccm to 500 sccm;The inner pressure of the process chamber301: from 133 Pa to 6,666 Pa; andA processing temperature: 100° C. to 600° C.

After a predetermined time has elapsed, a supply of the third gas through the fourth gas supplier340is stopped. Further, the inert gas is supplied through the fourth gas supplier340to exhaust an inner atmosphere of the process chamber301.

A substrate unloading step S216will be described. When a desired process is performed on the substrate S, the substrate S is transferred (unloaded) out of the process chamber301in the order reverse to that of loading the substrate S in the substrate loading step S212. When unloading the substrate S, the substrate S is being supported by the transfer robot180.

A substrate moving step S218will be described. The transfer robot180transfers (or unloads) the substrate S out of the reactor300, and moves the substrate S to the load lock chamber130. The substrate S is processed by performing the steps described above.

<Details of Lowering Method in Substrate Unloading Step S208>

Subsequently, the lowering method of lowering the substrate support structure240in the substrate unloading step S208will be described in detail. As described above, in the first film processing step S206before the substrate unloading step S208, the inner pressure of the transfer chamber270is controlled to be higher than the inner pressure of the inner reaction tube222. By performing such a control, the lid247is pressed against the furnace opening222bsuch that it is possible to suppress a leakage of the inner atmosphere of the inner reaction tube222. Therefore, it is possible to stably control the inner atmosphere of the inner reaction tube222.

By the way, in such a situation, the disclosers of the present application have found the following problems. Since the lid247is pressed against the furnace opening222b, the O-ring248arranged between the lid247and the furnace opening222bis crushed and deformed. When the O-ring248is fixed to the furnace opening222b, the O-ring248adheres to the lid247in a deformed state. Furthermore, an adhesion of the O-ring248becomes stronger as a temperature thereof becomes higher. Since the O-ring248is affected by the heater211and the heater247b, the O-ring248may adhere strongly. When the lid247is lowered with the O-ring248attached to the lid247, the O-ring248may be damaged due to a strong adhesive force. As a result, particles may be generated. One of purposes of the present embodiments is to lower the lid247while suppressing the damage to the O-ring248.

Subsequently, the lowering method in the substrate unloading step S208will be described in more detail with reference toFIG.9.

A pressure adjusting step S302is a step performed before lowering the substrate support structure240, that is, before communicating the inside of the inner reaction tube222and an inside of the transfer chamber270. After the substrate S is processed in the inner reaction tube222in the first film processing step S206, the supply of the process gases (that is, the first gas and the second gas) into the inner reaction tube222is stopped. Thereafter, before communicating the inner reaction tube222and the transfer chamber270, the inner pressure of the inner reaction tube222is controlled (or adjusted) to be higher than the inner pressure of the transfer chamber270. In the pressure adjusting step S302, the inert gas supplier226, the exhauster230, the inert gas supplier271and the exhauster280are controlled such that the inner pressure of the inner reaction tube222is adjusted as described above. Further, in the pressure adjusting step S302, the inner pressure of the inner reaction tube222may be adjusted by using the pressure detector234or the pressure detector284.

By controlling the inner pressure of the inner reaction tube222to be higher than the inner pressure of the transfer chamber270, it is possible to push out the lid247softly by the inner atmosphere of the inner reaction tube222. In the pressure adjusting step S302, a pressure difference between the inner pressure of the inner reaction tube222and the inner pressure of the transfer chamber270is set such that the O-ring248is not damaged. Specifically, the pressure difference is set to be within a range higher than 0 Pa and less than 3.0 kPa. Therefore, it is possible to restore a shape of the O-ring248while suppressing the damage to the O-ring248attached to the lid247. Further, in the pressure adjusting step S302, the O-ring248is in a state of sealing the inner atmosphere of the inner reaction tube222without being separated from the lid247.

When adjusting the pressure difference, the inner pressure of the inner reaction tube222may be gradually increased to be higher than the inner pressure of the transfer chamber270. Thereby, no sudden force is applied to the O-ring248in the deformed state. As a result, it is possible to restore the shape of the O-ring248while surely suppressing the damage to the O-ring248.

Before or when adjusting the pressure difference, the temperature of the O-ring248may be lowered by turning off the heater211or reducing the electric power supplied thereto such that a temperature of the heater211is set to be a second temperature lower than the first temperature which is the temperature of the heater211at which the substrate S is processed. When the temperature of the O-ring248is lowered, an adhesion state of the O-ring248can be softened. Thereby, it is possible to more easily peel off (or separate) the O-ring248from the lid247. The pressure adjusting step S302is described by way of an example in which the heater211is turned off or the electric power supplied thereto is reduced. However, the pressure adjusting step S302is not limited thereto. For example, when the heater247bis provided, the heater247bmay be turned off or the electric power supplied thereto may be reduced so as to lower the temperature of the O-ring248.

Further, it is preferable that the second temperature is equal to or lower than a heat resistant temperature of the transfer robot180. As described above, since the inner pressure of the transfer chamber270and the inner pressure of the vacuum transfer chamber140are set to a vacuum level pressure, a heat leakage efficiency from the substrate S is low. That is, a temperature of the substrate S is not easily lowered. When the temperature of the heater211or a temperature of the heater247bis maintained at a high temperature, it is preferable to wait until the temperature of the substrate S is lowered in the transfer chamber270, which significantly reduces a transfer throughput. When the substrates S are stacked as in the present embodiments, the temperature of the substrate S is less likely to be lowered due to an influence of the heat between the substrates S. Therefore, by setting the second temperature to be equal to or lower than the heat resistant temperature of the transfer robot180, it is possible to improve the transfer throughput. Further, it is preferable that the second temperature is set to be a temperature at which a temperature sensor250provided on the shaft243is not adversely affected. Further, the temperature sensor250may be provided on the elevator241.

Further, for example, the second temperature is set to be a temperature within a range from a room temperature (about 25° C.) to 100° C. By setting the second temperature within such a range, it is possible to easily peel off (or separate) the O-ring248from the lid247. Further, when the second temperature is equal to or lower than the heat resistant temperature of the transfer robot180, it is possible to increase a transfer efficiency (that is, the transfer throughput). Further, when the second temperature is set such that the temperature sensor250is not adversely affected, it is possible to avoid a failure of the temperature sensor250or a decrease in a processing throughput due to the failure.

After a predetermined time has elapsed with the inner pressure of the inner reaction tube222set to be higher than the inner pressure of the transfer chamber270, a substrate support structure lowering step S304is performed. For example, the “predetermined time” in the pressure adjusting step S302refers to a time (time duration) until a deformed shape of the O-ring248in the deformed state is restored. Further, in the pressure adjusting step S302, the inner pressure of the inner reaction tube222and the inner pressure of the transfer chamber270are measured, and the substrate support structure lowering step S304may be performed when the measured results reach predetermined values, respectively.

<Substrate Support Structure Lowering Step S304>

After the predetermined time has elapsed with the inner pressure of the inner reaction tube222set to be higher than the inner pressure of the transfer chamber270in the pressure adjusting step S302, in the substrate support structure lowering step S304, the elevator241lowers the substrate support structure240while maintaining a pressure control of setting the inner pressure of the inner reaction tube222to be higher than the inner pressure of the transfer chamber270. As described above, for example, the “predetermined time” in the pressure adjusting step S302refers to the time until the deformed shape of the O-ring248in the deformed state is restored. Therefore, in the substrate support structure lowering step S304, it is possible to easily peel off (or separate) the O-ring248from the lid247while suppressing the damage to the O-ring248. As a result, by lowering the substrate support structure240after the predetermined time has elapsed, it is possible to lower the substrate support structure240while suppressing a generation of the particles due to the damage of the O-ring248.

In the substrate support structure lowering step S304, a control of the inert gas supplier226, a control of the exhauster230and a control of the exhauster280may be performed such that a pressure relationship described above in the pressure adjusting step S302can be maintained. In such a case, the inner atmosphere of the inner reaction tube222and the inner atmosphere of the transfer chamber270are adjusted such that the inner pressure of the inner reaction tube222and the inner pressure of the transfer chamber270gradually become the same pressure. Thereby, the pressure does not change suddenly. Therefore, it is possible to prevent the turbulent flow of the atmosphere (such as the inner atmosphere of the transfer chamber270), which is generated by a sudden pressure change. As a result, it is possible to prevent (or suppress) the particles from adhering to the substrate S in the substrate support structure240or to prevent (or suppress) the particles from entering into inner reaction tube222, which is generated by a lifting up of the particles due to the turbulent flow. Further, when the pressure relationship described above in the pressure adjusting step S302is maintained, it is possible to control the inner atmosphere of the transfer chamber270to flow to the exhaust pipe281. Therefore, it is possible to prevent the inner atmosphere of the transfer chamber270from flowing back into the inner reaction tube222or flowing into the vacuum transfer chamber140.

Further, in the substrate support structure lowering step S304, the inner pressure of the transfer chamber270may be controlled to be further reduced. That is, the inner pressure of the inner reaction tube222may be controlled to be further higher than the inner pressure of the transfer chamber270. In such a case, for example, while maintaining the control of the inert gas supplier226, a control of the inert gas supplier271and the control of the exhauster230, an opening degree of the valve282is controlled so to increase an exhaust amount of the exhauster280. By maintaining the control of the inert gas supplier226, the control of the inert gas supplier271and the control of the exhauster230, it is possible to suppress a sudden change in the inner atmosphere of the inner reaction tube222.

Further, by setting the inner pressure of the inner reaction tube222to be higher than the inner pressure of the transfer chamber270, it is possible to form (or generate) a gas flow from the inside of the inner reaction tube222to the inside of the transfer chamber270. Thereby, it is possible to prevent (or suppress) the inner atmosphere of the transfer chamber270from entering the inner reaction tube222. As a result, the inner atmosphere of the inner reaction tube222and the inner atmosphere of the transfer chamber270can be maintained clean. Further, since the control of the exhauster280is changed while maintaining the control of the exhauster230, it is possible to exhaust the inner atmosphere of the inner reaction tube222without generating the turbulent flow in the inner reaction tube222or in the transfer chamber270. Therefore, it is possible to prevent (or suppress) the particles from being diffused in the inner reaction tube222. Further, by gradually reducing the opening degree of the valve282, it is possible to exhaust the inner atmosphere of the inner reaction tube222without generating the turbulent flow in the transfer chamber270. It is possible to prevent the turbulent flow of the inner atmosphere of the inner reaction tube222(which is generated by the sudden pressure change), and as a result, it is possible to prevent (or suppress) the particles from adhering to the substrate S in the substrate support structure240or to prevent (or suppress) the particles from entering into inner reaction tube222, which is generated by the lifting up of the particles due to the turbulent flow.

Further, the substrate support structure lowering step S304is described by way of an example in which the inner pressure of the inner reaction tube222is set to be higher than the inner pressure of the transfer chamber270in the pressure adjusting step S302and the elevator241lowers the substrate support structure240after the predetermined time has elapsed. However, the present embodiments are not limited thereto. For example, the shaft243may be lowered based on results detected by the pressure detector234and the pressure detector284. For example, when a pressure difference between the pressure detector234and the pressure detector284reaches a predetermined pressure difference, the shaft243is lowered. The “predetermined pressure difference” described above may refer to a pressure difference by which the O-ring248is not damaged. For example, the predetermined pressure difference is set to be within a range higher than 0 kPa and less than 3.0 kPa.

Other Embodiments

While the technique of the present disclosure is described in detail by way of the embodiments described above, the technique of the present disclosure is not limited thereto. The technique of the present disclosure may be modified in various ways without departing from the scope thereof. For example, the embodiments described above are described by way of an example in which the substrate processing apparatus100is provided with the reactor200and the reactor300(that is, four reactors200a,200b,200cand300). However, the technique of the present disclosure is not limited thereto. For example, the technique of the present disclosure may be applied when a substrate processing apparatus is provided with five or more reactors, more specifically, eight or more reactors including the reactor200and the reactor300.

For example, the embodiments described above are described by way of an example in which, in the film-forming process performed by the substrate processing apparatus100, the SiN film is formed on the substrate S by using the HCDS gas as the first element-containing gas (that is, the first gas) and the NH3gas as the second element-containing gas (that is, the second gas). However, the technique of the present disclosure is not limited thereto. That is, the process gases used in the film-forming process are not limited to the HCDS gas and the NH3gas, and other gases may be used to form different films. Further, the technique of the present disclosure may also be applied to film-forming processes using three or more different process gases. Further, for example, instead of silicon (Si), an element such as titanium (Ti), zirconium (Zr) and hafnium (Hf) may be used as the first element. In addition, for example, instead of nitrogen (N), an element such as oxygen (O) may be used as the second element.

For example, the embodiments described above are described by way of an example in which the hydrogen-containing gas (that is, the third gas) is used to perform a modification process. However, the technique of the present disclosure is not limited thereto. For example, a gas containing one of oxygen (O), nitrogen (N), carbon (C) and hydrogen (H) or a combination thereof may be used as the third gas to perform the modification process.

For example, the embodiments described above are described by way of an example in which the modification process is performed after the film-forming process. However, the technique of the present disclosure is not limited thereto. For example, the film-forming process may be performed after the modification process.

For example, the embodiments described above are described by way of an example in which the film-forming process and the modification process are performed by the substrate processing apparatus100. However, the technique of the present disclosure is not limited thereto. That is, the technique of the present disclosure can be applied not only to the film-forming process and the modification process exemplified in the embodiments described above but also to another film-forming process or another modification process of another film. Further, specific contents of the substrate processing are not limited. For example, in addition to or instead of the film-forming process and the modification process exemplified in the embodiments described above, a process such as an annealing process, a diffusion process, an oxidation process, a nitridation process and a lithography process may be performed as the substrate processing. Further, the technique of the present disclosure may also be applied to other substrate processing apparatuses such as an annealing apparatus, an etching apparatus, an oxidation apparatus, a nitridation apparatus, an exposure apparatus, a coating apparatus, a drying apparatus, a heating apparatus, an apparatus using the plasma and combinations thereof. The technique of the present disclosure may also be applied when a constituent of an embodiment of the technique of the present disclosure is substituted with another constituent of another embodiment of the technique of the present disclosure, or when a constituent of the embodiment is added to another embodiment. Further, the technique of the present disclosure may also be applied when the constituent of the embodiment is omitted or substituted, or when a constituent is added to the embodiment.

According to some embodiments of the present disclosure, it is possible to suppress interference between processes respectively performed in the plurality of reactors when the plurality of reactors are configured to be capable of performing different processes, respectively.