Multi-zone reactor, system including the reactor, and method of using the same

Multi-zone reactors, systems including a multi-zone reactor, and methods of using the systems and reactors are disclosed. Exemplary multi-zone reactors include a movable susceptor assembly and a moveable plate. The movable susceptor assembly and movable plate can move vertically between reaction zones of a reactor to expose a substrate to multiple processes or reactants.

FIELD OF DISCLOSURE

The present disclosure generally relates to gas-phase reactors and systems. More particularly, the disclosure relates to multi-zone gas-phase reactors, suitable for, e.g., spatial processing, to systems including the reactors, and to methods of using the same.

BACKGROUND OF THE DISCLOSURE

Gas-phase processes, such as chemical vapor deposition (CVD), plasma-enhanced CVD (PECVD), atomic layer deposition (ALD), atomic layer etch (ALE), and the like are often used to deposit materials onto a surface of a substrate, etch materials from a surface of a substrate, and/or clean or treat a surface of a substrate. For example, gas-phase processes can be used to deposit or etch layers on a substrate to form semiconductor devices, flat panel display devices, photovoltaic devices, microelectromechanical systems (MEMS), and the like.

Typically, multiple gas-phase processes are used to form such devices. Often, each process is carried out in its own reaction chamber, which may be a stand-alone chamber, or the chamber may be part of a cluster tool. Dedicating a reaction chamber to each process is desirable to prevent or mitigate cross contamination of reactants used or products formed within the reaction chamber. However, using dedicated reaction chambers requires significant capital costs and increases operating costs associated with making the devices. In addition, processing substrates in different reaction chambers often requires a vacuum and/or air break to remove a substrate from one reaction chamber and place the substrate in another reaction chamber.

In the case of ALD and ALE processes, multiple precursors are generally individually and sequentially introduced into a reaction chamber. Purge and/or exhaust steps are typically used to purge one precursor prior to introduction of another precursor. In other words, the precursors are introduced at different times to a reaction chamber to prevent unwanted mixing of the precursors. This is known as temporal processing. Although the introduction of different precursors is separated by time in such processes, the precursors can still undesirably mix and/or react, resulting in unwanted deposition within the reaction chamber and/or undesired particle formation.

To address these issues, spatial gas-phase reactors have been developed. Typical spatial gas-phase reactors include two or more processing regions coupled together along a horizontal direction, such that substrates can move from one processing region to another along a horizontal plane—e.g., along a conveyor or a turntable. Although these systems solve some problems associated with processing substrates in multiple reaction chambers and/or using multiple precursors within one reaction chamber, the systems still suffer drawbacks.

Horizontal transport systems require a significant amount of space, particularly floor space, for each processing region. In addition, the total process volume of such a system is relatively large, resulting in large purge gas requirements, long purge times, and slow substrate movement to maintain desired gas separation. Additionally, the relatively large processing region volumes can result in unwanted mixing of precursor gases.

In addition, precursor or reactant delivery schemes for horizontal transport systems are relatively complex. Further, the configuration of these systems is relatively inflexible, due at least in part to the timing requirements for the precursor or purge gas for each processing region relative to the speed at which the substrate moves. In addition, the mechanics of these systems can be relatively complicated and therefore such systems can be relatively unreliable and expensive to maintain.

Accordingly, improved gas-phase reactors, systems, and methods for carrying out multiple gas-phase processes are desired.

SUMMARY OF THE DISCLOSURE

Various embodiments of the present disclosure relate to multi-zone gas-phase reactors, to systems including the reactors, and to methods of using the reactors and systems. While the ways in which the multi-zone gas-phase reactors, systems, and methods of the present disclosure address the drawbacks or prior reactors, systems, and methods are described in greater detail below, in general, exemplary multi-zone gas-phase reactors, systems, and methods in accordance with the present disclosure include multiple reaction zones in a vertical stack, which allows reactors and systems to be run in unique ways, allows relatively fast throughput, employs relatively uncomplicated reactor design, uses relatively small volume, uses a relatively small amount of space, and/or provides relatively reliable reactor systems, compared to similar, prior spatial reactors and systems used to perform the same or similar processes. For example, exemplary reactors and systems can be used for spatial processing, such as spatial ALD and ALE processing.

In accordance with exemplary embodiments of the disclosure, a multi-zone gas-phase reactor includes a plurality of vertically-stacked reaction zones. Each reaction zone can include one or more gas inlets and/or one or more exhaust outlets. Processing regions including one or more reaction zones can be used for gas-phase processing and/or purging. For example, the reaction zones can be used for a step in an ALD process, for purging, and/or for other gas-phases processes. A load/unload region can be a zone. The gas inlets and outlets of adjacent zones can be offset (e.g., at 30, 60, 90, 120, 135, 180 degrees, or the like) from one another—e.g., to increase process uniformity and/or reduce a reactor volume. In accordance with exemplary aspects of these embodiments, a top surface of a processing region within the multi-zone gas-phase reactor includes a bottom surface of a movable top plate and a bottom surface of the processing region includes a top surface of a movable bottom plate. The top plate can include, for example, a heater, a showerhead, and/or can form part of a plasma system. The bottom plate can include part of a susceptor assembly, and can be heated, cooled, and/or form part of a plasma unit. Either or both of the top plate and the bottom plate can rotate—either continuously or in an indexed manner—in any reaction zone(s) and/or load/unload region. The top plate and the bottom plate can move independently (rotationally and/or vertically—e.g., along an axis)—e.g., the movement of either or both can be continuous or indexed. Because the plates can move independently, a volume of a processing region can be dynamically changed. As a result, a processing region can include one or more reaction zones, and can be varied—either between processes or during processing. For example, a processing region can be enlarged for a purge or clean process and reduced for a deposition or etch process. Alternatively, a processing region can be enlarged for, for example, an ALD or ALE process, and reduced for a purge process. A processing region can be configured in a cross-flow manner and/or can include a showerhead gas distribution system for initially vertical flow of one or more gases toward a substrate. A processing region can be configured to process a single or multiple substrates. Further, one or more reaction zones can be coupled to one or more remote plasma units that provide activated species to a processing region. To isolate one or more processing regions, inert gas flow, alone or in combination with an exhaust can be supplied on one or more sides (top and/or bottom) of a processing region—e.g., adjacent to each reaction zone. The reactor can be used for a variety of processes, including substrate and/or chamber treatment (e.g., plasma treatment, degasing, chlorine scrubbing), deposition (including plasma-enhanced deposition), etch, and/or clean processes.

In accordance with further exemplary embodiments of the disclosure, a reactor system includes one or more multi-zone gas-phase reactors as described herein. The reactor systems can also include one or more vacuum sources, one or more reactant/precursor sources, one or more inert gas sources, control systems, and the like.

In accordance with yet additional exemplary embodiments of the disclosure, a method (e.g., a method for spatial substrate processing) includes using a multi-zone gas-phase reactor having a plurality of vertically stacked reaction zones. The method can include the steps of providing a multi-zone gas-phase reactor, providing a substrate, moving the substrate in a vertical direction to a processing region including a first reaction zone, and exposing the substrate to a first process using the first reaction zone. The first process can include any suitable process, such as a process noted above. The substrate can be vertically moved to other reaction regions including one or more other reaction zones within the multi-zone gas-phase reactor for additional processing. For example, in an ALD or similar process, the substrate may be exposed to a first precursor in a first processing region including a first reaction zone and then be moved to a second processing region including a second reaction zone and exposed to a second precursor. The substrate can be exposed to a purge gas in reaction zone(s) between the first and second reaction zones. In this case, the substrate can move between the first and second reaction zones (and any purge reaction zones) until a desired amount of material is deposited or removed. Additionally or alternatively, the substrate may undergo a first process (e.g., substrate cleaning, etching, purging, or treatment) in a processing region including a first reaction zone and then be moved to a processing region including a second reaction zone or other zones for further processing (e.g., deposition, etch or treatment processing), and so on. Various plasma apparatus can be employed at one or more of the process steps. Additionally or alternatively, the substrate can be heated, cooled, or left at ambient temperature during one or more processes. Further, one or more substrates can undergo a process at one time. The one or more substrates can be continuously moved or indexed before, during, or after a process. Gas and/or gas/vacuum curtains can be used to isolate processing regions (which include one or more reaction zones) or reaction zones. Inert gas valving can be used to rapidly purge gas (e.g., precursor) lines and/or provide isolation to a processing regions or reaction zones. Various processes can operate in cross flow and/or showerhead configurations.

Inert gas valving can be accomplished by several methods. One technique uses dynamic seals, produced with, for example, inert (e.g., nitrogen) injection-vacuum withdraw-inert (e.g., nitrogen) injection plumbing arrangement, between reaction zones. This arrangement can be further improved by coupling the gas inlets, exhaust and dynamic seals with a channeled shield which allows the bulk of the gas at any blocked level to easily move around the shield to an exhaust. Another technique is pulsed back suction. Various other inert gas valve arrangements can be employed to maintain a gas curtain separating reaction zones in accordance with exemplary embodiments of the disclosure.

Both the foregoing summary and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure or the claimed invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE DISCLOSURE

The description of exemplary embodiments provided below is merely exemplary and is intended for purposes of illustration only; the following description is not intended to limit the scope of the disclosure or the claims. Moreover, recitation of multiple embodiments having stated features is not intended to exclude other embodiments having additional features or other embodiments incorporating different combinations of the stated features.

As set forth in more detail below, various embodiments of the disclosure relate to multi-zone gas-phase reactors and reactor systems that include a multi-zone gas-phase reactor and to methods of using the multi-zone gas-phase reactors and systems. The multi-zone gas-phase reactors, systems, and methods can be used for a variety of gas-phase processes, such as deposition, etch, clean, and/or treatment processes. By way of examples, a multi-zone gas-phase reactor can be used for ALD and/or ALE processes, wherein a substrate is exposed to a first precursor in a first reaction zone, a purge process (e.g., in another reaction zone), a second precursor in a second reaction zone, and another purge process (e.g., in yet another reaction zone). Other reaction zones can be used to expose the substrate to a purge gas. One or more processes can be performed in the same multi-zone gas-phase reactor, without an air or vacuum break. As set forth in more detail below, exemplary reactors, systems, and methods allow for relatively fast processing of substrates, require a relatively small footprint, allow for a variety of reaction processing region configurations (e.g., including one or more reaction zones), have processing regions and lines that can be purged relatively quickly, are relatively reliable, and/or have relatively simple precursor and/or reactant supply schemes.

FIGS. 1(a) and 1(b)illustrate an exterior andFIGS. 2(a) to 3(d)illustrate additional views of a multi-zone gas-phase reactor100in accordance with exemplary embodiments of the disclosure. Multi-zone gas-phase reactor100includes one or more gas inlets, which in the illustrated example, include diffusers102-114, one or more exhaust outlets, illustrated as collectors116-128, a gate valve130for loading and unloading substrates, a top plate202, a susceptor assembly206, including a susceptor or plate204, and conduits132,134for, e.g., providing electrical and/or gas lines to portions of multi-zone gas-phase reactor100.

Multi-zone gas-phase reactor100is illustrated with seven vertically-stacked reaction zones, wherein each reaction zone includes a gas inlet and an exhaust outlet. Multi-zone gas-phase reactors in accordance with other examples of the disclosure can include any suitable number of reaction zones. By way of examples, multi-zone gas-phase reactors can include 2-20, 2-15, 2-13, or 2-11 reaction zones. Further, although each reaction zone is illustrated with a gas inlet and a gas outlet, in some cases, the reaction zone may only include a gas outlet or a gas inlet. A height of a reaction zone can vary according to desired reactions. By way of some examples, e.g., in the case of ALD or ALE processing, a height of a reaction zone can be from about 0.1 mm to about 20, about 0.2 mm to about 10 mm, about 0.2 mm to about 0.5 mm, or be about 5 mm to about 10 mm. Flowrates, temperatures, and operating pressures within each reaction zone can also vary according to desired reactions and can include flowrates, pressures, and temperatures typically used for processing substrates. By way of examples, pressures can range from about 100 mtorr to about 50 torr, temperatures can range from about 100° C. to about 700° C., and flowrates (e.g., for purge gasses and/or precursor gasses) can range from about 10 sccm to about 10 slm.

A movable processing region208includes one or more reaction zones. In the illustrated example, processing region208includes a bottom surface of top plate202and an upper surface of susceptor assembly206(e.g., an upper surface of plate or susceptor204).FIGS. 2(a) and 2(b)illustrate processing region208in an upper region of multi-zone gas-phase reactor100. In this case, processing region208includes a gas inlet209, an exhaust outlet210, bottom surface212of plate202and top surface214of susceptor204.

Top plate202(also referred to herein as movable plate) can include a solid or permeable plate. In accordance with some embodiments of the disclosure, top plate202includes a showerhead. In accordance with additional or alternative embodiments, top plate202can include part of a direct plasma system—e.g., top plate202can form all or part of an electrode of the direct plasma system. In accordance with various aspects of these embodiments, top plate202can be heated, be cooled, be at ambient temperature, and/or run under isothermal conditions. As best illustrated inFIGS. 2(b) and 3(b), multi-zone gas-phase reactor100can include a shield216coupled to top plate202. Shield216helps isolate processing region208from other zones or regions within multi-zone gas-phase reactor100. In accordance with other exemplary embodiments, a reactor, such as a multi-zone gas-phase reactor described herein can include guide2802,2812and guide pads2804and/or guide bearings2806to guide shields2808,2810, as illustrated inFIG. 28.

Bottom plate204(also referred to herein as susceptor204) can be heated, be cooled, be at ambient temperature, and/or run under isothermal conditions. Additionally or alternatively, bottom plate204can form part of a direct plasma system—e.g., bottom plate202can form all or part of an electrode of the plasma system. Multi-zone gas-phase reactor100can also include a shield218coupled to susceptor204to help isolate processing region208from other zones or regions within multi-zone gas-phase reactor100.

Turning now toFIGS. 3(a) and 3(b), a portion of reactor100is illustrated with bottom plate204in a load/unload position. Top plate202can also be in a load/unload position to facilitate faster load/unload times. In this configuration, multi-zone gas-phase reactor100can receive a substrate or a substrate can be unloaded from multi-zone gas-phase reactor100from or to, for example, a wafer transfer station that may suitably be under vacuum conditions.

FIGS. 3(c) and 3(d)illustrate one exemplary technique to couple collectors (e.g., collectors116-128) to an exterior of multi-zone gas-phase reactor100. The same or similar technique can be used to couple diffusers102-114to an exterior of multi-zone gas-phase reactor100. In the illustrated example, O-rings302,304are used to form a seal between collector128and exterior310of multi-zone gas-phase reactor100. Exterior310can include O-ring grooves312,314to receive O-rings302,304. A space303between O-rings302,304can be vacuum pumped to form a static seal.

FIG. 4illustrates susceptor assembly206in greater detail. Susceptor assembly206is designed to hold a substrate (e.g., a semiconductor wafer) in place during processing. Susceptor assembly206includes susceptor204and a member402mechanically coupled to susceptor204. Member402can be a conduit through which heating and/or cooling lines are inserted. Further, member402and susceptor204can be rotatably coupled, such that subsector204can rotate (either continuously or indexed) during substrate processing and/or substrate loading or unloading.

FIGS. 5(a) to 5(c)illustrate a system500including a plurality of multi-zone gas-phase reactors502,504, and a substrate transfer station506. For illustration purposes, system500is illustrated with two multi-zone gas-phase reactors502,504. However, systems in accordance with this disclosure can include any suitable number of multi-zone gas-phase reactors. For example, wafer transfer station506can couple to, for example, two, four, five, six, or eight multi-zone gas-phase reactors, and one or more substrate load/unload areas. Substrates can be simultaneously loaded into respective load/unload areas of multi-zone gas-phase reactors502,504and/or other such reactors.

Similar to multi-zone gas-phase reactor100, multi-zone gas-phase reactors502,504include top plates552,554, which may be the same or similar to top plate202, and bottom plates556,558, which may be the same or similar to susceptor204. Top plates552and554can move in unison or independently from each other and/or their respective bottom plates/susceptors556,558.

Turning now toFIGS. 6(a) to 9(b), a multi-zone gas-phase reactor600suitable for simultaneously processing a plurality of substrates is illustrated. Multi-zone gas-phase reactor600can be the same or similar to multi-zone gas-phase reactor100,502, or504, although multi-zone gas-phase reactor600can be scaled to simultaneously process a plurality of substrates, such as 2, 3, 4, 5, 6, 7 or 8 substrates. Multi-zone gas-phase reactor600can be a stand-alone reactor or part of a system, such as system500. Reactor600includes a load/unload area630, which is configured to allow loading/unloading of substrates into or out of reactor600.

Similar to the reactors described above, multi-zone gas-phase reactor600includes a plurality of diffusers602-614and a plurality of collectors616-628. Diffusers602-614and collectors616-628can be the same or similar to other diffusers and collectors described herein; however, diffusers602-614and collectors616-628are scaled to simultaneously process multiple substrates within a processing region.

Multi-zone gas-phase reactor600includes a top plate702having a shield706associated therewith and a bottom plate/susceptor704having a shield708associated therewith. Associated shields706,708move with and can be coupled to respective plates702,704to help isolate a processing region720. For example, if multi-zone gas-phase reactor600includes n reaction zones, shields706,708extend over n-1, n-2, n-3, n-4, or the like reaction zones. In the illustrated example, shields706,708extend over n-1 zones.

Multi-zone gas-phase reactor600includes recesses712,714to receive shields706,708. Recesses712,714extend to allow plates to a bottom position (e.g., a load/unload position) and a top position (e.g., to serve as a top plate in or above a top reaction zone within reactor600). Multi-zone gas-phase reactor600also includes inserts716,718. Inserts716,718can form part of recesses712,714. Inserts716,718reduce an interior volume of reactor600, while allowing use of shield706,708. Reducing reactor600interior volume is beneficial, because pump-down times to obtain desired vacuum conditions can be reduced.

FIGS. 10 and 11illustrate a susceptor assembly1100, including susceptor704, for processing a plurality of substrates. Susceptor assembly1100can be the same or similar to susceptor assembly206, except a susceptor assembly1100includes a susceptor704that has a top surface1002, which can hold two or more substrates in place during processing. Susceptor assembly1100also includes a member1102mechanically coupled to susceptor1004. Member1102can include a conduit through which heating and or cooling lines are inserted or be a solid member. Member1102and susceptor704can be rotatably coupled together, such that subsector704can rotate during substrate processing and/or loading and unloading.

FIGS. 12(a) to 13(b)illustrate another multi-zone gas-phase reactor1200. Multi-zone gas-phase reactor1200is similar to multi-zone gas-phase reactors100,502,504,600, except multi-zone gas-phase reactor1200is illustrated with 11 reaction zones, each reaction zone including a diffuser (e.g. one of diffusers1202-1224) and a collector (e.g., one of corresponding collectors1226-1246). Similar to the multi-zone gas-phase reactors described above, multi-zone gas-phase reactor1200includes top plate1302, bottom plate1304, shields1306,1308, and a load/unload area1248. In the illustrated case, shields1306,1308extend over at least one adjacent reaction zone.

Turning now toFIGS. 14 and 15, exemplary integrated gate valve (IGV) assemblies1400and1500are schematically illustrated. As noted above, IGV assemblies can be used to isolate a processing region or reaction zone from other reaction zones and/or other regions within a reactor. IGV assemblies can be coupled to an inlet of a diffuser, such as any of the diffusers described herein. Generally, exemplary IGV assemblies as described herein provide desired isolation between reaction zones or regions via selection of pump and/or back suction conductance and/or pump speeds.

IGV assembly1400includes inlet precursor valve1402, exhaust precursor valve1404(e.g., a back suction valve connected to an exhaust source), and inert gas inlets1408and1410. As illustrated, inert gas inlets1408,1410can provide inert gas (e.g., nitrogen, argon, or the like) in a direction toward a reaction zone inlet1412and toward exhaust valves1414,1416, which can suitably include back suction valves. This facilitates purging of a precursor line1418and mitigates mixing with other precursor lines1420,1422. As illustrated, assembly1400can include additional inert gas inlets1424,1426for precursor lines1420and1422, respectively.

IGV assembly1500includes a precursor inlet valve, inert gas valves1504-1510, and exhaust valve1512. During operation of IGV assembly1500, when a precursor is introduced to a reaction zone inlet1514, precursor valve1502and inert gas valves1504,1508(e.g., low-flow valves) are on to provide an additional barrier to nearby reaction zones and the like. To purge a precursor line1516, valves1506and1510can be opened to provide additional inert gas flow. In accordance with some aspects of these embodiments, valves1502and1512can be left on or open during processing, because the primary exhaust for a reaction zone can be the highest conductance and thus when a shield (e.g., shield1306or the like) does not block a precursor from entering a reaction zone, the precursor flows across a substrate and a small amount of the precursor will flow to an exhaust (e.g., through valve1512). When an inlet is blocked—e.g., by a shield, a gas flow resistance is high enough, so that all or most of the precursor, along with purge gases from above and/or below, will flow directly to the exhaust and not to a reaction chamber.

FIGS. 26 and 27illustrate additional exemplary reactors that include a gas curtain to facilitate isolation of a reaction zone or processing region from other zones or regions of a reactor. Reactor2600includes precursor inlets2602,2604(which correspond to different reaction regions), inert gas inlets2606-2612, a movable plate2614, and a susceptor2616, which can be part of a susceptor assembly. During operation of reactor2600, inert gas flows as indicated by the respective arrows to provide a gas curtain. The inert gas flows from inlets2606-2612toward an exhaust2618.

Reactor2700includes inert gas inlets2702,2704. In the illustrated example, an inert gas enters gas inlet2702, runs through a conduit2706coupled to a movable plate2708, and continues to flow between a sidewall2712and a shield2710to an exhaust2714. Similarly, an inert gas (which can be the same or similar to the inert gas in conduit2706) flows from inlet2704through a conduit2716, which can be coupled to a susceptor2718, and continues to flow between a sidewall2720and a shield2722to an exhaust2724, which can be the same as exhaust2714. The inert gas flow, as illustrated by the arrows, provides a gas curtain to facilitate isolation between reaction zones and/or regions.

FIGS. 29-33illustrate another technique for isolating precursors in nearby reactions zones. In the illustrated example, a reactor2900includes a plurality of reaction zones2902-2920,2921, and2923. Similar to other reactors described herein, reactor2900includes a top plate2922, a bottom plate2924, and shields2926,2928. Although illustrated with a precursor reaction zone surrounded on each side by two precursor reaction zones, exemplary reactors are not so limited. Other reactors can include one or more purge reaction zones adjacent a precursor reaction zone.

Reaction zones2904,2910, and2916can be used to expose a substrate to a precursor—e.g., a precursor used in CVD processing, such as an ALD or ALE process. One or more (e.g., two) purge reaction zones2902,2906,2908,2912,2914,2918,2920are adjacent each precursor reaction zone2904,2910, and2916. Using one or more purge reaction zones2902,2906,2908,2912,2914,2918,2920adjacent precursor reaction zones2904,2910, and2916provides isolation of one or more precursors from other precursors used in nearby reaction zones. It is generally desirable to have separation of the gasses, and particularly of the precursors to prevent undesirable mixing of the gases. Mixing of the precursors, for example in one or more purge reaction zones2902,2906,2908,2912,2914,2918,2920, may cause particles to form in those regions.

Some purge gas from purge reaction zones2902,2906,2908,2912,2914,2918,2920may leak into nearby precursor reaction precursor reaction zones2904,2910, and2916. Generally, there is a tendency for more purge gas to leak into a precursor reaction zone2904,2910, and/or2916, where the purge gas pressure is highest—e.g. near an inlet of the purge gas. To increase gas (e.g., precursor separation), purge gas (e.g. in purge reaction zones2902,2906,2908,2912,2914,2918,2920) can be introduced at an angle offset from the angle of introduction of the precursor gasses. For example, the inlets and corresponding outlets for the precursor gasses and the inlets and corresponding outlets for the purge gasses can be offset by 30, 45, 60, 90, 120, 135, 180, or any combination of such degrees or other degrees. Introducing the purge gasses from another direction may increase dilution of a precursor within a precursor reaction zone2904,2910, and/or2916, but generally reduces potential of undesired mixing of the precursors. To provide additional isolation, precursors not in use in a reaction zone can be turned off.

By way of example, with reference toFIG. 29, a substrate2930is exposed to a first precursor “B” in reaction zone2910. In this case, precursor “A” is turned off (e.g., a valve is closed), and purge lines to purge reaction zones2902,2906,2908,2912,2914,2918,2920are on. Alternatively, purge lines to one or more adjacent purge reaction zones are on and other purge lines can be off.

As substrate2930continues to move upward in reactor2900, substrate2930is exposed to a first purge in reaction zone2912, as illustrated inFIG. 31. In this case, adjacent precursors “A” and “B” can be turned off, as shown. Substrate2930can then be exposed to a second purge in reaction zone2914, as illustrated inFIG. 32.

Substrate2930can then be exposed to precursor “A” in reaction zone2916, while precursor “B” is off, as illustrated inFIG. 33. Purge reaction zones2918,2920and2912,2914provide additional isolation to, for example, reaction zones2910and2921.

During substrate processing, top plate2922and bottom plate2924can move continuously through reactor2900from a load/unload area though the reaction zones2902-2923. An acceleration of the plates (without a vacuum chuck) can be about 0.67 g. By way of particular example, a unit cell can be defined as a purge reaction zone, a first precursor reaction zone, two adjacent purge reaction zones, a second precursor reaction zone, and another purge zone can be about 80 mm in height. In this case, a time to travel through a unit cell can be about 280 ms. With a vacuum chuck and 3 g acceleration, the travel time could be reduced to about 130 ms. If top plate2922and bottom plate2924move in an indexed fashion, the time to traverse a unit cell would generally increase.

Turning now toFIGS. 16-22, an exemplary method of using a multi-zone gas-phase reactor is illustrated. The method is conveniently illustrated using a reactor1600, which includes a movable susceptor assembly1602, a movable plate1604, a gate valve opening1606, and reaction zones1702,1802,1902,2002, and2102. Although not illustrated inFIGS. 16-22, reactor1600can include shields and/or IGV assemblies as described and illustrated elsewhere.

During operation of reactor1600, a substrate1608is loaded onto a top surface1610of a susceptor1612. As illustrated, substrate1608can be loaded onto and/or removed from susceptor1612using lift pins1614,1616, which go through at least a portion of susceptor1612. Once substrate1608is loaded onto susceptor1612, gate valve1606is closed.

Substrate1608can be moved to a processing region including reaction zone1702by moving susceptor assembly1602and movable plate1604to reaction zone1702positions. As noted above, susceptor assembly1602and movable plate1604can move together or move independently to positions for various reaction zones, processing regions, and load/unload positions.

A processing region including reaction zone1702can be used for various processes, including cleaning or treatment of a substrate surface. For example, hydrogen gas and/or ammonia gas can be used to treat a surface of a substrate in a processing region including reaction zone1702. Reactant can enter from an inlet1704and/or from top plate1604. The reactant can include activated species and/or can be exposed to a plasma process.

Next, substrate1608is moved to a processing region including reaction zone1802. As illustrated, susceptor assembly1602can rotate during processing in a processing region including reaction zone1802(or anywhere in reactor1600, including the loading/unloading zone). By way of example, a first precursor for an ALD deposition process can be introduced at an inlet1804. At a processing region including a reaction zone1902, a second precursor can be introduced at inlet1904. First and second precursors can be used for, for example, ALD or ALE processing.

At a processing region including a reaction zone2002, substrate1608is exposed to the first precursor (or another precursor). As illustrated, the precursor can be introduced at an opposite side of reactor1600. Introducing reactants or other gases at various locations for various reaction zones can facilitate uniform gas-phase processes, such as deposition, etch, clean, and treatment processes. Introducing reactants at various locations can also facilitate reactor design (e.g., reactors having less volume). As noted above, inlets and/or outlets of a reactor can be offset by, for example, 30, 45, 60, 90, 120, 135, or 180 degrees.

Substrate1608is exposed to another precursor from gas inlet2104in a processing region including reaction zone2102. The precursor can be the same or different from the precursor used in reaction zone1902.

Substrate1608can suitably be moved between reaction zones1702-2102a desired number of times—for example, until a desired amount of material is deposited or removed. Susceptor assembly1602can then be lowered to a load/unload position1620, illustrated inFIG. 16.

FIG. 22illustrates susceptor1612in a low position (e.g., a load/unload position) and movable plate1604in a high position (e.g., reaction zone1702position or above). When movable plate1604and susceptor1612are in these positions, a processing region2202, including reaction zones1702-2102can be cleaned or treated. For example, region2202can be exposed to a direct and/or remote plasma clean or treatment process. Although region2202is illustrated as encompassing reaction zones1702-2102, susceptor1612and movable plate1604, a processing region can encompass any of one or more reaction zones1702-2102during such processing. Similarly, movable plates and susceptors of other reactors described herein can be moved to similar locations to create such processing regions.

Another feature of exemplary multi-zone gas-phase reactors as described herein is the ability to apply an alumina or similar coating to areas of the reactor—e.g. to one or more reaction zones (e.g., zones1702-2102or any subset thereof). The alumina can serve as a barrier layer to the reactor surfaces for minimizing potential metallic contamination. The alumina coat can also be used to cap any undesirable film formation on the reactor walls in order to improve reactor lifetime. The alumina coat can also improve the ability to clean and refurbish the reactor.

FIGS. 23-25illustrate additional exemplary configurations of exemplary reactors in accordance with this disclosure.FIG. 23illustrates a multi-zone gas-phase reactor2300including seven reaction zones2302-2314and a load/unload zone2330.

During operation of multi-zone gas-phase reactor2300, a substrate2316is loaded onto a susceptor2318of a susceptor assembly2320via a gas valve opening2322. Substrate2316can be moved to various processing regions including one or more reaction zones2302-2314, by moving susceptor assembly2320and a movable plate2324. In the illustrated example, substrate2316is exposed to a first precursor in a processing region including reaction zone2302, a purge gas in a processing region including reaction zone2304, a second precursor in a processing region including reaction zone2306, a purge gas in a processing region including reaction zone2308, the first precursor in a processing region including reaction zone2310, a purge gas in a processing region including reaction zone2312, and the second precursor in a processing region including reaction zone2314. Substrate2316can be moved between processing regions including reaction zones2302-2314a desired number of times—e.g., until a desired amount of material is deposited or removed from a surface of substrate2316.

FIG. 24illustrates another exemplary reactor configuration. Multi-zone gas-phase reactor2400includes reaction zones2402-2410. In the illustrated example, a reaction processing region2430includes two reaction zones2408,2410between a movable plate2412and a susceptor2414. In this case, a first gas and a second gas can be introduced between a bottom surface2420of movable plate2412and a top surface2422of a susceptor2414. The first and second gases2416,2418can be introduced simultaneously or sequentially. For example, first and second precursor gases can be introduced simultaneously during a CVD process. One or more of the first and second gases can include an inert gas. Although illustrated with two gas inlets, reaction zones and/or processing regions of multi-zone gas-phase reactors as described herein can include any suitable number of gas inlets, for reactants, carrier, and/or purge gases.

Reactor2500is illustrated with one reaction zone2502, a movable plate2504, which includes a showerhead gas distribution apparatus2506, a susceptor assembly2508, and a load/unload zone2510. Movable plate and/or movable susceptor assembly2808allows for variable gap control of reaction zone2502. Gas distribution apparatus2506can form part of a direct plasma system. In the illustrated example, reactor2500allows for both cross flow and vertical flow of gases. This provides an alternate means of keeping precursors separated to avoid mixing and resulting particle generation. A precursor with the highest desirable degree of flux uniformity can be distributed through showerhead gas distribution apparatus2506, while another precursor can be delivered via the cross-flow path.

Although illustrated with one reaction zone2502, reactors in accordance with other exemplary embodiments can include a showerhead gas distribution apparatus and any suitable number of reaction zones.

Although exemplary embodiments of the present disclosure are set forth herein, it should be appreciated that the disclosure is not so limited. For example, although the reactors, reactor systems, and methods are described in connection with various specific configurations, the disclosure is not necessarily limited to these examples. Indeed, unless otherwise noted, features and components of various reactors and systems described herein can be interchanged. Various modifications, variations, and enhancements of the reactors, systems, and methods set forth herein may be made without departing from the spirit and scope of the present disclosure.

The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various systems, assemblies, reactors, components, and configurations, and other features, functions, acts, and/or properties disclosed herein, as well as any and all equivalents thereof.