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

Provided is a technique capable of obtaining a desired processing quality for each of a plurality of substrates even when the plurality of substrates are processed while being rotated. There is provided a technique that includes: a process chamber in which a plurality of substrates are processed; a gas supplier configured to be capable of supplying a gas to the process chamber; a substrate support provided in the process chamber so as to be rotatable and configured to be capable of supporting the plurality of substrates in a circumferential arrangement; and a detector configured to detect a rotation state of the substrate support.

CROSS REFERENCE TO RELATED APPLICATIONS

This non-provisional U.S. patent application is based on and claims priority under 35 U.S.C. § 119 of Japanese Patent Application No. 2023-141437 filed on Aug. 31, 2023, in the Japanese Patent Office, the entire contents of which are hereby incorporated by reference.

TECHNICAL FIELD

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

BACKGROUND

According to some related arts, as an apparatus used in a manufacturing process of a semiconductor device, a substrate processing apparatus may be used. For example, the substrate processing apparatus is configured to arrange a plurality of substrates in a circumferential arrangement and to perform a predetermined process such as a film forming process on each of the plurality of substrates by supplying a gas to each of the plurality of substrates while rotating the plurality of substrates.

When the plurality of substrates are processed while being rotated, a processing quality of each of the plurality of substrates may vary depending on a rotation state thereof.

SUMMARY

According to the present disclosure, there is provided a technique capable of obtaining a desired processing quality for each of a plurality of substrates even when the plurality of substrates are processed while being rotated.

According to an aspect of the present disclosure, there is provided a technique that includes a process chamber in which a plurality of substrates are processed; a gas supplier configured to be capable of supplying a gas to the process chamber; a substrate support provided in the process chamber so as to be rotatable and configured to be capable of supporting the plurality of substrates in a circumferential arrangement; and a detector configured to detect a rotation state of the substrate support.

DETAILED DESCRIPTION

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.

(1) Configuration of Substrate Processing Apparatus

Hereinafter, one or more embodiments (also simply referred to as “embodiments”) of the technique of the present disclosure will be described in detail with reference to mainlyFIGS.1and2. 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.

FIG.1is a diagram schematically illustrating a horizontal cross-section of a substrate processing apparatus200according to the embodiments of the present disclosure when viewed from above.FIG.2is a diagram schematically illustrating a vertical cross-section of the substrate processing apparatus200according to the embodiments of the present disclosure, taken along a line α-α′ shown inFIG.1. Further, the line α-α′ is a line extending from a toward a center of a chamber302and further extending from the center of the chamber302toward α′.

A specific configuration of the substrate processing apparatus200will be described below. The substrate processing apparatus200is controlled by a controller400described later.

Chamber

As shown inFIGS.1and2, the substrate processing apparatus200is constituted mainly by the chamber302which is an airtight sealed vessel (process vessel) of a cylindrical shape. A process chamber301in which a plurality of substrates including a substrate100are processed is provided in the chamber302. Hereinafter, the plurality of substrates including the substrate100may also be simply referred to as “substrates100”. A gate valve305is connected to the chamber302. The substrate100is loaded (transferred) into or unloaded (transferred) out of the chamber302through the gate valve305by a wafer transfer structure (not shown). The gate valve305is provided adjacent to a passage305a. The substrate100is moved through the passage305a.

In the process chamber301, a process region306(which includes a first process region306aand a second process region306b) serving as a domain (region) to which a process gas such as a first gas and a second gas is supplied and a purge region307(which includes a first purge region307aand a second purge region307b) serving as a domain (region) to which a purge gas is supplied are provided. According to the present embodiments, the process region306and the purge region307are alternately arranged along a circumferential direction of the process chamber301. For example, the first process region306aserving as a first domain, the first purge region307aserving as a first purge domain, the second process region306bserving as a second domain and the second purge region307bserving as a second purge domain are sequentially arranged along the circumferential direction in this order. As described later, for example, the first gas is supplied into the first process region306a, the second gas is supplied into the second process region306b, and an inert gas (that is, the purge gas) is supplied into the first purge region307aand the second purge region307b. As a result, a predetermined process (for example, a substrate processing) is performed with respect to the substrates100in accordance with the gas supplied into each region.

The purge region307(that is, the first purge region307aand the second purge region307b) is configured to spatially separate the first process region306aand the second process region306b. A ceiling308of the purge region307is disposed lower than a ceiling309of the process region306. Specifically, a ceiling308ais provided at the first purge region307aand a ceiling308bis provided at the second purge region307b. By lowering each of the ceiling308aand the ceiling308b, it is possible to increase a pressure of a space in the purge region307. By supplying the purge gas to the space described above, it is possible to partition the adjacent process region306(that is, the first process region306aand the second process region306b). In addition, by supplying the purge gas, it is possible to remove excess gases (undesired gases) on the substrates100.

A substrate support317configured to support the substrates100is provided in the chamber302. The substrate support317is made of a material capable of allowing a transmission of a heat, and is configured to transmit the heat radiated from a heater380described later. The substrate100is heated by the heat transmitted through the substrate support317.

The substrate support317is provided so as to be freely rotatable within the chamber302. Further, the substrate support317is configured such that the substrates100(for example, five substrates) can be arranged within the process chamber301on the same plane and along the same circumference along a rotation direction “R” shown inFIG.1.

Thus, the substrate support317includes a substrate placing plate (also referred to as a “substrate mounting plate”)318serving as a rotating structure of a plate shape configured to support the substrates100. Thereby, the substrate support317is capable of supporting the substrates100in a circumferential arrangement (that is, along the circumferential direction). The substrate placing plate318is supported by a support shaft (described later) disposed in the vicinity of the center of the chamber302, and is configured to be rotatable about the support shaft as a rotation axis. In other words, the substrate support317is constituted by at least the substrate placing plate318and a shaft322(described later) serving as the support shaft configured to support the substrate placing plate318.

For example, a surface of the substrate placing plate318is constituted by: a plurality of substrate placing surfaces including a substrate placing surface311; and a substrate non-placing surface325. Hereinafter, the plurality of substrate placing surfaces including the substrate placing surface311may also be simply referred to as substrate placing surfaces311. The substrates100may be placed on the substrate placing surfaces311, respectively. For example, the substrate placing surfaces311are arranged along a circle centered on a center of the substrate placing plate318. That is, the substrate placing surfaces311are arranged at the same distance from the center of the substrate placing plate318, and along the same circumference with equal intervals (for example, 72° intervals) therebetween. InFIG.1, the illustration of the substrate placing surfaces311is omitted for simplification.

For example, the substrate placing surfaces311are provided on bottom surfaces of a plurality of concave structures including a concave structure312, respectively. Hereinafter, the plurality of concave structures including the concave structure312may also be simply referred to as “concave structures312”. For example, each of the concave structures312is of a circular shape when viewed from an upper surface of the substrate placing plate318, and of a concave shape when viewed from a side surface of the substrate placing plate318. It is preferable that a diameter of each of the concave structures312is slightly greater than a diameter of the substrate100. For example, the substrate100may be placed on the substrate placing surface311by being placed on one of the concave structures312.

The substrate placing plate318is fixed to a core structure321. The core structure321is provided at the center of the substrate placing plate318and configured to fix the substrate placing plate318to the shaft322described later. The shaft322serving as the support shaft configured to support the substrate placing plate318is provided below the core structure321. The shaft322supports the core structure321.

A lower portion of the shaft322penetrates a hole323provided at a bottom of the chamber302, and a bellows304provided outside the chamber302and capable of airtightly (hermetically) sealing the shaft322covers the lower portion of the shaft322. In addition, an elevating and rotating structure319is provided at a lower end of the shaft322. The elevating and rotating structure319may also be referred to as an “elevator/rotator319”.

The elevator/rotator319mainly includes: a support shaft319aconfigured to support the shaft322; and an operating structure319bconfigured to elevate/lower or rotate the support shaft319a. For example, the operating structure319bmay include: an elevator (which is an elevating structure)319csuch as a motor configured to elevate and lower the support shaft319a; and a rotator (which is a rotating structure)319dsuch as a gear configured to rotate the support shaft319a.

The elevator/rotator319may further include an instruction controller319eserving as a part of the elevator/rotator319and configured to control the operating structure319bto move the support shaft319aup and down or to rotate the support shaft319a. The instruction controller319eis electrically connected to the controller400. The operating structure319bis controlled by the instruction controller319ebased on an instruction from the controller400.

By operating the elevator/rotator319to rotate the shaft322and the substrate placing plate318, the substrate support317is configured to be capable of rotating the substrates100placed on the substrate placing surfaces311along the circumferential direction. Further, by operating the elevator/rotator319to elevate or lower the shaft322and the substrate placing plate318, the substrate support317is configured to be capable of elevating or lowering the substrates100placed on the substrate placing surfaces311.

The elevator/rotator319may further include a rotation meter (such as a tachometer)319fserving as a part of the elevator/rotator319and configured to detect values related to a rotation of the support shaft319aor the shaft322supported thereby. For example, the rotation meter319fis configured to be capable of detecting the values related to the rotation, such as the number of rotations and a value of a rotation speed when the support shaft319arotates and fluctuations in the number of rotations and the value of the rotation speed over time.

A posture controller350configured to control a posture of the substrate support317(that is, a part including at least the substrate placing plate318and the shaft322) is provided between the shaft322and the elevator/rotator319. For example, the posture controller350includes: a base351configured to support the shaft322and the elevator/rotator319; and a plurality of actuators352configured to connect the base351to a lower surface of the chamber302.

The actuators (for example, four or six actuators)352are evenly arranged around the shaft322. Each of the actuators352is configured to be individually extendable and retractable. By changing a distance between the base351and the chamber302by individually extending and retracting the actuators352, it is possible to control a tilt (inclination) of the base351with respect to the chamber302. Thereby, it is possible to adjust the posture of the substrate support317(in particular, a tilt of the rotation axis caused by the shaft322). Further, for example, as each of the actuators352, a component such as an electric motor, an electromagnetic solenoid and an air cylinder may be used.

The posture controller350may further include a tilt regulator (which is a tilt adjusting structure)353serving as a part of the posture controller350and configured to instruct each of the actuators352to perform an extension and retraction operation. The tilt regulator353is electrically connected to the controller400. The tilt regulator353is configured to control the extension and retraction operation of each of the actuators352based on an instruction from the controller400.

In the chamber302, a heater structure381with the heater380serving as a heating structure (heating device) embedded therein is disposed below the substrate placing plate318. The heater380is disposed so as to face a lower surface of the substrate placing plate318, and is configured to heat each of the substrates100placed on the substrate placing plate318. The heater380is provided in the circumferential direction in accordance with a shape of the chamber302. The heater380may be divided into a plurality of zones along the circumferential direction. A heater temperature controller387is connected to the heater380. The heater temperature controller387is electrically connected to the controller400described later, and is configured to control a supply of the electric power to the heater380in accordance with an instruction from the controller400to perform a temperature control. When the heater380is divided into the plurality of zones, the heater temperature controller387is configured to be capable of individually performing the temperature control for each of the plurality of zones.

An exhaust buffer structure386is disposed at an outer periphery of the substrate placing plate318. The exhaust buffer structure386includes an exhaust groove388and an exhaust buffer space389. Each of the exhaust groove388and the exhaust buffer space389is arranged in the circumferential direction in accordance with the shape of the chamber302.

A plurality of exhaust holes392are provided at a bottom of the exhaust buffer structure386. Gases supplied into the process chamber301are exhausted through the plurality of exhaust holes392. Each of the gases is exhausted through the plurality of exhaust holes392via the exhaust groove388and the exhaust buffer space389.

Detector

Subsequently, a detector (which is a detecting structure) configured to detect a rotation state of the substrate support317will be described mainly with reference toFIGS.2,3,4,5,6,7and8.

FIGS.3and4are diagrams schematically illustrating a first specific example of the detector in the substrate processing apparatus200according to the present embodiments.FIGS.5and6are diagrams schematically illustrating a second specific example of the detector in the substrate processing apparatus200according to the present embodiments.FIGS.7and8are diagrams schematically illustrating a third specific example of the detector in the substrate processing apparatus200according to the present embodiments.

The substrate processing apparatus200according to the present embodiments includes the detector configured to detect the rotation state of the substrate support317in the chamber302. The rotation state of the substrate support317may refer to a state of the substrate placing plate318and a state of the shaft322when the substrate placing plate318is rotated around the shaft322as the rotation axis. More specifically, the rotation state of the substrate support317refers to, in particular, a presence or absence of an abnormality in the state of the substrate placing plate318when the substrate placing plate318is rotated. For example, the abnormality may include a tilt of the rotation axis, a bending of the substrate placing plate318, a rotational fluctuation of the substrate placing plate318and the like when the substrate placing plate318is rotated.

For example, as shown inFIGS.3and4, the chamber302may include a sensor361(which serves as the detector) configured to detect a position of an edge318a. The edge318ais an outer circumferential edge of the substrate placing plate318. For example, the sensor361is configured as a transmissive photoelectric sensor in which a light emitter and a light receiver are arranged such that a sensing light passes along a side of the edge318a. However, as long as it is possible to detect the position of the edge318a, a reflective photoelectric sensor may be used as the sensor361instead of the transmissive photoelectric sensor. Further, as long as it is possible to detect the position of the edge318a, a sensor of another detection type (for example, a proximity sensor) may be used as the sensor361instead of a photoelectric sensor such as the transmissive photoelectric sensor.

By the sensing light passing along the side of the edge318aof the substrate placing plate318, the sensor361is configured to be capable of detecting a presence or absence of the edge318aof the substrate placing plate318. Therefore, for example, as shown inFIG.4, in a case where the rotation axis tilts when the substrate placing plate318is rotated, since the edge318ablocks the sensing light, the tilt of the rotation axis is detected by the sensor361.

Further, it is preferable that a plurality of sensors including the sensor361are arranged in the circumferential direction in accordance with an outer peripheral shape of the substrate placing plate318. Hereinafter, the plurality of sensors including the sensor361may also be simply referred to as “sensors361”. By providing the sensors361in a manner described above, it is possible to detect the tilt of the rotation axis regardless of any tilting direction. However, as long as a directional dependency of a tilt detection can be eliminated, there is no particular limit to the number of the sensors361arranged in a manner described above.

Further, for example, as shown inFIGS.5and6, the chamber302may include a sensor362(which serves as the detector) arranged such that the sensing light passes along a plate surface of the substrate placing plate318(in particular, a lower surface318blocated opposite to the substrate placing surface311). For example, the sensor362is configured as a transmissive photoelectric sensor in which a light emitter and a light receiver are arranged such that the sensing light passes along the lower surface318bin the vicinity of the lower surface318bof the substrate placing plate318. However, as long as it is possible to detect a position of the lower surface318bof the substrate placing plate318, a reflective photoelectric sensor may be used as the sensor362instead of the transmissive photoelectric sensor. Further, as long as it is possible to detect the position of the plate surface (lower surface318b) of the substrate placing plate318, a sensor of another detection type (for example, a proximity sensor) may be used as the sensor362instead of a photoelectric sensor such as the transmissive photoelectric sensor.

By the sensing light passing along the vicinity of the plate surface of the substrate placing plate318, the sensor362is configured to be capable of detecting a presence or absence of the plate surface of the substrate placing plate318. Therefore, for example, as shown inFIG.6, in a case where the rotation axis tilts when the substrate placing plate318is rotated, since the lower surface318bof the substrate placing plate318blocks the sensing light, the tilt of the rotation axis is detected by the sensor362. Further, not only in the case where the rotation axis tilts, but also in a case where the substrate placing plate318bends (that is, the substrate placing plate318sags in the direction of gravity), since the lower surface318bof the substrate placing plate318blocks the sensing light, the bending of the substrate placing plate318is detected by the sensor362.

Further, for example, as shown inFIGS.7and8, the chamber302may include a sensor363(which serves as the detector) configured to detect a distance (gap318c) between the substrate placing plate318and the heater380. For example, the sensor363is configured as a laser length measurement sensor disposed in the vicinity of the heater380and configured to detect a distance from a position thereof to the lower surface of the substrate placing plate318. However, as long as it is possible to detect a size of the gap318c, a sensor of another detection type (for example, a proximity sensor) may be used as the sensor363instead of the laser length measurement sensor.

By detecting the distance between the substrate placing plate318and the heater380, the sensor363is configured to be capable of detecting whether the size of the gap318cis constant (that is, whether a predetermined size is maintained). Therefore, for example, as shown inFIG.8, in a case where the rotation axis tilts when the substrate placing plate318is rotated, since the distance between the substrate placing plate318and the heater380varies, the tilt of the rotation axis is detected by the sensor363. Further, not only in the case where the rotation axis tilts, but also in a case where the substrate placing plate318bends (that is, the substrate placing plate318sags in the direction of gravity), since the distance between the substrate placing plate318and the heater380varies, the bending of the substrate placing plate318is detected by the sensor363.

As described above, the detector is configured to detect the tilt of the substrate placing plate318, the bending of the substrate placing plate318or both of the tilt and the bending of the substrate placing plate318. As long as it is possible to detect the tilt, the bending or both of the tilt and the bending, the detector may include one of the sensors361,362and363described above, or may include an appropriate combination of two or more of the sensors361,362and363. By appropriately combining the sensors361,362and363, it is possible to reliably detect both of the tilt and the bending of the substrate placing plate318.

A detection of the tilt, the bending or the like of the substrate placing plate318is not limited to that using the sensors361,362and363described above, and may be performed as follows. For example, the detector may include a sensor configured to detect a distance (gap) (or distances (gaps)) between the substrate placing plate318and at least one among nozzles341,342,344and345of a gas supplier described later. Such a sensor may be configured in the same manner as the sensor363described above. Even with such a configuration, the detector is configured to detect the tilt, the bending or the like of the substrate placing plate318.

As long as it is possible to detect the rotation state of the substrate support317, the detector is not limited to that configured to detect the tilt, the bending or the like of the substrate placing plate318. For example, the detector may be configured to detect the rotational fluctuation when the substrate placing plate318is rotated, as the rotation state of the substrate support317. A detection of the rotational fluctuation may be performed in addition to the detection of the tilt, the bending or the like of the substrate placing plate318, or may be performed instead of the detection of the tilt, the bending or the like of the substrate placing plate318.

As an example of the detector configured to detect the rotational fluctuation, for example, by using the rotation meter319fof the elevator/rotator319shown inFIG.2, the detector is configured to monitor the number of rotations or the rotation speed when the substrate placing plate318is rotated and to detect an occurrence of the rotational fluctuation when a change in the number of rotations or the rotation speed exceeds a pre-set allowable value.

Further, as another example of the detector configured to detect the rotational fluctuation, for example, in a case where the operating structure319bof the elevator/rotator319shown inFIG.2includes an electric motor serving as a drive source configured to rotate the shaft322and the support shaft319a, the detector is configured to monitor an amount of the power supplied to the electric motor and to detect the occurrence of the rotational fluctuation when a change in the power exceeds a pre-set allowable value.

The detector may perform the following detection of the rotation state of the substrate support317. For example, the detector may include a vibration sensor configured to detect a vibration of the shaft322and a variation of the support shaft319awhen the substrate placing plate318is rotated. In such a case, by comparing a magnitude of a vibration value from the vibration sensor with a pre-set threshold value, it is possible to detect signs such as a defect in a bearing (such as a fluid seal) of the shaft322or the support shaft319a, an eccentricity of the rotation axis and the like. Thereby, it is possible to indirectly detect the rotation state of the substrate support317.

Gas Supplier

Subsequently, the gas supplier (which is a gas supply structure or a gas supply system) configured to supply the gases into the chamber302will be described mainly with reference toFIGS.1and9A through9C.FIGS.9A through9Care diagrams schematically illustrating exemplary configurations of the gas supplier in the substrate processing apparatus200according to the present embodiments.

The nozzles341,342,344and345are provided in the chamber302. A location indicated by a reference character “A” shown inFIG.1is connected to a location indicated by a reference character “A” shown inFIG.9A. That is, the nozzle341is connected to a supply pipe241. A location indicated by a reference character “B” shown inFIG.1is connected to a location indicated by a reference character “B” shown inFIG.9B. That is, the nozzle342is connected to a supply pipe251. A location indicated by a reference character “C” shown inFIG.1is connected to a location indicated by a reference character “C” shown inFIG.9C. That is, each of the nozzles344and345is connected to a supply pipe261.

FIG.9Ais a diagram schematically illustrating an exemplary configuration of a first gas supplier (which is a first gas supply structure or a first gas supply system)240serving as a part of the gas supplier. A first gas supply source242, a mass flow controller (MFC)243serving as a flow rate controller (flow rate control structure) and a valve244serving as an opening/closing valve are sequentially provided at the supply pipe (first gas supply pipe)241of the first gas supplier240in this order from an upstream side to a downstream side of the first gas supply pipe241in a gas flow direction.

A gas containing a first element (hereinafter, also referred to as the “first gas”) is mainly supplied through the first gas supply pipe241of the first gas supplier240. That is, the first gas is supplied to the nozzle341through the MFC243, the valve244and the first gas supply pipe241. Then, the first gas is supplied to the first process region306athrough nozzle341.

The first gas is one of process gases, and refers to a source gas containing the first element. According to the present embodiments, for example, the first element is silicon (Si). That is, the first gas is a silicon gas (also referred to as a “silicon-containing gas”) which is a gas containing silicon as a primary component. Specifically, dichlorosilane (SiH2Cl2, abbreviated as DCS) gas may be used as the silicon-containing gas.

The first gas supplier240is constituted mainly by the first gas supply pipe241, the MFC243, the valve244and the nozzle341. The first gas supplier240may further include the first gas supply source242.

FIG.9Bis a diagram schematically illustrating an exemplary configuration of a second gas supplier (which is a second gas supply structure or a second gas supply system)250serving as a part of the gas supplier. A second gas supply source252, a mass flow controller (MFC)253serving as a flow rate controller (flow rate control structure) and a valve254serving as an opening/closing valve are sequentially provided at the supply pipe (second gas supply pipe)251of the second gas supplier250in this order from an upstream side to a downstream side of the second gas supply pipe251in the gas flow direction.

A reactive gas reacting with the first gas (hereinafter, also referred to as the “second gas”) is mainly supplied through the second gas supply pipe251of the second gas supplier250. That is, the second gas is supplied to the nozzle342through the MFC253, the valve254and the second gas supply pipe251. Then, the second gas is supplied to the second process region306bthrough nozzle342.

The second gas is one of the process gases. For example, the second gas refers to a nitrogen-containing gas containing nitrogen (N) as a primary component. For example, ammonia (NH3) gas may be used as the nitrogen-containing gas.

The second gas supplier250is constituted mainly by the second gas supply pipe251, the MFC253, the valve254and the nozzle342. The second gas supplier250may further include the second gas supply source252. Since the second gas supplier250is configured to supply the reactive gas, the second gas supplier250may also be referred to as a “reactive gas supplier”250which is a reactive gas supply structure or a reactive gas supply system.

FIG.9Cis a diagram schematically illustrating an exemplary configuration of a purge gas supplier (which is a purge gas supply structure or a purge gas supply system)260serving as a part of the gas supplier. The purge gas supplier260may also be referred to as an “inert gas supplier260” which is an inert gas supply structure or an inert gas supply system. A purge gas supply source262, a mass flow controller (MFC)263serving as a flow rate controller (flow rate control structure) and a valve264serving as an opening/closing valve are sequentially provided at the supply pipe (purge gas supply pipe)261of the purge gas supplier260in this order from an upstream side to a downstream side of the purge gas supply pipe261in the gas flow direction.

The purge gas (inert gas) is supplied through the purge gas supply pipe261of the purge gas supplier260. That is, the purge gas is supplied to each of the nozzle344and the nozzle345through the MFC263, the valve264and the purge gas supply pipe261. Then, the purge gas is supplied to the first purge region307athrough the nozzle344, and is supplied to the second purge region307bthrough the nozzle345.

The purge gas refers to a gas that does not react with the first gas and the second gas. An inner atmosphere of the process chamber301can be purged by the purge gas. For example, nitrogen (N2) gas may be used as the purge gas.

The purge gas supplier260is constituted mainly by the purge gas supply pipe261, the MFC263, the valve264, the nozzle344and the nozzle345. The purge gas supplier260may further include the purge gas supply source262.

The first gas supplier240and the second gas supplier250may also be collectively or individually referred to as a “process gas supplier” which is a process gas supply structure or a process gas supply system. The process gas supplier may further include the purge gas supplier260.

Subsequently, a gas exhauster (which is a gas exhaust structure or a gas exhaust system) configured to exhaust the gases from the chamber302will be described mainly with reference toFIGS.1and2.

The plurality of exhaust holes392are provided at a lower portion of the chamber302. The plurality of exhaust holes392are provided for each process region306. For example, an exhaust hole392aamong the exhaust holes392is provided at a location corresponding to the first process region306a, and an exhaust hole392bamong the exhaust holes392is provided at a location corresponding to the second process region306b.

An exhaust pipe334aserving as a part of a first exhauster (which is a first exhaust structure)334is provided so as to communicate with the exhaust hole392a. A vacuum pump334bserving as a vacuum exhaust apparatus is connected to the exhaust pipe334avia a valve334dserving as an opening/closing valve and an APC (Automatic Pressure Controller) valve334cserving as a pressure regulator (which is a pressure adjusting structure). The vacuum pump334bis configured to vacuum-exhaust the inner atmosphere of the process chamber301such that an inner pressure of the process chamber301reaches and is maintained at a predetermined pressure (vacuum degree). The exhaust pipe334a, the valve334dand the APC valve334cmay also be collectively referred to as the first exhauster334. The first exhauster334may further include the vacuum pump334b.

Similarly, a second exhauster (which is a second exhaust structure)335is connected to the exhaust hole392bso as to communicate with the exhaust hole392a. An exhaust pipe335a, a valve335dand an APC valve335cmay also be collectively referred to as the second exhauster335. The second exhauster335may further include a vacuum pump335b. In addition, the first exhauster334and the second exhauster335may also be collectively referred to as the “gas exhauster”.

Controller

The substrate processing apparatus200configured as described above is controlled by the controller400serving as a control structure (control apparatus). Hereinafter, the controller400will be described mainly with reference toFIG.10.FIG.10is a block diagram schematically illustrating an exemplary functional configuration of the controller400and related components of the substrate processing apparatus200according to the present embodiments.

The substrate processing apparatus200includes the controller400configured to control operations of components of the substrate processing apparatus200such as the gas supplier, the elevator/rotator319, the valves described above and the MFCs described above. The controller400includes at least a CPU (Central Processing Unit)401serving as an arithmetic processor, a RAM (Random Access Memory)402serving as a temporary memory, a memory403and a transmitter/receiver404. The controller400is connected to the components of the substrate processing apparatus200via the transmitter/receiver404, calls a program or a recipe from the memory403in accordance with an instruction from a host controller or a user, and controls the operations of the components of the substrate processing apparatus200in accordance with the contents of the instruction. For example, the controller400may be embodied by a dedicated computer or by a general-purpose computer. According to the present embodiments, for example, the controller400may be embodied by preparing an external memory412storing the program and by installing the program onto the general-purpose computer using the external memory412. For example, the external memory412may include a magnetic tape, a magnetic disk such as a flexible disk and a hard disk, an optical disk such as a CD and a DVD, a magneto-optical disk such as an MO and a semiconductor memory such as a USB memory (USB flash drive) and a memory card. A method of providing the program to the computer is not limited to that using the external memory412. For example, the program may be supplied to the computer (general-purpose computer) using a communication interface such as the Internet and a dedicated line. The program may also be provided to the computer without using the external memory412by receiving information (that is, the program) from a host apparatus420via a transmitter/receiver411. In addition, a user can input an instruction to the controller400using an input/output device413such as a keyboard and a touch panel.

According to the present embodiments, the memory403or the external memory412may be embodied by a non-transitory computer readable recording medium. Hereafter, the memory403and the external memory412may 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 memory412alone, or may refer to both of the memory403and the external memory412.

Subsequently, a procedure of performing the substrate processing (which is a part of a manufacturing process of a semiconductor device) using the substrate processing apparatus200configured as described above will be described. The substrate processing will be described by way of an example in which a silicon nitride film (SiN film) is formed as a film on the substrate100using the silicon-containing gas as the first gas and the NH3gas as the second gas.

Hereinafter, the substrate processing will be described mainly with reference toFIG.11.FIG.11is a flow chart schematically illustrating an exemplary sequence of the substrate processing performed by the substrate processing apparatus200according to the present embodiments. In the following description, the operations of the components constituting the substrate processing apparatus200are controlled by the controller400.

Substrate Loading and Placing Step

In the substrate processing, first, a substrate loading and placing step is performed. InFIG.11, the illustration of the substrate loading and placing step is omitted.

In the substrate loading and placing step, the concave structure312is moved to a position adjacent to the gate valve305by rotating the substrate placing plate318. Then, the substrate100is placed on one of the substrate placing surfaces311from a transfer chamber by using the wafer transfer structure500.

After the substrate100is placed on the above-mentioned one of the substrate placing surfaces311, the substrate placing plate318is rotated until another one of the substrate placing surfaces311, where the substrate100is not placed, faces the gate valve305. Thereafter, another one of the substrates100is placed on the above-mentioned another one of the substrate placing surfaces311. An operation described above is repeatedly performed until the substrates100are placed on an entirety of the substrate placing surfaces311.

When the substrate100is placed on the substrate placing plate318, the electric power is supplied to the heater380in advance such that a temperature (surface temperature) of the substrate100is adjusted to a predetermined temperature. For example, the predetermined temperature of the substrate100according to the present embodiments may be set to a temperature of 400° C. or more and 500° C. or less. The heat radiated from the heater380is applied to a back surface of the substrate100via the substrate placing plate318. It is preferable that the electric power is continuously supplied to the heater380from the substrate loading and placing step until at least a substrate unloading step described later is completed.

Step of Starting Rotation of Substrate Placing Plate

After the substrates100are placed on an entirety of the concave structures312, a step S110of starting the rotation of the substrate placing plate318is performed. In the step S110of starting the rotation of the substrate placing plate318, the controller400controls the elevator/rotator319to rotate the substrate placing plate318in the direction “R” shown inFIG.1. By rotating the substrate placing plate318, the substrate100is moved to the first process region306a, the first purge region307a, the second process region306band the second purge region307bsequentially in this order.

Step of Starting Supply of Gas

When the substrate100is heated to a desired temperature in the substrate loading and placing step and when the rotation speed of the substrate placing plate318reaches and is maintained at a desired rotation speed in the step S110of starting the rotation of the substrate placing plate318, a step S120of starting a supply of the gas is then performed. In the step S120of starting the supply of the gas, the valve244is opened to start a supply of the silicon-containing gas into the first process region306a. In parallel with the supply of the silicon-containing gas, the valve254is opened to start a supply of the NH3gas into the second process region306b.

In the present step, a flow rate of the silicon-containing gas is adjusted by the MFC243to a predetermined flow rate. For example, the predetermined flow rate of the silicon-containing gas may be set to a flow rate of 50 sccm or more and 500 sccm or less.

Further, in the present step, a flow rate of the NH3gas is adjusted by the MFC253to a predetermined flow rate. For example, the predetermined flow rate of the NH3gas may be set to a flow rate of 100 sccm or more and 5,000 sccm or less.

In addition, after the substrate loading and placing step, the process chamber301is exhausted by the first exhauster334and the second exhauster335, and the N2gas serving as the purge gas is supplied into the first purge region307aand the second purge region307bthrough the purge gas supplier260.

Film Forming Step

Subsequently, a film forming step S130is performed. In the film forming step S130, a silicon-containing layer is formed on the substrate100in the first process region306a. After the substrate100is rotated to the second process region306b, by reacting the silicon-containing layer with the NH3gas in the second process region306b, the silicon containing film (such as the SiN film) is formed on the substrate100. Then, the substrate placing plate318is rotated a predetermined number of times such that the silicon containing film (such as the SiN film) on the substrate100is obtained with a desired thickness.

Step of Stopping Supply of Gas

After the substrate placing plate318is rotated the predetermined number of times in the film forming step S130, a step S140of stopping the supply of the gas is performed. In the step S140of stopping the supply of the gas, the valve244is closed to stop the supply of the silicon-containing gas to the first process region306aand the valve254is closed to stop the supply of the NH3gas to the second process region306b.

Step of Stopping Rotation of Substrate Placing Plate

After the step S140of stopping the supply of the gas, a step S150of stopping the rotation of the substrate placing plate318is performed. In the step S150of stopping the rotation of the substrate placing plate318, the rotation of the substrate placing plate318is stopped.

Substrate Unloading Step

After the step S150of stopping the rotation of the substrate placing plate318, the substrate unloading step is performed. InFIG.11, the illustration of the substrate unloading step is omitted.

In the substrate unloading step, the substrate placing plate318is rotated to move the substrate100(which is to be unloaded) to the position adjacent to the gate valve305. Thereafter, the substrate100to be unloaded is transferred (unloaded) out of the chamber302in a manner reverse to that of the substrate loading and placing step. An operation described above is repeatedly performed until an entirety of the substrates100are unloaded out of the chamber302.

(3) Rotation Control Process

As described above, in the substrate processing, by rotating the substrate placing plate318, each of the substrates100on the substrate placing plate318is processed. Therefore, depending on a rotation state of the substrate placing plate318, for example, a processing quality of each of the substrates100may vary.

For example, in a case where the rotation axis of the substrate placing plate318tilts, the substrate placing surface311on the substrate placing plate318also tilts accordingly. In such a sate, when the substrate placing plate318is rotated, the tilt may cause variations in a distance such as a distance between the substrate100on the substrate placing surface311and the heater380and a distance between the substrate100and at least one among the nozzles341,342,344and345configured to supply the gas. In such a case, a substrate processing state may differ between each of the substrates100placed on the substrate placing plate318or may differ between lots of the substrates100to be processed. As a result, the processing quality of each of the substrates100may vary.

Further, when the heat from the heater380accumulates, the substrate placing plate318may bend. When the substrate placing plate318is bent, similar to the case of the tilt described above, the substrate processing state may differ between each of the substrates100or may differ between the lots of the substrates100. As a result, the processing quality of each of the substrates100may vary.

Further, in a case where the rotational fluctuation (such as a fluctuation in the rotation speed) occurs when the substrate placing plate318is rotated, a time for the substrate100to pass through each of the regions306a,307a,306band307bmay vary. Then, for example, an amount of the gas exposed to the substrate100may vary. For example, an amount of a particular gas exposed to the substrate100may increase and an amount of another gas exposed to the substrate100may decrease. Then, the substrate processing state may differ between each of the substrates100or may differ between the lots of the substrates100. As a result, the processing quality of each of the substrates100may vary.

That is, when there is the abnormality in the rotation state of the substrate placing plate318during the substrate processing, it may cause the variation in the processing quality of each of the substrates100. As a result, it may not be possible to obtain the substrate100with a desired processing quality.

Therefore, before performing the substrate processing, the substrate processing apparatus200according to the present embodiments is configured to perform a rotation control process using the detector under control of the controller400, as described below. The rotation control process is a process in which the detector monitors the rotation state of the substrate support317and controls the rotation state of the substrate support317based on a monitoring result. After the rotation control process is performed, the substrate processing including the supply of the gas into the process chamber301is performed.

Monitoring

In the rotation control process, first, the rotation state of the substrate support317is monitored (that is, a rotation state monitoring of the substrate support317is performed). The rotation state monitoring is performed using the detector. Specifically, in the rotation state monitoring serving as a rotation state detection method, a step of rotating the substrate placing plate318of the substrate support317and a step of detecting the rotation state of the substrate support317using the detector are performed.

For example, in a case where the detector includes the sensor361, as shown inFIG.4, when the rotation axis of the substrate placing plate318tilts, such a tilt is detected by the sensor361. Therefore, by monitoring a result (detection result) detected by the sensor361, it is possible to detect the presence or absence of the abnormality in the rotation state of the substrate placing plate318(in particular, the tilt of the rotation axis thereof). In particular, when the detector includes the plurality of sensors361, it is possible to detect the presence or absence of the abnormality in the rotation state with a high accuracy.

Further, for example, in a case where the detector includes the sensor362, as shown inFIG.6, when the rotation axis of the substrate placing plate318tilts, such a tilt is detected by the sensor362. The same also applies to a case where the substrate placing plate318bends (that is, the substrate placing plate318sags in the direction of gravity). Therefore, by monitoring a result (detection result) detected by the sensor362, it is possible to detect the presence or absence of the abnormality in the rotation state of the substrate placing plate318(in particular, the tilt of the rotation axis thereof and the bending of the substrate placing plate318).

Further, for example, in a case where the detector includes the sensor363, as shown inFIG.8, when the rotation axis of the substrate placing plate318tilts or when the substrate placing plate318bends (that is, the substrate placing plate318sags in the direction of gravity), the distance318cbetween the substrate placing plate318and the heater380becomes non-constant (non-uniform), and such a state is detected by the sensor363. Therefore, by monitoring a result (detection result) detected by the sensor363, it is possible to detect the presence or absence of the abnormality in the rotation state of the substrate placing plate318(in particular, a variation in the distance from the heater380due to the tilt of the rotation axis thereof or the bending of the substrate placing plate318). For example, the same also applies to a case where a distance detection of the gap between the substrate placing plate318and at least one among the nozzles341,342,344and345is performed.

Further, for example, in a case where the number of rotations or the rotation speed of the substrate placing plate318is monitored by the rotation meter319fserving as the detector or in a case where the amount of the power supplied to the electric motor of the operating structure319b, when the occurrence of the rotational fluctuation of the substrate placing plate318is monitored, such a state is detected. Therefore, by monitoring a result (detection result) using the detector, it is possible to detect the presence or absence of the abnormality in the rotation state of the substrate placing plate318(for example, the rotational fluctuation due to a motor trouble).

In addition, for example, in a case where the detector includes the vibration sensor, when the defect in the bearing (such as a fluid seal) of the shaft322or the support shaft319aoccurs or when the eccentricity of the rotation axis occurs, such a state is detected by the vibration sensor. Therefore, by monitoring a result (detection result) detected by the vibration sensor, it is possible to detect the presence or absence of the abnormality in the rotation state of the substrate placing plate318(in particular, the defect in the bearing or the eccentricity of the rotation axis).

The rotation state monitoring of the substrate support317may be performed by using at least one among the examples mentioned above, and preferably, by using the examples mentioned above.

Execution Timing

The rotation state monitoring of the substrate support317may be performed at an execution timing described below.

As an example of the execution timing for the rotation state monitoring, the detector may detect the rotation state of the substrate support317before the apparatus (that is, the substrate processing apparatus200) is started up. The term “before the apparatus is started up” refers to a time before the substrate processing is started in the substrate processing apparatus200. Specifically, the rotation state of the substrate support317is detected before the substrate processing apparatus200starts operating (for example, when a test run of the substrate processing apparatus200is performed). By detecting the rotation state at such an execution timing, even when a difference in the rotation state occurs due to a machine difference in the substrate processing apparatus200, it is possible to accurately grasp the difference due to the machine difference.

The rotation state monitoring may be performed while the substrate processing apparatus200is in operation.FIG.12is a diagram schematically illustrating specific examples of the execution timing of the rotation state monitoring while operating the substrate processing apparatus200according to the present embodiments.

For example, consider a case where the rotation state monitoring of the substrate support317is performed from an upper side of the substrate support317, such as by detecting the distance (gap) between the substrate support317(that is, the substrate placing plate318) and at least one among the nozzles341,342,344and345. In such a case, the rotation state monitoring of the substrate support317may be performed at at least one selected from the group of: a timing before the substrate placing plate318supports the substrate100in the substrate loading and placing step; a timing at which the substrate placing plate318supports the substrate100in the substrate loading and placing step; a timing at which the rotation of the substrate placing plate318starts in the step S110of starting the rotation of the substrate placing plate318; and a timing after the film is formed on the substrate100in the film forming step S130.

Further, for example, consider a case where the rotation state monitoring of the substrate support317is performed from the position of the heater380, such as by detecting the distance (gap) between the substrate support317(that is, the substrate placing plate318) and the heater380. In such a case, similarly, the rotation state monitoring of the substrate support317may be performed at at least one selected from the group of: the timing before the substrate placing plate318supports the substrate100in the substrate loading and placing step; the timing at which the substrate placing plate318supports the substrate100in the substrate loading and placing step; the timing at which the rotation of the substrate placing plate318starts in the step S110of starting the rotation of the substrate placing plate318; and the timing after the film is formed on the substrate100in the film forming step S130.

Further, for example, consider a case where the rotation state monitoring of the substrate support317is performed mainly based on the rotation axis of the substrate placing plate318, such as by using the sensor361or the sensor362. In such a case, similarly, the rotation state monitoring of the substrate support317may be performed at at least one selected from the group of: the timing before the substrate placing plate318supports the substrate100in the substrate loading and placing step; the timing at which the substrate placing plate318supports the substrate100in the substrate loading and placing step; the timing at which the rotation of the substrate placing plate318starts in the step S110of starting the rotation of the substrate placing plate318; a timing at which the film is being formed on the substrate100in the film forming step S130; and the timing after the film is formed on the substrate100in the film forming step S130.

When the rotation state is detected at such timings exemplified above, even when a change in the rotation state occurs over time while the substrate processing apparatus200is in operation, it is possible to accurately grasp the change.

When the rotation state monitoring is performed while the substrate processing apparatus200is in operation, it is preferable to detect the rotation state of the substrate support317with the gas being supplied through the gas supplier. In the present embodiments, the gas may refer to one of the process gases or may refer to the inert gas. More specifically, when detecting the rotation state of the substrate support317, the gas is supplied to the process chamber301such that a pressure in the process chamber301reaches a pressure at which the substrate100is processed in the process chamber301. For example, when the rotation state is detected under the same conditions as when the substrate100is processed in the substrate processing, it is possible to detect the rotation state with a high accuracy. For example, when an apparatus maintenance work is performed, the inner pressure of the process chamber301may be lower than during the substrate processing. In such a case, the rotation state of the substrate support317may be different from that during the substrate processing when the rotation state monitoring is performed. In consideration of such a case, it is preferable to monitor the rotation state of the substrate support317under the same conditions (environment) as when the substrate processing is performed.

Control of Rotation State

After the rotation state monitoring is performed, the controller400serving as the control structure controls the rotation state of the substrate support317based on the detection result by the detector obtained by the rotation state monitoring.

Specifically, the controller400controls the rotation state of the substrate support317to be constant based on the detection result by the detector. For example, when parameters (such as the tilt of the rotation axis of the substrate placing plate318, the bending of the substrate placing plate318, the distance between the substrate placing plate318and the heater380, the distance between the substrate placing plate318and at least one among the nozzles341,342,344and345and the rotational fluctuation of the substrate placing plate318) are respectively within predetermined allowable ranges and are maintained in such a state, it can be said that the rotation state of the substrate support317is constant.

For example, when the detector detects the abnormality in which the number of rotations or the rotation speed of the substrate placing plate318goes beyond the allowable range related thereto, the controller400issues an operation instruction to the operating structure319bof the elevator/rotator319to recover from the abnormality (rotation abnormality), that is, to limiting the rotation within the allowable range related thereto. When the rotation of the substrate placing plate318slows down, the time duration for the substrate100to pass through each of the regions306a,307a,306band307bmay increase, and thereby, a substrate processing time in each of the regions306a,307a,306band307bmay also increase. As a result, a desired processing may not be achieved for each of the substrates100. In contrast, when the substrate placing plate318is controlled to maintain a constant rotation, a gas supply amount in each of the regions306a,307a,306band307bcan be maintained constant, and the desired processing can be achieved for each of the substrates100. When such a control of the rotation state is performed based on the detection result obtained by the rotation state monitoring before the apparatus is started up, it is possible to eliminate the rotation abnormality caused by the machine difference in the substrate processing apparatus200, and it is also possible to start up the apparatus in a state where such a machine difference is taken into consideration. Further, when such a control of the rotation state is performed based on the detection result obtained by the rotation state monitoring when the apparatus is in operation, it is possible to appropriately respond to the rotation abnormality which may occur due to the change over time.

In addition, for example, in a case where the heater380is divided into the plurality of zones, when the detector detects the abnormality in which the tilt of the rotation axis of the substrate placing plate318goes beyond the allowable range related thereto, the controller400issues an operation instruction to the heater temperature controller387to lower a heater temperature in the zone where the distance between the substrate placing plate318and the heater380is close. The same also applies to a case where the abnormality in which the bending of the substrate placing plate318occurs is detected, or a case where the abnormality in which the distance between the substrate placing plate318and the heater380goes beyond the allowable range related thereto is detected. By performing such a heater zone control described above, it is possible to recover from the rotation abnormality of the substrate placing plate318, and it is also possible to perform the desired processing for each of the substrates100.

In addition, for example, in a case where the posture controller350is provided, when the detector detects the abnormality in which the tilting of the rotation axis of the substrate placing plate318goes beyond the allowable range related thereto, the controller400issues an operation instruction to the tilt regulator353to adjust the posture of the substrate support317(in particular, the tilt of the rotation axis caused by the shaft322). By performing a control to adjust an angle of the rotation axis, it is possible to set the substrate support317to be at a predetermined substrate processing angle (that is, to set the angle of the rotation axis within the allowable range related thereto). Thereby, it is possible to recover from the rotation abnormality of the substrate placing plate318. When such a control of the posture is performed based on the detection result obtained by the rotation state monitoring before the apparatus is started up, it is possible to eliminate the rotation abnormality caused by the machine difference in the substrate processing apparatus200, and it is also possible to start up the apparatus in a state where such a machine difference is taken into consideration. In particular, the tilt of the rotation axis of the substrate placing plate318is likely to occur due to the machine difference of the substrate processing apparatus200for the convenience of manufacturing the apparatus. However, such a tilt (that is, a difference in a degree of the tilt) can be absorbed by the control of the posture. Further, when such a control of the posture is performed based on the detection result obtained by the rotation state monitoring when the apparatus is in operation, it is possible to appropriately respond to the rotation abnormality which may occur due to the change over time.

In addition, for example, in a case where the posture controller350is provided, the controller400may use a machine learning to control the posture of the substrate support317by the posture controller350. When the machine learning is used, a storage (memory or a recording structure) configured to store and accumulate information about the detection result by the detector may be prepared in the controller400or in a location accessible to the controller400. For example, the information stored and accumulated in the storage (that is, the information about the detection result by the detector) may include: information about the rotation state of the substrate placing plate318identified from the detection result by the detector; information about process conditions of the substrate processing when the information stored in the storage was obtained; information about a processing result of the substrate processing; and the like. Then, based on the information stored in the storage, the controller400analyzes the rotation state of the substrate placing plate318and an apparatus operation history (an execution history of the substrate processing) by the machine learning, and identifies model data about the posture of the substrate support317from an analysis result. Once the model data has been identified, the controller400issues an operation instruction to the tilt regulator353to adjust the posture of the substrate support317(in particular, the tilt of the rotation axis caused by the shaft322) based on the model data identified as described above prior to a start of a subsequent substrate processing. In a manner described above, by using the machine learning to control the posture of the substrate support317, it is possible to reflect other information (such as a history information) in addition to the detection result by the detector for the control ‘the posture, which is preferable for appropriately performing the substrate processing.

When the detector detects the abnormality in the rotation state of the substrate support317, in addition to or instead of the control mentioned above, the controller400may perform a transfer control such that the substrate100transferred into the process chamber301is unloaded from the process chamber301. By performing such a transfer control of unloading of the substrate100in a manner described above, it is possible to distinguish a substrate (which may not have been subjected to the desired processing due to the abnormality in the rotation state) among the substrates100from a normal substrate among the substrates100.

(4) Effects According to Present Embodiments

According to the present embodiments, it is possible to obtain one or more of the effects described below.(a) According to the present embodiments, when each of the substrates100is processed while rotating the substrate support317supporting the substrates100, the detector detects the rotation state of the substrate support317. Thus, even when the abnormality occurs in the rotation state of the substrate support317, such an abnormality is detected by the detector. Thereby, it is possible to eliminate effects of the abnormality in the rotation state causing the variation in the processing quality of each of the substrates100when each of the substrates100is processed. In other words, when the plurality of substrates100are processed while being rotated, it is possible to obtain the desired processing quality for each of the substrates100.(b) According to the present embodiments, the heater380is disposed so as to face the substrate placing plate318serving as a rotator constituting the substrate support317, and the detector detects the rotation state of the substrate placing plate318. Thus, when the abnormality occurs in the rotation state of the substrate placing plate318, a variation may occur in a relationship between the heater380and each of the substrates100on the substrate placing plate318. However, such an abnormality is detected by the detector. Therefore, it is possible to eliminate effects of such a variation. In other words, when the plurality of substrates100placed on the substrate placing plate318are processed while rotating the substrate placing plate318, it is possible to obtain the desired processing quality for each of the substrates100.(c) According to the present embodiments, as described above, when the detector includes at least one selected from the group of the sensor361(which is configured to detect the position of the edge318aof the substrate placing plate318), the sensor362(which is arranged such that the sensing light passes along the plate surface of the substrate placing plate318) and the sensor363(which is configured to detect the distance (gap318c) between the substrate placing plate318and the heater380, it is possible to reliably detect the tilt or the bending of the substrate placing plate318.(d) According to the present embodiments, as described above, when the detector is configured to detect the change in the power supplied to the electric motor, it is possible to reliably detect the rotational fluctuation when the substrate placing plate318is rotated.(e) According to the present embodiments, based on the detection result by the detector, the controller400controls the rotation state of the substrate support317. Therefore, even when the abnormality occurs in the rotation state of the substrate support317, it is possible to process each of the substrates100while controlling the rotation state to prevent the variation in the processing quality due to the abnormality in the rotation state. Thereby, it is possible to obtain the desired processing quality for each of the substrates100.(f) According to the present embodiments, as described above, when the rotation state monitoring of obtaining the detection result (which is detected by the detector before the apparatus is started up) is performed, even when the difference in the rotation state occurs due to the machine difference in the substrate processing apparatus200, it is possible to accurately grasp the difference due to the machine difference.(g) According to the present embodiments, in a case where the rotation state of the substrate support317is controlled, as described above, when the rotation state of the substrate support317is controlled to be constant, it is possible to reliably eliminate the effects of the abnormality causing the variation in the processing quality of each of the substrates100.(h) According to the present embodiments, as described above, in a case where the heater380is divided into the plurality of zones, when the temperature control is individually performed for each of the plurality of zones based on the detection result by the detector, it is possible to recover from the rotation abnormality of the substrate placing plate318and it is also possible to perform the desired processing on the substrate100.(i) According to the present embodiments, as described above, in a case where the posture controller350is provided, when the posture of the substrate support317(in particular, the tilt of the rotation axis caused by the shaft322) is adjusted based on the detection result by the detector to set the substrate support317to be at the predetermined substrate processing angle (that is, to set the angle of the rotation axis within the allowable range related thereto), it is possible to recover from the rotation abnormality of the substrate placing plate318. Further, when such a control of the posture is performed based on the detection result obtained by the rotation state monitoring before the apparatus is started up, it is possible to eliminate the rotation abnormality caused by the machine difference in the substrate processing apparatus200, and it is also possible to start up the apparatus in the state where the machine difference is taken into consideration.(j) According to the present embodiments, as described above, in a case where the detector detects the rotation state of the substrate support317with the gas being supplied through the gas supplier, it is possible to detect the rotation state under the same conditions as when the substrate100is processed in the substrate processing. Thereby, it is possible to detect the rotation state with a high accuracy.(k) According to the present embodiments, as described above, in a case where the detector detects the rotation state of the substrate support317, when the gas is supplied to the process chamber301such that the pressure in the process chamber301reaches a pressure at which the substrate100is processed in the process chamber301, it is possible to detect the rotation state under the same conditions as when the substrate100is processed in the substrate processing. Thereby, it is possible to detect the rotation state with a high accuracy.

(5) Modified Example and Other Embodiments

While the technique of the present disclosure is described in detail by way of the embodiments mentioned 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 mentioned above are described by way of an example in which the substrate placing plate318(on which the substrates100are placed) is rotated, that is, an example in which each of the substrates100revolves (is rotated) around a center of the substrate placing plate318. However, the technique of the present disclosure is not limited thereto. For example, each of the substrates100may be supported by the substrate placing plate318such that each of the substrates100can be rotated while revolving. In such a case, the substrate support317may include: a revolving structure (for example, the substrate placing plate318) configured to support the substrates100such that the substrates100can revolve around the center of the substrate placing plate318; and a rotating structure configured to support the substrates100such that each of the substrates100can be rotated around a center of each of the substrates100. The rotating structure may be configured using known technology. When the substrate support317includes the revolving structure and the rotating structure as described above, the detector is configured to be capable of detecting a rotation state of one of the revolving structure and the rotating structure, and preferably capable of detecting the rotation states of both of the revolving structure and the rotating structure. Thereby, it is possible to respond not only to the abnormality in the rotation state of the revolving structure but also to the abnormality in the rotation state of the rotating structure. Thus, it is extremely preferable for performing the desired processing on the substrate100.

For example, the embodiments mentioned above are described by way of an example in which the DCS gas is used as the source gas (first gas). However, the technique of the present disclosure is not limited thereto. For example, as the source gas, in addition to or instead of the DCS gas, a chlorosilane source gas containing a Si—Cl bond (silicon-chlorine bond) such as hexachlorodisilane (Si2C6, abbreviated as HCDS) gas, monochlorosilane (SiH3Cl, abbreviated as MCS) gas, trichlorosilane (SiHCl3, abbreviated as TCS) gas, tetrachlorosilane (SiCl4, abbreviated as STC) gas and octachlorotrisilane (Si3Cl8, abbreviated as OCTS) gas may be used.

For example, the embodiments mentioned above are described by way of an example in which the NH3gas is used as the reactive gas (second gas). However, the technique of the present disclosure is not limited thereto. For example, as the reactive gas, in addition to or instead of the NH3gas, a hydrogen nitride-based gas containing a N—H bond (nitrogen—hydrogen bond) such as diazene (N2H2) gas, hydrazine (N2H4) gas and N3H8gas may be used.

For example, the embodiments mentioned above are described by way of an example in which the N2gas is used as the inert gas. However, the technique of the present disclosure is not limited thereto. For example, as the inert gas, in addition to or instead of the N2gas, a rare gas such as argon (Ar) gas, helium (He) gas, neon (Ne) gas and xenon (Xe) gas may be used.

For example, the embodiments mentioned above are described by way of an example in which a film forming process of forming the film on the substrate100is performed as the substrate processing. However, the technique of the present disclosure is not limited thereto. For example, the technique of the present disclosure may also be applied to other processes as long as the supply and exhaust of the gas is preferably performed. For example, the technique of the present disclosure may also be applied to a process such as a diffusion process, an oxidation process, a nitridation process, an oxynitridation process, a reduction process, an oxidation-reduction process, an etching process and a heating process.

According to some embodiments of the present disclosure, it is possible to obtain a desired processing quality for each of the plurality of substrates even when the plurality of substrates are processed while being rotated.