Mixed gas multiple line supply system and substrate processing apparatus using same

A mixed gas multiple line supply system includes a flow splitter connected to a common mixed gas supplying passage, the flow splitter configured to split a mixed gas into a plurality of supply lines while adjusting a ratio of flow rates in the plurality of supply lines, and an least one injector including a gas introducing port and a gas discharge hole for each of a plurality of regions in the processing container and configured to supply the mixed gas to each of the plurality of regions. The plurality of supply lines of the flow splitter are connected in one-to-one correspondence to the respective gas introducing ports provided for the plurality of regions in the processing container.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of Japanese Patent Application No. 2016-042022, filed on Mar. 4, 2016, in the Japan Patent Office, the disclosure of which is incorporated herein in its entirety by reference.

TECHNICAL FIELD

The present disclosure relates to a mixed gas multiple line supply system and a substrate processing apparatus using the same.

BACKGROUND

Conventionally, there has been known a vapor deposition apparatus including a susceptor on which a target substrate is mounted, a gas supplying part configured to face the susceptor and to supply a plurality of material gases to the target substrate, a plurality of mixing pipes configured to mix a plurality of predetermined material gases among the plurality of material gases and to introduce the mixed gases into the gas supplying part, respectively, and a plurality of gas branch mechanisms configured to cause the plurality of material gases to be separated from one another while adjusting a flow rate of each of the material gases and to supply each of the separated material gases to any one of the plurality of mixing pipes, wherein the gas supplying part sprays a plurality of mixed gases mixed in the plurality of respective mixing pipes to a plurality of regions on the susceptor, respectively, and, in each of the plurality of mixed gases, each of the plurality of predetermined material gases is adjusted in terms of a concentration and a flow rate thereof.

In this vapor deposition apparatus, supply lines are branched off from each of gas supply sources by the gas branch mechanisms and the branched supply lines for gases are connected to the plurality of mixing pipes, respectively, so that a plurality of mixing pipes which supplies an identical mixed gas is provided and each of them sprays the mixed gas to a respective place of the plurality of regions on the susceptor.

In this configuration, however, the same number of mixing pipes, which is configured to supply the identical mixed gas, as the number of the regions on the susceptor is required. Accordingly, there are problems in that the apparatus has a complicated configuration and thus also becomes bulky as the number of the pipes is increased.

In particular, in the aforementioned configuration, there are problems in that, since an increase in the number of the mixing pipes results in a further need for an increase in the number of branch lines from each of gas sources, an increase in the number of the regions on the susceptor to which the mixed gases are supplied causes a remarkable increase in the number of pipes in the vicinity of the gas sources.

Recently, since the kinds of gases used for the substrate processing and the number of the regions on the susceptor tend to be increased from the viewpoint of improvement of in-plane uniformity, an increase in the number of pipes and enlargement of the apparatus becomes problematic.

SUMMARY

Some embodiments of the present disclosure provide a mixed gas multiple line supply system capable of achieving miniaturization of an apparatus by reducing the number of pipes when a mixed gas is separated into multiple lines and then supplied to a plurality of regions in a processing container, and a substrate processing apparatus using the same.

According to one embodiment of the present disclosure, there is provided a mixed gas multiple line supply system, including: a flow splitter connected to a common mixed gas supplying passage, the flow splitter configured to split a mixed gas into a plurality of supply lines while adjusting a ratio of flow rates in the plurality of supply lines; and an least one injector including a gas introducing port and a gas discharge hole for each of a plurality of regions in the processing container and configured to supply the mixed gas to each of the plurality of regions, wherein the plurality of supply lines of the flow splitter are connected in one-to-one correspondence to the respective gas introducing ports provided for the plurality of regions in the processing container.

According to another embodiment of the present disclosure, there is provided a substrate processing apparatus, including: the mixed gas multiple line supply system described above; a processing container; and a wafer holding unit configured to hold a wafer in the processing container.

DETAILED DESCRIPTION

FIG. 1is a view illustrating an example of a mixed gas multiple line supply system250and a substrate processing apparatus according to a first embodiment of the present disclosure. InFIG. 1, there are shown the mixed gas multiple line supply system250and the substrate processing apparatus300including the same.

The mixed gas multiple line supply system250includes a mixed gas generating part200, a flow splitter210, branch pipes221to223and injectors131to133. In addition, the substrate processing apparatus300has a processing container1and a rotary table2.

The mixed gas multiple line supply system250is a system configured to generate a mixed gas, to split the generated mixed gas into multiple lines and to supply the split mixed gas to a plurality of regions in the processing container1using the injectors131to133.

InFIG. 1, the flow splitter210is connected to the mixed gas generating part200, and the generated mixed gas is supplied from the flow splitter210to the injectors131to133via the branch pipes221to223.

The mixed gas generating part200is a unit configured to mix a plurality of process gases to generate the mixed gas. The mixed gas generating part200includes gas supply sources161to163, flow rate controllers171to173, individual pipes181to183and a mixing pipe190.

The gas supply sources161to163are units configured to supply respective gases constituting the mixed gas. Each of the gas supply sources may be formed of a tank containing the gas, and may have a unit such as a vaporizer to generate the gas, if necessary. The plurality of gas supply sources161to163which corresponds to the kinds of gases constituting the mixed gas, is provided.

Each of the flow rate controllers171to173is a unit configured to adjust a flow rate of a gas and is configured by, for example, a mass flow controller and the like. The flow rate controllers171to173are also provided to correspond to the kinds of gases constituting the mixed gas. Thus, the flow rate controllers171to173are provided to the gas supply sources161to163in one-to-one correspondence. With this configuration, the flow rate of each of the gases can be accurately set and adjusted. InFIG. 1, three (3) kinds of gases are employed as components of the mixed gas and three (3) gas supply sources161to163and three (3) flow rate controllers171to173are installed.

The individual pipes181to183are pipes configured to connect the flow rate controllers171to173to the mixing pipe190, respectively, and are installed in one-to-one correspondence to the kinds of gases constituting the mixed gas. Therefore, like the flow rate controllers171to173, three (3) individual pipes181to183are installed as shown inFIG. 1.

The mixing pipe190is a pipe configured to mix the plurality of gases supplied from the individual pipes181to183to generate the mixed gas. Therefore, only one mixing pipe190is provided, and the respective gases supplied from the individual pipes181to183are mixed in the mixing pipe190.

The flow splitter210is a flow-splitting unit configured to split the mixed gas supplied from the mixing pipe190into multiple lines. At this time, the flow splitter210can set a ratio of flow rates of the mixed gases to a predetermined value. Therefore, the flow splitter210supplies the mixed gas to the branch pipes221and223while adjusting the ratio of the flow rates of the mixed gases to the predetermined value.

The branch pipes221to223are units configured to supply the mixed gas to the injectors131to133at the predetermined ratio of the respective flow rates. The branch pipes221to223are connected to gas introducing ports141to143of the injectors131to133, respectively.

The injectors131to133are units configured to supply the mixed gas to the plurality of regions in the processing container1. The injectors131to133are configured, for example, in the form of a nozzle. The nozzle may be in a shape of a cylinder or a polygonal column such as a square column Therefore, the injectors131to133may be referred to as gas nozzles131to133.

In order to supply the mixed gas to the plurality of regions in the processing container1or to a plurality of regions on a wafer W, each of the injector131to133is installed to each of the plurality of regions in the processing container1in a one-to-one correspondence basis. Therefore, a plurality of injectors131to133are installed as a whole. Each of the plurality of injectors131to133has one gas introducing port141,142or143and at least one gas discharge hole151,152or153. Commonly, a plurality of gas discharge holes151to153are provided in each of the regions. An example in which three (3) gas discharge holes are provided in each of the injectors131to133is schematically shown inFIG. 1. Actually, in many cases, several tens of gas discharge holes are provided in each of the injectors131to133. Since the gas discharge holes151to153are provided in plural places, diameters or positions of the holes can be adjusted in various manners. In addition, it is also possible to supply the mixed gas such that the mixed gas can be uniformly spread in each of the plurality of regions to which each of the injectors131to133supplies the mixed gas. Therefore, it is preferable that each of the injectors131to133has the plurality of gas discharge holes151to153.

The plurality of injectors131to133are provided to the plurality of branch pipes221to223of the multiple lines split by the flow splitter220. Since the flow splitter210can adjust the ratio of the flow rates in the multiple lines as described above, it is possible to adjust a ratio of flow rates in the injectors131to133.

InFIG. 1, the plurality of injectors131to133are provided in different regions in the processing container1, respectively, so as to supply the mixed gas to different regions on the wafer W. There may a certain case where, due to the configuration of the substrate processing apparatus300including the processing container1and the like, the substrate processing to a specific region of the wafer W may be insufficiently or excessively performed. In such a case, by properly setting the ratio of the flow rates of the mixed gas, excess or shortage of the substrate processing can be cured and the substrate processing with higher uniformity over the entire surface of the wafer W can be performed. Moreover, as described above, by adjusting the diameters or positions of the gas discharge holes151to153as well as the ratio of the flow rates, it is possible to perform substrate processing with improved in-plane uniformity. Furthermore,FIG. 1schematically represents an extent of difference in the supply flow rates using arrows and shows an example in which the left injector131has the smallest flow rate, the right injector133has the largest flow rate and the middle injector132has an intermediate flow rate between the smallest and largest flow rates.

As such, it is possible to properly set the ratio of the flow rates in the injectors131to133provided in the plurality of regions in the processing container1.

Furthermore,FIG. 1show a configuration in which there is no overlapping region among the plurality of injectors131to133and in which the mixed gas is supplied to completely different regions. However, for example, the plurality of injectors131to133may be arranged such that the adjacent regions partially overlap with each other.

The processing container1is a container configured to receive the wafer W and performing predetermined substrate processing. In addition, the rotary table2is a substrate holding unit configured to hold the wafer. InFIG. 1, the rotary table2with the wafer W mounted and held on an upper surface thereof is shown by way of example. However, so far as the rotary table can hold the wafer W such that the wafer can be processed, the rotary table may have various configurations and is not necessarily rotatable and may be, for example, a simple mounting table.

As shown inFIG. 1, the mixed gas multiple line supply system according to the first embodiment is a supply system in which three kinds of process gases are mixed and the mixed gas are split and supplied into three lines. Here, pipes divided into three lines are only the individual pipes181to183and the branch pipes221to223. The number of the flow rate controllers171to173is also only three.

If this supply system is realized in the configuration of the related art disclosed in the section “BACKGROUND”, since there are three final supply lines, nine (3×3=9) flow rate controllers171to173and nine (3×3=9) individual pipes181to183are required for the three gas supply sources161to163. In addition, three mixing pipes190are required, whereby the number of necessary pipes becomes enormous and the apparatus is also enlarged.

As compared with the configuration described above, the mixed gas multiple line supply system according to the first embodiment can reduce the numbers of the respective components arranged from the gas supply sources161to163to the flow splitter210down to ⅓ thereof, thereby enabling considerable space saving and cost reduction.

As such, in the mixed gas multiple line supply system250and the substrate processing apparatus300according to the first embodiment, the flow splitter210is effectively utilized, thereby achieving great simplification of the gas unit and the entire apparatus.

FIG. 2is a view showing an example of a mixed gas multiple line supply system and a substrate processing apparatus according to a second embodiment of the present disclosure. Since a configuration of the mixed gas generating part200in the second embodiment is the same as that in the first embodiment, the components of the mixed gas generating part are designated by like reference numerals and descriptions thereof will be omitted.

The mixed gas multiple line supply system251and the substrate processing apparatus301according to the second embodiment are different from the mixed gas multiple line supply system250and the substrate processing apparatus300according to the first embodiment in that the number of an injector130is one as a whole and an interior of the injector is divided into a plurality of chambers131ato133aby partitions121and122.

There is no great difference in substantial functions between the mixed gas multiple line supply system251and the substrate processing apparatus301according to the second embodiment and the mixed gas multiple line supply system250and the substrate processing apparatus300according to the first embodiment in which the injectors131to133are individually installed. However, since only one injector130is used in this configuration, it is possible to reduce the number of parts, thereby enabling further miniaturization of the apparatus.

Since other functions and effects of the mixed gas multiple line supply system251and the substrate processing apparatus301according to the second embodiment are the same as those of the mixed gas multi-system supply system250and the substrate processing apparatus300according to the first embodiment, descriptions thereof will be omitted.

FIG. 3is a view showing an example of a mixed gas multiple line supply system252and a substrate processing apparatus302according to a third embodiment of the present disclosure. A configuration of a mixed gas generating part200in the third embodiment is the same as those in the first and second embodiments, the components of the mixed gas generating part are designated by like reference numerals and descriptions thereof will be omitted.

The mixed gas multiple line supply system252and the substrate processing apparatus302according to the third embodiment are the same as the mixed gas multiple line supply system251and the substrate processing apparatus301according to the second embodiment in that the number of an injector130ais one as a whole and an interior of the injector is divided into a plurality of chambers131ato133aby partitions121aand122a. However, the mixed gas multiple line supply system252and the substrate processing apparatus302according to the third embodiment is different from the mixed gas multiple line supply system251and the substrate processing apparatus301according to the second embodiment in that orifices111and112are provided in the partitions121aand122a.

Here, the orifices111and112are openings functioning as communicating holes through which a plurality of chambers131ato133ain the injector130can communicate with one another. If the mixed gas is supplied to the respective chambers131ato133aat different flow rates, pressures in the chambers are different from one another in proportion to the flow rates. By using the differences in pressure, it is possible to generate a variety of changes in flow-splitting ratios over the number of the multiple lines. In other words, the interior of the injector130ais not completely partitioned by the partitions121aand122a, but by forming the orifices111and112in the partitions121aand122, some of the mixed gas flows from one of the chambers131ato133ahaving a larger flow rate to another of the chambers131ato133ahaving a smaller flow rate (from one of the chambers131ato133ahaving a higher pressure to another of the chambers131ato133ahaving a lower pressure). Since gas discharge amounts from the respective gas discharge holes151to153are proportional to the internal pressures, the gas discharge amounts from one or more of the gas discharge holes151to153near the orifices111and112are more affected by the pressures from the adjacent chambers131ato133awith the orifices111and112interposed therebetween, as compared with the gas discharge amounts from one or more of the gas discharge holes151to153far from the orifices111and112. Thus, the flow split of the mixed gas is made smoother for the number of flow split by the flow splitter.

In the example inFIG. 3, since the flow rates and the pressures are higher in the order of the chamber133a, the chamber132aand the chamber131a, some of the mixed gas in the chamber133aflow into the chamber132avia the orifice112, and some of the mixed gas in the chamber132aflow into the chamber131avia the orifice111. As schematically shown by arrows inFIG. 3, the flow rates of three split lines are distributed in a pattern in which the flow rates are gradually decreased from a right side toward a left so that the mixed gas can be discharged at ten (10) stepwise flow rates.

As such, with the mixed gas multiple line supply system252and the substrate processing apparatus302according to the third embodiment, it is possible to discharge the mixed gas by smoothly splitting the mixed gas flow while realizing miniaturization of the apparatus.

FIGS. 4A and 4Bare views illustrating a difference between a discharge amount in the mixed gas multiple line supply system251and the substrate processing apparatus301according to the second embodiment and a discharge amount in the mixed gas multiple line supply system252and the substrate processing apparatus302according to the third embodiment of the present disclosure.

FIG. 4Ais a view showing a discharge amount of a mixed gas discharged from an injector130of the mixed gas multiple line supply system251and the substrate processing apparatus301according to the second embodiment. As shown inFIG. 4A, it is assumed that in setting a flow rate ratio of the flow splitter210, a flow rate of 100 sccm is set in the chamber131a, a flow rate of 200 sccm is set in the chamber132aand a flow rate of 300 sccm is set in the chamber133a, resulting in a flow rate ratio of 1:2:3. Assuming that, in this case, a discharge amount from each of the gas discharge holes151to153is an output amount of 25 sccm with respect to a supply of 100 sccm, the discharge amount from the gas discharge hole151of the chamber131ais 25 sccm, the discharge amount from the gas discharge hole152of the chamber132ais 50 sccm and the discharge amount from the gas discharge hole153of the chamber133ais 75 sccm, thereby also resulting in a stepwise output of 1:2:3.

FIG. 4Bis a view showing a discharge amount of a mixed gas discharged from an injector130aof the mixed gas multiple line supply system252and the substrate processing apparatus302according to the third embodiment. Similarly toFIG. 4A, it is assumed that, in setting the flow rate ratio of the flow splitter210, a flow rate of 100 sccm is set in the chamber131a, a flow rate of 200 sccm is set in the chamber132aand a flow rate of 300 sccm is set in the chamber133a, resulting in a flow rate ratio of 1:2:3. Further, likeFIG. 4A, a discharge amount from each of the gas discharge holes151to153is basically an output amount of 25 sccm with respect to a supply of 100 sccm.

In this case, some of the mixed gas in the chamber133aflow into the adjacent chamber132avia the orifice112, and some of the mixed gas in the chamber132aflow into the adjacent chamber131avia the orifice111. As a result, the mixed gas is discharged from the gas discharge hole153of the chamber133afar from the rightmost orifice112at about75sccm as calculated. The discharge amount is more influenced by the orifice112as going to the left side, so that the flow of the mixed gas is divided into the gas discharge hole153and the orifice112, whereby the discharge amount decreases as going to the left side.

Meanwhile, in the central chamber132a, the right gas discharge hole152is affected by the mixed gas flowing from the chamber133avia the orifice112, so that the discharge amount becomes greater than 50 sccm. Although the discharge amount from the second gas discharge hole from the right side is about 50 sccm as calculated, the flow rate is more affected by the orifice111as getting closer to the left side, so that the discharge amount is gradually decreased. A similar phenomenon also occurs in the left chamber131a, so that the flow rate of the leftmost gas discharge hole151farthest from the orifice111is 25 sccm as calculated. The flow rate is more affected by the mixed gas flowing from the adjacent chamber132avia the orifice111as getting closer to the right side, whereby the discharge amount is gradually increased.

As a result, the mixed gas is discharged from the gas discharge holes151to153with a smooth distribution of the discharge amount as a whole.

As such, if the partitions121and122are formed of fully partitioning plates, the discharge amounts of the mixed gas from the respective chambers131ato133abecome constant and have a stepwise distribution. If the partitions121aand122ahaving the orifices111and112are utilized, however, it is possible to discharge the mixed gas with a smooth distribution. By utilizing these properties, it is possible to realize a desired gas supply even though the flow splitter capable of setting only the ratio of the flow rates is used without installation of individual flow rate controllers.

In the following embodiment, an example in which the mixed gas multiple line supply system250and the substrate processing apparatuses300to302described in the first to third embodiments are applied as a more specific substrate processing apparatus will be described. A substrate processing apparatus303according to the fourth embodiment is configured as an ALD (atomic layer deposition) film-forming apparatus and is an apparatus configured to perform film formation using the ALD method.

FIG. 5is a view illustrating examples of a mixed gas multiple line supply system253and a substrate processing apparatus303according to a fourth embodiment of the present disclosure. InFIG. 5, an inner configuration of the processing container1of the substrate processing apparatus303is shown. In addition, since the processing container1and the rotary table2have the same shapes as those of the substrate processing apparatuses300to302according to the first to third embodiments, like reference numerals are used.

FIG. 5shows a container main body12, which defines a side surface and a bottom face of the processing container1, with a ceiling plate removed from the processing container1. The disk-shaped rotary table2is provided above a floor surface of the main body12.

As shown inFIG. 5, circular recesses24configured to place a plurality of wafers W (five (5) wafers in the illustrated example) therein are formed in a surface of the rotary table2in a rotational direction (a circumferential direction).FIG. 5shows that the wafer W is mounted in only one recess24for the sake of convenience. The inner diameter of the recess24is slightly greater, e.g., by 4 mm, than a diameter (for example, 300 mm) of the wafer W. The depth of the recess24is substantially equal to a thickness of the wafer W. Thus, when the wafer W is placed in the recess24, the surface of the wafer W is flush with the surface (a region on which the wafer W is not mounted) of the rotary table2.

Injectors131cto133c, a reaction gas nozzle32and separation gas nozzles41and42, which are made of, example, quartz, are arranged above the rotary table2. In the illustrated example, the separation gas nozzle41, the injectors131to133, the separation gas nozzle42and the reaction gas nozzles32are arranged in this order in a clockwise direction (the rotation direction of the rotary table2) from a transfer port15(described later) at certain intervals in a circumferential direction of the processing container1. The injectors131cto133care similar to the injectors131to133separately and independently provided for each of the plurality of regions as described in the first embodiment. InFIG. 5, in a radial direction of the rotary table2, the injector131cis provided at a region on a central side of the rotary table2, the injector133cis provided at a region on an outer peripheral side of the rotary table2and the injector132cis provided at a region on an intermediate side of the rotary table2. With rotation of the rotary table2, the wafer W mounted on the rotary table2is moved in the rotation direction. By discharging the mixed gas from the gas discharge holes151to153of the injectors131cto133c, the mixed gas is sequentially supplied to a plurality of wafers W (five (5) wafers inFIGS. 4A and 4B). Therefore, the entire diameter of the wafer W is covered with three injectors131cto133c, so that the mixed gas is supplied to the entire surface of the wafer W. Although the injectors131cto133cbasically cover the different regions on the outer peripheral, intermediate and central sides in the radial direction of the rotary table2without overlapping with one another, end portions of the adjacent injectors131cand132coverlap with each other and end portions of the adjacent injectors132cand133coverlap with each other.

The supply of the mixed gas to the respective injectors131cto133cis performed by splitting the mixed gas, which is generated in the mixed gas generating part200, in the flow splitter210and by supplying the split mixed gases to the gas introducing ports141to143via the branch pipes221to223, respectively. As shown inFIGS. 1 and 3, the branch pipes221to223are introduced through an upper face of the processing container1, and the mixed gas is introduced into the respective gas introducing ports141to143of the respective injectors131cto133c.

When the rotary table2is rotated, a movement distance on the outer peripheral side of the rotary table is larger than that on the central side thereof, so that a moving speed at the outer periphery is higher than that at the central portion. Therefore, since on the outer peripheral side of the rotary table2, a time for adsorption of the mixed gas on the wafer W may not be sufficient, there is a case where a flow rate on the outer peripheral side is set to be larger than a flow rate on an inner peripheral side. Therefore, the present embodiment also employs an example where the flow rates are set to be larger in the order of the injector133c, the injector132cand the injector131c, like the foregoing case.

The gas introducing ports32a,41aand42a, which are proximal ends of the nozzles32,41, and42, respectively, are fixed on an outer peripheral wall of the container main body12, such that the nozzles32,41, and42are introduced from the outer peripheral wall of the processing container1into the processing container1and extend in parallel to the rotary table2in a radial direction of the container main body12.

A gas supply source and, if necessary, a flow rate controller may be connected to each of the nozzles32,41and42, and various gases may be supplied to the nozzles depending on the processes.

For example, in order to oxidize a silicon-based gas to generate SiO2, a supply source (not shown) for supplying ozone (O3) gas may be connected to the reaction gas nozzle32via an opening/closing valve and a flow rate controller (both are not shown).

In addition, a supply source of a rare gas such as argon (Ar) gas and helium (He) gas or an inert gas such as nitrogen gas may be connected to the separation gas nozzles41and42via an opening/closing valve and a flow rate controller (both are not shown).FIG. 5shows an example in which N2gas is used as the inert gas.

FIG. 6shows a sectional view of the processing container1along a concentric circle of the rotary table2from the injectors131cto133cto the reaction gas nozzle32. As shown inFIG. 6, the branch pipes221to223are connected to the injectors131cto133cthrough the ceiling plate11of the processing container1, and the mixed gas is supplied to the gas introducing ports141to143. The gas discharge holes151to153are formed in lower surfaces of the respective injectors131cto133c.

Further, a plurality of gas discharge holes33opened downwardly toward the rotary table2are formed in the reaction gas nozzle32and are arranged in a longitudinal direction of the reaction gas nozzle32. A region below the injectors131cto133cbecomes a first processing region P1in which the mixed gas such as a silicon-based gas or the like is adsorbed onto the wafer W. A region below the reaction gas nozzle32becomes a second processing region P2in which the mixed gas adsorbed on the wafer W in the first processing region P1is oxidized.

Referring toFIGS. 5 and 6, two protruding portions4are provided in the processing container1. Each of the protruding portions4has a substantially fan-like planar shape whose apex is cut in an arc-shape. In the present embodiment, an inner arc portion of the protruding portion is connected to a protrusion5(described later) and the outer arc portion is disposed to conform to an inner peripheral surface of the container main body12of the processing container1. As shown in the figures, the protruding portions4are provided on a rear surface of the ceiling plate11. For this reason, flat low ceiling surfaces44(first ceiling surfaces), which are lower surfaces of the protruding portions4, and ceiling surfaces45(second ceiling surface), which are higher than the ceiling surfaces44and in which are placed on both circumferential sides of the ceiling surfaces44, exist within the processing container1.

In addition, as shown inFIG. 6, a groove portion43is formed at a circumferential center of one of the protruding portions4and extends in the radial direction of the rotary table2. The separation gas nozzle42is accommodated in the groove portion43. Similarly, a groove portion43is formed in the other protruding portion4and the separation gas nozzle41is accommodated in the groove portion43. Further, a gas discharge hole42his formed in the separation gas nozzle42.

The injectors131cto133cand the reaction gas nozzle32are provided in spaces below the higher ceiling surface45, respectively. The injectors131cto133cand the reaction gas nozzles31and32are provided in the vicinity of the wafer W while being spaced apart from the ceiling surface45.

The low ceiling surfaces44define a separation space H, which is a narrow space, with respect to the rotary table2. When N2gas is supplied from the separation gas nozzle42, N2gas flows toward spaces481and482through the separation space H. At this time, since the volume of the separation space H is smaller than those of the spaces481and482, the pressure in the separation space H can be made higher than that in the spaces481and482by nitrogen (N2) gas. In other words, the separation space H provides a pressure barrier between the spaces481and482. Therefore, the mixed gas such as 3DMAS from the first region P1and O3gas from the second region P2are separated by the separation space H. As a result, the mixed gas and O3gas are inhibited from being mixed and reacted with each other within the processing container1.

FIG. 7is a sectional view taken along line I-I′ inFIG. 5showing a region in which a ceiling surface45is provided.

As shown inFIG. 7, the substrate processing apparatus has the flat processing container1having a substantially circular planar shape and the rotary table2provided in the processing container1and having a rotation center at a center of the processing container1. The processing container1has the container main body12in the shape of a cylinder with a bottom surface, and the ceiling plate11detachably and hermetically disposed on an upper face of the container main body12with a seal member13such as an O-ring or the like interposed therebetween.

The rotary table2is fixed to a cylindrical core part21at the central portion of the rotary table, and the core part21is fixed to an upper end of a rotational shaft22extending in a vertical direction. The rotational shaft22passes through a bottom portion14of the processing container1and a lower end of the rotational shaft is attached to a driving part23configured to rotate the rotational shaft22around a vertical axis. The rotational shaft22and the driving part23are accommodated in a tube-shaped case body20with an opened top face. A flange portion provided at the upper face of the case body20is hermetically installed on a lower surface of the bottom portion14of the processing container1, so that an internal atmosphere of the case body20is isolated from an external atmosphere.

A first evacuation port610communicating with the space481and a second evacuation port620communicating with the space482are formed between the rotary table2and the inner peripheral surface of the container main body. As shown inFIG. 7, the first evacuation port610and the second evacuation port620are connected to a vacuum pump640, which is a vacuum evacuation unit, via an evacuation pipe630, respectively. In addition, a pressure regulator650is provided in the evacuation pipe630.

As shown inFIG. 7, a heater unit7functioning as a heating device is provided in a space between the rotary table2and the bottom portion14of the processing container1, and the wafer W on the rotary table2is heated through the rotary table2to a temperature (for example, 450 degrees C.) determined by a process recipe. A ring-shaped cover member71is provided below and near the outer periphery of the rotary table2in order to prevent a gas from entering the space below the rotary table2.

As shown inFIG. 7, a region of the bottom portion14of the processing container, which is closer to the rotation center rather than the space with the heater unit7disposed therein, protrudes upwardly to approach the core part21near a central portion of the lower surface of the rotary table2, thereby defining a protrusion12a. A narrow space is formed between the protrusion12aand the core part21. In addition, a narrow gap is formed between the rotational shaft22and an inner peripheral surface of a through hole which is formed through the bottom portion14and through which the rotational shaft22passes, and these narrow spaces communicate with the case body20. Moreover, a purge gas supplying pipe72is installed on the case body20in order to supply N2gas as a purge gas into the narrow spaces to purge the spaces. Further, a plurality of purge gas supplying pipes73configured to purge the space with the heater unit7placed therein are provided below the heater unit7and at the bottom portion14of the processing container1at predetermined angular intervals in the circumferential direction (two purge gas supplying pipes73are shown inFIG. 7).

Further, a separation gas supplying pipe51is connected to a central portion of the ceiling plate11of the processing container1so as to supply N2gas as a separation gas into a space52between the ceiling plate11and a core part21.

Further, as shown inFIG. 5, a sidewall of the processing container1is provided with the transfer port15used for transferring a wafer W, which is a substrate, between an external transfer arm10and the rotary table2.

Moreover, as shown inFIG. 7, the substrate processing apparatus according to the present embodiment is provided with a control part100configured by a computer configured to control operations of the entire apparatus. A program for allowing a film-forming method described later to be performed in a film forming apparatus under the control of the control part100is stored in a memory of the control part100. This program is stored in a medium102such as a hard disk, a compact disk, a magneto-optical disk, a memory card, a flexible disk or the like, and is read into a storage part101by a certain reading device and then installed into the control part100.

As such, the mixed gas multiple line supply system250can be suitably used for the substrate processing apparatus303that performs the film formation, whereby it is possible to accurately control the flow rates of the mixed gas for the respective regions in the processing container1in which the injectors131cto133care provided and to perform the film formation with good in-plane uniformity.

FIG. 8is a view illustrating examples of a mixed gas multiple line supply system254and a substrate processing apparatus304according to a fifth embodiment of the present disclosure. InFIG. 8, one injector130dis connected to the flow splitter210, and the injector130dhas chambers131to133as three (3) regions.

FIG. 9is a sectional view illustrating an example of the injector130dof the mixed gas multiple line supply system254and the substrate processing apparatus304according to the fifth embodiment of the present disclosure. The substrate processing apparatus according to the fifth embodiment has the same planar configuration as the substrate processing apparatus303according to the fourth embodiment shown inFIG. 5, although only a configuration of the injector130dis different from that of the injector in the fourth embodiment.

In the injector130dof the substrate processing apparatus according to the fifth embodiment, as shown inFIG. 9, complete plate-shaped partitions121band122bare provided within the injector130dto completely separate the chambers131dto133dfrom one another. This configuration is similar to that of the mixed gas multiple line supply system251and the substrate processing apparatus301according to the second embodiment.

As such, it is possible to employ the configuration in which the complete plate-shaped partitions121band122bare provided within the injector130dto completely separate the chambers131dto133dfrom one another. With such a configuration, it is possible to configure the injector130din a space-saving manner and at low costs as compared with independent installation of three separate injectors131cto133c.

Since other components are the same as those of the substrate processing apparatuses302and303according to the second and fourth embodiments, descriptions thereof will be omitted.

FIG. 10is a view illustrating an example of an injector130eof a mixed gas multiple line supply system and a substrate processing apparatus according to a sixth embodiment of the present disclosure. InFIG. 10, one injector130eis connected to the flow splitter210, and an interior of the injector130eis divided into three (3) chambers131e,132eand133eby partitions121cand122c. Orifices111band112bfunctioning as communicating holes are formed in the partitions121cand122cto allow the respective chambers131eto133eto communicate with one another. In other words, this configuration is an example in which the substrate processing apparatus302according to the third embodiment is applied to the specific ALD film forming apparatus. With the substrate processing apparatus according to the sixth embodiment as described above, it is possible to supply the mixed gas to respective regions in the processing container1with a smooth flow rate distribution, thereby performing ALD film forming processing.

Since other components are the same as those of the mixed gas multiple line supply systems252and254and the substrate processing apparatuses302and304according to the third to fifth embodiments, descriptions thereof will be omitted.

FIG. 11is a view illustrating examples of a mixed gas multiple line supply system255and a substrate processing apparatus305according to a seventh embodiment of the present disclosure. The mixed gas multiple line supply system255and the substrate processing apparatus305according to the seventh embodiment and the substrate processing apparatuses304according to the fifth and sixth embodiments, are the same in that one injector130fis employed, but are different from each other in that only one gas introducing port1130ais provided at an outer periphery of the processing container2.

In this case, the mixed gas is supplied from one gas introducing port1130a, and the injector130bis introduced into the processing container1through the outer peripheral wall of the container main body12and horizontally extends parallel to the rotary table2from an outer peripheral side toward a central side thereof.

FIG. 12is a view illustrating a sectional configuration of an example of the injector130f. As shown inFIG. 12, partitions121dand122dof the injector130fhave portions1210and1220that are disposed perpendicular to a longitudinal direction of the injector130bto divide the interior of the injector130finto chambers131fto133fin the longitudinal direction, as well as portions1211and1221that extend in the longitudinal direction to allow the injector130fto have a configuration of a concentric pipe such as a triple pipe and divide the respective chambers131fto133fin a radial direction of the injector130f. Accordingly, gas introducing ports141ato143aof the respective chambers131fto133fare provided at positions moved in the longitudinal direction of the injector130f, so that these gas introducing ports are provided at different positions in the longitudinal direction. Specifically, the gas introducing port143aof the chamber133flocated on a right innermost side (tip side) is provided at a position moved to the right side, the gas introducing port142aof the second chamber132fis slightly on a left side (entrance side) from the center of the injector, and the gas introducing port141aof the chamber131fon the entrance side is on the most entrance side like the gas introducing port of the entire injector130f.

As such, the injector130fmay be formed as a triple pipe by using the partitions121dand122dhaving the concentric tubular portions1211and1221. In this case, similarly to other nozzles32,41and42, it possible to introduce the mixed gas from the outer peripheral wall of the container main body12.

Since other components are the same as those of the mixed gas multiple line supply systems253to255and the substrate processing apparatuses303to305according to the fourth to sixth embodiments, descriptions thereof will be omitted.

FIG. 13is a view illustrating an example of an injector130gof a substrate processing apparatus according to an eighth embodiment of the present disclosure. A mixed gas multiple line supply system and the substrate processing apparatus according to the eighth embodiment have the same planar configuration as the mixed gas multiple line supply system255and the substrate processing apparatus305according to the seventh embodiment shown inFIG. 11, although a configuration of the injector130gis different from that of the injector in the seventh embodiment.

The injector130gof the substrate processing apparatus according to the eighth embodiment is different from the injector130bof the substrate processing apparatus304according to the sixth embodiment in that, as shown inFIG. 13, orifices111cand112care formed in the partitions121eand122eto allow the chambers131ato133ato communicate with one another.

As such, the injector may be configured such that the chambers131gto133gcommunicate with one another by forming the orifices111cand112cin portions of the partitions121eand122e. With such a configuration, it is possible to configure the injector130gin a space-saving manner and at low costs as compared with independent installation of three separate injectors131cto133c, and amounts of discharge from the gas discharge holes151to153can be smoothly distributed to perform control of flow rates with a higher accuracy. If the chambers131gto133gare configured to communicate with one another, the positions or sizes of the orifices111cand112cmay be variously adjusted according to usages thereof.

Since other components are the same as those of the substrate processing apparatuses303to305according to the fourth to seventh embodiments, descriptions thereof will be omitted.

FIG. 14is a view illustrating an example of a substrate processing apparatus according to a ninth embodiment of the present disclosure. A mixed gas multiple line supply system256and the substrate processing apparatus306according to the ninth embodiment will be described in connection with an example in which the mixed gas generating part200and the flow splitter210are applied to a vertical type heat treatment apparatus.

FIG. 14shows an overall configuration illustrating an example of the substrate processing apparatus306according to the ninth embodiment of the present disclosure. As shown in the figure, the substrate processing apparatus306has a processing container422capable of accommodating a plurality of wafers W. The processing container422is composed of a vertically elongated cylindrical inner tube424with a ceiling and a vertically elongated cylindrical outer tube426with a ceiling. The outer tube426is disposed to surround the inner tube424with a predetermined gap between an outer periphery of the inner tube424and an inner periphery of the outer tube426. In addition, all the inner and outer tubes424and426are made of, for example, quartz.

A cylindrical manifold428made of, for example, stainless steel is hermetically connected to a lower end of the outer tube426with a sealing member430such as an0-ring interposed therebetween, and the lower end of the outer tube426is supported by the manifold428. The manifold428is supported by a base plate (not shown). Further, a ring-shaped support432is provided on an inner wall of the manifold428, so that a lower end of the inner tube424is supported by the support432.

A wafer boat434as a wafer holding part is accommodated in the inner tube424of the processing container422. A plurality of wafers W are held at predetermined pitches on the wafer boat434. In the present embodiment, for example, approximately 50 to 100 wafers W having a diameter of 300 mm are held in a stacked state by the wafer boat434at a substantially equal pitch. The wafer boat434can be raised or lowered, so that the wafer boat is accommodated into the inner tube424from below the processing container422through a lower opening of the manifold428or is taken out from the inner tube424. The wafer boat434is made of, for example, quartz.

Further, when the wafer boat434is accommodated, the lower opening of the manifold428, which is a lower end of the processing container422, is hermetically closed by a cover part436made of, for example, quartz or stainless steel plate. A seal member438such as an O-ring is interposed between the lower end of the processing container422and the cover part436in order to maintain airtightness. The wafer boat434is placed on a table442with a heat-reserving tank440made of quartz interposed therebetween, and the table442is supported by an upper end of a rotational shaft444passing through the cover part436for opening/closing the lower opening of the manifold428.

For example, a magnetic fluid seal446is provided between the rotational shaft444and a hole of the cover part436through which the rotational shaft444passes, whereby the rotational shaft444is rotatably supported while being hermetically sealed. The rotational shaft444is mounted on a tip of an arm450supported by an elevation mechanism448such as a boat elevator or the like, so that the wafer boat434, the cover part436and the like can be integrally raised and lowered. Furthermore, the table442may be fixedly installed on the cover part436to perform film-forming processing on the wafer W without rotating the wafer boat434.

Moreover, a heating part (not shown) consisting of, for example, a carbon wire heater and surrounding the processing container422is provided on a lateral side of the processing container422, thereby heating the processing container422located inside this heating unit and the wafers W within the processing container.

In addition, the mixed gas generating part250configured to supply the mixed gas, a reaction gas supply source456configured to supply a reaction gas and a purge gas supply source458configured to supply an inert gas as a purge gas are installed in the substrate processing apparatus306.

The mixed gas generating part200is configured to connect, for example, three kinds of different gas supply sources and is connected to the injector130dvia the individual pipes181to183on which the flow rate controllers171to173and opening/closing valves191to193are installed (seeFIGS. 1 to 3), and the branch pipes221to223. The injector130dhermetically passes through the manifold428, is bent into an L-shape within the processing container422and then extends over an entire vertical region within the inner tube424. A plurality of gas discharge holes151to153are formed in the injector130dat a predetermined pitch, so that a material gas can be horizontally supplied to the wafers W supported by the wafer boat434. The injector130dmay be made of, for example, quartz.

The reaction gas supply source456stores, for example, ammonia (NH3) gas and is connected to a gas nozzle464via a pipe on which a flow rate controller and an opening/closing valve (not shown) are installed. The gas nozzle464hermetically passes through the manifold428, is bent into an L-shape within the processing container422and then extends over the entire vertical region within the inner tube424. A plurality of gas spraying holes464A are formed in the gas nozzle464at a predetermined pitch, so that the reaction gas can be horizontally supplied to the wafers W supported by the wafer boat434. The gas nozzle464may be made of, for example, quartz.

The purge gas supply source458stores a purge gas and is connected to a gas nozzle468via a pipe on which a flow rate controller and an opening/closing valve (not shown) are installed. The gas nozzle468hermetically passes through the manifold428, is bent into an L-shape within the processing container422and then extends over the entire vertical region within the inner tube424. A plurality of gas spraying holes468A are formed in the gas nozzle468at a predetermined pitch, so that the purge gas can be horizontally supplied to the wafers W supported by the wafer boat434. The gas nozzle468may be made of, for example, quartz. In addition, a rare gas such as argon (Ar) gas, helium (He) gas or the like, or an inert gas such as nitrogen gas or the like may be employed as the purge gas.

The injector130dand the respective gas nozzles464and468are collectively provided on one side within the inner tube424(in the illustrated example, the gas nozzle468is shown at a side opposite to the injector130dand the gas nozzles464due to a space problem), and a plurality of gas flowing holes472are formed to be arranged in a vertical direction in a sidewall of the inner tube424opposite to the injector130dand the gas nozzles464and468. Due to this, the gases supplied from the injector130dand the gas nozzles464and468horizontally flow between the wafers and are guided into a gap474between the inner tube424and the outer tube426through the gas flowing holes472.

An evacuation port476communicating with the gap474between the inner tube424and the outer tube426is formed on an upper side of the manifold428, and an evacuation system478configured to evacuate the processing container422is provided at the evacuation port476.

The evacuation system478has a pipe480connected to the evacuation port476, and a pressure regulating valve480B and a vacuum pump484are sequentially installed in the pipe480, wherein the degree of opening of a valve body of the pressure regulating valve480B is adjustable, so that a pressure in the processing container422can be adjusted by changing the degree of opening of the valve body. Accordingly, it is possible to evacuate an atmosphere in the process container422down to a predetermined pressure while adjusting the pressure.

FIG. 15is a sectional view illustrating a configuration of an example of an injector130h. As shown inFIG. 15, an interior of the vertically elongated injector130his divided into three (3) chambers131hto133hby partitions121fand122f. No orifice is formed in the partitions121fand122f, so that the respective chambers131hto133hare completely separated from one another. The partitions121fand122fare composed of portions1212and1222perpendicular to the longitudinal direction of the injector130h, and portions1213and1223parallel to the longitudinal direction, wherein the portions1213and1223parallel to the longitudinal direction concentrically extend to form the injector130dinto a triple pipe as a whole.

Like the injector130fshown inFIG. 12, the positions of the gas introducing ports141bto143bof the respective chambers131hto133hare arranged in the longitudinal direction (vertical direction) of the injector130hin the order of the gas introducing ports141b,142band143bfrom a lower position in the vertical direction.

Configurations of the gas discharge holes151to153are the same as those described above except that they are arranged in the vertical direction and face the wafers W disposed inward thereto.

As such, even in the vertical type heat treatment apparatus, a ratio of flow rates of vaporized raw materials in the vertical direction can be adjusted with a high accuracy by using the mixed gas multiple line supply system256according to this embodiment, thereby improving in-plane uniformity among the stacked wafers W.

FIG. 16is a view illustrating an example of an injector130iof a mixed gas multiple line supply system and a substrate processing apparatus according to a tenth embodiment of the present disclosure. The mixed gas multiple line supply system and the substrate processing apparatus according to the tenth embodiment have an overall configuration that is the same as that of the mixed gas multiple line supply system256and the substrate processing apparatus306according to the ninth embodiment shown inFIG. 14, except for a configuration of the injector130i.

The injector130eof the substrate processing apparatus according to the tenth embodiment is different from the injector130hof the mixed gas multiple line supply system256and the substrate processing apparatus306according to the ninth embodiment in that as shown inFIG. 16, orifices111dand112dare formed in portions of partitions121gand122gto allow the chambers131ito133ito communicate with one another. Moreover, the partitions121gand122gare composed of portions1212aand1222aperpendicular to the longitudinal direction of the injector130i, and portions1213aand1223aparallel to the longitudinal direction, wherein the portions1213aand1223aparallel to the longitudinal direction concentrically extend to form the injector130iinto a triple pipe as a whole. Further, the orifices111dand112dare formed in the portions1212aand1222aperpendicular to the longitudinal direction of the injector130i.

As such, the injector130imay be configured such that the chambers131ito133icommunicate with one another by forming the orifices111dand112din portions of the partitions121gand122g. With such a configuration, it is possible to configure the injector130iin a space-saving manner and at low costs as compared with independent installation of three separate injectors131cto133c, and amounts of discharge from the gas discharge holes151to153can be smoothly distributed to perform control of flow rates with a higher accuracy. In addition, if the chambers131ito133iare configured to communicate with one another, the positions or sizes of the orifices111dand112dmay be adjusted according to usages thereof.

Since other components are the same as those of the mixed gas multiple line supply system256and the substrate processing apparatus306according to the ninth embodiment, descriptions thereof will be omitted.

FIG. 17is a view illustrating an example of injectors131jto133jof a mixed gas multiple line supply system and a substrate processing apparatus according to an eleventh embodiment of the present disclosure. The mixed gas multiple line supply system and the substrate processing apparatus according to the eleventh embodiment have an entire configuration that is similar to that of the mixed gas multiple line supply system and the substrate processing apparatus305according to the ninth embodiment shown inFIG. 14. However, the mixed gas multiple line supply system and the substrate processing apparatus according to the eleventh embodiment are different from the mixed gas multiple line supply systems256and the substrate processing apparatuses306according to the ninth and tenth embodiments in that, as shown inFIG. 17, a plurality of injectors131jto133jconfigured to supply the vaporized raw material are provided and a plurality of gas discharge holes151to153are formed in the respective injectors131jto133jto enable the injectors131jto133jto supply the vaporized raw materials to different regions in the vertical direction in the processing container422.

The branch pipes221to223branched off from the flow splitter210are connected to gas introducing ports141cto143cof the respective injectors131jto133jin one-to-one correspondence so as to allow the injectors131jto133jto supply the vaporized raw materials into the processing container422at individually set flow rates. It can be said that the substrate processing apparatus according to the eleventh embodiment is one obtained by applying the substrate processing apparatus300according to the first embodiment to a vertical type heat treatment apparatus.

As such, a plurality of completely independent injectors131dto133dmay be used to supply the mixed gas to a plurality of regions in the processing container422at individually set flow rates.

As described above, the mixed gas multiple line supply system according to the embodiment of the present disclosure can use a plurality of injectors capable of supplying the mixed gas to the plurality of regions in the processing container, thereby constructing various types of substrate processing apparatuses and performing control of flow rates for the respective regions with a high accuracy so as to perform substrate processing with a higher accuracy.

In the first to eleventh embodiments, the film formation has been described by way of example. However, the substrate processing apparatuses according to the embodiments of the present disclosure may be applied to various substrate processing apparatuses so far as they employ a vaporized raw material such as an etching gas or the like. Further, the configurations of the injectors are not limited to the examples of the embodiments, but may be applied to various types of injectors.

According to the present disclosure, it is possible to reduce the number of pipes configured to supply gases, thereby resulting in miniaturization of the apparatus.