Method of manufacturing semiconductor device

The present disclosure provides a technique capable of suppressing a deviation in a characteristic of a semiconductor device. There is provided a technique includes: (a) receiving data representing a thickness distribution of a polished silicon-containing layer on a substrate comprising a convex structure whereon the polished silicon-containing layer is formed; (b) calculating, based on the data, a process data for reducing a difference between a thickness of a portion of the polished silicon-containing layer formed at a center portion of the substrate and that of the polished silicon-containing layer formed at a peripheral portion of the substrate; (c) loading the substrate into a process chamber; (d) supplying a process gas to the substrate; and (e) compensating for the difference based on the process data by activating the process gas with a magnetic field having a predetermined strength on the substrate.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This non-provisional U.S. patent application claims priority under 35 U.S.C. §119 of Japanese Patent Application No. 2015-071085, filed on Mar. 31, 2015, the entire contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

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

2. Description of the Related Art

Recently, semiconductor devices are becoming highly integrated. Thus, sizes of patterns are being significantly miniaturized. The patterns are formed through a hard mask or resist forming process, a lithography process, an etching process and the like. In forming the patterns, it is required that a deviation of the characteristics of semiconductor device does not occur.

SUMMARY OF THE INVENTION

Also, due to manufacturing problems, a deviation may occur in a width of a formed circuit or the like. Specifically, in a miniaturized semiconductor device, the deviation has a significant effect on the characteristics of the semiconductor device.

Thus, the present invention provides a technique capable of suppressing the deviation in the characteristics of the semiconductor device.

According to an aspect of the present disclosure, there is provided a technique including:

(a) receiving data representing a thickness distribution of a polished silicon-containing layer on a substrate comprising a convex structure whereon the polished silicon-containing layer is formed;

(b) calculating, based on the data, a process data for reducing a difference between a thickness of a portion of the polished silicon-containing layer formed at a center portion of the substrate and that of the polished silicon-containing layer formed at a peripheral portion of the substrate;

(c) loading the substrate into a process chamber;

(d) supplying a process gas to the substrate; and

(e) compensating for the difference based on the process data by activating the process gas with a magnetic field having a predetermined strength on the substrate.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

First, a process of manufacturing a semiconductor device using a fin field effect transistor (FET) which is a multi-gate device which is one of semiconductor devices as an example will be described with reference toFIGS. 1 through 4C.

A semiconductor device according to a manufacturing flow illustrated inFIG. 1is manufactured, for example, by a processing system4000illustrated inFIG. 2.

[Gate insulating film forming process (S101)]

In a gate insulating film forming process (S101), for example, a substrate200illustrated inFIGS. 3A and 3Bis loaded into a gate insulating film forming apparatus (not illustrated).FIG. 3Ais a perspective view for describing the substrate200andFIG. 3Bis a cross-sectional view taken along line α-α′ ofFIG. 3A. The substrate200is formed of silicon or the like, and a convex structure2001serving as a channel is formed on a portion thereof. A plurality of convex structures2001formed to be spaced apart from each other by a predetermined gap. The convex structures2001are formed by etching a portion of the substrate200.

For convenience of description, a portion having no convex structure on the substrate200is referred to as a concave structure2002. That is, the substrate200includes at least the convex structure2001and the concave structure2002. Also, in the present embodiment, an upper surface of the convex structure2001is referred to as a convex structure surface2001aand an upper surface of the concave structure2002is referred to as a concave structure surface2002afor convenience of description.

A device isolation film2003for electrically insulating the convex structures is formed on the concave structure surface2002abetween adjacent convex structures. The device isolation film2003is formed with, for example, a silicon oxide film.

The gate insulating film forming apparatus is a known single substrate processing apparatus capable of forming a thin film, and thus description thereof is omitted. In the gate insulating film forming apparatus, a gate insulating film2004formed of a dielectric such as a silicon oxide film (a SiO2film) or the like is formed as illustrated inFIG. 4A. A silicon-containing gas [e.g., hexachlorodisilane (HCDS) gas] and an oxygen-containing gas (e.g., O3gas) are supplied onto the gate insulating film forming apparatus and the gate insulating film2004is formed by reacting these gases. The gate insulating film2004is formed above the convex structure surface2001aand the concave structure surface2002a.After the gate insulating film2004is formed, the substrate200is unloaded from the gate insulating film forming apparatus.

Next, a first silicon-containing layer forming process (S102) will be described. After the substrate200is unloaded from the gate insulating film forming apparatus, the substrate200is loaded into a first silicon-containing layer forming device100a.Since a general single substrate processing chemical vapor deposition (CVD) apparatus is used as the first silicon-containing layer forming device100a,description thereof is omitted. Referring toFIG. 4B, a first silicon-containing layer2005[referred to as a first poly-Si layer2005or simply referred to as a poly-Si layer2005] formed of poly-Si (polycrystalline silicon) is formed on the gate insulating film2004using the first silicon-containing layer forming device100a.When the poly-Si layer2005is formed, disilane (Si2H6) gas is supplied onto the first silicon-containing layer forming device100a,and the poly-Si layer is formed by thermal decomposition of the gas. The poly-Si layer is used as a gate electrode or a dummy gate electrode. After the poly-Si layer2005is formed, the substrate200is unloaded from the first silicon-containing layer forming device100a.

Next, a chemical mechanical polishing (CMP) process (S103) will be described. The substrate200unloaded from the first silicon-containing layer forming device100ais loaded into a polishing apparatus400(100b).

Here, the poly-Si layer formed by the first silicon-containing layer forming device100awill be described. As illustrated inFIG. 4B, since the substrate200has the convex structure2001and the concave structure2002, a height of the poly-Si layer is changed. Specifically, a height from the concave structure surface2002ato a surface of the poly-Si layer2005aon the convex structure2001is greater than a height from the concave structure surface2002ato a surface of the poly-Si layer2005bon the concave structure surface2002a.

However, due to a relationship between either an exposure process or an etching process to be described below or both thereof, there is a need to adjust the height of the poly-Si layer2005aand the height of the poly-Si layer2005b.Thus, as in the present process, the height thereof is adjusted by polishing the poly-Si layer2005.

Hereinafter, the CMP process will be described in detail. After the substrate200is unloaded from the first silicon-containing layer forming device, the substrate200is loaded into the CMP apparatus400(100b) illustrated inFIG. 5.

InFIG. 5, reference numeral401refers to a polishing plate and reference numeral402refers to a polishing cloth for polishing the substrate200. The polishing plate401is connected to a rotating mechanism (not illustrated) and rotates in a direction of an arrow406during polishing the substrate200.

Reference numeral403refers to a polishing head, and a shaft404is connected to an upper surface of a polishing head403. The shaft404is connected to the rotating mechanism and a vertical driving mechanism (not illustrated). While the substrate200is being polished, the shaft404rotates in a direction of an arrow407.

Reference numeral405refers to a supply pipe for supplying slurry (abrasive). While the substrate200is being polished, the slurry is supplied from the supply pipe405onto the polishing cloth402.

FIG. 6is a cross-sectional view for describing the polishing head403and peripheral structures thereof. The polishing head403includes a top ring403a,a retainer ring403band an elastic mat403c.While the substrate200is being polished, a peripheral portion of the substrate200is surrounded by the retainer ring403b,and at the same time, is pressed by the polishing cloth402by the elastic mat403c.A groove403dthrough which the slurry is passed is formed in the retainer ring403bfrom an outside of the retainer ring403bto an inside thereof. A plurality of grooves403dare installed in a cylindrical shape to match a shape of the retainer ring403b.It is configured such that used slurry is replaced by unused fresh slurry through the groove403d.

Next, operations in the present process will be described. When the substrate200is loaded into the polishing head403, the slurry is supplied through the supply pipe405, and at the same time the polishing plate401and the polishing head403rotate. The slurry flows into the retainer ring403band polishes a surface of the substrate200. By polishing in this manner, as illustrated inFIG. 4C, the heights of the poly-Si layer2005aand the poly-Si layer2005bare adjusted. The heights herein refer to the heights of upper ends of the poly-Si layer2005aand the poly-Si layer2005b.After the polishing is performed for a predetermined time, the substrate200is unloaded from the CMP apparatus400.

Here, although the poly-Si layer2005aand the poly-Si layer2005bare polished by the CMP apparatus400to adjust the heights thereof, it is seen that the height of the poly-Si layer after the polishing is not adjusted in a surface of the substrate200. For example, as illustrated inFIG. 7, it is seen that there is a distribution A in which a film thickness of the peripheral portion of the substrate200is smaller than that of a center portion thereof or a distribution B in which the film thickness of the center portion of the substrate200is greater than that of the peripheral portion thereof.

Since a deviation in a width of a pattern occurs in a lithography process or an etching process to be described below when there is a deviation in the film thickness distribution, a deviation in a width of a gate or a width of a gate electrode occurs due to the deviation. As a result, there is the challenge that the yield is decreased.

To deal with this problem, according to the results of intensive research by the inventors, it is seen that there are causes for the distribution A and the distribution B. Hereinafter, the causes will be described.

The cause in the distribution A is a method of supplying the slurry to the substrate200. As described above, the slurry supplied onto the polishing cloth402is supplied through the retainer ring403bvia the vicinity of the substrate200. Therefore, while the slurry that polished the peripheral portion of the substrate200flows into the center portion of the substrate200, unused fresh slurry flows onto the peripheral portion of the substrate200. Since the fresh slurry has a high polishing efficiency, the peripheral portion of the substrate200is more polished than the center portion thereof From the above, it is seen that the film thickness of the poly-Si layer becomes the same as the distribution A.

The cause in the distribution B is the wear of the retainer ring403b.When a large number of the substrates200are polished in the CMP apparatus (polishing apparatus)400, a front end of the retainer ring403bpressed by the polishing cloth402is worn and a surface in contact with the groove403dor the polishing cloth402is deformed. Therefore, there is a case in which the slurry originally designed to be supplied is not supplied onto an inner peripheral portion of the retainer ring403b.In this case, since the slurry is not supplied onto the peripheral portion of the substrate200, the center portion of the substrate200is over polished, and the peripheral portion of the substrate200is not polished. Therefore, it is seen that the film thickness of the poly-Si layer becomes the same as the distribution B.

Thus, in the present embodiment, as described below, after the poly-Si layer on the substrate200is polished in the CMP apparatus400, the height of the poly-Si layer is adjusted. In such a configuration, the deviation of the width of the pattern in the exposure process or the etching process is suppressed. Specifically, in a film thickness measuring process after the CMP process (S103), the film thickness distribution of the poly-Si layer2005is measured, and a second silicon-containing layer forming process is performed based on the measured data.

Next, a film thickness measuring process (S104) will be described. In the film thickness measuring process (S104), a film thickness of a poly-Si layer2005after the polishing is measured using a general measuring apparatus100c.Since a general apparatus may be used as the measuring apparatus100c,detailed description thereof is omitted. The film thickness herein refers to, for example, a height from the concave structure surface2002ato a surface of the poly-Si layer2005.

After the CMP process (S103), the substrate200is loaded into the measuring apparatus100c.The measuring apparatus100cmeasures the film thickness (height) distribution of the poly-Si layer2005by measuring at least several positions of the center portion of the substrate200and the peripheral portion of the substrate200, which are easily affected by the polishing apparatus400. Measured data is transmitted to the substrate processing apparatus100. After the measuring process, the substrate200is unloaded from the measuring apparatus100c.

Next, a second silicon-containing layer forming process will be described. A second silicon-containing layer2006is a poly-Si layer and has the same configuration as the first silicon-containing layer2005. As illustrated inFIGS. 4C and 8B, the second silicon-containing layer2006is formed on the first silicon-containing layer2005after the polishing. Also, a layer in which the first silicon-containing layer2005and the second silicon-containing layer2006are stacked is referred to as a stacked silicon-containing layer.

The second silicon-containing layer2006[referred to as a second poly-Si layer2006or simply referred to as a poly-Si layer2006or a compensation film] is formed to compensate for the film thickness distribution of the first silicon-containing layer2005after the polishing. Preferably, the second silicon-containing layer2006is formed such that a height of a surface of the second silicon-containing layer2006is adjusted in the surface of the substrate200. The height herein refers to a height to the surface of the second silicon-containing layer2006, and in other words, refers to a distance from the concave structure surface2002ato the surface of the second silicon-containing layer2006.

Hereinafter, the present process will be described with reference toFIGS. 8A, 8B, 9A, 9B and 10.FIG. 8A and 8Bare views for describing the second poly-Si layer2006formed in the present process when the first poly-Si layer2005is the distribution A.FIG. 9A and 9Bare views for describing the second poly-Si layer2006formed in the present process when the first poly-Si layer2005is the distribution B.FIG. 10is an explanatory diagram illustrating the substrate processing apparatus100(100a) for implementing the present process.

FIG. 8Ais a top view illustrating the substrate200after forming the second poly-Si layer2006.FIG. 8Bis a view illustrating a portion of the center portion of the substrate200and the peripheral portion thereof in a cross-sectional taken along line α-α′ ofFIG. 8A.

FIG. 9Ais a top view illustrating the substrate200after forming the second poly-Si layer2006.FIG. 9Bis a view illustrating a portion of the center portion of the substrate200and the peripheral portion thereof in a cross-sectional view taken along line α-α′ ofFIG. 9A.

Here, the second poly-Si layer2006in the center portion of the substrate200is referred to as a poly-Si layer2006a,and the second poly-Si layer2006in the peripheral portion thereof is referred to as a second poly-Si layer2006b.

The substrate200unloaded from the measuring apparatus100cis loaded into the substrate processing apparatus100illustrated inFIG. 10, which is a second silicon-containing layer forming apparatus100(100a).

The substrate processing apparatus100controls the film thickness of the poly-Si layer2006in the surface of the substrate based on the film thickness distribution data measured in the film thickness measuring process (S104). First, predetermined process data is calculated by a controller121based on data received by a receiving unit285installed in the controller121. For example, when the received data is the distribution A, the poly-Si layer2006bin the peripheral portion of the substrate200is formed to be thick, and the film thickness is controlled such that a layer is formed to have the thickness of the poly-Si layer2006ain the center portion thereof smaller than that of the poly-Si layer2006ain the peripheral portion thereof. Also, when the data received from the upper apparatus is the distribution B, the poly-Si layer2006ain the center portion of the substrate200is formed to be thick, and the film thickness is controlled such that a layer is formed to have the thickness of the poly-Si layer2006bin the peripheral portion thereof smaller than that of the poly-Si layer2006ain the center portion thereof.

Preferably, the thickness of the second poly-Si layer2006is controlled such that a height in which the first poly-Si layer2005and the second poly-Si layer2006are stacked on the concave structure surface2002ais a predetermined height in the surface of the substrate200. In other words, the film thickness distribution of the second silicon-containing layer is controlled such that the distribution of the height of the second silicon-containing layer in the surface of the substrate200is within a predetermined range.

Next, the substrate processing apparatus100for forming the second poly-Si layer2006capable of controlling the film thickness of each of the poly-Si layers2006aand2006awill be described in detail.

The substrate processing apparatus100according to the present embodiment will be described. The substrate processing apparatus100is configured as a single substrate processing apparatus as illustrated inFIG. 10. The substrate processing apparatus100is used in one process of manufacturing a semiconductor device. Here, the substrate processing apparatus100is used in a second silicon-containing layer forming process (S105).

As illustrated inFIG. 10, the substrate processing apparatus100includes a process container202. The process container202includes, for example, an airtight container with a circular and flat cross section. A process space (process chamber)201which processes a silicon wafer or the like serving as a substrate and a transfer space203are formed in the process container202. The process container202includes an upper container202aand a lower container202b.The upper container202ais made of, for example, a non-metallic material such as quartz, ceramics or the like and the lower container202bis made of, for example, a metallic material such as aluminum (Al), stainless steel (SUS) or the like or quartz. A space above the substrate placement unit212is referred to as a process space201, and a space under the substrate placement unit212, which is surrounded by the lower container202b,is referred to as a transfer space203.

A substrate loading and unloading port206is installed adjacent to a gate valve205on a side surface of the lower container202band the substrate200moves to a transfer chamber104through the substrate loading and unloading port206. A plurality of lift pins207are installed at a bottom portion of the lower container202b.Also, the lower container202bis at a ground potential.

A substrate support210which supports the substrate200is installed in the process space201. The substrate support (susceptor)210mainly includes a placement surface211on which the substrate200is placed, a substrate placement unit212whose surface has the placement surface211and a heater213serving as a heating source embedded in the substrate placement unit212. Through holes214through which the lift pins207pass are installed in the substrate placement unit212at positions corresponding to the lift pins207.

The substrate placement unit212is supported by a shaft217. The shaft217passes through a bottom portion of the process container202and is connected to a lifting mechanism218outside the process container202. When the shaft217and the substrate placement unit212are lifted by operating the lifting mechanism218, it is possible to lift the substrate200placed on the placement surface211. Also, a vicinity of a lower end of the shaft217is covered with a bellows219, and thus an inside of the process space201is air-tightly retained.

The substrate placement unit212is lowered to the substrate placement unit such that the placement surface211is at a position of the substrate loading and unloading port206(substrate transfer position) when the substrate200is transferred, and is lifted to a processing position (substrate processing position) at which the substrate200is positioned in the process space201as illustrated inFIG. 10when the substrate200is processed.

Specifically, when the substrate placement unit212is lowered to the substrate transfer position, upper ends of the lift pins207protrude from an upper surface of the placement surface211and the lift pins207support the substrate200from below. Also, when the substrate placement unit212is lifted to the substrate processing position, the lift pins207are buried under the upper surface of the placement surface211and the placement surface211supports the substrate200from below. Also, since the lift pins207are directly in contact with the substrate200, the lift pins207are preferably formed of a material such as quartz, alumina or the like.

Also, as illustrated inFIG. 11, a first bias electrode219aand a second bias electrode219bserving as the bias adjuster219are installed in the substrate placement unit212. The first bias electrode219ais connected to a first impedance adjuster220aand the second bias electrode219bis connected to a second impedance adjuster220b,and thus it is configured to adjust electric potential of each of the electrodes. Also, as illustrated inFIG. 12, the first bias electrode219aand the second bias electrode219bare formed in a concentric circular shape and are configured to adjust the electric potential at the center portion of the substrate200and the peripheral portion thereof.

Also, it may be configured such that a first impedance adjusting power221ais installed in the first impedance adjuster220aand the second impedance adjusting power221bis installed in the second impedance adjuster220b.By installing the first impedance adjusting power221a, an adjustment width of the electric potential of the first bias electrode219amay be increased, and an adjustment width of an amount of active species which flow into the center portion of the substrate200may be increased. Also, by installing the second impedance adjusting power221b,an adjustment width for the electric potential of the second bias electrode219bmay be increased, and an adjustment width for the amount of active species which flow into the peripheral portion of the substrate200may be increased. For example, when the active species are at a positive potential, it is configured such that the electric potential of the first bias electrode219ais at a negative potential and the electric potential of the second bias electrode219bis higher than the electric potential of the first bias electrode219a,and thus the amount of the active species supplied onto the peripheral portion of the substrate200may be greater than the amount of the active species supplied onto the center portion thereof. Also, even when the electric potential of the active species generated in the process chamber201is close to neutral, the amount of the active species which flow onto the substrate200may be adjusted using either the first impedance adjusting power221a or the second impedance adjusting power221bor both thereof.

Also, a first heater213aand a second heater213bmay be installed as the heater213. The first heater213ais installed to face the first bias electrode219aand the second heater213bis installed to face the second bias electrode219b.The first heater213ais connected to the first heater power213cand the second heater213bis connected to the second heater power213d,and thus it is configured for adjusting an amount of power supplied to each of the heaters.

As illustrated inFIG. 10, a first coil250aserving as a first activation unit (an upper activation unit) is installed above the upper container202a.A first high frequency power250cis connected to the first coil250athrough a first matching box250d.When the high frequency power is supplied to the first coil250a,a gas supplied into the process chamber201is excited to generate plasma. Specifically, the plasma is generated in a space [first plasma generating region251] which is an upper portion of the process chamber201and faces the substrate200. Also, it may be configured such that the plasma is generated in a space facing the substrate placement unit212.

Also, as illustrated inFIG. 10, a second coil250bserving as a second activation unit (a side activation unit) may be installed at a side of the upper container202a.A second high frequency power250fis connected to the second coil250bthrough a second matching box250e.When the high frequency power is supplied to the second coil250b,the gas supplied into the process chamber201is excited to generate a plasma. Specifically, the plasma is generated in a space [second plasma generating region252] which is a side of the process chamber201and faces the substrate200. Also, it may be configured such that the plasma is generated in a space outer than the space facing the substrate placement unit212.

Here, an example in which separate matching boxes and separate high frequency power are installed in each of the first activation unit and the second activation unit in order to individually control is illustrated, but is not limited thereto. It may be configured to use a common matching box in the first coil250aand the second coil250b.Also, it may be configured to use a common high frequency power in the first coil250aand the second coil250b.

Also, each of the first high frequency power250cand the second high frequency power250fmay include a receiving unit and a power adjuster. The receiving unit may receive a control program (a control value) or the like received from the controller121and the power adjuster may adjust power according to the control program (the control value).

As illustrated inFIG. 10, a first electromagnet (upper electromagnet)250gserving as a first magnetic field generator is installed above the upper container202a.A first electromagnet power250ifor supplying power to the first electromagnet250gis connected to the first electromagnet250g.Also, the first electromagnet250ghas a ring shape and it is configured to generate a magnetic field in a Z1or Z2direction as illustrated inFIG. 10. A direction of the magnetic field is controlled by a direction of current supplied from the first electromagnet power250i.

Also, a second electromagnet (side electromagnet)250hserving as a second magnetic field generator is installed under the substrate200and at a side surface of the process container202. A second electromagnet power250jfor supplying power to the second electromagnet250his connected to the second electromagnet250h.Also, the second electromagnet250hhas a ring shape and it is configured to generate the magnetic field in the Z1or Z2direction as illustrated inFIG. 10. The direction of the magnetic field is controlled by a direction of current supplied from the second electromagnet power250j.

When the magnetic field is formed in the Z1direction by any one of the first electromagnet250gand the second electromagnet250h,the plasma formed in the first plasma generating region251may move into a third plasma generating region253or a fourth plasma generating region254. Also, in the third plasma generating region253, a degree of activity of the active species generated at a position facing the center portion of the substrate200is greater than a degree of activity of the active species generated at a position facing the peripheral portion of the substrate200. This occurs due to the supply of fresh gas molecules by having the gas inlet241a installed at a position facing the center portion. Also, in the fourth plasma generating region254, the degree of activity of the active species generated at the position facing the peripheral portion of the substrate200is greater than the degree of activity of the active species generated at the position facing the center portion thereof. This occurs due to the gas molecules being collected at the peripheral portion of the substrate200due to forming an exhaust path on the outer periphery of the substrate support210. The position of the plasma may be controlled by the power supplied to the first electromagnet250gand the second electromagnet250hand the plasma may be closer to the substrate200by increasing the power. Also, when the magnetic field is formed by both of the first electromagnet250gand the second electromagnet250hin the Z1direction, the plasma may be closer to the substrate200. Also, when the magnetic field is formed in the Z2direction, diffusion of the plasma formed in the first plasma generating region251into a direction of the substrate200may be suppressed, and the energy of the active species supplied onto the substrate200may be reduced. Also, a direction of the magnetic field formed by the first electromagnet250gmay be different from a direction of the magnetic field formed by the second electromagnet250h.Also, each of the first electromagnet power250iand the second electromagnet power250jmay include a receiving unit and a magnetic field strength adjuster. The receiving unit may receive a control program (the control value) or the like transmitted from the controller121, and the magnetic field strength adjuster may adjust the strength of the magnetic field according to the control program (the control value).

Also, an electronic shield plate250kserving as an electronic shield unit may be installed in the process chamber201and between the first electromagnet250gand the second electromagnet250h.The electronic shield plate250kmay be disposed between the first electromagnet250gand the second electromagnet250h,at a position in which at least some of electronic interference is suppressed, however may preferably be configured to be disposed in the process container202. Also, preferably, the electronic shield plate250kmay be configured to be disposed inside the upper container202ain the process container202. Also, when the electronic shield plate250khas a ring shape and is configured to be disposed outer than at least one of the first plasma generating region, the third plasma generating region and the fourth plasma generating region and outer than the peripheral portion of the substrate200, interference by the magnetic field can be suppressed while maintaining the plasma generating region. Also, when the electronic shield plate250kis installed, the magnetic field formed by the first electromagnet250gmay be separated from the magnetic field formed by the second electromagnet250h.It is easy to adjust the processing uniformity in the surface of the substrate200by adjusting the respective magnetic fields. Also, it may be configured to be adjustable a height of the electronic shield plate250kby an electronic shield plate lifting mechanism (not illustrated).

An exhaust port221serving as a first exhaust unit that exhausts an atmosphere in the process space201is installed on an inner wall of the transfer space203[lower container202b]. An exhaust pipe222is connected to the exhaust port221, and a pressure regulator223such as an auto pressure controller (APC) which controls a pressure in the process space201to a predeteiinined pressure and a vacuum pump224are sequentially connected to the exhaust pipe222in series. An exhaust system (exhaust line) mainly includes the exhaust port221, the exhaust pipe222and the pressure regulator223. Also, the vacuum pump224may be added to the exhaust system (exhaust line) as a component of the configuration.

A gas inlet241afor supplying various gases into the process space201is installed at an upper portion of the upper container202a,and a common gas supply pipe242is connected thereto.

As illustrated inFIG. 13, a first process gas supply pipe243a,a purge gas supply pipe245aand a cleaning gas supply pipe248aare connected to the common gas supply pipe242.

The common gas supply pipe242is connected to the gas inlet241a. As illustrated inFIG. 13, the first gas supply pipe243a,a second gas supply pipe244a,the third gas supply pipe245a,and the cleaning gas supply pipe248aare connected to the common gas supply pipe242.

A first-element-containing gas (first process gas) is mainly supplied through a first gas supply unit243including the first gas supply pipe243aand a second-element-containing gas (second process gas) is mainly supplied through a second gas supply unit244including the second gas supply pipe244a.A purge gas is mainly supplied through a third gas supply unit245including the third gas supply pipe245a,and a cleaning gas is mainly supplied through a cleaning gas supply unit248including the cleaning gas supply pipe248a.A process gas supply unit for supplying a process gas is configured as either a first process gas supply unit or a second process gas supply unit or both thereof, and the process gas is configured as either a first process gas or a second process gas or both thereof.

In the first gas supply pipe243a,a first gas supply source243b,a mass flow controller (MFC)243cserving as a flow rate controller (flow rate control unit) and a valve243dserving as an opening and closing valve are sequentially installed from an upstream end.

A gas containing a first element (hereinafter referred to as “a first process gas”) is supplied from the first gas supply source243band is supplied into the gas inlet241athrough the MFC243c,the valve243d,the first gas supply pipe243aand the common gas supply pipe242.

The first process gas is one of source gases, that is, the process gases. Here, the first element is, for example, silicon (Si). That is, the first process gas is, for example, a silicon-containing gas. As the silicon-containing gas, for example, dichlorosilane (DCS) (SiH2Cl2) gas may be used. Also, the first process gas source may be any one of a solid, a liquid and a gas at a room temperature and normal pressure. When the first process gas source is liquid at the room temperature and normal pressure, a vaporizer (not illustrated) may be installed between the first gas supply source243band the MFC243c.Here, the first process gas source serving as a gas will be described.

A downstream end of a first inert gas supply pipe246ais connected to a portion downstream from the valve243dof the first gas supply pipe243a.In the first inert gas supply pipe246a,an inert gas supply source246b,an MFC246cand a valve246dserving as an opening and closing valve are sequentially installed from an upstream end.

Here, the inert gas is, for example, nitrogen (N2) gas. Also, as an inert gas, in addition to the N2gas, rare gases such as helium (He) gas, neon (Ne) gas, argon (Ar) gas and the like may be used.

A first-element-containing gas supply unit243(referred to as a silicon-containing gas supply unit) mainly includes the first gas supply pipe243a,the MFC243cand the valve243d.

Also, a first inert gas supply unit mainly includes the first inert gas supply pipe246a, the MFC246cand the valve246d.Also, the inert gas supply source246band the first gas supply pipe243amay be considered as being included in the first inert gas supply unit.

Also, the first gas supply source243band the first inert gas supply unit may be considered as being included in the first-element-containing gas supply unit.

In the second gas supply pipe244a,a second gas supply source244b,an MFC244cand a valve244dserving as an opening and closing valve are sequentially installed from an upstream end.

A gas containing a second element (hereinafter referred to as “a second process gas”) is supplied from the second gas supply source244band is supplied into the gas inlet241a through the MFC244c,the valve244d,the second gas supply pipe244aand the common gas supply pipe242.

The second process gas is one of the process gases. Also, the second process gas may be a reactive gas or a modifying gas.

Here, the second process gas contains a second element different from the first element. The second element is, for example, a hydrogen-containing gas. Specifically, hydrogen (H) gas is used as the hydrogen-containing gas.

A second process gas supply unit244mainly includes the second gas supply pipe244a,the MFC244cand the valve244d.

In addition, a remote plasma unit (RPU)244eserving as an activation unit may be installed and may activate the second process gas.

Also, a downstream end of a second inert gas supply pipe247ais connected to a portion downstream from the valve244dof the second gas supply pipe244a.In the second inert gas supply pipe247a,an inert gas supply source247b,an MFC247cand a valve247dserving as an opening and closing valve are sequentially installed from an upstream end.

An inert gas is supplied into the gas inlet241a through the second inert gas supply pipe247avia the MFC247c,the valve247dand the second inert gas supply pipe247a.The inert gas serves as a carrier gas or a dilution gas in a thin film forming process (Operations S4100to S4005to be described below).

A second inert gas supply unit mainly includes the second inert gas supply pipe247a,the MFC247cand the valve247d.Also, the inert gas supply source247band the second gas supply pipe244amay be included in the second inert gas supply unit.

Also, the second gas supply source244band the second inert gas supply unit may be included in the second process gas supply unit244.

In the third gas supply pipe245a,a third gas supply source245b,an MFC245cserving as a flow rate controller (flow rate control unit) and a valve245dserving as an opening and closing valve are sequentially installed from an upstream end.

An inert gas serving as a purge gas is supplied from the third gas supply source245band is supplied into the gas inlet241athrough the MFC245c,the valve245d,the third gas supply pipe245aand the common gas supply pipe242.

Here, the inert gas is, for example, nitrogen (N2) gas. Also, as the inert gas, in addition to the N2gas, rare gases such as helium (He) gas, neon (Ne) gas, argon (Ar) gas and the like may be used.

The third gas supply unit245(referred to as a purge gas supply unit) mainly includes the third gas supply pipe245a,the MFC245cand the valve245d.

In the cleaning gas supply pipe243a,a cleaning gas supply source248b,an MFC248c,a valve248dand an RPU250are sequentially installed from an upstream end.

A cleaning gas is supplied from the cleaning gas supply source248band is supplied into the gas inlet241athrough the MFC248c,the valve248d,the RPU250, the cleaning gas supply pipe248aand the common gas supply pipe242.

A downstream end of a fourth inert gas supply pipe249ais connected to a portion downstream from the valve248dof the cleaning gas supply pipe248a.In the fourth inert gas supply pipe249a,a fourth inert gas supply source249b,an MFC249cand a valve249dare sequentially installed from an upstream end.

Also, a cleaning gas supply unit mainly includes the cleaning gas supply pipe248a, the MFC248cand the valve248d.Also, the cleaning gas supply source248b,the fourth inert gas supply pipe249aand the RPU250may be included in the cleaning gas supply unit.

Also, the inert gas supplied from the fourth inert gas supply source249bmay be supplied to serve as a carrier gas or a dilution gas of the cleaning gas.

The cleaning gas supplied from the cleaning gas supply source248bserves as the cleaning gas for removing by-products and the like attached to the gas inlet241a or the process chamber201in a cleaning process.

Here, the cleaning gas is, for example, nitrogen trifluoride (NF3) gas. Also, as the cleaning gas, hydrogen fluoride (HF) gas, chlorine trifluoride (ClF3) gas, fluorine (F2) gas or a combination thereof may be used.

Also, preferably, as the flow rate control unit installed in each of the above-described gas supply units, a flow rate control unit such as a needle valve or an orifice having high responsiveness with respect to the gas flow may be used. For example, although it may not be responsive in the MFC when the pulse width of the gas becomes of the order of milliseconds, it is possible to respond to the gas pulse of a millisecond or less in the needle valve or the orifice by adding a high-speed ON/OFF valve.

As illustrated inFIG. 14, the substrate processing apparatus100includes a controller121that controls operations of the respective units of the substrate processing apparatus100.

The controller121which is a control unit (control device) is configured as a computer that includes a central processing unit (CPU)121a,a random access memory (RAM)121b,a memory device121cand an input-and-output (I/O) port121d.The RAM121b, the memory device121c and the I/O port121d are configured to exchange data with the CPU121athrough an internal bus121e.An I/O device122configured as, for example, a touch panel or the like, an external memory device283, a receiving unit285or the like is configured to be connected to the controller121. Network284or the like is configured to be connected to the receiving unit285.

The memory device121c is configured as, for example, a flash memory, a hard disk drive (HDD) or the like. A control program controlling the operations of the substrate processing apparatus, a process recipe describing sequences or conditions of substrate processing to be described below, comparative film thickness distribution data used in a calculation process of process data to the substrate200, process data, and the like are readably stored in the memory device121c. Also, the process recipe or the control program, which in a sequential combination causes the controller121to execute each sequence in the substrate processing process to be described below, in order to obtain a predetermined result and functions as a program. Hereinafter, such a process recipe, a control program and the like are collectively simply called a “program.” Also, when the term “program” is used in this specification, it may refer to either the process recipe or the control program or both thereof. Also, the RAM121bis configured as a memory area (work area) in which a program, calculation data, process data and the like read by the CPU121aare temporarily stored.

The gate valve205, the lifting mechanism218, the pressure regulator223, the vacuum pump224, the RPU250, the MFCs243c,244c,245c,246c,247c,248cand249c, the valves243d,244d,245d,246d,247d,248dand249d,the first matching box250d,the second matching box250e,the first high frequency power250c,the second high frequency power250f,the first impedance adjuster220a,the second impedance adjuster220b,the first impedance adjusting power221a,the second impedance adjusting power221b,the first electromagnet power250i,the second electromagnet power250j,the first heater power213c,the second heater power213dand the like are connected to the I/O port121d.

The CPU121a serving as a calculation unit reads and executes the control program from the memory device121cand reads the process recipe from the memory device121caccording to an input of a control command from the I/O device122. Also, the film thickness distribution data input from the receiving unit285and the comparative film thickness distribution data stored in the memory device121c are compared and calculated to generate calculation data. Also, the determination process of process data (process recipe) corresponding to the calculating data or the like is performed. To comply with the contents of the read process recipe, the CPU121a is configured to control an on-off operation of the gate valve205, a lifting operation of the lifting mechanism218, a pressure regulating operation by the pressure regulator223, an on-off control of the vacuum pump224, a gas excitement operation of the RPU250, a flow rate regulating operation of the MFCs243c,244c,245c,246c,247c,248cand249c,an on-off control of a gas of the valves243d,244d,245d,246d,247d,248dand249d,a matching control of the first matching box250dand the second matching box250e,an on-off control of the first high frequency power250cand the second high frequency power250f,an impedance regulating operation by the first impedance adjuster220aand the second impedance adjuster220b,an on-off control of the first impedance adjusting power221aand the second impedance adjusting power221b, a power control for the first electromagnet power250iof the second electromagnet power250j,a power control for the first heater power213cand the second heater power213dand the like.

Also, the controller121is not limited to being configured as a dedicated computer, but may be configured as a general-purpose computer. For example, the controller121according to the present embodiment may be configured by preparing the external memory device283[e.g., a magnetic tape, a magnetic disk such as a flexible disk and a hard disk, an optical disc such as a CD or a DVD, a magneto-optical disc such as an MO and a semiconductor memory such as a USB memory and a memory card] recording the above-described program and then installing the program in the general-purpose computer using the external memory device283. Also, a method of supplying the program to the computer is not limited to supplying through the external memory device283. For example, a communication line such as the Internet or a dedicated line may be used to supply the program without the external memory device283. Also, the memory device121cor the external memory device283is configured as a non-transitory computer-readable recording medium. Hereinafter, these are also collectively simply called a recording medium. Also, when the term “recording medium” is used in this specification, it refers to either the memory device121cor the external memory device283or both thereof.

Next, a method of forming a film using the substrate processing apparatus100will be described. After the film thickness measuring process (S104), the measured substrate200is loaded into the substrate processing apparatus100. Also, in the following description, operations of the respective units constituting the substrate processing apparatus100are controlled by the controller121.

In the film thickness measuring process (S104), after the film thickness of the first poly-Si layer2005is measured, the substrate200is loaded into the substrate processing apparatus100. Specifically, the substrate support210is lowered by the lifting mechanism218, and the lift pins207protrude from an upper surface of the substrate support210from the through holes214. Also, after the pressure in the process chamber201is adjusted to a predetermined pressure, the gate valve205is opened and the substrate200is placed on the lift pins207from the gate valve205. After the substrate200is placed on the lift pins207, the substrate200is placed on the substrate support210from the lift pins207by lifting the substrate support210to a predetermined position by the lifting mechanism218. Here, the predetermined pressure is, for example, a pressure when the pressure in the process chamber201is greater than or equal to a pressure in the vacuum transfer chamber104.

[Pressure Decreasing and Temperature Adjusting Process (S4001)]

Next, the process chamber201is exhausted through the exhaust pipe222such that the pressure in the process chamber201becomes a predetermined pressure (a degree of vacuum). In this case, a degree of the valve opening of an APC valve serving as the pressure regulator223is feedback controlled based on a pressure value measured by a pressure sensor. Also, an amount of power supply to the heater213is feedback controlled based on a temperature value detected by a temperature sensor (not illustrated) such that a temperature in the process chamber201reaches a predetermined temperature. Specifically, the substrate support210is pre-heated by the heater213and remains for a predetermined time in a state in which the temperature of the substrate200or the substrate support210is not changed. During the time, when a gas is emitted from residual material or there is residual moisture in the process chamber201, the gases may be removed by vacuum exhaustion or purging by supplying N2gas. In this manner, the preparation before a film forming process is completed. Also, when the process chamber201is exhausted such that the pressure therein becomes the predetermined pressure, the process chamber201may be vacuum-exhausted to a degree of vacuum that it can reach at once.

Also, here, the first heater213aand the second heater213bmay be configured to tune their temperatures based on received data. When the temperature of the center portion of the substrate200is tuned to be different from that of the peripheral portion thereof, the process of the center portion of the substrate200may be different from that of the peripheral portion thereof.

Next, the first electromagnet power250iand the second electromagnet power250jsupply predetermined power to the first electromagnet250gand the second electromagnet250hrespectively so that a predetermined magnetic field is formed in the process chamber201. For example, a magnetic field in a Z1direction is formed. In this case, a magnetic field or magnetic flux density formed in an upper portion of the center portion of the substrate200or an upper portion of the peripheral portion thereof is tuned based on the received measurement data. The magnetic field or the magnetic flux density may be turned by a magnetic field strength generated from the first electromagnet250gand a magnetic field strength generated from the second electromagnet250h.

Here, when the electronic shield plate250kis installed in the process chamber201, a height of the electronic shield plate250kmay be turned. The magnetic field or the magnetic flux density may be turned by tuning the height of the electronic shield plate250k.

Also, here, the first bias electrode219aand the second bias electrode219bmay be configured to adjust the respective electric potential. For example, the first impedance adjuster220aand the second impedance adjuster220bare adjusted such that the electric potential of the first bias electrode219ais lower than that of the second bias electrode219b. When the electric potential of the first bias electrode219ais lower than that of the second bias electrode219b,an amount of the active species which flow onto the center portion of the substrate200may be greater than an amount of the active species which flow into the peripheral portion of the substrate200, and the throughput of the center portion of the substrate200may be greater than that of the peripheral portion thereof.

[Process Gas Supply Process (S4003)]

Next, a silicon-element-containing gas serving as a first process gas is supplied into the process chamber201through the first process gas supply unit. Also, by continuing the gas exhausting from the process chamber201through the exhaust system, the pressure in the process chamber201reaches a predetermined pressure (a first pressure). Specifically, the valve243dof the first process gas supply pipe243ais opened, and the silicon-element-containing gas flows into the first process gas supply pipe243a.The silicon-element-containing gas flows through the first process gas supply pipe243a,and a flow rate thereof is adjusted by the MFC243c.The silicon-element-containing gas of which the flow rate is adjusted is supplied into the process chamber201through the gas inlet241aand is exhausted through the exhaust pipe222. Also, in this case, the valve246dof the first carrier gas supply pipe246ais opened, and Ar gas may flow into the first carrier gas supply pipe246a.The Ar gas flows through the first carrier gas supply pipe246a,and a flow rate thereof is adjusted by the MFC246c.The Ar gas of which the flow rate is adjusted is mixed with the silicon-element-containing gas in the first process gas supply pipe243ato be supplied into the process chamber201through the gas inlet241aand is exhausted through the exhaust pipe222.

Next, high frequency power is supplied from the first high frequency power250cto the first coil250athrough the first matching box250d,and the silicon-element-containing gas present in the process chamber201is activated. In this case, specifically, silicon-element-containing plasma is generated in the first plasma generating region251, and the activated silicon-element-containing gas is supplied onto the substrate200. Preferably, it is configured such that different concentrations of active species are supplied onto the center portion of the substrate200and the peripheral portion thereof. For example, when a size of a magnetic field formed by the second electromagnet250his greater than a size of a magnetic field formed by the first electromagnet250g,the plasma density in the fourth plasma generating region254may be greater than the plasma density in the third plasma generating region253. In this case, in the substrate200, activated plasma may be generated in the upper portion of the peripheral portion of the substrate200as opposed the upper portion of the center portion of the substrate200.

In this manner, a state in which the silicon-element-containing plasma is generated is retained for a predetermined time, and a predetermined process is performed.

Also, it is configured such that the concentration of active species in the center portion is different from the concentration of active species in the peripheral portion by an electric potential difference between the first bias electrode219aand the second bias electrode219b.

Also, in this case, high frequency power is supplied from the second high frequency power250fto the second coil250bthrough the second matching box250e,and silicon-element-containing plasma may be generated in the second plasma generating region252.

In a state in which the silicon-element-containing plasma is generated, after a predetermined time has elapsed, the high frequency power is turned off and the plasma disappears. In this case, the supply of the silicon-element-containing gas serving as a process gas may be stopped, or the supply may continue for a predetermined time. After the supply of the silicon-element-containing gas is stopped, the gas remaining in the process chamber201is exhausted through the exhaust unit. In this case, it is configured such that an inert gas is supplied into the process chamber201through the inert gas supply unit to extrude the remaining gas. In such a configuration, the duration of the purge process may be reduced, and the throughput may be improved.

After the purge process (S4005) is performed, a substrate unloading process (S3006) is performed and the substrate200is unloaded from the process chamber201. Specifically, the process chamber201is purged with an inert gas, and the pressure therein is adjusted to transfer the inert gas. After the adjustment of the pressure, the substrate support210is lowered by the lifting mechanism218, the lift pins207protrude from the through holes214, and the substrate200is placed onto the lift pins207. After the substrate200is placed onto the lift pins207, the gate valve205is opened and the substrate200is unloaded from the process chamber201.

Next, a method of controlling a film thickness of the second silicon-containing layer using the present apparatus will be described. As described above, after the CMP process (S103) is completed, the film thickness of the first poly-Si layer2005in the center portion of the substrate200is different from the film thickness of the first poly-Si layer2005in the peripheral portion thereof. In the film thickness measuring process (S104), a distribution of the film thickness is measured. The measured result is stored in the RAM121bthrough an upper apparatus (not illustrated). Stored data is compared to a recipe in the memory device121c,and predetermined process data is calculated by the CPU121a.The apparatus is controlled based on the process data.

Next, the case in which the data stored in the RAM121bis a distribution A will be described. The case of the distribution A refers to the case in which the poly-Si layer2005ahas a greater thickness than that of the poly-Si layer2005bas illustrated inFIG. 7.

In the present process, thickness is controlled such that the film thickness of the second poly-Si layer on the peripheral portion of the substrate200is increased and the film thickness of the second poly-Si layer on the center portion of the substrate200is decreased, such that a target film thickness distribution A′ compensates for the distribution A as illustrated inFIG. 20. For example, when the strength of the magnetic field generated from the second electromagnet250his greater than the strength of the magnetic field generated from the first electromagnet250g,the plasma density in the fourth plasma generating region254may be greater than the plasma density in the third plasma generating region253, and activated plasma may be generated on the upper portion of the peripheral portion of the substrate200compared to the upper portion of the center portion of the substrate200. The film thickness of the peripheral portion of the substrate200may be increased by processing it under the generated plasma.

In this case, the thickness of the poly-Si layer2006is controlled such that the thickness of the poly-Si layer2005bon which the poly-Si layer2006bis stacked is substantially the same as the thickness of the poly-Si layer2005aon which the poly-Si layer2006ais stacked. Preferably, it should be controlled such that a distance from the surface of the substrate to an upper end of the second silicon-containing layer is within a predetermined range. Also, more preferably, the film thickness distribution of the second silicon-containing layer is controlled such that a distribution of the height of the second silicon-containing layer (the upper end of the second silicon-containing layer) in the surface of the substrate is within a predetermined range.

Also, as another method, the electric potential of the first bias electrode219aand the electric potential of the second bias electrode219bmay be individually controlled. For example, when the electric potential of the second bias electrode219bis lower than the electric potential of the first bias electrode219a,an amount of the active species which flow onto the peripheral portion of the substrate200is increased, and thus the film thickness of the peripheral portion of the substrate200may be increased.

Also, power supplied to the first coil250aand power supplied to the second coil250bmay be individually controlled. For example, when the power supplied to the second coil250bis greater than the power supplied to the first coil250a,an amount of the active species supplied onto the peripheral portion of the substrate200is increased, and thus the film thickness of the peripheral portion of the substrate200may be increased.

Also, a more careful control is possible by performing a plurality of controls in parallel.

In the present process, the thickness is controlled such that the film thickness of the second poly-Si layer on the center portion of the substrate200is increased and the film thickness of the second poly-Si layer on the peripheral portion of the substrate200is decreased, such that a target film thickness distribution B′ compensates for the distribution B as illustrated inFIG. 21. For example, the generation of the plasma in the third plasma generating region253may be controlled by controlling the magnetic field formed by the first electromagnet250gand the magnetic field formed by the second electromagnet250h.

In this case, the thickness of the poly-Si layer2006is controlled such that the thickness of the poly-Si layer2005bon which the poly-Si layer2006bis stacked is the same as the thickness of the poly-Si layer2005aon which the poly-Si layer2006ais stacked.

Also, as another method, the electric potential of the first bias electrode219aand the electric potential of the second bias electrode219bmay be individually controlled. For example, when the electric potential of the first bias electrode219ais lower than the electric potential of the second bias electrode219b,an amount of the active species which flow into the center portion of the substrate200is increased, and thus the film thickness of the center portion of the substrate200may be increased.

Also, the power supplied to the first coil250aand the power supplied to the second coil250bmay be individually controlled. For example, when the power supplied to the first coil250ais greater than the power supplied to the second coil250b,an amount of the active species supplied onto the center portion of the substrate200is increased, and thus the film thickness of the center portion of the substrate200may be increased.

A more careful control is possible by performing a plurality of controls in parallel.

Next, a film thickness measuring process (S106) will be described. In the film thickness measuring process (S106), a height of a layer on which the first poly-Si layer and the second poly-Si layer are stacked is measured, and it is determined whether or not the height of the stacked layer is aligned. That is, whether or not the film thickness of the poly-Si layer compensates is determined. Here, “the height is aligned” is not limited to the case in which the height is completely aligned, and there may be a difference in the height. For example, the difference in the height may be within a range that does not influence the subsequent exposure process or etching process. When the distribution of the height in the surface of the substrate200is within a predetermined range, a nitride film forming process (S107) is performed. Also, when it is already known that the film thickness distribution is within the predetermined range, the film thickness measuring process (S106) may be omitted.

Next, a nitride film forming process (S107) will be described. After the second silicon-containing layer forming process (S105) or the film thickness measuring process (S106), the substrate200is loaded into a nitride film forming device100d.Since the nitride film forming device100dis a general single substrate processing apparatus, description thereof is omitted.

In the present process, a silicon nitride film2007is formed on the second poly-Si layer2006as illustrated inFIG. 17B. The silicon nitride film serves as a hard mask in an etching process to be described below. Also, the distribution A is described as an example inFIG. 17B, but is not limited thereto. Needless to say that it is the same in the case of distribution B.

In the nitride film forming apparatus100d,a silicon-containing gas and a nitrogen-containing gas are supplied into the process chamber201to form the silicon nitride film2007on the substrate200. The silicon-containing gas is, for example, disilane (Si2H6) gas and the nitrogen-containing gas is, for example, ammonia (NH3) gas.

Since the silicon nitride film2007is formed on the poly-Si film of which the height is aligned in the second poly-Si layer forming process, the height of the silicon nitride film also has a height distribution within a predetermined range in the surface of the substrate. That is, a distance from the concave structure surface2002ato a surface of the nitride film2007in the surface of the substrate200is within a predetermined range in the surface of the substrate200.

Next, a film thickness measuring process (S108) will be described. In the film thickness measuring process (S108), a height of a layer on which the first poly-Si layer, the second poly-Si layer and the silicon nitride film are stacked is measured. When the height is within a predetermined range, a patterning process (S109) is performed. Here, “the height is within a predetermined range” is not limited to the case in which the height is completely aligned, and there may be a difference in the height. For example, the difference in the height may be within a range that does not influence the subsequent exposure process or etching process. Also, when it is already known that the height of the layer on which the first poly-Si layer, the second poly-Si layer and the silicon nitride film are stacked is a predetermined value, the film thickness measuring process (S108) may be omitted.

Next, a patterning process (S106) will be described with reference toFIGS. 18A, 18B, 19A and 19B.FIG. 18A and 18Bare explanatory diagrams illustrating the substrate200in an exposure process.FIG. 19A and 19Bare explanatory diagrams illustrating the substrate200after an etching process.

Hereinafter, detailed description thereof will be described. After the silicon nitride film is formed, the silicon nitride film is covered with a resist film2008. Then, a lamp501emits light and an exposure process is performed. In the exposure process, light503is emitted onto the resist film2008through the mask502to modify a portion of the resist film2008. Here, the modified resist film is referred to as a resist film2008aand the unmodified resist film is referred to as a resist film2008b.

As described above, a height from the concave structure surface2002ato the surface of the nitride film2007is within the predetermined range in the surface of the substrate200. Therefore, the height from the concave structure surface2002ato a surface of the resist film2008may be aligned. In the exposure process, a distance in which light travels to reach the resist film, that is, the travel of the light503, is equal in the surface of the substrate200. Therefore, it is possible to equalize the in-surface distribution of the depth of focus.

Since the depth of focus is equalized, a width of the resist film2008amay be constant in the surface of the substrate as illustrated in18B. Therefore, it is possible to remove the deviation of the pattern width.

Next, the state of the substrate200after the etching process will be described with reference toFIGS. 19A and 19B. As described above, since the width of the resist film2008ais constant, it is possible to make a constant etching condition in the surface of the substrate200. Therefore, in the center portion of the substrate200or the peripheral portion thereof, an etching gas is uniformly supplied and thus it is possible to constantly make the width β of the poly-Si layer (hereinafter referred to as a filler) after the etching process. Since the width β is constant in the surface of the substrate200, it is possible to constantly make the characteristic of the gate electrode in the surface of the substrate, thus improving the yield.

Next, comparative examples will be described with reference toFIGS. 22A, 22B, 23A and 23B. In the comparative examples, the second silicon-containing layer forming process (S105) is not performed. Therefore, the height at the center portion of the substrate200is different from that at the peripheral portion thereof.

First, a first comparative example will be described with reference toFIGS. 22Aand22B.FIGS. 22A and 22Bare views in comparison withFIGS. 18A and 18B. InFIG. 22B, since the height of the poly-Si layer at the center portion of the substrate200is different from that at the peripheral portion thereof, the distance the light travels to reach503at the center portion of the substrate200is different from that for reaching the peripheral portion of the substrate200. Therefore, the focal length at the center portion is different from at the peripheral portion, and as a result, the width of the resist film2008ais changed in the surface of the substrate. When the process is performed using the resist film2008, the width of the filler after the etching process is changed, and thus a variation occurs in the characteristics.

On the other hand, in the present embodiment, since the second silicon-containing layer forming process (S105) is performed, the width of the filler may be constant in the surface of the substrate200. Therefore, the semiconductor device having uniform characteristics is formed compared to the comparative example, and thus it may significantly contribute to improve the yield.

Next, a second comparative example will be described with reference toFIGS. 23A and 23B.FIGS. 23A and 23Bare views in comparison withFIGS. 19A and 19B.FIGS. 23A and 23Bare explanatory diagrams, for example, in the case in which there is no variation of the width of the resist film2008aat the center portion of the substrate200and the peripheral portion of the substrate200. That is, it refers to a case in which there is no variation in a width of an opening between the resist films2008a[a place where the resist film2008ais removed].

After the resist film2008bis removed, an etching process is performed. In the etching process, the poly-Si film is removed, and thus the height of the poly-Si film at the center portion of the substrate200is different from at the peripheral portion of the substrate200. Therefore, for example, when etching time is set according to an etching requirement for the height of the center portion, a desired amount of the poly-Si film may be etched in the center portion, but residual material remains for etching in the peripheral portion. Meanwhile, when the center portion is etched according to an etching requirement for the height of the peripheral portion, a desired amount of the poly-Si film may be etched in the peripheral portion, but a side wall of the filler, the gate insulating film2004, and the device isolation film2003are etched in the center portion.

When the side wall of the filler is etched, a distance γ between the poly-Si films of the filler at the center portion of the substrate200is different from that at the peripheral portion thereof. That is, a width β of the poly-Si film of the filler at the center portion of the substrate200is different from that at the peripheral portion thereof.

Since the characteristics of the electrode are likely to be affected by the width β, the deviation also occurs in the characteristics of the formed electrode when the variation in the width β occurs. Therefore, the deviation in the width β results in reduction of the yield.

Therefore, in the present embodiment, it is possible to align the width of the filler at the center portion of the substrate200and the peripheral portion thereof by aligning the height of the poly-Si film. Therefore, the yield may be improved.

Other Embodiments

The present invention is not limited to be a processing sequence example in which an amount of the film formed on the center portion of the substrate200is different from an amount of the film formed on the peripheral portion thereof, as illustrated inFIG. 16, as there are the following processing sequence examples.

For example, there is a processing sequence example as illustrated inFIG. 24.FIG. 24illustrates a processing example in which a magnetic field is generated by the second electromagnet250hafter a magnetic field is generated by the first electromagnet250g.By processing in this manner, the amount of film formed on the peripheral portion of the substrate200may be greater than the amount of film formed on the center portion thereof. On the other hand, when the magnetic field is generated by the first electromagnet250gafter the magnetic field is generated by the second electromagnet250h,the amount of film formed on the center portion of the substrate200may be greater than the amount of film formed on the peripheral portion thereof.

Also, there is a processing sequence example as illustrated inFIG. 25.FIG. 25illustrates a processing example in which power supplied to the second coil250bis greater than power supplied to the first coil250a.By processing in this manner, the amount film formed on the peripheral portion of the substrate200may be greater than the amount of film formed on the center portion thereof On the other hand, when the power supplied to the first electromagnet250gis greater than the power supplied to the second electromagnet250hand the power supplied to the first coil250ais greater than the power supplied to the second coil250b,the amount of film formed on the center portion of the substrate200may be greater than the amount of film formed on the peripheral portion thereof.

Also, there is a processing sequence example as illustrated inFIG. 26.FIG. 26illustrates a processing example in which an electric potential of the first bias electrode219ais greater than an electric potential of the second bias electrode219b.By processing in this manner, the amount of film formed on the peripheral portion of the substrate200may be greater than the amount of film formed on the center portion thereof. On the other hand, when the power supplied to the first electromagnet250gis greater than the power supplied to the second electromagnet250hand the electric potential of the second bias electrode219bis greater than the electric potential of the first bias electrode219a,the amount of film formed on the center portion of the substrate200may be greater than the amount of film formed on the peripheral portion thereof.

Also, although it is described above that the plasma is generated in the process chamber201using the first coil250a,the first electromagnet250gand the second electromagnet250h,the plasma generation method is not limited thereto. For example, the plasma may be generated in the process chamber201using the second coil250b,the first electromagnet250gand the second electromagnet250h.Although the plasma in the case of using only the second coil250bis mainly generated in the second plasma generating region252, the active species generated in the second plasma generating region is caused to diffuse to the center portion of the substrate200by using either the first electromagnet250gor the second electromagnet250hor both thereof, and thus be adjustable for the processing distribution.

Also, although it is described above that the center portion of the substrate200and the peripheral portion thereof are divided, but the present invention is not limited thereto. The film thickness of the silicon-containing film may be controlled by defining finer division of the regions along the radial direction. For example, it may be divided into three regions such as the center portion of the substrate200, the peripheral portion thereof, and a portion between the center portion and the peripheral portion.

Also, although it is described above that the diameter of the first electromagnet250gis the same as the diameter of the second electromagnet250h,but the present invention is not limited thereto. For example, the diameter of the second electromagnet250hmay be greater than the diameter of the first electromagnet250g,and the diameter of the first electromagnet250gmay be greater than the diameter of the second electromagnet250h.

Also, although the silicon nitride film serving as a hard mask is described above as an example here, but the present invention is not limited thereto. For example, the silicon oxide film may be used.

Also, the present invention is not limited to the silicon oxide film or the silicon nitride film, and the pattern may be formed of an oxide film, a nitride film, a carbide film, an oxynitride film, a metal film or a combination thereof, each of which contains different elements.

Also, although it is described above that the first silicon-containing layer forming device100a,the CMP apparatus100b,the measuring apparatus100cand the nitride film forming device100dare configured in the same processing system4000, but the present invention is not limited thereto. For example, a system including each of the first silicon-containing layer forming device100a,the CMP device100b,the measuring apparatus100cand the nitride film forming device100dmay be configured, and the processing system400including a combination of two or more components may be configured.

Also, although the substrate200of 300 mm is described above as an example, but the present invention is not limited thereto. For example, when the substrate200of 450 mm or more is used, the resulting effects are increased. In the case of a large substrate, the effects of the polishing process (S103) are significantly increased. That is, the difference between the film thicknesses of the poly-Si layer2005aand the poly-Si layer2005bis further increased. Also, the effects of the in-surface film quality distribution of the first poly-Si layer formed in the first silicon-containing layer forming process (S102) on the polishing process (S103) is increased, a challenge in which the difference between the film thicknesses is further increased occurs. The challenge may be resolved by optimizing the condition of each of the first silicon-containing layer forming process (S102) and the polishing process (S103). However, it takes much time and high cost for the optimization of the condition or the optimization of the condition that do not affect the operations. On the other hand, when the compensation process is performed as described above, the film compensates without the optimization of the condition of each of the first silicon-containing layer forming process (S102) or the polishing process (S103).

Also, although one process of the processes of manufacturing the semiconductor device is described above, but the process is not limited thereto. A backend processes including similar process may be used. Also, it may be applied to a technique for processing the substrate such as a patterning process in a liquid crystal panel manufacturing process, a patterning process in a solar cell manufacturing process, a patterning process in a power device manufacturing process or the like.

According to the technique in accordance with the present invention, it is possible to suppress the deviation of the characteristics of semiconductor device.

Preferred Embodiments of the Present Invention

Hereinafter, preferred embodiments according to the present invention are supplementarily noted.

According to an aspect of the present disclosure, there is provided a method of manufacturing a semiconductor device or a substrate processing method, the method including:

(a) receiving data representing a thickness distribution of a polished silicon-containing layer on a substrate including a convex structure whereon the polished silicon-containing layer is formed;

(b) calculating, based on the data, a process data for reducing a difference between a thickness of a portion of the polished silicon-containing layer formed at a center portion of the substrate and that of the polished silicon-containing layer formed at a peripheral portion of the substrate;

(c) loading the substrate into a process chamber;

(d) supplying a process gas to the substrate; and

(e) compensating for the difference based on the process data by activating the process gas with a magnetic field having a predetermined strength on the substrate.

In the method of Supplementary note 1, preferably, a strength of the magnetic field generated at a side of the substrate is adjusted to be greater than that of the magnetic field generated above the substrate in the step (e) when the data indicates the portion of the polished silicon-containing layer formed at the peripheral portion of the substrate is thinner than that of the polished silicon-containing layer formed at the center portion of the substrate.

In the method of any one of Supplementary notes 1 and 2, preferably, a high frequency power supplied to a second coil disposed at a side of the substrate is greater than a high frequency power supplied to a first coil disposed above the substrate in the step (e) when the data indicates the portion of the polished silicon-containing layer formed at the peripheral portion of the substrate is thinner than that of the polished silicon-containing layer formed at the center portion of the substrate.

In the method of any one of Supplementary notes 1 through 3, preferably, an electric potential applied to the peripheral portion of the substrate is lower than an electric potential applied to the center portion of the substrate in the step (e) when the data indicates the portion of the polished silicon-containing layer formed at the peripheral portion of the substrate is thinner than that of the polished silicon-containing layer formed at the center portion of the substrate.

In the method of Supplementary note 1, preferably, a strength of the magnetic field generated above the substrate is adjusted to be greater than that of the magnetic field generated at a side of the substrate in the step (e) when the data indicates the portion of the polished silicon-containing layer formed at the center portion of the substrate is thinner than that of the polished silicon-containing layer formed at the peripheral portion of the substrate.

In the method of any one of Supplementary notes 1 and 5, preferably, a high frequency power supplied to a first coil disposed above the substrate is greater than a high frequency power supplied to a second coil disposed at a side of the substrate in the step (e) when the data indicates the portion of the polished silicon-containing layer formed at the center portion of the substrate is thinner than that of the polished silicon-containing layer formed at the peripheral portion of the substrate.

In the method of any one of Supplementary notes 1, 5 and 6, preferably, an electric potential applied to the center portion of the substrate is lower than an electric potential applied to the peripheral portion of the substrate in the step (e) when the data indicates the portion of the polished silicon-containing layer formed at the center portion of the substrate is thinner than that of the polished silicon-containing layer formed at the peripheral portion of the substrate.

In the method of any one of Supplementary notes 1 through 7, preferably, the step (d) includes supplying a silicon-containing gas as the process gas, and the step (e) includes compensating for the difference by forming a silicon-containing layer on the polished silicon layer.

In the method of any one of Supplementary notes 1 through 8, preferably, the convex structure is disposed on a portion of the substrate.

According to another aspect of the present disclosure, there is provided a program or a non-transitory computer-readable recording medium storing a program for causing a computer to control a substrate processing apparatus to perform:

(a) receiving data representing a thickness distribution of a polished silicon-containing layer on a substrate including a convex structure whereon the polished silicon-containing layer is formed;

(b) calculating, based on the data, a process data for reducing a difference between a thickness of a portion of the polished silicon-containing layer formed at a center portion of the substrate and that of the polished silicon-containing layer formed at a peripheral portion of the substrate;

(c) loading the substrate into a process chamber;

(d) supplying a process gas to the substrate; and

(e) compensating for the difference based on the process data by activating the process gas with a magnetic field having a predetermined strength on the substrate.

According to still another aspect of the present disclosure, there is provided a substrate processing apparatus including:

a receiving unit configured to receive data representing a thickness distribution of a polished silicon-containing layer on a substrate including a convex structure whereon the polished silicon-containing layer is disposed;

a calculating unit configured to calculate, based on the data, a process data for reducing a difference between a thickness of a portion of the polished silicon-containing layer formed at a center portion of the substrate and that of the polished silicon-containing layer formed at a peripheral portion of the substrate;

a process chamber where the substrate is accommodated;

a process gas supply unit configured to supply a process gas into the process chamber;

a magnetic field generator configured to generate a magnetic field having a predetermined strength in the process chamber;

an activation unit configured to activate the process gas; and

a control unit configured to control at least one of the receiving unit, the calculating unit, the process gas supply unit, the magnetic field generator and the activation unit to compensate for the difference based on the process data by activating the process gas with the magnetic field.