SUBSTRATE PROCESSING APPARATUS

A substrate processing apparatus includes: a processing container; a stage provided in an interior of the processing container to place a substrate on the stage; an exhaust space arranged around the stage along an inner wall of the processing container; a first exhaust path provided between a processing space above the stage and the exhaust space and having a smaller conductance than the processing space; and a second exhaust path provided between a lower space below the stage and the exhaust space and having a smaller conductance than the processing space. A processing gas supplied into the processing space is exhausted via the first exhaust path, a purge gas supplied into the lower space is exhausted via the second exhaust path, and the second exhaust path is connected to the first exhaust path or to a space that is closer to the exhaust space than the first exhaust path.

CROSS-REFERENCE TO RELATED APPLICATION

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2022-097025, filed on Jun. 16, 2022, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

Various aspects and embodiments of the present disclosure relate to a substrate processing apparatus.

BACKGROUND

There is known a technique that supplies a gas containing two types of monomers into a processing container in which a substrate is accommodated, and forms an organic film of a polymer on the substrate by a polymerization reaction between the two types of monomers. For example, there is known a technique for forming an organic film of a polymer on a substrate by a vacuum deposition polymerization reaction between an aromatic alkyl, alicyclic or aliphatic diisocyanate monomer, and an aromatic alkyl, alicyclic or aliphatic diamine monomer (see, for example, Patent Document 1).

PRIOR ART DOCUMENT

Patent Document

SUMMARY

According to an embodiment of the present disclosure, there is provided a substrate processing apparatus, including: a processing container; a stage provided in an interior of the processing container to place a substrate on the stage; an exhaust space arranged around the stage along an inner wall of the processing container; a first exhaust path provided between a processing space above the stage and the exhaust space and having a smaller conductance than the processing space; and a second exhaust path provided between a lower space below the stage and the exhaust space and having a smaller conductance than the processing space, wherein a processing gas supplied into the processing space is exhausted via the first exhaust path, a purge gas supplied into the lower space is exhausted via the second exhaust path, and the second exhaust path is connected to the first exhaust path or to a space that is closer to the exhaust space than the first exhaust path.

DETAILED DESCRIPTION

Embodiments of a substrate processing apparatus of the present disclosure will be described in detail below with reference to the drawings. It should be noted that the disclosed substrate processing apparatus is not limited to the following embodiments. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one of ordinary skill in the art that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, systems, and components have not been described in detail so as not to unnecessarily obscure aspects of the various embodiments.

In vapor deposition polymerization of an organic film, a film-forming rate greatly changes depending on processing conditions. In particular, a concentration of a film-forming gas used for forming the organic film and a temperature of a place where a film is formed are important. For example, when the concentration of the film-forming gas is high and the temperature of the place where the film is formed is low, the film-forming rate becomes higher. When the concentration of the film-forming gas is low and the temperature of the place where the film is formed is high, the film-forming rate becomes lower. Therefore, in a space where a substrate in which a film is to be formed is arranged, the concentration of the film-forming gas needs to be kept high and the temperature of the substrate needs to be kept low.

Meanwhile, in a substrate processing apparatus for forming an organic film on a substrate, a film-forming gas that did not contribute to the formation of the organic film is exhausted. A portion of the film-forming gas that did not contribute to the formation of the organic film may diffuse inside a processing container of the substrate processing apparatus and may form an organic film on an inner wall and the like of the processing container. As a processing on a plurality of substrates progresses, the organic film formed on the inner wall and the like of the processing container may grow and may eventually become particles and adhere to the substrates. Therefore, a measure may be taken to suppress the formation of the organic film on the inner wall and the like of the processing container by heating the inner wall and the like of the processing container.

However, a certain portion inside the processing container may be less likely to be heated to a high temperature. For such a portion in the processing container, it is difficult to suppress the formation of the organic film. As a result, a film-forming process is frequently stopped to clean the interior of the processing container, which reduces throughput of the film-forming process. Thus, it is conceivable to suppress the formation of the organic film by supplying a purge gas to the certain portion inside the processing container, which is less likely to be heated, and diluting the film-forming gas supplied to the certain portion with the purge gas.

However, when the purge gas flows around the substrate, the concentration of the film-forming gas near the substrate decreases, which decreases the film-forming rate of the organic film on the substrate. As a result, the time required to form the organic film having a desired thickness on the substrate increases. This reduces the throughput of substrate processing such as film formation.

First Embodiment

[Configuration of Substrate Processing Apparatus10]

FIG.1is a schematic cross-sectional view showing an example of a substrate processing apparatus10according to an embodiment of the present disclosure. The substrate processing apparatus10includes an apparatus body200and a control device100that controls the apparatus body200. The apparatus body200includes a processing container209. The processing container209includes a lower container201, an exhaust duct202, a support structure210, and shower head230.

The lower container201is made of a metal such as aluminum. The exhaust duct202is provided on an upper peripheral edge of the lower container201. An annular insulating member204is arranged above the exhaust duct202. The shower head230is provided above lower container201and is supported by the insulating member204. The support structure210on which the substrate W is placed is provided substantially at the center of the lower container201. A space between the support structure210and the shower head230is defined as a processing space SP.

A sidewall of the lower container201is formed with an opening205for loading and unloading a substrate W therethrough. The opening205is opened and closed by a gate valve G. The exhaust duct202has a longitudinal cross-section of a hollow rectangular shape, and extends annularly along an upper portion of the lower container201.

One end of an exhaust pipe206is connected to the exhaust duct202. The other end of the exhaust pipe206is connected to an exhaust device208including a vacuum pump or the like via a pressure regulation valve207such as an APC (Auto Pressure Controller) valve. The pressure regulation valve207is controlled by the control device100to control an internal pressure of the processing space SPto a preset pressure.

A heater (not shown) is provided on the sidewall of the exhaust duct202and an upper surface of the shower head230to heat the exhaust duct202and the shower head230to a temperature of, for example, 200 degrees C. or higher. This suppresses reaction by-products (so-called deposits) from adhering to the exhaust duct202and the shower head230to some extent. The exhaust pipe206, the pressure regulation valve207, and the exhaust device208may also be provided with heaters and may be heated to a temperature at which deposits are less likely to adhere.

The support structure210includes a stage211and a support212. The stage211is made of a metal such as aluminum, and the substrate W is placed on an upper surface of the stage211. The shower head230is provided at a position facing the stage211. The support212is made of a metal such as aluminum in a cylindrical shape, and supports the stage211from below.

A heater214is embedded in the stage211. The heater214heats the substrate W placed on the stage211based on power supplied thereto. The power supplied to the heater214is controlled by the control device100.

Further, a flow path215through which a coolant flows is formed inside the stage211. A chiller unit (not shown) is connected to the flow path215via a pipe216aand a pipe216b. The coolant whose temperature is adjusted to a predetermined temperature by the chiller unit is supplied to the flow path215via the pipe216a. The coolant flowing in the flow path215is returned to the chiller unit via the pipe216b. The stage211is cooled down by the coolant circulating in the flow path215. The chiller unit is controlled by the control device100.

The support212is arranged inside the lower container201so as to pass through an opening formed at the bottom of the lower container201. The support212is moved up and down with driving of an elevating mechanism240. The elevating mechanism240is an example of a driver. When loading the substrate W, the support structure210is lowered with the driving of the elevating mechanism240, and the gate valve G is open. Then, the substrate W is loaded into the lower container201by a transfer robot (not shown) via the opening205and delivered to lift pins (not shown) protruding above the stage211. Then, the substrate W is placed on the stage211by lowering the lift pins (not shown). Then, the gate valve G is closed, the elevating mechanism240is driven to raise the support structure210, and a film-forming process is performed on the substrate W. Further, when unloading the substrate W, the support structure210is lowered with the driving of the elevating mechanism240, and the gate valve G is open. Then, the substrate W is lifted from the stage211by lifting the lift pins (not shown). Then, the substrate W on the lift pins (not shown) is transferred out of the lower container201via the opening205by the transfer robot (not shown).

The shower head230includes a diffusion chamber231aand a diffusion chamber231b. The diffusion chamber231aand the diffusion chamber231bare not in communication with each other. A gas supplier220is connected to the diffusion chambers231aand231b. Specifically, a valve224a, an MFC (Mass Flow Controller)223a, a vaporizer222a, and a raw material source221aare connected to the diffusion chamber231avia a pipe225a. The raw material source221ais a source of isocyanate, which is an example of a first monomer. The vaporizer222avaporizes an isocyanate liquid supplied from the raw material source221a. The MFC223acontrols a flow rate of an isocyanate vapor vaporized by the vaporizer222a. The valve224acontrols the supply and cutoff of the isocyanate vapor to the pipe225a.

A valve224b, an MFC223b, a vaporizer222b, and a raw material source221bare connected to the diffusion chamber231bvia a pipe225b. The raw material source221bis a source of amine, which is an example of a second monomer. The vaporizer222bvaporizes an amine liquid supplied from the raw material source221b. The MFC223bcontrols a flow rate of an amine vapor vaporized by the vaporizer222b. The valve224bcontrols the supply and cutoff of the amine vapor to the pipe225b. The isocyanate vapor and the amine vapor are examples of film-forming gases. Further, the isocyanate vapor is an example of a first process gas, and the amine vapor is an example of a second process gas.

A valve224c, an MFC223c, and a cleaning gas source221care connected to the shower head230via the pipe225aand the pipe225b. The cleaning gas source221cis a source of a cleaning gas containing molecules including, for example, oxygen atoms or fluorine atoms. The MFC223ccontrols a flow rate of the cleaning gas supplied from the cleaning gas source221c. The valve224ccontrols the supply and cutoff of the cleaning gas to the pipes225aand225b.

The diffusion chamber231acommunicates with the processing space SPvia a plurality of discharge ports232a, and the diffusion chamber231bcommunicates with the processing space SPvia a plurality of discharge ports232b. The gas supplied into the diffusion chamber231avia the pipe225ais diffused inside the diffusion chamber231aand discharged into the processing space SPvia the discharge ports232ain the form of a shower. Further, the gas supplied into the diffusion chamber231bthrough the pipe225bis diffused inside the diffusion chamber231band discharged into the processing space SPthrough the discharge ports232bin the form of a shower. The isocyanate vapor and the amine vapor are discharged into the processing space SPthrough the discharge ports232aand the discharge ports232b, and are mixed with each other inside the processing space SPto form an organic film of a polymer having urea bonds on the surface of the substrate W placed on the stage211.

For example, by using a diisocyanate as the first monomer and a diamine (e.g., primary amine) as the second monomer, linear polyurea may be produced. The combination of diisocyanate and diamine is, for example, a combination of 4,4′-diphenylmethane diisocyanate (MDI) and 1,12-diaminododecane (DAD). The combination of diisocyanate and diamine is, for example, a combination of 1,3-bis(isocyanatomethyl)cyclohexane (H6XDI) and 1,12-diaminododecane (DAD). The combination of diisocyanate and diamine is, for example, a combination of 1,3-bis(isocyanatomethyl)cyclohexane (H6XDI) and 1,3-bis(aminomethyl)cyclohexane (H6XDA). The combination of diisocyanate and diamine is, for example, a combination of 1,3-bis(isocyanatomethyl)cyclohexane (H6XDI) and hexamethylenediamine (HMDA). The combination of diisocyanate and diamine is, for example, a combination of m-xylylene diisocyanate (XDI) and m-xylylene diamine (XDA). The combination of diisocyanate and diamine is, for example, a combination of m-xylylene diisocyanate (XDI) and benzylamine (BA).

For example, by using diisocyanate as the first monomer and triamine (e.g., primary amine) or tetraamine (e.g., secondary amine) as the second monomer, cross-linkable polyurea may be produced. Further, by using a monoisocyanate as the first monomer and a diamine (e.g., primary amine) as the second monomer, trimers having urea bonds may be produced. Further, by using monoisocyanate as the first monomer and monoamine (e.g., primary amine) as the second monomer, dimers having urea bonds may be produced.

An RF power supply260that supplies RF (Radio Frequency) power for plasma generation is connected to the shower head230via a matcher261. The shower head230functions as a cathode electrode for the stage211. When cleaning the interior of the processing container209, a cleaning gas is supplied from the gas supplier220into the processing space SPthrough the shower head230, and the RF power is supplied into the processing space SPfrom the RF power supply260via the matcher261. As a result, the cleaning gas is plasmarized inside the processing space SP, and the interior of the processing container209is cleaned by active species contained in the plasma.

A valve224d, an MFC223d, and a purge gas source221dare connected to the lower container201below the stage211via a pipe225d. The purge gas source221dis a source of a purge gas. The purge gas is, for example, an inert gas such as a nitrogen gas or a noble gas. The MFC223dcontrols a flow rate of the purge gas supplied from the purge gas source221d. The valve224dcontrols the supply and cutoff of the purge gas to the pipe225d. An internal space of the lower container201below the stage211is defined as a lower space SL. By supplying the purge gas into the lower space SL, it is possible to prevent the film-forming gas supplied into the processing space SPfrom entering the lower space SL.

The control device100includes a memory, a processor, and an input/output interface. The memory stores control programs, processing recipes, and the like. The processor reads out a control program from the memory and executes the same to control each part of the apparatus body200via the input/output interface based on the recipe stored in the memory.

[Structure Near Peripheral Edge of Stage211]

FIG.2is an enlarged cross-sectional view showing an example of a structure near a peripheral edge of the stage211in the first embodiment. An annular stage cover250is provided around the peripheral edge of the upper surface of the stage211on which the substrate W is placed, so as to surround the peripheral edge of the upper surface of the stage211. In the present embodiment, for example, as shown inFIG.2, the stage cover250is provided with an annular exhaust blade2501that has a cross section extending away from a lateral surface of the stage211and protruding upward along the sidewall of the lower container201. The exhaust blade2501is annularly formed along an outer periphery of the stage211. The exhaust blade2501is an example of a first exhaust blade. A gap is provided between the exhaust blade2501and the sidewall of the lower container201.

An annular plate-shaped ring cover251is arranged on the stage cover250. A space between the lower surface of the shower head230and an upper surface of the ring cover251is defined as a first exhaust path30.

A duct cover252is provided on the exhaust duct202along the extension direction of the exhaust duct202. A slit-shaped exhaust port2520is formed in the duct cover252along the extension direction of the exhaust duct202. For example, as shown inFIG.2, the duct cover252is provided with an annular exhaust blade2521that has a cross section extending away from the sidewall of the lower container201and hanging downward along the sidewall of the lower container201. The exhaust blade2521is annularly formed along the sidewall of the lower container201. The exhaust blade2521is an example of a second exhaust blade. When forming an organic film on the substrate W, for example, as shown inFIG.2, the exhaust blade2501of the stage cover250is arranged between the exhaust blade2521of the duct cover252and the sidewall of the lower container201. Gaps are provided between the exhaust blade2521and the exhaust blade2501and between the exhaust blade2521and the sidewall of the lower container201.

A space between the lower container201and the exhaust blade2501and a space between the exhaust blade2521and the exhaust blade2501are defined as a second exhaust path31. Further, a space inside the exhaust port2520is defined as a third exhaust path32, and a space surrounded by the duct cover252and the exhaust duct202is defined as an exhaust space SE. A space between the first exhaust path30, the second exhaust path31, and the third exhaust path32is defined as an intermediate space SM.

In the process of forming the organic film on the substrate W, the gas supplied into the processing space SPis exhausted to the exhaust space SEvia the first exhaust path30, the intermediate space SM, and the third exhaust path32. Further, the purge gas supplied to the lower space SLis exhausted to the exhaust space SEvia the second exhaust path31, the intermediate space SM, and the third exhaust path32.

Further, a distance between the lower surface of the shower head230and the upper surface of the ring cover251is much shorter than a distance between the lower surface of the shower head230and the upper surface of the substrate W placed on the stage211. As a result, a conductance of the first exhaust path30is smaller than that of the processing space SP. Moreover, in the present embodiment, a conductance of the second exhaust path31is also smaller than that of the processing space SP.

A relationship between the conductances of these spaces is, for example, as shown inFIG.3.FIG.3is a diagram for explaining an example of the relationship between the conductances of the respective spaces in the first embodiment. In the example ofFIG.3, the thickness of each part represents the magnitude of conductance. For example, as shown inFIG.3, the processing space SPand the intermediate space SMcommunicate with each other via the first exhaust path30having a smaller conductance than the processing space SP. The lower space SLand the intermediate space SMcommunicate with each other via the second exhaust path31having a smaller conductance than the processing space SP. In addition, the intermediate space SMand the exhaust space SEcommunicate with each other via the third exhaust path32having a smaller conductance than the processing space SP.

Now, a case in which the structure near the peripheral edge of the stage211is, for example, a structure shown inFIG.4, is considered.FIG.4is an enlarged cross-sectional view showing an example of a structure near a peripheral edge of the stage211in Comparative Example. In the Comparative Example shown inFIG.4, the ring cover251is not provided. Thus, in the Comparative Example, the conductance of the processing space SPand the conductance of the exhaust path33between the lower surface of the shower head230and the upper surface of the stage cover250are substantially the same.

A relationship between the conductances of the respective spaces in the Comparative Example is, for example, as shown inFIG.5.FIG.5is a diagram for explaining an example of the relationship between the conductances of the respective spaces in the Comparative Example. In the Comparative Example, the ring cover251is not provided. Thus, in the Comparative Example, when a film-forming process is performed, a large amount of film-forming gas flows into the intermediate space SMfrom the processing space SPvia the exhaust path33. As a result, a partial pressure of the film-forming gas inside the intermediate space SMincreases. Therefore, a film forming gas having a high concentration flows into the intermediate space SM, the third exhaust path32, and the exhaust space SE, so that an organic film is likely to be formed as a deposit on the sidewalls of the intermediate space SM, the third exhaust path32, and the exhaust space SE. In a case in which there is a portion in the sidewalls of the intermediate space SM, the third exhaust path32, and the exhaust space SE, which is less likely to be sufficiently heated to the extent that the formation of the organic film is inhibited, it is necessary to stop the film-forming process and frequently clean the portion.

Further, in the Comparative Example, increasing the flow rate of the purge gas to be supplied to the lower space SLto lower the partial pressure of the film-forming gas inside the intermediate space SMis considered. As a result, the amount of purge gas supplied into the intermediate space SMis increased, which makes it possible to lower the partial pressure of the film-forming gas inside the intermediate space SM. However, in the Comparative Example, since the conductance of the exhaust path33is large, the purge gas supplied into the intermediate space SMeasily flows into the processing space SPvia the exhaust path33. When the purge gas flows into the processing space SP, the concentration of the film-forming gas in the processing space SPdecreases. When the concentration of the film-forming gas in the processing space SPdecreases, the film-forming rate decreases and the throughput in the film-forming process decreases.

On the other hand, in the present embodiment, for example, as shown inFIG.3, the processing space SPand the intermediate space SMcommunicate with each other via the first exhaust path30having a low conductance. This makes it possible to suppress the amount of the purge gas, which is supplied into the lower space SLand flows from the intermediate space SMinto the processing space SPvia the first exhaust path30, at a low level. Accordingly, even if the flow rate of the purge gas supplied to the lower space SLis increased, the flow rate of the purge gas flowing into the processing space SPcan be suppressed at a low level, which makes it possible to suppress the reduction in the film-forming rate of the organic film.

In addition, since the flow rate of the purge gas supplied to the lower space SLmay be increased while suppressing the reduction in the film-forming rate of the organic film, it is possible to reduce the partial pressure of the film-forming gas inside the intermediate space SM. As a result, the concentration of the film-forming gas flowing in the intermediate space SM, the third exhaust path32, and the exhaust space SEis lowered, which makes it possible to suppress the adhesion of the organic film to the sidewalls of the intermediate space SM, the third exhaust path32, and the exhaust space SE. Thus, the frequency of cleaning may be reduced, and the throughput in the film-forming process may be improved.

FIG.6is a diagram showing an example of a film thickness distribution of the organic film when the flow rate of the purge gas is changed in the first embodiment. InFIG.6, “Average” denotes the average film thickness of the organic films formed on the substrate W, “D/R” denotes the film-forming rate, “Max” denotes the maximum value of the film thickness, “Min” denotes the minimum value of the film thickness, and “Range” denotes the difference between the maximum and minimum values of the film thickness. “WiW±” denotes the value obtained by dividing the percentage of Range to the average film thickness by half, and “WiW1σ” denotes the percentage of the standard deviation to the average film thickness. For example, as shown inFIG.6, when the flow rate of the purge gas is increased to 1,600 sccm, the film-forming rate (D/R) is slightly changed. However, the reduction in the film-forming rate when the flow rate of the purge gas is 1,600 sccm is suppressed to 30% or lower of the film-forming rate when the flow rate of the purge gas is 100 sccm.

When the flow rate of the purge gas is 100 sccm, the partial pressure of the film-forming gas in the exhaust space SEwas 250 mTorr, and when the flow rate of the purge gas is 1,600 sccm, the partial pressure of the film-forming gas in the exhaust space SEwas 50 mTorr. That is, when the flow rate of the purge gas is increased to 1,600 sccm, the partial pressure of the film-forming gas in the exhaust space SEcould be reduced to 20% or less as compared with the case where the flow rate of the purge gas is 100 sccm. This makes it possible to suppress the formation of an organic film in the exhaust space SE, thus significantly reducing the frequency of cleaning.

FIG.7is an enlarged cross-sectional view showing an example of a state near the peripheral edge of the stage211during cleaning in the first embodiment. In order to suppress the adhesion of the organic film to portions other than the substrate W during the film-forming process, the portions other than the substrate W are heated, or the film-forming gas supplied to the portions other than the substrate W is diluted. However, it is difficult to completely prevent the adhesion of the organic film to the portions other than the substrate W. Therefore, as the film-forming process is repeated, the organic film may adhere to the portions other than the substrate W. Thus, the interior of the processing container209is cleaned before the organic film adhering to the portions other than the substrate W becomes particles and scatters within the processing container209.

In the present embodiment, the cleaning inside the processing container209is performed in a state in which the stage211is moved down by driving the elevating mechanism240. As the stage211is moved down from a position where the film-forming process is performed, the ring cover251descends together with the stage211. For example, as shown inFIG.7, the ring cover251is delivered from the upper surface of the stage cover250to the upper surface of the exhaust blade2521. As a result, the space between the lower surface of the shower head230and the upper surface of the ring cover251expands to a first exhaust path30′, thereby increasing a conductance of the first exhaust path30′. Thus, active species of the cleaning gas plasmarized inside the processing space SPare easily diffused into the intermediate space SMvia the first exhaust path30′. Accordingly, the organic film adhering to the wall surface of the intermediate space SMcan be efficiently removed.

Further, as the stage211descends and the ring cover251is delivered from the upper surface of the stage cover250to the upper surface of the exhaust blade2521, for example, as shown inFIG.7, the lower surface of the ring cover251and the upper surface of the stage cover250are moved away from each other. As a result, the organic film adhering to the lower surface of the ring cover251and the organic film adhering to the upper surface of the stage cover250may be efficiently removed by the active species of the cleaning gas plasmarized inside the processing space SP.

The first embodiment has been described above. As described above, the substrate processing apparatus10according to the present embodiment includes the processing container209, the stage211, the exhaust space SE, the first exhaust path30, and the second exhaust path31. The stage211is provided inside the processing container209, and the substrate W is placed on the stage211. The exhaust space SEis arranged around the stage211along the inner wall of the processing container209. The first exhaust path30is provided between the processing space SPabove the stage211and the exhaust space SE, and has a smaller conductance than the processing space SP. The second exhaust path31is provided between the lower space SLbelow the stage211and the exhaust space SE, and has a smaller conductance than the processing space SP. The processing gas supplied into the processing space SPis exhausted via the first exhaust path30, and the purge gas supplied into the lower space SLis exhausted via the second exhaust path31. Further, the second exhaust path31is connected to a space that is closer to the exhaust space SEthan the first exhaust path30. This makes it possible to suppress the flow rate of the purge gas flowing into the processing space SPat a low level, which suppresses the reduction in the film-forming rate of the organic film. Accordingly, it is possible to improve the throughput in the film-forming process.

In the above-described embodiment, the first exhaust path30corresponds the space between the ring cover251arranged on the annular stage cover250provided on the peripheral edge of the upper surface of the stage211and the lower surface of the shower head230arranged above the stage211to supply gases into the processing container209. Further, the second exhaust path31corresponds to the space between the annular exhaust blade2501provided on the stage cover250and the annular exhaust blade2521provided on the sidewall of the processing container209. Accordingly, it is possible to easily form the first exhaust path30and the second exhaust path31.

Further, in the above-described embodiment, the substrate processing apparatus10includes the elevating mechanism240configured to move the stage211up and down. The valve2240raises the conductance of the first exhaust path30by moving down the stage211when the interior of the processing container209is cleaned. Further, the ring cover251is delivered from the stage cover250to the exhaust blade2521as the stage211moves down. Accordingly, it is possible to efficiently remove the organic film adhering to the lower surface of the ring cover251and the organic film adhering to the upper surface of the stage cover250.

Moreover, in the above-described embodiment, the shower head230supplies the first processing gas containing the first monomer and the second processing gas containing the second monomer from the respective discharge ports232aand232binto the processing container209to form a film of a polymer which is the first monomer and the second monomer on the substrate W placed on the stage211. Further, the first monomer is, for example, isocyanate, the second monomer is, for example, amine. The polymer formed on the substrate W contains urea bonds. The thickness of the film of the polymer formed on the substrate W is affected by the concentrations of the first monomer gas and the second monomer gas on the substrate W. In the present embodiment, it is possible to suppress the reduction in the concentrations of the first monomer gas and the second monomer gas inside the processing space SP. Therefore, it is possible to suppress the reduction in the film-forming rate of the polymer film formed on the substrate W.

Second Embodiment

In the first embodiment, the processing space SPcommunicates with the intermediate space SMvia the first exhaust path30, the lower space SLcommunicates with the intermediate space SMvia the second exhaust path31, and the intermediate space SMcommunicates with the exhaust space SEvia the third exhaust path32. On the other hand, a second embodiment differs from the first embodiment in that the processing space SPcommunicates with the exhaust space SEvia the first exhaust path30, and the lower space SLcommunicates with the exhaust space SEvia the second exhaust path31. Next, differences between the first and second embodiments will be mainly described.

FIG.8is an enlarged cross-sectional view showing an example of a structure near the peripheral edge of the stage211in the second embodiment. In the present embodiment, the ring cover251is arranged on the peripheral edge of the upper surface of the stage211instead of arranging the stage cover250on the peripheral edge of the upper surface of the stage211. The ring cover251in the present embodiment includes an annular projection2510formed to stand in a direction intersecting with the upper surface of the stage211. In the present embodiment, a space between the lower surface of the shower head230and an upper surface of the ring cover251and the space between the lateral surface of the shower head230and a lateral surface of the projection2510are defined as the first exhaust path30.

The conductance of the first exhaust path30is smaller than the conductance of the processing space SP. In the example ofFIG.8, the ring cover251is formed with the projection2510. However, just like the ring cover251in the first embodiment, the ring cover251may not be provided with the projection2510. Even in this case, the conductance of the first exhaust path30may be made smaller than the conductance of the processing space SP.

Further, in the example ofFIG.8, the stage cover250is not arranged on the peripheral edge of the upper surface of the stage211, and the ring cover251is arranged on the peripheral edge of the upper surface of the stage211. However, the disclosed technique is limited thereto. Also in the present embodiment, the stage cover250without the exhaust blade2501may be arranged on the peripheral edge of the upper surface of the stage211, and the ring cover251may be arranged on the stage cover250.

Further, in the present embodiment, an annular exhaust blade253is provided along the exhaust duct202. For example, as shown inFIG.8, the exhaust blade253has a cross-sectional shape that extends away from the sidewall of the lower container201and hangs downward along the sidewall of the lower container201. In the present embodiment, a space between the lateral surface of the stage211and a lateral surface of the exhaust blade253is defined as the second exhaust path31. In the present embodiment, the exhaust duct202is not provided with the duct cover252. Further, the exhaust blade253does not need to have a portion that hangs downward along the sidewall of the lower container201as long as it has a cross-section shape extending away from the lower container201. The exhaust blade253is an example of the second exhaust blade.

A relationship between the conductances of the processing space SP, the lower space SL, the exhaust space SE, the first exhaust path30and the second exhaust path31is, for example, as shown inFIG.9.FIG.9is a diagram for explaining an example of the relationship between the conductances of the respective spaces in the second embodiment. In the example ofFIG.9, the thickness of each part represents the magnitude of conductance. In the process of forming an organic film on the substrate W, the film-forming gas supplied into the processing space SPis exhausted to the exhaust space SEvia the first exhaust path30, and the purge gas supplied to the lower space SLis exhausted to the exhaust space SEvia the second exhaust path31.

In the present embodiment, for example, as shown inFIG.9, the processing space SPand the exhaust space SEcommunicate with each other via the first exhaust path30having a low conductance. Therefore, the amount of the purge gas supplied to the lower space SLand flowing into the processing space SPfrom the exhaust space SEvia the first exhaust path30may be suppressed at a low level. Accordingly, even if the flow rate of the purge gas supplied to the lower space SLis increased, the flow rate of the purge gas flowing into the processing space SPcan be suppressed at a low level, which makes it possible to suppress the reduction in the film-forming rate of the organic film.

In addition, since the flow rate of the purge gas supplied to the lower space SLcan be increased while suppressing the reduction in the film-forming rate of the organic film, it is possible to reduce the partial pressure of the film-forming gas inside the exhaust space SE. This makes it possible to reduce the concentration of the film-forming gas flowing in the exhaust space SE, thus suppressing the adhesion of the organic film to the sidewalls of the exhaust space SE. Accordingly, the frequency of cleaning can be reduced, and the throughput in the film-forming process can be improved.

FIG.10is an enlarged cross-sectional view showing an example of the state near the peripheral edge of the stage211during cleaning in the second embodiment. In the present embodiment, the cleaning inside the processing container209is performed in a state in which the stage211is moved down by driving the elevating mechanism240. As the stage211is moved down from the position where the film-forming process is performed, the ring cover251is moved down together with the stage211. For example, as shown inFIG.10, the ring cover251is delivered from the upper surface of the stage211to the upper surface of the exhaust blade253. As a result, the space between the lower surface of the shower head230and the upper surface of the ring cover251and the space between the lateral surface of the shower head230and the lateral surface of the projection2510expand to the first exhaust path30′. Thus, the conductance of the first exhaust path30′ is increased, and the active species of the cleaning gas plasmarized inside the processing space SPare easily diffused into the exhaust space SEvia the first exhaust path30′. Accordingly, it is possible to efficiently remove the organic film adhering to the wall surface and the like of the exhaust space SE.

Further, when the stage211is moved down and the ring cover251is delivered from the upper surface of the stage211to the upper surface of the exhaust blade253, for example, as shown inFIG.10, the lower surface of the ring cover251and the upper surface of the stage211are moved away from each other. As a result, the organic film adhering to the lower surface of the ring cover251and the organic film adhering to the upper surface of the stage211can be efficiently removed by the active species of the cleaning gas plasmarized inside the processing space SP.

Further, the stage211and the exhaust blade253are moved away from each other by lowering the stage211, and the space between the stage211and the exhaust blade253expands to the second exhaust path31′. As a result, the conductance of the second exhaust path31′ is increased, and the active species of the cleaning gas plasmarized inside the processing space SPare easily diffused into the lower space SLvia the second exhaust path31′. Accordingly, it is possible to efficiently remove the organic film adhering to the wall surface and the like of the lower space SL.

In addition, in the example ofFIG.8, the annular exhaust blade253is provided along the exhaust duct202. However, the disclosed technique is not limited thereto. In the lower container201, for example, as shown inFIG.11, an annular shelf portion2010protruding toward the lower space SLmay be formed along the sidewall of the lower container201below the exhaust duct202. In this case, a space between a sidewall of the shelf portion2010and the sidewall of the stage211corresponds to the second exhaust path31.

The second embodiment has been described above. As described above, the substrate processing apparatus10according to the present embodiment further includes an annular ring cover251arranged on the peripheral edge of the upper surface of the stage211and having the annular projection2510formed to stand in the direction intersecting with the upper surface of the stage211. The first exhaust path30corresponds to at least one of the space between the upper surface of the ring cover251and the lower surface of the shower head230located above the stage211, and the space between the lateral surface of the projection2510of the ring cover251and the lateral surface of the shower head230. The second exhaust path31corresponds to the space between the lateral surface of the stage211and the annular exhaust blade253provided on the sidewall of the lower container201. Accordingly, it is possible to easily form the first exhaust path30and the second exhaust path31.

Further, in the above-described embodiment, the substrate processing apparatus10includes the elevating mechanism240configured to move the stage211up and down. The elevating mechanism240raises the conductances of the first exhaust path30and the second exhaust path31by moving down the stage211when the interior of the processing container209is cleaned. The ring cover251is delivered to the shelf portion2010provided on the inner wall of the processing container209by moving down the stage211. Accordingly, it is possible to efficiently remove the organic film adhering to the wall surfaces and the like of the exhaust space SEand the lower space SL.

Third Embodiment

In the first embodiment, the plate-shaped ring cover251is arranged on the stage cover250so as to extend along the upper surface of the stage211. In contrast, a third embodiment differs from the first embodiment in that a cylindrical ring cover251is fixed to an outer wall of the shower head230so as to surround the shower head230. Next, differences from the first embodiment will be mainly described.

FIG.12is an enlarged cross-sectional view showing an example of a structure near the peripheral edge of the stage211in the third embodiment. In the present embodiment, for example, as shown inFIG.12, the cylindrical ring cover251is fixed to the outer wall of the shower head230so as to surround the shower head230. In the present embodiment, a space between the lateral surface of the stage cover250provided on the stage211and a lateral surface of the ring cover251is defined as the first exhaust path30. The conductance of the first exhaust path30is smaller than the conductance of the processing space SP.

Further, in the present embodiment, the annular exhaust blade253is provided along the exhaust duct202. The exhaust blade253is an example of the second exhaust blade. For example, as shown inFIG.12, the exhaust blade253has a cross-sectional shape that extends away from the sidewall of the lower container201and hangs downward along the sidewall of the lower container201. In the process of forming an organic film on the substrate W, for example, as shown inFIG.12, the exhaust blade2501of the stage cover250is arranged between the exhaust blade253and the sidewall of the lower container201. Gaps are provided between the exhaust blade253and the exhaust blade2501and between the exhaust blade2501and the sidewall of the lower container201. In the present embodiment, the space between the lower container201and the exhaust blade2501and the space between the exhaust blades253and2501are defined as the second exhaust path31.

Further, in the present embodiment, the conductance of the space between the ring cover251and the exhaust blade253is larger than the conductance of the processing space SP. In the present embodiment, the relationship between the conductances of the processing space SP, the lower space SL, the exhaust space SE, the first exhaust path30and the second exhaust path31is, for example, as shown inFIG.9. In the process of forming an organic film on the substrate W, the gas supplied into the processing space SPis exhausted to the exhaust space SEvia the first exhaust path30, and the purge gas supplied to the lower space SLis exhausted to the exhaust space SEthrough the second exhaust port31.

Further, in the present embodiment, for example, as shown inFIG.9, the processing space SPand the exhaust space SEcommunicate with each other via the first exhaust path30having a low conductance. Therefore, the amount of the purge gas supplied to the lower space SLand flowing from the exhaust space SEinto the processing space SPvia the first exhaust path30may be suppressed at a low level. Accordingly, even if the flow rate of the purge gas supplied to the lower space SLis increased, the flow rate of the purge gas flowing into the processing space SPcan be suppressed at a low level, thus suppressing the reduction in the film-forming rate of the organic film.

In addition, since the flow rate of the purge gas supplied to the lower space SLmay be increased while suppressing the reduction in the film-forming rate of the organic film, it is possible to reduce the partial pressure of the film-forming gas inside the exhaust space SE. This makes it possible to reduce the concentration of the film-forming gas flowing in the exhaust space SE, thus suppressing the adhesion of the organic film to the sidewall of the exhaust space SE. Accordingly, the frequency of cleaning can be reduced, thus improving the throughput in the film-forming process.

FIG.13is an enlarged cross-sectional view showing an example of the state near the peripheral edge of the stage211during cleaning in the third embodiment. In the present embodiment, the cleaning inside the processing container209is performed in a state in which the stage211is moved down by driving the elevating mechanism240. When the stage211is moved down from the position where the film-forming process is performed, for example, as shown inFIG.13, the stage211is moved away from the ring cover251fixed to the sidewall of the shower head230. As a result, the space between the lateral surface of the stage211and the lateral surface of the ring cover251expands to the first exhaust path30′. Thus, the conductance of the first exhaust path30′ is increased, and the active species of the cleaning gas plasmarized inside the processing space SPis easily diffused into the exhaust space SEvia the first exhaust path30′. Accordingly, it is possible to efficiently remove the organic film adhering to the wall surface and the like of the exhaust space SE.

As another example of the third embodiment, for example, as shown inFIG.14, instead of the exhaust blade253, the annular shelf portion2010protruding toward the lower space SLmay be formed below the exhaust duct202along the sidewall of the lower container201. In this case, the space between the lateral surface of the shelf portion2010and the exhaust blade2501corresponds to the second exhaust path31. Even with such a configuration, the amount of the purge gas supplied to the lower space SLand flowing from the exhaust space SEinto the processing space SPvia the first exhaust path30can be suppressed at a low level, which makes it possible to lower the concentration of the film-forming gas flowing into the exhaust space SE.

During cleaning, the stage211is moved down from the position where the film-forming process is performed, whereby for example, as shown inFIG.15, the stage211is moved away from the ring cover251fixed to the sidewall of the shower head230. As a result, the space between the lateral surface of the stage211and the lateral surface of the ring cover251expands to the first exhaust path30′, thereby increasing the conductance of the first exhaust path30′. Accordingly, the active species of the cleaning gas plasmarized inside the processing space SPare easily diffused into the exhaust space SEvia the first exhaust path30′, which makes it possible to efficiently remove the organic film adhering to the wall surface and the like of the exhaust space SE.

Further, the stage211and the exhaust blade2501are moved away from each other by moving down the stage211, and the space between the stage211and the exhaust blade2501expands to the second exhaust path31′. As a result, the conductance of the second exhaust path31′ is increased, and the active species of the cleaning gas plasmarized inside the processing space SPare easily diffused into the lower space SLvia the second exhaust path31′. Accordingly, it is possible to efficiently remove the organic film adhering to the wall surface and the like of the lower space SL.

Further, in the example ofFIG.12, the conductance of the space between the ring cover251and the exhaust blade253is larger than the conductance of the processing space SP. However, the disclosed technique is not limited thereto. As another example, for example, as shown inFIG.16, the conductance of the space between the ring cover251and the exhaust blade253may be set to be smaller than the conductance of the processing space SP. The space between the ring cover251and the exhaust blade253is defined as a fourth exhaust path34.

In the example ofFIG.16, a relationship between the conductances of the processing space SP, the lower space SL, the exhaust space SE, the first exhaust path30, the second exhaust path31and the fourth exhaust path34is, for example, as shown inFIG.17. In the present embodiment, for example, as shown inFIG.17, the second exhaust path31is connected to the first exhaust path30. In the process of forming an organic film on the substrate W, the gas supplied into the processing space SPflows to the fourth exhaust path34via the first exhaust path30, and the purge gas supplied to the lower space SLflows to the fourth exhaust path34via the second exhaust path31. Further, the gas flowing in the fourth exhaust path34is exhausted to the exhaust space SE.

The third embodiment has been described above. As described above, the substrate processing apparatus10according to the present embodiment includes the cylindrical ring cover251provided on the sidewall of the shower head230so as to surround the shower head230. The first exhaust path30in the present embodiment corresponds to the space between the lateral surface of the annular stage cover250provided on the peripheral edge of the upper surface of the stage211and the lateral surface of the ring cover251. Further, the second exhaust path31in the present embodiment corresponds to the space between the annular exhaust blade2501provided on the stage cover250and the annular exhaust blade253provided on the sidewall of the processing container209. This makes it possible to easily form the first exhaust path30and the second exhaust path31.

Further, in the above-described embodiment, the substrate processing apparatus10includes the elevating mechanism240configured to move the stage211up and down. Further, in the present embodiment, the conductance of the space between the lateral surface of the ring cover251and the exhaust blade253is larger than both the conductance of the first exhaust path30and the conductance of the second exhaust path31. The elevating mechanism240raises the conductance of the first exhaust path30by moving down the stage211when the interior of the processing container209is cleaned. This makes it possible to be efficiently remove the organic film adhering to the wall surface and the like of the exhaust space SEduring cleaning.

The technique disclosed in the subject application is not limited to the above-described embodiments, and various modifications may be made within the scope of the gist thereof.

For example, in the above-described embodiments, a film of a polymer having urea bonds (—NH—CO—NH—) is formed on the surface of the substrate W by using isocyanate as the first monomer and amine as the second monomer. However, the disclosed technique is not limited thereto. For example, a film of a polymer having 2-aminoethanol bonds (—NH—CH2—CH(OH)—) may be formed on the surface of the substrate W by using epoxide as the first monomer and amine as the second monomer. Alternatively, a film of a polymer having urethane bonds (—NH—CO—O—) may be formed on the surface of the substrate W by using isocyanate as the first monomer and alcohol as the second monomer. Alternatively, a film of a polymer having amide bonds (—NH—CO—) may be formed on the surface of the substrate W by using acyl halide as the first monomer and amine as the second monomer. Alternatively, a film of a polymer having imide bonds (—CO-N(−)—CO—) may be formed on the surface of the substrate W by using carboxylic acid anhydride as the first monomer and amine as the second monomer.

In a case in which a film of a polymer having imide bonds is formed on the surface of the substrate W, for example, pyromellitic dianhydride (PMDA) or the like may be used as the first monomer. Further, in a case in which a film of a polymer having imide bonds is formed on the surface of the substrate W, for example, 4,4′-oxydianiline (44ODA), hexamethylenediamine (HMDA), or the like may be used as the second monomer.

Further, in the above-described embodiments, a film-forming apparatus has been described as an example of the substrate processing apparatus10. However, the disclosed technique is not limited thereto. In a case in which a distribution of a gas inside the processing container209affects a quality of the processing of the substrate W, the disclosed technique may be applied to an etching apparatus, an apparatus for modifying the substrate W, and the like, in addition to the film-forming apparatus.

According to the present disclosure in various aspects and embodiments, it is possible to improve throughput of a substrate processing.