SUBSTRATE PROCESSING METHOD

A substrate processing method includes providing a substrate processing apparatus including a vacuum container, a rotary table that includes a placement surface on which a plurality of substrates is disposed, and rotates the plurality of substrates, a plasma generator that includes an antenna and generates a plasma in the vacuum container, and a first driving unit that moves the antenna; storing ignition condition information that associate a process condition and a position of the antenna with each other, in a storage; determining the position of the antenna corresponding to the process condition of the ignition condition information that matches a process condition set in a recipe by referring to the storage; and moving the antenna to the determined position of the antenna using the first driving unit, thereby processing the plurality of the substrates.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority from Japanese Patent Application No. 2023-105040 filed on Jun. 27, 2023, with the Japan Patent Office, the disclosure of which is incorporated herein in its entirety by reference.

TECHNICAL FIELD

The present disclosure relates to a substrate processing method.

BACKGROUND

Japanese Patent No. 6584355 and Japanese Patent Laid-Open Publication No. 2022-112423 disclose a processing apparatus including an antenna provided to be movable above a processing chamber, the processing apparatus capable of locally irradiating a rotary table with plasma when performing film formation while rotating a plurality of substrates placed on the rotary table.

SUMMARY

According to an aspect of the present disclosure, a substrate processing method includes providing a substrate processing apparatus including a vacuum container, a rotary table that includes a placement surface on which a plurality of substrates is disposed, and rotates the plurality of substrates, a plasma generator that includes an antenna and generates a plasma in the vacuum container, and a first driving unit that moves the antenna; storing ignition condition information that associates a process condition and a position of the antenna, in a storage; determining the position of the antenna corresponding to the process condition of the ignition condition information that matches a process condition set in a recipe by referring to the storage; and moving the antenna to the determined position of the antenna using the first driving unit, thereby processing the plurality of the substrates.

DETAILED DESCRIPTION

Hereinafter, embodiments for carrying out the present disclosure will be described with reference to the drawings. In each drawing, the same reference numerals may be given to the same components, and redundant descriptions may be omitted.

Film Forming Apparatus

A film forming apparatus1according to the embodiments of the present disclosure will be described with reference toFIGS.1and2.FIG.1is a longitudinal-sectional side view illustrating an example of a film forming apparatus according to an embodiment.FIG.2is a cross-sectional plan view illustrating an example of a film forming apparatus according to an embodiment. The film forming apparatus1is an example of a substrate processing apparatus capable of executing a substrate processing method to be described hereinbelow. The film forming apparatus1includes a substantially circular flat vacuum container11and a disc-shaped horizontal rotary table2provided in the vacuum container11. The vacuum container11includes an upper plate12and a container body13. The container body13forms the sidewall and bottom of the vacuum container11.

A central shaft21is provided at the center of the vacuum container11to extend vertically downward from a central portion of the rotary table2. The central shaft21is connected to an orbiting rotational driving unit22, which is provided to block an opening14formed at the bottom of the container body13. The rotary table2is supported in the vacuum container11via the central shaft21and the orbiting rotational driving unit22. The rotary table2rotates clockwise or counterclockwise when viewed from the plane of the film forming apparatus1. The orbiting rotational driving unit22is, for example, an electric actuator such as a motor. A gas supply pipe15discharges N2(nitrogen) gas to a gap between the central shaft21and the container body13, thereby preventing a raw material gas and an oxidizing gas from flowing from a surface to a back surface of the rotary table2.

Further, the upper plate12of the vacuum container11has, at a lower surface thereof, a central region forming portion C, which is circular in plan view and protrudes to face the central portion of the rotary table2, and two convex portions17, which spread from the central region forming portion C toward the outside of the rotary table2as illustrated inFIG.2. The two convex portions17have a substantially fan-shaped planar shape with the top cut in an arc shape.

These central region forming portion C and convex portions17form a lower ceiling surface compared to an outer region thereof. A gap between the central region forming portion C and the central portion of the rotary table2form a flow path18for N2gas (see, e.g.,FIG.1). During the processing of a wafer W, which is an example of a substrate, N2gas is supplied to the flow path18from a gas supply pipe connected to the upper plate12and flows from the flow path18toward the entire outer circumference of the rotary table2. The N2gas prevents a raw material gas and oxidizing gas from coming into contact with each other on the central portion of the rotary table2.

A flat ring-shaped recess31is formed at the bottom of the container body13to extend along the circumference of the rotary table2below the rotary table2. A ring-shaped slit32is opened at a bottom surface of the recess31along the circumferential direction of the recess31. The slit32is formed to penetrate the bottom of the container body13in the thickness direction. Furthermore, seven ring-shaped heaters33are arranged on the bottom surface of the recess31to heat the wafer W placed on the rotary table2.

The heaters33are arranged along concentric circles centered on the rotation center of the rotary table2, with four of the seven heaters33provided inside the slit32and the other three provided outside the slit32. Further, a shield34is provided to cover the upper side of each heater33and to block the upper side of the recess31. A ring-shaped slit39is formed at the shield34to overlap with the slit32, and a strut41penetrates the slits32and39. Further, exhaust ports35and36are opened at the bottom of the container body13outside the recess31to exhaust the inside of the vacuum container11(see, e.g.,FIGS.1and2). An exhaust mechanism (not illustrated) combined with a vacuum pump and other components is connected to the exhaust ports35and36.

As illustrated inFIG.2, five circular recesses are formed at the surface of the rotary table2along the rotation direction of the rotary table2, and a circular wafer holder24is provided in each recess. As illustrated inFIG.1, a recess25is formed at a surface of the wafer holder24, and the wafer W is accommodated horizontally in the recess25. Accordingly, a bottom surface of the recess25forms a placement surface where the wafer W is placed. In this example, the height of the sidewall of the recess25is, for example, 1 mm, which is the same as the thickness of the wafer W.

For example, three struts41extend vertically downward from the back surface of the rotary table2at positions spaced apart from each other in the circumferential direction. As illustrated inFIG.1, each strut41penetrates the bottom of the container body13through the slits32and39and is connected to a support ring42, which is a connector provided below the container body13. The support ring42is formed along the rotation direction of the rotary table2and is installed horizontally to hang from the container body13by the strut41, thus rotating together with the rotary table2.

Further, a rotating shaft26, which is a rotating shaft that turns, extends vertically downward from a lower central portion of the wafer holder24. A lower end of the rotating shaft26penetrates the rotary table2, then penetrates the bottom of the container body13through the slit32, and further penetrates the support ring42as well as a magnetic seal unit20provided below the support ring42, thus being connected to a turning rotational driving unit27. The magnetic seal unit20includes a bearing that rotatably supports the rotating shaft26relative to the support ring42and a magnetic seal (e.g., magnetic fluid seal) that seals a gap around the rotating shaft26.

The magnetic seal is provided to prevent particles generated from the bearing, such as lubricating oil used in the bearing, from diffusing to the external vacuum atmosphere of the magnetic seal unit20. Further, the wafer holder24is, for example, slightly floating from the rotary table2with the rotating shaft26supported by the bearing. Further, the turning rotational driving unit27is provided below the support ring42so as to be supported by the support ring42via the magnetic seal unit20, and rotates the rotating shaft26around its axis. The turning rotational driving unit27is, for example, an electric actuator such as a motor. In the film forming apparatus1, as the rotary table2rotates, the wafer W undergoes orbital rotation, and the wafer holder24rotates in parallel with the rotation of the rotary table2, causing the wafer W to turn around its axis.

A shield ring44is provided to block the slit32of the container body13from below the container body13, as illustrated inFIG.1, and is configured to rotate together with the rotary table2. Accordingly, the above-mentioned rotating shaft26and strut41are provided to penetrate the shield ring44. The shield ring44serves as a heat shield to prevent the turning rotational driving unit27from being exposed to each gas and from being excessively heated.

Further, a lower wall45is formed to have a recessed shape in cross-section below the container body13to surround the support ring42, turning rotational driving unit27, and shield ring44. The lower wall45is formed in a ring shape along the rotation direction of the rotary table2. Further, five chargers46(only one is illustrated inFIG.1) are provided at the bottom of the lower wall45at intervals in the circumferential direction. When no processing is performed on the wafer W, the rotary table2is stationary so that the turning rotational driving unit27is positioned directly below the charger46, allowing charging of each turning rotational driving unit27via non-contact feeding from the charger46. A gas supply path47is open to a space surrounded by the lower wall45. For example, during the processing of the wafer W, a gas nozzle48supplies N2gas to the space surrounded by the lower wall45through the gas supply path47to purge the space. For example, the space is in communication with an exhaust path interconnecting the exhaust ports35and36and the exhaust mechanism (not illustrated), so that even when particles are generated in the space, the particles are purged and removed by the N2gas.

The sidewall of the container body13is provided with a transfer port37for the wafer W and a gate valve38for opening or closing the transfer port37(seeFIG.2), and the wafer W is transferred between a transfer device introduced into the vacuum container11through the transfer port37and the recess25. Specifically, through-holes are formed at corresponding positions, respectively, at the bottom surface of the recess25, the bottom of the container body13, and the rotary table2, and tips of pins are elevated through the respective through-holes. The wafer W is transferred via the pins. The illustration of the pins and through-holes for the passage of the pins therethrough is omitted.

Further, as illustrated inFIG.2, a raw material gas nozzle51, a separation gas nozzle52, an oxidizing gas nozzle53, a plasma generation gas nozzle54, and a separation gas nozzle55are arranged on the rotary table2in this order at intervals in the rotation direction of the rotary table2. Each of the gas nozzles51to55is formed in a rod shape to extend horizontally along the diameter of the rotary table2from the sidewall to the center of the vacuum container11, and discharges a gas from a plurality of discharge ports formed along the diameter. Each of the gas nozzles51to55is an example of a gas supply that supplies a gas into the vacuum container11.

For example, the film forming apparatus1performs formation of a SiO2film on the wafer W by atomic layer deposition (ALD). In this case, the film forming apparatus1supplies a bis (tertiary-butyl) aminosilane (BTBAS) gas as a raw material gas to the wafer W, and causes the BTBAS gas to be adsorbed onto the substrate W. Ozone (O3) gas, which is an oxidizing gas for oxidizing the adsorbed BTBAS gas, is supplied to form a molecular layer of silicon oxide (SiO2), which is then exposed to a plasma generated from a plasma generation gas, thereby modifying the molecular layer. This series of processing is repeated multiple times to form a SiO2film.

The raw material gas nozzle51, which forms a processing gas supply mechanism, discharges the bis(tertiary-butyl)aminosilane (BTBAS) gas. A nozzle cover57covers the raw material gas nozzle51and is formed in a fan shape spreading from the raw material gas nozzle51toward both upstream and downstream of the rotation direction of the rotary table2. The nozzle cover57serves to increase the concentration of the BTBAS gas below it, increasing the adsorption of the BTBAS gas onto the wafer W. Further, the oxidizing gas nozzle53discharges the ozone gas (O3). The separation gas nozzles52and55are gas nozzles that discharge N2gas, and are arranged to divide the fan-shaped convex portions17of the upper plate12in the circumferential direction, respectively. The plasma generation gas nozzle54discharges a plasma generation gas including, for example, a mixed gas of argon (Ar) gas and oxygen (O2) gas.

The upper plate12has a fan-shaped opening formed along the rotation direction of the rotary table2, and a cup-shaped sapphire glass61, which is made of a dielectric such as quartz and has a shape corresponding to that of the opening, is formed to block the opening (see e.g.,FIGS.1and2). The sapphire glass61is provided between the oxidizing gas nozzle53and a protrusion62when viewed in the rotation direction of the rotary table2. InFIG.2, the position where the sapphire glass61is provided is illustrated by a dashed line. The protrusion62is formed along the circumferential edge of a lower surface of the sapphire glass61. A tip end of the plasma generation gas nozzle54penetrates the protrusion62from the outer peripheral side of the rotary table2so as to be able to discharge a gas to a region surrounded by the protrusion62. The protrusion62serves to prevent the N2gas, ozone gas, and BTBAS gas from entering below the sapphire glass61, thereby preventing a decrease in the concentration of the plasma generation gas.

A recess is formed at the upper side of the sapphire glass61, and a box-shaped Faraday shield63, which is open upward, is located in the recess. An antenna65is provided on a bottom surface of the Faraday shield63via an insulating plate member. The antenna65is configured such that a metal wire is wound in a coil shape around a vertical axis. A support66is connected to the antenna65and is also connected to a matcher150and a radio frequency power supply160through the support66. A slit67is formed at the bottom surface of the Faraday shield63to prevent an electric field component of the electromagnetic field generated in the antenna65when applying radio frequency power to the antenna65from propagating downward and to direct a magnetic field component downward (see e.g.,FIG.2). The slit67extends in a direction perpendicular to (intersecting) the winding direction of the antenna65, and is formed in large numbers along the winding direction of the antenna65. With the components configured as described above, the antenna65is coupled to the vacuum container11and is configured to generate a plasma in the vacuum container11. When the radio frequency power supply160is turned on to apply radio frequency power to the antenna65, it is possible to form a plasma from the plasma generation gas supplied below the sapphire glass61.

A plasma generator180having the movably provided antenna65is provided above the vacuum container11. The plasma generator180includes the antenna65, the support66, an electric actuator140, a frame141, a fixing element142, and a driving force transmitter143. The frame141serves as a base to install the electric actuator140on the upper plate12forming an upper surface of the vacuum container11. The support66is connected to the upper center of the antenna65to support the antenna65. The support66is fixed to the fixing element142, and the antenna65hands from the support66. The electric actuator140, such as a motor, vertically moves (raises and lowers) the fixing element142via the driving force transmitter143. The driving force transmitter143transmits a driving force to the fixing element142to move the fixing element142up and down. Thus, the plasma generator180may move the antenna65supported by the support66in the vertical direction of the rotary table2by the driving of the electric actuator140. In this configuration, a driving system (electric actuator140, frame141, fixing element142, driving force transmitter143, and support66) of the plasma generator180is an example of a first driving unit configured to move the antenna65. In addition, the electric actuator140may also move the fixing element142horizontally via the driving force transmitter143.

On the rotary table2, a region below the nozzle cover57of the raw material gas nozzle51is referred to as an adsorption region R1where the BTBAS gas serving as the raw material gas is adsorbed, and a region below the oxidizing gas nozzle53is referred to as an oxidation region R2where the BTBAS gas is oxidated by the ozone gas. Further, a region below the sapphire glass61is referred to as a plasma formation region R3where a SiO2film is modified by a plasma. Regions below the convex portions17are referred to as separation regions D, respectively, by which the adsorption region R1and the oxidation region R2are separated from each other, which allows the N2gas discharged from the separation gas nozzles52and55to prevent mixing of the raw material gas and the oxidizing gas.

The exhaust port35is open outward between the adsorption region R1and the separation region D adjacent thereto downstream in the rotation direction, and exhausts the excess BTBAS gas. The exhaust port36is open outward near the boundary between the plasma formation region R3and the separation region D adjacent thereto downstream in the rotation direction, and exhausts the excess O3gas and plasma generation gas. The N2gas supplied respectively from each separation area D, the gas supply pipe15below the rotary table2, and the central region forming portion C of the rotary table2is also exhausted from the respective exhaust ports35and36.

The film forming apparatus1is provided with a controller100that controls the operation of the entire apparatus. The controller100is configured with, for example, a computer. The controller100stores a program for executing a substrate processing method. The program sends control signals to each part of the film forming apparatus1to control the operation of each part. For example, the flow rates of gases supplied from the gas holes56of the respective gas nozzles51to55, the temperature of the wafer W by the heater33, and the amount of N2gas supplied from the gas supply pipe15, the rotational speeds of the rotary table2and wafer holder24, and the position of the antenna65are controlled in response to the control signals. Further, recipes (programs) are set with process conditions for executing a substrate processing method step by step. The recipes and other programs are installed in the controller100from a storage medium such as a hard disk, compact disk, magneto-optical disk, memory card, or flexible disk.

Controller

Next, an example of a hardware configuration and functional configuration of the controller100according to an embodiment will be described with reference toFIGS.3and4.FIG.3is a diagram illustrating an example of a hardware configuration of the controller100according to an embodiment.FIG.4is a diagram illustrating an example of a functional configuration of the controller100according to an embodiment. As illustrated inFIG.3, the controller100includes a central processing unit (CPU)301, a read only memory (ROM)302, a random access memory (RAM)303, an I/O port304, an operation panel305, and a hard disk drive (HDD)306. The respective parts are connected by a bus B.

The CPU301controls the operation of the controller100based on recipes and other programs. For example, the CPU301controls substrate processing of a plurality of wafers W placed on the rotary table2based on recipes.

The ROM302is a storage medium including, for example, an electrically erasable programmable ROM (EEPROM), flash memory, and hard disk to store the recipes and other programs of the CPU301. The RAM303functions as, for example, a work area of the CPU301.

The I/O port304acquires detected values of various sensors, which are attached to the film forming apparatus1to detect temperature, pressure, gas flow rate, and others, and transmits them to the CPU301. Further, the I/O port304outputs the control signals from the CPU301to each part of the film forming apparatus1(rotary table2, vacuum pump, etc.). Further, the I/O port304is connected to the operation panel305through which an operator operates the film forming apparatus1. The HDD306may be an auxiliary storage device, and may store recipes, programs, and others that define a substrate processing sequence.

In an example of a functional configuration as illustrated inFIG.4, the controller100includes a storage unit101, a selection unit103, a determination unit104, a process execution unit105, and a display control unit106. The selection unit103, determination unit104, process execution unit105, and display control unit106are realized, for example, by causing the CPU301illustrated inFIG.3to execute the recipes and other programs loaded on the RAM303. The storage unit101is implemented by, for example, the ROM302, RAM303, or HDD306illustrated inFIG.3.

The storage unit101stores a recipe108(e.g., Recipe A) indicating a substrate processing sequence executed by the film forming apparatus1.FIG.5is a diagram illustrating an example of the recipe108according to an embodiment. For example, the recipe108includes steps such as Step 1, Step 2, and Step 3, and an item indicating a process condition108afor each step. Additionally, the recipe108includes an item indicating ignition condition table information (Table)108b.For example, in Steps 1 to 3, Table 1 is designated as the ignition condition table information108b.The ignition condition table information108bis selected from among a plurality of ignition condition tables110(see, e.g.,FIG.7) stored in the storage unit101.

Further, the storage unit101stores antenna position setting information109.FIG.6is a diagram illustrating an example of the antenna position setting information109according to an embodiment. The antenna position setting information109stores a correspondence between Positions 1 to 5 of the antenna65and setting values 1 to 5 mm of the antenna65from the origin position of the antenna65, which is set to 0 mm. For example, Position 1 of the antenna65is set 1 mm higher than the origin position of the antenna65. In the example ofFIG.6, five positions of the antenna65are set, but are not limited thereto, and a greater number of positions of the antenna65may be set.

Furthermore, the storage unit101stores the ignition condition tables110.FIG.7is a diagram illustrating an example of the ignition condition tables110according to an embodiment. The ignition condition tables110store ignition condition information111to115where process conditions110aand antenna positions110bare associated with each other. A plurality of pieces of ignition condition information may be stored for each of five ignition condition tables110(Tables 1 to 5).

The process conditions110ainclude process conditions related to plasma ignition conditions among plasma conditions set in the recipe108. In an example ofFIG.7, each ignition condition information111to115store gas species, gas flow rate of each gas, pressure in the vacuum container11, and RF power supplied to the antenna65. While multiple gas species may be set, a single gas may also be set. In the example ofFIG.7, three gas species are set.

A plasma ignition state varies depending on the gas species, gas flow rate, pressure, and RF power. For example, when the gas species is a hydrogen gas, it is more prone to ignition. In the meantime, ignition tends to be difficult with a relatively lower gas flow rate. Also, a relatively higher pressure in the vacuum container11or a relatively higher RF power makes ignition easier.

Therefore, the process conditions110aof the ignition condition information111to115include at least factors contributing to a variation in the plasma ignition state, such as gas species, gas flow rate of each gas, pressure in the vacuum container11, and RF power supplied to the antenna65. The storage unit101stores the antenna position110bfor each process condition110aof multiple pieces of ignition condition information111to115.

The selection unit103selects an ignition condition table identified in the recipe108from the plurality of ignition condition tables110stored in the storage unit101. In the example ofFIG.5, the selection unit103selects “Table 1” identified in the ignition condition table information108bof the recipe108.

The determination unit104refers to the selected ignition condition table to determine the antenna position110bcorresponding to the process condition110athat matches the process condition set in the recipe108.

The process execution unit105moves the antenna65to the determined antenna position using the electric actuator140. After moving the antenna65, the process execution unit105controls process conditions according to a designated recipe to simultaneously process a plurality of wafers W placed on the rotary table2.

The display control unit106displays various screens, such as a screen for setting the antenna position setting information109and a screen for selecting the ignition condition tables110identified in the recipe108, on the operation panel305operated by the operator. The display control unit106may also display the recipe108. The operation panel305is an example of a display device.

Substrate Processing Method

Next, a substrate processing method executed by the film forming apparatus1will be described with reference toFIG.8.FIG.8is a flowchart illustrating an example of a substrate processing method ST according to an embodiment. For example, the substrate processing method ST is controlled by the controller100and is executed by the film forming apparatus1.

In the substrate processing method ST, firstly, in step ST1, the selection unit103selects a recipe. Next, in step ST2, the selection unit103selects an ignition condition table identified in the selected recipe. When the recipe108illustrated inFIG.5is selected, the selection unit103selects “Table 1” in step ST2.

Next, in step ST3, the determination unit104determines which of the process conditions110aset in the ignition condition information of the selected ignition condition table matches the process condition set in Step 1 of the recipe.

In the example ofFIG.7, the determination unit104searches for one of the process conditions110aof the ignition condition information111to115set in the ignition condition table110of “Table 1” that matches the process condition108aset in Step 1 of the recipe108illustrated inFIG.5.

In this case, none of the process conditions110aof the ignition condition information111to115matches the process condition108aset in Step 1 of the recipe108. Therefore, the determination unit104determines “No” in step ST3and proceeds to step ST6. The process execution unit105controls the process condition of Step 1 of the recipe without moving the position of the antenna65from the origin position to process the plurality of wafers W placed on the rotary table2.

Next, in step ST7, the process execution unit105determines whether there is a next step in the recipe. In the example ofFIG.5, the recipe108has a next step (Step 2). Thus, the process execution unit105determines “Yes” in step ST7and returns to step ST3. The determination unit104determines which of the process conditions110aset in the ignition condition table110of “Table 1” matches the process condition108aset in Step 2 of the recipe.

In case ofFIGS.5and7, among the process conditions110aof the ignition condition table110, the process condition110aof the ignition condition information111matches the process condition108aset in Step 2 of the recipe108. Therefore, the determination unit104determines “Yes” in step ST3, and proceeds to step ST4, where the determination unit104determines the position of the antenna65as the antenna position110bof the ignition condition information111. In the example ofFIG.7, the determination unit104determines “Position 1” of the ignition condition information111.

Next, in step ST5, the process execution unit105moves the antenna65to the determined antenna position using the electric actuator140. In the example ofFIG.7, the process execution unit105moves the antenna65to Position 1. Thus, as illustrated inFIG.6, the position of the antenna65is lifted by 1 mm from the origin position of the antenna65.

After moving the antenna65, the process execution unit105controls the process condition of the designated recipe to simultaneously process the plurality of wafers W placed on the rotary table2.

Next, in step ST7, the process execution unit105determines whether there is a next step in the recipe. In the example ofFIG.5, the recipe108has a next step (Step 3). Thus, the process execution unit105determines “Yes” in step ST7and returns to step ST3. The determination unit104determines which of the process conditions110aset in the ignition condition table110of “Table 1” matches the process condition108aset in Step 3 of the recipe.

In case ofFIGS.5and7, among the process conditions110aof the ignition condition table110, the process condition110aof the ignition condition information115matches the process condition108aset in Step 3 of the recipe108. Therefore, the determination unit104determines “Yes” in step ST3and proceeds to step ST4, where the determination unit104determines the position of the antenna65as the antenna position110bof the ignition condition information115. In the example ofFIG.7, the determination unit104determines “Position 5” of the ignition condition information115.

Next, in step ST5, the process execution unit105moves the antenna65to the determined antenna position using the electric actuator140. In the example ofFIG.7, the process execution unit105moves the antenna65to Position 5. Thus, as illustrated inFIG.6, the position of the antenna65is lifted by 5 mm from the origin position of the antenna65.

After moving the antenna65, the process execution unit105controls the process condition of the designated recipe to simultaneously process the plurality of wafers W placed on the rotary table2.

Next, in step ST7, the process execution unit105determines whether there is a next step in the recipe. In the example ofFIG.5, there is no next step after Step 3 in the recipe108. Thus, this processing is terminated.

As described above, according to the substrate processing method of the present embodiment, in the ignition condition table110, the ignition condition information111to115store the process conditions110arelated to the plasma ignition conditions and the antenna positions110bin association with each other. Then, the position (height) of the antenna65is automatically adjusted to the antenna position110bcorresponding to the process condition110aof the ignition condition information that matches the process condition108aset in the recipe. As a result, a stable plasma ignition may be achieved under appropriate plasma ignition conditions by optimizing the position of the antenna65. This enhances the in-plane uniformity of a film in substrate processing using a plasma, improving process performance.

Further, by optimizing the position of the antenna65, it is possible to protect the equipment around the antenna65. When the process is performed with the antenna65at the same position as that during RF ignition, the damage to the equipment around the antenna65may become significant. For example, as illustrated inFIG.1, the sapphire glass61located near the antenna65is prone to the damage when the antenna65approaches. Therefore, for example, the position of the antenna65during the process of a subsequent step is automatically adjusted to be higher than the position of the antenna65during RF ignition in a certain step. This may protect the antenna65itself and the equipment around the antenna65such as the sapphire glass61. Thus, the lifespan of the equipment may be extended.

In addition, the recipe108inFIG.5omits the description of other process conditions such as the orbital and turning rotational speeds of the rotary table2. The process execution unit105rotates the rotary table2around the central shaft21according to the orbital rotational speed set in the recipe, and rotates the wafer holder24around the rotating shaft26according to the turning rotational speed.

While controlling the rotation of the rotary table2, the process execution unit105supplies a gas from a gas supply (e.g., gas nozzles51to55) to a gas supply region on a portion of the surface of the rotary table2, forming a film on the wafer W which repeatedly passes through the gas supply region due to orbital rotation. Furthermore, the wafer W, which repeatedly passes through the gas supply region, turns around its axis while orbiting via rotation of the wafer holder24. During plasma generation, the wafer W passing below the sapphire glass61is subjected to plasma processing.

Modifications

Instead of automatically adjusting the position (height) of the antenna65using the electric actuator140, the position (height) of the rotary table2may be automatically adjusted. Both the position (height) of the antenna65and the position (height) of the rotary table2may be automatically adjusted using the electric actuator140.

The position (height) of the rotary table2may be automatically adjusted using the orbiting rotational driving unit22. The orbiting rotational driving unit22is an example of a second driving unit configured to move the rotary table2. The orbiting rotational driving unit22moves (raises and lowers) the rotary table2while rotating it around the central shaft21to automatically adjust the rotary table2to a determined position. In this case, the position of the rotary table2is stored in the ignition condition table110in association with the process condition110a.Thus, the determination unit104refers to the ignition condition table110to determine the position of the rotary table corresponding to the process condition110aof the ignition condition information that matches the process condition108aset in the recipe. Then, the rotary table2is moved to the determined position of the rotary table by the orbiting rotational driving unit22, and the plurality of wafers W are processed in that state. This allows stable plasma ignition while enhancing the in-plane uniformity of substrate processing.

The tilt angle of the antenna may also be automatically adjusted. The tilt angle of the antenna may be automatically adjusted using the electric actuator140. At this time, a support66′ illustrated inFIG.1is connected to the right or left end of the antenna65. In this configuration, a driving system (e.g., electric actuator140, frame141, fixing element142, driving force transmitter143, and support66′) of the plasma generator180is an example of a third driving unit configured to change the tilt angle of the antenna65. The antenna65is tilted diagonally by raising the end of the antenna65with the electric actuator140. This allows the antenna65to be automatically adjusted to a determined tilt angle.

In this case, the tilt angle of the antenna is stored in the ignition condition table110in association with the process condition110a.Thus, the determination unit104refers to the ignition condition table110to determine the tilt angle corresponding to the process condition110aof the ignition condition information that matches the process condition108aset in the recipe. Then, the electric actuator140is driven to control the antenna65to the determined tilt angle, and then the plurality of wafers W are processed. This allows stable plasma ignition while enhancing the in-plane uniformity of substrate processing.

As described above, according to the substrate processing method of the present embodiment, it is possible to execute a process under appropriate ignition conditions.

When only one condition among the process conditions110aof the ignition condition table110differs and the other conditions are the same, it is possible to select whether to perform linear interpolation for that one condition. For example, inFIG.7, when the gas flow rate of Gas 1 is 1,000 sccm, the antenna position110bis “Position 1.” When the gas flow rate of Gas 1 is 1,100 sccm, the antenna position110bis “Position 2.” Assuming that the other process conditions [Gas 2 (gas flow rate), Gas 3 (gas flow rate), pressure, and RF power] are set to the same values. In a case where linear interpolation is selected for the recipe or specific parameters, when the gas flow rate of Gas 1 is 1,050 sccm, the antenna position may be determined as an intermediate position between “Position 1” and “Position 2” because the other process conditions are set to the same values. When “Position 1” is 1 mm above the origin position of the antenna65and “Position 2” is 2 mm above the origin position, the antenna65may be adjusted automatically to 1.5 mm above the origin position between “Position 1” and “Position 2.”

The substrate processing apparatus for executing the substrate processing method according to the present embodiment has been described using the film forming apparatus1inFIG.1by way of example, but is not limited thereto. A substrate processing apparatus having a different configuration from the film forming apparatus1inFIG.1may be used as long as the substrate processing apparatus includes a vacuum container, a rotary table having a placement surface for placing a plurality of substrates thereon and configured to rotate the plurality of substrates, an antenna coupled to the vacuum container and configured to generate a plasma in the vacuum container, and a first driving unit configured to move the antenna.

According to an aspect, it is possible to execute a process under appropriate ignition conditions.