SUBSTRATE PROCESSING APPARATUS, METHOD OF PROCESSING SUBSTRATE, METHOD OF MANUFACTURING SEMICONDUCTOR DEVICE, AND RECORDING MEDIUM

A technique includes at least one chamber including a process chamber that is capable of processing a substrate and a shower head arranged in an upstream of the process chamber; a gas supplier that is capable of supplying a gas into the process chamber via the shower head; a first exhaust pipe communicating with the shower head; a second exhaust pipe communicating with the process chamber; a first exhaust controller installed in the first exhaust pipe; a first heater installed in the first exhaust pipe; and a controller configured to be capable of: (a) controlling the gas supplier so as to supply a processing gas as the gas to the shower head, and (b) controlling the gas supplier so as to supply a non-processing gas as the gas to the shower head.

CROSS-REFERENCE TO RELATED APPLICATION

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2022-147102, filed on Sep. 15, 2022, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a substrate processing apparatus, a method of processing a substrate, a method of manufacturing a semiconductor device, and a recording medium.

BACKGROUND

In a process of manufacturing a semiconductor device, as a substrate processing apparatus for performing a predetermined process on a substrate such as a wafer or the like, there may be used an apparatus having a configuration in which a gas is supplied into a processing space via a shower head and gas and is exhausted from the shower head and the processing space.

SUMMARY

Some embodiments of the present disclosure provide a technique capable of enhancing the throughput when processing a plurality of substrates.

According to one embodiment of the present disclosure, there is provided a technique that includes at least one chamber including a process chamber that is capable of processing a substrate and a shower head arranged in an upstream of the process chamber; a gas supplier that is capable of supplying a gas into the process chamber via the shower head; a first exhaust pipe communicating with the shower head; a second exhaust pipe communicating with the process chamber; a first exhaust controller installed in the first exhaust pipe; a first heater installed in the first exhaust pipe; and a controller configured to be capable of: (a) controlling the gas supplier so as to supply a processing gas as the gas to the shower head in a state in which the substrate is present in the process chamber and the first exhaust controller such that an inside of the first exhaust pipe has a first conductance in a state in which the first heater is operated, and (b) controlling the gas supplier so as to supply a non-processing gas as the gas to the shower head in a state in which the substrate is not present in the process chamber and the first exhaust controller such that the inside of the first exhaust pipe has a second conductance smaller than the first conductance in a state in which the first heater is operated.

DETAILED DESCRIPTION

Embodiments of the Present Disclosure

Embodiments of the present disclosure will be described below with reference to the drawings. The drawings used in the following description are all schematic. The dimensional relationship of respective elements, the ratio of respective elements, and the like shown in the drawings do not necessarily match the actual ones. In addition, the dimensional relationship of respective elements, the ratio of respective elements, and the like do not necessarily match between a plurality of drawings.

(1) Configuration of Substrate Processing System

First, a substrate processing system including a substrate processing apparatus will be described.FIG.1is a horizontal cross-sectional view showing a configuration example of the substrate processing system according to the present embodiment.FIG.2is a vertical cross-sectional view taken along line α-α′ inFIG.1, showing a configuration example of the substrate processing system according to the present embodiment.

Referring toFIGS.1and2, the substrate processing system1000is configured to process a substrate200and is mainly composed of an IO stage1100, an atmospheric transfer chamber1200, a load lock chamber1300, a vacuum transfer chamber1400, and a process module110. Next, each configuration will be specifically described. In the description ofFIG.1, it is denoted that an X1 direction is right, an X2 direction is left, an Y1 direction is front, and the Y2 direction is rear.

An IO stage (load port)1100is installed in front of the substrate processing system1000. A plurality of pods1001are mounted on the IO stage1100. The pod1001is used as a carrier for transferring substrates200such as silicon (Si) wafers. A plurality of unprocessed substrates (wafers)200or a plurality of processed substrates200are stored in the pod1001in a horizontal posture.

The pod1001is provided with a cap1120, which is opened and closed by a pod opener1210which will be described later. The pod opener1210configured to open and close the cap1120of the pod1001placed on the IO stage1100and can load and unload the substrate200into and from the pod1001by opening and closing a substrate loading/unloading port.

The IO stage1100is adjacent to the atmosphere transfer chamber1200. The load lock chamber1300(to be described later) is connected to the surface of the atmospheric transfer chamber1200which is opposite from the IO stage1100.

An atmospheric transfer robot1220as a first transfer robot for transferring the substrate200is installed in the atmospheric transfer chamber1200.

As shown inFIGS.1and2, a substrate loading/unloading port1280for loading and unloading the substrate200into and from the atmospheric transfer chamber1200, and a pod opener1210are installed on a front side of a housing1270of the atmospheric transfer chamber1200. The IO stage (load port)1100is installed on the side opposite to the pod opener1210across the substrate loading/unloading port1280, that is, on the outside of the housing1270.

A substrate loading/unloading port1290for loading and unloading the substrate200into and from the load lock chamber1300is provided on the rear side of the housing1270of the atmospheric transfer chamber1200. The substrate loading/unloading port1290is opened and closed by a gate valve1330which will be described later, which makes it possible to load and unload the substrate200.

The load lock chamber1300is adjacent to the atmospheric transfer chamber1200. As will be described later, a vacuum transfer chamber1400is arranged on the surface of the housing1310constituting the load lock chamber1300which is opposite from the atmospheric transfer chamber1200.

A substrate loading/unloading port1340is provided on the side of the housing1310adjacent to the vacuum transfer chamber1400. The substrate loading/unloading port1340is opened/closed by a gate valve1350, which makes it possible to load and unload the substrate200.

Further, a substrate mounting table1320having at least two mounting surfaces1311(1311aand1311b) on which the substrate200is mounted is installed in the load lock chamber1300. The distance between the substrate mounting surfaces1311is set according to the distance between fingers of a vacuum transfer robot1700, which will be described later.

The substrate processing system1000includes a vacuum transfer chamber (transfer module)1400as a transfer chamber serving as a transfer space in which the substrate200is transferred at a negative pressure. The housing1410constituting the vacuum transfer chamber1400is formed in a shape of a pentagon when viewed from above, and the load lock chamber1300and the process modules110ato110dfor processing the substrate200are connected to the respective sides of the pentagon. A vacuum transfer robot1700serving as a second transfer robot that transfers the substrate200at a negative pressure is installed at substantially the center of the vacuum transfer chamber1400using a flange1430as a base.

A substrate loading/unloading port1420is provided at a side wall of the housing1410adjacent to the load lock chamber1300. The substrate loading/unloading port1420is opened and closed by a gate valve1350, which makes it possible to load and unload the substrate200.

As shown inFIG.2, the vacuum transfer robot1700installed in the vacuum transfer chamber1400is configured to be moved up and down by means of an elevator1450and a flange1430while maintaining the airtightness of the vacuum transfer chamber1400. The elevator1450is configured to independently raise and lower two arms1800and1900of the vacuum transfer robot1700. The arm1800and the arm1900are bifurcated, and are capable of loading and unloading the substrates into and from two chambers202in the process module110, which will be described later.

The vacuum transfer robot1700transfers the substrate200between each process module110and the load lock chamber1300.FIG.2shows an example of mounting the substrate200unloaded from the process module110c.

As shown inFIG.1, process modules110a,110b,110c, and110d, which perform desired processing on the substrate200, are connected to the side walls where the load lock chamber1300is not installed, among the five side walls of the housing1410. Hereinafter, these modules may be collectively referred to as process modules110.

Each of the process modules110a,110b,110c, and110dis provided with chambers202, which are one configuration of the substrate processing apparatus. Specifically, chambers202aand202bare installed in the process module110a. Chambers202cand202dare installed in the process module110b. Chambers202eand202fare installed in the process module110c. Chambers202gand202hare installed in the process module110d.

A substrate loading/unloading port1480is provided in the side wall of the housing1410facing each chamber202. For example, as shown inFIG.2, a substrate loading/unloading port1480eis provided in the side wall facing the chamber202e.

If the chamber202eis replaced with the chamber202ainFIG.2, a substrate loading/unloading port1480ais provided on the side wall facing the chamber202a.

Similarly, when the chamber202fis replaced with the chamber202b, a substrate loading/unloading port1480bis provided in the side wall facing the chamber202b.

A gate valve1490is provided for each process chamber as shown inFIG.1. Specifically, a gate valve1490ais provided between the chamber202aand the vacuum transfer chamber1400, and a gate valve1490bis provided between the chamber202band the vacuum transfer chamber1400. A gate valve1490cis provided between the chamber202cand the vacuum transfer chamber1400, and a gate valve1490dis provided between the chamber202dand the vacuum transfer chamber1400. A gate valve1490eis provided between the chamber202eand the vacuum transfer chamber1400, and a gate valve1490fis provided between the chamber202fand the vacuum transfer chamber1400. A gate valve1490gis provided between the chamber202gand the vacuum transfer chamber1400, and a gate valve1490his provided between the chamber202hand the vacuum transfer chamber1400.

By opening and closing each gate valve1490, the substrate200can be loaded and unloaded through the substrate loading/unloading port1480.

(2) Configuration of Substrate Processing Apparatus

Next, a substrate processing apparatus, which is one component of the substrate processing system1000, will be described. In the following descriptions, a single-substrate-type substrate processing apparatus that processes substrates200to be processed one by one will be described as an example of the substrate processing apparatus.FIG.3is a schematic configuration diagram of a single-substrate-type substrate processing apparatus according to the present embodiment.

As shown inFIG.3, the substrate processing apparatus100includes a chamber202as a process container. The chamber202corresponds to the chambers202a,202b,202c,202d,202e,202f,202gand202hin the substrate processing system1000having the configuration described above. That is, each chamber202may be configured similarly.

The chamber202is configured as, for example, a flat closed container having a circular cross section. Further, the chamber202is made of a metal material such as aluminum (Al) or stainless steel (SUS). A process chamber201, which is a processing space for processing a substrate200such as a silicon wafer, and a transfer space203through which the substrate200passes when transferring the substrate200to the process chamber201are formed in the chamber202. That is, the chamber202includes at least the process chamber201capable of processing the substrate.

The chamber202is composed of an upper container202aand a lower container202b. A partition plate204is provided between the upper container202aand the lower container202b.

An exhaust buffer chamber209is installed in the vicinity of the outer peripheral edge inside the upper container202a. The exhaust buffer chamber209functions as a buffer space when the gas inside the process chamber201is exhausted laterally. Therefore, the exhaust buffer chamber209has a space surrounding the lateral periphery of the process chamber201. In other words, the exhaust buffer chamber209has a space having a ring-shape (annular shape) in a plan view on the outer peripheral side of the process chamber201. The space of the exhaust buffer chamber209is formed such that its ceiling surface and both side wall surfaces is formed by the upper container202aand its floor surface is formed by the partition plate204. The inner peripheral side of the space communicates with the process chamber201, and it is configured to introduce the gas supplied into the process chamber201into the exhaust buffer chamber209through the communicating portion.

A substrate loading/unloading port206adjacent to a gate valve205is provided on the side surface of the lower container202b, and the substrate200is moved to and from the vacuum transfer chamber1400through the substrate loading/unloading port206. A plurality of lift pins207are provided at the bottom of the lower container202b.

A substrate support210that supports the substrate200is installed in the process chamber201. The substrate support210mainly includes a substrate mounting surface211on which the substrate200is mounted, a substrate mounting table212having the substrate mounting surface211on its front surface, and a heater213as a third heater built in the substrate mounting table212. Through-holes214through which the lift pins207pass are provided in the substrate mounting table212at positions corresponding to the lift pins207.

The substrate mounting table212is supported by a shaft217. The shaft217passes through the bottom of the chamber202and is connected to an elevating mechanism218outside the chamber202. By operating the elevating mechanism218to raise and lower the shaft217and the substrate mounting table212, it is possible to raise and lower the substrate200mounted on the substrate mounting surface211. The circumference of the lower end portion of the shaft217is covered with a bellows219, and the inside of the chamber202is kept airtight.

When transferring the substrate200, the substrate mounting table212is lowered to a position (wafer transfer position) where the substrate mounting surface211faces the substrate loading/unloading port206. When processing the substrate200, the substrate mounting table212is raised until the substrate200reaches the processing position (wafer processing position) in the process chamber201. Specifically, when the substrate mounting table212is lowered to the wafer transfer position, the upper ends of the lift pins207protrude from the upper surface of the substrate mounting surface211so that the lift pins207support the substrate200from below. Further, when the substrate mounting table212is raised to the wafer processing position, the lift pins207are retracted from the upper surface of the substrate mounting surface211so that the substrate mounting surface211supports the substrate200from below. Since the lift pins207are in direct contact with the substrate200, it is desirable that the lift pins207are made of a material such as quartz or alumina.

A shower head230as a gas dispersion mechanism is installed in the upper portion of the process chamber201(on the upstream side in the gas supply direction). In other words, the chamber202includes the process chamber201and the shower head230provided above the process chamber201. A lid231of the shower head230is provided with a gas introduction port241, and a gas supply system described later is connected to the gas introduction port241. A gas introduced from the gas introduction port241is supplied to a shower head buffer chamber232which is a space formed within the shower head230.

A support block233for supporting the lid231of the shower head230is provided between the lid231and the upper container202a.

The shower head230includes a distribution plate234for dispersing the gas supplied from the gas supply system through the gas introduction port241. The upstream side of the dispersion plate234is the shower head buffer chamber232, and the downstream side thereof is the process chamber201. The dispersion plate234is provided with a plurality of through-holes234a. The dispersion plate234is arranged above the substrate mounting surface211so as to face the substrate mounting surface211. Therefore, the shower head buffer chamber232communicates with the process chamber201through the through-holes234ainstalled in the dispersion plate234.

The shower head buffer chamber232is provided with a gas guide235that forms a flow of the supplied gas. The gas guide235has a conical shape such that the diameter thereof increases toward the dispersion plate234from the gas introduction port241as an apex. The gas guide235is formed so that the lower end thereof is located more outward than the through-holes234aformed on the outermost side of the dispersion plate234. That is, the shower head buffer chamber232includes the gas guide235that guides the gas supplied from above the dispersion plate234toward the process chamber201.

The shower head230may include a heater231bas a heat source for increasing the temperature of the shower head buffer chamber232and the process chamber201.

A common gas supply pipe242is connected to a gas introduction hole241provided in the lid231of the shower head230. The common gas supply pipe242communicates with the shower head buffer chamber232in the shower head230by being connected to the gas introduction hole241. Further, a first gas supply pipe243a, a second gas supply pipe244a, and a third gas supply pipe245aare connected to the common gas supply pipe242. The second gas supply pipe244ais connected to the common gas supply pipe242via a remote plasma unit (RPU)244e.

Among them, a precursor gas is mainly supplied from the precursor gas supply system243including the first gas supply pipe243a, and a reaction gas is mainly supplied from a reaction gas supply system244including the second gas supply pipe244a. The precursor gas and the reaction gas function as processing gases for processing the substrate200. Either or both of an inert gas and a cleaning gas are supplied from an inert gas supply system245including the third gas supply pipe245a. The inert gas and the cleaning gas function as non-processing gases that do not perform a process on the substrate200.

Thus, there is provided a gas supply system as a gas supplier capable of supplying various gases to the process chamber201through the shower head230.

As for the gases supplied to the shower head buffer chamber232of the shower head230through the common gas supply pipe242, the precursor gas is sometimes referred to as a first gas, the reaction gas is sometimes referred to as a second gas, the inert gas is sometimes referred to as a third gas, and the cleaning gas is sometimes referred to as a fourth gas.

In the first gas supply pipe243a, a precursor gas supply source243b, a mass flow controller (MFC)243cas a flow rate controller (flow rate control part), and a valve243das an opening/closing valve are installed sequentially from the upstream side. The precursor gas, which is the first gas, is supplied from the first gas supply pipe243ainto the shower head buffer chamber232via the MFC243c, the valve243d, and the common gas supply pipe242.

The precursor gas is one of the processing gases, and is, for example, a Si2Cl6(disilicon hexachloride or hexachlorodisilane) gas that is a precursor containing a Si (silicon) element. The precursor gas is also called a Si-containing gas. The precursor gas may be solid, liquid, or gaseous at a room temperature and an atmospheric pressure. If the precursor gas is liquid at the room temperature and the atmospheric pressure, a vaporizer (not shown) may be provided between the first gas supply source243band the MFC243c. Here, the precursor gas is described as a gas.

A precursor gas supply system243is mainly composed of the first gas supply pipe243a, the MFC243c, and the valve243d. The precursor gas supply system243may include the precursor gas supply source243band the first inert gas supply system described later. Since the precursor gas supply system243supplies a precursor gas which is one of the processing gases, it corresponds to one of the processing gas supply systems.

The downstream end of a first inert gas supply pipe246ais connected to the first gas supply pipe243aon the downstream side of the valve243d. In the first inert gas supply pipe246a, an inert gas supply source246b, an MFC246cas a flow rate controller (flow rate control part), and a valve246das an opening/closing valve are installed sequentially from the upstream side. The inert gas is supplied from the first inert gas supply pipe246ainto the shower head buffer chamber232via the MFC246c, the valve246dand the first gas supply pipe243a.

Since the inert gas acts as a carrier gas for the precursor gas, it is desirable that a gas that does not react with a precursor is used as the inert gas. Specifically, for example, a nitrogen (N2) gas may be used as the inert gas. In addition to the N2gas, rare gases such as a helium (He) gas, a neon (Ne) gas, and an argon (Ar) gas may be used as the inert gas.

A first inert gas supply system is mainly composed of the first inert gas supply pipe246a, the MFC246c, and the valve246d. The first inert gas supply system may include the inert gas supply source246band the first gas supply pipe243a. In addition, the first inert gas supply system may be included in the precursor gas supply system243.

An RPU244eis installed in the downstream region of the second gas supply pipe244a. In the upstream region of the second gas supply pipe244a, a reaction gas supply source244b, an MFC244cas a flow rate controller (flow rate control part), and a valve244das an opening/closing valve are installed sequentially from the upstream side. The reaction gas, which is the second gas, is supplied from the second gas supply pipe244ainto the shower head buffer chamber232via the MFC244c, the valve244d, the RPU244e, and the common gas supply pipe242. The reaction gas is brought into a plasma state by the remote plasma unit244eand is irradiated onto the substrate200in the process chamber201through the plurality of through-holes234aprovided in the dispersion plate234.

The reaction gas is one of the processing gases. For example, an ammonia (NH3) gas is used as the reaction gas. The reaction gas is a gas that reacts with the components constituting the precursor gas.

A reaction gas supply system244is mainly composed of the second gas supply pipe244a, the MFC244c, and the valve244d. The reaction gas supply system244may include the reaction gas supply source244b, the RPU244e, and the second inert gas supply system described later. Since the reaction gas supply system244supplies the reaction gas, which is one of the process gases, it corresponds to another one of the processing gas supply systems.

The downstream end of a second inert gas supply pipe247ais connected to the second gas supply pipe244aon the downstream side of the valve244d. In the second inert gas supply pipe247a, an inert gas supply source247b, an MFC247cas a flow rate controller (flow rate control part), and a valve247das an opening/closing valve are installed sequentially from the upstream side. The inert gas is supplied from the second inert gas supply pipe247ainto the shower head buffer chamber232via the MFC247c, the valve247d, the second gas supply pipe244a, and the RPU244e.

The inert gas is a gas that acts as a carrier gas or a dilution gas of the reaction gas. Specifically, for example, a N2gas may be used as the inert gas. In addition to the N2gas, rare gases such as a He gas, a Ne gas, and an Ar gas may be used as the inert gas.

A second inert gas supply system is mainly composed of the second inert gas supply pipe247a, the MFC247c, and the valve247d. The second inert gas supply system may include the inert gas supply source247b, the second gas supply pipe243a, and the RPU244e. In addition, the second inert gas supply system may be included in the reaction gas supply system244.

In the third gas supply pipe245a, an inert gas supply source245b, an MFC245cas a flow rate controller (a flow rate control part), and a valve245das an opening/closing valve are installed sequentially from the upstream side. The inert gas as a purge gas is supplied from the third gas supply pipe245ainto the shower head buffer chamber232via the MFC245c, the valve245d, and the common gas supply pipe242in the film-forming step to be described later. In addition, in the first cleaning step to be described later, the inert gas as a carrier gas or a dilution gas of the cleaning gas is supplied into the shower head buffer chamber232via the MFC245c, the valve245d, and the common gas supply pipe242, if necessary.

The inert gas supplied from the inert gas supply source245bis one of the non-processing gases, and acts as a purge gas for purging the gases remaining in the chamber202and the shower head230in the film-forming step. The inert gas may also act as a carrier gas or dilution gas of the cleaning gas in the first cleaning step. Specifically, for example, a N2gas may be used as the inert gas. In addition to the N2gas, rare gases such as a He gas, a Ne gas, and an Ar gas may also be used as the inert gas.

An inert gas supply system245is mainly composed of the third gas supply pipe245a, the MFC245c, and the valve245d. The inert gas supply system245may include the inert gas supply source245b.

The downstream end of a cleaning gas supply pipe248ais connected to the third gas supply pipe245aon the downstream side of the valve245d. In the cleaning gas supply pipe248a, a cleaning gas supply source248b, an MFC248cas a flow rate controller (flow rate control part), and a valve248das an opening/closing valve are installed sequentially from the upstream side. A cleaning gas is supplied from the third gas supply pipe245ainto the shower head buffer chamber232via the MFC248c, the valve248d, and the common gas supply pipe242in the first cleaning step.

The cleaning gas supplied from the cleaning gas supply source248bis one of the non-processing gases, and acts as a cleaning gas for removing byproducts and the like adhering to the shower head230and the chamber202in the first cleaning step. Specifically, a fluorine-containing gas containing fluorine (F) is used as the cleaning gas. For example, a nitrogen trifluoride (NF3) gas may be used as the cleaning gas. Further, for example, a hydrogen fluoride (HF) gas, a chlorine trifluoride gas (ClF3) gas, a fluorine (F2) gas, or a combination thereof may be used as the cleaning gas.

A cleaning gas supply system is mainly composed of the cleaning gas supply pipe248a, the MFC248c, and the valve248d. The cleaning gas supply system may include the cleaning gas supply source248band the third gas supply pipe245a.

An exhaust system for exhausting the atmosphere in the chamber202includes a plurality of exhaust pipes connected to the chamber202. Specifically, the exhaust system includes a basic exhaust pipe (not shown) connected to the transfer space203of the lower container202b, a first exhaust pipe236connected to the shower head buffer chamber232of the shower head230and communicating with the shower head230, and a second exhaust pipe222connected to the exhaust buffer chamber209of the upper container202aand communicating with the process chamber201.

A first exhaust pipe236is connected to the upper surface or the side surface of the shower head buffer chamber232. That is, the first exhaust pipe236is connected to the shower head230to thereby communicate with the shower head buffer chamber232in the shower head230.

A first valve237is installed in the first exhaust pipe236. Furthermore, a vacuum pump253, which will be described later, is installed in the first exhaust pipe236on the downstream side of the first valve237. The vacuum pump253exhausts the atmosphere in the shower head buffer chamber232through the first exhaust pipe236. This exhaust is controlled by the first valve237. That is, the first valve237functioning as a first exhaust controller that is capable of controlling the exhaust through the first exhaust pipe236is installed in the first exhaust pipe236. In the first exhaust pipe236, an APC (Auto Pressure Controller)238, which is a pressure controller for controlling the internal pressure of the shower head buffer chamber232to a predetermined pressure, may be installed between the vacuum pump253and the first valve237. In this case, the APC238may be included in the first exhaust controller.

A first gas exhaust system is mainly composed of the first exhaust pipe236and the first valve237. The APC238may be included in the first gas exhaust system.

A first heater239is installed in the first exhaust pipe236. As the first heater239, for example, a pipe heater arranged so as to wrap around the first exhaust pipe236and configured to heat the inside of the first exhaust pipe236by supplying a power may be used.

Furthermore, in addition to the first heater239, a temperature measurer264that is capable of measuring the internal temperature of the first exhaust pipe236may be installed in the first exhaust pipe236. As the temperature measurer264, for example, a temperature sensor arranged inside the first exhaust pipe236may be used.

When there is a plurality of chambers202(202a,202b,202c,202d,202e,202f,202g, and202h) in the substrate processing system1000, each of the chamber202includes the first exhaust pipe236as shown inFIG.4which will be described later.

The second exhaust pipe222is connected to the inside of the exhaust buffer chamber209via an exhaust-hole221provided on the upper surface or the lateral side of the exhaust buffer chamber209. That is, the second exhaust pipe222is connected to the exhaust buffer chamber209so as to communicate with the process chamber201through the exhaust buffer chamber209.

A second valve223is installed in the second exhaust pipe222. Further, in the second exhaust pipe222, an APC224as a pressure controller for controlling the internal pressure of the process chamber201communicating with the exhaust buffer chamber209to a predetermined pressure is installed on the downstream side of the second valve223. Furthermore, in the second exhaust pipe222, a vacuum pump253, which will be described later, is installed on the downstream side of the APC224. The vacuum pump253exhausts the atmosphere in the exhaust buffer chamber209and the process chamber201communicating therewith through the second exhaust pipe222. This exhaust is controlled by the APC224and the second valve223. That is, the APC224and the second valve223that function as a second exhaust controller capable of controlling the exhaust through the second exhaust pipe222are installed in the second exhaust pipe222.

A second gas exhaust system is mainly composed of the second exhaust pipe222, the second valve223, and the APC224.

A second heater225is installed in the second exhaust pipe222. The second heater225can be used as a pipe heater, just like the first heater239. Furthermore, a temperature measurer265that is capable of measuring the internal temperature of the second exhaust pipe222may be installed in the second exhaust pipe222.

When there is a plurality of chambers202(202a,202b,202c,202d,202e,202f,202g, and202h) in the substrate processing system1000, each of the chambers202includes the second exhaust pipe222as shown inFIG.4which will be described later.

(Common Exhaust System for a Plurality of Chambers)

Next, an exhaust system of a plurality of chambers202will be described. Here, as the plurality of chambers202, chambers202aand202bare described as an example.FIG.4is a schematic configuration diagram of the gas exhaust system of the substrate processing apparatus according to the present embodiment.

A junction pipe251afor joining the first exhaust pipe236aand the second exhaust pipe222ais connected to the downstream side portions of the first exhaust pipe236aand the second exhaust pipe222aextending from the chamber202a. A junction pipe251bfor joining the first exhaust pipe236band the second exhaust pipe222bis connected to the downstream side portions of the first exhaust pipe236band the second exhaust pipe222bextending from the chamber202b. A common exhaust pipe252is connected to the downstream side portions of the junction pipes251aand251b. In other words, the common exhaust pipe252is arranged in the downstream portions of the first exhaust pipes236aand236band the second exhaust pipes222aand222bso as to join the first exhaust pipes236aand236band the second exhaust pipes222aand222b.

A vacuum pump253is arranged in the downstream portion of the common exhaust pipe252. An APC254and a valve255are installed sequentially from the downstream side between the vacuum pump253and the junction of the junction pipes251aand251b. The APC254, the valve255, the junction pipes251aand251b, and the common exhaust pipe252constitute a common exhaust system of the plurality of chambers202aand202b. Thus, the atmosphere in the chamber202aand the atmosphere in the chamber202bare exhausted by one vacuum pump253.

Although the common exhaust system of the chambers202aand202bis described as an example, it is assumed that other chambers202c,202d,202e,202f,202gand202hhave the same configuration.

The substrate processing apparatus100includes a controller260that functions as a control part (control means) configured to control the operation of each part of the substrate processing apparatus100.

The controller260includes at least a calculator261and a memory262. The controller260is connected to the respective components described above. The controller260calls up a program and a recipe from the memory262in response to instructions from the host controller and the user, and controls the operations of the respective components according to the contents of the instructions. Specifically, the controller260controls the operations of the gate valve205, the elevating mechanism218, the heaters213and231b, a high-frequency power source, a matcher, the MFCs243cto248c, the valves243dto248d, the APCs224and238, the vacuum pump253, the first valve237, the second valve223, and the like.

The controller260may be configured as a dedicated computer, or may be configured as a general-purpose computer. For example, an external memory device (e.g., a magnetic tape, a magnetic disk such as a flexible disk or a hard disk, an optical disk such as a CD or a DVD, a magneto-optical disk such as an MO or the like, or a semiconductor memory such as a USB memory or a memory card) memory) for storing the above program may be prepared, and the program may be installed in a general-purpose computer using the external memory device to install the program in a general-purpose computer, thereby providing the controller260according to the present embodiment.

Moreover, the means for supplying the program to the computer is not limited to supplying the program via the external memory device. For example, the program may be supplied using communication means such as the Internet or a dedicated line, without having to use the external memory device. That is, the program may be provided by a computer-readable recording medium that records the program. The memory262and the external memory device are configured as computer-readable recording media. Hereinafter, the memory262and the external memory device are collectively and simply referred to as a recording medium. As used herein, the term “recording medium” may include only the memory262, only the external memory device, or both.

(3) Substrate Processing Process

Next, a process of forming a thin film on the substrate200using the substrate processing apparatus100configured as described above will be described as a process of a method of manufacturing a semiconductor device. In the following descriptions, the controller260controls the operations of the respective components of the substrate processing apparatus100.

As used herein, the term “substrate” may mean “a substrate itself,” or “a stacked body (aggregate) of a substrate and a predetermined layer or film formed on a surface of the substrate (i.e., a substrate including a predetermined layer or film formed on a surface of the substrate).” In addition, as used herein, the term “substrate surface” may mean “a surface (exposed surface) of a substrate itself,” or “a surface of a predetermined layer or film formed on a substrate, i.e., “the outermost surface of a substrate as a stacked body.”

Therefore, as used herein, the expression “a predetermined gas is supplied to a substrate” may mean “a predetermined gas is directly supplied to a surface (exposed surface) of a substrate itself,” or “a predetermined gas is supplied to a layer or film formed on a substrate, that is, the outermost surface of a substrate as a stacked body.” Further, as used herein, the expression “a layer or film is formed on a substrate” may mean “a predetermined layer or film is formed on a substrate itself, that is, a predetermined layer or film is formed on the outermost surface of a substrate as a stacked body.”

As used herein, the word “wafer” is synonymous with the word “substrate.” In that case, in the above descriptions, “substrate” may be replaced with “wafer.”

The substrate processing process will be described below. Descriptions will be made on an example where a SiN (silicon nitride) film as a silicon-containing film is formed on a substrate200by an alternate supply method in which a Si2Cl6gas is used as a precursor gas (first processing gas) and an NH3gas is used as a reaction gas (second processing gas).

FIG.5is a flowchart showing a substrate processing process and a cleaning process according to the present embodiment.FIG.6is a flowchart showing details of the film-forming step ofFIG.5.

In the substrate processing process, first, the substrate200is loaded into the process chamber201. Specifically, the substrate mounting table212is lowered by the elevating mechanism218so that the lift pins207protrude from the through-holes214toward the upper surface of the substrate mounting table212. After adjusting the internal pressure of the process chamber201to a predetermined pressure, the gate valve205is opened and the substrate200is mounted on the lift pins207from the gate valve205. After mounting the substrate200on the lift pins207, the substrate mounting table212is raised to a predetermined position by the elevating mechanism218, whereby the substrate200is moved from the lift pins207onto the substrate mounting surface211of the substrate mounting table212.

When the substrate200is loaded into the chamber202, subsequently, the inside of the process chamber201is exhausted through the second exhaust pipe222such that the internal pressure of the process chamber201becomes a predetermined pressure (degree of vacuum). At this time, the valve opening degree of the APC224is feedback-controlled based on the pressure value measured by the pressure sensor. Further, an amount of supplying a power to the heater213is feedback-controlled based on the temperature value detected by the temperature sensor (not shown), so that the internal temperature of the process chamber201reaches a predetermined temperature. Specifically, the substrate mounting table212is heated in advance by the heater213, and is left for a certain period of time after the temperature change of the substrate200or the substrate mounting table212disappears.

After the substrate loading/mounting step S102, subsequently, a film-forming step S104is performed. The film-forming step S104will be described in detail below with reference toFIG.6. The film-forming step S104is a cyclic process in which steps of alternately supplying different processing gases are repeated.

In the film-forming step S104, first, a first processing gas (precursor gas) supply step S202is performed.

When supplying the precursor gas (e.g., Si2Cl6gas) which is the first processing gas, the valve243dis opened and the MFC243cis adjusted such that the flow rate of the precursor gas becomes a predetermined flow rate. As a result, the supply of the precursor gas into the process chamber201is started. The supply flow rate of the precursor gas is, for example, 100 to 500 sccm. The precursor gas is dispersed by the shower head230and uniformly supplied onto the substrate200in the process chamber201.

That is, in the first processing gas supply step S202, the precursor gas supply system243supplies the precursor gas, which is one of the processing gases, to the shower head230while the substrate200is in the process chamber201.

At this time, the valve246dof the first inert gas supply system is opened to supply an inert gas (N2gas) from the first inert gas supply pipe246a. The supply flow rate of the inert gas is, for example, 500 to 5000 sccm. The inert gas may be supplied from the third gas supply pipe245aof the inert gas supply system245.

An excess precursor gas is uniformly introduced into the exhaust buffer chamber209from the process chamber201, flows through the second exhaust pipe222of the second gas exhaust system, and is exhausted. Specifically, the second valve223in the second gas exhaust system is opened, and the internal pressure of the process chamber201is controlled to a predetermined pressure by the APC224. All valves of the exhaust system other than the second valve223in the second gas exhaust system are closed.

After a predetermined time has elapsed since the start of supply of the precursor gas, the valve243din the precursor gas supply system243is closed to stop the supply of the precursor gas. The supply time of the precursor gas and the carrier gas is, for example, 2 to 20 seconds.

After stopping the supply of the precursor gas, an inert gas (N2gas) is supplied from the third gas supply pipe245ato purge the inside of the shower head buffer chamber232. At this time, among the valves of the gas exhaust system, the second valve223in the second gas exhaust system is closed, while the first valve237in the first gas exhaust system is opened. Other valves of the gas exhaust system remain closed. That is, when purging the inside of the shower head buffer chamber232, the exhaust buffer chamber209is cut off from the APC224to stop the pressure control by the APC224, while allowing the shower head buffer chamber232to communicate with the vacuum pump253. As a result, the precursor gas remaining in the shower head230(shower head buffer chamber232) is exhausted from the shower head buffer chamber232via the first exhaust pipe236by the vacuum pump253. At this time, the valve on the downstream side of the APC224may be opened.

The supply flow rate of the inert gas (N2gas) in the first shower head exhaust step S204is, for example, 1000 to 10000 sccm. In addition, the supply time of the inert gas is, for example, 2 to 10 seconds.

At this time, the internal temperature of the first exhaust pipe236for exhausting the remaining precursor gas is controlled by operating the first heater239. Specifically, the first heater239is controlled so that the internal temperature of the first exhaust pipe236reaches a temperature that does not promote thermal decomposition of the precursor gas. By setting the internal temperature of the first exhaust pipe236to a temperature that does not promote thermal decomposition in this way, it is possible to suppress adhesion of the precursor gas to the inside of the first exhaust pipe236.

As for the exhaust through the first exhaust pipe236, the conductance during the exhaust is adjusted by the first valve237. Specifically, the first valve237is controlled so that the first exhaust pipe236has the first conductance. At this time, the APC238may be used for control. Details of the first conductance will be described later.

After purging the inside of the shower head buffer chamber232, the process chamber201is purged by supplying an inert gas (N2gas) from the third gas supply pipe245a. At this time, the second valve223in the second gas exhaust system is opened, and the internal pressure of the process chamber201is controlled to a predetermined pressure by the APC224. On the other hand, all the valves of the gas exhaust system other than the second valve223are closed. As a result, the precursor gas that has not been adsorbed onto the substrate200in the first processing gas supply step S202is removed from the process chamber201by the vacuum pump253via the second exhaust pipe222and the exhaust buffer chamber209.

The supply flow rate of the inert gas (N2gas) in the first processing space exhaust step S206is, for example, 1,000 to 10,000 sccm. In addition, the supply time of the inert gas is, for example, 2 to 10 seconds.

Although the first processing space exhaust step S206is performed after the first shower head exhaust step S204in the above descriptions, the order of performing these steps may be reversed. Alternatively, these steps may be performed simultaneously.

After the shower head buffer chamber232and the process chamber201have been purged, a second processing gas (reaction gas) supply step S208is performed. In the second processing gas supply step S208, the valve244dis opened to start supplying a reaction gas (NH3gas) into the process chamber201via the remote plasma unit244eand the shower head230. At this time, the MFC244cis adjusted so that the flow rate of the reaction gas becomes a predetermined flow rate. The supply flow rate of the reaction gas is, for example, 1,000 to 10,000 sccm.

That is, in the second processing gas supply step S208, the reaction gas supply system244supplies the reaction gas, which is one of the processing gases, to the shower head230while the substrate200is present in the process chamber201.

The reaction gas in a plasma state is dispersed by the shower head230and uniformly supplied onto the substrate200in the process chamber201. The reaction gas reacts with the precursor gas-containing film adsorbed on the substrate200, and forms a SiN film on the substrate200.

At this time, the valve247dof the second inert gas supply system is opened to supply an inert gas (N2gas) from the second inert gas supply pipe247a. The supply flow rate of the inert gas is, for example, 500 to 5,000 sccm. The inert gas may be supplied from the third gas supply pipe245aof the inert gas supply system245.

An excess reaction gas and a reaction by-product are introduced into the exhaust buffer chamber209from the process chamber201, flow through the second exhaust pipe222of the second gas exhaust system, and are exhausted. Specifically, the second valve223in the second gas exhaust system is opened, and the internal pressure of the process chamber201is controlled to a predetermined pressure by the APC224. All the valves of the exhaust system other than the second valve223are closed.

After a predetermined time has elapsed since the start of the supply of the reaction gas, the valve244dis closed to stop the supply of the reaction gas. The supply time of the reaction gas and the carrier gas is, for example, 2 to 20 seconds.

After stopping the supply of the reaction gas, a second shower head exhaust step S210is performed to remove the reaction gas and the reaction by-product remaining in the shower head buffer chamber232. This second shower head exhaust step S210may be performed in the same manner as the already-described first shower head exhaust step S204.

That is, in the second shower head exhaust step S210as well, the internal temperature of the first exhaust pipe236for exhausting the remaining reaction gas and reaction by-product is controlled by operating the first heater239. Specifically, the first heater239is controlled such that the internal temperature of the first exhaust pipe236becomes a temperature that does not promote thermal decomposition of the reaction gas and the reaction by-product. In this way, by setting the internal temperature of the first exhaust pipe236to a temperature that does not promote thermal decomposition, it is possible to suppress adhesion of the reaction gas and the reaction by-product to the inside the first exhaust pipe236.

As for the exhaust through the first exhaust pipe236, the conductance during the exhaust is adjusted by the first valve237. Specifically, the first valve237is controlled so that the inside of the first exhaust pipe236has a first conductance. At this time, the APC238may be used for control. Details of the first conductance will be described later.

After the shower head buffer chamber232is purged, a second processing space exhaust step S212is performed to remove the reaction gas and the reaction by-products remaining in the process chamber201. Since this second processing space exhaust step S212can be performed in the same manner as the already-described first processing space exhaust step S206, the descriptions thereof are omitted here.

The controller260determines whether a cycle including the first processing gas supply step S202, the first shower head exhaust step S204, the first processing space exhaust step S206, the second processing gas supply step S208, the second shower head exhaust step S210, and the second processing space exhaust step S212has been executed a predetermined number of times (n times) at S214. After the cycle is executed the predetermined number of times, a silicon nitride (SiN) film having a desired thickness is formed on the substrate200.

(Number of Processing Times Determination Step: S106)

After the film-forming step S104including the above steps S202to S214, as shown inFIG.5, it is determined whether the number of times of execution of the film-forming step S104has reached a predetermined number of times at S106.

If the number of times of execution of the film-forming step S104has not reached the predetermined number of times, the processed substrate200is taken out, and the process proceeds to a substrate loading/unloading step S108to start to process a new substrate200waiting next. In addition, when the film-forming step S104has been executed a predetermined number of times, the process proceeds to a substrate unloading step S110to take out the processed substrate200so that the substrate200is not present in the chamber202.

In the substrate loading/unloading step S108, the substrate mounting table212is lowered and the substrate200is supported on the lift pins207protruding from the surface of the substrate mounting table212. As a result, the substrate200is moved from the processing position to the transfer position. Thereafter, the gate valve205is opened and the substrate200is unloaded from the chamber202using a wafer transfer machine.

Thereafter, in the substrate loading/unloading step S108, a new substrate200waiting next is loaded into the chamber202in the same procedure as the substrate loading/mounting step S102described above. The substrate is200is raised to the processing position in the process chamber201. The processing temperature and the processing pressure inside the process chamber201are set to a predetermined processing temperature and a predetermined processing pressure so that the next film-forming step S104can be started. Then, the new substrate200in the process chamber201is subjected to the film-forming step S104and the number of processing times determination step S106.

In the substrate unloading step S110, the processed substrate200is taken out from the chamber202and unloaded into the transfer chamber in the same procedure as in the substrate loading/unloading step S108. However, unlike the substrate loading/unloading step S108, in the substrate unloading step S110, the new substrate200waiting next is not loaded into the chamber202, whereby the chamber202is kept in a state in which the substrate200does not exist.

As described above, in the substrate loading/unloading step S108, the process chamber201is kept in a state in which the substrate200does not exist during a period from the start of loading the processed substrate200out of the chamber202to the end of loading the new substrate200into the chamber202. Similarly, even after the substrate unloading step S110, the process chamber201is kept in a state in which the substrate200does not exist during a period from the start of unloading the processed substrate200out of the chamber202to the start of the substrate loading/placing step S102for the new substrate200and the end of the substrate loading into the chamber202. Hereinafter, the state in which the substrate200is not present in the process chamber201and the processing of the next new substrate200is awaited will be referred to as an “idling step” or “idling time.”

During the idling time, when processing a new substrate200, it is desirable to be able to start the processing quickly in order to improve the throughput when processing a plurality of substrates.

Therefore, during the idling time in which the substrate200does not exist in the process chamber201, unlike the series of steps described above, the processing described below is performed.

In the first processing gas supply step S202and the first shower head exhaust step S204described above, (a) the precursor gas supply system243supplies a precursor gas, which is one of processing gases, to the shower head230in a state in which the substrate200is present in the process chamber201, and at least the first valve237is controlled so that the inside of the first exhaust pipe236has a first conductance in a state in which the first heater239is operated.

Furthermore, in the second processing gas supply step S208and the second shower head exhaust step S210described above, (a) the reaction gas supply system244supplies a reaction gas, which is one of processing gases, to the shower head230in a state in which the substrate200is present in the process chamber201, and at least the first valve237is controlled so that the inside of the first exhaust pipe236has a first conductance in a state in which the first heater239is operated.

On the other hand, during the idling time, (b) the inert gas supply system245supplies an inert gas, which is one of non-processing gases, to the shower head230in a state in which the substrate200is not present in the process chamber201, and at least the first valve237is controlled so that the inside of the first exhaust pipe236has a second conductance smaller than the first conductance in a state in which the first heater239is operated.

The first conductance in the above (a) and the second conductance in the above (b) are not limited to specific magnitudes as long as the magnitude relationship thereof is established, and may be set appropriately through the control of at least the first valve237.

By executing control as in the above (a) in a state in which the substrate200is present in the process chamber201and executing control as in the above (b) in a state in which the substrate200is not present in the process chamber201as described above, it is possible to allow the gas to stay in the first exhaust pipe236while operating the first heater239in a state in which the substrate200is not present in the process chamber201(e.g., during the idling time). As a result, it is possible to reduce an amount of temperature drop in the first exhaust pipe236during the idling time. Therefore, when processing the next new substrate200, it is possible to quickly set the temperature in the first exhaust pipe236to the temperature for substrate processing, and as a result, it is possible to enhance the throughput when processing a plurality of substrates.

More specifically, the following control is executed as an operation during the idling time.

As already mentioned, the first exhaust pipe236includes the first valve237which functions as a first exhaust controller. In such a configuration, the opening degree of the first valve237in the above (a) is controlled so as to be greater than the opening degree of the first valve237in the above (b) in which the inert gas, which is one of the non-processing gases, flows. By controlling the opening degree of the first valve237in this manner, it is possible to allow the heated inert gas to stay in the first exhaust pipe236. This is very desirable to reduce an amount of temperature drop in the first exhaust pipe236during the idling time, and to enhance the throughput when processing a plurality of substrates.

More specifically, the process in the above (a) is a cycle process. Substrate processing is performed by, for example, repeating a combination of “first process gas supply step: S202→first shower head exhaust process: S204(→first process space exhaust step: S206)→second processing gas supply step: S208→second shower head exhaust step: S210(→second processing space exhaust step: S212).” In other words, the above (a) includes steps S204and S210of exhausting the atmosphere in the shower head buffer chamber232. In such a case, the opening degree of the first valve237in the above (a) is the opening degree of the valve in the steps S204and S210of exhausting the atmosphere in the shower head buffer chamber232. The opening degree of the valve is greater than in the case of the above (b). Therefore, even if the heated inert gas is allowed to stay in the first exhaust pipe236in the above (b), the exhaust is not delayed in the steps S204and S210of exhausting the atmosphere in the shower head buffer chamber232.

Further, in the above (b), the following control operation may be performed as the control operation for the first valve237which functions as a first exhaust controller. For example, in the above (b), when the inert gas, which is one of the non-processing gases, flows through the first exhaust pipe236, (b-1) the first exhaust pipe236is caused to have a predetermined conductance in a state in which the first heater239is operated, and (b-2) the first exhaust pipe236is caused to have a conductance lower than the predetermined conductance after a predetermined time has elapsed. If the conductance in the first exhaust pipe236is controlled according to the elapsed time by controlling the first exhaust controller in this way, it is possible to realize maintaining the internal temperature of the first exhaust pipe236by which the inert gas is moved into the first exhaust pipe236by, first, increasing the conductance of the first exhaust pipe236(that is, allowing the inert gas to flow), and the inert gas stays in the first exhaust pipe236by closing the first valve237after a predetermined time has elapsed.

More specifically, as the control operation for the first valve237in the first exhaust pipe236, the first valve237is opened in the above (b-1), and the opening degree of the first valve237in the above (b-2) is set to be smaller than in the case of the above (b-1). The opening degree of the first valve237in the above (b-2) may be reduced as compared with the case of the above (b-1), or the first valve237may be closed. If the opening degree of the first valve237is controlled in this way, it is possible to reliably realize maintaining the internal temperature of the first exhaust pipe236by which the inert gas flows through the first exhaust pipe236by opening the first valve237, and the inert gas stays in the first exhaust pipe236by reducing the opening degree of the first valve237or closing the first valve237after a predetermined time has elapsed.

By the way, the chamber202of the substrate processing apparatus100includes the second gas exhaust system for exhausting the atmosphere in the process chamber201in addition to the first gas exhaust system which is the target of the control operation described above. As described above, the second gas exhaust system includes the second exhaust pipe222communicating with the process chamber201. The APC224functioning as a second exhaust controller and the second valve223are installed in the second exhaust pipe222.

In such a relationship with the second exhaust pipe222, the following control operation may be performed for the gas exhaust through the first exhaust pipe236. For example, at least the first valve237in the first exhaust pipe236and the APC224and the second valve223in the second exhaust pipe222are controlled such that, when the inert gas, which is one of the non-processing gases, flows through the first exhaust pipe236, an exhaust amount of gas from the second exhaust pipe222in the above (b) is greater than an exhaust amount of gas from the first exhaust pipe236.

If the exhaust amount from the second exhaust pipe222is increased as described above, the flow of the gas from the shower head buffer chamber232to the second exhaust pipe222increases. This makes it possible to reduce the exhaust amount of the gas from the first exhaust pipe236. Therefore, it is possible to reduce the amount of temperature drop in the first exhaust pipe236.

Further, as in the above (a) and (b), the following temperature control may be performed when the gas is exhausted through the first exhaust pipe236. For example, the output of the first heater239in the above (a) is set to be higher than the output in the above (b) in which the inert gas, which is one of the non-processing gases, flows through the first exhaust pipe236. Since the inert gas does not adhere to the inside of the first exhaust pipe236, the internal temperature of the first exhaust pipe236does not need to be increased unlike the case where the processing gas flows through the first exhaust pipe236. Therefore, power consumption can be reduced by suppressing the output of the first heater239in the case of the above (b) as compared with the case of the above (a).

Furthermore, the temperature control in the first exhaust pipe236may be performed as follows. For example, if the temperature measurer264capable of measuring the temperature in the first exhaust pipe236is installed, in the above (b) in which the inert gas, which is one of the non-processing gases, flows through the first exhaust pipe236, the operation of the first heater239is controlled so that, when the internal temperature of the first exhaust pipe236measured by the temperature measurer264is lower than a predetermined temperature, the internal temperature of the first exhaust pipe236becomes higher than the predetermined temperature.

If the operation of the first heater239is controlled in this way, the internal temperature of the first exhaust pipe236can be maintained so that the internal temperature of the first exhaust pipe236does not fall below the predetermined temperature. Therefore, when processing the next new substrate200, the internal temperature of the first exhaust pipe236can be quickly raised to the temperature for substrate processing. This is very desirable to enhance the throughput when processing a plurality of substrates.

After the substrate unloading step S110, the process may proceed to a cleaning step S112instead of the idling step described above.

In the cleaning step S112, a cleaning process for cleaning the inside of the shower head buffer chamber232and a second cleaning process for cleaning the inside of the process chamber201are mainly performed.

When the cleaning process on the inside of the shower head buffer chamber232is performed, a cleaning gas, which is one of the non-processing gases, is supplied into the shower head buffer chamber232by the cleaning gas supply system. Then, by using the flow of the cleaning gas, a cleaning process of removing deposits (reaction by-products, etc.), which adhere to the inside of the shower head buffer chamber232, particularly the lower surface of the gas guide235(the surface facing the dispersion plate234), the upper surface of the dispersion plate234, and the like, is performed.

The cleaning gas used in the cleaning process is exhausted from the shower head buffer chamber232through the first exhaust pipe236by the first gas exhaust system, or is exhausted from the inside of the process chamber201through the second exhaust pipe222by the second gas exhaust system.

That is, the cleaning gas, which is one of the non-processing gases, is exhausted through the first exhaust pipe236also in the cleaning step S112. At this time, the internal temperature of the first exhaust pipe236is controlled by operating the first heater239for the first exhaust pipe236. Further, for the exhaust through the first exhaust pipe236, the conductance during the exhaust is adjusted at least by the first valve237.

Therefore, the above (b) is also established in the cleaning step S112. Specifically, in the cleaning step S112, (b) the cleaning gas supply system supplies a cleaning gas, which is one of non-processing gases, to the shower head230in a state in which the substrate200is not present in the process chamber201, and at least the first valve237is controlled such that the inside of the first exhaust pipe236has a second conductance smaller than the first conductance in a state in which the first heater239is operated.

The first conductance in the above (a) and the second conductance in the above (b) are not limited to specific magnitudes as long as the their magnitude relationship is established, and may be set appropriately through the control of at least the first valve237.

By executing the control as in the above (a) in the state in which the substrate200is present in the process chamber201and executing the control as in the above (b) in the state in which the substrate200is not present in the process chamber201as described above, it is possible to allow a gas to stay in the first exhaust pipe236while operating the first heater239in the state in which the substrate200is not present (e.g., during the cleaning process). As a result, it is possible to reduce an amount of temperature drop inside the first exhaust pipe236during the cleaning process. Therefore, after the cleaning step S112is finished, when processing the next new substrate200, it is possible that the internal temperature of the first exhaust pipe236quickly approaches a temperature for substrate processing, and as a result, it is possible to enhance the throughput when processing a plurality of substrates.

More specifically, the following control is performed as the operation during the cleaning process.

Regarding the internal temperature of the first exhaust pipe236, the operation of the first heater239is controlled so that the internal temperature of the first exhaust pipe236in the above (a) is lower than the internal temperature of the first exhaust pipe236in the above (b). By controlling the first heater239in this way, the internal temperature of the first exhaust pipe236in the above (a) can be set to a temperature at which the gas in the first exhaust pipe236is not thermally decomposed, and the internal temperature of the first exhaust pipe236in the above (b) can be set to a temperature which is higher than the temperature in the above (a) and at which the deposits are thermally decomposed. This makes it possible to remove the cleaning target objects in the first exhaust pipe236.

In addition, in the cleaning step S112, the cleaning gas can also flow through the second exhaust pipe222communicating with the process chamber201. The APC224and the second valve223, which function as a second exhaust controller, are installed in the second exhaust pipe222.

In such a relationship between the second exhaust pipe222and the first exhaust pipe236, when the cleaning gas, which is one of the non-processing gases, flows, in the above (b), (b-1) at least the first valve237in the first exhaust pipe236and the APC224and the second valve223in the second exhaust pipe222are controlled so that the conductance of the first exhaust pipe236is lower than the conductance of the second exhaust pipe222, and (b-2) at least the first valve237in the first exhaust pipe236and the APC224and the second valve223in the second exhaust pipe222are controlled so that the conductance of the first exhaust pipe236is higher than the conductance of the second exhaust pipe222.

In the above (b-2), the operation of the first heater239is controlled so that the internal temperature of the first exhaust pipe236becomes higher than the internal temperature of the first exhaust pipe236in the above (a).

By such control, it is possible to allow the cleaning gas to flow while setting the internal temperature of the first exhaust pipe236in the above (a) to a temperature at which the gas is not thermally decomposed, and setting the internal temperature of the first exhaust pipe236in the above (b-2) to a temperature which is higher than the temperature in the above (a) and at which the deposits are thermally decomposed. Accordingly, it is possible to remove the cleaning target objects in the first exhaust pipe236.

The second heater225is installed in the second exhaust pipe222in the same manner as the first heater239of the first exhaust pipe236. A heater213as a third heater is installed in the substrate support210in the chamber202.

While using them, the following control operation may be performed when the cleaning gas, which is one of the non-processing gases, flows. For example, in the above (b), at least one or both of the first heater239and the second heater225is controlled so that the internal temperature of the first exhaust pipe236is higher than the internal temperature of the second exhaust pipe222.

In this case, the cleaning gas is heated to the thermal decomposition temperature of the cleaning target object by the heater213as the third heater prior to the second exhaust pipe222. Therefore, in the second heater225, just unlike the first heater239, it is not necessary to actively raise the temperature of the cleaning target object to the decomposition temperature. From the above, by suppressing the heating in the second heater225through the control operation described above, it is possible to reduce the energy consumption of the entire apparatus.

(4) Example of System Processing Operation

Next, an example of the system processing operation in the substrate processing system1000including the substrate processing apparatus100that executes the substrate processing process described above will be described.

As described above, in the substrate processing system1000, each process module110is provided with a plurality of (specifically, for example, two) chambers202, and the first exhaust pipes236extending from the respective chambers202are joined by the common exhaust pipe252.

Specifically, the process module110ais provided with the chambers202aand202b, the process module110bis provided with the chambers202cand202d, the process module110cis provided with the chambers202eand202f, and the process module110dis provided with the chambers202gand202h. In each of the chambers202ato202h, the substrate processing process having the series of procedures described above can be executed.

Here, one process module110is focused. Although the case of focusing on the process module110awill be describe as an example, the same applies to other process modules110bto110d.

For example, if the number of substrates in a lot to be processed in the process module110ais an odd number, there may be generated a situation in which the substrate200is processed in one chamber202awhile the substrate200is not processed in the other chamber202b. In such a case, if a gas is supplied to both chambers202aand202bin the same manner, the gas supply to the chamber202bthat does not perform processing is useless, so that a gas utilization efficiency is lowered and unnecessary film formation may be caused in the chamber202bthat does not perform processing. On the other hand, if a gas is supplied only to the process chamber202a, the processing conditions (gas flow rate, etc.) are different from those in the case where the gas is supplied to both the chambers202aand202b. Thus, the uniformity of processing for each substrate200may be degraded. In particular, when the common gas supply pipe252is used, if the gas flow rates are different between one chamber202aand the other chamber202b, the pressure in one junction pipe251ais affected by the pressure in the other junction pipe251b. Thus, a desired pressure may not be obtained. Since this also affects the processing pressure in the process chamber201, there is a concern that the desired substrate processing cannot be achieved. Therefore, it is desirable to align the processing conditions such as gas flow rates and the like in both chambers202aand202b.

Therefore, in the substrate processing system1000, when a situation in which the substrate200is processed in one chamber (hereinafter referred to as “first chamber”)202aof the plurality of chambers202aand202bconstituting the process module110a, and the substrate200is not processed in the other chamber (hereinafter referred to as “second chamber”)202boccurs, the following atmosphere adjustment process is performed in the second chamber202b.

FIG.7is a flowchart showing the atmosphere adjustment process according to the present embodiment. It is assumed that the atmosphere adjustment process in the second chamber202bthat does not process the substrate200is performed corresponding to the film-forming process (seeFIG.6) in the first chamber202a.

In the atmosphere adjustment process, first, a first inert gas supply step S302is performed. In the first inert gas supply step S302, while the first process gas supply step S202is being performed in the first chamber202a, an inert gas is supplied from the third gas supply pipe245ainto the process chamber201through the shower head buffer chamber232in the second chamber202b. That is, in the first inert gas supply step S302, the inert gas supply system245supplies an inert gas, which is one of the non-processing gases, to the shower head230in a state in which the substrate200is not present in the process chamber201.

Thereafter, when the first shower head exhaust step S204is the first chamber202aperforms, a first shower head exhaust step S304is also performed in the second chamber202b. The first shower head exhaust step S304in the second chamber202bmay be performed in the same manner as the first shower head exhaust step S204in the first chamber202a.

Further, when the first processing space exhaust step S206is performed in the first chamber202a, a first processing space exhaust step S306is also performed in the second chamber202balso performs. The first processing space exhaust step S306in the second chamber202bmay be performed in the same manner as the first processing space exhaust step S206in the first chamber202a.

After the exhaust inside the shower head buffer chamber232and the process chamber201have been completed, a second inert gas supply step S308) is performed. In the second inert gas supply step S308, while the second processing gas supply step S208is being performed in the first chamber202a, an inert gas is supplied from the third gas supply pipe245ainto the process chamber201through the shower head buffer chamber232in the second chamber202b. That is, in the second inert gas supply step S308, the inert gas supply system245supplies an inert gas, which is one of the non-processing gases, to the shower head230in a state in which the substrate200is not present in the process chamber201.

Thereafter, when the second shower head exhaust step S210is performed in the first chamber202a, a second shower head exhaust step S310is also performed in the second chamber202b. The second shower head exhaust step S310in the second chamber202bmay be performed in the same manner as the second shower head exhaust step S210in the first chamber202a.

Furthermore, when the second processing space exhaust step S212is performed in the first chamber202a, a second processing space exhaust step S312is also performed in the second chamber202b. The second processing space exhaust step S312in the second chamber202bmay be performed in the same manner as the second processing space exhaust step S212in the first chamber202a.

The controller260determines whether a cycle including the above steps S302to S312has been performed a predetermined number of times (n times) at S314. When the cycle is performed the predetermined number of times, the film-forming process at S104in the first chamber202ais ended. At the same time, in the second chamber202bas well, the atmosphere adjustment process including the above-described series of procedures is ended.

(System Operation of First Chamber and Second Chamber)

When the film-forming process is performed in the first chamber202aand the atmosphere adjustment process is performed in the second chamber202bas described above, the following control is performed as the operation of the system including these chambers202aand202b.

Specifically, while the processing gas is supplied to the first chamber202ain a state in which the substrate200is present, an inert gas, which is one of the non-processing gases, is supplied to the second chamber202bin a state in which the substrate200is not present. In that case, the operation of at least one or both of the first heaters239aand239bis controlled so that the temperature of the processing gas in the common exhaust pipe252is equal to or higher than a thermal decomposition temperature.

By controlling at least one of the first heaters239aand239bin this way, even when the film-forming process is performed in the first chamber202aand the atmosphere adjustment process is performed in the second chamber202b, the temperature of the common exhaust pipe252can be set to be equal to or higher than a thermal decomposition temperature. Therefore, it becomes possible to prevent unnecessary by-products from adhering to the common exhaust pipe252.

In addition, the operation of at least one or both of the first heaters239aand239bis controlled so that the difference between the internal temperature of the first exhaust pipe236aof the first chamber202aand the internal temperature of the first exhaust pipe236bof the second chamber202bfalls within a predetermined range. As used herein, the expression “temperature difference falls within a predetermined range” means that even if the temperature of the processing gas is lowered due to the temperature difference, the lowered temperature of the processing gas falls within a temperature difference range in which the lowered temperature of the processing gas is not lower than the thermal decomposition temperature. This includes the case where the respective temperatures are the same.

By controlling at least one of the first heater239aand239bin this way, even when the processing gas from the first chamber202aand the non-processing gas from the second chamber202bjoin in the common exhaust pipe252, the temperature of the processing gas does not become lower than the thermal decomposition temperature. Therefore, it becomes possible to prevent unnecessary by-products from adhering to the common exhaust pipe252. For example, if the temperature of the non-processing gas is lower than the temperature of the processing gas and the temperature difference is greater than or equal to a predetermined value, the non-processing gas may lower the temperature of the processing gas due to the joining in the common exhaust pipe252. Thus, the processing gas may adhere to the inner wall of the common exhaust pipe252. In contrast, by controlling the first heaters239aand239bas described above, it is possible to prevent such a phenomenon from occurring.

Furthermore, while using the respective first valves237aand237b, the difference between the opening degree of the first valve237ain the first chamber202aand the opening degree of the first valve237bin the second chamber202bis controlled to fall within a predetermined range. As used herein, the expression “difference between the opening degrees falls within a predetermined range” means that the difference in exhaust amount does not exist (falls within a predetermined range) such that the backflow of gases from the common exhaust pipe252that joins the flows of the respective gases does not occur. This includes the case where the exhaust amounts are the same.

By controlling the respective first valves237aand237bin this way, even when the flows of the respective gases are joined in the common exhaust pipe252, the backflow of the gases does not occur. For example, when the exhaust amount of the gas exhausted from one chamber202is large, that is, when the difference in the exhaust amount exceeds a predetermined range, the gas may flow back into the other chamber202from the place where the respective first exhaust pipes236aand236bjoin. In contrast, by keeping the difference between the respective exhaust amounts within the predetermined range, it is possible to prevent the backflow of the gas.

After the atmosphere adjustment process in the second chamber202b, for example, when starting the substrate processing for a new lot in the process module110a, a situation in which the substrates200are loaded into the first chamber202aand the second chamber202bmay occur. In such a case, the following control is performed as the operation of the system including the chambers202aand202b.

Specifically, when the substrates200are loaded into the first chamber202aand the second chamber202b, the operation of at least one or both of the first heaters239aand239bis controlled such that the difference between the internal temperature of the first exhaust pipe236aand the internal temperature of the first exhaust pipe236bfalls within a predetermined range. As used herein, the expression “difference between the temperatures falls within a predetermined range” means that the lower temperature falls within a temperature difference range in which the lower temperature can quickly (i.e., within a preset allowable time) approach the internal temperature of the first exhaust pipe236for substrate processing. This includes the case where the respective temperatures are the same.

It is more desirable to control the respective first heater239aand239bsimultaneously. By doing so, even when the substrates200are loaded into the first chamber202aand the second chamber202b, the internal temperatures of the first exhaust pipes236aand236bcan approach the temperature for substrate processing at the same time. For example, if the temperature of the first exhaust pipe236is only low, it is necessary to secure the time for the temperature to rise. However, by controlling the first heaters239aand239bas described above, it is possible to prevent such a phenomenon from occurring. As a result, it is possible to increase the throughput during substrate processing.

Further, if the difference between the temperature in the first exhaust pipe236aand the temperature in the first exhaust pipe236bis equal to or greater than a predetermined value, the operation of at least one or both of the first heaters239aand239bmay be controlled so that the internal temperature of the first exhaust pipe236bapproaches the internal temperature of the first exhaust pipe236a. As used herein, the expression “temperature difference equal to or greater than a predetermined value” means that there occurs a temperature difference equal to or greater than a predetermined value which is set to determine whether the temperature difference falls within the above-described predetermined range.

By controlling the respective first heaters239aand239bin this way, when the substrates200are loaded into the first chamber202aand the second chamber202b, feedback control can be performed to ensure that the temperature difference between the internal temperatures of the first exhaust pipes236aand236bfalls within a predetermined range. This is very desirable to increase the throughput during substrate processing.

(5) Effects of the Present Embodiment

According to the present embodiment, one or more of the following effects may be obtained.

(A) According to the present embodiment, control is executed as in the above (a) when the substrate200is present in the process chamber201, and control is executed as in the above (b) when the substrate200is not present in the process chamber201, so that it becomes possible to allow the gas to stay in the first exhaust pipe236while operating the first heater239in the state in which the substrate200is not present (e.g., during the idling time or cleaning time). Accordingly, it is possible to reduce the amount of temperature drop in the first exhaust pipe236in the state in which the substrate200is not present. Therefore, when processing the next new substrate200, it is possible to quickly set the internal temperature of the first exhaust pipe236to the temperature for substrate processing, and as a result, it is possible to enhance the throughput when processing a plurality of substrates.

(B) According to the present embodiment, in the above (a), the first heater239is controlled such that the internal temperature of the first exhaust pipe236becomes a temperature at which the thermal decomposition of the precursor gas is not promoted. This makes it possible to suppress adhesion of the precursor gas to the inside of the first exhaust pipe236.

(C) According to the present embodiment, the opening degree of the first valve237in the above (a) is controlled to be larger than the opening degree of the first valve237in the above (b) in which the inert gas, which is one of the non-processing gases, flows. Accordingly, the heated inert gas is allowed to stay in the first exhaust pipe236. This is very desirable to reduce the amount of temperature drop in the first exhaust pipe236, and to enhance the throughput when processing a plurality of substrates.

(D) According to the present embodiment, in the above (a), the steps S204and S210of exhausting the atmosphere in the shower head buffer chamber232are included, and the opening degree of the first valve237in the above (a) is the valve opening degree in the steps S204and S210of exhausting the atmosphere in the shower head buffer chamber232. Therefore, even if the heated inert gas is allowed to stay in the first exhaust pipe236in the above (b), the exhaust in the steps S204and S210of exhausting the atmosphere in the shower head buffer chamber232is not delayed.

(E) According to the present embodiment, in the above (b), (b-1) the first exhaust pipe236is caused to have a predetermined conductance in a state in which the first heater239is operated, and (b-2) the first exhaust pipe236is caused to have a conductance lower than the predetermined conductance after a predetermined time has elapsed. Therefore, the internal temperature of the first exhaust pipe236can be maintained by firstly increasing the conductance of the first exhaust pipe236(that is, allowing the inert gas to flow) so that the inert gas moves through the first exhaust pipe236, and then closing the first valve237after a predetermined time has elapsed so that the inert gas stays in the first exhaust pipe236.

(F) According to the present embodiment, the first valve237is opened in the above (b-1), and the opening degree of the first valve237in the above (b-2) is set to be smaller than in the case of the above (b-1). Therefore, the internal temperature of the first exhaust pipe236can be reliably maintained by firstly opening the first valve237so that the inert gas flows through the first exhaust pipe236, and then reducing the opening degree of the first valve237or closing the first valve237after a predetermined time has elapsed so that the inert gas stays in the first exhaust pipe236.

(G) According to the present embodiment, at least the first valve237, the APC224and the second valve223are controlled such that, when the inert gas, which is one of the non-processing gases, flows through the first exhaust pipe236, the exhaust amount from the second exhaust pipe222in the above (b) is greater than the exhaust amount from the first exhaust pipe236. If the exhaust amount from the second exhaust pipe222is increased as described above, the gas flow from the shower head buffer chamber232to the second exhaust pipe222increases. This makes it possible to reduce the exhaust amount of the gas from the first exhaust pipe236. Therefore, it is possible to reduce the amount of temperature drop in the first exhaust pipe236.

(H) According to the present embodiment, the first heater239is controlled so that the output of the first heater239in the above (a) becomes higher than the output of the first heater239in the above (b). Since the inert gas, which is one of the non-processing gases, does not adhere to the inside of the first exhaust pipe236, the internal temperature of the first exhaust pipe236does not need to be increased during the flow of the inert gas unlike the case where the processing gas flows through the first exhaust pipe236. Therefore, power consumption can be reduced by suppressing the output of the first heater239in the case of the above (b) as compared with the case of the above (a).

(I) According to the present embodiment, if the temperature measurer264capable of measuring the temperature in the first exhaust pipe236is installed, in the above (b) in which the inert gas, which is one of the non-processing gases, flows through the first exhaust pipe236, the first heater239is controlled such that, when the internal temperature of the first exhaust pipe236measured by the temperature measurer264is lower than a predetermined temperature, the internal temperature of the first exhaust pipe236becomes higher than the predetermined temperature. Therefore, the internal temperature of the first exhaust pipe236can be maintained so that the internal temperature of the first exhaust pipe236does not fall below the predetermined temperature. Therefore, when processing the next new substrate200, it is possible to quickly raise the internal temperature of the first exhaust pipe236to the temperature for substrate processing and this is very desirable to enhance the throughput when processing a plurality of substrates.

(J) According to the present embodiment, when the processing gas is supplied to the first chamber202ain a state in which the substrate200is present and the inert gas, which is one of the non-processing gases, is supplied to the second chamber202bin a state in which the substrate200is not present, at least one of the first heaters239aand239bis controlled so that the temperature of the processing gas in the common exhaust pipe252is equal to or higher than a thermal decomposition temperature. Therefore, the temperature of the common exhaust pipe252can be set to be equal to or higher than a thermal decomposition temperature. This makes it possible to prevent unnecessary by-products from adhering to the common exhaust pipe252.

(K) According to the present embodiment, at least one of the first heaters239aand239bis controlled so that, when the substrates200are loaded into the first chamber202aand the second chamber202b, the difference between the internal temperature of the first exhaust pipe236aand the internal temperature of the first exhaust pipe236bfalls within a predetermined range. Therefore, the internal temperatures of the first exhaust pipes236can approach the temperature for substrate processing at the same time. As a result, it is possible to enhance the throughput during substrate processing.

(L) According to the present embodiment, if the difference between the internal temperature of the first exhaust pipe236aand the internal temperature of the first exhaust pipe236bis equal to or greater than a predetermined value when loading the substrates200into the first chamber202aand the second chamber202b, at least one of the first heaters239aand239bis controlled so that the internal temperature of the first exhaust pipe236bapproaches the temperature in the first exhaust pipe236a. Therefore, feedback control is performed to ensure that the temperature difference between the internal temperatures of the respective first exhaust pipes falls within a predetermined range. This is very desirable to increase the throughput during substrate processing.

(M) According to the present embodiment, when the processing gas is supplied to the first chamber202ain a state in which the substrate200is present, and the inert gas, which is one of the non-processing gases, is supplied to the second chamber202bin a state in which the substrate200is not present, at least one of the first heaters239aand239bis controlled so that the difference between the internal temperature of the first exhaust pipe236aand the internal temperature of the first exhaust pipe236bfalls within a predetermined range. Therefore, even when the processing gas from the first chamber202aand the non-processing gas from the second chamber202bjoin in the common exhaust pipe252, the temperature of the processing gas does not drop below the thermal decomposition temperature. This makes it possible to prevent unnecessary adhesion of by-products and the like to the common exhaust pipe252.

(N) According to the present embodiment, when the cleaning gas, which is one of the non-processing gases, is supplied, the operation of the first heater239is controlled so that the internal temperature of the first exhaust pipe236in the above (a) is lower than the internal temperature of the first exhaust pipe236in the above (b). Therefore, in the above (a), the internal temperature of the first exhaust pipe236can be set to a temperature at which the gas is not thermally decomposed, and in the above (b), the internal temperature of the first exhaust pipe236can be set to a temperature higher than that in the above (a), at which the deposits are thermally decomposed. This makes it possible to remove the cleaning target object in the first exhaust pipe236.

(O) According to the present embodiment, in the above (b), (b-1) at least the first valve237, the APC224, and the second valve223are controlled so that the conductance of the first exhaust pipe236is lower than the conductance of the second exhaust pipe222, and (b-2) at least the first valve237, the APC224, and the second valve223are controlled so that the conductance of the first exhaust pipe236is higher than the conductance of the second exhaust pipe222. In addition, in the above (b-2), the operation of the first heater239is controlled so that the internal temperature of the first exhaust pipe236is higher than the internal temperature of the first exhaust pipe236in the above (a). Therefore, in the above (a), the internal temperature of the first exhaust pipe236can be set to a temperature at which the gas is not thermally decomposed, and in the above (b-2), the cleaning can be allowed to flow in a state in which the internal temperature of the first exhaust pipe236is set to a temperature higher than that in the above (a), at which the deposits are thermally decomposed. This makes it possible to remove the cleaning target objects in the first exhaust pipe236.

(P) According to the present embodiment, in the above (b), when the cleaning gas, which is one of the non-processing gases, flows, at least one selected from the group of the first heater239and the second heater225is controlled so that the internal temperature of the first exhaust pipe236is higher than the internal temperature of the second exhaust pipe222. Therefore, prior to the second exhaust pipe222, the temperature of the cleaning gas is raised to the thermal decomposition temperature of the cleaning target object by the heater213as a third heater. It is not necessary for the second heater225to actively heat the cleaning gas to the thermal decomposition temperature of the cleaning target object. By suppressing the heating in the second heater225in this way, it is possible to reduce the energy consumption of the entire apparatus.

(Q) According to the present embodiment, when the processing gas is supplied to the first chamber202ain a state in which the substrate200is present, and the inert gas or cleaning gas is supplied as a non-processing gas to the second chamber202bin a state in which the substrate200is not present, the first valve237is used to control the difference between the opening degree of the first valve237aand the opening degree of the first valve237bto fall within a predetermined range. Therefore, even when the gas flows from the first chamber202aand the second chamber202bare joined at the common exhaust pipe252, it is possible to prevent the backflow of the gas from occurring.

(6) Other Embodiments of the Present Disclosure

Although the embodiment of the present disclosure has been specifically described above, the present disclosure is not limited to the above-described embodiment, and may be variously modified without departing from the gist thereof.

For example, in the above-described embodiment, the case where, in the film-forming process performed by the substrate processing apparatus100, the Si2Cl6gas is used as the precursor gas (first processing gas), the NH3gas is used as the reaction gas (second processing gas), and the SiN film is formed on the substrate200by alternately supplying the Si2Cl6gas and the NH3gas has been described by way of example. However, the present disclosure is not limited thereto. That is, the processing gases used for the film-forming process are not limited to the Si2Cl6gas and the NH3gas. Other types of thin films may be formed by using other types of gases. Furthermore, even when three or more types of processing gases are used, the present disclosure can be applied as long as the film-forming process is performed by alternately supplying these gases.

Further, for example, in the above-described embodiment, the film-forming process is described as an example of the process performed by the substrate processing apparatus100. However, the present disclosure is not limited thereto. That is, in addition to the film-forming process, the process performed by the substrate processing apparatus100may be a process for forming an oxide film or a nitride film, or may be a process for forming a film containing a metal. Further, regardless of the specific content of the substrate processing, the present disclosure may be suitably applied not only to the film-forming process but also to other substrate processing such as annealing, oxidation, nitridation, diffusion, lithography, and the like. Moreover, the present disclosure can be suitably applied to other substrate processing apparatuses, for example, an annealing apparatus, an oxidation apparatus, a nitriding apparatus, an exposure apparatus, a coating apparatus, a drying apparatus, a heating apparatus, a plasma processing apparatus using plasma, and the like. Further, the present disclosure may be applied to a combination of these apparatuses. A part of the configurations of one embodiment can be replaced with the configuration of another embodiment, and the configuration of another embodiment can be added to the configuration of one embodiment. In addition, a part of the configuration of each embodiment can be added with another configuration, deleted, or replaced.

In this specification, the expression of a numerical range such as “1 to 2000 Pa” means that the lower limit and the upper limit are included in the range. Therefore, for example, “1 to 2,000 Pa” means “1 Pa or more and 2,000 Pa or less”. The same applies to other numerical ranges.

According to the present disclosure in some embodiments, it is possible to enhance the throughput when processing a plurality of substrates.