FLOW PATH MEMBER

A flow path member of the present disclosure includes: a base having a first surface, and further having a first inflow port and a first outflow port; and a flow path that connects to the first inflow port and the first outflow port in an inside of the base. The flow path includes a first flow path that goes along the first surface and a second flow path that intersects the first flow path. The base includes a first projection in the first flow path, and a surface of the first projection is continuous with a wall surface of the second flow path.

TECHNICAL FIELD

The present disclosure relates to a flow path member.

BACKGROUND ART

A flow path member is widely used in a variety of applications. For example, in a semiconductor manufacturing process, a film forming step is performed in which a gas is supplied onto a substrate, and a thin film of silicon oxide, silicon nitride, or the like is formed on the substrate by a chemical vapor deposition (CVD) method.

Herein, in the film forming step, when the gas is supplied, a flow path member (shower plate) is used that is provided with a flow path in an inside thereof and that can supply the gas from a plurality of discharge holes connected to this flow path (see Patent Document 1, for example).

Moreover, Patent Document 2 describes a flow path member (shower plate) in the form of a manifold made of ceramics.

Furthermore, Patent Document 3 describes creating a flow path member (shower plate) by laminating ceramic sheets on one another.

CITATION LIST

Patent Document

Patent Document 1: JP 2018-148143 A

Patent Document 3: JP 2015-95551 A

SUMMARY

A flow path member of the present disclosure includes: a base having a first surface, and further having a first inflow port and a first outflow port; and a flow path that connects to the first inflow port and the first outflow port in an inside of the base. The flow path includes a first flow path that goes along the first surface and a second flow path that intersects the first flow path. The first flow path includes a first projection. A surface of the first projection is continuous with a wall surface of the second flow path.

Advantageous Effects of Invention

The flow path member of the present disclosure has a low deterioration in quality of an inflow gas.

The flow path member of the present disclosure is unlikely to inhibit a flow of the inflow gas.

A shower plate of the present disclosure has high quality of a treatment target object.

A heat exchanger of the present disclosure has excellent heat exchange efficiency.

A chemical reactor of the present disclosure has excellent fluid reaction efficiency.

DESCRIPTION OF EMBODIMENTS

A flow path member of the present disclosure will be described in detail below with reference to the drawings.

FIG. 1Ais an example of the flow path member of the present disclosure, and is a perspective view.

FIG. 1Bis the example of the flow path member of the present disclosure, and is a side view.

FIG. 1Cis the example of the flow path member of the present disclosure, and is a rear view.

FIG. 1Dis the example of the flow path member of the present disclosure, and is a partially enlarged view of a cross section of a line B-B′ inFIG. 1C.

The flow path member1of the present disclosure includes a base2and a flow path3located inside the base2. The base2has a first surface2a. In the perspective view ofFIG. 1A, a top surface is the first surface2a. Moreover, the base2has a first inflow port2band a first outflow port2c. Note thatFIG. 1Aillustrates an example in which the single first inflow port2bis provided on the first surface2athat is the top surface. Moreover,FIG. 1Cillustrates an example in which a plurality of the first outflow ports2care provided on a surface located opposite the first surface2a. Note thatFIGS. 1A to 1Dillustrate an example in which the shape of the base2is a disc shape, but the shape of the base2is not limited thereto, and any shape may be used.

Next,FIG. 2is an example of a partially enlarged view of a cross section of a line A-A′ inFIG. 1B. Note that, in the following, those denoted by symbols not shown inFIG. 2but shown only inFIGS. 1A to 1Dwill also be described. The flow path member1of the present disclosure includes a flow path3that connects to the first inflow port2band the first outflow port2cinside the base2. The flow path3has a first flow path3athat goes along the first surface2a. Herein, “going along the first surface2a” does not need to be strictly parallel to the first surface2a, and may extend in a spreading direction of the first surface2a.

Moreover, the flow path3has a second flow path3bthat intersects the first flow path3a.FIG. 2illustrates an example in which the second flow path3bintersects the first flow path3aat 90°. Note that “intersecting the first flow path3a” refers to that an intersection angle of the first flow path3aand the second flow path3bis 80° to 100°.

Then, the base2in the flow path member1of the present disclosure has a first projection4in the first flow path3a, and a surface of the first projection4is continuous with a wall surface3cof the second flow path3b. In this way, the flow path member1has the first projection4in the first flow path3ain the flow path3, and the surface of the first projection4is continuous with the wall surface3cof the second flow path3b. Thus, even if foreign matter or the like is erroneously mixed into the flowing gas, which flows in the flow path3, during installation and piping of the flow path member1, the foreign matter can be retained by the first projection4. Therefore, if the flow path member1of the present disclosure is used, then there is little deterioration in the quality of the inflow gas since the foreign matter and the like are hardly contained in the flowing gas.

Note that the first projection4refers to the one that projects by 20 μm or more from a virtual line obtained by extending a straight line drawn while taking as a reference an inner wall (a lower wall in the drawing) in front of the first projection4on such a cross section as illustrated inFIG. 2. When the inner wall in front of the first projection4has roughness (unevenness), an average portion of the roughness is taken to draw the straight line.

Thus far, description of the flow path member1of the present disclosure has been given with reference to fromFIGS. 1A to 1DandFIG. 2. With regard to a fluid route of the flow path member1, the inflow gas enters from the first inflow port2b, passes at least through the first flow path3aand the second flow path3bin the flow path3, and is discharged from the first outflow port2c. Note that the fluid flowing through the flow path3of the flow path member1is only required to be suitable to its application, and may be a liquid or a gas.

Next,FIG. 3is another example of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In this example, the flow path member is described while being denoted by symbol11. As illustrated in this example, the base2in the flow path member11has a wall6on an end surface of the first flow path3a, and the wall6may be continuous with the wall surface3cof the second flow path3b. When such a configuration is satisfied, the flowing gas rises due to the presence of the first projection4and flows toward the wall6, and thus flowing into the second flow path3bbecomes easier due to a collision between the flowing gas that has returned from the wall6and the flowing gas flowing through the first flow path3a. Therefore, when the above-described configuration is satisfied, the flow of the flowing gas becomes smooth, and fallen matter can be retained by the first projection4.

Next,FIG. 4is another example of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In this example, the flow path member is described while being denoted by symbol12. As illustrated in this example, the flow path member has the wall6on the end surface of the first flow path3a, and may further have an extended portion3dof the first flow path3abetween the wall6and the second flow path3b. When such a configuration is satisfied, even if foreign matter and the like are carried by the flowing gas that has risen, the foreign matter and the like can be retained in the extended portion3d.

Next,FIGS. 5 and 6are other examples of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In the examples, the flow path members are described while being denoted by symbols13and14. As illustrated in each of the examples, the wall6of the base2in the flow path member13or14may have a recessed portion6a. When such a configuration is satisfied, a space created by the recessed portions6aserves as a pocket for the foreign matter and the like, and the foreign matter and the like, which are carried by the flowing gas that has risen due to the first projection4, can be retained.

Next,FIG. 7is another example of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In this example, the flow path member is described while being denoted by symbol15. As illustrated in this example, the base2in the flow path member15has a second projection on the extended portion3d, and the surface of the second projection5may be continuous with the wall surface3cof the second flow path3b. When such a configuration is satisfied, in addition to the effects illustrated inFIG. 4, the flow to the second flow path3bcan be made smoother due to the flowing gas that has returned from the wall6rising. Moreover, a pocket shape is formed between the second projection5provided on the extended portion3dand the wall6, and the foreign matter and the like, which are carried by the flowing gas that has risen due to the first projection4, can be retained.

Furthermore, between the first projection4and the second projection5, the first projection4may be higher. When such a configuration is satisfied, the flow of the flowing gas that has returned from the wall6does not become too strong, and the flowing gas can be guided into the second flow path3b.

Next,FIG. 8is another example of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In this example, the flow path member is described while being denoted by symbol16. As illustrated in this example, the first projection4in the flow path member16may include a first inclined surface4athat increases in height while approaching the second flow path3b. Even when such a configuration is satisfied, the foreign matter and the like can be retained, and the flowing gas can be made to rise more easily.

Next,FIG. 9is another example of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In this example, the flow path member is described while being denoted by symbol17. As illustrated in this example, the second projection5in the flow path member17may include a second inclined surface5athat increases in height while approaching the second flow path3b. Even when such a configuration is satisfied, the foreign matter and the like can be retained, and the flowing gas that has returned from the wall6can be made to rise more easily.

Next,FIG. 10is another example of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In this example, the flow path member is described while being denoted by symbol18. As illustrated in this example, the wall6of the base2in the flow path member18may have a recessed portion6a. When such a configuration is satisfied, in addition to the pocket shape between the second projection5provided on the extended portion3dand the wall6, a space created by the recessed portions6aalso serves as a pocket for the foreign matter and the like, and the foreign matter and the like, which are carried by the flowing gas that has risen due to the first projection4, can be further retained.

Next,FIG. 11is another example of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In this example, the flow path member is described while being denoted by symbol19. As illustrated in this example, at least one of the first projection4and the second projection5in the flow path member19has a smoothly connected top portion7, and the top portion7may be located further outward than the wall surface3cof the second flow path3b. When such a configuration is satisfied, the foreign matter and the like can be retained, and in addition, the flowing gas in an intersecting portion of the first flow path3aand the second flow path3b, where the flowing gas that has risen due to the first projection4and the flowing gas that has returned from the wall6and has risen due to the second projection5join together, and can flow into the second flow path3bsmoothly and efficiently.

Next,FIG. 12is another example of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In this example, the flow path member is described while being denoted by symbol111. As illustrated in this example, at least one of the first inclined surface4aand the second inclined surface5ain the flow path member111may have a recessed portion8with a recessed shape in a cross section of the center in the width direction of the flow path3, and the recessed portion8may be provided over the entire surface. When such a configuration is satisfied, the flowing gas can be made to rise more easily, and in addition, the flow of the flowing gas can be changed by the recessed portion8, and accordingly, the foreign matter and the like can be retained more.

Next,FIG. 13is another example of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In this example, the flow path member is described while being denoted by symbol112. As illustrated in this example, the top portion7in the flow path member112may be provided with a flat surface9along the first surface2a. When such a configuration is satisfied, the foreign matter and the like can be retained, and in addition, a flow rate of the rising flowing gas can be ensured greatly, and accordingly, the flowing gas can flow to the second flow path3befficiently.

Next,FIG. 14is another example of the partially enlarged view of the cross section of the line A-A′ inFIG. 1B. In this example, the flow path member is described while being denoted by symbol113. As illustrated in this example, the inclination of the second inclined surface5aof the flow path member113may be set greater than the inclination of the first inclined surface4a. When such a configuration is satisfied, the foreign matter and the like can be retained, and in addition, foreign matter and the like contained in the flowing gas that has returned from the wall6can be retained more.

Moreover,FIG. 15is another example of the flow path member of the present disclosure. In this example, a description will be given with reference to a perspective view of the intersecting portion of the first flow path3aand the second flow path3b. As illustrated in this example, a projection10including the first projection4and the second projection5may be provided so as to go around the intersecting portion of the first flow path3aand the second flow path3b. When such a configuration is satisfied, foreign matter and the like from any direction can be retained.

The flow path member has been described while being denoted by symbols1and11to113in accordance with differences in the configurations thereof, but below, the flow path member will be described as the flow path member1.

The base2in the flow path member1of the present disclosure may be composed of any material such as resin, metal, and ceramics. When the base2is made of ceramics, the base2is superior to that of resin or metal in terms of mechanical strength, heat resistance, corrosion resistance, and the like.

Then, for example, aluminum oxide ceramics is a material in which aluminum oxide accounts for 70 mass % or more among 100 mass % as all the components which constitute the ceramics. Note that the same applies to other ceramics.

Moreover, the material of a target base can be confirmed by the following method. First, a value of 2θ (2θ indicates a diffraction angle) obtained by measurement using an X-ray diffractometer (XRD) is identified via a JCPDS card. Herein, a case where the presence of aluminum oxide is confirmed in the target base by XRD is described as an example. Next, a quantitative analysis of aluminum (Al) is performed using an ICP emission spectrophotometer (ICP) or an X-ray fluorescent (XRF) analyzer. Then, if a content calculated from the content of Al measured by ICP or XRF to aluminum oxide (Al2O3) is 70 mass % or greater, the target base is composed of aluminum oxide ceramics.

Then, when the flow path member1of the present disclosure includes a plurality of the first outflow ports2cand the base2is made of ceramics, the flow path member1can be suitably used in a shower plate for use in a semiconductor manufacturing apparatus required to have corrosion resistance. Then, the flow path member1of the present disclosure has a low deterioration in the quality of the inflow gas, and accordingly, brings high quality of the treatment target.

Moreover, when the first projection4projects toward the first surface2a, the flow path member1of the present disclosure can efficiently exchange heat on the first surface2adue to the flowing gas flowing in the first flow path3arising due to the first projection4. At this time, the first surface2ais a heat exchange surface, and the flow path member1that satisfies such a configuration is a heat exchanger.

FIG. 16Ais another example of the flow path member of the present disclosure, and is a perspective view.

FIG. 16Bis another example of the flow path member of the present disclosure, and is a partially enlarged view of a cross section of a line C-C′ inFIG. 16A.

FIG. 16Cis another example of the flow path member of the present disclosure, and is a partially enlarged view of a cross section of a line D-D′ inFIG. 16A.

The flow path member114of the present disclosure further includes a second inflow port2din addition to the first inflow port2bthat connects to the flow path3illustrated in the flow path member1of the present disclosure. At this time, if a region including the first projection4is a reaction region, reaction efficiency is improved by promoting agitation of two types of fluids, and therefore is suitable as a chemical reactor.

An example of a method for manufacturing the flow path member of the present disclosure will be described below. Note that a case where the flow path member is composed of ceramics will be described as an example.

First, predetermined amounts of a sintering aid, a binder, a solvent, a dispersant, and the like are added to a raw material powder such as aluminum oxide (Al2O3) powder, silicon nitride (Si3N4) powder, aluminum nitride (AlN) powder, and silicon carbide (SiC) powder, followed by mixing, whereby slurry is prepared.

Next, using this slurry, a green sheet is formed by a doctor blade method. Alternatively, the slurry is spray dried by spray drying (spray drying method) to be granulated and form a green sheet by a roll compaction method.

Then, the obtained green sheet is processed using a publicly known method such as a laser and a mold so as to have a desired shape. At this time, in the green sheet, any shaped grooves or holes which serve as the first flow path and the second flow path are formed. Moreover, green sheets corresponding to the first projection and the second projection are prepared.

Next, the green sheets are laminated on one another by a lamination method to obtain a molded body. Herein, the green sheet corresponding to the first projection may be disposed so that the surface of the first projection is continuous with the wall surface of the second flow path as a result of confirming a flowing direction of the flowing gas. The green sheet corresponding to the second projection may be disposed so that the surface of the second projection is continuous with the wall surface of the second flow path. When the flow path member is formed to include the first projection and the second projection, the first projection and the second projection may be disposed so that the surfaces of both thereof are continuous with the wall surface of the second flow path.

Furthermore, when the flow path member is formed to include the first projection and the second projection, the green sheets corresponding to the first projection and the second projection may be arranged so as to go around the intersecting portions of the first flow path and the second flow path.

Moreover, when the first projection is formed to include a first inclined surface that increases in height while approaching the second flow path, an inclined green sheet corresponding to the first projection may be prepared, and at the time of disposing the green sheet, the green sheet may be disposed so as to increase in height while approaching the second flow path. Furthermore, when the second projection is formed to include a second inclined surface that increases in height while approaching the second flow path, an inclined green sheet corresponding to the second projection may be prepared, and at the time of disposing the green sheet, the green sheet may be disposed so as to increase in height while approaching the second flow path.

Moreover, in order for the base to have a wall on the end surface of the first flow path and to be continuous with the wall surface of the second flow path, the length of the groove or the hole may be adjusted so that the wall is continuous with the wall surface of the second flow path in the green sheet that constitutes the first flow path. Further, in order for the base to have a wall on the end surface of the first flow path and to have an extended portion of the first flow path between the wall and the second flow path, the length of the groove or the hole may be adjusted so that the extended portion of the first flow path is provided between the wall and the second flow path in the green sheet that constitutes the first flow path. Furthermore, when the wall is formed to have a recessed portion, the wall may be composed of a plurality of green sheets, and the length of the groove or the hole may be adjusted.

Further, when the first projection is formed to include the smoothly connected top portion located further outward than the wall surface of the second flow path, a green sheet corresponding to the first projection and having a smoothly connected top portion located further outward than the wall surface of the second flow path may be prepared. At the time of disposing the green sheet, the green sheet may be disposed so that the smoothly connected top portion is located further outward than the outer diameter of the second flow path.

Further, when the second projection is formed to include the smoothly connected top portion located further outward than the wall surface of the second flow path, a green sheet corresponding to the second projection and having a smoothly connected top portion located further outward than the wall surface of the second flow path may be prepared. At the time of disposing the green sheet, the green sheet may be disposed so that the smoothly connected top portion is located further outward than the outer diameter of the second flow path.

Further, when the first projection and the second projection are formed to include the smoothly connected top portions located further outward than the wall surface of the second flow path, green sheets corresponding to the first projection and the second projection and having smoothly connected top portions located further outward than the wall surface of the second flow path may be prepared. At the time of disposing the green sheets, the green sheets may be disposed so that the smoothly connected top portions are located further outward than the outer diameter of the second flow path.

Moreover, when the first projection is formed to include the recessed portion with a recessed shape in the cross section of the center in the width direction of the flow path over the entire surface on the first inclined surface, a green sheet corresponding to the first projection and having a recessed portion with a recessed shape in the cross section of the center in the width direction of the flow path over the entire surface of the first inclined surface may be prepared. At the time of disposing the green sheet, the green sheet may be disposed so that the recessed portion with a recessed shape in the cross section of the center of the width direction of the flow path is located over the entire surface of the first inclined surface.

Further, when the second projection is formed to include the recessed portion with a recessed shape in the cross section of the center in the width direction of the flow path over the entire surface on the second inclined surface, a green sheet corresponding to the second projection and having a recessed portion with a recessed shape in the cross section of the center in the width direction of the flow path over the entire surface of the second inclined surface may be prepared. At the time of disposing the green sheet, the green sheet may be disposed so that the recessed portion with a recessed shape in the cross section of the center of the width direction of the flow path is located over the entire surface of the second inclined surface.

Furthermore, when the first projection and the second projection are formed to include the recessed portions with recessed shapes in the cross section of the center in the width direction of the flow path over the entire surfaces on the first inclined surface and the second inclined surface, green sheets corresponding to the first projection and the second projection and having recessed portions with recessed shapes in the cross section of the center in the width direction of the flow path over the entire surfaces of the first inclined surface and the second inclined surface may be prepared. At the time of disposing the green sheets, the green sheets may be disposed so that the recessed portions with recessed shapes in the cross section of the center of the width direction of the flow path are located over the entire surfaces of the first inclined surface and the second inclined surface.

Moreover, when the first projection is formed to include the smoothly connected top portion having the flat surface that goes along the first surface, a green sheet corresponding to the first projection and having a smoothly connected top portion having the flat surface that goes along the first surface may be prepared. At the time of disposing the green sheet, the green sheet may be disposed so that the smoothly connected top portion becomes the flat surface that goes along the first surface.

Further, when the second projection is formed to include the smoothly connected top portion having the flat surface that goes along the first surface, a green sheet corresponding to the second projection and having a smoothly connected top portion having the flat surface that goes along the first surface may be prepared. At the time of disposing the green sheet, the green sheet may be disposed so that the smoothly connected top portion becomes the flat surface that goes along the first surface.

Furthermore, when the first projection and the second projection are formed to include the smoothly connected top portions having the flat surfaces that go along the first surface, green sheets corresponding to the first projection and the second projection and having smoothly connected top portions having the flat surfaces that go along the first surface may be prepared. At the time of disposing the green sheets, the green sheets may be disposed so that the smoothly connected top portions become the flat surfaces that go along the first surface.

Moreover, when the inclination of the second inclined surface of the second projection is set greater than the inclination of the first inclined surface of the first projection, green sheets corresponding to the second projection and the first projection and for which the inclination of the second inclined surface of the second projection is greater than the inclination of the first inclined surface of the first projection may be prepared. At the time of disposing the green sheets, the green sheets may be disposed so that the inclination of the second inclined surface of the second projection is greater than the inclination of the first inclined surface of the first projection.

Then, the above-mentioned slurry may be used as a bonding agent for use when laminating the green sheets together.

Next, the obtained molded body is dried and degreased, and then fired to match firing conditions of each raw material powder to obtain the flow path member of the present disclosure.

Moreover, at the time of forming the first projection, after a laminate in which only a portion that becomes the first flow path is formed is obtained, a process may be performed to advance a drill from the second flow path in the direction of the first flow path toward a desired position where the first flow path and the second flow path intersect each other, and a portion that becomes the first projection may be formed in conjunction with the formation of the second flow path. Furthermore, in the green sheet prior to the lamination, a process may be performed to advance the drill toward the desired position where the first flow path and the second flow path intersect each other.

Note that the present disclosure is not limited to the above-mentioned embodiment, and various modifications, improvements, and the like may be made to the embodiment within the scope without departing from the spirit of the present disclosure.

REFERENCE SIGNS LIST