Manufacturing method of semiconductor apparatus

The manufacturing method of a semiconductor apparatus has a step for carrying in the substrate into the processing chamber; a step for heating the processing chamber and the substrate to the predetermined temperature; and a gas supply and exhaust step for supplying and exhausting desired gas into and from the processing chamber, wherein the gas supply and exhaust step repeats by the predetermined times a first supply step for supplying silicon-type gas and hydrogen gas into the processing chamber; a first exhaust step for exhausting at least said silicon-type gas from the processing chamber; a second supply step for supplying chlorine gas and hydrogen gas into the processing chamber; and a second exhaust step for exhausting at least the chlorine gas from the processing chamber.

INCORPORATION BY REFERENCE

The present application claims priorities from Japanese applications JP2007-096059 filed on Apr. 2, 2007, JP2008-75763 filed on Mar. 24, 2008, the contents of which are hereby incorporated by reference into this application.

BACKGROUND OF THE INVENTION

The present invention relates to a manufacturing method of a semiconductor apparatus for manufacturing a semiconductor apparatus by carrying out processing such as thin film formation, impurity diffusion, annealing processing and etching on a substrate such as a silicon wafer, a glass substrate.

As one of semiconductor apparatuses, there is a MOSFET (Metal Oxide Semiconductor Field Effect Transistor), which is a polymerized structure of a metal, an oxide film and a semiconductor, and in recent years, it has been progressing to attain finer patterning and higher performance of MOSFET.

As a problem in attaining the finer patterning and higher performance MOSFET, there is decrease in contact resistance or the like, and as one method for solving this problem, there is a method of selectively growing a silicon epitaxial film on a source/drain.

Conventionally, growth of a silicon epitaxial film has been carried out by using SiH2Cl2and HCl and H2, as processing gas, and by continuously supplying these processing gases into a processing chamber at a processing temperature of from 750° C. to 850° C.

The above processing temperature of 750° C. to 800° C. is high temperature, and accompanying with the finer patterning and higher performance, influence of thermal damage and thermal budget on the substrate element increases, which makes a cause of inhibition of making a higher performance device, or a cause of lower yield.

As conventional technology, JP-A-2003-86511 and JP-A-5-21357 are included.

SUMMARY OF THE INVENTION

It is an object of the present invention, in consideration of the above situation, to provide a manufacturing method of a semiconductor apparatus, which is capable of formation of a high quality film at low temperature, and attains enhancements of device performance as well as yield.

The present invention relates to a manufacturing method of a semiconductor apparatus for selectively growing an epitaxial film at a silicon surface of a substrate, by storing the substrate having at least the silicon surface and an insulating surface at the surface thereof, into a processing chamber, and by using a substrate processing apparatus for heating an atmosphere of the inside of the processing chamber and the substrate to a predetermined temperature by a heating unit installed outside, comprising a step for carrying in the substrate into the processing chamber; a step for heating the atmosphere of the inside of the processing chamber and the substrate to the predetermined temperature; and a gas supply and exhaust step for supplying and exhausting desired gas into and from the processing chamber, wherein the gas supply and exhaust step repeats by the predetermined times and carries out, a first supply step for supplying silicon-containing gas and hydrogen gas into the processing chamber; a first exhaust step for exhausting at least the silicon-containing gas from the processing chamber; a second supply step for supplying chlorine gas and hydrogen gas into the processing chamber; and a second exhaust step for exhausting at least the chlorine gas from the processing chamber.

According to the present invention, there is provided a manufacturing method of a semiconductor apparatus for selectively growing an epitaxial film at a silicon surface of a substrate, by storing the substrate having at least the silicon surface and an insulating surface at the surface thereof into a processing chamber, and by using a substrate processing apparatus for heating an atmosphere of the inside of the processing chamber and the substrate to a predetermined temperature by a heating unit installed outside, comprising a step for carrying in the substrate into the processing chamber; a step for heating the atmosphere of the inside of the processing chamber and the substrate to the predetermined temperature; and a gas supply and exhaust step for supplying and exhausting desired gas into and from the processing chamber, wherein the gas supply and exhaust step repeats by the predetermined times and carries out, a first supply step for supplying silicon-containing gas and hydrogen gas into the processing chamber; a first exhaust step for exhausting at least the silicon-containing gas from the processing chamber; a second supply step for supplying chlorine gas and hydrogen gas into the processing chamber; and a second exhaust step for exhausting at least the chlorine gas from the processing chamber, therefore, throughput is enhanced because a gas purge step by inert gas can be omitted in a step before or after the second supply step, and also, excellent effect of enhancing processing uniformity is exerted, because processing by chlorine gas is carried out by supplying hydrogen gas along with chlorine gas.

DESCRIPTION OF THE EMBODIMENTS

Explanation will be given below on embodiments for carrying out the present invention with reference to drawings.

First, explanation will be given, inFIG. 1, on a substrate processing apparatus, where the present invention is carried out.

InFIG. 1, “1” represents a substrate processing apparatus, “2” represents a substrate storage container (cassette), and a substrate (wafer) “3” such as a silicon wafer, which is processed by the substrate processing apparatus1, is carried-in or carried-out in a stored state in the cassette2in required pieces, for example, 25 pieces.

At the lower part of a front side wall5of a housing4of the substrate processing apparatus1, a front side maintenance port6is installed as an opening part for maintenance, and said front side maintenance port6is designed to be capable of opening and closing by a front side maintenance door (not shown). At the upward of the front side maintenance port6, there is installed a substrate storage container gateway8for carrying in and carrying out the cassette2, and the substrate storage container gateway8is designed to be opened and closed by a gateway opening and closing facility (a front shutter) (not shown).

Adjacent to the inside of the housing4, and the substrate storage container gateway8, a substrate storage container receiving apparatus (a cassette receiving stage)11is installed, and facing the cassette receiving stage11, there are installed a lower substrate storage container storage shelf (a cassette shelf)12, and an upper substrate storage container storage shelf (a buffer cassette shelf)13, for storing the required pieces of the cassettes2.

Between the cassette receiving stage11and the cassette shelf12and the buffer cassette shelf13, a substrate storage container carrying apparatus (a cassette carrying apparatus)14is installed. Said cassette carrying apparatus14is provided with a traverse facility, a hoisting facility and a rotation facility, and is capable of carrying the cassette2in required position, between the cassette receiving stage11and the cassette shelf12and the buffer cassette shelf13, by a cooperation of the traverse facility, the hoisting facility and the rotation facility.

At the backward and the lower part of the inside of the housing4, a load lock chamber15, which is an air-tight container, is installed, and at the upper side of the load lock chamber15, a processing furnace16is installed. The processing furnace16is provided with an air-tight processing chamber17, and the processing chamber17is connected air-tightly to the load lock chamber15, and a furnace port part at the lower end of the processing chamber17is designed to be blockable air-tightly by a furnace port gate valve20.

At the inside of the load lock chamber15, a substrate holding tool (a boat)18can be stored, and said boat18is made of a heat resistant material, for example, quartz or silicon carbide or the like, which is designed to be capable of holding the wafer3in multiple stages, in a horizontal position. In addition, it is preferable that a shelf for supporting the wafer3is casted in a ring-like shape. It should be noted that at the lower part of the boat18, there are installed in multiple stages and in a horizontal position, multiple pieces of heat insulating plates (not shown) as a heat insulating member with a circular plate-like shape, made of a heat resistant material of, for example, quartz or silicon carbide or the like, so as to inhibit heat radiation downward.

In addition, there is installed a substrate holding tool hoisting facility (a boat elevator)19for supporting the boat18, and for mounting and dismounting said boat18to and from the processing chamber17, at the load lock chamber15.

Said load lock chamber15is provided with a substrate transfer port21for transferring the wafer3onto the boat18, and said substrate transfer port21is released and also blocked air-tightly by a gate valve25. At the load lock chamber15, there is connected a gas supply system22for supplying inert gas such as nitrogen gas, and also connected an exhaust apparatus (not shown) for exhausting the inside of the load lock chamber15to make negative pressure.

Between the load lock chamber15and the cassette shelf12, a substrate transfer apparatus (a substrate transfer machine)23is installed, and said substrate transfer machine23is provided with required pieces (for example, 5 pieces) of substrate holding plate24for mounting and holding the wafer3, as well as provided with an hoisting facility part for hoisting the substrate holding plates24, a rotation facility part for rotation thereof, and a forward and backward movement facility part for making forward and backward movement thereof.

The substrate transfer machine23is designed so that a substrate is transferred between the boat18in a descending state and the cassette shelf12, via the substrate transfer port21, by cooperation of the hoisting facility part, the rotation facility part and the forward and backward movement facility part.

It should be noted that at a required position of the inside of the housing4, for example, a clean unit26is installed facing the buffer cassette shelf13, and flow of clean atmosphere is formed in the inside of the housing4by said clean unit26.

Explanation will be given below on actuation of the substrate processing apparatus1.

The substrate storage container gateway8is released by a front shutter (not shown), and the cassette2is carried in from the substrate storage container gateway8. The cassette2carried in is mounted so that the wafer3takes a vertical position and a gateway of the wafer3faces an upward direction.

Then, by the cassette carrying apparatus14, the cassette2is carried to a designated shelf position of the cassette shelf12or the buffer cassette shelf13. The cassette2stored at the cassette shelf12or the buffer cassette shelf13is set to take horizontal position and the gateway faces the substrate transfer machine23. In addition, after being temporarily stored, the cassette2is transferred from the buffer cassette shelf13to the cassette shelf12by the cassette carrying apparatus14.

Inside of the load lock chamber15is made in an atmospheric pressure state in advance, and the boat18is descended to the inside of the load lock chamber15by the boat elevator19. By the gate valve25, the substrate transfer port21is released, and by the substrate transfer machine23, the wafer3is transferred into the boat18from the cassette2.

When previously designated pieces of the wafers3are charged onto the boat18, the substrate transfer port21is closed by the gate valve25, and a pressure of the load lock chamber15is reduced by vacuuming with an exhaust apparatus. When the pressure of the load lock chamber15is reduced to the same pressure in the processing chamber17, the furnace port part of the processing chamber17is released by the furnace port gate valve20, and the boat18is charged into the processing chamber17by the boat elevator19.

The wafer3is subjected to predetermined processing by carrying out the heating of the wafer3, the introduction of processing gas into the processing chamber17and exhaustion or the like.

After processing, the boat18is taken out by the boat elevator19, and still more, after pressure in the load lock chamber15is restored to atmospheric pressure, the gate valve25is opened. After that, the wafer3and the cassette2are carried out to the outside of the housing4by reversed procedure of the above.

Then explanation will be given, inFIG. 2, on the processing furnace16and the boat elevator19.

As shown inFIG. 2, the processing furnace16has a heater31as heating facility. Said heater31has a circular cylinder-like shape and is configured by a heater element line and an insulating member installed at the circumference thereof, and is installed vertically by being supported by a holding body not shown.

At the vicinity of the heater31, a temperature sensor (not shown) is installed as a temperature detecting body for detecting temperature in the processing chamber17. A temperature control part45is electrically connected to the heater31and the temperature sensor, and it is configured so as to control in desired timing so that temperature in the processing chamber17becomes desired temperature distribution by adjusting a current-carrying state to the heater31based on temperature information detected by the temperature sensor.

At the inside of the heater31, a reaction tube32is installed concentrically with the heater31. Said reaction tube32is made of a heat resistant material such as quartz (SiO2) or silicon carbide (SiC), and is formed in a circular cylinder-like shape with the upper end blocked and the lower end opened. The reaction tube32configures the processing chamber17, stores the boat18, and the wafer3is stored in the processing chamber17in a state held in the boat18.

At the downward of the reaction tube32, a manifold33is installed concentrically with the reaction tube32, and the reaction tube32is installed at the manifold33. Said manifold33is made of, for example, stainless steel or the like, and is formed in a circular cylinder-like shape with the upper end and the lower end opened. It should be noted that between the manifold33and the reaction tube32, an O-ring is installed as a sealing member. The manifold33is supported by a holding body, for example, the load lock chamber15, and thereby the reaction tube32becomes in a vertically installed state. A reaction container is formed by said reaction tube32and the manifold33.

At said manifold33, an exhaust pipeline34is installed, as well as a gas supply pipeline35is installed so as to pass through. The gas supply pipeline35is branched into three at the upstream side, and connected to a first gas supply source42, a second gas supply source43and a third gas supply source44, via valves36,37and38, and MFCs39,40and41as gas flow amount control apparatus, respectively. It is designed that the first gas supply source42supplies, for example, silane-type gas or halogen-containing silane-type gas as processing gas, the second gas supply source43supplies hydrogen gas as processing gas or carrier gas, and in addition, the third gas supply source44supplies nitrogen gas as carrier gas or purging gas.

A gas flow amount control part46is electrically connected to the MFCs39,40and41, and the valves36,37and38, and said gas flow amount control part46is configured to control in desired timing so that flow amount of supplying gas becomes desired flow amount.

At the lower stream side of the exhaust pipeline34, a vacuum exhaustion apparatus48such as a vacuum pump is connected, via a pressure sensor as a pressure detector not shown, and an APC valve47as a pressure regulator. As the vacuum exhaustion apparatus48, it is preferable that a ternary vacuum pump system with high exhaustion capability, for example, a molecular turbo pump+a machine booth and a pump+a dry pump or the like are used.

A pressure control part49is electrically connected to the pressure sensor and the APC valve47, and said pressure control part49is configured so as to control in desired timing so that pressure of the processing chamber17becomes desired pressure by adjusting degree of opening of the APC valve47, based on pressure detected with the pressure sensor.

In the configuration of the processing furnace16, the first processing gas is supplied from the first gas supply source42, and is introduced into the processing chamber17by the gas supply pipeline35, via the valve36, after adjustment of flow amount thereof by the MFC39. The second processing gas is supplied from the second gas supply source43, and is introduced into the processing chamber17by the gas supply pipeline35, via the valve37, after adjustment of flow amount thereof by the MFC40. The third processing gas is supplied from the third gas supply source44, and is introduced into the processing chamber17by the gas supply pipeline35, via the valve38, after adjustment of flow amount thereof by the MFC41. In addition, gas in the processing chamber17is exhausted from the processing chamber17by the vacuum exhaustion apparatus48connected to the exhaust pipeline34.

Then explanation will be given on the boat elevator19.

The drive facility part51of said boat elevator19is installed at the side wall of the load lock camber15.

The drive facility part51is provided with a guide shaft52installed in parallel and a ball screw53, and said ball screw53is supported in a free-rotation state, and is designed to be rotated by a hoisting motor54. A hoisting platform55is engaged slidably to the guide shaft52, as well as screwed in to the ball screw53, and at the hoisting platform55, a hollow hoisting shaft56is installed vertically in parallel to the guide shaft52.

Said hoisting shaft56is extended inside by passing thorough freely a ceiling surface of the load lock chamber15, and at the lower end thereof, a hollow drive part storage case57is installed air-tightly. A bellows58is installed so as to cover the hoisting shaft56in non-contact state, and the upper end of the bellows58is fixed at the lower surface of the hoisting platform55, and the lower end of the bellows58is fixed at the upper surface of the load lock chamber15, each air-tightly, and a free passing through part of the hoisting shaft56and said hoisting shaft56are sealed air-tightly.

At the ceiling part of the load lock chamber15, a furnace port59is installed concentrically with the manifold33, and the furnace port59is designed to be blockable air-tightly by a seal cap61. Said seal cap61is, for example, made of metal such as stainless steel, and formed in a circular disk-like shape, and fixed air-tightly at the upper surface of the drive part storage case57.

The drive part storage case57has an air-tight structure, and the inside thereof is isolated from atmosphere in the load lock chamber15. At the inside of the drive part storage case57, a boat rotation facility62is installed, and the rotation axis of the boat rotation facility62is extended upward by passing through freely a top panel of the drive part storage case57and the seal cap61, and at the upper end thereof, a boat mounting platform63is fixed, and the boat18is mounted on the boat mounting platform63.

The seal cap61and the boat rotation facility62are each cooled by a water-cooling-type cooling facilities64and65, and a cooling-water pipeline66to the cooling facilities64and65is connected to an external cooling water source (not shown) after passing the hoisting shaft56. In addition, power supply to the boat rotation facility62is carried out via a power supply cable67wired through the hoisting shaft56.

A drive control part68is electrically connected to the boat rotation facility62and the hoisting motor54, and it is configured so as to control in desired timing to perform desired motion.

The temperature control part45, the gas flow amount control part46, the pressure control part49and the drive control part68configure also an operation part and an input-output part, and electrically connected to a main control part69for controlling whole part of the substrate processing apparatus1.

As described above, a drive part of the boat elevator19, the boat rotation facility62, the cooling-water pipeline66, the power supply cable67and the like are isolated from the inside of the load lock chamber15, by the drive part storage case57and the bellows58, therefore, there is no risk that the wafer3is contaminated by organic substances and particles emitted from a driving system and a wiring system, by residual heat in vacuuming of the load lock chamber15, or in releasing of the furnace port gate valve20.

Then, explanation will be given on a method for carrying out film-formation processing on a substrate such as the wafer3, as one step of production steps of a semiconductor device, by using the processing furnace16, with reference toFIG. 3.

It should be noted that in the following explanation, movement of each part configuring the substrate processing apparatus1is controlled by the main control part69.

First, a naturally oxidized film on the surface of the wafer3is removed with diluted hydrofluoric acid, and at the same time, the surface was subjected to hydrogen termination (STEP:01).

The boat18is descended by the boat elevator19, and the furnace port59is blocked air-tightly by the furnace port gate valve20. The substrate transfer port21is released by the gate valve25, in a state that the inside of the load lock chamber15becomes a state having the same pressure as that in the outside of the load lock chamber15. By the substrate transfer machine23, predetermined pieces of the wafers3are charged onto the boat18(STEP:02).

The substrate transfer port21is blocked air-tightly by the gate valve25, and the inside of the load lock chamber15is subjected to repeated vacuuming and purging by inert gas (for example, nitrogen gas) to remove oxygen and moisture in the atmosphere of the inside of the load lock chamber15.

Then, the furnace port59is released by the furnace port gate valve20, and the boat elevator19is driven. The ball screw53is rotated by the drive of the hoisting motor54, and the drive part storage case57is ascended via the hoisting platform55and the hoisting shaft56, and the boat18is charged into the processing chamber17. In this state, the seal cap61blocks the furnace port59air-tightly via an O-ring.

It should be noted that temperature of the processing chamber17at charging is set at 200° C. or around 200° C., to prevent surface oxidation of the wafer3(STEP:03).

The inside of the processing chamber17is subjected to vacuum exhausting by the vacuum exhaustion apparatus48, so as to become desired pressure (degree of vacuum). In this case, pressure in the processing chamber17is measured with a pressure sensor, and based on this pressure measured, the APC valve47is feed-back controlled. In addition, the processing chamber17is heated by the heater31so that the inside thereof becomes desired temperature and desired temperature distribution, and the heating state is feed-back controlled by the temperature control part45, based on temperature information detected by the temperature sensor. Subsequently, the wafer3is rotated by rotation of the boat18, by the boat rotation facility62.

When the boat18is charged into the processing chamber17and exhaustion is completed, the processing chamber is set at pre-treatment temperature (it is usually the same as film-formation temperature, however, in treatment with only H2gas, it is from 750 to 800° C. Treatment under raising temperature after charging the boat is also possible), and pre-treatment is carried out. For the pre-treatment, hydrogen gas or silane-type gas (for example, SiH4), or halogen-containing silane gas or hydrogen chloride gas, or combination gas thereof is supplied along with inert gas or carrier gas such as hydrogen gas, from the first gas supply source42, the second gas supply source43and the third gas supply source44, via the MFCs39,40and41(STEP:04).

By carrying out the pre-treatment, interface oxygen and carbon density can be reduced, and high quality interface can be formed between a semiconductor substrate and a thin film.

After completion of the pre-treatment, residual gas in the processing chamber17is removed by carrier gas such as hydrogen.

Temperature of the processing chamber17is adjusted from pre-treatment temperature to film-formation temperature. In this time, hydrogen gas is flown to the processing chamber17, as carrier gas, to prevent contamination caused by reversed diffusion from an exhaustion system (STEP:05).

When temperature of the processing chamber17is stabilized at film-formation temperature, processing gas is introduced to carry out film-formation processing. Each processing gas is supplied from the first gas supply source42, the second gas supply source43and the third gas supply source44. In addition, after adjustment the degree of opening of the MFCs39,40and41, so as to attain desired flow amount, the valves36,37and38are opened, and each processing gas is introduced into the processing chamber17from the upper part of the processing chamber17, by flowing through the gas supply pipeline35.

As processing gas to be introduced, silane-type gas (SiH4), or halogen gas-containing gas or silane-type gas mixed with hydrogen gas, or halogen-containing silane-type gas mixed with hydrogen gas is used. In the case where processing gas is SiH4, film-formation temperature in the processing chamber17is adjusted at from 500 to 700° C.

Introduced processing gas passes through the inside of the processing chamber17, and is exhausted from the exhaust pipeline34. Processing gas contacts with the wafer3in passing through the inside of the processing chamber17, to grow and deposit an EPI film on the surface of the wafer3. In addition, unnecessary nuclei on an insulating film are removed by etching processing. A predetermined film is formed by repeating by the predetermined time's film-formation and etching (STEP:06).

When previously set time elapsed, inert gas is supplied from an inert gas supply source not shown, and the inside of the processing chamber17is replaced with inert gas, as well as pressure in the processing chamber17is restored to normal pressure (so as to be the same pressure as that of the inside of the load lock chamber15) (STEP:07).

After that, temperature in the processing chamber17is lowered to a temperature of, for example, 200° C., that is, temperature at which the surface of the wafer3is not oxidized (STEP:08).

The seal cap61is descended by the boat elevator19, and the boat18is carried out from the furnace port59into the inside of the load lock chamber15with opening of the furnace port59. The furnace port59is blocked by the furnace port gate valve20. After the wafer3is cooled to required temperature in the load lock chamber15, the substrate transfer port21is released to take out the processed wafer3from the boat18by the substrate transfer machine23(refer toFIG. 1) (STEP:09).

Explanation will be given, inFIGS. 4A and 4B, on an example of film-formation step of the STEP:06.

First,FIG. 4Ashows an example of the first film-formation step, and shows the case where Cl2is introduced by using N2as carrier gas, in carrying out etching.

By simultaneous introduction of SiH4and H2, the processing chamber17is maintained clean, and in addition, although SiH4is decomposed to Si+2H2, by presence of H2, which was supplied simultaneously, the decomposition action is inhibited. That is, by simultaneous introduction of SiH4and H2, decomposition degree of SiH4can be controlled.

After that, SiH4is excluded from the processing chamber17by H2purge (STEP:12). The H2purge removes processing gas, as well as brings the substrate surface H-termination.

Then, after introduction of nitrogen gas for N2purge (STEP:13), Cl2and N2are introduced to remove (etching) unnecessary nuclei on the insulating film (STEP:14). Then, Cl2is excluded from the processing chamber17, by N2purging (STEP:15), and still more N2is excluded by H2purging (STEP:16).

The STEP:11to the STEP:16are repeated to form a desired film.

Still more, in the case of forming an impurity diffused film, doping gas such as PH3, B2H6, BCl3is introduced in the midway of the STEP:11to the STEP:16.

In the present step, because SiH4is used as film-formation gas, film-formation temperature can be set as low as from 500 to 700° C., and influence of thermal damage or thermal budget on a substrate element can be alleviated. In addition, in the case where Si2H6is used as a film-forming gas, it is possible to set film-formation temperature as low as from 450 to 700° C. compared with the case where SiH4is used.

Then,FIG. 4Bshows an example of the second film-formation step, and shows the case where Cl2is introduced by using H2as carrier gas, in carrying out etching.

First, SiH4and H2are introduced for film-formation (STEP:21). In this case, it is preferable that flow amount of SiH4gas is from 100 to 500 sccm, flow amount of H2gas is from 100 to 20000 sccm, processing temperature is from 500 to 700° C., and processing pressure is equal to or lower than 1000 Pa.

The fact that decomposition degree of SiH4is controlled by simultaneous introduction of SiH4and H2, is similar to explanation inFIG. 4A.

After that, SiH4is excluded from the processing chamber17by H2purge (STEP:22). The H2purge removes processing gas, as well as brings the substrate surface H-termination.

Then, Cl2and H2are introduced to remove (by etching) unnecessary nuclei on the insulating film (STEP:23). In this case, it is preferable that flow amount of Cl2gas is from 50 to 200 sccm, flow amount of H2gas is from 100 to 20000 sccm, processing temperature is from 500 to 700° C., and processing pressure is equal to or lower than 1000 Pa.

STEP:21to STEP:24are repeated to form a desired film.

Still more, in the case of forming an impurity diffused film, doping gas such as PH3, B2H6, BCl3is introduced in the midway of the STEP:21to the STEP:24.

In addition, depending on film-formation state, a flow amount of one or more kinds of gas among SiH4, Cl2and H2is changed in the gas introduction step in the STEP:21and the STEP:23.

For example, by increasing the flow amount of SiH4, film-formation rate is increased, and by increasing the flow amount of Cl2, etching amount is increased. Therefore, by changing the flow amount of gas, the following embodiments become possible.

For example, SiN and SiO have characteristics that growth of an Si nucleus is easy, and growth of an Si nucleus is difficult, respectively. Therefore, for example, an insulating film SiO is formed in an overlapped state on an insulating film SiN, and on a substrate with the end surfaces of both insulating films exposed (refer toFIG. 5), in the initial film-formation processing, etching rate is strengthened (film-formation rate is slowed), and when thickness of the film formed is over thickness of the SiN, etching rate is weakened to be able to increase film-formation rate.

In addition, for example, when impurity is present on an Si surface, which is a target of film-formation processing, the film tends to be poly silicon film, therefore, etching rate is strengthened at the early growth stage to carry out film-formation while removing the impurity, and when an EPI film is formed in certain degree, etching rate is weakened to increase film-formation rate.

It should be noted that by increasing processing pressure, etching action and film-formation action are increased, therefore also by changing processing pressure during the film-formation processing, the above embodiment can be obtained.

Also in the second film-formation step, because SiH4is used as film-formation gas, film-formation temperature can be set as low as from 500 to 700° C., and influence of thermal damage or thermal budget on a substrate element can be alleviated. In addition, in the case where Si2H6is used as a film-forming gas, it is possible to set film-formation temperature as low as from 450 to 700° C. compared with the case where SiH4is used.

Still more, in the second film-formation step, because Cl2and H2are introduced as processing gas in etching, purging of N2is not necessary before or after the etching step, and a purge step of N2can be omitted, therefore simplification of the film-formation step and shortening of the processing time are possible, and throughput is enhanced.

In addition, uniformity of film-formation in an example of the first film-formation step is about 20%, and uniformity of film-formation in an example of the second film-formation step is from 5 to 10%, therefore enhancement of quality of a film formed was obtained in the example of the second film-formation step as compared with the example of the first film-formation step.

InFIG. 6, when the etching is carried out using Cl2to the monitor wafer formed Poly-Si film, there are shown the experimental results that the etching rate and the uniformity in wafer surface of etching amount are compared, respectively, in the case where N2is used and H2is used as a carrier gas.

InFIG. 6, marks ▴ and ● represent etching rate, and marks Δ and ◯ represent uniformity in wafer surface of etching amount.

The experiment was carried out under the following conditions:

Each value obtained by the experiment carried out under the above conditions is shown in Table 1. From these results, it is understood that etching by the case used H2as a carrier gas provides lower etching rate and better uniformity in surface of etched amount, as compared with etching by the case used N2as a carrier gas. Therefore, it can be said that etching by the case used H2as a carrier gas is capable of enhancing uniformity of film-formation.

In addition, fromFIG. 6, it is understood that etching by the case used H2as a carrier gas is capable of enhancing also uniformity between the wafer.

Next, it is described the reason why, when the etching is carried out using Cl2as a carrier gas, the case used H2as a carrier gas provides better uniformity of etching, as compared with the case used N2as a carrier gas.

When the etching is carried out only by Cl2without using carrier gas, and when the etching is carried out using N2as carrier gas, etching of Cl2becomes dominant. Therefore, etching at the edge part of a wafer becomes strong, and gas is almost consumed at the edge part, resulting in no reaching of etching gas to the center part of the wafer, which lowers uniformity.

On the other hand, when H2is used as a carrier gas, Cl2and H2react in the gas phase to form an intermediate, and then the reaction to form 2HCl occurs partially resulting in lowering the etching power. Because an intermediate of HCl is formed during the process thereof, etching gas is capable of reaching the center part of the wafer, therefore, it is considered that uniformity is improved.

In addition, it is considered to be one reason that the wafer surface is covered with H, which then reduces etching effect of Cl and increases amount of gas reaching to the center part of the wafer.

Further, it is described the reason why, when the etching is carried out using H2as a carrier gas, the case used Cl2as an etching gas is effective, as compared with the case used HCl as an etching gas.

Because the processing furnace16has a hot wall structure, is subjected to etching with gas decomposed in gas phase. However, HCl takes a long time to be decomposed at low processing temperature as in the present application, therefore it is difficult to secure selectivity. On the other hand, Cl2provides rapid progress of thermal decomposition even in low temperature processing, therefore Cl2provides higher etching rate, and is capable of securing higher selectivity.

And, the relation of this etching power does not change even in the case of dilution with H2, and because the case used Cl2as an etching gas provides stronger etching power than the case used HCl as an etching gas, the case used Cl2as an etching gas is capable of providing better result in low temperature processing like in the present application.

It should be noted that, because of occurrence of a reaction that an intermediate of HCl is generated in vapor phase by heat, uniformity of film-formation can be improved by using Cl2as etching gas, using H2as carrier gas as above. Therefore, because of a hot wall structure, where atmosphere in the reaction tube is heated, effect of the present application invention is attained.

It should be noted that explanation has been given on formation of an EPI-Si film on a substrate in the above embodiments, however, the present invention is capable of being carried out also in a single crystal film, a polycrystal film, an amorphous film or the like, or a doped single crystal film, a doped polycrystal film, a doped amorphous film or the like.

Still more, as a substrate processing apparatus where the present invention is carried out, there can be included a substrate processing apparatus in general such as a lateral-type substrate processing apparatus, and for example, also a sheet-type, hot wall-type substrate processing apparatus.

In addition, the present invention includes the following embodiments.

A manufacturing method of a semiconductor apparatus for selectively forming a thin film on a silicon substrate by a reduced pressure CVD method (Chemical Vapor Deposition), characterized in that the thin film with high quality interface is grown by intermittently supplying, in an alternately repeating state, silane-type gas such as SiH4and halogen-type gas such as Cl2, together with hydrogen gas, into a reaction furnace, and in addition, without making a silicon film or a silicon nucleus grown on an insulating film such as silicon nitride film, so as to secure selectivity.

A manufacturing method of a semiconductor apparatus by changing flow amount of one or more of silane-type gas such as SiH4and halogen-type gas such as Cl2, and hydrogen gas, during the repeating cycle shown in the Additional Statement 1.

A manufacturing method of a semiconductor apparatus by changing pressure in the reaction furnace during the repeating cycle shown in the Additional Statement 1 and the Additional Statement 2.

(Additional Statement 4) A manufacturing method of a semiconductor apparatus by introducing doping gas such as PH3, B2H6and BCl3during the repeating cycle shown in the Additional Statement 1, the Additional Statement 2 and the Additional Statement 3.

A manufacturing method of a semiconductor apparatus, in any of the Additional Statement 1, Additional Statement 2 and Additional Statement 3, in introducing a silicon substrate and a tool (boat) for silicon substrate processing from a front chamber of a reaction furnace into the reaction furnace, where the drive axis part thereof and a boat rotation facility part and a wiring part are isolated from the front chamber of the reaction furnace.