Abstract:
A CVD reactor, such as a MOCVD reactor conducting metalorganic chemical vapor deposition of epitaxial layers, is provided. The CVD or MOCVD reactor generally comprises a flow flange assembly, adjustable proportional flow injector assembly, a chamber assembly, and a multi-segment center rotation shaft. The reactor provides a novel geometry to specific components that function to reduce the gas usage while also improving the performance of the deposition.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 60/979,181, filed Oct. 11, 2007, the entirety of which is hereby incorporated by reference into this application. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention pertains to chemical vapor deposition (“CVD”) reactors, including metalorganic chemical vapor deposition (“MOCVD”) reactors. 
       DESCRIPTION OF THE RELATED ART 
       [0003]    Chemical vapor deposition (“CVD”) reactors, and in particular metalorganic chemical vapor deposition (“MOCVD”) reactors are used to deposit solid material layers onto a wafer. Such materials typically include compounds of the group III column and group V column elements of the periodic table (referred to as III-V material, but also include “II-VI materials” as well). Materials such as silicon (Si), silicon carbide (SiC), zinc oxide (ZnO) and others are also deposited on wafers or other surfaces using these reactors. Commercially, these reactors are used in the manufacture of solid-state (semiconductor) microelectronic devices, optical devices and photovoltaic (solar) devices, and other electronic/opto-electronic materials and devices. 
         [0004]    In operation, typically a flat-cylindrical wafer carrier with one or more wafers loaded in shallow pockets on the upper surface of the wafer carrier is heated to the required temperature (450-1400° C.) by a heater assembly located (typically) below the lower surface. 
         [0005]    A continuously-supplied gas mixture is directed to flow over the surface of the heated wafer carrier and wafers. The gas mixture is predominantly (about 75-95%) a carrier gas, which is an appropriate inert gas (typically hydrogen or nitrogen) that functions to define the general flow pattern in the reactor and to appropriately dilute the reactant gases. The remainder of the gas mixture is comprised of group V reactant gases (about 4-23%), group III reactant vapors (about 1-2%), and dopant gases or vapors (trace levels). 
         [0006]    The group V gases decompose immediately above and on the surface of the heated wafer carrier and wafers, allowing atoms of the central group V element to incorporate into the material layer being deposited (both on the wafers and on the surface of the wafer carrier). The group III gases similarly decompose to provide atoms of the group III element. The dopant gases similarly decompose to provide atoms which function to alter the electrical conductivity characteristics of the semiconductor material. 
         [0007]    After flowing radially outward over the surface of the wafer carrier and wafers, the gas mixture (now also containing reactant by-products) exits the reactor through one or more exhaust ports. A vacuum pump is typically used to draw the gas mixture through the reactor, particularly because most materials deposit optimally at pressures lower than atmospheric pressure. After passing over the heated wafer carrier, the gas mixture begins to cool rapidly, which results in rapid condensation of byproducts into the solid state. These tend to coat the interior surfaces of the reactor chamber (below the wafer carrier) and exhaust tubing. 
         [0008]    The wafer carrier is typically rotated from 100 to over 1000 RPM to aid in uniformly distributing the flowing gas mixture, and to reduce the thickness of the mass-transport boundary layer, which increases the efficiency of reactant usage as well as byproduct removal. 
         [0009]    Material is deposited using this method in batches. The reactants are not supplied continuously during the batch run. The typical batch run is conducted as follows. During the initial stage of the run, only the carrier gas is supplied at a low flowrate. Then, in unison, the wafer carrier rotation is gradually increased to the desired value, the wafer carrier temperature is increased to the desired value, and the carrier gas flowrate is increased to the desired value. The group V reactant gas is typically switched into the reactor first (at a specific temperature level) to stabilize the surface of the substrate wafers (prevent desorption of group V atoms), and then the group III and dopant gases are switched in to effect “growth” of material layers (material growth only occurs when at least one group V and at least one group III source are switched to the reactor). Brief pauses where no group III or dopant gases are supplied to the reactor may occur, but at least one group V gas is typically supplied during the entire growth stage (while temperature is above about 350-400° C.). 
         [0010]    Once all material layers have been grown, the temperature is gradually decreased. Once the temperature is below about 350° C., the group V reactant gas is switched off, and the rotation, temperature and carrier gas flowrate are decreased to the starting levels. The wafers are then removed from the wafer carrier, either by opening the reactor chamber top or by transfer of the entire wafer carrier out of the reactor chamber by mechanical means. Depending on the material being deposited, the same wafer carrier may be used for many batch runs, or for only one run, before the excess material deposited on the exposed top surface must be cleaned off. 
         [0011]    There are a number of known MOCVD reactor systems used in the market currently. Each of these known MOCVD reactors suffers from deficiencies and disadvantages. 
         [0012]    One design uses a tall cylindrical vessel with a gas flow injection top lid that attempts to spread flow evenly over the entire lid area. To a limited extent, the vertical separation prevents byproduct material deposition on the internal lid surface through which the gas flows enter. The lid design, however, has disadvantages that include: ineffective isolation of the multiple gas spreading “zones” in the lid, resulting in pre-reaction and byproduct material deposition; ineffective spreading of gas flows over the large zone areas from supply gas tubes, resulting in non-optimal material characteristics as well as additional material deposition on the internal lid surface; and the high flowrates of gas required to produce a relatively uniform outlet flow from the lid through the large chamber volume. 
         [0013]    A second design uses a short cylindrical vessel with a gas flow injection top lid that is closely spaced to the (heated) deposition surface. The close spacing is effective in minimizing the reactor volume and providing effective contacting of the gas to the deposition surface, and the gas chamber isolation is effective. However, the close spacing results in byproduct material deposition on the internal lid surface and requires cleaning after nearly every process run, which requires greater maintenance time and costs and less productive time. In addition to high maintenance costs, the cost to manufacture the top lid is very high due to the complexity of the lid and the large area. 
         [0014]    Both designs are expensive to use. The first design has a very high operating cost and produces a product of lower quality and performance. The second design has a relatively lower operating cost, but higher system maintenance requirements. 
         [0015]    A CVD reactor system that has a lower production price and operating costs is desirable. A CVD reactor system with improved characteristics of deposited material, high uptime and high quality is desirable. 
       SUMMARY OF THE INVENTION 
       [0016]    A CVD reactor, such as a MOCVD reactor conducting metalorganic chemical vapor deposition of epitaxial layers, is provided. The CVD or MOCVD reactor generally comprises one or more of a flow flange assembly, adjustable proportional flow injector assembly, a chamber assembly, and a multi-segment center rotation shaft. 
         [0017]    The CVD reactor provides a novel geometry to specific components that function to reduce the gas usage while also improving the performance of the deposition. In one aspect, a number of CVD reactor components with novel geometries are described. In another aspect, new components are described that address the problems of conventional CVD reactors. For example, the chamber top and side wall has a geometry that is significantly different from conventional components. The top and side walls form a flared or curved conical surface. The exit region of the reactor also has an improved geometry that includes a tapered or sloped surface. A novel gas injector is included in one embodiment of the invention to further improve on performance and economy. 
         [0018]    The inventive design provides a number of advantages. The CVD reactor reduces the volume of the reactor, provides a flow-guiding surface which directs entering gas flows to intimately contact a deposition surface, provides an additional flow-guiding surface to prevent back-entry of spent reaction gas into the main reaction volume, provides highly uniform fluid cooling or temperature control of key internal reactor surface, and provides means of reducing heat losses from the deposition surface. 
         [0019]    The reactor design addresses a number of the problems with existing designs including but not limited to the following: (1) high/inefficient gas and chemicals usage, (2) non-uniform distribution of entering gas flows, (3) high manufacturing costs of equipment, and (4) deposition of problematic byproduct materials on internal reactor surfaces. The result is advantages of lower operating cost, improved characteristics of deposited material layers, and lower machine maintenance requirements. 
         [0020]    The flow flange assembly comprises a three-dimensional tapered or flared cone upper surface and thin fluid gap immediately behind the surface, in contrast to vertical cylindrical walls of other designs. The design reduces reactor volume and gas usage, effectively guides gas towards deposition surface for more efficient chemicals usage, and provides for approximately uniform radial velocity for improved deposition uniformity. 
         [0021]    The adjustable proportional flow injector has several features including smaller area than deposition surface, isolated flow zones, a single adjustable flow zone with no separation barriers, and uniform cooling fluid flow profile. These features address several problems in prior art injectors by providing a lower gas flowrate, lower manufacturing cost, no zone cross leak and resulting pre-reaction and by-product material deposition, and improved uniformity of deposited material. 
         [0022]    In one embodiment, the adjustable proportional flow injector assembly comprises one or more gas chambers for separately maintaining one or more reactant gas flows and a fluid cavity for regulation of gas temperature prior to injection of the gas into the reactor chamber. The adjustable proportional flow injector assembly receives one or more gas inlet streams from supply tubes and spreads/diffuses these flows for a uniform outlet flow velocity, while keeping the gas streams separated until they exit, and also regulating the temperature of the gas as the gas exits the adjustable proportional flow injector assembly. 
         [0023]    In one embodiment, the chamber assembly generally comprises a conical or sloped lower flow guide. The lower flow guide prevents gas recirculation back into the reaction zone, improves smoothness of flow from the outer edge of the wafer carrier into the exhaust ports for a more stable overall reactor flow profile, reduces heat losses at the outer edge of the wafer carrier for better temperature uniformity and improved material characteristics. 
         [0024]    An embodiment of the wafer carrier has a cylindrical plate made of high temperature resistant material that holds the substrate wafer(s) within the reactor volume, and, in embodiments of the invention, transfers heat received from the heater assembly to the wafers. The center rotation shaft is generally in communication with the wafer carrier and causes rotational movement of the wafer carrier. In an embodiment, the center rotation shaft penetrates through the base plate center axis, usually in combination with a rotary vacuum feedthrough (such as a ferrofluid sealed type), and supports and rotates the wafer carrier within the reactor. 
         [0025]    In a particular embodiment, the reactor comprises a two-piece wafer carrier having a top and a bottom, the top having properties optimal for holding substrate wafers and the bottom having properties optimal for heat absorption. 
         [0026]    A multi-segment center rotation shaft is provided in one embodiment. The multi-segment shaft has two or more segments that may optionally be used in the reactor. At least one segment of the multi-segment shaft is made from a material having a low thermal conductivity. The multi-segment shaft may have segment interfaces designed to have a high thermal transfer resistance, to reduce thermal losses from the wafer carrier. The multi-segment shaft may generate additional heat near the center of the wafer carrier and provide a thermal barrier to heat losses from the water carrier and/or shaft. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]    The following is a general description of the drawings filed herewith. 
           [0028]      FIG. 1  is a perspective view of one embodiment of the entire reactor chamber assembly. 
           [0029]      FIG. 2  is a side view of one embodiment of the entire reactor chamber assembly. 
           [0030]      FIGS. 3-5  show cross-sectional views of one embodiment of the entire reactor chamber assembly. 
           [0031]      FIG. 6  shows a perspective view of one embodiment of the flow flange assembly. 
           [0032]      FIG. 7  shows an exploded side view of one embodiment of the flow flange assembly. 
           [0033]      FIG. 8  shows an exploded underside view of an embodiment of flow flange assembly. 
           [0034]      FIGS. 9   a - c  show three cross-sectional side views of an embodiment of the upper flow guide. 
           [0035]      FIG. 10  shows a close up cross sectional view of an embodiment of the upper flow guide. 
           [0036]      FIG. 11  shows a side view of an embodiment of the adjustable proportional flow injector assembly. 
           [0037]      FIG. 12  shows an exploded side view of an embodiment of the adjustable proportional flow injector assembly. 
           [0038]      FIGS. 13-15  show three cross-sectional views of an embodiment of the adjustable proportional flow injector assembly. 
           [0039]      FIG. 16  shows a top interior view of an embodiment of the adjustable proportional flow injector gas chamber machining. 
           [0040]      FIG. 17  shows a bottom view of an embodiment of the adjustable proportional flow injector assembly. 
           [0041]      FIG. 18  shows a close up cross-sectional view of the dual o-ring seal of the adjustable proportional flow injector assembly sealed to a flow flange assembly. 
           [0042]      FIG. 19  shows a perspective view of an embodiment of the chamber assembly. 
           [0043]      FIG. 20  shows a top view of an embodiment of the chamber assembly. 
           [0044]      FIGS. 21   a  and  21   b  show two exploded views of an embodiment of the center rotation shaft assembly. 
           [0045]      FIG. 22  shows a side view of an embodiment of the center rotation shaft assembly. 
           [0046]      FIG. 23  shows a cross-sectional view of an embodiment of the center rotation shaft assembly. 
           [0047]      FIG. 24  shows a close up cross-sectional view of an embodiment of the center rotation shaft assembly. 
           [0048]      FIG. 25   a - c  shows an alternate embodiment of subassemblies of the gas chambers of the adjustable proportional flow injector assembly. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0049]    The present invention is described in detail using preferred embodiments. The present invention, however, is not limited to these embodiments. Additionally, a requirement in an embodiment is freely applicable to other embodiments, and requirements are mutually replaceable unless special conditions are attached. Specifically, a CVD reactor or MOCVD reactor, and components and parts of the reactors, are described in further detail below. The CVD reactors or MOCVD reactors may comprise other components and parts which are not specifically mentioned herein. Further, it should be understood that the scope of the invention pertains to CVD reactors or MOCVD reactors which may comprise some of the components and parts discussed herein or may comprise all of the components and parts discussed herein. 
         [0050]      FIG. 1  illustrates a front perspective view of one embodiment of the entire reactor assembly  1 . The entire reactor assembly  1  is comprised of three subassemblies that together form the entire reactor assembly  1 . The three subassemblies are the flow flange assembly  3 , the adjustable proportional flow injector assembly  5 , and the chamber assembly  10 .  FIG. 2  illustrates a side view of the reactor assembly  1  as well as some of the individual components that are visible from the exterior of the reactor  1 . Those components are discussed in more detail below. 
         [0051]      FIGS. 3-5  illustrate a cross sectional view of the entire reactor assembly  1  showing the interconnection of the three subassemblies, and a cross-sectional view of the individual components that make up the three subassemblies. As in  FIGS. 1 and 2 , the flow flange assembly  2 , the adjustable proportional flow injector assembly  5  and the chamber assembly  7  are illustrated. The individual components of the three subassemblies  3 ,  5 , and  7  are also indicated and discussed in greater detail below. 
         [0052]      FIGS. 6-10  and  18  show several views of one embodiment of flow flange assembly  3 . The flow flange assembly  3  comprises a main flange body  30  and has an upper opening  31  which defines a mating port for the flow injector assembly  5  on the top and mates to the chamber assembly  10  on the bottom end (shown best in the cross section view of  FIGS. 3-5 .) The flow flange assembly  3  has an upper flow guide  32 , which, along with the flow injector and wafer carrier, defines the reactor volume  33  and the gas flow profile within the reactor volume, fitted within the main flange body  30 . 
         [0053]    The upper flow guide  32  preferably has a three-dimensional tapered cone outward facing surface  34  (as opposed to vertical cylindrical walls of prior art designs). The upper flow guide  32  is positioned and fits within the main flange body  30  (as best shown in  FIGS. 7 and 8 . The underside  35  of the main flange body  30  has a corresponding shape to receive the inward facing surface  36  of the upper flow guide  32  so that a thin fluid gap or cavity  37  is formed immediately behind the upper flow guide  32 , between the upper flow guide  32  and the main flange body  30  (best illustrated in  FIGS. 8-10 ). In an embodiment, such as depicted in the  FIGS. 9   a - c , fluid cavity collection channels  41 ,  42  (two points here connect with the thin fluid cavity  37  through flow orifices  40 . 
         [0054]    The geometry of the upper flow guide  32  minimizes reactor chamber volume, suppresses recirculation eddies within the reactor chamber volume  33  and provides for efficient contacting of the reactant gas with the wafer carrier surface  77 . 
         [0055]    In one embodiment, as best shown in  FIGS. 3-5  the upper flow guide  32  has a first (upper) diameter D 1  substantially equal to the diameter of the adjustable proportional flow injector (APFI)  7  and second (lower) diameter D 2  substantially equal to the diameter d 3  of the wafer carrier  76 . As illustrated in the figures, the first diameter D 1  is smaller than the second diameter D 2 . The first diameter D 1  preferably is from about 0.2 to 0.5 of the second diameter D 2 . The upper flow guide  32  is not strictly conical shaped, but rather curved as the guide extends downward and flares out as it approaches D 2 . The upper flow guide  32  creates a gas flow pattern where a uniformly distributed, downward-flowing gas stream is directed towards the wafer carrier  76 , but the gas stream is also turned laterally and expanded, so that a smaller diameter flow injector  5  can be used to uniformly distribute flow over a substantially larger wafer carrier  76 , without the occurrence of recirculation of gas within the reactor chamber volume  33 . 
         [0056]    The curved or flared profile of the upper flow guide  32  provides approximately equal radial gas velocity. An upper flow guide  32  with this geometry is alternately referred as an expanding cone upper flow guide  32 . While not bound by theory, for a gas flow moving radially outward, the gas must cross a continuously increasing cross sectional area (which increases with radius for cylindrical geometries), and as a result, the flow velocity must decrease. In order to maintain a substantially constant velocity, the height H 1  of the containing geometry may be gradually reduced, so that the cross sectional area (product of circumference multiplied by height) remains substantially constant, which counteracts the increase of the circumference with radius. 
         [0057]    The flow flange assembly  3  preferably has a fluid gap  37  positioned directly behind the upper flow guide  32  (between the upper flow guide  32  and the main flange body  30 ). In embodiments of the invention, the fluid gap  37  is relatively thin (about 0.1 inches or less) which, for fluid flow rates of approximately 1 gallon per minute and for fluids having density and viscosity values within an order of magnitude of water, will result in a Reynold&#39;s number value of less than 3200, which is indicative of laminar flow within the fluid gap and efficient usage of fluid. This configuration results in reduced usage of fluid and/or reduces the capacity of a fluid recirculator (if a reservoir/recirculator heat exchanger system is to be employed). 
         [0058]    The flow flange assembly  3  may further comprise bottom/outer to top/inner flow through the fluid gap  37  for air removal and counter-flow heat exchange. That is, fluid flows in a reverse direction through the fluid gap from the direction the gas is flowing in the reactor volume. This type of flow path through the fluid gap is achieved in one embodiment from a supply channel  41 , optionally down through one or more supply conduits (not shown). Each supply channel  41  has one or more flow restricting orifices  40  proximate to the end of each supply channel  41 . The flow restrictive orifices  40  sufficiently restrict the flow such that an equal flow rate of fluid passes through each supply channel, immediately prior to entering the fluid gap  37 , producing a uniform flow delivery around the outer circumference of the fluid gap  37 . Fluid flows radially inward though the fluid gap  37 , and then passes through a second set of flow restricting orifices  40  within that transfers the fluid to a return channel  42  (optionally via one or more return conduits (not shown). Fluid is supplied via supply channel inlet tube  45  and returned through a fluid outlet tube  46 . The flow characteristics of the fluid within the fluid gap  37  result in improved temperature uniformity within the reactor chamber volume  33 , which improves the uniformity of the gas flow profile and deposition uniformity. The bottom/outer to top/inner flow pattern in the fluid gap  37  results in counter-flow heat exchange and effective removal of air from the gap  37 . 
         [0059]    A gap  43  between upper flow guide  32  at the outermost diameter of the upper flow guide D 2  (i.e. at the end of the upper flow guide proximate to the wafer carrier  76 ) and wafer carrier upper surface  77  at the outermost diameter d 3  of the wafer carrier  76  generally inhibits or prevents recirculation of ejected gas above the wafer carrier  76 . As shown particularly in  FIGS. 3-5 , the wafer carrier  76  rests on the top of a center rotation shaft  75 . The upper flow guide  32  outer diameter D 2  is about equal to that of the wafer carrier d 3  where the upper flow guide  32  is closest to the wafer carrier  76 . At this point, the separation between these two parts H 2  is at a minimum value and the gap  43  facilitates the inhibition or prohibition of recirculation of the ejected gas within the reactor chamber volume  33 . For example, the gap may have a dimension H 2  of about 1.00 inch or less, such as about 0.25 inch or less. The gas flowing downward from the adjustable proportional flow injector assembly  5  turns laterally within the reactor chamber volume  33  and flows radially outward. When it reaches the gap  43 , the gas achieves a maximum flow velocity, and once past the gap  43 , the gas begins to expand and decelerate in an exhaust collection zone  44  that is proximate to the gap  43 , thereby preventing backward recirculation of the spent gas mixture, (i.e. the gas which has moved away from the reaction area at and above the wafer carrier  76 ). 
         [0060]    In a preferred embodiment of the invention, the reactor  1  with an expanding cone upper flow guide  32  also incorporates a lower flow guide  72  (discussed in more detail below). The lower flow guide  72  prevents gas recirculation back into the reaction zone, improves smoothness of flow from outer edge of wafer carrier into exhaust ports for more stable overall reactor flow profile, and reduces heat losses at outer edge of wafer carrier  76  for better temperature uniformity and improved material characteristics. 
         [0061]    The adjustable proportional flow injector assembly  5  in an embodiment of the invention is shown particularly in  FIGS. 11-18  and  25 . The adjustable proportional flow injection is a flow injector that receives multiple gas inlet streams from supply tubes and spreads or diffuses these flows for a uniform outlet flow velocity, while keeping the gas streams separated until they exit. Optionally the APFI  5  also regulates the temperature of the gases as they exit the adjustable proportional flow injector. The APFI  5  is typically cylindrical in shape (circular area and vertical height) and fits within the flow flange assembly  3 . A cylindrical APFI is shown in the figures however, the APFI can be made in any shape and the exact shape will generally be dictated by the shape (area) of the upper opening  31  into which it is being mated. For example, if the upper opening  31  has a square or rectangular shape, then the APFI will have a corresponding square or rectangular shape so that it can be mated. 
         [0062]    The adjustable proportional flow injector assembly  5  generally comprises a support flange  51 , which provides structural integrity for the components mated to the support flange  51  and gas chamber inlet tubes or ports  54  that penetrate through the support flange  51 . The support flange  51  further provides for mating the entire adjustable proportional flow injector assembly  5  to a main flange body  30 . 
         [0063]    The APFI  5  includes one or more gas chambers  52 . In an embodiment, one or more of the gas chambers  50  may be machined into a gas chamber machining  52  and are formed from a plurality of gas chamber top walls or surface  57  and gas chamber bottom walls or surface  58 . The gas chamber top wall  57  can be machined to form different zones as illustrated in the top views  FIGS. 16 and 17 . The gas chambers  50  are separated from the other gas chambers  50  by gas chamber vertical walls  59  that extend from the gas chamber top walls  57  to the gas chamber bottom walls  58  thereby forming the gas chambers  50 . The one or more gas inlets  54 , which may be incorporated into the gas chamber top walls  57 , deliver gas to the one or more gas chambers  50  of the adjustable proportional flow injector  5 , such as in a vertical direction (i.e. about perpendicular to the gas chamber top walls  57  and gas chamber bottom walls  58 ). 
         [0064]    Each gas chamber  50  may receive a different gas stream and one or more of these gas chambers may spread or diffuse the gas and keep a first gas stream separate from other gas streams or each gas stream separate from another, and create a uniform flow velocity over a specific outlet surface area. Additionally, each gas chamber  50  may be configured in the same shape or different shape as the other gas chambers  50 . 
         [0065]    For example, as shown in  FIG. 16  (the support flange  51  is removed from the figure) there is an outer gas chamber  50   a , and four intermediate gas chambers  50   b  and  50   c , and an inner gas chamber  50   d . In one embodiment, the gas chamber  50   b  receives Group III reactants and intermediate gas chambers  50   c  receive group V reactants. The chambers  50   a - d  are separated by the vertical walls  59 , the gas chamber top walls  57  (not shown) and the gas chamber bottom walls  58 . 
         [0066]    The APFI  5  may also include a fluid cavity  60 , which is located below the one or more gas chambers  50 . The fluid cavity  60  may be formed by the mating of a fluid cavity machining  53  to the gas chamber machining  52 .  FIG. 17  shows the bottom view of an embodiment of the adjustable proportional flow injector assembly  5 , showing the bottom face of the fluid cavity machining  53 . Gas chamber outlets  61  may extend or penetrate from the bottom wall  58  of a gas chamber through the fluid cavity  60 , such as through conduit tubes  63 , into the reactor chamber volume  33 . The conduit tubes  63  may have the same or different inner diameters and same or different outer diameters. Penetration of the conduit tubes  63  through the fluid cavity  60  permits the regulation of the gas temperature prior to introduction of the gases into the reactor chamber volume  33  by the appropriate control of the temperature of the fluid flowing through the fluid cavity  60 . The fluid cavity  60  has a fluid cavity outlet  66  positioned at about the center of the fluid cavity  60  connected to a fluid cavity outlet tube  67 . Additionally, fluid cavity inlets  68  are provided through fluid cavity inlet tubes  69  towards the periphery of the fluid cavity  60 . 
         [0067]    In embodiments that contain a fluid cavity diffuser  65  (discussed in more detail below), the fluid cavity outlet  68  is positioned inside the circumference of the diffuser  65 , while the fluid cavity inlets  68  are positioned outside of the circumference of the diffuser  65 . 
         [0068]    The adjustable proportional flow injector assembly  5  may optionally have one or more of the following features. In one embodiment, the gas outlet apertures  61  are preferably a smaller size than the gas inlets  54  (for example there may be from about 100 to about 10,000 gas outlet apertures). The number of gas outlet apertures  61  and the inside diameter and length of the conduit tubes  63  extending through the fluid cavity  60  depends on the specific gas composition, flowrate, temperature and pressure and are also limited by the total surface area of the bottom wall  58  of a gas chamber and by manufacturing capabilities and costs, the difficulty and cost increasing as the outside and inside diameters of the conduit tubes  63  decreases and as the spacing of adjacent gas outlet apertures  61  decreases. Generally, however, the total cross sectional area of all of the conduit tubes  63  is preferably a factor between 2 and 6 times larger than the cross sectional area of the gas inlet  54  to a given gas chamber. This arrangement accounts for the greater wall surface area and corresponding fluid shear and pressure drop of the smaller-diameter conduit tubes  63  compared to the gas inlet  54 , such that the pressure drop across the set of conduit tubes of a given gas chamber (that is, the pressure drop from the gas chamber to the reactor chamber volume  33 ) is preferably from several Torr to several tens of Torr. 
         [0069]    The gas chamber upper walls  57  and gas chamber bottom walls may preferably be substantially parallel. The upper walls/surface  57  of all gas chambers can be substantially co-planar they can alternatively be on different planes. Similarly gas chamber bottom walls  58  of all gas chambers  50  can be co-planar or alternatively on different planes. 
         [0070]    The adjustable proportional flow injector assembly  5  may optionally comprise one or more intermediate diffusing baffle plates  55  between and substantially parallel to the gas chamber upper walls  57  and the gas chamber bottom walls  58 . When an intermediate diffusing baffle plate  55  is used, an upper gas chamber section  50   a  and a lower gas chamber section  50   b  is formed in the gas chamber  50  comprising the intermediate diffusing baffle plates  55 . For example, the upper gas chamber section  50   a  may be defined, generally, by the gas chamber upper wall  57 , an upper surface of the intermediate diffusing baffle plate  55  and any side wall(s)  59  and the lower gas chamber section  50   b  may be defined generally by the gas chamber lower wall  58 , a lower surface of the intermediate diffusing baffle plate  55  and any side wall(s)  59 . 
         [0071]    Gas outlet apertures  61  of each gas chamber  50  are joined to outlet conduits (preferably small diameter tubes)  63  penetrating through the fluid cavity  60  which may be attached to or otherwise joined to the fluid cavity machining  53  thereby forming a lower fluid cavity wall proximate to the lowermost side of which is a boundary surface of the reactor chamber volume  33 . The outlet conduits  63  preferably have an aperture pattern matching that of the combined set of gas chamber outlet apertures  61 . 
         [0072]    A further embodiment of the adjustable proportional flow injector assembly  5  concerns a fluid temperature control zone with uniform, radial flow profile. Temperature regulating fluid, for example cooling fluid, flows into an outer distribution channel  62 . In an embodiment of the invention, the fluid cavity  60  has a fluid cavity diffuser  65 . The fluid cavity diffuser  65  is preferably a thin, cylindrical sheet metal ring having a height slightly larger than the height of the fluid cavity  60  and is preferably as thin as possible. In the preferred embodiment, the cylindrical sheet metal ring inserts into opposing circular grooves in the bottom surface of the gas chamber machining  53  and the upper surface of the fluid cavity machining  52 , the sum of the depth of these two grooves preferably being equal to the additional height of the flow diffusing barrier over that of the fluid cavity, so that fluid delivered to the fluid cavity  60  at multiple inlets  68  at the outermost periphery of the fluid cavity must immediately move tangentially before flowing through a plurality of preferably equally spaced small apertures  64  in the flow diffusing barrier  65 , resulting in a uniform flow distribution from the outermost periphery of the fluid cavity  60  radially inward towards the single outlet  66  at the center outlet  66  of the fluid cavity  60 . The small apertures  64  act as flow restricting orifices, which sufficiently restrict flow so as to result in an equal flow through each aperture  64   
         [0073]      FIG. 25(   a - c ) illustrates an alternate method of fabricating the APFI. Not all APFI components previously described are shown. In order to increase the ease and efficiency of both the manufacture and testing of the APFI, components of the APFI can be assembled from interchangeable modules or subassemblies. For example, gas outlet aperture sub-assemblies  150  can be constructed from an upper plate  151 , a lower plate  152 , and multiple conduits  63 . The upper plate  151  constitutes the bottom wall  58  of a gas chamber  50  described above. The lower plate  152  constitutes a portion of the bottom wall  58  of the fluid cavity machining  53  previously described. 
         [0074]    In this embodiment, the gas chamber machining  52  is constructed to receive multiple gas outlet aperture sub-assemblies  150 , such that the upper surface  153  of the upper plate  151  mates flush to one or more lower surfaces  155  of gas chamber walls  59  previously described. The seam between the upper plates  151  of adjacent gas outlet aperture sub-assemblies  150  falls along the centerline of a given lower surface  155  of a gas chamber wall  59  so that a seal may be formed that prevents any leakage between the fluid cavity  63  thus formed and any gas chamber  50 . 
         [0075]    In the embodiment shown in  FIGS. 25(   a - c ), the seam between the lower plates  152  of adjacent gas outlet aperture sub-assemblies  150  and between the lower plate  152  of a given gas outlet aperture sub-assembly  150  and the lower fluid cavity wall  157  integral with that gas chamber machining  52  may be sealed to prevent any leakage between the fluid cavity  63  and the reactor chamber volume  33 . In one embodiment, it may be sealed in such a manner that the lower surface  154  of each gas outlet aperture sub-assembly  150  is flush with the lower surface  154  of all other gas outlet aperture sub-assemblies  150  and the lower surface  156  of the gas chamber machining, although this is not required. Fluid is thus delivered into the fluid cavity  63  through multiple fluid cavity inlets  68  and exits through one or more fluid cavity outlets  66 , where the fluid cavity diffuser  65  (not shown) is positioned in a similar manner as previously described. 
         [0076]    A further embodiment of the invention concerns methods for creating patterns of substantially equally spaced gas outlets in one or more radial patterns. In accordance with these methods, one or more patterns of circular holes are arranged such that the holes are equidistant from each other, such as in square or hexagonal patterns. For the radial zones comprising the adjustable proportional flow injector gas chambers, a method comprises distributing holes so that they are substantially equidistant from each other as well as area boundaries. This method generally comprises the steps of (1) arranging a first set of holes on a first line adjacent and parallel to a first radial area boundary, with equal spacing between these holes in a radial direction, (2) determining the angle, with vertex at the center axis of the machining, between a first point on the first line at a first radial distance from the center axis and the corresponding second point on a second line adjacent and parallel to a second radial area boundary, (3) determining the length of the arc, with origin at the center of the gas chamber machining, between a first hole at a given radius lying adjacent to the first radial area boundary and the corresponding second hole at the same radius lying adjacent to the second corresponding radial area boundary, (4) dividing this arc length by the desired center-to-center hole spacing distance and (5) rounding the resulting number to the nearest integer. Steps (2)-(5) are repeated for each hole comprising the set described in step (1). This method produces a hole pattern with equal separation between radial sets of holes, and nearly equal separation of holes within each radial set of holes. This method is particularly useful for producing substantially equidistant sets of holes in circular or semi-circular patterns over small areas, where irregularities in hole spacing are more significant than for patterns over large areas. 
         [0077]    The reactors may also comprise a gas distribution zone having adjustability with no zone separating barriers (such as illustrated in  FIG. 17 ). In this embodiment, the reactors comprise two or more gas inlet tubes  54  and a plurality of outlet holes  61  that geometrically function to produce an adjustable outlet flow pattern through the plurality of holes  61 . While not bound by theory, by increasing or decreasing the amount flow to one or more of the inlet tubes  54 , without having any discrete vertical separation wall  59  between any of the inlet tubes  54 , stagnation areas that would normally be produced by the area below the separation walls, which can have not outlet flow holes, are eliminated. 
         [0078]    The adjustable proportional flow injector assembly  5  may further comprise one or more sealed chamber tops, such as one or more o-ring sealed chamber tops, for cleaning and/or baffle changes. In a preferred embodiment, the gas chamber machining  52  includes o-ring grooves machined into the top surface of the vertical walls  59  separating the gas chambers, which eliminates the gas chamber zone upper walls  57 . This is because an O-ring lying along the upper surface of the vertical walls can seal directly to the lower surface of the support flange  51  or other single intermediate sealing surface (rather than a plurality of welded surfaces). This configuration allows the gas chambers to be opened and cleaned or inspected, as well as reducing the number of parts required. 
         [0079]    In a further embodiment, the adjustable proportional flow injector assembly  7  comprises a dual o-ring seal with vacuum barrier zone, best illustrated in  FIG. 18 . Dual o-ring seal produced by o-rings  91  in o-ring grooves  92  in the gas chamber machining  52  and the fluid cavity machining  53 . One o-ring  91   a  is positioned between the gas chamber machining  52  and the main flange body  31 . A second  91   b  is positioned between the fluid cavity machining  53  and the main flange body  30 . A vacuum cavity  93  is created between the APFI, the main flange body  31 , and the o-rings  91 . A differential seal vacuum port tube  94  is included in the main flange body  31  to create and release the vacuum seal. This configuration permits easy removal of the adjustable proportional flow injector  5  while negating gas molecule permeation of the o-ring elastomer material, due to the significantly lower vacuum levels produced in the volume in between the two o-ring seals than on either side of each seal. 
         [0080]    An embodiment of the chamber assembly  7  is shown in  FIGS. 19-20  and  FIGS. 3-5 . The chamber assembly  7  has a reactor baseplate main body  70 . The reactor baseplate main body is connected to a reactor jar top flange  100  via a reactor jar wall  101 . The reactor jar top flange  100  mates with the main flange body  30  of the flow flange assembly  3 . The baseplate main body  70  contains ports for a number of components useful in CVD reactors such as a center rotation shaft  75  (discussed in more detail below), base plate exhaust tubes  79 ; (not currently included in design and other drawings so might be confusing, although I don&#39;t really mind if we leave it because we could use something like this in a later design); high current feedthrough  90 ; and rotary vacuum feedthrough housing  88 . 
         [0081]    The chamber assembly  7  has components typically found in a CVD reactor such as a heater assembly comprising a heat source and heat reflecting shields for heating the wafer carrier  76 . In the embodiment shown, one or more heating elements  83  are positioned under the wafer carrier  76  and one or more heat shields  84  are positioned under the heating elements  83 . For example, the heat source may be a filament for radiant heating or a copper tube for inductive heating, preferably arranged in a concentric circular pattern to match the circular area of the wafer carrier. Other types of heater assemblies may be used for heating the wafer carrier  76 . 
         [0082]    The chamber assembly  7  has a lower flow guide  72 . The lower flow guide  72  has a frustoconical shape. The conical shaped lower flow guide  74  has an inner diameter d 1  and an outer diameter d 2 . Preferably, the inner diameter d 1  is slightly larger than outer diameter d 3  of the wafer carrier  76 , although the inner diameter d 1  can be approximately the same, smaller or larger than the outer diameter d 3  of the wafer carrier  76 . The lower flow guide  72  is aligned approximately with the top surface  77  of wafer carrier  76 . The outer diameter d 2  of the lower flow guide  72  is larger than the inner diameter d 1  creating a sloping surface in the downward direction. 
         [0083]    In the preferred embodiment, the inner diameter d 1  is slightly larger than outer diameter d 3  of the wafer carrier  76 . The spacing between the inner diameter d 1  of the lower flow guide  72  and the outer diameter of the wafer carrier  76  forces the gas ejected from the gap  43  between the wafer carrier  76  and the upper flow guide  32  to expand gradually, and inhibits or prevents recirculation of the ejected gas below the outer edge of the wafer carrier  76 . Preferably, the inner diameter d 1  of the lower flow guide and the outer diameter of the wafer carrier  76  are in close proximity to provide a narrow lower flow guide gap between the two, as the narrower the lower flow guide gap the more efficient ejection of the gas and greater the inhibition or prevention of the recirculation of gases within the reactor chamber volume  33 . In a preferred embodiment, the lower flow guide  72  is fabricated from graphite. 
         [0084]    The chamber assembly  7  may contain a lower flow guide reflector  74 . The lower flow guide reflector  74  is positioned within the lower flow guide  72  and extending from the circumference of the wafer carrier  76  and angled in a downward direction. The reflector  74  is constructed of a thin piece of metal, preferably molybdenum. The reflector  74  acts to reflects heat inward and helps keep the heat constant over the surface of the lower flow guide  72 . 
         [0085]    In an embodiment, the lower flow guide  72  may be constructed of one or more sections or pieces, such as a two-piece lower flow guide  72 . Due to the close spacing between the lower flow guide  72  and the wafer carrier  76 , and due to the high temperature the wafer carrier  76  reaches during processing, in an alternate embodiment, the lower flow guide  76  has a first piece that is immediately adjacent to the wafer carrier  76  fabricated from a material having a superior temperature tolerance and coefficient of thermal expansion about equal to or similar to that of the wafer carrier  76  material (typically graphite, sapphire or a refractory metal), and a second piece fabricated from a material that does not have such temperature tolerance or coefficient of thermal expansion, such as a material that is less expensive and more easily formed than the material that comprises the first piece. In a preferred embodiment, the first piece is fabricated from graphite to provide the appropriate temperature tolerance and coefficient of thermal expansion match with the wafer carrier material. 
         [0086]    The lower flow guide  72  may be in part or wholly an extension of the wafer carrier  76  extending from the diameter d 3  of the surface of the wafer carrier  76  that holds the wafer, i.e. an outer edge profile of the wafer carrier surface  77  that holds the wafers. In this embodiment, all or a portion of the lower flow guide  76  is an extension of the wafer carrier from the outer circumference of preferably the wafer carrier top surface  77 , or alternatively the lower surface  78 , or at some point along the circumference in between. In a particular embodiment, the lower flow guide  72  has a first section which is an extension of the wafer carrier  76 , such as within the first few centimeters from the narrow gap  40  between the wafer carrier outer diameter  76  and the upper flow guide  72 , and a second piece that is completely separate from the wafer carrier  76  and is formed as a separate piece adjacent to the first piece. 
         [0087]    The wafer carrier  76  for the reactor  1  may be a conventional one piece structure, however, embodiments having alternative structures are within the scope of the invention. For example, in an embodiment of the invention, the reactor may comprise a two-piece wafer carrier  76  comprising a removable top (i.e. platter or surface that holds the wafers) and a bottom. The removable top may be made from a number of materials, preferably sapphire and bottom may comprise graphite and may further comprise a means for heating, such as RF heated (for inductive heating of bottom and conductive heating of removable top and any wafers on the surface of the removable top). The two-piece wafer carrier can have the removable top replaced when necessary while the bottom can be reused. 
         [0088]    For example, in one embodiment a two-piece wafer carrier has a sapphire removable top for holding the wafers and a graphite bottom that supports the sapphire removable top. The sapphire top is non-porous and will not degrade, which occurs with surfaces conventionally used, such as SiC encapsulant. The sapphire removable top can also be cleaned more rigorously (such as a rapid wet chemical etch, which is not easily performed with the graphite wafer carriers). The graphite bottom piece is a heat absorber for conductive heat transfer into the sapphire removable top and the wafers on the surface of the removable top, such as within wafer pockets that may be machined in an upper surface of the removable top. 
         [0089]    In a further embodiment, the wafer carrier  76  is integral with (i.e. machined directly into) a portion of the center rotation shaft  75 , which shaft  75  extends downward from the center of a bottom surface  78  of the wafer carrier  76 . The center shaft  75  (alternatively, the center rotation shaft  75 ) extends downward through a heating coil and is comprised of a material suitable for heating, for example a material suitable for induction heating. This center rotation  75  shaft can be heated just as the main portion of the wafer carrier  76  is, and provides a thermal barrier to the conductive heat losses that may occur with conventional supporting spindle shafts. 
         [0090]    The center rotation shaft  75  for the wafer carrier  76  may be a conventional one piece structure; however, embodiments having alternative structures may be used. For example, in one embodiment as shown in  FIGS. 21-24 , a multi-segment shaft  75  for the rotating wafer carrier, i.e. a shaft comprising one or more segments made from the same material or different material is used. In multi-segment embodiments, at least one segment will have a substantially lower thermal conductivity than the remaining shaft segment(s) used. The multi-segment spindle is particularly useful in conjunction with radiant heaters although the invention is not necessarily limited in this regard. 
         [0091]    In the embodiment shown in  FIGS. 21-24 , there are three segments. A shaft upper segment  81  is directly in contact with the wafer carrier  76 . The shaft upper segment  81  has a susceptor or flange  82  at the proximal end on which the bottom surface  78  of the wafer carrier  76  rests. When radiant heaters are used, the upper segment is preferably fabricated from a material (such as alumina or sapphire) having a lower thermal conductivity than the one or more of the remaining segment(s) of the multi-segment shaft  75 . This selection of material produces the highest possible thermal transfer resistance. Segment interfaces between the multi-segment center shaft  75  and the wafer carrier  76  can be designed with minimal surface to further enhance the thermal transfer resistance. These features improve the temperature uniformity near the center area of the wafer carrier, as well as reduce energy losses in operation of the reactor. 
         [0092]    Alternatively, when an inductive heater is used in the reactor, the segment in contact with the wafer carrier (the shaft upper segment  81 ) extends downward through an inductive heating coil. In this instance, the upper segment  81  is made of a material suitable for inductive heating. For example, when an inductive heater is used in the reactor, the upper segment  81  of the multi-segment center shaft  75  is preferably constructed of graphite. 
         [0093]    In one embodiment, the multi-segment shaft  75  has a shaft lower segment  85  is constructed of a material that does not readily heat inductively (such as sapphire). The shaft upper segment  81  and shaft lower segment  85  are connected via a spacer  86  that is, preferably, constructed from alumina. The interfaces between the three (or more) segments preferably have minimal surface contact area to produce the highest possible thermal transfer resistance. The surface area may be reduced by including machined recesses  87  in the segments at the point of interface (shown in  FIG. 24 ); to create thin rails  96  around the circumference of the ends of the segments. Contact between the segments only occurs at the thin rails  96  as opposed to the entire area of the segment ends. The segments are preferably secured by way of vented head cap screws  97 . 
         [0094]    There will be various modifications, adjustments, and applications of the disclosed invention that will be apparent to those of skill in the art, and the present application is intended to cover such embodiments. Accordingly, while the present invention has been described in the context of certain preferred embodiments, it is intended that the full scope of these be measured by reference to the scope of the following claims.