Patent ID: 12208405

DETAILED DESCRIPTION

According to one embodiment, a processing system includes a chamber, a supplier, a detector, and a controller. The chamber is configured to store a processing object inside. The supplier is configured to supply a plurality of particles and a gas inside the chamber. The detector is configured to detect a state of air flow in a vicinity of the processing object. The controller is configured to control the supplier based on a detection value from the detector. The controller determines generation of a vortex based on data regarding a steady state of the air flow and the detection value from the detector, and controls the supplier to stop supply of the plurality of particles when the generation of the vortex is determined.

Various embodiments are described below with reference to the accompanying drawings.

In the specification and drawings, components similar to those described previously or illustrated in an antecedent drawing are marked with like reference numerals, and a detailed description is omitted as appropriate.

A processing system1according to the embodiment is able to form a film by generating an aerosol, supplying the generated aerosol toward a processing object, and depositing a plurality of particles included in the aerosol on the surface of the processing object. In the specification, the aerosol can be a gas including a plurality of particles.

In this case, the particles can be solid or liquid. In the following, the case where the particles are solid will be described as an example. The material of the solid particles is not particularly limited, and examples thereof include carbon, ceramics, and a metal such as platinum. The size of the solid particles is not particularly limited, but the particle size can be set to 1 μm or less, for example.

FIG.1is a schematic view for illustrating a processing system1according to the embodiment.

As shown inFIG.1, the processing system1can be provided with a chamber2, a nozzle3, an aerosol supplier4, a detector5, and a controller6.

The chamber2has a box shape and can have an airtight structure to the extent that dust does not enter from the outside. The internal space of the chamber2is a region where a film is formed on the surface of a processing object100by using the aerosol102. In this case, an air flow is formed inside the chamber2.

As will be described later, when a vortex103is generated in the air flow, the deposition amount of particles, and hence the thickness of the formed film, is different below the region where the vortex103is generated and below the region where the vortex103is not generated. Therefore, it is preferable that the chamber2is shaped so that the turbulence of the air flow is reduced. For example, it is preferable that the cross-sectional dimension of the chamber2(the dimension in the direction perpendicular to the direction from the nozzle3to the region on which the processing object100is placed) gradually increases as it approaches the region on which the processing object100is placed. For example, the appearance shape of the chamber2can be a truncated pyramid or a truncated cone. In this case, as shown inFIG.1, if the appearance shape of the chamber2is a truncated cone, the distance from the center of the processing object100to the inner wall of the chamber2can be made substantially constant. Therefore, it is easy to make the influence of the inner wall of the chamber2on the air flow uniform.

The processing object100for film formation can be stored inside the chamber2. For example, the processing object100can be placed on a bottom surface of the chamber2or on a placement table provided on the bottom surface of the chamber2. When providing the placement table, a holding device such as an electrostatic chuck can be provided on the placement table. Further, the placement table may be movable in a horizontal direction, a vertical direction, or the like.

There is no particular limitation on the material, shape, size, etc. of the processing object100. For example, as illustrated inFIG.1, the shape of the processing object100may be a plate shape, that is, the processing object100may be a substrate or the like.

The nozzle3has a tubular shape, and a discharge port3afor discharging the aerosol102can be provided at one end. An inlet3bfor introducing the aerosol102can be provided on the other end side of the nozzle3. The nozzle3can be provided on the ceiling surface of the chamber2, for example. The nozzle3can be provided so that the discharge port3afaces the processing object100. Although the case where the nozzle3is provided on the ceiling surface of the chamber2has been illustrated, the attachment position of the nozzle3can be appropriately changed as long as the discharge port3afaces the processing object100. For example, the nozzle3may be provided on a side surface of the chamber2or may be provided inside the chamber2.

The aerosol supplier4can generate the aerosol102. Further, the aerosol supplier4can supply the generated aerosol102into the chamber2via the nozzle3. That is, the aerosol supplier4can supply a plurality of particles101and a gas into the chamber2.

The aerosol supplier4can include a container4a, a supply controller4b, a mixer4c, and a gas supplier4d.

The container4acan be connected to the mixer4cvia the supply controller4b. The container4ahas a tubular shape and can store the plurality of particles101described above inside. The container4acan send the stored plurality of particles101to the supply controller4bby using gravity, for example.

Further, the vibrator4a1may be provided on an outer surface of the container4a. The vibrator4a1can give kinetic energy to the plurality of particles101stored inside the container4aby ultrasonic vibration, electromagnetic vibration, mechanical vibration, or the like. The vibrator4a1is not always necessary, and may be appropriately provided according to the shape and size of the plurality of particles101. However, if the vibrator4a1is provided, supply control of the plurality of particles101to the supply controller4bcan be stabilized.

The supply controller4bcan control the supply amount of the plurality of particles101from the container4ato the mixer4c, and can control the start and stop of the supply of the plurality of particles101. For example, the supply controller4bcan change the size of the holes through which the plurality of particles101pass.

The mixer4ccan be provided between the gas supplier4dand the nozzle3. The mixer4ccan mix the plurality of particles101supplied from the supply controller4band the gas supplied from the gas supplier4dto generate the aerosol102. For example, the mixer4ccan generate the aerosol102by introducing a predetermined amount of the particles101supplied from the supply controller4binto the flow of the gas supplied from the gas supplier4d. In this case, the Venturi effect can be used to draw the plurality of particles101into the gas flow. The aerosol102generated by the mixer4cis introduced into the chamber2via the nozzle3.

Although the above is the case of the solid particles101, the aerosol can be similarly generated in the case of the liquid particles. For example, the liquid may be stored in the container4a, and the Venturi effect may be used in the mixer4cto atomize the liquid and draw the liquid into the gas flow.

The gas supplier4dcan supply a predetermined flow rate of gas to the mixer4c. The gas is not particularly limited as long as it is difficult to react with the processing object100and the particles101. The gas can be, for example, an inert gas such as helium gas or argon gas, nitrogen gas, or air.

The gas supplier4dcan have a gas source4d1, a flow rate controller4d2, and an open/close valve4d3.

The gas source4d1can supply the gas to the flow rate controller4d2. The gas source4d1can be, for example, a cylinder containing a high-pressure gas, a factory pipe for supplying a gas, or the like.

The flow rate controller4d2can control the flow rate of the gas supplied to the mixer4c. The flow rate controller4d2can be, for example, an MFC (Mass Flow Controller) or the like. The flow rate controller4d2may indirectly control the flow rate of gas by controlling the gas supply pressure. In this case, the flow rate controller4d2can be, for example, an APC (Auto Pressure Controller) or the like.

The open/close valve4d3can switch between starting the supply of gas and stopping the supply of gas. The open/close valve4d3can be, for example, a two-way valve or the like. If the flow rate controller4d2has a function of switching between starting the supply of gas and stopping the supply of gas, the open/close valve4d3can be omitted.

The detector5can detect the state of the air flow in the vicinity of the region on which the processing object100is placed inside the chamber2. The detector5is provided outside the chamber2, for example, and can detect the state of the air flow through a window provided on the side surface of the chamber2. The window provided on the side surface of the chamber2can be formed of a translucent material such as glass.

The detector5can directly detect a state of the air flow by detecting the flow velocity of the aerosol102, for example. In this case, the detector5can be, for example, a flow velocity meter or a flow meter. In addition, the detector5can indirectly detect the state of the air flow by detecting the behavior of the plurality of particles101included in the aerosol102. The behavior of the plurality of particles101can be obtained by changing the number of particles101or changing the concentration. In this case, the detector5can be, for example, a particle counter or the like.

The controller6may include an arithmetic part6asuch as a CPU (Central Processing Unit) and a memory part such as a memory. The controller6can be, for example, a computer or the like. The memory part can store the processing program according to the embodiment. Further, the memory part can store the above-mentioned data regarding the steady state of the air flow. The controller6can control the operation of each element provided in the processing system1based on the processing program stored in the memory part and the data regarding the steady state of the air flow. For example, the controller6can control the aerosol supplier4based on the detection value from the detector5. For example, the controller6can control the aerosol supplier4to deposit the plurality of particles101on the surface of the processing object100to form a film.

Here, the data regarding the steady state of the air flow will be described.

The state of the air flow inside the chamber2may change irregularly. For example, when the flow rate or flow velocity of the aerosol102supplied inside the chamber2changes, the state of the air flow inside the chamber2changes irregularly. When the state of the air flow changes, the vortex103is likely to be generated in the air flow. Further, if the flow rate of the aerosol102is increased or the flow velocity of the aerosol102is increased in order to improve productivity, the vortex103is more likely to be generated.

FIG.2is a schematic view for illustrating the vortex103.

As shown inFIG.2, when the vortex103is generated, the streamline104of the air flow becomes lateral around the vortex103. Therefore, even if the concentration of the particles101included in the aerosol102is made substantially constant, the deposition amount of particles, and hence the thickness of the film formed is different below the region where the vortex103is generated and below the region where the vortex103is not generated. That is, an in-plane distribution occurs in the thickness of the formed film.

The generation timing of the vortex103, the generation place of the vortex103, and the behavior of the generated vortex103change irregularly. That is, it is difficult to eliminate the generation of the vortex103, predict the generation time of the vortex103, the generation place of the vortex103, and the behavior of the generated vortex103routinely. In addition, even if a member for suppressing the generation of the vortex103is provided inside the chamber2or a condition for suppressing the generation of the vortex103is obtained by an experiment or the like, if the film forming condition (for example, the flow rate of the aerosol102or the flow velocity, the size, the material, the concentration, etc. of the particles101) changes, the generation of the vortex103cannot be suppressed.

Therefore, in the processing system1according to the embodiment, experiments and simulations are performed to determine the steady state of the air flow in the vicinity of the region where the processing object100is placed inside the chamber2(the state in which the vortex103is not generated).

FIG.3is a graph view for illustrating the steady state of the air flow.

FIG.3exemplifies a change in the flow velocity of the air flow in the vicinity of the region on which the processing object100is placed. The direction of the flow velocity (flow direction) is opposite between the upper side and the lower side of the vertical axis. As can be seen fromFIG.3, if the vortex103is not generated, the direction of the flow velocity is almost constant, and the flow velocity values are about the same. Therefore, such a state can be referred to as a “steady state”. For example, if an experiment or simulation is performed for each film forming condition, it is possible to obtain steady-state data of the air flow corresponding to the film forming condition. The steady-state data may be obtained at any time by machine learning, for example.

For example, the steady-state data of the air flow can be obtained at any time using a recursive neural network. The sampling frequency of the data can be appropriately changed according to the film forming conditions. In this case, if the sampling frequency is increased, more accurate steady-state data of the air flow can be obtained.

The steady-state data of the air flow that is obtained in advance and the steady-state data of the air flow that is obtained at any time by machine learning are stored in the memory part of the controller6and can be used in the film forming process described later.

The steady-state data can be used when detecting the presence or absence of the vortex103.

FIG.4is a graph view for illustrating detection of generation of vortex103.

As can be seen fromFIG.4, when the vortex103is generated, the flow velocity changes greatly. Therefore, if the flow velocity is continuously measured, it can be determined that the vortex103has been generated when the difference between the detected flow velocity and the steady-state flow velocity exceeds a predetermined threshold value. In this case, it is also possible to determine that the vortex103has been generated when the detected value exceeds the predetermined threshold value continuously for a predetermined number of times. By doing so, erroneous detection can be suppressed.

Further, as can be seen fromFIG.4, the vortex103generated over time may disappear. For example, when the greatly changed flow velocity becomes equal to the steady-state flow velocity, it can be determined that the vortex103has disappeared and returned to the steady state. In this case, it is possible to determine that the vortex103has disappeared when the flow velocity that is equal to the steady-state flow velocity is continuously generated a predetermined number of times. By doing so, erroneous detection can be suppressed.

In this case, the controller6can determine the generation and disappearance of the vortex103based on the data regarding the steady state of the air flow stored in the memory part and the detection value from the detector5.

When the controller6determines that the vortex103has been generated, it can control the aerosol supplier4(supply controller4b) to stop the supply of the plurality of particles101. When the supply of the plurality of particles101is stopped, only the gas is supplied to the inside of the chamber2, so that it is possible to suppress the generated vortex103to cause an in-plane distribution in the deposition amount of the plurality of particles101and hence in the thickness of the formed film.

When the controller6determines that the vortex103has disappeared, it can control the aerosol supplier4(supply controller4b) to restart the supply of the plurality of particles101. When the supply of the plurality of particles101is restarted, the aerosol102is supplied into the chamber2, so that the plurality of particles101can be deposited under a steady-state air flow.

That is, according to the embodiment, it is possible to perform film formation when the air flow is in a steady state, to interrupt film formation when the vortex103is generated, and to restart film formation when the generated vortex103disappears. By doing so, even if the generation timing of the vortex103, the generation place of the vortex103, and the behavior of the generated vortex103change irregularly, it is possible to select the time when the air flow is in a steady state to perform film formation. As a result, it is possible to make the deposition amount of the particles101uniform, and thus make the thickness of the formed film uniform.

If the detector5detects the flow velocity at a plurality of positions, the behavior of particles, and the like, the generation place of the vortex103and the behavior of the generated vortex103can be known. Therefore, the controller6can learn the generation time of the vortex103, the generation place of the vortex103, and the behavior of the generated vortex103by machine learning, and use the obtained data to predict the vortex103to be generated next time.

In this case, the accuracy of prediction can be increased by increasing the sampling frequency. For example, if data is acquired every 0.001 seconds, it is possible to accurately predict the state of the air flow after 0.001 seconds to 0.01 seconds.

If the generated vortex103can be predicted, the supply of the plurality of particles101can be stopped and the supply of the plurality of particles101can be restarted quickly. That is, the responsiveness of control can be improved. Therefore, the thickness of the film can be made more uniform.

As described above, when the controller6determines that the vortex103has been generated, it stops supplying the plurality of particles101, but maintains the supply of gas by the gas supplier4d. In this case, the vortex103can be disappeared by stopping the supply of gas by the gas supplier4d, but it takes a long time from the restart of the supply of gas to the steady state of the air flow. In the embodiment, since the supply of gas is maintained, the film formation can be immediately restarted by restarting the supply of the plurality of particles101at the time when the disappearance of the vortex103is detected. Therefore, it is possible to alleviate the lengthening of the film formation time by interrupting the film formation.

When the controller6determines that the vortex103has been generated, it can stop supplying the plurality of particles101and control the flow rate controller4d2to also change the flow velocity of gas. For example, when the vortex103can be disappeared by reducing the flow velocity of gas, the controller6can control the flow rate controller4d2to reduce the flow velocity of gas. For example, when the vortex103can be disappeared by increasing the flow velocity of gas, the controller6can control the flow rate controller4d2to increase the flow velocity of gas.

That is, when the controller6determines that the vortex103is generated, the controller6controls the aerosol supplier4(flow rate controller4d2) to maintain the flow rate of gas or change the flow rate of gas.

The relationship between the flow velocity of gas and the disappearance of the vortex103can be known by performing experiments or simulations in advance. Further, the relationship between the flow velocity of gas and the disappearance of the vortex103may be acquired at any time by machine learning. The relationship between the flow velocity of gas and the disappearance of the vortex103, which is obtained in advance, and the relationship between the flow velocity of gas and the disappearance of the vortex103, which is obtained at any time by machine learning, are stored in the memory part of the controller6, and can be used in the above-described film formation process.

Next, the operation of the processing system1and the processing method and processing program according to the embodiment will be described together with the operation of the processing system1.

First, the processing object100is loaded into the chamber2through the loading/unloading port of the chamber2. The processing object100that has been loaded in can be placed on the bottom surface side of the chamber2. The loading/unloading port of the chamber2is closed by a door.

Next, the controller6controls the gas supplier4dto supply a gas having a predetermined flow rate to the inside of the chamber2via the nozzle3.

After a predetermined time has elapsed and the state of the gas flow inside the chamber2has been stabilized, the controller6controls the supply controller4bto supply a predetermined amount of particles101to the mixer4c. In the mixer4c, the gas and the plurality of particles101are mixed to generate the aerosol102. The generated aerosol102is supplied into the chamber2via the nozzle3.

When the aerosol102reaches the surface of the processing object100inside the chamber2, the plurality of particles101are deposited on the surface of the processing object100and a film is formed.

At this time, the controller6monitors the state of the air flow in the vicinity of the region where the processing object100is placed, based on the detection value from the detector5. For example, the controller6can detect the generation of the vortex103based on the steady state data of the air flow stored in the memory part and the detection value from the detector5.

When the controller6determines that the vortex103is generated, the controller6controls the supply controller4bto stop the supply of the plurality of particles101. In this case, the controller6can maintain the supply of gas by the gas supplier4d. Further, in order to cause the vortex103to disappear, the controller6can control the gas supplier4dto also change the flow rate of gas.

When it is determined that the vortex103has disappeared, the controller6controls the supply controller4bto restart the supply of the plurality of particles101. When the supply of the plurality of particles101is restarted, the aerosol102is supplied into the chamber2, so that the plurality of particles101can be deposited under a steady-state air flow.

The control of the generation and disappearance of the vortex103and the control of the generation of the aerosol102based on the generation and disappearance of the vortex103can be performed in the same manner as described above, and thus detailed description thereof will be omitted.

The processing object100having a film formed on the surface is unloaded to the outside of the chamber2through the loading/unloading port of the chamber2.

As described above, a film based on the plurality of particles101can be formed on the surface of the processing object100.

As described above, the processing method according to the embodiment can include supplying the plurality of particles101and the gas to the processing object100.

Then, in this step, the state of the air flow in the vicinity of the processing object100is detected, and the generation of the vortex103is determined based on the data regarding the steady state of the air flow and the detected value of the state of the air flow, and when it is determined that the vortex103is generated, the supply of the plurality of particles101is stopped.

Further, in this step, the disappearance of the vortex103is determined based on the data regarding the steady state of the air flow and the detected value of the state of the air flow, and when it is determined that the vortex103has disappeared, the supply of the plurality of particles101is restarted.

Further, in this step, when it is determined that the vortex103has been generated, the flow rate of gas is maintained or the flow rate of gas is changed.

Further, in this step, at least one of the generation of the vortex103and the disappearance of the vortex103is predicted using the detected value of the state of the air flow and the prediction model of the recursive neural network.

In addition, in this step, the plurality of particles101is deposited on the surface of the processing object100to form a film.

Moreover, the processing program according to the embodiment can include following steps.

The aerosol supplier4is caused to supply the plurality of particles101and the gas to the processing object100. The detector5is caused to detect the state of the air flow in the vicinity of the processing object100. The arithmetic part6ais caused to determine the generation of the vortex103based on the data regarding the steady state of the air flow and the detected value of the state of the air flow. When the arithmetic part6adetermines that the vortex103has been generated, the supply of the plurality of particles101by the aerosol supplier4is stopped.

Further, the arithmetic part6ais caused to determine the disappearance of the vortex103based on the data regarding the steady state of the air flow and the detected value of the state of the airflow. When the arithmetic part6adetermines that the vortex103has disappeared, the supply of the plurality of particles101by the aerosol supplier4is restarted.

When the arithmetic part6adetermines that the vortex103is generated, the aerosol supplier4maintains the flow rate of gas or changes the flow rate of gas.

Using the detected value of the state of the air flow and the prediction model of the recursive neural network, the arithmetic part6ais caused to predict at least one of the generation of the vortex103and the disappearance of the vortex103.

The aerosol supplier4is caused to supply the plurality of particles101and the gas to deposit the plurality of particles101on the surface of the processing object100to form a film.

The storage medium according to the embodiment is a computer-readable storage medium. The storage medium stores the processing program described above, and causes the computer (controller6) to execute following steps when the processing program is executed by the processor.

Causing the aerosol supplier4to supply the plurality of particles101and the gas to the processing object100.

Causing the detector5to detect the state of the air flow in the vicinity of the processing object100.

Causing the arithmetic part6ato determine the generation of the vortex based on the data regarding the steady state of the air flow and the detected value of the state of the air flow.

Causing the aerosol supplier4to stop the supply of the plurality of particles101when the arithmetic part6adetermines that the vortex has been generated.

The storage medium stores the processing program that causes a computer to further execute following steps.

Causing the arithmetic part6ato determine the disappearance of the vortex103based on the data regarding the steady state of the air flow and the detected value of the state of the air flow.

Causing the aerosol supplier4to restart the supply of the plurality of particles101when the arithmetic part6adetermines that the vortex103has disappeared.

The storage medium stores the processing program that causes a computer to further execute a following step.

Causing the aerosol supplier4to maintain the flow rate of gas or changing the flow rate of gas when the arithmetic part6adetermines that the vortex103is generated.

The storage medium stores the processing program that causes a computer to further execute a following step.

Causing the arithmetic part6ato predict at least one of the generation of the vortex103and the disappearance of the vortex103by using the detected value of the state of the air flow and the prediction model of the recursive neural network.

The storage medium stores the processing program that causes a computer to further execute a following step.

Causing the aerosol supplier4to supply the plurality of particles101and the gas to perform film formation by depositing the plurality of particles101on the surface of the processing object100.

While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the invention. The above embodiments can be practiced in combination with each other.