Patent ID: 12224185

DETAILED DESCRIPTION

Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one of ordinary skill in the art that the present disclosure may be practiced without these specific details. In other instances, well-known methods, procedures, systems, and components have not been described in detail so as not to unnecessarily obscure aspects of the various embodiments.

Embodiments of the present disclosure will be now described in detail with reference to the drawings.

First Embodiments

First, the first embodiments of the present disclosure will be described with reference to the drawings.

(1) Configuration of Substrate Processing Apparatus

FIG.1is a schematic configuration diagram of a substrate processing apparatus according to the first embodiments. As shown inFIG.1, the substrate processing apparatus10is roughly classified into a process module110, and a gas supply part (gas supplier) and a gas exhaust part connected to the process module110.

(Process Module)

The process module110includes a chamber100for performing a predetermined process to the substrate200. The chamber100includes a chamber100aand a chamber100b. That is, the process module110includes a plurality of chambers100aand100b. A partition wall150is installed between the chambers100aand100bsuch that the atmospheres in the chambers100aand100bare not mixed. The detailed structure of the chamber100will be described later.

The substrate200to be processed includes, for example, a semiconductor wafer substrate in which a semiconductor integrated circuit device (semiconductor device) is embedded (hereinafter, also simply referred to as a “substrate” or a “wafer”).

(Gas Supply Part)

The gas supply part (gas supplier) that supplies a process gas or the like to each of the chambers100aand100bis connected to the process module110. The gas supply part includes a first gas supply part, a second gas supply part, and a third gas supply part. Hereinafter, the configuration of each gas supply part will be described.

(First Gas Supply Part)

First process gas supply pipes111aand111bare connected to the chambers100aand100b, respectively, and a first process gas common supply pipe112is connected to the first process gas supply pipes111aand111b. A first process gas source113is disposed on the upstream side of the first process gas common supply pipe112. Mass flow controllers (MFCs)115aand115band process chamber side valves116aand116bare installed between the first process gas source113and the chambers100aand100b, respectively, sequentially from the upstream side. The first gas supply part includes the first process gas common supply pipe112, the MFCs115aand115b, the process chamber side valves116aand116b, and the first process gas supply pipes111aand111bas first gas supply pipes. The first process gas source113may be included in the first gas supply part.

A precursor gas as a first process gas, which is one of the process gases, is supplied from the first process gas source113. Here, a first element is, for example, silicon (Si). That is, the precursor gas is, for example, a silicon-containing gas. Specifically, a hexachlorodisilane (Si2Cl6, abbreviation: HCDS) gas may be used as the silicon-containing gas.

(Second Gas Supply Part)

Second process gas supply pipes121aand121bare connected to the chambers100aand100b, respectively, and a second process gas common supply pipe122is connected to the second process gas supply pipes121aand121b. A second process gas source123is disposed on the upstream side of the second process gas common supply pipe122. Mass flow controllers (MFCs)125aand125band process chamber side valves126aand126bare installed between the second process gas source123and the chambers100aand100b, respectively, sequentially from the upstream side. The second gas supply part (reaction gas supply part) includes the MFCs125aand125b, the process chamber side valves126aand126b, the second process gas common supply pipe122, and the second process gas supply pipes121aand121bas second gas supply pipes. The second process gas source123may be included in the second gas supply part.

A reaction gas as a second process gas, which is one of the process gases, is supplied from the second process gas source123. The reaction gas is, for example, an oxygen-containing gas. Specifically, for example, an oxygen (02) gas is used as the oxygen-containing gas. Here, the first gas supply part and the second gas supply part are collectively referred to as a process gas supply part.

(Third Gas Supply Part)

First inert gas supply pipes131aand131bare connected to the first process gas supply pipes111aand111band the second process gas supply pipes121aand121b. Further, a first inert gas common supply pipe132is connected to the first inert gas supply pipes131aand131b. A first inert gas (purge gas) source133is disposed on the upstream side of the first inert gas common supply pipe132. MFCs135aand135b, process chamber side valves136aand136b, and valves176a,176b,186a, and186bare installed between the first inert gas source133and the chambers100a,100b, respectively, sequentially from the upstream side. The third gas supply part (inert gas supply part) includes the MFCs135aand135b, the process chamber side valves136aand136b, the valves176a,176b,186a, and186b, the first inert gas common supply pipe132, and the first inert gas supply pipes131aand131b. The first inert gas source133may be included in the third gas supply part. Further, the same configuration may be increased or decreased depending on the number of process modules installed in the substrate processing apparatus10.

An inert gas (purge gas) is supplied from the first inert gas source133. For example, a nitrogen (N2) gas is used as the inert gas.

(Gas Exhaust Part)

The gas exhaust part that exhausts an internal atmosphere of the chamber100aand an internal atmosphere of the chamber100bis connected to the process module110. Specifically, a process chamber exhaust pipe224is connected to the chamber100a, and a process chamber exhaust pipe226is connected to the chamber100b. That is, a plurality of process chamber exhaust pipes224and226are individually connected to a plurality of chambers100arespectively.

A common gas exhaust pipe225is connected to the process chamber exhaust pipes224and226. That is, the common gas exhaust pipe225is disposed on the downstream side of the process chamber exhaust pipes224and226so as to merge the process chamber exhaust pipes224and226. As a result, the process chamber exhaust pipe224and the process chamber exhaust pipe226are merged at a merging portion230at the downstream end and further connected to the common gas exhaust pipe225.

An exhaust pump223is disposed on the downstream side of the common gas exhaust pipe225. An auto pressure controller (APC; also called a pressure-adjusting valve)222, a valve221, and valves228aand228bare installed between the exhaust pump223and the chambers100aand100b, respectively, sequentially from the downstream side. The gas exhaust part includes the APC222, the valve221, the valves228aand228b, the process chamber exhaust pipes224and226, and the common gas exhaust pipe225. In this way, the internal atmosphere of the chamber100aand the internal atmosphere of the chamber100bare exhausted by one exhaust pump223.

The process chamber exhaust pipe224is installed with a pressure detector227a. The pressure detector227adetects an internal pressure of the process chamber exhaust pipe224and can be configured by using, for example, a pressure sensor.

Further, the process chamber exhaust pipe226is installed with a pressure detector227b. The pressure detector227bdetects an internal pressure of the process chamber exhaust pipe226and can be configured by using, for example, a pressure sensor. A second inert gas supply pipe141bis connected to the upstream side of the pressure detector227bin the process chamber exhaust pipe226. Any one of the pressure detectors227aand227b, or a combination thereof, may be referred to as an exhaust pipe pressure detector.

(Chamber)

Subsequently, the detailed structure of the chambers100aand100bin the process module110will be described. Here, since each of the plurality of chambers100aand100bhas the same configuration, one chamber100a(hereinafter, simply referred to as a chamber100) will be described as an example.

FIG.2is a configuration diagram of a chamber of the substrate processing apparatus according to the first embodiments. The chamber100is made of, for example, a metal material such as aluminum (Al) or stainless steel (SUS) and is configured as a flat and airtight process container (airtight container)302having a circular cross section. The airtight container302includes an upper container302aand a lower container302b, and a partition plate308is installed between the upper container302aand the lower container302b. A substrate-loading/unloading port148adjacent to a gate valve149is installed on the side surface of the lower container302b, and the substrate200moves between the interior of the lower container302band a vacuum transfer chamber (not shown) via the substrate-loading/unloading port148. A plurality of lift pins307are installed at the bottom of the lower container302b.

A substrate support310for supporting the substrate200is installed in the chamber100configured as the airtight container302. The substrate support310mainly includes a substrate-mounting surface311on which the substrate200is mounted, a substrate-mounting table312including the substrate-mounting surface311on the surface of the substrate-mounting table312, and a heater313as a heating source included in the substrate-mounting table312. The substrate-mounting table312is installed with through-holes314through which the lift pins307penetrate at positions corresponding to the lift pins307, respectively.

The substrate-mounting table312is supported by a shaft317. A support of the shaft317penetrates a hole installed in the bottom wall of the chamber100and is further connected to an elevating mechanism318outside the chamber100via a support plate316. By operating the elevating mechanism318to raise and lower the shaft317and the substrate-mounting table312, it is possible to raise and lower the substrate200mounted on the substrate-mounting surface311. Further, the circumference of the lower end of the shaft317is covered with a bellows319, whereby the interior of the chamber100is kept airtight.

When the elevating mechanism318raises the substrate-mounting table312, the substrate-mounting table312is located at a substrate-processing position shown inFIG.2. In the substrate-processing position, the lift pins307are buried from the upper surface of the substrate-mounting surface311so that the substrate-mounting surface311supports the substrate200from below. When processing the substrate200, the substrate-mounting table312is maintained at the substrate-processing position. Further, when the elevating mechanism318lowers the substrate-mounting table312, the substrate-mounting table312is located at a substrate transfer position (see a broken line inFIG.1) at which the substrate-mounting surface311faces the substrate-loading/unloading port148. In the substrate transfer position, the upper ends of the lift pins307protrude from the upper surface of the substrate-mounting surface311so that the lift pins307support the substrate200from below.

A process space305for processing the substrate200and a transfer space306through which the substrate200passes when the substrate200is transferred to the process space305are formed in the chamber100.

The process space305is a space formed between the substrate-mounting table312at the substrate-processing position and a ceiling330of the chamber100. The structure constituting the process space305is also referred to as a process chamber301. That is, the process space305is installed in the process chamber301.

The transfer space306is a space mainly formed of the lower container302band the lower structure of the substrate-mounting table312at the substrate-processing position. The structure constituting the transfer space306is also referred to as a transfer chamber. The transfer chamber is disposed below the process chamber301. It goes without saying that the transfer chamber is not limited to the above structure, but may be any structure as long as it constitutes the transfer space306.

The first process gas supply pipes111of the first gas supply part and the second process gas supply pipes121of the second gas supply part are connected to the ceiling330facing the process space305. More specifically, the first process gas supply pipe111aand the second process gas supply pipe121aare connected to the ceiling330in the chamber100a, and the first process gas supply pipe111band the second process gas supply pipe121bare connected to the ceiling330in the chamber100b. As a result, the first process gas, the second process gas, or the inert gas is supplied into the process space305.

The process chamber exhaust pipes224and226of the gas exhaust part are connected to a sidewall portion of the airtight container302facing the process space305. More specifically, the process chamber exhaust pipe224is connected to the sidewall portion of the airtight container302in the chamber100a, and the process chamber exhaust pipe226is connected to the sidewall portion of the airtight container302in the chamber100b. As a result, a gas supplied into the process space305is exhausted through the process chamber exhaust pipes224and226.

(Controller)

The substrate processing apparatus10has a controller380as a control part (control means) that controls the operations of various parts of the substrate processing apparatus10.

FIG.3is a configuration diagram of the controller of the substrate processing apparatus according to the first embodiments. The controller380is configured as a computer including at least an arithmetic part (CPU)380a, a temporary memory (RAM)380b, a memory380c, a transmitting/receiving part380d, and a timer380e. The controller380is connected to each configuration of the substrate processing apparatus10via the transmitting/receiving part380d, calls a program or a recipe from the memory380caccording to an instruction from a user who operates a host device370or an input/output device381connected via the transmitting/receiving part383, and controls the operation of each configuration according to the contents the program or the recipe. A notification part384includes, for example, a display, a microphone, and the like and notifies notification information based on the contents of a control information memory395.

The arithmetic part380ahas a calculation part391that calculates at least a pressure-rising speed value (pressure gradient value). The calculation part391obtains the pressure-rising speed value of pressure fluctuation based on a pressure fluctuation value detected by the pressure detector227during a period of time T1.

The memory380cincludes a pressure-recording part392, a comparison data memory393, a table394, and the control information memory395. The timer380ecounts the time taken for the pressure detector227to detect pressures of the exhaust pipes224and226in a pressure-rising-speed-value-calculating step S110to be described later.

The pressure-recording part392records a pressure value detected by each of the pressure detectors227aand227b. The pressure value is recorded, for example, every time one substrate is processed. The calculation part391calculates a pressure-rising speed value based on the detected pressure value and the detected time.

The comparison data memory393stores comparison data to be compared with the pressure-rising speed value calculated by the calculation part391. The comparison data is a preset value, for example, a pressure-rising speed value when the substrate processing apparatus10operates normally. The comparison data may be data updated after processing the substrate200. In this case, for example, the highest quality data is used as the comparison data. Here, the highest quality data is, for example, the data with the least pressure fluctuation.

As shown inFIG.4, the table394shows operations based on information comparing the calculated pressure-rising speed value and the comparison data and a difference between pressure-rising speed values calculated by the pressure detectors, further details of which will be described later.

The controller380may be configured as a dedicated computer or a general-purpose computer. For example, the controller380according to the present embodiments can be configured by preparing an external memory (for example, a magnetic tape, a magnetic disk such as a flexible disk or a hard disk, an optical disc such as a CD or a DVD, a magneto-optical disc such as a MO, a semiconductor memory such as a USB memory (USB Flash Drive) or a memory card, etc.)382that stores the above-mentioned program and installing the program on the general-purpose computer by using the external memory382.

Further, a means for supplying the program to the computer is not limited to the case of supplying the program via the external memory382. For example, a communication means such as the Internet or a dedicated line may be used to supply the program to the computer, or the program may be supplied by receiving information from the host device370via the transmitting/receiving part383without going through the external memory382. Further, the controller380may be instructed by using an input/output device381such as a keyboard or a touch panel.

Further, the memory380cand the external memory382may be configured as a non-transitory computer-readable recording medium. Hereinafter, these are also collectively referred simply to as a recording medium. When the term “recording medium” is used in the present disclosure, it may indicate a case of including the memory380conly, a case of including the external memory382only, or a case of including both the memory380cand the external memory382.

(2) Procedure of Substrate-Processing Process

Next, the procedure of the substrate-processing process performed by using the substrate processing apparatus10including the above-described configuration will be described. The substrate-processing process is performed as a process of manufacturing a semiconductor device and is for performing a predetermined process to the substrate200to be processed. In the following description, as the predetermined process, an example in which a HCDS gas is used as the first process gas and an O2gas is used as the second process gas to form a film on the surface of the substrate200will be described. Here, it is assumed that an alternate supplying process of alternately supplying different process gases is performed.

When the term “wafer” is used in the present disclosure, it may refer to “a wafer itself” or “a wafer and a stacked body of certain layers or films formed on a surface of the wafer.” When the phrase “a surface of a wafer” is used in the present disclosure, it may refer to “a surface of a wafer itself” or “a surface of a certain layer formed on a wafer.” When the expression “a certain layer is formed on a wafer” is used in the present disclosure, it may mean that “a certain layer is formed directly on a surface of a wafer itself” or that “a certain layer is formed on a layer formed on a wafer.” When the term “substrate” is used in the present disclosure, it may be synonymous with the term “wafer.”

Hereinafter, the substrate-processing process will be described with reference toFIGS.5to7.FIG.5illustrates the entire procedure of the substrate-processing process.FIG.6is a diagram for explaining an operating state of each part in each of the chambers100aand100bin the substrate-processing process shown inFIG.5.FIG.7illustrates the details of a film-processing step S106in the substrate-processing process.

In the following description, the operations of various parts constituting the substrate processing apparatus10are controlled by the controller380.

In the substrate-processing process, first, a substrate-loading/mounting step is performed. This step is not shown inFIG.5. In the substrate-loading/mounting step, the substrate-mounting table312in the chamber100is lowered to the substrate transfer position, and the lift pins307is passed through the through-holes314of the substrate-mounting table312. As a result, the lift pins307are in a state of protruding from the surface of the substrate-mounting table312by a predetermined height. Then, in that state, the gate valve149is opened to communicate the transfer space306with the vacuum transfer chamber (not shown), and the substrate200is loaded from the vacuum transfer chamber into the transfer space306by using a substrate transfer device (not shown) and is transferred onto the lift pins307. As a result, the substrate200is supported in a horizontal posture on the lift pins307protruding from the surface of the substrate-mounting table312.

(Substrate-Processing-Position-Moving Step: S102)

A substrate-processing-position-moving step S102will be described. After the substrate200is loaded into the chamber100, the substrate transfer device is retracted to the outside of the chamber100, and the gate valve149is closed to seal the interior of the chamber100. After that, the substrate200is mounted on the substrate-mounting surface311by raising the substrate-mounting table312, and the substrate-mounting table312is further raised to the substrate-processing position to locate the substrate200on the substrate-mounting surface311in the process space305.

At this time, electric power is supplied to the heater313embedded inside the substrate-mounting table312to control the surface of the substrate200on the substrate-mounting surface311to have a predetermined temperature. The temperature of the substrate200is, for example, the room temperature or higher and 800 degrees C. or lower, specifically the room temperature or higher and 500 degrees C. or lower. At that time, the temperature of the heater313is adjusted by the controller380to extract a control value based on temperature information detected by a temperature sensor (not shown) and control a degree of supplying electric power to the heater313.

In this step, as shown inFIG.6, without supplying the first process gas and the second process gas from the chambers100aand100b, respectively, an inert gas is supplied from the third gas supply part. Furthermore, the exhaust pump223is operated. At this time, the operations of the APC222, the pressure detectors227aand227b, and the timer380emay be stopped.

While the substrate-mounting table312moves to the substrate-processing position, the process chamber301of each chamber100is set to have an inert gas atmosphere so that dust and the like generated when the substrate-mounting table312moves does not enter into the process chamber301.

It is assumed that the operations in the substrate-loading/mounting step and the substrate-processing-position-moving step S102are performed in the same manner in each of the chambers100aand100b.

(First Pressure-Adjusting Step: S104)

A first pressure-adjusting step S104will be described. When the substrate200moves to the substrate-processing position, the internal pressure of the process chamber301is adjusted to a predetermined pressure. The predetermined pressure is, for example, a pressure in a first process-gas-supplying-step S202of the film-processing step S106. Therefore, here, the pressure is lowered. Here, as shown inFIG.6, for example, the third gas supply part is operated to supply the inert gas to the process chamber301, and the exhaust pump223is operated to set the process chamber301to an inert gas atmosphere. At this time, the opening degree of the APC222is adjusted and fixed. Further, the pressure detectors227aand227bmay also be operated, and the pressure of each process chamber301may be adjusted based on detection data.

(Film-Processing Step: S106)

Next, the film-processing step S106will be described. In the film-processing step S106, gases are supplied from the first gas supply part and the second gas supply part, respectively, to perform a process to the substrate200. Then, when the process is completed, the substrate200is unloaded from the chamber100. This operation is performed repeatedly for a predetermined number of substrates200. Details of this film-processing step S106will be described later. When the film-processing step S106is completed, the supply of the process gases from the first gas supply part and the second gas supply part is stopped. The supply of the inert gas from the third gas supply part may be stopped or continued. In this step, the opening degree of the APC222is fixed for the reason to be described later.

(Details of Film-Processing Step S106)

Subsequently, the details of the film-processing step S106will be described with reference toFIG.7.

(First Process-Gas-Supplying Step: S202)

The first process-gas-supplying step S202will be described. When the substrate200in the process space305reaches a predetermined temperature, first, the first process-gas-supplying step S202is performed. In the first process-gas-supplying step S202, the valves116aand116bare opened, and the MFCs115aand115bare adjusted so that a HCDS gas has a predetermined flow rate. The supply flow rate of the HCDS gas is set to, for example, 100 sccm or more and 800 sccm or less. At this time, a N2gas is supplied from the third gas supply part. The N2gas supplied from the third gas supply part is used as a carrier gas for the HCDS gas.

Further, in the first process-gas-supplying step S202, the valves221,228a, and228bare opened, and the opening degree of the APC222is adjusted while operating the pump223, so that the internal pressure of the chamber100becomes a desired pressure. Specifically, the pressure of each of the process space305and the transfer space306is controlled to be, for example, a predetermined value within the range of 50 to 300 Pa. The predetermined value is, for example, 250 Pa.

In the process space305to which the HCDS gas is supplied, the HCDS gas is decomposed into silicon components and the like by heat and is supplied onto the substrate200. As a result, a silicon-containing layer as a “first element-containing layer” is formed on the surface of the substrate200. The silicon-containing layer corresponds to a precursor of a thin film to be formed.

Then, after a predetermined time has elapsed from the start of this step, the valves116aand116bare closed to stop the supply of the HCDS gas.

(First Purging Step: S204)

A first purging step S204will be described. After the completion of the first process-gas-supplying step S202, the first purging step S204is then performed. In the first purging step S204, with the valves136a,136b,176a, and176bfixed at the open state, the valves186aand186bare further opened to supply a N2gas to the process space305, and the exhaust by the pump223or the like is continued to purge the atmosphere.

Then, after a predetermined time has elapsed from the start of this step, the valves136aand136bare closed to stop the purging of the atmosphere by the supply of the N2gas.

(Second Process-Gas-Supplying Step: S206)

A second process-gas-supplying step S206will be described. After closing the valves136aand136bto complete the first purging step S204, the second process-gas-supplying step S206is then performed. In the second process-gas-supplying step S206, the valves126aand126bare opened, the flow rate of an O2gas is adjusted by the MFCs125aand125b, and the supply of the O2gas into the process space305is started. The supply flow rate of the O2gas is set to, for example, 100 sccm or more and 6,000 sccm or less. At this time, the valves136aand136bare opened to supply a N2gas from the third gas supply part. The N2gas supplied from the third gas supply part is used as a carrier gas or a dilution gas for the O2gas.

Further, in the second process-gas-supplying step S206, as in the case of the first process-gas-supplying step S202, the exhaust by the pump223or the like is continued so that the internal pressure of the chamber100becomes a desired pressure.

The O2gas supplied to the process space305is decomposed by heat. In the process space305, the decomposed O2gas is supplied onto the substrate200. As a result, the silicon-containing layer is modified by the O2gas so that a thin film composed of a layer containing a silicon element and an oxygen element is formed on the surface of the substrate200.

Then, after a predetermined time has elapsed from the start of this step, the valves126aand126bare closed to stop the supply of the O2gas.

(Second Purging Step: S208)

A second purging step S208will be described. After the completion of the second process-gas-supplying step S206, the second purging step S208is then performed. In the second purging step S208, as in the first purging step S204, a N2gas is supplied from the first inert gas supply pipes131aand131bto purge the atmosphere of the process space305.

Then, after a predetermined time has elapsed from the start of this step, the valves136aand136bare closed to stop the purging of the atmosphere by the supply of the N2gas.

(Determining Step: S210)

A determining step S210will be described. When the second purging step S208is completed, the controller380determines whether or not one cycle including the first process-gas-supplying step S202, the first purging step S204, the second process-gas-supplying step S206, and the second purging step S208, which are sequentially performed, has been performed a predetermined number of times (n cycles).

When the cycle has not been performed a predetermined number of times (“No” in S210), the cycle including the first process-gas-supplying step S202, the first purging step S204, the second process-gas-supplying step S206, and the second purging step S208are repeated. When the cycle has been performed a predetermined number of times (“Yes” in S210), the series of steps shown inFIG.7is completed.

By the way, the opening degree of the APC222is fixed during the first process-gas-supplying step S202to the second purging step S208, as shown inFIG.6. Here, the reason for this will be explained.

In the present embodiments, the first process-gas-supplying step S202to the second purging step S208are continuously performed, but in consideration of a throughput, each step is performed in a very short period of time. For example, it takes less than 60 seconds, specifically about 50 seconds, from the first process-gas-supplying step S202to the second purging step S208.

This is the time that can be realized because the volume of the process chamber301is small. For example, as a comparative example, there is a vertical apparatus having a large volume for the process chamber. When the first process-gas-supplying step S202to the second purging step S208are performed in the vertical apparatus, the time for filling the process chamber with a gas or the time for discharging a gas from the process chamber is longer than in the present embodiments due to the large volume. For example, it takes about 120 seconds.

Since the process chamber301of the present embodiments has a smaller volume than the vertical apparatus which is the comparative example, the amount of gas supplied into the process chamber301can be smaller than that of the vertical apparatus. Therefore, in the first process-gas-supplying step S202and the second process-gas-supplying step S206, the gas can be filled more quickly than in the vertical apparatus, and further, in the first purging step S204and the second purging step S208, the atmosphere of the process chamber301can be more quickly exhausted than in the vertical apparatus.

By the way, since the gas is replaced in each step as described above, the pressure of the process chamber301may be adjusted in each step. It is conceivable that the pressure is adjusted by using an APC, for example, as in the first pressure-adjusting step S104. However, it is technically difficult to adjust the opening degree of the APC in a short time. Therefore, if the pressure is adjusted for each step by using the APC, the throughput will be significantly reduced.

Under such circumstances, in the substrate processing apparatus10of the present embodiments, the opening degree of the APC222is fixed during the first process-gas-supplying step S202to the second purging step S208. Further, even when a plurality of substrates are continuously processed, it is preferable to fix the opening degree of the APC222from the viewpoint of improving the throughput. That is, the opening degree of the APC222is fixed during A inFIG.5.

Further, in the apparatus of the present embodiments, since the opening degree of the APC222is fixed as described above, the diameters of the exhaust pipes224and226are set to be very thin, for example, 20 to 30 mm. With such a configuration, since the pressures of the exhaust pipes224and226can be accurately detected, even when the opening degree of the APC222is fixed, the pressure can accurately adjusted by the cooperation of the gas supply part and the exhaust pump.

(Second Pressure-Adjusting Step: S108)

Next, a second pressure-adjusting step S108will be described. After the film-processing step S106is completed, the internal pressure of the process chamber301is adjusted. For example, the internal pressure of the process chamber301is raised from a vacuum level pressure.

Specifically, while the supply of process gases from the first gas supply part and the second gas supply part is stopped, an inert gas is supplied from the third gas supply part to each process chamber301, and the exhaust flow rate of the inert gas is adjusted by the exhaust pump223to raise the internal pressure of the process chamber301. The inert gas supplied from the third gas supply part is supplied to each process chamber301at the same flow rate.

(Pressure-Rising-Speed-Calculating Step: S110)

Next, a pressure-rising-speed-calculating step S110will be described. The pressure-rising-speed-calculating step S110is a step performed in parallel with the second pressure-adjusting step S108. In the pressure-rising-speed-calculating step S110, the pressure at the exhaust pipes224and226is detected. Here, after the lapse of time T1after the pressure detection is started, the pressure detection is stopped and a pressure-rising speed value is calculated. For example, the pressure-rising speed value is calculated from a pressure value when the pressure detection is started and a pressure value detected after the time T1. The time T1is counted by the timer380e. In this step, the opening degree of the APC222is fixed for the reason to be described above.

The pressure detectors227aand227bstart detecting the pressure after the inert gas passes through connection portions with the exhaust pipes224and226. The measurement time is counted by the timer380e, and the detection is stopped after the lapse of time T1.

The time T1is a time during which the pressure-rising speed value can be detected, and is a time set before the pressure reaches a target pressure. Next, the reason for this will be explained.

As a method of detecting the pressure, it is conceivable to momentarily detect the pressure only once in a shorter time than T1or detect the pressure after time T1. However, when the pressure is detected momentarily only once, the pressure cannot be detected accurately if an exhaust flow is unstable.

Further, as a case of detecting the pressure after time T1, it is considered, for example, that the pressures of the process chamber100aand the process chamber100breach a target pressure. In this case, since the pressures have reached the target pressure in both the process chambers, the pressure in the exhaust pipe224becomes equal to the pressure in the exhaust pipe226. Therefore, since the pressure-rising speed in the exhaust pipe224becomes equal to that in the exhaust pipe226, it is unknown which of the pipes is clogged.

On the other hand, as in the present embodiments, when the pressure detection is completed before the pressure reaches the target pressure, it can be known which of the exhaust pipe224and the exhaust pipe226is clogged. For example, a pipe without being clogged has a larger pressure-rising speed value than that of a pipe being clogged.

Further, it is preferable that the pressure detectors227aand227bhave the same detection start time and detection end time and detect the pressures in parallel. By doing so, the pressure-rising speed value can be detected in each of the exhaust pipes224and226under the same exhaust conditions. Therefore, an accurate comparison can be made in a process-setting step S112to be described later.

Further, since this step is performed between the film-processing step S106and a substrate-replacing step S118to be described later, it is performed between the time when the supply of process gas to the process chamber is stopped and the time when the substrate is unloaded from the process chamber.

Further, since this step is performed between the film processing step S106and a substrate-transfer-position-moving step S114to be described later, it is performed between the time when the supply of process gas to the process chamber is stopped and the time when the substrate moves to the substrate transfer position.

Further, since this step is performed before the substrate-replacing step S118, it is performed before the substrate200is unloaded from the process chamber301.

Further, since this step is performed before the substrate-replacing step S118, the pressure detector227stops the pressure detection before the process gas is supplied from the process gas supply part into the process chamber301. At this time, the pressure detection of the pressure detectors227aand227binstalled in the exhaust pipes224and226of the respective process chambers is stopped.

(Process-Setting Step: S112)

Subsequently, the process-setting step S112will be described. When the second pressure-adjusting step S108and the pressure-rising-speed-calculating step S110are completed, the process proceeds to the process-setting step S112.

The pressure-rising speed value calculated in the pressure-rising-speed-calculating step S110is recorded in the pressure-recording part392. The pressure-rising speed value recorded in the pressure-recording part392is compared with the comparison data stored in the comparison data memory393. In addition, the data detected by the pressure detectors are compared with each other. Based on this, the subsequent operation of the substrate processing apparatus10is set.

As the type of comparison, the pressure-rising speed value calculated for each pressure detector is compared with the comparison data, and differences between the pressure-rising speed values calculated by the pressure detectors are compared with each other.

Further, as illustrated inFIG.4, in the comparison between the pressure-rising speed value calculated for each pressure detector and the comparison data, for example, an operation is set for each of three levels, level a, level b, and level c. For example, level a has a divergence of 0 to 5%, level b has a divergence of 6 to 10%, and level c has a divergence of 11% or more.

Here, when the pressure-rising speed value is level a, it is determined that there is no problem, and the setting is maintained to process the next substrate. When the pressure-rising speed value is level b, it is determined that clogging of the exhaust pipe may affect the substrate processing if the process is continued as it is, and the notification part384notifies to that effect. At this time, for example, a substrate to be processed next or a substrate in a lot to be processed next may not be loaded into the substrate processing apparatus10. Further, here, a message prompting maintenance (for example, cleaning or replacement) of the exhaust pipe may be notified. Further, when the pressure-rising speed value is level c, it is determined that the substrate processing cannot be continued any more, and the process is stopped. By setting the subsequent process in this way, it is possible to prevent defective substrates from being output.

Further, the pressure-rising speed value of the exhaust pipe224calculated based on the data detected by the pressure detector227amay be compared with the pressure-rising speed value of the exhaust pipe226calculated based on the data detected by the pressure detector227b. In this case, the differences between the pressure-rising speed values are calculated. The differences are, for example, four levels, level α, level β, level γ, and level δ, and an operation is set for each level.

For example, level α has a divergence of 0 to 3%, level β has a divergence of 4 to 6%, level γ has a divergence of 7 to 10%, and level δ has a divergence of 11% or more. When the difference is level α, it is determined that there is no problem, and the process is continued to process the next substrate.

When the difference is level β and both the pressure detectors are at level α, it can be determined that the entire exhaust pipe does not meet a desired exhaust capacity, although there is no clogging. In that case, the APC222is readjusted before the next substrate200is loaded. The readjustment is performed, for example, in a third pressure-adjusting step S122.

When the difference is level γ, it is determined that clogging of the exhaust pipe may affect the substrate processing if the process is continued as it is, and the notification part384notifies to that effect. At this time, for example, a substrate to be processed next or a substrate in a lot to be processed next may not be loaded into the substrate processing apparatus10. Further, here, a message prompting maintenance (for example, cleaning or replacement) of the exhaust pipe may be notified. Further, when the difference is level δ, it is determined that the substrate processing cannot be continued any more, and the process is stopped. By setting the subsequent process in this way, it is possible to prevent defective substrates from being output.

In the present embodiments, since it is possible to make determination before the next substrate200is loaded, the occurrence of defective substrates can be reduced.

(Substrate-Transfer-Position-Moving Step S114)

The substrate-transfer-position-moving step S114will be described. In the substrate-transfer-position-moving step S114, the substrate-mounting table312in the chamber100is lowered to the substrate transfer position, and the substrate200is supported on the lift pins307protruding from the surface of the substrate-mounting table312. As a result, the substrate200is transferred from the substrate-processing position to the substrate transfer position.

(Determining Step: S116)

Subsequently, a determining step S116will be described. In the determining step S116, it is determined whether or not a predetermined number of substrates200have been processed. When it is determined that the predetermined number of substrates200have been processed, the process is completed via a substrate-unloading step (not shown). When it is determined that the predetermined number of substrates200have not been processed, the process proceeds to the substrate-replacing step S118.

(Substrate-Replacing Step: S118)

Subsequently, the substrate-replacing step S118will be described. When it is determined in the determining step S116that the predetermined number of substrates200have not been processed, the processed substrate200is replaced with an unprocessed substrate200to be processed. The unprocessed substrate200is made to stand by on the lift pins207as described above.

(Substrate-Processing-Position-Moving Step: S120)

Subsequently, a substrate-processing-position-moving step S120will be described. The substrate200on standby on the lift pins207is moved to the substrate-processing position in the same manner as in the substrate-processing-position-moving step S102.

(Third Pressure-Adjusting Step: S122)

Subsequently, the third pressure-adjusting step S122will be described. Here, with the opening degree of the APC222fixed, the internal pressure of the process chamber301is adjusted in the same manner as in the first pressure-adjusting step S104. After adjusting the pressure, the process proceeds to the film-processing step S106where the film processing of the unprocessed substrate200is performed.

A dotted line region A shown inFIG.5indicates a region surrounding the steps in a state where the opening degree of the APC222is fixed. In this way, the opening degree of the APC222is fixed from the film-processing step S106to the third pressure-adjusting step S122.

(Substrate-Unloading Step)

A substrate-unloading step will be described. This step is not shown inFIG.5. When the substrate200is moved to the substrate transfer position, the gate valve149is opened and the substrate200is unloaded out of the chamber100by using the substrate transfer device (not shown).

Second Embodiments

Next, the second embodiments of the present disclosure will be described with reference toFIG.8.FIG.8is a flow chart of a substrate-processing process according to the second embodiments. A difference from the first embodiments is that a pressure-rising-speed-calculating step S302is performed in parallel with the third pressure-adjusting step S122, and the process-setting step is performed before the film-processing step S106. Other points are the same as in the case of the first embodiments. Hereinafter, the difference will be mainly described.

In the second embodiments, the pressure-rising-speed-calculating step S302is performed in parallel with the third pressure-adjusting step S122. Here, the pressure-rising speed values of the exhaust pipes224and226are calculated in the same manner as in the pressure-rising-speed-calculating step S110of the first embodiments.

Specifically, this is as follows.

(Pressure-Rising-Speed-Calculating Step: S302)

The pressure-rising-speed-calculating step S302will be described. In the pressure-rising-speed-calculating step S302, the pressure of each of the exhaust pipes224and226is detected for a predetermined time, and a pressure-rising speed value of the pressure is calculated. For the same reason as in the first embodiments, the opening degree of the APC222is fixed.

First, an inert gas is supplied from the third gas supply part into the process chamber301in a state where the supply of the process gas from the first gas supply part and the second gas supply part is stopped. At this time, the exhaust pump223is in operation following the first pressure-adjusting step S104. The supplied inert gas passes through each process chamber301, the exhaust pipes224and226, and the common gas exhaust pipe225to make the interior of each process chamber to an inert gas atmosphere.

The pressure detectors227aand227bstart measurement when the inert gas begins to pass through the connection parts with the exhaust pipes224and226. The measurement time is counted by the timer380e, and the measurement is stopped after the lapse of a predetermined time. The detected pressure is recorded in the pressure-recording part392. By detecting before proceeding to the film-processing step S106, the pressure can be detected in a more stable state.

The calculation part391calculates a pressure-rising speed value from a pressure value measured at the start of counting of the timer380e, a pressure value measured after the lapse of time T2from the start of counting, and the time T2. For example, the pressure-rising speed value is calculated based on the degree of pressure rise in a predetermined time.

Here, the reason for detecting the pressure during the limited time T2, instead of simply detecting the pressure, will be explained. As a method of detecting the pressure, it is conceivable to momentarily detect the pressure only once in a shorter time than T2or detect the pressure after time T2. However, when the pressure is detected momentarily only once, the pressure cannot be detected accurately if an exhaust flow is unstable.

Further, as a case of detecting after time T2, it is considered, for example, that the atmosphere is completely exhausted in either the process chamber100aor the process chamber100b. In this case, since the exhausting atmosphere changes between the exhaust pipe224and the exhaust pipe226, it is not possible to compare the pressures measured in the pipes.

On the other hand, as in the present embodiments, when the pressure detection is completed before the atmosphere is completely exhausted in any of the process chambers, since the exhaust pipe224and the exhaust pipe226have the same atmosphere, the comparison conditions can be the same. Therefore, an accurate comparison can be made in a process-setting step S304to be described later.

Further, since this step is performed between the substrate-replacing step S118and the film-processing step S106, it can be said that this step is performed between the time when the substrate200is loaded into the process chamber301and the time when a process gas is started to be supplied into the process chamber301.

Further, since this step is performed before the film-processing step S106, the pressure detector227stops the pressure detection before the process gas is supplied from the process gas supply part into the process chamber301. At this time, the pressure detection of the pressure detectors227aand227binstalled in the exhaust pipes224and226of the respective process chambers is stopped.

(Process-Setting Step: S304)

Subsequently, the process-setting step S304will be described. The calculated pressure-rising speed value is recorded in the pressure-recording part392. The pressure-rising speed value recorded in the pressure-recording part392is compared with the comparison data stored in the comparison data memory393. In addition, the data detected by the pressure detectors are compared with each other. The operation of the substrate processing apparatus10is selected based on the comparison result. Here, the determination is made in the same manner as in the first embodiments.

In the present embodiments, since the determination can be made in the state where the substrate200is loaded into the process chamber, the pressure of the exhaust pipe can be detected more accurately. Therefore, the state of clogging can be accurately grasped, and as a result, the number of defective substrates can be reduced.

Here, a vertical apparatus will be described as a comparative example. Since the vertical apparatus has a longer time of one cycle than the apparatus of the present embodiments and further processes a plurality of substrates at once, even if the processing time is long by using an APC, the productivity is not significantly reduced. Therefore, the APC is not fixed in the vertical apparatus.

Further, in the case of the vertical apparatus, since the volume of the process chamber is large, the diameter of the exhaust pipe is set to, for example, about 100 mm in order to quickly purge the atmosphere of the process chamber. Therefore, unlike the present embodiments, it is difficult to accurately detect the pressure of the exhaust pipe, which forces the pressure to be adjusted by using an APC.

Under such circumstances, it is difficult to realize the present embodiments with the configuration of the vertical apparatus.

OTHER EMBODIMENTS

Although the first embodiments and the second embodiments of the present disclosure have been described above, the present disclosure is not limited to the above-described embodiments, but various changes can be made without departing from the gist thereof.

In the above-described embodiments, the method of alternately supplying the precursor gas and the reaction gas to form a film has been described. However, the present disclosure can be applied to other methods only if the vapor phase reaction amount of the precursor gas and the reaction gas and the amount of by-products generated are within a permissible range. One example of such methods is to overlap the supply timings of the precursor gas and the reaction gas.

Further, in the above-described embodiments, the example of forming the silicon oxide film by using the silicon-containing gas as the precursor gas and the oxygen-containing gas as the reaction gas has been shown, but the present disclosure can also be applied to film formation where other gases are used. For example, there are an oxygen-containing film, a nitrogen-containing film, a carbon-containing film, a boron-containing film, a metal-containing film, a film containing two or more of these elements, and the like. Examples of these films may include a SiN film, an AlO film, a ZrO film, a HfO film, a HfAlO film, a ZrAlO film, a SiC film, a SiCN film, a SiBN film, a TiN film, a TiC film, a TiAlC film, and the like. By comparing the gas characteristics (adsorption, desorption, vapor pressure, etc.) of a precursor gas and a reaction gas used to form these films and appropriately changing the supply position and the structure of the process chamber, the same effects can be obtained.

Further, in the above-described embodiments, the N2gas has been described as an example of the inert gas, but the inert gas is not limited thereto but may be any gas as long as it cannot react with the process gas. For example, a rare gas such as a helium (He) gas, a neon (Ne) gas, or an argon (Ar) gas can be used as the inert gas.

Further, in the above-described embodiments, it has been described that the operation of each of the parts is stopped, but this does not necessarily mean that the operation of the entire parts is stopped. For example, the description that the operation of the gas supply is stopped means that a gas is not supplied to the process chamber301.

Further, in the above-described embodiments, the expression “the same” or “practically the same” is used for the pressure difference, but it goes without saying that the pressure difference is not limited to exactly the same. For example, it naturally includes a state that is substantially equal to the extent that the quality of substrate processing can be maintained.

Further, in the above-described embodiments, the example in which two pressure detectors are used has been described, but without being limited thereto, one pressure detector may be used. In this case, it may be installed in the common gas exhaust pipe225. By doing so, it is possible to determine the clogging state of the exhaust pipe even with a small number of parts. For example, it is determined whether or not the pressure reaches the target pressure within a predetermined time, and when the pressure does not reach the target pressure, it is determined that either one of the process chamber exhaust pipes or the common gas exhaust pipe225causes clogging.

According to the present disclosure in some embodiments, it is possible to predict a reduction in exhaust performance and maintain high productivity.

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 disclosures. Indeed, the 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 disclosures. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosures.